SM Mla 628 - 547860en

®
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REF : 547860 EN (23 / 04 / 2003)
MLA 628 Turbo POWERSHIFT

MLA 628 -120 LS POWERSHIFT
Série 2
REPAIR MANUAL
1st DATE OF ISSUE 23 / 04 / 2003
CATALOGUE
DATE OF ISSUE OBSERVATIONS
INFORMATION
23 / 04 / 2003 - 1st ISSUE
THE TEXTS AND PICTURES IN THIS DOCUMENT CANNOT BE REPRODUCED EITHER TOTALLY OR
PARTLY.
CONTENTS
Groups Chapters
0 General points
0-1-M91 EN Characteristics
10 I.C. Engine
10-3-13 EN Engine disassembly
20 Gear box / converter
20-3-15 EN Gear box / converter disassembly “ POWER SHIFT “
30 Axle assembly
30-3-11 EN Axle disassembly 112
40 Brake
40-8-3-M55 EN Operation and adjustment of the assisted braking system
70 Hydraulic
70-3-80-M91 EN Cylinder disassembly
70-6-M91 EN Hydraulic diagram
80 Electricity
80-6-M91 EN Electric diagram
80-8-15-M91 EN Operation of the “ EGS “ shift lever (kick down)
80-8-80 EN Safety system adjustment
85 AIR-CONDITIONING
85-8-10 EN air-conditioning operation and adjustment

LIFT TRUCK CHARACTERISTICS
0-1-M91 EN
Page
MLA 628 Turbo POWERSHIFT Série 2 2 à 15

MLA 628 -120 LS POWERSHIFT Série 2
18 / 04 / 2003
CHARACTERISTICS
ENGINE
- Type MLA 628 Turbo POWERSHIFT Série 2 PERKINS 1004.40T AK 81289
MLA 628 -120 LS POWERSHIFT Série 2 PERKINS 1004.40TW AM 80921
1004.40T AK 81289 1004.40TW AM 80921

- Number of cylinders 4 in line 4 in line
- Number of strokes 4 4
- Suction Compressed turbo Compressed turbo
- Injection system Direct Direct
- Ignition sequence 1.3.4.2. 1.3.4.2.
- Clearance of rocker valve (Cold)
. Inlet 0,20 mm 0,20 mm
. Exhaust 0,45 mm 0,45 mm
- Capacity 3990 cm3 3990 cm3
- Bore 100 mm 100 mm
- Stroke 127 mm 127 mm
- Compression ratio 17.25 / 1 17.25 / 1
- Nominal rating loaded 2200 rpm 2200 rpm
+20 +20
- Rating slow unladen 930 rpm - 0 930 rpm - 0
- Max. rating unladen 2400 rpm 2380 rpm
- Power ISO 3046-1 cv / kw 119 cv / 87,5 kw
- Power ISO/TR 14396 107 cv / 78,5 kw 124 cv / 91 kw
- Power SAE cv / kw 128 cv / 94,1 kw
- Maximum torque ISO 3046-1 Nm at rpm 428 Nm at 1500 rpm
- Maximum torque ISO/TR 14396 394 Nm at 1400 rpm 434 Nm at 1500 rpm
- Air cleaner Dry 3 micron Dry 3 micron
COOLING CIRCUIT
- Type By water
- Fan Puller
. Number of blades 10
. Diameter 457,2 mm
- Thermostat
. Start opening 77 °C to 85 °C
. Full opening 92 °C to 98 °C
ELECTRIC CIRCUIT
- Earth Negative
- Battery 12 V - 105 Ah - 680 A EN
- Alternator 12 V - 65 A
. Type Magneti Marelli A127
. Tension regulator Incorporated into the alternator
- Starter 12 V
. Type Magneti Marelli M127
2-2
TRANSMISSION
- Type CLARK-HURTH
- Torque converter CLARK-HURTH
- Gear box
. Gear shifting Electro-hydraulic
. Number of forward speeds 4
. Number of reverse speeds 3
- Gear reverser Electro-hydraulic
FRONT AXLE
- Type HURTH
- Limited slip differential 45 %
- Hub reducers Epicyclic
REAR AXLE
- Type HURTH
- Limited slip differential 45 %
- Hub reducers Epicyclic
BRAKE
- Service brake Foot pedal. Hydraulic servo-brake, applied on
the front and rear wheels.
. Type Multidisc brake immersed in oil.
- Parking brake Mechanical hand lever applied on the the front
wheels.
. Type Multidisc brake immersed in oil.
FRONT AND REAR TYRES

DIMENSIONS PRESSURE TYRE LOAD PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
STANDARD 17,5LR24 XM27 TL 145A8 Bar Front unladen kg kg/cm2 kg/cm2 cm2 cm2
MICHELIN Front laden kg kg/cm2 kg/cm2 cm2 cm2
Rear unladen kg kg/cm2 kg/cm2 cm2 cm2
Rear laden kg kg/cm2 kg/cm2 cm2 cm2
OPTION 440/70-24 T37 147B TL Bar Front unladen kg kg/cm2 kg/cm2 cm2 cm2
DUNLOP Front laden kg kg/cm2 kg/cm2 cm2 cm2
OPTION 15,5/80-24 SGI TL 10PR Bar Front unladen kg kg/cm2 kg/cm2 cm2 cm2
GOODYEAR Front laden kg kg/cm2 kg/cm2 cm2 cm2
460/70 R24 IT520 TL 150A8 Bar Front unladen kg kg/cm2 kg/cm2 cm2 cm2
445/70R24 IT510 151G Bar Front unladen kg kg/cm2 kg/cm2 cm2 cm2
2-3
HYDRAULIC CIRCUIT
MLA 628 Turbo POWERSHIFT Série 2
- Type of pump Gear pump with flow divider

. Capacity 41 cm3
- Lifting, tilting, telescoping, attachment circuit
. Max. rating capacity unladen 100 L/mn
. Pressure 230 Bar
- Steering circuit
. Pressure 175 Bar
- Filtration
. Return 20 Micron
. Suction 100 Micron
HYDRAULIC CIRCUIT
- Type of pump Variable displacement piston pump

. Capacity 63 cm3
- Lifting, tilting, telescoping, attachment circuit
. Pressure 250 Bar
- Steering circuit
. Pressure Bar
- Filtration
. Return 20 Micron
. Suction 125 Micron
2-4
SPECIFICATIONS
- Level of sound pressure in the driver's cab dBA
(According to standard prEN 12053 : 1995)
- Travel speed of the lift truck

. Forward km/h
. Reverse km/h
- Standard lift height 5110 mm
- Rated capacity with standard attachment 2500 kg
- Load center 500 mm
- Weight of forks (Each) 72,5 kg
- Lifting motions (Jib retracted)

. Unladen lifting 6,5 s m/mn
. Load lifting 7s m/mn
. Unladen lowering 4,7 s m/mn
. Load lowering 4,6 s m/mn
- Telescoping motions (Lifting jib)

. Unladen extending 3,3 s m/mn
. Laden extending 3,4 s m/mn
. Unladen retracting 2,1 s m/mn
. Laden retracting 2,2 s m/mn
- Reverse tilt time unladen 3,3 s °/s
- Forward tilt time unladen 3,4 s °/s
- Lift truck weight with standard attachment

. Unladen 6615 kg
. Rated load 9115 kg
- Axle weight with attached equipment (Transport position)

. Front unladen kg
Rated load kg
. Rear unladen kg
Rated load kg
- Tensible strain at coupling hook

. Unladen daN
. Rated load 7500 daN
- Break out force with bucket 5250 daN

(According to standard ISO 8313)
2-5
SPECIFICATIONS
- Level of sound pressure in the driver's cab dBA
(According to standard prEN 12053 : 1995)
- Travel speed of the lift truck

. Forward km/h
. Reverse km/h
- Standard lift height 5110 mm
- Rated capacity with standard attachment 2500 kg
- Load center 500 mm
- Weight of forks (Each) 72,5 kg
- Lifting motions (Jib retracted)

. Unladen lifting 6,5 s m/mn
. Load lifting 7s m/mn
. Unladen lowering 4,7 s m/mn
. Load lowering 4,6 s m/mn
- Telescoping motions (Lifting jib)

. Unladen extending 3,3 s m/mn
. Laden extending 3,4 s m/mn
. Unladen retracting 2,1 s m/mn
. Laden retracting 2,2 s m/mn
- Reverse tilt time unladen 3,3 s °/s
- Forward tilt time unladen 2,4 s °/s
- Lift truck weight with standard attachment

. Unladen 6740 kg
. Rated load 9240 kg
- Axle weight with attached equipment (Transport position)

. Front unladen
Rated load kg
. Rear unladen kg
Rated load kg
kg
- Tensible strain at coupling hook
. Unladen daN
. Rated load 8500 daN
- Break out force with bucket 5250 daN

(According to standard ISO 8313)
2-6
2-7
DIMENSIONS AND LOAD CHART
C1
U2
U1
N
P3
P2
G2
G1
G
Y
F1
Z
C B I F
A D W
V2
V1 R
V
U
K
O
MLA 628T
7
5.11 5
2500kg
4
2000kg
3
1700kg
2
1380kg
1
0.5m
0
N°230700
-1
4 3 2 1 0m
2.65 1.78
3.10 2.30
SUIVANT NORME EN 1459 annexe B.
2-8
MLA628 Turbo MLA628 120 LS
POWERSHIFT Série 2 POWERSHIFT Série 2
A 1200 mm 1200 mm
B 2500 mm 2500 mm
C 1415 mm 1415 mm
C1 1356 mm 1356 mm
D 5389 mm 5389 mm
D1 mm mm
D2 mm mm
E 6589 mm 6589 mm
F 1775 mm 1775 mm
F1 1775 mm 1775 mm
G 457 mm 457 mm
G1 386 mm 386 mm
G2 457 mm 457 mm
I 1473 mm 1473 mm
J mm mm
K 1260 mm 1260 mm
L 45 mm 45 mm
N 2022 mm 2022 mm
O 125 mm 125 mm
P2 42 ° 42 °
P3 27 ° 27 °
R 4004 mm 4004 mm
S mm mm
U 44 ° 44 °
U1 2645 mm 2645 mm
U2 2860 mm 2860 mm
V 4501 mm 4501 mm
V1 2004 mm 2004 mm
V2 4256 mm 4256 mm
W 2225 mm 2225 mm
Y 9° 9°
Z 151 ° 151 °
2-9
2 - 10
FILTERS CARTRIDGES AND BELTS

1 2 3 4 5 6 7 8 9
10 11 12 13
DESIGNATION PART NUMBER CLEAN CHANGE
1 - Engine oil filter

MLA 628 Turbo POWERSHIFT Série 2 133 755 400 H
MLA 628 -120 LS POWERSHIFT Série 2 476 954 400 H
2 - Dry air filter cartridge 563 416 50 H * 400 H *
3 - Safety dry air filter cartridge 563 415 800 H *
4 - Transmission oil filte 550 145 400 H
5 - Fuel filter cartridge 49 660 400 H
6 - Hydraulic return oil filter cartridge 485 696 400 H
7 - Suction strainer for hydraulic oil tank 77 402 800 H
8 - Filter cap for hydraulic oil tank 62 415 800 H
9 - Alternator / Fan belt 564 636
10 - Cab ventilation filter (Without air conditioning)(Qty: 2) 602 975 400 H
10 - Cab ventilation filter (With air conditioning)(Qty: 2) 602 975 50 H 200 H
11 - Cyclonic pre-filter 224 713 10 H
12 - Automatic vacuum-cleaning pre-filter (OPTION) 235 797
13 - Compressor belt (OPTION AIR CONDITIONING) 196 712
* : This periodicity is given for information only (See chapter : SERVICING SCHEDULE in paragraph : 3 -
MAINTENANCE) for cleaning and changing.
2 - 11
LUBRICANTS AND FUEL
I.C. ENGINE
ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING PART NUMBER
I.C. ENGINE 8 Liters MANITOU Oil 20 L. 582 357
API CG4 55 L. 582 358
209 L. 582 359
COOLING CIRCUIT 20 Liters Cooling liquid 2 L. 473 076
(Protection - 30 °C) 5 L. 470 077
20 L. 470 078
210 L. 470 079
20 Liters Cooling liquid 2 L. 554 002
(Protection - 25 °C) 5 L. 554 003
20 L. 554 004
210 L. 554 005
FUEL TANK 120 Liters Diesel fuel (*)
TRANSMISSION
TRANSMISSION 15,5 Liters MANITOU Oil 1 L. 62 148
Automatic transmission 25 L. 487 655
55 L. 546 217
209 L. 546 195
TRANSMISSION UNIVERSAL JOINT MANITOU Grease 1 Kg. 554 973
Multipurpose HD NLGI 2 5 Kg. 554 974
JIB
ORGANS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBER
JIB PADS MANITOU Grease 1 Kg. 161590
Multipurpose NLGI 2
GREASING OF THE JIB MANITOU Grease 1 Kg. 554 973
HYDRAULICS
HYDRAULIC OIL TANK 130 Liters MANITOU Oil 25 L. 161 588
Hydraulic ISO 46 55 L. 546 108
209 L. 546 109
BRAKE
BRAKE CIRCUIT MANITOU Oil 1 L. 490 408
Mineral brake fluid
CAB
CAB DOOR MANITOU Grease 1 Kg. 554 973
WINDSCREEN WASHER TANK Windscreen washer fluid 1 L. 490 402
5 L. 486 424
30 L. 505 527
225 L. 490 432
CHASSIS
ARTICULATION OF THE CHASSIS MANITOU Grease 1 Kg. 554 973
STEERING CYLINDER MANITOU Grease 1 Kg. 554 973
2 - 12
FRONT AND REAR AXLES
FRONT AXLE DIFFERENTIAL 6,3 Liters MANITOU Oil 25 L. 545 608
Special immersed brakes
REAR AXLE DIFFERENTIAL 6,4 Liters MANITOU Oil 25 L. 545 608
Special immersed brakes
FRONT WHEELS REDUCERS 0,8 Liter MANITOU Oil 2 L. 499 237
Mechanical transmission for 25 L. 161 585
axles and boxes SAE 80W90 55 L. 546 221
209 L. 546 220
REAR WHEELS REDUCERS 0,8 Liter MANITOU Oil 2 L. 499 237
Mechanical transmission for 25 L. 161 585
axles and boxes SAE 80W90 55 L. 546 221
209 L. 546 220
REAR AXLE OSCILLATION MANITOU Grease 1 Kg. 554 973
(*) FUEL SPECIFICATION
CETANE RATING : 45 minimum

VISCOSITY : 2 - 4,5 Centistokes at 40° C
DENSITY : 0,820 - 0,860 kg/litre
SULPHUR : 0,2 % mass maximum
DISTILLATION : 85 % at 350° C
- The cetane rating is a measure of the ignition quality of a diesel fuel. A fuel with a low cetane index may cause
problems with cold starts and affect combustion.
- Viscosity is the resistance to flow. If the viscosity is outside the limits, I.C. engine performance may be affected.
- A low density reduces the power of the I.C. engine, a high density increases the power of the I.C. engine and the
exhaust fumes.
- A high sulphur content (Not usually found in europe, north america or australasia) may cause wear to the I.C. engine.
If only fuels with a high sulphur content are available, it is necessary to use a highly alkaline greasing oil in the I.C.
engine or to replace the greasing oil more frequently.
- Distillation : this indicates the mixture of different hydrocarbons in the fuel. A high ratio of light hydrocarbons can affect
the characteristics of combustion.
- Fuels for low temperatures : special winter fuels may be available for use in the I.C. engine at temperatures below
0°C. These fuels have a lower viscosity and thus reduce the formation of paraffin in the fuel at low temperatures. The
formation of paraffin can prevent filtration of the fuel.
DIAGNOSTIC ANALYSIS OF OIL
In the event of a maintenance or service contract with the dealer you may be requested to provide a sample of a
selected component's oil, for diagnostic analysis.
2 - 13
2 - 14
DISASSEMBLY OF THE I.C. ENGINE
10-3-13 EN
22/10/2001
IMPORTANT
To identify the I.C. engine on your lift truck, see the LIFT TRUCK CHARACTERISTICS chapter in section O - GENERAL.
Contents
New 1000 Series
Contents EXIT
EXIT
Perkins New 1000 Series

Models AJ to AS and YG to YK
WORKSHOP MANUAL
4 and 6 cylinder diesel engines for industrial and

agricultural applications
Publication TPD 1350E issue 3

© Proprietary information of Perkins Engines Company Limited, all rights reserved.
The information is correct at the time of print.
Published in March 2000 by Technical Publications.
Workshop Manual, TPD 1350, issue 3 1

New 1000 Series
Chapters
10 General information
11 Specifications
12 Cylinder head assembly
13 Piston and connecting rod assemblies
14 Crankshaft assembly
15 Timing case and drive assembly
16 Cylinder block assembly
17 Engine timing
18 Aspiration system
19 Lubrication system
20 Fuel system
21 Cooling system
22 Flywheel and housing
23 Electrical equipment
24 Auxiliary equipment
25 Special tools
26 Service bulletin
The following pages contain a detailed table of contents.
2 Worksh op M anu al, TPD 1350, issue 3 (10/01)

New 1000 Series
Contents
10 General information
Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 15
Engine identification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 17
General safety precautions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 18
Engine lift equipment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 19
Viton seals . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 20
POWERPART recommended consumable products . ... ... ... ... ... ... ... ... ... ... ... ... . 21
11 Specifications
Basic engine data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 23
Thread sealant ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 24
Standard torque tensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 25
Specific torque tensions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 26
Compression test data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 29

New 1000 Series
12 Cylinder head assembly
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 31
Rocker cover
12-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 32
Rocker assembly
12-3 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34
12-4 To inspect and to correct ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34
Valve tip clearances

12-5 To check and to adjust ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 35
Valve springs
12-6 To change the valve springs (with cylinder head fitted) . ... ... ... ... ... ... ... ... ... ... 37
Cylinder head assembly

Valves and valve springs

Valve guides
12-10 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 51
12-11To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 52
Cylinder head
12-12 To inspect and to correct . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 54
12-13 To correct a valve seat with a valve seat cutter ... ... ... ... ... ... ... ... ... ... ... ... ... 55
12-14 To fit valve seat inserts ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 56
Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 57
4 Workshop Manual, TPD 1350, issue 3

New 1000 Series
13 Piston and connecting rod assemblies
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 63
Big end bearing

13-1 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 65
13-2 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 66
Piston and connecting rod

13-4 To check the piston height above the cylinder block . ... ... ... ... ... ... ... ... ... ... ... . 70
Piston rings
Piston and connecting rod assembly

13-6 To dismantle and to assemble .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 72
13-7 To check the length of a connecting rod ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 73
Piston and piston rings

13-8 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 74
Connecting rod
13-9 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 75
Partially finished small end bush

13-10 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 75
Piston cooling jets

13-12 To check the jet alignment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 76
Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 77

New 1000 Series
14 Crankshaft assembly
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 79
Crankshaft pulley
14-1 To remove and to fit - four cylinder engines .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... 80
Crankshaft pulley and damper

14-2 To remove and to fit - six cylinder engines ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 81
14-3 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 83
Rear oil seal assembly

14-5 To renew the rear oil seal .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 85
Thrust washers
14-6 To check crankshaft end-float ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 86
Main bearings
14-8 To remove and to fit (with the crankshaft in position) ... ... ... ... ... ... ... ... ... ... ... 89
14-9 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 90
Crankshaft
14-10 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 91
14-11 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 94
Balancer unit
14-12 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 95
14-13 To dismantle and to assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 96
14-14 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 101
14-15 To remove and to fit the needle roller bearings for the drive shaft .. ... ... ... ... .. 102
14-16 To remove and to fit the bushes for the balance weights ... ... ... ... ... ... ... ... .. 103
Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 104

New 1000 Series
15 Timing case and drive assembly
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 109
Timing case cover

15-1 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 110
Front oil seal

15-3 To fit wear sleeve .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 112
Idler gear and hub

Idler gear and hub for the Bendix compressor

Fuel pump gear

Camshaft gear
Crankshaft gear
Timing case
Camshaft and tappets

15-10 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 124

New 1000 Series
16 Cylinder block assembly
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 127
Cylinder block
16-1 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 128
16-2 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 129
Cylinder liner
16-3 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 130
16-4 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 131
Cylinder bore, engine types AR and AS

16-5 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 136
17 Engine timing
Engine timing
17-1 To set number 1 piston to TDC on the compression stroke .. ... ... ... ... ... ... ... .. 143
17-2 Another method to set number 1 piston to TDC on the compression stroke . ... .. 144
17-3 To check the valve timing .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 144
17-4 To check the timing of the fuel injection pump ... ... ... ... ... ... ... ... ... ... ... ... ... .. 145
18 Aspiration system
Turbocharger
18-2 To clean the impeller and the compressor casing . ... ... ... ... ... ... ... ... ... ... ... .. 151
18-3 To remove and to fit the actuator assembly of the waste-gate unit ... ... ... ... ... .. 152
18-4 To check and adjust the operation of the waste-gate ... ... ... ... ... ... ... ... ... ... .. 153
Turbocharger faults ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 154
Engine breather
18-5 To clean and to renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 156
18-6 To clean and to renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 157

New 1000 Series
Data and dimensions. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 158
19 Lubrication system
Filter canister
19-1 To renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 163
Filter head
Sump
Oil strainer and suction pipe

Lubricating oil pump

19-7 To renew the shaft for the idler gear . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 169
19-8 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 173
Relief valve
19-10 To dismantle and to assemble .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 175
19-11 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 175
Flexible oil pipes

19-12 To remove, to fit and to inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 176

New 1000 Series
Fuel system
General description. .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 181
Cold start advance unit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 183
Typical fuel system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 186
Fuel filters .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 187
Fuel filter element

20-1 To renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 188
Atomisers
20-2 Atomiser fault . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 191
Fuel lift pump

20-6 To test ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 195
Bosch fuel injection pump

20-8 To adjust ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 200
20-9 To eliminate air from the fuel system . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 201
Lucas DP 200 Series fuel injection pump

20-10 To remove to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 203
20-11 To adjust .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 207
20-12 To eliminate air from the fuel system Lucas DP200 pump .. ... ... ... ... ... ... ... .. 208
Stanadyne fuel injection pump

20-13 To remove to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 210
20-14 To adjust .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 214
20-15 To eliminate air from the fuel system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 215

New 1000 Series
21 Cooling system
Thermostats
21-1 To remove, to fit and to test .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 220
Coolant pump - early gear driven pumps

Coolant pump - latest gear driven pumps

Coolant pump - belt driven

Coolant pump - belt driven high position

21- 5 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 226



Fan
Fan drive (engines with gear driven coolant pumps)

21-10 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 240
Lubricating oil cooler

21-11 To remove and to fit - four cylinder turbocharged engines .. ... ... ... ... ... ... ... ... 241
21-12 To remove and to fit - six cylinder engines .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... 242
21-13 To remove and to fit - pressed steel cover type .. ... ... ... ... ... ... ... ... ... ... ... ... 243
21-14 To remove and to fit - canister type.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 245
21-15 To dismantle and to assemble - four cylinder turbocharged engines .. ... ... ... ... 246
21-16 To dismantle and to assemble - six cylinder turbocharged engines ... ... ... ... ... 247
Cooler by-pass valve

21-18 To dismantle and to assemble pressed steel cooler type . ... ... ... ... ... ... ... ... ... 248

New 1000 Series
Intercooler
21-19 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 250
21-20 To clean and to inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 254
22 Flywheel and housing

Flywheel
Ring gear
Flywheel housing

New 1000 Series
23 Electrical equipment
Alternators
Precautions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 261
Drive belts
23-1 To check ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 262
23-2 To adjust tension ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 262
Alternator
23-5 To maintain ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 263
Fault diagnosis
Starter motors
Starter motor
23-7 To maintain the brush gear and the commutator .. ... ... ... ... ... ... ... ... ... ... ... ... 269
23-8 To test on the engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 269
Starting aid
Starting aid ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 271
23-9 To remove and to fit a fuelled starting aid . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 271
23-10 To remove and to fit a port heater ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 273

New 1000 Series
24 Auxiliary equipment
Compressors
Operation... ... ... ... ... .... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 275
Bendix Compressors
Power steering pump
Adaptor for a hydraulic pump or a steering pump with a splined drive

Exhauster
25 Special tools
List of special tools ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 286

New 1000 Series
10
General information 10
Introduction
This workshop manual has been written to provide Read and remember the "Safety precautions".
assistance in the service and overhaul of Perkins New They are given for your protection and must be
1000 Series engines. For overhaul procedures the used at all times.
assumption is made that the engine is removed from
Danger is indicated in the text by two methods:
the application. The engine conforms with USA (EPA/
CARB) stage 1 and EEC stage 1 emissions legislation Warning! This indicates that there is a possible
for agricultural and industrial applications. danger to the person.
Most of the general information which is included Caution: This indicates that there is a possible
in the relevant User's Handbook (sections 1 to 9) danger to the engine.
has not been repeated in this workshop manual
Note: Is used where the information is important, but
and the two publications should be used together.
there is not a danger.
Where the information applies only to certain engine
types, this is indicated in the text.
The details of some operations will be different
according to the of fuel injection pump which is fitted.
The specific pump type used can be found by
reference to the manufacturer's identification plate on
the pump body. Generally, the type of pump fitted is
as shown below.
Lucas DP200 Series
Bosch EPVE
Stanadyne DB4
When reference is made to the "left" or "right" side of
the engine, this is as seen from the flywheel end of the
engine.
Special tools have been made available and a list of
these is given in section 25. Reference to the relevant
special tools is also made at the beginning of each
operation, where relevant.
POWERPART recommended consumable products
are listed on page 21. Reference to the relevant
consumable products is also made at the beginning of
each operation, where relevant.
Data and dimensions are included at the end of each
section.

10
L
New 1000 Series
A0378N
A0379

New 1000 Series 10
Engine identification
The Perkins New 1000 Series engines have been
designed for industrial and agricultural applications. 1 2
There are both four and six cylinder engines, each of
which will have three basic engine types, naturally
aspirated, turbocharged and turbocharged with an 3
intercooler.
In this workshop manual, the different engine types
are indicated by their code letters. These are the first
two letters of the engine number as indicated below:
Code letters Engine type
AJ Four cylinder, naturally A A0043
aspirated.
AK Four cylinder, turbocharged. AK80920*U510256B* 1
AM Four cylinder, turbocharged AJ39770 TPL N o 212 2

and intercooled. 3
AP Four cylinder, naturally
aspirated, belt driven coolant 4
pump.
AQ Four cylinder, turbocharged,
belt driven coolant pump.
AR Four cylinder, naturally
aspirated, 103 mm cylinder
bore. B A0045
AS Four cylinder, naturally If a short engine has been fitted in service two engine
aspirated, belt driven coolant serial numbers and a TPL number are stamped on the
pump, 103 mm cylinder bore. engine serial number pad (B3):
YG Six cylinder, naturally Examples of the serial numbers are shown in (B).
aspirated.
If parts for the short engine are needed in service, use
YH Six cylinder, turbocharged. the serial number (B4). If parts which were moved
from the original engine to the short engine are
YK Six cylinder, turbocharged and
needed, use the serial number (B1) and the TPL
intercooled.
number (B2).
The correct identification of the engine is by the full
engine number.
The engine number is stamped on a label which is
fastened to the left side (A2) of the cylinder block. An
example of an engine number is:
AK80920*U510256B*
If you need parts, service or information for your
engine, you must give the complete engine number to
your Perkins distributor. If there is a number in the
area of the label marked TPL No, then this number
must also be given to your Perkins distributor.
Other identification labels fitted to the engine include:
An emissions legislation label (A3) fitted to the side of
the cylinder block.
A label (A1) with the fuel injection pump part numbers.

10 New 1000 Series
General safety precautions ! Diesel fuel and lubricating oil (especially used
lubricating oil) can damage the skin of certain
These safety precautions are important. You must persons. Protect your hands with gloves or a
refer also to the local regulations in the country of use. special solution to protect the skin.
Some items only refer to specific applications. ! Do not wear clothing which is contaminated by
! Only use these engines in the type of application lubricating oil. Do not put material which is
for which they have been designed. contaminated with oil into the pockets of clothing.
! Do not change the specification of the engine. ! Discard used lubricating oil in a safe place to
prevent contamination.
! Do not smoke when you put fuel in the tank.
! Ensure that the control lever of the transmission
! Clean away fuel which has been spilt. Material
drive is in the "out-of-drive" position before the
which has been contaminated by fuel must be
engine is started.
moved to a safe place.
! Use extreme care if emergency repairs must be
! Do not put fuel in the tank while the engine runs
made in adverse conditions.
(unless it is absolutely necessary).
! The combustible material of some components of
! Do not clean, add lubricating oil, or adjust the
the engine (for example certain seals) can
engine while it runs (unless you have had the
become extremely dangerous if it is burned. Never
correct training; even then extreme care must be
allow this burnt material to come into contact with
used to prevent injury).
the skin or with the eyes, see page 20.
! Do not make adjustments that you do not
! Read and use the instructions relevant to lift
understand.
equipment which are given on page 19.
! Ensure that the engine does not run in a location
! Always use a safety cage to protect the operator
where it can cause a concentration of toxic
when a component is to be pressure tested in a
emissions.
container of water. Fit safety wires to secure the
! Other persons must be kept at a safe distance plugs which seal the hose connections of a
while the engine or auxiliary equipment is in component which is to be pressure tested.
operation.
! Do not allow compressed air to contact your skin.
! Do not permit loose clothing or long hair near If compressed air enters your skin, obtain medical
moving parts. help immediately.
! Keep away from moving parts during engine ! Turbochargers operate at high speed and at high
operation. Warning! Some moving parts cannot temperatures. Keep fingers, tools and items away
be seen clearly while the engine runs. from the inlet and outlet ports of the turbocharger
! Do not operate the engine if a safety guard has and prevent contact with hot surfaces.
been removed. ! Do not clean an engine while it runs. If cold
! Do not remove the filler cap or any component of cleaning fluids are applied to a hot engine, certain
the cooling system while the engine is hot and components on the engine may be damaged.
while the coolant is under pressure, because ! Fit only genuine Perkins parts.
dangerous hot coolant can be discharged.
! Do not use salt water or any other coolant which
can cause corrosion in the closed circuit of the
cooling system.
! Do not allow sparks or fire near the batteries
(especially when the batteries are on charge)
because the gases from the electrolyte are highly
flammable. The battery fluid is dangerous to the
skin and especially to the eyes.
! Disconnect the battery terminals before a repair is
made to the electrical system.
! Only one person must control the engine.
! Ensure that the engine is operated only from the
control panel or from the operators position.
! If your skin comes into contact with high-pressure
fuel, obtain medical assistance immediately.

New 1000 Series 10
Engine lift equipment
.
The maximum weight of the engine without coolant,

lubricant or a gearbox fitted will vary for different
applications. It is recommended that lift equipment of
the minimum capacity listed below is used:
Four cylinder engines . . . . . . . . . . 500 kg (1100 lbs)
Six cylinder engines. . . . . . . . . . . . 600 kg (1320 lbs)
Before the engine is lifted:
! Always use lift equipment of the approved type
and of the correct capacity to lift the engine. It is
recommended that lift equipment of the type 1
shown in (A) is used, to provide a vertical lift
directly above the engine lift brackets (A1). Never
use a single lift bracket to raise an engine.
! Check the engine lift brackets for damage and that
they are secure before the engine is lifted. The
torque for the setscrews for the engine lift brackets
is 44 Nm (33 lbf ft) 4,5 kgf m.
! To prevent damage to the rocker cover, ensure
that there is clearance between the hooks and the
rocker cover.
! Use lift equipment or obtain assistance to lift
heavy engine components such as the cylinder
block, cylinder head, balancer unit, flywheel
housing, crankshaft and flywheel. A A0044

10 New 1000 Series
Viton seals
.
Some seals used in engines and in components fitted

to engines are made of Viton.
Viton is used by many manufacturers and is a safe
material under normal conditions of operation.
If Viton is burned, a product of this burnt material is an
acid which is extremely dangerous. Never allow this
burnt material to come into contact with the skin or
with the eyes.
If it is necessary to come into contact with
components which have been burnt, ensure that the
precautions which follow are used:
! Ensure that the components have cooled.
! Use neoprene gloves and discard the gloves
safely after use.
! Wash the area with calcium hydroxide solution
and then with clean water.
! Disposal of components and gloves which are
contaminated must be in accordance with local
regulations.
If there is contamination of the skin or eyes, wash the
affected area with a continuous supply of clean water
or with calcium hydroxide solution for 15-60 minutes.
Obtain immediate medical attention.

New 1000 Series 10
POWERPART recommended POWERPART Studlock
consumable products To permanently retain large fasteners and studs.
Currently Loctite 270. Part number 21820270.
Perkins have made available the products
recommended below in order to assist in the correct POWERPART Nutlock
operation, service and maintenance of your engine
To retain and seal threaded fasteners and cup plugs
and your machine. The instructions for the use of
where easy removal is necessary. Currently Loctite
each product are given on the outside of each
242e. Part number 21820242
container. These products are available from your
Perkins distributor. POWERPART Liquid gasket
POWERPART Antifreeze To seal flat faces of components where no joint is
used. Especially suitable for aluminium components.
Protects the cooling system against frost and
Currently Loctite 518. Part number 21820518
corrosion. Part number 1 litre 21825166 or 5 litres
21825167, refer to the User's Handbook. POWERPART Threadlock (hydraulic/pnuematic)
POWERPART Easy Flush To retain and seal pipe connections with fine threads.
Especially suitable for hydraulic and pneumatic
Cleans the cooling system. Part number 2182501
systems. Currently Loctite 542. Part number
POWERPART Jointing compound 21820542
Universal jointing compound which seals joints. POWERPART Threadlock (pipe)
Currently Hylomar. Part number 1861155 or
To retain and seal pipe connections with coarse
1861117.
threads. Pressure systems can be used immediately.
POWERPART Silicone rubber sealant Currently Loctite 575. Part number 21820575.
Silicone rubber sealant which prevents leakage POWERPART Retainer (oil tolerant)
through gaps.Currently Hylosil. Part number
To retain components which have a transition fit.
1861108.
POWERPART Lay-Up 1
POWERPART Retainer (high strength)
A diesel fuel additive for protection against corrosion.
To retain components which have an interference fit.
Part number 1772204, refer to the User's Handbook.
POWERPART Lay-Up 2
POWERPART Atomiser thread sealant
Protects the inside of the engine and of other closed
To seal the threads of the atomiser into the cylinder
systems. Part number 1762811, refer to the User's
head. Currently Hylomar Advance Formulation. Part
Handbook.
number 21825474.
POWERPART Lay-Up 3
Continued
Protects outside metal parts. Part number 1734115,
refer to the User's Handbook.
POWERPART Chisel
Allows easy removal of old gaskets and joints.
Currently Loctite chisel. Part number 21825163.
POWERPART Repel
Dries damp equipment and gives protection against
corrosion. Passes through dirt and corrosion to
lubricate and to assist removal of components.
Currently Loctite repel. Part number 21825164.
POWERPART Threadlock
To retain small fasteners where easy removal is
necessary. Currently Loctite 222e. Part number
21820222.

10 New 1000 Series
POWERPART Compound
To seal the outer diameter of seals. Currently Loctite
Forma Gasket No 2. Part number 1861147.
POWERPART Platelock
For tight fitted metal surfaces. Suitable for metal
plated surfaces and stainless steel, Currently Loctite
243. Part number 21826039.
POWERPART Gasket eliminator
Improves flange sealing when a gasket is not used. It
provides a seal with temperature resistance that is
flexible in positions where vibration and pressure
occur. Currently Loctite 515. Part number 21826040.
POWERPART Silicone adhesive
An RTV silicone adhesive for application where low-
pressure tests occur before the adhesive sets. Used
to prevent leakage where movement of the joint
occurs. Currently Loctite 5900. Part number
21826038.

New 1000 Series
11
Specifications 11
Basic engine data

Number of cylinders:
AJ, AK, AM, AP, AQ, AR, AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
YG, YH, YK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .In line
Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four stroke
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise from the front
Induction system
AJ, AP, AR, AS, YG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Naturally aspirated
AK, AQ, YH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged
AM, YK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged, intercooled
Combustion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Direct injection
Nominal bore
AJ, AK, AM, AP, AQ, YG, YH, YK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm (3.937 in)
AR, AS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 mm (4.055 in)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 mm (5.00 in)
Compression ratio
AJ, AK, AM, AP, AQ, YG, YH, YK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.25:1
AR, AS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5:1
Cubic capacity
AJ, AK, AM, AP, AQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 litres (243 in3)
AR, AS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,23 litres (258 in3)
YG, YH, YK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 litres (365 in3)
Firing order
AJ, AK, AM, AP, AQ, AR, AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 3, 4, 2
YG, YH, YK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 5, 3, 6, 2, 4
Valve tip clearances (hot or cold)
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,20 mm (0.008 in)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,45 mm (0.018 in)
Lubricating oil pressure (1)

AJ, AK, AM, AP, AQ, YG, YH, YK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .280 kPa (40 lbf/in2) 2,5 kgf/cm2
AR, AS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207 kPa (30 lbf/in2) 2,1 kgf/cm2
(1) minimum at maximum engine speed and normal engine temperature

11 New 1000 Series
Thread sealant
When setscrews or studs are fitted into holes which
are tapped through the cylinder block, a suitable
sealant must be used to prevent leakage.
Micro encapsulated anaerobic sealant (M.E.A.S)
fasteners have been introduced instead of jointing
compounds or other sealants when the fasteners are
fitted in through holes into oil or coolant passages.
The identification of these fasteners, as supplied, is
by a red, blue, or other colour sealant around the
fastener threads.
With M.E.A.S. sealed studs, the sealed end must be
fitted into the cylinder head / cylinder block etc.
Ensure that the threaded holes have a 1,59 mm
(0.0625 in) 45° chamfer, to ensure that when the new
fasteners are fitted the M.E.A.S. sealant is not
removed. If the fasteners have to be removed and
fitted again, the threads must be cleaned and a
suitable sealant used.

New 1000 Series 11
Standard torque tensions
Most of the torque tensions on the engine are standard. Special torque tensions are listed in the separate
special torque tables. The standard torque tensions listed in the tables below can be used when a special
torque is not necessary.
The torque tensions below apply to components lubricated lightly with clean engine oil before they are fitted.
Standard torques for setscrews and nuts
Torque
Thread Size Nm lbf ft kgf m

M6 x 1,00 9 7 0,9
M8 x 1,25 22 16 2,2
M10 x 1,50 44 33 4,5
M12 x 1,75 78 58 8.0

M14 x 2,00 124 91 12,6
M16 x 2,00 190 140 19,3
Standard torques for studs (metal end)
Torque
Thread Size Nm lbf ft kgf m

M6 x 1,00 5 4 0,5
M8 x 1,25 11 9 1,1
M10 x 1,50 18 14 1,8
M12 x 1,75 25 19 2,5
Standard torques for pipe unions, plugs, and adaptors
Torque
Thread Size
Nm lbf ft kgf m
(Inches)
1/8 PTF 9 7 0.9
1/4 PTF 17 13 1,7
3/8 PTF 30 23 3,0
3/4 PTF 45 35 4,5

11 New 1000 Series
Specific torque tensions
The torque tensions below apply to components lubricated lightly with clean engine oil before they are fitted.
Special torques for setscrews and nuts
Torque
Thread
Description Nm lbf ft kgf m
size
Setscrews, cylinder head 1/2 UNF see operation 12-7
M10
Setscrews, cylinder head (Engine types AR and AS) see operation 12-7
1/2 UNF
Fasteners, rocker shaft brackets:
- Aluminium brackets M12 40 30 4,1
- Cast iron and sintered steel brackets M12 75 55 7,6
Cap nuts, composite plastic rocker cover M12 20 15 2,1
Cap nuts, aluminium rocker cover M12 30 22 3,0
Setscrews, inlet manifold to cylinder head M10 44 33 4,5
Fasteners, exhaust manifold to cylinder head M10 44 33 4,5
Setscrews, engine lift bracket M10 44 33 4,5
Piston and connecting rod assemblies
Nuts, connecting rods 1/2 UNF 125 92 12,7
Setscrews, connecting rods 1/2UNF 152 114 15,8
Banjo bolts, piston cooling jets 3/8 UNF 27 21 2,7
Crankshaft assembly
Setscrews, main bearings 5/8 UNF 265 196 27,0
Setscrews, crankshaft pulley 7/16 UNF 115 85 11,8
Setscrews, viscous damper to crankshaft pulley M12 75 55 7,6
Cap screws, viscous damper to crankshaft pulley M8 35 26 3,6
Cap screws, crankshaft bonded damper to crankshaft
M8 35 26 3,6
pulley
Setscrews, rear oil seal housing to cylinder block M8 22 16 2,2
Cap screws, bridge piece to cylinder block M6 16 12 1,6
Cap screws, rear oil seal housing to bridge piece M6 13 10 1,3
Torxscrew, rear oil seal housing to bridge piece M8 18 13 1,9
Setscrew, idler gear hub of balancer unit M12 93 68 9,5
Nut, drive gear of balance weight 1/2 UNF 82 60 8,4
Setscrews, rear cover of balancer frame M10 54 40 5,5
Setscrews, oil transfer plate (balancer unit) M10 30 22 3,1
Setscrews, oil pump to balancer frame M8 27 20 2,8
Setscrews, balancer to cylinder block M10 54 40 5,5

New 1000 Series 11
Torque
Thread
size
Timing case and drive assembly
Setscrews, timing case to cylinder block M8 22 16 2,2
Setscrews, timing case to cylinder block M10 44 33 4,5
Setscrews, hub of idler gear M10 44 33 4,5
Setscrew, camshaft gear M12 95 74 9,5
Setscrews, timing case cover to timing case M8 22 16 2,2
Nuts, timing case cover to timing case M8 22 16 2,2
Cylinder block
Setscrews, fitted instead of piston cooling jet(s) 3/8 UNF 27 21 2,7
Fuel system
Nuts, high-pressure fuel pipes M12 22 16 2,2
Bolt banjo, leak-off connection M8 9 7 0,9
Gland nut, atomiser body - 40 30 4,1
Setscrews, for the gear of the fuel injection pump M10 28 20 2,8
Torxscrew, for the gear of the fuel injection pump M10 22 16 2,2
Setscrews, fuel lift pump M8 22 16 2,2
Nuts for flange of fuel injection pump M8 22 16 2,2
Locking screw of Bosch VE fuel injection pump M10 27 20 2,8
Locking screw of DP 200 fuel injection pump 10 A/F 10 7 1
Lubrication system
Plug, lubricating oil sump 3/4 UNF 34 25 3,5
Setscrews, oil pump to front bearing cap M8 22 16 2,2
Setscrews, cover for oil pump M8 28 21 2,9
Fasteners, lubricating oil sump M8 22 16 2,2
Cooling system
Nut, drive pulley for coolant pump (Engine types AP, AQ,
M8 22 16 2,2
AS)
Setscrews, fan drive housing to timing case M10 44 33 4,5
Setscrews, fan drive pulley to hub M8 22 16 2,2
Setscrews, fan drive pulley to hub M10 44 33 4,5
Setscrews, fan M8 22 16 2,2
Connector, oil cooler to oil filter head 3/4 UNF 58 42 5,8
Setscrews, coolant pump to body of pump (Engine type AS) M8 29 21 2,9
Screw, cassette type cooler to oil filter head 3/4 UNF 37 29 3,7

11 New 1000 Series
Torque
Thread
size
Flywheel and housing
Setscrews, flywheel to crankshaft 1/2 UNF 105 77 10,7
Setscrews, cast iron flywheel housing to cylinder block M10 44 33 4,5
- Head stamped 8.8 M12 75 55 7,6
- Head stamped 10.9 M10 63 46 6,4
- Head stamped 10.9 M12 115 85 11,7
Setscrews, aluminium flywheel housing to cylinder block M10 70 52 7,1
Setscrews, flywheel housing to cylinder block (paper joint) M10 70 52 7,1
Aspiration system
Nuts, turbocharger to manifold M10 44 33 4,5
Electrical equipment
Nut, alternator pulley:
- CAV AC5RA and AC5RS 5/8 UNF 55 40 5,6
- Thin nut A127, and motorola pulley, 22 mm A/F M17 60 44 6,1
- Thick nut A127, and motorola pulley, 24 mm A/F M17 80 59 8,2
- Bosch 55A M14 45 33 4,5
- Bosch 55A M16 50 37 5,1
- Butec 5524 5/8 UNF 78 58 8,0
Fuelled start aid to induction manifold 7/8 UNF 31 23 3,1
Port heater to induction manifold M22 60 44 6,1
Nut/screw, starter motor 3/8 UNF 30 23 3,0
Auxiliary equipment
Nut, compressor drive gear to compressor crankshaft 5/8 UNF 120 93 12,0
Nut, (30 A/F) Compressor gears M20 130 101 13,0
Cap screw, bracket to idler hub M10 60 47 6,0
Cap screw, bracket to timing case M8 35 27 3,5

New 1000 Series 11
Compression test data
Tests have shown that many factors affect
compression pressures. Battery and starter motor
condition, ambient conditions and the type of gauge
used can give a wide variation of results for a given
engine.
It is not possible to give accurate data for
compression pressure, but tests have shown that the
results should be within 2000/3500 kPa (300/500 lbf/
in2) 21,0/35,0 kgf/cm2 for diesel engines.
Compression tests should only be used to compare
between the cylinders of an engine. If one or more
cylinders vary by more than 350 kPa (50 lbf/in2) 3,5
kgf/cm2, then those cylinders may be faulty.
Compression tests should not be the only method
used to show the condition of an engine, but they
should be used together with other symptoms and
tests.
How to do a compression test
Caution: Before the compression test, ensure that
the battery is in good condition and that it is fully
charged. Also ensure that the starter motor is in good
condition.
1 Ensure that the valve tip clearances are set
correctly.
2 Remove the atomisers.
3 Fit a suitable gauge into the atomiser hole of the
cylinder to be tested.
Caution: Ensure that the engine cannot start:
4 Disconnect the stop solenoid or put the stop control
in the no-fuel position.
5 Operate the starter motor and note the pressure
indicated on the gauge.
6 Repeat for each cylinder.

This page is intentionally blank
30
New 1000 Series
12
Cylinder head assembly 12
General description
In a diesel engine there is little carbon deposit and for
this reason the number of hours run is no indication of
when to overhaul a cylinder head assembly. The
factors which indicate when an overhaul is necessary
are how easily the engine starts and its general
performance.
The cylinder head assembly has two valves fitted for
each cylinder, each fitted with single valve springs.
The ports for the inlet and exhaust are on the right
side of the cylinder head.
The face angle of the valves is either 45° or 30°. The
angle of the valve seats in the cylinder head is either
46° or 31°.
The valves move in phosphated steel guides which
can be renewed. The exhaust valve guide has a
counterbore to prevent seizure of the valve stem
caused by a build up of carbon under the head of the
valve.
Both valve stems are fitted with oil seals that fit over
the top of the valve guides.
The engines have steel valve seat inserts fitted in the
cylinder head for both inlet and exhaust valves.

12 New 1000 Series
Rocker cover
1
To remove and to fit 12-1
Engines are supplied with rocker covers (A) made of

a plastic material or aluminum.
To remove
1 Disconnect the breather pipe.
2 Remove the cap nuts and rubber seal (A1) from the
top of the rocker cover and remove the heat shield, if
one is fitted. A A0045
3 Lift off the rocker cover and the joint.
Caution: When the rocker cover is fitted, the cap
nuts are tightened onto the nuts of the rocker
brackets. During removal of the cap nuts, it is possible 1
to loosen the nuts of the rocker brackets. The nuts of
the rocker brackets should be tightened to the correct 5 2
torque every time the cover is removed.
To fit
3
4
1 Check the seal of the oil filler cap (B1) and the
sealing washers (B3) for the cap nuts (B2).
Warning! The rocker cover joint may be made from
viton, read the safety precautions in section 10 for
viton seals. B A0046
2 Check the condition of the rocker cover joint (B4).

If necessary, the joint can be removed and renewed.
3 Clean the joint face of the cylinder head and fit the
rocker cover.
4 Fit the sealing washers, the heat shield, if one is
fitted, and the cap nuts.
Caution: Damage to the sealing washer can occur if
the cap nut is not tightened centrally through the
sealing washer and the rocker cover. If the sealing
washer is damaged, it must be renewed.
5 Tighten the rocker cover cap nuts to:
20 Nm (15 lbf ft) 2,1 kgf m for plastic covers.
30 Nm (22 lbf ft) 3,0 kgf m for aluminium covers.
6 Fit the breather pipe.

New 1000 Series 12
Rocker assembly
To remove
1 Remove the rocker cover, see operation 12-1.
2 Release evenly and gradually the fasteners of the
rocker shaft brackets; begin with the end brackets and
move toward the centre. Remove the fasteners and
lift off the rocker assembly.
3 Remove the rubber oil seal (A) from the oil supply
connection or from the oil supply hole in the cylinder
A A0047
head.
To fit
1 Fit a new rubber oil seal in the oil supply hole in the
cylinder head.
2 Check that the push rods fit correctly in the sockets
of the tappets. Fit the rocker assembly; ensure that
the oil supply connection is fitted correctly into the oil
seal. Check that the ends of the adjustment screws fit
correctly in the sockets of the push rods.
3 Fit the fasteners of the rocker shaft brackets and
tighten the fasteners evenly and gradually; begin with
the inner fasteners and work towards the end
fasteners. Tighten the fasteners evenly to the correct
torque according to the material of the rocker shaft
brackets:
Aluminium 40 Nm (30 lbf ft ) 4,1 kgf m.
Cast iron 75 Nm (55 lbf ft) 7,6 kgf m.
Sintered steel 75 Nm (55 lbf ft) 7,6 kgf m.
4 Check and adjust the valve tip clearances, see
operation 12-5.

12 New 1000 Series
To dismantle and to assemble 12-3 3 Ream the bush in the rocker lever to give a
clearance on the rocker shaft of 0,03/0,09 mm (0.001/
To dismantle 0.004 in). Clean thoroughly the bush and check that
the oil hole is free from debris.
1 Remove the clips from both ends of the rocker
shaft. Ensure that the ends of the rocker shaft are not
damaged. Release the location screw (A1) for the oil
supply connection.
2 Dismantle the assembly and make a note of the
position of each component to ensure that they can
be assembled more easily.
To assemble
1 Ensure that the oil holes in the rocker shaft and in
the rocker levers are not restricted.
2 Lubricate the components with clean engine
lubricating oil before assembly. Assemble the
components in the correct order (A) with the arrows
(A2) on the pedestals in the position shown. Ensure
that the location screw (A1) for the oil supply
connection is fitted correctly in the rocker shaft. Fit the
clips to the ends of the rocker shaft.
To inspect and to correct 12-4
To inspect
1 Clean and inspect all the components for wear and
any other damage. Check the clearance of the rocker
levers on the rocker shaft. If the clearance is larger
than 0,13 mm (0.005 in), renew the rocker lever bush
and/or the rocker shaft.
To correct
1 To renew the rocker lever bush, press out the old
bush with a suitable mandrel.
2 Align the lubrication hole of the new bush on the
same side as the rocker lever lubrication hole and
press the bush into position.
A A0048A

New 1000 Series 12
Valve tip clearances
To check and to adjust 12-5
Notes:
! The valve tip clearance is measured between the
top of the valve stem and the rocker lever (A). With
the engine hot or cold, the correct clearances are
0,20 mm (0.008 in) for the inlet valves and 0,45
mm (0.018 in) for the exhaust valves. The valve
positions are shown at (B).
! The sequence of valves from number 1 cylinder is
A A0049A
shown in the table below. Number 1 cylinder is at

the front of the engine.
Four cylinder engines
1 Rotate the crankshaft in the normal direction of
rotation until the inlet valve (B7) of number 4 cylinder
has just opened and the exhaust valve (B8) of the 1 2 3 4 5 6 7 8
same cylinder has not closed completely. Check the
clearances of the valves (B1 and B2) of number 1
cylinder and adjust them, if necessary.
2 Set the valves (B3 and B4) of number 2 cylinder as
indicated above for number 4 cylinder. Then check /
adjust the clearances of the valves (B5 and B6) of
number 3 cylinder. B A0050
3 Set the valves (B1 and B2) of number 1 cylinder.

Then check / adjust the clearances of the valves (B7
and B8) of number 4 cylinder.
4 Set the valves (B5 and B6) of number 3 cylinder.
Then check / adjust the clearances of the valves (B3
and B4) of number 2 cylinder.
Cylinder 1 2 3 4
and
Valve number 1 2 3 4 5 6 7 8
Valve
I = Inlet I E I E I E I E
E = Exhaust

12 New 1000 Series
Six cylinder engines
rotation until the inlet valve (A11) of number 6 cylinder
has just opened and the exhaust valve (A12) of the
same cylinder has not closed completely. Check the
clearances of the valves (A1 and A2) of number 1
cylinder and adjust them, if necessary. 1 2 3 4 5 6 7 8 9 10 11 12
2 Set the valves (A3 and A4) of number 2 cylinder as
indicated above for number 6 cylinder. Then check /
adjust the clearances of the valves (A9 and A10) of
number 5 cylinder.
3 Set the valves (A7 and A8) of number 4 cylinder.
Then check / adjust the clearances of the valves (A5 A A0028
and A6) of number 3 cylinder.
Then check / adjust the clearances of the valves (A11
Cylinder 1 2 3 4 5 6
and
Valve number 1 2 3 4 5 6 7 8 9 10 11 12
Valve
I = Inlet I E I E I E I E I E I E
E = Exhaust

New 1000 Series 12
Valve springs
To change the valve springs

(with cylinder head fitted) 12-6
1
3
Special tools
Valve spring compressor, PD.6118B
Stud adaptor used with PD.6118B, PD.6118-7
2
Setscrew adaptor used with PD.6118B, PD.6118-8
A A0051
Note: Paragraphs 1 to 12 refer to a change of valve
springs for a single cylinder.
Warning! Wear eye protection during this operation.
rotation until the inlet valve of the relevant cylinder
has just opened and the exhaust valve has not fully
closed. In this position the piston will be at
approximately top dead centre (TDC).
3 Remove the rocker assembly, see operation 12-2.
4 Fit the valve spring compressor (A1) and the
relevant adaptor (A2 or A3).
5 Compress the valve spring and remove the collets.
Ensure that the valve spring is compressed squarely
or damage to the valve stem can occur.
Caution: Do not rotate the crankshaft while the valve
springs are removed.
6 Release the valve spring compressor and remove
the valve spring caps and valve spring.
Caution: The outer diameter of the exhaust valve
guide is 1 mm larger than the inlet valve guide. To
prevent leakage past the inlet valve stem it is
important that the larger exhaust valve seal is not
fitted onto the inlet guide. The seals have a colour
code for identification.
7 Fit new valve stem seals on the valve guides.
ensure that the brown seal is fitted to the exhaust
valve and green seal is fitted to the inlet valves.
8 Put the new valve springs in position.
Continued

12 New 1000 Series
9 Fit the valve spring caps.
Caution: Ensure that the valve spring is compressed
squarely or damage can occur to the valve stem.
10 Fit the valve spring compressor, compress the
valve spring and fit the collets. Remove the valve
spring compressor.
11 Fit the rocker assembly, see operation 12-2.
12 Check the valve tip clearances, see operation 12-
5.
13 Fit the rocker cover, see operation 12-1.
Note: If other or all of the valve springs are to be
changed, they can be changed two cylinders at a
time. The sets of cylinders are:
For 4 cylinder engines: 1 and 4, 2 and 3
For 6 cylinder engines: 1 and 6, 2 and 5, 3 and 4
If the rocker assembly has been removed, piston TDC
can be found as follows:
1 Fit the valve spring compressor and compress the
valve springs to open the valve.
2 Rotate the crankshaft, by hand, in the normal
direction of rotation until the piston touches the valve.
3 Continue to rotate the crankshaft, and at the same
time, release pressure on the valve spring
compressor until the piston is at TDC (A).
A A 0 05 2

New 1000 Series 12
3
(Engine types AJ to AS and YG to YK) 1 2
To remove
1 Drain the cooling system.
2 Disconnect the battery terminals.
3 Remove the air filter/cleaner hose at the induction
manifold.
4 For engines fitted with turbochargers: Remove the A A0403
air filter/cleaner hose at the compressor inlet of the

turbocharger.
5 Remove the pipe which is fitted between the fuelled
starting aid in the induction manifold and the fuel filter.
Disconnect the electrical connection.
6 For engines fitted with a boost control device:
17 8 5 2 11 14
Remove the boost control pipe which is fitted between
the induction manifold and the top of the fuel injection
pump. 18 16 9 7 6 4 1 3 10 12 13 15
7 Remove the induction manifold.

For induction manifolds fitted to engine types AR and
AS: The top half of the induction manifold (A1) is
sealed to the bottom half (A2) with a liquid joint and
fastened together by six cap screws. 8 5 2 11
The top half of the manifold must be removed to 4 3 12
obtain access to four of the manifold fasteners (A3), 9 7 6 1 1
10
fitted inside the manifold. These fasteners retain the
bottom half of the manifold to the cylinder head.
8 For engines fitted with turbochargers: Disconnect
all connections to the turbocharger and remove the
turbocharger, see operation 18-1.
17 8 5 2 11 14
9 Release the exhaust manifold fasteners in the
reverse sequence to that shown in (B). The front of 18 4 1 15
the engine is shown at (B1). 16 9 7 6 3 10 12 13
10 Remove the low-pressure fuel pipes which are
fitted between the fuel injection pump and the fuel
filter. B A1444
Note: Where a Bosch fuel injection pump is fitted,

keep the fuel outlet banjo bolt with the fuel injection Continued
pump.
Remove the fuel pipe fitted between the fuel lift pump
and the fuel filter. Remove the fuel filter bracket
together with the fuel filter.
Caution: Where access to the fuel injection pump
outlet unions is possible, ensure that a separate
spanner is used to prevent movement of the fuel
injection pump outlets when the connections of the
high-pressure pipes are released. Fit suitable covers
to all open connections on the fuel injection pump.
11 Remove the high-pressure fuel pipes.

12 New 1000 Series
12 Remove the atomiser leak-off pipe.
13 Remove the atomisers, see operation 20-3. Fit
suitable covers to the nozzles and the open
connections.
14 If a compressor is fitted: Remove the coolant pipe M 18 M 8 M 2 M 13
19 14
which is fitted between the cylinder head and the L M 9 M 1 M 3 L
compressor. Then remove the coolant pipe which is

fitted between the by-pass connection and the
compressor. M 20 M 10 M 7 M 4 15 M
21
15 Release the clip of the coolant by-pass hose at the S S S S S S S S
22 11 12 6 5 17 16
cylinder head. Release the setscrews and remove the
coolant by-pass connection and the hose.
16 Disconnect the coolant temperature sender unit. B A0053
17 Four cylinder engines: Remove the oil cooler if it
is integral with the cylinder block, see operation 21-
11.
2 1
19 Remove the rocker assembly, see operation 12-2.
20 Remove the push rods.
21 Release the cylinder head setscrews evenly and
gradually in the reverse sequence to that shown in (A
or B). Check the setscrews for distortion with a
straight edge (C1) held along the setscrew (C2). If
there is a visual reduction in the diameter of the
thread (C3) that has not been in engagement with the 3
cylinder block, the setscrew must be discarded.
C A0054
Caution: Do not use a lever to separate the cylinder
head from the cylinder block.
22 Remove the cylinder head and put it on a surface
that will not damage the face of the cylinder head.
M 28 M 18 M 8 M 2 M 13 M 23
L 29 M 19 M 9 M 1 M 3 M 14 24 L
M 30 M 20 M 10 M 7 M 4 M 15 25 M
S 31 S 32 S 21 S 22 S 11 S 12 S 6 S 5 S 17 S 16 S 27 S 26
A A0055

New 1000 Series 12
To fit
(Engine types AJ to AQ and YG to YK) 1
2
See page 45 for AR and AS engine types
Special tools: 3
Angle gauge, to tighten cylinder head setscrews,

MS.1531
1 Clean the bottom face of the cylinder head and the

top face of the cylinder block. Ensure that there is no
debris in the cylinder bores. A A0404
Note: The engines have two location pins (A3), one
at each end of the cylinder head, pressed into the
cylinder block to hold the cylinder head and cylinder
head gasket in the correct position when the cylinder
head is fitted.
Cautions:
! To prevent damage to the cylinder head gasket, 1
ensure that the location pins are pressed in the
cylinder block before the cylinder head is fitted.
! The cylinder head gasket must be fitted without
jointing compound.
2 Put the cylinder head gasket in position; It is
stamped "FRONT TOP" (A2) for correct assembly. B A0057
3 To ensure the cylinder head is fitted into the correct

position, fit two suitable 1/2 UNF guide studs (A1) or
(B1) in positions 16 and 21 (page 40/B) or positions
25 and 30 (page 40/A). Put the cylinder head in
position. Ensure that the two location pins are fully
engaged in the cylinder head.
4 Lightly lubricate the threads of the cylinder head
setscrews and the thrust faces of the setscrew heads.
Engage some of the setscrews in their correct
positions and remove the guide studs. Engage the
remainder of the setscrews in their correct positions.
5 Gradually and evenly tighten the setscrews to 110
Nm (80 lbf ft) 11,1 kgf m in the sequence shown in
(page 40/A or B).
6 Repeat paragraph 5 to ensure that all the setscrews
are tightened to the correct torque.
Continued

12 New 1000 Series
7 Tighten the setscrews, in the correct sequence, a
further part of a turn according to the length of the
setscrews (page 40/A or B). Short setscrews (S) must
be turned a further 150° (2.5 flats). Medium length
1
setscrews (M) must be turned a further 180° (3 flats).
Long setscrews (L) must be turned a further 210° (3.5
flats). A special tool (A) can be used for this operation.
Fit the tool between the socket and the handle.
Position the stop (A1) against a suitable protrusion on
the cylinder head to prevent movement of the degree
dial in a clockwise direction. Rotate the pointer to
align with the relevant angle on the degree dial for the
length of setscrew. Tighten the setscrew until the
pointer on the tool is aligned with the zero position on A A0058
the degree dial.
If no tool is available, make a suitable mark on the
cylinder head in line with a corner of each setscrew
S M L
(B). Make another mark, at the correct angle (counter-
clockwise), on the edge of the flange of each fastener 150° 180° 210°
according to the length of the setscrew. Tighten each
setscrew in the correct sequence until the marks on
the flange are next to, and in line with, the marks on
the cylinder head.
8 Put the push rods in position. Ensure that the end
of each push rod fits correctly in the tappet socket.
10 Set the valve tip clearances, see operation 12-5. B A0059
11 Fit the atomisers, see operation 20-3.

12 Fit the high-pressure fuel pipes; tighten the
connection nuts to 22 Nm (16 lbf ft) 2,2 kgf m.
high pressure pipes are tightened.
13 Fit the fuel filter and the bracket. Fit the low-
pressure fuel pipes between the fuel injection pump
and the fuel filter.
14 Fit the coolant by-pass connection; tighten the
setscrews and hose clip.
15 If a compressor is fitted: Fit the coolant pipe
between the cylinder head and the compressor. Then
fit the pipe between the coolant by-pass and
compressor.
16 Four cylinder engines: Fit the oil cooler if it is
integral with the cylinder block, see operation 21-11.
Continued

12 New 1000 Series
20 For engines fitted with turbochargers: Fit the
turbocharger, see operation 18-1.
21 Fit the fuel pipe between the fuel filter and the fuel
lift pump.
22 Fit the fuel pipe between the fuel filter and the
fuelled starting aid in the induction manifold. Connect
the electrical connection to the cold start device.
23 For engines fitted with a boost control device: Fit
the boost control pipe between the induction manifold
and the top of the fuel injection pump.
24 Fit the electrical connection to the coolant
temperature sender unit.
25 Connect the coolant outlet and the hoses for the
cab heater. Tighten the clips.
26 Fill the cooling system.
27 Connect the air filter/cleaner.
28 Connect the battery.
29 Eliminate air from the fuel system, , see operation
20-9.
30 Start the engine and run it at low speed. Check
that oil flows from the holes in the rocker levers. If the
oil flow is correct, fit the rocker cover, see operation
12-1.
Note: It is not necessary to tighten the cylinder head
setscrews again with the engine hot or after a limited
period in service.

New 1000 Series 12
To fit
(Engine types AR and AS) 1
2
See page 41 for AJ to AQ and YG to YK engine types
Special tools: 3
Angle gauge, to tighten cylinder head setscrews,

MS.1531
1 Clean the bottom face of the cylinder head and the

top face of the cylinder block. Ensure that there is no
debris in the cylinder bores. A A0404
Note: The engines have two location pins (A3), one
at each end of the cylinder head, pressed into the
cylinder block to hold the cylinder head and cylinder
head gasket in the correct position when the cylinder
head is fitted.
M 18 M 8 M 2 M 13
19 14
L M 9 M 3 L
Cautions: M 1
! To prevent damage to the cylinder head gasket,

ensure that the location pins are pressed in the
M 20 M 10 M 7 M 4 15 M
cylinder block before the cylinder head is fitted. 21
S S S S S S S S
! The cylinder head gasket must be fitted without 22 11 12 6 5 17 16
jointing compound.
2 Put the cylinder head gasket in position; it is
stamped "FRONT TOP" (A2) for correct assembly. B A0053
3 To ensure the cylinder head is fitted into the correct

position, fit two suitable M10 guide studs (A1) in
positions 16 and 21 (B). Put the cylinder head in
position. Ensure that the two location pins are fully
engaged in the cylinder head.
4 Lightly lubricate the threads of the cylinder head
setscrews and the thrust faces of the setscrew heads.
Engage some of the setscrews in their correct
positions and remove the guide studs. Engage the
remainder of the setscrews in their correct positions.
The four 1/2 UNF setscrews are fitted in positions 2,
8, 13 and 18, refer to (B).
5 Gradually and evenly tighten all of the setscrews to
45 Nm (33 lbf ft) 4,5 kgf m in the sequence shown in
(B).
6 Repeat paragraph 5 to ensure that all the setscrews
7 Gradually and evenly tighten the four 1/2 UNF
setscrews, to 110 Nm (80 lbf ft) 11,1 kgf m in the
sequence 2, 8, 13 and 18, shown in (B).
8 Repeat paragraph 7 to ensure that these setscrews
Continued

12 New 1000 Series
9 Tighten the M10 setscrews, in the correct
sequence, a further part of a turn according to the
length of the setscrews, see (A) and (C). Short
setscrews (S) must be turned a further 120° (2 flats).
Medium length setscrews (M) must be turned a M 18 M 8 M 2 M 13
further 120° (2 flats). Long setscrews (L) must be 19 14
L M 9 M 1 M 3 L
turned a further 150° (2.5 flats). The four 1/2 UNF
setscrews in positions 2, 8, 13 and 18 must be turned
180° (3 flats).
M 20 M 10 M 7 M 4 15 M
A special tool (B) can be used to tighten all of the S
21
S S S S S S S
setscrews, instead of the method described in 22 11 12 6 5 17 16
paragraph 9. Fit the tool between the socket and the
handle. Position the stop (B1) against a suitable
protrusion on the cylinder head to prevent movement A A0053
of the degree dial in a clockwise direction. Rotate the
pointer to align with the relevant angle on the degree
dial for the length of setscrew. Tighten the setscrew
until the pointer on the tool is aligned with the zero
position on the degree dial. 1
If no tool is available, make a suitable mark on the

cylinder head in line with a corner of each setscrew
(C). Make another mark, at the correct angle (counter-
clockwise), on the edge of the flange of each fastener
according to the length of the setscrew. Tighten each
setscrew in the correct sequence until the marks on
the flange are next to, and in line with, the marks on
the cylinder head.
B A0058
10 Put the push rods in position. Ensure that the end
of each push rod fits correctly in the tappet socket.
12 Set the valve tip clearances, see operation 12-5. S 1/2 UNF S and M
13 Fit the atomisers, see operation 20-3. 150° 180° 210°
14 Fit the high-pressure fuel pipes; tighten the
connection nuts to 22 Nm (16 lbf ft) 2,2 kgf m.
high pressure pipes are tightened.
15 Fit the fuel filter and the bracket. Fit the low- C A0059
pressure fuel pipes between the fuel injection pump
and the fuel filter.
16 Fit the coolant by-pass connection; tighten the
setscrews and hose clip.
17 If a compressor is fitted: Fit the coolant pipe
between the cylinder head and the compressor. Then
fit the pipe between the coolant by-pass and
compressor.
18 Fit the oil cooler if it is integral with the cylinder
block, see operation 21-11.
Continued

12 New 1000 Series
22 The top half of the induction manifold (A1) is
sealed to the bottom half (A2) with a liquid joint and 3
fastened together by six cap screws. 1 2
The top half of the manifold must be removed to
obtain access to four of the manifold fasteners (A3)
inside the manifold. These fasteners and the four
fasteners (A4) on the outside of the manifold retain
the bottom half of the manifold to the cylinder head.
4
Note: The fasteners (A3) and (A4) which retain the
manifold to the cylinder head have M.E.A.S applied to
the threads. If the fasteners are removed and fitted
again, the threads must be cleaned and
POWERPART threadlock sealant used. 5
A A0403A
Cautions:
! Before the inlet manifold fasteners are fitted again,
any loose M.E.A.S in the cylinder head holes must
be removed to allow the manifold to be fully
tightened.
! Do not scratch or damage the flange faces of the
inlet manifold.
A paper joint (A5) is used in service instead of a liquid
joint. The liquid joint must be removed and the flange
faces thoroughly cleaned with a suitable nylon
scraper or solvent before the paper joint is fitted, the
paper joint is fitted dry.
23 Fit the fuel pipe between the fuel filter and the fuel
lift pump.
24 Fit the fuel pipe between the fuel filter and the
fuelled starting aid in the induction manifold. Connect
the electrical connection to the cold start device.
25 Fit the electrical connection to the coolant
temperature sender unit.
26 Connect the coolant outlet and the hoses for the
cab heater. Tighten the clips.
28 Connect the air filter/cleaner.
30 Eliminate air from the fuel system, see operation
20-9.
31 Start the engine and run it at low speed. Check
that oil flows from the holes in the rocker levers. If the
oil flow is correct, fit the rocker cover, see operation
12-1.
Note: It is not necessary to tighten the cylinder head
setscrews again with the engine hot or after a limited
period in service.

New 1000 Series 12
Valves and valve springs
1
2
Special tools:
3
Stud adaptor, PD.6118-7
Setscrew adaptor, PD.6118-8
4
To remove
1 Remove the cylinder head, see operation 12-7.
2 Clean the bottom face of the cylinder head and
check the depth of the heads of the valves below the
face of the cylinder head, see operation 12-9.
3 Make a suitable mark on the heads of the valves to
ensure that the valves can be fitted in their original
positions, if they are to be used again. 5
Caution: Ensure that the valve springs are
compressed squarely or the valve stem can be
damaged.
4 Use the valve spring compressor and the relevant
adaptor to compress the valve spring (A3) and A C039
remove the collets (A2).
Caution: Ensure that the valve spring is compressed
5 Release the valve spring compressor and remove squarely or damage can occur to the valve stem.
the valve spring cap (A1), valve spring and valve stem
seal (A4). 4 Use the valve spring compressor and the relevant
adaptor to compress the valve spring and fit the
6 Repeat items 4 and 5 for the other valves.
collets.
To fit
Note: The components of the valve assembly are
shown in A.
1 Lubricate the valve stem (A5) with clean engine oil
and fit the valves in their respective guides.
Caution: The outer diameter of the exhaust valve
guide is 1 mm larger than the inlet valve guide. To
prevent leakage past the inlet valve stem it is
important that the larger exhaust valve seal is not
fitted onto the inlet guide. The seals in the service kit
have different colours for identification.
2 Fit new valve stem seals on the valve guides.
ensure that the brown seal is fitted to the exhaust
valve and green seal is fitted to the inlet valves.
3 Put the valve springs in position, they can be fitted
with either end to the cylinder head. Fit the valve
spring cap.

12 New 1000 Series
Special tools:
Gauge, valve depth, PD.41D
Dial gauge for use with PD.41D, PD.208
1 Check the depth of the valves below the face of the

cylinder head before the valve springs are removed.
2 Ensure that the heads of the valves and the bottom
face of the cylinder head are clean.
3 Put the valve depth gauge on the face of the
cylinder head and zero the dial gauge. A A0063
4 Carefully put the valve depth gauge in position over

the head of each valve (A) and make a note of the
measurement. The maximum depth, in service, is
given in the data and dimensions.
5 If a valve is below the depth limit, check the valve
depth with a new valve in position. If the valve depth
is still below the limit and a valve seat insert is fitted,
the insert must be renewed.
6 Check the valves for cracks. Check the stems of the
valves for wear and for correct fit in their valve guides.
Caution: Renew damaged valves, the special heat
resistant layer on the face of the valve will be detroyed
if valves are lapped.
7 Check that the seat faces of the valves are not
badly burnt or damaged. Seat faces of valves which
are damaged can be ground on a special machine.
When new valves are fitted, the valve depths must be
checked after the valve springs are fitted.
8 Check that the load on the valve springs is correct
at their fitted length, see the data and dimensions. Fit
new valve springs at every complete engine overhaul.

New 1000 Series 12
Valve guides
4
To inspect 12-10 1 2
5
To check the valve guides for wear: The maximum
permissible clearance (A5) with a valve lift of 15,0 mm
(0.6 in), between the valve stem and the bore of the
guide is 0,100 mm (0.008 in) for inlet valves and 0,121
mm (0.011 in) for exhaust valves. If the clearance,
with a new valve fitted, is more than the limit, then a
new valve guide (A4) must be fitted.
3
It is recommended that the procedure given below is A A0298
used to check the valve guide clearance:
1 Put a new valve in the valve guide.
2 Put a dial test indicator with a magnetic base (A1)
onto the face of the cylinder head.
3 With the valve lifted 15,0 mm (0.6 in) and the gauge
(A2) in contact with the edge of the valve head (A3),
move the valve radially away from the gauge. With the
valve held in this position, set the gauge to zero.
4 Move the valve radially across the axis of the
cylinder head towards the gauge. Make a note of the
reading on the gauge. If the reading is equal to or
greater than the data given below, a new valve guide
(A4) must be fitted.
Note: The partially finished valve guides are reamed
and the valve seats are cut in one operation with a
special tool. The valve seat and the guide are cut in
one operation to ensure the concentricity of the valve
seat to the valve guide. This will ensure a good seal
between the guide and its seat. New valves and new
valve seat inserts must be fitted each time a new
valve guide is fitted. Valves must not be lapped, see
operation 12-13. If all or most of the original valve
guides need to be renewed it may be cost effective to
overhaul or exchange the cylinder head.

12 New 1000 Series
1
Special tools:
Remover/replacer for valve guides (main tool), PD.1D
Adaptor PD.1D-13 used with PD.1D, PD.1C-6 and
PD.248
2
Distance piece, inlet guide, PD.1C-6 used with PD.1D
and PD.1D-13
Distance piece, exhaust guide, PD.248 used with
PD.1D and PD.1D-13 3
The partially finished valve guides are reamed and

the valve seats are cut in one operation with a special
tool. The valve seat and the guide are cut in one
4
operation to ensure the concentricity of the valve seat
to the valve guide. This will ensure a good seal
between the guide and its seat. New valves and new 5
valve seat inserts must be fitted each time a new
valve guide is fitted. Valves must not be lapped, see 6
operation 12-13. If all or most of the original valve
guides need to be renewed it may be cost effective to
To remove 7
1 Fit the adaptor (A4) into the remover/replacer tool
(A3). A A0064
2 With the adaptor fitted to the tool, put the spacer

(A5) in position on the tool. Pass the adaptor through
the valve guide (A6) and put the spacer and tool in
position on the valve seat.
3 Fit the attachment (A7) to secure the adaptor to the
valve guide.
4 Hold the top handle (A1) and turn the bottom
handle (A2) clockwise to pull the valve guide out of
the cylinder head.

New 1000 Series 12
To fit
1 Clean the parent bore in the cylinder head for the 1
valve guide.
2
2 Lubricate the outer surface of the new valve guide
(A6) with clean engine lubricating oil.
3 Fit the adaptor (A5) into the remover/replacer tool
(A3).
4 With the adaptor fitted to the tool, put the spacer
(A4) in position on the tool. Pass the adaptor through
3 9
the cylinder head and put the spacer and tool
assembly in position on the valve seat.
5 Put the valve guide in position on the adaptor and
fit the distance piece (A7), PD.1C-6 for inlet valve
guides and PD.248 for exhaust valve guides. Fit the
attachment (A8) to secure the valve guide to the 4
adaptor.
Note: The internal recess in the valve guide must be
towards the tool.
6 Hold the top handle (A1) and turn the bottom 5
handle (A2) clockwise to pull the valve guide until the
distance piece contacts the cylinder head.
7 When the valve guide is fitted correctly, the top of 6
the valve guide will have a protrusion (A9) of 14,85/
7
15,15 mm (0.585/0.596 in) above the valve spring
seat. 8
8 Ream the valve guide to the finished size, see A A0065/1
operation 12-13.

12 New 1000 Series
Cylinder head
1 Remove the cylinder head assembly, see operation

12-7.
2 Remove the thermostat housing.
3 Inspect the cylinder head for signs of gas or coolant
leakage.
4 Remove the valve springs and the valves, see
operation 12-8.
5 Clean the face of the cylinder head and the
passages for coolant and for lubricating oil. The water
jacket can be cleaned with a special solvent which
must be used in accordance with the manufacturer's
instructions.
6 Test the cylinder head for leaks at the pressure
given in the data and dimensions.
7 When the cylinder head is thoroughly clean, check
it for cracks. Inspect carefully the areas around the
valve seats and around the holes for the atomiser
nozzles.
8 The bottom face of the cylinder head can be
machined if there is distortion, see paragraph 9; there
are deep scratches; or, for engines without valve seat
inserts, the valve depths are below the service limit.
9 Use a straight edge and feeler gauges to check the
cylinder head for distortion across and along its
bottom face, see the data and dimensions. If the
distortion is more than the limit given in the data and
dimensions, the bottom face can be machined, see
the data and dimensions for the surface grade finish
of the cylinder head face.
Caution: Remove only the minimum material and
ensure that the thickness of the cylinder head will not
be less than 102,48 mm (4.035 in) after the cylinder
head has been machined.
Caution: After the cylinder head has been machined
the valve seats must be corrected to give the correct
valve head depth. Work to the minimum limit to allow
for later wear.
10 Check the valve seats for wear and for damage.
11 Before any work is done on the valve seats, new
valve guides must be fitted, see operation 12-11.
12 More badly damaged valve seats can be
corrected by use of the cutter tool, see operation 12-
13, or new inserts can be fitted, see operation 12-14.

New 1000 Series 12
To correct a valve seat
with a valve seat cutter 12-13
Special tools:
Cutter (31° or 46°) for inlet and exhaust valve seats
and valve guides reamer PD.242.
Caution: Valves must not be lapped.

The valve seats are cut and the valve guides are
reamed in one operation with a special tool (A). The
valve seat and the guide are cut in one operation to
ensure the concentricity of the valve seat to the valve
guide. This will ensure a good seal between the guide
1
and its seat. New valves and new guides must be
fitted each time a new seat insert is fitted. Valves must
not be lapped.
1 Before any work is done on the valve seats, new
valve guides must be fitted, see operation 12-11.
2
Cautions:
! Ensure that the correct cutter is fitted, 31° or 46°
valve seats may be fitted.
3
! Ensure that the valve seat cutter is not allowed to
fall on to the seat as this can damage the blades.
2 Select the relevant valve seat cutter, 31° or 46°,
4
(A2) and the valve guide reamer (A3). Set the blades A C040
of the cutters to the diameter of the valve seat to be
cut. Fit the cutter onto the reamer and push the
handle fully onto the reamer. Ensure that the flat part
of the reamer shank is towards the grub screw (A1)
and tighten the grub screw to secure the reamer to the
handle. The blades of the reamer must not cut the
valve guide when the seat is cut.
3 Fit the reamer/cutter assembly into the valve guide.
Ensure that the valve seat cutter is not allowed to fall
on to the seat as this can damage the blades.
Carefully turn the handle in a clockwise direction (A4)
and gradually move the reamer into the valve guide
until the valve guide is reamed to the finished size. A
lubricant is not necessary.
4 Continue to turn the handle in a clockwise direction
to cut the valve seat. Remove only the minimum
material to ensure a good valve seat. Keep the seat
as narrow as possible.
5 When the seat is cut, remove the reamer/cutter
assembly. Remove any debris from the area of the
valve guide, valve seat and the port.
6 Fit the valve.
7 Check that the valve depth is within limits, see data
and dimensions.
Note: If a valve seat has become too damaged or too
worn to correct, a valve seat insert can be fitted, see
operation 12-14. If all or most of the original valve seat
inserts need to be renewed, it may be cost effective to
12 New 1000 Series
To fit valve seat inserts 12-14
1 Remove the valve guide and clean the bore into

which the guide is to be fitted.
2 Fit new partially finished valve guides, see
operation 12-11.
3 With the bore of the new partially finished valve
guide used as a pilot, machine the recess in the
cylinder head to the dimensions shown in data and
dimensions at the end of this section, or machine out
the old insert. Remove all debris and clean the insert
recess.
4 If the bottom face of the cylinder head has been
machined, the insert will have to be surface ground on
the back face to ensure that there is no protrusion of
the insert above the bottom face of the cylinder head.
After the back of the insert has been ground, ensure
that the outer edge of the back face has a 0,9/1,3 mm
(0.035/0.051 in) chamfer at 30° to the vertical.
5 With the bore of the new, partially finished, valve
guide used as a pilot, and with the rear face of the
insert towards the cylinder head, press in the insert
with the valve seat insert tool, see data and
dimensions. Do not use a hammer on the insert and
do not use lubrication. Use a hydraulic press or a
hand press in one continuous movement. Ensure that
the bottom of the insert is in contact with the bottom of
the recess.
6 Ream the valve guide and cut the valve seat at an
included angle of 88° for 46° valve seats or 118° for
31° valve seats, see operation 12-13. Ensure that the
depth of the valve head below the face of the cylinder
head is within the production limits, see data and
dimensions. Work as near as possible to the minimum
figure to allow for future wear on the valve seat.

New 1000 Series 12
Data and dimensions
Note: This information is given as a guide for personnel engaged on engine overhauls. The dimensions which
are shown are those which are mainly used in the factory. The information applies to all engines, unless an
engine type code is shown.
Cylinder head
Angle of valve seat:
- Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46° (88° included angle) or 31° (118° included angle)
- Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46° (88° included angle) or 31° (118° included angle)
Leak test pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 kPa (29 lbf/in2) 2,04 kgf/cm2
Head thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102,79/103,59 mm (4.047/4.078 in)
Finish grade of head face for cylinder head gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,10/3,20 micrometers
Diameter of parent bore for valve guide:
- Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,00/13,027 mm (0.5118/0.5128 in)
- Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14,00/14,027 mm (0.5512/0.5522 in)
Minimum permissible thickness after head face has been machined . . . . . . . . . . . . . . . 102,48 mm (4.035 in)
Inlet valves
Diameter of valve stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,953/8,975 mm (0.3525/0.3533 in)
Clearance in valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025/0,069 mm (0.001/0.0027 in)
Maximum permissible clearance in valve guide:
- Production limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,089 mm (0.0035 in)
- Service limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,100 mm (0.008 in)
Diameter of valve head:
- Engine types AJ, AK, AM, AP, AQ, YG, YH, YK . . . . . . . . . . . . . . . . . . . . . 42,88/43,12 mm (1.688/1.698 in)
- Engine types AR and AS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,88/45,12 mm (1.776/1.767 in)
Angle of valve face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° or 30°
Full length, engine types AJ, AK, AM, AP, AQ, YG, YH, YK . . . . . . . . . . . 122,65/123,30 mm (4.829/4.854 in)
Full length, engine types AR and AS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123,75/124,40 mm (4.872/4.897 in)
Seal arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rubber seal fitted to valve guide, colour green
Depth of valve head below the face of cylinder head
- Production limits, engine types AJ, AK, AM, AP, AQ, YG, YH, YK . . . . . . . . . 1,40/1,70 mm (0.055/0.067 in)
- Service limit, engine types AJ, AK, AM, AP, AQ, YG, YH, YK . . . . . . . . . . . . . . . . . . . . . 1,95 mm (0.077 in)
- Production limits, engine types AR and AS. . . . . . . . . . . . . . . . . . . . . . . . . . . 0,40/0,60 mm (0.016/0.024 in)
- Service limit, engine types AR and AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,805 mm (0.032 in)

12 New 1000 Series
Exhaust valves
Diameter of valve stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,938/8,960 mm (0.3519/0.3528 in)
Clearance in valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,040/0,84 mm (0.0016/0.0033 in)
Maximum permissible clearance in valve guide
- Production limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,104 mm (0.0041 in)
- Service limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,121 mm (0.011 in)
Diameter of valve head:
- Engine types, AJ, AK, AM, AP, AQ, YG, YH, YK. . . . . . . . . . . . . . . . . . . . . 40,88/41,12 mm (1.609/1.619 in)
- Engine types AR and AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41,88/42,12 mm (1.649/1.658 in)
Angle of valve face. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° or 30°
Full length, engine types, AJ, AK, AM, AP, AQ, YG, YH, YK. . . . . . . . . . . 122,65/123,30 mm (4.829/4.854 in)
Full length, engine types AR and AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123,75/124,40 mm (4.872/4.897 in)
Seal arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rubber seal fitted to valve guide, colour brown
Depth of valve head below face of cylinder head:
- Production limits, engine types, AJ, AK, AM, AP, AQ, YG, YH, YK. . . . . . . . . 1,50/1,80 mm (0.059/0.071 in)
- Service limit, engine types, AJ, AK, AM, AP, AQ, YG, YH, YK . . . . . . . . . . . . . . . . . . . . . 2,05 mm (0.081 in)
- Production limits, engine types AR and AS . . . . . . . . . . . . . . . . . . . . . . . . . . .0,40/0,60 mm (0.016/0 .024 in)
- Service limit, engine types AR and AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,805 mm (0.032 in)

New 1000 Series 12
Maximum permissible distortion of cylinder head
(A)
1 1 1 1 1 1 1
3
A1 . . . 0,08 mm (0.003 in)
2
A2 . . . 0,15 mm (0.006 in)
A3 . . . 0,15 mm (0.006 in)
3
2
A1 . . . 0,13 mm (0.005 in)
A2 . . . 0,25 mm (0.010 in)
A3 . . . 0,25 mm (0.010 in) A A0067
Dimensions of recesses for valve seat inserts,

engine types AJ to AQ and YG to YK (B)
Inlet 2
B1 . . . 10,585/10,715 mm (0.4167/0.4219 in)
1
B2 . . . 45,535/45,560 mm (1.7927/1.7937 in) 3
B3 . . . Radius 0,38 mm (0.015 in) maximum 3
Exhaust
B1 . . . 10,585/10,715 mm (0.4167/0.4219 in)
B2 . . . 43,535/43,560 mm (1.7139/1.7149 in)
B3 . . . Radius 0,38 mm (0.015 in) maximum
B PA068
Dimensions of recesses for valve seat inserts,
engine types AR and AS (B)
Inlet
B1 . . . 10,585/10,715 mm (0.4167/0.4219 in)
B2 . . . 48,035/48,060 mm (1.8911/1.8921 in)
Exhaust
B1 . . . 10,585/10,715 mm (0.4167/0.4219 in)
B2 . . . 44,035/44,060 mm (1.7336/1.7346 in)

12 New 1000 Series
Valve seat insert tool (A)
Inlet (for 45° valves and 30° valves), engine types 1 6
AJ to AQ and YG to YK 1 5
A1. . . . 1,5 mm (0.06 in)
2
A2. . . . 20 mm (0.800 in)
A3. . . . 7,0 mm (0.28 in) 7
4 3 8
A4. . . . 100 mm (4.00 in)
A5. . . . 37,25/37,45 mm (1.467/1.474 in)
9
A6. . . . 44,75/45,00 mm (1.772/1.762 in)
10
A7. . . . Radius 1,4 mm (0.055) maximum A 9 A0069
A8. . . . Radius 1,5 mm (0.06) Exhaust (45° valves ), engine types AR and AS
A9. . . . 1,5 mm (0.06 in) A1 . . . .1,5 mm (0.06 in)
A10. . . 8,54/8,57 mm (0.336/0.337 in) A2 . . . .20 mm (0.80 in)
Exhaust (for 45° valves and 30° valves), engine A3 . . . .7,0 mm (0.28 in) maximum
types AJ to AQ and YG to YK
A4 . . . .100 mm (4.00 in)
A1. . . . 1,5 mm (0.06 in)
A5 . . . .36,62/36,82 mm (1.441/1.449 in)
A2. . . . 20 mm (0.80 in)
A6 . . . .43,25/43,50 mm (1,702/1.712 in)
A3. . . . 7,0 mm (0.28 in) maximum
A7 . . . .Radius 1,4 mm (0.055 in) maximum
A4. . . . 100 mm (4.00 in)
A8 . . . .Radius 1,5 mm (0.06 in)
A5. . . . 34,38/34,58 mm (1.354/1.361 in)
A9 . . . .1,5 mm (0.06 in)
A6. . . . 42,75/43,00 mm (1,683/1.693 in)
A10 . . .8,54/8,57 mm (0.336/0.337 in
A7. . . . Radius 1,4 mm (0.055 in) maximum
A8. . . . Radius 1,5 mm (0.06 in)
A9. . . . 1,5 mm (0.06 in)
A10. . . 8,54/8,57 mm (0.336/0.337 in)
Inlet (45° valves), engine types AR and AS
A1. . . . 1,5 mm (0.06 in)
A2. . . . 20 mm (0.800 in)
A3. . . . 7,0 mm (0.28 in)
A4. . . . 100 mm (4.00 in)
A5. . . . 37,82/38,02 mm (1.488/1.496 in)
A6. . . . 47,25/47,50 mm (1.860/1.870 in)
A7. . . . Radius 1,4 mm (0.055) maximum
A8. . . . Radius 1,5 mm (0.06)
A9. . . . 1,5 mm (0.06 in)
A10. . . 8,54/8,57 mm (0.336/0.337)

New 1000 Series 12
Valve guides
Inside diameter of partially finished guide . . . . . . . . . . . . . . . . . . . . . . . . . 8,600/8,700 mm (0.3386/0.3425 in)
Inside diameter of finished guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,000/9,022 mm (0.3543/0.3552 in)
Outside diameter:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,034/13,047 mm (0.5131/0.5137 in)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14,034/14,047 mm (0.5525/0.5530 in)
Interference fit of valve guide in cylinder head . . . . . . . . . . . . . . . . . . . . . 0,047/0,007 mm (0.0003/0.0019 in)
Full length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51,25 mm (2.018 in)
Protrusion from bottom of recess for valve spring . . . . . . . . . . . . . . . . . . . . . 14,85/15,15 mm (0.585/0.596 in)
Valve springs
Fitted length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39,0 mm (1.54 in)
Load at fitted length:
- Engine types, AJ, AK, AM, AP, AQ, YG, YH, YK . . . . . . . . . . . . . . 246/277,5 N (55.3/62.4 lbf) 25,1/28,3 kgf
- Engine types AR and AS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136,3/153,7 N (30.6/34.5 lbf) 13,9/15,7 kgf
Number of active coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Number of damper coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Direction of coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left hand
Tappets
Diameter of tappet stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,99/19,01 mm (0.7475/0.7485 in)
Diameter of tappet bore in cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . 19,05/19,08 mm (0.7500/0.7512 in)
Clearance of tappet in cylinder block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,04/0,09 mm (0.0015/0.0037 in
Rocker shaft
Outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,01/19,04 mm (0.7485/0.7495 in)
Rocker levers and bushes
Diameter of parent bore for bush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22,23/22,26 mm (0.8750/0.8762 in)
Outside diameter of bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22,28/22,31 mm (0.8770/0.8785 in)
Interference fit of bush in rocker lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,020/0,089 mm (0.0008/0.0035 in)
Internal diameter of fitted bush when reamed . . . . . . . . . . . . . . . . . . . . . . 19,06/19,10 mm (0.7505/0.7520 in)
Clearance between rocker lever bush and rocker shaft . . . . . . . . . . . . . . . . . 0,03/0,09 mm (0.001/0.0035 in)
Maximum permissible clearance between
rocker lever bush and rocker shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,13 mm (0.005 in)

62
New 1000 Series
13
assemblies 13
General description
The pistons used in the New 1000 Series engines
have a "Fastram" combustion chamber in the top of
the piston (A). The piston (B) for engine types AR and
AS has two recesses in the top face for the valves.
The combustion chamber is designed to give an
efficient mix of fuel and air.
The pistons and connecting rods are matched to the
relevant cylinder.
The pistons have two compression rings and an oil
control ring. The groove for the top ring has a hard
metal insert to reduce wear of the groove. The piston
skirt has a layer of graphite to improve the wear A A0071
characteristics.
Axial location of the fully floating gudgeon pin is by
circlips. The gudgeon pin is off-centre to reduce the
noise level.
Piston cooling jets are fitted in the cylinder block to
spray lubricating oil onto the inner surface of the
pistons.
Note: Engine types AR and AS have only one cooling
jet fitted to spray the number one piston.
The correct piston height is important to ensure that
the piston does not contact the cylinder head and to
ensure the efficient combustion of fuel.
B A0071
The piston height is controlled by the length of the
connecting rod. In the factory there are six length
grades of connecting rods and one piston are used to
obtain the correct piston height.
To obtain the different grades, the small-end bush is
machined off-centre. The amount that the bush is off-
centre gives the different length grades.
In service, a partially finished small-end bush is
available, which can be fitted to the original
connecting rod and machined to obtain the correct
length grade, see operation 13-10. Specialist
equipment and personnel with the correct training are
needed to machine the partially finished small-end
bush. Connecting rod kits are also available with the
small end bush fitted and machined to obtain the
correct connecting rod grade. For further information
refer to your nearest Perkins distributor.
Continued

13 New 1000 Series
Notes:
! If the crankshaft or the cylinder block is to be
renewed, it may be necessary to change the grade
of the connecting rods, see operation 13-10. This
will occur if the correct piston height above the
cylinder block face cannot be maintained with the
original connecting rod assemblies, see operation
13-4. 1
! Engine types AR and AS do not have cylinder
liners fitted and the cylinder bores must be
machined oversize to correct a worn cylinder bore.
Two oversize pistons and piston rings are
available in service 0,5 mm (0.020 in) and 1,00 A A0072
mm (0.040 in).
! Always use the engine identification number to
order new parts.
The connecting rods are machined from "H" section
forgings of molybdenum steel. They have wedge
shaped small ends.
Location of the bearing cap to the connecting rod is
made by dowels (A1) fitted in the bearing cap. The
faces of the connecting rods and caps are flat and the 1
caps are retained by two setscrews.
Some engines have bearing caps with serrations (B1)
which are used to ensure the correct location of the
bearing caps to the connecting rods. These caps are B A0073
retained by two nuts and bolts.

New 1000 Series 13
Big end bearing
1
There are location thimbles (B1) fitted to the latest

bolts used with connecting rods that have serrated
faces. 2
The location thimbles are used in the factory to
prevent movement of the bolts when the nuts for the 4
big end cap are tightened by automatic equipment.
3
When the connecting rods are fitted in service it is not
necessary to use the location thimbles and they can
A A0072
be discarded.
2
To remove 1
1 Drain the engine lubricating oil.
2 Remove the lubricating oil sump, see operation 19-
3.
3 Remove the lubricating oil strainer and suction
pipe, see operation 19-4 or remove the balancer unit,
see operation 14-12.
4 Release the nuts (B4) and remove the bearing cap
(B3). Remove the bolts from the connecting rod (B2). 4
If the bearing cap is retained by setscrews (A4), the 3
location of the bearing cap (A3) will be by two dowels B A0073
(A2). To remove these bearing caps, release the
setscrews by approximately four turns. Lightly hit the
heads of the setscrews with a soft face hammer to
separate the connecting rod (A1) from the bearing
cap. Remove the setscrews and the bearing cap.
5 Rotate the crankshaft until the relevant connecting
rod is at its lowest position.
6 Remove the lower half of the shell bearing from the
cap, but keep it with its relevant cap.
7 Carefully push the connecting rod up the cylinder
bore just enough to allow access to the upper half of
the shell bearing. Remove the bearing from the
connecting rod. Keep the bearings from the
connecting rod and cap together.
Caution: Do not allow the connecting rod to hit the
piston cooling jet, if fitted.

13 New 1000 Series
To fit
1
1 Clean the bearing faces of the connecting rod and
the crank pin.
2 Ensure that the protrusion for the location dowels is
3,0/4,5 mm (0.12/0.18 in) above the cap faces. Clean
the complete bearing and lubricate the bearing
surface and the crank pin with clean engine
lubricating oil.
1
Fit the upper half of the shell bearing to the
connecting rod; ensure that the location tag is fitted
correctly in its recess (A1). Fit the connecting rod to
the crank pin; ensure that the assembly number on
the connecting rod is on the same side as the other A A0074A
connecting rods.
3 Clean, lubricate and fit the lower half of the shell
bearings into the cap; ensure that the location tag is
fitted correctly in its recess (A1). Fit the connecting
rod setscrews. Fit the cap to the connecting rod.
Ensure that the assembly number on the cap is the
same as that on the connecting rod and that both of
the assembly numbers are on the same side (B1).
4 Tighten the fasteners gradually and evenly to the
1
recommended torque of 155 Nm (114 lbf ft) 15,8 kgf
1
m for setscrews, or 125 Nm (92 lbf ft) 12,7 kgf m for
nuts.
1
5 Ensure that the crankshaft rotates freely.
B A0072
6 Fit the lubricating oil strainer and suction pipe, see
operation 19-4.
7 Fit the lubricating oil sump, see operation 19-3 and
fill the sump to the correct level with lubricating oil of
an approved grade.
To inspect 13-2
Check the bearings and the crank pin for wear or

other damage.

New 1000 Series 13
To remove
1 Drain the lubricating oil and the cooling system.
12-7.
3 Remove all carbon from the top of the bores of the
cylinder liners.
4 Remove the lubricating oil sump, see operation 19-3.
5 Remove the lubricating oil strainer and suction
pipe, see operation 19-4.
Caution: The pistons and connecting rods are
matched to the relevant cylinder. Note the position of
each connecting rod and piston for correct assembly.
6 Remove the big end caps and the big end bearings
from the connecting rods, see operation 13-1.
Caution: Do not allow the connecting rods to hit the
piston cooling jets. If a cooling jet is hit, check its
alignment, see operation 13-12, and renew it, if
necessary.
7 Rotate the connecting rods 90° to prevent contact
with the piston cooling jets. Push the pistons and the
connecting rods out through the top of the cylinder
liners. Keep the bearings and caps together to ensure
that they can be fitted in their original positions.
8 Inspect the crank pins for damage.

13 New 1000 Series
To fit
Special tools:
Piston replacer tool, PD.206
1 Ensure that the piston, the cylinder bore, the crank

pin and the big end of the connecting rod are clean.
Lubricate the piston and the cylinder liner with clean
engine lubricating oil.
2 Rotate the crankshaft until the relevant crank pin is
at its lowest position. Lubricate the crank pin with
clean engine lubricating oil. A A0350
3 Fit the upper half of the shell bearings to the

connecting rod. Ensure that the location tag is fitted
correctly in its recess. Lubricate the bearing with
clean engine lubricating oil.
4 Put the piston replacer tool in position at the top of
the relevant cylinder. The tool has a tapered bore to
compress the piston rings when the piston and
connecting rod assembly is fitted. Ensure that the
smaller end of the tapered bore is towards the face of
the cylinder block.
5 Put the piston ring gaps 120° apart. Pass the
connecting rod through the piston replacer tool and
allow the piston to enter the tool. The arrow mark on
the top of the piston (B) must be towards the front of B A0351
the engine.
Caution: Ensure that the connecting rod will not hit
the piston cooling jet as the connecting rod assembly
is fitted.
6 Push the piston and connecting rod assembly
through the piston replacer tool (A) and onto the crank
pin. The piston and connecting rod assembly must be
rotated to ensure that the connecting rod will not hit
the piston cooling jet as the assembly is fitted. When
the connecting rod has passed the piston cooling jet,
rotate the connecting rod until the arrow mark on top
of the piston is towards the front of the engine.
Continued

New 1000 Series 13
7 Clean the connecting rod cap and the lower half of
the shell bearings. Fit the bearing to the cap; ensure
that the location tag is fitted correctly in its recess.
Lubricate the bearing with clean engine lubricating oil.
Fit the cap and ensure that the assembly number is
the same as that on the connecting rod and that the
numbers are on the same side. Tighten the fasteners
gradually and evenly to the recommended torque of
155 Nm (114 lbf ft) 15,8 kgf m for setscrews, or 125
Nm (92 lbf ft) 12,7 kgf m for nuts.
8 Check that the crankshaft will rotate freely.
9 Check the piston height above the top face of the
cylinder block, see operation 13-4.
10 Fit the lubricating oil strainer and suction pipe, see
operation 19-4.
11 Fit the lubricating oil sump, see operation 19-3
12 Fit the cylinder head assembly, see operation 12-
7.
13 Fill the sump to the correct level with lubricating oil
of an approved grade.

13 New 1000 Series
To check the piston height above
the cylinder block 13-4
Special tools:
Piston height tool, PD.41D
Caution: If the correct piston height above the

cylinder block is not obtained, damage to the engine
can occur.
Put the piston height tool (A) on the face of the
cylinder block and rotate the gauge dial to the zero A A0352
position. Rotate the crankshaft until the piston crown

is approximately at top dead centre (TDC). Carefully
put the tool over the top of the piston with the plunger
of the gauge in contact with the piston above the axis
of the gudgeon pin. Rotate the crankshaft to ensure
that the piston is at the highest position and make a
note of the gauge indication.
The piston height above the top face of the cylinder
block should be 0,36/0,50 mm (0.014/0.020 in).
Notes:
! The top of the piston should not be machined.
! If the original piston is used, ensure that it is
assembled to the correct connecting rod and is
used in the original cylinder.
If any of the components listed below are renewed,
refer to the relevant operation:
! The connecting rod, see operation 13-7.
! The small end bush, see operation 13-10.

New 1000 Series 13
Piston rings
The pistons have two compression rings and an oil

control ring. All the piston rings are above the
gudgeon pin. To ensure that the correct type is
obtained always use the engine identification number
to order new parts.
Caution: Only expand the ring gaps enough to
ensure that the ends of the rings do not damage the 1
piston when the ring is removed or put into position. A A0353
To remove
Remove the piston rings with a suitable ring
expander. Keep the rings with their relevant piston. 1
To fit
Use a suitable piston ring expander to fit the piston
rings.
2
1 Fit the spring of the oil control ring in the bottom
groove with the latch pin (A1) inside both ends of the
spring (A). Fit the oil control ring over the spring (B3) 3
or (C3). Ensure that the ring gap is at 180° to the latch
pin.
2 Fit the cast iron ring with the taper face into the B A1447/1
second groove, with the word "TOP" towards the top

of the piston.
New second rings have a green identification mark
which must be on the left of the ring gap when the ring 1
is fitted and the piston is upright.
The second ring has a step (B2) or (C2) at the bottom
of the tapered face.
2
3 Fit the tapered, top ring (B1) or (C1) with the word
'TOP' towards the top of the piston.
Note: The top ring (C1) of engine types AR and AS is 3
parallel.
New top rings have a red identification mark which
C A1447
must be on the left of the ring gap when the ring is
fitted and the piston is upright.
4 Ensure that the ring gaps are 120° apart.

13 New 1000 Series
Piston and connecting rod assembly
To dismantle and to assemble 13-6
Caution: The pistons and connecting rods are

matched to the relevant cylinder. Note the position of 4
4
each connecting rod and piston for correct assembly.
To dismantle
1 Remove the piston rings, see operation 13-5.
2 Remove the circlips which retain the gudgeon pin.
Caution: Make a temporary mark on the piston. Do A A0354
not scratch, etch or stamp the piston surface.
3 Put a temporary mark on the piston to indicate the
cylinder number as shown on the connecting rod. Put
the temporary mark on the piston on the same side as
the mark on the big end to ensure that they are
assembled correctly (A).
4 Push the gudgeon pin out by hand. If the gudgeon
pin is tight, heat the piston to 40/50°C (100/120°F) for
easy removal of the gudgeon pin. 1
5 Inspect the piston and connecting rod assembly,
see operation 13-8 and operation 13-9. 2
To assemble
1 Clean the bore of the small end bush and lubricate B A0086A
it with clean engine lubricating oil.

2 Fit a new circlip in the circlip groove of one of the
gudgeon pin bosses. Ensure that it fits correctly in the
groove.
3 With the piston upside down, put the connecting rod
in position with the recess for the location of the big
end bearing (B1) on the same side as the recess in
the gudgeon pin boss (B2). If the original piston is
used, ensure that it is assembled to the correct
connecting rod and is used in the original cylinder.
New 1000 Series engines have six connecting rod
length grades, if a new connecting rod is fitted, ensure
that it is of the correct length grade, see operation 13-
7.
4 Lubricate the gudgeon pin bosses with clean
engine lubricating oil and push in the gudgeon pin
towards the circlip. If the gudgeon pin is a tight fit in
the piston, heat the piston to 40/50 °C (100/120 °F)
before the gudgeon pin is fitted.
5 Fit a new circlip in the groove in the other gudgeon
pin boss. Ensure that it fits correctly in the groove.
6 Fit the piston rings, see operation 13-5.

New 1000 Series 13
To check the length of a
connecting rod 13-7
A partially finished small end bush, which can be fitted

to the original connecting rod and machined to obtain
the correct length grade is available, see operation
13-10. Specialist equipment and personnel with the X 1
correct training are needed to machine the partially
finished small end bush.
Connecting rod kits are also available with the small
end bush fitted and machined to obtain the correct
connecting rod grade.
A G0009
Cautions:
! It is important that the piston does not contact the
cylinder head. Ensure that the piston height above
the cylinder block is correct.
! Ensure that the connecting rods are fitted in the
correct cylinder. Record the position of the
connecting rod and its relevant cylinder when it is
removed from the engine.
To ensure that the piston height above the cylinder
block is correct, the engine may have up to six length
grades (F to L) of connecting rods fitted.
Identification of the length grade is by a letter or colour
which is marked on the side of each connecting rod
(A1). The letter F is the longest grade of connecting
rod and letter L is the shortest grade. The difference
between grades is 0,046 mm (0.0018 in).
If the grade letter or colour on the side of the
connecting rod cannot be seen the length can be
checked by the measurement of the dimension (x)
shown in (A). Before the length of the connecting rod
is measured, ensure that the bores of the big end and
the small end are square and parallel, see operation
13-10. The length is checked with the big end bearing
removed and the original small end bush fitted. The
dimensions for each grade are listed in the table
below:
Grade Length
Colour code
letter (mm)
F Red 165,728/165,761
G Orange 165,682/165,715
H White 165,637/165,670
J Green 165,591/165,624
K Purple 165,545/165,578
L Blue 165,499/165,532

13 New 1000 Series
Piston and piston rings
To inspect 13-8
1 Check the piston for wear and other damage.

2 Check that the piston rings are free to move in their
grooves and that the the rings are not broken.
3 Remove the piston rings, see operation 13-5, and
clean the piston ring grooves and the piston rings.
4 Fit new piston rings in the grooves and check for
wear of the grooves with feeler gauges (A). Compare
the piston ring clearance in the groove to that given A C049
for new components in the data and dimensions and

renew the piston, if necessary.
Note: The pistons have a tapered top groove and the
piston ring is wedge shaped (page 71/B); the top
piston ring clearance cannot be checked by this
method.
5 Clean all carbon from the top of the cylinder liners.
Fit each piston ring in the top part of the cylinder liner
and measure the ring gap with feeler gauges (B). The
coil spring must be fitted to the oil control ring when
the gap of this piston ring is measured. The piston ring
gaps for new components are given in the data and
dimensions.
B A0088

New 1000 Series 13
Connecting rod
To inspect 13-9
127mm 127mm
1 Check the small end bush for wear or for other L±0.25mm (5in) (5in) L±0.25mm
damage and renew it, if necessary. (0.010in) (0.010in)
Note: Connecting rod kits are available with a new

small-end bush fitted and finished to the correct
grade, see operation 13-7 to identify the correct
connecting rod grade.
A partially finished small end bush, which can be fitted
to the original connecting rod and machined to obtain A G0009A
the correct length grade is also available, see

operation 13-10. Note: The small end is wedge shaped. After the
small end bush has been fitted, machine the bush to
2 Check the connecting rod for distortion (A). Use the
the shape of the small end and remove any sharp
data and dimensions, in the workshop manual, to
edges.
identify the correct mandrel sizes.
Note: The large and small end bores must be square Caution: Do not use a letter stamp to mark the
and parallel with each other within the limits of +/- 0,25 connecting rod.
mm (0.010 in) measured 127 mm (5.0 in) each side of 5 Check that the grade letter on the connecting rod is
the connecting rod axis on a test mandrel. With the correct, if necessary, delete the letter and etch a new
small end bush fitted, the limits are reduced to +/- 0,06 letter on to the side of the rod.
mm (0.0025 in).
3 Check the fit of the gudgeon pin in the small end
bush and check the gudgeon pin for wear, see the
data and dimensions.
Partially finished small end bush
1 Press out the old bush with a suitable adaptor.

2 Clean the parent bore of the connecting rod and
remove any sharp edges.
3 Press in the partially finished bush. Ensure that the
lubrication hole in the bush is on the same side as,
and is aligned with, the hole in the top of the
connecting rod.
Caution: Do not use a reamer, specialist equipment
and personnel with the correct training are needed to
machine the partially finished small end bush. For
further information refer to your nearest Perkins
distributor.
4 Machine the partially finished bush. To obtain the
correct connecting rod grade, see operation 13-7, see
the data and dimensions.
To obtain the correct clearance between the gudgeon
pin and the bush, refer to the data and dimensions in
the workshop manual.

13 New 1000 Series
Piston cooling jets
To remove
Release the valve assembly and remove the piston
cooling jet assembly (A).
Notes: 1
! The crankshaft is removed in (A) to show clearly
the piston cooling jet.
! Engine types AR and AS have a single piston
A A0089
cooling jet, fitted to the number one cylinder

position. The piston cooling jet positions for
cylinders 2, 3 and 4 have a blanking plug fitted. 33mm
(1.3in)
To fit
21mm
1 Check that the ball moves freely against spring 14mm (0.8in)
pressure in the valve assembly and that the jet tube is (0.5in)
not damaged. Renew the valve assembly and/or the
body as necessary.
2 Fit the piston cooling jet; ensure that the assembly
is fitted correctly on the dowel in the cylinder block.
Tighten the valve assembly to 20 Nm (15 lbf ft) 2,0 kgf m.
B A0090
To check the jet alignment 13-12
Insert a 1,70 mm (0.067 in) diameter rod, of suitable

34,5mm
length, into the jet. If a suitable rod is not available, (1.36in)
reduce the end of a thicker rod to 1,70 mm (0.067 in)
diameter for a length of 16,00 mm (0.630 in). When 22,5mm
the rod is inserted into the jet it must extend out of the 14mm (0.89in)
(0.5in)
top of the cylinder within the area shown in B. For
engine types AR and AS use the dimensions shown
in C.
C A0090

New 1000 Series 13
Data and dimensions
Pistons
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ."Fastram" combustion bowl
inserted top ring groove, graphite skirt
Diameter of bore for gudgeon pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39,703/39,709 mm (1.5631/1.5633 in)
Height of piston above top face of cylinder block . . . . . . . . . . . . . . . . . . . . . . . 0,38/0,50 mm (0.015/0.020 in)
Width of groove for top ring:
- Engine types AJ, AK, AM, AP, AQ, YG, YH, YK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Tapered
- Engine types AR and AS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,60/2,62 mm (0.1023/0.1031
Width of groove for second ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,56/2,58 mm (0.1008/0.1016 in)
Width of groove for third ring:
- Engine types, AJ, AK, AM, AP, AQ, YG, YH, YK . . . . . . . . . . . . . . . . . . . . 3,54/3,56 mm (0.1393/0.1401 in)
- Engine types, AR and AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,53/3,55 mm (0.1389/0.1397 in)
Piston cooling jets
Valve open pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178/250 kPa (26/36 lbf/in2) 1,8/2,6 kgf/cm2
Piston rings
Top compression ring:
- Engine types, AJ, AK, AM, AP, AQ, YG, YH, YK . . . . . . . . . . . . . . . Barrel face, molybdenum insert, wedge
- Engine types AR and AS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Barrel face, molybdenum insert, rectangular
Second compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Taper face, cast iron, outside bottom step
Oil scraper ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil spring loaded, chromium faced
Width of top ring:
- Engine types, AJ, AK, AM, AP, AQ, YG, YH, YK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tapered
- Engine types AR and AS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,475/2,49 mm (0.097/0.098 in)
Width of second ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,48/2,49 mm (0.097/0.098 in)
Width of third ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,47/3,49 mm (0.1366/0.1374 in)
Clearance of top ring in groove:
- Engine types, AJ, AK, AM, AP, AQ, YG, YH, YK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Wedge
- Engine types AR and AS only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,110/0,145 mm (0.004/0.006 in)
Clearance of second ring in groove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,07/0,1 mm (0.003/0.004 in)
Clearance of third ring in groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05/0,09 mm (0.002/0.003 in)
Gap of top ring:
- Engine types, AJ, AK, AM, AP, AQ, YG, YH, YK . . . . . . . . . . . . . . . . . . . . . . 0,28/0,63 mm (0.011/0.025 in)
- Engine types AR and AS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,28/0,51 mm (0.011/0.020 in)
Gap of second ring:
Gap of third ring:

13 New 1000 Series
Connecting rods
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 'H' section, wedge shape small end
Location of cap to connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flat joint face with dowels or serrations
Diameter of parent bore for big end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67,21/67,22 mm (2.6460/2.6465 in)
Diameter of parent bore for small end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43,01/43,04 mm (1.693/1.694 in)
Length grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F, G, H, J, K, L
Length between centres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219,05/219,10 mm (8.624/8.626 in)
Big end bearings
Type:
- Naturally aspirated engines: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel back, aluminium/tin bearing material
- Turbocharged engines: . . . . . . . . . . . . . . . . . . . . . .Steel back, lead bronze bearing material with lead finish
Width:
- Naturally aspirated engines: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31,62/31,88 mm (1.245/1.255 in)
- Turbocharged engines: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31,55/31,88 mm (1.240/1.255 in)
Thickness at centre of bearings:
- Naturally aspirated engines: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,835/1,842 mm (0.0723/0.0725 in)
- Turbocharged engines: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,835/1,844 mm (0.0723/0.0726 in)
Bearing clearance:
- Naturally aspirated engines: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,035/0,081 mm (0.0014/0.0032 in)
- Turbocharged engines: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,030/0,081 mm (0.0012/0.0032 in)
Available undersize bearings . . . . . . . . . . . . -0,25 mm (-0.010 in); -0,51 mm (-0.020 in); -0,76 mm (-0.030 in)
Gudgeon pins
Production:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fully floating
Outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39,694/39,700 mm (1.5628/1.5630 in)
Clearance fit in piston boss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,003/0,015 mm (0.0001/0.0006 in)
Small end bushes
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steel back, lead bronze tin bearing materials
Outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43,11/43,15 mm (1.6972/1.6988 in)
Inside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39,723/39,738 mm (1.5638/1.5645 in)
Surface finish grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ra 0,8 micrometers
Clearance between bush in small end and gudgeon pin . . . . . . . . . . . . . . 0,023/0,044 mm (0.0009/0.0017 in)

New 1000 Series
14
Crankshaft assembly 14
General description
The crankshaft is a chrome-molybdenum forging
which has five main journals for four cylinder engines
and seven main journals for six cylinder engines.
1 2
End-float is controlled by thrust washers on both sides
of the centre main bearing.
The main bearings have steel backs with a
aluminium/tin bearing material except the centre main
bearing of six cylinder engines, which has a bearing
material of lead bronze with a lead finish. The main
bearing caps are made of cast iron or spheroidal
graphite (SG) iron.
The front and the rear oil seals are Viton lip seals with 3
a dust lip to the outside of the main lip and with oil A A0357
return grooves on the face of the main lip.

Warning! Read the safety precautions for "Viton" 1 2 3 4
seals on page 18.
The crankshaft pulley (A3) of the four cylinder engine,
usually fitted without a damper, is held in position by
a plain thrust block (A1) and three setscrews (A2).
The nose of the crankshaft is serrated for location.
The location of the front pulley of six cylinder engines
is by a key in the crankshaft nose and the pulley is
held in position by a tapered rings arrangement (B).
6 5
An integral damper, with a rubber insert (B6) is built
into the pulley of six cylinder engines and some four B A0093
cylinder engines. Six cylinder engines have a viscous
damper (C2) which is fastened to the front or rear face
of the pulley (C1). All of the dampers are designed for
the suppression of torsional vibrations in the engine
crankshaft.
A balancer unit is fitted to certain four cylinder engines
which have rigid mountings or which are part of the
chassis or frame. The purpose of the balancer unit is
to reduce the effect of the out-of-balance forces.
1
2
C A0165

14 New 1000 Series
Crankshaft pulley
1 2
To remove and to fit - four cylinder
engines 14-1
To remove
1 Remove the drive belt(s), see operation 23-3.
2 Release the three setscrews (A2 which hold the
pulley and remove the setscrews), the thrust block
(A1) and the pulley (A3).
3 Clean the components and check for damage. 3
Renew damaged components.
A A0357
To fit
1 Put the pulley in position on the crankshaft.
Lubricate lightly the threads of the setscrews with
engine lubricating oil. Lubricate the main lip of the
seal with clean engine oil. Fit the thrust block and the
setscrews and tighten the setscrews gradually and
evenly to 115 Nm (85 lbf ft) 11,8 kgf m.
2 Check each setscrew again to ensure that they are
still to the correct torque.
3 Fit the drive belt(s), see operation 23-3.

New 1000 Series 14
Crankshaft pulley and damper
To remove and to fit - six cylinder

engines 14-2
Consumable products:
POWERPART Retainer (oil tolerant)
Caution: A viscous damper (C1) should be renewed

if there is impact damage to the outer casing or if
there is leakage of the viscous fluid from the cover A A0097
plate. Check the area around the holes for the damper
fasteners for damage.
To remove 1 2 3 4
1 Remove the drive belts, see operation 23-3.
Warning! The crankshaft pulley and damper
assembly is heavy and must be given support before
removal.
2 Release the fasteners which secure the clamp ring
(C2) for the damper to the pulley, if one is fitted, and
remove the damper.
6 5
Caution: Do not use an extractor to remove the
pulley.
B A0093
3 Remove the three setscrews and the thrust block
(B4). If the pulley is not free. Hold a wooden block
against the inner hub of the pulley and with a hammer,
lightly hit the wooden block towards the rear (A) to
loosen the tapered rings (B2 and B3).
2
C A0165

14 New 1000 Series
To fit
1 If the damper is fitted to the rear face of the pulley,
fit the damper to the pulley with its inner flange
against the rear face of the pulley. If a viscous damper 3
is fitted, put the damper in position on the face of the
pulley (A1). Fit the clamp ring (A3) or the washers.
4
Notes:
! On some engines the viscous damper is fitted to
the rear of the pulley.
! If a clamp ring with a chamfer on the outside edge 1
of the ring is used, ensure that the chamfer is
towards the damper when the ring is fitted. Clamp 2
A A0165
rings may be fitted to viscous or plate dampers.
Apply POWERPART Retainer (oil tolerant) to the
cap screws (A4) for the clamp ring and tighten the 1 2 3 4
cap screws gradually and evenly to 35 Nm (26 lbf ft)
3,6 kgf m. For viscous dampers fitted with M12
setscrews tighten the fasteners to 75 Nm (55 lb ft)
7,6 kgf m.
Caution: Do not use a degreasing solution.
2 Clean thoroughly the nose of the crankshaft, the
bore of the pulley and the tapered rings components.
Do not expand the tapered rings. 6 5
3 Put the pulley on the crankshaft with the key
engaged and push the pulley towards the rear. 7
B A0093
4 Fit the spacer (B1), then the inner ring (B2) and
then the outer ring (B3). Ensure that the ring gaps are
not aligned.
Caution: It can be very difficult to remove the pulley
if the tapered rings are not fitted correctly.
5 Lubricate lightly the "O" ring (B5) and the threads
and the thrust faces of the setscrews with clean
engine oil. Put the thrust block (B4) and setscrews in
position.
6 While the pulley is pressed to the rear, tighten the
setscrews gradually and evenly to 115 Nm (85 lbf ft)
11,8 kgf m. Apply the torque again to ensure the
pulley is fully tightened.
7 Fit the drive belts, see operation 24-3.

New 1000 Series 14
To inspect 14-3
1 When an integral pulley and damper (A) is fitted,

the assembly should be renewed if:
! The rubber insert (A1) between the hub and the
outer ring is split.
! The rubber insert is damaged by oil or solvents
! There is movement of the pulley or outer ring on
the hub.
Check the area around the holes for the damper
1
fasteners for cracks or wear.
Caution: Do not use excessive force to lever the 2
A A0093
damper away from the engine.
2 Remove any paint or dirt in four positions 90° apart
on the face (A2) of the damper, above the rubber
insert. Use a lever to move the damper forward and
eliminate the crankshaft end-float. Fit a dial test
indicator on the front cover of the timing case.
Measure the alignment of the damper face at four
locations, 90° apart. The maximum permissible
difference between the maximum and minimum
figures obtained is 0,18 mm (0.007 in).
3 Remove any paint or dirt from the circumference of
the damper. Fit a dial test indicator on the front cover
of the timing case. 1
4 Rotate the crankshaft slowly one complete B A0165
revolution and measure for run-out on the
circumference of the damper with the dial test
indicator. The maximum permissible difference
between the maximum and minimum figures obtained
is 0,12 mm (0.005 in).
5 If the alignment or the run-out is in excess of the
permissible limit, renew the pulley.
6 A viscous damper (B1) must be renewed if there is
impact damage to the outer casing or if there is
leakage of the viscous fluid from the cover plate.
Check the area around the holes for the damper
fasteners for damage.

14 New 1000 Series
Rear oil seal assembly
1 2
Special tools:
Replacer tool for rear oil seal, PD.145D
POWERPART Threadlock 3
POWERPART Silicone rubber sealant
A 4 A0098
1 Remove the drive components from the rear end of

the engine.
2 Remove the flywheel and the flywheel housing, see
section 22.
3 Remove the setscrews and the cap screws from the
housing and remove the housing and seal assembly.
4 Inspect the seal for wear or for damage to the main
lip and renew the seal, if necessary. If there is only a
small scratch across the lip, renew the seal.
5 Clean the faces of the cylinder block, the oil seal
housing and the crankshaft flange.
6 Check that the seal and the outer circumference of
the crankshaft flange are not damaged. Where a new B 1 A0099
seal has been fitted, check that it is in the correct
position in the housing.
7 Ensure that the two dowels (A4) are fitted in the
cylinder block. Put a new joint (A3) in position on the
dowels, no jointing compound is necessary.
8 Put the seal replacer tool on the crankshaft flange.
Lubricate the crankshaft flange, the main lip of the
seal and the seal replacer tool with clean engine
lubricating oil. The lubrication of the seal is necessary
to prevent damage to the seal when the engine is first
started.
9 Put the seal and housing (A2) on the replacer tool
(A1) and carefully push the assembly into position on
the crankshaft flange and onto the dowels. Remove
the tool, fit the setscrews and the torx screws (B1).
Tighten the setscrews and the torx screws to 22 Nm
(16 lbf ft) 2,2 kgf m.

New 1000 Series 14
To renew the rear oil seal 14-5
Special tools:
Replacer tool for rear oil seal, PD.145D
3
There are three positions in which the seal can be

fitted in the housing (A).
Position "1" (A1) is used when a new seal is first fitted 1 4,6mm (0.18in)
in service. 2 6,9mm (0.27in)
Position "2" (A2) is used when a new seal is fitted in

service and the crankshaft flange is worn in positions
"1". A C057
Position "3" (A3) can be used with a new seal in

service, if a wet clutch is not used and the crankshaft
is new or the crankshaft palm area has been
corrected. Ensure that the seal is fitted square in the
housing.
If all positions have been used it is permissible to
grind the crankshaft flange, see section 11.
1 Remove the seal and housing assembly, see
operation 14-4.
2 Put the engine side of the housing on a suitable
support and press out the seal with a suitable adaptor.
3 Lubricate the outer circumference of the seal and
the bore of the seal housing with clean engine
lubricating oil.
4 Put the engine side of the housing on a suitable
support. Put the seal into position on the flywheel end
of the bore with the spring of the seal towards the
housing.
5 Use a press and the replacer tool, PD.145D, to fit
the seal at the correct depth. The special tool has two
sides and is used in accordance with either position
"1" or "2". Press the seal into the housing to the
correct position with the relevant side of the tool.

14 New 1000 Series
Thrust washers
To check crankshaft end-float 14-6
The axial movement of the crankshaft is controlled by

thrust washers fitted both sides of the centre main
bearing (A). The end-float can be checked with a
feeler gauge between a thrust washer and the
crankshaft (B), or with a dial test indicator on one end
of the crankshaft to check the movement (C).
If the end-float is more than the tolerance given in
data and dimensions, thrust washers which are 0,019 A A0103
mm (0.0075 in) oversize can be fitted.
The oversize thrust washers can be fitted to one or to
both sides of the main bearing. They are fitted instead
of the standard size washer, to reduce the end-float to
the factory tolerances.
B A0104
C A0105

New 1000 Series 14
To remove 1
1 Drain the lubricating oil and remove the lubricating
oil sump, see operation 19-3.
2 If necessary, remove the balancer unit, see
operation 14-12.
3 If necessary, remove the lubricating oil strainer and
suction pipe, see operation 19-4.
4 Release the setscrews of the centre main bearing
and remove the main bearing cap complete with the
lower halves of the thrust washers.
A A0106
5 Use a suitable tool (A1) made of a soft material to
push the upper halves of the thrust washers from their
recesses. Where necessary, move the crankshaft to
the front or to the rear to loosen a tight washer.
Use a suitable tool (A1) made of a soft material to
push the upper halves of the thrust washers from their
recesses.
To fit
1 Lubricate the thrust washers with clean engine
lubricating oil.
2 Slide the upper halves of the thrust washers into
their recesses in the cylinder block. Ensure that the
sides of the thrust washers that have the grooves (B1)
are against the crankshaft.
3 Fit the lower half thrust washers to the main bearing
cap with the location tags in their recesses. 1
4 Ensure that the location thimbles are fitted correctly
in the main bearing cap or in the cylinder block.
5 Ensure that the bearing is fitted correctly in the cap
and that the the bearing and the crankshaft journal
are clean. Lubricate the bearing with clean engine
lubricating oil.
Continued
B C063

14 New 1000 Series
6 Fit the cap with the location tags of both halves
of the shell bearings to the same side (A1). Tighten
the main bearing setscrews gradually and evenly to
265 Nm (196 lbf ft) 27,0 kgf m.
7 Check the crankshaft end-float, see operation 14-6.
8 If necessary, fit the balancer unit, see operation 14-
12.
1
9 If necessary, fit the lubricating oil strainer and the
suction pipe, see operation 19-4.
10 Fit the lubricating oil sump, see operation 19-3,
and fill it to the correct level with an approved
lubricating oil.
A A0107

New 1000 Series 14
Main bearings
1
To remove and to fit

(with the crankshaft in position) 14-8
If the rear main bearing is to be removed with the 2

crankshaft in position, the flywheel, the flywheel
housing, the rear oil seal housing and the bridge piece
3
will have to be removed.
Except for engines with a balancer unit fitted, the front
main bearing can only be removed if a suitable
spanner is available that will enable the torque to be A C066
applied correctly to the setscrews of the main bearing
cap. If a suitable spanner is available, the front main
bearing cap can be removed together with the oil
pump. For six cylinder engines, it will be necessary to
remove the suction pipe and strainer and the delivery
pipe. For four cylinder engines, either the balancer
unit or the suction pipe and strainer, the delivery pipe
and the relief valve will have to be removed.
To remove
1 Drain the lubricating oil and remove the sump, see
operation 19-3.
2 Remove all necessary components to get access to
the specific bearing cap.
3 Release the setscrews of the bearing cap and
remove the bearing cap. Remove the lower half of the
shell bearing from the cap.
4 With a suitable tool (A1), push the upper half of the
shell bearing from the side opposite to the location tag
(A2) to remove the bearing tag from its recess (A3) in
the bearing housing. Carefully rotate the crankshaft to
release the bearing from its housing. Keep the
bearing halves in their relevant positions.

14 New 1000 Series
To fit
1 Clean the upper half of the shell bearing and
lubricate the bearing surface with clean engine
lubricating oil.
Caution: Only the upper half of the bearing has
lubrication holes and must be fitted to the cylinder
block.
1
2 Fit the plain end of the upper half of the bearing
between the crankshaft journal and the side of the
bearing housing which has the recess for the location
tag. Slide the bearing into its housing until the tag on
the bearing is fitted correctly in its recess in the
housing. A A0107
3 Clean the lower half of the bearing and the cap,

lubricate the bearing surface with clean engine
lubricating oil.
4 Fit the bearing into the cap with the tag of the
bearing fitted correctly in the recess in the cap.
5 Ensure that the location thimbles are fitted correctly
to the cap or to the cylinder block. Fit the bearing cap
with the location tags of both bearings on the same
side (A1).
6 Inspect the setscrews for damage and for distortion
and renew them if necessary. Lightly lubricate the
setscrew threads with clean engine lubricating oil. Fit
the setscrews and tighten the setscrews gradually
and evenly to 265 Nm (196 lbf ft) 27,0 kgf m.
7 Ensure that the crankshaft turns freely. If the thrust
washers have been removed and fitted, check the
crankshaft end-float, see operation 14-6.
8 Fit all the components which were removed for
access to the main bearing cap.
fill it to the correct level with an approved lubricating
oil.
To inspect 14-9
Inspect the bearings for wear and for other damage.

If a bearing is worn or damaged, renew both halves of
the shell bearings and check the condition of the other
bearings.

New 1000 Series 14
Crankshaft 13 Remove the bridge piece.
Warning! The engine should be upside down before
the fasteners for the crankshaft are removed. If the
To remove and to fit 14-10 engine cannot be turned upside down support the
crankshaft before the fasteners are removed.
Consumable products: 14 Remove the caps of the connecting rods. Keep
POWERPART Silicone rubber sealant the bearings and caps together. Remove the bolts of
the connecting rods and carefully push the pistons
POWERPART liquid gasket towards the top their bores.
15 Ensure that the tops of the main bearing caps are
Note: If the crankshaft is to be renewed, it may be stamped with their relevant position number. Remove
necessary to change the grade of the connecting the main bearing caps, the lower half of the shell
rods, see operation 13-7. This will occur if the correct bearings and the upper and lower thrust washers.
piston height above the block face cannot be Keep the bearings with their relevant caps.
maintained with the original piston and connecting rod 16 Lift out the crankshaft. Remove the upper half of
assemblies, see operation 13-4. the bearings and keep each bearing with its relevant
lower half and cap.
Warning! Use lift equipment or obtain assistance to
lift heavy engine components such as the flywheel,
flywheel housing and the crankshaft.
To remove
1 Before the engine is removed from the vehicle or
from the machine, drain the lubricating oil and the
coolant.
2 Remove the lubricating oil sump, see operation 19-
3.
3 Remove the fan, the drive belts, the fan drive pulley
and housing and the coolant pump, see section 21.
4 Remove the fuel injection pump, see section 20.
5 Remove the crankshaft pulley, see operation 14-1
or operation 14-2.
6 Remove the alternator and its mounting bracket,
see section 23.
7 Remove the compressor and its drive assembly or
remove the exhauster, see section 24.
8 Remove the timing case cover, see operation 15-1.
9 Remove the timing gears and the timing case, see
section 15.
10 Remove the flywheel and the flywheel housing,
see section 22.
11 Remove the rear oil seal housing, see operation
14-4.
12 If a balancer unit is fitted, remove it, see operation
14-12. If a balancer unit is not fitted, remove the
lubricating oil suction pipe and strainer, the lubricating
oil pump, the delivery pipe and the relief valve (four
cylinder engines) and the lubricating oil crossover
pipe, if fitted, see section 19.

14 New 1000 Series
To fit
1 Ensure that all lubricating oil passages are clean
and free from restriction.
2 Clean the main bearing housings and the upper half
of the bearings. Fit the shell bearings with the location
tags fitted correctly in their recesses. Lubricate the
bearings with clean engine lubricating oil.
3 Ensure that the main journals of the crankshaft are
clean. Put the crankshaft in position on the upper
bearings.
4 Clean and lubricate the upper halves of the thrust
washers and slide them into their recesses on both
sides of the bearing housing. Ensure that the slotted
sides of the thrust washers are towards the
crankshaft.
5 Clean the bearing caps and the lower half of the
bearings. Fit the bearings to the caps with the location
tags fitted correctly in their recesses. Lubricate the
bearings with clean engine lubricating oil.
6 Clean the lower halves of the thrust washers and
lubricate them with clean engine lubricating oil. Fit the
thrust washers on both sides of the bearing cap for
the centre main bearing.
7 Check that the location thimbles for the main
bearing caps are fitted correctly in the caps or in the
cylinder block. Fit the bearing caps in their correct
positions (as shown by the position number stamped
on the top of the cap) with the location tags of the
bearings on the same side. In this position the serial
numbers stamped on the bearing caps will be in line.
The serial number stamped on the bearing caps must
be the same as the number stamped on the bottom
face of the cylinder block. The third and fifth bearing
caps of six cylinder engines are not stamped with a
serial number.
Continued

New 1000 Series 14
8 Fit the setscrews to the main bearing caps and
tighten them gradually and evenly to 265 Nm (196
lbf ft) 27,0 kgf m.
9 Clean the bridge piece and the location areas for
the bridge piece in the cylinder block. Use a straight
edge (A2) to ensure that the bridge piece is in line with
the rear face of the cylinder block. Tighten the bridge
piece cap screws (A1) to 16 Nm (12 lbf ft) 1,6 kgf m.
10 When the bridge piece is in position, inject
POWERPART silicone adhesive or POWERPART
silicone rubber into the groove (B2) at each end of the 1
bridge piece. Continue to inject sealant until the 2
groove is completely full and the sealant leaves the
lower groove (B1) at the front and rear of the bridge A A0109
piece.
It may be necessary to stop the sealant at one side of
the lower groove in order to ensure it will flow from the
opposite side of the groove. 2
1
Caution: When the sump joint is removed, damage
can occur to the seal in the grooves of the bridge
piece. If the seal is damaged, apply enough sealant to
completely fill the grooves.
Note: Most of the latest engines have setscrews in
place of studs to fasten the sump to the bridge piece.
The threads of the setscrews have a sealant applied
by the manufacturer. When the setscrews are to be
used again, ensure that the threads of the setscrews B A0110
and of the bridge piece are clean and a sealant is
applied to the threads of the setscrews. These 21 Fit the coolant pump, the fan drive pulley and
instructions also apply to studs. housing, the drive belts and the fan, see section 21.
22 Fit the lubricating oil sump, see operation 19-3.
11 Fit the connecting rod caps, see operation 13-1.
Rotate the crankshaft two turns to ensure free 23 After the engine has been installed, fill the
movement. lubricating oil sump to the correct level with an
approved oil. Fill the cooling system.
12 On four cylinder engines, if necessary, fit the
balancer unit, see operation 14-12. If a balancer unit
is not used, fit the lubricating oil pump, the lubricating
oil suction pipe and strainer, the delivery pipe and the
relief valve (four cylinder engines) and if necessary,
the lubricating oil crossover pipe, see section 19.
13 Fit the rear oil seal housing, see operation 14-4.
14 Fit the flywheel housing and the flywheel, see
section 22.
15 Fit the timing case and the timing gears, see
section 15.
16 Fit the timing case cover, see operation 15-1.
17 Fit the compressor and its drive assembly or fit the
exhauster, see section 24.
18 Fit the alternator and its mounting bracket, see
section 23.
19 Fit the crankshaft pulley, see operation 14-1 or
operation 14-2.
20 Fit the fuel injection pump, see section 20.

14 New 1000 Series
To inspect 14-11
Check the crankshaft for wear and other damage. The

maximum permissible wear and ovality on the
crankshaft journals and crank pins is 0,04 mm
(0.0016 in).
The main journals and the crank pins of standard size
crank shafts can be machined to 0,25mm (0.010 in),
0,50mm (0.020 in) or 0,75 mm (0.030 in) undersize on
diameter, see the data and dimensions. Special
undersize bearings are available.
If the seal has been used in all of the service
positions, the crankshaft palm can be machined to
remove the wear marks. Further information can be
found in the data and dimensions.

New 1000 Series 14
Balancer unit

1
To remove
1 Drain the lubricating oil from the sump and remove
the sump, see operation 19-3.
Warning! The weight of the unit is approximately 25
kg (55 lb).
2 Provide a support for the balancer unit before
release of the setscrews from the engine. A A0111
3 Release the setscrews and lower carefully the
balancer unit. Make a note of the positions of the
setscrews of different lengths.
To fit 2
1 Ensure that the contact faces of the cylinder block
and of the balancer unit are clean and that the two
thimbles (A1) are fitted correctly to the cylinder block.
2 Set the piston of number 1 cylinder to TDC, see
operation 17-1.
3 Before the balancer unit is fitted, ensure that the flat
faces of the balance weights are level with each other
(B1) and the weights hang down away from the
1
cylinder block (B2). The timing of the balance weights B A0112
to the drive shaft is correct when the large hole and
small hole in the front of the drive shaft gear are in the
positions shown in the illustration (B).
Note: If the gear position shown in (B) cannot be
obtained, then the balancer must be partially
dismantled and the timing corrected (page 99/A).
4 Fit the balancer unit to the cylinder block with the
correct screws in the centre positions of the balancer
frame. Ensure, when the idler and crankshaft gears
are in mesh, that the flat faces of the balance weight
are level with each other and that they are towards the
cylinder block. Check that the balancer unit is fitted
correctly on the thimbles and fit the remainder of the
setscrews in their correct position. Tighten the
setscrews to 54 Nm (40 lbf ft) 5,5 kgf m.
5 Rotate the crankshaft through two turns to ensure
that it is free to rotate.
fill the sump to the correct level with an approved oil.

14 New 1000 Series
To dismantle and to assemble 14-13 4 Release the setscrews which hold the lubricating oil
pump and the suction pipe (A10 and A9) to the
Consumable products: balancer frame and remove the lubricating oil pump
and the suction pipe.
POWERPART Nutlock
5 Release the setscrews and remove the transfer
plate and joint for the lubricating oil (A7) from the rear
To dismantle of the balancer unit. Make a note of the position of the
direction arrows on the outside of the transfer plate
1 Remove the balance weight cover (A8). (page 99/B or C) to ensure that it can be assembled
2 Release the setscrew and remove the idler gear correctly.
assembly (A1). Keep the components together as an
assembly to protect the needle roller bearing.
3 Prevent movement of the drive shaft (A2) and
loosen the nut (A4) of the drive gear for the balance
weights (A3). Put a suitable flat distance piece in
position between the nut and the balancer frame.
Turn the nut until it is against the face of the distance
piece. Continue to turn the nut with a suitable spanner
until the Loctite seal on the splines of the drive shaft
is broken and the gear is loose on the shaft. Remove
the nut and the drive gear and remove the drive shaft.
Ensure that the needle roller bearings are not
damaged when the drive shaft is removed.
9
7
10
4
3
2
A A0113

New 1000 Series 14
Notes:
! The latest oil transfer plate is fitted without a joint
or sealant; always give the correct engine number
when parts are needed.
! There are two plugs in the balancer frame, a short
tapered plug with a hexagonal socket head and a
long plug with a square socket head. These plugs
control the flow of oil through the balancer frame.
The position of the plugs is decided by which side
of the engine the filter is fitted. When the filter is
fitted on the left side, the short plug is fitted in the
side of the balancer and the long plug is fitted in
the bottom. When the filter is fitted on the right side A A0116
of the engine, the short plug is fitted in the bottom
of the balancer and the long plug is fitted in the
side.
Caution: Removal of these plugs can cause damage
to the threads in the balancer frame and a new
balancer frame will be needed. When a balancer unit
is to be fitted, ensure that the lubricating oil flow
through the balancer frame is correct for the position
of the lubricating oil filter.
6 Release the setscrews and remove the rear cover
of the balancer frame (page 96/A6). A hammer and a
suitable drift will be necessary to remove the rear
cover from the dowels.
7 Remove the balance weights (page 96/A5). Ensure B A0117
that the gear of the driven weight does not damage

the bush in the balancer frame.
8 Dismantle the lubricating oil relief valve, see
operation 19-10.
9 Clean the lubricating oil passages with an approved
kerosene cleaning solution and dry them with low
pressure compressed air.

14 New 1000 Series
To assemble 5 Ensure that the drive shaft turns freely. Check the
end-float of the drive shaft with feeler gauges
1 Ensure that the location spigot (A8) on the rear face
between the front face of the drive gear for the
of the lubricating oil pump is clean. Clean the contact
balance weights and the frame (A).
faces of the lubricating oil pump and the balancer
frame. Fit the lubricating oil pump (A16) to the
Continued
balancer frame and tighten the setscrews to 27 Nm
2 Assemble the lubricating oil relief valve, see
operation 19-10.
3 Lubricate the needle roller bearings (A7 and A10)
with clean engine lubricating oil. Fit the drive shaft
(A9) and engage the splines for the lubricating oil
pump with the pump rotor. Ensure that the needle
roller bearing at the front of the balancer frame is not
damaged by the splines on the drive shaft.
4 Clean and dry the splines (A6) and the thread on
the end of the drive shaft. Apply a small amount of
Loctite Nutlock to the splines and to the thread. Fit
the drive gear of the balance weights (A1) with the
flat face of the gear towards the rear of the balancer
unit. Fit and tighten the nut (A2) to 82 Nm (60 lbf ft)
8,4 kgf m. To tighten the nut, a peg spanner must be
made to fit into the two holes in the front of the drive
shaft and be suitable for use with a torque wrench.
Fit the peg spanner to the front of the drive shaft.
Hold the nut with a suitable spanner and apply the
torque to the peg spanner.
0,07/0,23m m
(0.003/0.009in)
15
0,13/0,30m m
130,0/131,0m m (0.005/0.012in)
14 3 4
(5.12/5.16in)
1 2
16
13
12
11
10
5
2,3/3,0m m
(0.10/0.12in) 9 8 7 6
A A0114

New 1000 Series 14
6 Put the balancer frame upside down on the bench
(A1). Turn the gear of the drive shaft (A3) until the 4
larger of the two outer holes (A2) - in the front face of
the drive gear - is in the position shown in (A). Ensure
that the drive shaft will not move from this position.
Lubricate the bushes in the rear of the balancer frame 3
with clean engine lubricating oil and fit the balance
weights in the position shown in figure A. Ensure that 2
the flats on the balance weights are level with each
other (A4). With the balance weights in the correct
position, check that the drive shaft is still in the correct 1
position.
7 Fit the two dowels to the rear face of the balancer
frame. Lubricate the bushes in the rear cover of the A A0115
balance frame with clean engine lubricating oil. Put
the rear cover (page 100/A4) in position with the rear
spigots of the balance weights in the bushes of the
cover. Hit lightly the rear cover with a soft face
hammer to fit the cover onto the dowels. Fit the cover
setscrews and tighten them to 54 Nm (40 lbf ft) 5,5 kgf
m. Check the end-float of the balance weights with
feeler gauges between the rear face of the balance
weights and the front face of the rear cover (page 103/
B). The correct end-float is given in the data and
dimensions. Check the backlash between the drive
gear of the balance weights and the driven gear on
the balance weight. The correct backlash is given in
B A0116
8 Fit the oil transfer plate to the rear of the rear cover
and tighten the setscrews to 30 Nm (22 lbf ft) 3,1 kgf
m. Ensure that the plate is fitted correctly for the oil
filter position. The direction arrow (B or C) indicates
the direction of lubricating oil flow for left side (B) and
right side (C) oil filter positions. The symbols and
arrows (B or C) indicate the position of the plugs in the
balancer frame and the shape of their socket heads.
Ensure that the plug on the bottom face of the frame
is just below the face. If a new frame and plugs are
used, ensure that the plugs are fitted correctly for the
oil filter position and the symbols on the oil transfer
plate.
Continued C A0117

14 New 1000 Series
9 If necessary, press a new bearing (A14) into the
idler gear (A12). Lubricate the bearing with clean
engine lubricating oil. Fit the hub (A13) into the
bearing and fit the thrust washer (A15) onto the rear
of the hub. Ensure that the threads of the setscrew
are clean and dry. Fit the setscrew through the
assembly and apply a small amount of Loctite
Nutlock to the thread. Fit the assembly to the front of
the balancer unit with the idler gear in mesh with the
gear of the drive shaft (A11). Tighten the setscrew to
93 Nm (68 lbf ft) 9,5 kgf m. Check the end-float of the
idler gear with a feeler gauge between the front face
of the idler gear and the hub (A). Check the backlash
between the idler gear and the drive shaft gear. The
correct backlash is given in the data and dimensions.
10 Fit the balance weight cover and tighten the
setscrews.
11 Fit the suction tube and the joint and tighten the
setscrews.
0,07/0,23m m
(0.003/0.009in)
15
0,13/0,30m m
130,0/131,0m m (0.005/0.012in)
14 3 4
(5.12/5.16in)
1 2
16
13
12
11
10
5
2,3/3,0m m
(0.10/0.12in) 9 8 7 6
A A0114

New 1000 Series 14
To inspect 14-14
1 Clean all the components before inspection.

2 Check the gear teeth and the splines of the drive
shaft for wear or other damage. Renew the drive shaft
if necessary.
3 Check the idler gear, needle roller bearing, hub and
thrust washer for wear or other damage. Renew the
components if necessary.
4 Check the drive gear for the balance weights for
wear or other damage. Renew the gear if necessary.
5 Check the balance weights for wear or other
damage. If either balance weight is worn or damaged,
both balance weights must be renewed.
6 Check the needle roller bearings for the drive shaft
for wear or other damage. Renew the bearings, see
operation 14-15, if necessary.
7 Check the bushes for the balance weights for wear
or other damage. Renew the bushes, see operation
14-16, if necessary.
8 To inspect the lubricating oil pump, see operation
19-8.

14 New 1000 Series
To remove and to fit the needle
roller bearings for the drive shaft 14-15 2,5/3,0
3,25/ 31,70 17,0/17,8

3,30
1 Press out the bearings with a suitable adaptor.
2 Clean the parent bores and lubricate them with 3 37,84 42 50,8 38 1 28,45 34,3
3 Make a suitable adaptor to the dimensions given in
(A2). Fit the rear bearing (page 100/A7) onto the
adaptor with the stamped face of the bearing towards
38 2 29,26 23,5
the shoulder of the adaptor. Press the bearing into the
parent bore in a continuous movement until the
shoulder of the adaptor is against the front face of the 130/131 27
balancer frame. In this position the front face of the A MILLIMETRES

A0118
bearing should be 130,0/131,0 mm (5.12/5.16 in)
from the front face of the balancer frame (page 100/
A).
(A1). Fit the front bearing (page 100/A10) onto the
adaptor with the stamped face of the bearing toward
the shoulder. Press the bearing into the parent bore in
a continuous movement until the shoulder of the
adaptor is against the front face of the balancer frame.
In this position the front face of the bearing should be
2,5/3,0 mm (0.01/0.12 in) from the front face of the
balancer frame (page 100/A).

New 1000 Series 14
To remove and to fit the bushes for
the balance weights 14-16 2,5/3,0
3,25/ 31,70 17,0/17,8

3,30
1 Press the bushes out of the balancer frame and the
rear cover with a suitable adaptor. 3 37,84 42 50,8 38 1 28,45 34,3
2 Clean the parent bores and lubricate them with
(A3). Fit a bush onto the adaptor. Press the bush (B4)
38 2 29,26 23,5
into the parent bore in the rear of the balancer frame
(B3), in a continuous movement, until the shoulder of
the adaptor is against the rear face of the balancer 130/131 27
frame. In this position the rear face of the bush should A MILLIMETRES
A0118
be 3,25/3,30 mm (0.128/0.130 in) from the rear face
of the balancer frame (B). Repeat this operation for 3,25/3,30mm (0.128/0.130in) 3,25/3,30mm
(0.128/0.130in)
the other bush.
4 Fit a bush (B1) onto the adaptor and put it into
position at the front end of one of the parent bores in 4
1
the rear cover (B2). Press in the bush, in a continuous
movement, until the shoulder of the adaptor is against
the front face of the rear cover. In this position the
front face of the bush should be 3,25/3,30 mm (0.128/
0.130 in) from the front face of the rear cover (B).
Repeat this operation for the other bush.
3 2
B 0,19/0,40mm
(0.007/0.016in) A0119

14 New 1000 Series
Data and dimensions
Crankshaft
Diameter of main journals:
- Four cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76,16/76,18 mm (2.998/2.999 in)
- Six cylinder engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76,159/76,190 mm (2.9984/2.9996 in)
Maximum wear and ovality on journals and crank pins . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,04 mm (0.0016 in)
Width of front journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,93/37,69 mm (1.454/1.484 in)
Width of centre journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,15/44,22 mm (1.738/1.741 in)
Width of all other journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39,24/39,35 mm (1.545/1.549 in)
Diameter of crank pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63,47/63,49 mm (2.499/2.500 in)
Width of crank pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,35/40,42 mm (1.589/1.591 in)
Diameter of flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133,27/133,37 mm (5.247/5.251 in)
Depth of recess for spigot bearing:
- Six cylinder engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14,72/15,48 mm (0.579/0.609 in)
Bore of recess for spigot bearing:
- Six cylinder engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51,97/51,99 mm (2.046/2.047 in)
Crankshaft end-float. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05/0,38 mm (0.002/0.015 in)
Maximum permissible end-float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,51 mm (0.020 in)
Fillet radii of journals and crank pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,68/3,96 mm (0.145/0.156 in)
Undersize journals and crank pins. . . . . . . . . . . . . . . . . . . . . . . . . -0,25 mm (-0.010 in); -0,51 mm (-0.020 in);
-0,76 mm (-0.030 in).
Crankshaft heat treatment
- Induction hardened . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Part numbers 3131H024
- Nitrocarburised . . . . . . . . . . . . . . . . . . . . . . . . . .Part numbers 3131H022, 31315991, 31315995, 31315681
- 60 hour Nitride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Part numbers 3131H021
Crankshaft overhaul
Notes:
! Induction hardened crank shafts need not be hardened after they have been machined undersize.
! Nitrocarburised crankshafts must be hardened again each time they are machined. These crankshafts
must be nitrocarburised or, if this process is not available, they can be nitrided for 20 hours. If neither
process is available a new crankshaft, or Power Exchange crankshaft, must be fitted.
! Crankshafts which have been nitrided for 60 hours can be reground 0,25 mm (0.010 in) without the need
to harden them again.
! Check the crankshaft for cracks before and after it is ground. Demagnetise the crankshaft after it has been
checked for cracks.
! After the crankshaft has been machined remove any sharp corners from the lubricating oil holes.
! Surface finish and fillet radii must be maintained.

New 1000 Series 14
The finished sizes for crankshaft journals (A) which have been ground undersize are given in the table below:
Item 0,25 mm (0.010 in) 0,51 mm (0.020 in) 0,76 mm (0.030 in)
75,905/75,926 mm 75,651/75,672 mm 75,397/75,418 mm
1
(2.9884/2.9892 in) (2.9784/2.9792 in) (2.9684/2.9692 in)
63,216/63,236 mm 62,962/62,982 mm 62,708/62,728 mm
2
(2.4888/2.4896 in) (2.4788/2.4796 in) (2.4688/2.4696 in)
3 39,47 mm (1.554 in) maximum - -
4 37,82 mm (1.489 in) maximum - -
5 44,68 mm (1.759 in) maximum - -
6 40,55 mm (1.596 in) maximum - -
7 133,17 mm (5.243 in) minimum - -
8 Do not machine this diameter - -
9 3,68/3,96 mm (0.145/0.156 in) - -
Surface finish for journals, crank pins and fillet radii must be 0,4 microns (16 micro inches). Surface finish for
seal area of crankshaft palm must be 0,4/1,1 microns (16/43 micro inches).
6 6 6 6 8
9 2 9 9 9 2 9
1 9 1 1 1 9 1 7
4,8mm
2 2 0.189in
4 3 9 5 9 3 3
6 6 6 6 6 6 8
9 2 9 9 9 9 9 2
1 1 1 1 1 1 1 7
2 2 2 2
4 3 9 3 9 3 9 3 9 3 3
A A0120

14 New 1000 Series
With the crankshaft on mountings at the front and rear journals, the maximum run-out (total indicator reading)
at the journals must not be more than shown below:
Journal 4 cylinder crankshafts 6 cylinder crankshafts
1 Mounting Mounting
2 0,08 mm (0.003 in) 0,10 mm (0.004 in)
3 0,15 mm (0.006 in) 0,20 mm (0.008 in)
4 0,08 mm (0.003 in) 0,25 mm (0.010 in)
5 Mounting 0,20 mm (0.008 in)
6 - 0,10 mm (0.004 in)
7 - Mounting
Run-out must not be opposite. The difference in run-out between one journal and the next must not be more
than 0,10 mm (0.004 in).
Run-out on the crankshaft pulley diameter, rear oil seal diameter and the rear flange diameter must not be
more than 0,05 mm (0.002 in) total indicator reading.
Main bearings
Four cylinder engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steel back, 20% tin-aluminium bearing material
Six cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steel back, 20% tin-aluminium bearing material
Bearing width
Four cylinder engines:
Centre bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,32/36,70 mm (1.430/1.445 in)
All other bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31,62/31,88 mm (1.245/1.255 in)
Six cylinder engines:
Centre bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,32/36,70 mm (1.430/1.445 in)
All other bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30,86/31,12 mm (1.215/1.225 in)
Bearing thickness at centre
Four cylinder engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,083/2,089 mm (0.0820/0.0823 in)
Six cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,083/2,089 mm (0.0820/0.0823 in)

New 1000 Series 14
Bearing clearance
Four cylinder engines:
All bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,057/0,117 mm (0.0022/0.0046 in)
Six cylinder engines:
All other bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,047/0,117 mm (0.0018/0.0046 in)
Available undersize bearings. . . . . . . . . . . -0,25 mm (-0.010 in); -0,51 mm (-0.020 in); -0,76 mm (-0.030 in).
Crankshaft thrust washers
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel back, lead bronze bearing material
Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Each side of centre main bearing
Thickness:
- Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,26/2,31 mm (0.089/0.091 in)
- Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,45/2,50 mm (0.096/0.098 in)
Balancer unit
Diameter of drive shaft for front bearing . . . . . . . . . . . . . . . . . . . . . . . . 28,562/28,575 mm (1.1245/1.1250 in)
Diameter of drive shaft for rear bearing. . . . . . . . . . . . . . . . . . . . . . . . . 23,787/23,800 mm (0.9365/0.9370 in)
Number of teeth on gear of drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Backlash from gear of drive shaft to idler gear . . . . . . . . . . . . . . . . . . . . . . . . . 0,17/0,29 mm (0.007/0.011 in)
End-float of drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,13/0,30 mm (0.005/0.012 in)
Diameter of bore for front bearing of drive shaft . . . . . . . . . . . . . . . . . . 34,912/34,937 mm (1.3745/1.3755 in)
Diameter of bore for rear bearing of drive shaft. . . . . . . . . . . . . . . . . . . 29,972/29,993 mm (1.1800/1.1808 in)
Diameter of bore for idler gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47,64/47,65 mm (1.8755/1.8760 in)
Diameter of hub of idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38,09/38,10 mm (1.4996/1.5000 in)
End-float of idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,07/0,23 mm (0.003/0.009 in)
Thickness of thrust washer for idler gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,14/4,29 mm (0.163/0.169 in)
Number of teeth on idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Inside diameter of bushes in balancer frame and end cover (fitted) . . . . . . . . . . . . . . . . . . 38,133/38,174 mm
(1.5013/1.5029 in)
Diameter of spigots for balance weights . . . . . . . . . . . . . . . . . . . . . . . . 38,054/38,069 mm (1.4982/1.4988 in)
Fit of spigot in bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,064/0,120 mm (0.0025/0.0047 in)
End-float of balance weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,19/0,40 mm (0.007/0.016 in)
Backlash of gears on balance weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,10/0,27 mm (0.004/0.011 in)
Backlash of drive gear to spline on balance weight. . . . . . . . . . . . . . . . . . . . . . 0,05/0,20 mm (0.002/0.008 in)
Number of teeth on drive gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Number of teeth on spline on balance weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

108
New 1000 Series
15
Timing case and drive assembly 15
General description
The timing case (A) is for engines fitted with a gear
driven coolant pump. The timing case (B) is for
engines fitted with a belt driven coolant pump. The
timing case is made of either aluminium or cast iron.
The timing gears on most engines are made of steel,
but cast iron gears are used on certain low rated
engines. A power take-off is available on the left side
of the aluminium timing case or from both sides of the
timing case made of cast iron. Some applications that
need a power take-off from both sides of the timing
case can have an idler gear assembly that uses
needle roller bearings.
The drive from the crankshaft gear passes through an A A0129
idler gear to the camshaft gear and to the gear of the
fuel injection pump. The drive from the crankshaft
gear also passes through a lower idler gear to the
gear of the lubricating oil pump or, on some four
cylinder engines, to the gear of the balancer unit. The
gear driven coolant pump is driven by the gear of the
fuel injection pump. The camshaft and the fuel
injection pump run at half the speed of the crankshaft.
The aluminium cover of the timing case contains the
front oil seal; this is made of viton and has a dust lip
in front of the main lip. On some engines the cover
has a noise shield fitted to its front face.
Warning! Read the safety precautions for "Viton"
seals on page 20. B A0307
The camshaft is made of cast iron. The cam lobes and

the eccentric for the fuel lift pump are chill hardened.

15 New 1000 Series
Timing case cover
1 2
To remove
1 Remove the fan, see operation 21-9.
2 Remove the alternator, see operation 23-4.
or operation 14-2.
4 Drain the coolant and remove the coolant pump,
see section 21. Gear driven pumps only.
5 Release the setscrews and nuts of the cover (A5)
and remove the cover, from the timing case assembly
(A2).
6 Discard the joint (A4).
To fit
5
Special tools:
4
Centralising tool, PD.163A (6 cylinder engines)
Centralising tool, PD.162B (4 cylinder engines)
1 Clean the joint faces of the timing case cover and 3

top cover. A A0375
2 Put the cover and a new joint in position on the

timing case. Ensure that the two studs (A3) are
tightened correctly. Loosely fit two setscrews (A1)
which are in opposite locations to hold the cover in
position. Fit the centralising tool in the oil seal housing
(B) and use the special washer and the crankshaft
pulley setscrews to put the cover in its correct
position. Do not overtighten the setscrews. Fit the
remainder of the setscrews and nuts and tighten all of
the cover fasteners to 22 Nm (16 lbf ft) 2,2 kgf m.
Remove the centralising tool.
Caution: For engines with gear driven coolant
pumps, It is important that the cover of the timing case
is centred correctly. If the cover is not centred, the
B A0126
backlash between the fuel pump gear and coolant

pump gear could be affected. This could cause the
seizure of the fuel injection pump.
3 Fit the coolant pump, see section 21. Gear driven
pumps only.
operation 14-2.
5 Fit the alternator, see operation 23-4.
6 Fit the drive belts, see operation 23-3 and adjust
the belt tension, see operation 23-2.
7 Fit the fan, see operation 21-9.

New 1000 Series 15
Front oil seal
Special tools:
Replacer tool for front oil seal (main tool), PD170
Pressure plate for use with PD.170, PD.170-1
Sleeve for use with PD.170, PD.170-2
Fastener plate for use with PD.170, PD.170-3
Adaptor for use with PD.170 (1) A 1 2 3 4 5 A 0 12 7
(1) Refer to your nearest Perkins distributor. Fit a rod through the hole in the end of the threaded
bar to prevent movement of the bar when the nut is
To remove tightened. Tighten the nut to push the seal into the
housing to the correct depth.
1 Remove the fan, see operation 21-9. and the drive
belts, see operation 23-3. 4 Remove the replacer tool and lightly lubricate the
2 Remove the crankshaft pulley, see operation 14-1 seal location area of the crankshaft pulley with clean
or operation 14-2. engine lubricating oil. Fit the crankshaft pulley, see
operation 14-1 or operation 14-2.
3 Remove the oil seal with a suitable lever behind the
main lip of the oil seal. Do not damage the edge of the 5 Fit the drive belts, see operation 23-3 and adjust
oil seal housing. the belt tension, see operation 23-2.
To fit
Note: The seal is fitted to a depth of 10,20/10,70 mm
(0.402/0.421 in) from the front face of the oil seal
housing to the flat front face of the oil seal. If, in
service, there is wear in the seal location area of the
crankshaft pulley, oil will continue to leak after a new
oil seal is fitted. To renew a worn crankshaft pulley,
see operation 15-3.
1 Clean the oil seal housing. Inspect the new seal for
damage. If a scratch can be seen across the lip of the
seal, do not fit the seal.
2 Lubricate the outer circumference of the oil seal
with clean engine lubricating oil and enter the seal into
the housing. Ensure that the spring loaded lip of the
oil seal is towards the inside of the timing case cover
and that the oil seal is square to the bore of the seal
housing.
3 Assemble the oil seal replacer tool (A). Fit the
fastener plate, PD.170-3, (A3) to the front of the
crankshaft. Put the adaptor, (A5) on the nose of the
crankshaft and against the seal. Ensure that the
adaptor has the side stamped 10,5 mm towards the
seal.
Assemble the pressure plate, PD.170-1, (A2)
together with the sleeve, PD.170-2, (A4) onto the
threaded bar, PD.170, (A1). Put the tool assembly in
position on the adaptor, and tighten the threaded bar
onto the stud of PD.170-3 (A3).

15 New 1000 Series
To fit wear sleeve 15-3
1
To renew a worn crankshaft pulley, a wear sleeve
(A2) is fitted over the spigot (A1).
or operation 14-2.
Note: Full instructions and a special tool to fit the
wear sleeve are in each service kit.
2 Fit the wear sleeve, in accordance with the 3 2
manufacturer's instructions. It is not necessary to
remove the flange (A3) of the wear sleeve after it has
been fitted. 4
A A0402
A new front oil seal (A4) must be used when a wear
sleeve is fitted.
The dimension, to press the new oil seal into the
timing case, with a wear sleeve fitted, is 10,20/
10,70 mm (0.402/0.421 in), from the front face of
the timing case.
operation 14-2.

New 1000 Series 15
Idler gear and hub
To remove
2 Rotate the crankshaft until the marked teeth of the
crankshaft gear and the camshaft gear and the fuel
pump gear are all aligned with the marked teeth of the
idler gear (A).
Note: The marked teeth of the idler gear will not
necessarily be in mesh with the marked teeth of the
A A0129
other gears because of the different speed of rotation

of the idler gear.
2 3
3 Release the three setscrews (B8), remove the plate 4
(B1) of the idler gear and remove the gear (B3) from 1
the idler gear hub (B5). The drive gear of the fuel
injection pump may rotate counterclockwise when the 8
idler gear is removed. 5
4 Remove the idler gear hub, note the position of the
oil hole (B6).
6
Caution: The valve timing and fuel injection pump
timing will be lost if the crankshaft is rotated when the 7
idler gear is removed.
5 Inspect the gear and the bushes (B2) and (B7) for B L 00 30
wear and other damage and renew as necessary. The
gear and bushes are available as an assembly or
separate bushes are available.
6 If the bushes are to be changed, remove them with 1 2 3 4 5 6 7 8
a suitable puller. If a puller is not available, machine
off the face of one of the bushes and press them out.
Press in new bushes, machine the bores to get the
correct clearance on the hub and machine the faces
to get the correct end clearance, see the data and
dimensions and the end of this section.
7 For engines that use the idler gear assembly with
needle roller bearings - Release the three setscrews,
remove the plate of the idler gear (C1). Remove the
front thrust washer (C2), the front spacer (C3) and the
C A0132
gear (C4). Remove the two needle roller bearings
(C5), if these are to be used again, they should be
fitted in their original positions. Remove the rear thrust
washer (C6) and the rear spacer (C7). Remove the
hub (C8).

15 New 1000 Series
To fit
1 Use the three idler gear setscrews to ensure the
correct position of the idler gear hub (A2) with the 1
lubrication hole (A1) at the top. Push the hub into 2
position and remove the setscrews.
2 Lubricate the idler gear bushes with clean engine
lubricating oil. Align the timing marks on the idler gear
with the marks on the crankshaft and camshaft gears.
If necessary, rotate the gear of the fuel injection pump
clockwise to align the relevant timing mark with the
marks on the idler gear and slide the idler gear into
position. Check that all the timing marks are in correct
mesh (B), or (C) for engines fitted with a belt driven A A0312
coolant pump. Fit the plate and the setscrews to the
idler gear hub and tighten the setscrews to 44 Nm (33
lbf ft) 4,5 kgf m.
3 For engines that use the idler gear assembly with
needle roller bearings - Inspect the components for
wear and other damage and renew them as
necessary. Lightly lubricate the components with
clean lubricating oil before assembly onto the hub. Fit
the hub (D8) as shown in , go to paragraph 1. Put the
rear spacer (D7) in position on the hub. Put the rear
thrust washer (D6) in position on the rear spacer. Put
the bearings (D5) in position on the hub in the same
position as they were before they were removed.
Lightly lubricate the bore and thrust washer faces of
the gear (D4) with clean lubricating oil and put the B A0129
gear in position on the bearings. Put the front spacer

(D3) in position on the hub then put the front thrust
washer (D2) in position on the spacer. Put the plate
(D1) in position. The plate has TOP stamped on the
front face as the holes in the plate are not equally
spaced. Fit the setscrews and tighten them to 44 Nm
(33 lbf ft) 4,5 kgf m).
Continued
C A0307
1 2 3 4 5 6 7 8
D A0132

New 1000 Series 15
4 Check the idler gear end-float (A) and the timing
gear backlash (B).
6 Fit the coolant pump, see operation 21-2.
operation 14-2.
8 Where necessary, fit the fan drive pulley, see
operation 21-10.
11 Fill the cooling system. A A0130
B A0131

15 New 1000 Series
Idler gear and hub for the Bendix
compressor 1 2 3 4 5
The latest compressor is made by Bendix and is

driven directly from the engine timing case and does
not have an auxiliary drive assembly. The engine idler
gear (A12) drives the compressor gear (A4) through a
separate idler gear (A11/B4) fitted onto a hub (A9).
The hub is fastened to the back of the timing case
(A5) by a bracket (A3).
The idler gear is fitted on a needle roller bearing (A7)
which is fitted onto the hub. The hub has an "O" ring
(A1) to prevent oil leakage from the rear of the timing 12 11 10 9 8 7 6
case. The roller bearing and the idler gear are A A 0 29 1
retained on the hub by a plate (A10) which is fastened

to the idler hub.
1 2

4
To remove
3
2 Remove the timing case cover (A6), see operation
15-1.
Caution: Do not rotate the engine crankshaft or the
compressor crankshaft if the idler gear is removed. If
either of the crankshafts are moved, the compressor B A 0 29 5
must be timed to the engine.

3 Release the three setscrews (A8). Remove the
plate (A10) which retains the idler gear (A11).
Remove the gear and the needle roller bearing (A7)
from the idler hub (A9).
4 Remove the three cap screws (B3) which fasten the
idler hub to the bracket (B2) at the rear of the timing
case (B1). Remove the idler gear hub.
5 Remove and discard the "O" ring (A1).
6 Inspect the idler gear, needle roller bearing and
idler gear hub for wear and other damage and, if
necessary, renew them.

New 1000 Series 15
To fit
1 2 3 4 5
1 Renew the "O" ring (A1). Lightly lubricate the
components with clean lubricating oil before they are
assembled onto the hub.
Check that the four cap screws (B4) which secure the
idler hub bracket (B2) to the timing case are tightened
to the correct torque 35 Nm (26 lbf ft) 3,5 kgf m.
Fit the hub (A9) with the "O" ring towards timing case.
Fit the three M10 cap screws (B3) and tighten them to
60 Nm (44 lbf ft) 6 kgf m). Put the needle roller bearing
(A7) into position on the hub.
Caution: Do not rotate the engine crankshaft or the 12 11 10 9 8 7 6
A A0291
compressor crankshaft if the idler gear (B5) is
removed. If either of the crankshafts are moved, the
compressor must be timed to the engine.
1 2
2 Lightly lubricate the bore of the gear (A11) with
clean lubricating oil and put the gear in position on the
bearing. Put the plate (A10) in position. Fit the 4
setscrews (A8) and tighten them to 22 Nm (16 lbf ft)
2,2 kgf m. 3
3 Use the method shown on page 114/A to check the
compressor idler gear end-float and on page 114/B
for the timing gear backlash. See the data and
dimensions at the end of this section for the
compressor idler gear end-float and backlash
dimensions. B A0295

15 New 1000 Series
Fuel pump gear
The fuel injection timing is set with specialist tools in 1
the factory after the engine has been accurately set to
TDC, number 1 cylinder on the compression stroke.
The fuel pump gear has timing marks (A) which can
be used to find the approximate position of TDC on
number 1 cylinder compression stroke. The marked
teeth of the crankshaft, the camshaft and the fuel
pump gears will be in mesh with the idler gear when
number 1 piston is close to top dead centre (TDC) on
the compression stroke. The marked teeth of the idler
gear may not necessarily be in mesh in this position,
because of the different speeds at which the gears A A0129
rotate.
The fuel injection pump is timed at TDC on the
compression stroke of number 1 cylinder. It is 1
important that fuel injection timing is accurate to 2
conform to emissions legislation. Always use
operation 17-1 or operation 17-2 to obtain TDC on the
4
compression stroke of number 1 cylinder accurately. 3
5
To remove
Special tools: B A 0 37 2/1
Bosch fuel injection pump timing pin, PD.245 Note: On the latest engines with belt driven coolant
pumps, four tamper proof fasteners retain the fuel
Stanadyne and Lucas fuel injection pump timing pin, pump gear. Special tools are needed to remove these
PD.246 fasteners, refer to your Perkins distributor.
4 Inspect the gear for wear and other damage and
1 Remove the timing case cover, see operation 15-1. renew it, if necessary.
Caution: Do not lock the shaft of the fuel injection
pump, see operation 20-7 or operation 20-10.
2 Set the number one piston to TDC on the
compression stroke, see operation 17-1 or operation
17-2.
Fit the timing pin (B3) until the small end of the pin
(B2) is pushed fully into the hole in the fuel pump body
(B4). The pin can only be fitted when the number one
piston is correctly in position at TDC on the
compression stroke. If the timing pin cannot be
pushed into the pump body, check the timing of the
fuel injection pump, see operation 17-3.
Caution: Do not remove the nut (B5) which retains
the hub (B1) to the shaft of the fuel injection pump.
The hub is fitted permanently to the shaft. If the hub is
moved, it will be necessary for a fuel injection pump
specialist to correctly position the hub on the shaft
with special test equipment.
3 Remove the four fasteners (A1) from the fuel pump
gear and remove the gear from the hub of the fuel
pump.

New 1000 Series 15
To fit
The fuel pump gear will only fit in one position. The 1
gear is fitted with the letters C and M at the front.
Caution: Check that the shaft of the fuel injection 2
pump is released, see operation 20-7 for Bosch
pumps or operation 20-10 for Lucas DP 200 Series 3
pumps.
1 Ensure that the engine is set to TDC with the
number one piston on the compression stroke,
2 If the pin (B3) has been removed before the gear is
fitted rotate the hub (B1) until the hole (B4) can be A A0129
seen in the slot. Fit the small end of the pin (B2) fully
into the hole in the pump body. Leave the pin (B5) in
position. 1
3 Fit the fuel pump gear (C1), over the pin (C3) and 2
into mesh with the idler gear (C2).
4 Loosely fit the four fasteners in the centre of the
4 5
slots (C1) in the gear. 3
Carefully rotate the gear (B6) counter-clockwise until
the backlash between the idler gear and the fuel 7
pump gear has been removed. Do not rotate the
crankshaft or it will be necessary to set TDC again. 6
5 Tighten the four fastenerss (A3) to retain the gear
to 28 Nm (20 Ib ft) 2,8 kgf m. Remove the timing pin.
B
6 If a new gear has been fitted, use a feeler gauge to A0372
check the backlash.

7 Fit the timing case cover, see operation 15-1. 1
3
C 2
A0383

15 New 1000 Series
Camshaft gear
To remove
Special tools:
Gear puller, PD.155C
Adaptors for use with PD.155C, PD.155B-5
A A0134A
crankshaft gear and the camshaft gear are in mesh
with the idler gear. The marked teeth of the idler gear
will not necessarily be in mesh with the marked teeth
of the other gears because of the different speed of
rotation of the idler gear.
3 Remove the setscrew and washer of the camshaft
gear. Put a suitable adaptor onto the end of the
camshaft and remove the gear with the puller and
adaptor (A). Ensure that the key in the camshaft is not
lost.
4 Inspect the gear for wear and any other damage
and renew it, if necessary.
To fit
1 Ensure that the key in the camshaft is fitted
correctly.
2 Remove the idler gear, see operation 15-4.
3 Fit the camshaft gear to the camshaft with the
marked teeth towards the front and the keyway
correctly aligned with the key. If necessary, lightly hit
the gear with a soft face hammer to engage the key
into the keyway.
4 Fit the idler gear with the marked teeth in correct
mesh, see operation 15-4. If the camshaft has to be
turned and a valve hits a piston, disengage the rocker
assembly.
5 Fit the washer and the setscrew for the camshaft
gear and tighten the setscrew to press the camshaft
gear into position. Tighten the setscrew to 78 Nm (58
lbf ft) 8,0 kgf m. If a new camshaft gear has been
fitted, check the backlash.

New 1000 Series 15
Crankshaft gear
To remove
3 Remove the idler gear, see operation 15-4.
4 The crankshaft gear is a transition fit on the
crankshaft. It may slide off easily or, if it is a tight fit
and the gear is to be renewed, it may be necessary to
remove the crankshaft, see operation 14-10, to
remove the gear safely.
To fit
1 The gear can fit easily, or it may be necessary to
heat the gear before it will fit onto the crankshaft. If the
gear is to be heated, heat it in an oven to not more
than 180 °C (226 °F). If an oven is not available, heat
it in coolant which is at its boiling point. Do not use a
flame as this can cause local damage. Fit the gear
with the timing marks to the front.
2 Fit the idler gear, see operation 15-4 and ensure
that all the timing marks are correctly aligned.

15 New 1000 Series
Timing case
POWERPART Jointing compound
POWERPART Nutlock
To remove
2 Remove the drive belts, see operation 23-3.
or , see operation 14-2.
4 If necessary, remove the fan drive assembly, see
operation 21-10.
5 Drain the coolant and remove the coolant pump,
see operation 21-2.
6 Remove the alternator together with its mounting
bracket and front support plate.
7 Remove the compressor the drive assembly, and
the exhauster, if fitted, see section 24.
10 Remove the fuel injection pump, see section 20.
11 Remove the idler gear, see operation 15-4 and the
camshaft gear, see operation 15-7.
12 Remove the setscrews which hold the timing case
to the cylinder block and the setscrews which hold the
sump to the bottom of the timing case.
13 Remove the timing case and the joint, do not allow
the idler gear hub to fall. Ensure that the camshaft
thrust washer is not lost.

New 1000 Series 15
To fit
1 Ensure that the sump joint is not damaged. If the
joint is damaged, remove the sump and fit it with a
new joint after the timing case has been fitted. The 1
front section of the joint can be cut away and the front
section of a new joint fitted, without the removal of the
sump, but extreme care must be used to prevent 2
possible leaks.
2 If the sump has been removed, fit the idler gear hub 1
(A2) or (B2) to the front of the cylinder block; use the
three setscrews of the idler gear to hold the hub in
position. Ensure that the oil hole is at the top.
3 Ensure that the thrust washer for the camshaft is in A A 0 13 5
position.
4 Fit a new joint for the timing case to the cylinder
block. Cut the bottom ends of the joint to fit correctly.
1
Apply POWERPART Jointing compound to the
2
bottom ends of the joint.
5 Put the timing case in position. If the sump has not
1
been removed, fit the idler gear hub, see , go to
paragraph 2. Fit the four setscrews (A1), or three
setscrews (B1) for engines fitted with a belt driven
coolant pump, around the idler gear hub. Ensure that
the bottom of the timing case is correctly aligned with
the bottom of the cylinder block before the setscrews
are tightened. Put the fan drive assembly and/or the
alternator and its front support plate in position and fit B A0312
and tighten the remainder of the setscrews of the
timing case. If the front support plate has been 13 If necessary, fit the fan drive pulley, see operation
separated from the alternator bracket, ensure that the 21-10.
right side of the plate is level with the machined face 14 Fit the alternator, see operation 23-4 and the
on the cylinder block where the alternator bracket is alternator front bracket.
fitted. If a new timing case is fitted, remove the two
studs from the timing case and clean the threads
which fit into the timing case. Seal the threads with
POWERPART Nutlock and fit the studs into the new 16 Fit the fan, see operation 21-9.
timing case. Remove the setscrews from the idler 17 Fill the cooling system.
gear hub.
6 If necessary, fit the lubricating oil sump, see
operation 19-3, and fill it to the correct level with an
approved oil.
7 Fit the camshaft gear, see operation 15-7 and the
idler gear, see operation 15-4. Ensure that all the
timing marks are correctly aligned.
8 Fit the fuel injection pump and the drive gear, see
section 20. Eliminate air from the fuel system, see
section 20.
9 Fit the compressor and its drive assembly, if fitted,
see operation 24-1.
11 Fit the coolant pump, see operation 21-2.
12 Fit the crankshaft pulley, see operation 14-1 or ,
see operation 14-2.

15 New 1000 Series
Camshaft and tappets
To remove
1 Before the engine is removed from the vehicle or
the machine, drain the lubricating oil and the coolant.
2 Remove the timing case, see operation 15-9.
3 Remove the rocker cover, the rocker assembly and
the push rods, see section 12.
4 Remove the fuel lift pump, see operation 20-4. A A0136
5 Turn the engine upside down and remove the
lubricating oil sump, see operation 19-3.
6 Remove the camshaft thrust washer (B1) and 1 2
carefully remove the camshaft (A).
7 Remove the tappets.
8 Inspect the camshaft and the tappets for wear and
other damage, also inspect the camshaft bush.
Renew the components as necessary.
To fit
1 Ensure that all components are clean and are
lubricated with clean engine lubricating oil.
2 Fit the tappets in position.
B A0137
3 Carefully fit the camshaft.
4 Fit the camshaft thrust washer. Ensure that it is
fitted correctly on the hollow dowel (B2).
5 Fit the timing case together with a new joint, see
operation 15-9.
6 Check that the camshaft end-float is within the
limits shown in data and dimensions.
7 Rotate the camshaft until the cam for the fuel lift
pump is at the minimum lift position and fit the fuel lift
pump, see operation 20-4.
8 Turn the engine to an upright position. Rotate the
crankshaft until the keyway in the crankshaft is at the
top. Fit the timing gears, see operation 15-4,
operation 15-6 and operation 15-7, and ensure that all
the timing marks are correctly aligned.
9 Fit the fuel injection pump, see section 20.
10 Fit the push rods and the rocker assembly, see
section 12.
11 Set the valve tip clearances, see operation 12-5.
12 Fit the timing case cover, see operation 15-1 and
the lubricating oil sump, see operation 19-3.
13 After the engine has been installed: Fill the cooling
system. Fill the lubricating oil sump to the correct level
with an approved lubricating oil. Eliminate air from the
fuel system, see section 20.

New 1000 Series 15
Data and dimensions
Timing case and drive assembly
Camshaft
Diameter of number 1 journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,71/50,74 mm (1.9965/1.9975 in)
Diameter of number 2 journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,46/50,48 mm (1.9865.1.9875 in)
Diameter of number 3 journal:
- Four cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49,95/49,98 mm (1.9665/1.9675 in)
- Six cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,20/50,23 mm (1.9765/1.9775 in)
Diameter of number 4 journal:
- Six cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49,95/49,98 mm (1.9665/1.9675 in)
Clearance of all journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,06/0,14 mm (0.0025/0.0055 in)
Cam lift:
- Inlet, engine types AJ, AK, AM, AP, AQ, YG, YH, YK. . . . . . . . . . . . . . . . . 7,62/7,69 mm (0.2999/0.3029 in)
- Inlet, engine types AR and AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,58 mm (0.3378 in)
- Exhaust, engine types AJ, AK, AM, AP, AQ, YG, YH, YK. . . . . . . . . . . . . . 7,71/7,79 mm (0.3036/0.3066 in)
- Exhaust, engine types AR and AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,80 mm (0.3464 in)
Maximum permissible ovality and wear on journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05 mm (0.021 in)
End-float:
- Production limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,10/0,41 mm (0.004/0.016 in)
- Service limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,53 mm (0.021 in)
Width of spigot for thrust washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,64/5,89 mm (0.222/0.232 in)
Camshaft thrust washer
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .360°
Depth of recess in cylinder block for thrust washer . . . . . . . . . . . . . . . . . . . . . . 5,46/5,54 mm (0.215/0.218 in)
Thickness of thrust washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,49/5,54 mm (0.216/0.218 in)
Relationship of thrust washer to front face of cylinder block . . . . . . . . . . . . -0,05/+0,08 mm (-0.002/+0.003 in)
Camshaft gear
Number of teeth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Diameter of bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34,93/34,95 mm (1.3750/1.3760 in)
Outside diameter of hub of camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34,90/34,92 mm (1.3741/1.3747 in)
Clearance fit of gear on hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,008/0,048 mm (0.0003/0.0019 in)
Fuel pump gear
Number of teeth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,00/36,06 mm (1.417/1.419 in)
Clearance fit on hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,003/0,075 mm (0.0001/0.0030 in)

15 New 1000 Series
Crankshaft gear
Number of teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Diameter of bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47,625/47,650 mm (1.8750/1.8760 in)
Diameter of hub for gear on crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . 47,625/47,645 mm (1.8750/1.8758 in)
Transition fit of gear on crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . -0,020/+0,048 mm (-0.0008/+0.0010 in)
Idler gear and hub
Number of teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Diameter of bore of gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57,14/57,18 mm (2.2495/2.2512 in)
- with needle roller bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69,01/69,03 mm (2.717/2.718 in)
Width of gear and split bush assembly (fitted in position) . . . . . . . . . . . . . . . 30,14/30,16 mm (1.186/1.187 in)
Inside diameter of flanged bushes (fitted in position). . . . . . . . . . . . . . . . . . 50,78/50,80 mm (1.9999/2.000 in)
Outside diameter of hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,70/50,74 mm (1.9960/1.9975 in)
-with needle roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54,987/55,000 mm (2.1648/2.1654 in)
Clearance of bushes on hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,04/0,10 mm (0.0016/0.0039 in)
End float of gear:
- Production limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,10/0,20 mm (0.004/0.008 in)
- with needle roller bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,24/0,33 mm (0.009/0.013 in)
- Service limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,38 mm (0.015 in)
Backlash for all gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,08 mm (0.003 in) minimum
Idler gear and hub for the Bendix compressor
Number of teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Diameter of bore of gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55,010/55,025 mm ( 2.1657/2.1663 in)
Outside diameter of hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,000/49,990 mm (1.9960/1.9975 in)
End float of gear with needle roller bearing fitted: . . . . . . . . . . . . . . . . . . . . . . . 0,12/0,16 mm (0.005/0.006 in)
Backlash gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,07 mm (0.003 in) minimum
Timing case front cover
Front cover oil seal depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10,20/10,70 mm (0.402/0.421 in)

New 1000 Series
16
Cylinder block assembly 16
General description
The cylinder block is made of cast iron and provides
a full length support for the dry liners which are also
made of cast iron. Production liners are a press fit in
the block. In service two liners are available:
! A finished liner, which has a transition fit in the
parent bore.
! A partially finished liner, which is an interference fit
in the parent bore and must be machine finished
after it has been installed.
All liners are honed with silicon carbide tools to a
controlled finish to ensure long life and low oil
consumption. The cylinder liners have a flame ring
above the flange. A bush is fitted in the cylinder block
for the front camshaft journal and the other camshaft
journals run directly in the block.
Engine types AR and AS do not have cylinder liners
fitted and the cylinder bores must be machined
oversize to correct a worn cylinder bore, refer to the
data and dimensions at the end of this section for
further details.
Note: Short engines are also available.
Your Perkins distributor has specialist equipment and
personnel with the correct training to repair worn
cylinder bores.

16 New 1000 Series
Cylinder block
POWERPART Nutlock
Note: If the cylinder block is to be renewed, it may be

necessary to change the grade connecting rods, see
operation 13-7. This will occur if the correct piston
height above the block face cannot be maintained
with the original piston and connecting rod
assemblies, see operation 13-4.
To dismantle
1 Drain the cooling system and the lubricating oil.
2 Remove the engine from the vehicle or machine.
3 Remove the alternator drive belts and the alternator
and its mounting brackets, see section 23.
4 Remove the fan, the fan drive and the water pump,
see section 21.
5 Remove the compressor or the exhauster, where
fitted, see section 24.
6 Remove the fuel filter, the atomisers and the fuel
injection pump, see section 20.
7 Remove the lubricating oil cooler, where fitted, see
operation 21-11.
8 Remove the lubricating oil filter assembly and the
lubricating oil sump, see section 19.
9 If necessary, remove the turbocharger, see
operation 18-1.
10 Remove the fuel lift pump, see operation 20-4
11 Remove the starter motor, see operation 23-6.
12 Remove the cylinder head assembly, see
operation 12-7.
13 Remove the timing case and the timing gears, see
section 15.
14 Remove the lubricating oil pump and the pressure
relief valve, see section 19, or remove the balancer
unit, see operation 14-12.
15 Remove the piston and connecting rod
assemblies, see operation 13-3.
16 Remove the camshaft and the tappets, see
operation 15-10.
17 Remove the flywheel and the flywheel housing,
see section 22.
18 Remove the rear oil seal assembly and the
crankshaft, see section 14.
19 Remove the piston cooling jets, see operation 13-
11.
20 Inspect the cylinder block, see operation 16-2.

New 1000 Series 16
To assemble To inspect 16-2
1 Clean thoroughly the new cylinder block. Ensure
that all the oil passages are clean and free from 1 Clean the passages for the coolant and for the oil.
debris. 2 Check the cylinder block for cracks and for other
2 Remove the threaded plugs from the old cylinder damage.
block and clean the threads. Seal the threads with 3 The top face of the cylinder block must not be
POWERPART Nutlock, or a similar sealant, and fit the machined as this will affect the liner flange depth and
threaded plugs into the new cylinder block. the piston height above the top face of the cylinder
3 Fit the piston cooling jets, see operation 13-11. block.
4 Fit the crankshaft and the rear oil seal assembly, 4 Check the camshaft bush for wear. If the bush is to
see section 14. be renewed, use a suitable adaptor to press it out of
the bore. Ensure that the lubricating oil hole in the
5 Fit the piston and connecting rod assembly, see
new bush will be towards the front of the engine, when
operation 13-3.
fitted. Press in the bush with the oil hole on the same
6 Fit the flywheel housing and the flywheel, see side and aligned with the oil hole in the block until the
section 22. front end of the bush is aligned with the face of the
7 Fit the tappets and the camshaft, see operation 15- recess.
10.
8 Fit the lubricating oil pump and the pressure relief
valve, see section 19, or fit the balancer unit, see
operation 14-12.
9 Fit the timing case and the timing gears, see
section 15.
10 Fit the cylinder head assembly, see operation
12-7.
11 Fit the starter motor, see operation 23-6.
12 Fit the fuel lift pump, see operation 20-4.
13 If necessary, fit the turbocharger, see operation
18-1.
14 Fit the lubricating oil filter assembly and the
lubricating oil sump, see section 19.
15 If necessary, fit the lubricating oil cooler, see
operation 21-11.
16 Fit the fuel filter, the atomisers and the fuel
injection pump, see section 20.
17 If necessary, fit the compressor or the exhauster,
see section 24.
18 Fit the fan, the fan drive and the water pump, see
section 21.
19 Fit the alternator and its mounting brackets and
the alternator drive belts, see section 23.
20 Install the engine into the vehicle or machine.
22 Fill the lubricating oil sump to the correct level with
an approved lubricating oil.
23 Eliminate air from the fuel system, see section 20.

16 New 1000 Series
Cylinder liner
To inspect 16-3
To ensure the best performance during the life of the

engine it is important that worn or damaged cylinder
liners are renewed. If a change of liner becomes
necessary in service, transition fit liners and partially
finished liners are available.
The condition of a cylinder liner is decided by:
! The amount and location of any polished areas.
! Wear.
! Damage to the liner wall.
Notes:
! It will not be necessary to renew the liners if:
! The honed finish can still be clearly seen.
! The engine performance and oil consumption is
acceptable.
To check the condition of a cylinder liner
1 Inspect the liner surface for cracks and deep
scratches.
2 Check the liner wall for areas where the honed
finish has been polished away. Check especially the
area around the top of the liner bore just below the
carbon ring. In this area, thrust from the top piston ring
is at its maximum.
Cautions:
! Do not use "Flex-hone" to repair cylinder liners.
! Damaged or worn liners must be discarded.
! New piston rings must be fitted when the cylinder
liner is renewed.
! An engine can have high oil consumption with very
little wear of the liner bores, if the surfaces of the
liners are glazed.
! Specialist training and equipment is needed to
machine the finish of a partially finished liner.
Partially finished cylinder liners must be bored and
then diamond honed, silicon carbide base honed and
silicon carbide plateau honed to the finished size to
conform to the dimensions in the data and dimensions
at the end of this section. Specialist training and
equipment is needed to machine a partially finished
liner. For further information contact your nearest
Perkins Distributor.

New 1000 Series 16
2
Special tools:
Remover/replacer for cylinder liner (main tool), 1
PD.150B
3
Adaptors for use with PD.150B, PD.150B-17A
Depth gauge, liner flange, PD.41D
4
Consumable products: (See Section 10)
Loctite Safety Solvent or a similar product
5
Where several liners are to be removed or a very tight

production liner is fitted, a press should be used.
Where a single liner is to be removed or the
crankshaft is to remain in position, a tool for hand
operation is available.
To remove
1 Drain the lubricating oil and remove the lubricating 6
12-7.
3 Remove the piston and connecting rod assembly, A A0212
see operation 13-3.
4 Carefully remove the piston cooling jet, where
fitted, see operation 13-11.
5 Rotate the crankshaft to give access to the cylinder
liner. Protect the crank pin.
6 Put the tool (A4) on the top face of the cylinder
block and over the centre of the liner (A5). Ensure that
the base of the tool is not on top of the liner flange of
the next cylinder.
7 Put the bearing (A3) in the recess in the top of the
tool with the flat face of the bearing to the bottom of
the recess.
8 Fit the threaded rod (A2) through the bearing and
the top of the tool until the handle (A1) is in the recess
in the top of the bearing. In this position adjust the
threaded rod until the end is below the bottom of the
cylinder liner. Fit the adaptor PD.150B-17/1 (A6) onto
the threaded rod and against the bottom of the
cylinder liner. Ensure that the two lugs on the top of
the adaptor engage with the flats on the threaded rod.
Fit the washer and nut and tighten the nut onto the
adaptor.
9 Lubricate the ratchet of the handle and the
threaded rod with Shell Spirax oil or an equivalent oil.
Operate the handle and pull the cylinder liner out of
the top of the cylinder block.

16 New 1000 Series
To fit a service liner
A service liner is a transition fit of +/- 0,03 mm (+/- 1
0.001 in) in the parent bore. A special tool will not be
necessary to fit some liners, but where a liner is a tight 2
fit, tool PD.150B can be used.
3
Caution: Do not hit a liner with a hammer.
1 Clean thoroughly the parent bore. Clean the top 5 4
50 mm (2.0 in) and the recess for the liner flange
with Loctite Safety Solvent or a similar product; use it
in accordance with the manufacturer's instructions.
2 Clean thoroughly the outer surface of the liner with
Loctite Safety Solvent.
3 Lubricate lightly the parent bore with clean engine
lubricating oil, except for the top 50 mm (2.0 in).
4 Engage the cylinder liner (A5) into the parent bore;
ensure that the liner is vertical. Put the adaptor
PD.150B-17/2 (A4) onto the top of the liner with the
shoulder of the adaptor on the liner flange. Put the
bearing (A3) into position in the recess in the top of
the adaptor with the flat face of the bearing to the
bottom of the recess.
5 Fit the threaded rod (A1) through the bearing, the
adaptor and the liner until the handle (A2) is against
the recess in the bearing. In this position adjust the
threaded rod until the end is below the bottom face of 6
the cylinder block.
A A0213
6 Fit the adaptor PD.150B/6 (A6) onto the threaded
rod; ensure that the flat face of the adaptor is against
the bottom face of the cylinder block. Fit the washer
and the nut; ensure that the threaded rod is in the
centre of the liner and tighten the nut onto the
adaptor.
Continued

New 1000 Series 16
threaded rod with Shell Spirax oil or an equivalent oil. 1
Operate the handle and press the liner into the parent
bore to within 50 mm (2.0 in) of the fitted position. 2
Clean the area below the flange of the liner with
Loctite Safety Solvent. Apply POWERPART Retainer
(oil tolerant) to the top 25 mm (1.0 in) of the outer
surface of the liner and under the flange; also apply
POWERPART Retainer (oil tolerant) to the bottom of
the flange recess in the parent bore.
8 Press the liner in to the fully fitted position. Remove
the tool and clean the retainer from the top of the
cylinder block.
9 Allow 15 minutes to elapse before the liner bore A A0214
dimension is checked. The retainer will reach full

strength after 6 hours. The inside diameter of a
service liner, when fitted, should be 100,00/100,06
mm (3.937/3.939 in).
10 Use tool PD.41D to check that the liner flange is
between 0,10 mm (0.004 in) above to 0,10 mm (0.004
in) below the top face of the cylinder block (A).
11 Fit new piston rings, see operation 13-5.
12 Fit the piston and connecting rod assembly, see
operation 13-3.
13 If necessary, fit the piston cooling jet, see
operation 13-11.
14 Fit the cylinder head assembly, see operation 12-
7.
15 Fit the lubricating oil sump, see operation 19-3,
lubricating oil.
Caution: After a new service liner has been fitted,
these recommendations are advised for the first 240
km (150 miles) or 5 hours of operation:
! Do not operate the engine at full load.
! Do not operate the engine at high speed.
! Do not allow the engine to run at low idle speed for
long periods.

16 New 1000 Series
To fit a partially finished liner
The liner is an interference fit in the parent bore. A 1
special tool will be necessary to fit the liners, tool
PD.150B can be used. If a liner is a very tight fit it may 2
be necessary to use a hydraulic press.
3
Caution: Do not hit a liner with a hammer.
1 Clean thoroughly the parent bore of the cylinder 5 4
block with an approved degreasing fluid.
2 Inspect the parent bore for damage and corrosion.
Damaged cylinder blocks should be discarded.
3 Clean thoroughly the outer surface of the liner with
an approved degreasing fluid.
4 Apply a small amount of engine oil around the top
of the parent bore to assist the entry of the liner.
5 Engage the cylinder liner (A5) into the parent bore;
ensure that the liner is vertical. Put the adaptor
PD.150B-17A (A4) onto the top of the liner with the
flame ring in the groove of the adaptor. Put the
bearing (A3) into position in the recess in the top of
the adaptor with the flat face of the bearing to the
bottom of the recess.
6 Fit the threaded rod (A1) through the bearing, the
adaptor and the liner until the handle (A2) is against
the recess in the bearing. In this position adjust the
threaded rod until the end is below the bottom face of 6
the cylinder block. A A0213
7 Fit the adaptor PD.150B/6 (A6) onto the threaded
rod; ensure that the flat face of the adaptor is against
the bottom face of the cylinder block as shown (A). Fit
the washer and the nut; ensure that the threaded rod
is in the centre of the liner and tighten the nut onto the
adaptor.
threaded rod with Shell Spirax oil or an equivalent oil.
Operate the handle and press the liner into the fully
fitted position.
9 Remove the tool PD.150B and thoroughly clean the
top of the cylinder block.
Continued

New 1000 Series 16
10 Use tool PD.41D to check that the flange of the
cylinder liner is between 0,10 mm (0.004 in) above to 1
0,10 mm (0.004 in) below the top face of the cylinder
block (A). 2
This measurement must be from the flange (A2) of the

cylinder liner, not the top of the flame ring (A1).
Caution: Specialist training and equipment is
needed to machine the finish of a partially finished
liner.
Partially finished cylinder liners must be bored and
then diamond honed, silicon carbide base honed and
silicon carbide plateau honed to the finished size to
conform to the dimensions in the data and dimensions A A0214
at the end of this section. Specialist training and
equipment is needed to machine the partially finished
liner. For further information contact your nearest
Perkins distributor.
11 Fit new piston rings, see operation 13-2.
12 Fit the piston and connecting rod assembly.
13 If necessary, fit the piston cooling jet, see
operation 13-11.
14 Fit the cylinder head assembly, see operation
12-7.
15 Fit the lubricating oil sump, see operation 19-3
lubricating oil.
Caution: After a new cylinder liner has been fitted,
these recommendations are advised for the first 240
km (150 miles) or 5 hours of operation:
! Do not operate the engine at full load.
! Do not operate the engine at high speed.
! Do not allow the engine to run at low idle speed for
long periods.

16 New 1000 Series
Cylinder bore, engine types AR and AS
To inspect 16-5
To ensure the best performance during the life of the

engine it is important that worn or damaged cylinder
bores are corrected.
The condition of a cylinder bore is decided by:
! The amount and location of any polished areas.
! Wear.
! Damage to the cylinder wall.
Note: It will not be necessary to correct the bore if:
! The honed finish can still be clearly seen.
! The engine performance and oil consumption is
acceptable.
1 Inspect the surface of the cylinder bore for cracks
and deep scratches.
2 Check the bore wall for areas where the honed
finish has been polished away. Check especially the
area around the top of the liner bore just below the
carbon ring. In this area, thrust from the top piston ring
is at its maximum.
Cautions:
! Do not use "Flex-hone" to repair cylinder bores.
! An engine can have high oil consumption with very
little wear of the cylinder bores, if the surfaces of
the bores are glazed.
! Specialist training and equipment is needed to
machine the finish of a cylinder bore.
If necessary, the cylinder bores can be bored and
honed 0,50 mm (0.0197 in) and 1,00 mm (0.0394 in)
oversize in diameter and oversize pistons fitted.
To obtain oversize cylinder bores they must be bored
and then diamond honed, silicon carbide base honed
and silicon carbide plateau honed to the finished size
to conform to the dimensions in the data and
dimensions at the end of this section. Specialist
training and equipment is needed to machine a
cylinder bore. For further information contact your
nearest Perkins distributor.

New 1000 Series 16
Data and dimensions
Cylinder block assembly
Cylinder block
Height between top and bottom faces . . . . . . . . . . . . . . . . . . . . . . . . . . 441,12/441,33 mm (17.367/17.375 in)
Diameter of parent bore for cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . 104,20/104,23 mm (4.103/4.104 in)
Depth of recess for flange of cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,81/3,91 mm (0.150/0.154 in)
Diameter of recess for flange of cylinder liner . . . . . . . . . . . . . . . . . . . . . . 107,82/107,95 mm (4.245/4.250 in)
Diameter of cylinder bore, engine types AR and AS only . . . . . . . . . 103,000/103,025 mm (4.0551/4.0561 in)
Maximum permissible bore wear, engine types AR and AS only . . . . . . . . . . . . . . . . . . . 0,15 mm ( 0.006 in)
Diameter of first oversize cylinder bore,
engine types AR and AS only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103,500/103,525 mm (4.0748/4.0757 in)
Diameter of second oversize cylinder bore,
engine types AR and AS only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104,000/104,025 mm (4.0944/4.0954 in)
Diameter of parent bore for main bearing . . . . . . . . . . . . . . . . . . . . . . . 80,416/80,442 mm (3.1660/3.1670 in)
Camshaft bore diameter
- Four cylinder engines:
Number 1 (for bush) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55,56/55,59 mm (2.188/2.189 in)
Number 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,55/50,60 mm (1.990/1.992 in)
Number 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,04/50,09 mm (1.970/1.972 in)
- Six cylinder engines:
Number 1 (for bush) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55,56/55,59 mm (2.188/2.189 in)
Number 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,55/50,60 mm (1.990/1.992 in)
Number 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,29/50,34 mm (1.980.1.982 in)
Number 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,04/50,09 mm (1.970/1.972 in)
Bore of bush for number 1 camshaft journal . . . . . . . . . . . . . . . . . . . . . . . . . 50,79/50,85 mm (2.000/2.002 in)
Cylinder liners
Type:
- Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dry, interference fit, flanged, with flame ring
- Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry, transition fit, flanged, with flame ring
- Partially finished liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dry, interference fit, flanged, with flame ring
Outside diameter of production liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104,25/104,28 mm (4.105/4.106 in)
Interference fit of production liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,03/0,08 mm (0.001/0.003 in)
Inside diameter of production liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100,00/100,03 mm (3.937/3.938 in)
Transition fit of service liner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +/- 0,03 mm (+/- 0.001 in)
Inside diameter of service liner with a flame ring (fitted) . . . . . . . . . . . . . 100,00/100,063 mm (3.937/3.939 in)
Maximum permissible wear of liner bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,25 mm (0.010 in)
Thickness of flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,81/3,86 mm (0.150/0.152 in)
Relative position of top of liner flange to top face of cylinder block . . . . . . . . . . . . . 0,10 mm (0.004 in) above
0,10 mm (0.004 in) below

16 New 1000 Series
Cylinder liner specifications
Caution: Specialist training and equipment is needed to machine the finish of a partially finished liner. For
further information contact your nearest Perkins Distributor.
Partially finished liner
Interference fit of liner in parent bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025/0,076 mm (0.003/0.001 in)
Inside diameter of partially machined liner. . . . . . . . . . . . . . . . . . . . . . . 99,162/99,415 mm (3.9040/3.9139 in)
Preliminary bore
Final size of liner before it is honed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99,873/99,924 mm (3.9320/3.9340 in)
Surface finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ra 3,2 to 4,0 micrometers
Maximum ovality and taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,02 mm (0.0008 in)
Diamond hone
Hone angle (cross hatch). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35°
Finish size, diamond honed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99,95 mm (3.9350 in)
Maximum ovality and taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,012 mm (0.0005 in)
Silicone carbide base hone
Hone angle (cross hatch). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35°
Finish size, silicon carbide base hone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100,012 mm (3.9374 in)
Silicone carbide plateau hone
Final finish size, silicon carbide (plateau hone) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100,017 mm (3.9376 in)
Final surface finish grade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,65/1,3 micrometers

New 1000 Series 16
Cylinder bore specifications, engine types AR and AS
Note: Two oversize pistons are available in service:- 0,5 mm (0.020 in) and 1,0 mm (0.040 in).
Caution: Specialist training and equipment is needed to machine the cylinder bore. For further information
contact your nearest Perkins Distributor.
Preliminary bore
Final size of standard bore before it is honed . . . . . . . . . . . . . . . . . . 102,873/102,924 mm (4.0501/4.0521 in)
First oversize of bore before it is honed . . . . . . . . . . . . . . . . . . . . . . 103,373/103,424 mm (4.0698/4.0718 in)
Second oversize of bore before it is honed . . . . . . . . . . . . . . . . . . . . 103,873/103,924 mm (4.0894/4.0914 in)
Surface finish. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ra 3,2 to 4,0 micrometers
Maximum ovality and taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,02 mm (0.0008 in)
Diamond hone
Hone angle (cross hatch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35°
Finish size of standard bore, diamond honed . . . . . . . . . . . . . . . . . . 102,949/102,961 mm (4.0531/4.0536 in)
Finish size of first oversize of bore, diamond honed . . . . . . . . . . . . . 103,449/103,461 mm (4.0727/4.0732 in)
Finish size of second oversize of bore, diamond honed . . . . . . . . . . 103,949/103,961 mm (4.0924/4.0929 in)
Silicone carbide base hone
Hone angle (cross hatch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35°
Finish size of standard bore,
silicon carbide base hone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103,000/103,025 mm (4.0551/4.0561 in)
Finish size of first oversize of bore,
silicon carbide honed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103,500/103,525 mm (4.0748/4.0757 in)
Finish size of second oversize of bore,
silicon carbide honed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104,000/104,025 mm (4.0944/4.0954 in)
Silicone carbide plateau hone
Final finish size of standard bore,
silicon carbide (plateau hone) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103,000/103,025 mm (4.0551/4.0561 in)
Final finish size of first oversize of bore,
Final finish size of second oversize of bore,
Final surface finish grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ra 0,65/1,3 micrometers

140
New 1000 Series
17
Engine timing 17
General description
To reach the accurate fuel injection needed for
engines to conform to emissions legislation, the latest
fuel injection pumps operate at a static timing very
close to TDC.
The timing gears are stamped with timing marks to
ensure that they are assembled correctly (A). The
marked teeth of the crankshaft, the camshaft and the
fuel pump gears will be in mesh with the idler gear
when number 1 piston is close to top dead centre
(TDC) on the compression stroke. The marked teeth
of the idler gear may not necessarily be in mesh in this
position, because of the different speeds at which the
gears rotate.
A A0129
The fuel injection pump is timed at TDC on the
compression stroke of number 1 cylinder. It is
important that fuel injection timing is accurate to
conform to emissions legislation. Always use
operation 17-1 or operation 17-2 to obtain TDC on the
1
compression stroke of number 1 cylinder accurately.
Caution: The fuel injection pump has a lock screw
(B1) which locks the shaft. It is important that the
lock screw is released and the pump shaft is free to 2
turn. The drive shaft of the pump must not be rotated
without the spacer (B2) in position under the locking
screw. If the drive shaft is rotated with the locking
screw tightened on to the shaft, the drive shaft will be
damaged. B A0256
Continued

17 New 1000 Series
The latest fuel injection pumps have a hub (A2) which
is mounted permanently onto the drive shaft.
The manufacturer fits the hub to the pump to ensure 2
very accurate timing. Engines that have this 1
arrangement have the drive gear fastened to the hub
instead of to the shaft of the pump. A pin (A1) is used
to accurately time these pumps in service.
Caution: Do not release the nut (A3) from the fuel
injection pump. Illustration (B) shows the nut (B2) in
position when the fuel pump is fitted to the engine.
The fuel pump hub is fitted to the shaft in the factory
to ensure that the fuel pump is in the correct position 3
for timing. If the nut is removed and the hub moves, A A1448
the hub will need to be accurately fitted to the pump
by use of specialist equipment before the pump can
be fitted to the engine.
The fuel pump gear is fastened to the hub of the fuel
pump by four setscrews. The setscrews pass through
slots in the gear which allow removal of the backlash.
Note: On the latest engines with belt driven coolant
pump gear. Special tools are needed to remove these 1
fasteners, refer to your Perkins distributor.
To remove the fuel injection pump from the engine it
is only necessary to remove the four setscrews (B1)
2
which secure the fuel pump gear to the hub, see B A0374
operation 20-7.

New 1000 Series 17
Engine timing
2
To set number 1 piston to TDC on the

compression stroke 17-1
Special tools:
Stud adaptor for use with PD.6118B, PD.6118B-7
Setscrew adaptor for use with PD.6118B, PD.6118B- 1
8
A A0173
1 Fasten a temporary pointer to the timing case cover

with its tip near to the outer edge of the crankshaft
pulley or damper (A1).
2 Loosen the gland nuts that retain the atomisers,
see operation 20-3.
4 Rotate the crankshaft, clockwise from the front,
until the push rod for the inlet valve of the rear cylinder
just tightens.
5 Remove the spring clip and the spacer from the
front of the rocker shaft. Release the fasteners of the
front two pedestals of the rocker shaft and remove the
front rocker lever; tighten the fasteners of the rocker
shaft pedestals.
6 Remove the valve springs from the front valve with
the valve spring compressor PD.6118B and the
adaptor PD.6118-7, for pedestal studs, or the adaptor
PD.6118-8, for pedestal setscrews.
Caution: Fit a suitable collar near the top of the valve
to hold the valve if the crankshaft is rotated too far.
7 Allow the valve to be held by the top of the piston.
8 Fasten a dial test indicator with its plunger in
contact with the top of the valve stem (A2) and with a
reading shown on the gauge. Rotate slowly the
crankshaft, clockwise from the front, until the
clockwise movement of the dial gauge pointer just
stops. Make a suitable mark on the crankshaft pulley
or damper to align with the temporary pointer.
Continue to rotate the crankshaft, in the same
direction, until the gauge pointer just begins to move
in a counter-clockwise direction. Make another mark
on the pulley or damper to align with the pointer. Mark
the centre point between the two marks on the pulley
or damper and remove the other two marks.
9 Rotate the crankshaft approximately 45°
counterclockwise from the front and then clockwise
until the mark on the pulley or damper is aligned with
the pointer. Number 1 piston is now at TDC on the
compression stroke.

17 New 1000 Series
Another method to set number 1 piston to To check the valve timing 17-3
TDC on the compression stroke 17-2
1 Set the piston of number 1 cylinder to TDC on the
1 Fasten a temporary pointer to the timing case cover compression stroke, see operation 17-1.
(or other suitable position) with its tip near to the outer 2 Remove the dial test indicator from number 1 inlet
edge of the crankshaft damper or pulley. valve and fit the valve springs and the rocker lever.
2 Loosen the gland nuts that retain the atomisers, Ensure that the fasteners for the rocker shaft
see operation 20-3. pedestals are to the correct torque.
3 Remove the rocker cover. 3 Rotate the crankshaft, clockwise from the front,
4 Rotate the crankshaft clockwise, from the front, until the inlet valve of the rear cylinder is fully open.
until the push rod for the inlet valve of the rear cylinder 4 Set the valve tip clearance of number 1 cylinder
just tightens. inlet valve to 1,5 mm (0.059 in).
5 Rotate the crankshaft a further 1/8 of a turn 5 Rotate the crankshaft, clockwise from the front,
clockwise. Insert a suitable lever between the rocker until the push rod of number 1 cylinder inlet valve just
lever and the valve spring cap of number 1 inlet valve. tightens. In this position, check if the mark on the
Open the inlet valve and put a spacer approximately crankshaft pulley or damper is within +/- 2 1/2° of the
5,0 mm (0.2 in) thick between the valve tip and the temporary pointer. Use the formula below to find the
rocker lever. measurement which is equal to 2 1/2° on the pulley or
6 Slowly rotate the crankshaft counter-clockwise until damper.
the piston makes contact with the open valve. Make a
temporary mark on the damper or pulley to align CxP
accurately with the tip of the pointer. 360
7 Rotate the crankshaft clockwise one or two degrees C = circumference of pulley or damper
and remove the spacer between the valve and the
rocker lever. Rotate the crankshaft 1/4 of a turn P = 2.5 degrees
counter-clockwise. Put the spacer between the valve 6 If the timing is more than 2 1/2° out of position, the
tip and the rocker lever. timing gears are probablely not in correct mesh.
8 Slowly rotate the crankshaft clockwise until the Note: One tooth on the camshaft gear is equivalent
piston makes contact with the open valve. Make to 23 mm (0.9 in) at the circumference of a pulley of
another temporary mark on the damper or pulley to 203 mm (8 in) diameter. If a large damper is fitted, one
align accurately with the tip of the pointer. tooth on the camshaft gear is equivalent to 35 mm
9 Make a temporary mark at the centre point between (1.4 in) at the circumference of a damper of 310 mm
the two marks on the damper or pulley and remove (12.2 in) diameter, or 37 mm (1.5 in) at the
the other two marks. Rotate the crankshaft counter- circumference of a damper of 327 mm (12.8 in)
clockwise 1/8 of a rotate and remove the spacer diameter.
between the valve and the rocker lever. Slowly rotate
7 Rotate the crankshaft, clockwise from the front,
the crankshaft clockwise until the mark on the damper
until the inlet valve of the rear cylinder is fully open.
or pulley aligns accurately with the tip of the pointer.
Set the valve tip clearance of the inlet valve of number
Number 1 piston is now at TDC on the compression
1 cylinder to 0,20 mm (0.008 in).
stroke.
8 Fit the rocker cover, see operation 12-1.
9 Remove the temporary pointer from the timing case
and the timing mark from the pulley or damper.

New 1000 Series 17
To check the timing of the fuel injection
pump 17-4
Special tools:
Timing pin PD.245, Bosch fuel injection pumps
1
Timing pin PD.246, Lucas and Stanadyne fuel 2
injection pumps
Caution: Do not remove the nut (A2) which retains 5

the hub (A4) to the shaft of the fuel injection pump.
The hub is fitted permanently to the shaft. If the hub is 4 3
moved, it will be necessary for a fuel injection pump A A0374C
specialist to correctly position the hub on the shaft
with special test equipment available to Perkins
distributors.
1 Set the piston of number 1 cylinder to TDC on the
compression stroke, see operation 17-1 or operation
17-2.
2 Remove the gear cover from the cover of the timing
case. For gear driven coolant pumps: Remove the
coolant pump, see operation 21-2. 1
pump gear. Special tools and personnel with the
correct training are necessary to remove these
fasteners, refer to your nearest Perkins distributor. B A 03 74 /4
3 Insert the timing pin (A1) through the hole (A5) in

the fuel pump gear and the slot of the hub (A4). Push
the pin fully into the hole (A3) in the body of the fuel
pump. If the pin can be fully inserted then the pump
timing is correct. There should be no resistance when
the pin is inserted.
Note: The position for the timing pin for Lucas and
Stanadyne fuel injection pumps is (A1). The position
for the timing pin for Bosch EPVE fuel injection pumps
is (B1).
4 Remove the timing pin.
5 If the timing pin cannot be pushed into the pump
body, check that the engine is correctly set at TDC on
the number 1 cylinder compression stroke, see
If the engine is set correctly at TDC on the number 1
cylinder compression stroke, but the pin does not fit
into the hole, the fuel pump must be removed and set
by a specialist.
6 Fit the gear cover to the cover of the timing case.
For gear driven coolant pumps: Fit the coolant pump,
see operation 21-2.

17 New 1000 Series
Data and dimensions
Fuel system
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EPVE, pin timed, with a locking screw
Direction of rotation from drive end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise from drive end
Lucas fuel injection pump
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lucas DP200 Series, pin timed, with a locking screw
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise from drive end
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stanadyne DB4, pin timed, with a locking screw

New 1000 Series
18
Aspiration system 18
General description
Warning! Turbochargers operate at high speed and
at high temperatures. Keep fingers, tools and debris
away from the inlet and outlet ports of the
turbocharger and prevent contact with hot surfaces.
Continued

18 New 1000 Series
A turbocharger (A), is fitted between the exhaust and
induction manifolds. The turbocharger is driven by
exhaust gases and passes air to the engine at more
than atmospheric pressure. It is lubricated by oil from
the main gallery. The oil passes through the bearing
housing of the turbocharger and returns to the
lubricating oil sump; arrows are included on the
illustration to indicate the typical oil flow.
Some turbochargers are fitted with a waste-gate unit
(B). This unit, which is controlled by boost pressure,
allows some of the exhaust gases to bypass the
turbine rotor at higher engine speeds. With this
arrangement, the turbocharger can be designed to be
more effective at lower engine speeds. A waste-gate B A0180
guard (A1, page 148) is fitted to protect the actuator

rod (A2, page 148) of some engines.
Always use the manufacturers instructions and
specialist assistance to fit the service kit for the
turbocharger.
A A0181

New 1000 Series 18
Turbocharger
1
POWERPART Threadlock (pipe)
To remove
1 Thoroughly clean the turbocharger.
2 Remove the air cleaner hose at the compressor
inlet. A A0221
3 Remove or disconnect the support bracket for the

turbocharger. If necessary, remove the heat shield for
the fuel lift pump. Disconnect the exhaust pipe for the
application and remove the exhaust elbow from the
turbocharger. Where the elbow has a gasket, release
the nuts and remove the elbow and the gasket. Where
the elbow has a sleeve, pull the elbow together with
the sleeve away from the turbocharger.
4 Release the hose clips and push the hose of the
compressor outlet up the elbow of the induction
manifold.
5 Release the setscrews from the flange of the oil
supply pipe at the top of the bearing housing and the
union nut/connection at the other end of the pipe. If
the lower section of the oil supply pipe is flexible, use
a spanner to hold the flats on the pipe while the union
connection is removed from the oil filter head/adaptor
plate. This will prevent damage to the flexible section
of the pipe. If an adaptor is used in the oil filter head/
adaptor plate, use a spanner to hold the adaptor when
the union nut is released. Remove the pipe and the
flange joint.
6 Release the setscrews from the flange of the oil
drain pipe at the bottom of the bearing housing. If
necessary, release the hose clip(s) from the oil drain
pipe and push the hose down. Remove the oil drain
pipe and the joint from the flange.
Caution: If the turbocharger has a waste-gate,
ensure that the actuator rod of the waste-gate is not
used to lift or move the turbocharger. This could
damage the waste-gate and affect the calibration.
7 Release the nuts at the turbocharger to exhaust
manifold flange and remove the turbocharger and the
gasket. Cover the open ports in the manifolds, the
turbocharger and the pipes to ensure that dirt, etc. will
not enter.
8 Check the air hoses and the oil drain hose for
cracks or other damage and renew them, if
necessary.

18 New 1000 Series
To fit
1 Remove the covers from the pipes, manifolds and 1 2
the turbocharger. 10
2 Check that the turbocharger inlets and outlets are
clean and free from restriction and that the 3
turbocharger shaft rotates freely. Also check that the
open ports in the manifolds and the exhaust pipe are 4
clean and free from restriction.
5
3 Fit a new gasket to the exhaust manifold to
turbocharger flange (page 149/A1). If the original nuts 9 6
are to be used, ensure that the threads of the studs 7
are clean and apply a suitable compound to the studs 8
to prevent seizure. The threads of new nuts are A A0222
phosphated to prevent seizure. Fit the turbocharger.
Fit the nuts and tighten them to 44 Nm (33 lbf ft) 4,5 10 Fit the gasket and connect the exhaust pipe for the
kgf m. application to the exhaust elbow. Tighten the studs
(A10) to the recommended torque.
4 Lubricate the bearing housing of the turbocharger
with clean engine lubricating oil. Fit the oil supply pipe 11 Fully tighten the setscrews that hold the bracket to
together with a new joint and tighten the flange the elbow. Check that there is a gap of 6,5 mm (0.25
setscrews. If the lower section of the pipe is flexible, in) (A8) between the turbocharger outlet and the end
clean the thread of the union connection and apply of the elbow. This gap should be equal all around the
POWERPART Threadlock (pipe). Ensure that dirt elbow. Fully tighten the setscrews that hold the
does not enter the oil filter head/adaptor plate. Use a bracket to the cylinder block.
spanner to hold the flats on the pipe while the union 12 Slide the hose on the induction manifold elbow
connection is fitted to the oil filter head/adaptor plate. onto the compressor outlet and tighten the hose clips.
If an adaptor is used in the oil filter head/adaptor 13 Check that there is no restriction in the air filter to
plate, use a spanner to hold the adaptor when the turbocharger hose. Fit the hose and tighten the clip.
union nut is tightened.
14 Operate the stop control or, where fitted,
5 Fit the oil drain pipe together with a new joint and disconnect the electrical stop control. Operate the
tighten the flange setscrews, but do not connect the starter motor until there is a flow of lubricating oil from
hose. the oil drain pipe of the turbocharger. Connect the oil
6 Where the exhaust elbow has a flange, clean the drain pipe. Where fitted, connect the electrical stop
threads of the studs in the flange of the turbocharger. control.
Apply a suitable compound to the studs to prevent
seizure of the nuts. Put a new gasket in position on
the flange and fit the elbow. Tighten the nuts to 22 Nm
(16 lbf ft) 2,2 kgf m (plated) or 25 Nm (18 lbf ft) 2,5 kgf
m (non-plated). Fit or connect the support bracket
between the elbow and the cylinder block. Ensure that
there is no stress on the exhaust elbow. If necessary
fit the heat shield for the fuel lift pump.
7 Where the exhaust elbow (A2) has a sleeve (A1),
check that the sleeve protrusion from the end of the
elbow is 23 mm (0.90in) (A9).
8 Fit the elbow in the correct position to the support
bracket (A5) and tighten the setscrews (A4) finger
tight. Some engines have an aluminium heat shield
(A3) between the elbow and the bracket.
9 Fit the sleeve together with the elbow and bracket
into the turbocharger outlet. Fit the setscrews (A6 and
A7) which hold the bracket to the cylinder block, finger
tight. Ensure that the setscrew (A6) has a thick
washer fitted between the setscrew and the bracket.

New 1000 Series 18
To clean the impeller and the
compressor casing 18-2
Generally, it is not necessary to remove the

turbocharger to remove the compressor casing,
except on some engines where the compressor
casing is held by a circlip and access to the circlip is
not always possible. This type of turbocharger is 1
usually fitted to engines used in vehicle applications.
1 Release the clip and remove the hose from the
compressor inlet. Release the clips and push the
hose on the compressor outlet up the elbow of the
induction manifold. A A0183
2 Make a reference mark on the compressor casing
(A1) and on the bearing housing to ensure correct
assembly later.
3 Release the setscrews and remove the lock plates.
If the compressor casing is retained by a circlip,
remove the circlip. It may be necessary to remove the
turbocharger if access to the circlip is not possible. If
the turbocharger has a waste-gate unit, remove the
actuator and bracket assembly, see operation 18-3.
Caution: Be careful not to damage the impeller
blades. If the impeller is damaged, the turbocharger
must be renewed.
4 Remove carefully the compressor casing from the
turbocharger (A). If the casing is tight, lightly hit it with
a soft faced hammer.
5 Put the compressor casing in a suitable container
that contains a non-caustic solution. Allow the dirt to
become soft and then clean the casing with a hard
brush and/or a soft scraper. Dry the casing with clean,
compressed air at low pressure.
6 Clean the impeller with a soft brush.
7 Push carefully the compressor impeller towards the
bearing housing and turn the impeller by hand. Check
that there is no restriction of movement and that there
is no noise which can indicate a fault. If there is a fault,
remove the turbocharger for inspection by a
specialist.
8 Fit the casing to the turbocharger and align the
mark on the casing with the mark on the bearing
housing. Fit the lock plates and the setscrews and
tighten the setscrews.If the compressor casing of the
turbocharger is retained by a circlip, fit the circlip
loosely to the bearing housing. Ensure that the flat
face of the circlip is toward the compressor casing. Fit
the casing to the turbocharger and align the marks on
the casing and on the bearing housing. Fit the circlip
in its groove. If the turbocharger has a waste-gate
unit, fit the actuator and bracket assembly, see
operation 18-3.
9 Fit the hoses to the compressor inlet and outlet and
tighten the clips.
10 If necessary, fit the turbocharger to the engine,
see operation 18-1.
18 New 1000 Series
To remove and to fit the actuator assembly of
the waste-gate unit 18-3 4 5
2
It is important that the waste-gate actuator setting is
not altered. Do not remove the actuator or mounting
3 6
bracket unless it is necessary to renew the actuator
assembly. 1
If a waste-gate actuator or mounting bracket

assembly is removed from a turbine or compressor
housing it is important that the bracket is fitted into the
correct position on the housing.
To remove
A A0184
1 Disconnect the boost sensor pipe (A1) at the
actuator (A2).
2 Remove the clip (A4) which retains the actuator rod
(A3) and lift the end of the actuator rod off the pin (A5)
3 Release the setscrews which retain the actuator

bracket to the turbocharger and remove the actuator
and bracket assembly.
To fit
1 Put the actuator and bracket assembly in position
on the turbocharger and tighten the setscrews.
2 Connect to the actuator (A2) an air supply which
can be adjusted accurately and is fitted with an
accurate gauge.
3 Operate the arm (A6) of the waste-gate valve by
hand to check that the valve is free to move.
4 Push the arm of the waste-gate valve as far as
possible toward the actuator and hold the arm in this
position. Slowly apply air pressure to the actuator until
the end of the actuator rod (A3) will fit easily onto the
pin (A5) of the waste-gate valve. Fit the clip (A4).
Release the air pressure.
Caution: Do not apply an air pressure of more than
205 kPa (30 lbf/in2) 2,1 kgf/cm2 to the actuator. Higher
pressures may damage the actuator.
5 Check the operation of the waste-gate unit, see
operation 18-4.

New 1000 Series 18
To check and adjust the operation of
the waste-gate 18-4
If the waste-gate valve does not operate at the correct

pressure, it can affect the engine performance.
If the valve opens at a low pressure, this can cause
black exhaust smoke and loss of power at lower
engine speeds.
Caution: A high pressure setting can cause high
6
cylinder pressures. This can cause failure of the
cylinder head gasket and damage to the bearings and 5
pistons. 2 3 4
A 1
A0185
1 Disconnect the boost sensor pipe (A6) at the
actuator. Connect to the actuator an air supply which 9 Put the dial gauge in position on the end of the
can be adjusted accurately and is fitted with an actuator rod. Apply air pressure to move the actuator
accurate gauge. rod 1,00 mm (0.039 in) and check if the air pressure
2 Fasten a dial test indicator (A1) to the turbocharger is correct. If the air pressure is not correct, repeat from
with its plunger in contact with the end of the actuator paragraph 6 of the operation until the correct pressure
rod (A4) to measure the axial movement of the rod. is obtained.
3 Slowly apply air pressure. Check that the pressure 10 If the air pressure is correct, release the air
necessary to move the rod 1,00 mm (0.039 in), is pressure, remove the test equipment and connect the
within the limits shown in the data and dimensions at boost sensor pipe.
the end of this section. Ensure that the pointer returns
to zero when the pressure is released. Repeat the test
several times to ensure that an accurate reading is
obtained. It may be necessary to lightly hit the turbine
housing with a soft hammer during the test operation.
4 If the operation of the waste-gate is not correct, the
actuator rod can be adjusted.
5 Remove the dial gauge from the end of the actuator
rod.
6 With the air pressure still applied, release the lock
nut (A5) on the actuator arm. Remove the clip (A2)
and remove the actuator rod from the pin (A3) on the
arm of the waste-gate valve.
7 If the air pressure is too low, rotate the end of the
actuator rod to reduce the length of the actuator rod.
If the air pressure is too high, rotate the end of the
actuator rod to increase the length of the actuator rod.
Rotate the end of the actuator rod in half-turn
increments.
Caution: Use only the end of the threaded rod to
make adjustments. To pull or push the actuator rod
could change the calibration of the actuator. The
result could be damage to the engine because of too
much boost.
8 Put the actuator rod in position on the pin of the
waste-gate arm. Fit the clip. Tighten the lock nut.
Release the air pressure.

18 New 1000 Series
Turbocharger faults
The chart below is given to assist in the correct diagnosis of turbocharger faults.
If the inside of the induction manifold is wet, check that there is not a fuel leak from the fuelled starting aid, if
there is one fitted, see operation 23-9.
Problems Possible causes code numbers

1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28, 34,
Not enough power
35, 36
1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28, 34,
Black smoke
35, 36
Blue smoke 1, 2, 4, 6, 8, 9, 17, 19, 20, 21, 22, 30, 31, 32, 34
High lubricating oil consumption 2, 8, 15, 17, 19, 20, 28, 29, 31, 32, 34
Too much lubricating oil at turbine end 2, 7, 8, 17, 19, 20, 22, 28, 30, 31, 32
Too much lubricating oil at compressor end 1, 2, 4, 5, 6, 8, 19, 20, 21, 28, 31, 32
Not enough lubrication 8, 12, 14, 15, 16, 23, 24, 29, 32, 33, 37, 38
Lubricating oil in the exhaust manifold 2, 7, 17, 18, 19, 20, 22, 28, 31, 32
Inside of the induction manifold wet 1, 2, 3, 4, 5, 6, 8, 10, 11, 17, 18, 19, 20, 21, 28, 32, 34, 39, 40
Damaged compressor impeller 3, 4, 6, 8, 12, 15, 16, 20, 21, 23, 24, 29, 32, 33, 37, 38
7, 8, 12, 13, 14, 15, 16, 18, 20, 22, 23, 24, 25, 27, 29, 32, 33,
Damaged turbine rotor
37, 38
3, 6, 7, 8, 12, 13, 14, 15, 16, 18, 20, 21, 22, 23, 24, 29, 32,
Rotating assembly does not turn freely
33, 37, 38
Worn bearings, bearing bores, journals 6, 7, 8, 12, 13, 14, 15, 16, 23, 24, 29, 33, 37, 38
1, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 20, 21, 22,
Noise from turbocharger
23, 24, 29, 32, 33, 34, 37, 38
Sludge or carbon deposit in bearing housing 2, 11, 13, 14, 15, 17, 18, 24, 29, 33, 37, 38

New 1000 Series 18
1 Element of the air filter dirty.
2 Restricted crankcase breather.
3 Element of the air filter not fitted, or not sealing
correctly. Loose connection to turbocharger.
4 Internal distortion or restriction in pipe from air filter
to turbocharger.
5 Damaged/restricted crossover pipe, turbocharger
to induction manifold.
6 Restriction between air filter and turbocharger.
7 Restriction in exhaust system.
8 Turbocharger loose or clamps/setscrews loose.
9 Induction manifold has cracks, is loose, or has
flange distortion.
10 Exhaust manifold has cracks, is loose, or has
flange distortion.
11 Restricted exhaust system.
12 Delay of lubricating oil to turbocharger at engine
start.
13 Insufficient lubrication.
14 Dirty lubricating oil.
15 Incorrect lubricating oil.
16 Restricted lubricating oil supply pipe.
17 Restricted lubricating oil drain pipe.
18 Turbine housing damaged or restricted.
19 Leakage from turbocharger seals.
20 Worn turbocharger bearings.
21 Excessive dirt in compressor housing.
22 Excessive carbon behind turbine rotor.
23 Engine speed raised too rapidly at initial start.
24 Insufficient engine idle period.
25 Faulty fuel injection pump.
26 Worn or damaged atomisers.
27 Valves burned.
28 Worn piston rings.
29 Lubricating oil leakage from supply pipe.
30 Excessive preservation fluid (on initial engine
start).
31 Excessive engine idle period.
32 Restriction in turbocharger bearing housing.
33 Restriction in lubricating oil filter.
34 Wet type air cleaner: Restricted, dirty element,
viscosity of oil to low/high.
35 Waste-gate actuator faulty or damaged.
36 Waste-gate valve not free.
37 Engine stopped too soon from high load.
38 Insufficient lubricating oil.
39 Fuel leakage from fuelled starting aid.
40 Crack in backplate of compressor.

18 New 1000 Series
Engine breather
Open breathers fitted to New 1000 Series engines
have a pipe connected to the rocker cover which will
1
allow any crankcase pressure to pass directly from
the engine. A gauze strainer (A) may be fitted to
remove any oil mist and return it to the rocker cover.
Open breather 2
4
To clean and to renew 18-5

3
To clean
A A0035A
Note: It is not necessary to remove the body of the
breather from the rocker cover to obtain access to the
gauze.
1 Release the hose clip and remove the hose from
the breather cover (A1). Release the breather cover
from the body of the breather (A4). The cover is a
press fit onto the body.
2 Remove and discard the plastic gauze (A2).
3 Clean the body of the breather with clean kerosene.
Ensure that all of the kerosene is removed from the
breather after cleaning.
4 If necessary, renew the "O" ring seal (A3).
5 Check that the inside of the breather pipe is clean.
If the pipe is not clean, release the setscrews and
remove the pipe. Wash the pipe with kerosene and
dry it with low-pressure air.
6 Renew the plastic gauze.
7 Fit the cover to the breather body, ensure that it is
securely fitted.
8 Fit the breather pipe and tighten the hose clips.
To renew
To renew the complete breather assembly the body of
the breather must be removed from the rocker cover:
Note: The breather is fastened to the rocker cover by
a screw thread on the bottom of the breather body.
1 Release the hose clip and remove the hose from
the breather cover.
2 Fit a "C" spanner to the lugs at the bottom of the
breather body and turn the spanner counterclockwise
to release and discard the breather.
3 Clean the threads in the rocker cover and on the
new breather assembly.
4 Fit the new breather by hand and tighten it into the
rocker cover with the "C" Spanner.
5 Fit the breather pipe and tighten the hose clip.

New 1000 Series 18
Closed breather
Closed breather systems fitted to New 1000 Series
engines have an oil separator which is fastened to the
crankcase and a breather valve is fitted between the
oil separator and the induction manifold. Crankcase
gases pass through the oil separator where oil from
the gases is returned to the sump. The crankcase
gases then pass through the breather valve to the
induction manifold.
Closed breather
To clean and to renew 18-6
To be notified, refer to your nearest Perkins

distributor.

18 New 1000 Series
Data and dimensions
are shown are those which are mainly used in the factory.
Turbocharger
The make and type of turbocharger fitted is marked on the turbocharger identification plate; as a general guide
the make and type of turbocharger fitted are as follows:
4 Cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Garrett T20
6 Cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Garrett T32
Waste-gate test pressure for rod movement of 1,00 mm (0.039 in)
The turbocharger part number is on the turbocharger identification plate, which is fitted to the body of the
turbocharger.
Waste-gate pressure
Turbocharger
part number (kPa) (lbf/in2) (kgf/cm2)
(+/-5) (+/-0.72) (+/-0,05 )
2674A089 150 21.8 1,53
2674A092 150 21.8 1,53
2674A093 110 15.9 1,11
2674A094 105 15.2 1,07
2674A095 145 21.0 1,48
2674A096 150 21.8 1,53
2674A097 138 20.0 1,40
2674A098 96 13.9 0,97
2674A099 107 15.5 1,09
2674A306 138 20.0 1,40
2674A307 150 21.8 1,53
2674A308 96 13.9 0,97
2674A311 145 21.0 1,48
2674A315 150 21.8 1,53
2674A316 96 13.9 0,97

New 1000 Series
19
Lubrication system 19
General description
Four cylinder engine lubrication system (page The lubricating oil passes from the filter to the
160/A) pressure rail which is drilled the complete length of
the left side of the cylinder block. If the oil filter is on
Pressure lubrication is supplied by a rotor type pump
the right side of the engine, the oil passes through a
which is driven through an idler gear from the
passage drilled across the cylinder block to the
crankshaft gear. The pump has an inner rotor and an
pressure rail.
outer rotor which are off-centre to each other. There
is a key between the inner rotor and the drive shaft. From the pressure rail, lubricating oil passes to the
The inner rotor has six lobes which mesh with the main bearings of the crankshaft and through
seven lobes of the outer rotor. When the pump passages in the crankshaft to the big end bearings.
rotates, the space between the lobes of the outer rotor The pistons and the cylinder bores are lubricated by
which are in mesh increases to cause a suction or splash and oil mist.
decreases to cause a pressure increase. If a balancer
Lubricating oil (page 160/A3) passes from the main
unit (page 161/A) is fitted, the oil pump is fitted to the
bearings through passages in the cylinder block to the
balancer frame and is driven by the balancer drive
journals of the camshaft. Lubricating oil passes from
shaft.
the centre journal of the camshaft through a passage
Lubricating oil (page 160/A1) from the sump passes in the cylinder block and cylinder head to a restriction
through a strainer and pipe to the suction side of the in the pedestal of the rocker shaft, at a reduced
pump. pressure (page 160/A4), to the rocker bushes. The oil
passes through a passage in the rocker shaft to the
The lubricating oil (page 160/A2) passes from the
bearings of the rocker levers. The valve stems, valve
outlet side of the pump through a pipe to a relief valve,
springs and the tappets are lubricated by splash and
which is fitted to the bottom of the left side of the
oil mist.
cylinder block. If a balancer unit is fitted, the relief
valve is fitted in the frame of the balancer. The relief The hub of the idler gear is lubricated by oil from the
valves opens if the oil pressure is too high and allows pressure rail and the timing gears are splash
some of the lubricating oil to return to the sump. lubricated.
From the relief valve, lubricating oil passes to a plate The turbocharger is lubricated by oil after the filter. Oil
type oil cooler (some naturally aspirated engines do is supplied from a connection on the right side of the
not have an oil cooler). The oil cooler is either fitted to cylinder block through an external pipe to the
the left side of the cylinder block and has seven turbocharger. The oil passes through the
plates, or it is fitted between the oil filter head and the turbocharger and returns through a pipe to the sump.
filter canister and has ten plates. Some oil coolers are
Turbocharged engines have piston cooling jets fitted.
fitted with a by-pass valve. If cold oil increases the
These jets are connected to the oil pressure rail and
restriction in the cooler, the by-pass valve opens and
spray lubricating oil inside the pistons to keep them
the oil passes directly from the inlet side to the outlet
cool. Naturally aspirated engine types AR and AS
side of the cooler.
have one piston cooling jet fitted to the number one
Lubricating oil from the oil cooler, passes to an oil cylinder position.
filter. The oil filter can be fitted to the left or right side
of the engine. If the filter is fitted to the right side
(19A.04/A) of the engine, the oil passes through a
pipe connected between the relief valve and the right
side of the cylinder block. The oil passes from the pipe
through a passage in the right side of the cylinder
block to an oil cooler and then to the oil filter. When
the oil filter is on the right side of the engine, and an
oil cooler is fitted, the oil cooler will be between the oil
filter head and the oil filter canister.

19 New 1000 Series
A A0289

New 1000 Series 19
A A0290

19 New 1000 Series
Six cylinder engine lubrication system (page The turbocharger is lubricated by oil after the filter. Oil
160/A) is supplied from a connection on the right side of the
cylinder block through an external pipe to the
The oil pump is similar to that used on four cylinder
turbocharger. The oil passes through the
engines and is also driven through an idler gear from
turbocharger and returns through a pipe to the sump.
the crankshaft gear. The inner rotor has four lobes
and the outer rotor has five lobes. Turbocharged engines have piston cooling jets fitted.
These jets are connected to the oil pressure rail and
Lubricating oil from the sump passes through a
spray lubricating oil inside the pistons to keep them
strainer and pipe to the suction side of the pump. The
cool.
oil passes from the outlet side of the pump, through a
pipe and a passage in the cylinder block to the oil filter
head. The oil then passes through a passage in the
filter head and a pipe to a plate type oil cooler, see the
off set (page 160/A), which is an integral part on the
left of the cylinder block. On naturally aspirated
engines the oil cooler has four plates and on
turbocharged engines the cooler has eight plates.
The oil cooler is fitted with a by-pass valve. If cold oil
increases the restriction in the cooler, the by-pass
valve opens and the oil passes directly from the inlet
side to the outlet side of the cooler. If the engine is not
fitted with an oil cooler, the oil passes from the oil
pump to the relief valve.
From the oil cooler, the oil returns through a pipe to
the filter head where the oil divides to the relief valve
and to the oil filter. The oil filter can be fitted on the left
or right side of the engine. If the filter is fitted on the
right side of the engine, the oil passes through a pipe
connected between the relief valve and the right side
of the cylinder block to the oil filter.
The lubricating oil passes from the filter to the
pressure rail which is drilled the full length of the left
side of the cylinder block. If the oil filter is on the right
side of the engine, the oil passes through a passage
drilled across the cylinder block to the pressure rail.
From the pressure rail, lubricating oil passes to the
main bearings of the crankshaft and through
passages in the crankshaft to the big end bearings.
The pistons and the cylinder bores are lubricated by
splash and oil mist.
Lubricating oil passes from the main bearings through
passages in the cylinder block to the journals of the
camshaft. Lubricating oil passes, at a reduced
pressure, from the second journal of the camshaft
through a passage in the cylinder block and cylinder
head to the rocker shaft. The oil passes through a
passage in the rocker shaft to the bearings of the
rocker levers. The valve stems, valve springs and the
tappets are lubricated by splash and oil mist.
The hub of the idler gear is lubricated by oil from the
pressure rail and the timing gears are splash
lubricated.

New 1000 Series 19
Filter canister
2
To renew 19-1 1
3
Warning! Discard the used canister (B4) and
lubricating oil in a safe place and in accordance with
local regulations.
Caution: The canister contains a valve and special
tube to ensure that lubricating oil does not drain from
the filter. Therefore, ensure that the correct Perkins
POWERPART canister is used.
The filter can have one or two canisters (B4) or (A1) A A 0 22 3/1
fitted. When two canisters are fitted, both must be

renewed at the same time. On some engines an oil
cooler (B2) is fitted to the filter head. This
arrangement is fitted on the left side or the right side
of the engine.
On some four and six cylinder engines the adaptor 1
(A2) or (B1) is sealed into the filter head. A new filter
head is supplied without the adaptor fitted; if either the
adaptor or the filter head is to be renewed, both parts 3 2
will be necessary.
1 Put a tray under the filter to contain spilt lubricating 4
oil.
2 Remove the filter canister with a strap wrench or a
similar tool and then discard the canister.
B L0016
Note: If the adaptor is to be renewed, insert the end

of the adaptor, which has the thread sealant applied
during manufacture, into the filter head.
3 Clean the seal face of the filter head (A3).
Caution: Ensure that the adaptor (A2) or (B1) is
secure in the filter head.
4 Add clean engine lubricating oil to the new canister.
Give the oil time to fill the canister through the filter
element.
5 Lubricate the top of the canister seal (B3) with clean
6 Install the new canister and tighten it by hand only.
Do not use a strap wrench.
For turbocharged engines: Ensure that the engine will
not start and operate the starter motor until oil
pressure is obtained. To ensure that the engine will
not start, either put the manual stop control in the
"stop" position or disconnect the electrical stop control
of the fuel injection pump. Oil pressure is indicated
when the warning light is extinguished or by a reading
on the gauge.
7 After the lubricating oil has been added to the
sump, operate the engine and check for leakage from
the filter. When the engine has cooled, check the oil
level on the dipstick and add oil to the sump, as
necessary.

New 1000 Series 19
Sump
Warning! Discard the used lubricating oil in a safe 2

place and in accordance with local regulations.
1 Operate the engine until it is warm. 1
2 Stop the engine, remove the sump drain plug (B1)
and its "O" ring and drain the oil. Where necessary,
remove the dipstick and the dipstick tube.
3 Provide a support for the sump and remove the
setscrews and the two nuts which fasten the sump to
A A0227
the cylinder block and to the timing case. Lower the

sump and remove the joint.
4 Wash the sump with an approved cleaning fluid,
ensure all the cleaning fluid is removed. Clean the
flange face of the sump and of the cylinder block. If
necessary, renew the felt dust seal which is fitted to
the rear of the sump flange on some engines.
5 Fit the sump together with a new joint and ensure
the correct location with a setscrew on each side. Fit
the remainder of the setscrews and the nuts and
tighten all the fasteners to 22 Nm (16 lbf ft) 2,2 kgf m.
Fit the drain plug together with a new "O" ring and
2
tighten the plug to 34 Nm (25 lbf ft) 3,5 kgf m. Where 1
necessary, fit the dipstick tube and the dipstick. B A0360
Fill the sump to the mark (B2) on the dipstick with new
and clean lubricating oil of an approved grade.
Oil strainer and suction pipe
The oil strainer is an integral part of the suction pipe.

No regular service is necessary but wash the strainer
when it is removed. On four cylinder engines which
have a balancer fitted, the suction pipe is normally a
short pipe which is fastened to the balancer frame and
a pipe bracket is not fitted.
Some four cylinder engines have an oil strainer and
suction pipe which are made of a composite material.
This arrangement has an "O" ring seal on the flange
face of the oil pump instead of a joint.
1 Remove the sump, see operation 19-3.
2 Release the setscrew which holds the bracket to
the main bearing cap (A2).
3 Release the setscrews from the flange of the
suction pipe (A1). Remove the suction pipe and
strainer. Remove and the old joint or the "O" ring.
Clean the flange face of the oil pump and of the
suction pipe.

19 New 1000 Series
4 Loosely assemble the bracket of the suction pipe to
the correct main bearing cap. Fit the suction pipe to
the oil pump together with a new joint or an "O" ring.
Tighten the setscrews. Tighten the setscrew of the
suction pipe bracket. If the clamp type bracket, used
on some four cylinder engines, has been removed,
ensure that the clamp, the bracket and the pipe are
correctly aligned before the setscrews are tightened.
Ensure that there is no stress on the suction pipe.
5 Fit the sump, see operation 19-3.
1 Wash the assembly in an approved cleaning fluid

and dry it thoroughly.
2 Check the pipe, the strainer and the welded joints
for cracks and other damage. Check that the
mounting bracket is secure.
3 If the damaged component cannot be welded
correctly, renew the assembly.
4 Composite material parts must be renewed if they
have cracks or damage.

New 1000 Series 19
Lubricating oil pump
For four cylinder engines fitted with a balancer unit,

the oil pump is integral with the balancer unit, see
section 14 for removal instructions.
The lubricating oil pump has a channel (B1) in the
body of the pump. Lubricating oil from the front main
bearing passes down the channel in the body of the 3
pump to an oil hole in the idler shaft. The lubricating
1 2
oil then passes through the hole in the idler shaft to A A0228
the bush in the idler gear.
To remove
1 Drain the lubricating oil and remove the lubricating
2 Remove the suction pipe and strainer, see
operation 19-4.
3 For four cylinder engines: Remove the oil pressure
relief valve, see operation 19-9, and the delivery pipe.
For six cylinder engines: Remove the delivery pipe of
the oil pump.
4 The oil pump is fitted to number 1 main bearing cap.
The oil pump can be removed with the main bearing
cap, if a suitable spanner is available that will enable B 1
A0229
the torque to be applied correctly to the setscrews of
the main bearing cap when it is fitted. If a suitable
spanner is not available, the timing case must be
removed, see operation 15-9.
5 Release the circlip which retains the idler gear of
the oil pump and remove the washer (A1) and the
idler gear (A2).
6 Release the setscrews and remove the oil pump
(B).

19 New 1000 Series
To fit
1 Fill the oil pump with clean engine lubricating oil. Fit
the oil pump to the main bearing cap and tighten the
setscrews to 22 Nm (16 lbf ft) 2,2 kgf m.
2 Check the idler gear and the bush for wear and
other damage. If the gear and/or bush are damaged,
they can be renewed as an assembly or the bush can
be renewed as a single item. Check the shaft of the
idler gear for wear or other damage. If the shaft is
worn or damaged, renew the shaft, see operation 19-
7. Lubricate the bush (A3) with clean engine
3
lubricating oil and fit the idler gear (A2), the washer
(A1) and the circlip. Check that there is a minimum of 1 2
A A0228
0,076 mm (0.003 in) backlash between the oil pump
gear and the idler gear (B).
3 If number 1 main bearing cap was removed,
lubricate the bearing with clean engine lubricating oil
and fit the bearing cap. Tighten the setscrews to 265
Nm (196 lbf ft) 27,0 kgf m. If the timing case was
removed, fit the timing case, see operation 15-9.
Check that there is a minimum of 0,076 mm (0.003
in) backlash between the oil pump idler gear and the
crankshaft gear.
The end-float for the idler gear is as follows:
! Four cylinder engines 0,012/0,643 mm (0.0005/
0.0253 in)
! Six cylinder engines 0,020/0,650 mm (0.0008/ B A0230
0.0256 in)
4 Fit the suction pipe and strainer, see operation 19-
4.
5 For four cylinder engines: Fit the delivery pipe and
oil pressure relief valve, see operation 19-9. For six
cylinder engines: Fit the delivery pipe and tighten the
setscrews. Use new joints.
6 Fit the lubricating oil sump, see operation 19-3.

New 1000 Series 19
To renew the shaft for the idler gear 19-7
1
The idler shaft for the lubricating oil pump fitted in the 2
front main bearing cap of six cylinder engines is
retained by a pin and POWERPART Retainer (oil
tolerant). If it is necessary to renew the idler shaft on
these engines, follow the procedure given below.
3
The idler shaft (A3) has an oil hole (A2) to provide
lubrication to the bush for the idler gear. The A A0229
lubricating oil pump has a channel (A4) in the body of
the pump. Lubricating oil from the front main bearing
passes down the channel in the body of the pump to
the oil hole in the idler shaft. The lubricating oil then 1
passes through the hole in the idler shaft to the bush
in the idler gear.
To remove the idler shaft
Caution: The pin is very hard; if the tap is broken or
the pin cannot be removed, then the other method on
page 172 must be used to remove the pin.
1 Carefully use an M5 X 0,8 mm taper tap to put a
chamfer in the end of the pin (A1). Remove the tap.
2 Carefully use an M5 X 0,8 mm plug tap to cut not B A 02 32 /1
less than three complete threads in the end of the pin.
Remove the tap.
3 Obtain the parts listed below:
! An M5 X 0,8 mm setscrew, part number 2314E007
or a setscrew which has a thread which is at least
15 mm long.
! An M5 X 0,8 mm nut, part number 2318A601.
! A spacer with a 15,88 mm or 19,05 mm outside
diameter and an internal diameter of 8,73 mm
which is 9,53 mm long, part number(s), 0920481
or 0330819.
4 Fit the nut fully onto the threads of the setscrew and
put the spacer onto the nut.
Continued

19 New 1000 Series
Caution: Do not use excessive torque.
5 Hold the spacer in position and engage the
8
setscrew fully into the threads in the pin. 2
1
6 Put the spacer into position centrally over the pin 9
and tighten the nut onto the spacer. Continue to 3
tighten the nut and pull the pin through the spacer. 4
Withdraw the pin enough to pull the pin out of the 9
8
bearing cap with pliers.
7
7 Put a suitable adaptor on the small diameter of the
idler shaft and press the idler shaft out of the bearing 5
cap.
6
Optional method to remove the idler shaft
A A0231
1 This method to remove the pin from the idler shaft
must only be used if the pin cannot be removed by the
earlier method.
1 2
Make a drill guide (A) to the dimensions given below:
A1 8,3 mm (0.327 in)
A2 20,0 mm (0.984 in)
A3 1,0 mm (0.039 in)
A4 16,1/16,4 mm (0.633/0.646 in) 4
A5 6,9 x 22 mm (0.272 x 0.866 in) diameter

hole for 5/16-24 UNF x 18 mm thread 3
A6 36,0 mm (1.42 in)

B A0232
A7 6,5/6,6 mm (0.256/0.260 in) diameter hole,
countersink 9,0 mm x 900 included
A8 31,75 mm (1.250 in)
A9 15,9 mm (0.626 in)
2 Put the drill guide (B1) into position in the setscrew
hole on the opposite side of the bearing cap to the pin
(B2). Ensure that the countersink in the guide faces to
the outside and that the edge of the guide is aligned
with the front edge of the bearing cap. Use a 5/16
UNF setscrew (B3) and a plain washer (B4) to retain
the guide in position.
3 Drill a 6,35 mm (0.25 in) diameter hole in the
bearing cap 47,0 mm (1.85 in) deep.
4 Remove the drill and the drill guide.
5 Insert a suitable drift into the hole in the bearing cap
and drive out the pin.
6 Put a suitable adaptor on the small diameter of the
idler shaft and press the idler shaft out of the bearing
cap.
Continued

New 1000 Series 19
To fit the idler shaft
1 Check that the new idler shaft, part number
3271H002 or 3271H004 and the hole for the idler
shaft in the bearing cap are clean and free from oil or 1
grease. Remove any rough edges from the hole of the
bearing cap.
2
2 Support the rear of the bearing cap and ensure that
the cap will not move when the idler shaft is pressed
in. Apply only enough POWERPART Retainer (oil
tolerant) around the chamfer of the shaft to fully cover
the surface of the hole when the shaft is pressed into
3
position. Enter the chamfer of the idler shaft into the
hole. A A0229
If the idler shaft (A3) has an oil hole ensure that the
hole (A2) in the idler shaft is at the top and that the flat
(A1) is at the bottom before the shaft is pressed into
the bearing cap.
Ensure that the idler shaft is square to the bearing cap
and press the shaft in onto its shoulder. Remove the
surplus POWERPART Retainer from the idler shaft,
the oil hole and the bearing cap before the oil pump is
fitted.
3 Use the original hole for the pin in the bearing cap
as a guide and drill a 6,35 mm (0.25 in) diameter hole
in the idler shaft 9,5 mm (0.37 in) deep.
4 Fit a new pin, part number 2116087, into the
bearing cap and idler shaft.

19 New 1000 Series
To fit the idler shaft (where a pin was not fitted)
1 Follow the procedure to fit the idler shaft,
paragraphs 1 and 2 above.
2 Put the drill guide (A1) into position in the right hand 1
(seen from the front face of the bearing cap) setscrew
hole of the bearing cap. Ensure that the countersink
in the guide faces to the outside and that the edge of
the guide is aligned with the front edge of the bearing
cap. Use a 5/16 UNF setscrew (A3) and a plain 2
washer (A2) to retain the guide in position.
3 Drill a 6,35 mm (0.25 in) diameter hole in the 3
bearing cap 25,4 mm (1.0 in) deep.
4 Remove the drill and the drill guide. A A0233
5 Fit a pin, part number 2116087, into the bearing cap

and idler shaft.
To remove and to fit the idler shaft
1
- For four cylinder engines:
1 Support the front of the bearing cap. Put a suitable
adaptor on the small diameter of the idler shaft and 2
press the idler shaft out of the bearing cap.
2 Ensure that the idler shaft and the hole in the
bearing cap are clean. Support the rear of the bearing
cap and ensure that the cap will not move when the
3
idler shaft is pressed in. Apply POWERPART
Retainer to the small diameter of the idler shaft. The
B A0229
idler shaft for four cylinder engines is not retained by
a pin.
If the idler shaft (B3) has an oil hole ensure that the
hole (B2) in the idler shaft is at the top and that the flat
(B1) is at the bottom before the shaft is pressed into
the bearing cap.
Enter the chamfer of the idler shaft into the hole.
Ensure that the idler shaft is square to the bearing cap
and press in the shaft onto its shoulder. Remove the
surplus POWERPART Retainer.

New 1000 Series 19
To inspect 19-8
If any part is worn enough to have an effect on the

performance of the oil pump, the complete oil pump
must be renewed.
1 Release the setscrews and remove the cover of the
oil pump. For pumps which are fitted to a balancer
unit, remove the single setscrew and the cover.
2 Remove the outer rotor and clean thoroughly all the
parts. Check for cracks and any other damage.
3 Fit the outer rotor and check the outer rotor to body
clearance (A).
4 Check the inner rotor to outer rotor clearance (B). A A0234
5 Check the rotor end-float with a straight edge and

a feeler gauge (C). For all the above clearances, see
6 Clean the top face of the oil pump and the bottom
face of the cover and fit the cover. Tighten the
setscrews to 28 Nm (21 lbf ft) 2,9 kgf m. For pumps
which are fitted to a balancer unit, put the cover in
position and tighten the single setscrew to 22 Nm
B A0235
C A0236

19 New 1000 Series
Relief valve
2
1
Four cylinder engines that have a balancer unit have

a relief valve fitted inside the balancer frame. The
relief valve of these engines cannot be removed as an
assembly.
1 Drain the lubricating oil and remove the sump, see
operation 19-3.
2 For four cylinder engines: Release the setscrew
and rotate the relief valve to withdraw the thimble from A A0237
the cylinder block (A1). Pull the relief valve from the
delivery pipe and pull the delivery pipe from the oil
pump. Renew the "O" rings (A2). Lightly lubricate the
"O" rings with clean engine lubricating oil and push
1
the delivery pipe into the oil pump. Push the relief
valve onto the delivery pipe and fit the relief valve to
the cylinder block; ensure that the thimble is correctly
fitted and tighten the setscrew. 2
3 For six cylinder engines: Remove the setscrews
which fasten the cross flow pipe to the relief valve
(B2). The cross flow pipe is only fitted to engines
which have the oil filter on the right side of the engine.
Remove the flange joint. Release the two setscrews
(B1) which fasten the relief valve to the cylinder block B A0238
and remove the valve. Ensure that the faces of the
cross flow pipe and the relief valve are clean. Put the
valve in position, complete with a new flange joint.
Engage the four setscrews and tighten the flange
setscrews and then the valve setscrews.

New 1000 Series 19
If necessary, the relief valve can be dismantled and 1

assembled while it is fitted to the engine. 2
1 Apply pressure to the end plate (A4 or B5) of the 3
spring assembly; release the circlip (A5) or remove
the pin (B1) and carefully release the pressure to 4
remove the end plate and the spring (A3 or B4) from 5
the valve body. Remove the plunger (A2 or B3) from
the bore of the body (A1 or B2).
2 Ensure that all the components are cleaned and
then lubricated lightly with clean engine lubricating oil.
3 Fit the plunger into the bore with its hollow end to A A0239
the inside. Fit the spring and the end cap into the bore
with the ends of the spring fitted around the bosses of
the plunger and the end plate. Apply pressure to the
end plate and fit the circlip into its groove or fit the pin
into the holes in the balancer frame. 1
To inspect 19-11 2
Do not try to change the operation pressure of the 3

relief valve by a method other than the installation of
new components. 4
1 Check the spring for wear and other damage and, 5
if possible, check the load necessary to compress the B A0240
spring to its fitted length, see the data and
dimensions.
2 Check the plunger for wear and other damage and
ensure that it slides easily in the bore of the relief
valve.
3 Check the body and the end plate for wear and
other damage.
4 Renew worn or damaged components.

19 New 1000 Series
Flexible oil pipes
4
The oil cooler pipes fitted to 6 cylinder New 1000
Series engines do not have metal braid and are 2
separate pipes. The part number of the pipes is
stamped on a clip which is fastened to one end of 1 3
each pipe. The pipes are not interchangeable and it is 5
9
important that the correct pipes are fitted to the
engine. 6
10
7
To remove, to fit and to inspect 19-12
There are two arrangements (A) or (B) for the pipes A 8

A0304
which are used in accordance with the application:
To remove
Warning! The engine oil may be hot, allow the
engine temperature to cool before the oil pipes are
released.
1 Allow the engine temperature to cool down and put
a suitable drip tray under the filter head.
2 Remove the three setscrews which retain the oil
pipes to the filter head. Release the oil pipes and
allow the oil to drain into the drip tray. Discard the
joint.
3 Remove the three setscrews which retain the oil
pipes to the oil cooler. Discard the joint.
To fit the pipes - arrangement 1:
1 Put the three setscrews into position in the flange
(A3) of the inner pipe (A5), part number 2483A005.
Put a new joint (A2) in position on the setscrews.
2 Engage the setscrews by three or four threads in
the flange of the oil cooler (A4). Engage the spigot
(A1) of the outer pipe (A9), part number 2483A006, in
the hole in the flange (A3) of the first pipe, ensure that
it fits squarely in the flange.
3 Support the pipes by hand and tighten the centre
setscrew finger tight. Tighten the other setscrews until
they are finger tight. Ensure that the pipes are as
close together as possible, then tighten the setscrews
gradually and evenly to 22 Nm (16 lbf ft) 2,2 kgf m.
4 Put a setscrew (A7) in position in the flange of the
inner pipe (A5) for the oil filter head (A10). Put a new
joint in position on the setscrew. Hold the flange and
the joint in position and fit the centre setscrew (A8).
Tighten the setscrews finger tight. Put the flange of
the outer pipe (A9) in position and fit the third
setscrew (A6), tighten it finger tight. Beginning with
the centre setscrew, tighten the three setscrews to 22
Nm (16 lbf ft) 2,2 kgf m.

New 1000 Series 19
To fit the pipes - arrangement 2
1 2
1 Put a setscrew (A5) in position in the flange of the 4
3
inner oil cooler pipe (A6), part number 2483A004. Put
a new joint (A4) in position on the setscrew. Hold the
flange and the joint in position and fit the centre 5
setscrew (A8). Tighten the setscrews finger tight. 9
2 Put the outer pipe (A7), part number 2483A003, in 8
position on the flange of the oil cooler and fit the third
setscrew (A9) finger tight. Beginning with the centre 7
6
setscrew, tighten the three setscrews to 22 Nm (16 lbf
ft) 2,2 kgf m.
3 Put a setscrew (A3) in position in the flange of the
inner pipe for the oil filter head. Put a new joint in A A0305
position on the setscrew. Hold the flange and the joint
in position and fit the centre setscrew (A2). Tighten
the setscrew finger tight.
4 Put the flange of the outer pipe in position and fit the
third setscrew (A1), tighten it finger tight. Beginning
with the centre setscrew, tighten the three setscrews
to 22 Nm (16 lbf ft) 2,2 kgf m.
To Inspect
1 Remove any old pieces of the joint and clean the
flange faces of the oil pipes.
2 Thoroughly clean the oil pipes in an approved
detergent cleaning solution.
3 Check the outer cover of the pipes for signs of
leakage, cracks or splits. If the outer cover or the
flanges are damaged the pipe must be renewed.
To fit the pipes - for engines fitted with a pressed
steel oil cooler - arrangement 3
Refer to , see operation 21-13, to remove the pipes
from the oil cooler cover. Refer to arrangements 1 and
2 above, to remove the pipes from the relevant oil
filter head.

19 New 1000 Series
Data and dimensions
Lubrication system
Lubricating oil pump - four cylinder engines
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential rotor, gear driven
Number of lobes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inner rotor 6, outer rotor 7
Clearance of outer rotor to body:
- Without balancer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,15/0,34 mm (0.006/0.013 in)
- With balancer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,31/0,45 mm (0.012/0.017 in)
Clearance of inner rotor to outer rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,04/0,13 mm (0.0015/0.0050 in)
End-float of rotor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,03/0,10 mm (0.001/0.004 in)
Lubricating oil pump - six cylinder engines
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential rotor, gear driven
Number of lobes:
- Inner rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Outer rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Clearance of outer rotor to body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,15/0,34 mm (0.006/0.013 in)
Clearance of inner rotor to outer rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,04/0,13 mm (0.0015/0.0050 in)
End clearance (naturally aspirated engines)
- Inner rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05/0,12 mm (0.002/0.005 in)
- Outer rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,04/0,11 mm (0.0015/0.0044 in)
End clearance (turbocharged engines)
- Inner rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,043/0,118 mm (0.0017/0.0046 in)
- Outer rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,031/0,106 mm (0.0012/0.0042 in)
Idler gear for lubricating oil pump
End float:
- Four cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,012/0,643 mm (0.0005/0.0253 in)
- Six cylinder engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,020/0,650 mm (0.0008/0.0256 in)
Inside diameter of bush (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22,23/22,26 mm (0.875/0.866 in)
Outside diameter of idler shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22,19/22,21 mm (0.873/0.874 in)
Clearance of bush of idler gear on shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 0,020/0,066 mm (0.0008/0.0026 in)

New 1000 Series 19
Oil pressure relief valve (standard)
Diameter of bore for plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,24/18,27 mm (0.718/0.719 in)
Outside diameter of plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,16/18,18 mm (0.715/0.716 in)
Clearance of plunger in bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,06/0,11 mm (0.002/0.004 in)
Length of spring (fitted):
- Four cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59,8 mm (2.4 in)
- Six cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55,6 mm (2.2 in)
Load on spring (fitted):
- Four cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15,9/23,1 N (3.6/5.2 lbf) 1,6/2,4 kgf
- Six cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12,9/18,6 N (2.9/4.2 lbf) 1,3/1,9 kgf
Pressure to open valve (Four cylinder engines):
- Without piston cooling jets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .340/395 kPa (49/57 lbf/in2) 3,4/4,0 kgf/cm2
- With piston cooling jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415/470 kPa (60/68 lbf/in2) 4,2/4,8 kgf/cm2
- Six cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345/414 kPa (50/60 lbf/in2) 3,5/4,2 kgf/cm2
Oil pressure relief valve (with balancer)
Diameter of bore for plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,00/16,03 mm (0.630/0.631 in)
Outside diameter of plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,95/15,98 mm (0.628/0.629 in)
Clearance of plunger in bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,02/0,08 mm (0.0008/0.003 in)
Length of spring (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42,7 mm (1.7 in)
Load on spring (fitted)34/38 N (7.6/8.5 lbf) 3,5/3,9 kgf
Pressure to open valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .523 kPa (76 lbf/in2) 5,3 kgf/cm2
Oil filter
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full flow, screw-on type canister
Pressure to open by-pass valve in filter. . . . . . . . . . . . . . . . . . . . . . . . 55/83 kPa (8/12 lbf/in2) 0,6/0,8 kgf/cm2
Pressure to open by-pass valve in oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . .172 kPa (25 lbf/in2) 1,8 kgf/cm2

180
New 1000 Series
20
Fuel system 20
General description.
Cautions:
! The fuel injection equipment must only be
checked and adjusted by personnel who have had
the correct training. 1
! Do not clean an engine while it runs. If cold
cleaning fluids are applied to a hot engine, certain
components on the engine may be damaged.
New 1000 Series engines are used for industrial and
agricultural applications and use various fuel injection
pumps. Either Bosch (A), Lucas (B) or Stanadyne (C)
pumps may be fitted.
2
All of the fuel pumps conform to emissions legislation.
A A0381
Both the pump timing and the speed adjustment are
tamper proof.
All of the fuel injection pumps have mechanical
governors to control the engine speed.
Bosch and Lucas fuel injection pumps have locking
screws (A2) and (B1) which lock the shaft. It is
1
important that the lock screw is released and the
pump shaft is free to turn when the pump is fitted to
the engine. Stanadyne pumps do not have a locking
screw fitted.
All of the fuel injection pumps have a pin timing hole
(A1), refer to section 17 for the correct method to time
the pump.
B A0299
Turbocharged engines have pumps with a boost
control (B2). The boost control is a device which is
affected by boost pressure (from the turbocharger)
and reduces the maximum fuel delivery at lower
engine speeds to match the reduced air supply to the
cylinders.
A data plate is fitted to the bracket of the fuel injection
pump. The data plate information is shown below:
Perkins part number
Fuel pump serial number
Manufacturers model number
The maximum no-load speed is shown on the C A0152
emissions data plate fitted to the left side of the
cylinder block.
Continued

20 New 1000 Series
The boost control fitted to the Bosch fuel pump is a
diaphragm type (A1). A KSB type cold starting aid and 1
a stop solenoid may also be fitted to these pumps.
Lucas DP200 Series fuel injection pump 1
Lucas DP200 Series fuel injection pumps are fitted to
naturally aspirated engines and turbocharged
engines.
These pumps have an electrically operated cold start
device (B3) which retards the timing for normal
operation. Other features of this pump include a boost
control (B1) and a stop solenoid (B2). These pumps A A0244
are fitted with a self-vent feature.
Stanadyne fuel injection pump 1
Some naturally aspirated engines have a Stanadyne
fuel injection pump (C) fitted. The electrical stop 2
solenoid on these fuel pumps is fitted inside the
governor housing. The earth connection (C1) and the
electrical supply connection (C2) are on top of the
governor housing.
Atomisers
The atomisers, which are of the valve covered orifice
(VCO) type, have nozzles with five holes. the
atomisers inject fuel in a very fine spray into the 3
combustion chamber in the top of each piston. Each B A 02 99 /1
atomiser is fastened to the cylinder head by a gland
nut.
The atomisers are set in the factory, but they must be 2
checked in accordance with the preventive 1
maintenance schedules. The pressure at which
atomisers operate can be adjusted by a change of
shims fitted above the spring.
For details of the atomiser setting pressures for the
engine, see the data and dimensions at the end of this
section.
Continued
C A0152

New 1000 Series 20
Cold start advance unit
Some Lucas, Bosch and Stanadyne rotary fuel
injection pumps have a cold start advance unit that
holds the timing of the pump in an advanced position
when the engine is cold.
Caution: It is important that the electrical
connections to the sender unit are connected
correctly. Failure of the starting aid to operate
correctly could result in damage to the engine as the
timing will be fully advanced for normal operation.
The sender unit, for engines fitted with belt driven
coolant pumps, is on the top of the thermostat
housing. The sender unit, for engines fitted with gear
driven coolant pumps, is on the rear of the timing case
on the left side of the engine.
As the engine warms, the sender unit energises to
retard the pump timing to the correct timing for normal
operation of the Lucas and Bosch fuel injection
pumps. The sender unit for the Stanadyne cold start
unit de-energises to retard the pump timing to the
correct timing for normal operation.
Note: The wiring diagrams on page 184 show the
sender unit (component 3) position when the engine
is cold.
To ensure that the engine conforms to the emissions
legislation, it is important that the electrical
connections of the engine cold start advance unit are
fitted correctly before the engine is operated.
Caution: Damage to the engine will occur if the
engine is load tested at more than 80% of full load
with the cold start device disconnected.
Continued

20 New 1000 Series
Wiring diagrams for the cold start advance unit fitted
to some Lucas DP200 Series, Bosch and Stanadyne
fuel injection pumps are shown in the illustrations (A),
(B) and (C) respectively. For easy identification the 1 1
cables are shown in circles on the illustrations. 2
The amperage of each of the cables is listed in the 2
3
cable identification table below. The identification
numbers for the electrical components on the wiring
diagram are shown in triangles. Refer to the 3
component identification list for the relevant wiring 5 OR
H
diagram to find a component. H
4 S
Cable identification table
For numbers shown in circles A A0398
Cable Current
(Number) (Amperes)
1 3 4
2 3 1 2
3 6
5
3 5
4 3
5 3 6
OR
H
6 6 H
4 S
7 3
8 6 B A0399
9 3
7
Component identification list
2
For numbers shown in triangles
8
Component Description 1
1 Fuel injection pump
2 Engine stop solenoid 5 3 OR
H
3 Sender unit 9 H
4 S
4 Start switch
5 Cold start advance unit C A0400
Continued

New 1000 Series 20
Cold start advance unit (KSB)
Bosch EPVE rotary fuel injection pump has a starting
aid which holds the timing of the pump in an advanced
1 2
position when cold.
The device (A) is operated electrically and is
connected by a shaft to the advance lever (A3) of the
fuel injection pump.
Warning! Do not touch the body (A1) of the hot wax
filled element during operation of the engine.
As the engine warms, a sender unit in the coolant 3
passage at the rear of the timing case energises to
apply 24V to the wax filled element (A1). As the wax A A1449
expands it causes a rod connected to a lever to retard
the pump timing to the correct timing for normal
operation.
Cautions:
! It is important that the electrical connection (A2)
and the connection to the sender unit on the rear
of the timing case are correctly connected. Failure
of the starting aid to operate correctly could result
in damage to the engine as the timing will be fully
advanced.
! Do not release the connection (A3) from the pull
rod; this will result in the loss of adjustment set in
the factory.

20 New 1000 Series
Typical fuel system The fuel injection pump increases the fuel pressure
and injects high-pressure fuel at the correct time and
six cylinder engines
sequence through pipes to the atomisers (A11). A fuel
Fuel systems vary from application to application, this leak-off rail is fitted to the top of each atomiser and
information is provided for training purposes only. leak-off fuel (A10), used to lubricate the atomisers, is
returned to the fuel tank through a pipe (A3).
Fuel (A9) from the tank (A2) leaves the pre-filter (A4)
and then passes to the diaphragm type lift pump (A1),
which is driven by an eccentric on the camshaft. Fuel
leaves the lift pump under pressure and passes
through a full flow filter (A5) to the fuel injection pump
(A8).
Some fuel injection pumps have a self-vent pipe (A7)
to remove air from the fuel system back into the fuel
tank. The fuel in the injection pump also lubricates
and cools the pump. A fuel heater or cooler may be
fitted between the filter head and filter canister. The
pump has a mechanical governor to control the
engine speed.
The pumps also have an electrical stop solonoid and
an electrically operated cold start advance unit fitted.
8 7 6 5 4
9
10
A A0406

New 1000 Series 20
Fuel filters
1
Cautions:
! It is important that only the genuine Perkins parts
are used. The use of a wrong canister or element
can damage the fuel injection pump.
! The pre-filter and main filter canisters must be
renewed at the same time.
! Do not allow dirt to enter the fuel system. Before a 2
connection is disconnected, clean thoroughly the
area around the connection. After a component 3
has been disconnected, fit a suitable cover to all
open connections. A A0248
There are three types of fuel filter element in use:

The separate element type (A2) where the filter 1
element is held between the filter head (A1) and the
2
bottom cover (A3). The filter can have two elements
(A).
The canister type where the filter element has an
internal thread at the top (B2) and is fastened to a
threaded adaptor in the filter head (B1).
A fuel filter with a quick release canister (C). The filter
can have two canisters. Some engines are fitted with
a pre-filter (C2) of the same type. This filter is fitted
next to the main filter (C1), but connected in the fuel
system before the fuel lift pump. It is important to B A0249
ensure that the main and pre-filters are fitted in the

correct positions.
2
1
C A0368

20 New 1000 Series
Fuel filter element
1
To renew 20-1 3
Warning! Discard the used canister and fuel oil in a 2

safe place and in accordance with local regulations.
Cautions:
4
can damage the fuel injection pump. 5
! Do not allow dirt to enter the fuel system. Before a A A0248
area around the connection. After a component
open connections.
Separate element type
1 Clean the outside surfaces of the fuel filter
assembly. If a drain tap is fitted to the bottom of the
filter bowl, drain the fuel from the filter.
2 Hold the bottom cover of the filter element and
release the setscrew (A3) which is fitted through the
filter head (A1) above the centre of the element.
3 Lower the bottom cover of the filter.
4 Remove the element (A4) and discard it.
5 Clean the inside surfaces of the filter head and of
the cover.
6 Renew the seals (A2) and (A5) and lightly lubricate
them with clean fuel.
7 Put the bottom cover under the new element and
hold the element squarely to the filter head. Ensure
that the element is fitted in the centre against the joint
in the filter head. With the assembly in this position,
engage and tighten the setscrew.
8 Eliminate the air from the fuel filter, see operation
20-9, operation 20-12 and operation 20-15.

New 1000 Series 20
Canister type
Warning! Discard the used canister and fuel oil in a
safe place and in accordance with local regulations.
Cautions:
can damage the fuel injection pump.
1
! Do not allow dirt to enter the fuel system. Before a
area around the connection. After a component
open connections. A A0247
1 Thoroughly clean the outside surfaces of the fuel
filter assembly.
1
2 Loosen the drain device at the bottom of the filter
(A1) and allow the water / fuel to drain into a suitable 2
container.
3 Use a strap wrench or similar tool to loosen the filter
canister and remove the canister.
4 Ensure that the threaded adaptor (B1) is secure in
the filter head and that the inside of the head is clean.
5 Lubricate lightly the top seals (B2) of the new
canister with clean fuel. Fit the new canister to the
filter head and tighten, by hand only.
6 Eliminate the air from the fuel filter, see operation B A0249

20 New 1000 Series
Quick release canister type
Warning! Discard the used canister and fuel oil in a
safe place and in accordance with local regulations. 2
Cautions: 7
! It is important that only the genuine Perkins parts 1 3
can damage the fuel injection pump. 4
9
! Do not allow dirt to enter the fuel system. Before a
area around the connection. After a component 8 5
open connections. A 6 A0368
1 Thoroughly clean the outside surfaces of the filter
assembly.
2 Loosen the drain device (A6), and (A8) if a pre-filter
is fitted, at the bottom of the canister or sediment bowl
(A5) and allow the water or fuel to drain into a suitable
container.
Note: If the filter does not have a drain device fitted,
release the cap (A2) on top of the filter head. Remove
the nylon insert to lower the level of the fuel in the filter
canister. This will prevent fuel spill when the gland
ring (A7) is released.
3 Support the filter canister(s) and rotate the gland
ring to the left and remove the gland ring.
4 Remove the canister(s) from the filter head by a
direct pull downwards (A1), and discard the old
canister.
5 If a sediment bowl is fitted, remove the bowl and
thoroughly clean the cover of the bowl.
6 Check the two 'O' ring seals of the sediment bowl
for damage and renew them if necessary.
7 Clean the threads of the sediment bowl and fit the
bowl to the canister and tighten by hand only.
Caution: It is important to ensure that the main and
pre-filters are fitted in the correct positions.
8 Ensure the filter head is clean. Push the new
canister(s) fully into the filter head (A3).
9 Support the canister(s), fit the gland ring and rotate
it to the right to fasten the canister to the filter head.
10 If it was removed, fit the nylon insert used to lower
the level of the fuel in the filter canister and fasten the
cap.
11 Eliminate the air from the fuel filter, see operation

New 1000 Series 20
Atomisers
Atomiser fault 20-2 1
Regular maintenance of the atomisers is not 2

necessary. The atomiser nozzles should be renewed
and not cleaned, and renewed only if an atomiser fault
occurs. The major problems that may indicate that 3
new nozzles are needed are listed below:
Engine will not start or is difficult to start
Not enough power
Engine misfires or runs erratically
High fuel consumption
Black exhaust smoke
Engine knocks or vibration
Excessive engine temperature
Warnings!
! If your skin comes into contact with high-pressure
fuel, obtain medical assistance immediately.
! Keep away from moving parts during engine
operation. Some moving parts cannot be seen
clearly while the engine runs. A A0369
In order to find which atomiser is defective, operate
the engine at a fast idle speed. Loosen and tighten the 2 Remove the union nuts of the high-pressure pipe
union nut of the high-pressure fuel pipe at each from the atomiser and from the fuel injection pump.
atomiser. Do not loosen the union nut more than half Do not bend the pipe. If necessary, remove the pipe
a turn. When the union nut of the defective atomiser connection. Fit a plastic cap (A1) to cover the fuel inlet
is loosened, there is little or no effect on the engine connection and the nozzle.
speed. 3 Release the gland nut (A3) and remove the
atomiser and its seat washer from the recess in the
cylinder head.
Continued
POWERPART atomiser thread sealant
To remove
Caution: Do not allow dirt to enter the fuel system.
Before a connection is disconnected, clean
thoroughly the area around the connection. After a
component has been disconnected, fit a suitable
cover to all open connections.
1 Remove the fuel leak-off pipe from the connection
(A2).

20 New 1000 Series
To fit
1 Thoroughly clean the threads of the gland nut (A3)
and the cylinder head.
1
Caution: Do not allow any thread sealant to get
below the gland nut threads.
2
2 Ensure that the wire clip (A4) is in position. Put a 2
mm (0.08 in) bead of POWERPART atomiser thread
sealant onto the first two threads of the gland nut. The 7
3
bead should extend approximately 6 mm (0.24 in)
around each of the threads. Ensure that the sealant
does not contact the body of the atomiser. 4
Caution: Remove and discard the original seat 6
washer (A6). If the original seat washer remains in the
recess for the atomiser, the nozzle protrusion will be
incorrect when a new seat washer is added.
Put the new seat washer (A6) into the seat recess in
the cylinder head. 5
Put the atomiser in position, ensure that the location
ball (A7) is fitted in the groove (A5) correctly. Carefully
engage the threads of the gland nut (A3) with the
threads in the cylinder head.
Caution: Do not move the thread after it has been
tightened, the seal that is made when torque has
been applied will be broken and leakage past the
atomiser seat may occur.
A A0369
Tighten the nut gradually and evenly to 40 Nm (30 lbf
ft) 4,1 kgf m. As the nut is tightened the atomiser will
rotate clockwise as the ball moves in the slot, this is
acceptable. Remove any excess thread sealant.
Caution: Do not tighten the union nuts of the high-
pressure pipes more than the recommended torque
tension. If there is a leakage from the union nut,
ensure that the pipe is correctly aligned with the
atomiser inlet. Do not tighten the atomiser union nut
more, as this can cause a restriction at the end of the
pipe. This can affect the fuel delivery.
3 Remove the plastic cap (A1) and fit the high-
pressure fuel pipe and tighten the union nuts to 22 Nm
(16 lbf ft) 2,2 kgf m. If necessary, fit the pipe
connections.
4 Renew the sealing washers and fit the leak-off pipe
to the leak off connection (A2). Tighten the banjo bolt
to 9,5 Nm (7,0 lbf ft) 1,0 kgf m.
5 Operate the engine and check for leakage of fuel
and air.

New 1000 Series 20
Fuel lift pump
1
POWERPART nutlock
1 If a heat shield is fitted, remove it. Disconnect the

fuel pipes from the fuel lift pump.
2
2 Release the setscrews, remove the fuel lift pump
(A). The lift pump may be difficult to remove from the A P 0 0 29
engine. If this occurs, the crankshaft must be rotated
until the camshaft eccentric, which operates the lift
pump, is in a position that will free the rocker lever of
the lift pump.
3 Ensure that the camshaft eccentric is in the
minimum lift position before the lift pump is fitted.
Clean the joint face of the lift pump (A2) and the
cylinder block and fit the lift pump together with a new
joint (A1). Apply POWERPART Nutlock to the first
three threads of the setscrews and tighten them
gradually and evenly to 22 Nm (16 lbf ft) 2,2 kgf m.
4 Connect the fuel pipes and, if necessary, fit the heat
shield.
5 Release the vent screw on the fuel filter head and
operate the priming lever of the fuel lift pump to
eliminate any air between the lift pump and the fuel
filter. Operate the lift pump until fuel, free of air, comes
from the vent screw. Tighten the vent screw.
6 Operate the engine and check for any fuel or air
leakage.

20 New 1000 Series
13 1 2
4 3
To dismantle
1 Clean the outside surfaces of the fuel lift pump. 4
2 Make a mark across the flanges of the two halves
of the pump to ensure correct relationship when the 5
3
pump is assembled.
3 Remove the cover (A1) and the gauze (A2). 12
Release the setscrews and separate the two halves of 6
the pump.
4 Turn the diaphragm assembly (A5) 90° to release 11
the pull rod from the link arm (A8) and remove the 7
diaphragm assembly. Remove the stem seal (A6), the
spring seat washer (A7) and the spring (A12) from the 9 8
10
pull rod. The diaphragm and pull rod assembly is
renewed as an assembly and no service is possible
on the diaphragm.
5 The valves (A4) are peened in and can be removed
with a suitable lever. Some of the peened metal will
have to be removed before the valves can be
removed.
6 To remove the link arm: Hold the rocker lever (A11)
in a vice and hit the body of the lift pump with a soft
face hammer to release the two retainers (A10). Be
careful not to damage the joint face of the pump body.
Remove the rocker lever, the pin (A9), the link arm
and the return spring. Check the components for wear A A0252
and other damage.
To assemble
1 Thoroughly clean the valve housings. Fit new seat
washers (A3) and push the new valves (A4) into
position. As the valves are the same, but one valve is
fitted in reverse of the other, it is possible to fit the
valves upside down. To ensure that the valves are
fitted correctly, fit them as shown in A. When the
valves are correctly fitted, peen the edge of the valve
housings in six places, evenly divided, to keep the
valves in position.
2 Fit the rocker lever (A11), pin (A9) and link arm
assembly (A8) into the bottom half of the lift pump. Fit
the return spring; ensure that the ends of the spring
are in their correct location.
3 With a light hammer and a suitable adaptor, fit two
new retainers (A10) in their grooves in the casing until
they fasten the pin. Peen the open ends of the
grooves to fasten the retainers in position.
4 Fit the diaphragm spring (A12) into its location
under the diaphragm (A5) and put the spring seat
washer (A7) and a new stem seal (A6) into position on
the pull rod. Ensure that the small diameter at the top
of the seal is on the round section of the pull rod.
Continued

New 1000 Series 20
5 Put the diaphragm assembly in position over the
lower half of the body with the blade of the pull rod 13 1 2
aligned with the slot in the link arm. Press lightly down 4 3
on the diaphragm until the notch in the pull rod is in
the slot in the link arm and turn the diaphragm 90° in 4
either direction. This action will engage and retain the
pull rod in the slot of the link arm. 5
3
6 Push the rocker arm towards the pump body until
the diaphragm is level with the body flange and fit the 12
top half of the body in position with the marks on the 6
flanges aligned. Keep the pressure on the rocker arm;
fit the spring washers and the screws and tighten
11
them evenly. 7
7 Fit the gauze filter (A2) and the cover (A1), ensure
that the rubber seal (A13) is fitted correctly and 9 8
10
tighten the screw.
To test 20-6
1 Disconnect the fuel outlet pipe from the fuel lift

pump. Fit a 0-70 kPa (0-10 lbf/in2) 0-0,7 kgf/cm2
pressure gauge to the outlet of the lift pump. Release
the connection at the gauge and operate the priming
lever of the lift pump to eliminate air from the pipe.
When fuel, free of air, flows from the pipe tighten the
connection. Ensure that there are no leaks at the
connections between the pump and the gauge.
A A0252
2 Operate the starter motor for 10 seconds with the
engine stop control in the stop position or with the
stop solenoid disconnected.
3 Note the maximum pressure indicated on the
gauge. If the pressure indicated is less than the test
pressure shown in the data and dimensions, repair or
renew the pump. Also check the rate at which the
pressure reduces to half the maximum pressure
obtained. If this is less than 30 seconds, repair or
renew the pump.
4 Remove the gauge and connect the outlet pipe to
the lift pump. Release the vent screw on the fuel filter
head and operate the priming lever until fuel, free of
air, flows from the vent screw. Tighten the vent screw.
5 Connect the engine stop solenoid.

20 New 1000 Series
To remove and to fit 20-7 1 2 3
Special tools:
Spanner for flange nut of the Bosch fuel injection
pump PD.239
Timing pin PD.245
6
General description 5 4
A PW000
injection pump. Illustration (B) shows the nut (B2) in
position when the fuel pump is fitted to the engine.
to ensure that the fuel pump is in the correct position
for timing. If the nut is removed and the hub moves,
The manufacturer fits the hub (A2) to the pump to 1
ensure very accurate timing. Engines that have this
instead of to the shaft of the pump.
2
To prevent incorrect adjustments to the engine timing B A0374
by rotation of the fuel pump, the mounting flange (A5)
has holes instead of slots.
1
Accurate timing of the pump to the engine is by a pin
(A1) used to align the fuel pump gear and the hub
(A2), with a hole in the body (A3) of the fuel pump.
2
The gear is passed over the pin and fastened to the
hub with four fasteners (B1).
pumps, four tamper proof fasteners retain the fuel 3
pump gear. Special tools and personnel with the
correct training are necessary to remove these
fasteners, refer to your nearest Perkins distributor.
Caution: A new fuel injection pump may be supplied
with the pump shaft in the locked position. The drive C A 0 25 6
shaft of the pump must not be turned without the

spacer (C3) in position under the locking screw (C2)
The fuel injection pump has a locking screw (C2) and
a spacer (C3). The locking screw prevents the
rotation of the drive shaft.
An "O" ring (C1) is fitted into a groove in the pump
flange. This "O" ring is fitted instead of a joint between
the pump flange and the timing case.
Continued

New 1000 Series 20
To remove
Caution: A new fuel injection pump may be supplied
with the pump shaft in the locked position. The drive
shaft of the pump must not be turned without the 1
spacer (A2) in position under the locking screw (A1).
Before the crankshaft is turned or the pump is fitted,
put the spacer into position under the locking screw to
ensure that the pump drive shaft is released. 2
1 Disconnect the battery before the fuel injection
pump is removed from the engine.
2 Set the engine to TDC on the number 1 cylinder on
the compression stroke, see operation 17-1 or , see
operation 17-2. A A0256

case. For gear driven coolant pumps: Remove the
coolant pump, see operation 21-2. 1 2
4 Insert the timing pin (B5) through the hole (B3) in
the fuel pump gear and the slot of the hub (B2). Push 3
the pin fully into the hole (B1) in the body of the fuel
pump. If the pin can be fully inserted then the pump 4
timing is correct. There should be no resistance when 6
the pin is inserted. 5
Caution: Use a second spanner to prevent
movement of the high-pressure outlet when the union
nut for each high-pressure pipe is released.
5 Remove the pipes. Remove the cables and the
connections for the cold start device and the electrical B A0 37 4/3
stop solenoid from the fuel pump.
Cautions:
! Do not rotate the crankshaft when the pump is not
on the engine; the loose fuel pump gear may
damage the timing case. If it is necessary to rotate
the crankshaft, fit the fuel pump temporarily to
ensure that the gear is in the correct position. If the
fuel pump is fitted temporarily in order to rotate the
crankshaft, the locking screw (A1) must be
released and a spacer (A2) fitted.
! Do not release the nut (B6) from the fuel injection
pump. The fuel pump hub is fitted to the shaft in
the factory to ensure that the fuel pump is in the
correct position for timing. If the hub is moved, the
hub will need to be accurately fitted to the pump by
use of special equipment available to Perkins
distributors.
6 Remove the four fasteners (B4) and release the
fuel pump gear from the hub of the fuel injection
pump.
7 Remove the nuts from the flange of the fuel pump
and remove the pump. If access to the nuts is
restricted by, for example, a compressor, use tool
PD.239 to release the nuts.

20 New 1000 Series
To fit
Cautions:
! The engine must be set to TDC number 1 cylinder,
1
compression stroke before the pump is fitted. If the
crankshaft needs to be rotated, the pump must be
fitted temporarily, or the loose gear could damage
the timing case. 2
! The drive shaft of the pump must not be rotated
without the spacer (A1) in position under the
locking screw (A2). If the drive shaft is rotated with
the locking screw tightened on to the shaft, the
drive shaft will be damaged. 3
A A 02 56 /1
1 Inspect the "O" ring (A3) in the pump flange and, if
necessary, fit a new "O" ring.
2 Lightly lubricate the "O" ring with clean engine
1 2
lubricating oil and put the pump into position on the
timing case.
3 Put the fuel pump into position on the three studs 3
and fit the flange nuts.
4
4 Fit the setscrew and nut of the support bracket.
6
Ensure that force is not applied to the fuel pump when
5
the support bracket is fitted.
5 Tighten the flange nuts of the fuel pump to 28 Nm
Caution: Do not release the nut (B6) from the fuel
injection pump. The fuel pump hub is fitted to the shaft B A0 37 4/3
in the factory to ensure that the fuel pump is in the
correct position for timing. If the hub is moved, the hub
will need to be accurately fitted to the pump by use of
special equipment available to Perkins distributors.
6 Put the fuel pump gear onto the hub of the fuel
pump. The fasteners (B4) for the fuel pump gear
should be in the centre of the slots to allow for the
removal of the backlash. Tighten the setscrews finger
tight.
Note: The fuel pump gear will only fit in one position.
The gear is fitted with the letters C and M at the front.
7 Insert the timing pin (B5) through the hole (B3) of
the fuel pump gear and the slot of the hub (B1) until it
can be pushed fully into the hole (B2) in the body of
the fuel pump. If the timing pin cannot be pushed into
the pump body, check that the engine is correctly set
at TDC on the number 1 cylinder, see operation 17-1
Continued

New 1000 Series 20
Caution: The fuel pump gear must be fitted to the
engine before the crankshaft is rotated. 1
8 Carefully turn the gear counter-clockwise, by hand
(A1), to remove the backlash between the idler gear
and the fuel pump gear. Do not rotate the crankshaft
or the fuel pump shaft. Tighten the setscrews for the
fuel pump gear to 28 Nm (20 lbf ft) 2,8 kgf m.
see operation 21-2.
pressure pipes more than the recommended torque A A 0 37 4/1
11 Fit all the pipes. Connect the stop control and the
control rod of the fuel injection pump. Fit the cables
and connection for the cold start device and electrical
stop solenoid to the pump. Ensure that a spanner is
used to prevent movement of the pump outlets when
the high-pressure pipes are fitted and tighten the
union nuts to 22 Nm (16 lbf ft) 2,2 kgf m.
20-9.
13 Fit the cylinder head rocker cover.
14 Operate the engine and check for leakage. With
the engine at the normal temperature of operation,
check that the idle speed and the maximum no-load
speed are correct, see operation 20-8.

20 New 1000 Series
To adjust 20-8
The engine conforms with USA (EPA/CARB) stage 1

1
and EEC stage 1 emissions legislation for agricultural
and industrial applications.
1
The idle or maximum speed settings must not be
changed by the engine operator, because this can
damage the engine or the transmission.
Specialist equipment, which is available at your
Perkins distributor, is needed to adjust the idle or
maximum speed settings. The warranty of the engine
can be affected if the seals on the fuel injection pump
are broken during the warranty period by a person A A0244
who is not approved by Perkins.
1 Operate the engine until it reaches its normal
temperature of operation and check the idle speed. If
necessary, adjustment can be made by the inner
adjustment screw (A1). Release the lock nut and
rotate the adjustment screw clockwise to increase the
speed, or counter-clockwise to decrease the speed.
When the speed is correct, tighten the lock nut. The
setting of the idle speed can change for different
applications. Normally the correct speed will be given
in the manufacturer's handbook for the application. If
it is not given, refer to your nearest Perkins distributor.
Caution: The setting for the maximum no load speed
can change for different applications. For the correct
maximum no-load speed, check the emissions data
plate fitted to the left side of the cylinder block before
any adjustment is made to the maximum no load
speed.
2 With the engine at its normal temperature of
operation, check the maximum no load speed. A
typical maximum no load speed is 2860 rev/min. If
necessary, this speed can be adjusted by the outer
rotate the adjustment screw counter-clockwise to
increase the speed or clockwise to decrease the
speed. When the speed is correct, tighten the lock nut
and seal the screw.
The person who fits the pump must ensure that the
adjustment screw is suitably sealed against
interference after it has been set initially.

New 1000 Series 20
To eliminate air from the fuel system 20-9
1
If air enters the fuel system, it must be removed
before the engine can be started.
Air can enter the system if:
! The fuel tank is drained during normal operation.
! The low-pressure fuel pipes are disconnected.
! A part of the low-pressure fuel system leaks during
engine operation.
In order to eliminate air from the fuel system, proceed
as follows:
Caution: If the fuel system is empty or if the canister A A0254
of the fuel filter have been renewed, it will be

necessary to eliminate air from the fuel system,
especially the fuel injection pump.
1 Loosen the banjo bolt (A1) on the top of the filter
head. If a vent plug is fitted, loosen the vent plug
instead.
2 Operate the priming lever of the fuel lift pump (B)
until fuel, free from air, comes from the banjo bolt.
Tighten the banjo bolt. If the drive cam of the fuel lift
pump is at the point of maximum lift, it will not be
possible to operate the priming lever. In this situation,
the crankshaft must be rotated one revolution.
Caution: Use a spanner to prevent movement of the B L0012
fuelled starting aid (C1) when the union nut (C2) is
loosened or tightened.
3 Loosen the union nut (C2) at the fuelled starting aid
and operate the priming lever of the fuel lift pump until 1
fuel, free of air, comes from the connection. Tighten
the union nut at the starting aid. 2
4 Loosen the union nut of the fuel inlet pipe (D1).
Operate the priming lever of the fuel lift pump until
fuel, free from air, comes from the loose connection.
Tighten the union nut.
Continued
C A 0367/2
D A0262

20 New 1000 Series
5 Loosen the high-pressure connections at two of the
atomisers (A1).
1
6 Put the electrical system switch to the "ON"
position. Ensure that the manual stop control, if one is
fitted, is in the "run" position. Operate the starter
motor until fuel, free from air, comes from the pipe A A0366
connections. Tighten the high-pressure pipe
connections to 22 Nm (16 lbf ft) 2,2 kgf m. Return the
switch to the "OFF" position.
7 The engine is now ready to start.
If the engine runs correctly for a short time and then
stops or runs roughly, check for air in the fuel system.
If there is air in the fuel system, there is probablely a
leakage in the low pressure system.

New 1000 Series 20
Lucas DP 200 Series fuel injection pump
1
To remove to fit 20-10
Special tools: 2
3
Timing pin PD.246, Lucas fuel injection pumps
General description
Caution: Do not release the nut (C2) from the fuel
injection pump. Illustration (C) shows the nut in
position when the fuel pump is fitted to the engine. A A0299
for timing. If the nut is removed and the hub moves,
the hub will need to be accurately fitted to the pump 1
The manufacturer fits the hub (A2) to the pump to
ensure very accurate timing. Engines that have this 2
The hub is permanently mounted onto the drive shaft
by the pump manufacturer to allow the pump timing to
be set accurately when the engine is in service. 3
B C 00 73 /2
To prevent incorrect adjustments to the engine timing
by rotation of the fuel pump, the mounting flange (B1)
has holes instead of slots.
(C1) used to align the fuel pump gear and the the hub
(C4), with a hole in the body (C3) of the fuel pump.
The gear is passed over the pin and fastened to the 1
hub with four fasteners (C6). 2
6
5
pump gear. Special tools to remove these fasteners
are available at your Perkins distributor.
4 3
Caution: A new fuel injection pump may be supplied C A 03 74
with the pump shaft in the locked position. The drive
shaft of the pump must not be turned without the
spacer (B2) in position under the locking screw (B3).
The fuel injection pump has a locking screw (A3) and
(B3) and a spacer (B2). The locking screw prevents
the rotation of the drive shaft.
An "O" ring (A1) is fitted into a groove in the pump
flange. This "O" ring is fitted instead of a joint between
the pump flange and the timing case.

20 New 1000 Series
To remove
Before the crankshaft is turned or the pump is fitted,
put the spacer (A1) into position under the locking
screw (A2) to ensure that the pump drive shaft is
released.
pump is removed from the engine. 1
operation 17-2.
case. For gear driven coolant pumps: Remove the 2
coolant pump, see operation 21-3. A C 0 07 3/1
4 Insert the timing pin (B1) through the hole (B5) in

the fuel pump gear and the slot of the hub (B4). Push
the pin fully into the hole (B3) in the body of the fuel
pump. If the pin can be fully inserted then the pump
Caution: Use a second spanner to prevent 1
movement of the high-pressure outlet when the union 2
nut for each high-pressure pipe is released. 6
5 Remove the pipes, the cables and the connections

5
for the cold start device and the electrical stop
solenoid from the fuel pump.
4 3
Cautions: B A 0 37 4/2

the crankshaft, fit the fuel pump temporarily to
crankshaft, the locking screw (A2) must be
released and a spacer (A1) fitted.
! Do not release the nut (B2) from the fuel injection
correct position for timing. If the hub is removed,
the hub will need to be accurately fitted to the
pump by use of special equipment available to
Perkins distributors.
6 Remove the four fasteners (B6) and release the
pump.
and remove the pump.

New 1000 Series 20
To fit
Cautions:
! The engine must be set to TDC number 1 cylinder,
compression stroke before the pump is fitted. If the
crankshaft needs to be rotated, the pump must be
fitted temporarily, or the loose gear could damage
1
the timing case.
! The drive shaft of the pump must not be rotated
without the spacer (A1) in position under the
locking screw (A2). If the drive shaft is rotated with
the locking screw tightened on to the shaft, the
drive shaft will be damaged. 2
A C 0 07 3/1
1 Inspect the "O" ring (B1) in the pump flange and, if
necessary, fit a new "O" ring.
2 Lightly lubricate the "O" ring with clean engine 1
lubricating oil and put the pump into position on the
timing case.
3 Put the fuel pump in position on the three studs and
fit the flange nuts. 2
3
4 Fit the setscrew and nut of the support bracket.
Ensure that force is not applied to the fuel pump when
the support bracket is fitted.
Caution: Do not remove the nut (C2) from the shaft
of the fuel injection pump. The fuel pump hub is fitted B A0299
to the shaft in the factory to ensure that the fuel pump

is in the correct position for timing. If the hub is
removed, the hub will need to be accurately fitted to
the pump by use of special equipment available to
6 Put the fuel pump gear onto the hub of the fuel
pump. The fasteners (C6) for the fuel pump gear 1
should be in the centre of the slots to allow for the 2
removal of the backlash. Tighten the setscrews finger 6
tight.
Note: The fuel pump gear will only fit in one position. 5
4 3
7 Insert the timing pin (C1) through the hole (C5) of
C A 03 74
the fuel pump gear and the slot of the hub (C4) until it
can be pushed fully into the hole (C3) in the body of
Continued

20 New 1000 Series
see operation 21-3.
11 Fit all the pipes. Connect the control rod of the fuel
injection pump. Fit the cables and connection for the
cold start device and electrical stop solenoid to the
pump. Ensure that a spanner is used to prevent
movement of the pump outlets when the high-
pressure pipes are fitted and tighten the union nuts to
22 Nm (16 lbf ft) 2,2 kgf m.
20-12.

New 1000 Series 20
To adjust 20-11
1
The engine conforms with USA (EPA/CARB) stage 1 2
and EEC stage 1 emissions legislation for agricultural
Perkins Distributor, is needed to adjust the idle or
necessary, adjustment can be made by the outer
rotate the adjustment screw clockwise to increase the
speed, or counter-clockwise to decrease the speed.
When the speed is correct, tighten the lock nut. The
setting of the idle speed can change for different
applications. Normally the correct speed will be given
in the manufacturer's handbook for the application. If
it is not given, refer to your nearest Perkins distributor.
speed.
necessary, this speed can be adjusted by the inner
rotate the adjustment screw counter-clockwise to
increase the speed or clockwise to decrease the
speed. When the speed is correct, tighten the lock nut
and seal the screw.

20 New 1000 Series
To eliminate air from the fuel system
Lucas DP200 pump 20-12
1
Air will usually be removed from the fuel pump
automatically when the engine is in operation. If the
fuel pipes are disconnected or if the canister of the
fuel filter has been renewed, or the engine runs out of
fuel, it will be necessary to eliminate air from the fuel
system.
Caution: If the fuel system is empty or if the
canister(s) of the fuel filter have been renewed, it will
be necessary to eliminate air from the fuel system,
especially the fuel injection pump. A A0254
1 Release the vent plug on the fuel filter head (A1).
2 Operate the priming lever of the fuel lift pump (B)
until fuel, free of air, comes from the vent plug.
Tighten the vent plug. If the drive cam of the fuel lift
pump is at the point of maximum lift, it will not be
possible to operate the priming lever. In this situation,
the crankshaft must be rotated one revolution.
Caution: Use a spanner to prevent movement of the
fuelled starting aid (C1) when the union nut (C2) is
3 Loosen the union nut (C2) at the fuelled starting aid
and operate the priming lever of the fuel lift pump until
B A0015
the union nut at the starting aid.
4 Loosen the union nut at the outlet connection of the
low pressure fuel leak off pipe which is on top of the
governor housing of the fuel injection pump. Operate
the priming lever of the fuel lift pump until fuel, free of 1
air, comes from the connection. Tighten the union nut.
2
5 Loosen the high-pressure connections at two of the C A 03 67 /2
atomisers (D1).
Continued
D A0366

New 1000 Series 20
Caution: Damage to the fuel injection pump, battery
and starter motor can occur if the starter motor is used
excessively to eliminate air from the fuel system.
motor until fuel, free from air, comes from the pipe
Caution: Operate the engine at low idle speed for a
minimum of five minutes immediately after air has
been removed from the fuel system. This will ensure
that the pump is completely free of air and prevent
any damage to the pumps internal parts by metal to
metal contact.

20 New 1000 Series
To remove to fit 20-13
Special tools: 1
Timing pin PD.246, Stanadyne fuel injection pumps 2
6
General description 5
injection pump. Illustration (A) shows the nut in 4 3
position when the fuel pump is fitted to the engine. A A0374A
for timing. If the nut is removed and the hub moves, 2
1
The manufacturer fits the hub (B3) to the pump to
ensure very accurate timing. Engines that have this
The hub (B3) is permanently mounted onto drive shaft
3
by the pump manufacturer to allow the pump timing to
be set accurately when the engine is in service.
B A0163
To prevent incorrect adjustments to the engine timing
by rotation of the fuel pump, the mounting flange has
holes instead of slots.
(A1) used to align the fuel pump gear and the the hub
(A4), with a hole in the body (A3) of the fuel pump.
The gear is passed over the pin and fastened to the
hub with four fasteners (A6).
pump gear. Special tools to remove these fasteners
are available at your Perkins distributor.
Fit a new joint (B1) to the timing case. Fit a new "O"
ring (B2) to the fuel pump. DB4 fuel pumps are fitted
with a rubber seal which has a square shape instead
of an "O" ring. When a rubber seal is fitted it is not
necessary to fit a joint.
Continued

New 1000 Series 20
To remove
pump is removed from the engine.
operation 17-2. 1
3 Remove the gear cover from the cover of the timing 2
case. For gear driven coolant pumps: Remove the 6
coolant pump, see operation 21-3.
4 Insert the timing pin (A1) through the hole (A5) in 5
the fuel pump gear and the slot of the hub (A4). Push
the pin fully into the hole (A3) in the body of the fuel 4 3
pump. If the pin can be fully inserted then the pump A A0374A
Caution: Use a second spanner to prevent 1
movement of the high-pressure outlet when the union
nut for each high-pressure pipe is released.
5 Remove the pipes, the cables and the connections
for the cold start device (B2) and the electrical stop
solenoid (B1) from the fuel pump.
Cautions:
the crankshaft, fit the fuel pump temporarily to B 2
A 01 52 /1
crankshaft.
! Do not release the nut (A2) from the fuel injection
correct position for timing. If the hub is removed,
the hub will need to be accurately fitted to the
pump by use of special equipment available to
6 Remove the four fasteners (A6) and release the
pump.
and remove the pump.

20 New 1000 Series
To fit
Caution: The engine must be set to TDC number 1
cylinder, compression stroke before the pump is 2
fitted. If the crankshaft needs to be rotated, the pump
must be fitted temporarily, or the loose gear could 1
damage the timing case.
1 Fit a new joint (A1) to the timing case. Fit a new "O"
ring (A2) to the fuel pump. DB4 fuel pumps are fitted
with a rubber seal which has a square shape instead
of an "O" ring. When a rubber seal is fitted it is not
necessary to fit a joint.
2 Lightly lubricate the "O" ring with clean engine
lubricating oil and put the pump into position on the A A0163
timing case.
3 Put the fuel pump in to position on the three studs
and fit the flange nuts.
Caution: Do not remove the nut (B2) from the shaft
of the fuel injection pump. The fuel pump hub is fitted 1
to the shaft in the factory to ensure that the fuel pump 2
is in the correct position for timing. If the hub is 6
removed, the hub will need to be accurately fitted to
the pump by use of special equipment available to 5
5 Put the fuel pump gear onto the hub of the fuel 4 3
pump. The fasteners (B6) for the fuel pump gear B A 0 37 4/2
should be in the centre of the slots to allow for the

removal of the backlash. Tighten the setscrews finger
tight.
Note: The fuel pump gear will only fit in one position.
6 Insert the timing pin (B1) through the hole (B5) of
the fuel pump gear and the slot of the hub (B4) until it
can be pushed fully into the hole (B3) in the body of
Continued

New 1000 Series 20
see operation 21-3.
10 Fit all the pipes. Connect the control rod of the fuel
injection pump. Fit the cables and connection for the
cold start device and electrical stop solenoid to the
pump. Ensure that a spanner is used to prevent
movement of the pump outlets when the high-
pressure pipes are fitted and tighten the union nuts to
22 Nm (16 lbf ft) 2,2 kgf m.
20-15.

20 New 1000 Series
To adjust 20-14
1
The engine conforms with USA (EPA/CARB) stage 1
and EEC stage 1 emissions legislation for agricultural 2
Perkins distributor, is needed to adjust the idle or
necessary, adjustment can be made by adjustment
screw (A1). Release the lock nut and rotate the
adjustment screw clockwise to increase the speed, or
counter-clockwise to decrease the speed. When the
speed is correct, tighten the lock nut. The setting of
the idle speed can change for different applications.
Normally the correct speed will be given in the
manufacturer's handbook for the application. If it is
not given, refer to your nearest Perkins distributor.
speed.
necessary, this speed can be adjusted by adjustment
screw (A2). Release the lock nut and rotate the
adjustment screw counter-clockwise to increase the
speed or clockwise to decrease the speed. When the
speed is correct, tighten the lock nut and seal the
screw.

New 1000 Series 20
To eliminate air from the fuel system 20-15
1 2
If air enters the fuel system, it must be removed
before the engine can be started.
Air can enter the system if:
! The fuel tank is drained during normal operation.
! The low-pressure fuel pipes are disconnected.
! A part of the low-pressure fuel system leaks during
engine operation.
In order to eliminate air from the fuel system, proceed
as follows:
Vent screws are not fitted to the fuel injection pump. A A0368
Air will usually be removed from the fuel pump

automatically.
Caution: If the fuel system is empty or if the
canister(s) of the fuel filter have been renewed, it will
be necessary to eliminate air from the fuel system,
especially the fuel injection pump.
1 Loosen the vent plug on the filter head of the pre-
filter (A2). Operate the priming lever of the fuel lift
pump (B) until fuel, free of air, comes from the vent
plug. Tighten the vent plug.
Note: If the drive cam of the fuel lift pump is at the
point of maximum lift, it will not be possible to operate
the priming lever. In this situation, the crankshaft must B L0012A
be rotated one revolution.
2 Loosen the vent plug (A1) on the top of the filter
head. Operate the priming lever of the fuel lift pump
until fuel, free of air, comes from the vent plug.
Tighten the vent plug.
Continued

20 New 1000 Series
Caution: Use a spanner to prevent movement of the
fuelled starting aid (A1) when the union nut (A2) is
3 Loosen the union nut (A2) at the fuelled starting aid 1
and operate the priming lever of the fuel lift pump until
2
the union nut at the starting aid.
A A 0 36 7/3
4 Loosen the high-pressure connections at two of the
atomisers (B1).
Caution: Damage to the fuel injection pump, battery
and starter motor can occur if the starter motor is used
excessively to eliminate air from the fuel system. 1

motor until fuel, free from air, comes from the pipe
B A0366
Caution: Operate the engine at low idle speed for a
minimum of five minutes immediately after air has
been removed from the fuel system. This will ensure
that the pump is free of air and prevent any damage
to the pumps internal parts by metal to metal contact.

New 1000 Series 20
Data and dimensions
Fuel system
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EPVE, pin timed, with a locking screw
Lucus fuel injection pump
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lucas DP200 Series, pin timed, with a locking screw
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise from drive end
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stanadyne DB2 or DB4, pin timed
Fuel lift pump - four cylinder engines
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diaphragm, A.C.Delco, type XD
Method of drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eccentric on camshaft of engine
Static pressure (no delivery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42/70 kPa (6/10 lbf/in2) 0,4/0,7 kgf/cm2
Test pressure (75% of minimum static pressure) . . . . . . . . . . . . . . . . . . . . . . 31 kPa (4.5 lbf/in2) 0,32 kgf/cm2
Fuel lift pump - Six cylinder engines
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diaphragm, A.C.Delco, type LU
Method of drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eccentric on camshaft of engine
Static pressure (no delivery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34,5/55,2 kPa (5/8 lbf/in2) 0,35/0,56 kgf/cm2
Test pressure (75% of minimum static pressure) . . . . . . . . . . . . . . . . . . . . . 26 kPa (3.75 lbf/in2) 0,26 kgf/cm2
Fuel filter
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Twin parallel flow or single element

20 New 1000 Series
Atomiser service setting
The code letters are stamped on the side of the atomiser body just below the connection for the nut of the high
pressure pipe.
Set and reset pressure

Code Holder Nozzle
atm (lbf/in2) MP
KB 2645A308 2645A624 300 4410 30,4
KC 2645A309 2645A625 290 4263 29,4
KD 2645A310 2645A626 290 4263 29,4
KE 2645A311 2645A627 290 4337 29,9
KF 2645A311 2645A628 295 4337 29,9
KG 2645A314 2645A629 300 4410 30,4
KH 2645A314 2645A630 290 4263 29,4
KJ 2645A315 2645A631 250 3675 25,3
KK 2645A312 2645A632 300 4410 30,4
KL 2645A312 2645A633 300 4410 30,4
KM 2645A313 2645A634 300 4410 30,4
KN 2645A315 2645A635 290 4263 29,4
KP 2645A311 2645A636 290 4410 30,4
KR 2645A311 2645A608 290 4263 29,4
KT 2645A311 2645A638 290 4263 29,4
KS 2645A316 2645A637 290 4263 29,4
KU 2645A317 2645A627 290 4322 29,8
KV 2645A304 2645L615 250 3675 25,3
KW 2645A311 2645K609 290 4263 29,4
NX 2645L306 2645L617 290 4263 29,4
NY 2645L308 2645L618 290 4263 29,4
NZ 2645L307 2645L619 290 4263 29,4
PA 2645L309 2645L620 290 4263 29,4
PB 2645L310 2645L621 290 4263 29,4
PC 2645L310 2645L622 290 4263 29,4
PD 2645L310 2645L622 275 4043 27,9
RZ 0430 133 005 DSLA140P707 250 3675 25,3
SA 2645F316 2645F620 250 3675 25,3
SB 2645F316 2645F621 250 3675 25,3
SC 043013306 DSLA150PV3378123 250 3675 25,3

New 1000 Series
21
Cooling system 21
General description
Coolant from the bottom of the radiator passes The coolant then passes from the rear of the cylinder
through the centrifugal coolant pump, which is fitted block and into the cylinder head. The coolant leaves
onto the front of the timing case to assist the flow of the cylinder head at the front and passes into the
the coolant through the system. thermostat housing.
The pump is gear driven from the gear of the fuel If the thermostat is closed, the coolant goes directly
injection pump. through a by-pass to the inlet side of the coolant
pump. If the thermostat is open, the thermostat closes
On certain four cylinder applications the pump is
the by-pass and the coolant passes to the top of the
driven by a "V" belt from the crankshaft pulley. Some
radiator.
engines are fitted with a belt driven coolant pump in a
high position, these are identified by the thermostat Some engines are fitted with two thermostats.
housing which is part of the pump rear body. The rear
body of these pumps has a connection to a coolant
transfer plate, which allows coolant from the pump On six cylinder engines the coolant divides as it
impeller to pass into the cylinder block. enters the cylinder block. Most of the coolant passes
along the right hand side of the cylinder block and
Two types oil cooler are available for use on four
around the outside of the cylinders to the rear of the
cylinder engines: An integral oil cooler which is fitted
cylinder block.
to the left side of the cylinder block or a separate
(cassette type cooler) fitted to the filter head. The remainder of the coolant passes along a passage
on the left hand side of the cylinder block to the
The integral oil cooler has an aluminium cover with
lubricating oil cooler.
plate element and is fitted to the left side of the
cylinder block. The coolant flows around the element of the
lubricating oil cooler to the rear of the cylinder block.
The latest integral oil coolers for 6 cylinder engines
The coolant then passes to the rear of the cylinder
have a pressed steel cover.
head.
Coolant passes forward through the cylinder head
From the pump, the coolant passes through a and into the thermostat housing. These engines have
passage in the timing case to the water jacket in the one thermostat. If the thermostat is closed, the
left side of the cylinder block. Coolant pumps driven coolant goes, through a by-pass, directly to the inlet
by a "V" belt do not pass the coolant through a side of the coolant pump. If the thermostat is open,
passage in the timing case but direct to the front of the the coolant passes to the top of the radiator.
cylinder block. The coolant continues to the rear of the
Some engines are fitted with two thermostats.
cylinder block where some of the coolant passes into
the lubricating oil cooler, if one is fitted. Some of the
coolant passes around the element of the integral
cooler and then to the rear of the cylinder block.
Some four cylinder engines have a cassette type oil
cooler fitted between the oil filter canister and the oil
filter head. If the cassette oil cooler is fitted on the left
side of the engine, coolant from the by-pass
connection at the rear of the coolant pump passes
through a pipe to the oil cooler. If the cassette oil
cooler is fitted to the right side of the engine, a pipe is
connected between the thermostat housing and the
oil cooler. The coolant passes around the plates of the
cooler and passes through a pipe to the cylinder
block.

New 1000 Series 21
Identification of the coolant pump is by the last four
digits of the part number, for example 4131E011, 1
stamped on the front of the pump body.
To remove
1 Drain the cooling system and disconnect the hose
at the inlet connection of the coolant pump. 2
2 Release the setscrews from the flange of the A A0268
coolant by-pass.
3 Release the three setscrews which retain the
coolant pump to the cover of the timing case - two
from the front and one from the rear.
4 Release the setscrews from the rear face of the
timing case, which fasten the pump to the timing case,
and remove the coolant pump (A). Ensure that the "O"
ring (A1) on the cover of the timing case is not lost.
To fit
1 Check the "O" rings on the pump body (A2) and on
the cover of the timing case (A1) for damage. If either
of the "O" rings are damaged, they must be renewed.
Ensure that all joint faces are clean.
2 Check the drive gear of the coolant pump for wear
or other damage. If the gear is damaged, it must be
renewed.
3 Lightly lubricate the "O" ring on the pump body with
clean engine lubricating oil. Fit the pump to the timing
case cover with its gear in mesh with the gear of the
fuel injection pump. The pump is a tight fit in the
cover, but can be pulled into position if the nuts for the
pump studs are gradually and evenly tightened.
Ensure that the "O" ring in the cover remains in
position while the pump is fitted.
Note: The setscrews have a sealant applied to the
threads by the manufacturer. If the original setscrews
are to be used again, the threads of the setscrews
and the threads in which they will be engaged must be
cleaned. A suitable sealant must then be applied to
the threads of the setscrews.
4 Fit and tighten the three setscrews which retain the
pump to the cover of the timing case - two from the
front and one from the rear.
5 Fit a new joint to the flange of the coolant bypass.
Fit the by-pass and tighten the setscrews.
6 Connect the hose to the inlet connection of the
coolant pump and fill the cooling system. Operate the
engine and check for leakage.

21 New 1000 Series
Caution: Do not remove the pressed steel cover.
The latest coolant pump has a pressed steel cover 1
(A2) of the impeller housing. Early gear driven pumps
have a steel cover fastened by setscrews.
Identification of the coolant pump is by the last four
digits of the part number, for example 4131E011,
stamped on the front of the pump body.
POWERPART Threadlock 2
To remove
1 Drain the cooling system and disconnect the hose
at the inlet connection (A3) of the coolant pump.
2 Release the two fasteners from the rear face of the
timing case (A1).
3 Release the eight setscrews in (A) which retain the
coolant pump to the cover of the timing case and 3
remove the coolant pump.
4 Remove and discard the joint.
A A0371

New 1000 Series 21
To fit
1 Ensure that the joint faces on the pump body (A3)
3
and on the cover of the timing case (A1) are clean.
Check the joint faces for damage. Check that the 1
spigot (A4) is clean. 2
2 Check the drive gear of the coolant pump for wear
or other damage. If the gear is damaged, it must be
renewed.
3 Fit a new joint to the flange of the coolant body. The
joint is fitted without sealant.
4 Ensure that the studs (A2) are tightened into the
body of the coolant pump.
5 Fit the pump to the timing case cover with its gear
in mesh with the gear of the fuel injection pump.
Note: Three of the setscrews (B3) have a sealant
applied to the threads by the manufacturer. If the
original setscrews are to be used again, the threads
of the setscrews must be cleaned and POWERPART
threadlock applied to the first three threads. 4
6 Fit and tighten the two nuts (B1) at the rear face of
the timing case.
7 Fit and tighten the eight setscrews which retain the
pump to the cover of the timing case.
8 Connect the hose to the inlet connection (B2) of the
coolant pump and fill the cooling system. Operate the
engine and check for leakage. A A0373
B A0371

21 New 1000 Series
Special tool:
To remove A A0311
2 Remove the fan belt, see operation 23-3. 1
3 Drain the coolant system, refer to section 4 of the
User's handbook.
4 Disconnect the hose connections to the coolant
pump.
5 Remove the nut, spring washer and plain washer
from the pump pulley. It may be necessary to use
extractor PD.155C to remove the pulley from the
pump shaft (A).
6 If the pump is to be dismantled, remove the key
2
from the keyway of the pump shaft.
7 Remove the four setscrews which secure the B A0309
coolant pump to the rear body of the pump.
8 Remove the coolant pump (B1) and discard the
joint (B2).
9 If it is necessary to remove the rear body (C1) of the 1
pump from the cylinder block: Remove the setscrew
for the alternator adjustment linkage and the spacer.
Remove the four other setscrews and remove the rear
body from the cylinder block. Discard the joint (C2).
C A0308

New 1000 Series 21
To fit
Note: The joints are fitted without jointing compound.
1 If the rear body of the pump (A1) was removed from
1
the cylinder block: Thoroughly clean the joint faces of
the cylinder block and pump rear body. Fit a new joint
(A2) between the rear body of the pump and the
cylinder block.
2 Fit the rear body of the pump and the joint to the
cylinder block. Fit the spacer and adjustment linkage
for the alternator and tighten the M10 setscrews to 44
Nm (33 lbf ft) 4,5 kgf m and the M12 setscrews to 75
3 Thoroughly clean the joint faces of the pump rear
body and coolant pump (B2). Fit a new joint (B4) to
the coolant the pump.
4 Fit the coolant pump and joint to the rear pump
body and tighten the four M10 setscrews (B3) to 44
5 Fit the key to the keyway and put the pulley onto the
pump shaft. Put the plain washer and the spring
washer in position onto the pulley. Fit the nut and 2
tighten it to 82 Nm (60 lbf ft) 8,2 kgf m.
Note: It may be necessary to fit two setscrews into
the holes for the fan to enable a lever to be used to
prevent rotation of the coolant pump shaft when the
nut for the pulley is tightened.
A A0308
6 Connect the hoses to the coolant pump and tighten
the clips. 2
7 Fit the fan belt, see operation 23-3.
1
9 Fill the coolant system, refer to section 4 of the
User's handbook.
4
3
B A0309

21 New 1000 Series
Coolant pump - belt driven high position
1 2
Some engines are fitted with a coolant pump in a high
position (A5), these are identified by the thermostat 5
housing (A1) which is part of the pump rear body.
The pump rear body has a connection (A4) to a
coolant transfer plate (A3), which allows coolant from
the pump impeller to pass into the cylinder block (A2).
Special tool: 4 3
A A 04 01
To remove
2 Remove the fan belt, see operation 23-3.
3 Drain the coolant system, refer to section 4 of the
User's handbook.
4 Disconnect the hose connections to the coolant
pump.
B A0311
5 Remove the nut, spring washer and plain washer
from the pump pulley. It may be necessary to use
extractor PD.155C to remove the pulley from the
pump shaft (B).
6 If the pump is to be dismantled, remove the key
from the keyway of the pump shaft.
Continued

New 1000 Series 21
7 Remove the four setscrews "D", in illustration (A),
which secure the coolant pump to the rear body of the 1
pump (A1).
8 Remove the coolant pump (B5) and discard the
joint. 2
5
9 If it is necessary to remove the rear body of the
pump from the cylinder block: Remove the setscrew A
for the alternator adjustment linkage and the spacer. D
Remove the four setscrews "A" and the other three D
B A
setscrews "B", in illustration (A) and carefully remove
the rear body from the cylinder block and the transfer
plate connection. Discard the joint, and the "O" ring B
A B A
(A3).
D C
10 If it is necessary to remove the transfer plate (A4)
remove the five setscrews, "C" in illustration (A), and D
discard the joint.
Continued C
C
C
C 3
A A0401A
1 2
4 3
B A0401

21 New 1000 Series
To fit
Note: The joints are fitted without jointing compound. 1
1 If the transfer plate (A4) was removed from the
cylinder block: Thoroughly clean the joint faces of the 2
cylinder block and transfer plate. Fit a new joint 5
between the transfer plate and the cylinder block. Fit
A
the transfer plate and tighten the five setscrews, "C"
D
in illustration (A), to 22 Nm (22 lbf ft) 2,2 kgf m.
D
2 If the rear body of the pump (A1) was removed from B A
the cylinder block: Thoroughly clean the joint faces of
the cylinder block and pump rear body. Fit a new "O" B
ring to the transfer plate connection (A3) and lubricate A B A
the "O" ring with a suitable fluid or grease. D C
Fit two suitable M10 guide studs in positions (A2 and D
A5). Fit a new joint onto the guide studs. Put the rear
body of the pump into position, with the outlet
connection fitted over the "O" ring of the transfer C
C
plate. Fit the three setscrews, "B" in illustration (A),
and remove the two guide studs. Fit the other four
setscrews, "A" in illustration (A). Tighten the C
C 3
setscrews "A" to 44 Nm (33 lbf ft) 4,5 kgf m and the
setscrews "B" to 22 Nm (22 lbf ft) 2,2 kgf m. Fit the
setscrew for the alternator adjustment linkage and the
spacer.
3 Fit the coolant pump and joint to the rear pump 4
body and tighten the four M8 setscrews, "D" in
illustration (C), to 29 Nm (21 lbf ft) 2,9 kgf m. A A0401A
4 Fit the key to the keyway and put the pulley onto the
pump shaft. Put the plain washer and the spring 2
washer in position onto the pulley. Fit the nut and
tighten it to 82 Nm (60 lbf ft) 8,2 kgf m.
1
Note: It may be necessary to fit two setscrews into
the holes for the fan to enable a lever to be used to
prevent rotation of the coolant pump shaft when the
nut for the pulley is tightened.
5 Connect the hoses to the coolant pump and tighten
the clips.
6 Fit the fan belt, see operation 23-3. 4
7 Fit the fan, see operation 21-9. 3
8 Fill the coolant system, refer to section 4 of the

B A0309
User's handbook.

New 1000 Series 21
11
To dismantle and to assemble 21-6 10 12
To dismantle
The coolant pump will need an overhaul if coolant
leaks from the hole (A4) in the body of the pump.
When this occurs coolant has passed through the 9
coolant seal (A7) and has contaminated the bearings. 8
Special tool: 7
Gear puller, MS.99
6 1
2
POWERPART Nutlock
5 3
The coolant pump has a bearing assembly which has
an integral oil seal. Identification of the new coolant 4
pump is by the last four digits of the part numbers,
(4131E011) stamped on the front of the coolant pump
body and by the bearing which extends approximately
5 mm (0.2 in) past the end of the pump body.
1 Remove the coolant pump, see operation 21-2.
A A 0 27 0
2 Remove the "O" ring (A2) from the pump body (A4).
3 Remove the front cover (A8) and the joint (A9).
4 Remove the gear (A1) with the puller MS.99.
5 With a support under the drive end of the pump, use
a suitable adaptor to press out the shaft and bearing
assembly (A3) and discard it. Remove and discard
the impeller (A6) from the body.
6 With a suitable support under the impeller end of
the pump, press out the coolant seal and discard it.

21 New 1000 Series
To assemble
Caution: It is important that all of the components in
the coolant pump kit are used during the overhaul of 11
the pump. Coolant pump kits include the latest 10 12
components which may be of a different design to the
original components fitted to the engine.
1 Clean thoroughly the inside of the pump body (A5).
Ensure that the bore for the bearing and the chamfer
at the coolant seal end of the bore are clean and free 9
from corrosion. 8
2 Make a suitable adaptor which will apply force to
the outer edge of the bearing and not to the shaft.
Apply a thin layer of POWERPART Retainer (high 7
strength) to the outer surface of the bearing (A3), but
keep the retainer away from the ends of the bearing. 6 1
3 Provide a suitable support under the impeller end
of the pump body. Put the bearing and shaft assembly 2
in position with the bearing square to the pump body
and the longest end of the shaft in the pump body. 3
5
Use the adaptor to press in the bearing and shaft
assembly. Press in the bearing until the rear face of
the bearing is 21,0/21,5 mm (0.83/0.85 in) (A11) 4
above the rear face of the pump body.#
4 If the original gear is used, POWERPART Retainer
(high strength) must be applied to the bore of the
gear. Press the gear (A1) onto the shaft until the
clearance between the front face of the gear and the
A A 0 27 0
rear face of the bearing (A12) is 0,47/1,53 mm (0.018/
0.060 in). Remove all excess retainer after the gear
has been fitted.
Continued

New 1000 Series 21
5 A tool (A) can be made to press the coolant seal
into position. The tool should be made of a suitable A
material to the dimensions listed below:
A 44,0 mm (1.73 in)
G
B 40,0 mm (1.57 in)
C 11,6 mm (0.46 in)
B
D 35,8 mm (1.41 in)
E 16,1 mm (0.63 in)
E C
F 1,00 mm (0.04 in) at 45°
G 2,00 mm (0.08 in) at 45° F D
A A0188
The dimensions of the tool to fit the coolant seal, will
ensure that the seal is the correct length after it is
installed. It will also prevent axial distortion of the seal
when it is pressed onto the shaft.
6 Turn the pump over and support the drive end of the 1
body. Do not lubricate the coolant seal (B4). It is
important that the seal is not contaminated by oil or
grease and if it is held in the hand, it should be held
by the edge of the flange. Do not damage the ring of
green sealant applied to the body of the coolant seal 6
just behind the flange. Put the seal into position on the
end of the shaft. Ensure that the ring of sealant is 5
towards the bearing. Use the tool to press the seal
onto the shaft until the bottom of the seal flange is in 4
complete contact with the pump body.
7 Hold the pump with the drive end of the shaft on a 3
suitable support. With the use of a suitable distance
piece and a flat bar, press the new impeller (B3) onto
the shaft until the front face of the impeller is 6,7/7,0 2
mm (0.26/0.28 in) below the front face of the pump
body (B1). Remove the flat bar and distance piece
and ensure that the shaft is free to rotate.
8 Clean the threads in the front face of the pump
body. Fit a new joint (B6) and the cover (B5). Fit the
setscrews and tighten them to 9 Nm (6 lbf ft) 0,9 kgf
m. If the setscrews are new, a sealant will have been
applied to the threads by the manufacturer. If the
original setscrews are to be used again, the threads
should be cleaned and a POWERPART Nutlock B A0270
applied.
9 Fit a new "O" ring (B2) to the body of the pump.

21 New 1000 Series
The coolant pump will need an overhaul if coolant or
engine lubricating oil leaks from the hole (A3) in the
body of the pump. When this occurs coolant or
lubricating oil has passed through the coolant seal
(A4) or the oil seal (A2). 1
5 2
To dismantle
Special tool:
Coolant seal replacer tool, PD. 247
4
POWERPART Flange sealant
3
1 Remove the two studs from the pump body.
2 Use a lever under the edge of the pressed steel
cover (A1) and remove the cover, there are three
recesses (B1) around the edge of the pump body to
give access for a lever. Discard the cover after
removal.
A
3 Remove the impeller (A5) from the pump shaft: Drill A0377
four 6.35 mm (0.25 in) holes at equal distance around

the end of the pump shaft, between the shaft and the
hub for the impeller. These holes will break the
interference fit between the impeller and the pump
shaft and allow removal of the impeller.
Caution: Do not damage the sealing face of the
coolant seal housing during removal of the seal.
4 To remove the coolant seal (A4), it will be
necessary to break the carbon seal and use an
extractor to remove the centre sleeve of the seal from
the body of the shaft. This will loosen the grip of the
seal on the shaft. To remove the body of the seal, drill
three 3.175 mm (0.125 in ) holes through the top of
the coolant seal 120° apart. Fit three 25.4 mm (1.00
in) self-tapping screws. Insert a suitable lever through 1
the coolant inlet of the pump body and gradually and
evenly apply the lever under the head of each self-
tapping screw to remove the seal. Discard the seal.
Continued
B A0371

21 New 1000 Series
To assemble
Caution: It is important that all of the components in
the kit for the coolant pump are used. The kit includes
the latest components which may be of a different 1
design to the original components fitted to the engine.
1 Clean thoroughly the inside of the pump body
especially the bearing bores and the counterbore for
the coolant seal. These bores and their chamfers 2 3 4
must be clean and free of corrosion.
5
2 Fit a new circlip (A7) onto the gear end of the shaft
(A6). Put the drive gear end of the pump body face
down on a suitable press. Put the drive gear (A4) into
position in the housing. If the original gear is to be 6
used, POWERPART Retainer (high strength) must be
applied to the bore of the gear. fit the shaft into the
housing. Ensure that the shaft and gear are aligned.
7
Press the impeller end of the shaft until the gear is
against the shoulder of the shaft. 8
3 Apply a thin layer of POWERPART Retainer (high 9
strength) to the outer surface of the bearing, but keep
the retainer away from the ends of the bearing. Put
the cover end of the pump body (A1) face down on a
suitable press. Press the needle roller bearing (A5)
into the bearing housing until the end of the bearing is
level with or 0.5 mm (0,020 in) below the top of the
housing.
4 Apply a thin layer of POWERPART Retainer (high A A0377B
strength) to the outer surface of the ball bearing (A2),
but keep the retainer away from the ends of the
bearing. Use a suitable spacer to support the drive
gear end of the shaft. Ensure that the drive gear is
against face (A3).
5 Use a suitable adaptor to press the new ball
bearing onto the shaft until the inner race is in contact
the circlip. Ensure that the adaptor is pressed onto the
inner race and outer race of the bearing as it enters
the bearing housing.
6 Lubricate the ball bearing and the needle roller
bearings with clean engine oil.
7 Remove the spacer from the gear end of the shaft
and support the body of the pump at the gear end.
Continue to press the bearing fully into the end of the
bearing housing, fit the second circlip (A8) on to the
shaft.
8 Clean all POWERPART Retainer from the ends of
the bearings and the drive gear.
9 Fit the new circlip (A9), with the bevel edge towards
the oil seal, to retain the bearing and shaft assembly
in the body of the pump.
Continued

New 1000 Series 21
10 Lightly lubricate the oil seal (A2) with clean engine
lubricating oil. Put the tapered tool PD.247 onto the
drive shaft with the tapered end towards the bearing.
The tapered tool ensures that the lip of the oil seal is
correctly fitted when the seal is pressed into position.
11 Lubricate the oil seal with clean engine oil. Push
the oil seal over the tapered tool and into position in 1
the pump body with the flat face of the seal towards
the impeller end. 2
12 Press the oil seal into the oil seal housing:
A tool (B) can be made to press the new oil seal into
position. The tool should be made of steel to the
dimensions shown below:
A 40,0 mm (1.57 in)
B 80,0 mm (3.15 in)
C 60,0 mm (2.36 in)
D 42,0 mm (1.65 in)
E 29,0 mm (1.14 in)
F 14,5 mm (0.57 in)
G 12,0 mm (0.47 in)
The dimensions of the tool to fit the oil seal, will
ensure that the seal is in the correct position after it is
when it is pressed onto the shaft. A A0377D
13 Use tool (B) and press the oil seal into the body
A
until the seal is 14,5 mm (0.57 in) from the end of the
flange for the coolant seal (A1). When the seal is in
position, continue to apply force for approximately ten
seconds to ensure that the seal remains in position
when the force is released. Clean off excess oil.
B
Continued
G
F
E
D
B C A1450

21 New 1000 Series
Caution: Do not lubricate the coolant seal (A4). It is
important that it is not contaminated with oil or grease
and, if it is held in the hand, it should be held by the
edge of the outside flange. Do not damage the ring of 1
green sealant applied to the body of the coolant seal
just behind the flange.
2
14 With the widest end of the coolant seal towards
the oil seal, push the seal onto the shaft until it is in 3
contact with the coolant seal counterbore. Ensure that
the seal is square with the bore and press the seal
into the counterbore, with a suitable adaptor, until the
outer flange is in contact with the pump body. The
adaptor must apply force only to the outer flange of
the seal. Continue to apply force for approximately ten
seconds to ensure that the seal remains in position.
15 A tool (B) can be made to press the new seal into
position. The tool should be made of a suitable
material to the dimensions shown below: 4
A 44,0 mm (1.73 in)
B 40,0 mm (1.57 in)
C 12,2 mm (0.48 in)
D 35,8 mm (1.41 in)
E 16,1 mm (0.63 in)
F 1,00 mm (0.04 in) at 45°
5
G 2,00 mm (0.08 in) at 45° A A0377A

ensure that the seal is the correct length after it is A
G
16 Ensure that the drive end of the shaft has support.
Use a suitable distance piece and a flat bar to press
the impeller (A3) onto the shaft until the front face of B
the impeller is 10,35/10,48 mm (0.41/0.40 in) from the
front face of the pump body (A5). This dimension will
ensure an impeller clearance (A1) of 0,44/1,06 E C
(0.017/0.042in). Rotate the impeller to ensure free
movement.
F D
17 Put a bead of POWERPART Flange sealant, B A0188
currently Loctite 290, on the contact surface of the
pressed steel cover (A2). Ensure that the cover is
square with the body of the pump and use a suitable
adaptor to press the cover until the edge of the cover
is fully onto the flange of the coolant pump body.
18 Fit the two studs to the pump.

New 1000 Series 21
The coolant pump will need an overhaul if coolant
leaks from the hole (A9) in the body of the pump.
When this occurs coolant has passed through the
coolant seal (A2) and has contaminated the bearings.
To dismantle and to assemble 21-8 1 2 3 4
Special tool:
5
Standard bench press
To dismantle
1 Remove the coolant pump (A) from the engine, see
operation 21-4. 6
2 Remove the circlip (A4) for the bearing housing
(A3). 8 7
3 Support the pulley end of the pump and press the
9
shaft (A6) through the impeller (A1) and coolant seal
(A2). This will also remove the bearing (A7). Discard
the bearing and the shaft.
4 Remove and discard the impeller. Discard the
A A0306
coolant seal.
5 Support the pulley end of the pump and press out
the bearing (A8). Discard the bearing.
6 Clean the body of the pump in a suitable safe
cleaning fluid. Inspect the pump body for cracks.

21 New 1000 Series
To assemble
The service kit for the pump contains two bearings,
the shaft, a circlip, a key, a joint and a coolant seal.
Each bearing is filled with grease and sealed by the
bearing manufacturer. The bearings will not need
attention during service.
1 Support the impeller end of the pump body. Apply
a narrow ring of POWERPART Retainer (oil tolerant) 1
to the face of the outer race of each bearing. Put the 2
bearing (A5) into position on the pump housing. Use
a suitable adaptor on the outer race and press the
bearing fully into the back of the bearing housing.
2 Support the inner race of the bearing just fitted from
the impeller end of the pump body. Use a suitable
adaptor which will allow the shaft (A3) to pass through
it. Press the new shaft into the bearing until the
shoulder of the shaft is fully against the inner race of
the bearing. Put the bearing (A4) into position on the
pump housing and shaft. Use a suitable adaptor on 3
the inner and outer race to ensure the pressure is
applied evenly. Press the bearing onto the shaft and
housing until the inner race of the bearing is against 5 4
the shoulder of the shaft. Remove excess retainer
and fit the new circlip (A2).
3 Fit a new coolant seal (A1) as follows:
Caution: It is important that only the tool, shown in
(B), is used to fit the new coolant seal. A A0306
The coolant seal is an interference fit on the shaft and

a tool will be necessary to fit the seal correctly. A
The tool should be made of mild steel bar to the
dimensions shown in (B), listed as follows:
G
A 44,0 mm (1.73 in)
B 40,0 mm (1.57 in) B
C 10,7 mm (0.42 in)
D 37,3 mm (1.47 in)
E C
E 16,1 mm (0.63 in)
F 1,00 mm (0.04 in) at 45° F D
B A0188
G 2,00 mm (0.08 in) at 45°
ensure that the seal is the correct length after it is
Continued

New 1000 Series 21
Caution: Do not lubricate the seal. It is important that
the seal is not contaminated by oil or grease and if it
is held in the hand, it should be held by the edge of the 2
flange. Do not damage the ring of green sealant
applied to the body of the coolant seal just behind the
flange of the seal.
Support the pulley end of the shaft, ensure that there
are no sharp edges on the edge of the shaft and put
the seal into position on the end of the shaft. Ensure 1
that the ring of sealant is towards the bearings. Use
the tool to press the seal onto the shaft until the
bottom of the seal flange is in complete contact with
the pump body. Continue to apply force for
approximately ten seconds to ensure that the seal
remains in position when the force is released.
4 Support the pulley end of the shaft and press the
new impeller (A1) onto the shaft until the clearance
(A2) between the impeller blades and the pump body
is 0,69/0,89 mm (0.027/0.035 in). For engine type AS
the impeller blade clearance is 0,20/0,60 mm (0.008/
0.024 in).
The clearance can be checked with a feeler gauge
(B). The minimum clearance with end-float is 0,19 mm
(0.007 in). Rotate the shaft to ensure that the impeller
is free.
5 Fit the coolant pump to the engine, see operation
21-4. A A0306
B A0310

21 New 1000 Series
Fan
To remove
Release the setscrews and remove the fan. If
necessary, fit the setscrews to retain the fan
extension and the pulley to the hub.
To fit
Clean thoroughly the rear of the fan where it fits onto
the fan extension. Also ensure that all paint is
removed from this area. Put the pulley into position on
the hub and the fan extension onto the pulley. Clean
the front face of the fan extension. Fit the fan and
tighten the setscrews to the torque shown in section
11.
Fan drive (engines with gear driven

coolant pumps)
To remove
1 Loosen the pivot fasteners of the alternator and the
fasteners of the adjustment link. Remove the drive
belt(s).
2 Release the setscrews and remove the fan.
Remove the fan extension, if fitted, and the pulley.
3 Check the end-float of the drive shaft. If it is more
than 0,25 mm (0.010 in), the assembly must be
renewed.
4 Release the setscrews and remove the fan drive.
To fit
1 Fit the fan drive and tighten the setscrews to 44 Nm
3 Fit the belt(s) and adjust the tension, see operation
23-2.

New 1000 Series 21
Lubricating oil cooler
1
2
To remove and to fit - four cylinder
turbocharged engines 21-11
3
To remove
1 Drain the cooling system.
2 Release the support bracket at the cooler (A3).
3 Release the setscrew and nut (A2) which fasten the
low-pressure fuel pipes to the top of the cooler.
4 Release the hose clip at the top rear of the cooler 4 4
A A0272
(A1).
5 Release the six setscrews (A4) which are fitted
below the cover and the setscrew (A4) to the left of 1 2
the cover. Remove the cooler.
3
To fit
4
1 Renew the "O" rings on the inlet connection for the
coolant (B3) and the outlet flange for the coolant (B5).
Ensure that the joint faces are clean. Renew the joint
(B4) for the oil pipe flange.
2 Lightly lubricate the bore of the vent connection
(B2) and the "O" ring on the coolant inlet connection 5
with engine lubricating oil.
3 Loosely fit the hose clip to the vent connection. B A0273
4 Fit the cooler to the engine with the vent (B1) fitted
correctly in its connection. Tighten the setscrews and
the hose clip of the vent connection.
5 Fit and tighten the setscrew of the support bracket.
6 Fit the setscrew and nut which fasten the low-
pressure fuel pipes to the top of the oil cooler.
7 Fill the coolant system.
8 Operate the engine and check for leakage of
coolant or oil.

21 New 1000 Series
To remove and to fit - six cylinder
engines 21-12
1
2
Some oil coolers fitted to six cylinder engines have a
baffle (A3) to control coolant flow. The cooler element
must be fitted with the baffle toward the front of the
engine (A1).
The latest oil coolers have a pressed steel cover. The
cooler element for these coolers does not have a
baffle, see operation 21-13.
To remove 4 3
1 Drain the cooling system. A A0274
2 Disconnect the lubricating oil pipes at the flange on
the cooler cover, see operation 19-12.
3 Release the setscrews and nuts of the cover of the
oil cooler and remove the cover together with the
element (A2). Thoroughly clean the flange face of the
cover and the cylinder block.
To fit
1 If the studs (A4) have been removed and are to be
fitted again, clean the threads in the cylinder block
and on the studs. Apply a suitable sealant before the
studs are fitted to the cylinder block.
2 Apply Loctite 5204 sealant to the flange face of the
oil cooler and fit the oil cooler and a new joint to the
cylinder block. Tighten the setscrews and nuts to 22
3 Fit a new joint and connect the lubricating oil pipes
to the flange on the cover, see operation 19-12.
5 Operate the engine and check for oil or coolant
leakage.

New 1000 Series 21
To remove and to fit - pressed steel
cover type 21-13
Some of the latest six cylinder engines are fitted with

oil cooler with a pressed steel cover.
To remove
1 Drain the cooling system, refer to the User's
Handbook.
Warning! The engine oil may be hot, allow the
engine temperature to cool down before the oil pipes
are released.
Caution: Do not remove both of the oil pipes
together.
2 Put a drip tray under the oil cooler and remove the
lubricating oil pipes from the oil cooler. Do not remove
both of the oil pipes together. Remove one of the
pipes, then fit the flanges (A4) and nuts (A5) onto the
studs again, before the other pipe is removed. This
will ensure that the element (A6) is fastened to the
cover when the assembly is removed.
3 Discard the "O" rings (A1).
4 Release the fasteners (A2) from the cover of the oil
cooler and remove the oil cooler assembly (A3).
Continued
1
6
2
5
3
4
A A0397

21 New 1000 Series
5 Thoroughly clean the flange face of the cover and Caution: Do not remove the flanges (A7) and nuts
of the cylinder block. (A9) from the studs (A8), before one of the oil pipes is
Note: A liquid joint is used in the factory, this must be fitted to the cover. This will ensure that the element is
removed and a paper joint (A5), part number held in position on the cover (A3) while the oil pipes
3684R012, fitted in its place. are fitted.
6 If an overhaul of the oil cooler is necessary, see 4 Fit the oil pipes to the oil cooler and tighten the nuts
operation 21-18. to 22 Nm (16 lbf ft) 2,2 kgf m.
To fit
6 Operate the engine and check for oil or coolant
1 If the four studs (A6) have been removed from the leakage.
cylinder block flange and are to be fitted again, clean
the threads in the cylinder block and on the studs.
Apply POWERPART studlock, currently Loctite 270,
before the studs are fitted to the cylinder block to
prevent the leakage of coolant.
2 Put a new paper joint into position on the studs; the
joint is fitted dry. Fit the oil cooler assembly (A3) to the
cylinder block. Gradually and evenly tighten the
fasteners (A2) to 22 Nm (16 lbf ft) 2,2 kgf m.
3 Clean the seats for the "O" rings and renew the "O"
rings (A1) of the pipe connections.
2
9
3
7
6
8
5
4
A A0397A

New 1000 Series 21
To remove and to fit - canister type 21-14
3 4
2
To remove
1 Drain the cooling system. 1
2 Release the hose clips of the coolant pipes at the
oil cooler (A3). Release the threaded adaptor (A5)
from the lubricating oil cooler and pull the oil cooler
(A6) from the hose connections and the filter head 5
(A1).
To fit
1 Clean the joint face of the filter head (A2).
8 7 6
2 Check the washer (A4) and the seals (A7 and A8) A L0027
for damage. Renew the washer and the seals if they
are damaged or worn. Lightly lubricate the seals with
clean lubricating oil.
3 Push the hose connections for the coolant pipes
onto the lubricating oil cooler. Hold the oil cooler in
position against the filter head and fit the threaded
adaptor. Tighten the threaded adaptor to 37 Nm (27
lbf ft) 3,8 kgf m. Ensure that the hose connections are
fitted correctly and tighten the hose clips.

21 New 1000 Series
To dismantle and to assemble -
four cylinder turbocharged engines 21-15
To dismantle
1 Remove the oil cooler from the cylinder block, see
operation 21-11.
2 Release the setscrews and remove the cover.
3 Release the self-locking nuts at the back of the oil
cooler and remove the cooler element. 1
4 Clean the element and check for cracks. If a
solution is used to clean the outside of the element, 2
ensure that this does not enter the element. Check 1
that there is nothing to restrict the flow of lubricating A A0276
oil through the element of the oil cooler. If the inside

of the element needs to be cleaned, use a solvent
which is suitable for copper. Dry the element with low
pressure air and then flush it with clean engine
lubricating oil.
To assemble
1 Renew the "O" rings (A1 and A2) on the flanges of
the element and the self-locking nuts for the studs.
2 Fit the element to the backplate and tighten the self-
locking nuts to 22 Nm (16 lbf ft) 2,2 kgf m.
3 Fit the cover and a new joint to the cooler backplate
and tighten the setscrews to 11 Nm (8 lbf ft) 1,1 kgf m.

New 1000 Series 21
To dismantle and to assemble -
six cylinder turbocharged engines 21-16
1
Some oil coolers fitted to six cylinder engines have a
baffle (A2) to control coolant flow.
To dismantle
1 Remove the oil cooler, see operation 21-12.
2 Release the nuts on the front of the cover and
remove the element of the oil cooler (B).
solution is used to clean the outside of the element, 2
ensure that this does not enter the element. Check A A0274
that there is nothing to restrict the flow of lubricating
which is suitable for copper. Dry the element with low 1
lubricating oil.
To assemble
1 Renew the "O" rings (B1) on the flanges of the
element. 1
Caution: Some oil coolers fitted to six cylinder
engines have a baffle (A3) to control coolant flow. The
cooler element must be fitted with the baffle towards
the front of the engine (A1).
B A 0 27 7
2 Fit the element of the oil cooler to the cover and
tighten the nuts to 22 Nm (16 lbf ft) 2,2 kgf m.
Cooler by-pass valve

1
1 Release the hexagonal cap and remove the bypass

valve (C).
2 Check the valve spring and the seat for damage
and renew the complete assembly, as necessary.
3 Renew the aluminium washer (C1). Fit the bypass C A0278
valve into the oil cooler and tighten the cap to 50 Nm

21 New 1000 Series
To dismantle and to assemble
pressed steel cooler type 21-18
To dismantle
1 Remove the oil cooler from the cylinder block, see
operation 21-13.
2 Put the oil cooler assembly (A5) on a clean work
surface. Release the four nuts (A8) that retain the
flanges for the lubricating oil pipes. The pipe flanges
are in two pieces (A6 and A7).
3 Remove the cover (A1) from the four studs (A2) of
the oil cooler element (A3).
4 Remove and discard the three-piece "O" ring (A4)
from the element.
Warning! Do not allow compressed air to contact
your skin. If compressed air enters your skin, obtain
medical help immediately.
solution is used to clean the outside of the element,
ensure that this does not enter the element. Check
that there is nothing to restrict the flow of lubricating
which is suitable for copper. Dry the element with low
lubricating oil.
2 3 4
6 5
A A0397B

New 1000 Series 21
To assemble
1 Clean the seats of the three-piece "O" ring and
renew the "O" rings (A3).
2 Clean the flange face (A1) for the three-piece "O"
rings on the inside of the cover.
3 Fit the cover of the oil cooler to the element (A2).
4 Fit the two-piece flanges (A4) onto the studs (A5).
Tighten the nuts to retain the element when the oil
cooler assembly is fitted to the engine.
5 Fit the oil cooler to the cylinder block, see operation
21-13.
2 3
1
A A0397C

21 New 1000 Series
Intercooler
A water-to-air intercooler assembly is fitted to the
induction manifold of some four and six cylinder high-
rated engines to cool the air between the
turbocharger and the combustion chamber. Hot air
from the turbocharger passes through the casing of 1 2 3
the intercooler and over the fins on the integral tube
stack (A1) before it enters the combustion chamber.
The air is cooled by the coolant which passes through
the tubes of the tube stack. Coolant is circulated
through the tube stack by the engine coolant pump
and is returned to the thermostat housing.
The tube stack can be removed from the induction
8 6 4
manifold, and if necessary renewed.
The intercooler assembly may be mounted either
horizontally or vertically.
Horizontally mounted intercooler

9
To remove
7 5
1 Release the hose clips (A9) which fasten the air
hose from the turbocharger to the intercooler. Slide
the hose away from the intercooler air inlet pipe.
Warning! Do not drain the coolant while the engine A A0382
is still hot and the system is under pressure because 6 Carefully lift the tubestack from the induction
dangerous hot coolant can be discharged. manifold, Do not use force. It may be necessary to
2 Drain the coolant system and release the hose clips push the inlet and outlet connections from the outside
(A5) which fasten the hoses to the coolant inlet and of the manifold to fully release the tubestack. Remove
the outlet connections of the tube stack. Remove the and discard the "O" rings (A3) for the inlet and outlet
hoses. connections.
3 If a fuelled starting aid (A4) is fitted to the top cover 7 Clean and inspect the intercooler assembly, see
(A6), remove the electrical connection and the fuel operation 21-20.
pipe.
Caution: Do not use a lever between the flange
faces to separate the intercooler top cover from the
induction manifold.
4 Release the setscrews (A8) which retain the
intercooler cover to the induction manifold (A7); work
from the outside of the flange to the centre. Remove
the top cover and discard the joint.
Caution: Be careful with the tubestack (A1) when it
is removed and fitted, be especially careful not to
damage the fins.
5 Remove the four setscrews (A2); six cylinder
engines have six setscrews, that secure the
tubestack to the induction manifold.

New 1000 Series 21
To fit
Adhesive sealing strips are fitted to the top cover and 1
the induction manifold to seal the external surfaces of
the tubestack. This is necessary to ensure that all of
the air which enters the intercooler passes through
the fins of the tubestack. 2
1 Renew the adhesive sealing strips (A1) that fitted to
the bottom of the induction manifold and the top
cover:
Remove the tape from the adhesive strip. Ensure that
the sealing strip is fitted in a straight line, onto the flat
3
machined surface on the cover and the cast surface
of the manifold. Ensure that the ends are aligned with A A1445
the vertical machined surface (A3) on each side of the

manifold.
Note: Be careful with the tubestack when it is
removed and fitted, be especially careful not to
damage the fins.
2 Put the "O" rings (A2) into position against the large
shoulder, on the inlet and outlet connections of the
tubestack. Carefully position the tubestack in the
induction manifold, ensure that the inlet and outlet
connections are centred as they enter the holes in the
manifold.
The tubestack will be in contact with the bottom of the
manifold, if the "O" rings are fitted correctly.
3 Fit the setscrews which retain the tubestack to the
induction manifold and tighten them gradually and
evenly to 22 Nm (16 lb ft) 2,2 kgf m.
4 Renew the joint between the flange face of the top
cover and induction manifold. The joint is fitted
without sealant.
5 Put the top cover into position and fit the setscrews
which retain the top cover to the induction manifold
and tighten them gradually and evenly to 22 Nm (16
lb ft) 2,2 kgf m. Work from the centre of the flange to
the outside.
6 Connect the fuel pipe to the connection of the
fuelled starting aid and fit the electrical connection.
Eliminate air from the fuelled starting aid, see
operation 20-9.
7 Fit the hoses and the hose clips to the coolant inlet
and the outlet connections of the tube stack and
tighten the clips. Fill the coolant system.
8 Fit the air hose from the turbocharger to the
intercooler assembly and tighten the hose clips.
Note: If a hose that has a heat shield is renewed,
ensure that the new part is of the correct type and it is
fitted in the correct position.
9 Operate the engine and check for coolant and air
leaks.

21 New 1000 Series
Vertically mounted intercooler
1 2 3
To remove
4 5
1 Release the hose clips (A7) which fasten the air
hose from the turbocharger to the intercooler. Slide 9
the hose away from the intercooler air inlet pipe.
Warning! Do not drain the coolant while the engine 8
is still hot and the system is under pressure because
dangerous hot coolant can be discharged.
7
2 Drain the coolant system and release the hose clips 6
(A5) which fasten the hoses to the coolant inlet and
the outlet connections of the tube stack. Remove the
hoses. A A0385
3 If a fuelled starting aid (A8) is fitted to the top cover
(A4), remove the electrical connection and the fuel
pipe.
Caution: Do not use a lever between the flange
faces to separate the intercooler top cover from the
induction manifold.
4 Release the setscrews (A2) which retain the
intercooler cover to the induction manifold (A6); work
from the outside of the flange to the centre. Remove
the top cover and discard the joint.
Caution: Be careful with the tubestack (A9) when it
is removed and fitted, be especially careful not to
damage the fins.
5 Remove the four setscrews (A1), six cylinder
engines have six setscrews, that secure the
tubestack to the induction manifold.
6 Carefully lift the tubestack from the induction
manifold, Do not use force. It may be necessary to
push the inlet and outlet connections from the outside
of the manifold to fully release the tubestack. Remove
and discard the "O" rings (A3) for the inlet and outlet
connections.
7 Clean and inspect the intercooler assembly, see
operation 21-20.

New 1000 Series 21
To fit
Adhesive sealing strips are fitted to the top cover and 1
the induction manifold to seal the external surfaces of
the tubestack. This is necessary to ensure that all of
the air which enters the intercooler passes through
the fins of the tubestack. 2
1 Renew the adhesive sealing strips (A1) that fitted to
the bottom of the induction manifold and the top
cover:
Remove the tape from the adhesive strip. Ensure that
the sealing strip is fitted in a straight line, onto the flat
3
machined surface on the cover and the cast surface
of the manifold. Ensure that the ends are aligned with A A1445
the vertical machined surface (A3) on each side of the

manifold.
Note: Be careful with the tubestack when it is
removed and fitted, be especially careful not to
damage the fins.
2 Put the "O" rings (A2) into position against the large
shoulder, on the inlet and outlet connections of the
tubestack. Carefully position the tubestack in the
induction manifold, ensure that the inlet and outlet
connections are centred as they enter the holes in the
manifold.
The tubestack will be in contact with the bottom of the
manifold, if the "O" rings are fitted correctly.
3 Fit the setscrews which retain the tubestack to the
induction manifold and tighten them gradually and
evenly to 22 Nm (16 lb ft) 2,2 kgf m.
4 Renew the joint between the flange face of the top
cover and induction manifold. The joint is fitted
without sealant.
5 Put the top cover into position and fit the setscrews
which retain the top cover to the induction manifold
and tighten them gradually and evenly to 22 Nm (16
lb ft) 2,2 kgf m. Work from the centre of the flange to
the outside.
6 Connect the fuel pipe to the connection of the
fuelled starting aid and fit the electrical connection.
Eliminate air from the fuelled starting aid, see
operation 20-9.
7 Fit the hoses and the hose clips to the coolant inlet
and the outlet connections of the tube stack and
tighten the clips. Fill the coolant system.
8 Fit the air hose from the turbocharger to the
intercooler assembly and tighten the hose clips.
Note: If a hose that has a heat shield is renewed,
ensure that the new part is of the correct type and it is
fitted in the correct position.
9 Operate the engine and check for coolant and air
leaks.

21 New 1000 Series
To clean and to inspect 21-20
To clean
1 Thoroughly clean the flange face of the top cover
and the induction manifold with an approved
detergent solution.
Warning! Do not allow compressed air to contact
your skin, if compressed air enters your skin obtain
medical help immediately.
Caution: Do not clean the tube stack in a caustic
solution.
2 Soak the fins of the tube stack in an approved
detergent degreasing fluid. Allow the excess fluid to
drain off and dry the fins with low pressure
compressed air.
3 Flush the tube stack through the outlet connection,
in the opposite direction of coolant flow, with clean
water.
4 Thoroughly clean the internal and external surfaces
of the intercooler casing, with an approved detergent
solution. It is important that the seats for the "O" rings
are thoroughly cleaned.
To inspect
1 Check the casing of the intercooler for cracks or
distortion, especially the flange faces which must be
flat to prevent leakage.
2 Check the tube stack for signs of leakage, cracks,
damaged fins or damaged hose connections. If the
tube stack is damaged or the tubes are restricted the
tubestack must be renewed.

New 1000 Series 21
Data and dimensions
Coolant pump, early gear driven pump
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Centrifugal
Outside diameter of shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,95/18,96 mm (0.7460/0.7465 in)
Diameter of bore of drive gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,90/18,92 mm (0.7441/0.7449 in)
Interference fit of drive gear on shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,03/0,06 mm (0.0012/0.0024 in)
Diameter of bore of impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,87/15,89 mm (0.6249/0.6257 in)
Outside diameter of shaft for impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,91/15,92 mm (0.6264/0.6268 in)
Interference fit of impeller on shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,02/0,05 mm (0.0007/0.0020 in)
Diameter of bore for bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38,06/38,08 mm (1.4983/1.4993 in)
Diameter of bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38,09/38,10 mm (1.4995/1.5000 in)
Interference fit of bearing in pump body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,01/0,04 mm (0.0004/0.0016 in)
Dimension of impeller boss to front face of pump body (fitted) . . . . . . . . . . . . . . . 7,7/8,0 mm (0.303./0.315 in)
Dimension of gear from rear flat face of pump body (fitted) . . . . . . . . . . . . . . . 21,0/21,5 mm (0.827/0.846 in)
Dimension of gear from rear face of bearing (fitted) . . . . . . . . . . . . . . . . . . . . . 0,47/1,53 mm (0.018/0.060 in)
Coolant pump, latest gear driven pump
Coolant pump, belt driven
Outside diameter of shaft for pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24,587/24,600 mm (0.9679/0.9685 in)
Inside diameter of bore of pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24,628/24,648 mm (0.9696/0.9704 in)
Clearance fit of pulley on shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,03/0,06 mm (0.001/0.002 in)
Diameter of bore of impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,872/15,893 mm (0.6248/0.6257 in)
Outside diameter of shaft for impeller . . . . . . . . . . . . . . . . . . . . . . . . 15,9055/15,9182 mm (0.6263/0.6267 in)
Interference fit of impeller on shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,01/0,04 mm (0.0004/0.0016 in)
Impeller to body clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,69/0,89 mm (0.027/0.035 in)
Impeller to body clearance, engine type AS . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,20/0,60 mm (0.008/0.024 in)
Diameter of bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62,000 mm (2.440 in)
Diameter of bore for bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62,019/62,000 mm (2.441/24.000 in)
Interference fit of bearing in pump body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,01/0,04 mm (0.0004/0.0016 in)

21 New 1000 Series
Thermostat
Type:
- Single. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .wax element, by-pass blanking
- Twin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .wax element, by-pass blanking
Nominal temperature
"Start to open" "Fully open" Minimum valve
Part number stamped on thermostat
temperature temperature lift, fully open
by-pass valve
82 °C 77/85 °C 92/98 °C 9 mm
2485613
(180 °F) (170/185 °F) (198/208 °F) (0.35 in)
82 °C 77/85 °C 92/98 °C 9 mm
2485604
(180 °F) (170 /185 °F) (198/208 °F) (0.35 in)
82 °C 80/84 °C 96 °C 9 mm
2485C023
(180 °F) (176/183 °F) (205 °F) (0.35 in)
82 °C 80/84 °C 96 °C 9 mm
2485C025
(180 °F) (176/183 °F) (205 °F) (0.35 in)
Fan drive housing

Bore of housing for bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41,9655/41,9785 mm (1.6529/1.6522 in)
Outside diameter of bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41,987/42,00 mm (1.6535/1.6530 in)
Interference fit of bearing in housing . . . . . . . . . . . . . . . . . . . . . . . . . 0,0085/0,0345 mm (0.00136/0.00033 in)
Bore of hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21,938/21,958 mm (0.8637/0.8645 in)
Outside diameter of shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21,987/22,000 mm (0.8656/0.8661 in)
Interference fit of shaft in hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,029/0,062 mm (0.0011/0.0024 in)
Maximum permissible end-float of shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,200 mm (0.0079 in)

New 1000 Series
22
Flywheel and housing 22
General description
The steel flywheel is fitted with a hardened starter
ring. Generally the starter rings have 126 or 115 teeth.
The flywheel housing is normally made of cast iron,
but certain flywheel housings are made of aluminium
alloy.

22 New 1000 Series
Flywheel
Warning! The flywheel is heavy, use lift equipment

or get help to assist with the lift operation before
removal of the flywheel fasteners.
To remove
1 Remove two opposite setscrews from the flywheel
and fit temporarily two guide studs to ensure safety
when the flywheel is removed and fitted.
A A0279
2 Remove the remainder of the setscrews and
washers and remove the flywheel.
3 Check the flywheel and ring gear for damage and
renew, if necessary.
To fit
1 Ensure that the location faces of the crankshaft and
the flywheel are clean and free from damage.
2 Fit the flywheel over the guide studs. Fit four
setscrews and their washers. Remove the guide
studs and fit the remainder of the setscrews and the
washers. Tighten the setscrews to 105 Nm (77 lbf ft)
10,7 kgf m.
3 Check the flywheel run-out with a dial test indicator B A0280
(A). This must be less than 0,30 mm (0.012 in) total
indicator reading.
4 Check the alignment of the flywheel face (B). The
error in alignment must not be more than 0,03 mm
(0.001 in) total indicator reading for every 25 mm (1.0
in) of the flywheel radius from the crankshaft axis to
the indicator plunger. During this check, keep the
crankshaft pressed toward the front to remove the
effect of crankshaft end-float.
Ring gear
To remove
Before the ring gear is removed, check the position of
the chamfer on the teeth.To remove the ring gear use
a hammer and a chisel to break the ring. Ensure that
the flywheel is not damaged during this operation.
To fit
The ring gear is heated onto the flywheel. When a
new gear is to be fitted, ensure that it is not heated to
more than 250 °C (480 °F). Ensure that the chamfer
on the teeth of the gear is in the correct direction.

New 1000 Series 22
Flywheel housing
Warning! The flywheel housing is heavy, use lift

equipment or get help to assist with the lift operation
before removal of the flywheel housing fasteners.
To remove
1 Remove the starter, see operation 23-6, and the
flywheel, see operation 22-1.
2 Release the housing setscrews and with a soft face A A0177
hammer, hit carefully the housing to remove it from
the dowels.
To fit
1 Ensure that the rear face of the cylinder block and
the faces of the housing are clean and free from
damage. Ensure that the location dowels are fitted
correctly. If a felt seal is fitted to the rear flange of the
sump, renew the seal.
2 Fit the housing onto the dowels and tighten lightly
the setscrews.
3 Check the housing concentricity with a dial test
indicator (A). The run-out limit is given in the data and
dimensions. If any adjustment is necessary, it must be B A0178
made on the housing and the concentricity checked
again.
4 Tighten the setscrews to the torque recommended
in section 11.
5 Check the housing alignment (B). The maximum
tolerance is given in the data and dimensions. Any
necessary adjustment must be made on the housing
and not on the cylinder block.
6 Fit the flywheel, see operation 22-1 and the starter
motor, see operation 23-6.

22 New 1000 Series
Data and dimensions
Flywheel and housing
Limits for flywheel housing run-out and alignment (total indicator reading)
Diameter of housing flange bore Maximum limit (total indicator reading)
mm in mm in
362 14.25 0,23 0.009
410 16.14 0,25 0.010
448 17.63 0,28 0.011
511 20.11 0,30 0.012

584 22.99 0,36 0.014
648 25.51 0,41 0.016
787 30.98 0,48 0.019

New 1000 Series
23
Electrical equipment 23
Alternators
General description
The alternator is driven from the crankshaft pulley by
single or double belt(s).
The Lucas AC5RS, Magneti Marelli A127 and the
Bosch KI 12 volt and NI 24 volt alternators have solid
state regulators fitted at the rear. The regulator of the
Magneti Marelli A127 alternator includes the brush
box as a part of the unit. The regulators of both
alternators are sealed and repair is not possible.
Precautions
To prevent damage to the diodes and to the resistors,
the precautions given below must be followed:
! Do not disconnect the battery while the engine is
in operation. This will cause a voltage surge in the
alternator charge system which will immediately
cause damage to the diodes or to the transistors.
! Do not disconnect an electrical wire before the
engine is stopped and all electrical switches are in
the "off" position.
! Do not cause a short circuit by the connection of
electrical wires to the wrong terminals. The correct
electrical wire must be connected to the correct
terminal. A short circuit or wrong connection which
gives reverse polarity will immediately cause
permanent damage to the diodes and to the
transistors.
! Do not connect a battery into the system until it
has been checked for correct polarity and voltage.
! Do not check for current flow with a spark contact
as damage can be caused to the transistors.

23 New 1000 Series
Drive belts
1
To check 23-1
1 Check the belt(s) for wear and damage and renew

the belt(s), if necessary. If twin belts are fitted, they
should both be renewed.
2 Check the belt tension. If twin belts are fitted,
check/adjust the tension on the tighter belt. To ensure
maximum belt life, it is recommended that a belt
tension gauge is used. Fit the gauge (A1) at the
centre of the longest free length and check the A A0281
tension. If a Burroughs gauge is used, the correct
tension is 355 N (80 lbf) 36 kgf. If the tension is equal
to or less than 220 N (50 lbf) 22 kgf, adjust it to 355 N
(80 lbf) 36 kgf, see operation 23-2. If no gauge is
1
available, press down the belt with the thumb at the
centre of the longest free length and check the
deflection (B). With moderate thumb pressure, 45 N
(10 lbf) 4,5 kgf, the correct belt deflection is 10 mm (3/
8 in).
To adjust tension 23-2
1 Loosen the pivot fasteners (B1) of the alternator

and the fasteners of the adjustment link (B2). 2
2 Change the position of the alternator to give the
correct tension. Tighten the adjustment link fasteners
and then the pivot link fasteners. If there are two pivot
fasteners, tighten the front fastener and then the rear
fastener.
3 Check the belt tension again to ensure that it is still
correct.
Where twin belts are fitted, they are supplied as a set

and must be renewed as a set.
1 Loosen the pivot fasteners (B1) of the alternator B A0282A
and the adjustment link fasteners (B2).
2 Release all of the tension from the belt(s) and
remove the belt(s).
3 Fit the new belt(s) and adjust the tension, see
operation 23-2. The belt tension must be checked
again after the first 1000 km (600 miles) or 20 hours
of operation.

New 1000 Series 23
Alternator
To remove
1 Disconnect the electrical connection.
2 Loosen the pivot fasteners of the alternator and the
fasteners of the adjustment link.
3 Release all the belt tension and remove the belt(s).
4 Remove the adjustment link from the alternator and
remove the pivot bolt(s). Make a note of the position
of the washers and distance pieces to ensure that
they are fitted correctly. Remove the alternator.
To fit
1 Put the alternator in position and assemble loosely
the pivot fasteners and the adjustment link and its
fasteners. Ensure that the washers and the distance
pieces are fitted in their correct positions and that the
alternator pulley is aligned to the crankshaft pulley
within +/- 2,4 mm (3/32 in).
2 Fit the drive belt(s) and adjust the drive belt tension,
see operation 23-2. Tighten the fasteners and check
the tension again.
3 Connect the electrical connection.
To maintain 23-5
1 Ensure that the drive belts are not worn and that the
belt tension is correct.
2 Keep the alternator clean. To clean the alternator,
use a material which is damp with kerosene or a
special fluid used for this purpose. Ensure that the
fluid does not enter the cover of the alternator.
3 Ensure that air can pass easily over the casing to
keep it cool.

23 New 1000 Series
Fault diagnosis Any change in the above data can indicate a fault and
the procedure that follows should be used before any
The alternator is designed in such a way that a flow of components are disconnected. This procedure is not
current (indicated by no light at the warning light or a suitable for A127 alternators and, if a fault is found,
reading shown on an ammeter) shows that the the alternator should be removed for test by a
system is in correct operation. If the system is in specialist.
correct operation, no open circuit, voltage or current
The regulator is a sealed unit and a repair is not
output checks need to be done on the installation
possible. If there is a regulator fault, the regulator
unless:
must be renewed.
! The warning light does not show when the
alternator is stationary and the switch is in the "on"
position or it shows a light when the alternator is in
operation.
! No charge current is shown on the ammeter.
! The battery is discharged.
! The battery is hotter than normal which is an
indication of loss of voltage control.
If one or more of the above symptoms occur, the
procedure indicated below should be applied.
1 Ensure that the battery is fully charged.
2 Connect a moving-coil voltmeter of good quality,
with a range of 0-50 volts, across the positive and
negative terminals of the alternator. If an ammeter is
not fitted in the electrical circuit, fit a moving-coil
ammeter of good quality, with a range of 0-100
ampere, in the wire between the alternator and the
positive terminal of the battery.
3 Turn the warning light switch to the "on" position
(main switch on instrument panel); the warning light
should be illuminated.
4 Switch on a 10-15 ampere load, for example, lights,
fans, etc.
5 Start the engine and operate it at a fast idle speed;
either the warning light should be extinguished or the
ammeter indicates a small change in the current in
relationship to the engine speed.
6 Increase the engine speed for a moment to near
maximum speed, when the charge current should be
approximately equal to the rating for the alternator, as
shown in the data and dimensions.
7 Operate the alternator at approximately half speed
(engine speed approximately 1500 rev/min) and
remove the electrical load. The voltage should go up
to 14 volts for a 12 volt system or 28 volts for a 24 volt
system and then remain constant. At the same time
the current reading should show a reduction.

New 1000 Series 23
If the warning light is not illuminated when the
switch is in the "on" position:
Check the bulb. If no fault:
Check all the connections at the regulator, at the
alternator and at the battery.
If no fault:
Turn the switch to the "off" position. Disconnect the
wire from the "F" terminal on the alternator and
connect a wire between the "F" terminal and the
negative terminal on the alternator. Turn the switch to
the "on" position.
If the warning light shows, the fault is in the regulator.
If the warning light does not show, the fault is in the
alternator.
If the warning light continues to show and the
ammeter shows no output when the alternator is
in operation:
Check all the connections at the regulator, alternator
and battery.
If no fault:
Turn the switch to the "off" position. Disconnect the
wire from the "F" terminal on the alternator and
connect a wire between the "F" terminal and the
negative terminal on the alternator. Turn the switch to
the "on" position and operate the engine at fast idle.
If there is no output, there is a fault in the alternator.
If there is an output, there is a fault in the regulator.
If the warning light continues to show when the
alternator is in operation and the ammeter shows
a reduced output with maximum output only at
maximum engine speed or,if the warning light
does not show, but there is a reduced output from
the alternator with maximum output only at
maximum engine speed:
There is a fault in the alternator.
If there is an intermittent light from the warning
light and the ammeter needle is not stationary
when the battery is charged fully and no load is
applied:
Check for a higher than normal resistance in the
negative control wire of the regulator.
If the resistance is normal, there is a fault in the
regulator.
If the battery charge is too high and the ammeter
indicates high or maximum output at all times:
Check the positive control wire and its connection at
the regulator.
If the wire and its connection are correct, there is a
fault in the regulator.

23 New 1000 Series
Data and dimensions
The information which follows is general and can change with specific applications.
Alternators
Make and type
- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lucas, AC5RS
- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magneti Marelli, A127
- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bosch KI and Bosch NI
Rating:
Lucas AC5RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24V/55A
Magneti Marelli A127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V/55A or 12V/65A or 12V/72A
Bosch KI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V/55A
Bosch NI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24V/55A
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise from drive end

New 1000 Series 23
Starter motors
General description
The Magneti Marelli M127 starter motor is operated
by a solenoid and has a six roller clutch. The solenoid
engages the starter drive in two operations to ensure
that the motor gets its maximum torque only when the
starter motor is engaged fully with the flywheel. The
clutch prevents rotation of the armature at high speed
if the starter is held in the engaged position.
The Lucas S115 starter motor has a smooth surface
with no protrusions. This is because the solenoid and
the main switch assemblies are inside the drive end
cover around (co-axially with) the armature shaft. The
main feature of the co-axial starter is that only the
pinion assembly moves axially to engage the engine
flywheel. There is no axial movement of the whole
armature as with the axial type motor. To ensure
smooth engagement of the pinion, full load is not
applied until the pinion is completely engaged with the
flywheel.

23 New 1000 Series
Starter motor
4
1
To remove and to fit 23-6 5
2
POWERPART Hylosil
Warning! Always disconnect the battery terminals

before the removal of any component of the electrical
system. 3
To remove A A0150
If the engine has a flywheel housing which is oil filled,

drain the flywheel housing before the starter motor is
removed.
1 Disconnect the battery.
2 Disconnect the starter motor cables.
3 Release the fasteners and remove the starter motor
and the distance piece, if one is fitted.
To fit
1 Clean the flange face of the starter motor, the
distance piece, if one is fitted, and the face of the
flywheel housing.
If the engine has a flywheel housing which is oil filled,
the starter motor must be sealed before it is fitted.
Apply a 2,0 mm (0.080 in) continuous bead of
POWERPART silicone rubber sealant to the flange
face of the starter motor (A2) and to the flywheel
housing (A3).
Caution: For engines fitted with a distance piece: Do
not fit the starter motor without the distance piece.
2 If one is fitted, ensure that the distance piece (A4)
is fitted in position, with its location lip to the flywheel
housing, and that the cap screws (A5) are tight.
3 Fit the starter motor and tighten the fasteners.
4 Connect the starter motor cables.

New 1000 Series 23
To maintain the brush gear and the To test on the engine 23-8
commutator 23-7
Ensure that the battery is fully charged.
S115 starter motors
Turn on the lights and operate the starter switch. If no
Inspect the brushes at intervals to ensure that they lights are fitted to the machine, connect a voltmeter
are free in their guides and that the wire connections across the battery terminals and operate the starter
are free to move. To check this, lift the spring from the switch.
brush and pull carefully on the flexible connections. If
If the starter does not operate but the lights keep their
the brush does not move freely, remove it from its
power or there is no voltage drop across the battery,
holder and clean the sides with a material which is
check the switch and all the connections and wires.
damp with gasolene.
Slow action of the starter can be caused by faulty
Ensure that the brushes are fitted in their original connections.
positions to keep the original wear seat. The brushes
Failure to engage smoothly between the starter and
must have good seats which conform to the shape of
the flywheel can be caused, on some types of starter
the commutator. If the brush seat is not correct, put a
motor, by dirt on the helical grooves of the starter
piece of very fine carborundum paper or similar
motor drive, which can prevent free pinion movement.
material tight around the commutator with the rough
Clean the shaft thoroughly with gasolene, or a fluid
face to the outside. With the brush in position, turn the
made especially for the purpose, and apply a small
armature by hand, in the normal direction of rotation,
quantity of Aero Shell 6B or its equal.
until the brush has the correct shape. If the brushes
are worn and the springs do not give enough
pressure, they must be renewed. Check the spring
pressure with the hook of a spring balance under the
spring lip. The correct tension is 8,34/11,00 N (30/40
ozf) 0,85/1,13 kgf.
The new brushes must be the exact same grade as
the original brushes. To ensure that correct brushes
are fitted, use only parts from the approved
manufacturer. To remove the brushes, remove the
four setscrews that hold the brushes, one for each
brush. When the new brushes are assembled,
connect carefully the field coil and connector wires,
held by two of the setscrews. Before the brushes are
inserted in their holders, it is advised that the holders
are cleaned with compressed air or with a material
which is damp with gasolene.
The commutator must be completely clean; dirt or oil
must be removed by a piece of clean dry material
(with no loose fibres) pressed against it, while the
armature is turned by hand. If the commutator is dirty
and has a colour other than its natural colour, lift the
brushes and put a strip of fine carborundum paper or
similar material around the commutator, with the
rough surface to the inside. Turn the armature by
hand until the surface has returned to its natural
colour. Clean the commutator with a material which is
damp with gasolene.
If a repair is necessary to the commutator or switch
gear, etc. the starter must be removed for specialist
repair.
M127 Starter motor
Repair of this starter motor is more difficult. If
necessary, remove the starter motor for specialist
repair.

23 New 1000 Series
Data and dimensions
Starter motors
Make and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lucas S115 or Magneti Marelli M127 or Bosch JF
Voltage:
Lucas S115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V or 24V
Magneti Marelli M127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V
Bosch JF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V or 24V
Number of teeth on pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maximum starter cable resistance at 200 °C (680 °F):
- 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0017 ohms
- 24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0034 ohms

New 1000 Series 23
Starting aid
1
General description
There are two types of electrical starting aid in use: 2
The fuelled starting aid and the port heater.
The fuelled starting aid (B1) is a device which is
operated electrically and ignites a controlled amount
of diesel fuel in the induction manifold to heat the
induction air. A heater coil in the body expands a
valve holder to allow fuel to flow into the device. The 3
fuel is ignited by the hot coil and heats the air which
passes through the induction manifold when the A A 03 67 /1
starter motor is operated.
The port heater has an electrically heated coil that 1
heats the air as it enters the induction manifold. Port
heaters are used in a group of two or three.
Starting aid
2
To remove and to fit a fuelled

starting aid 23-9
3
To remove
B A0303
1 Disconnect the fuel pipe (A2) and the electrical
connection (A3).
2 Turn the spanner (A1) counter-clockwise and
remove the starting aid.
To fit
1 Ensure that the contact faces of the manifold and
the starting aid are clean. Put the sealing washer into
position and fit the starting aid. Tighten the starting aid
to 31 Nm (23 lbf ft) 3,2 kgf m.
2 Check the fuel pipe and, if it is still full of fuel,
connect it to the starting aid. If the fuel has drained
from the pipe, eliminate the air from the pipe as shown
in paragraph 3 of operation 20-9.
3 Connect the electrical connection (A2).
Some engines which have water-to-air intercoolers
are fitted with twin fuelled starting aids (B3). These
starting aids are in a recess on top of the induction
manifold. In this situation, access to the electrical
terminals (B2) can be restricted if the starting aids are
not fitted correctly, see page 272.

23 New 1000 Series
Twin fuelled-starting-aid
1
The correct procedure to remove and to fit twin fuelled
starting aids is as follows:
To remove
1 Disconnect the fuel connections and the electrical
connections.
2
2 Remove the starting aids.
To fit
1 Ensure that the seat faces of the manifold and the 3
fuelled starting aids are free of dirt.
2 Fit the nylon spacer(s) (A3) over the threads of the A A0303
starting aid. Screw the fuel starting aid into the
manifold and tighten to 31 Nm (23 lbf ft) 3,1 kgf m.
Ensure that the electrical connector(s) (A2) are in the
correct position. It is not necessary to use
POWERPART threadlock.
Caution: To prevent electrical contact when the
circuit is on and for easy removal during maintenance,
It is important that the electrical terminals face away
from the casing .
3 When the fuelled starting aids are tightened fully
into the manifold. If necessary, rotate them back, no
more than half of one complete turn, until the
electrical terminals face away from the casing.
4 Check the fuel pipes and if they are still full of fuel,
connect them to the starting aids. If the fuel has
drained from the pipes, eliminate the air from the
pipes, refer to section 20.
5 Connect the electrical connections.

New 1000 Series 23
How to check the fuelled starting aid
If the inside of the induction manifold is wet, check
that there is not a fuel leak from the fuelled starting
aid.
1 Disconnect the fuel pipe and the electrical
connection at the starting aid. Remove the starting aid
from the manifold and fit a suitable plug in the
manifold.
2 Connect the fuel pipe to the starting aid, but leave
the connection loose. Do not fit the electrical
connection, but ensure that the connector has a
suitable insulator fitted. Operate the priming lever of
the fuel lift pump until fuel free of air comes from the
connection. Tighten the connection.
3 Start the engine and operate it at low speed. Check
that there is no fuel leakage from the valve of the
starting aid.
4 If there is no leakage, remove the plug from the
induction manifold and fit the starting aid. Connect the
fuel pipe to the starting aid and remove the air from
the pipe as shown above. Connect the electrical
connection.
If there is a leak from the valve of the starting aid, fit a
new starting aid.
To remove and to fit a port heater 23-10
1 Disconnect the electrical connection.

2 Remove the port heater from the induction manifold
or from the elbow.
3 Fit the port heater and tighten it to 60 Nm (44 lbf ft)
6,1 kgf m.
4 Connect the electrical connection.

23 New 1000 Series
Data and dimensions
Starting aid
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrically operated heater, with a fuel supply
Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V (dropping resistor used on 24V system)
Flow rate of fuel through starting aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,5/5,9 ml/min

New 1000 Series
24
Auxiliary equipment 24
Compressors
General description
The engines can be fitted with either a Bendix
1W150R or 1W250R compressor. The compressor is
fitted on the left side of the engine directly onto the
rear face of the timing case. The compressor is driven
from the main idler gear through an idler gear for the
compressor.
The cylinder head of the single cylinder compressor is
cooled by coolant from the engine. The compressor is
lubricated from the lubrication system of the engine.
Oil passes through a pipe from the engine pressure
rail to the compressor crankcase. The oil passes to A A0069
the main bearings and the big end bearings of the

compressor and also to the rear bush for the drive
shaft. Oil which drains from the compressor
crankcase into the drive housing, lubricates the drive
gears and the bearing. The oil returns to the engine
sump through the timing case.
Operation
As the piston moves down the cylinder, air pressure
above the piston is reduced. The reduction in air
pressure opens the inlet valve and allows air to enter
the cylinder above the piston. As the piston moves up
the cylinder, air pressure under the valve and the
action of the valve spring, closes the valve. The
increase in air pressure under the delivery valve,
opens the valve and air is discharged to the reservoir.
Air pressure in the reservoir is controlled by an
unloader valve which, at a certain pressure, holds the
inlet valve of the compressor open until air pressure
in the reservoir is reduced.

24 New 1000 Series
Bendix Compressors
2 3
To remove and to fit 24-1 1

5 4
To remove
1 Drain the engine cooling system.
2 Release the air pressure in the air system.
Disconnect the air pipes and the coolant pipes (A1) to 7
and from the cylinder head of the compressor.
3 Remove the lubricating oil pipe (A6) which is fitted 6
between the compressor and the engine cylinder
block.
A A0294
4 If necessary, remove the steering pump from the

rear of the compressor.
5 Loosen the two setscrews (A3) of the support
bracket (A4) at the rear end of the compressor.
Remove the two fasteners (A5) which fasten the
support bracket to the cylinder block or filter head and
remove the bracket.
Note: Spacers (A2) are used between the bracket of
the 1W150R compressor and the compressor body.
Remove the nut from the stud at the bottom of the
compressor flange. Remove the nut (A7) from the
stud at the front of the timing case and remove the
compressor from the engine.
If it is necessary to remove the idler gear of the
compressor, see operation 15-4.

New 1000 Series 24
To fit
2
operation 17-1 or , see operation 17-2.
2 Fit a new "O" ring (A5) in its recess in the drive 3
housing. Lubricate the "O" ring with clean engine
lubricating oil.
3 Rotate the crankshaft of the compressor until the
mark (B1) or (C1) on the rear face of the crankshaft 1
aligns with the 6A line (six cylinder engines) or the 4A
line (four cylinder engines) on the label on the rear 4
face of the compressor.
4 Push the shortest thread of the stud (A4) through
5
the hole at the top of the compressor flange and fit the A A0069
nut fully onto the thread. Engage the stud in the hole
(A1) in the timing case. Slide the compressor onto the
stud (A3) for the bottom of the flange.
5 Slide the compressor forward until the teeth of the
drive gear are against the teeth of the idler gear (A2). 1
Slowly rotate the crankshaft of the compressor
clockwise (from the rear) until the drive gear and the
idler gear are in mesh.
6 Carefully push the compressor forward until the
spigot on the compressor is fully fitted in the timing
case. In this position, the mark on the rear of the
crankshaft should align with the dark area on the
timing label marked 6 (six cylinder engines) or 4 (four
cylinder engines). B A0292
7 If the alignment is not correct, pull the compressor

out of engagement and move the crankshaft of the
compressor in the relevant direction to mesh with the
next gear tooth. Carefully push the compressor
assembly into position. Check that the mark on the
rear of the crankshaft is in the correct position. Fit the
nuts to the stud (A4) which passes through the timing
case (A1) and to the stud at the bottom of the flange.
Tighten the two nuts to 75 Nm (55 lbf ft) 7,6 kgf m. 1
Continued
C A0293

24 New 1000 Series
Caution: If the support bracket is mounted on the oil
filter head, check that the nuts for the filter head are 2 3
tightened correctly before the compressor support
bracket is fitted. 1
5 4
8 Put the support bracket (A4) in position between
the cylinder block or the filter head and the
compressor. Loosely fit the fasteners (A5) the spacer
(A2), if fitted, and the setscrews (A3). Adjust the
support bracket to ensure that there will be no tension
on the compressor. Tighten the two setscrews to 22 7
Nm (16 lbf ft) 2,2 kgf m for the setscrews (A3) and 44
Nm (33 lbf ft) 4,5 kgf m for the fasteners (A5). 6
Note: Spacers (A2) are used between the bracket A A0294
and the body of the 1W150R compressor.
9 Check that the "O" ring in the cover for the rear of
the compressor is not damaged. Fit the cover and
tighten the setscrews.
10 Ensure that there is no restriction in the oil pipe
(A6) between the engine and the compressor. Before
the oil pipe is connected to the compressor, ensure
that the engine stop solenoid is disconnected or that
the engine stop control is in the 'stop' position.
Operate the starter motor until a free flow of oil comes
from the oil pipe. Connect the oil pipe. Connect the
engine stop solenoid.
11 Connect the compressor coolant pipes (A1) and
the air pipes to the compressor.
12 Fill the engine cooling system. Operate the engine
and check for leakage of oil, coolant and air from the
compressor.

New 1000 Series 24
Data and dimensions
Bendix compressor
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bendix 1W150R or 1W250R
Number of teeth on compressor drive gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Taper of compressor drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 in 8

24 New 1000 Series
Power steering pump
To remove
1 Disconnect the pipe connections at the power
steering pump and fit covers to the open ends of the
pipes.
2 Release the setscrews and remove the pump. If the
pump is fitted to the rear of the compressor, ensure
that the drive coupling is not lost.
To fit
1 Renew the "O" ring and lubricate it with clean
2 Check the drive coupling or the gear for wear or for
damage. Renew it, if necessary.
3 If necessary, fit the drive coupling to the end of the
compressor shaft and rotate the pump shaft to align
the drive with the coupling. Fit the pump to the
compressor and tighten the setscrews.
4 Remove the covers from the open ends of the
pipes.and connect the connections.

New 1000 Series 24
Adaptor for a hydraulic pump or a
steering pump with a splined drive
To remove
1 Release the cap screws and remove the adaptor
assembly from the rear of the timing case.
2 Check the gear, the spline and the bearings for 1
wear and other damage and renew the components 1
as necessary. 2
To fit
3
1 Fit a new "O" ring (A6) in its recess in the housing 7
(A5) and lightly lubricate it with clean engine
lubricating oil. Lubricate the bearings (A2) and (A7) 4
with clean engine lubricating oil. Fit the adaptor
assembly to the timing case and tighten the cap
screws.

6 5
POWERPART retainer (oil tolerant)
A A0288
To dismantle
1 Remove the hydraulic pump or steering pump.
2 Remove the adaptor assembly, see operation 24-3.
3 Remove the circlip (A4). Provide a support for the
flange face of the housing (A5). Use a suitable
adaptor on the front bearing (A7) to press the gear
and bearings out of the housing.
4 Remove the bearings from the gear (A3) with a
suitable gear puller.

24 New 1000 Series
To assemble
5 Apply a narrow ring of POWERPART retainer (oil
tolerant) to the outer face of the front bearing (A7) in
the position shown (A1). Provide a support for the
front face of the housing. Use a suitable adaptor on
the outer ball guide of the bearing to press the front
bearing onto the shoulder in the housing. Remove
excess retainer (oil tolerant).
6 Apply a narrow ring of POWERPART retainer (oil
tolerant) to the inner face of the front bearing in the 1
position shown (A1). Provide a support for the
1
bearing. With the small diameter of the gear toward
2
the bearing, press the gear into the bearing until the
gear is onto its shoulder.
7 Apply a narrow ring of POWERPART retainer (oil 3
7
tolerant) to the outer face and to the inner face of the
rear bearing (A2) in the positions shown (A1). Ensure
4
that the support is under the front bearing. Use a
suitable adaptor on the outer ball guide of the bearing
to press the bearing into the housing and onto the
shoulder on the gear. Remove excess retainer. Fit the
circlip into its groove in the housing.
8 Check the backlash between the power take-off
gear and the idler gear: Power take-off gears are 6 5
identified by the part number stamped on the gear
face. The backlash for gears with part numbers
3117C111, 3117C112 or 3117C113, is 0,08 mm
(0.003 in) minimum. The backlash for gears with part A A0288
numbers 3117C114, 3117C115 and 3117C116 is

0,18/0,25 mm (0.007/0.010 in) minimum.

New 1000 Series 24
Exhauster
To remove
1 Disconnect the lubricating oil and vacuum pipes
from the exhauster and fit covers to the open ends of
the pipes.
2 Release the setscrews and remove the exhauster.
To fit
1 Ensure that the joint faces of the exhauster and the
timing case are clean and renew the joint. Fit the
exhauster to the timing case and tighten the
setscrews.
2 Remove the covers from the open ends of the pipes
and connect the oil pipe and the vacuum pipe to the
exhauster.

284
New 1000 Series
25
Special tools 25
These tools are available through your local Perkins

Distributor. If you cannot obtain the correct tool locally
contact:
The Perkins Service Department, Peterborough, PE1
5NA, England, UK. Tel 01733 583000, Fax 01733
582240, Telex 32501 PERKEN G.

25 New 1000 Series
List of special tools
Part number Description Illustration
Remover /replacer for valve guides (main tool)

PD.1D
Part number 21825478
MANITOU
Réf. 404520
Adaptor for use with PD.1D.

PD.1D-13
MANITOU
Réf. 564830
Inlet valve guide adaptor for use with

PD.1C-6 PD.1D and PD.1D-1A.
MANITOU
Réf. 474171
Exhaust valve guide adaptor for use with

PD.248 PD.1D and PD.1D-1A.
MANITOU
Réf. 564831
Timing pin for Bosch fuel injection pumps.

PD.245
MANITOU
Réf. 564832
Timing pin for Lucas and Stanadyne fuel

PD.246 injection pumps.
MANITOU
Réf. 564833
Gauge for piston height, valve depth and

PD.41D cylinder liner flange; for use with PD.208.
MANITOU
Réf. 474172

New 1000 Series 25
Replacer tool for crankshaft rear seal.

PD.145D
MANITOU
Réf. 474176
Remover / replacer for cylinder liner (main tool).

PD.150B
MANITOU
Réf. 474177
Adaptors for use with PD.150B.

PD.150B-17A
MANITOU
Réf. 474178
Basic puller for camshaft gear.

PD.155C
MANITOU
Réf. 563033
Adaptors for use with PD.155C.

PD.155B-5
MANITOU
Réf. 474179
Centralising tool for timing case cover

PD.162B (four cylinder engines).
MANITOU
Réf. 563034

25 New 1000 Series
Centralising tool for timing case cover

PD.163A (Six cylinder engines).
MANITOU
Réf. 474180
Crankshaft rotation adaptor for use with a

PD.165B 12,7 mm (0.5 in) square drive.
MANITOU
Réf. 563035
Replacer tool for seal of timing case cover

PD.170 (main tool).
MANITOU
Réf. 474181
Pressure plate for use with PD.170.

PD.170-1
MANITOU
Réf. 474182
Sleeve for use with PD.170.

PD.170-2
MANITOU
Réf. 474183
Fastener plate for use with PD.170.

PD.170-3
MANITOU
Réf. 474184
Adaptor for front seal for use with PD.170.

PD. (1)
Part number (1)

New 1000 Series 25
Spanner for flange nuts of the Bosch

PD.239 fuel injection pump.
MANITOU
Réf. 563037
Replacer tool for pistons.

PD.206
MANITOU
Réf. 474187
Dial gauge for use with PD.41D.

PD.208
MANITOU
Réf. 474188
Valve spring compressor.

PD.6118B
MANITOU
Réf. 404537
Stud adaptor for use with PD.6118B.

PD.6118-7
MANITOU
Réf. 474189
Setscrew adaptor for use with PD.6118B.

PD.6118-8
MANITOU
Réf. 474190

25 New 1000 Series
PD 198 Angle gauge to tighten cylinder head setscrews

(MS.1531) Part number 21825607
MANITOU
Réf. 474197
Combined reamer/cutters and handle for

PD.242 valve guides and 31•/ 46•valve seat inserts.
MANITOU
Réf. 564834
Coolant pump, oil seal replacer tool

PD.247
MANITOU
Réf. 564835
(1) Refer to your nearest Perkins distributor

Service bulletin 26
Service bulletin Nr 76 issue 2 June 1999

Service bulletin Nr 84 March 1998
Service bulletin Nr 97 issue 1 July 2000
Service bulletin Nr 139 issue 2 August 2000
Service bulletin Nr 144 issue 1 October 2000
Service bulletin Nr 99 issue 2 January 2001
GEAR BOX DISASSEMBLY
GEAR BOX "POWER SHIFT"
20-3-15EN
17 / 04 / 2003
TOWING OR PUSHING
Before towing the vehicle, be sure to lift the rear wheels off the ground or disconnect the driveline to avoid
damage to the transmission during towing.
Note
IF THE TRANSMISSION HAS 4 WHEEL DRIVE, DISCONNECT BOTH FRONT AND REAR DRIVELINES.
BECAUSE OF THE DESIGN OF THE HYDRAULIC SYSTEM, THE ENGINE CANNOT BE STARTED
BY PUSHING OR TOWING.
T12000 ID 04/99
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 MANITOU product.
Extreme care has been exercised in the design, selection of materials, and manufacturing of these units.
The slight outlay in personal attention and cost required to provide regular and proper lubrication, inspection
at stated intervals, and such adjustments as may be indicated will be reimbursed many times in low cost
operation and trouble free service.
In order to become familiar with the various parts of the product, its principle of operation, troubleshooting
and adjustments, it is urged that the mechanic studies the instructions in this manual carefully and uses it as
a reference when performing maintenance and repair operations.
Whenever repair or replacement of component parts is required, only MANITOU

approved parts as listed in the applicable parts manual should be used. Use of “will-fit” or non-approved
parts may endanger proper operation and performance of the equipment. MANITOU
does not warrant repair or replacement parts, nor failures resulting from the use of parts which are not
supplied by or approved by MANITOU
.
IMPORTANT
ALWAYS FURNISH THE DISTRIBUTOR WITH THE SERIAL AND MODEL NUMBER WHEN ORDERING PARTS.
T12000 ID 04/99
Table of Contents
1. SAFETY PRECAUTIONS
2. CLEANING, INSPECTION AND LEGEND SYMBOLS

2.1 CLEANING .............................................................................................................................. 2-1
2.1.1 Bearings ......................................................................................................................... 2-1
2.1.2 Housings ........................................................................................................................ 2-1
2.2 INSPECTION ........................................................................................................................... 2-1
2.2.1 Bearings ......................................................................................................................... 2-1
2.2.2 Oil Seals, Gaskets, Etc. ................................................................................................. 2-2
2.2.3 Gears and Shafts ........................................................................................................... 2-2
2.2.4 Housing, Covers, etc. ..................................................................................................... 2-2
2.3 LEGEND SYMBOLS ................................................................................................................ 2-2
3. TECHNICAL SPECIFICATIONS
3.1 IDENTIFICATION OF THE UNIT ............................................................................................. 3-1
3.2 WEIGHT, DIMENSIONS, OIL CAPACITY ................................................................................ 3-1
3.3 TIGHTENING TORQUES ........................................................................................................ 3-2
3.3.1 Torque specifications for lubricated or plated screw threads ......................................... 3-2
3.3.2 Pipe plug torque chart .................................................................................................... 3-3
3.3.3 Permanent metric plug torque chart ............................................................................... 3-3
3.3.4 Coil and cartridge torque ................................................................................................ 3-3
3.4 PRESSURE AND TEMPERATURE SPECIFICATIONS .......................................................... 3-4
3.5 ELECTRICAL SPECIFICATIONS ............................................................................................ 3-5
3.6 HYDRAULIC COOLER AND FILTER LINE SPECIFICATIONS ............................................... 3-5
5. INSTALLATION DETAILS
5.1 CONVERTER DRIVE COUPLING .......................................................................................... 5-1
5.2 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE ............................................... 5-2
5.4 SPEED SENSOR INSTALLATION .......................................................................................... 5-4
T12000 ID 04/99 I-i

6. OPERATION OF THE TRANSMISSION
6.1 THE TRANSMISSION ASSEMBLY ......................................................................................... 6-1
6.1.1 The converter, pump drive section and pressure regulating valve ................................. 6-2
6.1.2 The input shaft and directional clutches ......................................................................... 6-3
6.1.3 The range clutches ........................................................................................................ 6-4
6.1.4 The output section ......................................................................................................... 6-4
6.1.5 The transmission controls (refer to hydraulic diagram) .................................................. 6-5
6.2 ELECTRIC SOLENOID CONTROLS ...................................................................................... 6-6
6.2.2 4-speed transmission ................................................................................................... 6-6

6.2.2.1 Standard 4-speed transmission ......................................................................... 6-6
6.3 POWERFLOWS, ACTIVATED SOLENOIDS AND HYDRAULIC CIRCUIT ............................. 6-8
6.3.2 4-Speed transmission ................................................................................................ 6-18

6.3.2.1 Standard 4-speed transmission ....................................................................... 6-18
6.3.2.1.1 Neutral and 3rd clutch engaged ......................................................... 6-18
6.3.2.1.2 Forward 1st speed .............................................................................. 6-19
6.3.2.1.3 Forward 2nd speed ............................................................................ 6-21
6.3.2.1.4 Forward 3rd speed ............................................................................. 6-24
6.3.2.1.5 Forward 4th speed ............................................................................. 6-26
6.3.2.1.6 Reverse 1st speed ............................................................................. 6-28
6.4 GEAR AND CLUTCH LAY-OUT (4-SPEED AND 6-SPEED) ................................................. 6-59
7. TROUBLESHOOTING GUIDE FOR THE T12000 TRANSMISSION

7.1 T12000 TRANSMISSION ........................................................................................................ 7-1
7.2 TROUBLESHOOTING PROCEDURES .................................................................................. 7-1
7.2.1 Stall Test ......................................................................................................................... 7-1
7.2.2 Transmission pressure checks ....................................................................................... 7-2
7.2.3 Mechanical and electrical checks .................................................................................. 7-2
7.2.4 Hydraulic checks ............................................................................................................ 7-2
T12000 ID 04/99 I-ii

7.3 TROUBLESHOOTING GUIDE ................................................................................................ 7-3
7.3.1 Low clutch pressure ....................................................................................................... 7-3
7.3.2 Low charging pump output ............................................................................................. 7-3
7.3.3 Overheating ................................................................................................................... 7-3
7.3.4 Noisy converter .............................................................................................................. 7-3
7.3.5 Lack of power ................................................................................................................. 7-3
7.4 CHECK POINTS ...................................................................................................................... 7-4
7.6 SPEED SENSOR - STATIC STANDALONE TEST ................................................................. 7-11
8. SECTIONAL VIEWS AND PARTS IDENTIFICATION

GROUP - CONVERTER HOUSING ................................................................................................ 8-2
GROUP - TRANSMISSION CASE AND PLATE .............................................................................. 8-4
GROUP - TORQUE CONVERTER .................................................................................................. 8-6
GROUP - PUMP DRIVE .................................................................................................................. 8-8
GROUP - CHARGING PUMP ........................................................................................................ 8-10
GROUP - REVERSE IDLER .......................................................................................................... 8-12
GROUP - FORWARD AND REVERSE SHAFT ............................................................................. 8-14
GROUP - HIGH (4TH) AND 3RD SHAFT ...................................................................................... 8-18

GROUP - 1ST AND 2ND SHAFT ................................................................................................... 8-20
GROUP - OUTPUT SHAFT (FRONT & REAR) ............................................................................. 8-26
GROUP - ELECTRIC CONTROL .................................................................................................. 8-32

GROUP - DRIVE PLATE ............................................................................................................... 8-34
9. ASSEMBLY INSTRUCTIONS
10. DISASSEMBLY AND REASSEMBLY OF THE T12000 TRANSMISSION
11. OPTIONS
11.1 ELECTRIC CONTROL-SINGLE MODULATION HYDRAULIC ACTUATED INCHING .......... 11-1
11.1.1 Sectional views and parts identification ..................................................................... 11-1
11.1.2 Single modulation and hydraulic inching removal ...................................................... 11-6
11.1.3 Disassembly single modulator assembly ................................................................... 11-8
11.1.4 Reassembly single modulator assembly .................................................................. 11-10
11.1.5 Disassembly hydraulic inching actuator ................................................................... 11-12
11.1.6 Reassembly hydraulic inching actuator ................................................................... 11-14
11.1.7 Single modulation and hydraulic inching installation ................................................ 11-16
11.2 MT SECTION ........................................................................................................................11-19
11.2.1 Sectional views and parts identification ................................................................... 11-19
11.2.2 Assembly instructions ..............................................................................................11-21
T12000 ID 04/99 I-iii

1. SAFETY PRECAUTIONS
To reduce the chance of personal injury and/or property damage, the following instruction must be carefully
observed.
Proper service and repair are important to the safety of the service technician and the safe, reliable operation
of the machine. If replacement parts are required the part must be replaced by a spare part which has the
same part number or with an equivalent part. Do not use a spare part of lesser quality.
The service procedures recommended in this manual are effective methods for performing service and
repair. Some of these procedures require the use of tools specifically designed for the purpose.
Accordingly, anyone who intends to use a spare part, service procedure or tool, which is not recommended
by MANITOU, must first determine that neither his safety nor the safe operation of
the machine will be jeopardized by the spare part, service procedure or tool selected.
IMPORTANT
IT IS IMPORTANT TO NOTE THAT THIS MANUAL CONTAINS VARIOUS ’CAUTIONS’ AND ‘NOTICES’ THAT MUST BE
CAREFULLY OBSERVED IN ORDER TO REDUCE THE RISK OF PERSONAL INJURY DURING SERVICE OR REPAIR,
OR THE POSSIBILITY THAT IMPROPER SERVICE OR REPAIR MAY DAMAGE THE UNIT OR RENDER IT UNSAFE.
IT IS ALSO IMPORTANT TO UNDERSTAND THAT THESE ‘CAUTIONS’ AND ‘NOTICES’ ARE NOT EXHAUSTIVE,
BECAUSE IT IS IMPOSSIBLE TO WARN ABOUT ALL THE POSSIBLE HAZARDOUS CONSEQUENCES THAT MIGHT RESULT
FROM FAILURE TO FOLLOW THESE INSTRUCTIONS.
T12000 ID 04/99 1-1

2. CLEANING, INSPECTION AND LEGEND SYMBOLS
2.1 CLEANING
Clean all parts thoroughly using solvent type cleaning fluid. It is recommended that parts be immersed in
cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts
are thoroughly cleaned.
CAUTION
CARE SHOULD BE EXERCISED TO AVOID SKIN RASHES, FIRE HAZARDS, AND INHALATION OF VAPOURS WHEN USING
SOLVENT TYPE CLEANERS.
2.1.1 Bearings
Remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of
lubricant. Immerse again in cleaning fluid to flush out particles. Repeat above operation until bearings are
thoroughly clean. Dry bearings using moisture-free compressed air. Be careful to direct air stream across
bearing to avoid spinning. Do not spin bearings when drying. Bearings may be rotated slowly by hand to
facilitate drying process.
2.1.2 Housings
Clean interior and exterior of housings, bearing caps, etc…, thoroughly. Cast parts may be cleaned in hot
solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces.
Parts should remain in solution long enough to be thoroughly cleaned and heated. This will aid the evaporation
of the cleaning solution and rinse water. Parts cleaned in solution tanks must be thoroughly rinsed with clean
water to remove all traces of alkali. Cast parts may also be cleaned with steam cleaner.
CAUTION
CARE SHOULD BE EXERCISED TO AVOID INHALATION OF VAPOURS AND SKIN RASHES WHEN USING ALKALI CLEANERS.
All parts cleaned must be thoroughly dried immediately by using moisture-free compressed air or soft, lintless
absorbent wiping rags free of abrasive materials such as metal fillings, contaminated oil, or lapping compound.
2.2 INSPECTION
The importance of careful and thorough inspection of all parts cannot be overstressed. Replacement of all
parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date.
2.2.1 Bearings
Carefully inspect all rollers: cages and cups for wear, chipping, or nicks to determine fitness of bearings for
further use. Do not replace a bearing cone or cup individually without replacing the mating cup or cone at the
same time. After inspection, dip bearings in Automatic Transmission Fluid and wrap in clean lintless cloth or
paper to protect them until installed.
T12000 ID 04/99 2-1

Cleaning, inspection and legend symbols
2.2.2 Oil Seals, Gaskets, Etc.

Replacement of spring load oil seals, “O”-rings, metal sealing rings, gaskets, and snap rings is more economical
when unit is disassembled than premature overhaul to replace these parts at a future time.
Further loss of lubricant through a worn seal may result in failure of other more expensive parts of the
assembly. Sealing members should be handled carefully, particularly when being installed. Cutting, scratching,
or curling under of lip of seal seriously impairs its efficiency. When assembling new metal type sealing rings,
these should be lubricated with coat of chassis grease to stabilize rings in their grooves for ease of assembly
of mating members. Lubricate all “O”-rings and seals with recommended type Automatic Transmission Fluid
before assembly.
2.2.3 Gears and Shafts

If magna-flux process is available, use process to check parts. Examine teeth on all gears carefully for wear,
pitting, chipping, nicks, cracks, or scores. If gear teeth show spots where case hardening is worn through or
cracked, replace with new gear. Small nicks may be removed with suitable hone. Inspect shafts and quills to
make certain they are not sprung, bent, or splines twisted, and that shafts are true.
2.2.4 Housing, Covers, etc.

Inspect housings, covers and bearing caps to ensure that they are thoroughly clean and that mating surfaces,
bearing bores, etc…, are free from nicks or burrs. Check all parts carefully for evidence of cracks or conditions
which would cause subsequent oil leaks or failures.
2.3 LEGEND SYMBOLS
Smontaggio di sottogruppi Sostituire con ogni montaggio

Disassembly of assembly groups Renew at each reassembly
Montaggio di sottogruppi Togliere - mettere la sicura

Reassemble to from assembly group Unlock - lock e.g. split pin, locking plate, etc.
Smontaggio di particollari ingombranti Mettere la sicura, incollare (mastice liquido)

Remove obstruction parts Lock - adhere (liquid sealant)
Montaggio di particollari ingombranti Evitare danni ai materiali, danni ai pezzi

Reinstall - remount parts which had obstructed disassembly Guard against material damage, damage to parts
Attenzione, indicazione importante Marchiari prima dello smontaggio (per il montaggio)

Attention! important notice Mark before disassembly, observe marks when reasembl.
Controllare regolare p.e. coppie, misure, pressione etc. Carricare riempire (olio - lubrificante)
Check - adjust e.g. torque, dimensions, pressures etc. Filling - topping up - refilling e.g. oil, cooling water, etc.
T = Attrezzature speciali P = Pagina Scarricare olio, lubrificante

T = Special tool P = Page Drain off oil, lubricant
Rispettare direzione di montaggio Tendere

Note direction of installation Tighten - clamp ; tightening a clamping device
Controllare esaminare controllo visuale Insere pressione nel circuito idraulico

Visual inspection Apply pressure into hydraulic circuit
Eventualimente riutilizzable (sostituire se necessario) Pulire

Possibly still serviceable, renew if necessary To clean
T12000 ID 04/99 2-2

3. TECHNICAL SPECIFICATIONS
OFF-HIGHWAY
TEN BRIELE 3
B-8200
BELGIUM
MODEL
SERIAL
3.1 IDENTIFICATION OF THE UNIT

1. Model and type of the unit.
2. Serial number.
3.2 WEIGHT, DIMENSIONS, OIL CAPACITY

Weight (dry): ±174.6 kg (385 lb.)
T-model MT-model
Maximum length: 623.1 mm (24.53”) 712.5 mm (28.05”)
Maximum width: 477.0 mm (18.78”) 477.0 mm (18.78”)
Maximum height: 701.1 mm (27.60”) 701.1 mm (27.60”)
Oil capacity
±12.9 l (3.4 US Gallon) without cooler and hydraulic lines.
Consult operator’s manual on applicable machine for system capacity.
T12000 ID 04/99 3-1

Technical specifications
3.3 TIGHTENING TORQUES
3.3.1 Torque specifications for lubricated or plated screw threads
NOM. SIZE GRADE 5

FINE THREAD COARSE THREAD
LBF - FT [N.m] LBF - FT [N.m]
.2500 9 - 11 [12 - 15] 8 - 10 [11 - 14]

.3125 16 - 20 [22 - 27] 12 - 16 [16 - 22]
.3750 26 - 29 [35 - 39] 23 - 25 [31 - 34]
.4375 41 - 45 [56 - 61] 37 - 41 [50 - 56]
.5000 64 - 70 [87 - 95] 57 - 63 [77 - 85]
.5625 91 - 100 [123 - 136] 82 - 90 [111 - 122]
.6250 128 - 141 [174 - 191] 113 - 124 [153 - 168]
.7500 223 - 245 [302 - 332] 200 - 220 [271 - 298]
NOM. SIZE GRADE 8

FINE THREAD COARSE THREAD
.2500 11 - 13 [15 - 18] 9 - 11 [12 - 15]

.3125 28 - 32 [38 - 43] 26 - 30 [35 - 41]
.3750 37 - 41 [50 - 56] 33 - 36 [45 - 49]
.4375 58 - 64 [79 - 87] 52 - 57 [71 - 77]
.5000 90 - 99 [122 - 134] 80 - 88 [108 - 119]
.5625 128 - 141 [174 - 191] 115 - 127 [156 - 172]
.6250 180 - 198 [224 - 268] 159 - 175 [216 - 237]
.7500 315 - 347 [427 - 470] 282 - 310 [382 - 420]
NOM. SIZE GRADE 8.8 or 9.8 GRADE 10.9

COARSE THREAD COARSE THREAD
M10 30 - 37 [40 - 50] 44 - 48 [60 - 65]

M12 50 - 55 [65 - 75] 74 - 81 [100 - 110]
T12000 ID 04/99 3-2

3.3.2 Pipe plug torque chart
THREAD NPTF TORQUE

LBF - FT [N.m]
1/16-27 5-7 [7-9]

1/8-27 7-10 [9-14]
1/4-18 15-20 [20-27]
3/8-18 25-30 [34-41]
1/2-14 30-35 [41-47]
3/4-10 40-45 [54-61]
3.3.3 Permanent metric plug torque chart
THREAD SIZE TORQUE

LBF - FT [N.m]
M18 x 1.5 6H 25-30 [34-41]

M18 x 1.5 6H 45-50 [61-68]
3.3.4 Coil and cartridge torque
Plug used for 3-speed version
A: tighten cartridge to 22-27 N.m (16-20 LBF-FT)

B: tighten cartridge nuts to 5-7 N.m (4-5 LBF-FT)
T12000 ID 04/99 3-3

3.4 PRESSURE AND TEMPERATURE SPECIFICATIONS

• Normal operating temperature 70 - 120 °C (158 - 248 F) measured at temperature check port
converter out (port 71 - **).
• Maximum allowed transmission temperature 120 °C (248 F).
• Transmission regulator pressure (*) - (neutral) - port 31 (**).
- At 600 RPM min. 12.76 bar (185 PSI) minimum.
- At 2000 RPM: 19.31 bar (280 PSI) maximum.
• Pump flow (*)

- At 2000 RPM in neutral: 53 l/min. minimum (14 GPM).
• Clutch pressures (*)

- 1st clutch: port 41 (**).
- 2nd clutch: port 42 (**).
- 3rd clutch: port 43 (**).
- Forward High clutch: port 44 (**).
- Forward clutch: port 45 (**).
- Reverse clutch: port 46 (**).
At 1800 RPM :
- 16.5 - 19.3 bar (240 - 280 PSI) clutch activated.
- 0 - 0.2 bar (0 - 3 PSI) clutch released.
• Filter bypass valve set at 2.1 - 3.5 bar (*) (30 - 50 PSI).
• Lube pressure (*) (por t 33) 2.9 - 4.0 bar (42 - 58 PSI) at 49 l/min. (13 GPM) pump flow
(±1850 RPM).
• Safety valve: cracking pressure (*) 8.27 - 10.20 bar (120 - 148 PSI), measured at port 32 with convertor out
shut off.
• Transmission out pressure (*) (port 32) 2.9-6.41 bar (42-93 PSI) at 49 l/min, (13 GPM) pump flow
(±1850 RPM), and max. 8.27 bar (120 PSI) at no load governed speed.
(*) All pressures and flows to be measured with oil temperature of 82-93 °C (180-200 F)
(**) Refer to section 7 “Troubleshooting” for check port identification.
T12000 ID 04/99 3-4

3.5 ELECTRICAL SPECIFICATIONS

• Solenoid (forward, reverse, 1st, 2nd and splitter).
Coil resistance:
- 12V: 9.79 Ω ±0.5 Ω.
- 24V: 39.3 Ω ±2 Ω.
• Speed sensor:
- Type: magneto resistive sensor.
- Sensing distance: 0 - 1.8 mm (0” - 0.07”).
- Sensor signal: generates a square current with a fixed amplitude changing between 7 and 14 mA.
3.6 HYDRAULIC COOLER AND FILTER LINE SPECIFICATIONS

• Minimum 19 mm (.75”) internal diameter for lines and fittings.
• Suitable for operation from ambient to 120 °C (248 F) continuous operating temperature.
• Must withstand 20 bar (290 PSI) continuous pressure and with 40 bar (580 PSI) intermittent surges.
• Conform SAE J1019 and SAE J517, 100RI.
T12000 ID 04/99 3-5

5. INSTALLATION DETAILS
5.1 CONVERTER DRIVE COUPLING

Measure the “A” dimension (bolt circle diameter) and order drive plate kit listed below. Note three (3) kits
have two (2) intermediate drive plates and one (1) drive plate and weld nut assembly. Three (3) kits with
three intermediate drive plates.
ALIGNMENT HOLES
(1) DRIVE PLATE AND

WELD NUT ASSEMBLY
A
A
BOLT CIRCLE DIA. BOLT CIRCLE DIA.

BACKING RING (2) INTERMEDIATE DRIVE PLATES BACKING RING (3) INTERMEDIATE DRIVE PLATES
“A” Dimension (Bolt circle diameter) “A” Dimension (Bolt circle diameter)
• 11.380” (288.900 mm) diameter • 11.380” (288.900 mm) diameter
Kit No. 802501. Kit No. 802543.
Kit No. 802424. Kit No. 802426.
Kit No. 802425. Kit No. 802427.
Each kit will include the following parts: Each kit will include the following parts:
• 2 Intermediate drive plates. • 3 Intermediate drive plates.
• 1 Drive plate and weld nut assembly. • 1 Backing ring.
• 1 Backing ring. • 6 Mounting screws.
• 6 Mounting screws. • 6 Lockwashers.
• 6 Lockwashers. • 1 Instruction sheet.
• 1 Instruction sheet.
Note
TO FACILITATE ASSEMBLY, ALIGN SMALL HOLES IN DRIVE PLATES - SEE ILLUSTRATION ABOVE - ALIGNMENT HOLES.
Position drive plate and weld nut assembly on torque converter assembly with weld nuts toward converter.
Align intermediate drive plates and backing plate with holes in torque converter assembly.
Note
TWO DIMPLES 180° APART IN BACKING RING MUST BE OUT TOWARD ENGINE FLYWHEEL
(HOLLOW SIDE FACING TORQUE CONVERTER ASSEMBLY). INSTALL CAP SCREWS AND LOCKWASHERS.
TIGHTEN CAP SCREWS TORQUE 35 - 39 N.M. (26 - 29 LB. FT.).
T12000 ID 04/99 5-1

Installation details
5.2 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE
1. Remove all burrs from flywheel mounting face and

nose pilot bore. Clean drive plate surface with FLYWHEEL HOUSING MOUNT
DIAL INDICATOR
solvent. HERE
2. Check engine flywheel & housing for conformance

ENGINE
to standard SAE No. 3 per SAE J927 and J1033
tolerance specifications for pilot bore size, pilot
FLYWHEEL
bore runout and mounting face flatness. Measure PILOT BORE
and record engine crankshaft end play (Fig. 1).

3. Install two 63,50 mm (2.50”) long transmission to FLYWHEEL
flywheel housing guide studs in the engine

flywheel housing as shown. Rotate the engine FIG. 1
flywheel to align a drive plate mounting screw hole
with the flywheel housing access hole
(Fig. 2).
*4. Install a 101,60 mm (4.00”) long drive plate
locating stud .3750-24 fine thread in a drive plate
FLYWHEEL HOUSING CONVERTER HOUSING
nut. Align the locating stud in the drive plate with
the flywheel drive plate mounting screw hole
positioned in step No. 3.
4"STUD
5. Rotate the transmission torque converter to align
the locating stud in the drive plate with the flywheel
drive plate mounting screw hole positioned in step 21/2"ALIGNING
No. 3. Locate transmission on flywheel housing. STUDS
DRIVE
FLYWHEEL
Aligning drive plate to flywheel and transmission PLATE
to flywheel housing guide studs. Install

transmission to flywheel housing screws. Tighten FIG. 2
screws to specified torque. Remove transmission
to engine guide studs. Install remaining screws
and tighten to specified torque.
SPECIAL STUD, WASHER AND
*6. Remove drive plate locating stud. FLYWHEEL HOUSING
SELF LOCK NUT FURNISHED
BY ENGINE MANUFACTURER.
7. Install drive plate attaching screw and washer.

Snug screw but do not tighten. Some engine
flywheel housings have a hole located on the FLYWHEEL
flywheel housing circumference in line with the

IMPELLER
drive plate screw access hole. A screwdriver or COVER
pry bar used to hold the drive plate against the
flywheel will facilitate installation of the drive plate INTERMEDIATE
DRIVE PLATES
screws. Rotate the engine flywheel and install the
remaining seven (7) flywheel to drive plate
attaching screws. Snug screws but do not tighten.
After all eight (8) screws are installed. FIG. 3 FIG.4
Torque each one 35 to 39 N.m. (26- 29ft.lbs.).

This will require tightening each screw and rotating PLATES TO BE INSTALLED
WITH CONCAVE SIDE
the engine flywheel until the full amount of eight TOWARD ENGINE FLYWHEEL
(8) screws have been tightened to specified

torque.
8. Measure engine crankshaft end play after
transmission has been completely installed on
engine flywheel. This value must be within FIG. 5
0,025 mm (0.001”) of the end play recorded in
step No. 2.
* Does not apply to units having 3 intermediate drive
plates. See Fig.4.
T12000 ID 04/99 5-2

5.4 SPEED SENSOR INSTALLATION
On the sensor body there is a small plastic triangular position

sign. Make sure the position sign on the sensor points as shown
Position sign
below in the direction of the movement of the gearteeth (Teeth
rotation as shown).
Teeth rotation
1.65
(42.0)
Screw
Tighten to 5.9 - 7.4 lbf-ft
Position sign (8 - 10 Nm) Plug Screw
"O"-ring Support "O"-ring (8 - 10 Nm)
Sensor installed Hole plugged
Sensor position on transmission

Turbine speed sensor location
T12000 ID 04/99 5-4

5.4 SPEED SENSOR INSTALLATION (Continued)
Position sign
Pin 2 ( - ) Pin 1 ( + )
The magneto resistive sensor generates a square wave current with a fixed amplitude changing
between 7 mA and 14 mA.
The sensor has an integrated AMP superseal 2 pin connector.
The two pins are numbered 1 and 2.
Following table shows the relation between wire colour, pin number and connection.
COLOUR PIN NUMBER FUNCTION CONNECTION

BROWN 1 Current input Hot wire
BLUE 2 Current output Ground wire
Note
THE SENSOR WIRES HAVE A POLARITY.
BE SURE TO CORRECTLY OBSERVE SENSOR POLARITIES, AS WRONG CONNECTIONS WILL DEACTIVATE THE SENSOR !
T12000 ID 04/99 5-5

6. OPERATION OF THE TRANSMISSION
6.1 THE TRANSMISSION ASSEMBLY
Basically the transmission is composed of five main assemblies:

1. The converter, pump drive section and pressure regulating valve.
2. The input shaft and directional clutches.
3. The range clutches.
4. The output section.
5. The transmission solenoids.
REV FWD
4TH-HI 3RD
1ST 2ND
3RD
T12000 ID 04/99 6-1

Operation of the transmission
6.1.1 The converter, pump drive section and pressure regulating valve
Engine power is transmitted from the engine flywheel to the impeller through the impeller cover.
This element is the pump portion of the hydraulic torque converter and is the primary component which starts
the oil flowing to the other components which results in torque multiplication. This element can be compared
to a centrifugal pump, that picks up fluid at its centre and discharges it at the outer diameter.
The torque converter turbine is mounted opposite the impeller and is connected to the turbine shaft of the
torque converter. This element receives fluid at its outer diameter and discharges it at its centre.
The reaction member of the torque converter is located between and at the centre of the inner diameters of
the impeller and turbine elements. Its function is to take the fluid which is exhausting from the inner portion of
the turbine and change its direction to allow correct entry for recirculation into the impeller element.
This recirculation will make the converter to multiply torque.
The torque multiplication is function of the blading (impeller, turbine and reaction member) and the converter
output speed (turbine speed). The converter will multiply engine torque to its designed maximum multiplication
ratio when the turbine shaft is at zero RPM (stall).
Therefore we can say that as the turbine shaft is decreasing in speed, the torque multiplication is increasing.
The hydraulic pump is connected with the pump drive gear. This pump drive gear is driven by the impeller hub
gear. Since the impeller hub gear is connected with the impeller cover, the pump speed is in direct relation
with the engine speed.
Note
THE PRESSURE REGULATOR VALVE IS MOUNTED BEHIND THE FILTER, IN THE FILTER ADAPTER HOUSING.
REV FWD
4TH-HI 3RD
1ST 2ND
3RD
THE CONVERTER, PUMP DRIVE SECTION AND PRESSURE REGULATING VALVE
T12000 ID 04/99 6-2

6.1.2 The input shaft and directional clutches

The turbine shaft driven from the turbine transmits power to the forward, 4th-High or reverse clutch.
These clutches consist of a drum with internal splines and a bore to receive a hydraulic actuated piston.
The piston is oil tight by the use of sealing rings. The steel discs with external splines, and friction discs
with internal splines, are alternated until the required total is achieved.
A back-up plate is then inserted and secured with a retainer ring. A hub with outer diameter splines is
inserted into the splines of discs with teeth on the inner diameter. The discs and hub are free to increase in
speed or rotate in the opposite direction as long as no pressure is present in that specific clutch.
To engage the clutch, the solenoid will direct oil under pressure through tubes and passages to the selected
clutch shafts.
Oil sealing rings are located on the clutch shafts. These rings direct the oil through a drilled passage in the
shaft to the desired clutch.
Pressure of the oil forces the piston and discs against the back-up plate. The discs with splines on the outer
diameter clamping against discs with teeth on the inner diameter enables the drum and hub to be locked
together and allows them to drive as one unit.
When the clutch is released, a return spring will push the piston back and oil will drain back via the solenoid,
the bleed valve or holes in the clutch piston into the transmission sump.
These bleed valves will only allow quick escape of oil when the pressure to the piston is released.
The T12000 transmission, 3-speed version, has one reverse clutch and one forward clutch. This in combination
with the 3 range clutches results in the transmission having 3 forward and 3 reverse speeds.
The T12000 transmission, 4- and 6-speed versions, have one reverse clutch and two forward clutches (forward
and 4th-High). This in combination with the 3 range clutches results in the transmission having 4 forward (for
the 4-speed) or 6 forward (for the 6-speed) and 3 reverse speeds.
The engagement of the directional clutches (forward and reverse) are modulated. This means that clutch
pressure is built up gradually. This will enable the unit to make forward, reverse shifts while the vehicle is still
moving and will allow smooth engagement of drive. The modulation is done hydraulically.
REV FWD
4TH-HI 3RD
1ST 2ND
3RD
THE INPUT SHAFT AND DIRECTIONAL CLUTCHES
T12000 ID 04/99 6-3

6.1.3 The range clutches

Once a directional clutch is engaged power is transmitted to the range clutches (1st, 2nd or 3rd).
Operation and actuation of the range clutches is similar to the directional clutches.
The engagement of the range clutches is not modulated.
6.1.4 The output section

With a range clutch engaged, power is finally transmitted to the output shaft.
Output rotation is same as the engine rotation when the forward clutch is engaged.
A front axle disconnect is optional and is located on the output shaft. The drive to the front axle can be
disconnected or connected by manual shifting.
REV FWD REV FWD
4TH-HI 3RD 4TH-HI 3RD
1ST 2ND 1ST 2ND
3RD 3RD
THE RANGE CLUTCHES THE OUTPUT SECTION
T12000 ID 04/99 6-4

6.1.5 The transmission controls (refer to hydraulic diagram)

The transmission is controlled by the direction and range solenoids. The solenoids are mounted on the left
side of the transmission case. When the selected direction and range solenoids are energised, oil under
pressure will flow through tubes and passages to the selected clutch shafts. Oil sealing rings are located on
the clutch shafts. These rings direct oil under pressure through a drilled passage way in the shaft to the
desired clutch.
Reverse solenoid R
Forward solenoid F
Splitter solenoid S
1st solenoid 1
2nd solenoid 2
Rear view
THE TRANSMISSION CONTROLS
T12000 ID 04/99 6-5

6.2 ELECTRIC SOLENOID CONTROLS
6.2.2 4-speed transmission
6.2.2.1 Standard 4-speed transmission (1, 3, 5, 6 ≈ 6-speed)
Transmission gear Activated solenoids Activated clutches
Forward 4 Forward, Splitter 4th-High, 3rd

Forward 3 Forward Forward, 3rd
Forward 2 Forward, 2nd Forward, 2nd
Forward 1 Forward, 1st, 2nd Forward, 1st
Neutral 3 — 3rd
Neutral 2 2nd 2nd
Neutral 1 1st, 2nd 1st
Reverse 3 Reverse Reverse, 3rd

Reverse 2 Reverse, 2nd Reverse, 2nd
Reverse 1 Reverse, 1st, 2nd Reverse, 1st
T12000 ID 04/99 6-6

6.3 POWERFLOWS, ACTIVATED SOLENOIDS AND HYDRAULIC CIRCUIT

6.3.2 4-Speed transmission
6.3.2.1 Standard 4-speed transmission
6.3.2.1.1 Neutral and 3rd clutch engaged
REV FWD
NEUTRAL 3rd (POWERFLOW)
4TH-HI 3RD
1ST 2ND
3RD
NEUTRAL 3rd (ACTIVATED SOLENOIDS)
T12000 ID 04/99 6-18

T12000 TRANSMISSION - HYDRAULIC DIAGRAM OPERATOR COMPARTMENT
STANDARD 4 SPEED TRANSMISSION PRESSURE TEMPERATURE : PRESSURE
X
GAUGE GAUGE CHECK PORT
NEUTRAL AND 3RD CLUTCH ENGAGED bar
T12000 ID
X : TEMPERATURE
°C CHECK PORT
SAFETY VALVE
8.27 - 10.2 BAR
CRACKING PRESSURE
32 CC AA 33 71
bar °C °C bar °C
LUBRICATION
4TH-HIGH
AND RANGE
CLUTCHES
HOSE COOLER HOSE TORQUE

LUBRICATION CONVERTER
FORWARD AND
REVERSE CLUTCH
PRESSURE MODULATION MODULATION
REGULATOR VALVE VALVE
VALVE
16.5 - 19.3 bar
AT 1800 RPM
31
bar
04/99
6.3.2.1.1 Neutral and 3rd clutch engaged (continued)
1ST 2ND FORWARD SPLITTER REVERSE

SOLENOID SOLENOID SOLENOID SOLENOID SOLENOID
BY-PASS FILTER
VALVE
2.1 - 3.5 bar
PUMP
41 42 43 44 45 46
bar bar bar bar bar bar
AIR
BREATHER
1ST 2ND 3 RD 4TH- HIGH FORWARD REVERSE
SCREEN CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH
OIL SUMP
6-19
6.3.2.1.2 Forward 1st speed
REV FWD
FORWARD 1st (POWERFLOW)
4TH-HI 3RD
1ST 2ND
3RD
FORWARD 1st (ACTIVATED SOLENOIDS)
T12000 ID 04/99 6-20

X
bar
T12000 ID
FORWARD 1ST SPEED
X : TEMPERATURE
°C CHECK PORT
SAFETY VALVE
8.27 - 10.2 BAR
CRACKING PRESSURE
32 CC AA 33 71
bar °C °C bar °C
LUBRICATION
4TH-HIGH
AND RANGE
CLUTCHES

FORWARD AND
6.3.2.1.2 Forward 1st speed (continued)
REVERSE CLUTCH
VALVE
16.5 - 19.3 bar
AT 1800 RPM
31
bar
04/99
BY-PASS FILTER
VALVE
2.1 - 3.5 bar
PUMP
41 42 43 44 45 46
AIR
BREATHER
1ST 2ND 3 RD 4TH-HIGH FORWARD REVERSE
OIL SUMP
6-21
6.3.2.1.3 Forward 2nd speed
REV FWD
FORWARD 2nd (POWERFLOW)
4TH-HI 3RD
1ST 2ND
3RD
FORWARD 2nd (ACTIVATED SOLENOIDS)
T12000 ID 04/99 6-22

X
bar
T12000 ID
FORWARD 2ND SPEED
X : TEMPERATURE
°C CHECK PORT
SAFETY VALVE
8.27 - 10.2 BAR
CRACKING PRESSURE
32 CC AA 33 71
bar °C °C bar °C
LUBRICATION
4TH-HIGH
AND RANGE
CLUTCHES

FORWARD AND
REVERSE CLUTCH
6.3.2.1.3 Forward 2nd speed (continued)

VALVE
16.5 - 19.3 bar
AT 1800 RPM
31
bar
04/99
BY-PASS FILTER
VALVE
2.1 - 3.5 bar
PUMP
41 42 43 44 45 46
AIR
BREATHER
OIL SUMP
6-23
6.3.2.1.4 Forward 3rd speed
REV FWD
FORWARD 3rd (POWERFLOW)
4TH-HI 3RD
1ST 2ND
3RD
FORWARD 3rd (ACTIVATED SOLENOIDS)
T12000 ID 04/99 6-24

X
bar
T12000 ID
FORWARD 3RD SPEED
X : TEMPERATURE
°C CHECK PORT
SAFETY VALVE
8.27 - 10.2 BAR
CRACKING PRESSURE
32 CC AA 33 71
bar °C °C bar °C
LUBRICATION
4TH-HIGH
AND RANGE
CLUTCHES

FORWARD AND
6.3.2.1.4 Forward 3rd speed (continued)
REVERSE CLUTCH
VALVE
16.5 - 19.3 bar
AT 1800 RPM
31
bar
04/99
BY-PASS FILTER
VALVE
2.1 - 3.5 bar
PUMP
41 42 43 44 45 46
AIR
BREATHER
1ST 2ND 3 RD 4TH-HIGH FORWARD REVERSE
OIL SUMP
6-25
6.3.2.1.5 Forward 4th speed
REV FWD
FORWARD 4th (POWERFLOW)
4TH-HI 3RD
1ST 2ND
3RD
FORWARD 4th (ACTIVATED SOLENOIDS)
T12000 ID 04/99 6-26

X
bar
T12000 ID
FORWARD 4TH SPEED
X : TEMPERATURE
°C CHECK PORT
SAFETY VALVE
8.27 - 10.2 BAR
CRACKING PRESSURE
32 CC AA 33 71
bar °C °C bar °C
LUBRICATION
4TH-HIGH
AND RANGE
CLUTCHES

FORWARD AND
6.3.2.1.5 Forward 4th speed (continued)
REVERSE CLUTCH
VALVE
16.5 - 19.3 bar
AT 1800 RPM
31
bar
04/99
BY-PASS FILTER
VALVE
2.1 - 3.5 bar
PUMP
41 42 43 44 45 46
AIR
BREATHER
OIL SUMP
6-27
6.3.2.1.6 Reverse 1st speed
REV FWD
REVERSE 1st (POWERFLOW)
4TH-HI 3RD
1ST 2ND
3RD
REVERSE 1st (ACTIVATED SOLENOIDS)
T12000 ID 04/99 6-28

X
bar
T12000 ID
REVERSE 1ST SPEED
X : TEMPERATURE
°C CHECK PORT
SAFETY VALVE
8.27 - 10.2 BAR
CRACKING PRESSURE
32 CC AA 33 71
bar °C °C bar °C
LUBRICATION
4TH-HIGH
AND RANGE
CLUTCHES

FORWARD AND
6.3.2.1.6 Reverse 1st speed (continued)
REVERSE CLUTCH
VALVE
16.5 - 19.3 bar
AT 1800 RPM
31
bar
04/99
BY-PASS FILTER
VALVE
2.1 - 3.5 bar
PUMP
41 42 43 44 45 46
AIR
BREATHER
OIL SUMP
6-29
6.4 GEAR AND CLUTCH LAY-OUT (4-SPEED AND 6-SPEED)
2
1 F
R2
1 3
4igh put
H Out
t
pu
In
put
Out
Reverse and Forward
1st and 2nd
Reverse idler
4th-High & 3rd
Output Section
T12000 ID 04/99 6-59

7. TROUBLESHOOTING GUIDE FOR THE T12000 TRANSMISSION
The following information is presented as an aid to isolating and determining the specific problem area in a
transmission that is not functioning correctly.
When troubleshooting a “transmission” problem, it should be kept in mind that the transmission is only the
central unit of a group of related powertrain components. Proper operation of the transmission depends on
the condition and correct functioning of the other components of the group. Therefore, to properly diagnose
a suspected problem in the transmission, it is necessary to consider the transmission fluid, charging pump,
torque converter, transmission assembly, oil cooler, filter, connecting lines, and controls, including the engine,
as a complete system.
By analysing the principles of operation together with the information in this section, it should be possible to
identify and correct any malfunction which may occur in the system.
7.1 T12000 TRANSMISSION

T12000 (power shift with torque converter transmission) troubles fall into three general categories:
1. Mechanical problems.
2. Hydraulic problems.
3. Electrical problems.
In addition to the mechanical and electrical components, all of which must be in the proper condition and
functioning correctly, the correct functioning of the hydraulic circuit is most important. Transmission fluid is
the “life blood” of the transmission. It must be supplied in an adequate quantity and delivered to the system
at the correct pressures to ensure converter operation, to engage and hold the clutches from slipping, and to
cool and lubricate the working components.
7.2 TROUBLESHOOTING PROCEDURES
7.2.1 Stall Test

A stall test to identifies transmission, converter, or engine problems.
Use following procedure:
1. Put the vehicle against a solid barrier, such as a wall, and/or apply the parking brake and block the
wheels.
2. Put the directional control lever in FORWARD (or REVERSE, as applicable).
3. Select the highest speed.
With the engine running, slowly increase engine speed to approximately one-half throttle and hold until
transmission (converter outlet) oil temperature reaches the operating range.
CAUTION
DO NOT OPERATE THE CONVERTER AT STALL CONDITION LONGER THAN 30 SECONDS AT ONE TIME, SHIFT TO NEUTRAL
FOR15 SECONDS AND REPEAT THE PROCEDURE UNTIL DESIRED TEMPERATURE IS REACHED.
EXCESSIVE TEMPERATURE 120 °C (250 F) MAXIMUM WILL CAUSE DAMAGE TO TRANSMISSION CLUTCHES, FLUID,
CONVERTER, AND SEALS.
T12000 ID 04/99 7-1

Troubleshooting guide
7.2.2 Transmission pressure checks

Transmission problems can be isolated by the use of pressure tests. When the stall test indicates slipping
clutches, then measure clutch pack pressure to determine if the slippage is due to low pressure or clutch
plate friction material failure.
In addition, converter charging pressure and transmission lubrication pressure can also be measured.
7.2.3 Mechanical and electrical checks

Prior to checking any part of the system for hydraulic function (pressure testing), the following mechanical
and electrical checks should be made:
• Check the parking brake and inching pedal for correct adjustment.
• Be sure all lever linkage is properly connected and adjusted in each segment and at all connecting points.
• The controls are actuated electrically. Check the wiring and electrical components.
• Be sure that all components of the cooling system are in good condition and operating correctly.
The radiator must be clean to maintain the proper cooling and operating temperatures for the engine and
transmission. Air clean the radiator, if necessary.
• The engine must be operating correctly. Be sure that it is correctly tuned and adjusted to the correct idle
and maximum no-load governed speed specifications.
7.2.4 Hydraulic checks

Also, before checking the transmission clutches, torque converter, charging pump, and hydraulic circuit for
pressure and rate of oil flow, it is important to make the following transmission fluid check:
Check oil level in the transmission. The transmission fluid must be at the correct (full level).
All clutches and the converter and its fluid circuit lines must be fully charged (filled) at all times.
Note
THE TRANSMISSION FLUID MUST BE AT OPERATING TEMPERATURE OF 82 - 93 °C (180 - 200 F) TO OBTAIN
CORRECT FLUID LEVEL AND PRESSURE READINGS.
DO NOT ATTEMPT TO MAKE THESE CHECKS WITH COLD OIL.
To raise the oil temperature to this specification it is necessary to either operate (work) the vehicle or run the
engine with converter at “stall” (Refer to 7.2.1 “Stall test”).
CAUTION
BE CAREFUL THAT THE VEHICLE DOES NOT MOVE UNEXPECTEDLY WHEN OPERATING THE ENGINE AND
CONVERTER AT STALL RPM.
T12000 ID 04/99 7-2

7.3 TROUBLESHOOTING GUIDE

Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles.
7.3.1 Low clutch pressure
CAUSE REMEDY
1. Low oil level. 1. Fill to proper level.
2. Clutch pressure regulating valve stuck open. 2. Clean valve spool and housing.
3. Faulty charging pump. 3. Replace pump.
4. Broken or worn clutch shaft or piston sealing rings. 4. Replace sealing rings.
5. Clutch piston bleed valve stuck open. 5. Clean bleed valves thoroughly.
7.3.2 Low charging pump output
CAUSE REMEDY
2. Suction screen plugged. 2. Clean suction pump.
3. Defective charging pump. 3. Replace pump.
7.3.3 Overheating
Cause Remedy
1. Worn oil sealing rings. 1. Remove, disassemble, and rebuild converter
assembly.
2. Worn charging pump. 2. Replace charging pump.
4. Dirty oil cooler. 4. Clean cooler.
5. Restriction in cooler lines. 5. Change cooler lines.
7.3.4 Noisy converter
Cause Remedy
1. Worn charging pump. 1. Replace charging pump.
2. Worn or damaged bearings. 2. A complete disassembly will be necessary to
determine which bearing is faulty.
7.3.5 Lack of power
Cause Remedy
1. Low engine RPM at converter stall. 1. Tune engine check governor.
2. See “Overheating” and make same checks. 2. Make corrections as explained in “Overheating”.
T12000 ID 04/99 7-3

7.4 CHECK POINTS
Magnet drain plug

3/4-14 NPSF THD
FRONT VIEW
TURBINE SPEED SENSOR

CLUTCH DRUM GEAR
FULL OIL LEVEL

CHECK PORT FULL
.4375-20 UNF-2B THD

LOW
SAE "O"-RING PORT
LOW OIL LEVEL
CHECK PORT
.4375-20 UNF-2B THD
SAE "O"-RING PORT
REAR VIEW
T12000 ID 04/99 7-4

7.4 CHECK POINTS (CONTINUED)
PORT 12
FROM COOLER
1.0625- 12 UN -2B
SAE "O"-RING PORT
PORT 41
CHECK PORT - 1ST CLUTCH PRESSURE
.3750- 24 UNF -2B
SAE "O"-RING PORT
PORT 42
CHECK PORT 2ND CLUTCH PRESSURE
.3750- 24 UNF -2B
SAE "O"-RING PORT
PORT 71
TEMPERATURE CHECK PORT
CONVERTER OUT
1/4-18 NPTF
PORT 43
CHECK PORT - 3RD CLUTCH PRESSURE
.3750- 24 UNF -2B
SAE "O"-RING
RIGHT SIDE VIEW
PORT 11
TO COOLER
.8750- 14 UNF -2B
SAE "O"-RING PORT
PORT 31
CLUTCH PRESSURE
1/8 - 27 NPTF BREATHER
PORT 45
CHECK PORT - FORWARD PRESSURE
.3750- 24 UNF -2B
SAE "O"-RING PORT
PORT 46
CHECK PORT - REVERSE PRESSURE
.3750- 24 UNF -2B
SAE "O"-RING
PORT 44
CHECK PORT - 4TH HIGH PRESSURE
.3750- 24 UNF -2B
SAE "O"-RING PORT
LEFT SIDE VIEW
T12000 ID 04/99 7-5

7.4 CHECK POINTS (CONTINUED)
PORT 33
PRESSURE CHECK PORT
PORT 31 FROM COOLER
CLUTCH PRESSURE .3750-24UNF-2B
.3750-24 UNF 2B SAE "O"-RING PORT
SAE "O"-RING PORT
LIFTING EYE LOCATION
.5000-13 UNC-3B THD
PORT 32 DEEP .88 (22.4)
PRESSURE CHECK PORT
TO COOLER OIL FILL HOLE
1/8-27 NPTF 3/4-14 NPSF THD
TOP VIEW
T12000 ID 04/99 7-6

7.6 SPEED SENSOR - STATIC STANDALONE TEST
In order to be able to sense the currents, a series resistor of e.g. 200 Ohms must be used. This resistor is
integrated in the controller, but when the sensor is to be tested, it must be connected externally.
The idea is to connect the sensor to an external power source and measure the DC voltage across the series
resistor.
The voltage reading should be either 1.2V-1.6V (for the 7mA ± 1mA current level) or 2.6-3.0V
(for the 14mA ± 1mA current level)
If the teeth can be moved slowly, distinct toggling between the two levels should be noticed.
T12000 ID 04/99 7-11

8. SECTIONAL VIEWS AND PARTS IDENTIFICATION
T12000 ID 04/99 8-1

GROUP - CONVERTER HOUSING
14
5
1 6
7 4
2
3
11
9
13
12
11
10
8
11
15 3
8-2 04/99 T12000 ID

GROUP - CONVERTER HOUSING
Item Description Quantity
1 Housing - Converter 1
2 Plug 4
3 “O”-ring 4
4 Plug 1
5 Plug 1
6 “O”-ring 1
7 Plug 1
8 Screw - Converter housing to plate 6
11 Lockwasher - Converter housing to plate screw 10
12 Screw - Converter housing to transmission case 13
13 Lockwasher - Converter housing to transmission case screw 13
14 Gasket - Converter housing to plate 1
15 Plug 1
T12000 ID 04/99 8-3

GROUP - TRANSMISSION CASE AND PLATE
7
31
29 24
30 10 28
25
13
12
27
38
32
21 33
19
31 17
18
11 29
14 1 30 16
21 23
2
15
21
20
19
6
18
6 3 17
4
26
35
34
5
37 22
36
9
8-4 04/99 T12000 ID

GROUP -TRANSMISSION CASE AND PLATE
1 Case - Transmission 1
2 Breather - Air 1
3 Plug - Oil level 1
4 “O”-ring 1
5 Plug - Magnetic drain 1
6 Pin - Plate to transmission case dowel 2
7 Gasket - Plate to transmission case 1
8 Ring - Oil supply tube seal 1
9 Clip - Oil supply tube retainer 1
10 Spacer - Plate 1
11 Seat - Safety valve 1
12 Snap ring - Seat 1
13 Poppet - Converter safety valve 1
14 Spring - Converter safety valve 1
15 Washer - Poppet retaining 1
16 Plug 1
17 Plug 3
18 “O”-ring 3
19 Screw - Plate to transmission case 7
20 Screw - Plate to transmission case 2
21 Lockwasher - Plate to transmission case screw 9
22 Assembly - Tube & screen 1
23 Plug - Filler 1
24 Plug 1
25 Plug 1
26 Plug - Drain back port 1
27 Tube - Dipstick 1
28 Assembly - Dipstick 1
29 Plug - Speed sensor port 2
30 “O”-ring - Speed sensor 2
31 Screw - Speed sensor 2
32 Screw - Baffle hole 1
33 Washer - Baffle seal 1
34 Screw 1
35 Washer - Seal 1
36 Washer 1
37 Nut 1
38 Plug - Dipstick hole 1
T12000 ID 04/99 8-5

GROUP - TORQUE CONVERTER
8
13
10
11
13
6
9
4 14
12 2
16 5
6
15
8-6 04/99 T12000 ID

GROUP - TORQUE CONVERTER
1 Stator support 1
2 Bushing 1
3 Bearing 1
4 Ring - Stator support piston 1
5 Expander - Stator support piston ring 1
6 Snap ring - Stator support 2
7 Seal - Converter housing oil 1
8 Assembly - Torque converter 1
9 Plug - Torque converter 1
10 “O”-ring - Torque converter plug 1
11 Snap ring - Torque converter plug 1
12 Gear - Impeller hub 1
13 Snap ring - Impeller hub 2
14 Washer - Impeller hub gear 1
15 Bearing - Torque converter 1
16 Ring - Oil distributor 1
T12000 ID 04/99 8-7

GROUP - PUMP DRIVE
6
1
4
6
2
8-8 04/99 T12000 ID

GROUP - PUMP DRIVE
1 Shaft - Pump drive idler & pilot 1

2 Pin - Roll 1
3 Gear - Pump drive idler 1
4 Bearing - Idler gear 1
5 Gear - Pump drive 1
6 Washer - Pump drive idler thrust 2
7 Snap ring - Pump drive gear retaining 1
T12000 ID 04/99 8-9

GROUP - CHARGING PUMP
14 13
15
1
12 2
16
17
11
5
7 10 6
8
4
9
8-10 04/99 T12000 ID

GROUP - CHARGING PUMP
1 Assembly - Charge pump 1

2 Assembly - Hydraulic spin filter 1
3 Sleeve - Regulator valve 1
4 Piston - Regulator valve 1
5 Spring - Regulator valve 1
6 Pin 1
7 Body - Check valve 1
8 Ball 1
9 Spring - Check valve 1
10 Pin - Check valve 1
11 “O”-ring 1
12 Gasket - Charging pump 1
13 Screw - Pump mounting 4
15 Lockwasher - Pump mounting screw 5
17 Lockwasher - Pump mounting screw 1
T12000 ID 04/99 8-11

GROUP - REVERSE IDLER
6
7
5
9
3
4 8
8-12 04/99 T12000 ID

GROUP - REVERSE IDLER
1 Shaft - Idler & pilot 1

2 Snap ring - Idler shaft 1
3 Bearing - Reverse idler gear 1
4 Washer - Thrust 1
5 Plate - End 1
6 Capscrew - Reverse idler end plate 1
7 Washer - End plate cap screw 1
8 Roll pin - End plate to shaft 1
9 Gear - Reverse idler 1
T12000 ID 04/99 8-13

GROUP - FORWARD AND REVERSE SHAFT
21 11
19
20
19
17 14 13
16 11
17 15
10
5
8 12
9
17 rse 18
16 eve
17 R
16
19
1 6 19
7
6 7 22
17
5 17 17
9 17 20
10
8
3
16
15
ward
r
Fo 2
13 14 4
12
8-14 04/99 T12000 ID

GROUP - FORWARD AND REVERSE SHAFT
1 Assembly - Turbine shaft, drum & plug 1

2 Sleeve - Oil distributor 1
3 Screw - Retainer 1
4 Ring - Piston 3
5 Piston - Clutch 2
6 Seal - Clutch piston (Outer) 2
7 Seal - Clutch piston (Inner) 2
8 Plate - End 2
9 Snap ring - End plate 2
10 Plate - Clutch piston wear 2
11 Assembly - Disc spring 2
12 Retainer - Snap ring 2
13 Snap ring - retainer 2
14 Disc - Outer (6 forward - 6 reverse) 12
15 Disc - Inner (6 forward - 6 reverse) 12
16 Bearing - Clutch gear thrust 4
17 Washer - Clutch gear thrust 8
18 Bearing - Turbine shaft rear 1
19 Bearing 4
20 Spacer 2
21 Gear - Reverse clutch 1
22 Gear - Forward clutch 1
T12000 ID 04/99 8-15

GROUP - HIGH (4TH) AND 3RD SHAFT
19
11 20
12
23
29
15
4 16
3
8
gh
23 - Hi
7 h 9
6 4t
5 21
10
27 1
25
22
21 9 10
8 21
24 23
17 16
22 15
18 14
13 22
19 20
3rd
18
17
23
21
28
26
2
22
8-18 04/99 T12000 ID

GROUP - HIGH (4TH) AND 3RD SHAFT
1 Assembly - High and 3rd shaft, drum and plug 1

2 Bearing - Roller 1
3 Assembly - Bearing and seal 1
4 Washer - Bearing support 1
6 Screw - Sleeve retaining 1
7 Ring - Piston 2
8 Clutch - Piston 2
11 Disc (Outer) Hi 6
12 Disc (Inner) Hi 6
13 Disc (Outer) 3rd 5
14 Disc (Inner) 3rd 5
15 Plate - End 2
20 Snap ring - Retainer 2
21 Bearing - thrust needle roller 4
23 Snap ring - Gear hub 5
24 Bearing - 4th clutch gear 2
25 Spacer 1
26 Bearing - 3rd clutch gear 2
27 Gear 4th clutch 1
28 Gear 3rd clutch 1
29 Gear - First drive 1
T12000 ID 04/99 8-19

GROUP - 1ST AND 2ND SHAFT
25
12
24
13
15
20 14
3
21
13
4
19 18
16 11
10
8
5
9 t)
(1s 6
27
w
Lo
15
1 17
15
7 26 24
16 6 7
5
15 16
10
9
8
23 16
22
2
14
d
2n
8-20 04/99 T12000 ID

GROUP - 1ST AND 2ND SHAFT
1 Assembly 1st and 2nd shaft, drum, plug and seat 1

2 Bearing - Roller 1
3 Assembly - Bearing and seal 1
4 Ring - Piston 2
5 Piston - Clutch 2
8 Plate - End 2
14 Snap ring - Retainer 2
15 Bearing - Clutch gear thrust 4
17 Snap ring - 2nd clutch gear hub 2
19 Screw - Sleeve retaining 1
20 Disc (Outer) 1st 10
21 Disc (Inner) 1st 10
22 Disc (Outer) 2nd 5
23 Disc (Inner) 2nd 5
24 Bearing 4
25 Gear - 1st clutch 1
26 Gear - 2nd clutch 1
27 Gear - 3rd driven 1
T12000 ID 04/99 8-21

GROUP - OUTPUT SHAFT (FRONT & REAR)
10
7
7
6
2
3
5
4
6
8
1
9
6
4
5
3
2
6
8-26 04/99 T12000 ID

GROUP - OUTPUT SHAFT (FRONT & REAR)
1 Shaft - Output 1
2 Bearing - Output shaft 2
3 Sleeve - Oil seal 2
4 “O”-ring - Oil seal sleeve 2
5 Seal - Output shaft oil 2
6 Snap ring - Output shaft bearing 4
7 Snap ring - Gear & bearing retaining 2
8 Flange - Output 1
9 Plug - Flange 1
10 Gear - Output shaft 1
T12000 ID 04/99 8-27

GROUP - ELECTRIC CONTROL
14
22
15
25
21
26
24
16
23
17
27 19
18 20
28
11
13
12
3 4
5 6
32 8
31
30 9
10
29 7
3
4
5
6
2
1 7
8
9
10
8-32 04/99 T12000 ID

GROUP - ELECTRIC CONTROL
1 Assembly - Solenoid cartridge 5*

2 Cartridge - Valve 4-way including items 3, 4, 5 and 6 5*
3 “O”-ring - Cartridge 5*
7 “O”-ring - Cartridge to coil 5*
8 Coil - Solenoid 5*
9 “O”-ring - Coil to nut 5*
10 Nut - Valve cartridge retainer 5*
11 Cover - Protective 1
12 Screw - Protective cover 2
13 Lockwasher - Protective cover screw 2
14 Housing - Modulation valve 2
15 “O”-ring - Modulation housing 2
16 Spring (Inner) 2
17 Spring (Middle) 2
18 Spring (Outer) 2
19 Sleeve - Modulation valve 2
20 “O”-Ring - Sleeve 2
21 Pin - Stop 2
22 Spool - Accumulator 2
23 Spool - Regulator 2
24 Spring - Modulation valve 2
25 Retainer - Spring 2
26 Spacer - Spring 2
27 Pin (Upper) 2
28 Pin (Lower) 2
29 Plug - Solenoid bore plug, used at forward high and low 1**
30 “O”-ring - Plug 1**
* - Quantity = 4, with 3-speed.

** - Used with 3-speed only.
T12000 ID 04/99 8-33

GROUP - DRIVE PLATE
5
4
8-34 04/99 T12000 ID

GROUP - DRIVE PLATE
1 Assembly - Drive plate and (when used) weld nut 1

2 Plate - Drive 2
3 Ring - Drive plate backing 1
4 Screw - Drive plate mounting 6
5 Lockwasher - Drive plate mounting screw 6
T12000 ID 04/99 8-35

9. ASSEMBLY INSTRUCTIONS
T12000 ID 04/99 9-1

Assembly instructions
9. ASSEMBLY INSTRUCTIONS (CONTINUED)

4 and 6-speed cross section
13 1
VIEW T
OIL FILTER
VIEW K
10 4
VIEW H REV FWD

7
4
6 2
7
4
11
4TH-HI 3RD VIEW F

3
10
6
8
5
1ST 2ND
2
3RD
2
EXPANDER
.13 (3.2) PISTON RING

5
VIEW K VIEW T
7
REVERSE IDLER ENLARGED VIEW OF SEAL
VIEW H VIEW F
T12000 ID 04/99 9-3

Filler Turbine speed Engine speed Charging pump

18 plug sensor location 23 21 21 sensor location SAE-A
22
15 B
Breather
30 B
23
14
Solenoid bore
plug 21
22
21
Charging pump
SAE-B optional
FULL
16
LOW
29
27
17
28
27
Charging pump
SAE-C optional
SECTION B-B
T12000 ID 04/99 9-4

20
20 20
20
20
19
17
TT
SECTION TT-TT TT
Mechanical disconnect
Front only - option
FRONT AND REAR OUTPUT WITH

BRAKE (OPTIONAL) AND DISCONNECT (OPTIONAL)
T12000 ID 04/99 9-5


Use Permatex and Loctite only where specified.
All lead in chamfers for oil seals, piston rings, and “O”-rings must be smooth and free from burrs.
Inspect before assembly.
Lubricate all piston ring grooves and “O”-rings with oil before assembly.
Apply a thin coat of grease between seal lips on lip type seals prior to assembly.
Apply a thin coat of Permatex No. 2 or Loctite No. 641 to O.D. of all oil seals before assembly.
Apply a thin coat of Loctite No. 592 or 506 Dryseal to all pipe plugs.
After assembly of parts using Loctite or Permatex, there must not be any free or excess material which might
enter the oil circuit.
1 Assemble oil filter and tighten to 20-25 lbf.ft [27-34 N.m].
2 Teflon seals must be sized prior to assembly.
3 10 outer steel plates, 10 inner plates, alternately assemble, starting with outer steel plate.
6 Shield bearing, assembly with shield as shown.
Add a coating of Loctite 641 to outer diameter of bearings.
7 Fwd. ,Rev., 2nd and 3rd. clutch return disc springs. Concave side of first disc spring to be placed
against clutch piston wear sleeve. Remaining four springs to be stacked alternately as shown.
8 Low clutch return disc springs concave side of first disc spring to be placed against clutch piston wear
sleeve. Remaining six springs to be stacked alternately as shown.
10 Clearance between clutch piston and steel seperator plate to be .048-.108 [1.22-2.74]. If over .108
[2.74] clearance, add one steel outer disc under end plate.
T12000 ID 04/99 9-6

11 Clearance between clutch piston and steel separator plate to be .080-.135 [2.03-3.43]. If over .135
[3.43] clearance, add one steel outer disc under end plate.
13 Tighten regulator sleeve to 45-50 lbf.ft [61-68 N.m].
14 Use solenoid bore plug in middle position for 3-speed version only.
15 Solenoid cartridge to be assembled and tightened to 16-20 lbf.ft [22-27 N.m].
16 Apply Loctite No. 243 to thread of disc mounting screws.
17 See page 4-4 for brake information.
18 Tighten modulation valve and inching valve to 60-65 lbf.ft [81-88 N.m].
19 M10 x 1.17 - 1.20. [M10 x 30].
20 M10 x 2.32 - 2.4. [M10 x 60].
21 Use 5/16-18 x 5.00 screw.
22 Use 5/16-18 x 3.500 screw.
23 Use 3/8-16 x 5.00 screw.
24 Use 5/16-18 x 3.250 screw.
25 Use 5/16-18 x 2.00 screw.
26 Use 3/8-18 x 3.250 screw.
27 Use 5/16-24 nut.
28 Use 5/16-24 nut.
29 Use 3/8-24 nut.
30 Tighten all cartridge nuts to 4-5 lbf.ft [5-7 N.m].
T12000 ID 04/99 9-7

10. Disassembly and reassembly of T12000 ID transmission
T12000 ID 04/99 10-1

Disassembly T12000 ID transmission
Figure 1 Figure 4
Side view of T12000 intermediate drop transmission. Remove torque converter plug retainer ring.
Figure 2 Figure 5
Rear view showing disc brake and electric control. Remove plug and “O”-ring.
Figure 3 Figure 6
Remove drive plate attaching capscrews and Remove torque converter to turbine shaft retainer
washers. Remove drive plate and backing ring. ring.
T12000 ID 04/99 10-2

Figure 7 Figure 10
Remove torque converter assembly. Remove charging pump permanent pump hole cover
(not used when auxiliary pump is used).
Figure 8 Figure 11
Remove torque converter to shaft locating ring. Remove pump mounting bolts and washers.
Remove pump and gasket.
Figure 9 Figure 12
Remove filter assembly. Remove pressure regulator and regulator
sleeve.
NOTE: special tool can be fabricated.
See Figure 427.
T12000 ID 04/99 10-3

Figure 13 Figure 16
Remove sensor port plug and “O”-ring. Remove impeller hub gear.
Figure 14 Figure 17
Remove converter housing to transmission case Remove pump drive idler gear washer.
bolts and washers.
Figure 15 Figure 18
Remove converter housing and gasket. Remove pump drive gear and bearing.
T12000 ID 04/99 10-4

Figure 19 Figure 22
Remove pump drive idler shaft and washer. Remove solenoid valve cartridge retainer nut and
“O”-ring.
Figure 20 Figure 23
Remove solenoid protection cover screws. Remove solenoid coil and “O”-ring.
Figure 21 Figure 24
Remove solenoid protection cover . Remove valve cartridge and “O”-ring.
T12000 ID 04/99 10-5

Figure 25 Figure 28
Repeat procedures figures 22 through 25 for Remove spacer plate and gasket.
remaining solenoid valves.
NOTE: A 3-speed will have a bore plug in the center
box. Remove bore plug.
Figure 26 Figure 29
Remove spacer plate bolts and washers. Remove 1st and 2nd clutch assembly.
Figure 27 Figure 30
Pry spacer plate away from transmission case at Remove forward and reverse clutch assembly.
dowel pin holes.
T12000 ID 04/99 10-6

Figure 31 Figure 34
Remove high and 3rd clutch assembly. Remove brake caliper assembly.
NOTE: A 3-speed will only have 3rd clutch.
Figure 32 Figure 35
Remove clutch shaft rear bearing outer races. Turn front output flange as shown. Remove retainer
ring from ring groove and pry output flange from
housing.
Figure 33 Figure 36
Remove brake disc assembly bolts from brake and Output flange, oil seal sleeve and front bearing
housing. removed.
NOTE: brake is an option and will not be on all units.
T12000 ID 04/99 10-7

Figure 37 Figure 40
Remove bearing locating ring. Flange removed.
NOTE: brake disc is optional and was
removed with flange.
Figure 38 Figure 41
Remove output gear to shaft retainer ring. Remove output gear.
Figure 39 Figure 42
Tap output shaft and flange from housing. Remove flange oil seal sleeve retainer ring.
T12000 ID 04/99 10-8

Figure 43 Figure 46
Remove sleeve and “O”-ring. Remove modulator valve housing.
NOTE: for single modulation and hydraulic inching.
See section 11.1.
Figure 44 Figure 47
Remove output shaft rear bearing. Remove inner, middle and outer springs.
Remove valve stop pin and accumulator spool.
Remove regulator spool and sleeve assembly.
Figure 45 Figure 48
Remove bearing locating ring. Remove sensor hole plug and “O”-ring.
T12000 ID 04/99 10-9

Figure 49 Figure 52
Remove dipstick and dipstick tube. Tube retainer, screw, sealwasher, clip, washer and
nut removed as shown.
Figure 50 Figure 53
Remove air breather. Remove supply tube “O”-ring.
Figure 51 Figure 54
Remove supply tube retainer screw. Remove supply tube and screen assembly.
T12000 ID 04/99 10-10

Figure 55 Figure 58
Remove oil sleeve distributor lock screw plug. Pilot bearing and oil distributor sleeve removed.
Remove lock screw.
Figure 56
Use a hammer puller as shown to remove distributor
sleeve.
Figure 57
Sleeve being removed. Remove pilot bearing.
T12000 ID 04/99 10-11

Disassembly low (1st) clutch
Figure 59 Figure 62
Remove clutch shaft oil sealing rings. Remove clutch gear and disc hub.
Figure 60 Figure 63
Remove front bearing. Clutch gear and pilot bearings removed.
Figure 61 Figure 64
Remove outer thrust washer, bearing and inner thrust Remove outer thrust washer, thrust bearing and inner
washer. thrust washer.
T12000 ID 04/99 10-12

Figure 65 Figure 68
Remove clutch disc end plate retainer ring. Compress disc springs and remove retainer ring.
Figure 66 Figure 69
Remove clutch disc end plate. Remove retainer ring.
Figure 67 Figure 70
Remove inner and outer clutch discs. Remove retainer ring retainer.
T12000 ID 04/99 10-13

Figure 71
Remove disc spring.
NOTE: See page 10-85.
Figure 72
Remove clutch piston wear plate.
Figure 73
Turn clutch over and tap clutch shaft on a block of
wood to remove clutch piston.
T12000 ID 04/99 10-14

Disassembly 2nd clutch
Figure 74 Figure 77
Remove clutch shaft rear bearing outer race. Remove gear from shaft.
Figure 75 Figure 78
Using a gear puller as shown, remove gear and rear Remove gear locating ring from shaft.
bearing inner race.
Figure 76 Figure 79
Remove inner race from shaft. Remove thrust bearing and clutch gear retainer ring.
T12000 ID 04/99 10-15

Figure 80 Figure 83
Remove outer thrust washer, thrust bearing and inner Remove clutch disc and end plate retainer ring.
thrust washer.
Figure 81 Figure 84
Remove clutch gear and hub and gear bearings. Remove end plate.
Figure 82 Figure 85
Remove outer thrust washer, thrust bearing and inner Remove inner and outer clutch discs.
thrust washer.
T12000 ID 04/99 10-16

Figure 86 Figure 89
Compress disc springs and remove retainer ring. Remove disc springs.
NOTE: see page 10-85.
Figure 87 Figure 90
Remove retainer ring. Remove clutch piston wear plate.
Figure 88 Figure 91
Remove retainer ring retainer. Remove clutch piston.
T12000 ID 04/99 10-17

Reassembly 1st clutch
Figure 92 Figure 95
The two bleed valves in the clutch drum must be Position clutch piston wear plate on piston.
clean and free of any foreign material.
Refer to the “Cleaning and inspection” pages.
Install clutch piston outer seal ring.
Figure 93 Figure 96
Install clutch piston inner seal ring. Install piston return disc springs. First spring with
NOTE: Ring must be sized before installing in clutch drum. large diameter of bevel toward wear plate.
Sizing is best accomplished by rotating piston while holding a
Alternate seven (7) springs. NOTE: see page 10-85.
round object against the new seal ring as shown. Rotate piston
until seal ring is flush with outer diameter of piston.
Figure 94 Figure 97
Position piston in low clutch drum as shown. Position return spring retainer on clutch shaft.
Use caution as not to damage inner and outer
piston sealing rings.
T12000 ID 04/99 10-18

Figure 98 Figure 101

Start ring on shaft with snap ring pliers. Install first friction (inner) clutch disc.
Alternate steel and friction until ten (10) steel and ten
(10) friction discs are in position.

Use a sleeve with the proper inner diameter to fit over Install clutch disc end plate.
shaft and against retainer ring. A sharp blow with a
soft hammer will compress springs and seat retainer
ring. Be sure ring is in full position in groove.

Install first steel outer clutch disc. Install end plate retainer ring.
T12000 ID 04/99 10-19

2nd
1st
Gauge

NOTE: Low (1st) clutch pack must be checked for clutch disc Install outer thrust bearing washer against bearing.
clearance. Stand the clutch assembly on end. The clutch discs
on the bottom will fall to the end plate. Measure the distance between the
clutch piston and the first steel disc by inserting a feeler gauge or taper
gauge through the slots in the clutch drum. The required clearance is .080-
.135 [2.03-3.43]. If the clearance is greater than .135 [3.43], add one steel
disc under the end plate.

Position thrust bearing inner washer on clutch shaft. Press bearings in clutch gear and disc hub, being
certain bearings are pressed flush with face of gear
on both sides.

Position thrust bearing on clutch shaft against inner Install clutch gear in the clutch assembly by
thrust bearing washer. aligning the clutch hub teeth with the clutch
inner discs.
Be sure the clutch hub is in full position in the clutch
assembly. Do not force this operation.
T12000 ID 04/99 10-20


Position inner thrust washer on shaft. Install clutch shaft front bearing.
NOTE: bearing has a shield in it.
This shield must be up.

Position thrust bearing on shaft. Install clutch shaft oil sealing rings.
Grease rings to facilitate reassembly into front
housing.
Figure 112
Position outer thrust washer on shaft.
T12000 ID 04/99 10-21

Reassembly 2nd clutch

Install inner and outer clutch piston seal rings. Install piston return disc springs. First spring with
Size inner ring as explained in figure 93. large diameter of bevel towards wear plate.
Refer to the cleaning and inspection pages. Alternate (5) springs. NOTE: see page 10-85.

Position piston in clutch drum, using caution Position return spring ring retainer on clutch shaft.
as not to damage piston sealing rings.

Install clutch piston wear plate. Start ring on shaft with snap ring pliers.
T12000 ID 04/99 10-22


shaft hammer will compress springs and seat
retainer ring. Be sure ring is in full position in groove.

Install first steel (outer) clutch disc. Install end plate retainer ring.

Install first friction (inner) clutch disc. Position thrust bearing inner washer on clutch shaft.
Alternate steel and friction until five (5) steel and
five (5) friction discs are in position.
T12000 ID 04/99 10-23


Position thrust bearing on clutch shaft against inner Install the clutch gear in the clutch assembly
thrust bearing washer. by aligning the clutch hub teeth with the clutch inner
discs. Be sure the clutch hub is in full position in the
clutch assembly. Do not force this operation.

Install outer thrust bearing washer against thrust Position thrust bearing inner washer on clutch shaft.
bearing.

Press needle bearings in clutch gear and disc hub, Position thrust bearing on clutch shaft against inner
being certain bearings are pressed with face of gear thrust bearing washer.
on both sides.
T12000 ID 04/99 10-24


Install outer thrust bearing washer against bearing. Install clutch shaft gear on clutch shaft with long hub
of gear down.

Install thrust washer retainer ring. Install rear bearing inner race on clutch shaft with
bearing race shoulder down.

Install clutch shaft gear locating ring. Position rear bearing on bearing race.
T12000 ID 04/99 10-25

Disassembly
Figure 139
Remove clutch shaft oil sealing rings.
NOTE: The 4th clutch is only used on the 4 and 6
speed models.
Figure 140
Using a gear puller as shown, remove first drive gear
and front bearing.
Figure 141
Remove first drive gear locating ring.
For 3-speed models, proceed to figure 155.
T12000 ID 04/99 10-26

Disassembly 4th (high) clutch

Remove outer thrust washer retainer ring. Remove bearings and spacer from clutch gear.

Remove outer washer, thrust bearing and inner thrust Remove outer thrust washer, thrust bearing and inner
washer. thrust washer.

Remove clutch gear and disc hub. Remove end plate retainer ring.
T12000 ID 04/99 10-27


Remove end plate. Remove retainer ring retainer.

Remove clutch discs. Remove disc springs.

Compress disc springs and remove retainer ring. Remove clutch piston wear plate.
T12000 ID 04/99 10-28

Figure 154
Remove clutch piston.
T12000 ID 04/99 10-29

Disassembly 3rd clutch

Remove clutch shaft rear bearing outer race. Remove outer thrust washer, thrust bearing and inner
thrust washer.

Use gear puller to remove clutch gear and bearing Remove clutch gear and hub and gear bearings.
inner race.

Remove clutch shaft rear bearing inner race. Remove outer thrust washer, thrust bearing and inner
thrust washer.
T12000 ID 04/99 10-30


Remove end plate retainer ring. Compress disc springs and remove retainer ring.


NOTE: See page 10-85.
T12000 ID 04/99 10-31

Figure 167
Remove clutch piston wear plate.
Figure 168
T12000 ID 04/99 10-32

Reassembly 4th clutch

Clutch piston bleed ball must be clean and Install piston return disc springs. First spring with
free of any foreign material. Refer to the cleaning large diameter of bevel towards wear plate.
and inspection page. For the 3-speed version, Alternate five (5) springs. NOTE: see page 10-85.
proceed to figure 189

Install inner and outer clutch piston seal rings. Position return spring ring retainer on clutch shaft.
Size inner ring as explained in figure 93.
Install clutch piston in clutch drum.
Use caution as not to damage sealing rings.

T12000 ID 04/99 10-33


ring; be sure ring is in full position in groove.

3rd
4th
Gauge

Install first friction (inner) clutch disc. Alternate steel NOTE: 4th (high) clutch pack must be checked for clutch
disc clearance. Stand the clutch assembly on end. The clutch
and friction until six (6) steel and six (6) friction discs
discs on the bottom will fall to the end plate. Measure the distance
are in position. between the clutch piston and the first steel disc by inserting a
feeler gauge or taper gauge through the slots in the clutch drum.
The required clearance is .048-.108 [1,22-2,74]. If the clearance is
greater than .108 [2,74), add one steel disc under the end plate.
T12000 ID 04/99 10-34


Position thrust bearing inner washer on clutch shaft. Press one bearing in clutch gear. Install bearing spacer next to
bearing. Press second bearing in gear, being certain bearings
are pressed flush with face of gears on both sides. Install the clutch
gear in the clutch assembly by aligning the clutch hub teeth with the
clutch inner discs. Be sure the clutch hub is in full position in the

Position thrust bearing on clutch shaft against inner Position thrust washer on shaft.
thrust bearing washer.

Install outer thrust bearing washer against bearing. Position thrust bearing on shaft.
T12000 ID 04/99 10-35


Position thrust washer on shaft. Position gear on clutch shaft.

Install thrust washer retainer ring Install clutch shaft front bearing. Note bearing has a
NOTE: 3-speed clutch drum not as shown. shield in it. This shield must be up.

Install clutch shaft gear locating ring. Install clutch shaft oil sealing rings.
Grease rings to facilitate reassembly into
front housing.
T12000 ID 04/99 10-36

Reassembly 3rd clutch

Clutch piston bleed ball must be clean and Install piston return disc springs. First spring with
and inspection pages. Alternate five (5) springs. NOTE: see page 10-85.

Size inner ring as explained in figure 93. Install clutch
piston in clutch drum. Use caution as not to damage
sealing rings.

T12000 ID 04/99 10-37


soft hammer will compress springs and retainer ring;
be sure ring is in full position in groove.


Install first friction (inner) clutch disc. Position thrust bearing inner washer on clutch shaft.
Alternate steel and friction until five (5) steel and five
(5) friction discs are in position.
T12000 ID 04/99 10-38


Position thrust bearing on clutch shaft against inner Install clutch gear in the clutch assembly by
thrust bearing washer. aligning the clutch hub teeth with the clutch inner
discs. Be sure the clutch hub is in full position in the

Install outer thrust bearing washer against thrust Position thrust bearing inner washer on clutch shaft.
bearing.

Press needle bearings in clutch gear and disc hub, Position thrust bearing on clutch shaft against inner
being certain bearings are pressed flush with face of thrust bearing washer.
gear on both sides.
T12000 ID 04/99 10-39

Figure 211
Install outer thrust bearing washer against thrust
bearing.
Figure 212
Install clutch shaft rear bearing inner race.
Figure 213
Install clutch shaft rear bearing outer race.
T12000 ID 04/99 10-40

Disassembly reverse clutch

Remove outer thrust washer, thrust bearing and inner Remove outer thrust washer, thrust bearing and inner
thrust washer. Note: a 3-speed transmission will not thrust washer.
have external gear teeth on the forward and reverse
clutch drum.


Remove bearings and spacer from clutch gear. Remove end plate.
T12000 ID 04/99 10-41

Disassembly reverse clutch



Remove retainer ring retainer. Remove clutch piston.
T12000 ID 04/99 10-42

Disassembly forward clutch

Remove clutch shaft oil sealing rings. Remove bearings and spacer from clutch gear.

Remove outer thrust washer, thrust bearing and inner Remove outer thrust washer, thrust bearing and inner
thrust washer. thrust washer.

T12000 ID 04/98 10-43




T12000 ID 04/98 10-44

Figure 238
T12000 ID 04/98 10-45

Reassembly forward clutch

Clutch piston bleed orific must be clean free Install piston return disc springs. First spring with
of any foreign material. Refer to the cleaning and large diameter of bevel towards wear plate.
inspection pages. Alternate five (5) springs. NOTE: see page 10-85.

Size inner ring as explained in figure 93. Install clutch
piston in clutch drum. Use caution as not to damage
sealing rings.

Install clutch piston wear plate. Start ring on clutch with snap ring pliers.
T12000 ID 04/99 10-46



REV
FWD
Gauge

Install first friction (inner) clutch disc. Alternate steel NOTE: forward clutch pack must be checked for clutch disc
and friction until six (6) steel and six (6) friction discs clearance. Stand the clutch assembly on end. The clutch discs on
the bottom will fall to the end plate. Measure the distance between
are in position.
the clutch piston and the first steel disc by inserting a feeler gauge
or taper gauge through the slots in the clutch drum.
The required clearance is .048-.108 [1.22 - 2.74]. If the clearance is
greater than .108 [2.74], add one steel disc under the end plate.
T12000 ID 04/99 10-47


Position thrust bearing inner washer on clutch shaft. Press one bearing in clutch gear, flush with face of gear.
Install bearing spacer next to bearing, press second bearing in
gear, flush with face of gear. Install the clutch gear in the clutch
assembly by aligning the clutch hub teeth with the clutch inner
discs. Be sure the clutch hub is in full position in the clutch

Position thrust bearing on clutch shaft against inner Position inner thrust washer on shaft.

Install outer thrust bearing washer against thrust Position thrust bearing on shaft.
bearing.
T12000 ID 04/99 10-48

Figure 257
Figure 258
Install clutch shaft oil sealing rings.
Grease rings to facilitate reassembly into
front housing.
T12000 ID 04/99 10-49

Reassembly reverse clutch

Clutch piston bleed orifice must be clean and Install piston return disc springs. First spring with
and inspection pages. Alternate five (5) springs. NOTE: see page 10-85.

Size inner ring as explained in figure 93.
Install clutch piston in clutch drum.
Use caution as not to damage sealing rings.

T12000 ID 04/99 10-50



FWD
REV
Gauge

Install first friction (inner) clutch disc. Alternate steel NOTE: reverse clutch pack must be checked for clutch disc
clearance. Stand the clutch assembly on end. The clutch disc on
and friction until six (6) steel and six (6) friction discs
the bottom will fall to the end plate. Measure the distance between
are in position. the clutch piston and the first steel disc by inserting a feeler gauge
or taper gauge through the slots in the clutch drum. The required
clearance is .048-.108 [1,22-2,74]. If the clearance is greater than
.108 [2,74] add one steel disc under the end plate.
T12000 ID 04/99 10-51


Position thrust bearing inner washer on clutch shaft. Press one bearing in clutch gear, flush with face of gear.
Install bearing spacer next to bearing. Press second bearing in
gear, flush with face of gear. Install the clutch gear in the clutch
assembly by aligning the clutch hub teeth with the clutch inner
discs. Be sure the clutch hub is in full position in the clutch

Position thrust bearing on clutch shaft against inner Position inner thrust washer on shaft.

Install outer thrust bearing washer against bearing. Position thrust bearing on shaft.
T12000 ID 04/99 10-52

Figure 277
T12000 ID 04/99 10-53

Disassembly regulator valve
Figure 278
Tap pin from regulator valve sleeve. Use caution as
valve spool is under spring pressure.
Figure 279
Remove regulator valve piston and pressure
regulator valve spring.
Figure 280
Spring and piston removed.
T12000 ID 04/99 10-54

Reassembly regulator valve
Figure 281
Position pressure regulator valve spring into
regulator valve piston. Refer to the cleaning and
inspection pages.
Figure 282
Install pressure regulator valve spring and regulator
valve piston as an assembly into regulator valve
sleeve.
Figure 283
Compress valve spring and valve and install pin into
regulator valve sleeve.
T12000 ID 04/99 10-55

Disassembly dual modulated valve assembly

Remove inner, middle and outer spring and stop pin Remove regulator spool, spring, retainer spring and
from modulation housing sleeve. Reference figure 47. spacer spring from housing sleeve.
Figure 285
Remove accumulator spool. Reference figure 47.
Figure 286
Remove cross pin from sleeve
NOTE: Some units will have two cross pins the same
length. Some units will have two pins of different
lengths. The longest pin goes in the bottom hole.
T12000 ID 04/98 10-56

Reassembly dual modulated valve assembly

Install spring spacer in spring retainer. Install spring retainer, spring and regulator valve in
Refer to the cleaning and inspection pages. sleeve against inner cross pin.

Install spring in spring retainer. Compress regulator spool and spring in sleeve far
enough to install cross pin.

Check orifice in regulator spool to be free and Install cross pin.
clear of any foreign material. NOTE: Some units will have two cross pins the same
length. Some units will have two pins of different
lengths. The longest pin goes in the bottom hole.
T12000 ID 04/99 10-57

Reassembly dual modulated valve assembly

From opposite end, position accumulator spool in Install inner spring.
sleeve as shown.

Install outer accumulator spring. Install stop pin in inner spring.

Install middle spring. If charging pump or pump drive gear are to be
replaced, remove retainer ring and drive gear.
T12000 ID 04/99 10-58

Disassembly spacer plate

Remove reverse idler gear end plate capscrew and Remove reverse idler gear bearing.
washer.

Remove end plate and dowel pin. Remove idler gear tanged thrust washer.

Remove reverse idler gear. If reverse idler shaft is to be replaced, support
spacer plate around idler shaft opening and press
idler shaft from spacer.
T12000 ID 04/99 10-59


Idler shaft and locating ring removed. Remove pump drive idler shaft and thrust washer.

Remove locating ring from idler shaft. The stator support is held in place by two retaining
rings. Remove converter end retainer ring from
groove.

Tap pump drive idler shaft from spacer plate. Push support towards transmission side far enough
to expose retainer ring. Remove retainer ring.
T12000 ID 04/99 10-60


From converter end, remove stator support and If support bushing or bearing is to be replaced,
thrust washer. remove from stator support.

Remove stator support oil sealing ring. Compress converter safety valve spring and remove
retaining washer.

Remove sealing ring expander ring. Remove safety valve spring.
T12000 ID 04/99 10-61

Figure 318
Turn spacer plate over and remove safety valve
poppet.
Figure 319
Remove plug and seal washer from spacer plate.
T12000 ID 04/99 10-62

Reassembly spacer plate

From transmission side of spacer plate, Install plug and seal washer.
position converter safety valve poppet
in bore in spacer. Refer to the cleaning and
inspection pages.

Turn spacer over and position safety valve spring on If stator support bushing was removed, install
poppet. bushing in support. Install needle bearing in stator
support.

Compress spring and install poppet retaining washer. Install stator support oil sealing ring expander ring.
NOTE: end of spring must go in recessed side of
washer.
T12000 ID 04/99 10-63


Install oil sealing ring on expander ring. Install stator support locating ring.
NOTE: Expander spring gap to be 180 degrees
from sealing ring hook joint.

Position impeller hub gear washer on spacer plate. Push support back through spacer until locating ring
shoulders in support bore.
Turn spacer plate over and install support retaining
ring.

Install stator support through washer and spacer Position pump drive idler shaft washer on spacer
plate. plate.
T12000 ID 04/99 10-64


Position pump drive shaft through washer and into Support spacer plate and press reverse idler shaft
spacer plate. Align roll pin in spacer plate. into position and tight against locating ring.

Tap shaft into place. Turn spacer plate over and position tanged thrust
washer on shaft, being certain tang in washer is in
notch in spacer plate.

Install locating ring on reverse idler shaft. Position idler gear needle bearing on shaft.
Lubricate bearing.
T12000 ID 04/99 10-65


Position idler gear on bearing. Tighten capscrew to specified torque (see torque
chart).
Figure 339
Position idler gear end plate and roll pin on idler shaft
aligning roll pin with hole in idler shaft.
Figure 340
Install end plate capscrew and washer.
T12000 ID 04/99 10-66

Disassembly front output flange

Remove flange to bearing retainer ring. Oil seal sleeve and “O”-ring removed.
NOTE: do not remove expansion plug unless it is
being replaced.

Using a bearing puller as shown, remove bearing. Remove oil seal from sleeve.

Bearing removed. Remove oil seal retainer ring from output flange.
T12000 ID 04/99 10-67

Reassembly front output flange

Position bearing retainer ring on output flange. Press bearing on output flange.
Refer to the cleaning and inspection pages.

Apply a very light coat of permatex #2 to the outer Install bearing to flange retainer ring.
diameter of the output flange oil seal, press oil seal in
oil seal sleeve. Oil seal must be flush with one side of
face of oil seal sleeve, and lip of seal must be in.
Figure 350
Install new “O”-ring on oil seal sleeve.
Position oil seal sleeve assembly on output flange.
NOTE: recessed position of oil seal and sleeve must be up,
with lip of seal up. This leaves a space between oil seal and
output bearing.
T12000 ID 04/99 10-68

Disassembly converter housing assembly

Remove torque converter bearing. Remove converter housing plug
(high and 3rd clutch shaft).

Remove oil distributor. Remove oil distributor sleeve set screw.

Remove converter oil seal. Using a hammer puller as shown, remove oil
distributor sleeve (high and 3rd).
T12000 ID 04/99 10-69

Disassembly converter housing assembly

Sleeve removed. Using a hammer puller as shown, remove oil
distributor sleeve (1st and 2nd).

Remove converter housing plug Sleeve removed.
(1st and 2nd clutch shaft).
Figure 361
Remove oil distributor sleeve set screw.
T12000 ID 04/99 10-70

Reassembly converter housing

Apply a very light coat of Permatex #2 to Install 1st and 2nd clutch shaft oil distributor sleeve
the outer diameter of the converter housing in converter housing, with inside diameter chamfer
oil seal. Press seal in housing with lip of seal in. up, and the notch in the distributor aligned up with
Refer to the cleaning and inspection pages. the retaining set screw hole in the converter housing.

Install oil distributor in converter housing with long Apply Loctite #243 to threads of sleeve set screw
hub towards oil seal. (NOTE: this screw has a hole in it. Use caution as
not to allow any loctite to plug hole). Install set screw
in converter housing and in oil distributor.

Press converter bearing in housing against shoulder. Install set screw plug.
T12000 ID 04/99 10-71

Reassembly converter housing
Figure 370
Install high-3rd clutch shaft oil distributor sleeve in
converter housing with inside diameter chamfer up
and the notch in the distributor aligned up with the
retaining set screw hole in the converter housing.
Figure 371
Apply loctite #243 to threads of sleeve set screw.
(NOTE: this set screw has a hole in it. Use caution
as not to allow any loctite to plug hole). Install set
screw in converter housing and in oil distributor.
Figure 372
Install set screw plug.
T12000 ID 04/99 10-72

Reassembly transmission

Install forward - reverse oil distributor sleeve in Install reverse and forward clutch shaft rear bearing
transmission case with inside diameter chamfer out in transmission case.
(towards front of transmission) and the notch in the distributor
aligned up withthe retaining set screw hole in the transmission
case. Refer to the cleaning and inspection pages.

Apply Loctite #243 and install set screw in Position a new “O”-ring on lower end of the modulation
transmission case and in oil distributor sleeve. valve sleeve and spring assembly.
Install “O”-ring on other valve sleeve.
NOTE: for single modulation and hydraulic inching see
section 11.1.

Install set screw plug. Install valve or valves in transmission case.
T12000 ID 04/99 10-73


Position a new “O”-ring on modulator valve housing. Push supply tube through opening in case and
install “O”-ring.

Install housing over sleeve and spring assembly and Install supply tube mounting screw, seal washer, clip,
tighten to 60-65 LBF-FT [81-88 N.m]. washer and nut. Tighten mounting screw securely
(see figure 384).
washer
Seal washer Nut
Apply Loctite 270
Screw
Clip
Trans case

Position supply tube and screen assembly in
transmission case sump.
T12000 ID 04/99 10-74


Install sensor hole plug and “O”-ring. Install output shaft inner bearing locating ring in rear
of transmission.

Install air breather. Install rear bearing in case against locating ring.

Install dipstick tube and dipstick. Install new “O”-ring on rear oil seal sleeve.
T12000 ID 04/99 10-75


Apply a very light coat of Permatex #2 to the outer diameter Install rear output flange and shaft through ouput oil seal.
of the output flange oil seal, press oil seal in oil seal sleeve. Oil seal Align splines on shaft with splines on output gear.
must be flush with one side of face of oil seal sleeve and lip of seal Install shaft through gear. Use caution as not to damage oil
must be in. Position oil seal sleeve in transmission case with
recessed portion of oil seal towards output bearing. This leaves seal. Brake disc is an option and will not be on all units.
space between oil seal and output bearing.

Install oil seal sleeve retainer ring. Install output shaft to output gear retainer ring.

From front of transmission case, position output gear Install front output shaft bearing locating ring.
with long hub of gear towards front.
T12000 ID 04/99 10-76


Position front output flange and bearing assembly Install forward and reverse clutch assembly.
on output shaft. Using snap ring pliers as shown.
Squeeze snap ring ends together and tap flange
assembly into case until snap ring can seat in snap ring
groove.

Install high and 3rd clutch shaft rear bearing outer Install 1st and 2nd clutch shaft rear bearing outer
race. race.

Install high and 3rd clutch assembly. Install 1st and 2nd clutch assembly.
T12000 ID 04/99 10-77


Position new transmission case to converter housing Position impeller hub gear on stator support.
gasket on transmission case. A light coat of grease
will hold gasket in position.

Install spacer plate assembly on transmission, Install pump idler gear bearing on idler shaft.
aligning clutch shaft with openings in
spacer plate.
Use caution as not to damage oil sealing rings.

Spacer plate must be tight against transmission case. Install pump idler on bearing.
Do not use bolts to pull spacer plate and case together.
Tap spacer plate into position at dowel pins.
Install spacer plate to transmission case capscrews.
Tighten capscrews to specified torque.
T12000 ID 04/99 10-78

Figure 409
Install idler gear thrust washer, aligning hole with roll
pin.
T12000 ID 04/99 10-79

Reassembly electric control

Install bore plug and “O”-rings in center hole on With cartridge to coil “O”-ring in place, position
3-speed transmissions only. Refer to the cleaning solenoid coil on cartridge.
and inspection pages.

With “O”-rings in position, install solenoid cartridges. With new “O”-ring in position, install coil to cartridge
nut. Tighten cartridge nut per assembly instruction
drawing.

Tighten cartridges to specified torque. Install solenoid protection cover and mounting
See assembly instruction drawing. screws. Tighten screws to specified torque.
T12000 ID 04/99 10-80


Position spacer to converter housing gasket on Tighten bolts to specified torque. See note in figure
spacer. A light coat of grease will hold gasket in 417.
place.

The use of aligning studs will facilitate converter housing to Install converter locating ring on turbine shaft.
spacer installation. The transmission could be laid down to align the end
of the clutch shafts into sealing ring sleeves in converter housing. Do
not force this operation. Converter housing must be tight against
transmission spacer.
NOTE: Do not use bolts to pull converter housing in place.

Install converter housing to transmission case screws Position converter assembly on stator support
and lockwashers. and turbine shaft.
See assembly instructions for proper screw location
and installation.
T12000 ID 04/99 10-81


Install converter assembly retainer ring. Install sensor hole plug end “O”-ring.

With new “O”-ring in place, install bore plug in Install regulator sleeve assembly in converter
converter assembly. housing.
2.16(55)
1.57(40)
.31(8)
.23(6)
.47(12)
.78(20)
1.10(28)
1.37(35)
1/2" Drive socket

.5(13) 1/8" Fillet weld

Install bore plug retainer ring. Using a special tool tighten sleeve to 45-50 lbf.ft
[61.1-67.7 N.m].
T12000 ID 04/99 10-82


Position new charging pump to converter housing If auxiliary pump is used, it is not necessary to install the
gasket. permanent pump hole cover. With new gasket in place,
install pump hole cover on charging pump. Install bolts and
washers and tighten to specified torque. See torque chart.

Install charging pump in converter housing. Install oil filter on regulating valve. Tighten filter to
20-25 lbf. ft [27-34 N.m]. If parking brake is not used
proceed to figure 436.

Install charging pump to converter housing bolts and Position calliper brake assembly on brake disc.
washers and tighten to specified torque.
See torque chart.
T12000 ID 04/99 10-83

Figure 434
Install calliper brake mounting screw through brake
assembly and through lock nut. Apply Loctite #262 to
threads and install screw in transmission case.
Figure 435
Mounting screws to be installed to allow free
movement of calliper pads to disc. Tighten jam nut.
See torque chart. See page 4-4 for brake
information.
Figure 436
See special section on page 5-1 for drive plate
installation.
T12000 ID 04/99 10-84

NOTE: The disc springs are to be used as complete assemblies and care should be taken not to intermix the
individual disc springs with disc springs in another clutch or disc spring pack. Service replacement
assemblies are banded together and must be replaced as assembly.
T12000 ID 04/99 10-85

11. OPTIONS
11.1 ELECTRIC CONTROL-SINGLE MODULATION HYDRAULIC ACTUATED INCHING

The information contained herein must be used in conjunction with a T12000 ID section.
11.1.1 Sectional views and parts identification

Refer to following pages.
T12000 ID 04/99 11-1

GROUP - ELECTRIC CONTROL- SINGLE MODULATION HYDRAULIC ACTUATED INCHING
20
48 47
14 21
40
22 45
15
24 46
19
41 44
25 43
16
42
26
38
52
17 36
29 27
39
28
31
30 51 35
18 32
34 23
37
33
49
50
11
13
12
3
4
5 6
56
55 8
54 9
53 10
3 7
4
5
6
2
1 7
8
9
10
11-2 04/99 T12000 ID

1 Assembly - Solenoid cartridge 5*

2 Cartridge - Valve 4-way including items 3, 4, 5 and 6 5*
7 “O”-ring - Cartridge to coil 5*
8 Coil-Solenoid 5*
9 “O”-ring-Coil to nut 5*
10 Nut - Valve cartridge retainer 5*
11 Cover - Protective 1
12 Screw - Protective cover 2
13 Lockwasher - Protective cover screw 2
14 Housing - Modulation valve 1
15 “O”-ring - Modulation housing 1
16 Spring (Inner) 1
17 Spring (Middle) 1
18 Spring (Outer) 1
19 Pin-Stop 1
20 Spool - Accumulator 1
21 Sleeve - Modulation housing 1
22 Pin - Modulation sleeve 1
23 “O”-ring - Modulation sleeve 1
24 Stop - Regulator spool 1
25 Spring - Regulator spool 1
26 Regulator - Spool 1
27 Sleeve - Regulator 1
28 Ball 1
29 Pin - Regulator spool sleeve 1
30 Snap ring 1
31 “O”-ring - Regulator spool sleeve 1
32 Snap ring 1
33 Sleeve - Shuttle 1
34 Spool - Shuttle 1
35 Body - Hydraulic inching 1
36 Seal - Hydraulic inching body 1
37 “O”-ring - Hydraulic inching body to case 1
38 Snap ring - Hydraulic inching body to cover 1
39 “O”-ring - Hydraulic inching body to cover 1
40 Rod - Hydraulic inching actuator 1
41 Spring - Inching return 1
42 Piston - Hydraulic inching (Lower) 1
43 Seal - Hydraulic inching piston 1
44 “O”-ring - Piston 1
45 Spring - Piston 1
46 Piston - Hydraulic inching (Upper) 1
47 Cover - Hydraulic inching 1
48 Plug - Hydraulic inching conver 3
49 Sleeve - Inching 1
50 “O”-ring - Inching sleeve 1
* quantity= 4, with 3-speed.

** used with 3-speed only.
T12000 ID 04/99 11-3

20
48 47
14 21
40
22 45
15
24 46
19
41 44
25 43
16
42
26
38
52
17 36
29 27
39
28
31
30 51 35
18 32
34 23
37
33
49
50
11
13
12
3
4
5 6
56
55 8
54 9
53 10
3 7
4
5
6
2
1 7
8
9
10
11-4 04/99 T12000 ID

50 “O”-ring - Inching sleeve 1

51 Spool - Inching 1
52 Spring - Inching regulator 1
53 Plug - Solenoid bore plug, used at forward-High and Low 1**
* quantity= 4, with 3-speed.

** used with 3-speed only.
T12000 ID 04/99 11-5

Single modulation and hydraulic inching removal
Figure 1 Figure 4
If inching is used install plug as shown. Remove inching spool.
Figure 2 Figure 5
Remove hydraulic inching actuator. Remove inching sleeve and “O”-ring.
Figure 3 Figure 6
Remove inching regulator spring. Remove modulator valve housing and “O”-ring.
T12000 ID 04/99 11-6

Single modulation and hydraulic inching removal
Figure 7
Remove modulator valve outer, middle, and inner
springs and spring stop.
Figure 8
Remove modulation housing sleeve and
accumulator spool.
Figure 9
Remove shuttle sleeve and spool.
T12000 ID 04/99 11-7

Disassembly single modulator valve assembly
Figure 10 Figure 13
Remove modulator valve body “O”-ring. Remove modulator sleeve pin.
Figure 11 Figure 14
Remove modulator valve outer, middle and inner Remove regulator spool assembly retainer ring.
springs and spring stop ref. figure 7.
Figure 12 Figure 15
Remove accumulator spool. Ref. figure 8. Remove regulator spool stop, spring and spring and
sleeve assembly .
T12000 ID 04/99 11-8

Disassembly single modulator valve assembly
Figure 16 Figure 19
Remove regulator spool sleeve retainer ring. Remove check ball.
Figure 17
Remove regulator spool sleeve assembly.
Remove “O”-ring.
Figure 18
Remove sleeve check ball retainer pin.
T12000 ID 04/99 11-9

Reassembly single modulator valve assembly
Figure 20 Figure 23
Install a new “O”-ring on regulator spool sleeve. Install sleeve retainer ring.
Position check ball in sleeve.
Figure 21 Figure 24
Install check ball retainer pin. Install housing sleeve pin.
Figure 22 Figure 25
Position sleeve and ball assembly in regulator spool Install regulator spool stop, spring and regulator
with check ball retainer pin up. spool and sleeve assembly in housing sleeve.
T12000 ID 04/99 11-10

Reassembly single modulator valve assembly
Figure 26
Compress regulator spool spring and install retainer
ring.
Figure 27
Position new “O”-ring on modulation sleeve.
T12000 ID 04/99 11-11

Disassembly hydraulic inching actuator
Figure 28 Figure 31
Remove hydraulic inching cover. Inching upper piston removed.
Figure 29 Figure 32
Remove inching return spring. Remove hydraulic piston seal.
Figure 30 Figure 33
Remove hydraulic inching upper piston. Remove inching lower piston and “O”-ring.
T12000 ID 04/99 11-12

Disassembly hydraulic inching actuator
Figure 34 Figure 37
Remove snap ring. Remove inching return spring.
Figure 35
Remove hydraulic inching body seal.
Figure 36
Remove hydraulic inching body and “O”-rings.
T12000 ID 04/99 11-13

Reassembly hydraulic inching actuator
Figure 38 Figure 41
Install inching return spring.
Figure 39 Figure 42
Install hydraulic inching body and “O”-rings. Install snap ring.
Figure 40 Figure 43
Install inching body seal. Be sure seal is Install inching lower piston and “O”-ring.
mounted correctly. See figure 41.
T12000 ID 04/99 11-14

Reassembly hydraulic inching actuator
Figure 44 Figure 47
Install hydraulic piston seal. Install inching cover.
Figure 45
Apply Loctite nr. 243 to thread of inching actuator
rod, install inching upper piston.
Figure 46
Install inching return spring.
T12000 ID 04/99 11-15

Single modulation and hydraulic inching installation
Figure 48 Figure 51
Position shuttle spool in shuttle sleeve. Install stop pin, inner, middle and outer springs in
Install spool and sleeve in modulator valve bore. accumulator and housing sleeve.
Figure 49 Figure 52
With new “O”-ring in position, install modulation Position a new “O”-ring on modulator valve housing.
housing sleeve assembly in bore. Thread housing into valve bore.
Figure 50 Figure 53
Install accumulator spool in housing sleeve as Tighten modulator valve housing to specified torque.
shown. See assembly instruction drawing. Ref. to figure 380.
T12000 ID 04/99 11-16

Single modulation and hydraulic inching installation
Figure 54 Figure 57
Install inching sleeve and “O”-ring. Tighten inching actuator to specified torque.
See assembly instruction drawing. Ref. to figure 380.
Figure 55
Install inching spool and regulator spring.
Figure 56
Install hydraulic inching actuator and “O”-ring.
T12000 ID 04/99 11-17

Options
11.2 MT SECTION
The information contained herein must be used in conjunction with a T12000 ID section.
The MT model is the midship mounted T12000 series transmission with an integral convertor unit.
11.2.1 Sectional views and parts identification
11.2.2 Assembly instructions
T12000 ID 04/99 11-18

11.2.1 Parts identification
GROUP - FRONT COVER & INPUT DRIVE
6
5
4
10 14
2
3
9
11 1
12
13
14
7 15
8
17
16
11-19 04/99 T12000 ID

11.2.1 Parts identification
GROUP - FRONT COVER & INPUT DRIVE
1 Cover - Front 1
2 Screw - Front cover to converter housing 12
3 Lockwasher - Front cover to converter housing 12
4 Shaft - Input Drive 1
5 Screw - Input drive shaft to torque converter 6
6 Lockwasher - Input drive shaft to torque converter 6
7 Flange - Input 1
8 Plug - Flange 1
9 Bearing - Input shaft 1
10 Snap ring - Flang retainer 1
11 Sleeve - Oil seal 1
12 “O”-ring - Oil seal sleeve 1
13 Seal - Input shaft oil 1
14 Snap ring - Input Shaft Bearing 2
15 Fitting 1
16 Fitting 1
17 Tube - Drain 1
T12000 ID 04/99 11-20

Options
11.2.2 MT cross section and assembly instructions
USE LOCTITE 515 BETWEEN CONVERETER HOUSING AND FRONT COVER
DRAIN BACK LINE TO TRANSMISSION
T12000 ID 04/99 11-21

DISASSEMBLY OF THE AXLE ASSEMBLY 112
30-3-11 EN
15 / 10 / 2002
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4
INTRODUCTION - INTRODUZIONE - VORAUSSETZUNG - PROLOGO - INTRODUCTION
The efficiency and continued operation of mechan- martelli in plastica o rame, leve appropriate estrattori e chiavi
GB ical units depend on constant, correct maintenance specifiche, al fine di facilitare il lavoro salvaguardando nel
and also on efficient repair work, should there be a contempo le superfici lavorate e la sicurezza degli operatori.
break-down or malfunction. The instructions contained in this Prima di procedere al disassemblaggio delle parti e scaricare
manual have been based on a complete overhaul of the unit. l'olio, eÁ opportuno eseguire un'accurata pulizia del ponte,
However, it is up to the mechanic to decide whether or not it is asportando incrostazioni ed accumuli di grasso.
necessary to assemble only individual components, when
partial repair work is needed. The manual provides a quick PREMESSA: Tutti gli organi meccanici smontati, devono
and sure guide which, with the use of photographs and essere accuratamente puliti con prodotti appropriati, quindi
diagrams illustrating the various phases of the operations, ripristinati o sostituiti nel caso presentino danni, usura,
allows accurate work to be performed. incrinature, grippaggi, ecc. In particolare, verificare l'integritaÁ
All the information needed for correct disassembly, checks and di tutte quelle parti in movimento (cuscinetti, ingranaggi, coppia
assembly of each individual component is set out below. In conica, alberi) e di tenuta (anelli OR, paraolio), soggette a
order to remove the differential unit from the vehicle, the maggiori sollecitazioni ed usura. EÁ consigliabile, comunque, la
manuals provided by the vehicle manufacturer should be sostituzione degli organi di tenuta ogni qualvolta si proceda alla
consulted. In describing the following operations it is presumed revisione o riparazione dei componenti. Al momento del
that the unit has already been removed from the vehicle.
montaggio, gli anelli di tenuta devono essere lubrificati sui
IMPORTANT: In order to facilitate work and protect both bordi di tenuta. Nel caso della coppia conica, la sostituzione di
working surfaces and operators, it is advisable to use proper uno dei suoi ingranaggi comporta anche la sostituzione
equipment such as: trestles or supporting benches, plastic or dell'altro. In fase di montaggio sono da rispettare scrupolosa-
copper hammers, appropriate levers, pullers and specific mente i giochi, i precarichi e le coppie prescritte.
spanners or wrenches. Á : Il manuale fornisce le validitaÁ dei gruppi sotto forma
VALIDITA
Before going on to disassemble the parts and drain the oil, it is
di matricola. Al fine di una corretta interpretazione, le validitaÁ
best to thoroughly clean the unit, removing any encrusted or
sono indicate come:
accumulated grease.
= fino alla matricola
INTRODUCTORY REMARKS: All the disassembled mechan-
ical units should be thoroughly cleaned with appropriate = dalla matricola
products and restored or replaced if damage, wear, cracking or
seizing have occurred. Se non sono indicate validitaÁ, le operazioni di smontaggio ed
In particular, thoroughly check the condition of all moving parts assemblaggio sono comuni a tutte le versioni.
(bearings, gears, crown wheel and pinion, shafts) and sealing
parts (O-rings, oil shields) which are subject to major stress and MANUTENZIONE E RIPARAZIONE: Al fine di facilitare
wear. In any case, it is advisable to replace the seals every time interventi sui gruppi ponte differenziali e cambi di velocitaÁ la
a component is overhauled or repaired. During assembly, the SPICER CLARK-HURTH, ha ritenuto opportuno compilare
sealing rings must be lubricated on the sealing edge. In the queste istruzioni di manutenzione e riparazione. I disegni delle
case of the crown wheel and pinion, replacement of one attrezzature specifiche eventualmente necessarie per l'esecu-
component requires the replacement of the other one. During zione di interventi di manutenzione e riparazione possono
assembly, the prescribed pre-loading, backlash and torque of essere acquistati direttamente presso il costruttore; i ricambi
parts must be maintained. possono essere ordinati tramite il costruttore della macchina o
direttamente presso la SPICER CLARK-HURTH.
CLASSIFICATION: This manual classifies units according to
part numbers. For a correct interpretation, classification is
indicated as follows:
= up to the part number Die Leistung und Lebensdauer der mechanischen
D Teile haÈngt nicht nur von einer staÈndigen und
= from the part number on richtig durchgefuÈhrten Wartung sondern auch von
einem sofortigen Eingriff im StoÈrungsfall ab. Um dieses
When no classification is given, disassembly and assembly Handbuch zu erstellen sind wir von einer allgemeinen U È ber-
operations are the same for all versions. pruÈfung der Einheit ausgegangen, doch entscheidet der
Mechaniker ob die einzelnen Teile bei Reparaturen montiert
SPECIFIC EQUIPMENT AND SPARE PARTS: The drawings of werden muÈssen oder nicht. Das Handbuch ist schnell und
all specific tools required for maintenance and repair work can einfach nachzuschlagen und ermoÈglicht es anhand der Abbild-
be found at the end of this manual ; spare parts may be ordered ungen und der Zeichnungen, die die verschiedenen VorgaÈnge
either from the vehicle manufacturer or directly from the darstellen, gezielt einzugreifen. Nachstehend sind alle Infor-
Service Centers or Authorised Distributors of SPICER mationen und Hinweise aufgefuÈhrt, die zur Zerlegung, PruÈfung
CLARK-HURTH. und Montage der Einzelteile noÈtig sind. Um die Differentia-
lachse des Fahrzeugs abzumontieren, lesen Sie bitte die
Anweisungen in den HandbuÈchern des Fahrzeugherstellers.
Die nachstehenden Beschreibungen gehen davon aus, daû die
Il rendimento e la continuitaÁ degli organi meccanici Fahrzeugachse schon abmontiert worden ist.
ITA dipendono oltre che da una costante e corretta
manutenzione, anche dal tempestivo intervento, WICHTIG: Um die Arbeit zu erleichtern und gleichzeitig die
nell'eventualitaÁ di guasti o anomalie. verarbeiteten FlaÈchen zu schuÈtzen und die Sicherheit der
Nel proporre questo manuale si eÁ considerata l'ipotesi di una Arbeiter zu gewaÈhrleisten, empfehlen wir geeignete Werk-
revisione generale del gruppo ma eÁ il meccanico a valutare la zeuge wie BoÈcke, Tisch, Gummi- oder Kupferhammer, geeig-
necessitaÁ di montare solo i singoli componenti nel caso di nete Abzieher und SchluÈssel zu verwenden.
Bevor mit der Zerlegung der Teile begonnen und das O Èl
riparazione. Il manuale eÁ una guida rapida e sicura che
consente interventi precisi, tramite le fotografie ed i disegni abgelassen wird, muû die Achse sorgfaÈltig gereinigt und
prospettici che illustrano le varie fasi delle operazioni. Di Verkrustungen und Fettablagen abgetragen werden.
seguito sono riportate tutte quelle informazioni ed avvertenze VORAUSSETZUNG: Alle abmontierten mechanischen Teile
necessarie al corretto disassemblaggio, alle relative verifiche muÈssen sorgfaÈltig mit geeigneten Reinigungsmitteln gereinigt
ed all'assemblaggio dei singoli componenti. Per la rimozione oder, wenn beschaÈdigt, verschleiût, gerissen, festgefressen
del ponte differenziale dal veicolo, eÁ necessario consultare i usw. ausgewechselt werden. Insbesondere muû der einwand-
manuali forniti dal costruttore del veicolo. Nel descrivere le freie Zustand aller beweglichen Teile (Lager, ZahnraÈder,
operazioni seguenti, si presuppone che il ponte sia giaÁ stato Kegelradpaare, Wellen) und der Dichtungen (O-Ringe, O È lab-
rimosso dal veicolo. dichtungen), die am meisten beansprucht werden und ver-
schleiûen, kontrolliert werden. Wir empfehlen auf jeden Fall die
IMPORTANTE: In tutte le operazioni, eÁ consigliabile usare Abdichtungselemente immer auszuwechseln, wenn eine U È ber-
attrezzature idonee quali cavalletti o banchi di sostegno, holung oder eine Reparatur der Teile vorgenommen wird. Bei
5
INTRODUCTION - INTRODUZIONE - VORAUSSETZUNG - PROLOGO - INTRODUCTION
der Montage muÈssen die RaÈnder der Dichtringe geschmiert Si no ha sido indicada validez, las operacioÂn de desmontaje y
werden. Wenn beim Kegelradpaar ein Zahnrad ausgewechselt montaje son comunes a todas las versiones.
werden muû, muû auch das andere Zahnrad ausgewechselt
werden. Bei der Montage muÈssen die vorgeschriebenen HERRAMIENTAS ESPECIFICAS Y RECAMBIOS: Los planos
Spiele, Vorspannungen und Drehmomente strengstens ein- de las herramientas especificas necesarias para la ejecucioÂn
gehalten werden. de las intervenciones de mantenimiento figuran al final del
manual; los recambios se pueden pedir al fabricante de la
GUÈ LTIGKEIT: Das Handbuch gibt an zu welchen Kennummern maÂquina o directamente al Service Center o a Distribuidores
die Einheiten gehoÈren. Der Einfachheit halber sind die autorizados de SPICER CLARK-HURTH.
AngehoÈrigkeiten folgendermaûen aufgefuÈhrt:
= bis Kennummer
= ab Kennummer Le rendement et la continuiteÂ des organes meÂca-

F niques deÂpendent, non seulement d'une mainte-
Wenn keine AngehoÈrigkeit angegeben ist, verstehen sich die nance correcte et constante, mais eÂgalement de la
Arbeiten zur Zerlegung und Montage fuÈr alle AusfuÈhrungen rapiditeÂ d'intervention en cas de pannes ou d'anomalies. En
guÈltig. vous proposant ce manuel, on envisage l'hypotheÁse d'une
reÂvision geÂneÂrale du groupe, mais c'est au meÂcanicien
SPEZIFISCHE WERKZEUGE UND ERSATZTEILE: die Zeich- d'eÂvaluer la neÂcessiteÂ de monter ou non chacun des
nungen der fuÈr Wartungsarbeiten erforderlichen spezifischen composants en cas de reÂparation. Le manuel est un guide
Werkzeuge, sind am Ende des Handbuchs aufgefuÈhrt; Ersatz- rapide et suÃr consentant des interventions preÂcises, au travers
teile koÈnnen beim Fahrzeughersteller oder direkt bei der de photographies et de dessins prospectifs qui illustrent les
Kundendienststelle oder bei einem zugelassenen HaÈndler der diffeÂrentes phases des opeÂrations. Ensuite, sont reporteÂes
SPICER CLARK-HURTH bezogen werden. toutes les informations et preÂcautions neÂcessaires pour un
deÂmontage correct et les veÂrifications et assemblage de
chaque composant. En ce qui concerne le deÂplacement du
pont d'eÂtai du veÂhicule, il est neÂcessaire consulter les manuels
fournis par le constructeur du veÂhicule. En deÂcrivant les
El rendimiento y la duracioÂn de los oÂrganos
ESP opeÂrations suivantes, on preÂsume que le pont ait deÂjaÁ eÂteÂ
mecaÂnicos depende, ademaÂs que del constante y
enleveÂ du veÂhicule.
correcto mantenimiento, tambieÂn de la interven-
cioÂn inmediata en caso de averõÂas o anomalõÂas. IMPORTANT: Pour faciliter le travail en sauvegardant en
Al proponer este manual, ha sido considerada la suposicioÂn de meÃme temps les surfaces usineÂes et la seÂcuriteÂ des opeÂra-
una revisioÂn general del grupo, pero es el mecaÂnico quien tiene teurs, il est preÂconiseÂ d'utiliser des installations approprieÂes
que valorar la necesidad de montar cada uno de los telles que des eÂtais ou banc de support, maillets en plastique
componentes en caso de reparacioÂn. El manual es una guõÂa ou cuivre, leviers approprieÂs, extracteurs et cleÂs speÂcifiques.
raÂpida y segura que permite intervenciones precisas por medio Avant de proceÂder au deÂmontage des parties et vidanger
de fotografõÂas y de planos que muestran las distintas fases de l'huile, il vaut mieux nettoyer soigneusement le pont, en
las operaciones. A continuacioÂn figuran todas las informacio- enlevant incrustations et blocs de gras.
nes y advertencias necesarias para ejecutar un montaje
correcto, para las comprobaciones y el montaje de cada uno PRELIMINAIRE: Tous les organes meÂcaniques deÂmonteÂs
de los componentes. Para remover el puente diferencial del doivent eÃtre soigneusement nettoyeÂs aÁ l'aide de produits
vehõÂculo hay que consultar los manuales de los fabricantes del approprieÂs et reÂpareÂs ou remplaceÂs dans le cas ouÁ ils seraient
vehõÂculo. En la descripcioÂn de las operaciones siguientes se abõÃmeÂs, useÂs, feÃleÂs, grippeÂs, etc. VeÂrifier, l'inteÂgriteÂ, en
supone que el puente ya ha sido sacado del vahõÂculo. particulier, de toutes les parties en mouvement (paliers,
engrenages, couple conique, arbres) et l'eÂtancheÂiteÂ des
IMPORTANTE: Para facilitar el trabajo salvaguardando al bagues (bagues OR, parahuile), qui sont sujettes aÁ plus de
mismo tiempo las superficies mecanizadas y la seguridad de sollicitations et aÁ l'usure. Il est preÂconiseÂ, de toute facËon, de
los operadores, se aconseja que se usen equipos y herra- substituer les organes d'eÂtancheÂiteÂ, chaque fois que l'on
mientas adecuados como caballetes y bancos de soporte, effectue une reÂvision ou une reÂparation des composants. Au
martillos de plaÂstico o de cobre, palancas adecuadas, moment du montage, les bagues d'eÂtancheÂiteÂ doivent eÃtre
extractores y llaves especõÂficas. lubrifieÂes sur les bords eÂtanches. Dans le cas du couple
Antes de desmontar las partes y descargar el aceite, es conique, la substitution de l'un de ses engrenages comporte
conveniente que se haga una limpieza minuciosa del puente eÂgalement la substitution de l'autre. En phase de montage, il
sacando las incrustaciones y acumulaciones de grasa. faut respecter scrupuleusement les jeux, les preÂcharges et les
couples prescrits.
INTRODUCCION: Todos los oÂrganos mecaÂnicos desmontados
tienen que ser limpiados minuciosamente con productos VALIDITE: Le manuel fournit la validiteÂ des groupes sous
adecuados y restaurados o sustituidos en el caso de que forme de matricule. Pour une meilleure interpreÂtation, les
presenten danÄos, desgaste, rajaduras, agarrotamientos, etc. validiteÂs sont indiqueÂes comme:
En particular, comprobar la integridad de todas las partes en
movimiento (cojinetes, engranajes, par coÂnico, ejes) y de = jusqu'aÁ l'immatriculation
estanqueidad (anillos OR, detenedor de aceite) sujetas a
mayores solicitaciones y desgaste. = aÁ partir de l'immatriculation et apreÁs
Se aconseja, de todas formas, que se sustituyan los oÂrganos
de estanqueidad cada vez que se ejecute la revisioÂn o Si les validiteÂs ne sont pas indiqueÂes, les opeÂrations de
reparacioÂn de los componentes. deÂmontage et d'assemblage sont pareilles dans toutes les
Al volver a montar, los segmentos de compresioÂn tienen que versions.
estar lubricados en los bordes de estanqueidad. En el caso del
par coÂnico, la sustitucioÂn de uno de sus engranajes comporta INSTALLATIONS SPECIFIQUES ET PIECES DETACHEES:
tambieÂn la sustitucioÂn del otro. Al montar hay que tener en Les dessins des installations speÂcifiques neÂcessaires pour
cuenta escrupulosamente los juegos, las precargas y los pares effectuer des interventions d'entretien sont reporteÂes aÁ la fin du
descriptos. manuel, les pieÁces deÂtacheÂes peuvent eÃtre commandeÂes au
constructeur de la machine ou directement aux Centres de
VALIDEZ: El manual suministra la validez de los grupos en Services, ou Distributeurs agreÂeÂs de la SocieÂteÂ SPICER
forma de matrõÂcula. Para poder tener una interpretacioÂn CLARK-HURTH.
correcta, la validez estaÂ indicada:
= hasta la matrõÂcula
= desde la matrõÂcula en adelante
6
MAINTENANCE AND LUBRICANT - MANUTENZIONE E LUBRIFICANTI - WARTUNG UND SCHMIERSTOFFE
MANTENIMIENTO Y LUBRICANTES - ENTRETIEN ET LUBRIFIANTS
DEFINITION OF VIEWPOINTS - DEFINIZIONE VISTE - DEFINITION DER ANSICHTEN - DEFINICION VISTAS - DEÂFINITION VUES
LEFT SIDE RIGHT SIDE

LATO SINISTRO LATO DESTRO
LINKE SEITE RECHTE SEITE
LADO IZQUIERDO LADO DERECHO
COTE GAUCHE COTE DROITE
D1240111
DATA PLATE - TARGA MATRICOLA - KENNUMMERNSCHILD - MATRICULA - PLAQUE D'IMMATRICULATION
Type and model unit - modification index
1
Tipo e modello gruppo - indice di modifica
Typ und Modelleles Antriebes - AÈ nderungsverzeichnis
Tipo y modelo grupo - indice de modificacion
Type et modeÂle de ensemble - tableau des modifications
1 2 Serial number
2
Numero di serie
Seriennummer
3 NuÂmero de serie
Numero de serie
MFG. BY CLARK-HURTH COMPONENTS S.P.A. Lubricant
3
38062 Arco (Trento) Lubrificante
Schmieroel
MADE IN ITALY Lubricante
Lubrificant
D1240011
MAINTENANCE POINTS - PUNTI DI MANUTENZIONE - WARTUNGSSTELLEN - PUNTOS DE MANUTENCION - POINTS D'ENTRETIEN
3 1 2 3
2 2
1
Oil filling plug - Tappo di carico
EinfuÈllstopfen - Tapon de carga
Bouchon de ravitaillement
2
Oil draining plug - Tappo di scarico
1 3 Ablasstopfen - Tapon de descarga
Bouchon de vidange
2
3
Check level plug - Tappo controllo livello
È lpegelkontrolle -
Stopfen zur O
D1240112
Tapon de contrl de nivel - Jauge de niveau
7
MAINTENANCE INTERVALS - INTERVALLI DI MANUTENZIONE - WARTUNGSINTERVALLE - INTERVALOS DE MANUTENCIOÁN - INTERVALLE DE SERVICE
OPERATION - OPERAZIONE - FREQUENCY - PERIODICITAÁ

LUBRICANTS - LUBRIFICANTI - SCHMIERSTOFFE -
ARBEITSVORGANG - - ZEITABSTAND -
LUBRICANTES - LUBRIFIANTS
OPERACION - OPERATION FRECUENCIA - PERIODICITE
Differential monthly
Differenziale mensile
Im differential monatlich . SAE85W90 (API GL4 - MIL L-2105)
. Check levels: Diferencial cada mes With additives for oil-bath brakes
. Controllo livelli: Differentiel mensuel Con additivi per freni a bagno d'olio
. È lstandkontrolle:
O Mit Zusatzmittel fuÈr Bremsen in OÈ lbad
. Control niveles: Planetary reduction every 200 hours
Con aditivos para frenos de banÄo de aceite
. ControÃle niveaux: Riduzione epicicloidale ogni 200 ore
Avec adjuvants pour freins en bain d'huile
Planetengetrieb alle 200 Std.
ReduccioÂn epicicloidal cada 200 horas . SAE85W90 (API GL5 - MIL 2105-B)
Reduction epicycloidale toutes les 200 heures With additives for oil-bath brakes, for units pre-
Differential every 800 hours ] senting hypoid crown wheel and pinion and /or
Differenziale ogni 800 ore self-locking differential gear
Im differential alle 800 Std. Per esecuzioni con coppia conica ipoide e/o con
Diferencial cada 800 horas differenziale autobloccante, con additivi per freni
Differentiel toutes les 800 heures a bagno d'olio
Bei AusfuÈhrungen mit Kegel- und Telleradpaar
. Oil change: Planetary reduction every 1000 hours ]
und/oder Selbstsperrdifferential, mit Zusatzmit-
. Cambio olio: Riduzione epicicloidale ogni 1000 ore È lbad
È lwechsel: teln fuÈr Bremsen in O
. O Planetengetrieb alle 1000 Std.
Para ejecuciones con par coÂnico hipoide y/o con
. Cambio aceite: ReduccioÂn epicicloidal cada 1000 horas
diferencial autobloqueante con aditivos para fre-
. Vidange huile: Reduction epicycloidale toutes les 1000 heures
nos de banÄo de aceite.
Self-locking differential gear every 700 hours ] r Pour exeÂcutions avec couple conique hypoõÈde et/
Differenziale autobloccante ogni 700 ore ou diffeÂrentiel autobloquant, avec adjuvants pour
Selbstsperrdifferential alle 700 Std. freins en bain d'huile
Diferencial autobloqueante cada 700 horas
Differentiel autobloquant toutes les 700 heures
] Initially after 100 working hours - Inizialmente dopo 100 ore di lavoro - Erstmals nach 100 Betriebstunden - Al principio, despueÂs de 100 horas
de trabajo - Initialement apreÁs 100 heures de travail
r When it starts sounding noisy - Anche ai primi cenni di rumorositaÁ - Auch falls ungewoÈhnliche GeraÈusche zu bemerken sind - TambieÂn al primer
indicio de ruido - MeÃme aux premiers signaux de bruit
OPERATION - OPERAZIONE - MEMBER - ORGANO - CONDITIONS - CONDIZIONI - FREQUENCY - PERIODICITAÁ - LUBRICANTS - LUBRIFICANTI -
ARBEITSVORGANG - ELEMENT - BEDINGUNG - ZEITABSTAND - SCHMIERSTOFFE -
OPERACION - OPERATION ORGANO - ORGANE CONDICIONES - CONDITIONS FRECUENCIA - PERIODICITE LUBRICANTES - LUBRIFIANTS
Normal work monthly
Lavori normali mensile
Normale Arbeit monatlich
Greasing Articulations Trabajos normales cada mes
Ingrassaggio Snodi TaÃches ordinaires mensuel
Schmieren Gelenk MOLIKOTE
Engrase RoÂtula Awkward work Weekly
Graissage Articulations Lavori gravosi Settimanale
Schwere Arbeit WoÈchentlich
Trabajos pesados Semanal
TaÃches extraordinaires Hebdomadaire
ADJUSTMENT AND CHECKS - REGISTRAZIONE E CONTROLLI - EINSTELLUNGEN UND KONTROLLEN - AJUSTE Y CONTROLES - REGLAGES ET CONTROLES
UNIT - GRUPPO - OPERATION - OPERAZIONE FREQUENCY - PERIODICITAÁ - SERVICE BRAKE CIRCUIT - CIRCUITO COMANDO FRENI -
AGGREGAT - ARBEITSVORGANG - ZEITABSTAND - BREMSKREISLAUF - CIRCUITO MANDOS FRENOS -
GRUPO - GROUPE OPERACION - OPERATION FRECUENCIA - PERIODICITE CIRCUIT DE COMMANDE DES FREINS
Negative brake Adjustment every 1000 hours ]
Freno negativo Registrazione ogni 1000 ore Only for mineral oil use e.g. ATF Dexron II. Make sure
Federspeicherbremse Einstellen alle 1000 Std. that master cylinder seals are suitable for mineral oil.
Freno negativo Ajuste cada 1000 horas Usare esclusivamente olio minerale ATF Dexron II. Ac-
Frein neÂgatif ReÂglage toutes les 1000 hours certarsi che le guarnizioni del cilindro master siano
adatte a questo olio.
Service brake Adjustment every 500 hours È l verwenden, z.B.: ATF Dexron II.
Nur mineralisches O
Freni di servizio Registrazione ogni 500 ore
Achtung: Dichtringe des Hauptbremszylinders muÈs-
Hilfsbremse Einstellen alle 500 Std. È l geeignet sein.
sen fuÈr dieses O
Frenos de ejercicio Ajuste cada 500 horas
Usar exclusivamente aceite mineral ATF Dexron II.
Freins de service ReÂglage toutes les 500 hours
Asegurarse de que las juntas del cilindro principal
Wheel nuts Tightening every 200 hours son adecuadas para este aceite.
Dadi ruota Serraggio - ogni 200 ore Utiliser exclusivement huile mineÂrale ATF Dexron II.
Radmuttern Festziehen alle 200 Std. VeÂrifier que les joints du maõÃtre-cylindre, soien compa-
Tuercas rueda Apriete cada 200 horas tibles avec cette huile.
Ecrous de roue Serrage toutes les 200 hours
] Initially after 100 working hours - Inizialmente dopo 100 ore di lavoro - Erstmals nach 100 Betriebstunden - Al principio, despueÂs de 100
horas de trabajo - Initialement apreÁs 100 heures de travail
8
CONVERSION TABLES - TABELLE DI CONVERSIONE - UMRECHNUNGSTABELLEN
TABLAS DE CONVERSION - TABLEAUX DE CONVERSION
Units of pressure - UnitaÁ di pressione - Druckeinheiten

Unidad de presioÂn - UniteÂs de pression: 1 Atm%1 bar%105 PA%14.4 PSi
Units of weight - UnitaÁ di peso - Gewichtseinheiten Units of torque - UnitaÁ di coppia - Drehmomenteinheiten
Unidad de peso - UniteÂs de poids Unidad de par - UniteÂs de couple
N daN kN kg lbs Nm daNm kNm kgm lb-in
1N 1 0,1 0,001 0,102 0,225 1Nm 1 0,1 0,001 0,102 8,854
1daN 10 1 0,01 1,02 2,25 1daNm 10 1 0,01 1,02 88,54
1kN 1000 100 1 102 225 1kNm 1000 100 1 102 8854
1kg 9,81 0,981 0,00981 1 2,205 1kgm 9,81 0,981 0,00981 1 86,8
1lb-in 0,1129 0,01129 0,0001129 0,01152 1
TIGHTENING TORQUES - COPPIE DI SERRAGGIO - ANZIEHDREHMOMENTE

PARES DE TORSION - COUPLES DE SERRAGE
Unit - UnitaÁ di misura - Meûeinheiten - Unidad de medida - UniteÂs de mesure: Nm

TYPE OF BOLT - TIPO VITE - GEWINDE - TIPO DE TORNILLO - TYPE DE VIS
SIZE OF BOLT
MISURA VITE
SCHRAUBENMASS 8.8 10.9 12.9
TAMAN Ä O TORNILLO
MESURE VIS Normali Normali Normali
Loctite 242
+ Loctite 270 + Loctite 242 Loctite 270 + Loctite 242 Loctite 270
M6 x 1 9,5-10,5 10,5-11,5 14,3-15,7 15,2-16,8 16,2-17,8 18,1-20,0
COARSE PITCH - PASSO GROSSO - GROûER
M8 x 1,25 23,8-26,2 25,6-28,4 34,2-37,8 36,7-40,5 39,0-43,0 43,7-48,3

SCHRITT - PASO GRUESO - GROS PAS
M10 x 1,5 48-53 52-58 68-75 73-81 80-88 88-97

M12 x 1,75 82-91 90-100 116-128 126-139 139-153 152-168
M14 x 2 129-143 143-158 182-202 200-221 221-244 238-263
M16 x 2 200-221 219-242 283-312 309-341 337-373 371-410
M18 x 2,5 276-305 299-331 390-431 428-473 466-515 509-562
M20 x 2,5 390-431 428-473 553-611 603-667 660-730 722-798
M22 x 2,5 523-578 575-635 746-824 817-903 893-987 974-1076
M24 x 3 675-746 732-809 950-1050 1040-1150 1140-1260 1240-1370
M27 x 3 998-1103 1088-1202 1411-1559 1539-1701 1710-1890 1838-2032
M30 x 3,5 1378-1523 1473-1628 1914-2115 2085-2305 2280-2520 2494-2757
M8 x 1 25,7-28,3 27,5-30,5 36,2-39,8 40,0-44,0 42,8-47,2 47,5-52,5

FINE PITCH - PASSO FINE - KLEINER SCHRITT
M10 x 1,25 49,4-54,6 55,2-61,0 71,5-78,5 78,0-86,0 86,0-94,0 93,0-103,0

M12 x 1,25 90-100 98-109 128-142 139-154 152-168 166-184
M12 x 1,5 86-95 94-104 120-132 133-147 143-158 159-175
PASO FINO - PAS FIN
M14 x 1,5 143-158 157-173 200-222 219-242 238-263 261-289

M16 x 1,5 214-236 233-257 302-334 333-368 361-399 394-436
M18 x 1,5 312-345 342-378 442-489 485-536 527-583 580-641
M20 x 1,5 437-483 475-525 613-677 674-745 736-814 808-893
M22 x 1,5 581-642 637-704 822-908 903-998 998-1103 1078-1191
M24 x 2 741-819 808-893 1045-1155 1140-1260 1235-1365 1363-1507
M27 x 2 1083-1197 1178-1302 1520-1680 1672-1848 1834-2027 2000-2210
M30 x 2 1511-1670 1648-1822 2138-2363 2332-2577 2565-2835 2788-3082
9
SCREW-LOCKING, SEALING AND LUBRICATING MATERIALS - MATERIALI PER BLOCCAGGIO VITI, TENUTA E LUBRIFICAZIONE - MATERIAL ZUR
BLOCKIERUNG VON SCHRAUBEN UND FUÈR DICHTUNGEN UND SCHMIERMITTEL - MATERIALES PARA EL BLOQUEO, ESTANQUEIDAD Y LUBRICACION -
MATEÂRIAUX POUR LE BLOCAGE VIS, EÂTANCHEÂITEÂ ET LUBRIFICATION
1 - Locking, sealing and lubricating materials referred to in this manual are the same used in the shop-floor.
I materiali per il bloccaggio, tenuta e lubrificazione specifica indicati nel manuale, sono quelli usati in fabbrica.
Die Materialien zur Blockierung von Schrauben, fuÈr Dichtungen und Schmiermittel, die im Handbuch aufgefuÈhrt sind, sind
dieselben die auch vom Hersteller verwendet werden.
Los materiales para el bloqueo, estanqueidad y lubricacioÂn especõÂfica indicados en el manual, son los que se usan en la faÂbrica
Les mateÂriaux de blocage, d'eÂtancheÂiteÂ et de lubrification speÂcifieÂs indiqueÂs dans ce manuel sont ceux employeÂs aÁ l'usine.
2 - The table below gives an account of the typical applications of each single material, in order to facilitate replacement with similar
products marketed by different brand names with different trade marks.
Di questi materiali, vengono riportate le applicazioni tipiche che li distinguono, in modo da poterli sostituire con prodotti similari
commercializzati da altre marche e quindi con altre sigle.
Von diesen Materialien werden die typischen Anwendungen genannt, um sie mit aÈhnlichen Materialien zu ersetzen, die unter
anderen Namen und Kennzeichnungen im Handel erhaÈltlich sind.
De estos materiales damos las aplicaciones tõÂpicas que los distinguen, de manera que se puedan sustituir con productos similares
comercializados por otras marcas y por tanto con otras siglas.
De ces mateÂriaux ne sont reporteÂes que les applications typiques qui les distinguent de telle sorte qu'ils puissent eÃtre substitueÂs
par des produits semblables se trouvant dans le commerce sous d'autres marques et par conseÂquent sous d'autres sigles.
DENOMINATION
DENOMINAZIONE
BEZEICHNUNG APPLICATION - APPLICAZIONE - ANWENDUNG - APLICACION - APPLICATION
DENOMINACION
DENOMINATION
. Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength loc-
king. Before using it, completely remove any lubricant by using the specific activator.
. Prodotto anaerobico adatto a prevenire l'allentamento di viti, dadi e tappi. Usato per la frenatura a media re-
sistenza. Deve essere usato dopo aver asportato ogni traccia di lubrificante con l'attivatore specifico.
. Anaerobes Produkt, um das Lockern von Schrauben, Muttern und Stopfen zu verhindern. FuÈr mittlere Wi-
derstandskraÈfte geeignet. Darf erst aufgetragen werden, wenn die FlaÈchen von Schmiermittel richtig sauber
Loctite 242
sind. Dazu das entsprechende Produkt verwenden.
. Producto anaeroÂbico apto para prevenir el aflojamiento de tornillos, tuerca y tapones. Usado para el frenado
de media resistencia. Tiene que ser usado soÂlo despueÂs de haber quitado todo residuo de lubricante con el
activador especõÂfico.
. Produit anareÂobic servant aÁ preÂvenir le relaÃchement des vis, eÂcrous et bouchons. UtiliseÂ pour le freinage
demi reÂsistant. Il doit eÃtre utiliseÂ apreÁs avoir enleveÂ toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial.
. The oleocompatible alternative to 242. Does not require the activation of lubricated surfaces.
. Prodotto alternativo al 242 che, essendo oleocompatibile, non richiede l'attivazione di superfici lubrificate.
. Alternatives Produkt zu Loctite 242. Da es oÈlkompatibel ist muÈssen die geschmierten FlaÈchen nicht aktiviert
Loctite 243 werden.
. Producto alternativo al 242 que, siendo oleocompatible, no requiere la activacioÂn de superficies lubricadas.
. Produit en alternance avec le 242 lequel eÂtant oleÂocompatible ne requiert aucune activation des surfaces
lubrifieÂes.
. Anaerobic product for very-high strength locking of screws and nuts. Before using it, completely remove any
lubricant by using the specific activator. To remove parts, it may be necessary to heat them at 80ëC approx.
. Prodotto anaerobico adatto per la frenatura ad altissima resistenza di viti e dadi. Deve essere usato dopo aver
asportato ogni traccia di lubrificante con l'attivatore specifico.
La rimozione delle parti, puoÁ richiedere un riscaldamento a circa 80ëC.
. Anaerobes Produkt fuÈr hohe WiderstandskraÈfte fuÈr Schrauben und Muttern geeignet. Zuerst die FlaÈche sorg-
Loctite 270
faÈltig aktivieren. Um die FlaÈchen zu saÈubern, diese auf ca. 80ëC erwaÈrmen.
. Producto anaeroÂbico apto para el frenado de alta resistencia de tornillos y tuercas. tiene que ser usado de-
spueÂs de haber quitado todo residuo de lubricante con el activador especõÂfico.
La remocioÂn de las partes, puede requerir un calentamiento a unos 80ëC.
. Produit anareÂobic apte au freinage aÁ treÁs haute reÂsistance des vis et des eÂcrous. Il doit eÃtre utiliseÂ apreÁs avoir
enleveÂ toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial.
. Anaerobic product suitable for high-strength locking and sealing of large threaded parts, bolts and stud bolts,
for pipe sealing and for protecting parts against tampering; suitable for sealing coupling surfaces with a max.
diametrical clearance of 0.25 mm.
. Prodotto anaerobico adatto per la frenatura e sigillatura ad alta resistenza di parti filettate, bulloni e prigionieri
di grandi dimensioni, protezione antimanomissione e sigillatura di tubazioni; puoÁ sigillare accoppiamenti con
gioco diametrale massimo di 0,25 mm.
. Anaerobes Produkt zum Bremsen und Siegeln von groûen Gewinden, Muttern und Stiftschrauben , sehr
Loctite 275 widerstandsfaÈhig, verschleierungsbestaÈndig, und zum Siegeln von Rohrleitungen geeignet; kann Kupplun-
gen mit einer maximalen Lagerluft von 0,25 mm siegeln.
. Producto anaerobico apto para el frenado y selladura a alta resistencia de tornillos, tuercas y prisioneros de
grandes dimensiones, protecion anti manomision y selladura de tubaciones ; puede sellar encolcados con
juego diametral.
. Produit anaeÂrobie adapteÂ au freinage et au scellage aÁ haute reÂsistance des parties fileteÂes, boulons et pri-
sonniers de grandes dimensions, protection anti-alteÂration et scellage de tuyauteries; il peut sceller des ac-
couplements ayant un jeu diameÂtral maximal de 0,25 mm.
10
DENOMINATION
DENOMINAZIONE
DENOMINACION
DENOMINATION
. Anaerobic product for the hermetic sealing of flanged units and screw holes communicating with fluids. Can
seal clearances between flanges up to 0.2 mm.
. Prodotto anaerobico adatto alla tenuta ermetica di fluidi tra assiemi flangiati e di viti a foro comunicante con i
fluidi. PuoÁ sigillare giochi tra le flange fino a 0,2 mm.
. Anaerobes Produkt zur Abdichtung von FluÈssigkeiten an Flanschen und Schrauben mit LoÈcher, die mit FluÈs-
Loctite 510
sigkeiten in Kontakt stehen. Kann ein Spiel zwischen Flanschen bis 0,2 mm abdichten.
. Producto anaeroÂbico apto para le estanqueidad de fluidos entre grupos bridados y de tornillos de orificio co-
municante con los fluidos. Puede sellar juegos entre las bridas hasta 0,2 mm.
. Produit anareÂobic apte aÁ la tenue eÂtanche des fluides entre les pieÁces aÁ brides et des vis aÁ trou en contact
avec les fluides. Il peut sceller un jeu parmi les flasques jusqu'aÁ 0,2 mm.
. Quick anaerobic sealant for sealing threaded portions of conical or cylindrical unions up to M80. Before using
it, remove any lubricant with the specific activator. After polymerisation, disassembly may result rather dif-
ficult, so heating may be necessary for larger diameters.
. Prodotto anaerobico sigillante rapido per la tenuta di filettature di raccordi conici o cilindrici fino a M80.
Deve essere usato dopo aver asportato ogni traccia di lubrificante con l'attivatore specifico.
Dopo la polimerizzazione presenta una moderata difficoltaÁ di smontaggio per cui puoÁ richiedere, per i diametri
maggiori, un riscaldamento.
. Anaerobes Produkt zum schnellen Siegeln und Abdichten von Kegel- oder Zylinderkupplungen bis M80.
Darf erst aufgetragen werden, nachdem mit einem spezifischen Wirkstoff jede Spur von Schmiermittel ab-
getragen worden ist.
Loctite 577
Nach der Polymerisation koÈnnte das Abmontieren etwas schwierig sein weshalb groÈûere Durchmesser
zuerst erhitzt werden muÈssen.
. Producto anaerobico sellante rapido para el estanqueido de tornillos de empalme conico o cilindrico hasta
M80. Debe de ser utilisado despues de haber quitado cada mancha de lubrificante con activador especifico.
Despues de la polimeracion presenta una moderada dificultaÁde desmontaje por lo tanto puede necesitar, para
los diametros majores, un calientamiento.
. Produit anaeÂrobie collage rapide assurant l'eÂtancheÂiteÂ des filetages des raccords coniques ou cylindriques
jusqu'aÁ M80. Il doit eÃtre utiliseÂ apreÁs qu'on ait enleveÂ toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial.
Une certaine difficulteÂ de deÂmontage se preÂsente apreÁs la polymeÂrisation, on peut donc avoir la neÂcessiteÂ de
devoir chauffer preÂalablement pour de plus amples diameÁtres.
. Anaerobic adhesive for fast and high-strength gluing of cylindrical metal joints (hub on shaft). Can glue to-
gether parts with clearance ranging between 0.1 and 0.25 mm.
. Adesivo anaerobico per l'incollaggio rapido ad alta resistenza di giunti cilindrici in metallo (mozzo su albero).
PuoÁ incollare particolari con gioco tra 0,1 e 0, 25 mm.
. Anaerober Klebstoff fuÈr groûe WiderstandskraÈfte fuÈr Zylinderkupplungen aus Metall geeignet (Wellenna-
Loctite 638
ben). Kann Einzelteil mit einem Radialspiel zwischen 0,1 mm und 0,25 mm zusammenkleben.
. Adhesivo anaeroÂbico para el encolado raÂpido de alta resistencia de juntas cilõÂndricas de metal (cubo en el eje).
Puede encolar piezas con juego entre 0,1 mm y 0,25 mm.
. AdheÂsif anaeÂrobic servant aÁ un collage rapide et hautement reÂsistant des joints cylindriques en meÂtal
(moyeu sur l'arbre). Il peut servir aÁ coller des pieÁces avec un jeu allant de 0,1 aÁ 0,25 mm.
. Anaerobic adhesive for fast and medium-strength gluing of cylindrical metal joints (hub on shaft). Can glue
together parts with radial clearance below 0.1 mm.
. Adesivo anaerobico per l'incollaggio rapido a media resistenza di giunti cilindrici in metallo (mozzo su albero).
PuoÁ incollare particolari con gioco radiale inferiore a 0,1 mm.
. Anaerober Klebstoff fuÈr mittlere WiderstandskraÈfte fuÈr Zylinderkupplungen aus Metall geeignet (Wellenna-
Loctite 648 ben). Kann Einzelteil mit einem Radialspiel von weniger als 0,1 mm zusammenkleben.
. Adhesivo anaeroÂbico para encolado raÂpido de media resistencia juntas cilõÂndricas de metal (cubo en el eje).
Puede encolar piezas con juego radial inferior a 0,1 mm.
. AdheÂsif anaeÂrobic servant aÁ un collage rapide moyennement reÂsistant des joints cylindriques en meÂtal
(moyeu sur l'arbre).
Il peut servir aÁ coller des pieÁces avec un jeu radial infeÂrieur aÁ 0,1 mm.
. Solvent-based sealing compound for elastic seals, drying through evaporation. Used for sealing the outer
diameter of sealing rings for rotating shafts with outer metal reinforcement.
(AREXONS) . Mastice sigillante per guarnizioni elastiche a base di solvente, essicante per evaporazione.
Repositionable jointing
compound for seals Viene utilizzato per la tenuta sul diamentro esterno di anelli di tenuta per alberi rotanti con armatura metallica
Mastice per guarnizioni esterna.
riposizionabile . Klebstoff fuÈr Gummidichtung auf LoÈsemittelbasis, trocknet durch Verdampfung.
Klebstoff fuÈr verstellbare Wird am aÈuûeren Durchmesser von Dichtungsringe bei rotierenden Wellen mit Metallmantel verwendet.
Dichtungen . Pasta para juntas de sellado para juntas elaÂsticas a base de disolvente, deshidratante por evaporacioÂn.
Pasta para juntas Se utiliza para la estanqueidad en el diaÂmetro externo de segmentos de compresioÂn, para ejes giratorios con
reposicionable
armadura metaÂlica exterior.
Mastic pour garnitures aÁ
remettre en place . Mastic adheÂsif aÁ base de solvants pour garnitures eÂlastiques, seÂchant par eÂvaporation.
Il sert garder eÂtanche le diameÁtre exteÂrieur des bagues d'eÂtancheÂiteÂ des arbres rotatifs ayant une arma-
ture meÂtallique externe.
11
DENOMINATION
DENOMINAZIONE
DENOMINACION
DENOMINATION
. Semi-fluid adhesive material used for sealing and filling and to protect components from environmental and
physical elements. Polymerises with non-corrosive dampness.
Silicone . Materiale adesivo semifluido usato per sigillatura, riempimenti e per la protezione di componenti dagli elementi
Silicone ambientali e fisici. Polimerizza con umiditaÁ non corrosiva.
. HalbfluÈssiger Klebstoff zum Befestigen, FuÈllen und zum Schutz von Bestandteilen vor aÈuûeren Einwirkun-
Silikon
gen. Polymerisiert durch nicht korrosive Feuchtigkeit
Silicona . Material adhesivo semifluido usado para el sellado, llenado y para la proteccioÂn de componentes de elemen-
Silicone tos ambientales y fõÂsicos. Polimeriza con humedad no corrosiva.
. Produit adheÂsif semi-fluide utiliseÂ pour le scellage, remplissage et protection des eÂleÂments ambiants et phy-
siques. PolymeÂrise aÁ une humiditeÂ non corrosive.
. Highly adhesive synthetic grease, with silicone compounds added.
Applied to adjustment screws with hole communicating with oil-type fluids.
Used when frequent adjusting is required.
. Grasso sintetico con elevato grado di adesivitaÁ, additivato con composti siliconici.
(TECNO LUPE/101) Applicato su viti di registrazione a foro comunicante con fluidi di tipo oleoso.
Silicone-based grease Usato quando si richiedono frequenti interventi di registrazione.
Grasso al silicone . Synthetisches Fett mit hoher Haftfestigkeit, mit silikonhaltigen Stoffen legiert.
Wird auf Stellschrauben mit Loch, die mit oÈlhaltigen FluÈssigkeiten in Kontakt stehen, angebracht.
Silikonfett Wird verwendet, wenn die Schraub oÈfters eingestellt werden muû.
Grasa a la silicona . Grasa sinteÂtica con elevado grado de adhesioÂn, aditivada con componentes silicoÂnicos.
Graisse au silicone Aplicada en tornillos de ajuste de orificio comunicante con fluidos de tipo oleoso.
Se usa cuando se requieren frecuentes intervenciones de ajuste.
. Graisse syntheÂtique ayant un degreÂ d'adheÂsiviteÂ eÂleveÂ, adjuveÂ de composeÂs au silicone.
AppliqueÂ sur les vis de reÂglage aÁ trou communiquant avec des fluides du type huileux.
UtiliseÂ quand il y a besoin de reÂglages freÂquents.
. Lubricating compound containing molybdenum disulphide, used to lubricate articulation pins and to prevent
sticking and oxidation of parts that are not lubricated on a regular basis.
. Composto lubrificante contenente bisolfuro di molibdeno, usato per la lubrificazione di perni snodo e per pre-
venire incollamenti ed ossidazioni di particolari non lubrificati in modo continuo.
Molikote . Schmierstoff mit MolybidaÈndisulfid; wird zum Schmieren von Gelenkstiften und gegen Ankleben und Oxy-
(DOW CORNING) dation von nicht dauergeschmierten Einzelteilen verwendet.
. Compuesto lubricante que contiene bisulfuro de molibdeno, usado para la lubricacioÂn de roÂtulas y para pre-
venir encoladuras y oxidaciones de piezas no lubricadas de manera continua.
. ComposeÂ lubrifiant contenant du bisulfure de molybdeÁne, utiliseÂ pour lubrifier les axes d'articulation et preÂ-
venir collages et oxydations des pieÁces qui ne sont pas continuellement lubrifieÂes.
. Applied to bearings, sliding parts and used to lubricate seals or parts during assembly
(Lithium-based) Grease . Applicato a cuscinetti, parti scorrevoli e per lubrificare guarnizioni o pezzi in fase di montaggio.
Grasso (al Litio) . Wird auf Lager, Gleitteilen aufgetragen und zum Schmieren von Dichtungen oder von Teilen bei der Mon-
(Lithium) Fett tage verwendet.
Grasa (al Litio) . Aplicada a cojinetes, partes deslizables o para lubricar juntas o piezas en fase de montaje.
Graisse (au Lithium) . AppliqueÂ sur les paliers, parties coulissantes et pour lubrifier les garnitures ou pieÁces pendant la phase de
montage.
12
NOTES ON SAFETY PRECAUTIONS - NOTE RIGUARDANTI LA SICUREZZA - BEMERKUNGEN ZUR
SICHERHEIT - NORMAS CONCERNIENTES A LA SEGURIDAD - NOTES EN MATIERE DE SECURITE
1 - During all operations described in this manual, the LoÈsemittel muÈssen als SondermuÈll und auf jeden Fall laut den
GB axle should be fastened onto a trestle, while the oÈrtlich geltenden Vorschriften entsorgt werden.
other parts mentioned should rest on supporting 9- Zur Reinigung ausschlieûlich schwache LoÈsemittel wie Petroleum,
benches. Terpentin oder wasserhaltige LoÈsemittel verwenden. Auf keinen
2- When removing one of the arms, an anti-tilting safety trestle Fall TrichloraÈthylen, tuolol- oder xylolhlatige LoÈsemittel usw.
should be placed under the other arm. verwenden.
3- When working on an arm that is fitted on the machine, make sure 10 - Um die ArbeitsvorgaÈnge verstaÈndlich abzubilden, werden in
that the supporting trestles are correctly positioned and that the einigen Fotos die Aggregate ohne Einzelteile gezeigt, die sonst
machine is locked lengthways. bei der Arbeit nicht abmontiert werden muÈssen.
4- Do not admit any other person inside the work area; mark off the Nur die beschriebenen Teile abmontieren.
area, hang warning signs and remove the ignition key from the 11 - Unter RECHTS und LINKS versteht man in diesem Handbuch die
machine. Seite einer Person, die zur Achse schaut und zwar dem Antrieb
5- Use only clean, quality tools; discard all worn, damaged, low- entgegengesetzt.
quality or improvised wrenches and tools. Ensure that all 12 - Nach beendeten Arbeiten und um Rostbildungen zu vermeiden,
dynamometric wrenches have been checked and calibrated. die Teile an denen der Lack ggf. beschaÈdigt worden ist,
6- Always wear gloves and non-slip rubber shoes when performing anstreichen.
repair work. 1 - Las operaciones descritas se refieren al eje blo-
7- Should you stain a surface with oil, remove marks straight away. ESP queado en un caballete y a algunas partes apoyadas
8- Dispose of all lubricants, seals, rags and solvents once work has en el banco de trabajo.
been completed. Treat them as special waste and dispose of them 2- Cuando se saca un brazo del eje, colocar debajo del otro un
according to the relative law provisions obtaining in the country caballete de seguridad antivuelco.
where the axles are being overhauled. 3- Si se trabaja con un eje montado en la maÂquina, asegurarse de
9- Make sure that only weak solvents are used for cleaning haber colocado caballetes soporte y de haber inmovilizado
purposes; avoid using turpentine, dilutants and toluol-, xylol- longitudinalmente la maÂquina.
based or similar solvents; use light solvents such as Kerosene, 4- No permitir que personas extranÄas entren en la zona de trabajo;
mineral spirits or water-based, environment friendly solvents. delimitar esta zona, colgar carteles de aviso de hombres
10 - For the sake of clarity, the parts that do not normally need to be trabajando y sacar las llaves de arranque de la maÂquina.
removed have not been reproduced in some of the diagrams. 5- Usar soÂlo y exclusivamente herramientas limpias y de buena
11 - The terms RIGHT and LEFT in this manual refer to the position of cualidad; descartar llaves o herramientas gastadas o danÄadas, de
the operator facing the axle from the side opposite the drive. calidad mediocre o improvisadas. Asegurarse de que las llaves
12 - After repair work has been completed, accurately touch up any dinamomeÂtricas han sido controladas y calibradas.
coated part that may have been damaged. 6- Durante las operaciones de reparacioÂn, llevar siempre guantes y
calzado antideslizamiento.
1 - Le operazioni descritte sono riferite all'assale bloc- 7- Limpiar inmediatamente las zonas que pudieran estar sucias de
ITA cato su cavalletto ed alcuni particolari appoggiati su aceite.
un banco di lavoro.
8- Los lubricantes, las juntas, los trapos para la limpieza y los
2 - Quando si asporta un braccio dell'assale, sistemare sotto l'altro disolventes usados hay que eliminarlos como desechos especia-
braccio un cavalletto di sicurezza antiribaltamento. les y, de todas formas, de acuerdo con las normativas vigentes en
3 - Se si opera su un'assale montato sulla macchina, assicurarsi di el paõÂs en el que se revisan los ejes.
aver sistemato dei cavalletti di sostentamento e di aver immobi- 9- Para limpiar, utilizar soÂlo disolventes deÂbiles excluyendo en
lizzato longitudinalmente la macchina. absoluto tricloroetileno, diluyentes y disolventes a base de toluol,
4 - Non permettere che persone estranee entrino nella zona di lavoro; silol, etc.; usar soÂlo disolventes ligeros como queroseno, aguarraÂs
delimitare questa zona, appendere dei cartelli di avviso di lavori in minerales o disolventes ecoloÂgicos a base de agua.
corso ed asportare le chiavi di avviamento della macchina. 10 - Para que resulte clara la exposicioÂn y la ilustracioÂn, en las figuras
5 - Usare solo ed esclusivamente attrezzi puliti e di buona qualitaÁ; de algunos grupos faltan algunas piezas que por lo general se
scartare chiavi od attrezzi usurati o danneggiati, di bassa qualitaÁ pueden dejar montadas. Sacar soÂlo las partes descritas.
od improvvisati. Assicurarsi che le chiavi dinamometriche siano 11 - Las palabras DERECHA E IZQUIERDA usadas en el manual se
state controllate e tarate. refieren a la persona que mira el eje del lado opuesto a la toma de
6 - Durante le operazioni di riparazione, indossare sempre guanti e movimiento.
scarpe antiscivolo. 12 - Al final de las reparaciones, para evitar oxidaciones, retocar
7 - Pulire immediatamente le zone eventualmente imbrattate d'olio. cuidadosamente las partes pintadas que estuvieran danÄadas.
8 - I lubrificanti, le guarnizioni, gli eventuali stracci di pulizia ed i
solventi usati devono essere smaltiti come rifiuti speciali e 1 - Les opeÂrations deÂcrites se rapportent aÁ l'essieu
comunque secondo le normative vigenti nel Paese ove vengono F bloqueÂ sur chevalet et de quelques pieÁces poseÂes
revisionati gli assali. sur un eÂtabli de travail.
9 - Per la pulizia, usare solo solventi deboli escludendo categorica- 2- Quand on enleÁve un essieu monteÂ sur la machine, ajuster sous
mente trielina, diluenti e solventi a base di toluolo, xilolo, ecc.; l'autre bras un chevalet de seÂcuriteÂ contre tout basculement.
usare solo solventi leggeri quali cherosene, ragie minerali o 3- Si on oeuvre sur un essieu monteÂ sur la machine, s'assurer
solventi ecologici a base d'acqua. d'avoir ameÂnageÂ des chevalets de soutien et d'avoir bloqueÂ la
10 - Per chiarezza di illustrazione ed esposizione, sulle figure di alcuni machine en longueur.
gruppi mancano dei particolari che, normalmente, possono essere 4- Ne jamais permettre aÁ des eÂtrangers de peÂneÂtrer dans la zone de
lasciati montati. Rimuovere solo i particolari descritti. travail; deÂlimiter cette zone, mettre des pancartes de signalisation
11 - I termini DESTRA e SINISTRA usati nel manuale sono riferiti alla de travaux en cours et enlever les cleÂs de contact de la machine.
persona che guarda l'assale dal lato opposto alla presa di moto. 5- N'utiliser que des outils propres et de bonne qualiteÂ; eÂliminer cleÂ
12 - Al termine delle riparazioni, per evitare dannose ossidazioni, ou autres outils useÂs, abõÃmeÂs, de mauvaise qualiteÂ ou improviseÂs.
ritoccare con cura le parti verniciate eventualmente danneggiate. Veiller aÁ ce que les cleÂs dynamomeÂtriques aient eÂteÂ controÃleÂes et
calibreÂes.
1 - Die beschriebenen VorgaÈnge werden an der Achse 6- Pendant les opeÂrations de reÂparation, endosser toujours gants et
D vorgenommen, wenn diese auf einem Bock blockiert chaussures antideÂrapantes.
ist. Zur Bearbeitung der Einzelteile, werden diese 7- Nettoyer tout de suite les eÂventuelles zones souilleÂes d'huile.
auf die Werkbank gelegt. 8- Les lubrifiants, les garnitures, les eÂventuels chiffons servant au
2- Wenn eine Achse abgenommen wird, einen Sicherheitsbock unter nettoyage et les solvants utiliseÂs devront eÃtre reÂcolteÂs et traiteÂs
den zweiten Arm legen. comme rebut speÂcial conformeÂment aux lois en vigueur dans le
3- Werden Arbeiten an der Achse vorgenommen, wenn diese noch pays ouÁ les essieux sont en reÂvision.
an der Maschine montiert ist, BoÈcke zur Halterung unter die 9- Pour le nettoyage, n'utiliser que des solvants aÁ base de toluol,
Achse stellen und die Maschine der LaÈnge nach blockieren. xylol, etc.; n'utiliser que des solvants leÂgers tels que keÂroseÁne,
4- Es duÈrfen sich keine fremde Personen in der NaÈhe der Maschine essences mineÂrales, ou solvants eÂcologiques aÁ base d'eau.
waÈhrend der Arbeiten aufhalten; diesen Bereich absperren und 10 - En ce qui concerne la clarteÂ en matieÁre d'illustration et exposition,
mit Schilder kennzeichnen, die auf die laufenden Arbeiten sur les figures de certains groupes, il y a des pieÁces manquantes
hinweisen. ZuÈndschluÈssel von der Maschine abnehmen. qui normalement peuvent rester monteÂes.
5- Nur saubere Werkzeuge guter QualitaÈt verwenden; alte, beschaÈ- Enlever uniquement les pieÁces deÂcrites.
digte oder improvisierte Hilfsmittel nicht verwenden. Sicher- 11 - Les termes DROITE et GAUCHE utiliseÂs dans ce manuel se
stellen, daû die Dynamometer gepruÈft und geeicht worden sind. rapportent aÁ la personne regardant l'essieu du coÃteÂ opposeÂ aÁ celui
6- Bei Reparaturen, stets Handschuhe und rutschfeste Schuhe tragen. de la prise de mouvement.
7- Mit OÈ l beschmutzte Stellen, sofort reinigen. 12 - A la fin des opeÂrations, afin d'eÂviter un risque d'oxydation
8- Gebrauchte Schmiermittel, Dichtungen, Reinigungslappen und nuisible, retoucher soigneusement les parties vernies eÂventuelle-
ment abõÃmeÂes.
13
SYMBOLS - SIMBOLI - SYMBOLS
SIMBOLOS - SYMBOLES
Disassembly of assembly groups

Smontaggio di sottogruppi
Zerlegen von Baugruppen
Desmontaje de subgrupos
Demontage des sous-groupes
Reassemble to from assembly groups
Montaggio di sottogruppi
Zusasmmenbauen von Baugruppen
Ensamblaje de subgrupos
Montage des sous-groupes
Remove obstruction parts
Smontaggio di particolari ingombri
Abbauen-Ausbauen
Desmontaje de componentes abultados
Demontage des pieces encombrante
Reinstall-remount parts which had obstructed disassembly
Montaggio di particolari ingombri
Einbauen-Ausbauen
Montaje de componentes abultados
Montage des pieces encombrante
Attention ! Important notice
Attenzione, indicazione importante
Achtung, wichtiger Hinweis
¡ Cuidado ! IndicacioÂn importante
Attention, indication importante
Check - adjust e.g. torque, dimensions, pressures, etc.
Controllare - regolare p.e. coppie, misure, pressioni ecc.
PruÈfen - Einstellen z.B. Momente, Maûe, Drucke u.s.cs.
Controlar y ajustar, por ej. pares, medidas, presiones, etc.
Controler, regler p.e. couples, mesures, pressions ecc.
T=Special tool P=page
T=Attrezzature speciali P=Pagina
T=Spezialwerkzeug P=Seite
T=Herramientas especiales P=PaÂgina
T=Outils P=Page
Note direction of installation
Rispettare direzione di montaggio
Einbaurichtung beachten
Respetar la direccioÂn de ensamblaje
Respecter direction de montage
Visual inspection
Esaminare con controllo visuale
Kontrollieren -PruÈfen
Examinar mediante inspeccioÂn visual
Controler, examiner, controle visuel
Possibly still serviceable, renew if necessary
Eventualmente riutilizzare (sostituire se necessario)
Bedingt weiderverwendbar
Puede volver a utilizarse (reemplazar, si es preciso)
Eventuellement a utiliser a noveau (remplacer si neÂcessaire)
Renew at each reassembly
Sostituire ad ogni montaggio
Beim Zusammenbau immer erneuern
Puede reemplazarse a cada ensamblaje
Remplacer avec chaque montage
Unlock - lock e.g. split pin, locking plate, etc.
Togliere-mettere la sicura
Entsichern-Sichern
Quitar-colocar el seguro
Enlever-mettre la securite
Lock-adhere (liquid sealant)
Mettere la sicura, incollare (mastice liquido)
Sichern-Kleben (fluÈssige Dichtung)
Colocar el seguro, pegar (mastique lõÂquido)
Mettre la securite, coller (mastic liquide)
Guard against material damage, damage to parts
Evitare danni materiali, danni a pezzi
Materialschaden verhuÈten
Evitar danÄar los materials o las piezas
Eviter dommages au materiaux, dommages au pieces
Mark before disassembly, observe marks when reassembly
Marchiare prima dello smontaggio (per il montaggio)
Vor dem Ausbau markieren (fuÈ r den Zusammenbau)
Marcar antes de desmontar (para facilitar el ensamblaje)
Marquer avant le demontage (pour le montage)
Filling - topping up - refilling e.g. oil, cooling water, etc.
Caricare - riempire (olio - lubrificante)
EinfuÈllen - AuffuÈ llen - NachfuÈ llen (OÈ l-Schmiermittel)
Cargar - llenar (aceite lubricante)
Charger - remplir (huile - lubrifiant)
Drain off oil, lubricant
Scaricare olio, lubrificante
OÈ l, bzw. Schmiermittel Ablassen
Descargar aceite lubricante
Vidanger, lubrifiant
Tighten
Tendere
Spannen
Tensar
Tendre
Apply pressure into hydraulic circuit
Inserire pressione nel circuito idraulico
Leitung unter Druck setzen
Introducir presioÂn en el circuito hidraÂulico
Inserer pression dans le circuit hydraulique
To clean
Pulire
Reinigen
Limpiar
Nettoyer
Lubricate - grease
Lubrificare - ingrassare
Schmieren - einfetten
Lubrificar - Engrasar
Lubrifier - Graisser
CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO - VERSCHLEISS
KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO -
CONTROLE D'USURE ET SUBSTITUTION DES DISQUES DE FREINAGE
1 T1
S
F1240601 F1240602
GB a bar GB b
CAUTION! Perform all operations on both arms. Apply the brakes and, keeping them under pressure, check the
Remove the oil-level plug (1). linings "S" between the disks using tool T1.
Minimum "S": 4.5 mm.
CAUTION! Replace the braking disks and the intermediate disks
on both sides if necessary.
3
2
5
6
F1240593
2 F1240603
GB c GB d
Unloose and remove the screws (3) and the washers (4) that fix the Remove the arm (2) together with the pack of the braking disks (6).
arm (2) to the central body (5). Place the arm on a bench.
7
8
9
7 7
F1240388 F1240389
GB e GB f
Remove the braking disks (6) and note down their order of Remove the reversal springs (7) from the piston (8).
assembly. NOTE. If the springs (7) are weak or deformed they must be
NOTE. 1 - If the disks do not need replacing, avoid switching their replaced.
position.
2 - Extract the axle shaft (9).
14
ATTENZIONE! Eseguire tutte le operazioni per i due Eseguire una frenata e, mantenendo la pressione,
ITA bracci. ITA controllare con l'attrezzo T1 lo spessore "S" tra i
Asportare il tappo (1) di livello olio. dischi.
"S" minimo: 4,5 mm
ATTENZIONE! Se necessario, sostituire i dischi freno ed intermedi
di ambedue i lati.
ACHTUNG! Alle VorgaÈnge fuÈr beide Arme durch- Die Bremse einmal betaÈtigen und bei betaÈtigter
D fuÈhren. D Bremse mit dem T1 Werkzeug das DistanzstuÈck "S"
OÈ lpegelstopfen (1) abnehmen. zwischen den Scheiben kontrollieren.
"S" mindestens: 4,5 mm
a b ACHTUNG! Wenn noÈtig, die Bremsscheiben und die mittleren
Scheiben auf beiden Seiten auswechseln.
CUIDADO! Ejecutar todas las operaciones para los Ejecutar un frenado y, manteniendo la presioÂn,
ESP dos brazos. ESP controlar con la herramienta T1, el espesor "S" entre
Sacar el tapoÂn (1) de carga de nivel aceite. los discos.
"S" mõÂnimo: 4,5 mm
CUIDADO! Si fuera necesario, sustituir los discos del freno y los
intermedios a ambos lados.
ATTENTION! Effectuer toutes les opeÂrations sur les 2 Effectuer un freinage, puis en tenant sous pression,
F bras. F controÃler aÁ l'aide de l'outil T1 la cale "S" entre les
Enlever le bouchon de la jauge d'huile (1). disques.
"S" minimum: 4,5 mm.
ATTENTION! Si besoin, substituer les disques de freinage et les
intermeÂdiaires des deux coÃteÂs.
Allentare ed asportare le viti (3) e le rondelle (4) che Rimuovere il braccio (2) e con esso il pacco dei dischi
ITA fissano il braccio (2) al corpo centrale (5). ITA di frenatura (6).
Posizionare il braccio su un banco di lavoro.
Schrauben (3) mit den Unterlegscheiben (4) lockern Arm (2) samt Bremsscheiben (6) abnehmen.
D und abschrauben, die den Arm (2) am zentralen D Arm auf die Werkbank legen.
KoÈrper (5) befestigen.
c d
Aflojar y extraer los tornillos (3) y las arandelas (4) que Remover el brazo (2) y con el mismo el paquete de
ESP fijan el brazo (2) al cuerpo central (5). ESP discos de frenado (6).
Posicionar el brazo en un banco de trabajo.
Desserrer et enlever les vis (3), les rondelles (4) qui DeÂposer le bras (2) et avec ce dernier le paquet de
F fixent le bras (2) au corps central (5). F disques de freinage (6).
Placer le bras sur l'eÂtabli d'usinage.
Rimuovere i dischi di frenatura (6) annotando l'ordine Rimuovere le molle (7) di rientro del pistone (8).
ITA di montaggio. ITA
NOTA. Se le molle (7) risultano snervate o deformate,
NOTA. 1 - Se i dischi non vanno sostituiti, evitare lo devono essere sostituite.
scambio di posizione.
2 - Estrarre il semiasse (9).
Bremsscheiben (6) abnehmen und auf die Reihenfolge RuÈckzugsfedern (7) des Kolbens (8) abnehmen.
D der Montage achten. D
BEMERKUNG. Wenn die Federn (7) nachgesetzt oder
BEMERKUNG. 1 - Sollen die Scheiben nicht ausge- verformt sind, diese auswechseln.
wechselt werden, diese in der richtigen Reihenfolge zur Seite
e legen. f
2 - Halbachse (9) abnehmen.
Remover los discos de frenado (6) anotando el orden Remover los muelles (7) de vuelta del pistoÂn (8).
ESP de montaje. ESP
NOTA. Si los muelles (7) estaÂn desnervados o
NOTA. 1 - Si los discos no tienen que ser sustituidos, deformados, hay que sustituirlos.
evitar el intercambio de posicioÂn.
2 - Extraer el semieje (9).
Enlever les disques de freinage (6) en prenant note de Enlever les ressorts (7) de rentreÂe du piston (8).
F l'ordre de montage. F
NOTE. Si les ressorts (7) sont eÂnerveÂs ou deÂformeÂs, il
NOTE. 1 - Si les disques ne sont pas aÁ remplacer, faut les remplacer.
eÂviter le changement de position.
2 - Extraire le demi-essieu (9).
15
CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO - VERSCHLEISS
KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO -
CONTROLE D'USURE ET SUBSTITUTION DES DISQUES DE FREINAGE
10 8
F1240390 F1240391
GB a bar GB b
Remove the pin screws (10) guiding the piston (8). Slowly introduce compressed air through the connection of the
CAUTION! If the screws are to be replaced, note down the different braking circuit in order to extract the entire piston.
colours for the different brake gaps. CAUTION! Hold on to the piston as it may be suddenly ejected and
(See «HOW TO ASSEMBLE THE BRAKING UNITS») damaged.
10
15
8
7
1 11
14 16
2
13
12
5
GB c 9
GB d
6
4
3
D1240076
GB e GB f
16
Rimuovere le viti a perno (10) di guida del pistone (8). Immettere lentamente aria compressa attraverso
ITA ITA l'attacco del circuito frenante per estrarre il pistone
ATTENZIONE! Se le viti devono essere sostituite,
annotare la colorazione distintiva per i giochi freno completo.
(Vedere «ASSEMBLAGGIO GRUPPI DI FRENATURA»). ATTENZIONE! Trattenere il pistone che puoÁ essere espulso
velocemente ed essere danneggiato.
Die Stiftschraube (10) zur KolbenfuÈhrung (8) entfer- Langsam Druckluft in den Bremskreislauf blasen, um
D nen. D den kompletten Kolben herauszuziehen.
ACHTUNG! Sollen die Schrauben ausgewechselt ACHTUNG! Den Kolben mit der Hand halten, um zu
werden, auf die farbige Kennzeichnung fuÈr das Bremsenspiel vermeiden daû er zu schnell herausgestoûen und beschaÈdigt wird.
a achten (Siehe «ZUSAMMENBAU DER BREMSAGGREGATE»). b
Remover los pernos roscados (10) de guõÂa del pistoÂn Introducir lentamente aire comprimido a traveÂs de la
ESP (8). ESP unioÂn del circuito frenante para extraer el pistoÂn
CUIDADO! Si hay que sustituir los pernos, anotar el completo.
color distintivo para los juegos del freno (VeÂase «MONTAJE DE CUIDADO! Retener el pistoÂn porque puede ser expulsado
LOS GRUPOS DE FRENADO»). raÂpidamente y quedar danÄado.
Enlever les vis goujon (10) de guidage du piston (8). Injecter tout doucement de l'air comprimeÂ aÁ travers le
F F raccord du circuit freinant pour extraire le piston
ATTENTION! Si les vis doivent eÃtre remplaceÂes,
prendre note de la couleur de distinction des jeux de complet.
frein (Voir «ASSEMBLAGE DU GROUPE DE FREINAGE»). ATTENTION! Retenir le piston qui pourrait eÃtre eÂjecteÂ fortement et
s'abõÃmer.
17
HOW TO ASSEMBLE THE BRAKING UNITS - ASSEMBLAGGIO DEI GRUPPI DI FRENATURA - BREMSAGGREGATE MONTIEREN -
MONTAJE DE LOS GRUPOS DE FRENADO - ASSEMBLAGE DES GROUPES DE FREINAGE
14
12
11
13
15
2 15 8
8
F1240392 F1240393
GB a GB b
Accurately clean the piston (8) and the seats of slide and seal. Insert the stroke automatic regulation springs (15); place them in
Replace the O-rings (11) and (12) and the anti-extrusion rings (13) line with the piston (8).
and (14); make sure that the assembly side is correct.
CAUTION! Accurately check the positioning of the anti-extrusion
rings (13) and (14).
8
8
F1240394 F1240395
GB c GB d
Lubricate the seals (11) and (12) and fit the piston (8) into the arm Assist the insertion of the piston (8) by lightly hammering around
(2). the edge with a plastic hammer.
CAUTION! Make sure that the piston seat fits into the stop pin "A"
inside the arm.
7
8
10 7
F1240390 F1240389
GB e GB f
Fit the pin screws (10) making sure that they are all of the same Fit the reversal springs (7) on the piston (8).
colour. White: 1 mm gap CAUTION! Pay due attention not to deform the connections of the
Yellow: 0.75 mm gap springs.
Blue: 0.5 mm gap
Apply Loctite 270 to the thread.
Torque wrench setting: 5±7 Nm.
18
Pulire accuratamente il pistone (8) e le sedi di Inserire a filo del pistone (8) le molle (15) per
ITA scorrimento e tenuta. ITA l'autoregolazione della corsa.
Sostituire le guarnizioni OR (11) e (12) e gli anelli
antiestrusione (13) e (14), rispettando il senso di montaggio.
ATTENZIONE! Controllare attentamente il posizionamento degli
anelli antiestrusione (13) e (14).
Kolben (8) sowie Gleit- und Dichtungssitze sorgfaÈltig Den Kolben (8) und die Federn (15) zur Selbstregelung
D reinigen. D des Hubs genau einsetzen.
O-Ringe (11) und (12) sowie die Halteringe (13) und
(14) auswechseln; dabei auf die Reihenfolge der Montage achten.
a ACHTUNG! Position der Halteringe (13) und (14) sorgfaÈltig b
kontrollieren.
Limpiar minuciosamente el pistoÂn (8) y los alojamien- Introducir a ras del pistoÂn (8) los muelles (15) para la
ESP tos de deslizamiento y estanqueidad. ESP autorregulacioÂn de la carrera.
Sustituir las juntas OR (11) y (12) y los anillos
antiextrusioÂn (13) y (14) teniendo en cuenta el sentido de montaje.
CUIDADO! Controlar atentamente el posicionamiento de los anillos
antiextrusioÂn (13) y (14).
Nettoyer soigneusement le piston (8), les logements Introduire, au fil du bord du piston (8) les ressorts (15)
F de coulissement et d'eÂtancheÂiteÂ. F pour l'autoreÂgulation de la course.
Remplacer les garnitures OR (11) et (12), les anneaux
anti-extrusion (13) et (14) en respectant le sens du montage.
ATTENTION! ControÃler soigneusement la position des anneaux
anti-extrusion (13) et (14).
Lubrificare le guarnizioni (11) e (12) e montare nel Aiutare l'inserimento del pistone (8) con leggeri colpi
ITA braccio (2) il pistone (8). ITA di mazzuolo in materiale plastico distribuiti lungo la
ATTENZIONE!: Controllare che la sede del pistone circonferenza.
imbocchi la spina di arresto "A" interna al braccio.
Dichtungen (11) und (12) schmieren und Arm (2) und Den Kolben (8) einsetzen; diesen dazu leicht mit
D Kolben (8) montieren. D einem Gummihammer entlang seiner Kreislinie schla-
ACHTUNG! Der Kolben muû den Anhaltestift "A" im gen.
Inneren des Arms aufnehmen.
c d
Lubricar las juntas (11) y (12) y montar en el brazo (2) Facilitar la insercioÂn del pistoÂn (8) con ligeros golpes
ESP el pistoÂn (8). ESP de martillo de material plaÂstico distribuidos en toda la
CUIDADO! Controlar que el alojamiento del pistoÂn circunferencia.
encaje en la clavija de tope "A" dentro del brazo.
Lubrifier les garnitures (11) et (12), puis monter dans le Accompagner l'introduction du piston (8) par de leÂgers
F bras (2) le piston (8). F coups de maillet en matieÁre plastique distribueÂs tout le
ATTENTION! ControÃler que le logement du piston long de la circonfeÂrence.
s'emboõÃte bien avec la broche d'arreÃt "A" aÁ l'inteÂrieur du bras.
Montare le viti a perno (10) controllando che siano Montare le molle (7) di ritorno del pistone (8).
ITA tutte dello stesso colore. Bianco: gioco 1 mm ITA
ATTENZIONE! Usare molta cautela per non deforma-
Giallo: gioco 0,75 mm re gli attacchi delle molle.
Azzurro: gioco 0,5 mm.
Spalmare la filettatura con Loctite 270.
Coppia di serraggio: 5v7 Nm
Die Stiftschrauben (10) einsetzen. Diese muÈssen alle Die RuÈckzugsfedern (7) des Kolbens (8) montieren.
D gleichfarbig sein. Weiû: Spiel 1 mm D
ACHTUNG! Sehr vorsichtig vorgehen, um die Federn
Gelb: Spiel 0,75 mm am Anschluû nicht zu verformen.
Hellblau: Spiel 0,5 mm.
e Das Gewinde mit Loctite 270 schmieren.
Anzugsmoment: 5v7 Nm.
f
Montar los pernos roscados (10) controlando que sean Montar los muelles (7) de retorno del pistoÂn (8).
ESP todos del mismo color. Blanco: juego 1 mm ESP
CUIDADO! Tener mucho cuidado a fin de no deformar
Amarillo: juego 0,75 mm las uniones de los muelles.
Azul: juego 0,5 mm.
Pasar en la rosca Loctite 270.
Par de torsioÂn: 5v7 Nm.
Monter les vis aÁ tourillon (10) en controÃlant si elles sont Monter les ressorts (7) de retour du piston (8).
F toutes de ma meÃme couleur. Blanc: jeu 1 mm F
ATTENTION! Faire treÁs attention aÁ ne pas deÂformer
Jaune: jeu 0,75 mm les raccords des ressorts.
Bleu ciel: jeu 0,5 mm.
Enduire le filetage de Loctite 270.
Couple de serrage: 5v7 Nm.
19
HOW TO ASSEMBLE THE BRAKING UNITS - ASSEMBLAGGIO DEI GRUPPI DI FRENATURA - BREMSAGGREGATE MONTIEREN -
MONTAJE DE LOS GRUPOS DE FRENADO - ASSEMBLAGE DES GROUPES DE FREINAGE
16
6
F1240398
2 F1240603
GB a GB b
Slightly lubricate the braking disks (6) and fit them in the arm Check that the positioning of the sealing ring (16) on the arm is
following the correct sequence; orient them so that the oil intact; install the complete arm (2). Lock it into position using two
circulation holes and the marks "B" are perfectly lined up. facing screws (3) and washers (4).
T2
F1240703
GB c
Check the flatness of the arms using tool T2 and finally lock the
arms with the screws (3) and the washer (4) using the cross-
tightening method.
Torque wrench setting: 298 Nm
20
Lubrificare leggermente i dischi di frenatura (6) e Verificare l'integritaÁ ed il posizionamento dell'anello di
ITA montarli nel braccio con la giusta sequenza, orientati ITA tenuta (16) del braccio; installare il braccio completo
in modo che i fori di circolazione dell'olio ed i (2).
contrassegni "B" siano perfettamente allineati. Fissarlo in posizione con due viti (3) e rondelle (4) contrapposte.
Die Bremsscheiben (6) leicht schmieren und in der Kontrollieren ob der Kolbenring (16) unbeschaÈdigt und
D richtigen Reihenfolge auf den Arm montieren. Dabei D auf den Arm richtig montiert ist; den kompletten Arm
È lleitungsloÈcher
muÈssen sie so orientiert sein, daû O (2) montieren.
genau mit den Kennzeichnungen "B" uÈbereinstimmen. In seiner Position mit zwei Schrauben (3) und den entgegen-
a b gesetzten Unterlegscheiben (4) befestigen.
Lubricar ligeramente los discos de frenado (6) y Comprobar la integridad y el posicionamiento del
ESP montarlos en el brazo con la secuencia exacta, ESP segmento de compresioÂn (16) del brazo; instalar el
orientados de manera que los orificios de circulacioÂn brazo completo (2).
del aceite y las marcas "B" esteÂn perfectamente alineados. Fijarlo en su posicioÂn con dos tornillos (3) y arandelas (4)
contrapuestas.
Lubrifier leÂgeÁrement les disques de freinage (6), puis VeÂrifier le bon eÂtat et la position de la bague
F monter ceux-ci dans le bras aÁ la juste seÂquence, F d'eÂtancheÂiteÂ (16) du bras, installer le bras complet (2).
orienteÂs de telle sorte aÁ ce que les trous de circulation Fixer celui-ci aÁ sa place aÁ l'aide des deux vis (3) et des
de l'huile et ceux marqueÂs "B" soient parfaitement aligneÂs. rondelles (4) superposeÂes.
Controllare la planaritaÁ dei bracci con l'attrezzo T2 e

ITA fissarli definitivamente con le viti (3) e le rondelle (4)
con il metodo del serraggio incrociato.
Coppia di serraggio: 298 Nm
Die Ebenheit der Arme mit dem Werkzeug T2 kontroll-

D ieren und die Arme endguÈltig mit den Schrauben (3)
und Unterlegscheiben (4) abwechselnd und gegen-
seitig festschrauben.
c Anzugsmoments: 298 Nm
Controlar la planaridad de los brazos utilizando la

ESP herramienta T2 y fijarlos definitivamente con los
tornillos (3) y las arandelas (4) con el meÂtodo de
torsioÂn cruzado.
Par de torsioÂn: 298 Nm
ControÃler l'uniformiteÂ des bras aÁ l'aide de l'outil T2

F puis fixer deÂfinitivement ces derniers avec les vis (3) et
les rondelles (4) par le biais du mode de serrage
croiseÂ.
Couple de serrage: 298 Nm
21
HOW TO DISASSEMBLE THE PLANETARY REDUCTION AND AXLE SHAFT - SMONTAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE -
PLANETENGETRIEB UND HALBACHSEN ABMONTIEREN - DESMONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - DESASSEMBLAGE DU
REDUCTEUR EPICYCLOIDAL ET DU DEMI-ESSIEUX
4
GB a 10
GB b
13 16
17
3
7 11
8
14 12
2
15
5
11
GB c 12 GB d
1
F1240081
2
1 2 3
F1240604 F1240605
GB e GB f
Remove the securing screws (1) from the spider cover (2). Disjoin the spider cover (2) from the hub (3) by alternatively forcing
a screwdriver into the appropriate slots.
22
NOTES ON SAFETY PRECAUTIONS - NOTE RIGUARDANTI LA SICUREZZA - BEMERKUNGEN ZUR
SICHERHEIT - NORMAS CONCERNIENTES A LA SEGURIDAD - NOTES EN MATIERE DE SECURITE
GB The axle shafts can only be removed after extraction 3 - Achse mit mechanisch gesteuerten Bremsen: in diesem Fall
has been performed. Different procedures need to be muÈssen die aÈuûeren Steuerhebel untereinander unter Span-
followed depending on the kind of repair operation nung gesetzt werden.
needed and the type of axle:
4 - Zum Abmontieren, Arm auf die Werkbank legen.
1 - Axle without parking brakes: compressed air (7 bar approx.)
should be introduced in the braking circuit in order to hold the Die ErlaÈuterungen beziehen sich auf das Abmontieren an der
braking disks in position. Werkbank, wobei die VorgaÈnge fuÈr alle anderen LoÈsungen oder
AusfuÈhrungen gleich sind.
2 - Axle with negative brake: does not require any preparation as
the disks are mechanically locked in position.
La remocioÂn de los semiejes se puede ejecutar
3 - Axle with mechanical brake: requires that the external control ESP solamente despueÂs de la remocioÂn y de manera
levers are put under tension in relation to each other. diversificada en funcioÂn del tipo de reparacioÂn que
4 - Disassembly to be carried out with the arm resting on the bench. hay que ejecutar y del tipo de eje:
The explanations reported herewith refer to removal operations 1 - Eje sin frenos de estacionamiento: es necesario hacer entrar
carried out on the bench; the different stages of axle shaft removal aire comprimido (aproximadamente 7 bares) en el circuito de
also apply to all other solutions or versions. frenado para mantener en posicioÂn los discos de los frenos.
2 - Eje con freno negativo: no requiere ninguna preparacioÂn puesto
que los discos quedan bloqueados mecaÂnicamente.
La rimozione dei semiassi puoÁ essere eseguita solo 3 - Eje con freno de mando mecaÂnico: requiere la puesta en tensioÂn
ITA dopo la rimozione del coperchio portasatelliti ed in entre sõÂ de las palancas exteriores de mando.
modo diversificato, in funzione del tipo di riparazione 4 - Desmontaje ejecutado con el brazo apoyado en el banco.
da eseguire e del tipo di assale:
Las explicaciones que aquõÂ figuran se refieren a la remocioÂn
1 - Assale senza freni di stazionamento: eÁ necessario immettere ejecutada en el banco y las fases son comunes para otras
aria compressa (circa 7 bar) nel circuito di frenatura per tenere in soluciones o versiones.
posizione i dischi freni.
2 - Assale con freno negativo: non richiede alcuna preparazione in
quanto i dischi restano bloccati meccanicamente.
La deÂpose des demi-essieux ne peut eÃtre effectueÂe
3 - Assale con freno a comando meccanico: richiede di mettere in F qu'apreÁs la deÂpose, d'une facËon diversifieÂe, en fonction
tensione tra loro le leve esterne di comando. du type de reÂparation aÁ effectuer et du type d'essieu:
4 - Smontaggio eseguito con il braccio appoggiato sul banco. 1 - Essieu sans freins de stationnement: il faut introduire de l'air
Le spiegazioni riportate si riferiscono alla rimozione eseguita al comprimeÂ (environ 7 bar) dans le circuit de freinage pour
banco e le fasi sono comuni alle altre soluzioni o versioni. maintenir les disques de freinage en place.
2 - Essieu aÁ frein neÂgatif: ne requiert aucune preÂparation parce que
les disques meÂcaniquement restent bloqueÂs.
3 - Essieu aÁ frein de commande meÂcanique: requiert de mettre sous
Die Halbachsen koÈnnen erst abmontiert werden, wenn tension des leviers externes de commande entre-eux.
D das GelenkgehaÈuse schon abgenommen worden ist. 4 - DeÂmontage effectueÂ et bras deÂposeÂ sur l'eÂtabli.
Der Vorgang ist je nach benoÈtigter Reparatur und je
nach Achsentyp unterschiedlich: Les explications reporteÂes se reÂfeÁrent aÁ la deÂpose effectueÂe sur
1 - Achse ohne Feststellbremse: die Bremsanlage mit ca. 7 bar l'eÂtabli, les phases sont les meÃmes que pour les autres solutions ou
unter Druck setzen, um die Bremsscheiben in ihrer Position versions.
festzuhalten.
2 - Achse mit negativer Bremse: benoÈtigt keinerlei Vorbereitung, da
die Scheiben mechanisch blockiert bleiben.
Asportare le viti (1) di fissaggio del coperchio Utilizzando un cacciavite inserito alternativamente
ITA portasatelliti (2). ITA nelle cave predisposte, staccare il coperchio portasa-
telliti (2) dal mozzo portaruota (3).
Befestigungsschrauben (1) vom Planetenradhalter- Mit einem Schraubenzieher den Panetenradhalterdek-

D deckel (2) abschrauben. D kel (2) von der Radhaltenabe (3) trennen. Dazu den
Schraubenzieher abwechselnd in die vorgesehenen
Nuten stecken und anheben.
a b
Sacar los tornillos (1) de fijacioÂn de la tapa portasa- Utilizando un destornillador introducido alternativa-
ESP teÂlites (2). ESP mente en las ranuras predispuestas, desprender la
tapa portasateÂlites (2) del cubo portarruedas (3).
Enlever les vis de fixation (1) du couvercle porte- A l'aide d'un tournevis introduit au fur et aÁ mesure
F satellites (2). F dans les creux preÂdisposeÂs, deÂcrocher le couvercle
porte-satellites (2) du moyeu porte-roue (3).
23
F1240606 F1240607
GB a GB b
Remove the complete planetary carrier cover (2). Remove the complete axle-shaft (4).
5
7
6
F1240608 F1240609
GB c GB d
Unloose and remove the tightening nuts (5) from the crown flange Remove the safety flange (7).
(6).
6
3
F1240610 F1240611
GB e GB f
Using and puller, remove the complete crown flange (6) by acting Partially extract the hub (3) using a plastic hammer.
on the stud bolts. NOTE. Alternately hammer on several equidistant points.
24
Asportare il coperchio portasatelliti (2) completo. Asportare il semiasse (4).
ITA ITA
Kompletter Planetenradhalterdeckel (2) abnehmen. Komplette Hallachse (4) heraus ziehen.

D D
a b
Sacar la tapa portasateÂlites (2) completa. Extraer el semieje (4) completo.
ESP ESP
Enlever le couvercle porte-satellites (2) complet. Extraire de demi-essieu (4) complet.

F F
Allentare ed asportare i dadi (5) che fissano la flangia Rimuovere la flangia di sicurezza (7).
ITA portacorona (6). ITA
Befestigungsmuttern (5) des Kranzhalterflansches (6) Sicherheitsflansch (7) abnehmen.

D lockern. D
c d
Aflojar y quitar las tuercas (5) que fijan la brida Remover la brida de seguridad (7).
ESP portacorona (6). ESP
Desserrer et enlever les eÂcrous (5) de fixation de la Enlever la flasque de seÂcuriteÂ (7).
F flasque porte-couronne (6). F
Utilizzando un estrattore e, facendo reazione sui Utilizzando un mazzuolo in materiale plastico, sfilare
ITA prigionieri, rimuovere la flangia portacorona (6) com- ITA parzialmente il mozzo portaruota (3).
pleta. NOTA. Battere alternativamente in piuÁ punti equidi-
stanti.
Durch einen Abzieher uÈber die Stiftschrauben, den Mit einem Gummihammer, die Radhalternabe (3)
D kompletten Kranzhalterflansch (6) abnehmen. D etwas heraus schieben.
BEMERKUNG. Abwechselnd an verschiedenen,
gleich entfernten Stellen schlagen.
e f
Utilizando un extractor y apalancando los prisioneros, Utilizando un martillo de material plaÂstico, extraer
ESP remover la brida portacorona (6) completa. ESP parcialmente el cubo portarruedas (3).
NOTA. Golpear alternativamente en varios puntos
equidistantes.
En utilisant l'extracteur et en faisant reÂagir les A l'aide d'un maillet en matieÁre plastique, extraire
F prisonniers, enlever la flasque porte-couronne (6) F partiellement le moyeu porte-roue (3).
compleÁte. NOTE. Frapper sur plusieurs points aÁ la meÃme
distance.
25
3
8
10
F1240612 F1240613
GB a GB b
Remove the external bearing (8). Extract the hub (3).
11
F1240614 F1240615
GB c GB d
Remove snap ring (10) from the arm (9). Remove the snap rings (11).
12 2
13
F1240616 F1240617
GB e GB f
With the help of an puller, remove the planet wheel gears (12). Using a puller for inner parts, remove shim washer (13) from
NOTE. Note down the assembly side of planet wheels. planetary cover (2).
26
Asportare il cuscinetto esterno (8). Sfilare il mozzo portaruota (3).
ITA ITA
AÈuûeres (8) Lager abnehmen. Radhalternabe (3) herausziehen.

D D
a b
Sacar el cojinete exterior (8). Extraer el cubo portarruedas (3).
ESP ESP
Enlever le palier externe (8). Extraire le moyeu porte-roue (3).

F F
Rimuovere dal braccio (9) l'anello di tenuta (10). Asportare gli anelli elastici (11).
ITA ITA
Kolbenring (9) vom Arm (10) abnehmen. Die Kolbenringe (11) entfernen.
D D
c d
Sacar el anillo de retencioÂn (9) del brazo (10). Sacar los anillos elaÂsticos (11).
ESP ESP
Enlever l'anneau eÂlastique (9) du bras (10). Enlever les anneaux eÂlastiques (11).
F F
Utilizzando un estrattore, asportare gli ingranaggi Utilizzando un estrattore per interni, asportare dal
ITA satelliti (12). ITA coperchio portasatelliti (2) la rondella di rasamento
NOTA. Annotare il senso di montaggio dei satelliti. (13).
Mit einem Abzieher, die PlanetenraÈder (12) heraus Mit einem Abzieher den Deckel der Planetengetriebe
D nehmen. D (2) und die Zwischenlegscheibe (13) abziehen.
BEMERKUNG. Montagerichtung der PlanetenraÈder
beachten.
e f
Utilizando un extractor, sacar los engranajes sateÂlites Utilizar un extractor por internos, sacar de la tapa
ESP (12). ESP portasatelites (2) la arandela de rasadura (13).
NOTA. Anotar el sentido de montaje de los sateÂlites.
A l'aide d'un extracteur, extraire les engrenages A l'aide d'un extracteur d'internes, extraire du
F satellites (12). F couvercle porte-satellite (2) la rondelle de rasage (13).
NOTE. Prendre note du sens de montage des
satellites.
27
14 6
15
F1240450 F1240451
GB a GB b
Remove the snap ring (14) from the crown (15). Remove the crown flange (6).
3 16 17
3
F1240452 F1240453
GB c GB d
Remove the sealing ring (16) from the hub (3). Remove the internal bearing (15).
F1240454
GB e
Remove the external thrust blocks from the bearings (8) and (17)
forcing a pin-driver into the appropriate slots on the hub (3).
NOTE. Hammer in an alternate way so as to avoid crawling or
deformation of the thrust blocks.
28
Asportare l'anello elastico (14) di ritegno della corona Rimuovere la flangia portacorona (6).
ITA (15). ITA
Den Kolbenring (14) vom Kranz (15) abnehmen. Kranzhalterflansch (6) abnehmen.
D D
a b
Sacar el anillo elaÂstico (14) de retencioÂn de la corona Remover la brida portacorona (6).
ESP (15). ESP
Enlever l'anneau eÂlastique (14) de retenue de la DeÂposer la flasque porte-couronne (6).

F couronne (15). F
Rimuovere dal mozzo portaruota (3) l'anello di tenuta Rimuovere il cuscinetto interno (17).
ITA (16). ITA
Von der Radhalternabe (3) den Kolbenring abnehmen Inneres Lager (17) abnehmen.
D (16). D
c d
Remover del cubo portarruedas (3) el segmento de Remover el cojinete interior (17).
ESP compresioÂn (16). ESP
Enlever, du moyeu porte-roue (3), la bague d'eÂtan- Enlever le palier interne (17).
F cheÂiteÂ (16). F
Rimuovere le ralle esterne dei cuscinetti (8) e (17)

ITA utilizzando un cacciaspine inserito nelle cave predi-
sposte sul mozzo (3).
NOTA. Battere in modo alternato per evitare impuntamenti e
deformazione delle ralle.
Die aÈuûeren Scheiben der Lager (8) und (17) mit einem
D DuÈbel durch die NabenloÈcher (3) herausschlagen.
BEMERKUNG. Abwechselnd herausschlagen, um
Verformungen zu vermeiden.
e
Remover las ranguas exteriores (8) y (17) de los
ESP cojinetes utilizando un extractor para clavijas inser-
tado en las ranuras predispuestas en el cubo (3).
NOTA. Golpear de manera alternada para evitar danÄos y
deformaciones de las ranguas.
Enlever les crapaudines externes des paliers (8) et (17)

F aÁ l'aide d'une chasse-goupilles placeÂ dans les creux
speÂcialement concËus aÁ cet effet sur le moyeu (3).
NOTE. Taper d'une manieÁre alterneÂe afin d'eÂviter talonnage et
deÂformation des crapaudines.
29
ASSEMBLING THE PLANETARY REDUCTION AND AXLE SHAFT - ASSEMBLAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE -
PLANETENGETRIEB UND HALBACHSEN MONTIEREN - MONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - ASSEMBLAGE DU REDUCTEUR
EPICYCLOIDAL ET DU DEMI-ESSIEUX
8 3 17
T9A T9A
F1240458 F1240459
GB a GB b
Position the lower part of tool T9A and the thrust block of the Lubricate the seats of the bearings and position the hub (3) on tool
external bearing (8) under the press. T9A; position the thrust block of the internal bearing (17).
NOTE. Check that the thrust block is correctly oriented.
17
T9B
F1240460 F1240461
GB c GB d
Position the upper part of tool T9B and press the thrust blocks into Fit the bearing (15) into the internal thrust block.
the hub (3) all the way down.
T10
16
3 16
F1240462 F1240463
GB e GB f
Apply a sealant for removable seals to the outer surface of the Position tool T10 and press the sealing ring (16) into its seat.
sealing ring (16). Position the sealing ring (16) in the hub (3).
NOTE. Check that the ring (16) is correctly oriented.
30
Posizionare sotto la pressa la parte inferiore dell'at- Lubrificare le sedi dei cuscinetti e posizionare sull'at-
ITA trezzo T9A e la ralla del cuscinetto esterno (8). ITA trezzo T9A il mozzo portaruota (3); posizionare la ralla
del cuscinetto interno (17).
NOTA. Controllare l'orientamento della ralla.
Unter einer Presse den unteren Teil des Werkzeugs Die Lagersitze schmieren und am Werkzeug T9A die
D T9A und die Scheibe des aÈuûeren Lagers (8) D Radhalternabe (3) positionieren; die Scheibe des
positionieren. inneren Lagers (17) positionieren.
BEMERKUNG. Die Position der Scheibe beachten.
a b
Posicionar debajo de la prensa la parte inferior de la Lubricar los alojamientos de los cojinetes y posicionar
ESP herramienta T9A y la rangua del cojinete exterior (8). ESP en la herramienta T9A el cubo portarruedas (3);
posicionar la rangua del cojinete interior (17).
NOTA. Controlar la orientacioÂn de la rangua.
Placer sous la presse la partie infeÂrieure de l'outil T9A Lubrifier le logement des paliers et placer sur l'outil
F et la crapaudine du palier externe (8). F T9A le moyeu porte-roue (3); placer la crapaudine du
palier interne (17).
NOTE. ControÃler les sens de la crapaudine.
Posizionare la parte superiore dell'attrezzo T9B e Montare il cuscinetto (17) nella ralla interna.
ITA pressare a fondo le ralle nel mozzo portaruota (3). ITA
Das obere Teil des Werkzeugs T9B positionieren und Lager (17) in die innere Scheibe montieren.
D die Scheiben in die Radhalternabe (3) fest eindruÈcken. D
c d
Posicionar la parte superior de la herramienta T9B y Montar el cojinete (17) en la rangua interior.
ESP presionar a fondo las ranguas en el cubo portarruedas (3). ESP
Placer la partie supeÂrieure de l'outil T9B, puis presser aÁ Monter le palier (17) dans la crapaudine interne.
F fond les crapaudines du moyeu porte-roue (3). F
Spalmare la superficie esterna dell'anello di tenuta Posizionare l'attrezzo T10 e pressare in sede l'anello
ITA (16) con sigillante per guarnizioni removibili. ITA di tenuta (16).
Posizionare l'anello di tenuta (16) nel mozzo (3).
NOTA. Controllare l'orientamento dell'anello (16).
Die aÈuûere FlaÈche des Kolbenringes (16) mit Dicht- Das Werkzeug T10 positionieren und den Kolbenring
D masse fuÈr abnehmbare Dichtungen schmieren. D (16) in seinen Sitz pressen.
Den Kolbenring (16) in die Nabe (3) montieren.
BEMERKUNG. Richtung des Ringes (14) beachten.
e f
Pasar sobre la superficie exterior del anillo de Posicionar la herramienta T10 y presionar en su
ESP compresioÂn (16) un elemento de sellado por guarni- ESP alojamiento el segmento de compresioÂn (16).
ciones removibles.
Posicionar el segmento de compresioÂn (16) en el cubo (3).
NOTA. Controlar la orientacioÂn del anillo (16).
Enduire la surface externe de la bague d'eÂtancheÂiteÂ Placer l'outil T10 et presser dans son logement la
F (16) d'enduit pour garnitures deÂmontables. F bague d'eÂtancheÂiteÂ (16).
Placer la bague d'eÂtancheÂiteÂ (16) dans le moyeu (3).
NOTE. ControÃler le sens de la bague (16).
31
6 14
15
15
6
F1240451 F1240450
GB a GB b
Insert the flange (6) in the crown (15). Insert the snap ring (14) in order to fix the flange (6) in the crown
(15).
NOTE. Carefully check that ring (14) is properly inserted in the slot
of the crown (15).
T33
2 T11
2
13 12
F1240618 F1240619
GB c GB d
Using tool T33, fit shim washer (13) into planetary cover (2). With the help of tool T11, insert the planet wheel gears (12) into the
cover (2).
Accurately check the orientation.
T 34
12
11
F1240615 F1240620
GB e GB f
Lock the gears (12) into position by fitting the snap rings (11). Lubricate the outer face of the sealing ring (10) and, with the help of
tool T34, fit it in the arm.
NOTE. Accurately check direction of assembly.
32
Inserire la flangia (6) nella corona (15). Inserire l'anello elastico (14) per fissare la posizione
ITA ITA della flangia (6) nella corona (15).
NOTA. Controllare attentamente l'inserimento dell'a-
nello (14) nella cava della corona (15).
Flansch (6) in den Kranz (15) montieren. Den Kolbenring (14) einsetzen, um die Position des
D D Flansches (6) im Kranz (15) zu sichern.
BEMERKUNG. SorgfaÈltig kontrollieren, ob der Ring
(14) in der Nut des Kranzes (15) richtig eingesetzt ist.
a b
Introducir la brida (6) en la corona (15). Introducir el anillo elaÂstico (14) para fijar la posicioÂn de
ESP ESP la brida (6) en la corona (15).
NOTA. Controlar atentamente la insercioÂn del anillo
(14) en la ranura de la corona (15).
Introduire la flasque (6) dans la couronne (15). Introduire l'anneau eÂlastique (14) pour fixer la position
F F de la flasque (6) dans la couronne (15).
NOTE. ControÃler soigneusement l'introduction de la
bague (14) dans le creux de la couronne (15).
Utilizzando l'attrezzo T33 montare nel coperchio Utilizzando l'attrezzo T11 inserire nel coperchio (2) gli
ITA portasatelliti (2) la rondella di rasamento (13). ITA ingranaggi satelliti (12).
Controllare attentamente l'orientamento.
Mit dem Werkzeug T33, den Deckel der Planetenge- Mit dem Werkzeug T11 in den Deckel (2) die
D triebe (2) und die Zwischenscheibe (13) montieren. D PlanetenraÈder (12) einsetzen.
Die Position sorgfaÈltig kontrollieren.
c d
Utilizando la herramienta T33 montar en la tapa Utilizando la herramienta T11 introducir en la tapa (2)
ESP portasatelites (2) la arandela de rasadura (13). ESP los engranajes sateÂlites (12).
Controlar atentamente la orientacioÂn.
A l'aide de l'outil T33 monter le couvercle porte- A l'aide de l'outil T11 introduire dans le couvercle (2)
F satellite (2), la rondelle de rasage (13). F les engrenages satellites (12).
ControÃler attentivement le sens.
Bloccare la posizione degli ingranaggi (12) montando Lubrificare l'esterno dell'anello di tenuta (10) e, con
ITA gli anelli elastici di ritegno (11). ITA l'attrezzo T34, montarlo nel braccio.
NOTA. Controllare attentamente il senso di montaggio.
Die Position der RaÈder (12) mit den Halteringen (11) Den Kolbenring (10) auûen schmieren und mit dem
D blockieren. D Werkzeug T34 in den Arm montieren.
BEMERKUNG. Montagerichtung sorgfaÈltig pruÈfen.
e f
Bloquear la posicioÂn de los engranajes (12) montando Lubrificar el esterior del anillo de retencioÁn (10) y, con
ESP los anillos elaÂsticos de retencioÂn (11). ESP la herramienta T34, montarlo en el brazo.
NOTA. Controlar cuidadosamente el sentido de
montaje.
Bloquer la position des engrenages (12) en montant Lubrifier l'exteÂrieur de la bague d'eÂtancheÂiteÂ (10) et au
F les anneaux eÂlastiques de retenue (11). F moyen de l'outil T34 monter cette dernieÁre dans le
bras.
NOTE. ControÃler attentivement le sens du montage.
33
3
9
16
8
10 F1240613 F1240612
GB a GB b
Lubricate with grease the sealing ring (16) and the hub of the arm Install the external bearing (8).
(9). NOTE. Using a plastic hammer, drive the bearing to the limit stop
Install the hub (3). by lightly hammering around the edge.
6
6
7
F1240621 F1240609
GB c GB d
Fit the complete crown flange (6). Apply Tecnolube Seal 101 grease to the surface of the safety
NOTE. In order to fasten the flange (6), use a plastic hammer and flange (7) which touches the crown flange (6).
alternately hammer on several equidistant points. Fit the safety flange (7).
F1240622 F1240623
GB e GB f
Apply Loctite 242 to the studs and fit in the nuts (5). Cross tighten the nuts (5) in two stages.
Initial torque wrench setting: 130 Nm
Final torque wrench setting: 255±285 Nm
34
Lubrificare con grasso l'anello di tenuta (16) ed il Montare il cuscinetto esterno (8).
ITA mozzo del braccio (9). ITA
NOTA. Mandare a fondo corsa il cuscinetto con
Montare il mozzo portaruota (3). leggeri colpi di mazzuolo distribuiti su tutta la
circonferenza.
Kolbenring (16) und Armnabe (9) mit Fett schmieren. AÈuûeres Lager (8) montieren.
D Radhalternabe (3) montieren. D
BEMERKUNG. Das Lager bis zum Anschlag ein-
setzen; dazu einen Gummihammer verwenden und
entlang der Kreislinie einschlagen.
a b
Lubrificar con grasa el segmento de compresioÁn (16) y Montar el cojinete exterior (8).
ESP el cubo del brazo (9). ESP
NOTA. Llevar al fondo de carrera el cojinete con
Montar el cubo portarruedas (3). ligeros golpes de martillo distribuidos en toda la
circunferencia.
Lubrifier avec de la graisse la bague d'eÂtancheÂiteÂ (16) Monter le palier externe (8).
F et le moyeu du bras (9). F
NOTE. Envoyer le palier en fin de course avec des
Monter le moyeu porte-roue (3). petits coups de maillet distribueÂs sur toute la circonfeÂ-
rence.
Montare la flangia portacorona (6) completa. Lubrificare con grasso Tecnolube Seal 101 la superfi-
ITA ITA cie della flangia di sicurezza (7) a contatto con la
NOTA. Per mandare in battuta la flangia (6), usare un
mazzuolo in materiale plastico battuto alternativamen- flangia portacorona (6).
Á
te in piu punti equidistanti. Montare la flangia di sicurezza (7).
Kompletter Kranzhlaterflansch (6) montieren. Mit Fett Typ Tecnolube Seal 101 die OberflaÈche des
D D Sicherheitsflansch (7) schmieren, der am Kranzhalter-
BEMERKUNG. Um den Flansch (6) bis zum Anschlag
einzusetzen, einen Gummihammer verwenden und flansch (6) anliegt.
abwechselnd an gleich entfernten Stellen einschlagen. Sicherheitsflansch (7) montieren.
c d
Montar la brida portacorona (6). Lubricar con grasa Tecnolube Seal 101 la superficie
ESP ESP de la brida de seguridad (7) en contacto con la brida
NOTA. Para llevar a tope la brida (6) usar un martillo
de material plaÂstico golpeaÂndolo alternativamente en portacorona (6).
varios puntos equidistantes. Montar la brida de seguridad (7).
Monter la flasque porte-couronne (6) compleÁte. Lubrifier avec du gras Tecnolube Seal 101 la surface
F F de la flasque de seÂcuriteÂ (7) en contact avec la flasque
NOTE. Pour envoyer la flasque (6) en buteÂe, utiliser un
maillet en matieÁre plastique en battant sur plusieurs porte-couronne (6).
points eÂquidistants. Monter la flasque de seÂcuriteÂ (7).
Spalmare i prigionieri con Loctite 242 e montare i dadi Serrare i dadi (5) in due tempi e con il metodo del
ITA (5). ITA serraggio incrociato.
Coppia di serraggio iniziale: 130 Nm
Coppia di serraggio finale 255v285 Nm
Die Stiftschrauben mit Loctite 242 schmieren und die Die Mutter (5) abwechseln und entgegengesetzt fest-
D Muttern (5) montieren. D schrauben.
AnfaÈnglicher Anzugsmoment: 130 Nm
EndguÈltiger Anzugsmoment: 255v285 Nm
e f
Pasar en los prisioneros Loctite 242 y montar las Apretar las tuercas (5) en dos tiempos y siempre con el
ESP tuercas (5). ESP meÂtodo de torsioÂn cruzada.
Par de torsioÂn inicial: 130 Nm
Par de torsioÂn final 255v285 Nm
Enduire les prisonniers avec du Loctite 242 puis Serrer les eÂcrous (5) en deux temps par le biais du
F monter les eÂcrous (5). F mode de serrage croiseÂ.
Couple de serrage initial: 130 Nm
Couple de serrage final: 255v285 Nm
35
2 3
F1240607
18 F1240606
GB a GB b
Grease snap ring (10) and sealing face of axle-shaft (4). Fit the planetary carrier cover (2) onto the hub (3).
Install the axle shaft (4) making sure it is properly engaged in the CAUTION! Check that the O-ring (18) is in good condition and in
braking disks and in the differential unit. position.
NOTE. Be very careful not to damage the snap ring (10).
1 2
1 F1240624
GB c
Lock the planetary carrier cover (2) by tightening the screws (1).
Torque wrench setting for screws: 40±50 Nm
Lubrificare l'anello di tenuta (10) la superficie di tenuta Montare il coperchio portasatelliti (2) sul mozzo
ITA del semiasse (4). ITA portaruota (3).
Montare il semiasse (4) assicurandosi che si innesti ATTENZIONE! Controllare lo stato e la posizione della
nei dischi freno e nel differenziale. guarnizione OR (18).
NOTA. Prestare molta attenzione per non danneggiare l'anello di
tenuta (10).
Kolbenring (10) und DichtungsflaÈche der Halbachse Planetenradhalterdeckel (2) auf die Radhalternabe (3)
D (4) schmieren. D montieren.
Halbachse (4) montieren und darauf achten, daû sie ACHTUNG! Den Zustand und die Position des O-
richtig in den Bremsscheiben und im Differential sitzt. Ringes (18) kontrollieren.
a BEMERKUNG. Sehr vorsichtig vorgehen, um den Kolbenring (10) b
nicht zu beschaÈdigen.
Lubrificar el segmento de compresioÁn (10) la superfi- Montar la tapa portasateÂlites (2) en el cubo portarrue-
ESP cie de compresioÁn del semieje (4). ESP das (3).
Montar el semieje (4) asegurandose que se injerte en CUIDADO! Controlar el estado y la posicioÂn de la junta
los discos y en el diferencial. OR (18).
NOTA. Prestar mucha atencioÁn para no danar el segmento de
compresioÁn (10).
Lubrifier la bague d'eÂtancheÂiteÂ (10), la surface eÂtanche Monter le couvercle porte-satellites (2) sur le moyeu
F du demi-essieu (4). F porte-roue (3).
Monter le demi-essieu (4) en s'assurant qu'il est bien ATTENTION! ControÃler l'eÂtat et la position de la
engageÂ dans les disques freins et dans le diffeÂrentiel. garniture OR (18).
NOTE. Faire treÁs attention aÁ ne pas abõÃmer la bague d'eÂtancheÂiteÂ
(10).
Bloccare il coperchio portasatelliti (2) con le viti (1).

ITA Coppia di serraggio viti: 40v50 Nm
Planetenhalterdeckel (2) mit den Schraube (1) fest-

D schrauben.
Anzugsmoment der Schrauben: 40v50 Nm
c
Bloquear la tapa portasateÂlites (2) con los tornillos (1).
ESP Par de torsioÂn tornillos: 40v50 Nm
Bloquer le couvercle porte-satellites (2) avec les vis

F (1).
Couple de serrage vis: 40v50 Nm
37
HOW TO REMOVE THE BEVEL PINION - RIMOZIONE PIGNONE CONICO - KEGELRAD ABMONTIEREN -
REMOCION PINÄON CONICO - DEPOSE DU PIGNON CONIQUE
F1241060 F1240514
GB a GB b
ATTENTION! Though the photos in this manual refer to a steering If disassembly is awkward, heat the check nut (1) of the flange (2) at
and oscillating axle, the operations described apply anyway. 80ëC.
Remove the complete arms and the differential unit. NOTE. Heating is meant to unloose the setting of Loctite on the nut
For details, see «CHECKING WEAR AND REPLACING THE (1).
BRAKING DISKS» and «REMOVING THE DIFFERENTIAL UNIT».
T20A
(T20B)
3 2
F1240515 F1240516
GB c GB d
Position tool T20A (or T20B), so as to avoid pinion rotation. Remove the flange (2) complete with guard (4) by means of a
Unloose and remove the nut (1); also remove the O-ring (3). puller.
F1240517 F1240518
GB e GB f
ATTENTION! This operation does not apply to the fixed axle. Remove the sealing ring (6).
Remove the swinging support (5).
38
ATTENZIONE! Le foto rsono riferite ad un assale Se lo smontaggio risulta faticoso, scaldare a circa
ITA sterzante ed oscillante, ma le operazioni descritte ITA 80ëC il dado (1) di ritegno della flangia (2).
sono valide. NOTA. Il riscaldamento ha lo scopo di allentare la
Rimuovere i bracci completi ed il differenziale. presa del Loctite di bloccaggio del dado (1).
Per i dettagli, vedere «CONTROLLO USURA E SOSTITUZIONE
DISCHI FRENO» e «RIMOZIONE GRUPPO DIFFERENZIALE».
ACHTUNG! Die Abbildungen beziehen sich auf eine Wenn das Abmontieren schwierig ist, die Mutter (1)
D Lenk- und Schwenkachse. Die beschriebenen Vor- D zur Halterung des Flansches (2) auf ca. 80ëC erwaÈr-
gaÈnge gelten aber auch in diesem Fall. men.
Komplette Arme und Differential abnehmen. Siehe «VER- BEMERKUNG. Durch das Erhitzen wird das Fett aufgeweicht, das
a SCHLEISS KONTROLLIEREN UND BREMSSCHEIBEN AUS- b die Mutter (1) blockiert.
WECHSELN» und «DIFFERENTIALAGGREGAT ABMONTIEREN».
ATENCION! Las fotos se refieren a un eje desviante y Si el desmontaje resulta difõÂcil, calentar a unos 80ëC la
ESP oscilante, pero las operacioÁnes descritas son validas. ESP tuerca (1) de retencioÂn de la brida (2).
Remover los brazos completos y el diferencial. Para NOTA. El calentamiento tiene la finalidad de aflojar la
los detalles veÂase «CONTROL DESGASTE Y SUSTITUCION DE adhesioÂn del Loctite de bloqueo de la tuerca (1).
LOS DISCOS DEL FRENO» y «REMOCION GRUPO DIFEREN-
CIAL».
ATTENTION! Les photos sont reÂfeÂreÂes aÁ un essieu Si deÂmonter est difficile, chauffer l'eÂcrou (1) de fixation
F braquant et oscillant, mais les opeÂrations ci-deÂcrites F de la flasque (2) aÁ environ 80ëC.
sont valables. NOTE. Le chauffage aÁ pour objet de ralentir la prise du
Enlever compleÁtement les bras complets et le diffeÂrentiel. Pour de plus Loctite de blocage de l'eÂcrou (1).
amples deÂtails, voir «CONTROLE USURE ET SUBSTITUTION DES
DISQUES DE FREINAGE» et «DEPOSE DU GROUPE DIFFERENTIEL».
Applicare l'attrezzo T20A (oppure T20B) ed impe- Utilizzando un estrattore, rimuovere la flangia (2)
ITA gnarlo in modo da evitare la rotazione del pignone. ITA completa della protezione (4).
Allentare ed asportare il dado (1); asportare anche
l'anello OR (3).
Werkzeug T20A (T20B) so anbringen, daû das Rad Mit einem Abzieher, Flansch (2) samt Schutzteil (4)
D nicht mehr drehen kann. D abnehmen.
Mutter (1) lockern und abschrauben; O-Ring (3)
ebenfalls abnehmen.
c d
Aplicar la herramienta T20A (T20B) y bloquearla a fin Utilizando un extractor, remover la brida (2) completa
ESP de evitar la rotacioÂn del pinÄoÂn. ESP con la proteccioÂn (4).
Aflojar y sacar la tuerca (1); sacar tambieÂn el anillo OR (3).
Appliquer l'outil T20A (ou T20B) engager ce dernier A l'aide d'un extracteur, enlever la flasque (2)
F de manieÁre aÁ eÂviter la rotation du pignon. F compleÁte de la protection (4).
RelaÃcher et enlever l'eÂcrou (1) enlever eÂgalement la
garniture OR (3).
ATTENZIONE! Questa operazione non eÁ valida per Rimuovere l'anello di tenuta (6).
ITA l'assale fisso. ITA
Rimuovere il supporto oscillante (5).
ACHTUNG! Dieser Vorgang gilt nicht fuÈr die feste Kolbenring (6) entfernen.
D Achse. D
Schwenkbare Halterung (5) entfernen.
e f
ATENCION! Esta operacioÁn no es valida para el eje Remover el segmento de compresioÂn (6).
ESP fijo. ESP
Remover el soporte oscilante (5).
ATTENTION! Cette opeÂration n'est pas valable en Enlever la bague d'eÂtancheÂiteÂ (6).
F case d'essieu fixe. F
Enlever le support oscillant (5).
39
12
T23
7
8
T21
T22
F1240519 F1240520
GB a GB b
Position wrench T22 onto the ring nut (7) and apply bar hold T21 to Apply blocks T23 and, with the help of a puller, extract the pinion
the pinion (8). (8) complete with the internal bearing (9), the distance piece (10)
Stop wrench T22 and rotate the pinion so as to release and remove and shims (11).
the ring nut (7). NOTE. The thrust blocks of the bearings remain in the central body
NOTE. If disassembly proves awkward, weld the ring nut at approx. (12).
80ëC.
10
8
8
9
11
F1240543 F1240578
GB c GB d
Remove the pinion (8), shims (11) and distance piece (10). Using a puller and a press, remove the inner bearing (9) from the
pinion (8).
13
14
9
F1240521 F1240522
GB e GB f
Remove the thrust block of the external bearing (13). Insert a drift in the appropriate holes and remove the thrust block of
the internal bearing (9) as well as the shim washers (14).
40
Impegnare la chiave speciale T22 sulla ghiera (7) ed Applicare i blocchi T23 e con un estrattore, estrarre il
ITA applicare sul pignone (8) il codolo T21. ITA pignone (8) completo del cuscinetto interno (9), del
Fermare la chiave T22 e ruotare il pignone per distanziale (10) e degli spessori (11).
allentare ed asportare la ghiera (7). NOTA. Le ralle dei cuscinetti rimangono nel corpo centrale (12).
NOTA. Se lo smontaggio risulta faticoso, scaldare la ghiera a circa
80 ëC.
Den speziellen SchluÈssel T22 in die Nutmutter (7) Die BloÈcke T23 anbringen und mit einem Abzieher das
D setzen und am Rad (8) den Schaft T21 anbringen. D Rad (8) samt dem inneren Lager (9), DistanzstuÈck (10)
SchluÈssel T22 festhalten und das Rad drehen, um die und der Scheiben (11) herausziehen.
Nutmutter (7) zu lockern und abzunehmen. BEMERKUNG. Die Lagerscheiben bleiben im zentralen KoÈrper (12)
a BEMERKUNG. Falls die Nutmutter zu fest sitzt, diese auf ca. 80ëC b sitzen.
erhitzen.
Bloquear la llave especial T22 en la virola (7) y aplicar Aplicar los bloqueos T23 y con un extractor, extraer el
ESP en el pinÄoÂn (8) el mango T21. ESP pinÄoÂn (8) con su cojinete interior (9) del separador (10)
Bloquear la llave T22 y girar el pinÄoÂn para aflojar y y de los posibles espesores (11).
extraer la virola (7). NOTA. Las ranguas de los cojinetes quedan en el cuerpo central
NOTA. Si el desmontaje resulta difõÂcil, calentar la virola a unos (12).
80ëC.
Engager la cleÂ speÂciale T22 sur le collier de serrage Appliquer les blocs T23 et aÁ l'aide d'un extracteur,
F (7) et appliquer sur le pignon (8) le coÃne T21. F extraire le pignon (8) complet du palier interne (9), du
Bloquer la cleÂ T22, tourner le pignon pour relaÃcher et diffeÂrentiel (10) et des eÂventuelles cales (11).
enlever le collier de serrage (7). NOTE. Les crapaudines des paliers demeurent dans le corps
NOTE. Si le deÂsassemblage est rendu difficile, chauffer la bague aÁ central (12).
une chaleur de 80ëC.
Asportare il pignone (8), gli spessori (11) ed il Utilizzando un estrattore ed una pressa, rimuovere dal
ITA distanziale (10). ITA pignone (8) il cuscinetto interno (9).
Rad (8), Unterlegscheibe (11) und DistanzstuÈck (10) Mit einem Abzieher und einer Presse, vom Rad (8) das
D abnehmen. D innere Lager (9) abnehmen.
c d
Sacar el pinÄoÂn (8), los espesores (11) y el separador Utilizando un extractor y una prensa, remover del
ESP (10). ESP pinÄoÂn (8) el cojinete interior (9).
Enlever le pignon (8), les cales (11) et l'entretoise (10). A l'aide de l'extracteur et d'une presse, oÃter du pignon
F F (8) le palier interne (9).
Rimuovere la ralla del cuscinetto esterno (13). Con un punzone inserito nelle cave predisposte,
ITA ITA rimuovere la ralla del cuscinetto interno (9) e gli
spessori di rasamento (14).
Scheibe vom aÈuûeren Lager (13) abnehmen. Einen DuÈbel in die vorgesehenen Nuten stecken und
D D die Scheibe des inneren Lagers (9) und die Zwischen-
legscheiben (14) entfernen.
e f
Remover la rangua del cojinete exterior (13). Utilizando un punzoÂn introducido en las ranuras
ESP ESP predispuestas, remover la rangua del cojinete interior
(9) y los espesores (14).
Enlever la crapaudine du palier externe (13). A l'aide d'un poussoir introduit dans le creux
F F preÂdisposeÂ, enlever la crapaudine du palier interne
(9) et les cales de rasage (14).
41
15 16
F1241061
GB a
ONLY IF NECESSARY
Unloose and remove the screws (15) locking the support (16);
remove the whole support.
8
15
9
20 14
GB c GB d
11
13 16
7
6
4
2
3 10
1
D1240109
GB e GB f
42
SOLO SE NECESSARIO
ITA Allentare ed asportare le viti (15) di fissaggio del
supporto (16); rimuovere il supporto completo.
NUR WENN NOTWENDIG

D Schrauben (15) zur Befestigung der Halterung (16)
abschrauben; Halterung abnehmen.
a
SOLO SI NECESARIO
ESP Aflojar y sacar los tornillos (15) de fisaje del suporte
(16); remover el suporte completo.
SEUL SI BESOIN
F Desserrer et enlever les vis (15) de fixation du support
(16); enlever le support complet.
43
HOW TO INSTALL AND ADJUST THE BEVEL PINION - INSTALLAZIONE E REGISTRAZIONE PIGNONE CONICO - KEGELRAD INSTALLIEREN
UND EINSTELLEN - INSTALACION Y AJUSTE DEL PINÄON CONICO - INSTALLATION ET REGLAGE DU PIGNON CONIQUE
16
15
F1241062 F1241063
GB a GB b
ONLY IF HAS BEEN REMOVED Fasten support with screws (15) previously coated with Loctite 270.
Fit support (16), including O-ring (20), onto the intermediate body. Tighten using the criss-cross method to a tightening torque of 90 ±
NOTE. 1 - The cavity located on the outer diameter must face 100 Nm.
upwards.
2 - Check and lubricate the O-ring (20).
DG DG
T24
9
F1240523 F1240524
GB c GB d
Using a surface plate, reset a centesimal comparator "DG" and Bring the internal bearing (9), complete with its thrust block, under
place it on the measurement ring T24 (with a thickness of 30.2 the comparator "DG".
mm). Determine overall thickness "D" of the bearing checking the
Preset the comparator to approx. 2 mm. discrepancy between this size and the size of the measurement
ring.
CAUTION! Press the thrust block in the centre and take several
measurements while rotating the thrust block.
T25B T24 T25C T25A
13
T25C
T25A 13
F1240525 F1240526
GB e GB f
Partially insert the thrust block of the external bearing (13). Install tension rod T25C, measurement ring T24 and front guide
tool T25A on the thrust block of the external bearing (13).
44
SOLO SE EÁ STATO RIMOSSO Fissare il supporto con le viti (15) spalmate con Loctite
ITA Montare sul corpo intermedio il supporto (16) completo ITA 270.
di guarnizione OR (20). Serrare con il metodo incrociato ad una coppia di
NOTA. 1 - La nicchia ricavata sul diametro esterno deve essere 90v100 Nm.
rivolta verso l'alto.
2 - Controllare e lubrificare la guarnizione OR (20).
NUR WENN ABGENOMMEN Halterung mit den zuvor mit Loctite 270 ge-
D Auf den mittleren KoÈrper die Halterung (16) samt O- D schmierten Schrauben (15) befestigen.
Ring (20) montieren. Im Kreuz abwechselnd fest ziehen. Anzugsmoment:
BEMERKUNG. 1 - Die Nische am aÈuûeren Durchmesser muû nach 90v100 Nm.
a oben gerichtet sein. b
2 - Ring (20) kontrollieren und schmieren.
SOLO SI HA SIDO REMOVIDO Fijar el suporte con los tornillos (15) pasar con Loctite
ESP Montar sobre el cuerpo intermedio el suporte (16) ESP 270.
completo de guarnicion OR (20). Apretar con el metodo cruzado a un par de 90v100 Nm.
NOTA. 1 - El nicho recavado sobre el diametro externo debe de
ser dirigido hacia el alto.
2 - Controlar y lubrificar la guarnicion OR (20).
UNIQUEMENT S'IL A ETE ENLEVE Fixer le support avec les vis (15) enduire de Loctite
F Monter sur le corps intermeÂdiaire le support (16) F 270.
eÂquipeÂ de garnitures OR (20). Serrer aÁ l'aide du systeÁme croiseÂ aÁ un couple de
NOTE. 1 - La niche obtenue sur le diameÁtre externe doit eÃtre 90v100 Nm.
tourneÂe vers le haut.
2 - ControÃler et lubrifier la garniture OR (20).
Utilizzando un piano di riscontro, azzerare sull'anello Portare sotto il comparatore "DG" il cuscinetto interno
ITA di misura T24 (di spessore conosciuto pari a 30,2 mm) ITA (9) completo di ralla.
un comparatore centesimale "DG". Determinare lo spessore totale "D" del cuscinetto
Precaricare il comparatore di circa 2 mm. controllando lo scostamento rispetto la misura dell'anello di misura.
ATTENZIONE! Premere la ralla in modo centrato ed eseguire piuÁ
volte la misurazione ruotando la ralla.
Mit Hilfe eines Anschlags am Meûring T24 (bekannte Unter die Meûuhr "DG" das innere Lager (9) samt
D StaÈrke 30,2 mm) eine hundertteilige Meûuhr "DG" auf D Scheibe legen.
Null stellen. Gesamte StaÈrke "D" des Lagers messen und die
Meûuhr auf 2 mm vorladen. Abweichung im VerhaÈltnis zum Meûring kontrollieren.
c d ACHTUNG! Die Scheibe muû zentriert sein und den Meûvorgang
mehrmals bei gedrehter Scheibe wiederholen.
Utilizando una superficie para la comparacioÂn, poner Poner debajo del comparador "DG" el cojinete interior
ESP a cero en el anillo de medida T24 (del que se conoce ESP (9) con la rangua.
el espesor igual a 30,2 mm) un comparador centesi- Determinar el espesor total "D" del cojinete controlan-
mal "DG". do la diferencia con respecto al tamanÄo del anillo de medida.
Precargar el comparador en 2 mm aproximadamente. CUIDADO! Presionar la rangua de manera centrada y ejecutar
varias veces la medida girando la rangua.
A l'aide d'un plan de comparaison, mettre aÁ zeÂro sur Amener sous le comparateur "DG" le palier interne (9)
F l'anneau de mesurage T24 (d'une eÂpaisseur connue F eÂquipeÂ de crapaudine.
eÂgale aÁ 30,2 mm), un comparateur centeÂsimal "DG". DeÂfinir l'eÂpaisseur totale "D" du palier en controÃlant
PreÂcharger le comparateur d'environ 2 mm. l'eÂcart par rapport aÁ celle mesureÂe par l'anneau de mesurage.
ATTENTION! Presser la crapaudine vers le centre, puis en
effectuer plusieurs fois le mesurage en tournant la crapaudine.
Inserire parzialmente nel corpo centrale (12) la ralla Montare il tirante T25C, l'anello di misura T24, ed
ITA del cuscinetto esterno (13). ITA infine l'attrezzo anteriore T25A di guida della ralla (13)
del cuscinetto esterno.
Auf den zentralen KoÈrper (12) die Scheibe des Die Spannstange T25C, den Meûring T24, und zuletzt
D aÈuûeren Lagers (13). D das vordere Werkzeug T25A zur FuÈhrung der Scheibe
(13) des aÈuûeren Lagers montieren.
e f
Introducir parcialmente en el cuerpo central (12) la Montar el tirante T25C, el anillo de medida T24, y por
ESP rangua el cojinete exterior (13). ESP uÂltimo la herramienta anterior T25A guõÂa de la rangua
(13) del cojinete exterior.
Introduire, partiellement dans le corps central (12), la Monter la tringle T25C, l'anneau de mesurage T24, et
F crapaudine du palier externe (13). F enfin l'outil anteÂrieur T25A de guidage de la crapau-
dine (13) du palier externe.
45
T26C T24 T26B

13
F1240527 F1240528
GB a GB b
Connect the tension rod to the press and move the thrust block of Insert tool T26B complete with external bearing (13), measurement
the external bearing (13) into its seat. ring T24 and gauged ring nut T26C.
Disconnect the press and remove the tension rod. Manually tighten.
NOTE. Before starting the next stage, make sure that the thrust
block has been completely inserted into its seat.
DG1
T26A T26C
GB
GB T26A
A
F1240529 F1240530
GB c GB d
Fit a centesimal comparator "DG1" with long stem into bar T26A; Lay bar T26A on gauged nut T26C and take the size "A" at about
when the bar rests on two size- blocks "GB" of 57 mm, reset the 57 mm corresponding to the maximum diameter of arms centring.
comparator.
Preset the comparator to approx. 2 mm and reset.
T24
T26C 8
X
R115
T26B
A Y
30.2 61
(61-A)+115+30.2=B B D1240070
F1240531
GB e GB f
Calculate size "B" which will be the first useful value for calculating Check the nominal size (X) marked on the pinion and add or
the size of the shims (14) that are to be inserted under the thrust subtract the indicated variation (Y) so as to obtain size "Z".
block of the internal bearing (9). e.g.: Z= 118 + 0.1 = 118.1
Z= 118 ± 0.2 = 117.8
46
Collegare il tirante alla pressa e mandare in sede la Inserire l'attrezzo T26B completo di cuscinetto ester-
ITA ralla del cuscinetto esterno (13). ITA no (13) anello di misura T24 e ghiera di altezza
Scollegare la pressa e rimuovere il tirante. calibrata T26C.
NOTA. Prima di proseguire, assicurarsi dell'inserimento totale Serrare a fondo manualmente.
della ralla.
Spannstange mit der Presse verbinden und die Werkzeug T26B mit dem aÈuûeren Lager (13), Meûring
D Scheibe in ihren Sitz im aÈuûeren Lager (13) einsetzen. D T24 und in der HoÈhe kalibrierte Nutmutter T26C
Von der Presse abnehmen und Spannstange ab- einsetzen.
nehmen. Von Hand festschrauben.
a BEMERKUNG. SorgfaÈltig kontrollieren, ob die Scheibe richtig b
eingesetzt worden ist.
Conectar el tirante a la prensa y colocar en el Introducir la herramienta T26B con el cojinete exterior
ESP alojamiento la rangua del cojinete exterior (13). ESP (13), el anillo de medida T24 y la virola de altura
Sacar la prensa y remover el tirante. calibrada T26C.
NOTA. Antes de continuar, asegurarse de que la rangua estaÂ Apretar a fondo manualmente.
completamente insertada.
Brancher la tringle aÁ la presse, puis envoyer dans son Introduire l'outil T26C eÂquipeÂ du palier externe (13),
F logement la crapaudine du palier externe (13). F l'anneau de mesurage T24 et le collier de serrage de
DeÂbrancher la presse et enlever la tringle. hauteur taraudeÂ T26C.
NOTE. Avant de continuer, s'assurer que la crapaudine est Serrer aÁ fond manuellement.
compleÁtement inseÂreÂe.
Montare un comparatore centesimale "DG1" con stelo Appoggiare la barra T26A sulla ghiera calibrata T26C
ITA prolungato, nella barra T26A; azzerare il comparatore ITA e rilevare la misura "A" circa 57mm in corrispondenza
quando la barra appoggia su due blocchetti "GB" del diametro massimo della centratura dei bracci.
calibrati da 57 mm.
Precaricare il comparatore di circa 2 mm ed azzerarlo.
Die hundertteilige Meûuhr "DG1" mit dem VerlaÈng- Stab T26A auf die kalibrierte Nutmutter T26C legen
D erungsstift in den Stab T26A montieren; die Meûuhr D und das Maû "A" bei ca. 57 mm am maximalen
auf Null stellen, nachdem der Stab auf zwei kalibrierte Durchmesser der Armzentrierung messen.
BloÈcke "GB" zu 57 mm gelegt worden ist.
c Meûuhr auf 2 mm vorladen und auf Null stellen. d
Montar un comparador centesimal "DG1" con vaÂstago Apoyar la barra T26A en la virola calibrada T26C y
ESP prolongado en la barra T26A; poner a cero el ESP registrar la medida "A" unos 57 mm en correspon-
comparador cuando la barra estaÂ apoyada en dos dencia del diaÂmetro maÂximo del centraje de los
bloques "GB" calibrados de 57 mm. brazos.
Precargar el comparador en 2 mm aproximadamente y ponerlo a
cero.
Monter un comparateur centeÂsimal "DG1" muni de Poser la barre T26A sur le collier de serrage taraudeÂ
F tige de prolongation dans la barre T26A; mettre le F T26C, relever la mesure "A" aÁ environ 57 mm en
comparateur aÁ zeÂro lorsque la barre poseÂe sur les correspondance du diameÁtre de centrage maximal des
deux blocs calibreÂs "GB" est aÁ 57 mm. bras.
PreÂcharger le comparateur aÁ environ 2 mm et remettre aÁ zeÂro.
Eseguire il calcolo per ottenere la prima misura utile Controllare la misura nominale (X) segnata sul
ITA "B", per il calcolo degli spessori (14) da inserire sotto ITA pignone e sommare o sottrarre ad essa la variazione
la ralla del cuscinetto interno (9). indicata: (Y) per ottenere la misurazione "Z".
Es: Z=118+0,1=118,1
Z=118 ± 0,2=117,8
Das Maû "B" ausrechnen, das zur Ermittlung der Das Nennmaû (X), das am Rad markiert ist, kontroll-
D DistanzstuÈcke (14) dient, die unterhalb der Scheibe D ieren und die Abweichung addieren oder abziehen. (Y)
des inneren Lagers (9) eingesetzt werden sollen. fuÈr das Maû "Z".
Beisp.: Z= 118 + 0,1 = 118,1
e f Z= 118 ± 0,2 = 117,8
Ejecutar el caÂlculo para obtener la primera medida uÂtil Controlar la medida nominal (X) marcada en el pinÄoÂn y
ESP "B" para el caÂlculo de los espesores (14) que hay que ESP sumarle o restarle la variacioÂn indicada (Y) para
insertar debajo de la rangua del cojinete interior (9). obtener la medida "Z".
Ej.: Z= 118 + 0,1 = 118,1
Z= 118 ± 0,2 = 117,8
Faire le calcul pour obtenir la premieÁre mesure utile ControÃler la mesure nominale (X) marqueÂe sur le
F "B" pour calculer les cales (14) aÁ introduire au- F pignon et additionner ou soustraire aÁ celle-ci la
dessous de la crapaudine du palier interne (9). variation indiqueÂe (Y) pour obtenir le mesurage "Z".
Exp. Z= 118 + 0,1 = 118,1
Z= 118 ± 0,2 = 117,8
47
B-C=S
14
(14) S
D Z
C=Z+D C
D1240069
F1240541
GB a GB b
Calculate size "C" which represents the second value for Calculate the difference between sizes "B" and "C" so as to obtain
calculating the size of the shims "S" that are to be placed under the size "S" of the shim (14) that will go under the thrust block of the
the thrust block of the internal bearing (9). internal bearing (9).
14
T25C T25A
9
F1240533 F1240534
GB c GB d
Insert shim "S" (14) and the thrust block of the internal bearing (9) Position tool T25A and tension rod T25C.
in the central body. Connect the tension rod to the press, fasten the thrust block and
NOTE. To hold shim "S" (14) in position, apply grease. then remove the tools.
NOTE. Before going on to the next stage, make sure that the thrust
block has been completely inserted.
DDG
T26C 9 13
T26B
F1240535 F1240536
GB e GB f
Position tools T26C and T26B complete with tapered bearings (9) Insert the stem of a depth comparator "DDG" in either side hole of
and (13); manually tighten until a rolling torque has been obtained. tool T26C; reset the comparator with a presetting of approx. 3 mm.
48
Calcolare la seconda misura utile "C" per il calcolo Eseguire la differenza tra le misure "B" e "C" per
ITA dello spessore "S" da inserire sotto la ralla del ITA stabilire la misura "S" dello spessore (14) da inserire
cuscinetto interno (9). sotto la ralla del cuscinetto interno (9).
Das zweite Maû "C" fuÈ r das DistanzstuÈ ck "S" Den Unterschied zwischen Maû "B" und "C" ausrech-
D ausrechnen, das unter die Scheibe des inneren D nen, um das DistanzstuÈck "S" (14) auszurechnen, das
Lagers (9) eingesetzt werden soll. unter die Scheibe des inneren Lagers (9) eingesetzt
werden soll.
a b
Calcular la segunda medida uÂtil "C" para el caÂlculo del Sacar la diferencia entre las medidas "B" y "C" para
ESP espesor "S" a insertar debajo de la rangua del cojinete ESP establecer la medida "S" del espesor (14) a insertar
interior (9). debajo de la rangua del cojinete interior (9).
Calculer la seconde mesure utile "C" pour calculer la Effectuer la diffeÂrence entre les mesures "B" et "C"
F cale "S" aÁ introduire au-dessous de la crapaudine du F pour eÂtablir la mesure "S" de la cale (14) aÁ introduire
palier interne (9). au-dessous de la crapaudine du palier interne (9).
Inserire nel corpo centrale lo spessore "S" (14) e la Montare l'attrezzo T25A ed il tirante T25C.
ITA ralla del cuscinetto interno (9). ITA Collegare il tirante alla pressa, mandare in battuta la
NOTA. Per tenere in posizione lo spessore "S" (14), ralla e quindi smontare gli attrezzi.
spalmarlo leggermente con grasso. NOTA. Prima di proseguire, assicurarsi dell'inserimento totale
della ralla.
In den zentralen KoÈrper das DistanzstuÈck "S" (14) und Werkzeug T25A und Spannstange T25C montieren.
D die Scheibe des inneren Lagers (9) einsetzen. D Spannstange mit der Presse verbinden und die
BEMERKUNG. Um das DistanzstuÈck "S" (14) in seiner Scheibe bis zum Anschlag einsetzen. Danach die
Position festzuhalten, dieses leicht mit Fett schmieren. Werkzeuge abmontieren.
c d BEMERKUNG. SorgfaÈltig kontrollieren ob die Scheibe richtig
eingesetzt worden ist.
Introducir en el cuerpo central el espesor "S" (14) y la Montar la herramienta T25A y el tirante T25C.
ESP rangua del cojinete interior (9). ESP Conectar el tirante a la prensa, llevar a tope la rangua
NOTA. Para mantener en su posicioÂn el espesor "S" y luego desmontar las herramientas.
(14), pasarle ligeramente un poco de grasa. NOTA. Antes de continuar, asegurarse de que la rangua ha sido
totalmente introducida.
Introduire dans le corps central la cale "S" (14) et la Monter l'outil T25A et la tringle T25C.
F cale du palier interne (9). F Relier la tringle aÁ la presse, envoyer en buteÂe la
NOTE. Enduire leÂgeÁrement celle-ci de gras pour la crapaudine, puis deÂmonter les outils.
maintenir dans sa position. NOTE. Avant de continuer, s'assurer que la crapaudine est
entieÁrement inseÂreÂe.
Inserire gli attrezzi T26C e T26B completi dei Inserire in uno dei due fori laterali dell'attrezzo T26C lo
ITA cuscinetti conici (9) e (13); serrare manualmente fino ITA stelo di un comparatore di profonditaÁ "DDG"; azzerare
ad avere sicuramente una coppia di rotolamento. il comparatore con un precarico di circa 3 mm.
Die Werkzeuge T26C und T26B samt Kegellager (9) In eines der beiden seitlichen LoÈcher des Werkzeugs
D und (13) einsetzen; von Hand zudrehen bis ein D T26C den Stift der Meûuhr "DDG" stecken; die Meûuhr
Drehmoment erreicht worden ist. auf 3 mm vorladen und auf Null stellen.
e f
Introducir las herramientas T26C y T26B con sus Introducir en uno de los dos orificios laterales de la
ESP cojinetes coÂnicos (9) y (13); apretar manualmente ESP herramienta T26C el vaÂstago de un comparador de
hasta obtener con seguridad un par de rodamiento. profundidad "DDG"; poner a cero el comparador con
una precarga de aproximadamente 3 mm.
Introduire les outils T26C et T26B eÂquipeÂs des paliers Introduire dans l'un des deux trous lateÂraux de l'outil
F coniques (9) et (13); serrer manuellement jusqu'aÁ eÃtre F T26C, la tige d'un comparateur de profondeur "DDG",
suÃr d'avoir un couple de roulement. mettre le comparateur aÁ zeÂro avec une preÂcharge
d'environ 3 mm.
49
H
DDG
T26C 9
10 13
T26B
9 T26C
13
T26B
F1240574 F1240537
GB a GB b
Remove the comparator and release tools and bearings from the Insert depth comparator "DDG" into tool T26B-T26C and measure
central body. variation "H" in relation to the zero setting performed back at point
Re-install all and insert the distance piece (10) between bearings d.
(9) and (13); manually tighten the whole pack.
H+0,12÷ 0,13=S1
11 S1
F1240541 F1240542
GB c GB d
The variation is to be added to a set value of 0.12±0.13 mm., so as Position the internal bearing (9) and the pinion (8) under a press;
to obtain the size of shim "S1" (11) which will be inserted between force the bearing onto the pinion.
the external bearing (13) and the distance piece (10) and
subsequently, to determine the preload for the bearings.
12
10
8 9 11 10
13
11
F1240543 F1240538
GB e GB f
Fit the pinion (8), shim "S1" (11) and distance piece (10) in the main Insert the external bearing (13) in the central body in order to
body (12). complete the pack arranged as in the figure.
NOTE. The finer shims must be placed in- between the thicker
ones
50
Rimuovere il comparatore e smontare dal corpo Inserire nell'attrezzo T26B-T26C il comparatore di
ITA centrale il gruppo attrezzi e cuscinetti. ITA profonditaÁ "DDG" e rilevare lo scostamento "H"
Rimontare il tutto inserendo tra i cuscinetti (9) e (13) il rispetto l'azzeramento eseguito al punto d.
distanziale (10); serrare manualmente l'intero pacco.
Die Meûuhr abnehmen und vom zentralen KoÈrper die In das Werkzeug T26B-T26C die Meûuhr "DDG" fuÈr
D Werkzeuge und Lager abmontieren. D die Tiefe einsetzen und die Abweichung "H" im
Das ganze wieder montieren und dabei zwischen den VerhaÈltnis zur unter Punkt d vorgenommenen Null-
Lagern (9) und (13) das DistanzstuÈck (10) einsetzen; von Hand das stellung messen.
a Ganze festschrauben. b
Remover el comparador y desmontar del cuerpo Introducir en la herramienta T26B-T26C el compara-
ESP central el grupo de las herramientas y cojinetes. ESP dor de profundidad "DDG" y relevar el alejamiento "H"
Volver a montar todo introduciendo entre los cojinetes respecto al aceramiento efectuado al punto d.
(9) y (13) el separador (10); apretar manualmente todo el paquete.
Enlever le comparateur et deÂmonter du corps central Introduire l'outil T26B-T26C le comparateur de pro-
F le groupe outils et paliers. F fondeur "DDG" et relever l'eÂcart "H" par rapport aÁ la
Remonter le tout en inseÂrant entre les paliers (9) et mise aÁ zeÂro effectueÂ au point d.
(13), l'entretoise (10); serrer tout le paquet aÁ la main.
Lo scostamento rilevato eÁ da sommare ad una misura Posizionare il cuscinetto interno (9) e pignone (8) sotto
ITA fissa di 0,12v0,13 mm, per ottenere lo spessore "S1" ITA una pressa; forzare sul pignone il cuscinetto.
(11) da inserire tra cuscinetto esterno (13) e distanziale
(10) e quindi, determinare il precarico stabilito per i cuscinetti.
Die ermittelte Abweichung wird dem festen Maû von Das innere Lager (9) und das Rad (8) unter eine
D 0,12v0,13 mm hinzu gerechnet, um das DistanzstuÈck D Presse setzen; auf das Rad das Lager druÈcken.
"S1" (11) zu ermitteln, das zwischen dem aÈuûeren
Lager (13) und das DistanzstuÈck (10) eingesetzt werden soll und
c folglich die benoÈtigte Vorbelastung der Lager festzulegen. d
La separacioÂn registrada hay que sumarla a una Posicionar el cojinete interior (9) y el pinÄoÂn (8) debajo
ESP medida fija de 0,12v0,13 mm para obtener el espesor ESP de una prensa; forzar en el pinÄoÂn el cojinete.
"S1" (11) que hay que introducir entre el cojinete
exterior (13) y el separador (10) y luego, determinar la precarga
establecida para los cojinetes.
L'eÂcart releveÂ est aÁ additionner aÁ une mesure fixe de Placer le palier interne (9) et le pignon (8) sous presse;
F 0,12v0,13 mm pour obtenir la cale "S1" (11) aÁ F forcer sur pignon et palier.
introduire entre le palier externe (13) et entretoise
(10) et par conseÂquent deÂterminer la preÂcharge preÂconiseÂe pour les
paliers.
Montare nel corpo centrale (12), il pignone (8), gli Inserire nel corpo centrale il cuscinetto esterno (13) in
ITA spessori "S1" (11) e il distanziale (10). ITA modo da completare il pacco come composto in figura.
NOTA. Gli spessori piuÁ fini devono essere contenuti
tra quelli piuÁ spessi.
Zentralen KoÈrper (12), Rad (8), Unterlegscheibe "S1" In den zentralen KoÈrper das aÈuûere Lager (13)
D (11) und DistanzstuÈck (10) montieren. D einsetzen wie in der Abbildung gezeigt.
BEMERKUNG. Die duÈnneren Unterlegscheiben muÈs-
sen zwischen den staÈrkeren gelegt werden.
e f
Montar en el cuerpo central (12) el pinÄoÂn (8) los Introducir en el cuerpo central el cojinete exterior (13)
ESP espesores "S1" (11) y el separador (10). ESP de manera que el paquete quede completo como ha
NOTA. Los espesores maÂs delgados tienen que sido formado en la figura.
colocarse entre los maÂs gruesos.
Monter le corps central (12), le pignon (8), les cales Introduire dans le corps central, le palier externe (13),
F "S1" (11) et l'entretoise (10). F de manieÁre aÁ compleÂter le paquet comme composeÂ
NOTE. Les cales plus minces doivent eÃtre intercaleÂes sur la figure.
parmi les plus eÂpaisses.
51
8
8
7
F1240575 F1240539
GB a GB b
Connect the pinion (8) to the tie rod T28A and T28B; connect the Apply Loctite 242 to the thread of the ring nut (7) and screw the nut
tie rod T28C (see special tools) to the press and block. onto the pinion (8).
T21 T19
T22
F1240540 F1240510
GB c GB d
Apply special wrench T22 to the ring nut (7) and bar-hold T21 to the Apply onto the pinion (8) the bar-hold and with the help of a torque
pinion (8). metre, check the torque of the pinion (8).
Lock the wrench T22 and rotate the pinion using a dynamometric Torque: 120±170 Ncm
wrench, up to a minimum required torque setting of 500 Nm. CAUTION! If torque exceeds the maximum value, then the size of
shim "S1" (11) between the bearing (13) and the distance piece (10)
needs to be increased.
If torque does not reach the set value, increase the torque setting
of the ring nut (7) in different stages to obtain a maximum value of
570 Nm.
CAUTION! If torque does not reach the minimum value, then the
size of shim "S1" (11) needs to be reduced.
CAUTION! When calculating the increase or decrease in size of
shim "S1", bear in mind that a variation of shim (11) of 0.01 mm
corresponds to a variation of 60 Ncm in the torque of the pinion (8).
52
Collegare il pignone (8) al tirante T28A e T28B; Spalmare la filettatura della ghiera (7) con Loctite 242
ITA collegare il tirante T28C (Vedere attrezzature speciali) ITA ed avvitarla sul pignone (8).
alla pressa e mandare in blocco.
Ritzel (8) mit der Zugstange T28A und T28B ver- Das Gewinde der Nutmutter (7) mit Loctite 242
D binden; Zugstange T28C (siehe SpezialausruÈstung) D schmieren und auf das Rad (8) schrauben.
mit der Presse verbinden und blockieren.
a b
Conectar el pignon (8) al tirante T28A y T28B; Pasar sobre la rosca de la virola (7) Loctite 242 y
ESP conectar el tirante T28C (Vease herramientas espe- ESP atornillarla en el pinÄoÂn (8).
ciales) a la prensa y bloquear.
Brancher le pignon (8) aÁ la tringle T28A et T28B; relier Enduire le filetage du collier de serrage (7) avec du
F la tringle T28C (voir installations speÂciales) aÁ la presse F Loctite 242, puis visser celui-ci sur le pignon (8).
puis envoyer en buteÂe.
Impegnare la chiave speciale T22 sulla ghiera (7) ed Applicare sul pignone (8) il codolo T19 e con un
ITA applicare il codolo T21 sul pignone (8). ITA torsiometro, controllare la coppia di rotazione del
Fermare la chiave T22 e ruotare il pignone con una pignone. Coppia di rotazione: 120v170 Ncm
chiave dinamometrica fino alla coppia minima richiesta di 500 Nm. ATTENZIONE! Se la coppia supera il valore massimo bisogna
aumentare lo spessore "S1" (11) tra cuscinetto (13) e distanziale (10).
Se la coppia di rotazione non raggiunge il valore stabilito,
aumentare la coppia di serraggio della ghiera (7) in piuÁ tempi fino
Den speziellen SchluÈssel T22 auf die Nutmutter (7) a raggiungere il valore massimo ammesso di 570 Nm.
D setzen und den Schaft T21 auf das Rad (8) montieren. ATTENZIONE! Se la coppia di rotazione non raggiunge il valore
Den SchluÈssel T22 festhalten und das Rad mit einem minimo, eÁ necessario diminuire lo spessore "S1" (11).
MomentenschluÈssel drehen bis das mindeste Anzugsmoment von ATTENZIONE! Al fine di poter calcolare gli incrementi o la
c 500 Nm erreicht worden ist. diminuzione dello spessore "S1", eÁ necessario considerare che la
variazione dello spessore (11) di 0,01 mm, fa variare la coppia di
rotazione del pignone (8) di 60 Ncm.
Colocar la llave especial T22 en la virola (7) y aplicar el Den Shaft T19 montieren auf das Rad (8) und mit
ESP mango T21 en el pinÄoÂn (8). D einem Drehungsmesser das Drehmoment des Rads
Parar la llave T22 y girar el pinÄoÂn con una llave kontrollieren. Drehmoment: 120v170 Ncm
dinamomeÂtrica hasta el par mõÂnimo requerido de 500 Nm. ACHTUNG! Falls das Drehmoment groÈûer als der maximale Wert
sein sollte, muû ein groÈûeres DistanzstuÈck "S1" (11) zwischen
Lager (13) und DistanzstuÈck (10) eingesetzt werden.
Falls das Drehmoment den benoÈtigten Wert nicht erreicht, muû das
Engager la cleÂ speÂciale T22 sur le collier (7) et Drehmoment der Nutmutter (7) stufenweise erhoÈht werden, bis der
F appliquer la queue T21 sur le pignon (8). maximal zugelassene Wert von 570 Nm erreicht worden ist.
Bloquer la cleÂ T22, tourner le pignon avec une cleÂ ACHTUNG! Falls das Drehmoment den minimalen Wert nicht
dynamomeÂtrique jusqu'au couple minimum requis de 500 Nm. erreicht, muû das DistanzstuÈck "S1" (11) kleiner gewaÈhlt werden.
ACHTUNG! Um die ErhoÈhungen oder Verringerungen des Distanz-
stuÈcks "S1" ausrechnen zu koÈnnen, muû beachtet werden, daû ein
d Unterschied von 0,01 mm des DistanzstuÈcks (11), das Drehmoment
des Rads (8) um 60 Ncm veraÈndert.
Aplicar el mango T19 en el pinÄoÂn (8) y con un
ESP torsioÂmetro, controlar el par de rotacioÂn del pinÄoÂn.
Par de rotacioÂn: 120v170 Ncm
CUIDADO! Si el par supera el valor maÂximo, hay que aumentar el
espesor "S1" (11) entre el cojinete (13) y el separador (10).
Si el par de rotacioÂn no alcanza el valor establecido, aumentar el
par de torsioÂn de la virola (7) varias veces hasta alcanzar el valor
maÂximo admitido de 570 Nm.
CUIDADO! Si el par de rotacioÂn no alcanza el valor mõÂnimo, hay
que disminuir el espesor "S1" (11).
CUIDADO! A fin de poder calcular los incrementos o la disminucioÂn
del espesor "S1", hay que considerar que el espesor (11) de 0,01
mm hace variar el par de rotacioÂn del pinÄoÂn (8) en 60 Ncm.
Appliquer la queue T19 sur le pignon (8) et l'aide d'un
F torsiomeÁtre, controÃler le couple de rotation du pignon.
Couple de rotation: 120v170 Ncm
ATTENTION! Si le couple deÂpasse la valeur maximale, il faut
augmenter la cale "S1" (11) entre palier (13) et entretoise (10).
Si le couple de rotation n'atteint pas la valeur eÂtablie, augmenter le
couple de serrage du collier de serrage (7) en plusieurs fois jusqu'aÁ
atteindre la valeur maximale preÂconiseÂe de 570 Nm.
ATTENTION! Si le couple de rotation n'atteint pas la valeur
minimale, il faut diminuer la cale "S1" (11).
ATTENTION! Pour pouvoir calculer l'increÂmentation ou la diminution
de la cale "S1", il faut tenir compte que la variation de la cale (11) de
0,01 mm, modifie le couple de rotation du pignon (8) de 60 Ncm.
53
5
6
T27 12
F1240545 F1240517
GB a GB b
Lubricate the outer surface of the new sealing ring (6) and fit it onto ATTENTION! This operation does not apply to the fixed axle.
the central body (12) using tool T27. NOTE. Check that it is properly oriented.
T20A
(T20B)
2 4
F1240546 F1240547
GB c GB d
Fit the flange (2) complete with the guard (4) and fasten it. Apply Loctite 242 to the threaded part of the pinion (8).
For keying the flange (2), use a plastic hammer if necessary. Position tool T20A (or T20B) and fasten it in order to avoid rotation.
NOTE. Make sure that the guard (4) is securely fastened onto the Insert O-ring (3) the nut (1) and tighten it using a dynamometric
flange and that it is not deformed. wrench.
Torque wrench setting: 280±310 Nm
T23
F1240579
GB e
Remove blocks T23 (used for extracting the pinion) and re-install
the arms.
For details, see «CHECKING WEAR AND REPLACING THE
BRAKING DISKS».
54
Lubrificare la superficie esterna del nuovo anello di ATTENZIONE! Questa operazione non eÁ valida per
ITA tenuta (6) e montarlo nel corpo centrale (12) utilizzan- ITA l'assale fisso.
do l'attrezzo T27. Montare il supporto oscillante (5).
NOTA: Controllare attentamente l'orientamento.
Die aÈuûere FlaÈche des neuen Ringes (6) schmieren ACHTUNG! Dieser Vorgang gilt nicht fuÈr die feste
D und den zentralen KoÈrper (12) mit Hilfe des Werk- D Achse.
zeugs T27 montieren. Die schwenkbare Halterung (5) montieren.
BEMERKUNG. Richtung sorgfaÈltig kontrollieren.
a b
Lubricar la superficie exterior del nuevo segmento de ATENCION! Esta operacioÁn no es valida para el eje
ESP compresioÂn (6) y montarlo en el cuerpo central (12) ESP fijo.
utilizando la herramienta T27. Montar el soporte oscilante (5).
NOTA. Controlar atentamente la orientacioÂn.
Lubrifier la surface externe de la bague d'eÂtancheÂiteÂ ATTENTION! Cette opeÂration n'est pas valable en
F neuve (6), puis monter celle-ci dans le corps central F case d'essieu fixe.
(12) aÁ l'aide de l'outil T27. Monter le support oscillant (5).
NOTE. ControÃler attentivement le sens.
Montare la flangia (2) completa della protezione (4) e Spalmare la porzione filettata del pignone (8) con
ITA mandarla in battuta. ITA Loctite 242.
Se necessario, per il calettamento della flangia (2), Montare l'attrezzo T20A (oppure T20B) ed impegnarlo
usare un mazzuolo in materiale plastico. per evitare la rotazione. Montare l'anello OR (3) ed il dado (1);
NOTA. Controllare che la protezione (4) sia ben forzata sulla serrare con chiave dinamometrica.
flangia e che non sia deformata. Coppia di serraggio: 280v310 Nm
Flansch (2) samt Schutzteil (4) montieren und bis zum Das Gewinde des Rads (8) mit Loctite 242 schmieren.
D Anschlag bringen. D Das Werkzeug T20A (T20B) montieren und blok-
Wenn noÈtig, den Flansch (2) mit einem Gummi- kieren, damit es nicht drehen kann.
hammer einschieben. O-Ring (3) und Mutter (1) montieren und mit einem Momenten-
c BEMERKUNG. Kontrollieren ob das Schutzteil (4) richtig auf dem
Flansch sitzt und nicht verformt ist.
d schluÈssel festschrauben.
Anzugsmoment: 280v310 Nm
Montar la brida (2) con su proteccioÂn (4) y llevarla Pasar en la parte roscada del pinÄoÂn (8) Loctite 242.
ESP hasta el tope. ESP Montar la herramienta T20A (o T20B) y bloquearla
Si fuera necesario, para ensamblar de la brida (2) usar para evitar la rotacioÂn.
un martillo de material plaÂstico. Montar el anillo OR (3) y la tuerca (1) y apretarlos con llave
NOTA. Controlar que la proteccioÂn (4) estaÂ bien forzada en la brida dinamomeÂtrica.
y que no estaÂ deformada. Par de torsioÂn: 280v310 Nm
Monter la flasque (2) eÂquipeÂe de protection (4), puis Enduire la partie fileteÂe du pignon (8) avec du Loctite
F envoyer celle-ci en buteÂe. F 242. Monter et fixer l'outil T20A (ou T20B) pour eÂviter
Si besoin, pour caler la flasque (2) utiliser un maillet en la rotation.
matieÁre plastique. Monter le OR (3) et l'eÂcrou (1), puis serrer aÁ l'aide de la cleÂ
NOTE. Veiller aÁ ce que la protection (4) est bien forceÂe sur la dynamomeÂtrique.
flasque et qu'elle n'est pas deÂformeÂe. Couple de serrage: 280v310 Nm
Asportare i blocchi T23 montati per l'estrazione del

ITA pignone e rimontare i bracci. ITA
Per i dettagli, vedere «CONTROLLO USURA E
SOSTITUZIONE DISCHI FRENO».
BloÈcke T23 abnehmen, die zum Herausnehmen des

D Rads montiert wurden und Arme wieder montieren. D
Siehe «VERSCHLEISS KONTROLLIEREN UND
BREMSSCHEIBEN AUSWECHSELN».
e f
Sacar los bloques T23 montados para la extraccioÂn
ESP del pinÄoÂn y volver a montar los brazos. ESP
Para los detalles, veÂase «CONTROL DEL DESGASTE
Y SUSTITUCION DE LOS DISCOS DEL FRENO».
Enlever les blocs T23 monteÂs pour l'extraction des

F pignons, puis remonter les bras. F
Pour de plus amples deÂtails, voir «CONTROLE DE
L'USURE ET SUBSTITUTION DES FREINS».
55
HOW TO REMOVE AND DISASSEMBLE THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE - DIFFERENTIAL
ABMONTIEREN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL - DEPOSE ET DEMONTAGE DU GROUPE DIFFERENTIEL
REMOVING - RIMOZIONE - ABMONTIEREN - REMOCION - DEPOSE
1
F1240385 F1240478
GB a GB b
Remove the complete arms. Mark the position of the ring nuts (1). Remove the fittin screws (3)
For details, see «CHECKING WEAR AND REPLACING THE from the ring nuts (1).
BRAKING DISKS».
1 T13
F1240479 F1240480
GB c GB d
Uniformly heat the ring nuts (1) up to a temperature of 80ë C. Apply tool T13 and remove the ring nuts.
NOTE. Accurately clean the threaded portions on ring nuts of body
and cover.
4 5 6
5
4
F1240481 F1240482
GB e GB f
Remove the fittin screws (4) from the middle cover (5). Insert a screw-driver in the opposing slots then force and remove
the middle cover (5) and the complete differential unit (6).
NOTE. Support the pieces using a rod.
56
Rimuovere i bracci completi. Contrassegnare la posizione delle ghiere (1).
ITA Per i dettagli, vedere «CONTROLLO USURA E ITA Rimuovere le viti (3) di ritegno delle ghiere (1).
SOSTITUZIONE DISCHI FRENO».
Die kompletten Arme abmontieren. Position der Nutmutter (1) markieren. Schrauben (3)
D Siehe «VERSCHLEISS KONTROLLIEREN UND D der Nutmutter (1) abschrauben.
BREMSSCHEIBEN AUSWECHSELN».
a b
Remover los brazos completos. Marcar la posicioÂn de las virolas (1).
ESP Para los detalles, veÂase «CONTROL DEL DESGASTE ESP Remover los tornillos (3) de retencioÂn de las virolas (1).
Y SUSTITUCION DE LOS DISCOS DEL FRENO».
DeÂposer les bras complets. Marquer la position des colliers de serrage (1). Enlever
F Pour de plus amples deÂ tails voir «CONTROLE F les vis (3) de fixation des colliers de serrage (1).
D'USURE ET SUBSTITUTION DES DISQUES DE
FREINAGE».
Scaldare le ghiere (1) in modo uniforme fino ad una Applicare l'attrezzo T13 ed asportare le ghiere.
ITA temperatura di circa 80ëC. ITA
NOTA. Pulire accuratamente le filettature delle ghiere
del corpo e del coperchio.
Nutmutter (1) gleichmaÈûig auf ca. 80ëC erhitzen. Werkzeug T13 anbringen und Nutmutter entfernen.
D D
BEMERKUNG. SorgfaÈltig das Gewinde der Nutmutter,
des KoÈrpers und des Deckels reinigen.
c d
Calentar las virolas (1) de manera uniforme hasta un Aplicar la herramienta T13 y sacar las virolas.
ESP temperatura de unos 80ëC. ESP
NOTA. limpiar con cuidado las roscas de las virolas
del cuerpo y de la tapa.
Chauffer les colliers de serrage (1) de facËon uniforme Appliquer l'outil T13 et enlever les anneaux de
F jusqu'aÁ une tempeÂrature d'environ 80ëC. F fixation.
NOTE. Nettoyer soigneusement le filetage des an-
neaux de fixation, du corps et du couvercle.
Asportare le viti (4) di ritegno del coperchio intermedio Forzare con un cacciavite introdotto nei vani contrap-
ITA (5). ITA posti e rimuovere il coperchio intermedio (5) ed il
gruppo differenziale completo (6).
NOTA. Sostenere i pezzi con un'asta.
Schrauben (4) des mittleren Deckels (5) abschrauben. Einen Schraubenzieher in die HohlraÈume stecken und
D D anheben, um den mittleren Deckel (5) und das
komplette Differentialaggregat (6) zu entfernen.
BEMERKUNG. Die Teile mit einem Stab halten.
e f
Sacar los tornillos (4) de retencioÂn de la tapa Forzar utilizando un destornillador introducido en los
ESP intermedia (5). ESP compartimentos contrapuestos y remover la tapa
intermedia (5) y el grupo diferencial completo (6).
NOTA. Sostener las piezas utilizando una varilla.
Enlever les vis (4) de fixation du couvercle intermeÂ- Forcer aÁ l'aide d'un tournevis, introduit dans les creux
F diaire (5). F interposeÂs, enlever le couvercle intermeÂdiaire (5) et le
groupe diffeÂrentiel complet (6).
NOTE. Soutenir les pieÁces avec une tige.
57
2 8 10
7
5 9
F1240483 F1240484
GB a GB b
If the bearings need replacing, extract the external thrust blocks of Remove the top plug (10).
the bearings (7) and (8) from middle cover (5) and central body (2).
NOTE. Accurately check the O-ring (9).
DISASSEMBLING - SMONTAGGIO - ZERLEGEN - DESMONTAJE - DESASSEMBLAGE
11
12 12
F1240485 F1240486
GB c GB d
Remove the fittin screws (11) from the crown (12). If the bearing need replacing, extract the bearing (7) and remove
the crown (12).
13
14
8
15
F1240487 F1240488
GB e GB f
Remove the shim washer (13) and the planetary gear (14). If the bearing need replacing, extract the bearing (8) from the
differential carrier (15).
58
Se si devono sostituire i cuscinetti, estrarre dal Rimuovere il tappo superiore (10).
ITA coperchio intermedio (5) e dal corpo centrale (2) le ITA
NOTA. Il tappo deve essere sostituito ad ogni
ralle esterne dei cuscinetti (7) e (8). rimozione.
NOTA. Controllare attentamente l'anello OR (9).
Wenn Lager ausgewechselt werden muÈssen, vom Oberer Stopfen (10) entfernen.
D mittleren Deckel (5) und vom zentralen KoÈrper (2) die D
aÈuûeren Scheiben der Lager (7) und (8) entfernen.
BEMERKUNG. O-Ring (9) sorgfaÈltig kontrollieren.
a b
Si hay que sustituir los cojinetes, extraer de la tapa Remover el tapoÂn superior (10).
ESP intermedia (5) y del cuerpo central (2) las ranguas ESP
exteriores (7) y (8) de los cojinetes.
NOTA. Controlar atentamente el anillo OR (9).
Si on doit remplacer les paliers, extraire du couvercle Enlever le bouchon supeÂrieur (10).
F intermeÂdiaire (5) et du corps central (2), les crapau- F
dines externes des paliers (7) et (8).
NOTE. ControÃler attentivement la garniture OR (9).
Rimuovere le viti (11) di ritegno della corona (12). Se si deve sostituire, estrarre il cuscinetto (7) e
ITA ITA rimuovere la corona (12).
Die Schrauben (11) des Kranzes (12) abschrauben. Falls das Lager ausgewechselt werden muû, Lager (7)
D D heraus nehmen und Kranz (12) entfernen.
c d
Remover los tornillos (11) de retencioÂn de la corona Si hay que sustituirlo, extraer el cojinete (7) y remover
ESP (12). ESP la corona (12).
Enlever les vis (11) de fixation de la couronne (12). Extraire le palier (7) et deÂposer la couronne (12) en cas
F F que le premier doit eÃtre remplaceÂ.
Rimuovere la rondella di rasamento (13) e l'ingranag- Se si deve sostituire, estrarre il cuscinetto (8) dalla
ITA gio planetario (14). ITA scatola differenziale (15).
Zwischenlegscheibe (13) und Planetenrad (14) entfer- Wenn das Lager ausgewechselt werden muû, Lager
D nen. D (8) aus dem DifferentialgehaÈuse (15) nehmen.
e f
Remover la arandela de espesor (13) y el engranaje Si hay que sustituirlo, extraer el cojinete (8) de la caja
ESP planetario (14). ESP del diferencial (15).
Enlever la rondelle de rasage (13) et l'engrenage Extraire le palier (8) du boõÃtier diffeÂrentiel (15) en cas
F planeÂtaire (14). F que le premier doit eÃtre remplaceÂ.
59
T14
18 18
16 17
F1240489 F1240490
GB a GB b
Remove the snap rings (16) from the two pins (17) of the planet Insert tool T14 between the planet wheel gears (18).
wheel gears (18).
T16B
T15
T16B
17
15 15
17
F1240491 F1240492
GB c GB d
Force tool T14 in-between the planet wheel gears (18) using two Place the differential carrier (15) under a press, position bush T15
pin-drivers. and insert gudgeon T16A. Press T16A pin to limit position.
CAUTION! Make sure that tool T14 is perfectly lined up with the
pins (17) when locked.
T16A
T15
15
F1240493 F1240491
GB e GB f
Remove gudgeon T16A and bush T15. Remove tool T14 together with the pin (17) of the planet wheel.
NOTE. In this condition the tool T14 contains pin (17).
60
Rimuovere gli anelli elastici (16) dai perni (17) degli Inserire tra gli ingranaggi satelliti (18) l'attrezzo T14.
ITA ingranaggi satelliti (18). ITA
Kolbenringe (16) von den Stiften (17) der PlantenraÈder Zwischen den PlanetenraÈdern (18) das Werkzeug T14
D (18) entfernen. D einsetzen.
a b
Remover los anillos elaÂsticos (16) de los dos pernos Introducir entre los engranajes sateÂlites (18) la
ESP (17) de los engranajes sateÂlites (18). ESP herramienta T14.
Enlever les anneaux eÂlastiques (16) des tourillons (17) Introduire entre les engrenages satellites (18) l'outil
F des engrenages satellites (18). F T14.
Operando con due cacciaspine, forzare l'attrezzo T14 Sistemare il corpo differenziale (15) sotto una pressa,
ITA tra gli ingranaggi satelliti (18). ITA posizionare la boccola T15 ed inserire lo spinotto
ATTENZIONE! Controllare attentamente che l'attrez- T16A. Pressare lo spinotto T16A fino a fondo corsa.
zo T14 rimanga allineato ai perni (17) quando eÁ bloccato.
Mit zwei DuÈbeln, das Werkzeug T14 zwischen den Das DifferentialgehaÈuse (15) unter eine Presse legen
D PlanetenraÈdern (18) fest einsetzen. D und die Buchse T15 positionieren; Bolzen T16A
ACHTUNG: SorgfaÈltig darauf achten, daû das blok- einsetzen. DruÈcken, bis der Bolzen T16A.
kierte Werkzeug T14 mit den Stiften (17) fluchtgerecht ist.
c d
Trabajando con dos extractores de clavijas, forzar la Colocar la caja del diferencial (15) debajo de una
ESP herramienta T14 entre los engranajes sateÂlite (18). ESP prensa; posicionar el casquillo T15 e introducir la
CUIDADO! Controlar atentamente que la herramienta cruceta T16A. Presionar la cruceta T16A.
T14 quede alineada con los pernos (17) cuando estaÂ bloqueada.
En oeuvrant avec deux chasse-goupilles, forcer l'outil Ajuster le boõÃtier diffeÂrentiel (15) sous la presse, placer
F T14 entre les engrenages satellites (18). F la bague T15 et introduire le goujon T16A.
ATTENTION! ControÃler attentivement si l'outil T14 Presser le goujon T16A.
reste aligneÂ aux tourillons (17) quand il est bloqueÂ.
Asportare lo spinotto T16A e la bussola T15. Rimuovere l'attrezzo T14 e con esso il perno (17) del
ITA ITA satellite.
NOTA. In questa condizione, il perno (17) eÁ contenuto
nell'attrezzo T14.
Bolzen T16A und die Buchse T15 abnehmen. Das Werkzeug T14 und damit den Stift (17) des
D D Planetenrades abnehmen.
BEMERKUNG. In diesem Zustand, ist der Stift (17) im
Werkzeug T14 enthalten.
e f
Sacar la cruceta T16A y el manguito T15. Remover la herramienta T14 y con ella el perno (17)
ESP ESP del sateÂlite.
NOTA. En esta condicioÂn el perno (17) se encuentra
en la herramienta T14.
Enlever le goujon T16A et la douille T15. Enlever l'outil T14 et, avec ce dernier, le tourillon (17)
F F du satellite.
NOTE. Dans cette condition le tourillon (17) se trouve
dans l'outil T14.
61
T14 18 14
13
15
18
F1240490 F1240494
GB a GB b
Leave the released planetary gear in position and again lock tool Remove tool T14 and remove the last two planet wheel gears (18),
T14. the 2nd differential unit gear (14) and the relative shim washer (13)
Repeat the operations for the extraction of the pin of the 2nd planet from the differential carrier.
wheel (17).
Repeat the operations for all other pins.
4
3 5 16
1
20
9 11
17
19
20
17 16
19
18
13
GB c GB d
14
7 13
15 10
12 18 8
2
19
17
20 19
16
17
20
6
16
3
1
GB e GB f
D1240036
62
Lasciando in posizione l'ingranaggio satellite che si eÁ Rimuovere l'attrezzo T14 ed asportare dal corpo
ITA liberato, bloccare nuovamente l'attrezzo T14. ITA differenziale gli ultimi due ingranaggi satelliti (18), il
Ripetere le operazioni di estrazione del perno del 2ë ingranaggio planetario (14) e la relativa rondella di
secondo perno satellite (17). rasamento (13).
Ripetere le operazioni per gli altri perni.
Das nun freie Planetenrad in seiner Position lassen Werkzeug T14 entfernen und vom DifferentialgehaÈuse
D und das Werkzeug T14 wieder blockieren. D die letzten beiden PlanetenraÈder (18), das 2. Differen-
Die VorgaÈnge fuÈr das Herausnehmen des Stiftes des tialrad (14) und die Zwischenlegscheibe (13) abneh-
2. Planetenrades (17) wiederholen. men.
a Die VorgaÈnge auch fuÈr die anderen Stifte wiederholen. b
Dejando en posicioÂn el engranaje sateÂlite que ha Remover la herramienta T14 y sacar de la caja del
ESP quedado libre, bloquear otra vez la herramienta T14. ESP diferencial los uÂltimos dos engranajes sateÂlite (18), el
Repetir las operaciones de extraccioÂn del perno del 2ë engranaje diferencial (14) y la arandela de espesor
segundo perno sateÂlite (17). correspondiente (13).
Repetir las operaciones con los demaÂs pernos.
En maintenant la position de l'engrenage satellite Enlever l'outil T14 et extraire du boõÃtier diffeÂrentiel les
F deÂgageÂ, bloquer de nouveau l'outil T14. F deux derniers engrenages satellites (18), le 2ë
ReÂpeÂter les opeÂrations d'extraction du tourillon du 2ë engrenage du diffeÂrentiel (14) et la relative rondelle
satellite (17). de rasage (13).
ReÂpeÂter les opeÂrations pour les autres tourillons.
ITA ITA
D D
c d
ESP ESP
F F
ITA ITA
D D
e f
ESP ESP
F F
62
HOW TO ASSEMBLE AND INSTALL THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE -
DIFFERENTIALAGGREGAT MONTIEREN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL
ASSEMBLING - ASSEMBLAGGIO - MONTIEREN - MONTAJE - MONTAGE
18
14
19
13
15 T16C
F1240494 F1240495
GB a GB b
Insert the shim washer (13) and the planetary gear (14) in the Position the shim washer (19) and the first planet wheel gear (18).
differential carrier (15). Hold them in position using bar T16C.
18 T14
T16A
19 15
T16C
T16C
F1240496 F1240497
GB c GB d
With the help of gudgeon T16A, position the second planet wheel Insert tool T14 between the two planetary gears (18). Line up the
gear (18) and the relative shim washer (19). entire unit by pushing bar T16C all the way down until gudgeon
T16A is ejected.
T14 20 17
18 18
F1240490 F1240498
GB e GB f
Lock tool T14 behind the planet wheel gears (18). Fit the snap rings (20) onto the pins (17).
After locking, remove bar T16C.
64
Inserire nel corpo differenziale (15), la rondella di Posizionare la rondella di rasamento (19), il primo
ITA rasamento (13) e l'ingranaggio planetario (14). ITA ingranaggio satellite (18).
Tenerli in posizione con la barra T16C.
Das DifferentialgehaÈuse (15), die Zwischenlegscheibe Die Zwischenlegscheibe (19) und das erste Planeten-
D (13) und das Planetenrad (14) einsetzen. D rad (18) positionieren.
Mit dem Stab T16C diese in ihrer Position halten.
a b
Introducir en la caja del diferencial (15) la arandela de Posicionar la arandela de espesor (19), el primer
ESP espesor (13) y el engranaje planetario (14). ESP engranaje sateÂlite (18).
Mantenerlos en posicioÂn por medio de la barra T16C.
Introduire, dans le boõÃtier du diffeÂrentiel (15), la Placer la rondelle de rasage (19) et le premier
F rondelle de rasage (13) et l'engrenage planeÂtaire (14). F engrenage satellite (18).
Maintenir ceux-ci en place aÁ l'aide de la barre T16C.
Utilizzando lo spinotto T16A, posizionare il secondo Inserire tra i due ingranaggi satelliti (18) l'attrezzo T14.
ITA ingranaggio satellite (18) e la relativa rondella di ITA Allineare tutto il gruppo inserendo a fondo la barra
rasamento (19). T16C fino ad espellere lo spinotto T16A.
Mit dem Bolzen T16A das zweite Planetenrad (18) und Zwischen den beiden PlanetenraÈder (18) das Werk-
D die entsprechende Zwischenlegscheibe (19) positio- D zeug T14 einsetzen.
nieren. Das gesamte Aggregat fluchten; dazu den Stab T16C
ganz einschieben bis die Bolzen T16A herausgestoûen worden
c d sind.
Utilizando la cruceta T16A, posicionar el segundo Introducir entre los dos engranajes sateÂlite (18) la
ESP engranaje sateÂlite (18) y la arandela de espesor ESP herramienta T14.
correspondiente (19). Alinear todo el grupo introduciendo a fondo la barra
T16C hasta expulsar la cruceta T16A.
A l'aide du goujon T16A placer le second engrenage Introduire entre les deux engrenages satellites (18)
F satellite (18) et sa relative rondelle de rasage (19). F l'outil T14.
Aligner tout le groupe en inseÂrant aÁ fond la barre T16C
jusqu'aÁ eÂjecter le goujon T16A.
Bloccare l'attrezzo T14 a ridosso degli ingranaggi Montare sui perni (17) gli anelli elastici (20).
ITA satelliti (18). ITA
Dopo il bloccaggio, rimuovere la barra T16C.
Werkzeug T14 an den PlanetenraÈdern (18) anliegend, Auf die Stifte (17) die Kolbenringe (20) montieren.
D blockieren. D
Danach Stab T16C entfernen.
e f
Bloquear la herramienta T14 detraÂs de los engranajes Montar en los pernos (17) los anillos elaÂsticos (20).
ESP sateÂlite (18). ESP
DespueÂs de bloquearlos, remover la barra T16C.
Bloquer l'outil T14 aÁ l'abri des engrenages satellites Monter sur les tourillons (17) les anneaux eÂlastiques
F (18). F (20).
ApreÁs avoir bloqueÂ, enlever la barre T16C.
65
T16B 17
17
T15
T15
T16B
17
F1240499 F1240500
GB a GB b
Place the differential carrier (15) under the press, position bush Put gudgeon T16B on top of the planet wheel pin (17).
T15 and insert the planet wheel pin (17).
T16B
T15
T16B
16
17
17
15
F1240492 F1240502
GB c GB d
Press T16B pin all the way down. Remove gudgeon T16B, bush T15 and fit the snap ring (16) on the
pin (17).
CAUTION! Make sure that the snap ring centres the seat and that it
rests on the surface of the differential carrier.
Repeat the operations on the other planet wheel pin or planet
wheel axle.
13
14
12
15
F1240487 F1240504
GB e GB f
Position the second planetary gear (14) in the differential carrier Position the shim washer (13) on the crown (12).
(15). NOTE. In order to hold the shim washer (13) in position, apply
grease to it.
66
Posizionare sotto la pressa il corpo differenziale (15), Sovrapporre al perno satellite (17) lo spinotto T16B.
ITA sistemare la boccola T15 ed inserire il perno satellite ITA
(17).
Unter der Presse das DifferentialgehaÈuse (15) positio- È ber den Planetenradstift (17) den Bolzen T16B
U
D nieren, die Buchse T15 anbringen und den Planeten- D anbringen.
radstift (17) einsetzen.
a b
Posicionar debajo de la prensa la caja del diferencial Superponer al perno sateÂlite (17) la cruceta T16B.
ESP (15), colocar el casquillo T15 e introducir el engranaje ESP
sateÂlite (17).
Placer sous la presse le boõÃtier diffeÂrentiel (15), ajuster Juxtaposer sur le tourillon satellite (17) le goujon
F la bague T15 et introduire le tourillon satellite (17). F T16B.
Pressare lo spinotto T16B a fondo. Rimuovere lo spinotto T16B, la boccola T15 e montare
ITA ITA sul perno (17) l'anello elastico (16).
ATTENZIONE! Assicurarsi che l'anello elastico centri
la sede e che appoggi sul piano del corpo differenziale.
Ripetere le operazioni per l'altro perno satellite e per l'altro asse
satelliti.
Den Stift T16B fest hinein druÈcken. Bolzen T16B, Buchse T15 entfernen und auf den Stift
D D (17) den Kolbenring (16) montieren.
ACHTUNG! Der Kolbenring muû im Sitz zentriert sein
und an der FlaÈche des DifferentialgehaÈuses anliegen.
c d Dieselben VorgaÈnge fuÈr den anderen Planetenradstift und die
andere Planetenradachse wiederholen.
Apretar la cruceta T16B a hondo. Remover la cruceta T16B, el casquillo T15 y montar
ESP ESP en el perno (17) el anillo elaÂstico (16).
CUIDADO! Asegurarse de que el anillo elaÂstico esteÂ
centrado en el alojamiento y que esteÂ apoyado en la superficie de
la caja del diferencial. Repetir las operaciones en el otro perno
sateÂlite y en el otro eje sateÂlite.
Presser aÁ fond sur l'axe T16B. Enlever le goujon T16B de la douille T15 puis monter
F F sur le tourillon (17) l'anneau eÂlastique (16).
ATTENTION! S'assurer que l'anneau eÂlastique est
bien centreÂ dans son logement et qu'il repose sur le plan du boõÃtier
diffeÂrentiel. ReÂpeÂter ces meÃmes opeÂrations pour l'autre tourillon
satellite et pour l'autre axe satellites.
Posizionare il secondo ingranaggio planetario (14) nel Posizionare la rondella di rasamento (13) sulla corona
ITA corpo differenziale (15). ITA (12).
NOTA. Per mantenere la posizione, spalmare la
rondella di rasamento (13) con grasso.
Das zweite Planetenrad (14) im DifferentialkoÈrper (15) Zwischenlegscheibe (13) auf den Kranz (12) positio-
D positionieren. D nieren.
BEMERKUNG. Um die Position zu sichern, die
Zwischenlegscheibe (13) mit Fett einschmieren.
e f
Posicionar el segundo engranaje planetario (14) en el Posicionar la arandela de espesor (13) en la corona
ESP cuerpo del diferencial (15). ESP (12).
NOTA. Para mantener la posicioÂn, pasar grasa en la
arandela de espesor (13).
Placer le second engrenage planeÂtaire (14) dans le Placer la rondelle de rasage (13) sur la couronne (12).
F corps diffeÂrentiel (15). F
NOTE. Pour maintenir cette position, enduire la
rondelle de rasage (13) avec du gras.
67
11 12 T17 8
T17 7
15
F1240505 F1240506
GB a GB b
Position the crown (12) on the differential carrier (15) and lock it Install the bearings (7) and (8) using tool T17.
with screws (11) applied with Loctite 242.
Torque wrench setting for screws: 128±142 Nm
NOTE. Secure the screws using the cross-tightening method.
F1240507
GB c GB d
If the bearings are replaced, insert the external thrust blocks in the
middle cover (5) and in the central body (2).
INSTALLING - INSTALLAZIONE - INSTALLIEREN - INSTALACION - INSTALLATION
1 2 9 4
5 5
4
4
F1240482 F1240852
GB e GB f
Position the differential unit (6) in the central body (2) with the help Lock the middle cover (5) with screws (4).
of a bar and fit the middle cover (5). Torque wrench setting for screw: 23.8±26.2 Nm
NOTE. Thoroughly check the state of the O-ring (9) and make sure
that the cover is fitted with the oil discharge in the lower position.
68
Posizionare la corona (12) sul corpo differenziale (15) Utilizzando l'attrezzo T17, montare i cuscinetti (7) e
ITA e bloccarla con le viti (11) spalmate con Loctite 242. ITA (8).
Coppia di serraggio viti: 128v142 Nm
NOTA. Serrare le viti con il metodo del serraggio incrociato.
Den Kranz (12) auf den DifferentialkoÈrper (15) positio- Mit dem Werkzeug T17 die Lager (7) und (8)
D nieren und mit den Schrauben (11) blockieren. D montieren.
Anzugsmoment der Schrauben: 128v142 Nm
BEMERKUNG. Die Schrauben abwechselnd und entgegengesetzt
a festschrauben. b
Posicionar la corona (12) en el cuerpo del diferencial Utilizando la herramienta T17, montar los cojinetes (7)
ESP (15) y bloquearla con los tornillos (11) pasarles Loctite ESP y (8).
242.
Par de torsioÂn: 128v142 Nm
NOTA. Apretar los tornillos con el meÂtodo de torsioÂn cruzado.
Placer la couronne (12) sur le corps du diffeÂrentiel (15) A l'aide de l'outil T17 monter les paliers (7) et (8).
F puis bloquer avec les vis (11) enduites avec Loctite F
242.
Couple de serrage des vis: 128v142 Nm.
NOTE. Serrer les vis par le biais du mode de serrage croiseÂ.
Se vengono sostituiti i cuscinetti, inserire nel coper-

ITA chio intermedio (5) e nel corpo centrale (2) le ralle ITA
esterne.
Falls die Lager ausgewechselt werden sollen, in den

D mittleren Deckel (5) und in den zentralen KoÈrper (2) die D
aÈuûeren Scheiben einsetzen.
c d
Si se sustituyen los cojinetes, introducir en la tapa
ESP intermedia (5) y en el cuerpo central (2) las ranguas ESP
exteriores.
Si les paliers doivent eÃtre remplaceÂs, introduire dans

F le couvercle intermeÂdiaire (5) et, dans le corps central F
(2), les crapaudines externes.
Utilizzando una barra, posizionare il gruppo differen- Bloccare il coperchio intermedio (5) con le viti (4).
ITA ziale (6) nel corpo centrale (2) e montare il coperchio ITA Coppia di serraggio viti: 23,8v26,2 Nm
intermedio (5).
NOTA. Controllare attentamente la condizione dell'anello OR (9) e
che il coperchio venga montato con lo scarico olio nella posizione
inferiore.
Mit einem Stab das Differentialaggregat (6) in den Mit den Schrauben (4) blockieren den mittleren Deckel
D zentralen KoÈrper (2) positionieren und den mittleren D (5).
Deckel (5) montieren. Anzugsmoment der Schrauben: 23,8v26,2 Nm
BEMERKUNG. SorgfaÈltig den Zustand des O-Ringes (9) kontroll-
e ieren und sicherstellen, daû der Deckel mit dem O È lablaûstopfen f
nach unten gerichtet montiert wird.
Utilizando una barra, posicionar el grupo diferencial Bloqueare la tapa intermedia (5) con los tornillos (4).
ESP (6) en el cuerpo central (2) y montar la tapa intermedia ESP Par de torsioÂn tornillos: 23,8v26,2 Nm
(5).
NOTA. Controlar atentamente las condicioÁnes del segmento OR (9)
y que la tapa venga montada con el descarge aceite en la posicioÁn
inferior.
A l'aide d'une barre, placer le groupe diffeÂrentiel (6) Bloquer le couvercle intermeÂdiaire (5) dernier avec les
F dans le corps central (2) et monter le couvercle F vis (4).
intermeÂdiaire (5). Couple de serrage des vis: 23,8v26,2 Nm
NOTE. ControÃler attentivement les conditions de l'anneau torique
(9) te que le couvercle soit monteÂ avec le bouchon de vidange pour
l'huile dans la position infeÂrieure.
69
T13 T19
F1240509 F1240510
GB a GB b
NOTE. If the ring nuts (1) are removed, spread them with Loctite Pre-set the bearings by means of the ring nut situated on the
242. opposite side of the crown, so as to increase pinion torque up to
Tighten ring nuts on the crown side until clearance between pinion 140v210 Ncm.
and crown is zero, then lock the crown; go back 1/4v1/2 turn. CAUTION! If bearings are not new, check the static torque; if
bearings are new, check the continuous torque.
12 A A
F1240511 F1240512
GB c GB d
Introduce a comparator with rotary key "A" through the top plug Manually move the crown (12) in both directions in order to check
hole (10). Position the comparator on the centre of one of the teeth the existing backlash between the pinion and the crown.
of the crown (12), pre-set it to 1mm and reset it.
RATIO - RAPPORTO CLEARANCE - GIOCO - SPIEL

VERHAÈ LTNIS JUEGO - JEU
RAPORTE - RAPPORT MIN. MAX.
9v34 0,18 0,23
T13 9v35 0,13 0,18
11v31 0,20 0,28
11v35 0,13 0,18
12v35 0,13 0,18
12v41 0,15 0,20
14v32 0,18 0,23
14v36 0,15 0,20
14v41 0,15 0,20
15v32 0,18 0,23
F1240509
15v47 0,13 0,18
Difference between MIN and MAX clearance for whole circumference should
GB e not exceed 0.09 mm. GB f
La differenza tra gioco MIN e MAX rilevata sull'intera circonferenza non deve
superare il valore di 0,09 mm.
Adjust the backlash between the pinion and the crown by Der Unterschied zwischen dem MIN e MAX Spiel der gesamten Kreislinie darf
unloosing one of the ring nuts (1) and tightening the opposite to den Wert von 0,09 mm nicht uÈberschreiten.
compensate. La diferencia entre el juego Min y Max determinada sobre la entera
Normal backlash: see table. circonferencia no debe de superar el valor de 0,09 mm.
La diffeÂrence de jeu entre MIN et MAX releveÂe sur toute la circonfeÂrence ne
doit pas aller au-delaÁ de la valeur de 0,09 mm.
70
NOTA. Se le ghiere (1) vengono rimosse, spalmarle Precaricare i cuscinetti tramite la ghiera lato opposto
ITA con Loctite 242. ITA corona per incrementare la coppia di rotazione
Serrare le ghiere dal lato corona fino ad azzerare i pignone fino a 140v210 Ncm.
giochi tra pignone e corona e bloccarla; ritornare indietro di circa ATTENZIONE! Con cuscinetti usati, controllare la coppia di spunto;
1/4v1/2 giro. con cuscinetti nuovi, controllare la coppia di rotazione continua.
BEMERKUNG. Wenn die Nutmuttern (1) ausgewech- Lager durch die Nutmutter an der dem Kranz ent-
D selt werden, diese mit Loctite 242 schmieren. D gegengesetzten Seite vorladen, um das Gegenmo-
Nutmuttern an der Kranzseite fest ziehen bis kein ment des Rades auf 140v210 Ncm zu bringen.
Spiel mehr zwischen Rad und Kranz uÈbrig bleibt ; danach um 1/ ACHTUNG! Bei verbrauchten Lagern, das Anlaufdrehmoment kontroll-
a 4v1/2 Umdrehung wieder aufschrauben. b ieren; bei neuen Lagern, das kontinuierliche Drehmoment kontrollieren.
NOTA. Si se remueven las virolas (1) pasarles Loctite Precargar los cojinetes atraves la virola lado opuesto
ESP 242. ESP corona para incrementar el par de rotacion pinon
Apretar las virolas del lado corona hasta acerar los hasta 140v210 Ncm.
juegos entre el pinon y la corona y bloquearla, volver atras de 1/ CUIDADO! Con cojinetes usados, controlar el par de inicio, con
4v1/2 giro approx. cojinetes nuevos, controlar el par de rotacioÂn continua.
NOTE. Si les anneaux (1) sont enleveÂs, les enduire PreÂcharger les paliers au moyen d'anneaux de fixation
F avec du Loctite 242. F du coÃteÂ opposeÂ de la couronne pour augmenter le
Serrer les anneaux de fixation du coÃteÂ couronne couple de rotation pignon jusqu'aÁ 140v210 Ncm.
jusqu'aÁ mettre aÁ zeÂro les jeux entre pignon et couronne et bloquer: ATTENTION! Avec les paliers useÂs, controÃler le couple de pointe;
revenir en arrieÁre d'environ 1/4v1/2 tour. avec les paliers neufs, controÃler le couple de rotation continu.
Posizionare, attraverso il foro per il tappo superiore Muovere manualmente nei due sensi la corona (12)
ITA (10), un comparatore a tasto orientabile "A". ITA per controllare il gioco esistente tra pignone e corona.
Posizionarlo sul centro di un dente della corona (12),
precaricarlo di circa 1 mm ed azzerarlo.
Durch das Loch des oberen Stopfens (10) eine Den Kranz (12) von Hand in beide Richtungen
D schwenkbare Meûuhr "A" in der Mitte eine Kranzzah- D bewegen und das Spiel zwischen Rad und Kranz
nes (12) anbringen. Die Meûuhr auf 1 mm vorladen pruÈfen.
und auf Null stellen.
c d
Posicionar, a traveÂs del orificio para el tapoÂn superior Mover manualmente en los dos sentidos la corona (12)
ESP (10), un comparador de tecla orientable "A". ESP para controlar el juego que hay entre el pinÄoÂn y la
Posicionarlo en el centro de un diente de la corona corona.
(12), precargarlo de aproximadamente 1 mm y ponerlo a cero.
Placer, par le trou du bouchon supeÂrieur (10), un DeÂplacer la couronne (12) manuellement dans les
F comparateur aÁ touche orientable "A". F deux sens pour controÃler le jeu existant entre pignon
Placer ce dernier au centre d'une dent de la couronne et couronne.
(12), preÂcharger d'environ 1 mm, puis le mettre aÁ zeÂro.
Regolare il gioco tra pignone e corona allentando una

ITA ghiera (1) e serrando la ghiera opposta in egual ITA
misura.
Gioco normale: vedere tabella.
Das Spiel zwischen Rad und Kranz einstellen; dazu

D eine Nutmutter (1) lockern und die entgegengesetzte D
Nutmutter auf dieselbe Weise zuschrauben.
Normales Spiel: siehe Tabelle.
e f
Regular el juego entre el pinÄoÂn y la corona aflojando
ESP una virola (1) y apretando la virola opuesta en la ESP
misma medida.
Juego normal: veÂase la tabla.
ReÂgler le jeu entre pignon et couronne en desserrant

F un collier de serrage (1) puis en serrant le collier de F
serrage opposeÂ avec la meÃme mesure de jeu.
Jeu normal: voir tableau.
71
10
3 3
F1240513 F1240385
GB a GB b
Apply Loctite 242 to the screws (3), fit them into one of the two Re-install the complete arms.
holes and tighten. For details, see «CHECKING WEAR AND REPLACING THE
Torque wrench setting: 23.8±26.2 Nm BRAKING DISKS».
Fit the top plug (10) after applying repositionable jointing
compound for seals to the rims.
GB c GB d
GB e GB f
72
Spalmare le viti (3) con Loctite 242 ed avvitarle in uno Rimontare i bracci completi.
ITA dei due fori predisposti. ITA Per i dettagli, vedere «CONTROLLO USURA E
Coppia di serraggio: 23,8v26,2 Nm SOSTITUZIONE DISCHI FRENO».
Montare il tappo superiore (10) dopo aver spalmato i bordi con
mastice per guarnizioni riposizionabile.
Die Schrauben (3) mit Loctite 242 schmieren und in Die beiden kompletten Arme montieren.
D eines der beiden vorgesehenen LoÈcher schrauben. D Siehe «VERSCHLEISS KONTROLLIEREN UND
Anzugsmoment: 23,8v26,2 Nm BREMSSCHEIBEN AUSWECHSELN».
Die RaÈnder des oberen Stopfens (10) mit Klebstoff fuÈr verstellbare
a Dichtungen schmieren und den Stopfen montieren. b
Pasar Loctite 242 en los tornillos (3) y atornillarlos en Volver a montar los brazos completos.
ESP uno de los dos orificios predispuestos. ESP Para los detalles, veÂase «CONTROL DEL DESGASTE
Par de torsioÂn: 23,8v26,2 Nm Y SUSTITUCION DE LOS DISCOS DEL FRENO».
Montar el tapoÂn superior (10) despueÂs de repasar los bordes con
pasta para juntas reposicionable.
Enduire les vis (3) avec du Loctite 242, puis visser Remonter les bras complets.
F celles-ci dans l'un des deux trous preÂdisposeÂs. F Pour de plus amples deÂtails, voir «CONTROLE
Couple de serrage: 23,8v26,2 Nm USURE ET SUBSTITUTION DES DISQUES DE
Monter le bouchon supeÂrieur (10) apreÁs avoir enduit les bords avec FREINAGE».
mastic pour garnitures aÁ remettre en place.
ITA ITA
D D
c d
ESP ESP
F F
ITA ITA
D D
e f
ESP ESP
F F
73
SPECIAL TOOLS - ATTREZZI SPECIALI - SONDERWERZZEUGE
HERRAMIENTAS ESPECIALES - OUTILS SPECIAL
4.3 T1 T2
45°
20
25
1
32
32
=
200
=
90
= =
50
160
110
120± 0.1
120± 0.1
32
32
25
1
840
45 °
10 4.5 930
D1240043
D1240046
2313 2305
Ø30 T6 Ø64 T7
Ø25
3x45°
30
3x15°
cementazione
Proteggere da
50
130
155
Proteggere da
cementazione
150
1.5 x45°
0
R1
213
2 x45°
10
R1
R1
3-- 00.2
0
0.8
13
49.5
0.8
89 0.8
.5
0.8
2301
R1
D1240048
52
50
5x15°
Ø35
Ø50 ---- 0.1

0.2
D1240049
2303
74
Ø158.5
] Ø158.5
T9
Ø50 H7 20° Ø35
Ø30
0.8
16
0.8
R3
113
Ø132 -- 0.3
0.5
129
R3
117
--
148
102
R5 20°
100
25
R3
8x15°
Ø40
Ø140
Ø50---- 0.12
0.08
Ø150
]
Ø200 ±0.03
Ø95
] é148 For Timken thrust block

Per ralla TIMKEN
FuÈr TIMKEN scheibe
Para rangua TIMKEN
Pour ralla TIMKEN
é150 For Koyo thrust block
Per ralla KOYO
FuÈr KOYO scheibe
Para rangua KOYO
Pour ralla KOYO
D1240058
3354
Ø40
T10 Ø35 T11
2 x45°
2x45°
120
1x45°
175
0.8
-- 0.2
-- 0.3
1
41
26
19
0.8 0.8
5.5
5x15°
0.8
Ø139.5 -- 0.1
0
R3
Ø153
10 15
Ø168
0.8
25
Ø180 D1260052
Ø39
2x15°
0.8
Ø50 D1260051
3502 2304
75
Ø125 T13 T14
10x15°
Ø35.5 ---- 0.1
0.2 Ø41
0.8
Ø25
Ø20 + 00.2
Ø15H7-n6
1x45°
R1
Ø5.5
0.8
100
Ø14
2 x15°
5
8
0.8
36
31
26
24
20
17
20
238
0
R1 Ø25
0.8
Ø10
Ø35 M26X1.5
123
125
33
36
Ø5.5
18
22.5
0.8
33
Ø37H7-n6
69
10.5
Ø47
1 x45°
6
0.8
Ø106 ± 0.1
Ø20 + 00.2
R30
25
Ø25
Ø41 D1240055
D1240054
3333 3708
T15 T16A T16B

T16
3x30° 2x30°
24.5 ⫾ 0.0.1
Ø28.5 ± 0.2
-- 0.1
Ø19.9 +-- 0.1

+0
0
Ø19.9
Ø30
8.5
0.8
Ø6
10 46.45 ± 0.1
10 19.6
± 0.5
15°
56.6 29.6 0.5x45°
Ø20 ++ 0.08
0.12
Ø27 ---- 0.1
0.2
T16C
Ø23
Ø30
0.8
Ø19.9 +-- 0.1
0
D1240056
1x30°
175
3424 2306 D1240057
T17
1.5x45°
0.8
3
1
68
0.8
38
0.8
Ø38.5 ---- 0.1

0.2
Ø55
Ø63
Ø65 D1240059
3332
76
T19 T20
T20A Ø185 ± 0.2
] 38x1.25x29 DIN 5480
Ø105 ± 0.2
120
80
Ø75
Ø55 ---- 0.08

0.12
]
Ø105 ± 0.2
25
5x15
Tornito Ø 125
0.8
32,25
10
15
125
25
35
Ø10
60
15
Ø34.5--+ 00.2
14
Ø50 2307
48
59
T20B 135 ±0.5

R5
30
97
73
M6
Ø20
5
61.5
61.5
Ø40H7-n6 1/4”
85
Ø44
126 12
Ø32 150
10
15
100
D1240060
3317/4 2308 Ø45 D1240061
T21 Ø85
T22
] 38x1.25x29 DIN 5480
Ø66
Ø55H7
Ø75
0.8
Ø55 –– 0.08
0.12
0.8
]
22
5 x15
Tornito Ø
0.8
75
32,25
7
10
35
6
60
15
14
34
60
6
20 40 20
3/4"
Ø15H7-n6
15°
60
100
275
D1240064
3317/3 D1240063
3317/A
77
99.5 T23 Ø30.2 ± 0.001 T24
Ø17
5x45°
25
Ø88.8 ± 0.005
131
Ø42
20
D1240066
2309 2310 D1240065
T25
T25A
Ø19.55H7
21°
0.8
R5
R2
T25B
23
Ø83
3x15°
Ø40
Ø88
R2
0.8
0.8
T25C
Ø20 +-- 00.1
0.8 T25C T25B

T25B T25A
T25A
21°
Ø89 ---- 0.12

0.08
Ø55
Ø83
0.8
23 40 R2
3329/2 73
0.8
R2
10 56
66 2311
T25C
Ø19.5 ---- 0.12
0.08
473.5
Ø16.5---- 0.2
0.1
M18x1.5
M18x1.5
433.5
0.8 0.8 0.8
Ø35
Ø40
15°
5 5x15°
11 30
45
3329/3 D1240067
T26 T27
Ø50
4 x45°
T26A
5x45°
15
14
40 300
63
87
Ø20 T26B Ø110

R5
74
Ø65
2 -- 0.2
M14 x1
0
M14 x1
12
0.8
41 20
25 25
12
50
61-- 0.02
-- 0.01
3x15°
R5
0.8
30
Ø37.75 ++ 0.08
0.8
Ø41.2 +-- 0.03

0
Ø20 0.12
Ø9
195
T26C Ø55 ---- 0.2

95
0.3
Ø89
Ø11
35
Ø99
Ø80
D1240073
10
50
Ø6.5
2312 D1240075
3327
78
T28
ENERPAC Mod. RCH-123 T28C T28B T28A
23
3x15°
64
R2
0.8
0.8
R3
0.8
21°
Ø89 ---- 0.08

0.12
Ø55
Ø83
Ø40
Ø40H8
Ø70
Ø54
0.8 R2
R2
10 56
66
312
M18X1.5
M18X1.5
267
50 5x15° 0.8
0.8
15°
Ø40H8
R3
-- 0.2
-- 0
17min.
Ø19
30
D1240074
3329
Ø28 ---- 0.08

0.12
T29 T31
3x15°
Ø24 -- 0.08
0.8
-- 0.12
10
5x45°
0.8
15
65
Proteggere da
cementazione
50
30
110
140.5
120
5°
3x45°
Ø26
R5
0.5
Ø33 D1240093
3543
15
0.8 0.8
3
3x15°
T30
15
M12x1.25 Ø50
0.8
Ø64 + 0.2
0
Ø84.5
15
18
Ø94.5
Ø110
35
D1240097
17
Ø16.2 -- 00.1
Ø17 ++ 0.2
0.1 D1240096
2316 3739
79
T33 T34
3x45°
Ø25
Ø30
3x45°
30
30
cementazione
Proteggere da
cementazione
Proteggere da
130
140
130
136.5
1.5x45°
1.5 x45°
0
R1
1
3
7
10
0.8
R1
R0
0.8
0.8
Ø19.8
.5
45H7
0.8
6.5
Ø25
54.5
Ø45 D1240116
D1240117
2321 2322
80
TROUBLESHOOTING - RICERCA GUASTI - FEHLERSUCHE - BUSQUEDA DE AVERIAS -
RECHERCHE DES PANNES
81
TROUBLESHOOTING - RICERCA GUASTI - FEHLERSUCHE - BUSQUEDA DE AVERIAS - RECHERCHE DES PANNES
PROBLEM - PROBLEMA - PROBLEM - CAUSE - CAUSE - URSACHE - CORRECTION - RIMEDI - ABHILFE -

PROBLEMA - PROBLEME CAUSAS - CAUSE REMEDIOS - REMEDE
Insufficient braking 1. Incorrect adjustment Inspect disc thickness and if discs are usable read-
just brakes to the specifications in the vehicle's man-
Frenatura insufficiente ual.
UngeneÈgende Bremswirkung 1. Incorretta registrazione Controllare lo spessore dei dischi freno e, se i dischi
Frenado insuficiente freno possono essere riutilizzati, registrarli come da
istruzioni del manuale del veicolo.
Freinage insuffisant
1. Fehlerhafte Einstellung BremsscheibenstaÈrke uÈberpruÈfen, koennen die
Bremscheiben noch verwendet werden, Spiel neu
einstellen gemaÈû Anweisungen im Handbuch des
Fahrzeuges.
1. Ajuste incorrecto Controlar el espesor de los discos del freno y, si los
discos del freno pueden volver a utilizarse, ajustarlos
de acuerdo con las instrucciones del manual del ve-
hõÂculo.
1. Mauvais reglage Inspecter l'eÂpaisseur des disques frein et, si les dis-
ques frein sont en bon etat, regler selon les instruc-
tions du manuel du vehicule.
2. Brake discs worn out Inspect disc thickness and replace if necessary.
2. Dischi freno usurati Controllare lo spessore dei dischi freno e, se neces-
sario, sostituirli.
2. Bremsscheiben verschlissen BremsscheibenstaÈrke uÈberpruÈfen und falls erforder-
lich ersetzen.
2. Discos del freno gastados Controlar el espesor de los discos del freno y, si fuera
necesario, sustituirlos.
2. Disques frein useÂs Inspecter l'eÂpaisseur des disques frein et si neÂces-
saire remplacer les disques.
Replace all seals in axle and master cylinder that

3. Incorrect brake fluid have made contact with the incorrect fluid and all
brake hoses.
If incorrect fluid leaked into axle oil, seals and o-rings
in axle must be replaced.
3. Fluido non idoneo nel circuito Sostituire tutti gli anelli di tenuta del ponte e del cilin-
dro master che sono venuti a contatto con il fluido
non idoneo noncheÂ i tubi flessibili.
Se il fluido non idoneo eÁ entrato nel ponte e si eÁ me-
scolato con il lubrificante devono essere sostituiti tutti
gli anelli di tenuta ed gli O-rings.
3. Ungeeignete Fluessigkeit in der Alle Dichtringe und GummischlaÈuche die mit der fal-
Bremsanlage schen FluÈssigkeit in Kontakt gekommen sind, in der
Achse und im Hauptbremszylinder ersetzen.
Sollte diese FluÈssigkeit auch in die Achse gelaugt
sein, sind auch saÈmtliche O-Ringe und Dichtringe
der Achse zu ersetzen.
3. Fluido no adecuado para el circuito Sustituir todos los segmentos de compresioÂn del
puente y del cilindro principal que han estado en con-
tacto con el fluido no adecuado como asõÂ tambieÂn los
tubos flexibles.
Si el fluido no adecuado ha entrado en el puente y se
ha mezclado con el lubricante, hay que sustituir to-
dos los segmentos de compresioÂn y los O-Rings.
3. Fluide inadeÂquat dans le circuit Substituer tous les joints d'eÂtencheiteÂ du pont et du
maõÃtre-cylindre qui ont eÂteÂ en contact avec ce fluide
mais aussi les tubes flexibles.
Si le fluide incorrect est entreÂ dans le pont et s'est
melange avec le lubrifiant tous les joints d'eÂtancheÂiteÂ
et o-ring doivent eÃtre changeÂs.
82
Insufficient braking 4. Loss of brake fluid Inspect for and repair any leaks in outside circuit or
master cylinder.
Frenatura insufficiente If caused by incorrect brake fluid see correction N. 3.
UngeneÈgende Bremswirkung If leak is to the outside replace the o-rings between
the center and intermediate housings.
Frenado insuficiente If leak is to the inside replace above o-rings and brake
Freinage insuffisant piston o-rings.
4. Perdita del fluido dal circuito freno Controllare e riparare tutte le perdite del circuito ester-
no o del circuito master.
Se la causa eÁ dovuta al fluido non idoneo vedere rime-
dio n. 3.
Se la perdita eÁ verso l'esterno del ponte sostituire gli
O-ring tra la scatola centrale ed il coperchio interme-
dio.
Se la perdita eÁ verso l'interno del ponte, sostituire gli
O-ring sopra menzionati e quelli del pistone freno.
4. Verlust von BremsfluÈssigkeit AÈussere Bremsanlage und Hauptbremszylinder auf
OÈ lverluste pruÈfen.
Sollte der Verlust auf ungeeignete Bremsfluessigkeit
zuruÈckzufuÈhren sein, siehe Abhilfe N.3.
Sollte der Verlust nach aussen sein, die O-Ringe zwi-
schen dem AchsmittengehaÈuse und den Zwischen-
gehaÈuse ersetzen.
Sollte der Verlust nach innen sein, oben genannte O-
Ringe und jene der Bremskolben ersetzen.
4. PeÂrdida del fluido del circuito Controlar y reparar todas las peÂrdidas del circuito ex-
del freno terior o del cilindro principal.
Si la causa se debe al fluido no idoÂneo, veÂase el reme-
dio në3.
Si la peÂrdida es hacia fuera del puente, sustituir los O-
Ring entre la caja central y la tapa intermedia.
Si la peÂrdida es hacia el interior del puente, sustituir
los O-Ring mencionados maÂs arriba y los del pistoÂn
del freno.
4. FluideÂ dans le circuit de freinage Inspecter et reÂparer toutes les fuites du circuit ex-
terne ou du maõÃtre-cylindre.
Si la cause est duÃe aÁ l'utilisation d'un fluide non in-
dique voir remeÁde N. 3.
Si la fruite est vers l'exterieur du pont, substituer les
o-rings entre le carter central et les carters interme-
diaires.
Si la fruite est vers l'interieur du pont substituer les o-
rings mentionneÂs ci-dessus et ceux des pistons frein.
5. Overheated axle causing brake See «overheating» problem.

fluid to vaporize.
(Brake return when axle cools)
5. Surriscaldamento del ponte con va- Vedere problema: Surriscaldamento.
porizzazione del fluido.
(I freni ritornano quando il ponte si
raffredda)
5. Verdunstung der Bremsflussigkeit È berhitzung.
Siehe Problem: U
wegen UÈ berhitzung.
(Im abgekuÈhlten Zustand ist die
Bremswirkung wieder hergestellt)
5. Sobrecalentamiento del puente con VeÂase el problema: Sobrecalentamiento.
vaporizacioÂn del fluido.
(Los frenos vuelven a funcionar
cuando se enfrõÂa el puente)
5. Surchauffe du pont avec vaporisa- Voir probleme: Surchauffe.
tion du fluide.
(Les freins fonctionnent aÁ nouveau
quand le fluide se refroidit).
83

Soft brake pedal 6. Air in brake circuit Bleed brakes as described in the vehicle's service
manual.
Pedale del freno non risponde
6. Aria nel circuito frenante Spurgare il circuito frenante come da istruzioni di spur-
Leichtes Bremspedal go del manuale del veicolo.
El pedal del freno no funciona 6. Luft in der Bremsanlage Bremsen entluÈften gemaÈû Anweisungen im Hand-
Pedale du frein ne repond pas buch des Failrzeuges.
6. Aire en el circuito frenante Purgar el circuito frenante se acuerdo con las instruc-
ciones de purga del manual del vehõÂculo.
6. Air dans le circuit Purger le circuit de frein selon «instructions de purge»
du manuel du veÂhicule.
Ineffective safety brake 7. Incorrect adjustment See correction N. 1.

Freno negativo inefficiente 7. Registrazione incorretta Vedere rimedio N. 1.
Federspeicherbremse ohne 7. Fehlerhafte Einstellung des Siehe Abhilfe N. 1.
Funktion. Bremsscheibenspieles
Freno negativo ineficiente 7. Ajuste incorrecto VeÂase remedio N.1.
Inefficacite du frein negatif 7. Mauvais reglage Voir remeÁde N. 1.
8. Brake disc worn out See correction N. 2.

8. Dischi freno usurati Vedere rimedio N. 2.
8. Bremslamellen verschlissen Siehe Abhilfe N. 2.
8. Discos del freno gastados VeÂase remedio N. 2.
8. Usure disques frein Voir remeÁde N. 2.
Overheating 9. Oil level wrong Drain, flush and refill oil to proper level.
Surriscaldamento 9. Livello olio non corretto Scaricare, eseguire un lavaggio e riempire d'olio fino a
È berhitzung livello.
U
È lspiegel-Falscher
9. Niedriger O OÈ l ablassen, reinigen und richtigen O
È lstand wieder
Sobrecalentamiento È lstand
O herstellen.
Surchauffe 9. Nivel de aceite no correcto Descargar, ejecutar un lavado y llenar con aceite has-
ta el nivel.
9. Niveau d'huile pas incorrect Vidanger, rincer et refaire le niveau d'huile.
10. Too small of a brake gap Readjust brakes to the specifications in the vehicle's
service manual.
10. Poco gioco tra i dischi freno Registrare il freno come istruzioni da manuale del vei-
colo.
10. Zu wenig Spiel zwischen den Spiel gemaÈû Anweisungen im Handbuch des Fahr-
Bremslamellen zeuges herstellen.
10. Poco juego entre los discos del Ajustar el freno de acuerdo con las instrucciones del
freno manual del vehõÂculo
10. Peu de jeu entre les disques frein Regler le frein selon les instructions du manuel du veÂ-
hicule.
11. Park brake dragging Unlock the brake and adjust the correct gap.
11. Freno di parcheggio in trazione Sbloccare il freno ripristinando il gioco corretto.
11. Feststellbremse zieht Bremsen loÈsen und richtiges Lamellenspiel einstel-
len.
11. Freno de estacionamiento en Desbloquear el freno restableciendo el juego correcto.
traccioÂn
11. Frein de parc mal reÂgleÂ DeÂbloquer le frein et reÂgler le jeu.
84
Overheating 12. Incorrect brake fluid in system See correction N. 3.

Surriscaldamento 12. Fluido non idoneo nel circuito Vedere rimedio N. 3.
È berhitzung
U 12. Ungeeignete FluÈssigkeit in der Siehe Abhilfe N. 3.
Bremsanlage
Sobrecalentamiento
12. Fluido no adecuado en el circuito VeÂase remedio N. 3
Surchauffe
12. Fluide incorrect dans le circuit Voir remeÁde N. 3.
13. No free-pedal at master cylinder Readjust brake pedal as described in the vehicle's
service manual.
13. Non c'eÁ corsa a vuoto sul cilindro Registrare il pedale del freno come istruzioni da ma-
master nuale del veicolo.
13. Kein Leerweg am Bremspedal Bremspedal gemaÈû Anweisungen im Handbuch des
Fahrzeuges einstellen.
13. No hay carrera en vacõÂo en el Ajustar el pedal del freno de acuerdo con las instruc-
cilindro principal ciones del manual del vehõÂculo.
13. Pas de garde sur la pedale du ReÂgler la pedale du frein selon les instructions du ma-
maõÃtre-cylindre nuel du veÂhicule.
14. Restriction in brake lines Inspect for and replace damage lines.
14. Restringimento sul circuito del Controllare e riparare i condotti ammaccati o piegati.
freno
14. Verengung in der Bremsanlage Anlage uÈberpruÈfen und verbeulte oder geknickte Lei-
tungen ersetzen.
14. Circuito del freno restringido Controlar y reparar los conductos golpeados o plega-
dos.
14. Reglage sur circuit du frein Inspecter et reÂparer les conduites endommageÂes.
15. Restriction in return line of brake Inspect for and replace damaged return line.
Servo system Inspect for and remove any filter, tee'd in line or any
other source of back pressure from the return line.
15. Restringimento sul condotto di Controllare e riparare il condotto ammaccato o piegato.
ritorno del sistema servo Controllare e sostituire tutti i filtri e raccordi sul circuito o
qualsiasi altro ostacolo nel condotto di ritorno.
15. Verengung in der RuÈckflussleitung Anlage uÈberpruÈfen und verbeulte oder geknickte Lei-
des Servobremssystems tungen ersetzen.
Alle Filter und Abzweigungen in der Anlage uÈberpruÈ-
fen, saÈmtliche Hindernisse fuÈr den freien Durchfluû
entfernen.
15. Conducto de retorno del sistema Controlar y reparar el conducto golpeado o plegado.
servo restringido Controlar y sustituir todos los filtros y empalmes en el
circuito o cualquier otro obstaÂculo en el conducto de
retorno.
15. Etranglement sur la conduite de Inspecter et reÂparer la conduite endommageÂe.
retour du servo-frein Inspecter et changer tous les filtres, raccords en «T»
ou autre obstacle sur le circuit de retour.
16. Incorrect lubricant Change the retaining rings of the brake circuit and
brake pump.
16. Lubrificante non idoneo Sostituire gli anelli di tenuta del circuito freno e della
pompa freno.
16. Ungeeignetes Schmieroel Die Abdichtungsringe des Bremskreislaufs der Brem-
spumpe ersetzen.
16. Lubricante no adecuado Sustituir los segmentos de compresioÂn del circuito del
freno y de la bomba del freno.
16. Lubrifiant incorrect Replacer les anneaux d'eÂtancheÂiteÂ du circuit et de la
pompe de frein.
85

Diff-lock inoperative 17. If manual control, loose or misadju- Inspect and correct linkage and readjust as indicated
sted linkage in vehicle's service manual.
Il blocco differenziale non
funziona 17. Se il comando eÁ manuale: comando Controllare, riparare e registrare il comando indicato
scollegato o registrato male nel manuale del veicolo.
Differentialsperre ohne
Wirkung 17. Bei mechanisch betaÈtigter Sperre, Hebel uÈberpruÈfen und gemaÈû Anweisungen im Hand-
loser oder schlecht eingestellter buch des Fahrzeuges einstellen.
El bloque del diferencial Hebel
no funciona
17. Si el mando es manual: mando des- Controlar, reparar y ajustar el mando indicado en el
Mauvais fonctionnement du conectado o mal ajustado manual del vehõÂculo.
blocage du diffeÂrentiel
17. Si la commande est manuel: com- Inspecter, reÂparer er reÂgler la commande selon le ma-
mande deÂconnecteÂe ou mal reÂgleÂe nuel du veÂhicule.
18. If hydraulic control, problems in the Refer to the service manual for the vehicle.
hydraulic or electrical circuits of the
vehicle
18. Se il comando eÁ idraulico: problemi Fare riferimento alle istruzioni nel manuale del veicolo.
nel circuito elettrico del veicolo
18. Bei hydraulisch betaÈtigter Sperre, Siehe Anweisungen im Handbuch des Fahrzeuges.
Probleme in der hydraulischen oder
elektrischen Anlage des Fahrzeuges
18. Si el mando es hidraÂulico: problemas Consultar las instrucciones del manual del vehõÂculo.
en el circuito eleÂctrico del vehõÂculo
18. Si la commande est hydraulique: Voir instructions dans manuel du veÂhicule.
probleÁme dans le circuit eÂlectrique
dans le veÂhicule
19. If hydraulic control: problems in ac- Rebuilt cylinder.

tuating cylinder (noteable through
loss of hydraulic oil or increase of
the oillevel in axle)
19. Se il comando eÁ idraulico: problemi Controllare e riparare il cilindro.
nell'attuatore (caratterizzati da per-
dite del fluido idraulico o da aumen-
to del livello d'olio nel ponte)
19. Bei hydraulisch betaÈtigter Sperre, È berpruÈfen und Zylinder reparieren.
U
OÈ lverlust im BetaÈtigungszylinder
(erkentlich durch Verlust von hy-
draulisch Fluessigkeit oder Anstieg
des Oelniveaus in der Achse)
19. Si el mando es hidraÂulico: proble- Controlar y reparar el cilindro.
mas en el actuador (caracterizados
por peÂrdidas del fluido hidraÂulico o
por un aumento del nivel del aceite
en el puente)
19. Si la commande est hydraulique: Inspecter et reparer le cylindre.
probleÁmes dans le veÂrin (caracteri-
seÂs par des fuites de fluide hydrau-
lique ou augmentation du niveau
d'huile dans le pont)
20. If with lim. slip differential, worn Replace discs.

discs
20. Se il differenziale eÁ del tipo Sostituire i dischi.
autobloccante, dischi usurati
20. Wenn mit Selbstsperrdifferential, Scheiben ersetzen.
Scheiben verschlissen
20. Si el diferencial es del tipo autoblo- Sustituir los discos.
queante: discos gastados
20. Si avec diffeÂrentiel aÁ glissement Remplacer les disques.
limiteÂ, usure sur les disques
86
Oil coming out of breather 21. Leak in internal brake system See correction N. 2 and 3.
Olio fuoriesce dallo sfiato 21. Perdita di fluido idraulico dal siste- Vedere rimedio N. 2 e 3.
È laustritt aus dem EntluÈfter ma frenante
O
21. Verlust von hydraulisch FluÈssigkeit Siehe Abhilfe N. 2 und 3.
El aceite sale del purgador der Bremsanlage
Huile sort du reniflard 21. PeÂrdida de fluido hidraÂulico del sis- VeÂanse remedios N. 2 y 3.
tema frenante
21. Fuite de fluide hydraulique du sys- Voir remeÁde N. 2 et 3.
teme de freinage
22. Leak in diff-lock actuating cylinder See correction N. 19.

22. Perdita d'olio idraulico dal circuito Vedere rimedio N. 19.
del blocco differenziale
22. Verlust von Hydraulisch FluÈssigkeit Siehe Abhilfe N. 19.
der hydraulisch Anlage der Diffe-
rentialsperre
22. PeÂrdida de aceite hidraÂulico del cir- VeÂase remedio N. 19.
cuito del bloque del diferencial
22. Fuite d'huile hydraulique du circuit Voir remeÁde N. 19.
de blocage du diffeÂrentiel
NoSpin indexing noise when 23. Unequal tire pressure left anal right Inflate tires to the recommended pressure in the ser-
driving straight vice manual, or until the rolling radius is equal.
CAUTION! With NoSpin, fatigue
damage can occur on the side 23. Pressione disuguale nei pneumatici Gonfiare i pneumatici alla pressione raccomandata nel
with the larger tire. sui due lati manuale o comunque fino ad ottenere un raggio stati-
co uguale.
Il NoSpin eÁ rumoroso viaggian-
do sul rettilineo 23. UngleichmaÈssiger Reifendruck Reifen vorschriftsgemaÈû auf pumpen bis ein gleich-
ATTENZIONE! Con il NoSpin links und rechts groûer statischer Halbmesser erreicht wird.
possono verificarsi avarie da fa- 23. PresioÂn desigual en los neumaÂticos Hinchar los neumaÂticos a la presioÂn recomendada en
tica sul lato con il pneumatico a ambos lados el manual o, de todas formas, hasta obtener un rayo
piuÁ grande.
estaÂtico igual.
NoSpin macht GeraÈusche bei
Geracheausfahrt 23. Pressions diffeÂrentes dans les Gonfler les pneumatiques selon la pression recom-
ACHTUNG! Mit NoSpin koÈnnen
pneumatiques sur les deux cotes mandeÂe dans le manuel os jusq'aÁ obtenir le meÃme
auf der Seite mit dem groÈsseren du veÂhicule rayon sous charge.
Reifenradius ErmuÈdungsschaÈ-
den auftreten.
24. Different style, size or brand of tires Change tires to make the rolling radius equal.
El NoSpin hace ruido andando between left and right hand side Vary the tire pressure within the specifications until
en un rectilõÂneo the rolling radius is equal.
CUIDADO! con el No Spin se
pueden producir averõÂas por fa- 24. Pneumatico di disegno, marca o co- Cambiare pneumatici o rendere i raggi statici dei pneu-
tiga en un lado en el neumaÂtico struttore diversi sui due lati matici eguali.
maÂs grande. Variare la pressione dei pneumatici nei campi di tolle-
ranza prescritti dai costruttori dei pneumatici stessi, fi-
Le No-Spin fait du bruit en rou- no ad ottenere un raggio statico uguale.
lant en ligne droite
ATTENTION! Avec le NoSpin, 24. Unterschiedliche Reifen, -groÈûen - Reifen ersetzen sodaû ein gleich-groûer Statischer
des ruptures de fatigue peu- marken, links und rechts Halbmesser erreicht wird.
vent se produire du coÃteÂ des Reifendruck im Bereich der Vorschriften aÈndern bis
pneumatiques les plus grands. ein gleichgroûer Halbmesser erreicht wird.
24. NeumaÂticos de disenÄo, marca o fa- Cambiar los neumaÂticos o hacer que los rayos estaÂti-
bricante distintos a los dos lados cos de los neumaÂticos sean iguales.
Variar la presioÂn de los neumaÂticos en los campos de
tolerancia prescritos por los fabricantes de dichos
neumaÂticos, hasta obtener un radio estaÂtico igual.uÁ
24. Pneumatiques de sculptures ou de Changer les pneumatiques ou rendre les rayons sans
constructeurs differents sur les charge des pneumatiques eÂgaux.
deux coÃtes du vehicule Modifier la pression des pneumatiques dans les toleÂ-
rances prescrites par les constructeurs de ces me-
mes pneumatiques, jusq'aÁ obtenir un rayon sous
charge identique.
87

Noise during coast and under

power the same
25. Wheel bearings damaged Replace and adjust.
RumorositaÁ uguale sia in tiro
che in rilascio 25. Cuscinetti dei mozzi danneggiati Sostituire i particolari in avaria.
GeraÈusch im Zug und im 25. Lager der Radnaben beschaÈdigt BeschaÈdigte Teile gemaÈû Anweisungen.
Schub gleich stark 25. Cojinetes de los cubos danÄados Sustituir las piezas averiadas.
Ruido igual tanto en traccioÂn 25. Roulements des moyeux endom- Remplacer les pieÁces endommageÂes.
como en inercia mageÂs
Bruit en traction ou en retenue
Noise under power greater 26. Low oil level Refill oil to proper level.
than during coast
26. Livello olio basso Ripristinare il livello olio.
RumorositaÁ piuÁ elevata in tiro È lstand È lstand wieder
26. Niedriger O SchmieroÈl nachfuÈllen bis richtiger O
piuttosto che in rilascio
hergestellt ist.
GeraÈeusch staÈerker im Zug als
26. Nivel de aceite bajo Restablecer el nivel del aceite.
im Schub
26. Niveau d'huile insuffisant Refaire le niveau d'huile.
Ruido maÂs elevado en traccioÂn
que en inercia
Bruit pus eÂleve en traction 27. Incorrect lubricant See correction N. 16.
qu'en retenue. 27. Olio non idoneo Vedere rimedio N. 16.
27. Ungeeignetes SchmieroÈl Siehe Abhilfe N. 16.
27. Aceite no adecuado VeÂase remedio N. 16.
27. Huile incorrect Voir remeÁde N. 16.
28. Ring and pinion worn Inspect through top cover. Replace and adjust.
28. Coppia conica usurata Controllare attraverso il coperchio superiore.
Sostituire la coppia conica.
28. Kegel- und Tellerrad verschlissen Durch die obere Bohrung uÈberpruÈfen. Kegel- und Tel-
lerrad ersetzen.
28. Par coÂnico gastado Controlar a traveÂs de la tapa superior.
Sustituir el par coÂnico.
28. Usure du couple conique Inspectioner au travers du couvercle superieur.
Remplacer le couple conique.
29. Worn ring and pinion bearings Replace and adjust.

29. Cuscinetti della coppia conica Sostituire i particolari in avaria.
usurati
29. Kegelrollenlager des Kegel- und BeschaÈdigte Teile ersetzen.
Tellerradpaares verschlissen
29. Cojinetes del par coÂnico gastados Sustituir las piezas averiadas.
29. Usure des roulements du couple Remplacer les pieÁces endommageÂes.
conique
30. Worn planetary gears or bearings Replace.

30. Planetari o cuscinetti dell'epicicloi- Sostituire i particolari in avaria.
dale usurati
30. PlanetenraÈder oder Lager der Pla- BeschaÈdigte Teile ersetzen.
netenabtriebe verschlissen
30. Planetarios y cojinetes del epicicloi- Sustituir las piezas averiadas.
dal gastados
30. Usure des planeÂtaires ou roule- Remplacer les pieÁces endommageÂes.
ment de l'eÂpicycloõÈdale
88
Noise during coast greater 31. Loose pinion nut Inspect ring, pinion and pinion bearings. If unda-
than under power maged, retighten nut.
RumorositaÁ piuÁ elevata in rilas- 31. Ghiera pignone allentata Controllare la coppia conica ed i rispettivi cuscinetti,
cio piuttosto che in tiro se non fossero danneggiati serrare la ghiera.
GeraÈeusch staÈerker im Schub 31. Wellenmutter des Kegelritzels lose Kegel- und Tellerrad und Lager uÈberpruÈfen. Sollten
als im Zug diese nicht beschaÈdigt sein, Wellenmutter anziehen.
Ruido maÂs elevado en inercia 31. Virola del pinÄoÂn floja Controlar el par coÂnico y los cojinetes correspondientes.
que en traccioÂn
31. Ecrou du pinion deÂvisseÂ Inspecter le couple conique et les roulements et si
Bruit plus eÂleve en retenue rien n'est endommageÂ, resserrer l'ecrou.
qu'en traction
See correction N. 29.
32. Only pinion bearing damaged
32. Solo un cuscinetto del pignone eÁ
Vedere rimedio N. 29.
danneggiato
32. Nur eines der Lager des Kegelrit-
Siehe Abhilfe N. 29.
zels ist beschaÈdigt
32. SoÂlo un cojinete del pinÄoÂn estaÂ da-
VeÂase remedio N. 29.
nÄado
32. Seulement un roulement du pignon
Voir remeÁde N. 29.
est endommageÂ
Noise during turn

(without NoSpin) 33. Worn spider and/or side gears Replace.
Rumore sotto sterzo 33. Satelliti e/o planetari del differenzia- Sostituire i particolari danneggiati.
(senza NoSpin) le danneggiati
GeraÈusch waÈhrend der 33. Ausgleich kegelraÈder und/oder BeschaÈdigte Teile ersetzen.
Kurvenfahrt (ohne NoSpin) welleraÈder verschlissen
Ruido en la direccioÂn 33. SateÂlites y/o planetarios del diferen- Sustituir las piezas danÄadas.
(sin NoSpin) cial danÄados
Bruit en braquage 33. Satellites et/ou planeÂtaires du diffeÂ- Remplacer les pieÁces endommageÂes.
(sans NoSpin) rentiel endommageÂes
A «Stick slip» noise when 34. Worn or damaged cardanshaft Inspect and replace as described in vehicle's service
going from forward to reverse manual.
Un rumore tipo «Stick slip» si 34. Giunto cardanico danneggiato Controllare e sostituire il giunto come indicato nel ma-
manifesta durante l'inversione nuale del veicolo.
di marcia È berpruÈfen und Kardanwelle gemaÈû. Anweisungen
34. Kardanwelle beschaÈdigt U
«Stick slip» -GeraÈusch bei AÈn- im Handbuch des Fahrzeuges ersetzen.
derung der Fahrtrichtung
34. Junta cardaÂnica danÄada Controlar y sustituir la junta como se indica en el ma-
Un ruido tipo «Stick slip» se nual del vehõÂculo.
manifiesta al invertir la marcha
34. Joint cardan endommageÂ Inspecter et remplacer le joint cardan selon les indi-
Un bruit type «Stick slip» se cations du manuel du veÂhicule.
manifeste pendant l'inversion
35. Loose wheel Inspect for wheel and wheel stud damage. Replace if
needed and retorque lugnuts.
35. Ruota allentata Ispezionare eventuali danni al disco ed alle colonnette
del mozzo ruota, se necessario sostituire i particolari
danneggiati e serrare i dadi alla coppia prescritta.
35. Rad lose Eventuelle SchaÈden an der Felge und an den Radbol-
zen uÈberpruÈfen. Falls erforderlich beschaÈdigte Teile
ersetzen und Radmuttern gemaÈû vorgeschriebenem
Drehmoment anziehen.
35. Rueda floja Inspeccionar los posibles danÄos al disco y a las colum-
nas del cubo de la rueda; si fuera necesario, sustituir las
piezas danÄadas y apretar las tuercas al par prescrito.
35. Roue deÂvisseÂe Inspecter les eÂventuels dommages au disque et aux
goujons du moyeu de rue. Si neÂcessaire remplace les
pieces endommageÂes et serrer les eÂcrous au couple
prescrit.
89
91
HOW TO DISASSEMBLE THE MECHANIC PARKING BRAKE UNIT - SMONTAGGIO GRUPPO FRENO DI STAZIONAMENTO A COMANDO
MECCANICO - MECHANISQUE HANDBREMSE ABMONTIEREN - DESMONTAJE GRUPO FRENO ESTACIONAMIENTO MECANICO -
DEMONTAGE DU FREIN DE STATIONNEMENT MECANIQUE
2
3
F1241060 F1240658
GB a GB b
ATTENTION! Though the photos in this manual refer to a steering Draw out the screw (1) locking the washer (2) that stops the lever
and oscillating axle, the operations described apply anyway. (3).
6
2
4 3 7
12 13
F1240659
5 F1240660
GB c GB d
Remove washer (2), lever (3) and O-rings (4). Draw out the screws (5) and remove bush (6) along with O-ring (7).
Mark the positions of levers (3) in relation to the thrust levers (12)
and (13).
10
F1241060
9 F1240661
GB e GB f
Connect the whole arm (8) to the hoist and put the rod under light Remove the braking disks (9) and the whole piston (10).
tension. For details, see «CHECKING AND REPLACING THE BRAKING
Remove the whole arm; for details, see «CHECKING AND DISKS».
REPLACING THE BRAKING DISKS».
92
ATTENZIONE! Le foto rsono riferite ad un assale Asportare la vite (1) di bloccaggio della rondella (2) di
ITA sterzante ed oscillante, ma le operazioni descritte ITA ritegno della leva (3).
sono valide.
ACHTUNG! Die Abbildungen beziehen sich auf eine Die Schraube (1) zur Befestigung der Unterlegscheibe
D Lenk- und Schwenkachse. Die beschriebenen Vor- D (2) des Hebels (3) abschrauben.
gaÈnge gelten aber auch in diesem Fall.
a b
ATENCION! Las fotos se refieren a un eje desviante y Sacar el tornillo (1) de bloqueo de la arandela (2) de
ESP oscilante, pero las operacioÁnes descritas son validas. ESP retencion palanca (3).
ATTENTION! Les photos sont reÂfeÂreÂes aÁ un essieu Enlever la vis (1) de blocage de la rondelle (2) de
F braquant et oscillant, mais les opeÂrations ci-deÂcrites F fixation du levier (3).
sont valables.
Rimuovere la rondella (2), la leva (3) e le guarnizioni Asportare le viti (5) e rimuovere la boccola (6) completa
ITA OR (4). ITA di guarnizione OR (7).
Contrassegnare le posizioni delle leve (3) rispetto le
leve di spinta (12) e (13).
Unterlegscheibe (2), Hebel (3) und O-Ringe (4) ab- Schrauben (5) abschrauben und Buchse (6) samt O-
D nehmen. D Ring (7) abnehmen.
Die Positionen der Hebel (3) im VerhaÈltnis zu den
Druckhebeln (12) und (13) kennzeichnen.
c d
Remover la arandela (2), la palanca (3) y las Sacar los tornillos (5) y remover el casquillo (6)
ESP guarniciones OR (4). ESP completo de guarniciones OR (7).
Senalar las posicioÁnes de las palancas (3) respecto a
las palancas de empuje (12)
Enlever la rondelle (2), le levier (3) et les garnitures OR Enlever les vis (5) et extraire la douille (6) eÂquipeÂe de
F (4). F garnitures OR (7).
Marquer les positions des leviers (3) par rapport aux
leviers (12) et (13).
Agganciare il braccio completo (8) ad un mezzo di Rimuovere i dischi freni (9) ed il pistone completo (10).
ITA sollevamento e mettere il leggera tensione la fune. ITA Per i dettagli, vedere «CONTROLLO E SOSTITUZIO-
Rimuovere il braccio completo; per i dettagli, vedere NE DISCHI FRENI».
«CONTROLLO E SOSTITUZIONE DISCHI FRENI».
VollstaÈndigen Arm (8) mit einem Hebekarren anheben Bremsscheiben (9) und den ganzen Kolben (10)
D bis das Seil gespannt ist. D abnehmen. Weitere Einzelheiten im Paragraph
VollstaÈndigen Arm abtrennen; weitere Einzelheiten im «BREMSSCHEIBEN KONTROLLIEREN UND AUS-
Paragraph «BREMSSCHEIBEN KONTROLLIEREN UND AUS- WECHSELN».
e WECHSELN». f
Enganchar el brazo completo (8) y un medio de Remover los discos frenos (9) y el piston completo
ESP levantamiento y poner en ligera tension el cable. ESP (10).
Remover el brazo completo; por los detalles, vease Por los detalles, vease «CONTROL Y SUSTITUCION
«CONTROL Y SUSTITUCION DISCOS FRENOS». DISCOS FRENOS».
Accrocher le bras complet (8) aÁ un moyen de relevage Enlever les disques freins (9) et le piston complet (10).
F et mettre la corde leÂgeÁrement en tension. F Pour tout deÂtail, voir «CONTROLE ET SUBSTITUTION
Enlever le bras complet: pour tout deÂ tail, voir DES DISQUES FREINS».
«CONTROLE ET SUBSTITUTION DES DISQUES FREINS».
93
HOW TO DISASSEMBLE THE MECHANIC PARKING BRAKE UNIT - SMONTAGGIO GRUPPO FRENO DI STAZIONAMENTO A COMANDO
MECCANICO - MECHANISQUE HANDBREMSE ABMONTIEREN - DESMONTAJE GRUPO FRENO ESTACIONAMIENTO MECANICO -
DEMONTAGE DU FREIN DE STATIONNEMENT MECANIQUE
10
8
11
14 12 13
F1240662 F1240663
GB a GB b
If pins (11) need replacing, block the piston (10) into a vice whose If thrust levers (12) and (13) need replacing, remove the axle shaft
jaws are covered in smooth material and remove the pins. (14) before removing the arms (8).
For details, see «HOW TO REMOVE THE AXLE SHAFT».
1
16 2
15 4
3
4
5 6
GB c 12 GB d
13
11
10
8 14
9
11
F1240079
GB e GB f
94
Se si devono sostituire i puntali (11), bloccare il Se si devono sostituire le leve di spinta (12) e (13),
ITA pistone (10) in una morsa con ganasce in materiale ITA prima di rimuovere i bracci (8) rimuovere il semiasse
tenero e rimuovere i puntali. (14).
Per i dettagli, vedere «RIMOZIONE DEL SEMIASSE».
Falls die Schafte (11) ausgewechselt werden sollen, Falls die Druckhebel (12) und (13) ausgewechselt
D Kolben (10) in einem Spannbackenpaar aus weichem D werden sollen, zuerst die Halbachse (14) und dann die
Material blockieren und Schafte abnehmen. Arme (8) abnehmen. Weitere Einzelheiten im Para-
graph «HALBACHSE INSTALLIEREN».
a b
Si se deben cambiar las puntas (11), bloquear el Si se deben cambiar las palancas de empuje (12) y
ESP piston (10) en un corchete con mordazas en material ESP (13), antes de remover los brazos (8) remover los
tierno y remover las puntas. semiejes (14).
Por los detalles, vease «REMOCION DE LOS SEMIEJES».
Si l'on doit substituer les tiges (11), bloquer le piston Si l'on doit substituer les leviers de pousseÂe (12) et
F (10) dans un eÂtau aÁ maÃchoire en mateÂriel tendre, puis F (13), avant d'enlever les bras (8) enlever le demi-
enlever les tiges. essieu (14).
Pour tout deÂtail, voir «DEPOSE DE DEMI-ESSIEU».
95
HOW TO ASSEMBLE THE MECHANIC PARKING BRAKE UNIT - ASSEMBLAGGIO GRUPPO FRENO DI STAZIONAMENTO A COMANDO
MECCANICO - MECHANISQUE HANDBREMSE MONTIEREN - ASEMBLAJE GRUPO FRENO ESTACIONAMIENTO MECANICO -
ASSEMBLAGE DU FREIN DE STATIONNEMENT MECANIQUE
10
11
14 12 13
F1240663 F1240664
GB a GB b
Install thrust levers (12) and (13), then install the axle shaft (14). For Apply Loctite 270 to the threaded portion of the pins (11) and fit
details, see «HOW TO INSTALL THE AXLE SHAFT». them onto the piston (10).
Block them: torque wrench setting 30 ± 35 Nm.
10
9 F1240661 F1241060
GB c GB d
Re-install the piston (10) and the braking disks (9). For details, see Install the arms (8) into the main body; check flatness and block
«HOW TO ASSEMBLE THE BRAKING UNITS». arms following the appropriate procedures illustrated in section
«HOW TO ASSEMBLE THE BRAKING UNITS».
6
1
3
5
F1240665 F1240666
GB e GB f
Install the bush (6) complete with O-ring (7) and block it with screws Install in sequence the lower O-ring (4), the lever (3) and the washer
(5). Tighten screws with a torque wrench setting of 23.8 ± 26.2 Nm. (2) with the relative O-ring (4). Block with screw (1) and tighten
using a torque wrench setting of 23.8 ± 26.2 Nm.
CAUTION! Refer and keep to the positions marked during
disassembly.
96
Montare le leve di spinta (12) e (13) e successivamente Spalmare la filettatura dei puntali (11) con Loctite 270
ITA il semiasse (14). ITA e montarli sul pistone (10).
Per i dettagli di montaggio del semiasse, vedere Bloccarli con una coppia di serraggio di 30v35 Nm.
«INSTALLAZIONE DEL SEMIASSE».
Druckhebel (12) und (13) montieren; danach Halb- Schafte (11) mit Loctite 270 schmieren und auf den
D achse (14) montieren. D Kolben (10) montieren.
Weitere Einzelheiten im Paragraph «HHALBACHSE Anzugsmoment: 30v35 Nm.
INSTALLIEREN».
a b
Montar la palancas de empuje (12) y (13) y al final los Pasar la rosca de las puntales (11) con Loctite 270 y
ESP semiejes (14). ESP montarlas sobre los pistones (10).
Por los detalles de montaje de los semiejes, vease Bloquearlos con un par de torsion de 30v35 Nm.
«INSTALACION DE LOS SEMIEJES».
Monter les leviers de pousseÂe (12) et (13) et ensuite le Enduire le filetage des tiges (11) avec du Loctite 270
F demi-essieu (14). F puis les monter sur le piston (10).
Pour tout deÂtail, voir «DEPOSE DE DEMI-ESSIEU». Bloquer aÁ un couple de serrage de 30v35 Nm.
Rimontare il pistone (10) ed i dischi freno (9). Montare i bracci (8) sul corpo centrale; controllare il
ITA Per i dettagli, vedere «ASSEMBLAGGIO DEI GRUPPI ITA livellamento e quindi bloccarli con le modalitaÁ descritte
DI FRENATURA». per l'«ASSEMBLAGGIO DEI GRUPPI DI FRENATU-
RA».
Kolben (10) und Bremsscheiben (9) wieder montieren. Die Arme (8) auf den zentralen KoÈrper montieren;
D Weitere Einzelheiten im Paragraph «ZUSAMMENBAU D danach abrichten und laut Anweisungen des Para-
DER BREMSAGGREGATE». graphs «ZUSAMMENBAU DER BREMSAGGREGAT»
blockieren.
c d
Remontar los pistones (10) y los discos frenos (9). Montar los brazos (8) sobre el cuerpo central, controlar
ESP Por los detalles, vease «ASEMBLAJE DE LOS ESP el nivelamiento y entonces bloquearlos con las
GRUPOS DE FRENADURA». modalidades descritas por «ASEMBLAJE DE LOS
GRUPOS DE FRENADURA».
Remonter le piston (10) et les disques freins (9). Monter les bras (8) sur le corps central; controÃler le
F Pour tout deÂtail, voir «ASSEMBLAGE DES GROUPES F niveau, puis bloquer en suivant le mode deÂcrit dans
DE FREINAGE». l'«ASSEMBLAGE DES GROUPES DE FREINAGE».
Montare la boccola (6) completa di guarnizione OR (7) Montare nell'ordine la guarnizione OR inferiore (4), la
ITA e bloccarla con le viti (5). ITA leva (3) e la rondella (2) completa della relativa
Serrare le viti con una coppia di 23,8v26,2 Nm. guarnizione OR (4).
Bloccarla con la vite (1) serrata ad una coppia di 23,8v26,2 Nm.
ATTENZIONE! Rispettare le posizioni contrassegnate in fase di
smontaggio.
Buchse (6) samt O-Ring (7) montieren und mit den Der Reihenfolge nach den unteren O-Ring (4), Hebel
D Schrauben (5) festschrauben. D (3) und Unterlegscheibe (2) samt O-Ring (4) montieren.
Anzugsmoment der Schrauben: 23,8v26,2 Nm. Mit der Schraube (1) festschrauben. Anzugsmoment
der Schraube: 23,8v26,2 Nm.
e f ACHTUNG! Die beim Abmontieren markierten Positionen einhal-
ten.
Montar el casquillo (6) completa de guarnicion OR (7) y Montar en el orden la guarnicion OR inferior (4), la
ESP bloquearla con tornillos (5). ESP palanca (3) y la arandela (2) completa de la relativa
Apretar los tornillos con un par de 23,8v26,2 Nm. guarnicion OR (4).
Bloquearla con el tornillo (1) apretada a un par de 23,8v26,2 Nm.
ATENCION! Respectar las posicioÁnes senaladas en fase de
montaje.
Monter la douille (6) eÂquipeÂe de garniture OR (7) et Monter dans l'ordre la garniture OR infeÂrieure (4), le
F bloquer cette dernieÁre avec les vis (5). F levier (3) et la rondelle (2) eÂquipeÂe de sa relative
Serrer les vis aÁ un couple de serrage de 23,8v26,2 garniture OR (4).
Nm. Bloquer celle-ci avec la vis (1) serrer aÁ un couple de 23,8v26,2 Nm.
ATTENTION! Respecter les positions noteÂes en phase de
deÂmontage.
97
HOW TO ASSEMBLE THE MECHANIC PARKING BRAKE UNIT - ASSEMBLAGGIO GRUPPO FRENO DI STAZIONAMENTO A COMANDO
MECCANICO - MECHANISQUE HANDBREMSE MONTIEREN - ASEMBLAJE GRUPO FRENO ESTACIONAMIENTO MECANICO -
ASSEMBLAGE DU FREIN DE STATIONNEMENT MECANIQUE
16 6
3
16
15
8÷10 N
3 (0,8÷1 kg)
F1240936 F1240938
GB a GB b
Connect the braking circuit and apply maximum working pressure Apply a force of 8 ± 10 N (0.8 ± 1 kg) to lever (3). Direct the force
to set the disks. towards the braking direction in order to eliminate the idle stroke.
Release the pressure, loosen nut (15) and unscrew dowel (16) by a While the force is being applied, tighten dowel (16) until it is caused
few turns. to rest onto bush (6).
16
15
F1240936
GB c GB d
Lock dowel (16) in this position with nut (15). CAUTION! After connecting the control cable, check that when
Torque wrench setting: 20 ± 25 Nm. brakes are released both dowels (16) do lean against bush (6).
CAUTION! The idle stroke should be eliminated without preloading
thrust levers (12) and (13).
GB e GB f
98
Collegare il circuito frenante ed inserire la massima Applicare alla leva (3) una forza di 8v10 N (0,8v1 kg),
ITA pressione di lavoro per assestare i dischi. ITA diretta nel senso di frenatura per eliminare la corsa a
Rilasciare la pressione, allentare il dado (15) e svitare vuoto.
di qualche giro il grano (16). Mantenendo la forza, avvitare il grano (16) fino all'appoggio sulla
boccola (6).
Den Bremskreislauf anschlieûen und den maximale Auf den Hebel (3) eine Kraft von 8v0 N (0,8v1 kg) in
D Arbeitsdruck einlassen, um die Scheiben zu setzen. D die Bremsrichtung anbringen, um den leeren Lauf
Den Druck ablassen, die Mutter (15) lockern und den auszuschlieûen.
Stift (16), um einige Umdrehungen aufschrauben. Bei angebrachter Kraft, Stift (16) aufschrauben, bis er an der
a b Buchse (6) anliegt.
Conectar el circuito frenante y introducir la maxima Aplicar a la palanca (3) una fuerza de 8v10 N (0,8v1
ESP presioÁn de trabajo para ajustar los discos. ESP kg), directa en el sentido de frenadura para eliminar la
Soltar la presion, aflojar las tuercas (15) y destornillar carrera a vacio.
de algun giro la espiga (16). Manteniendo la fuerza, atornillar la espiga (16) hasta el apoyo
sobre el casquillo (6).
Brancher le circuit freinant et inseÂrer le maximum de Appliquer au levier (3) une contrainte de 8v10 N
F pression d'usinage pour ajuster les disques. F (0,8v1 kg), orienteÂe dans le sens du freinage pour
RelaÃcher la pression, desserrer l'eÂcrou (15) et deÂvisser eÂliminer la course aÁ vide.
le grain (16) de quelques tours. En maintenant la contrainte, visser le grain (16) jusqu'aÁ ce qu'il se
pose sur le fourreau (6).
Bloccare il grano (16) in questa posizione con il dado (15). ATTENZIONE! Dopo il collegamento del cavo di coman-
ITA Coppia di serraggio: 20v25 Nm. ITA do, controllare che in fase di rilascio dei freni, ambedue i
ATTENZIONE! La corsa a vuoto va eliminata senza grani (16) vadano in appoggio sulla boccola (6).
precaricare le leve di spinta (12) e (13).
Stift (16) in dieser Position mit der Mutter (15) blok- ACHTUNG! Nach dem Anschluû des Steuerkabels,
D kieren. D kontrollieren, ob beim Loslassen der Bremsen, beide
Anzugsmoment: 20v25 Nm. Stifte (16) an der Buchse anliegen (6).
ACHTUNG! Der leere Lauf muû beseitigt werden ohne die
c Druckhebel (12) und (13) vorzuladen. d
Bloquear la espiga (16) en esta colocacion con la ATENCION! Despues de la conexion del cable de
ESP tuerca (15). ESP mando, controlar que en fase de suelte de los frenos,
Par de torsion: 20v25 Nm. las dos espigas (16) vayan en apoyo sobre el
ATENCION! La carrera a vacio debe de ser eliminada sin precargar casquillo (6).
las palancas de impulso (12) y (13).
Bloquer le grain (16) dans cette position aÁ l'aide de ATTENTION! ApreÁs avoir brancheÂ le caÃ ble de
F l'eÂcrou (15). F commande, controÃler que pendant la phase de
Couple de serrage: 20v25 Nm. relaÃchement des freins, les deux grains (16) aillent
ATTENTION! La course aÁ vide doit eÃtre eÂlimineÂe sans preÂcharger se poser sur l'embout (6).
les leviers d'appui (12) et (13).
ITA ITA
D D
e f
ESP ESP
F F
99
HOW TO DISASSEMBLE THE LIMITED SLIP DIFFERENTIAL UNIT (25% AND 45%) - SMONTAGGIO DIFFERENZIALE A SLITTAMENTO LIMITATO
(25% E 45%) - DIFFERENTIAL MIT BEGRENZTEM GLEITVERMOÈGEN (25% UND 45%) ABMONTIEREN - DESMONTAJE DIFERENCIAL A
DESLIZAMIENTO LIMITADO (25% Y 45%) - DESMONTAJE DIFFERENTIEL A GLISSEMENT REDUIT (25% ET 45%)
2 3
F1241065 F1240485
GB a GB b
Remove the whole differential unit (2) from the central axle unit (1). Remove the check screws (3) of the crown (4).
For details, see «REMOVING THE DIFFERENTIAL UNIT». NOTE. Note down the position of the niches of the central hole in
relation to the protrusions of the friction unit steel discs.
7
5
6
4
F1240806 F1240803
GB c GB d
If bearing (5) needs replacing, remove it; remove crown (4). Remove the planetary gear (6) and the whole friction unit (7).
8
10 11
9
F1240807 F1240489
GB e GB f
If bearing (8) needs replacing, extract it from the differential unit (9). Remove the snap rings (10) from the pins (11) of the planet gears
(12).
160
Asportare dal corpo centrale assale (1) il gruppo Rimuovere le viti (3) di ritegno della corona (4).
ITA differenziale (2) completo. ITA
NOTA. Annotare la posizione delle nicchie del foro
Per i dettagli, vedere «RIMOZIONE GRUPPO DIFFE- centrale rispetto alle sporgenze dei dischi d'acciaio
RENZIALE». dei gruppi di frizione.
Vom zentralen AchsenkoÈrper (1) das vollstaÈndige Die Schrauben (3) zur Halterung des Kranzes (4)
D Differentialaggregat (2) abnehmen. D abnehmen.
Weitere Einzelheiten, siehe «DIFFERENTIALAGGRE- BEMERKUNG. Die Position der Nischen des zentralen
GAT ABNEHMEN». Lochs im VerhaÈltnis zu den Stahlscheiben der Kupplungsaggre-
a b gate anmerken.
Sacar del cuerpo central axial (1) el grupo diferencial Remover los tornillos (3) de retencioÁn de la corona (4).
ESP (2) completo. ESP
NOTA. Anotar la colocacioÁn de los nichos del agujero
Por los detalles, vease «REMOCION GRUPO DIFE- central respecto a las partes salientes de los discos de
RENCIAL». acero de los grupos de fricioÁn.
Enlever le corps central essieu (1) le groupe diffeÂren- Enlever les vis (3) de fixation de la couronne (4).
F tiel (2) complet. F
NOTE. Prendre note de la position des logements du
Pour tout deÂtail, voir «DEPOSE DU GROUPE DIFFE- trou central par rapport aÁ la saillie des disques d'acier
RENTIEL». des groupes de friction.
Se si deve sostituire, estrarre il cuscinetto (5); Rimuovere l'ingranaggio planetario (6) ed il gruppo
ITA rimuovere la corona (4). ITA frizione (7) completo.
Wenn es ausgewechselt werden muû, das Lager (5) Das Planetengetriebe (6) und das vollstaÈndige Kup-
D heraus nehmen; Kranz (4) abnehmen. D plungsaggregat (7) abnehmen.
c d
Si se debe de sobstituir, extraer el cojinete (5); Remover el engranaje planetario (6) y el grupo fricioÁn
ESP remover la corona (4). ESP (7) completo.
Si on doit substituer, extraire le palier (5); enlever la Enlever l'engrenage planeÂtaire (6) et le groupe de
F couronne (4). F friction (7) complet.
Se si deve sostituire, estrarre il cuscinetto (8) dal corpo Rimuovere gli anelli elastici (10) dai perni (11) degli
ITA differenziale (9). ITA ingranaggi satelliti (12).
Wenn es ausgewechselt werden muû, das Lager (8) Die Kolbenringen (10) von den Stiften (11) der
D vom DifferentialkoÈrper (9) heraus nehmen. D Planetengetriebe (12) abnehmen.
e f
Si se debe de sobstituir, extraer el cojinete (8) del Remover los segmentos elasticos (10) de los pernos
ESP cuerpo diferencial (9). ESP (11) de los engranajes satelites (12).
Si on doit substituer, extraire le palier (8) du corps Enlever les anneaux aÁ ressort (10) des axes (11) des
F diffeÂrentiel (9). F engrenages satellites (12).
161
T14
12 12
11
F1240809 F1240491
GB a GB b
Introduce tool T14 in-between the planet gears (12). Using two pin-drivers, engage tool T14 in between the planet gears
(12).
CAUTION! Carefully check that tool T14 keeps in an aligned
position with the pins (11) when locked.
T16A T16A
T15 T15
T16A
11
F1240492 F1240493
bar GB c GB d
Place the differential unit (9) under a press, position bush T15 and Remove gudgeon T16A and bush T15.
insert gudgeon T16A. Press gudgeon T16A to end of stroke. NOTE. In this state, the pin (11) is contained within tool T14.
T14
12
12
9
F1240491 F1240809
GB e GB f
Remove tool T14 and planet pin (11) with it. Leaving the released planet in its position, lock again tool T14.
Repeat pin extraction operation on the second planet pin (11).
Repeat the same operations on the remaining pins.
162
Inserire tra gli ingranaggi satelliti (12) l'attrezzo T14. Operando con due cacciaspine, forzare l'attrezzo T14
ITA ITA tra gli ingranaggi satelliti (12).
ATTENZIONE! Controllare attentamente che l'attrez-
zo T14 rimanga allineato ai perni (11) quando eÁ bloccato.
Zwischen den Planetengetriebe (12) das Werkzeug Mit zwei DuÈbeln das Werkzeug T14 zwischen den
D T14 stecken. D ZahnraÈdern des Planetengetriebes (12) forcieren.
ACHTUNG! SorgfaÈltig kontrollieren, ob das Werkzeug
T14 mit den Stiften (11) ausgerichtet ist, nachdem es blockiert
a b worden ist.
Introducir entre los engranajes satelites (12) la Obrando con dos extractores de clivijas, hacer fuerza
ESP herramienta T14. ESP sobre la herramienta T14 entre los engranajes
satelites (12).
ATENCION! Controlar con cuidado que la herramienta T14 quede
en linea a los pernos (11) cuando esta bloqueado.
Introduire entre les engrenages satellites (12) l'outil En oeuvrant avec deux dispositifs arrache-broches,
F T14. F forcer l'outil T14 entre les engrenages satellites (12).
ATTENTION! ControÃler attentivement que l'outil T14
demeure aligneÂ aux axes (11) quand il est bloqueÂ.
Sistemare il corpo differenziale (9) sotto una pressa, Asportare lo spinotto T16A e la bussola T15.
ITA posizionare la boccola T15 ed inserire lo spinotto ITA
NOTA. In questa condizione, il perno (11) eÁ contenuto
T16A. Pressare lo spinotto T16A fino a fondo corsa. nell'attrezzo T14.
Den DifferentialkoÈrper (9) unter eine Presse legen, die Den Bolzen T16A und die Buchse T15 abnehmen.
D Buchse T15 positionieren und den Bolzen T16A D
BEMERKUNG. In diesem Zustand befindet sich der
einsetzen. Den Bolzen T16A bis zum Anschlag Stift (11) im Werkzeug T14.
einpressen.
c d
Sistemar el cuerpo diferencial (9) bajo una presa, Sacar la cruceta T16A y el manguito T15.
ESP colocar el carquillo T15 y introducir la cruceta T16A. ESP
NOTA. En esta condicion, el perno (11) esta contenido
Empujar la cruceta T16A a tope. en la herramineta T14.
Ajuster le corps diffeÂrentiel (9) sous une presse, placer Enlever la cheville T16A et la bague T15.
F l'embout T15 et introduire la cheville T16A. Presser la F
NOTE. Dans ces conditions, l'axe (11) est contenu
cheville T16A jusqu'en fin de course. dans l'outil T14.
Rimuovere l'attrezzo T14 e con esso il perno (11) del Lasciando in posizione l'ingranaggio satellite che si eÁ
ITA satellite. ITA liberato, bloccare nuovamente l'attrezzo T14.
Ripetere le operazioni di estrazione del perno del
secondo perno satellite (11).
Ripetere le operazioni per gli altri perni.
Das Werkzeug T14 und damit auch den Stift (11) des Das Planetengetriebe, das sich freigesetzt hat, in
D Planetengetriebes abnehmen. D seiner Position lassen, und Werkzeug T14 wieder
blockieren.
Die VorgaÈnge zum Abnehmen des zweiten Stiftes des Planeten-
e f getriebes (11) wiederholen.
Die VorgaÈnge fuÈr alle anderen Stifte wiederholen.
Remover la herramienta T14 y con esta el perno (11) Dejando en posicioÁn el engranaje satelite que se ha
ESP del satelite. ESP librado, bloquear de nuevo la herramienta T14.
Repetir las operaciones de extracioÁn del perno de
segundo perno satelite (11).
Repetir las operacioÁnes para los otros pernos.
Enlever l'outil T14 et avec celui-ci l'axe (11) du En laissant dans sa position l'engrenage satellite qui
F satellite. F s'est deÂgageÂ, bloquer de nouveau l'outil T14.
ReÂpeÂter les opeÂrations pour extraire l'axe du deu-
xieÁme axe satellite (11).
ReÂpeÂter les opeÂrations pour les autres axes.
163
F1240814
GB a GB b
Remove tool T14 and extract from the differential unit (9) the two
final planet gears (12), the 2nd planet gear (6) and the whole friction
assembly concerned (7).
45% VERSION
15 VERSIONE 45%
AUSFUÈ HRUNG 45%
3 13 VERSION 45%
VERSION 45%
5 10
4
19
16 13
11
14
17 18 15
16 7
14
12 18 11 6
6
14
GB c 19 10 GB d
15 7 16
14
13 16
7 17
12 9
13 8 1
18 15
11
19 7
10
18
11
19
10
2
e f
D1240113
GB GB
164
Rimuovere l'attrezzo T14 ed asportare dal corpo
ITA differenziale (9) gli ultimi due ingranaggi satelliti (12),
il 2ë ingranaggio planetario (6) ed il relativo gruppo di
frizione (7) completo.
Das Werkzeug T14 abnehmen und vom Differential-

D koÈrper (9) die letzten beiden ZahnraÈder des Planeten-
getriebes (12), das 2. Planetengetriebe und das
entsprechende Kupplungsaggregat (7) abnehmen.
a
Remover la herramienta T14 y sacar del cuerpo
ESP diferencial (9) los ultimos dos engranajes satelites
(12), el 2ë engranaje planetario (6) y el relativo grupo
de fricioÁn (7) completo.
Enlever l'outil T14 puis extraire du corps diffeÂrentiel

F (9) les deux derniers engrenages satellites (12), le 2ë
engrenage planeÂtaire (6) et le groupe de friction relatif
(7) complet.
165
HOW TO ASSEMBLE THE LIMITED SLIP DIFFERENTIAL UNIT (25% AND 45%) - ASSEMBLAGGIO DIFFERENZIALE A SLITTAMENTO LIMITATO
(25% E 45%) - DIFFERENTIAL MIT BEGRENZTEM GLEITVERMOÈGEN (25% UND 45%) MONTIEREN - ASEMBLAJE DIFERENCIAL A
DESLIZAMIENTO LIMITADO (25% Y 45%) - MONTAJE DIFFERENTIEL A GLISSEMENT REDUIT (25% ET 45%)
18,2 ± 0,1
6
6 13
14
7
6 17
9
15
16
F1240814
25% F1240815
GB a GB b
Place a friction unit (7) - suitable for the specific type of slipping - 25% FRICTION UNIT COMPOSITION
and planetary gear (6) into the differential unit (9). Friction ring with increased shim (13), steel rings (14) and friction
The composition of the unit is illustrated in the points below. rings (15) alternated, end ring (16) and distance piece (17).
CAUTION! As to rings (13) and (16), the side without notches must
face outwards.
18,2 ± 0,1
6 12
6
13 14 18
T16C
15
16
45% F1240816 F1240495
GB c GB d
45% FRICTION UNIT COMPOSITION Position shim washer (18) and the first planet gear (12).
Friction ring with increased shim (13), steel rings (14) and friction Hold them in position with bar T16C.
rings (15) alternated, end ring (16) and distance piece (17).
CAUTION! As to rings (13) and (16), the side without notches must
face outwards.
12 T14
T16A
18 9
T16C
T16C
F1240496 F1240497
GB e GB f
Using gudgeon T16A, position the second planet gear (12) and Insert tool T14 in-between the two planet gears (12). Align the
relative shim washer (18). whole unit, pushing bar T16C in as far as it will go, until gudgeon
T16A is expelled.
166
Inserire nel corpo differenziale (9), il gruppo di frizione COMPOSIZIONE GRUPPO DI FRIZIONE 25%
ITA (7) specifico per il tipo di slittamento e l'ingranaggio ITA Anello di frizione con spessore maggiorato (13), anelli
planetario (6). d'acciaio (14) ed anelli di frizione (15) alternati, anello
La composizione del gruppo di frizione eÁ indicata in seguito. terminale (16), anello distanziatore (17).
ATTENZIONE! Gli anelli (13) e (16) devono avere la parte senza
intagli rivolta verso l'esterno.
In den DifferentialkoÈrper (9) das fuÈr die Gleitungsart ZUSAMMENBAU DES KUPPLUNGSAGGREGATS 25%
D und das Planetengetriebe (6) geeignete Kupplungsag- D Kupplungsringe mit groÈûerer StaÈrke (13), Stahlringe
gregat (7) einsetzen. (14) und Kupplungsringe (15), Abschluûring (16),
Die Zusammensetzung des Kupplungsaggregats ist nachstehend Distanzscheibe (17).
a beschrieben. b ACHTUNG! Die Ringe (13) und (16) muÈssen die glatte Seite nach
auûen gerichtet haben.
Introducir en el cuerpo diferencial (9), el grupo de COMPOSICION GRUPO DE FRICION 25%

ESP fricioÁn (7) especifico por el tipo de deslizamiento y el ESP Segmento de fricioÁn con espesor major (13), segmen-
engranaje planetario (6). to de acero (14) y segmento de fricioÁn (15) alternados,
La composicioÁn del grupo de fricioÁn es indicada a seguir. segmento terminal(16), segmento distancial (17).
ATENCION! Los segmentos (13) y (16) deben de tener la parte sin
ranaduras hacia el esterno.
Introduire dans le corps diffeÂrentiel (9), le groupe de COMPOSITION DU GROUPE DE FRICTION 25%
F friction (7) speÂcifique pour le type de patinage et F Garniture de friction avec cale majoreÂe (13), anneaux
l'engrenage planeÂtaire (6). d'acier (14) et garniture de friction (15) alterneÂs,
La composition du groupe de friction est indiqueÂe ci-dessous. anneau terminal (16), bague entretoise (17).
ATTENTION! Les garnitures (13) et (16) doivent avoir la partie sans
entailles tourneÂe vers l'exteÂrieur.
COMPOSIZIONE GRUPPO DI FRIZIONE 45% Posizionare la rondella di rasamento (18), il primo

ITA Anello di frizione con spessore maggiorato (13), anelli ITA ingranaggio satellite (12).
d'acciaio (14) ed anelli di frizione (15) alternati, anello Tenerli in posizione con la barra T16C.
terminale (16).
ATTENZIONE! Gli anelli (13) e (16) devono avere la parte senza
intagli rivolta verso l'esterno.
ZUSAMMENBAU DES KUPPLUNGSAGGREGATS 45% Die Zwischenlegscheibe (18) und das erste Planeten-
D Kupplungsringe mit groÈûerer StaÈrke (13), Stahlringe D getriebe (12) positionieren.
(14) und Kupplungsringe (15), Abschluûring (16). In dieser Position mit dem Stab T16C halten.
ACHTUNG! Die Ringe (13) und (16) muÈssen die glatte Seite nach
c auûen gerichtet haben. d
COMPOSICION GRUPO DE FRICION 45% Colocar la arandela de raspadura (18), el primer
ESP Segmento de fricioÁn con espesor major (13), segmen- ESP engranaje satelite (12).
to de acero (14) y anillo de fricioÁn (15) alternados, Tenerlos en posicioÁn con la barra T16C.
segmento terminal (16).
ATENCION! Los segmentos (13) y (16) deben tener la parte sin
ranaduras hacia el esterno.
COMPOSITION DU GROUPE DE FRICTION 45% Mettre la rondelle de rasage (18) en place, puis le
F Garniture de la friction avec cale majoreÂe (13), F premier engrenage satellite (12).
anneaux d'acier (14) et garniture de friction (15) Maintenir ceux-ci en place avec la barre T16C.
alterneÂs, anneau terminal (16).
ATTENTION! Les garnitures (13) et (16) doivent avoir la partie sans
entailles tourneÂe vers l'exteÂrieur.
Utilizzando lo spinotto T16A, posizionare il secondo Inserire tra i due ingranaggi satelliti (12) l'attrezzo T14.
ITA ingranaggio satellite (12) e la relativa rondella di ITA Allineare tutto il gruppo inserendo a fondo la barra
rasamento (18). T16C fino ad espellere lo spinotto T16A.
Mit einem Bolzen T16A das zweite Planetengetriebe Die beiden Planetengetriebe (12) mit dem Werkzeug
D (12) und die Zwischenlegscheibe (18) positionieren. D T14 einsetzen. Das ganze Aggregat ausrichten indem
der Stab T16C eingesetzt wird, bis der Bolzen T16A
ausgestoûen wird.
e f
Utilizando la cruceta T16A, colocar el segundo Introducir entre los dos engranajes satelites (12) la
ESP engranaje satelite (12) y la relativa arandela de ESP herramienta T14.
raspadura (18). Alinear todo el grupo introduciendo a tope la barra
T16C hasta sacar la cruceta T16A.
A l'aide de la cheville T16C, mettre en place le Introduire entre les deux engrenages satellites (12)
F deuxieÁme engrenage satellite (12) et sa rondelle de F l'outil T14.
rasage (18). Aligner tout le groupe en introduisant la barre T16C aÁ
fond jusqu'aÁ expulser la cheville T16A.
167
T14 19 11
6 6
F1240809 F1240498
GB a GB b
Lock tool T14 behind the planet gears (12). Fit snap rings (19) onto the pins (11).
After locking the tool, remove bar T16C.
T16B 11
11
T15
T15
T16B
11
9
F1240499 F1240500
bar GB c GB d
Position the differential unit (9) under the press, position bush T15 Place gudgeon T16B on top of the planet pin (11).
and insert the planet pin (11).
T16A
T15
T16A
10
11
11
9
F1240492 F1240502
bar GB e GB f
Press gudgeon T16B as far down as it will go. Remove gudgeon T16B, bush T15, and fit the snap ring (10) onto
the pin (11).
CAUTION! Make sure that the snap ring centers the seat and
positions itself on the differential unit face.
Repeat the operations on the other planet pin and on the other
planet unit.
168
Bloccare l'attrezzo T14 a ridosso degli ingranaggi Montare sui perni (11) gli anelli elastici (19).
ITA satelliti (12). ITA
Dopo il bloccaggio, rimuovere la barra T16C.
Das Werkzeug T14 am Anschlag der Planetengetriebe Auf die Stifte (11) die Kolbenringe (19) montieren.
D (12) blockieren. D
Danach Stab T16C abnehmen.
a b
Bloquear la herramienta T14 detras de los engranajes Montar sobre los pernos (11) los segmentos elasticos
ESP satelites (12). ESP (19).
Despues del bloqueo, remover la barra T16C.
Bloquer l'outil T14 au-dessus des engrenages satel- Monter sur les axes (11) les anneaux aÁ ressort (19).
F lites (12). F
ApreÁs le blocage, enlever la barre T16C.
Posizionare sotto la pressa il corpo differenziale (9), Sovrapporre al perno satellite (11) lo spinotto T16B.
ITA sistemare la boccola T15 ed inserire il perno satellite ITA
(11).
Unter einer Presse den DifferentialkoÈrper (9) positio- Auf den Planetenstift (11) den Bolzen T16B legen.
D nieren, die Buchse T15 einlegen und den Planetenstift D
(11) einsetzen.
c d
Colocar bajo la prensa el cuerpo diferencial (9), Sobreponer al perno satelite (11) la cruceta T16B.
ESP colocar el casquillo T15 y introducir el perno satelite ESP
(11).
Placer le corps diffeÂrentiel (9) sous la presse, ajuster Poser sur l'axe satellite (11) la cheville T16B.
F l'embout T15 et inseÂrer l'axe satellite (11). F
Pressare lo spinotto T16B a fondo. Rimuovere lo spinotto T16B, la boccola T15 e montare
ITA ITA sul perno (11) l'anello elastico (10).
ATTENZIONE! Assicurarsi che l'anello elastico centri
la sede e che appoggi sul piano del corpo differenziale.
Ripetere le operazioni per l'altro perno satellite e per l'altro asse
satelliti.
Den Bolzen T16B fest einpressen. Den Bolzen T16B, die Buchse T15 abnehmen und auf
D D den Stift (11) den Kolbenring (10) montieren.
ACHTUNG! Kontrollieren, ob der Kolbenring im Sitz zentriert ist
und auf der FlaÈche der FlaÈche des DifferentialkoÈrpers liegt.
e f Die VorgaÈnge fuÈr den anderen Planetenstift und die andere
Planetenachse wiederholen.
Apretar la cruceta T16B a tope. Remover la cruceta T16B, el casquillo T15 y montar
ESP ESP sobre el perno (11) el segmento elastico (10).
ATENCION! Averiguar que el segmento elastico sea centrado en su
alojamiento y que apoye sobre la superficie del cuerpo diferencial.
Repetir las operacioÁnes para el otro perno satelite y para el otro eje
satelite.
Presser la cheville T16B aÁ fond. Enlever la cheville T16B, l'embout T15 et monter sur
F F l'axe (11) l'anneau aÁ ressort (10).
ATTENTION! S'assurer que l'anneau aÁ ressort soit
bien centreÂ sur le sieÁge et poseÂ sur la surface du corps diffeÂrentiel.
ReÂpeÂter les opeÂrations pour l'autre axe satellite et l'autre essieu
satellite.
169
3
4
6
9
9
F1240803 F1240946
GB a GB b
Check that planets have a light clearance in relation to the first Line the lubrication holes up with the slots in the differential carrier.
planet gear. Orient the holes of the crown (4) towards the protrusions of the
Position the second planetary gear (6) and the second friction unit braking unit.
(7) into the differential unit (9). Position the crown (4) on the differential unit (9) and lock it with the
screws (3) previously coated with Loctite 242.
Torque wrench setting for screws: 128 ± 142 Nm.
NOTE. Tighten screws using the criss-cross method.
T17 8 2
T17 5
F1240506 F1241065
GB c GB d
If bearings (5) and (8) have been removed, install them using tool Install the whole differential assembly (2) into the central body (1).
T17. For details, see «INSTALLING THE DIFFERENTIAL UNIT».
GB e GB f
170
Controllare che i satelliti abbiano un leggero gioco Allineare i fori di lubrificazione della corona (4) con le
ITA rispetto il primo ingranaggio planetario. ITA cave della scatola differenziale sulle sporgenze del
Posizionare il secondo ingranaggio planetario (6) ed il gruppo di frenatura. Posizionare la corona (4) sul corpo
secondo gruppo di frizione (7) nel corpo differenziale (9). differenziale (9) e bloccarla con le viti (3) spalmate con Loctite 242.
Coppia di serraggio viti: 128v142 Nm
NOTA. Serrare le viti con il metodo del serraggio incrociato.
Kontrollieren, ob die Planetengetriebe etwas Spiel im Die SchmierloÈcher des Kranzes (4) der Differential-
D VerhaÈltnis zum ersten Planetengetriebe haben. D schachtel mit den VorspruÈngen des Bremsaggregats
Das zweite Planetengetriebe (6) und das zweite ausrichten. Den Kranz (4) auf den DifferentialkoÈrper (9) positionieren
Kupplungsaggregat (7) in den DifferentialkoÈrper (9) einsetzen. und mit den Schrauben (3), die zuvor mit Loctite 242 geschmiert
a b wurden, blockieren. Anzugsmoment der Schrauben: 128v142 Nm.
BEMERKUNG. Sie Schrauben im Kreuz fest schrauben.
Controlar que los satelites tengan un ligero juego Alinear los agujeros de lubrificar de la corona con los
ESP respecto al primero engranaje planetario. ESP nichos de la caja diferencial (4) sobre las partes
Colocar el segundo engranaje planetario (6) y el salientes del grupo de frenadura.
segundo grupo de fricioÁn (7) en el cuerpo diferencial (9). Colocar la corona (4) sobre el cuerpo diferencial (9) y bloquearla
con los tornilloss: 128v142 Nm.
NOTA. Apretar los tornillos de manera cruzada.
ControÃler que les satellites aient un peu de jeu par Aligner les trous de lubrification de la couronne (4) avec
F rapport au premier engrenage planeÂtaire. F les creux du carter diffeÂrentiel sur les saillies du groupe
Mettre le deuxieÁme engrenage planeÂtaire (6) en place de freinage. Placer la couronne (4) sur le corps diffeÂrentiel
ainsi que le second groupe de friction (7) du corps diffeÂrentiel (9). (9) et bloquer celle-ci avec les vis (3) enduites de Loctite 242.
Couple de serrage des vis: 128v142 Nm.
NOTE. Serrer les vis avec la meÂthode de serrage croiseÂe.
Se sono stati rimossi, montare i cuscinetti (5) e (8) Installare nel corpo centrale (1) il gruppo differenziale
ITA utilizzando l'attrezzo T17. ITA (2) completo.
Per i dettagli, vedere «INSTALLAZIONE GRUPPO
DIFFERENZIALE».
Falls sie abmontiert wurden, die Lager (5) und (8) mit In den zentralen KoÈrper (1) das vollstaÈndige Differen-
D dem Werkzeug T17 montieren. D tialaggregat (2) installieren.
FuÈr weitere Einzelheiten, siehe «INSTALLATION DES
DIFFERENTIALAGGREGATS».
c d
Si han sido removidos, montar los cojinetes (5) y (8) Introducir en el cuerpo central (1) el grupo diferencial
ESP utilizando la herramienta T17. ESP (2) completo.
Para los detalles, vease «INSTALACION GRUPO
DIFERENCIAL»
S'ils ont eÂteÂ enleveÂs, remonter les paliers (5) et (8) aÁ Installer dans le corps central (1) le groupe diffeÂrentiel
F l'aide de l'outil T17. F (2) complet.
Pour tout deÂtail, voir «INSTALLATION DU GROUPE
DIFFERENTIEL».
171
HOW TO DISASSEMBLE THE HYDRAULIC DIFFERENTIAL LOCK - SMONTAGGIO BLOCCAGGIO DIFFERENZIALE A COMANDO IDRAULICO -
DIFFERENTIALBLOCKIERUNG MIT HYDRAULISCHER STEUERUNG ABMONTIEREN - DESMONTAJE BLOQUEO DIFERENCIAL A MANDO
HYDRAULICO - DESMONTAJE BLOCAGE DIFFERENTIEL A COMMANDE HYDRAULIQUE
F1241060 F1240827
GB a GB b
Remove the arms. Remove the top cap (1).
For details, see «CHECKING WEAR AND REPLACING THE NOTE. The cap must be replaced each time the unit is
BRAKING DISCS». disassembled.
5 4
2
F1240828 F1240829
GB c GB d
Remove the microswitch (2), signalling differential lock operation. Loosen the lock nut (4) of fork (5) by about 2 turns.
NOTE. Check the state of the O-ring (3).
5
6 6
F1240830 F1240831
GB e GB f
Using a metal punch and a hammer, disengage fork (5) from piston Using two wrenches, lock piston (6) and remove nut (4).
cone (6).
172
Asportare i bracci. Rimuovere il tappo superiore (1).
ITA Per i dettagli, vedere «CONTROLLO USURA E ITA
NOTA. Il tappo deve essere sostituito ad ogni
SOSTITUZIONE DISCHI FRENO». smontaggio.
Die Arme abnehmen. Unterer Stopfen (1) abnehmen.

D FuÈr weitere Einzelheiten, siehe «VERSCHLEISS D
BEMERKUNG. Der Stopfen muû jedesmal ausge-
KONTROLLIEREN UND BREMSSCHEIBEN AUS- wechselt werden, wenn er abmontiert wird.
WECHSELN».
a b
Sacar los brazos. Remover la tapa superior (1).
ESP Para los detalles, vease «CONTROL DESGASTE Y ESP
NOTA. La tapa debe de ser sobstituida a cada
SOBSTITUCION DISCOS FRENOS». desmontaje.
Enlever les bras. Enlever le bouchon supeÂrieur (1).

F Pour tout deÂtail, voir «CONTROLE DE L'USURE ET F
NOTE. Le bouchon doit eÃtre remplaceÂ aÁ chaque
SUBSTITUTION DES DISQUES FREIN». deÂmontage.
Rimuovere il microinterruttore (2) di segnalazione Allentare il dado (4) di bloccaggio della forcella (5) di
ITA inserimento bloccaggio differenziale. ITA circa 2 giri.
NOTA. Controllare lo stato della guarnizione OR (3).
Den Mikroschalter (2) abnehmen, der den Einsatz der Mutter (4) zur Blockierung der Gabel (5) um ca. 2
D Differentialblockierung meldet. D Umdrehungen lockern.
BEMERKUNG. Zustand des O-Rings (3) kontrollieren.
c d
Remover el microinterruptor (2) de senalacioÁn intro- Aflojar la tuerca (4) de bloqueo de la horquilla (5) de 2
ESP ducioÁn bloqueo diferencial. ESP giros approx.
NOTA. Controlar el estado de la guarnicioÁn OR (3).
Enlever le microinterrupteur (2) qui signale l'insertion Desserrer l'eÂcrou (4) de blocage de la fourchette (5)
F du blocage diffeÂrentiel. F d'environ 2 tours.
NOTE. ControÃler l'eÂtat des garnitures OR (3).
Utilizzando un punzone metallico ed un mazzuolo, Utilizzando due chiavi, bloccare il pistone (6) ed
ITA sbloccare la forcella (5) dal cono del pistone (6). ITA asportare il dado (4).
Mit einem Metallstift und einem Hammer die Gabel (5) Mit Hilfe von zwei SchluÈsseln, den Kolben (6) blok-
D von dem Kolbentrichter (6) freisetzen. D kieren und die Mutter (4) abnehmen.
e f
Utilizando un punzon metalico y un martillo, bloquear Utilizando dos llaves, bloquear el pistoÁn (6) y sacar la
ESP l'horquilla (5) del cono del pistoÁn (6). ESP tuerca (4).
A l'aide d'un poussoir meÂtallique et d'un maillet, A l'aide de deux cleÂs, bloquer le piston (6) et enlever
F deÂbloquer la fourchette (5) du coÃne du piston (6). F l'eÂcrou (4).
173
14 13 5
15
F1240832 F1240833
GB a GB b
Remove screws (14) and remove the intermediate cover (13). Disconnect fork (5) from piston (6). While holding the fork up,
NOTE. Support the differential unit with a lever. remove the differential unit (15).
5 6
12
F1240834 F1240835
GB c GB d
Extract fork (5). Remove snap ring (12) and whole piston (6).
6
11
9
10
7
8
9
F1240836 F1240837
GB e GB f
Remove guide ring (11) and O-ring (10). Remove snap ring (9) and take piston unit (6) apart. Remove all
NOTE. The guide ring (11) and O-ring (10) must be replaced each component parts.
time the unit is disassembled.
174
Rimuovere le viti (14) e rimuovere il coperchio Scollegare dal pistone (6) la forcella (5) e, tenendola
ITA intermedio (13). ITA sollevata, rimuovere il gruppo differenziale (15).
NOTA. Sostenere il gruppo differenziale con una leva.
Die Schrauben (14) abnehmen und den mittleren Dek- Vom Kolben (6) die Gabel (5) abtrennen. Die anheben
D kel (13) entfernen. D und des Differentialaggregat (15) entfernen.
BEMERKUNG. Das Differentialaggregat mit einem
Hebel stuÈtzen.
a b
Remover los tornillos (14) y remover la tapa intermedia Desconectar del pistoÁn (6) la horquilla y, teniendola
ESP (13). ESP levantada, remover el grupo diferencial (15).
NOTA. Sostener el grupo diferencial con una palanca.
Enlever les vis (14) puis enlever le couvercle inter- DeÂbrancher du piston (6) la fourchette (5) et en tenant
F meÂdiaire (13). F cette dernieÁre souleveÂe, enlever le groupe diffeÂrentiel
NOTE. Soutenir le groupe diffeÂrentiel aÁ l'aide d'un (15).
levier.
Estrarre la forcella (5). Rimuovere l'anello elastico (12) ed il pistone completo

ITA ITA (6).
Die Gabel (5) heraus nehmen. Den Kolbenring (12) und den vollstaÈndigen Kolben (6)
D D abnehmen.
c d
Extraer la harquilla (5). Remover el segmento elastico (12) y el pistoÁn
ESP ESP completo (6).
Extraire la fourchette (5). Enlever l'anneau aÁ ressort (12) et le piston complet (6).
F F
Asportare l'anello di guida (11) e la guarnizione OR Rimuovere l'anello elastico (9) e scomporre il gruppo
ITA (10). ITA pistone (6) in tutti i suoi componenti (7), (8).
NOTA. L'anello di guida (11) e la guarnizione (10)
devono essere sostituiti ad ogni smontaggio.
Den FuÈhrungsring (11) und den O-Ring (10) ab- Den Kolbenring (9) abnehmen und das Kolbenaggre-
D nehmen. D gat (6) auseinander nehmen, um die Teile (7) und (8)
BEMERKUNG. Der FuÈhrungsring (11) und die Dich- frei zu setzen.
tung (10) muÈssen jedesmal ausgewechselt werden, wenn sie
e abmontiert werden. f
Sacar el segmento de guõÁa (11) y la guarnicioÁn OR Remover el segmento elastico (9) y descomponer el
ESP (10). ESP grupo pistoÁn (6) en todos sus componentes (7) y (8).
NOTA. El segmento de guõÁa (11) y la guarnicioÁn (10)
deben de ser sobstituidos a cada desmontaje.
Enlever la bague de guidage (11) et la garniture OR Enlever l'anneau aÁ ressort (9) et deÂsassembler le
F (10). F groupe piston (6) de tous ses composants (7), (8).
NOTE. La bague de guidage (11) et la garniture (10)
doivent eÃtre substitueÂes aÁ chaque deÂmontage.
175
21
19
18 15
16
17 20
F1240838 F1240839
GB a GB b
Remove bearing (16) from the differential carrier (17) as well as the ONLY IF NECESSARY
stop ring (18), the coupling (19) and the spheres (20). Remove the coupling guide key (21) and disassemble the
NOTE. Note down the direction of assembly of the stop ring (18). differential unit (15).
(For details, see «HOW TO DISASSEMBLE THE DIFFERENTIAL
UNIT».
14
2
13
3
23 4
5
15 20 12
8
7
6
10
11
9
21 1
GB c GB d
22
17
19
18
16
D1240114
GB e GB f
176
Rimuovere il cuscinetto (16) dalla scatola differenziale SOLO SE NECESSARIO
ITA (17), l'anello di arresto (18), il manicotto (19) e le sfere ITA Rimuovere la chiavetta (21) di guida del manicotto e
(20). smontare il gruppo differenziale (15).
NOTA. Annotare il senso di montaggio dell'anello di arresto (18). (Per i dettagli, vedere «SMONTAGGIO GRUPPO DIFFERENZIA-
LE»).
Lager (16) von der Differentialschachtel (17), den NUR FALLS NOTWENDIG
D Sperring (18), die HuÈlse (19) und die Kugeln (20) D Den Keil (21) zur FuÈhrung der HuÈlse entfernen und
entfernen. das Differentialaggregat (15) abmontieren.
BEMERKUNG. Montagerichtung des Sperrings (18) bemerken. (FuÈr weitere Einzelheiten, siehe «DIFFERENTIALAGGREGAT AB-
a b MONTIEREN»).
Remover los cojinetes (16) de la caja diferencial (17), SOLO SI NECESARIO

ESP el segmento de paro (18) el manguito (19) y las ESP Remover la Laave (21) de guõÁa del manguito y
espheras (20). desmontar el grupo diferencial (15).
NOTA. Anotar el sentido de montaje del segmento de paro (18). Para los detalles, vease «DESMONTAJE GRUPO DIFERENCIAL».
Enlever le palier (16) du carter diffeÂrentiel (17), la SEULEMENT SI BESOIN

F bague de buteÂe (18), le manchon (19) et les spheÁres F Enlever la clavette (21) de guidage du manchon et
(20). deÂmonter le groupe diffeÂrentiel (15).
NOTE. Prendre note du sens de montage de la bague de buteÂe (Pour tout deÂtail, voir «DEMONTAAGE DU GROUPE DIFFEREN-
(18). TIEL».
ITA ITA
D D
c d
ESP ESP
F F
ITA ITA
D D
e f
ESP ESP
F F
177
HOW TO ASSEMBLE THE HYDRAULIC DIFFERENTIAL LOCK - ASSEMBLAGGIO BLOCCAGGIO DIFFERENZIALE A COMANDO IDRAULICO -
DIFFERENTIALBLOCKIERUNG MIT HYDRAULISCHER STEUERUNG MONTIEREN - ASEMBLAJE BLOQUEO DIFERENCIAL A MANDO
HYDRAULICO - MONTAJE BLOCAGE DIFFERENTIEL A COMMANDE HYDRAULIQUE
21 18
19
15
20
F1240839 F1240840
GB a GB b
ONLY IF PREVIOUSLY DISASSEMBLED Install spheres (20), coupling (19) and stop ring (18).
Assemble the differential unit (15). NOTE. Pay great attention to ring orientation (18).
(For details, see «HOW TO ASSEMBLE THE DIFFERENTIAL
UNIT»).
Position the guide key (21) of coupling (19).
11 10
6
16
17
T29
F1240841 F1240842
GB c GB d
Fit bearing (16) onto the differential carrier (17). Fit O-ring (10) and guide ring (11) onto the piston (6). Lubricate
NOTE. Make sure that the bearing is well set in the differential seals and insert the assembly into tool T29.
carrier.
7 T30
T29 22
8 6
F1240843 D1240089
GB e GB f
Insert tool T29 in the central unit (22) and push the piston (6) into Fit spring (7) and washer (8) on the piston (6) and install tool T30.
the seat.
Remove tool T29.
178
SOLO SE EÁ STATO SMONTATO Montare le sfere (20), il manicotto (19) e l'anello di
ITA Assemblare il gruppo differenziale (15). ITA arresto (18).
(Per i dettagli, vedere «ASSEMBLAGGIO GRUPPO NOTA. Controllare attentamente l'orientamento del-
DIFFERENZIALE»). l'anello (18).
Posizionare la chiavetta (21) di guida del manicotto (19).
NUR WENN ES ABMONTIERT WURDE Die Kugeln (20), die HuÈlse (19) und den Sperring (18)
D Differentialaggregat (15) zusammenbauen. D montieren.
(FuÈr weitere Einzelheiten, siehe «DIFFERENTIALAG-
GREGAT ZUSAMMENBAUEN»).
a Den Keil (21) auf die FuÈhrung der HuÈlse (19) positionieren. b
SOLO SI ESTA DESMONTADO Montar las espheras (20), el manguito (19) y el
ESP Asemblar el grupo diferencial (15). ESP segmento de paro (18).
(Para los detalles, vease «ASEMBLAJE GRUPO NOTA. Controlar atentamente la direccioÁn del seg-
DIFERENCIAL»). mento (18).
Colocar la llave (21) de guõÁa del manguito (19).
SEULEMENT SI DEMONTE Monter les spheÁres (20), le manchon (19) et l'anneau

F Assembler le groupe diffeÂrentiel (15). F de buteÂe (18).
(Pour tout deÂtail, voir «ASSEMBLAGE DU GROUPE NOTE. ControÃler attentivement l'orientation de l'an-
DIFFERENTIEL»). neau (18).
Mettre la clavette (21) de guidage du manchon (19) en place.
Montare sulla scatola differenziale (17) il cuscinetto Montare sul pistone (6) l'anello OR (10) e l'anello di
ITA (16). ITA guida (11). Lubrificare le guarnizioni ed inserire il
NOTA. Assicurarsi che il cuscinetto vada in sicura gruppo nell'attrezzo T29.
battuta sulla scatola differenziale.
Auf die Diffenrentialschachtel (17) das Lager (16) Auf den Kolben (6) den O-Ring (10) und den
D montieren. D FuÈhrungsring (11) montieren. Die Dichtungen Schmie-
BEMERKUNG. Sicherstellen, daû das Lager richtig in ren und das Aggregat in das Werkzeug T29 setzen.
der Differentialschachtel anschlaÈgt.
c d
Montar sobre la caja diferencial (17) el cojinete (16). Montar sobre el piston (6) el segmento OR (10) y el
ESP ESP segmento de guõÁa (11). Lubrificar las guarnicioÁnes y
NOTA. Asegurarse que el cojinete vaya seguramente
a tope sobre la caja diferencial. insertar el grupo en la herramienta T29.
Monter sur le carter du diffeÂrentiel (17) le palier (16). Monter sur le piston (6) la garniture OR (10) et la
F F bague de guidage (11). Lubrifier les garnitures et
NOTE. S'assurer que le palier aille en buteÂe sur le
carter du diffeÂrentiel. introduire le groupe dans l'outil T29.
Inserire l'attrezzo T29 nel corpo centrale (22) e Montare sul pistone (6) la molla (7) e la rondella (8) e
ITA spingere il pistone (6) nella sede. ITA montare l'attrezzo T30.
Rimuovere l'attrezzo T29.
Das Werkzeug T19 in den zentralen KoÈrper (22) Auf den Kolben (6) die Feder (7) und die Scheibe (8)
D setzen und den Kolben (6) in den Sitz druÈcken. D montieren und das Werkzeug T30 montieren.
Das Werkzeug T29 entfernen.
e f
Introducir la herramienta T29 en el cuerpo central (22) Montar sobre el pistoÁn (6) el muelle (7) y la arandela (8)
ESP y empujar el pistoÁn (6) en su alojamiento. ESP y montar la herramienta T30.
Remover la herramienta T29.
Introduire l'outil T29 dans le corps central (22) et Monter sur le piston (6) le ressort (7) et la rondelle (8)
F pousser le piston (6) dans son sieÁge. F puis monter l'outil T30.
Enlever l'outil T29.
179
HOW TO ASSEMBLE THE HYDRAULIC DIFFERENTIAL LOCK - ASSEMBLAGGIO BLOCCAGGIO DIFFERENZIALE A COMANDO IDRAULICO -
DIFFERENTIALBLOCKIERUNG MIT HYDRAULISCHER STEUERUNG MONTIEREN - ASEMBLAJE BLOQUEO DIFERENCIAL A MANDO
HYDRAULICO - MONTAJE BLOCAGE DIFFERENTIEL A COMMANDE HYDRAULIQUE
6
12
T30
F1240844 F1240845
GB a GB b
Screw tool T30 on the thread of the piston (6) to compress spring Fit the snap ring (12) of the unit.
(7) and vacate the seat for introducing the snap ring (12). Remove tool T30 and fit the snap ring (9) of spring (7).
5 14 13 23
22
15
F1240833 F1240850
GB c GB d
Insert the fork (5) and the differential unit (15) into the central unit Fit the intermediate cover (13) and lock it with screws (14). Tighten
(22). screws using a torque wrench setting of 23.8 ± 26.2 Nm.
Engage the fork (5) in the coupling (19) and on the piston (6). NOTE. Carefully check the state of the O-ring (23).
4 1
F1240846 F1240847
GB e GB f
Fit the lock nut (4) of the fork (5) and lock it with a dynamometric Fit the microswitch (2) complete with O-ring; torque wrench setting:
wrench set to a torque of 70 ± 75 Nm. max. 30 Nm.
If necessary, adjust differential unit clearances. (see «DIFFEREN-
TIAL UNIT ASSEMBLY»).
Fit the top cap (1) and the arms. (For details, see «CHECKING
WEAR AND REPLACING THE BRAKING DISKS»).
180
Avvitare l'attrezzo T30 sul filetto del pistone (6) per Montare l'anello elastico (12) di ritegno del gruppo.
ITA comprimere la molla (7) e liberare la sede per l'anello ITA Rimuovere l'attrezzo T30 e montare l'anello elastico
elastico (12). (9) di ritegno molla (7).
Das Werkzeug T30 auf das Kolbengewinde (6) Den Kolbenring (12) zur Halterung des Aggregats
D schrauben, um die Feder (7) zu komprimieren und D montieren.
den Sitz fuÈr den Kolbenring (12) freizusetzen. Das Werkzeug T30 abnehmen und den Kolbenring (9)
zur Halterung der Feder (7) montieren.
a b
Atornillar la herramienta T30 sobre la rosca del pistoÁn IMontar el segmento elastico (12) de compresioÁn del
ESP (6) para comprimir el muelle (7) y dejar libre el ESP grupo.
alojamiento para el anillo elastico(12). Removerla herramienta T30 y montar el segmento
elastico (9) de compresion muelle (7).
Visser l'outil T30 sur le filet du piston (6) pour Monter l'anneau aÁ ressort (12) de retenue du groupe.
F comprimer le ressort (7) et deÂgager le sieÁge pour F Enlever l'outil T30 et monter l'anneau aÁ ressort (9) de
l'anneau aÁ ressort (12). retenue ressort (7).
Inserire nel corpo centrale (22) la forcella (5) ed il Montare il coperchio intermedio (13) e bloccarlo con le
ITA gruppo differenziale (15). ITA viti (14) serrate con una coppia di 23,8v26,2 Nm.
Impegnare la forcella (5) nel manicotto (19) e sul NOTA. Controllare attentamente la condizione dell'a-
pistone (6). nello OR (23).
In den zentralen KoÈrper (22) die Gabel (5) und das Den mittleren Deckel (13) montieren und mit den
D Differentialaggregat (15) einsetzen. D Schrauben (14) mit einem Anzugsmoment von
Die Gabel (5) in der HuÈllse (19) und auf den Kolben (6) 23,8v26,2 Nm blockieren.
einsetzen. BEMERKUNG. Zustand des O-Ringes (23) sorgfaÈltig kontrollieren.
c d
ntroducir en el cuerpo (22) la horquilla (5) y el grupo Montar la tapa intermedia (13) y bloquearla con
ESP diferencial (15). ESP tornillos (14) apretadas con un par de 23,8v26,2 Nm.
Insertar la horquilla (5) en el manguito (19) y sobre el NOTA. Controlar con cuidado la condicioÁn del
pistyoÁn (6). segmento OR (23).
Introduire dans le corps central (22) la fourchette (5) et Monter le couvercle intermeÂdiaire (13) et bloquer celui-
F le groupe diffeÂrentiel (15). F ci avec les vis (14) serreÂes aÁ un couple de 23,8v26,2
Engager la fourchette (5) dans le manchon (19) puis Nm.
sur le piston (6). NOTE. ControÃler attentivement l'eÂtat de la garniture OR (23).
Montare il dado (4) di ritegno forcella (5) e bloccarlo Montare il microinterruttore (2) completo di guarnizione OR;
ITA con una chiave dinamometrica tarata ad una coppia di ITA coppia di serraggio: max. 30 Nm.
70v75 Nm. Se necessario, registrare i giochi differenziale. (Vede-
re «ASSEMBLAGGIO DIFFERENZIALE»).
Montare il tappo superiore (1) ed i bracci. (Per i dettagli, vedere
«CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO»).
Die Mutter (4) zur Halterung der Gabel (5) montieren Die Mikroschalter (2) samt O-Ring montieren. Anzu-
D und mit einem MomentenschluÈssel und einem Anzu- D gsmoment: max. 30 Nm.
gsmoment von 70v75 Nm blockieren. Wenn noÈtig, die Differentialspiele einstellen (Siehe «DIFFEREN-
TIAL ZUSAMMENBAUEN»). Den unteren Stopfen (1) und die Arme
e f montieren. (FuÈr weitere Einzelheiten, sieh «VERSCHLEISS KON-
TROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN»).
Montar la tuerca (4) de compresioÁn horquilla (5) y Montar el microinterruptor (2) completo de guarnicioÁn
ESP bloquearla con un llave dinamometrica tarada a un par ESP OR; par de torsion: max. 30 Nm.
de 70v75 Nm. Si necesario, registrar los juegos diferenciales.
(Vease «ASEMBLAJE DIFERENCIAL»):
Montar la tapa superior (1) y los ejes. (Para los detalles, vease
«CONTROL DESGASTE Y SOBSTITUCION DISCOS FRENOS»).
Monter l'eÂcrou (4) de fixation fourchette (5) et bloquer Monter le microinterrupteur (2) eÂquipeÂ de garniture
F celui-ci aÁ l'aide d'une cleÂ dynamomeÂtrique calibreÂe aÁ F OR; couple de serrage: max. 30 Nm.
un couple de 70v75 Nm. Si besoin, reÂgler les jeux du diffeÂrentiel (Voir «ASSEM-
BLAGE DU DIFFERENTIEL»). Monter le bouchon supeÂrieur (1) et
les bras. (Pour tout deÂtail, voir «CONTROLE DE L'USURE ET
SUBSTITUTION DES DISQUES FREIN»).
181
OPERATION AND ADJUSTMENT OF THE
ASSISTED BRAKING SYSTEM
40-8-3-M55 EN
14 / 02 / 2003
THE COMPONENTS
Brake circuit supply pressure switch accumulator

(LED on control panel)
F R
master
cylinder
Stop lights
T1 switch
Brake
P T circuit
N
accumulator
charging system
flow
divider
The MLA master cylinder is completely different to the assisted models fitted on the MLT and MT.
It consists of four components:
- A brake accumulator
- A master cylinder
- An accumulator charging system
- A flow divider
The accumulator ensures pressure stability and maintains a small amount of hydraulic power in order to
supply the master cylinder when the engine is off.
The master cylinder operates a bit like a pressure limiter. When the driver presses the brake pedal, it
compresses a spring which allows the pressure to increase in the brake circuit.
The accumulator charging system provides the supply to the accumulator when its pressure falls below
a value which is adjusted using an adjustable spring.
The flow divider distributes the flow between the charging system and the accumulator unit of the
machine's Mono-Ultra circuit.
3
BRAKING ASSISTANCE ACCUMULATOR
1 - CHECKING AND ADJUSTING THE ACCUMULATOR CHARGING PRESSURE

- Engine off, release the pressure from the accumulator.
- Connect a pressure gauge to the accumulator supply line.
- Start the engine and press the brake pedal so as to charge the accumulator.
- Read the pressure on the gauge (90 bars).
- The pressure read corresponds to the maximum accumulator charging pressure.
2 - ADJUSTING THE BRAKING ASSISTANCE PRESSURE

- Connect a pressure gauge to the brake circuit (Fig. A) between hose 1 and connector 2.
- Press the brake pedal and check that the pressure gauge shows 90 bars.
- Adjust the braking pressure by adjusting the screw 3 (Fig. C) after having slackened the locknut 4.
3 - ADJUSTING THE PEDAL HEIGHT

- Remove the pedal cap 5 (Fig. A).
- Press the pedal 6 (Fig. B) and check the height which should be 30 mm above the cab floor (Fig. B).
- If necessary, adjust the height of the pedal using the screw 7 and the locknut 8 (Fig. B).
4 - CHECKING THE OPERATION OF THE ACCUMULATOR

- Connect a pressure gauge to the accumulator supply circuit.
- Charge the accumulator.
- Switch off the engine and press the brake pedal.
- If the accumulator is in good working order, the pressure will drop slowly when the pedal is pressed for
the first few times.
- Then the pressure drops suddenly to 0 bar.
- The pressure read on the pressure gauge just before this rapid pressure drop corresponds to the gas
charging pressure of the accumulator (approximately 60 bars).
5 - ADJUSTING THE PRESSURE SWITCHES

- Charge the accumulator until the LED on the control panel extinguishes.
- Tighten or slacken the pressure adjusting screw, ref B (Fig. C) so as to alter the accumulator
recharging time.
IMPORTANT : The correct adjustment is obtained when the brake pedal can be pressed 4 - 5 times
before the LED indicates an accumulator charging fault.
- The recharging time can be checked using a pressure gauge on the accumulator charging circuit. A
pressure drop is seen when the pedal is pressed for the first 4 - 5 times before the accumulator is
charged again.
4
Fig.A
front axle
5
3
NOTE: The screw 3 is accessed

from underneath the dashboard
(4 mm Allen key).
Fig.B
5
Fig.C
F R
T1
P T
valve
pressure gauge
accumulator
pump
6
MLA BRAKE ACCUMULATOR CHARGING SYSTEM
Pressure Brake
R switch accumulator
P charging valve
Flow divider (brake

accumulator and
accumulator unit)
7
8
CYLINDER DISASSEMBLY
MLA 628 S2
70-3-80-M91 EN
28 / 01 / 2003
CONTENTS
A - REMOVAL AND REASSEMBLY OF THE COMPLETE STEM ........... 4
B - REMOVAL AND REASSEMBLY OF THE PISTON AND

LOCKING RING ................................................................................................ 6
C - REMOVAL AND REASSEMBLY OF THE PISTON

SEALS AND RING ........................................................................................... 8
D - REMOVAL AND REASSEMBLY OF THE LOCKING RING

SEALS AND RING ........................................................................................... 9
E - APPLICATION OF THE THREAD LOCKING MATERIAL .................... 10
F - CYLINDER DIAGRAMS.................................................................................. 11
3
A - REMOVAL AND REASSEMBLY OF THE COMPLETE STEM
REMOVAL A1
- Place the cylinder in a vice fitted with false jaws
Locking
Bague dering 2
fermeture 2
- Tighten the vice, ensuring that the body does not
get distorted. Stem11
Tige Body 33
Corps Piston44
Piston
- Free locking ring 2 (Fig. A1) using a spanner
wrench.
- If you find it difficult to free the ring, see subsection
"REMOVAL" in section E.
- Completely unscrew locking ring 2 (Fig. A1).
- Extract the complete stem from the cylinder body.
NOTE : VERY LONG CYLINDERS

- Take out the stem over 200 mm maximum.
- Give a half turn to the locking ring to loosen it (very
slowly and evenly).
- Take out the stem by about 2500 mm.
- Support the stem end to prevent it from weighing
on the locking ring (Fig. A2).
- Carry on unscrewing the locking ring. If the effort is A2
excessive, lift and lower the stem to reduce the
friction.
Never force the ring when unscrewing it as

this could cause it to seize.
INSPECTION
- Degrease and clean the cylinder chamber.
- Visually inspect the cylinder chamber, there should
be no scratches, burrs, oxidisation, etc…
4
REASSEMBLY A3
- Apply hydraulic oil on the piston seals and ring, Locking
Bague ring
de fermeture
using a brush. Loctite
Frein Stem
filet Tige
- Reassemble the complete stem inside the cylinder

body 3 (Fig. A1).
- Ensure that the seals are not damaged while
passing through the inside thread in the cylinder
body.
- Apply hydraulic oil to the outside seals on the Seal
Joint
locking ring.
- Apply Loctite 222 (See section E) on the locking
ring (Fig. A3). A4
- Screw the ring in.
LOCKING
COUPLE RING
DE SERRAGE
- Block using a spanner wrench and a torque TIGHTENING TORQUE
BAGUE DE FERMETURE
wrench, see table for the tightening torque (Fig.
450
A4).
400
- Give one turn to the screw to ensure that the seals 350
are correctly positoned.
CoupleinenN.m
300
N.m
250
Torque
200
150
REMARK
100
- We advise completing a hydraulic test of the 50
cylinder before reasembling it on the machine. 0

M40 M50 M60 M70 M80 M90 M100
- Operate the stem several times in both directions. Filetage
Thread
5
B - REMOVAL AND REASSEMBLY OF THE PISTON AND LOCKING RING
REMOVAL B1
Lockingde
Bague ring 2
fermeture 2
- Place the stem in a vice fitted with false jaws.
Stem 1 Piston 44 Piston
- Tighten so as to stop it turning. Tige 1 Piston Piston 77
Nut 5
Ecrou 5 Screw
Vis 66
- Loosen nut 5 (Fig. B1) and sunscrew it completely
using a box wrench. Or depending on the version,
remove locking screw 6 (Fig. 1) using a hexagonal
wrench.
NOTE : Locking ring 6 (Fig. B1) is fitted using
Loctite, then blocked by striking it with a B2
chisel Locking ring 2
Bague de fermeture 2
- Remove piston 4 (Fig. B2) by pulling it out manually
Stem Piston 4
or, depending on the version, by unscrewing piston Tige1 1 Piston 4
7 (Fig. B1) using a hook wrench.
- Remove locking ring 2 (Fig. B3) by sliding it along
the stem.
INSPECTION
B3
- Check that the stem is straight over its whole
length, using a comparator (Fig. B4). Locking ring 2
Bague de fermeture 2
- Check that the stem is not scaling, corroded or Stem
Tige 11
scratched.
REASSEMBLY
- Reassemble locking ring 2 (Fig. B5) on stem 1
(Fig. B5).
B4
- Reassemble piston 4 (Fig. B1) on the stem.
- Screw and lock nut 5 (Fig. B1) using a box wrench Comparator
Comparateur
and a torque wrench. See the table for the
Stem11
Tige
tightening torque (Fig. B6). Or, depending on the
version, screw piston 7 (Fig. B1) using a spanner
wrench (see tightening torque Fig. B6) and block it
with locking screw 6 (Fig. B1).
NOTE : • The locking screw should be fitted using
Loctite 243, see section E. B5
• Tightening torque for the screw = 20 Nm.
• Strike with a chisel to drive the screw into Locking ring
Bague de 2
fermeture 2
the metal. Stem
Tige 1
1
6
B6
PISTON
COUPLETIGHTENING TORQUE
DE SERRAGE PISTON
1400
1200
1000
en N.m
in N.m
800
TorqueCouple
600
400
200
0
M20 M30 M40 M50 M60 M70
Thread
Filetage
7
C - REMOVAL AND REASSEMBLY OF THE PISTON SEALS AND RING
NOTE : C1
Never use cutting or sharp tools (screw drivers, Seals
Joints d'étanchéité
blades, etc.) when assembling and removing seals.
Ensure that there are no chippings on the work
bench.
REMOVAL
- Remove the piston seals and ring (Fig. C1 or C2).
- Take care not to damage the edges or the bottom
of the grooves. O-ring
Joint torique
INSPECTION
- Degrease and clean the piston. C2
- Check that the grooves bottoms and sides are Seals
Joint d'étanchéité
smooth and without scratches.
- There should be no extraneous bodies in the
grooves.
REASSEMBLY
- Fit the seals and ring as in Fig. C1 or C2).
- When fitting the outside seals, open them
sufficiently to slip them into the grooves while O-ring
Joint torique
ensuring that they do not break.
- The inside ring should be fitted by hand.
8
D - REMOVAL AND REASSEMBLY OF THE SEALS AND RINGS ON THE LOCKING
NOTE : D1
Never use cutting or sharp tools (screw drivers, Extrusion proof ring 2
Joint anti-extrusion 2
Seals
Joint 3
torique Seals 1
3 Joint torique 1
blades, etc.) when assembling and removing seals.
Ensure that there are no chippings on the work
bench.
REMOVAL
- Remove the locking ring seals and rings.
- Take care not to damage the edges or the bottom
of the grooves. Racleurring
Scraper 4 4
INSPECTION
Stem
Joint tigeseal
5 5
- Degrease and clean the locking ring.
- Check that the groove bottoms and sides are
D2
smooth and without scratches.
- There should be no extraneous bodies in the
grooves. Seal
Joint
- Thread the bare ring on the stem and slide it over
its whole length.
- The gap should not be excessive, but it should not
grip either.
REASSEMBLY
Embout
Bit 1 1
- Fit the seals and rings as in Fig. D1. The lips of the
stem seal should face the pressure side.
- When fitting the stem seal, first introduce it in the
groove, holding it back either with your thumb or a D3
bit (item 1) with no sharp edges (Fig. D2). Plug 22
Poinçon
- Push it into the groove with the other hand or a
smooth die (item 2) (Fig. D3). If the seal is too tight,
dip it into hydraulic oil heated to 50°C.
Fit scraper ring 4 (Fig. D1) using a plug and a mallet.
Seal
Joint
O-rings 1 and 3 (Fig. D1) and extrusion proof ring 2
(Fig. D1) will be fitted by hand.
Bit 1 1
Embout
9
E - APPLICATION OF THE THREAD LOCKING MATERIAL
CHARACTERISTICS
Light thread locking material (Loctite 222)
Application on the locking ring threads.
Without activation agent

Handling time 10 - 30 minutes
Use time 3 - 6 hours
(Placing of the cylinder under pressure)
With N Loctite activation agent
Shearing strength 1,5 - 4 N/mm2
Medium thread locking material (Loctite 243)
Application on the M8 screws to lock the pistons.
Without activation agent

With N Loctite activation agent
Shearing strength 5 - 7,5 N/mm2
REMOVAL
If the parts fitted with locking material cannot be removed using standard tools, we recommend
heating the glued area to T = 250°C, preferably using a hot air pistol rather than a blowpipe.
REMARK
If the temperature is near 0°C, we recommend using a Loctite activation agent for the assembly,
in addition, this will limit the polymerisation time.
10
LIFTING CYLINDER
S
INT
JO
DE
TE Z
HET SAT TAS
C G
PO HTUNE JUN
DIC GO D NE
E IZIO
JU L KIT ARN
E A GU
S IE
R
SE
228636
COMPENSATION CYLINDER
S
INT
JO
DE
T TE ATZ S
E
CH GS TA
PO HTUNE JUN
DIC GO D NE
E IZIO
JU L KIT ARN
A U
SE IE G
R
SE
228637
11
TELESCOPE CYLINDER
3
TS 4
IN
JO
DE
5 15
TE TZ 6
11 8
H ET SA A S
C
PO TU
NG UN
J
T
7 9
CH DE NE
DI O IO
12 12
EG IT IZ
JU L K ARN
A U
SE IE G
R
SE
1 10
13
14
228634
3
4
2
5
6
7
TILTING CYLINDER
11
12 x 2
INTS
13
E JO 14
E T
H G T
TESDATZ AS 15
16
21
POCHTUNE JUN E
DICEGO DT IZION
18
19
19
JU AL KI UARN
SERIE G 9
SE
7
8
1
18 7
2 17 6
20
228635
11
12
5 13
3 12
4
10
5 14
16 15
12
STEERING CYLINDER
9
11 8
12
INTS 13
O
E J
TESDATZ AS 14 19
E T
H G T
POCHTUNE JUN E 17
16 1 7
IC D
D EGO T IZIO N
JU AL KI UARN
SERIE G
SE 16
15 6
17
18
2
11
226808 10
13
5 14
4 12
LOCKING CYLINDER OF ATTACHMENT
13
14
HYDRAULIC DIAGRAM
70-6-M91 EN
22 / 01 / 2003
CONTENTS
– MLA 628 Turbo POWERSHIFT Série 2 HYDRAULIC DIAGRAM. ............. 4
VALVE BANK . ................... 8
– MLA 628 - 120 LS POWERSHIFT Série 2 HYDRAULIC DIAGRAM. ............. 10
VALVE BANK . ................... 14
3
HYDRAULIC DIAGRAM MLA 628 Turbo POWERSHIFT Série 2
B P 90 BAR
SHF F 0,7 LITRE
70 BAR
R
AF
N
R1
T1
T
FDAV R L FDAR
225-245b
PD VDD
400 cm3/tr
FDAV VDG FDAR

LS
170-175b
0,7 LITRE
T P 13 BAR
P1 BA
40b
U
45b
P2 T
FR
PAF LS P EF
2b
M
4,8 cm3/tr P 10 MICR.
41 cm3/tr M
100 L/min
N 100 MICRONS
R CA
4
VVT(O) VL VI VC VT
( UNIQUEMENT )
C1 C2 +15
315b 0 C1 C2 +15
CSP CS 320b 0
C1 C2 +15 110b CSP
V1 V2 160b
VAI 320b 0 270b +6
30b 0
PA CSP V V
HYDRAULIC DIAGRAM
+6 V1 V2 T
30b 0
V V
0,7 LITRE
13 BAR
5
P1 BA PAAR(O)
40b
U
45b
P2 T
P
x
x
x
T B5 A5 X5 B4 A4 X4 B3 A3 X3 B2 A2 X2 B1 A1 X1 P
P
270b 200b 270b 200b
P FR 2
PAF LS P EF
2b
M
4,8 cm3/tr 10 MICR.
T
41 cm3/tr M P
250b
100 L/min
N 100 MICRONS EA EL EI ET EAO EE
R CA Y5 Y4 Y3 Y2 Y1
D
x
HYDRAULIC DIAGRAM
MA
P M2 M1
x
x
M4 M3
T B5 A5 X5 B4 A4 X4 B3 A3 X3 B2 A2 X2 B1 A1 X1 P
P
S-2F S-AR(O)
270b 200b 270b 200b M4 T P M3 MA
T P
B2 B1 T B
6
A2 A1 P A
T
P M2 M1 1 3 2 4
250b
EA EL EI ET EAO EE
Y5 Y4 Y3 Y2 Y1 D
x
AF Braking accumulateur NOTE : 1 - The main relief valve's pressure, on inlet

sections are given at engine's maximum
BA Power unit + Accumulator rating.
2 - The secundary valve's pressure, are
CA Suction strainer given at 1000 rpm of the engine.
CSP Piloted safety valve
3 - Pressure relief valve's control must be
done at an oil temperature of 50°C.
D Valve bank (4) sections
EA Attachment section
EA(O) Attachment section (Option)
EE Inlet section
EI Tilting section
EL Lifting section
ET Telescope section
FDAR Rear disk brake

FDAV Front disk brake
FR Return filter
M I.C. Engine
Rating slow unladen
Nominal rating load
Max. Rating unladen
MA Joystick
M1 Attachment
M2 Extending telescope
M3 Attachment
M4 Retracting telescope
N Level
P Hydraulic pump
PAAV Front attachment fitting
PAAR(O) Rear attachment fitting (Option)
PD Steering pump
PAF Brake pumpe
PP Pressure test
R Hydraulic tank
S2F Selector 2 functions

SA-AR(O) Selector Rear attachment (Option)
SHF Braking hydraulic system
VAI Insulation valve

VC Compensation cylinder DE
VDD R.H. steering cylinder DE
VDG L.H. steering cylinder DE
VI Tilting cylinder DE
VL Lifting cylinder DE
VT Telescoping cylinder DE
VVT(O) Locking carriage cylinder DE (Option)
7
270b 200b
EI ET
EE 250b
(EA)
(ET) EI 200b
(EI)
(EL)
(EA)
EL 270b

EE Inlet section
EI Tilting section
EL Lifting section
8
9
HYDRAULIC DIAGRAM MLA 628 - 120 LS POWERSHIFT Série 2
B P SHF AF
90 bar 0,7 Litre
F 70 bar
N
R
T1
T
FDAV R L FDAR
225-245b
PD VDD
3
400 cm /tr
FDAV VDG FDAR

LS
170-175b
0,7 Litre
T P 13 bar
P1 BA
40b
U
45b
P2 T
B FR
P
M 2b
PAF
S 63 cm3/tr L1 L 10 microns
M
4.8 cm3/tr
100 L/min
N 100 microns
R CA
10
VC VI VL VVT(O) VT
UNIQUEMENT
C1 C2 +15
315b 0
C1 C2
CSP +15
CSP 320b 0
110b
CSP C1 C2 +15 V
V1 V2 320b 0
HYDRAULIC DIAGRAM
160b +6
270b
CSP PAAV 30b 0
+6
V V
30b 0
V V T V V
PAAR(O)
PP
11
LS D b1 B1 A1 b2 B2 A2 b3 B3 A3 b4 B4 A4 b5 B5 A5
D
P DLS
X M
PP
23b
250b
T T
B FR T LS BA B B
MLA 628 - 120 LS POWERSHIFT Série 2
P 190b 280b 280b 200b

2b EE
PAF M a1 EI a2 EL a3 EA a4 ET a5 EA EF
S 63 cm3/tr L1 L 10 microns
M
4.8 cm3/tr
100 L/min
N 100 microns
R CA
P MA
HYDRAULIC DIAGRAM
T
M2 M1
M4 M3
1 3 2 4
LS D b1 B1 A1 b2 B2 A2 b3 B3 A3 b4 B4 A4 b5 B5 A5 B1
D
12
TEL
A1
DLS
P
B2
ACC
M
PP A2
23b
250b
T T B3
T LS BA B B
200b
ACCES
EE 190b 280b 280b A3

a1 EI a2 EL a3 EA a4 ET a5 EA EF S-2F
MLA 628 - 120 LS POWERSHIFT Série 2
AF Braking accumulateur NOTE : 1 - The main relief valve's pressure, on inlet

sections are given at engine's maximum
BA Power unit + Accumulator rating.
2 - The secundary valve's pressure, are
CA Suction strainer given at 1000 rpm of the engine.
CSP Piloted safety valve
3 - Pressure relief valve's control must be
done at an oil temperature of 50°C.
EE Inlet section
EI Tilting section
EL Lifting section
FDAR Rear disk brake

FDAV Front disk brake
FR Return filter
M I.C. Engine
Rating slow unladen
Nominal rating load
Max. Rating unladen
MA Joystick
M1 Attachment
M2 Extending telescope
M3 Attachment
M4 Retracting telescope
N Level
P Hydraulic pump
PAAV Front attachment fitting
PAAR(O) Rear attachment fitting (Option)
PD Steering pump
PAF Brake pumpe
PP Pressure test
R Hydraulic tank

SA-AR(O) Selector Rear attachment (Option)
SHF Braking hydraulic system
VAI Insulation valve

VC Compensation cylinder DE
VDD R.H. steering cylinder DE
VDG L.H. steering cylinder DE
VI Tilting cylinder DE
VL Lifting cylinder DE
VT Telescoping cylinder DE
VVT(O) Locking carriage cylinder DE (Option)
13
D ES
EA ET
ET 200 b.
EA
EL
EE EI
EL
280 b.
EI
190 b.
EI
280 b.
EE
250 b.
EE Inlet section
EI Tilting section
EL Lifting section
14
15
16
ELECTRIC DIAGRAM
80-6-M91 EN
14 / 04 / 2003
CONTENTS
– ELECTRIC DIAGRAM
MLA 628 Turbo POWERSHIFT Serie 2.................................................. 4
MLA 628 - 120 LS POWERSHIFT Serie 2 ............................................ 8
3
+ PERM
+ PERM
+ AC
+ AC
+ AC
+ AC
F15
S1 r
G B A B C D A B C D B2 F13
AA AAAA H
I I I OP H1 H2 H3 H4 H5 H6 H7 H8
30 30 17 17 50 19 19 54 15 58 B1
J J r r r r ro vt
bc j
bc B B B B B B B B Q K K H H
K Y1
v n n/s V2 r j K g
j j EGS
H n/s v
bl g vt n o v m Q
F31 vers 79 shunt ext
KO V1 V1 V1 V1 V1 V1 V1 j 6 5 S9
S42 n F G H H H G H H9
H 8 2 7 1
3,5s K5 K K K K K K K H
n V1 M M N N
V1 V1 V1 V1 V1 K3
+
G shunt ext
M M bl
G1 v vt
H H G H H
- M g n n/s bl o ro o
M1 M n/g r/n
n D
N g
P N S8 K4
bc bc bl bl j r m m r ro ro n P P P P P jvt N
M R2 R3 P P P T P o
r/n P1 P2 P3 jvt G
j/vt G2 S2 S4 S7 S6 S5 jvt
R1 K0 K3 Y3 Y6 Y5 Y4 Y2 E1 E2 B3
jvt jvt
A
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
+ PERM
+ PERM
4
+ AC
+ AC
+ AC
+ AC
I F22
o
F26 S17a S17b F9 F1 F10 F4 F14
ZB ZB
Y G
r F vt
F G H H H
o o I I I bl r vt r r B4
r r r r r
J r r r
ZA ZA S14 6 5 S41 5 S18 6 5 S19 6 5 S20 5 S22
D D H10 W H11 bl vers 59 H15 H16 H17 H18
8 2 7 1 8 2 7 1 8 2 7 1 1
r 1 0 1 V3 U 0 1 0 1 0 1 0 1
bc bl m bc vt J g J
S10 S11 S12 S13 r S15 S16 Q V3 Q bc v
jvt v bl o g
ELECTRIC DIAGRAM MLA 628 Turbo POWERSHIFT Serie 2
F6 F7 F20 F18 OOOOOOOO

C U C L Tempo
C
S21
ZB ZB C E E E E E E E E E vers 49 bl
D D D D bc m g bl m r g J v bl n
L D bl/bc bl/bc bl bl bl J J bc bc bc
J
V V V V K9 V V N V V N B B B J S23
jvt jvt A1 T
jvt ro bl jvt jvt j n jvt m bl/s bl/s bl/s bl/s bl/s
Y9 jvt jvt O
L jvt KSB
R4
jvt
Y7 Y8 Y10 Y11 K9 E28 E3 E3 E4 E5 E6 E7 E8 E9 H12 E10 E11 H13 E12 E13 H14 E14 E15 E16 E17 E26 E27 Y12 Y13 Y14
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
+ PERM
+ PERM
+ AC
+ AC
+ AC
+ AC
I
F17 F21 F16 F23 F12 F3 F27 F8
S17c m o
G F F F H Y F
ro vers 8 m
ro ro r m bl
7 1 3 6 S26 j bl r r
r ro bl bl I I 5 4 ro ro I G r r
S28 7 2 S29 S31 5 S32
5
S24 7 3 8 4 S25 o m g n 0 1 vt vt
10 5 8 2
H23 H24 H25 H26
H19 H20 7 1 1
n H22 210 2 7 5 6 4 10 2
2 0 1 0 1
1 0
1 5 1 6 2 0 1 2 CL
g g
j K6 S30
53c/86/T r
n/bc jvt m r vt bl
15 F19 F5 n/s
ro C ro S17d C
31b/53S
bl/bc 53e/53M
C C C C C C
j jvt m
bl I J g n jvt j r
vt/n vt r j g
31
Jvt K12
V V
E E E E S27 vt ro bl N
K8 g g n n H jvt o vt
J J J jvt N V N V jvt v m r jvt v m r m r
g g n n T T T T T T
B T T S S S jvt
J Y15 Y16
jvt jvt M4 jvt jvt V
jvt
M3 H21 E19 E20 E21 E22 E23 M5 M6 M7 M8 B5 E24 E25 K4 jvt E18 M2
5
69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91
+ PERM
+ PERM
+ AC
+ AC
+ AC
+ AC
J
F25 F11 F2 F29 F24 F28 A F30
J
Y F G G Y F Y R Y Z Z
r X j
C o v g B6
bl
S33 S38
C + + C X2 X2
j M
H28 R
BP HP C
3210 S35 S36 K10 A
C
vt r r
S39 L
S34 H27 --
tempo 12mn K11 T C
0 1 X X K13 C A2 X1
S40 vt r R7
r r
S37
C o
T1 X2
B7
T2 S43 W1
M9 K11 K13
Y17 R
C C M R6
jvt jvt jvt Z
K10
jvt jvt R5 M10 jvt jvt
92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110
PRINCIPLE ELECTRIC CIRCUIT 85 - Sound alarm
1 - Battery 86 - L.H. stoplight
2 - Battery cut-off 87 - R.H. stoplight
3 - Starter 88 - Transmission cut-off relay control
4 - Starting safety relay 89 - Extended rear hook electrovalve (Option)
5 - Key switch 90 - Retracted rear hook electrovalve (Option)
6 - Preheating 91 - Revolving light
7 - Alternator 92 - Ventilation
8 - Hourmeter/rev counter 93 - Air conditioning (Option)
9 - Fuel level 94 - Antifreeze thermostat (air conditioning option)
10 - Fuel level sensor 95 - Low pressure switch (air conditioning option)
11 - Engine water temperature 96 - High pressure switch (air conditioning option)
12 - Engine water temperature sensor 97 - Compressor control relay (air conditioning option)
13 - Machine fault warning 98 - Compressor clutching (air conditioning option)
14 - Load indicator 99 - Free
15 - Engine oil pressure 100 - Free
16 - Engine water temperature 101 - Timer relay : defrosting
17 - Air filter clogging 102 - Rear defrosting
18 - Brake oil pressure 103 - Pneumatic seat (Option)
19 - Transmission oil temperature 104 - Fuel reheating (Option)
20 - Hydraulic return filter clogging 105 - Sensor and relay (Reheating option)
21 - Hand brake 106 - Radio aerial (Option)
22 - Transmission cut-off switch to brake pedal 107 - Autoradio (Option)
23 - Transmission cut-off relay 108 - Speakers (Option)
24 - Starting safety relay 109 - Cab internal socket (Option)
25 - Reverse relay 110 - Engine block preheating (Option)
26 - Reverse electrovalve
27 - Electrovalve 1 gear box COLOUR CODING
28 - Electrovalve 2 gear box bc : White bl : Blue g : Grey
29 - Electrovalve VR gear box j : Yellow jvt : Yellow/Green m : Brown
30 - Forward electrovalve n : Black o : Orange r : Red
31 - R.H. rear reverse light ro : Pink vt : Green v : Purple
32 - L.H. rear reverse light
33 - Reverse gear sound alarm (Option) CONNECTOR
34 - Transmission cut-off on hydraulic control lever A - Fuse box / relay (8 pin connection)
35 - Extended telescope electrovalve B - Indicator light module
36 - Retracted telescope electrovalve C - Cab
37 - Kick-down control or jib head control (Option) D - MU joystick (on/off)
38 - Electrovalve on jib head (Option) E - Fuse box / relay (13 pin connection)
39 - Retracted attachment electrovalve (telescope) F - Fuse box / relay (7 pin connection)
40 - Extended attachment electrovalve (telescope) G - Fuse box / relay (11 pin connection)
41 - Kick down switch/Jib head EV H - Fuse box / relay (21 pin connection)
42 - Jib head relay control I - Lighting switch
43 - Operating plate lighting or heating LED (Option) J - Front windscreen wiper
44 - Cigar lighter lighting K - EGS (21 pin connection)
45 - Control panel lighting L - Working headlight on jib/jib head EV
46 - Rear right position light M - Engine harness
47 - Front right position light N - Rear harness
48 - Front left position light O - Safety system/Strain gauge
49 - Rear left position light P - Gear box cable harness
50 - Sidelights indicator light Q - Diode bracket
51 - L.H. front low beam R - Autoradio
52 - R.H. front low beam S - Roof windscreen wiper
53 - Low beam indicator light T - Rear windscreen wiper
54 - L.H. front main beam U - Front work light / sidelight connection
55 - R.H. front main beam V - Front lighting harness + Sound alarm
56 - Main beam indicator light W - Attachment hydraulic locking shunt
57 - L.H. working tail light X - Air conditioning
58 - R.H. working tail light Y - Fuse box (Option)
59 - L.H. front working headlight Z - Preheating
60 - Front right work headlight ZA - Kick-down control
61 - Right work headlight on jib (Option) ZB - Electrovalve on jib head
62 - Left work headlight on jib (Option)
63 - Cigar lighter ELECTRICS COMPONENTS
64 - Hydraulics movements cut-off electrovalve (Option)
65 - Safety system A1 - Safety system
66 - Overload strain gauge A2 - Autoradio (Option)
67 - Engine stop electrovalve
68 - Cold start-up B1 - Machine fault warning
69 - Front windscreen washer B2 - Rotational speed sensor
70 - Front windscreen wiper B3 - Reverse gear sound alarm (Option)
71 - Front wiper speed regulator B4 - Strain gauge
72 - Warning centre/blinker B5 - Sound alarm
73 - Flashing lights B6 - RH speaker
74 - R.H. rear indicator B7 - LH speaker
75 - R.H. front indicator
76 - L.H. rear indicator E1 - R.H. rear reverse light
77 - L.H. front indicator E2 - L.H. rear reverse light
78 - Warning unit indicator light E3 - Operating plate lighting (Option)
79 - Roof light E4 - Cigar lighter lighting
80 - Left rear windscreen wiper E5 - Control panel lighting
81 - Right rear windscreen wiper E6 - Rear right position light
82 - Rear wiper speed regulator E7 - Front right position light
83 - Rear windscreen washer E8 - Front left position light
84 - Roof windscreen wiper (Option) E9 - Rear left position light
6
E10 - L.H. front low beam H28 - Rear defrosting light
E11 - R.H. front low beam
E12 - L.H. front main beam K0 - Starting safety relay
E13 - R.H. front main beam K1 - Free
E14 - R.H. working tail light K2 - Free
E15 - L.H. working tail light K3 - Reverse relay
E16 - L.H. front working headlight K4 - Transmission cut-off relay
E17 - Front right work headlight K5 - Timer relay
E18 - Revolving light K6 - Flasher unit/warning unit
E19 - R.H. rear indicator K7 - Machine fault warning
E20 - R.H. front indicator K8 - Front wiper speed regulator
E21 - L.H. rear indicator K9 - Electrovalve on jib head (Option)
E22 - L.H. front indicator K10 - Air conditioning compressor control (Option)
E23 - Roof light K11 - Defrosting control
E24 - L.H. stoplight K12 - Rear wiper valve bank/Speed regulator
E25 - R.H. stoplight K13 - Fuel reheating control (Option)
E26 - Left work headlight on jib (Option)
E27 - Right work headlight on jib (Option) M1 - Starter
E28 - Air conditioning /heating LED lighting (Option) M2 - Revolving light motor
M3 - Front screen washer pump
FUSES M4 - Front wiper motor
F1 - R.H. front working headlights M5 - Rear LH wiper motor
F2 - Free M6 - Rear RH wiper motor
F3 - Sound alarm/Stop switch M7 - Rear screen washer pump
F4 - Cigar lighter M8 - Roof wiper motor
F5 - L.H. indicators M9 - Air conditioning/heating fans
F6 - Right sidelights + Control instruments panel lighting M10 - Pneumatic seat compressor motor
F7 - L.H. sidelights + Operating plate lighting
F8 - Revolving light P1 - Module Hourmeter/rev counter
F9 - Working tail light P2 - Fuel level module
F10 - Jib headlight (Option) P3 - Engine water temperature module
F11 - Air conditioning compressor (Option)
F12 - Roof windscreen wiper (Option) R1 - Preheating resistor
F13 - Transmission R2 - Fuel sensor
F14 - Safety module + Engine stop EV + KSB R3 - Engine water temperature sensor
+ Hydraulics movements cut-off EV (Option) R4 - Cigar lighter resistor
F15 - Fault sound alarm light R5 - Rear defrosting resistor
F16 - Flasher unit R6 - Fuel reheating resistor
F17 - Front windscreen wiper and front windscreen washer R7 - Engine block preheating resistor
F18 - Main beam
F19 - R.H. indicators S1 - Key switch
F20 - Low beam S2 - Engine oil pressure switch
F21 - Warning unit + roof light S3 - Engine water temperature
F22 - Light switch, sound alarm and indicators S4 - Air filter pressure switch
F23 - Front windscreen wiper and rear windscreen washer S5 - Brake oil pressure switch
F24 - Pneumatic seat (Option) S6 - Transmission oil thermostat
F25 - Ventilation S7 - Hydraulic filter pressure switch
F26 - ON/OFF mono Ultra + EVT df option S8 - Hand brake switch
F27 - Rear hook (Option) S9 - Brake pedal transmission cut-off switch
F28 - Fuel reheating (Option) S10 - Transmission cut-off switch to hydraulic controls lever
F29 - Rear defrosting (Option) S11 - Extended telescope switch
F30 - +Permanent cab internal socket (option) S12 - Retracted telescope switch
F31 - Engine preheating S13 - Kick-down switch or jib head EV
S14 - Attachment hydraulic locking switch
S15 - Attachment retract switch
G1 - Battery S16 - Attachment extend switch
G2 - Alternator S17a - Sidelight lighting switch
S17b - Low beam/main beam lighting switch
H1 - Battery load indicator light S17c - Indicators lighting switch
H2 - Engine oil pressure indicator light S17d - Sound alarm control
H3 - Engine water temperature indicator light S18 - Rear work light switch
H4 - Air filter clogging indicator light S19 - Front work headlight switch
H5 - Hydraulic return filter clogging indicator light S20 - Work headlight switch on jib
H6 - Transmission oil temperature indicator light S21 - Cigar lighter switch
H7 - Brake circuit pressure LED S22 - Hydraulics movements cut-off
H8 - Hand brake light S23 - Cold start-up switch
H9 - Brake pedal transmission cut-off light S24 - Front windscreen washer switch
H10 - Attachment hydraulic locking safety LED S25 - Front windscreen wiper switch
H11 - Kick-down selector light or EVT D.F. S26 - Warning unit switch
H12 - Sidelights indicator light S27 - Roof light switch
H13 - Low beam indicator light S28 - Windscreen wiper/rear windscreen washer switch
H14 - Main beam indicator light S29 - Windscreen wiper/roof switch
H15 - Rear work lights LED S30 - Stop switch
H16 - Front work lights LED S31 - Rear hook switch
H17 - Work light on jib LED S32 - Revolving light switch
H18 - Hydraulic movement cut-off LED S33 - Ventilation switch
H19 - Front windscreen washer light S34 - Air conditioning switch
H20 - Front windscreen wiper light S35 - Low pressure switch
H21 - Flashing lights S36 - High pressure switch
H22 - Warning unit indicator light S37 - Evaporator thermostat T1
H23 - Front windscreen wiper light and rear windscreen washer S38 - Rear defrosting switch (Option)
H24 - Roof windscreen wiper light S39 - Pneumatic seat switch
H25 - Rear hook light S40 - Fuel heater control thermostat
H26 - Revolving light LED S41 - Kick down switch
H27 - Air conditioning light S42 - Battery cut-off switch
7
S43 - Antifreeze thermostat T2
V1 - Fault test diode/Hand brake light
V2 - Hand brake
V3 - Tell-tale LED on front work light
X1 - Cab internal socket

X2 - Engine block preheating external socket
Y1 - Gear box electronic controls
Y2 - Forward electrovalve gear box
Y3 - Reverse electrovalve gear box
Y4 - Electrovalve VR gear box
Y5 - Electrovalve 2 gear box
Y7 - Extended telescope electrovalve
Y8 - Retracted telescope electrovalve
Y9 - Jib head electrovalve (Option)
Y10 - Retracted attachment electrovalve
Y11 - Extended attachment electrovalve
Y12 - Hydraulics movements cut-off electrovalve (Option)
Y13 - Engine stop electrovalve
Y14 - Cold start-up electrovalve
Y15 - Extended rear hook electrovalve (Option)
Y16 - Retracted rear hook electrovalve (Option)
Y17 - Compressor clutch solenoid valve
GEAR BOX CONTROL MODULE OPERATION
FRONT SPEED ELECTROVALVE REAR SPEED ELECTROVALVE

1 Y2 + Y6 + Y5 1 Y3 + Y6 + Y5
2 Y2 + Y5 2 Y3 + Y5
3 Y2 3 Y3
4 Y2 + Y4
8
9
+ PERM
+ PERM
+ AC
+ AC
+ AC
+ AC
F15
S1 r
G B A B C D A B C D B2 F13
AA AAAA H
I I I OP B1 H1 H2 H3 H4 H5 H6 H7 H8
30 30 17 17 50 19 19 54 15 58
J J r r r r ro vt
bc j
bc B B B B B B B B Q K K H H
v
K g
n n/s V2 r j Y1 K
j j EGS
H m n/s v
bl g vt n o v Q
F31 shunt ext
KO vers 79 V1 V1 V1 V1 V1 V1 V1 j 6 5 S9
S42 n F G H H H G H H9
H 8 2 7 1
3,5s K5 K K K K K K K H
V1 M M N N
n V1 V1 V1 V1 V1 K3
+
G shunt ext
M M bl
G1 v vt H H G H H
- M g n n/s bl o ro o
M1 M n/g r/n
n D
N g S8
r m m r ro ro P N K4 P P P P P N
bc bc bl bl j n jvt
vers 99
M R2 R3 G o
r/n P1 P2 P3 P P P T P jvt
j/vt G2 S2 S4 S7 S6 S5 jvt
R1 K0 K3 Y3 Y6 Y5 Y4 Y2 E1 E2 B3
jvt jvt
A
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
10
+ PERM
+ PERM
+ AC
+ AC
+ AC
+ AC
I F22
o
F26 S17a S17b F9 F1 F10 F4 F14
ZB ZB
Y G
r F vt F G H H H
o o I I I bl r vt r r B4
r r r r r r
J r r
S14 6 5 S41 5 S18 6 5 S19 6 5 S20 5 S22
D D H10 W H11 bl vers 59 H15 H16 H17 H18
ZA ZA 8 2 7 1 8 2 7 1 8 2 7 1 1
r 1 0 1 V3 U 0 1 0 1 0 1 0 1
Q bc bl m bc vt J g J
S10 S11 S12 S13 r S15 S16 V3 Q bc v
jvt v bl
ELECTRIC DIAGRAM MLA 628 - 120 LS POWERSHIFT Serie 2
o g
F6 F7 F20 F18 O OOOOOO
ZB ZB C U C L Tempo C O
S21
C E E E E E E E E E vers 49 bl
D D D L D D bc m g bl m r g J v bl n
bl/bc bl/bc bl bl bl J J bc bc bc
J
V V V V K9 V V N V V N B B B S23
J
jvt jvt A1 T
jvt ro bl jvt jvt j n jvt m bl/s bl/s bl/s bl/s bl/s
Y9 O
jvt jvt
L KSB
R4 jvt
jvt
Y7 Y8 Y10 Y11 K9 E28 E3 E3 E4 E5 E6 E7 E8 E9 H12 E10 E11 H13 E12 E13 H14 E14 E15 E16 E17 E26 E27 Y12 Y13 Y14
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
+ PERM
+ PERM
+ AC
+ AC
+ AC
+ AC
F17 F21 F16 F23 F12 F3 F27 F8

I S17c m o
G F F F H Y F
ro vers 8 m
r m bl
ro ro 7 1 3 6 S26 j bl r r
r ro bl bl I I ro ro I G r r
S28 5 4 7 2 S29 S31 5 S32
5
S24 7 3 8 4 S25 o m 0 1 vt vt
g n H23 H24 H25 H26
H20 10 5 8 2 7 1 1
H19 1 0 2 2 0 1 0 1
1 0 5 1 6 2 n H22 210 2 7 5 6 4
1 0 1 2 CL
g g
j K6
53c/86/T r S30
n/bc 15 jvt m r n/s vt ro bl
ro F19 F5
31b/53S
C S17d C
bl/bc 53e/53M
C C C C C
j C
bl I J g n jvt j jvt m r
vt/n vt r j g
31 V V
Jvt K12
E E E E S27 vt ro bl N
K8 g g n n H jvt o vt
J J J jvt N V N V jvt v m r jvt v m r m r
g g n n T T T T T T
B T T S S S jvt
J Y15 Y16
jvt jvt M4 jvt V
jvt jvt
jvt M2
M3 H21 E19 E20 E21 E22 E23 M5 M6 M7 M8 B5 E24 E25 K4 E18
69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91
11
+ PERM
+ PERM
+ AC
+ AC
+ AC
+ AC
J
F2
F25 F11 F29 F24 F28 A F30
G G J
Y F v Y F Y R Y Z Z
r F33
X W r r ZC j
o
C ZC v g B6
S33 ZC S38
C + + C X2 X2
ZC j M
ZC R
BP HP vers 8 C
3210 K10 ZC A
S35 S36 H28 C
r r r
r/n n vt o v jvt bl vt
S34 L
H27 A3 tempo 12mn K11 -
T C
0 1 X X1
X B4 B15 B7 B14 B2 K13 S40 C A2 R7
vt r
r S39 r
T1 C W1
S37 o
A7 A8 A16 A6 A10 A1 A2 X2
B7
T2
S43
M9 r r jvt m vt r j jvt
Y17 K11 K13 R Z
C C M R6
jvt jvt jvt
jvt K10 jvt R8 R5 M10 jvt jvt
Y18
92 93 94 95 96 97 98 99 100 111 112 113 114 101 102 103 104 105 106 107 108 109 110
PRINCIPLE ELECTRIC CIRCUIT 85 - Sound alarm
1 - Battery 86 - L.H. stoplight
2 - Battery cut-off 87 - R.H. stoplight
3 - Starter 88 - Transmission cut-off relay control
4 - Starting safety relay 89 - Extended rear hook electrovalve (Option)
5 - Key switch 90 - Retracted rear hook electrovalve (Option)
6 - Preheating 91 - Revolving light
7 - Alternator 92 - Ventilation
8 - Hourmeter/rev counter 93 - Air conditioning (Option)
9 - Fuel level 94 - Antifreeze thermostat (air conditioning option)
10 - Fuel level sensor 95 - Low pressure switch (air conditioning option)
11 - Engine water temperature 96 - High pressure switch (air conditioning option)
12 - Engine water temperature sensor 97 - Compressor control relay (air conditioning option)
13 - Machine fault warning 98 - Compressor clutching (air conditioning option)
14 - Load indicator 99 - Electronic control unit
15 - Engine oil pressure 100 - Free
16 - Engine water temperature 101 - Timer relay : defrosting
17 - Air filter clogging 102 - Rear defrosting
18 - Brake oil pressure 103 - Pneumatic seat (Option)
19 - Transmission oil temperature 104 - Fuel reheating (Option)
20 - Hydraulic return filter clogging 105 - Sensor and relay (Reheating option)
21 - Hand brake 106 - Radio aerial (Option)
22 - Transmission cut-off switch to brake pedal 107 - Autoradio (Option)
23 - Transmission cut-off relay 108 - Speakers (Option)
24 - Starting safety relay 109 - Cab internal socket (Option)
25 - Reverse relay 110 - Engine block preheating (Option)
26 - Reverse electrovalve 111 - Speed switch
27 - Electrovalve 1 gear box 112 - Hydraulic pump solenoid valve
28 - Electrovalve 2 gear box 113 - Accelerator potentiometer on injection pump
29 - Electrovalve VR gear box 114 - Pump data input and diagnostic socket
30 - Forward electrovalve
31 - R.H. rear reverse light COLOUR CODING
32 - L.H. rear reverse light bc : White bl : Blue g : Grey
33 - Reverse gear sound alarm (Option) j : Yellow jvt : Yellow/Green m : Brown
34 - Transmission cut-off on hydraulic control lever n : Black o : Orange r : Red
35 - Extended telescope electrovalve ro : Pink vt : Green v : Purple
36 - Retracted telescope electrovalve
37 - Kick-down control or jib head control (Option) CONNECTOR
38 - Electrovalve on jib head (Option) A - Fuse box / relay (8 pin connection)
39 - Retracted attachment electrovalve (telescope) B - Indicator light module
40 - Extended attachment electrovalve (telescope) C - Cab
41 - Kick down switch/Jib head EV D - MU joystick (on/off)
42 - Jib head relay control E - Fuse box / relay (13 pin connection)
43 - Operating plate lighting or heating LED (Option) F - Fuse box / relay (7 pin connection)
44 - Cigar lighter lighting G - Fuse box / relay (11 pin connection)
45 - Control panel lighting H - Fuse box / relay (15 pin connection)
46 - Rear right position light I - Lighting switch
47 - Front right position light J - Front windscreen wiper
48 - Front left position light K - EGS (21 pin connection)
49 - Rear left position light L - Working headlight on jib/jib head EV
50 - Sidelights indicator light M - Engine harness
51 - L.H. front low beam N - Rear harness
52 - R.H. front low beam O - Safety system/Strain gauge
53 - Low beam indicator light P - Gear box cable harness
54 - L.H. front main beam Q - Diode bracket
55 - R.H. front main beam R - Autoradio
56 - Main beam indicator light S - Roof windscreen wiper
57 - L.H. working tail light T - Rear windscreen wiper
58 - R.H. working tail light U - Front work light/sidelight connection
59 - L.H. front working headlight V - Front lighting harness + Sound alarm
60 - Front right work headlight W - Attachment hydraulic locking shunt
61 - Right work headlight on jib (Option) X - Air conditioning
62 - Left work headlight on jib (Option) Y - Fuse box (Option)
63 - Cigar lighter Z - Engine block preheating
64 - Hydraulics movements cut-off electrovalve (Option) ZA - Kick-down control
65 - Safety system ZB - Electrovalve on jib head
66 - Overload strain gauge ZC - Diagnostic connector
67 - Engine stop electrovalve
68 - Cold start-up ELECTRICS COMPONENTS
69 - Front windscreen washer
70 - Front windscreen wiper A1 - Safety system
71 - Front wiper speed regulator A2 - Autoradio (Option)
72 - Warning centre/blinker A3 - Electronic control unit
73 - Flashing lights
74 - R.H. rear indicator B1 - Machine fault warning
75 - R.H. front indicator B2 - Rotational speed sensor
76 - L.H. rear indicator B3 - Reverse gear sound alarm (Option)
77 - L.H. front indicator B4 - Strain gauge
78 - Warning unit indicator light B5 - Sound alarm
79 - Roof light B6 - RH speaker
80 - Left rear windscreen wiper B7 - LH speaker
81 - Right rear windscreen wiper
82 - Rear wiper speed regulator E1 - R.H. rear reverse light
83 - Rear windscreen washer E2 - L.H. rear reverse light
84 - Roof windscreen wiper (Option) E3 - Operating plate lighting (Option)
12
E4 - Cigar lighter lighting H21 - Flashing lights
E5 - Control panel lighting H22 - Warning unit indicator light
E6 - Rear right position light H23 - Front windscreen wiper light and rear windscreen washer
E7 - Front right position light H24 - Roof windscreen wiper light
E8 - Front left position light H25 - Rear hook light
E9 - Rear left position light H26 - Revolving light LED
E10 - L.H. front low beam H27 - Air conditioning light
E11 - R.H. front low beam H28 - Rear defrosting light
E12 - L.H. front main beam
E13 - R.H. front main beam K0 - Starting safety relay
E14 - R.H. working tail light K1 - Free
E15 - L.H. working tail light K2 - Free
E16 - L.H. front working headlight K3 - Reverse relay
E17 - Front right work headlight K4 - Transmission cut-off relay
E18 - Revolving light K5 - Timer relay
E19 - R.H. rear indicator K6 - Flasher unit/warning unit
E20 - R.H. front indicator K7 - Machine fault warning
E21 - L.H. rear indicator K8 - Front wiper speed regulator
E22 - L.H. front indicator K9 - Electrovalve on jib head (Option)
E23 - Roof light K10 - Air conditioning compressor control (Option)
E24 - L.H. stoplight K11 - Defrosting control
E25 - R.H. stoplight K12 - Rear wiper valve bank/Speed regulator
E26 - Left work headlight on jib (Option) K13 - Fuel reheating control (Option)
E27 - Right work headlight on jib (Option)
E28 - Air conditioning /heating LED lighting (Option) M1 - Starter
M2 - Revolving light motor
FUSES M3 - Front screen washer pump
F1 - R.H. front working headlights M4 - Front wiper motor
F2 - E.C.U. + Variable displacement pump M5 - Rear LH wiper motor
F3 - Sound alarm/Stop switch M6 - Rear RH wiper motor
F4 - Cigar lighter M7 - Rear screen washer pump
F5 - L.H. indicators M8 - Roof wiper motor
F6 - Right sidelights + Control instruments panel M9 - Air conditioning/heating fans
lighting M10 - Pneumatic seat compressor motor
F7 - L.H. sidelights + Operating plate lighting
F8 - Revolving light P1 - Module Hourmeter/rev counter
F9 - Working tail light P2 - Fuel level module
F10 - Jib headlight (Option) P3 - Engine water temperature module
F11 - Air conditioning compressor (Option)
F12 - Roof windscreen wiper (Option) R1 - Preheating resistor
F13 - Transmission R2 - Fuel sensor
F14 - Safety module + Engine stop EV + KSB R3 - Engine water temperature sensor
+ Hydraulics movements cut-off EV (Option) R4 - Cigar lighter resistor
F15 - Fault sound alarm light R5 - Rear defrosting resistor
F16 - Flasher unit R6 - Fuel reheating resistor
F17 - Front windscreen wiper and front windscreen washer R7 - Engine block preheating resistor
F18 - Main beam R8 - Accelerator potentiometer on injection pump
F19 - R.H. indicators
F20 - Low beam S1 - Key switch
F21 - Warning unit + roof light S2 - Engine oil pressure switch
F22 - Light switch, sound alarm and indicators S3 - Engine water temperature
F23 - Front windscreen wiper and rear windscreen washer S4 - Air filter pressure switch
F24 - Pneumatic seat (Option) S5 - Brake oil pressure switch
F25 - Ventilation S6 - Transmission oil thermostat
F26 - ON/OFF mono Ultra + EVT df option S7 - Hydraulic filter pressure switch
F27 - Rear hook (Option) S8 - Hand brake switch
F28 - Fuel reheating (Option) S9 - Brake pedal transmission cut-off switch
F29 - Rear defrosting (Option) S10 - Transmission cut-off switch to hydraulic controls
F30 - +Permanent cab internal socket (option) lever
F31 - Engine preheating S11 - Extended telescope switch
F33 - Diagnostic connector S12 - Retracted telescope switch
S13 - Kick-down switch or jib head EV
G1 - Battery S14 - Attachment hydraulic locking switch
G2 - Alternator S15 - Attachment retract switch
S16 - Attachment extend switch
H1 - Battery load indicator light S17a - Sidelight lighting switch
H2 - Engine oil pressure indicator light S17b - Low beam/main beam lighting switch
H3 - Engine water temperature indicator light S17c - Indicators lighting switch
H4 - Air filter clogging indicator light S17d - Sound alarm control
H5 - Hydraulic return filter clogging indicator light S18 - Rear work light switch
H6 - Transmission oil temperature indicator light S19 - Front work headlight switch
H7 - Brake circuit pressure LED S20 - Work headlight switch on jib
H8 - Hand brake light S21 - Cigar lighter switch
H9 - Brake pedal transmission cut-off light S22 - Hydraulics movements cut-off
H10 - Attachment hydraulic locking safety LED S23 - Cold start-up switch
H11 - Kick-down switch LED or EVT D.F. S24 - Front windscreen washer switch
H12 - Sidelights indicator light S25 - Front windscreen wiper switch
H13 - Low beam indicator light S26 - Warning unit switch
H14 - Main beam indicator light S27 - Roof light switch
H15 - Rear work lights LED S28 - Windscreen wiper/rear windscreen washer switch
H16 - Front work lights LED S29 - Windscreen wiper/roof switch
H17 - Work light on jib LED S30 - Stop switch
H18 - Hydraulic movement cut-off LED S31 - Rear hook switch
H19 - Front windscreen washer light S32 - Revolving light switch
H20 - Front windscreen wiper light S33 - Ventilation switch
13
S34 - Air conditioning switch
S35 - Low pressure switch
S36 - High pressure switch
S37 - Evaporator thermostat T1
S38 - Rear defrosting switch (Option)
S39 - Pneumatic seat switch
S40 - Fuel heater control thermostat
S41 - Kick down switch
S42 - Battery cut-off switch
S43 - Antifreeze thermostat T2
V1 - Fault test diode/Hand brake light
V2 - Hand brake
V3 - Tell-tale LED on front work light
X1 - Cab internal socket

X2 - Engine block preheating external socket
Y1 - Gear box electronic controls
Y2 - Forward electrovalve gear box
Y3 - Reverse electrovalve gear box
Y4 - Electrovalve VR gear box
Y7 - Extended telescope electrovalve
Y8 - Retracted telescope electrovalve
Y9 - Jib head electrovalve (Option)
Y10 - Retracted attachment electrovalve
Y11 - Extended attachment electrovalve
Y12 - Hydraulics movements cut-off electrovalve (Option)
Y13 - Engine stop electrovalve
Y14 - Cold start-up electrovalve
Y15 - Extended rear hook electrovalve (Option)
Y16 - Retracted rear hook electrovalve (Option)
Y17 - Compressor clutch solenoid valve
Y18 - Hydraulic pump solenoid valve
GEAR BOX CONTROL MODULE OPERATION
FRONT SPEED ELECTROVALVE REAR SPEED ELECTROVALVE

1 Y2 + Y6 + Y5 1 Y3 + Y6 + Y5
2 Y2 + Y5 2 Y3 + Y5
3 Y2 3 Y3
4 Y2 + Y4
14
15
16
OPERATION OF THE “EGS” SHIFT LEVERTY-
PE "EGS" (KICK DOWN)
80-8-15-M91 EN
13 / 05 / 2003
TABLE OF CONTENTS
A - Descriptions - Characteristics ...................................................... 2
B - Functionning - Forward/reverse lever ................................ 2
C - Functionning - speed selector .................................................. 3
D - Functionning - switch (kick -Down) ....................................... 4
E - Connector ..................................................................................................... 5
F - Leds display ................................................................................................ 7
G - Selftest Functions .................................................................................. 8
H – Speed sensor and installation ..................................................... 11
1
A - Descriptions - Characteristics
– 4 forward running speeds (Fwd).
– 3 reversing speeds (Rev.).
LED
Colors Inverting lever
RED NEUTRAL
GREEN FWD
Forward running YELLOW REV.
LED (green) for fwd

Upshift
LED lights up in
"test" mode (see
Neutral paragraphs C,D,E)
1 2 3 4 5 6 7 8 LED (green) lights up
N T F N R
when the machine is
Downshift immobile
LED "T" lights up in

reversing "test" mode (yellow)
LED "N" Neutral (red) (lights
up when the “egs” shift lever
is in neutral)
B - Functionning - Forward/reverse lever

A
When operating this control, the lift truck should be travelling at low speed and
not accelerating.
2
C
During the direction change, depeding on the original selection the speed
may also change (see diagram A) it can be reset using the button 2 or 4 B
1
(kick down see diagram B/ kick up see diagram C).
4
FORWARD : Push the lever forwards (Position A).
REVERSE : Pull the lever backwards (Position B).
NEUTRAL : To start the lift truck, the lever must be in neutral (Position
C).After starting the lift truck, the 3nd gear is automatically selec-
ted after a few seconds.
NOTE : The reverse lights indicate that the lift truck is running in reverse
motion. As well, an OPTION sound alarm on reverse motion exists.
2
C - Functionning - speed selector
The selected gear is indicated on display 1 by a signal light.
FORWARD GEAR :
The gears can be gradually increased from the 1st to the 4th by turning the handle forwards or by a double pulse (<
0.5 seconds) (kick up) on the button 2,
and decreased from the 4th to the 1st by turning the handle backwards. Press once (kickdown) on the one-touch but-
ton 2 or 4 to change down a gear.
REVERSE GEAR :
The gears can be gradually increased from the 1st to the 3rd by turning the handle forwards or by a double pulse (<
0.5 seconds)(kick up) on the button 2,
and decreased from the 3rd to the 1st by turning the handle backwards. Press once (kickdown) on the one-touch but-
ton 2 or 4 to change down a gear.
A
SPEED RATIO
FORWARD REVERSE
1st 1st
2nd 2nd
3rd 3rd
4th
B C
kick down kick down kick up kick up
SPEED RATIO SPEED RATIO SPEED RATIO SPEED RATIO
FORWARD REVERSE REVERSE FORWARD FORWARD REVERSE REVERSE FORWARD
1st 1st 1st 1st 1st 1st 1st 1st
2nd 2nd 2nd 2nd 2nd 2nd 2nd 2nd
3rd 3rd 3rd 3rd 3rd 3rd 3rd 3rd
4th 4th 4th 4th
3
D - Functionning - switch (kick -Down) B
Switch 3 selects kick-down with knob 4 on the hydraulic control lever or the
3
solenoid valve at the jib head OPTION.
.
Position A : The LED is off, enabling kick-down with knob 4 on the hydrau- A
lic control lever.
Position B : The LED is on, enabling operation of the solenoid valve at the
jib head with the hydraulic control lever.
4
USING THE GEARS ON THE GEARBOX

- On these lift trucks with a torque converter, it is not necessary to automatically start up in 1st speed and progress up the
gears.
The choice of gear ratio should be made carefully according to the nature of the work being carried out. A poor choice
may result in the extremely rapid elevation of the transmission oil temperature through excessive slipping of the conver-
ter, which could lead to serious damage to the transmission (it is essential to stop and change the working conditions if
the transmission oil temperature indicator light comes on). This poor choice may also result in a reduction in the lift
truck's performance in forward speed. When the forward force increases, the forward speed in the r gear (for example
3rd gear) may be lower than the forward speed that could be obtained with the r-1 gear (in 2nd instead of the 3rd).
In general, we would advise you to use the following gears according to the nature of the work being carried out.
• On the road: Move off in 3rd gear and change to 4th. In hilly areas, set off in 3rd gear and go up to 4th if the conditions
and state of the road permit it.
• With a trailer on the road : Set off in 2nd gear and go up to 3rd and then to 4th if the conditions and state of the road per-
mit it.
• When lifting: 3rd gear tolerated.
2nd gear in restricted spaces.
• Earth moving : 1st gear.
• Loading (reclaiming with bucket, manure fork, etc.) : 2nd gear.
4
E - Connector
oS
j33
viH
15
nI
roS
blS
n/sS
gC
EGS
jvtT
rI 9
1
ro24
vt24
Below table shows the connector pin assignments of the EGS50.
PIN FUNCTION
1 Battery plus
2 Battery ground
3 Neutral start solenoid (off in neutral)
4 C.V. Solenoid 1
5 C.V. Solenoid 2
6 C.V. Forward solenoid
7 C.V. Reverse solenoid
8 Warning lamp
9 Blocking 4th gear
10 Speed sensor input HOT
11 Speed sensor input GND
12 Not used
13 C.V. Splitter solenoid
14 Declutch request
15 External kickdown request
16 Shield ground (internally connected to wire 2)
5
1. Input options
1.1 Declutch request (input wire 14)
When the declutch input is closed and the vehicle speed drops below 5 km/h, the transmission is put in
neutral. The led turns red.
When the declutch input is released, the transmission re-engages the direction if following conditions are
fulfilled.
1.2 Kickdown request (input wire 15)
The kickdown request can be made when pressing the EGS50 kickdown button, or by activating the input
wire 15.
The kickdown function can be used in all gears, except 1st.
Downshift request by using the kickdown function :
If the kickdown is pressed a downshift will be made, if no risk for overspeeding the transmission exists.
Upshift request by using the kickdown function :
When a lower gear is reached by kickdown, pressing the kickdown button a 2nd time will revert to the ini-
tial gear.
Examples :
2. Output options
2.1 Warning lamp (output wire 08)
If a downshift is made at a too high speed, or a direction change is requested at a too high speed, this
switch, on. the control panel, will illuminate if the option is used.
2.2 Neutral start (output wire 03)
Output 03 switches on when the transmission is in F or in R. This provides a protection to inhibit engine
start when the transmission is not in neutral (the output controls a normal closed relay).
2.3 Blocking 4th gear (output wire 09)
This option is designed to limit machine speed to 20 kph, especially for the German market.
All 4 gears are available if wire 9 is disconnected.
The gearbox is limited to 3 gears if wire 9 is connected to a 1 kOhm/1 Watt resistor.
6
F - The LED Display
1 Normal Display
Led N ON if the transmission is placed in neutral

Led T Used in self diagnostic modes
Led 1-4 Indicates the direction of travel selected / direction (colour)
Indicates the gear selected / direction (colour)
Led S/8 This LED flashes when the speed sensor detects that the machine is stationary
The LED’s 1 to 4 indicate the shiftlever direction (based upon colour selection) and it's position. The
same LED’s are also used to supply the driver with information about the transmission gear and direction
(based upon colour selection) and the gear actually engaged (authorised by the electronics).
This means that 2 LED’s can be switched on at the same time.
.
The colour assignment is as follows:
Direction Colour
Forward Green
Neutral Red
Reverse Yellow
7
G - Selftest Functions
The EGS50 has special circuitry to help verifying its operation.
Three selftest modes are built into the EGS50 control programs :
. INPUT TEST
SPEED SENSOR TEST + LAMPTEST
OUTPUT TEST
Operation of the 'N' and 'T' LED’s
In normal situations (driving, no problems) 'T' LED is always OFF

When error is detected 'T' LED is ON or BLINKING
In selftest mode 'T' LED is always ON
Detailed operation
Situation 'N' LED 'T' LED

Normal Operation On when transmission neutral OFF
INPUT TEST blinking SLOWLY ON
OUTPUT TEST blinking FAST ON
SPEED SENSOR TEST OFF ON
Selftest Operation
All tests are performed from the EGS. To enter one of the test modes, the lever must be placed in a spe-
cific position when the ignition is switched on.
Simply switch off the ignition to exit test mode.
Selftest mode invocation
SELFTEST MODE To enter mode

INPUT TEST FWD & UP
SPEED SENSOR TEST REV & UP
OUTPUT TEST FWD & DOWN
8
1.Input test
The aim of this test is to check whether the information sent by the lever, the external kickdown and the
transmission cut-off is correctly received by the EGS.
Warning: the machine cannot be moved whilst the EGS is in input test mode.
SHIFT LEVER POSITION LED COLOUR LED NUMBER

Neutral RED 4
UP RED 5
DOWN RED 3
FWD GREEN 4
FWD & UP GREEN 5
FWD & DOWN GREEN 3
REV YELLOW 4
REV & UP YELLOW 5
REV & DOWN YELLOW 3
Kickdown transmission RED 1
cut-off (button no. 4) GREEN 1
Note : LED 1 will be yellow if wires 14 and 15 are active at the same time.
2. Speed sensor test
Select the speed sensor test position (see 522)
In this mode, driving is possible.
In this test, the LED table (indication of gear engaged) becomes a speedo and will indicate the speed of
the converter impeller.
Lamptest :
Upon entering this test mode, all LEDs will illuminate in turn in order to check that they illuminate correctly.
Speed display :
For this test, start the engine, select forwards or reverse gear and accelerate to vary the speed of the
converter impeller, (or gearbox input shaft) and therefore to check the speed sensor.
Turbine rpm LED number (GREEN)

0 1 blinks
0 - 249 1 on
250 - 499 2 on
500 - 749 3 on
750 - 999 4 on
1000 - 1249 5 on
1250 - 1499 6 on
1500 - 1749 7 on
1750 - 1999 8 on
above 2000 8 blinks
9
3.Output test
Put the EGS in output test mode (see 522)
In this mode, driving is not possible, since all EGS50 outputs remain off until the testmode is left.
LED’s '1'-'8' light up sequentially during output test
The colour of the LED indicates its status
COLOUR STATUS
Green Output OK
Yellow Output not connected or shorted to battery plus
Red Short circuit
LED number Output wire Output function

1 6 Forward
2 7 Reverse
3 4 Solenoid 1
4 5 Solenoid 2
5 9 Bloking 4th gear
6 13 Splitter solenoid
7 8 Warning lamp
8 3 Neutral start
10
H. Speed sensor and installation
1 Magneto Resistive sensor
Position sign
Position sign
Teeth rotation
Pin 2 ( - ) Pin 1 ( + )
On the sensor body there's a small plastic triangular position sign. Make sure the position sign on the sensor
points as shown below in the direction of the movement of the gearteeth (Teeth Rotation as shown below).
1.65
(42.0)
Screw
Position sign (8 - 10 Nm) Plug Screw
"O"-ring Support "O"-ring (8 - 10 Nm)
Sensor installed Hole plugged
Sensor position on transmission

speed sensor
11
12
OPERATING AND SETTING OF THE SAFETY SYSTEM
80-8-80EN
06 / 09 / 2001
3
OPERATING AND SETTING OF THE SAFETY SYSTEM
OPERATOR UNIT VISUAL DISPLAY AUDIO SIGNAL
Switch the machine

on All the LEDS are on
Engine turning over
To position "0", machine :

- Stable (no movement) Start of setting
- With no attachments
- Jib raised to max., telescope
retracted
- On wheels (stabilizers raised)
- Wheels aligned
- On machines fitted withtilting
corrector.
- Frame an horizontal position.
Press for 2 s the adjust button

located at the back of the unit
(see diagram 2)
2 yellow LEDS and 2

Enter set mode green LEDS in the
middle flash alternately
2 green LEDS at the bottom

Press the "STOP remain on
BUZZER" button
5 beeps indicate that the setting

"O" setting saved has been saved
To position "MAX":
Jib on horizontal position.
Take the machine's rated load, 2 red LEDS at the top remain
position it at max. startup as on
indicate on load chart minus
100mm. 2 yellow LEDS and 2
green LEDS in the
middle flash alternately
Press the "TEST"

button
5 beeps indicate that the setting

"MAX" setting saved has been saved
setting The unit returns to the

conforms "locked" position Operator starts setting over
consistency NO again
All the LEDS are on, with
"MAX" and "0" no buzzer ignition on
A continuous 2s beep
YES indicates to the operator that
the settings have been taken
into account and that the unit
is passing automatically into
The unit automatically leaves the set
the normal operation position
position the LEDS stop coming on
End of setting
Check the setting against the load

chart : put the rated load at max.
startup
setting
conforms Operator starts setting over
to load NO again
chart
The LEDS come on up to
YES the first red LED
Stick on the other part of the

"SESALY" sticker to seal the setting
(see diagram 2)
The operator can put the truck in the

desired position
4
WARNING
1 - This setting must be made with the rear axle assembly at a stable temperature.
Do not carry out after braking tests as the temperature difference between the
axle assembly and the gauge would disturb the setting.
2 - Before setting the unit, it is important to operate the machine for placing the strain
gauge (for example, when testing the machine, in which case make sure to
comply with point N° 1).
3 - Last checking of setting must be done before forwarding the machine
DIAGRAM 1 DIAGRAM 2
Place the sticker after setting and

1 red LED conformity checks
2 red LEDS
2 yellow LEDS
4 green LEDS
Set button clearance hole

(tool Ø 2, min. length 40)
5
SAFETY SYSTEM
2 red LEDS
Test switch
Sound alarm signal light off
2 yellow LEDS Sound alarm

off switch
4 green LEDS
Power supply connector +

aggravating movements cut-off
signal output
Connection to the strain

gauge adjustment microswitch (accessible with a 6 mm
male hexagonal wrench)
6
INSPECTION PROCEDURE FOR THE SAFETY SYSTEM STRAIN GAUGE
Connector engineering :
+ power supply red wire / contact N° 1

- power supply and PT 100 brown wire / contact N° 2
+ measurement yellow wire / contact N° 3
- measurement green wire / contact N° 4
PT 100 blue wire / contact N° 5
Shielding white / contact N° 6
Prior to any electrical inspection, carry out a visual check on the state of the gauge and its
connections
Electrical Inspection
Disconnect the gauge from the electrical circuit.

Use a multimeter to take the following measurements :
- Measure the impedance between A+(m) and A-(bc) = Z power (power supply
impedance)
Values : 300Ω ≤ Z power ≤ 400Ω
- Measure the impedance between M+(v) and M-(j) = Z meas. (measuring system
impedance)
Values : 300Ω ≤ Z power ≤ 400Ω
- Measure the impedance between A- (bc) and PT 100(g) = Z PT100

Values : 101Ω + 0.39xT T corresponds to the gauge temperature.
Example : T=20°C then Z PT 100 = 101Ω + 7.8Ω = 109Ω
- Measure the impedance between A+ (m) and shielding : Zbl

Zbl > 30 MΩ (infinite resistance or open circuit)
- Measure the impedance between A+ and the machine frame : Z frame

Z frame > 30 MΩ (infinite resistance or open circuit)
Description of the connectors of strain gauge.
Shielding 6 + power supply 1
PT 100 5 - power supply 2
Measurement + 3
Measurement - 4
7
8
AIR-CONDITIONING
OPERATION AND ADJUSTMENT
85-8-10 EN
06 / 02 / 2003
INSTRUCTIONS - CONTENTS
1 -MANITOU S.A. AIR CONDITIONING UNIT OPERATING
PRINCIPLE
1.1- GENERAL INFORMATION ON THE MANITOU AIR-CONDITIONING FUNCTION
1.2- THE COMPRESSOR
1.3- THE CONDENSER
1.4- THE DEHYDRATING FILTER
1.5- THE EXPANSION VALVE
1.6- THE EVAPORATOR
1.7- SAFETY PRESSURE SENSITIVE SWITCHES
1.8- THE THERMOSTAT
1.9- THE HOSES
2 -INSTRUCTIONS FOR STARTING UP THE MANITOU

PRODUCTION UNIT
2.1- CHECK BEFORE LOADING
2.2- CHARACTERISTICS OF COOLANT R134a
2.3- SAFETY MEASURES FOR HANDLING COOLANT R134a
2.4- COOLING LOAD
2.5- CHECKING SETTINGS
3- MANITOU DEALER STARTING UP INSTRUCTIONS

3.1- CONTROL BEFORE USE
3.2- REGULATION CONTROL
3.3- FORMATION CLIENT
4- CUSTOMER USE MANUAL

4.1- PRESENTING THE MANITOU AIR CONDITIONER
4.2- FUNCTION OF THE MANITOU AIR CONDITIONER
4.3- DESCRIPTION OF THE CLIMATE CONTROL
4.4- HEATING FUNCTION
4.5- AIR CONDITIONING FUNCTION
4.6- DEMISTING FUNCTION
1 / 32
INSTRUCTIONS - CONTENTS
5- CUSTOMER MAINTENANCE MANUAL
5.1- MAINTENANCE
5.2- PRECAUTIONS
6- AFTER SALES SERVICE PRODUCT SHEETS

6.1- THE COMPRESSOR
6.2- THE CONDENSER
6.3- FILTER DRIER
6.5- THE EVAPORATOR
6.6- THE PRESSURE SWITCH
6.7- THE THERMOSTAT
6.8- THE HOSES LINE
7- FLOWCHART
2 / 32
1 -MANITOU S.A. AIR CONDITIONING UNIT OPERATING
PRINCIPLE
1.1- GENERAL INFORMATION ON THE MANITOU AIR-CONDITIONING FUNCTION
1 Compressor
2 Condenser
3 Dehydrating
filter
4 Expansion valve
5 Evaporator
6 Blower system
The MANITOU air-conditioning unit is based on the coolant's ability to absorb heat in considerable
quantities when it is subjected to physical changes on being transformed from a liquid state to a gas.
Operating cycle (see diagram) :

The gas coolant, at low temperature and pressure, is sucked in by the compressor which is driven by the
vehicle engine.
The compressor expulses the coolant, still as a gas, at high pressure and temperature, and it goes into the
condenser in this state.
Inside the condenser, the fluid undergoes a physical transformation from a gas to a liquid state, giving off
heat in the process. The warm air which passes through the condenser is evacuated by a dynamic effect
produced by the engine cooling fans. The liquid coolant leaving the condenser crosses the dehumidifying
filter which removes the humidity and solid impurities, then goes on to the expansion valve.
When the liquid is vaporized in the expansion valve, the pressure falls and lowers the temperature in the
evaporator. During its travel through the evaporator, the coolant is physically transformed from a liquid to
a gaseous state and then sent to the compressor. The air which flows over the cold surfaces of the
evaporator is cooled in turn, lowering the temperature in the cab.
This air, which is circulated by an electric blower system is dehumidified because the vapour in the air, is
condensed following contact with the cold walls of the evaporator. This condensation water is collected in
a drainage trap and evacuated outside the machine.
3 / 32
Electric skeleton diagram
TC Control panel CONNECTORS

BP Bouton poussoir C1 5-way, black AMP MIC IV-TV - Ref. 144 518-2
L Tongue C2 6.35 x 0.8 mm female connector
S Blower C3 90" 6.35 x 0.8 mm female connector
T Thermostat C4 Deutsch Ref. HD10-6-12P
P1 Low pressure gauge C5 1-way RKG female connector Ref. 920 510
P2 High pressure gauge C6 Deutsch Ref. HD16-6-12S-B010
R Relay C7 2-way female DT - Ref. 552 459
EC Compressor clutch C8 2-way male DT - Ref. 552 457
F1 7.5 A fuse C9 2-way male DT - Ref. 552 457
F2 30 A fuse C10 2-way female DT - Ref. 552 459
4 / 32
1.2- THE COMPRESSOR
The compressor's job is to pump the coolant leaving the evaporator, in gas phase, at low temperature and
pressure, and compress it into the condensor at high pressure and temperature.
The compressor mechanisms are lubricated with a special oil which is included in the compressor during
manufacture. Part of this lubricant is circulated through the installation by the coolant.
The compressor is driven by the engine via a belt and activated by engaging an electromagnetic clutch.
10 cm3 extra oil PAG SP20 is added to the original quantity to compensate for the length of
the hoses.
A fluorotracer additive, miscible in the oil lubricant, is used to detect leaks in the system
during after sales service operations and this is in the compressor casing.
5 / 32
1.3- THE CONDENSER
The condenser is a heat exchanger which condenses the coolant. This arrives in the form of a gas at high
pressure and temperature, and the condenser liquefies it through the fall in temperature caused by the air
passing throught it. The condenser is fitted with easily identified input and output connections. The fluid
arriving as a gas goes in through the large connection and leaves by the small one in liquid form. The
condenser must be supplied with air by the radiator cooling fan which pulses air through it to condense
the fluid.
6 / 32
1.4- THE DEHYDRATING FILTER
The dehydrating filter is the only part of the installation which must be changed periodically, at least
every 2 years.
The dehydrating filter has 6 very important functions. Remember that it is between the condenser and the
expansion valve and is therefore crossed by fluid in liquid form.
1st FUNCTION :
It provides a reserve of fluid in liquid form.
2nd FUNCTION :
Known as the damping function or "buffer" function. Indeed, any compressed and liquefied gas has on
its liquid surface a gaseous cap which ensures the fluid storage pressure. This naturally compressible gas
cap absorbs the shocks generated by the sudden engagement of the compressor, particularly at high
engine speeds, thus protecting the installation, above all the expansion valve.
3rd FUNCTION :
The microfiltering provided by synthetic components designed to stop any solid impurities which could
have got into the installation during assembly or later operations.
4th FUNCTION :
Dehydration. The filter is crossed by coolant in liquid form. The outer humidity or that produced by the
installation penetrates the compressor tubes and ring seal. This humidity can produce hydrochloric and
hydrofluoric acid on contact with the coolant. When the humidity is in contact with oil and metals, it can
promote corrosion which can damage the compressor, condenser and evaporator. Humidity can also
produce so much ice that the expansion valve is blocked, making the installation inefficient. To avoid
these problems, humidity absorbing material has been fitted inside the filter through which the refrigerant
flows, to absorb it to saturation point. These materials are silica gel, activated aluminium and the
molecule trap.
5th FUNCTION :
Decantation. The direction of flow of the fluid is always shown clearly on the filter body because the
inner plunger tube stops 20 mm from the bottom of the filter, creating a decantation zone allowing heavy
foreign bodies (e.g. welding debris) left over from manufacture to be deposited.
7 / 32
The expansion valve's function is to reduce the pressure of the coolant at the evaporator input to a preset
value, so that on leaving the evaporator, the fluid is in a fully gaseous state before being sucked into the
compressor.
While circulating through the evaporator, the fluid removes heat from the atmosphere which is being
conditioned, i.e. cooled, by passing it over the evaporator louvres.
The expansion valve therefore plays a very important role in the installation because it controls the fluid
flow rate to achieve maximum cooling power from the installation, and it is fitted at the entrance to the
evaporator.
The expansion valve has 3 functions. It acts as a :
1st FUNCTION :
Doser. A calibrated hole inside the body of the expansion valve, by throttling, creates a difference in
pressure between the fluid entering in liquid form and the mixed liquid + gas leaving. This throttling also
promotes vaporization of the fluid.
2nd FUNCTION :
Modulator. Inside the expansion valve a special, thermostatically controlled component, controls the
coolant flow rate between the maximum open and maximum closed positions. In this way, the correct
quantity is guaranteed and evaporation is complete.
8 / 32
3rd FUNCTION :
Controller. Its modulating function is controlled by a thermostatic expansion valve which must act
rapidly in situations where the value given by the probe changes.
In this expansion valve, there are 2 flows of coolant, one on entering and one on leaving the evaporator.
To set the correct flow rate at the fluid input on the thermostatically controlled expansion valve, a probe
measures the temperature of the fluid leaving the evaporator. At the end of the probe, a diaphragm is in
contact with a volume of highly temperature-sensitive gas.
This volume rises or falls according to the variation in temperature of the coolant leaving the evaporator
and exerts more or less pressure on the diaphragm which is in contact with a modulating component.
For example, when the probe registers an increase in temperature on leaving the evaporator (overheating)
the gas in the probe volume dilates. It exerts a pressure called VP (volume pressure) on the diaphragm,
itself being in contact with the modulator which is held in place by the spring exerting a pressure called
SP (spring pressure).
The balance point, i.e. the point of closure is VP=SP.
SP is set when the expansion valve is manufactured, so as to obtain the desired temperature and only VP
varies with the temperature of the fluid leaving the evaporator ; when VP is greater than SP the valve will
be open and when VP is less than SP the valve will be closed, for a temperature variation of 2 to 3
degrees, depending on the manufacturer.
9 / 32
1.6- THE EVAPORATOR
The evaporator is the last of the main components of the MANITOU air-conditioning system. It is a heat
exchanger like the condenser but it changes the state of the fluid in the opposite direction. In the
condenser the fluid is liquefied, in the evaporator, on the other hand it is 100% gasified. The coolant
leaving the expansion valve is a mixture of gas and liquid at low pressure and temperature ; in the
evaporator it absorbs heat from the air, to provide the cooling effect required. The evaporator therefore
cools the air in the cab. The fluid must evaporate completely because the compressor would be
automatically damaged by fluid in liquid form, even in small quantities.
The cooling capacity of the evaporator lead to dehumidification of the air, providing optimal conditions in
the cab. Indeed, unlike the condenser where the hottest fluid is inside, condensation in the evaporator
takes place on the outside. The humidity in the air blown through by the fans is deposited on the louvres
and emerges dry into the cab. The water which runs off the evaporator louvres is collected in a container
and evacuated under the machine cab. A release valve ensures that the unit is sealed against the
penetration of water from the outside.
10 / 32
1.7- SAFETY PRESSURE SENSITIVE SWITCHES :
Protection is needed to avoid damaging components in the event of abnormal operation.

The protection systems are controlled by electrical transducers sensitive to pressure values, called
pressure sensitive switches. These will continually monitor the installation operations so that it does not
exceed the authorized pressures, either minimal or maximum.
These pressure sensitive switches act on the power supply to the compressor's electrical clutch. When
given values are exceeded, the clutch power is cut and the air-conditioning system stops running.
LOW PRESSURE SENSITIVE SWITCH :

When there is a considerable lack of coolant in the system or there is a blockage in the circuit, the
normally closed pressure sensitive switch records minimum pressure and opens the compressor power
supply circuit.
HIGH PRESSURE SENSITIVE SWITCH :

Excessive fluid or pressure can cause damage because the pressure is always directly linked to the
temperature of the fluid. To avoid this situation, the high pressure sensitive switch which is normally
closed registers maximum pressure and opens the power circuit to the clutch beyond a pressure threshold
generally set to 24 bars.
11 / 32
1.8- THE THERMOSTAT
It is used to switch on and then obtain the desired temperature in the cab (exactly like a domestic
refrigerator), managing the installation operating time. Indeed, when the coolant is circulating, the
temperature in the evaporator is almost constant, so that the temperature in the cab changes according to
the quantity of fresh air blown into it on the one hand and the calories recorded in it on the other. The
thermostat acts on the compressor power circuit.
The thermostat is a control device which is sensitive to the temparature of the evaporator. The system is
the same as that of the expansion valve. A volume of gas enclosed in a small bladder communicating with
a capillary tube acting as a probe and inserted between the evaporator louvres, checks temperature
variations and compares them with required values.
The bladder, which records variations in gas pressure in the probe due to temperature variations in the
evaporator, acts directly on a rocker which opens or closes the compressor clutch power circuit according
to the mechanical resistance of the adjustment spring.
The more compressed the spring, the more "cold" must be produced to keep the bladder traction greater
than that of the spring.
In other words, the more compressed the spring, the longer the compressor clutch is engaged and the
more fresh air is pulsed into the cab.
With its capillary probe, the thermostat is not only a device for switching on and adjusting the system but
also a safety device. It prevents the condensation water deposited on the evaporator louvres from freezing,
which would slow the flow rate of air through the evaporator. The position of the probe in the evaporator
must be carefully checked, particularly the length of probe inserted into the louvres, to ensure a correct
operating range.
The range of settings of the thermostat for the evaporator louvre temperatures is between +2 and +16 °C.
12 / 32
1.9- THE HOSES
The hoses connect the air-conditioning system components between compressor and condenser,
dehydrating filter and evaporator expansion valve and evaporator and compressor. The different materials
and textile reinforcements used in the hose composition protects them against external attack and
guarantees that loading is maintained in the system.
SITUATION HOSE INNER EXTERNAL CONNECTION

MODULE DIAMETER DIAMETER THREAD
Between Module 8 10 mm 20.5 mm _

compressor and 16 per inch
condenser
Between Module 6 8 mm 18 mm 5/8
dehydrating filter 18 per inch
and expansion
valve
Between Module 10 13 mm 23.5 mm 7/8
evaporator and 18 per inch
compressor
13 / 32
2 -INSTRUCTIONS FOR STARTING UP THE MANITOU
PRODUCTION UNIT
2.1- CHECK BEFORE LOADING

Tightening the coolant connections according to the torque table.
CONNECTION MODULE TORQUE Nm

COMPRESSOR DISCHARGE 8 _ ‘’ 15.4 Nm
COMPRESSOR SUCTION 10 7/8 ‘’ 24.4 Nm
CONDENSER INPUT 8 _ ‘’ 15.4 Nm
DEHYDRATOR OUTPUT 6 5/8 ‘’ 15.4 Nm
EVAPORATOR INPUT 6 5/8 ‘’ 15.4 Nm
EVAPORATOR OUTPUT 10 7/8 ‘’ 24.4 Nm
2.2- CHARACTERISTICS OF COOLANT R134a
WARNING : The MANITOU air-conditioning system uses

coolant R134a only (Ref. MANITOU 4500421 – 14.5 Kg bottle)
and PAG SP20 oil code : 430A08 only.
Characteristics of coolant R134a

* Trade name : Fluorocarbon 134a
* Use : Coolant
* Chemical characteristics : Tetrafluoroethane 134a
* Chemical formula : CH2FCF3
* Physical state : Liquefied gas
* Colour : Colourless
* Odour : Slightly of ether
* Boiling point (s/1bar) : -26.5 °C
* Melting point : -101°C
* Density at 25°C : 1.21kg/l
* Critical pressure : 40.56 bar
* Critical temperature : +100.6 °C
* Weight as gas : 5 times heavier than air
* 1 kg in liquid state at 1 bar : 200 l in gaseous state
* Thermal decomposition : from 110°C
* Hazardous decomposition products : hydrogen halides and traces of carbonyl halides
* Dangerous reactions : With alkaline metals and alkaline-earths of
powdered metal salts : Al-Zn-Be...
* Flash point : No flash point
* Self-ignition temperature : Over 750°C
* Limit of explosivity : Below none, above none
* Ozone destruction potential : Zero (none).
14 / 32
2.3- SAFETY MEASURES FOR HANDLING COOLANT R134a
Personal protective measures :

For the eyes : complete protective goggles
For the hands : rubber gloves.
Storage :
To be stored hermetically sealed in a dry, cool, well-ventilated place.
Handling :
Only in well-ventilated areas.
Waste disposal :
Can be reused after reconditioning by a collection and recycling centre.
Action to take in the event of accident :

After accidental spillage, overflow, escape of gas, the liquid evaporates.
In the event of fire there is no contraindication with respect to the means of extinction.
Be careful however, the fire may cause hydrogen halide to be given off ; autonomous respiratory
apparatus should be worn.
First aid :
On inhalation, place the victim in the fresh air. Give oxygen or artificial respiration as necessary (do not
give medication) and consult a doctor.
On contact with the eyes, rinse well in running water for at least 15 minutes and consult a doctor .
On contact with the skin, wash immediately in running water and remove contaminated clothing.
2.4- COOLING LOAD
THE QUANTITY OF COOLANT TO LOAD FOR MANITOU AIR-CONDITIONING

EQUIPMENT IS :
FORKLIFT TRUCK QUANTITY OF COOLANT

MLA 628 S2 ------------------------------------------------------ 1000 G ±50G
MT 845/940/1233/1240/1330/1337/1637 LINE 2---------- 950 G ±25G
MT 845/940/1332/1637 H LINE 1--------------------------- 950 G ±25G
MLT 629/633/730 LINE A / MT732/932 LINE A------ 800 G ±25G
MT/MLT 523 LINE A----------------------------------------- 800 G ±25G
MT/MLT 526 LINE A----------------------------------------- 800 G ±25G
MLT 733/740 / MT 1033 HLT--------------------------------- 800 G ±25G
M 26-2 /M 30-2 / M40-4 / M50-4 / ---------------------------- 850 G ±50G
MC 30 / 40 / 50 / 60 / 70
MA 470 ------------------------------------------------------------ 900 G
MSI 20 / 25 / 30 D ----------------------------------------------- 880 G
15 / 32
2.5- CHECKING SETTINGS
During this check the machine engine is running.
HEATING CHECK
The controls must be set as follows :

D : Control with light indicator off
E : Set to maximum temperature
F : Set to the left limit of travel
G : Set to 3
After inserting the thermometer in one of the two air diffusers, note the temperature.
OUTSIDE TEMPERATURE AT TIME TO REACH

TEMPERATURE DIFFUSER OUTPUT TEMPERATURE
-10°C +40°C 30 min.
-5°C +40°C 25 min.
0°C +40°C 20 min.
+10°C +40°C 10 min.
+15°C +40°C 15 min.
+20°C +40°C 5 min.
+25°C +45°C 15 min.
+30°C +50°C 10 min.
AIR-CONDITIONING CHECK
The controls must be set as follows :

D : Control with light indicator on
E : Set to the left limit of travel
F : Set to maximum temperature
G : Set to 3
16 / 32
After inserting the thermometer in one of the two air diffusers, note the temperature.
OUTSIDE TEMPERATURE AT TIME TO REACH

TEMPERATURE DIFFUSER OUTPUT TEMPERATURE
+20°C +7°C 5 min.
+25°C +10°C 10 min.
+30°C +12°C 15 min.
Compressor regulation must be switched off before reading a temperature lower than +1°C .
17 / 32
3- MANITOU DEALER STARTING UP INSTRUCTIONS
3.1- CONTROL BEFORE USE (GB)
Check that the air inlet are not obturated either by frost, snow or leaves.
Check that at least the cabin air louvers are opened to avoid the evaporator to freeze.
Check the tension of the compressor driving belt :

too high tension : early wearing of the compressor bearings
too low tension : early wearing of the belt
THE MANITOU AIR CONDITIONING SYSTEM WORKS ONLY IF THE VEHICLE IS

RUNNING.
WHILE USING YOUR AIR CONDITIONING SYSTEM, IMPERATIVELY WORK WITH
CLOSED DOORS AND WINDOWS.
3.2- REGULATION CONTROL (GB)
During this control, the machine engine is running.
HEATER CONTROL
Controls must be set as follows :
D : control switch with led turned off

E : on max. temperature
F : on left position
G : on position n°3
After having positioned the thermometer in one of the two air inlet distributors, start collecting
temperatures.
EXTERNAL OUTLET TEMPERATURE TEMPS DE MONTEE EN

TEMPERATURES TEMPERATURE
-10°C +40°C 30 MN
-5°C +40°C 25 MN
0°C +40°C 20 MN
+10°C +40°C 10 MN
+15°C +40°C 15 MN
+20°C +40°C 5 MN
+25°C +45°C 15 MN
+30°C +50°C 10 MN
AIR CONDITIONING CONTROL
18 / 32
Controls must be set as follows :
D : Control switch with led turned on

E : On left position
F : On max. temperature
G : On position n°3
After having positioned the thermometer in one of the two air inlet distributors, start collecting
temperatures.
EXTERNAL OUTLET DISTRIBUTOR TEMPS DE MONTEE EN

TEMPERATURE TEMPERATURE TEMPERATURE
+20°C +7°C 5 MN
+25°C +10°C 10 MN
+30°C +12°C 15 MN
The compressor regulation must happened before reading a inferior temperature of + 1°C.
19 / 32
4- CUSTOMER USE MANUAL
4.1- PRESENTING THE MANITOU AIR CONDITIONER (GB)
4.1.1- The Manitou air conditioning system allows the driver to control the temperature in
the cabin without causing extreme temperatures.
It ultimately improves the working conditions in the cabin, reducing tiredness and any
discomfort and increasing the level of concentration even during the hottest hours. It
improves comfort and security behind the wheel.
4.1.2- It dehumidifies the air in the cabin, keeping the windows dry, allowing good
visibility and ultimately reducing any accidents.
4.1.3- The air is filtered by various ways, firstly through the foam. The air is also passed
through the evaporator coil past the moist surfaces on the blades, which destroys any build
up of dust, pollen, etc. Naturally, it's a plus if the driver is allergic.
4.1.4- The difference in pressure levels inside and outside the cabin helps preventing dust
setting inside. This pressure can be increased by increasing the ventilation speed.
4.1.5- The unit can be operated with the doors and windows closed, clearly protecting the
driver from any risk of cold or rheumatism as well as easing noise levels inside the cabin.
4.2- FUNCTION OF THE MANITOU AIR CONDITIONER (GB)
The principle of how the conditioner works is based on physical laws what govern the evaporation and
condensation of a fluid.
Function cycle (see drawing) :

The compressor that is engaged through the drive belt and electromagnetic clutch, raises the refrigerant to
the pressure at which the corresponding temperature is above that outside : therefore the refrigerant in the
condenser condenses and the heat flows out from the radiator fan.
The refrigerant then passes through the receiver drier that maintains any solid impurities and traces of
humidity.
At this point, the expansion valve reduces the fluid pressure to below outside the cabin. In the following
phase of evaporation (from liquid to gas the heat is absorbed in the cabin, blown by the electric fan
through the evaporator.
The air withheld is blown back into the cabin, fresh and deshumidificated. Any humidity in the
evaporator blades is the released into the drain tubes.
20 / 32
4.3- DESCRIPTION OF THE CLIMATE CONTROL (GB)
IMPORTANT :
THE MANITOU AIR CONDITIONER ONLY OPERATES WITH THE VEHICLE ENGINE
RUNNING.
ALSO MAKE SURE ALL WINDOWS AND DOORS ARE CLOSED.
D : Control with warning light connects and disconnects the air conditioner and, if control G is in
position 1, 2 or 3
E : Control regulating the temperature of the heater
F : Control regulating the temperature of the air conditioning
G : Airflow adjuster and fan speed control. In position ‘0’ the air conditioning system is off
OBSERVATIONS :
1 It is possible that water loss could occur under the vehicle, from the drain pan. This can happen in
very hot and humid conditions.
2 Please insure that the air intake of the air conditioner MANITOU is free from ice, snow and
leaves.
3 One of the louvers in the cabin must be open when the system is in operation in order to prevent
the evaporator freezing over.
21 / 32
4.4- HEATING FUNCTION (GB)
The control described are adjusted as follows :
D : Control with warning light disconnects

E : On the desired temperature
F : All the way to the left
G :On the desired position 1,2 or 3
4.5- AIR CONDITIONING FUNCTION (GB)

D : Control with warning light connect
E : All the way to the left
F : On the desired temperature
4.6- DEMISTING FUNCTION (GB)

D : Control with warning light connect
E : On the desired temperature
F : On the desired temperature
22 / 32
5- CUSTOMER MAINTENANCE MANUAL
5.1- MAINTENANCE (GB)
Every 50 hours :
Check the condenser coil (clean it if necessary).
Check the air filter cleanness (clean it if necessary).
In winter :
To ensure maximum efficiency of the air conditioner, allow it to run once a week, even for a short while.
This will lubricate the O rings.
During cold weather :

Allow the vehicle itself to run a few minutes before starting the air conditioner so as to allow the liquid
refrigerant situated in the lower part of the compressor to evaporate under the engine heat. A liquid
refrigerant could damage the compressor.
Every 200 hours :

Check the belt tension
Higher tension : Wears the compressor bearings.
Lower tension : Wears the belt.
Replace the air filter cabin.
Every 2 years : (Manitou dealer’s process)

Clean the condenser and evaporator coils
Clean the drain pan and the check valve.
Refrigerant recovery for replacing the filter drier.
Refrigerant charge and check the thermostatic control and pressure switches
Don't forget to replace de gasket cover, after opening the evaporator unit.
23 / 32
5.2- PRECAUTIONS (GB)
5.2.1- Once the A/C system is slowing down, it is losing its efficiency. Contact an
approved MANITOU dealer if this is the case with your air conditioner.
CAUTION : Never repair your air conditioner by yourself. An approved MANITOU dealer will
have the technical know-how, all the necessary tools and the spare parts.
5.2.2- Do not open the A/C system, as it will cause loss of refrigerant.
The refrigerant in the A/C system can carry some risks. The R-134a refrigerant is
colourless, odourless and denser than the air.
5.2.3- Never loosen the compressor-draining plug, as it will cause loss of the refrigerant.
Always check the oil level in the compressor when the A/C system is empty
24 / 32
6- AFTER SALES SERVICE PRODUCT SHEETS
6.1- THE COMPRESSOR (GB)
ATTENTION : PRIOR USING YOUR COMPRESSOR, PLEASE READ WHAT FOLLOWS

CAREFULLY : THE REPLACEMENT OF A COMPRESSOR IMPLIES SOME PRECAUTIONS
:
SHOULD YOU NOT COMPLY WITH THE HERE BELOW INSTRUCTIONS, BE AWARE
THAT YOU TAKE THE RISK TO BOTH INJURE YOURSELF BADLY AND SPOIL THE
COMPRESSOR. THE NON RESPECT OF THE PRESENT USE INSTRUCTIONS WILL LEAD
THE WARRANTY TO BE VOID.
6.1.1- RECEIVER DRIER

The receiver drier has to be replaced each time the compressor is replaced. It must not be let at the open
air in order to protect it from the humidity contamination.
6.1.2- UNSETTING OF THE COMPRESSOR

Remove the refrigerant from the air conditioning system thanks to recuperation, filling, recycling and
flushing station.
The collected oil quantity must be stored (see compressor oil level).
Disconnect the battery ground cabinle and the clutch coil.
Disconnect the compressor pipes
Loosen the holding bolts. Hold the compressor while running this operation. Take the compressor out
being aware not to spill its oil. This compressor oil will later help to determine the required quantity for
the new compressor (see compressor oil level).
6.1.3- CLEANESS OF THE SYSTEM

The compressor breakdowns are mostly due to the refrigerant contamination. This contamination is
provoked by various material introductions such as metallic particles, hydrocarbons sediments, humidity,
acids or decayed dehydrates.
Check the pipes and the expansion valve to see if there are no bits left. Should there be some tracks of
contamination on the parts, in the oil or if the previous compressor is replaced because of an internal
breakdown, take the required measures to protect the new compressor from contamination by cleaning the
air conditioning system and being aware of not introducing new contaminants in the system.
ATTENTION : ALL COMPRESSOR OR SYSTEM THAT WILL HAVE BEEN FLUSHED AND
CLEANED WITH ANOTHER REFRIGERANT THAN THE SYSTEM ONE, WILL NOT BE
CONCERNED BY THE CONTRACTUAL WARRANTY.
25 / 32
6.1.4- NEW COMPRESSOR OIL LEVEL
Your compressor is consigned with a load of 200cc. Before setting the new compressor, flush in a
graduated container, the old compressor oil, then flush the new compressor oil in another clean container.
Pour in the new compressor the same collected oil quantity as the one collected in the old compressor.
You must add new oil for each replaced or cleaned component, as explained here below :
NEVER REUSE OLD OIL BUT ONLY NEW OIL OF TYPE SP 20
Evaporator : 30cc Expansion valve : 30cc

Condenser : 30cc Drier : 30cc
After complete flushing of the system, the compressor oil load is of 160cc.
6.1.5- COMPRESSOR SETTING

Set the compressor on its support
Set the hoses by installing new O'ring gaskets. Lubricate the O'ring gaskets with the system oil before
mounting them.
Set clutch belt. Set the belt at the required tension.
Electrically link the clutch
Flush the system during at least 30 minutes
Connect again the battery ground wire
Fill the system in according to the instructions given
Proceed to a leak checking
6.1.6- CHECK IN LIST

To set the compressor and properly maintain and fix the air conditioning system, one has to plan the
following operations :
Refrigerant recovery and recycling

Cleaning of the system
Replacement of the expansion valve
Replacement of the new filter drier
System vacuum during 30 minutes
Setting the new O'ring gaskets
Checking of the system waterproofness
Refrigerant charging
Compressor regulation control.
6.1.7- WARRANTY REGISTRATION

The return of the warranty certificate is COMPULSORY. Its non-return leads to the loss of the warranty.
26 / 32
6.2- THE CONDENSER (GB)
ATTENTION : PRIOR USING YOUR CONDENSER, PLEASE READ WHAT FOLLOWS

CAREFULLY : THE REPLACEMENT OF A CONDENSER IMPLIES SOME PRECAUTIONS :
CONDENSER. THE NON RESPECT OF THE PRESENT USE INSTRUCTIONS WILL LEAD
The receiver drier has to be replaced each time the compressor is changed. It must not be let at the open
6.2.2- PRECAUTIONS
Avoid any risks of contaminants introduction or foreign bodies in the condenser or inside the air
conditioning system.
Prior to any operations implying the circuit opening, the area located around the hoses must be cleaned
carefully with the cleaning spray. All the components that have to be reused or set reinstalled must be
cleaned with this cleaning spray and dried with a fluffyless cloth.
6.2.3- POSITIONING
Therefore the risk of mistake is low, make sure the inlet is higher than the outlet, bearing in mind that the
inlet fitting is always bigger than the outlet fitting. What's more, one needs to respect scrupulously the
mounting dimensions and the distance between the condenser and the radiator.
The installation has been sharply studied so that the condenser setting does not modify the terminal
breaking point of the engine work.
Any "funny" setting would lead to bad condenser turn over and in some cases, to the early destruction of
the machine engine.
After the setting has been carried out, proceed to a system leak checking.
6.2.4- LUBRIFICATION
For parts which have to be lubricated before their installation, such as O'ring's gaskets, use the oil
recommended for the system refrigerant.
Further to the condenser replacement, you must add 30cc of new oil.
NEVER REUSE OLD OIL BUT ONLY NEW OIL OF TYPE SP 20
After complete flushing of the system, the compressor oil load is of 160cc.
27 / 32
6.3- FILTER DRIER (GB)
ATTENTION : PRIOR USING YOUR FILTER DRIER, PLEASE READ WHAT FOLLOWS
:

The receiver drier has to be replaced each time the compressor is replaced. It must not be let at the open
6.3.2- PRECAUTIONS
The tank drier filter is an important component for the protection of the circuit against corrosion. It must
not be left at the open air for its absorbs humidity quickly. Therefore, it has a very low capacity and it can
lead to the dehydrating agent saturation prior to its use.
That is why it is compulsory to show a new drier during operations implying the air conditioning circuit
opening, such as the replacement of a component.
If the dehydrating agent is saturated, the refrigerant is going to be full of humidity. Apart from the fact the
circuit frigorific capacity will be reduced, this will have two bad consequences for the system :
some acids are going to be chemically created and will slow the liquid circulation by decomposing the
materials,
the humidity contained in the refrigerant can frost around the expansion valve and have the system
know a breakdown, leading to a loss of aspiration pressure or a high evaporation, that can lead to the
compressor breaking because of a lack of lubrication.
The drier must always be upright. It cannot be repaired but has to be replaced.
6.3.3- REPLACEMENT OF A DRIER

Remove the new receiver drier buttons only when you are ready to install it on the machine. Avoid all
risks of contaminants or foreign bodies introduction in the drier or inside the air conditioning
system.Before opening the circuit, the area located around the hoses fittings must be cleaned carefully
with the cleaning spray.
All the components that have to be reused or reinstalled must be cleaned with this cleaning spray and
dried with a fluffyless cloth.
6.3.4- LUBRICATION
For parts which have to be lubricated before their installation, such as O'rings gaskets, use the oil
Further to the receiver drier replacement, you must add 30cc of new oil.
28 / 32
6.4- THE EXPANSION VALVE (GB)
ATTENTION : PRIOR USING YOUR EXPANSION VALVE, PLEASE READ WHAT

FOLLOWS CAREFULLY : THE REPLACEMENT OF AN EXPANSION VALVE IMPLIES
SOME PRECAUTIONS :
EXPANSION VALVE. THE NON RESPECT OF THE PRESENT USE INSTRUCTIONS WILL
LEAD THE WARRANTY TO BE VOID.

The drier filter has to be replaced each time the expansion valve is replaced. It must not be let at the open
6.4.2- EXPANSION VALVE INSTALLATION

Avoid any risks of contaminants or foreign bodies introduction inside the air conditioning system.
The expansion valve internal pressure monobloc technology, is specifically calibrated to be used on
MANITOU machines. It can in no other case be replaced by a standard component.
The expansion valve must be installed with the thermostatic head upright. It is thermically isolated to
work with the best turn over possible. Its interchangeability is quite easy and requires no particular tools.
6.4.3- LUBRICATION
For parts such as O'rings gaskets, which have to be lubricated before their installation, use the oil
Further to the expansion valve replacement, you must add 30cc of new oil.
29 / 32
6.5- THE EVAPORATOR (GB)
ATTENTION : PRIOR USING YOUR EVAPORATOR, PLEASE READ WHAT FOLLOWS

:

The drier filter has to be replaced each time the compressor is replaced. It must not be let at the open air
in order to protect it from the humidity contamination.
6.5.2- PRECAUTIONS
Avoid any risks of contaminants introduction or foreign bodies in the evaporator or inside the air
6.5.3- POSITIONING
The evaporator inlet corresponds to the 4 capillary tubes pipes and the outlet to a unique large diameter
pipe. The expansion valve fittings being the same and therefore the risk of mistake is low, make sure the
inlet is not linked to the outlet of the expansion valve, know the large diameter hose corresponds to the
smallest expansion valve pipe and that the biggest corresponds to the outlet fitting.
What's more, one has to scrupulously respect the mounting dimensions and the distance between the
condenser and the radiator.
The installation has been sharply studied so that the condenser setting does not modify the thermical
breaking point of the engine work.
Any "funny" setting would lead to bad condenser turn over and in some cases, to the early destruction of
the machine engine.
6.5.4- LUBRICATION
For parts which have to be lubricated before their installation, such as O'rings gaskets, use the oil
Further to the evaporator replacement, you must add 30cc of new oil.
30 / 32
6.6- THE PRESSURE SWITCH (GB)
ATTENTION : PRIOR USING YOUR PRESSURE SWITCH, PLEASE READ WHAT

FOLLOWS CAREFULLY : THE REPLACEMENT OF A COMPRESSOR IMPLIES SOME
PRECAUTIONS :
6.6.1- IDENTIFICATION
Pressure switches are security components that when detecting a variation of low or high pressure, allow
to avoid the compressor to seize up or the installation to break.
They cut the electrical installation of the compressor clutch. They reactivate the clutch for values slightly
moved in order to be sure that what caused its start, disappears.
6.6.2- REPLACEMENT
The minimum pressure or low-pressure switch is located on the low-pressure circuit in the evaporator
unit. The maximum pressure or high-pressure switch is placed on the high-pressure gas line of the
receiver drier, after the condenser.
To remove it is easy for they are screwed on a fitting made of a valve allowing their removal without
flushing the system.
Before installation, make sure the pressure switch corresponds to the low or high-pressure circuit. The
low-pressure switch is marked with a white point and the high-pressure switch is market with a red point.
The screw fitting must be cleaned with the cleaning spray. Dry with a fluffyless cloth.
31 / 32
6.7- THE THERMOSTAT (GB)
ATTENTION : PRIOR USING YOUR THERMOSTAT, PLEASE READ WHAT FOLLOWS

:
6.7.1- IDENTIFICATION
The thermostat is a component that enables to run the compressor and set temperatures but also assures
the air conditioning system security. It is made to avoid water condensation to frost and to limit the
airflow through the evaporator fins. The thermostat tuning range concerns evaporator outlet temperatures
included between +2°C and +16°C.
6.7.2- REPLACEMENT
The thermostat is located in the evaporator unit. Its removal is easy and does require the refrigerant
flushing.
Scrupulously respect the position of the thermostatic probe in the evaporator and introduce only 50mm,
that shall guaranty a proper use.
Beware not to break the thermostatic probe while moving the thermostat.
Proceed to the cabinle setting so as to guarantee the control handle run.
6.8- THE HOSES LINE (GB)
ATTENTION : PRIOR USING YOUR HOSES LINE, PLEASE READ WHAT FOLLOWS
CAREFULLY : THE REPLACEMENT OF A HOSES LINE IMPLIES SOME PRECAUTIONS :

The receiver drier has to be replaced each time one of the hoses line is changed. It must not be let at the
open air in order to protect it from the humidity contamination.
6.8.2- REPLACEMENT
The charge connectors of the hoses lines are not similar on purpose, to avoid any installation mistake.
Avoid any risks of contaminants introduction or foreign bodies in the hoses line or inside the air
Prior to any operations implying the circuit opening, the area located around the hoses fittings must be
cleaned carefully with the cleaning spray. All the components that have to be reused or set reinstalled
must be cleaned with this cleaning spray and dried with a fluffyless cloth.
32 / 32
1 VACUUM
Vacuumizing the circuit

Min. time : 20 minutes
Check vacuum seal
Min. pressure : - 800 mbar

Time : 15 minutes
Constant pressure Slight loss of pressure Steep pressure drop

Result : -500 mbar Result: 0 mbar
2 LOAD 2 LOAD 4. CHECK USING NITROGEN
3 CHECK USING ELECTRONIC DETECTOR

2 LOAD
Verification of the quantity to use
HP loading
Liquid phase
Possible LP complement
Gas phase
HP reading: (Condensation temp.) LP reading: (Evaporation temp.)

Max.: Ext. temp. + 16°c Mini : 0.2 bar
3 CHECK USING ELECTRONIC DETECTOR 3 CHECK USING ELECTRONIC DETECTOR

3 CHECK USING ELECTRONIC DETECTOR
2.CHARGE
Switch on A/C max. Aerosol leak confirmation
CHECK CONNECTIONS Leak detected Leak not detected
REPAIR 6. CHECK USING TRACER
1. VACUUM
2. LOAD
4 CHECK USING NITROGEN
Pressurization using nitrogen

Maxi : 10.5 bar
CHECK CONNECTIONS
Aerosol leak confirmation
Leak detected Leak not detected
REPAIR 3.CHECK USING ELECTRONIC DETECTOR
1. VACUUM
2.LOAD

SM Mla 628 - 547860en

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REF : 547860 EN (23 / 04 / 2003)

MLA 628 Turbo POWERSHIFT

23 / 04 / 2003 - 1st ISSUE

10-3-13 EN Engine disassembly

20 Gear box / converter

20-3-15 EN Gear box / converter disassembly “ POWER SHIFT “

30-3-11 EN Axle disassembly 112

40-8-3-M55 EN Operation and adjustment of the assisted braking system

70-3-80-M91 EN Cylinder disassembly

70-6-M91 EN Hydraulic diagram

80-6-M91 EN Electric diagram

80-8-15-M91 EN Operation of the “ EGS “ shift lever (kick down)

80-8-80 EN Safety system adjustment

85-8-10 EN air-conditioning operation and adjustment

MLA 628 Turbo POWERSHIFT Série 2 2 à 15

1004.40T AK 81289 1004.40TW AM 80921

FRONT AND REAR TYRES

- Type of pump Gear pump with flow divider

- Type of pump Variable displacement piston pump

- Travel speed of the lift truck

- Standard lift height 5110 mm

- Rated capacity with standard attachment 2500 kg

- Load center 500 mm

- Weight of forks (Each) 72,5 kg

- Lifting motions (Jib retracted)

- Telescoping motions (Lifting jib)

- Reverse tilt time unladen 3,3 s °/s

- Forward tilt time unladen 3,4 s °/s

- Lift truck weight with standard attachment

- Axle weight with attached equipment (Transport position)

- Tensible strain at coupling hook

- Break out force with bucket 5250 daN

- Travel speed of the lift truck

- Standard lift height 5110 mm

- Rated capacity with standard attachment 2500 kg

- Load center 500 mm

- Weight of forks (Each) 72,5 kg

- Lifting motions (Jib retracted)

- Telescoping motions (Lifting jib)

- Reverse tilt time unladen 3,3 s °/s

- Forward tilt time unladen 2,4 s °/s

- Lift truck weight with standard attachment

- Axle weight with attached equipment (Transport position)

- Break out force with bucket 5250 daN

SUIVANT NORME EN 1459 annexe B.

MLA 628 Turbo POWERSHIFT Série 2

DESIGNATION PART NUMBER CLEAN CHANGE

1 - Engine oil filter

2 - Dry air filter cartridge 563 416 50 H * 400 H *

3 - Safety dry air filter cartridge 563 415 800 H *

4 - Transmission oil filte 550 145 400 H

5 - Fuel filter cartridge 49 660 400 H

6 - Hydraulic return oil filter cartridge 485 696 400 H

7 - Suction strainer for hydraulic oil tank 77 402 800 H

8 - Filter cap for hydraulic oil tank 62 415 800 H

9 - Alternator / Fan belt 564 636

10 - Cab ventilation filter (Without air conditioning)(Qty: 2) 602 975 400 H

10 - Cab ventilation filter (With air conditioning)(Qty: 2) 602 975 50 H 200 H

11 - Cyclonic pre-filter 224 713 10 H

12 - Automatic vacuum-cleaning pre-filter (OPTION) 235 797

13 - Compressor belt (OPTION AIR CONDITIONING) 196 712

(*) FUEL SPECIFICATION