Telehandlers: Service Manual

T13
T14
T17
TELEHANDLERS
Service Manual
Print N. 604.02.395.00 (XII -- 2002)
THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.

Read and heed carefully the safety instructions listed and follow the precautions recommended to avoid
potential risks and to safeguard your health and your safety.
You will find this symbol in the text of this Manual referred to the following key words:
WARNING -- Cautions directed to avoid improper repair interventions involving potential consequences for
the operator’s safety.
DANGER -- These warnings qualify specifically potential dangers for the safety of the operator or other
persons directly or indirectly involved.
IMPORTANT NOTICE
All maintenance and repair interventions explained in this Manual must be performed exclusively by the Service
Organization of the Manufacturer, observing strictly the instructions explained using, whenever necessary, the
recommended specific tools.
Whoever performs the operations reported without following exactly the precautions is responsible on his own, for
the damages that may result.
Neither the Factory nor any Organizations in its Distribution Network, including but not limited to national, regional
or local distributors, are responsible for any liability arising from any damage resulting from defects caused by parts
and/or components not approved by the Factory for use in maintaining and/or repairing products manufactured or
merchandized by the Factory.
In any case, no warranty of any kind is made or shall be imposed with respect to products manufactured or
merchandized by the Factory, when failures are caused by the use of parts and/or components not approved by the
Factory.
AVOID ACCIDENTS
Most accidents and injuries occurring in industry, on the farm, at home or on the road, are caused by the failure of
some individual to follow simple and fundamental safety rules or precautions. For this reason, MOST
ACCIDENTS CAN BE PREVENTED by recognizing the real cause and taking the necessary precautions, before
the accident occurs.
Regardless of the care used in design and construction of any type of equipment, there may be conditions that
cannot be completely safeguarded against without interfering with reasonable accessibility and efficient
operation.
A careful operator is the best insurance against accidents. The complete observance of one simple rule would
prevent many thousands serious injuries each year.
This rule is: Never attempt to clean, lubricate or adjust a machine while it is in motion.
WARNING
On machines having hydraulically, mechanically and/or cable controlled equipment (such as showels,
loaders, dozers, scrapers etc.) be certain the equipment is lowered to the ground before servicing,
adjusting and/or repairing.
If it is necessary to have the equipment partially or fully raised to gain access to certain items, be sure
the equipment is suitably supported by means other than the hydraulic lift cylinders, cable and/or
mechanical device used for controlling the equipment.
MODEL CODES
The complete range of telescopic handlers (Telehandler) described in this manual is identified in the text by
reference to the maximum extension of the telescopic arm.
The vehicles listed below may not be available in all countries or markets, therefore for the latest information
consult your authorised dealer.
Model T13 T14 T17

Not stab. stab. Not stab. stab. Not stab. stab.
88 kW (120 CV) 88 kW (120 CV) 88 kW (120 CV)
Engine Turbo Aftercooler Turbo Aftercooler Turbo Aftercooler
Max. lift height 12,30 12,45 13,30 13,45 16,24 16,60
Max. capacity (at 500
mm from fork ledge) 4000 4000 4000 4000 4000 4000
Capacity at maximum
height 3000 4000 2500 3500 2000 3000
Extension at max.
height 1,40 1,23 1,70 0,85 2,70 1,80
Max. longitudinal
extension 8,65 9,33 12,54
Capacity at max.
extension 600 1500 450 1350 0 600
Weight (kg) 10700 11340 12090

Service manual
T13 -- T14 -- T17
TELESCOPIC HANDLERS
GENERAL LIST OF CONTENTS
SECTION 00 -- GENERAL
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Maintenance techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 10 -- ENGINE
Description Page
Engine identification code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Engine main characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General characteristics of engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Description of the main mechanical components of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Mechanical injection supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Injection assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Timing gear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Injection pump setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Assembly clearance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
604.02.395.00 - 12 - 2002
4 GENERAL LIST OF CONTENTS
SECTION 21 -- POWERSHIFT GEARBOX

Description Page
Gearbox assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Idler gear case assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Gearbox operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission and Hydraulic oil circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Modulation valve operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Torque converter and heat exchanger hydraulic oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Troubleshooting procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Pressure testing clutch and high pressure circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Pressure testing torque converter and cooler circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Check points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Assembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SECTION 25 -- FRONT AXLE

Description Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Wheel toe--in check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Component overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front axle removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Front axle overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Axle drive pinion bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Bevel gear pinion installation and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Front drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
604.02.395.00 - 12 - 2002
GENERAL LIST OF CONTENTS 5
SECTION 27 -- REAR AXLE

Description Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Operation diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear axle removal procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 33 -- BRAKES
Description Page
Power brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Brake release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake disc adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Brake disc replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 35 -- HYDRAULIC SYSTEM

Description Page
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Steering system hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Telescopic boom hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Component operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Front loader controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power steering (OSPQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Telescopic boom distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Auxiliary controls distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Boom removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
604.02.395.00 - 12 - 2002
6 GENERAL LIST OF CONTENTS
SECTION 55 -- ELECTRICAL SYSTEM

Description Page
Electrical equipment specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Electrical system and fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Controls and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bulb replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
System precautions for battery charging and welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Starting the machine using jump leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Temporary wiring repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Electrical system general fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
List of connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
List of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cable key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
How to use the circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Circuit 1: Starting/Recharge/Warning lights/Indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Circuit 2: Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Circuit 3: Wheel alignment/Hydraulic solenoids/Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Circuit 4: Arm control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Circuit 5: Stabiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Circuit 6: Lights/Windscreen wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Circuit 7: Work lamps/Roof beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Circuit 8: Tilting prevention system/Roof wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Circuit 9: Sound system heating/Electric socket/Roof lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Circuit 10: Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
604.02.395.00 - 12 - 2002
SECTION 00 -- GENERAL 1
GENERAL INSTRUCTIONS
IMPORTANT NOTICE
All maintenance and repair interventions listed in this Manual must be performed exclusively by the Service
Network of the Manufacturer, complying strictly with the indications herein and using, when required, the
prescribed special tools.
Whoever performs service operations described herein without complying strictly with the instructions becomes
solely responsible for any consequential damage that could occur.
ADJUSTING SHIMS
For each adjustment select the adjusting shims, measuring them one by one with a micrometer and adding to
gether subsequently, the values measured. Do not rely on the measurement of the entire pack, that could be
wrong, or the nominal value indicated on each ring.
SEALS FOR ROTATING SHAFTS

For correct installation of the seals for rotating shafts, please comply with the following precautions:
-- prior to installation, keep the seals soaking for at least half an hour in the same oil they are going to seal;
-- clean thoroughly the shaft and make sure that its working face is undamaged;
-- direct the sealing lip toward the fluid; in the event the lip is of the hydro dynamic type, the grooves must be
directed so that, in relation to the rotating direction of the shaft, they tend to return the fluid toward the inside
of the sealing device;
-- smear the sealing lip with a film of lubricant (oil to be preferred to grease) and fill with grease the gap between
sealing lip and dust lip in twin lip seals;
-- insert the seal in its seat, pressing it with a punch with a flat face; never strike it with a hammer or mallet;
-- when pressing in the seal, make sure that it is inserted perpendicularly in relation to the seat and, once in
position, make sure that, when required, it contacts the shoulder;
-- to prevent the sealing lip of the seal being damaged by the shaft, insert appropriate protection during the
installation of the two parts.
“0--RING” TOROIDAL SEALS
Lubricate O--rings before inserting them in the relevant seats to prevent them becoming twisted and rolled during
installation, thus jeopardising their sealing capacity.
SELAING COMPOUNDS
Mating surface marked X must be smeared with a sealing compound recommended by the Manufacturer or an
adequate equivalent.
Prior to applying the compound, prepare the surfaces in the following manner:
-- remove all possible scaling with a metal brush;
-- degrease the surfaces thoroughly using the degreesing agent recommended by the Manufacturer or an
adequate equivalent.
BEARINGS
When installing bearings, it is recommended to:
-- warm them up to 80 – 90 ° C (176 – 194 °F) before installing them on the relevant shafts;
-- cool them down before inserting them in the relevant seats with an outer fitting.
SPLIT PINS
When installing split pins, make sure that the cut is pointing in the direction of the load on the pin.
604.02.395.00 - 12 - 2002
2 SECTION 00 -- GENERAL
NOTES ON SPARE PARTS

Use genuine spare parts guaranteed by the Manufacturer only.
Genuine spare parts are the only ones ensuring the same quality, the same life and the same safety as the
originally mounted parts, since they are the same as the ones installed in production.
Only genuine parts from the manufacturer ensure this guarantee.
Orders for spare parts must include the following indications:
-- model of the vehicle (commercial designation) and serial number;
-- type and number of the engine;
-- part number for the item ordered, as provided by the “Microfiches” or the “Spare Part Catalogue”, on which
the order is based.
NOTES ON TOOLING
The tooling that the Manufacturer recommends and illustrates in this Manual is:
-- studied and designed specifically for servicing vehicles of this range;
-- required to ensure a reliable repair;
-- accurately developed and inspected to provide effective and long lasting working.
You are also reminded that correct tooling allows you to:
-- to operate under optimised technical conditions;
-- to achieve the best results;
-- to save time and effort;
-- to work in safer conditions.
WARNING
The wear limits provided for some items must be considered as recommended values, but not absolutely binding.
The indications “front”, “rear, “right”, “left” refer to different parts as seen seating from in the operator’s seat
oriented in the normal travel direction of the vehicle.
HOW TO MOVE A VEHICLE WITHOUT BATTERIES

The cables of the external power supply must be connected exclusively to the respective terminals of the positive
and negative cables of the vehicle, using efficient clamps providing adequate and safe contact. In the event it
is necessary to check the operation of the electrical system of the vehicle, do it exclusively with the power supply
connected. At the end of the inspection, disconnect all actuators and deactivate the power supply before
disconnecting the cables.
604.02.395.00 - 12 - 2002
SAFETY RULES
PAY ATTENTION TO THIS SYMBOL

This alert symbol announces important messages involving your safety.
Read carefully the safety instructions listed and follow the precautions recommended
to avoid potential risks and to safeguard your health and your safety.
You will find this symbol in the text of this Manual with the following key words:
WARNING -- Cautions intended to avoid improper repair interventions involving
potential consequences for the safety of the personnel performing the repairs.
DANGER -- These warnings qualify specifically potential dangers for the safety of the
operator or other persons directly or indirectly involved.
AVOID ACCIDENTS ◊ Never attempt to operate the machine or its tools

from any position other than seated in the oper-
Most accidents, whether they occur in workshop, on ator’s seat.
the farm, at home or on the road, are caused by the ◊ Never perform any intervention on the machine
failure of some individuals to follow simple and fun- with engine running unless this is prescribed.
damental safety rules and precautions. For this rea-
◊ Cut--off the engine and make sure that all pres-
son MOST ACCIDENTS CAN BE PREVENTED by sures in the hydraulic systems are released
recognising the real cause and doing something before removing caps, covers, valves etc.
about it before the accident occurs.
◊ All service interventions must be performed with
Regardless of the care used in the design and con- the utmost care and attention.
struction of any type of equipment, there are many
conditions that cannot be completely safeguarded ◊ Shop and/or field service platforms or ladders
must be constructed and maintained in accord-
against without hindering reasonable accessibility ance with local and national regulations.
and efficient operation.
◊ Disconnect the batteries and tag all controls to
A careful operator is the best insurance against an signal that an intervention is in progress. Block
accident. the machine and all equipment that must be
The complete observance of one simple rule would lifted.
prevent many serious accidents. ◊ Do not check nor refill fuel tanks, as well as bat-
DANGER. Never attempt to clean, lubricate or main- teries, nor use starting fluid while smoking or
tain a machine while it is in motion. near open flames since these fluids are flam-
mable.
◊ Brakes are inactive when manually released for
SAFETY RULES service interventions. Under such circum-
stances it is necessary to maintain the control of
SAFETY RULES the machine using appropriate blocks or similar
devices.
◊ Read and heed all safety rules before any inter-
vention. ◊ The fuel--filling nozzle must be kept constantly
inside the filling neck. Keep this contact from the
◊ Do not wear rings, wristwatches, jewellery, and beginning to the end of the fuelling operation to
loose or hanging apparels, such as ties, torn avoid the possibility that sparks due to static
clothing, scarves, unbuttoned or unzipped electricity are generated.
jackets that can catch on moving parts. Wear
proper safety equipment as recommended for ◊ Use only designated towing or attaching points.
the job. Examples: hard hat, heavy gloves, ear Use care in making attachments. Make sure pins
protection, safety glasses or goggles, reflector and/or locks are secure before pulling. Stay clear
vests, respirator. Consult your employer for spe- of drawbars, cables or chains under load.
cific safety equipment requirements. ◊ To move a disabled machine, use a trailer or a
◊ Do not perform any service operation on the low--boy, if available.
machine with a person seated in the operator’s ◊ To load/unload a machine from transporter,
compartment, unless he is an authorised oper- choose a level surface ensuring firm support to
ator co--operating in the operation to be per- the wheels of truck or trailer. Anchor the machine
formed.
604.02.395.00 - 12 - 2002
securely to the bed of truck or trailer and block ground as soon as possible with a certain margin
wheels or tracks with appropriate wedges. of safety.
◊ Use only approved grounded auxiliary power ◊ Do not trust worn and /or kinked chains and
sources for heaters, chargers, pumps and simi- cables: do not use them for lifting or pulling oper-
lar equipment to reduce the hazards of electrical ations. To handle them, always use heavy
shocks. gloves.
◊ Lift and handle heavy parts with a lifting device ◊ Be sure chains and cables are anchored and the
of proper capacity. anchor points are strong enough to handle the
expected load. Keep exposed personnel clear of
◊ Beware of bystanders. anchor points and cables or chains. No
◊ Never pour gasoline or diesel fuel into open, bystanders are allowed near the hooking points,
wide and low containers. chains or cables.
◊ Never use gasoline, solvent or other flammable ◊ Keep the area where maintenance operations
fluid to clean parts. Use exclusively qualified, are performed CLEAN and DRY. Eliminate
non--flammable, non--toxic commercial sol- immediately all water and oil spillages.
vents. ◊ Do not pile up oily or greasy rags; they represent
◊ When using compressed air for cleaning parts, a fire hazard. Store in a closed metal container.
use safety glasses with side shields or goggles.
Before starting machine, check, adjust and lock
◊ Limit pressure to 2.1 bar, in accordance with the operator’s seat for maximum comfort and
local and national regulations. control of the machine. Be sure exposed
personnel in the area of operation are clear of the
◊ Do not run the engine in closed areas without
proper ventilation to remove deadly exhaust machine before moving it or its attachments.
fumes. Sound the horn.
◊ Do not smoke or permit any open flames or spark ◊ Do not carry loose objects in pockets that might
near when re--fuelling or handling flammable fall unnoticed into open compartments.
materials.
◊ Wear proper protective equipment such as
◊ Do not use an open flame as a light source to safety goggles or safety glasses with side
look for leaks or for inspection anywhere on the shields, hard hat, safety shoes, heavy gloves
machine. when metal or other particles are apt to fly or fall.
◊ Move with extreme care when working under the ◊ Wear welders protective equipment such as
machine, its attachments and or on or near dark safety glasses, helmets, protective cloth-
them. Always wear protective safety equipment ing, gloves and safety shoes, when welding or
as required, such as hard hat, goggles, safety burning. Wear dark safety glasses near welding
shoes, ear plugs. zones. DO NOT LOOK AT ARC WITHOUT
PROPER EYE PROTECTION.
◊ When performing operations requiring running of
the engine, have a qualified operator in the oper- ◊ Steel cables are frayed after prolonged use;
ator’s seat at all times with the mechanic on always wear appropriate protections (heavy
sight. Place the transmission in neutral and set gloves, goggles etc.).
the brakes and safety lock.
◊ Handle all parts carefully. Keep hands and
◊ For field service, move machine to level ground, fingers away from structures, gears or moving
if possible, and block it. If work on an incline is parts. Use and wear always the appropriate
absolutely necessary, first block machine and its protections, such as safety goggles, gloves and
attachments securely, than move it to level safety shoes.
604.02.395.00 - 12 - 2002
STARTING HYDRAULIC SYSTEM
◊ Do not run the engine in closed areas without ◊ Fluid escaping under pressure from a very small
proper ventilation to remove deadly exhaust hole can be almost invisible and can have suffi-
fumes. cient force to penetrate the skin. Use a piece of
cardboard or wood to search for suspected pres-
◊ Do not place head, body, limbs, feet, hands or sure leaks. do not use hands. If injured by escap-
fingers, near rotating fans or belts. Be especially ing fluid, see a doctor at once. Serious infection
alert near pusher fans. or reaction can develop if proper medical treat-
ment is not administered immediately.
ENGINE
◊ In case pressures must be measured, use
◊ Loosen the radiator cap very slowly, to release instruments of adequate capacity. Always follow
pressure from the system, before removing it. All the recommended procedures.
coolant level top--ups must be performed with
engine inoperative or at low idle, if warm WHEELS AND TYRES
◊ Do not run engine when refuelling and use care ◊ Make sure that the inflation pressure of the tyres
if the engine is hot due to the increased possibil- is according to the specifications issued by the
ity of a fire if fuel is spilled. Manufacturer and check it periodically.
◊ Never attempt to check or adjust fan belts when ◊ Should the pressure be changed, stand on the
engine is running. Do not adjust engine fuel side of the tyre at a safe distance.
pump when machine is moving.
◊ Pressure check operations must be performed
◊ Never lubricate the machine with engine run- with unloaded machine and cold tyres. Never
ning. use reconditioned tyre rims, since eventual
weldings, heat--treatments or repairs not per-
ELECTRICAL SYSTEM formed correctly can weaken the wheel, thus
causing subsequent damages or dangers.
◊ Should booster batteries be used, remember to
connect both ends of the booster cables in the ◊ Do not perform torch cutting or welding oper-
proper manner (+) with (+) and (--) with (--). Avoid ations on rims with inflated tyres installed.
short--circuits of the terminals. Follow thoroughly
the instructions of this Manual. ◊ Before operating on tyres, block all wheels, front
Avoid short circuiting the terminals. BATTERY and rear. After jacking the machine, block it with
GAS IS HIGHLY FLAMMABLE. Leave battery stands according to current safety rules and
box open to improve ventilation when recharging regulations.
batteries. Never check charge by placing metal ◊ Before removing objects from the tyre tread,
objects across the posts. Keep sparks or open deflate it.
flames away from batteries. Do not smoke near
battery to guard against the possibility of causing ◊ Never inflate tyres with flammable gas;
an explosion. explosions and serious bodily injuries may
result.
◊ Before any intervention, make sure that there
are no fuel or electrolyte leakages; eliminate REMOVALS AND INSTALLATIONS
them before proceeding with further work.
◊ When recharging batteries in closed ambient, ◊ Lift and handle all heavy parts with lifting devices
make sure that there is appropriate ventilation to of adequate capacity. Make sue that the parts
prevent possible accidental explosions due to are attached to lifting devices are properly
the accumulation of gases generated during the slinged. Use the lifting eyes provided. Beware of
recharge. persons in the vicinity.
◊ Before any intervention, make sure that the main ◊ Handle all parts carefully. Keep hands and
switch is OFF. fingers away from structures, gears or moving
parts. Use and wear always the appropriate
protections, such s goggles, gloves and safety
shoes.
◊ Prevent chains and cables from kinking. To
handle them, always use heavy gloves.
604.02.395.00 - 12 - 2002
PRODUCT IDENTIFICATION
The Telehandler and its main components are identi-
fied by various numbers and letters providing its
identification by the Service network. The following
information gives the location of the identification
plates, of the numbers stamped on the machine and
various examples of what can be found on the
machine.
VEHICLE SERIAL NUMBER

The serial number is stamped on the front part of the
machine, on the upper side of the main frame, right
side. Example: *ZEFK1740A00000000*.
NOTE: The serial number and the identification
number of the components can be requested by the
Dealer when Spare Parts are ordered or interven-
tions are required. These numbers are also required
as help in identifying the machine in the event of theft.
Keep them in a safe place.
TH001027
1
VEHICLE IDENTIFICATION PLATES
The vehicle identification plate is located on the left
side of the seat location. Record here below the data
for your machine.
TECHNICAL TYPE/MODEL
SERIAL NO. OF VEHICLE
YEAR
TH001048
2
IDENTIFICATION OF ENGINE
The identification data of the engine are on the left
side of the engine cylinder block. Please record here
below these data for easier consultation, when
required.
MODEL NO.
SERIAL NO.
DATE CODE
TH001029
3
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IDENTIFICATION OF FRONT AXLE

The serial number and the axle type are indicated on
plate (1) located on the front side of the axle housing.
Please record here below the data indicated for
faster consultation when required.
AXLE TYPE
SERIAL NO.
DATE CODE
IDENTIFICATION OF 4x3 POWER SHIFT

TRANSMISSION
The serial number and the model are indicated on
plate (1) located on the lower side of the trans-
mission. Please record here below the data indicated
for faster consultation when required.
MODEL NO.
SERIAL NO.
DATE CODE
1
TH001030
4
IDENTIFICATION OF REAR
TRANSMSSION
The serial number is indicated on plate (1) located on
the lower side of the rear transmission. Please
record here below the data indicated for faster con-
sultation when required.
AXLE TYPE
SERIAL NO.
DATE CODE
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IDENTIFICATION PLATES IN THE CAB

The cab identification plate contains a series of
further details and it is located on the left rear side of
the seat. Please record here below the data indicated
for faster consultation when required.
SERIAL NO.
DATE CODE
The data relative to the engine are indicated on the

conformity plates installed together with the Cab
Plate. Please record here below the serial number
indicated for faster consultation when required.
SERIAL NO.
DATE CODE
604.02.395.00 - 12 - 2002
ENVIRONMENTAL CONSIDERATIONS
The following recommendations can be useful: 4. Avoid spillage when draining used coolant mix-
tures, engine oils, transmission and hydraulic
fluids, brake fluid. After draining, do not mix
• Become familiar and make sure you have well brake fluid or fuel with lubricants. Store them in a
understood the relevant legislation in effect in risk free manner until when they can be disposed
your country. of in an adequate way, in accordance with local
regulations and the resources available.
• In the event no regulations exist, ask for specific

information with the suppliers of lubricants, anti- 5. Modern cooling mixtures, such as antifreeze and
freeze and detergents regarding their effects on other additives, must be changed every two
humans and the environment and how to store, years. Maximum attention must be paid to pre-
handle and dispose of these substances safely. vent that they spill over the ground. They must be
collected and disposed of so that do not create
any danger.
6. Do not unseal air conditioning system by your-

selves, since they can contain gases that must
not be released into the atmosphere. The per-
sonnel specialised in air conditioners uses
special equipment to charge and discharge air
conditioning systems.
7. Repair at once any leakage or defect of the

Useful indications engine cooling system or hydraulic system.
1. Do not fill tanks with inadequate canisters or dis- 8. Do not increase the pressure of any pressurised
pensing pressurised systems that could cause system, since this could cause serious problems
considerable spillage. to the components of the system.
2. In general, avoid the contact of the skin with any 9. Protect hoses when performing any welding,
fuel, oil, acid, solvent etc. The majority of them since a splash of welding materials could pen-
contain substance dangerous for your health. etrate and burn them, causing a hole or weaken-
ing the wall with subsequent leakages of oil,
coolant etc.
3. Modern lubricants contain additives. Do not burn
contaminated fuels and/or wed oils in normal
heating burners.
604.02.395.00 - 12 - 2002
MAINTENANCE TECHNIQUES
GENERAL NOTICES If a hose swells, this indicates that there is an internal
leakage due to a structural failure. This condition
Clean the outside of all the components prior to per- deteriorates very quickly and causes the failure of
forming any type of repair. Dirt and abrasive dust can the hose.
reduce the efficient life expectancy of a component
and result in expensive repairs. Clogged, squeezed, excessively tensioned or
deformed hoses are generally easily subject to flow
The time spent in preparing and cleaning working reduction, decrement of the operational speed of the
surfaces is giving results, making work easier and fluid and the final failure of the hose.
safer, and the components overhauled will be more
reliable and operate better. Loose hoses move freely and must be prevented
from touching each other and nearby surfaces. This
Use cleaning fluids proven to be safe. Some types of causes a rubbing action shortening the useful life of
fluid can cause serious problems to O--Rings and irri- the hose.
tate the skin. It is necessary to check that the sol-
vents are suitable to clean the components and that
of they are free of risks for the health of workers.
Replace O--Rings, sealing rings and seals every time CONNECTIONS WITH FRONT SEALING
they are moved. Never use old O--Rings or seals and O--RINGS
new ones together, independently from their condi-
tions. Always lubricate new O--Rings and seals with When repairing connections with front sealing
hydraulic oil before installing them. O--Rings, please comply with the following pro-
cedures.
When replacing components, always use the tooling
required by this type of work.
HOSES AND STEEL PIPES

Always replace hoses and steel pipes when the taper WARNING: NEVER DISCONNECT, NOR
end or connections are damaged. TIGHTEN A HOSE OR A STEEL PIPE UNDER
PRESSURE. IF IN DOUBT, MOVE THE CONTROL
When a new hose is installed, connect it without LVERS SEVERAL TIMES WITH THE ENGINE
tightening the ends and make sure that it is routed in INOPERATIVE BEFORE DISCONNECTING A
the correct manner, before tightening the ends. Fix-
HOSE OR A STEEL PIPE.
tures must be tightened just enough to hold the hose
without squeezing it, avoiding rubbing as well. 1. Loosen the connections and separate the hose
After replacing a hose of moving components, make or steel pipe, then remove and eliminate the
sure that the hose is not disturbed by the movement O--Rings from the connection.
of the component in any position. 2. Dip a new O--Ring in clean, hydraulic oil before
Make sure that all hoses installed are not choked or installing it. Install the new O--Ring in the con-
bent. nection and, if necessary, hold it in its position
If hose connections are damaged, dented, choked or with vaseline.
leaking, decrease the flow of oil and the productivity 3. Install a new hose or steel pipe and tighten man-
of the relevant actuators. Connections showing ually the connection holding, at the same time,
signs of displacement from their original pre-- the pipe still to prevent it from turning.
pressed position must be considered as already
broken, since they are going to fail or separate soon. 4. Use two wrenches to tighten the connection to
the torque prescribed for its size. Please refer to
A hose with a ragged outer sleeve allows water to the table to follow for the tightening torques.
penetrate. Thus, hidden corrosion of the reinforcing
wire will develop along the entire length of the hose, NOTE: to ensure that a joint does not leak, it is
with the subsequent failure of the hose itself. important that the connections are neither
excessively tightened nor too little.
604.02.395.00 - 12 - 2002
SPECIFIC SEALING COMPOUNDS
The following sealing compounds must be used, complying with the indications provided by the Manual:
SEALANTS COMMERCIAL NAME
Anaerobic sealant LOCTITE 518 (liquid gasket)
RTV silicon sealant LOCTITE SUPERFLEX 593,595 or 596

LOCTITE ULTRA BLUE 587 DOW CORNING SILASTIC
732 GENERAL ELECTRIC RTV 103 or 108
Pipe sealant PST 592 (pipe sealant with teflon)
Locking compound for LOCTITE 271/RED (sealant/locking for threads)

threads
TIGHTENING VALUES FOR FASTENERS

Check periodically that the fasteners are properly or tightening procedure for a specific application. The
tightened. torque values are provided for general use only.
Based upon the tables to follow, determine the cor- Make sure that the threads of the fasteners are clean
rect tightening torque when parts of the fastening and undamaged.
components are checked, adjusted or replaced. NOTE: use a torque wrench to tighten fasteners cor-
IMPORTANT: DO NOT use the values listed in the rectly.
tables when the Manual indicates a different torque
604.02.395.00 - 12 - 2002
MINIMUM TIGTENING TORQUES FOR FASTENERS

IN NEWTON-- METRES (Nm)
FOR NORMAL INSTALLATION APPLICATIONS
METRIC BOLTS AND LOCK NUTS
CLASS 5.8 CLASS 8.8 CLASS 10.9 LOCK NUT
NOT PLATED CL 8
NOMINAL NOT PLATED NOT PLATED
PLATED Zn/Cr with BOLT
DIMENSION PLATED Zn/Cr PLATED Zn/Cr
CL 8.8
M4 1.7 2.2 2.6 3.4 3.7 4.8 1.8

M6 5.8 7.6 8.9 12 13 17 6.3
M8 14 18 22 28 31 40 15
M10 28 36 43 56 61 79 30
M12 49 63 75 97 107 138 53
M16 121 158 186 240 266 344 131
M20 237 307 375 485 519 671 265
M24 411 531 648 839 897 1160 458
IDENTIFICATION
HEX SCREWS (WITHOUT NUT) AND ROUND HEAD BOLTS
CLASS 5.6 AND HIGHER
IDENTIFICATION OF THE MANUFACTURER
COMMERCIAL CLASS
HEX NUTS AND TIGHTENING NUTS

CLASS 05 AND HIGHER
IDENTIFICATION OF THE MANUFACTURER
COMMERCIAL CLASS MARKING
604.02.395.00 - 12 - 2002
MINIMUM TIGTENING TORQUES FOR FASTENERS

IN NEWTON-- METRES (Nm)
FOR NORMAL INSTALLATION APPLICATIONS
INCH MEASUREMENT SCREWS AND LOCK NUTS

GRADE SAE 2 GRADE SAE 5 GRADE SAE 8 LOCK NUTS
NOT PLATED NOT PLATED NOT PLATED NOT PLATED NOMINAL
NOMINAL PLATED PLATED Zn/Cr
Zn/Cr PLATED Zn/Cr PLATED Zn/Cr DIMENSION
DIMENSION OR OR
OR OR OR OR OR OR
SILVER NOT SILVER NOT SILVER NOT SILVER NOT
PLATED PLATED PLATED PLATED PLATED PLATED PLATED PLATED
1/4 6.2 8.1 9.7 13 14 18 6.9 9.8 1/4
5/16 13 17 20 26 28 37 14 20 5/16
3/8 23 30 35 46 50 65 26 35 3/8
7/16 37 47 57 73 80 104 41 57 7/16
1/2 57 73 87 113 123 159 61 88 1/2
9/16 81 104 125 163 176 229 88 125 9/16
5/8 112 145 174 224 244 316 122 172 5/8
3/4 198 256 306 397 432 560 217 306 3/4
7/8 193 248 495 641 698 904 350 494 7/8
1 289 373 742 960 1048 1356 523 739 1
IDENTIFICATION
SCREWS (WITHOUT NUT) AND ROUND HEADED SCREWS
GRADE SAE 2 GRADE SAE 5 GRADE SAE 8
NORMAL NUTS HEX NUTS HEX NUTS

GRADE SAE 5 GRADE SAE 8
LOCK NUTS
GRADE IDENTIFICATION GRADE IDENTIFICATION

GRADE A: NO CUTS GRADE A: NEW MARK
GRADE B: ONE PERIMETER CUT GRADE B: THREE MARKS
GRADE C: TWO PERIMETER CUTS GRADE C. SIX MARKS
THE MARKS ARE NOT COMPULSORILY
LOCATED IN THE CORNERS
GRADE A. NO MARKS
GRADE B: LETTER B
GRADE C: LETTER C
GRADE IDENTIFICATION
604.02.395.00 - 12 - 2002
SPECIAL TOOLS
POWERSHIFT TRANSMISSION
Q.TY NUMBER SKETCH DESCRIPTION HOW TO USE/MODEL
Sleeve wrench for power-- For oil delivery control valve

shift oil delivery control valve
2 380000606
RECOMMENDED ALL
Hydraulic clutch springs com- To press the hydraulic clutch

pression adapter springs
2 380000607 1,2,3,4 FW REV
RECOMMENDED ALL
Tool for installation of power-- For the installation of new

shift FW REV hydraulic clutch bearings (use with
2 380000430 shaft needle bearing 380000xxx)
COMPULSORY ALL
FRONT AND REAR AXLES
Device for the inspection of To check the wear of brake

the axle brake clutch disc discs
2 380000581 wear
COMPULSORY ALL
Tool for the installation of axle To install a new bush to be

2 380000582
housing universal joint seal used with (380000258)
Tool for the installation of the To install a new bush to be

swing axle housing universal used with (380000258)
2 380000583 joint seal
RECOMMENDED ALL
604.02.395.00 - 12 - 2002
Tool for the installation of axle To install a new seal to be

housing u--joint shaft spindle used w/ (380000258)
2 380000584 seal
COMPULSORY ALL
Tool for installation of axle To install a new seal to be

wheel hub seal used w/ (380000258)
2 380000585
COMPULSORY ALL
Wrench for axle differential To adjust the play of the

ring gear bevel gear set
2 380000586
COMPULSORY ALL
Retainer for axle differential To hold the planetary gears

planetary gear for removal of pins
2 380000587
COMPULSORY ALL
Guide for axle differential To guide the pins

gear pin
2 380000588
COMPULSORY ALL
Set of pins for disassembly/ To remove/install the pins.

assembly of axle differential
2 380000589 planetary gear pins
COMPULSORY ALL
Retainer for axle bevel pinion To hold the bevel pinion (to
slotted key be used w/ 380000591
2 380000590
COMPULSORY ALL
Wrench for axle bevel pinion For bevel pinion ringnut

380000591 ringnut
2
(297410)
COMPULSORY ALL
604.02.395.00 - 12 - 2002
Set of brackets for disassem- To disassemble the bevel

bly of axle bevel pinion pinion with a general puller
2 380000592
RECOMMENDED ALL
Adjuster for axle bevel pinion To adjust the bearings

380000463 bearings
2
(293438)
COMPULSORY ALL
Spacer (to be used w/

380000463)
2 380000593
COMPULSORY ALL
Tool for the installation of axle To install a new seal

bevel pinion seal
2 380000594
COMPULSORY ALL
Tool for the installation of To install a new seal

front axle parking brake shaft
2 380000595 support seal
COMPULSORY ALL
Adapter for the arrangement To adjust the pinion.

of axle bevel pinion
2 380000609
COMPULSORY ALL

380000281 Roto--Glyd DANFOSS seal
2
(294056)
COMPULSORY ALL
Tool for the installation of To install the springs
380000306 DANFOSS rotor springs
2
(293389)
RECOMMENDED ALL

DANFOSS dust seal
2 380000210
COMPULSORY ALL
604.02.395.00 - 12 - 2002
GENERAL
NOTE: “The Manufacturer” pursues a policy of constant improvements, thus reserves the right to modify at any
moment technical and design data, without notice, and without any obligation to modify the machines previously
manufactured.
All the data provided in this Manual are subject to variations in production. Dimensions and weights are
approximate and the illustrations do not necessarily show the machines in normal conditions. In order to have
specific information about a determined machine, please consult an Authorised Dealer.
Model T13 T14 T17

non stab. stab. non stab. stab. non stab. stab.
88 kW (120 CV) 88 kW (120 CV) 88 kW (120 CV)
Engine
Turbo Aftercooler Turbo Aftercooler Turbo Aftercooler
Max. lift height 12.30 12.45 13.30 13.45 16.24 16.60
Max. capacity (at 500
4000 4000 4000 4000 4000 4000
mm from fork heel)
Capacity at maximum
3000 4000 2500 3500 2000 3000
height
Extension at max.
1.40 1.23 1.70 0.85 2.70 1.80
height
Max. longitudinal
8.65 9.33 12.54
extension
Capacity at max.
600 1500 450 1350 0 600
extension
Weight (kg) 10700 11340 12090
604.02.395.00 - 12 - 2002
TH008001
6
T13
A 1200 mm K 1260 mm
B 3120 mm T 4396 mm
C 1617 mm U 2730 mm
D 5850 mm V 5204 mm
E 7050 mm V1 980 mm
F 2080 mm V2 3890 mm
G 452* mm W 2445 mm
I 1100 mm
* Value measured with tyres 13.00 -- 24
604.02.395.00 - 12 - 2002
TH001040
7
T13 without stabilisers or stabilisers raised
604.02.395.00 - 12 - 2002
TH001041
8
T13 with large stabilisers lowered
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TH001042
9
T13 with small stabilisers lowered
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TH008001
10
T14
A 1200 mm K 1260 mm
B 3120 mm T 4552 mm
C 18370 mm U 2730 mm
D 60700 mm V 5390 mm
E 7270 mm V1 980 mm
F 2080 mm V2 3890 mm
G 452* mm W 2445 mm
I 1100 mm
604.02.395.00 - 12 - 2002
TH001043
11
T14 with stabilisers raised
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TH001044
12
T14 with large stabilisers lowered
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TH001045
13
T14 with small stabilisers lowered
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TH008002
14
T17
A 1200 mm K 1260 mm
B 3120 mm T 4598 mm
C 1902 mm U1 2730 mm
D 6135 mm V 5445 mm
E 7335 mm V1 980 mm
F 2080 mm V2 3890 mm
G 452* mm W 2445 mm
I 1100 mm
604.02.395.00 - 12 - 2002
TH001046
15
T17 with stabilisers raised
604.02.395.00 - 12 - 2002
TH001047
16
T17 with stabilisers lowered
604.02.395.00 - 12 - 2002
ENGINE DATA 88 kW (120 CV)

Turbo Aftercooler
Model Diesel
Number of cylinders 4 in--line
Bore mm 102
Stroke mm 120
Displacement cm3 3900
Total displacement 17 : 1
Firing order 1.3.4.2
Low idle rpm 825--875

Max. idle rpm 2425--2475
Nominal speed rpm 2200

Maximum torque 450 Nm
COOLING SYSTEM
Type Pressurised, full--flow,

w/ by--pass
con camera di espansione
Fan 7 blades
Fan belt deflection 10 -- 16 mm
Drive belt deflection
Air conditioner compressor 16 mm
Thermostat:
Starts opening at 81 °C
Radiator cap 1 bar
INTAKE SYSTEM
Injection pump
Type Rotary
Cold start device Thermostart
Excess fuel device Automatic governor
Fuel shut off Solenoid
Lift pump Mechanical
604.02.395.00 - 12 - 2002
TRANSMISSION
POWERSHIFT – T 12000 4x3 = 4 speeds forward and 3 reverse
Speed Ratio Stall speed (RPM)
I 4.025 2349
II 2.048 2309
III 1.000 2248
IV 0.662 2170
ELECTRICAL SYSTEM
Alternator 65 amp.
Type of battery 12 Volt grounded negative
Optional 160 Amph
Battery cut--off by switch on negative/frame cable
Regulator Transistor
Ground Negative
Starter motor Positive engagement, electrically controlled (3.1 kW)
Light bulb 40/45W
Stop light/tail light 5/21 W with bayonet socket
Outer light bulb 5 W (string) 10 W bayonet socket
Flashing light bulb 21 W with bayonet socket
Work light bulb 55W H3 halogen
Instrument/indicator lights bulb 1.2 W w/out socket
Switch light bulb 1.2 W w/out socket
BRAKES
Type Oil--bath, multiple disc. 8 per axle

Disc diameter 203.2mm
Type of parking brake Negative on front axle
STEERING
Steering type Orbitrol

Pump type Gear
System pressure 175 bar
Wheel toe--in 0 -- 2mm
FRONT TRANSMISSION
Mounted on front frame Swinging with levelling cylinder
Differential lock No
REAR TRANSMISSION
Mounted on frame Floating with swing and automatic locking when boom
angle exceeds 10°
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HYDRAULIC SYSTEM
Gear pump Hydraulic and steering system
Hydraulic system pressure:
Main system pressure 245 bar
Steering system pressure 175 bar
TORQUES Nm
Wheel nuts 540

Cab securing screws 380
RADIATOR COOLANT
The antifreeze must be changed every 1000 hours or every 24 months
NOTE: To reduce deposits and limit corrosion, the water used in the cooling system must not exceed the follow-
ing limits:
Total hardness Chloride Sulphates

300 ppm 100 ppm 100 ppm
TYRE COMBINATION FOR 4-- WHEEL DRIVE VEHICLES

The tyres mounted on 4--wheel drive machines are selected so that they are compatible with the transmission
and axle gears. When damaged or worn tyres are replaced, always mount tyres of brand, model and dimension
equal to the previous ones. The installation of combined tyres can result in an excessive wear, loss of available
power or serious damage to the transmission components. If in doubt, consult your Dealer.
MACHINE WEIGHT
Weight
12 metre= 8.950 kg
14 metre= 11.050 kg
16 metre= 11.700 kg
TH001001
17
IMPORTANT: The data listed here above and below ence of additional equipment. To establish precisely
are general data provided as a guide to evaluate the the weight of your machine, it is necessary to place
weight of the machine and do not necessarily con- it on an official weight bridge.
sider the tyres installed, the level of fluids or the pres-
604.02.395.00 - 12 - 2002
TYRE PRESSURES
The tables are provided for reference only. For specific information relative to inflation pressures and the load
of the tyres used, please consult your Dealer.
AXLE WEIGHT AXLE WEIGHT

TYRE FRONT PRESSURE
Model (static, empty) (Dynamic, nominal)
DIMENSION REAR [bar]*
[kg] [kg]
front 4.5 4650 6390
14 00 -- 24 12 ply
14.00
rear 4.5 6060 5321
front 4.5 4650 6390
13 00 -- 24 14 ply
13.00
rear 4.5 6060 5321
front 4 4650 6390
405/70 -- 24 14 ply
rear 4 6060 5321
T13
front 4.5 4650 6390
15 5 R25
15.5
rear 4.5 6060 5321
front 4.5 4650 6390
15 R22.5
R22 5
rear 4.5 6060 5321
front 4.25 4650 6390
400/80 -- 24 14 ply
rear 4.25 6060 5321
front 4.5 5380 7300
14 00 -- 24 12 ply
14.00
rear 4.5 6000 5200
front 4.5 5380 7300
13 00 -- 24 14 ply
13.00
rear 4.5 6000 5200
front 4 5380 7300
405/70 -- 24 14 ply
rear 4 6000 5200
T14
front 4.5 5380 7300
15 5 R25
15.5
rear 4.5 6000 5200
front 4.5 5380 7300
15 R22.5
R22 5
rear 4.5 6000 5200
front 4.25 5380 7300
400/80 -- 24 14 ply
rear 4.25 6000 5200
front 4.5 5730 7470
14 00 -- 24 12 ply
14.00
rear 4.5 6360 5620
front 4.5 5730 7470
13 00 -- 24 14 ply
13.00
rear 4.5 6360 5620
front 4 5730 7470
405/70 -- 24 14 ply
rear 4 6360 5620
T17
front 4.5 5730 7470
15 5 R25
15.5
rear 4.5 6360 5620
front 4.5 5730 7470
15 R22.5
R22 5
rear 4.5 6360 5620
front 4.25 5730 7470
400/80 -- 24 14 ply
rear 4.25 6360 5620
* The pressures listed refer to inflation for site use.

The data listed here above correspond to the “approximate weight” of a standard machine, without equipment.
604.02.395.00 - 12 - 2002
TELEHANDLER TELESCOPIC LIFTER

LUBRICANTS AND COOLANTS
Engine oil correct viscosity grade depends on ambient --30 °C --25 °C --15 °C +20 °C +40 °C
temperature. Refer to the table on the right for selecting
engine oil for your machine.
NOTE: In areas with long periods of extreme temperature,
local lubrication procedures are admissible, such as using SAE 5W--30
SAE 5W30 where there are extremely low temperatures or
SAE 50 where there are extremely high temperatures.
Sulphur contents in fuel. SAE 10W--30
Engine oil replacement interval is shown in Section 3. Local
fuel can however have a high sulphur content: in this case
engine oil replacement interval must be changed as follows: SAE 15W--40
Sulphur contents in % Oil replacement interval
Below 0.5 Normal
05.5 to 1.0 Half the normal --22 °F --13 °F +5 °F +68 °F +104 °F
Over 1.0 One fourth the normal
NOTE: It is advised to use fuel with a sulphur content
below 1.3%
SUGGESTED FLUIDS AND THEIR International Specification Quantity Ambient

APPLICATION Temperature (°C)
Oil – ENGINE API CF--4/SG
Ambra Super Gold 15W40 ACEA E2 7,6 litres From –10 to +50
Ambra Super Gold 10W30 MIL--L--2104E (including engine oil filter)
Oil – POWERSHIFT 12,9 + 4 litres
TRANSMISSION ATF Type A Suffix A (lines and radiator)
Ambra Hydropower ALLISON C4
Oil – FRONT AND REAR AXLE API GL5 e API GL5 LS
GO 90 LS
FUCHS Titan Gear LS 85W90 ZF TE--ML 05 7 litres From --20 to +50
Oil – DROP BOX
Ambra Hypoide LS 90 80W90 API GL5 0,75 litres
OIL – FRONT/REAR AXLE HUB
Ambra Hypoide LS 90 80W90 API GL5 0,65 litres
OIL – FRONT LOADER
HYDRAULIC SYSTEM ISO VG 46
Ambra Hydrosystem 46 HV DIN 51524 185 litres
ENGINE RADIATOR
Water H2O 12 litres
Ambra Agriflu 12 litres
BRAKE CONTROL CIRCUIT –
OIL
Ambra Brake LHM M6C 59--A 1 litre
CRANE ARM SHOES –
GREASE
Ambra Tutela MRM2 NLGI 2 As required
GENERAL – GREASE
Ambra GR 9 NLGI 2 As required From --40 to +50
CONDITIONER COMPRESSOR
Freon R134a
FUEL
Diesel Fuel 135 litres
NOTE: Fluid and lubricant quantities are comprehensive. Drained quantities may be less, due to certain amonnts
of fluid or lubricant remaining trapped inside the machine.
604.02.395.00 - 12 - 2002
SECTION 10 -- ENGINE 1
SECTION 10 -- ENGINE
CONTENTS
Section Description Page
10 000 Engine identification code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Engine main characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General characteristics of engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Description of the main mechanical components of the engine . . . . . . . . . . . . . . . . . . . . . 12
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Mechanical injection supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Injection assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Timing gear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Injection pump setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Assembly clearance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
604.02.395.00 - 12 - 2002
2 SECTION 10 -- ENGINE
ENGINE IDENTIFICATION CODE
F 4 B E 0 4 8 4 F * D +
Emissions level
Approved power
Application
Fuel / injection
D = TIER 2
Nº Cylinders
Cylinder position:
0 = 4 vertical strokes
Engine
Engine crankcase type:

B = Non--structural crankcase 4 = 4 cylinders
Engine
family
8 = turbocharged diesel
ID with Intercooler
4 = Ground machines
X Y Y Y Y Y Y Y Y
X = 6 Two--valve rotative injection pump Sequential production number

Y = Engine versions
604.02.395.00 - 12 - 2002
ENGINE MAIN CHARACTERISTICS
F4BE0484
A G*D600 F*D601
C 3900 cm3
74 kW 88 kW
D 2200 rpm. 2200 rpm.
E Direct injection
F Rotative injection pump
T.C.A.
G
(Turbocharged with aftercooler)
A Engine type
B Number of cylinders
C Total displacement
p
D Maximum power
p currentlyy available
E Injection type
F Injection system
G Ai
Air d
delivery
li system
604.02.395.00 - 12 - 2002
GENERAL CHARACTERISTICS
OF ENGINES
F4BE0484
Type
G*D600 F*D601
Cycle Diesel 4 stroke

Supply Turbocharged with aftercooler
Injection Direct
Number of cylinders 4 in line
Bore mm 102
Stroke mm 120
Total displacement cm3 3900
Compression ratio 17 : 1
Maximum power kW 74 88
(HP) 100 120
rpm 2200 2200
Maximum torque Nm (kgm) -- --

rpm -- --
Low idle speed rpm

850 850
High idle speed rpm

2450 2450
TURBOCHARGING With aftercooler

Turbocharger type: HOLSET HX25W
Forced by means of gear pump,

LUBRICATION pressure relief valve,
oil filter
Oil pressure with engine warm:
at idle speed bar 1.2
at maximum speed bar 3.8
604.02.395.00 - 12 - 2002
F4BE0484
Type
G*D600 F*D601
COOLING Liquid
Water pump drive: Belt
Thermostat:
starts to open at: °C 81÷ 2
REPLENISHING FLUIDS
Uraniac Total capacity 1st filling litres --
Urania Turbo kg
U i Turbo
Urania T b LD -- engine sump litres --
kg
Uraniac -- engine sump + filter litres --
Urania Turbo
Urania Turbo LD kg
SUPPLY
VE4 / 12 F 1100 L
Bosch type injection
Pump timing 0° ÷ 0°,5
Begining of delivery mm 1
Injectors DSLA 145 P603
Firing order 1 -- 3 -- 4 -- 2
Injection pressure 245 bar
604.02.395.00 - 12 - 2002
GENERAL
A G
F
B
C
D
TH110001
1
A. Drive belt for: water pump – alternator – fan E. Belt rightener
B. Alternator F. Rotary injection pump
C. Water pump G. Air heater for cold start
D. Oil pump
604.02.395.00 - 12 - 2002
Top view
D E F G
C B A
TH110002
2
A. Alternator E. Injection pump
B. Injector F. Inlet manifold
C. Turbocompressor G. Fuel filter
D. Blow-- by
604.02.395.00 - 12 - 2002
Front view
B
H
TH110003
3
A. Blow -- by F. Poly – V belt
B. Fuel filter G. Water pump
C. Priming pump H. Alternator
D. Fixed belt tensioner I. Thermostat
E. Oil filter
604.02.395.00 - 12 - 2002
Right side view
H
F
TH110004
4
A. Blow -- by F. Poly -- V belt
B. Turbocompressor G. Union for oil filter
C. Thermostat H. Starter motor
D. Alternator I. Oil exhaust pipe from turbocompressor
E. Water pump L. Exhaust manifold
604.02.395.00 - 12 - 2002
Left side view
L
A
B
I
H C
TH110005
5
A. Blow -- by F. Fuel filter
B. Fuel pipes for injectors G. Fuel heater
C. Injection pump H. Poly – V belt
D. Oil filter I. Air heater
E. Priming pump L. Intake manifold
604.02.395.00 - 12 - 2002
Rear view
O A B C D
E
M
L
I
TH110006
6
A. Blow -- by H. Starter motor
B. Fuel pipes for injectors I. Engine flywheel
C. WASTEGATE Valve L. Oil filter
D. Turbocompressor M. Injection pump
E. Oil exhaust pipe from turbocompressor N. Air heater
F. Alternator O. Intake manifold
G. Exhaust manifold
604.02.395.00 - 12 - 2002
DESCRIPTION OF THE MAIN MECHANICAL

COMPONENTS OF THE ENGINE
Cylinder block
The cylider block is a cast iron structure containing The cylinder block also contains the chambers for
the cylinder liners (1), the main bearing housings (5) circulation of coolant and oil passages for the
and the following housings: for the camshaft lubrication circuit feeding the various moving parts.
bushings (3) and the tappets, for the water/oil heat Sole plate (6) is applied to the underside of the
exchanger (7), for the water pump 2 and for the oil cylinder block to increase resistance to mechanical
pump (4). stress.
2
7
3
TH110008
7
604.02.395.00 - 12 - 2002
Crankshaft
The crankshaft is made of steel. The rear spigot of the crankshaft is fitted with the
The crankshaft is held in five bearings for the four timing gear and the engine flywheel attachment hub.
cylinder version of engine F4 and in seven bearings The main bearing shells are made of steel with an
for the six cylinder version. The bearings are antifriction alloy plating.
induction hardened. The penultimate main bearing shells are equipped
The crankshaft features a series of internal oil with shoulders to limit crankshaft end float.
passages for lubrication purposes. Parts (1, 2) are mounted on the crankshaft rear
The crankshaft front spigot is fitted with the oil pump spigot with an interference fit and cannot be
drive gear, the speed sensor phonic wheel, the replaced.
damper flywheel, and the auxiliary equipment driving
pulley.
TH110009
8
1. Timing gear 3. Oil pump drive gear
2. Flywheel hub
Crankshaft oil seals

Front and rear seal rings are of drawer type, with
radial tightness. They must be extracted with tools
380000663 and 380000665, and mounted with tools
380000664 and 380000666.
604.02.395.00 - 12 - 2002
Connecting rods
Forged in steel, the connecting rod big ends are The connecting rod big end bearing shells are made
made with an oblique splitting plane angle, with sep- of steel plated with an antifriction alloy.
aration of rod and cap achieved by means of the
innovative fracture splitting system rather than the
conventional machining procedure.
TH110010
9
Each connecting rod is marked:

• On the body and on the cap by a number indicat-
ing the match and the cylinder in which they are
assembled.
• The rod shank is marked with a letter indicating
the weight class of the connecting rod installed
in production.
604.02.395.00 - 12 - 2002
Pistons
TH110011
10
The piston crown features a high turbulence com- 1st piston ring with trapezoidal section and ceramic
bustion chamber. The piston crown is cooled by chrome plating.
engine oil delivered by a spray nozzle installed in the 2nd piston ring with torsional conical rectangular sec-
crankcase, through the annular chamber inside the tion.
piston.
3rd piston ring with double oil wiper with internal
There are three piston ring grooves; the first is com- spring.
posed of a trapezoidal section cast iron insert.
The identification number and manufacturing data
The piston rings have different functions and differ- are printed in the piston crown area (1).
ent geometry.
TH110012
11
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Camshaft
The camshaft is mounted in the cylinder block on 5 A. Intake valves control

bearings. B. Exhaust valves control
The front and rear bearings are equipped with steel The camshaft is driven directly by the crankshaft by
bushings plated with antifriction material assembled means of spur tooth gears.
by means of an interference fit. The camshaft has
two cam lobes for each cylinder.
TH110013
TH110014
12
604.02.395.00 - 12 - 2002
Valve operation
2
1
4
6
7
8
TH110015
13
1. Rocker arm 6. Spring cup
2. Rocker support 7. Spring
3. Adjusting screw 8. Tappet
4. Rod 9. Camshaft
5. Half--cones
604.02.395.00 - 12 - 2002
Cylinder head
The cast iron cylinder head is machined to accom- The cylinder head is also equipped with:
modate the following parts: • exhaust manifold (1) in one block;
• valve seat inserts (4); • intake manifold (2) with seat for cold start air
• injector (6); heater (3) (if present in the application).
• thermostat (5);
TH110016
14
Cylinder head with inserted valve seats
604.02.395.00 - 12 - 2002
Valves and valve seats
S
1
TH110017
15
1. Intake valve A. Intake side
2. Exhaust valve S. Exhaust side.
The valve seats machined in the cylinder head have The exhaust valves (2) have an identification recess
the following angles: at the centre of the poppet.
• 45° for the exhaust valves
• 60° for the intake valves
TH110018
16
Figure 16 shows the oil seals mounted on the valve
stems.
604.02.395.00 - 12 - 2002
Valve guides
The valve guides are not inserted.
TH110019
17
604.02.395.00 - 12 - 2002
Engine flywheel
The flywheel (1) needs not be fitted in a specific posi- sors or for timing purposes. The fixing holes (2) are
tion on the crankshaft, as it is not equipped with equally spaced so that the flywheel can effectively be
punch markings, notches, or reference holes for sen- installed in various different positions.
TH110020
18
604.02.395.00 - 12 - 2002
Accessory Component Drive The belt is tensioned through the slot on the alterna-
A Poly--V (1) belt transmits drive from the crankshaft tor bracket.
(4) to the water pump (3) and the alternator (2).
TH110021
19
1. Poly--V belt 4. Pulley camshaft
2. Alternator 5. Fixed pulley
3. Water pump
604.02.395.00 - 12 - 2002
LUBRICATION • oil pressure control valve incorporated in the filter

The forced circulation lubrication system is made up support;
of the following components: • by–pass valve to exclude a clogged oil filter,
• rotor oil pump, housed in the front of the crank- incorporated in the filter support;
case and driven by a spur tooth gear fitted on the • cartridge type oil filter.
crankshaft spigot;
• water / oil heat exchanger, housed in the crank-
case, with oil filter support;
TH110022
20
Gravity oil return circuit Oil filling
Pressurized oil circuit
604.02.395.00 - 12 - 2002
Heat exchanger
TH110023
21
1. Heat exchanger body 4. Gasket between heat exchanger and cylinder block
2. Internal gasket 5. Oil return to filter
3. Water -- oil heat exchanger 6. Oil inlet from filter
604.02.395.00 - 12 - 2002
Oil pump
TH110024
22
TH110025
23
1. Crankshaft with oil pump drive gear
604.02.395.00 - 12 - 2002
Sump
The sump (1) is flexibly fixed to the cylinder block by This type of gasket should be renewed exclusively in
means of an aluminium plate (3), Figure 25. the event of deterioration or breakage.
The “C” section rubber gasket (2), fitted on the sump It need not be renewed at each disassembly--reas-
attachment profile, serves to enhance oil tightness sembly.
while also reducing the noise level.
TH110026
24
TH110027
25
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Recirculation of oil vapour Due to gravity, the condensed vapours fall down
The oil vapour recirculation is ensured by valve (1) under the tappet cover (2) while the remaining
installed on the tappet cover (2). vapours are collected by the breather (3) and disp-
ersed (i.e., intake).
TH110028
26
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COOLING
The engine cooling system is a closed circuit forced • centrifugal water pump housed at the front of the
circulation type composed of the following compo- crankcase;
nents: • thermostat controlling coolant circulation.
• heat exchanger to cool lubricating engine oil;
TH110029
27
Water from the thermostat Water to the pump
Water circulating in the engine
604.02.395.00 - 12 - 2002
Water pump
The water pump, which is accommodated in a hous- The engine temperature is controlled by a thermo-
ing in the crankcase, is driven by a Poly – V belt. stat.
The almost total absence of external pipes, hoses The coolant circulates also in the oil heat exchanger.
and hose clamps eliminates the number of connec-
tions and reduces possible sources of leaks.
TH110030
28
TH110031
29
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TURBOCHARGING
Turbocharging system with HOLSET HX25W turbocharger and aftercooler.
Operating diagram for turbocharger
TH110032
30
Exhaust Hot intake air
604.02.395.00 - 12 - 2002
MECHANICAL INJECTION SUPPLY Engine

F4BE0484 G*D600
SYSTEM F48E0484 F*D601
Fuel filter
The fuel filter (4) type is of the high water separation
type; the water drain screw (3) is installed at the base
of the cartridge. The heater (2) and the temperature 5
sensor 5 for filters on F4BE0484 F*D601 – G*D600 1
engines are installed on the support (1).
TH110034
31
604.02.395.00 - 12 - 2002
Priming pump is priming the fuel in the tank and sending it to the
The priming pump (1) is installed on the cylinder injection pump.
block and it is driven by the camshaft (2). Its function
2
TH110036
32
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INJECTION ASSEMBLY
3
4
2
5
1
6
10
TH110037
33
1. Injector 1 fuel pipe 7. Thermal bulb for KKSB
2. Injector 2 fuel pipe 8. Injection pump
3. Injector 3 fuel pipe 9. Solenoid valve
4. Injector 4 fuel pipe 10. Injector
5. Fuel exhaust pipe from injectors
6. Connection whith the intake manifold for LDA
604.02.395.00 - 12 - 2002
Injection pump Marking

The pump is of the rotary type and it is driven by a V = rotary distributor piston;
gear engaging with the camshaft gear. E = size of pump;
4 = for 4--cylinder engines;
12 = diameter distributor piston in mm;
1100 = pump rpm;
L = anticlockwise rotation direction
1
15
2
14
3
5
13
12
7
8
9
10 11
TH110038
34
Longitudinal section of injection pump
1. Membrane 9. Timing adjuster
2. Adjusting hub nut 10. Distributor piston
3. Feeler 11. Feed connection piece
4. Control lever 12. Hydraulic head
5. Speed controller 13. Control plate
6. Booster pump 14. Control rod
7. Drive shaft 15. Counterspring
8. Cam disk
604.02.395.00 - 12 - 2002
Mode of operation of injection pump
Supply step
1
2
3
6
4
7 9
8 5
TH110039
35
1. Fuel intake pipe 6. Distributor piston
2. Solenoid valve 7. Bore for fuel cut--off
3. Axial spline 8. Slide valve
4. Compression chamber 9. Injector
5. Fuel pipe between pump element and injectors
The distributor piston (6) is placed at B.D.C and slide fuel is fed into the compression chamber via feed
valve (8) shuts the bore for the fuel cut--off (7). The pipe (1) that is kept open by the solenoid valve (2).
604.02.395.00 - 12 - 2002
Feed step
5 3 4
TH110040
36
1. Fuel intake pipe 4. Fuel pipe between pump element and injectors
2. Compression chamber 5. Distributor piston
3. Inner pipe of distributor piston 6. Injectors
The distributor piston (5) is lifted under influence of in the compression chamber (2) is simultaneously
the cam disk to T.D.C. and rotates at the same time compressed. The inner pipe (3) of the distributor pis-
around its own axis. By means of these two move- ton is connected to pipe (4) and makes the fuel feed
ments the fuel intake pipe (1) is closed and the fuel to the injectors (6) possible.
604.02.395.00 - 12 - 2002
Feed end
6 5 4 3
TH110041
37
1. Fuel intake pipe 4. Pipe for fuel cut--off
2. Compression chamber 5. Slide valve
3. Feed pipe 6. Distributor piston
The distributor piston (6) opens the high--pressure injection valves and inner chamber of the pump
chamber by means of pipe (4) during its lift to T.D.C., housing.
ensuring pressure compensation between the inner As the pressure subsequently is too low to operate
chamber of the distributor piston, feed pipe to the the injection valve, the fuel is cut--off.
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Stopping the engine

1
4
3
2
5
TH110042
38
1. Fuel intake pipe 4. Solenoid valve
2. Moveable valve pin 5. Compression chamber
3. Spring
The engine is stopped by means of disconnecting the By means of the spring (3) the solenoid valve pres-
starter contact. ses the moveable valve pin (2) to the stop, and thus
The solenoid valve current supply (4) is interrupted. the fuel intake pipe (1) is closed.
LDA device (load--dependent feed adjustment)
1
2
3
4
5
6
7
8
TH110043
39
L.D.A. Mode of operation
The LDA device adjusts the fuel flow independently axial displacement of the controller pin (4) the feeler
of the air pressure in the suction manifold. This air pin (6) is also displaced and acts upon the stop lever
pressure acts upon the membrane (1) which is rigidly (7). The stop lever rotates on its own axis (8) and acts
connected to the controller pin (4). The lower part of upon the controller disk in such a way that the fuel
the controller pin (4) is provided with a conical mount- flow is adjusted to match the air quantity fed into the
ing (5) with a feeler pin (6). By means of the cylinders.
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Starting
6
5
2 1 4
7
TH110044
40
1. Starter lifter 5. Governor collar
2. Leaf spring 6. Solenoid valve
4. Slider 7. Compression chamber
If the solenoid valve (6) is supplied with current, fuel Thus the whole lift of the pump element is used for
is fed into the compression chamber (7); in this case the feed to the injection valve.
the governor weights of the governor collar (5) are
closed, and the leaf spring (2) presses the lifter (1)
and the slider (4) into the additional feed position.
Starting device disconnected
6
5
7 2
4
TH110045
41
1. Starter lever 5. Governor collar
2. Leaf spring 6. Solenoid valve
3. Tension lever 7. Weight
4. Slider
After starting of the engine the governor collar (5) Under these conditions the slider (4) is moved to
moves axially as a result of the centrifugal force idling position.
caused by the expansion of the governor weights (7),
and causes the starter lifter (1) to contact the tension
lever (3) and compress the leaf spring (2).
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Load--dependent start of delivery (L.F.B.)
1 2
7 8
5
TH110046
42
Design of the controller with feed--dependent adjustment
of the start of delivery
1. Control spring 5. Slider
2. Governor collar 6. Distributor piston
3. Tension lever 7. Control shaft
4. Starter lever 8. Governor weights
Description
The load--dependent adjustment of the start of deliv- • Controller shaft with an oblong hole and two
ery (LFB) enables a ”smoother” engine operation cross holes
(reduced noise). • Pump housing with a hole that is closed from out-
The LFB effect is obtained by means of the following side by means of a ball and that is connected to
changes: the feed chamber.
• Governor collar with an additional bore to the
antipump bore.
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Position of the governor collar

in the LFB device
1 2 3 4
5 67
TH110047
43
a. Collar in idling position 3. Crossing orifice, governor collar
b. Collar in movement 4. Governor collar
c. Collar in adjustment condition, inner pressure loss 5. Crossing orifice, controller shaft
1. Longitudinal orifice in controller shaft 6. Edge from controller center
2. Controller shaft 7. Crossing orifice, controller shaft
Mode of operation
Independently of the position of the outer accelerator reduced in order to obtain a decreasing start of deliv-
pedal the fuel feed is reduced, if the governor collar ery: this is obtained by means of the LFB device.
(4) is displaced by the governor weights of the con- If the governor collar (4) that runs on the controller
troller by means of the centrifugal force in case of an shaft (2) connects the bore (3) to the hub (6) and the
increase of the speed. bore (7), a part of the diesel fuel under pressure is fed
For smoother engine operation and reduced fuel via the pipe (1 and 5) into the feed chamber. This fuel
feed the start of delivery must be reduced. As the causes a reduced pressure increase in the pump and
injection adjustment device in the rotary piston pump a reduced start of delivery.
is a hydraulic device, the pressure increase must be
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Cold start automatic injection advance system

(KKSB)
1
TH110048
44
1. KKSB Bulb
The KKSB device makes it possible to determine the

required cold start injection advance.
45
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TIMING GEAR DRIVE

The timing gear drive is obtained by means of a spur Correct timing is achieved by aligning the (⇐) marks
tooth gear fitted on the rear spigot of the crankshaft, punched on the two gears.
which meshes with a corresponding spur tooth gear
on the camshaft.
TH110049
46
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INJECTION PUMP SETTING The dial gauge should display 1 mm, corresponding
After setting the drive shaft and camshaft timing, to the pump distributor piston stroke compared to the
take the first cylinder to the top dead centre. This can bottom dead centre. If the prescribed value is not
be achieved by turning the drive shaft until the gear- detected, slacken the screws fastening the pump to
case pin next to the pump fits into the housing on the the gearcase and turn the pump body through the
timing gear. slots, until the correct preset value is reached.
When the injection pump is removed and has already If the injection pump has been overhauled, when it is
been preset, it is enough to key it on the timing gear, keyed on the engine, it should be preset at 1 mm
fasten it to the gearcase and remove the seal which compared to the distributor piston bottom dead
guarantees the pump presetting and then fasten centre.
shaft. Install dial gauge 380000228 and its support
To check correct setting, install dial gauge 380000229 as illustrated in Figure 47, then turn the
380000228 (2) and adapter 380000229 (1) on the body pump through the slots, until the dial gauge dis-
pump, as illustrated in Figure 47. plays 1 mm. Fasten the pump to the gearcase and
check as described above.
Turn the drive shaft for the gear clearances and put
back the engine first cylinder in top dead centre posi-
tion.
TH110050
47
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ELECTRICAL COMPONENTS (*) Control unit, engine water temperature sensor,

• Pre--post heating kit (for F4BE0484 G*D600 – heater
F4BE0484 F*D601 engines) (*).
• KKSB water temperature sensor on injection Pre--post heating control unit
pump. Control unit (1) sets the heater (pre--post heating)
• Oil pressure sensors for the oil pressure warning operating time according to the signal received by
lamp on the instrument panel. the engine water temperature sensor (2).
• Thermal bulb for KKSB on injection pump.
Operation diagram
TH110051
48
1. Pre--post heating control unit 4. Heater
2. Water temperature sensor 5. Warning lamp on pre--heating warning panel
3. Heater electromagnetic switch
604.02.395.00 - 12 - 2002
TROUBLESHOOTING
Engine does not start

Possible causes Remedies
1. Battery partially discharged. 1. Check and recharge battery.
Replace if necessary.
2. Battery terminal connections corroded or loose. 2. Clean, inspect and tighten terminal nuts.
Replace terminals and nuts if excessively cor-
roded.
3. Injection pump timing incorrect. 3. Adjust injection pump timing.
4. Impurities or water in fuel lines. 4. Disconnect fuel lines from injection pump and
clean thoroughly.
If necessary clean and dry the fuel tank.
5. No fuel in tank. 5. Fill tank.
6. Fuel supply pump malfunction. 6. Check and replace pump if necessary.
7. Air in fuel system. 7. Check fuel lines, unions, supply pump, filters and
injection pump for air, then bleed system.
8. Starter motor faulty. 8. Repair or replace starter motor.
9. Faulty cold start device. 9. Check and replace thermostarter if necessary.
Engine stalls
1. Idle speed too low. 1. Adjust idle speed.
2. Irregular delivery from injection pump. 2. Check injection pump delivery on test bench.
clean thoroughly. If necessary clean and dry the
fuel tank.
4. Fuel filters clogged. 4. Renew filter cartridges.
5. Incorrect valve clearances. 5. Adjust valve clearances.
6. Burnt or cracked valves. 6. Replace valves.
7. Air in fuel system. 7. Check fuel lines, unions supply pump, filters and
injection pump for air, then bleed system.
8. Injection pump drive mechanism damaged. 8. Replace damaged parts.
Coolant pump malfunction

1. Coolant pump malfunction. 1. Overhaul pump or replace.
2. Thermostat faulty. 2. Replace thermostat.
3. Radiator inefficient. 3. Remove internal deposits by flushing. Check for
leaks and repair.
4. Deposits in cylinder head and cylinder block 4. Flush out coolant system.
coolant passages.
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Coolant pump malfunction (to follow)

5. Coolant pump and fan drive belt slack. 5. Check and adjust belt tension.
6. Coolant level low. 6. Top up expansion tank with specified coolant
mixture.
7. Incorrect timing motor phasing. 7. Check and adjust.
8. Injection pump calibration incorrect – delivering 8. Calibrate pump on test bench to values specified
too much or too little fuel. in calibration tables.
9. Air filter clogged. 9. Clean filter unit and replace filter element if
necessary.
Engine lacks power and runs unevenly

1. Injection pump timing incorrect. 1. Carry out the correct injection pump phasing on
the engine.
2. Auto advance in injection pump damaged. 2. Overhaul injection pump and adjust on test
bench to values specified in calibration table.
3. Distributor journal worn. 3. Overhaul injection pump and adjust on test
4. Injection pump delivery irregular. 4. Overhaul injection pump and adjust on test
5. All--speed governor damaged. 5. Overhaul injection pump and adjust on test
6. Injectors partially obstructed or damaged. 6. Clean, overhaul and calibrate injectors.
clean thoroughly.
If necessary clean and dry the fuel tank.
8. Fuel supply pump damaged. 8. Replace fuel supply pump.
9. Incorrect valve clearances. 9. Adjust valve clearances.
10. Cylinder compression low. 10. Test compression and overhaul engine if necess-
ary.
11. Air filter clogged. 11. Clean air filter unit and replace element if necess-
ary.
12. Tie--rod in linkage between accelerator and injec- 12. Adjust to correct length.
tion pump incorrectly adjusted.
13. Maximum speed screw on injection pump incor- 13. Adjust max. speed screw.
rectly adjusted.
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Engine produces abnormal knocking noises

1. Injectors partially obstructed or damaged. 1. Clean, overhaul and calibrate injectors.
2. Impurities accumulating in fuel lines. 2. Clean fuel lines and replace severely dented
pipes. Clean injection pump if necessary.
3. Incorrect injection pump timing. 3. Adjust injection pump timing.
4. Crankshaft knocking due to to excessive play in 4. Re--grind crankshaft journals and crankpins. Fit
one or more main or big--end bearings or excess- oversize shell bearings and thrust washers.
ive endfloat.
5. Crankshaft unbalanced. 5. Check crankshaft alignment and balance;
replace if necessary.
6. Flywheel bolts loose. 6. Replace any bolts that have worked loose and
tighten all bolts to the specified preliminary and
angular torque values.
7. Connecting rod axes not parallel. 7. Straighten connecting rods, check axes parallel-
ism; replace con rods if necessary.
8. Piston knock due to excessive wear. 8. Rebore cylinder liners and fit oversize pistons.
9. Noise caused by excessive play of gudgeon pins 9. Fit oversize gudgeon pin, rebore piston seats
in small--end and piston bushings, or loose fit of and small--end bushings. Replace bushings.
small--end bushing.
10. Excessive tappet/valve noise. 10. Check for broken springs or excessive play
between valve stems and guides, cam followers
and bores. Adjust valve clearances.
Engine produces excessive black or dark grey smoke

1. Maximum delivery of injection pump too high. 1. Adjust injectio pump on test bench to the values
specified in calibration table.
2. Injection pump delivery excessively retarded or 2. Adjust injectin pump/engine timing or check
automatic advance regulator damaged. automatic advance regulator.
3. Injection pump delivery excessively advanced. 3. Adjust injection pump--engine timing.
4. Injectors partially or totally obstructed or incor- 4. Clean and overhaul injectors and adjust pressure
rectly adjusted. setting; replace if necessary.
5. Air filter clogged. 5. Clean air filter unit and replace element if necess-
ary.
6. Loss of engine compression due to: 6. Replace damaged parts or, if necessary,
-- piston rings sticking; recondition engine.
-- cylinder liner wear;
-- worn or incorrectly adjusted valves.
7. Damaged high--pressure fuel lines. 7. Inspect and replace if necessary.
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Blue, grey--blue or grey--white smoke

1. Injection pump delivery excessively retarded or 1. Adjust injection pump/engine timing or check
automatic advance regulator damaged automatic advance regulator
2. njectors obstructed or damaged 2. Clean and overhaul injectors and adjust pressure
setting; replace if necessary.
3. Oil lealing past piston rings due to sticking rings 3. Replace damaged parts or, if necessary,
or cylinder lines wear recondition engine.
4. Oil leeaking through the inlet valve guides due to 4. Recondition cylinder head
guide or valve stem wear
5. Engine does not reach correct operating tem- 5. Replace thermostat.
perature (thermostat faulty)
Engine runs on after switching off

1. Engine stop solenoid damaged 1. Replace solenoid
2. All--speed governor damaged 2. Recondition injection pump and adjust on test
bench to values specified in calibration data
chart.
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TOOLS
TOOL No. DESCRIPTION
Tool kit for valve seat regrinding
Spring load checking tool
380000301 Rotary stand for engine overhaul

(1000 N lifting, 120 N/m torque)
380000322 Puller for injection pump to engine mounting gear
380000665 Crankshaft front seal puller
380000663 Crankshaft rear seal puller
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380000671 Injector removal tool
Double acting bridge
Brackets pair
Pipe--clamp fixture
380000666 Driver for crankshaft front oil seal
380000664 Driver for crankshaft rear oil seal
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380000670 Engine oil filter wrench
380000221 Pliers for disassembling/reassembling piston rings (65--110mm)
380000302 Tool for disassembling/reassembling engine valves
380000667 Drift for removing and fitting camshaft bushings

(use with 380000668)
380000262 Lifting tool for crankshaft
380000216 Equalizer for removing and fitting engine
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380000220 Insertion band for piston into cylinder liner (60--125mm)
380000661 Brackets for securing engine to rotary stand 380000301
380000669 Oil seal puller tool
380000668 Handle for interchangeable drivers
380000364 Gauge support for different measurements

(use with 380000228)
380000229 Gauge support tool for rotary pump timing

(use with 380000228)
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380000304 Pair of gauges for angle tightening with 1 /2“

and 3 /4 “square connector
Complete square for connecting rod quadrature check
380000228 Gauge (0--5mm)
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ASSEMBLY CLEARANCE DATA
F4BE0484
Type
G*D600 F*D601
CYLINDER BLOCK AND CRANK MEMBERS mm
Cylinder ∅1 102.01 ÷ 102.03
Pistons: supplied as spares

type
Distance X 61
Outside diameter ∅1 101.777 ÷ 101.795
Seat for pin ∅2 40.006 ÷ 40.012
Piston – cylinder liners 0.215 ÷ 0.253
Piston diameter ∅1 0.5
Protrusion of pistons
0.28 ÷ 0.52
from cylinder block X
Gudgeon pin ∅3 39.9968 ÷ 40.0032
Gudgeon pin – pin seat 0.0028 ÷ 0.0152
Piston type X1* 2.69

Piston ring grooves X2 2.425 ÷ 2.445
X3 4.04 ÷ 4.06
* measured over ∅ 99 mm
S1* 2.560 ÷ 2.605
Piston rings S2 2.310 ÷ 2.340
S3 3.075 ÷ 4.000
* measured over ∅ 99 mm
1 0.245 ÷ 0.265
Piston rings – grooves 2 0.085 ÷ 0.135
3 0.040 ÷ 0.985
Piston rings 0.5
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F4BE0484
Type
G*D600 F*D601
Piston ring gaps in cylinder liner:

X1
0.40 ÷ 0.70
X2
0.25 ÷ 0.55
X3
0.25 ÷ 0.55
Small end bushing seat ∅1 42.987 ÷ 43.013

Connecting rod bearing seat ∅2 77.075 ÷ 78.25
Small end bushing diameter

Outside ∅4 43.279 ÷ 43.553
Inside ∅3 40.019 ÷ 40.033
Small end bushing – seat 0.266 ÷ 0.566
Gudgeon pin – bushing 0.0158 ÷ 0.0362
Measurement distance X --
Maximum error on parallelism of

connecting rod axes = --
Main journals ∅1 82.99 ÷ 83.01

Crankpins ∅2 68.987 ÷ 69.013
Main bearing shells S1* 2.456 ÷ 2.464
Big end bearing shells S2* 1.955 ÷ 1.968
* supplied as spare parts
Main bearing housings no:

no. 1--5 ∅3 87.982 ÷ 88.008
no. 2--3--4 87.977 ÷ 88.013
604.02.395.00 - 12 - 2002
F4BE0484
Type
G*D600 F*D601
Bearing shells – main journals:
no. 1--5 0.041 ÷ 0.119
no. 2--3--4 0.041 ÷ 0.103
Bearing shells – crankpins 0.033 ÷ 0.041
Main bearing shells

+ 0.250; + 0.500
Big end bearing shells
Main journal of
thrust bearing X1 37.475 ÷ 37.545
Main bearing housing of

thrust bearing X2 25.98 ÷ 26.48
Shoulder half rings X3 37.28 ÷ 37.38
Crankshaft shoulder 0.068 ÷ 0.41
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F4BE0484
Type
G*D600 F*D601
CYLINDER HEAD – TIMING SYSTEM mm
Valve guide seats

on cylinder head ∅1 8.019 ÷ 8.039
Valves:
∅4 7.96 ÷ 7.98
α 60°
∅4 7.96 ÷ 7.98
α 45°
Valve stem and valve guide 0.052 ÷ 0.092
Seat on head for valve seat:

∅1 46.987 ÷ 47.013
∅1 43.637 ÷ 43.663
Valve seat outside diameter; angle

of valve seats on cylinder head:
∅2
47.063 ÷ 47.089
α
60°
∅2
43.713 ÷ 43.739
α
45°
Recessing X 0.356 ÷ 1.102
X 0.104 ÷ 0.840
Between valve seat 0.050 ÷ 0.102

and head
0.050 ÷ 0.102
Valve seats --
604.02.395.00 - 12 - 2002
F4BE0484
Type
G*D600 F*D601
Valve spring height:
free spring H 63.5
under load of:
329 N H1 49.02
641 N H2 38.2
Injector protrusion X not adjustable
Seats for camshaft bushings n° 1–5

--
Seats for camshaft pins n° 2–3–4 --
Camshaft main journals:

1⇒5 ∅
53.995 ÷ 54.045
Camshaft bushings
outside diameter: ∅ --
Bushing inside diameter ∅ 54.083 ÷ 54.147
Bushings and seats in crankcase --
Bushings and main journals 0.038 ÷ 0.162

Useful cam lift:
6.045
7.239
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F4BE0484
Type
G*D600 F*D601
∅1 Tappet plate
seat
in cylinder block ∅1 16.000 ÷ 16.030
∅2
Tappet plate outside
diameter:
∅3
∅2 15.929 ÷ 15.959
∅2 ∅3 15.965 ÷ 15.980
Between tappets and seats 0.020 ÷ 0.065
Tappets --
∅1
Rocker carrier shaft ∅1 18.963 ÷ 18.975
Rockers ∅2 19.000 ÷ 19.026

∅2
Between rockers and shaft 0.025 ÷ 0.063
604.02.395.00 - 12 - 2002
SECTION 21 -- POWERSHIFT 1
SECTION 21 -- POWERSHIFT GEARBOX

CONTENT
21 000 Gearbox assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Idler gear case assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Gearbox operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission and Hydraulic oil circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Modulation valve operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Torque converter and heat exchanger hydraulic oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Troubleshooting guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Troubleshooting procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Pressure testing clutch and high pressure circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Pressure testing torque converter and cooler circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Check points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Assembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
604.02.395.00 - 12 - 2002
2 SECTION 21 -- POWERSHIFT
POWERSHIFT GEARBOX 4 X 3
Gearbox control
The microprocessor--controlled gearbox assembled
on this machine is called Powershift.
The Powershift gearbox lever is assembled on the
left side of the steering column and it enables the
electronic selection of four forward gears and three
reverse gears.
s
1
DRIVING WITH THE POWERSHIFT
GEARBOX
A
Neutral position
Select the neutral position by shifting the gearbox N

level to the centre.
Selecting the forward gear R
To select the forward gear, pull the lever towards the

steering wheel and push it upwards.
2
NOTE: Actual forward gear selection at this time
depends upon vehicle conditions; if it is moving, the
microprocessor will take into consideration speed on
road and running direction before any gear shift can
take place.
Selecting the reverse gear
To select the reverse gear pull the lever towards the

steering wheel and push it downwards.
NOTE: Actual reverse gear selection at this time

depends upon vehicle conditions; if it is moving, the
microprocessor will take into consideration speed on
road and running direction before any gear shift can
take place.
604.02.395.00 - 12 - 2002
Automatic gear increase
Automatic increase from the 1st gear position to the

required gear is achieved by turning the handgrip
anticlockwise by single movements. If the lever is
kept on this position, the processor will make the
gear selection advance from the 2nd gear to the 4th
gear by intervals of 1.8 seconds.
NOTES: The request for automatic increase, after a

decrease, is delayed by 2 seconds. In the case of a
speed sensor error, the microprocessor will not auth-
orize increases over the 2 nd gear.
NOTES: Should a steep slope be driven up, select 3

the 2 nd gear speed and proceed, if enabled by speed
and power, to the 3 rd and 4 th gear speed.
s
s
s
Automatic gear decrease
ATTENTION
To drive down a steep slope, select the 2nd speed
gear and proceed by increasing it only when this is
possible in full safety. As a matter of fact IT IS NOT
POSSIBLE TO SHIFT DOWN A GEAR TO
REDUCE VEHICLE SPEED IF THIS IS OVER 15
Km/h.
Automatic gear decrease down to the required speed

gear is obtained by turning the handgrip clockwise by
single movements.
Changing direction
Running direction is simply inverted by moving the

Powershift lever to the reverse gear and the other
way round, and this operation is allowed at any time.
System response in any case depends upon vehicle

speed and upon the speed gear used at the moment.
When driving in 1st or 2nd speed gear, changes in
direction have no limits and they are performed
immediately.
604.02.395.00 - 12 - 2002
When driving in 3rd or 4th forward speed gear, two

responses are possible, depending on vehicle
speed.
RESPONSE 1: If vehicle forward speed is over 15

km/h and a reverse gear is selected, automatic down
shift is activated, but inertia however remains until
speed is reduced sufficiently to enable performing
inversion in 2nd speed gear.
RESPONSE 2: If vehicle forward speed is below 15

km/h, the reverse gear is immediately obteined in
2nd speed gear.
Shown speed ranges refer to a Powershift gear-

box with 13.00 – 2h wheels corresponding to a
wheel diameter of 1200 mm.
s
4
DISCONNECTING THE GEARBOX
Gearbox disconnection can be performed in four dif- 2

ferent ways:
1. Powershift speed gear lever
2. Parking brake push button
1
3. Push button on manipulator 3
Gearbox disconnection is a consequence of applying
the parking brake. Normal gearbox operation is
restored as soon as the brake is released. 2
604.02.395.00 - 12 - 2002
GEARBOX ASSEMBLY
The gearbox comprises five main assemblies
TH121001
6
1. The converter 3. The output shaft with C (4th speed) and D
(3rd speed) clutch assemblies
2. The input shaft and directional clutches:
A – Reverse 4. The lower shaft with E (1st speed) and F (2nd speed)
B – Forward clutch assemblies
5. The output shaft to the idler gear case
604.02.395.00 - 12 - 2002
GEAR AND CLUTCH POSITION
TH121002
7
Reverse (A)/Forward (B) 4th speed (C)/3rd speed (D)
1st speed (E)/2nd speed (F) Output shaft with gear
Idler gear
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IDLER GEAR CASE ASSEMBLY

The idler gear case is mounted directly on the trans-
mission. The sleeve (3) connects the transmission
output shaft directly to the idler gear case input shaft
(1). The front and rear axles are set in motion by the
output shaft (2) via the drive shafts.
TH121003
8
1. The input shaft 3. The connecting sleeve
2. The output shaft
604.02.395.00 - 12 - 2002
GEARBOX OPERATION
Through the converter, the thermal engine transmits under pressure to engage the clutch packages corre-
motion to the gearbox input shaft, on which the sponding to the selected direction and speed.
advance/reverse motion clutches are assembled.
Depending on the gearbox control lever selection, sole-
NOTE: For details, see the following pages.
noid valves are energised/de--energised to enable oil
TH121004
9
1. Control pump converter and pressure
adjusting valve 4. Output shaft
2. Input shaft and direction clutches
(forward/reverse) 5. Speed clutches
3. Speed gears
604.02.395.00 - 12 - 2002
Converter, pump control section

and pressure adjustment valve
Engine power is transmitted from the engine flywheel The torque multiplication is function of the blading
to the impeller through the impeller cover. (impeller, turbine and reaction member) and the con-
This element is the pump portion of the hydraulic verter output speed (turbine speed). The converter
torque converter and is the primary component which will multiply engine torque to its designed maximum
starts the oil flowing to the other components which multiplication ratio when the turbine shaft is at zero
results in torque multiplication. This element can be RPM (stall).
compared to a centrifugal pump, that picks up fluid at Therefore we can say that as the turbine shaft is
its centre and discharges it at the outer diameter. decreasing in speed, the torque multiplication is
The torque converter turbine is mounted opposite increasing.
the impeller and is connected to the turbine shaft of The hydraulic pump is connected to the pump mech-
the torque converter. This element receives fluid at anism. The compressor hub gear drives this mech-
its outer diameter and discharges it at its centre. anism. Since the compressor hub gear is connected
The reaction member of the torque converter is to the compressor cover, pump speed is directly
located between and at the centre of the inner diam- related to engine speed.
eters of the impeller and turbine elements. Its func- NOTE: The pressure regulator valve is mounted
tion is to take the fluid which is exhausting from the behind the filter, in the filter adapter housing.
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 multiply torque.
D
E
TH121005
10
Converter, pump control section and pressure adjustment valve.
604.02.395.00 - 12 - 2002
Input shaft and directional clutches

The turbine shaft, driven by the turbine, transmits Pressure of the oil forces the piston and discs against
power to forward gear, at 4th speed or at reverse the back--up plate. The discs with splines on the
speed. outer diameter clamping against discs with teeth on
These clutches consist of a drum with internal the inner diameter enables the drum and hub to be
splines and a bore to receive a hydraulically actuated locked together and allows them to drive as one unit.
piston. The piston is kept oil tight by the use of sealing When the clutch is released, a return spring will push
rings. The steel discs with external splines, and fric- the piston back and oil will drain back via the sole-
tion discs with internal splines, are alternated until noid, the bleed valve or holes in the clutch piston into
the required total is achieved. the transmission sump.
A back--up plate is then inserted and secured with a These bleed valves will only allow quick escape of oil
retainer ring. A hub with outer diameter splines is when the pressure to the piston is released.
inserted into the splines of discs with teeth on the The transmission is equipped with a reverse gear
inner diameter. The discs and hub are free to and two forward gears (forward and 4th gear): These
increase in speed or rotate in the opposite direction speeds combined with a 3--speed clutch, produces
as long as no pressure is present in that specific a type of transmission with 4--forward gears and
clutch. 3--reverse gears at different speeds.
To engage the clutch, the solenoid will direct oil under The engagement of the directional clutches (forward
pressure through tubes and passages to the and reverse) are modulated. This means that clutch
selected clutch shafts. pressure is built up gradually. This will enable the unit
Oil sealing rings are located on the clutch shafts. to make forward, reverse shifts while the vehicle is
These rings direct the oil through a drilled passage still moving and will allow smooth engagement of
in the shaft to the desired clutch. drive. The modulation is done hydraulically.
D
E
TH121006
11
The input shaft and directional clutches
604.02.395.00 - 12 - 2002
The range clutches The output section

Once a directional clutch is engaged power is trans- With a range clutch engaged, power is finally trans-
mitted to the range clutches (1st, 2nd or 3rd). mitted to the output shaft.
Operation and actuation of the range clutches is Output rotation is same as the engine rotation when
similar to the directional clutches. the forward clutch is engaged.
The engagement of the range clutches is not modu- A front axle disconnect is optional and is located on
lated. the output shaft. The drive to the front axle can be
disconnected or connected by manual shifting.
A A
B B
C C
D D
E E
F F
TH121007 TH121008
12 13
The range clutches The output section
604.02.395.00 - 12 - 2002
The transmission controls

(refer to hydraulic diagram)
The transmission is controlled by the direction and to the selected clutch shafts. Oil sealing rings are
range solenoids. The solenoids are mounted on the located on the clutch shafts. These rings direct oil
left side of the transmission case. When the selected under pressure through a drilled passage in the shaft
direction and range solenoids are energised, oil to the desired clutch.
under pressure will flow through tubes and passages
TH121009
14
The transmission controls
R. Reverse gear solenoid valve 1. Solenoid valve (1)

T. Forward gear solenoid valve 2. Solenoid valve (2)
S. Splitter solenoid valve
604.02.395.00 - 12 - 2002
SOLENOID/CLUTCH COMBINATION
The 6 transmission clutch packs are controlled by 5

solenoids, therefore combinations of between 1 and
3 activated solenoids are required for clutch
engagement. These combinations are shown in the
table below.
SOLENOIDS CLUTCHPACKS
GEAR R T S 1 2 A B C D E F
A4
A3
A2
A1
N
R1
R2
R3
15
The clutches are engaged by hydraulic pressure and

disengaged by spring. The other four speed clutches are not modulated
The forward and reverse clutch packs are during engagement.
hydraulically modulated using a mechanical valve. Output is in the oposite direction to engine rotation.
604.02.395.00 - 12 - 2002
2
1
4
8
5
TH121010
16
Operating Valves and Solenoids
1. Forward Feathering Valve 5. Solenoid (S)
2. Reverse Feathering Valve 6. Solenoid (1)
3. Solenoid (R) 7. Solenoid (2)
4. Solenoid (T) 8. Housing
604.02.395.00 - 12 - 2002
TRANSMISSION AND HYDRAULIC OIL CIRCUIT DIAGRAMS
NEUTRAL GEAR ENGAGED
A – Reverse clutch
B – Forward clutch
C – 4th speed clutch
D – 3th speed clutch
E – 1st speed clutch
F – 2nd speed clutch
Operating solenoids: none
TH121011
17
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VT VR
1 2 T S R
E F D C B A
TH121012
18
Torque converter and lubrication oil

Aspirated oil (2 -- 7 bar)
High pressure oil (16.5 -- 19.5 bar) Return to reservoir
VT Forward modulation valve VR Reverse modulation valve
Pressure oil from the system regulating valve flows Clutches B, C, D and F are open to reservoir.
to the 1st solenoid and forward solenoid T.
None of the solenoids are engaged, allowing the oil
to flow through to the clutch D only.
604.02.395.00 - 12 - 2002
TRANSMISSION OPERATION FIRST GEAR ENGAGED
Operating solenoids: T, 1 and 2
TH121013
19
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VT VR
1 2 T S R
E F D C B A
TH121014
20

High pressure oil (16.5 -- 19.3 bar)

Return to reservoir
Pressurised oil coming from the system regulation The forward solenoid is energised allowing system
valve arrives at solenoid valve 1 and at the forward pressure to flow through the splitter solenoid, to the
gear solenoid valve. forward B clutch. Modulation is controlled by the
Solenoid valve 1 is energised and it enables system modulation valve in the circuit.
pressure to engage clutch E. As pressure increases in the forward clutch line drive
At this point solenoid valve 2 is energised enabling increases with smooth modulation.
pressurised oil possibly present in clutches D or F to Clutches A, C, D and F are open to the reservoir.
be discharged into the sump.
604.02.395.00 - 12 - 2002
TRANSMISSION OPERATION SECOND GEAR ENGAGED
Operating solenoids: T and 2
TH121015
21
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VT VR
1 2 T S R
E F D C B A
TH121016
22


Return to reservoir
Pressurised oil coming from the system regulation forward B clutch. Modulation is controlled by the
valve arrives at solenoid valve 1 and at the forward modulation valve in the circuit.
gear solenoid valve. As pressure increases in the forward clutch line,
Solenoid valve 2 is energised enabling system pres- drive increases with smooth modulation.
sure to engage clutch F. Clutches A, C, D and E are open to the reservoir.
The forward solenoid is energised allowing system
pressure to flow through the splitter solenoid, to the
604.02.395.00 - 12 - 2002
TRANSMISSION OPERATION THIRD GEAR ENGAGED
Operating solenoids: T
TH121017
23
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VT VR
1 2 T S R
E F D C B A
TH121018
24


Return to reservoir
Pressurised oil coming from the system regulation Forward gear T solenoid valve is energised and it
valve arrives at solenoid valve 1 and at the forward enables oil to flow through the separation solenoid
gear solenoid valve. valve S. which is not energised, and from there to
Since neither solenoid valve 1, nor solenoid valve 2 clutch B.
are energised, pressurised oil can engage clutch D. Clutches A, C, E and F are open to the reservoir.
604.02.395.00 - 12 - 2002
TRANSMISSION OPERATION FOURTH GEAR ENGAGED
Operating solenoids: T and S
TH121019
25
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VT VR
1 2 T S R
E F D C B A
TH121020
26


Return to reservoir
Pressurised oil coming from the system regulation Oil flows through forward gear T solenoid valve
valve arrives at solenoid valve 1 and at the forward which is energised, then through separation solenoid
gear solenoid valve. valve S which is also energised, and which engages
Oil flows through solenoid valve 2 and engages the multi--disk C clutch.
multi--disk clutch D. Clutches A, B, E and F are open to the reservoir.
604.02.395.00 - 12 - 2002
TRANSMISSION OPERATION REVERSE FIRST GEAR ENGAGED
Operating solenoids: R, 1 and 2
TH121021
27
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VT VR
1 2 T S R
E F D C B A
TH121022
28


Return to reservoir
Pressurised oil coming from the system regulation The forward solenoid is not energised allowing oil to
valve arrives at solenoid valve 1 and at the forward flow through the reverse solenoid which is then
gear solenoid valve. energised. Oil flows to the reverse clutch. Modulation
Solenoid valve 1 is energised and enables system is controlled by the modulation valve in the circuit.
pressure to engage clutch E. Clutches B, C, D and F are open to the reservoir.
At this point solenoid valve 2 is energised enabling
pressurised oil possibly existing in clutches F and D
to be discharged into the sump.
604.02.395.00 - 12 - 2002
TRANSMISSION OPERATION REVERSE SECOND GEAR ENGAGED
Operating solenoids: R and 2

TH121023
29
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VT VR
1 2 T S R
E F D C B A
TH121024
30

Solenoid valve 1 is not energised and it enables oil is controlled by the modulation valve in the circuit.
at system pressure to continue towards solenoid Clutches B, C, D and E are open to the reservoir.
valve 2.
At this point solenoid valve 2 is energised enabling
oil to flow towards clutch F and opening clutch D at
the same time towards the tank.
604.02.395.00 - 12 - 2002
TRANSMISSION OPERATION REVERSE THIRD GEAR ENGAGED
Operating solenoids: R
TH121025
31
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VT VR
1 2 T S R
E F D C B A
TH121026
32


Return to reservoir
VT Forward modulation valve VR Revese modulation valve
Solenoid valve 1 is not energised and it enables oil is controlled by the modulation valve in the circuit.
at system pressure to flow towards solenoid valve 2. Clutches B, C, E and F are open to the reservoir.
Solenoid valve 2 is not energised and hence oil flows
towards clutch D.
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MODULATION VALVE OPERATION

The modulation valve shown on the pages opposite Diagram D
consists of the following components:
When the top side of the regulator valve is full of pres-
1. Modulation Valve Housing surized oil the spring pressure pushes the regulator
2. Modulation Sleeve valve back to its seat. Pressure then begins to act on
the bottom of the accumulator valve.
3. Accumulator Valve
Diagram E
4. Regulator Valve
The accumulator valve starts to move up the sleeve
5. Stop Pin
and as it does the oil pressure required to push it up
The graph shows how the pressure increases in the becomes greater and greater as the opposing spring
clutch pack from the moment of solenoid activation pressure increases. This gradual increase in
(A) until maximum clutch pressure is achieved (F). pressure feathers the clutch plates into engagment.
The pressure increase stops when the accumulator
Diagram A
hits the limit rod at the top.
Oil is just about to enter the modulation valves and
both the accumulator and regulator valves are Diagram F
seated on the stop pins. As the oil supply continues to the clutch pack excess
flow is bled off via the regulator valve.
Diagram B
Oil initially flows in to the bottom of the regulator valve Diagram G
and unseats the regulator valve. This momentarily When the supply of oil to the clutch pack is cut off the
sends a high pressure pulse to the clutch pack which regulator valve seats on the bottom pin allowing oil
takes up the freeplay between the clutch pack plates. to flow out the top of the regulator valve allowing the
modulation valve to become seated.
Diagram C
Oil starts to flow through the small orifice in the
regulator valve and equalises the pressure on either
side.
604.02.395.00 - 12 - 2002
B F A
1
E Clutch pressure
Modulated
pressure 2
Pressure
C D
3
A Time
TH121229 4
Modulated pressure 5
Clutch pressure
Zero Pressure (Reservoir)

TH121230
B C
1 1
2 2
3 3
4 4
5 5
TH121231 TH121232
604.02.395.00 - 12 - 2002
D E
1 1
2 2
3 3
4 4
5 5
TH121233 TH121234
F G
1 1
2 2
3 3
4 4
5 5
TH121235 TH121236
604.02.395.00 - 12 - 2002
TORQUE CONVERTER AND HEAT EXCHANGER HYDRAULIC OIL CIRCUIT
11 12 14
13
10
15
9 8
16
7
6
5
2 3
1
TH121027
33

1. Transmission sump 9. System pressure regulating valve

2. Transmission breather 10. Safety valve (10 bar)
3. Suction filter 11. Oil cooler test port
4. Oil pump 12. Torque converter pressure
5. Pressure filter 13. Torque converter
6. Filter by pass valve 14. Torque converter temperature
7. To clutch pack solenoids 15. Lubrication galleries
8. Clutch pressure (240 -- 280 psi) (16.5 -- 19.5 bar) 16. Forward and reverse clutch lubrication
604.02.395.00 - 12 - 2002
TROUBLESHOOTING GUIDE TROUBLESHOOTING PROCEDURES

The following information is presented as an aid to Stall test
isolating and determining the specific problem area
in a transmission that is not functioning correctly. A stall test to identifies transmission, converter, or
When troubleshooting a “transmission” problem, it engine problems.
should be kept in mind that the transmission is only Use following procedure:
the central unit of a group of related powertrain com- 1. Put the vehicle against a solid barrier, such as a
ponents. Proper operation of the transmission wall, and/or apply the parking brake and block the
depends on the condition and correct functioning of wheels.
the other components of the group. Therefore, to 2. Put the directional control lever in FORWARD (or
properly diagnose a suspected problem in the tran- REVERSE, as applicable).
smission, it is necessary to consider the transmis-
sion fluid, charging pump, torque converter, tran- 3. Select the highest speed.
smission assembly, oil cooler, filter, connecting lines, With the engine running, slowly increase engine
and controls, including the engine, as a complete speed to approximately one--half throttle and hold
system. until transmission (converter outlet) oil temperature
By analysing the principles of operation together with reaches the operating range.
the information in this section, it should be possible
to identify and correct any malfunction which may ATTENTION
occur in the system.
Do not operate the converter at stall condition longer
The transmission (power shift with torque converter than 30 seconds at one time, shift to neutral for 15
transmission) troubles fall into three general catego- seconds and repeat the procedure until desired tem-
ries: perature is reached.
1. Mechanical problems. Excesssive temperature 120 °C (250 F) maximum
2. Hydraulic problems. will cause damage to transmission clutches, fluid,
3. Electrical problems. converter, and seals.
In addition to the mechanical and electrical compo-
nents, 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 mus 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 slip-
ping, and to cool and lubricate the working compo-
nents.
604.02.395.00 - 12 - 2002
Transmission pressure checks Hydraulic checks

Transmission problems can be isolated by the use of Also, before checking the transmission clutches,
pressure tests. When the stall test indicates slipping torque converter, charging pump, and hydraulic cir-
clutches, then measure clutch pack pressure to cuit for pressure and rate of oil flow, it is important to
determine if the slippage is due to low pressure or make the following transmission fluid check.
clutch plate friction material failure. Check oil level in the transmission. The transmission
In addition, converter charging pressure and trans- fluid must be at the correct (full level). All clutches
mission lubrication pressure can also be measured. and the converter and its fluid circuit lines must be
fully charged (filled) at all times..
Mechanical and electrical checks
NOTE: The transmission fluid must be at operating
Prior to checking any part of the system for hydraulic temperature of 82--93 C (180--200 F) to obtain cor-
function (pressure testing), the following mechanical rect fluid level and pressure readings.
and electrical checks should be made: Do not attempt to make these checks with cold oil.
• Check the parking brake and inching pedal for To raise the oil temperature to this specification it is
correct adjustment. necessary to either operate (work) the vehicle or run
• Be sure all lever linkage is properly connected the engine with converter at “stall” (Refer to “Stall
and adjusted in each segment and at all connect- test”).
ing points.
• The controls are actuated electrically. Check the ATTENTION
wiring and electrical components. Be careful that the vehicle does not move unexpect-
• Be sure that all components of the cooling sys- edly when operating the engine and converter at stall
tem are in good condition and operating cor- rpm.
rectly. The radiator must be clean to maintain the
proper cooling and operating temperatures for
the engine and transmission. Air clean the radi-
ator, if necessary.
• The engine must be operating correctly. Be sure
that it is correctly tuned and adjusted to the cor-
rect idle and maximum no--load governed speed
specifications..
604.02.395.00 - 12 - 2002
TROUBLESHOOTING
Refer to the following troubleshooting guide for the
diagnosis of typical transmission troubles.
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. Valvola di spurgo pistone della frizione aperta. 5. Clean bleed valves thoroughly.
Low charging pump output

Cause Remedy
2. Suction screen plugged. 2. Clean suction pump.
3. Defective charging pump. 3. Replace pump.
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.
Noisy converter
Cause Remedy
1. Worn charging pump. 1. Replace charging pump.
2. Worn of damaged bearings. 2. A complete disassembly will be necessary to
determine which bearing is faulty.
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”.
604.02.395.00 - 12 - 2002
PRESSURE TESTING CLUTCH AND HIGH PRESSURE CIRCUIT
2 3 4 5 6 7
E F D C B A
TH121028
34
Port 1 System pressure Port 5 C Clutch
Engine set to idle. Engine set to idle
Minimum pressure 13 bar. Pressure range clutch activated 16 -- 19 bar.
Desired oil pressure 16 -- 19 bar. Clutch released 0 -- 0.2 bar (0 -- 3 lb/in2).
Port 2 E Clutch Port 6 B Clutch
Engine set to idle. Engine set to idle.
Pressure range clutch activated 16 -- 19 bar. Pressure range clutch activated 16 -- 19 bar.
Clutch released 0 -- 0.2 bar (0 -- 3 lb/in2). Clutch released 0 -- 0.2 bar (0 -- 3 lb/in2).
Port 3 F Clutch Port 7 A Clutch
Engine set to idle. Engine set to idle.
Pressure range clutch activated 16 -- 19 bar. Pressure range clutch activated 16 -- 19 bar.
Clutch released 0 -- 0.2 bar (0 -- 3 lb/in2). Clutch released 0 -- 0.2 bar (0 -- 3 lb/in2).
Port 4 D Clutch
Engine set to idle.
Pressure range clutch activated 16 -- 19 bar.
Clutch released 0 -- 0.2 bar (0 -- 3 lb/in2).
604.02.395.00 - 12 - 2002
PRESSURE TESTING TORQUE CONVERTER AND COOLER CIRCUIT
8 9 10
TH121029
35
All pressure and flow testing should be measured
with an oil temperature of 82--93 degrees Celsius
(180 -- 200 F). For operating speed refer to each test.
Port 1 System pressure

Engine set to 2000 revs/min.
Minimum pressure 13 bar ( lb/in2).
Desired pressure 16.5 -- 19.5 bar ( -- lb/in2).
Port 8 Oil cooler in

Engine set to 2000 revs/min.
Pressure range 2 -- 7 bar ( -- lb/in2).
Port 9 Heat exchanger (output)
Port 10 Converter output temperature
604.02.395.00 - 12 - 2002
CHECK POINTS
1
2
TH121030
36
Left hand side view
1. Forward clutch pressure oil (B clutch) 3. Clutch circuit pressurised oil
2. Reverse clutch pressure oil (A clutch) 4. Heat exchanger pressure oil
TH121031
37
Top view
1. Regulated clutch pressure 3. Pressure from cooler
2. Oil temperature to cooler
604.02.395.00 - 12 - 2002
TH121032
38
Right hand side view
1. E multi--disc clutch pressure oil 4. D multi--disc clutch pressure oil
2. F multi--disc clutch pressure oil 5. C multi--disc clutch pressure oil
3. Converter output temperature
4
1
TH121033 3 2
39
Rear view
1. Visual oil indicator on idler gear case 4. Transmission oil level check bar
2. Magnetic plug for oil draining from idle gear case 5. Transmission oil breather
3. Transmission oil draining magnetic plug
604.02.395.00 - 12 - 2002
ASSEMBLY INSTRUCTIONS
13
T 1
10 4
7
4
6 2
7
4
11
3 R
6
10
8
5
2
TH121034
40
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20
20
20
20
20
19
TH121036
21 21
23
22
18
16
17
TH121035
41
604.02.395.00 - 12 - 2002
Use Permatex and Loctite only where specified. 8. Lower clutch disc return spring concave side is
All lead in chamfers for oil seals, piston rings, and to be placed against clutch piston wear sleeve.
“O”--rings must be smooth and free from burrs. Remaining six springs to be stacked alternately
Inspect before assembly. as shown.
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. 10. Clearance between clutch piston and steel sep-
arator plate to be 1.22--2.74 mm. If over 2.74 mm
Apply a thin coat of Loctite No. 592 or 506 Dryseal to clearance, add one steel outer disc under end
all pipe plugs. plate.
After assembly of parts using Loctite or Permatex, 11. Clearance between clutch piston and steel sep-
there must not be any free or excess material which arator plate to be 2.03--3.43 mm. If over 3.43 mm
might enter the oil circuit. clearance, add one steel outer disc under end
plate.
13. Tighten regulator sleeve to 61--68 Nm.
1. Assemble oil filter and tighten to 27--34 Nm. 14. Use solenoid bore plug in middle position for
2. Teflon seals must be sized prior to assembly. 3--speed version only.
3. 10 outer steel plates, 10 inner plates, alternately 15. Solenoid cartridge to be assembled and tigh-
assemble, starting with outer steel plate. tened to 22--27 Nm.
4. 6 outer steel plates, 6 inner plates, alternately 16. Tighten nut to 339--407 Nm.
assemble, starting with outer steel plate. 17. Tighten all cartridge nuts to 5--7 Nm.
5. 5 outer steel plates, 5 inner plates, alternately 18. Tighten modulation valve and inching valve to
assemble, starting with outer steel plate. 81--88 Nm.
6. Shield bearing, assembly with shield as shown 19. M10 x 30.
Add a coating of Loctite 641 to outer diameter of 20. M10 x 60.
bearings.
21. Use 5/16 – 18 screw.
7. Fwd., Rev., 2nd and 3rd clutch return disc springs.
Concave side of first disc spring to be placed 22. Use 5/16 – 18 screw.
against clutch piston wear sleeve. 23. Use 3/8 – 16 screw.
Remaining four springs to be stacked alternately
as shown.
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OVERHAUL
Remove the capscrews and washers connecting the
drive plate to the torque converter and remove the
drive plates and backing ring.
TH121037
42
Support the idler gear case appropriately and
remove the lock screws and their washers.
TH121038
43
Use a lever to remove the idler gear case.
TH121039
44
Remove the torque converter plug snap ring and
then lever out the plug.
TH121040
45
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Remove the torque converter to turbine shaft snap

ring. Then pull off the torque converter.
TH121041
46
Remove the torque converter to shaft locating ring.
TH121042
47
Remove the filter assembly.
TH121043
48
Remove the pump mounting bolts and washers and
detach them from the pump body with the relative
gasket.
TH121044
49
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Remove the pressure adjuster and its housing where

the filter is screwed in with the tool shown in the fol-
lowing figure.
TH121045
50
Tool diagram to remove the pressure adjuster and its
housing.
TH121046
51
Remove the converter housing to transmission case
bolts and washers.
NOTE: There is a hex head screw attaching the
converter housing to the middle manifold plate, this
is located at the top of the transmission on the other
side and must also be removed.
TH121047
52
Remove the converter housing and gasket.
TH121048
53
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Remove impeller hub gear.
TH121049
54
Remove pump drive gear washer.
TH121050
55
Remove pump drive gear and bearing.
TH121051
56
Remove pump drive shaft and washer.
NOTE: In some cases the pump drive shaft can be
removed with the converter case plate, but when
subsequently reassembling it, the countershaft and
the gear must be mounted on the manifold plate.
TH121052
57
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Remove the solenoid cover retaining nuts and the

cover (1). Then remove the five solenoid valves (2)
by firstly removing the retaining nuts, then the 1
solenoid coils and finally unscrew the valve and
remove.
TH121053
58
Remove the manifold plate retaining bolts and
washers. Position the transmission so the manifold
plate is horizontal and lift the manifold plate upwards
and away from the shafts and main transmission
housing. The end of the gear shafts may need to be
tapped with a rubber mallet to keep them in the
transmission.
TH121054
59
Remove the gear clusters in the order shown in the
drawing.
(1) E/F clutch and shaft 1
2
(2) Input shaft and A/B clutches, and finally
(3) C/D clutches and output shaft.
Remove the roller bearing located behind the F
clutch.
NOTE: The D clutch gear must remain in the
transmission.
3
TH121055
60
Remove the oil supply tube ’O’ ring and remove the
supply tube and screen assembly.
1
TH121056
61
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From inside the transmission remove the D clutch

gear and the roller bearing in which it was located,
also remove the bearing locating ring.
TH121057
62
Then using a suitable brass drift and hammer tap out
the drive shaft, seal, ball bearing and snap ring, and
remove the remaining retaining ring from the casing.
TH121058
63
Remove the inner case set screw plug. Remove the
clutch shaft distributor sleeve set screw.
TH121059
64
Using a suitable puller, remove the distributor sleeve
and shaft pilot bearing.
TH121060
65
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Remove the coupling sleeve.
TH121061
66
Remove the output shaft front bearing snap ring.
TH121062
67
Remove the output gear snap ring
TH121063
68
From the rear, remove the output shaft bore plug.
TH121064
69
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From the front tap the output shaft and rear bearing
from the housing.
TH121065
70
Output shaft and rear bearing removed.
TH121066
71
Remove the output shaft gear and snap ring.
TH121067
72
Remove the output shaft front bearing.
TH121068
73
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Remove the output shaft front bearing snap ring.
TH121069
74
Remove the clutch shaft rear bearing outer races.
TH121070
75
From the rear, remove the rear bearing snap ring.
TH121071
76
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Modulation Valve Removal

Remove the modulation valve housing and ’O’ ring.
TH121072
77
Remove the inner, middle and outer valve springs,
the valve stop pin and the accumulator spool.
TH121073
78
Remove the modulation housing sleeve and ’O’ ring.
TH121074
79
To assist in removing the diverter, use a 5/16--24
threaded rod.
TH121075
80
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Disassembly of the A and B clutches A

A clutch disassembly (Reverse)
Remove the outer thrust washer, thrust bearing and

inner thrust washer.
TH121076
81
Remove the clutch hub and gear assembly and press A
out the 2 bearings and spacer.
TH121077
82
Remove the outer thrust washer, thrust bearing and A
TH121078
83
Remove the end plate retaining ring. A
TH121079
84
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Remove the end plate and also the 6 friction discs A

and 6 separator plates.
TH121080
85
Compress the belleville washers and remove the A
snap ring, also remove the snap ring retainer,
belleville washers and the clutch piston wear plate.
TH121081
86
To remove the piston turn the clutch pack upside A
down and tap the shaft on a block of wood.
TH121082
87
Disassembly of B clutch (Forward) B
Remove the 3 oil slip rings.
TH121083
88
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Remove the external thrust washer, the thrust bear- B

ing and the internal thrust washer.
TH121084
89
Slide off the clutch hub and gear assembly and press B
out the 2 bearings and spacer.
TH121085
90
Remove the outer thrust washer, thrust bearing and B
TH121086
91
Lever out the end plate retaining ring. B
TH121087
92
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Remove the end plate and the 6 friction discs and 6 B

steel sparator plates.
TH121088
93
Compress the belleville washers and remove the B
snap ring, then proceed to remove the snap ring
retainer, belleville washers and the clutch piston
wear plate.
TH121089
94
Turn the clutch pack upside down and tap the shaft B
on a block of wood, this will dislodge the piston for
removal.
TH121090
95
A clutch reassembly (Reverse) A
Install the clutch piston in the clutch housing.
TH121082
96
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Install the clutch piston wear plate, followed by the A

five belleville washers starting with the first washer
with the larger diameter towards the wear plate, then
alternate the remaining four. Position the snap ring
retainer on to the belleville washers and then fit the
snap ring.
TH121081
97
Fit the 6 steel separator plates and the 6 friction discs A
and the the end pate.
TH121080
98
Then fit the end plate retaining ring. A
TH121091
99
To check the A clutch pack disc clearance position A
the clutch pack upside down. Measure the distance
between the clutch piston and the first steel sparator
A
disc by inserting a feeler gauge (1).
The required clearance is 1.22 -- 2.74 mm (0.48 --
0.108 inches). If the clearance is greater than
2.74 mm (0.108 inches) add one steel disc under the
end plate.
B
1
TH121092
100
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Position the inner thrust washer, thrust bearing and A

outer thrust washer.
TH121078
101
Press one bearing into the clutch hub and gear A
assembly then place the spacer and second bearing
on top and press the second bearing flush to the top
of the gear. Then install the hub assembly into the
clutch pack.
TH121077
102
Then place the inner thrust washer, thrust bearing A
and outer thrust washer over the shaft.
TH121076
103
Reassembly of the B clutch (Forward) B
Install the piston into the clutch pack.
TH121090
104
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Place the piston wear plate over the shaft and then B
place the first belleville washer with the larger
diameter towards the piston wear plate, then
alternate the remaining 4 washers.
Position the snap ring retainer, compress the
belleville washers and fit the snap ring.
TH121089
105
Install the 6 steel separator plates and 6 friction B
discs, starting with a steel separator plate first, then
fit the end plate.
TH121088
106
Install the end plate retaining ring. B
TH121093
107
To check the clutch disc clearance place the clutch B
pack upside down and place a feeler gauge (1)
between the clutch piston and the steel separator
plate.
The required clearance should be 1.22 -- 2.74 mm
(0.048 -- 0.108 inches). If the clearance is greater B
than 2.74 mm (0.108 inches) add one steel disc
under the end plate.
1
TH121094
108
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Then position the inner thrust washer, thrust bearing B

and outer thrust washer over the shaft.
TH121086
109
Press one bearing flush to the top of the B clutch hub B
gear then place the spacer and bearing on top of the
pressed bearing and press the second bearing flush
to the gear face.
TH121085
110
Install the inner thrust washer, thrust bearing and B
outer thrust washer.
TH121084
111
Fit the 3 oil slip rings. B
TH121083
112
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Disassembly of C and D clutches and shaft C

C clutch disassembly (4th speed)
Remove clutch shaft oil slip rings.
TH121095
113
Using a suitable puller, remove the clutch gear and C
front bearing.
TH121096
114
Remove the clutch gear locating snap ring, thrust C
washer retaining ring and then the outer thrust
washer, thrust bearing and inner thrust washer.
TH121097
115
Remove the clutch gear and hub assembly and press C
the 2 bearings and spacer from the gear.
TH121098
116
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Remove the end plate retaining ring. C
TH121099
117
Remove the end plate and six friction discs and six C
separator plates.
TH121100
118
Compress the belleville washers and remove the C
snap ring, then proceed to remove the snap ring
retainer, belleville washers and clutch piston wear
plate.
TH121101
119
Remove the clutch piston by turning the clutch pack C
upside down and tapping the shaft on a block of
wood.
TH121102
120
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Disassembly of D clutch (3rd speed) D

Use an extractor to remove the clutch pack gear.
TH121107
121
Remove also the shaft bearing inner race, the thrust D
bearing with its inner and outer washers and the two
gear bearings.
TH121108
122
Remove the thrust washer retaining ring, then D
remove the outer thrust washer, thrust bearing and
TH121103
123
Remove the end plate retaining ring. D
TH121104
124
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Remove the end plate and the five friction discs and D
five steel separator plates.
TH121105
125
Compress the belleville washers and remove the D
snap ring, snap ring retainer, belleville washers and
the clutch piston wear plate.
TH121106
126
Remove the clutch piston by turning the clutch pack D
upside down and tapping the shaft on a block of
wood.
TH121109
127
Reassembly of C clutch (4th speed) C
Install the clutch piston into the housing.
TH121102
128
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Assemble the clutch piston wear plate. C

First enter the Belleville washer by setting it with the
larger diameter turned towards the wear plate, and
then add, by alternating them the other four springs.
Position the elastic ring check device over the shaft,
compress the Belleville washers, then assemble the
elastic ring.
Check that the elastic ring is correctly fitted in its own
channel.
TH121101
129
Install the 6 separator discs and friction discs. Install C
a steel separator first and then alternate the
remaining discs and finish with the end plate.
TH121100
130
Fit the end plate retaining ring. C
TH121099
131
To check clearance, position the disk package C
upside down and use a thickness gauge (1) to
measure the distance between clutch piston and the
steel separation disk.
The desired clearance should be 1.22 -- 2.74 mm
(0.048 -- 0.108 inches) if the clearance is greater than C
2.74 mm (0.108 inches) then fit another steel disc
under the end plate.
TH121110
132
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Position the thrust bearing inner washer, thrust C

bearing and thrust bearing outer washer over the
shaft.
TH121111
133
Press one bearing into the hub then place the spacer C
on top and press the next bearing flush to the face of
the gear. Install into the clutch assembly.
TH121098
134
Position the inner thrust washer, thrust bearing and C
outer thrust washer over the shaft. Then fit the snap
ring on top and end gear locating snap ring.
TH121112
135
Install the end gear and then press on the bearing C
with the bearing shield upwards.
TH121113
136
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Refit the two oil slip rings and lubricate. C
TH121095
137
Disassembly of D clutch (3rd speed) D
Refit the clutch piston.
TH121109
138
Install the clutch piston wear plate and then the D
belleville washers, place the first belleville washer
with the larger diameter towards the wear plate,
alternate the remaining four. Then position the snap
ring retainer, compress the belleville washers and fit
the snap ring.
TH121106
139
Fit the 5 steel separator plates and 5 friction discs, D
start with a steel separator plate on the piston and
then alternate between friction disc and steel
separator plates. Finally install the plate with the
thickes section.
TH121105
140
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Fit the end plate retaining ring. D
TH121104
141
Install the thrust bearing washer, thrust bearing and D
the outer thrust washer.
TH121103
142
Install the first the gear with its two bearings, the D
inner washer, the thrust bearing, the outer washer
and the shaft bearing inner race.
TH121108
143
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Disassembly and reassembly of the E/F clutch E

packs
Disassembly of E Clutch (1st speed)

Remove the clutch shaft oil slip rings.
TH121114
144
Remove the front bearing using a suitable puller. E
TH121115
145
Remove the outer thrust washer, bearing and inner E
thrust washer.
TH121116
146
Remove the clutch gear and hub assembly and press E
out the two pilot bearings.
TH121117
147
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Remove the outer thrust washer, thrust bearing and E

TH121118
148
Remove the clutch disc end plate retaining ring. E
TH121119
149
Remove the clutch disc end plate, then remove the E
10 friction and 10 steel separator discs.
TH121120
150
Compress the belleville washers and remove the E
snap ring, the belleville washers and the clutch piston
wear plate.
TH121121
151
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To remove the clutch piston turn the clutch over and E

tap the shaft on a block of wood.
TH121122
152
Disassembly of F Clutch (2nd speed) F
Using a suitable puller, remove the gear and rear
bearing inner race.
TH121123
153
Remove the gear locating ring from the shaft. F
TH121124
154
Remove the thrust bearing and clutch gear snap ring, F
followed by the outer thrust washer, thrust bearing
and inner thrust washer. Then remove the clutch
gear and hub with the pilot bearings.
TH121125
155
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Remove the outer thrust washer, thrust bearing and F

TH121126
156
Remove the clutch disc end plate retaining ring. F
TH121127
157
Remove the end plate and 5 friction and 5 steel F
separator discs.
TH121128
158
Compress the belleville washers and remove the F
snap ring, followed by the snap ring retainer,
belleville washers and the clutch piston wear plate.
TH121129
159
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Remove the clutch piston by turning the clutch pack F

over and tapping the shaft on a block of wood.
TH121130
160
Clean and inspect all parts for damage. Where
damage is evident replace parts and also all gaskets.
NOTE: It is more economical to replace parts when
the unit is disassembled than to carry out overhaul
due to premature faliure.
Reassembly of the E Clutch (1st speed) E

If new seal rings have been fitted to the piston make
sure they have been sized. After sizing wipe the
surfaces with a little transmission oil, the fit to the
clutch housing.
TH121131
161
Place the clutch piston wear plate onto the piston, E
then place the first belleville washer on top of the
wear plate with the large diameter downwards, then
alternate the remaining 6 washers followed by the
snap ring retainer. Compress the washers and fit the
snap ring.
TH121132
162
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Then fit the 10 steel separator discs and 10 friction E

discs.
Fit a steel separator plate first and then alternate the
friction and separator discs. Finish with the clutch
disc end pate.
TH121133
163
Then fit the end plate retaining ring. E
TH121134
164
To check the clutch disc clearance, place the clutch E
plate on end as shown so that the clutch discs are
resting on the piston. Measure the distance between
the end plate and the retainer ring using a set of 1
feeler gauges. The measurement should be within
the limits of 2.03 -- 3.43mm (0.08 -- 0.135 inches).
If the clearance is greater than 3.43mm (0.135 E
inches) add one steel sepataror disc under the end
plate.
TH121135
165
Position the inner thrust washer, thrust bearing and E
outer thrust washer over the shaft.
TH121136
166
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Press the 2 pilot bearings into the clutch gear and E

hub. Press the bearings flush with the face of the
gear. Place the clutch gear and hub on the shaft.
TH121137
167
Position the inner thrust washer, thrust bearing and E
outer thrust washer over the shaft onto the top of the
gear.
Offer the side of the bearing up to the shaft on top of
the thrust washer and visually check the snap ring
will fit. If it does not, ensure the gear and hub
assembly is fully seated on the discs.
TH121138
168
With the bearing shield upwards press on the shaft E
bearing.
TH121139
169
Fit the oil slip rings. Use some vaseline to facilitate E
reassembly into the housing.
TH121140
170
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Reassembly of the F Clutch (2nd speed) F

If new seal rings have been fitted to the piston make
sure they have been sized. After sizing wipe the
surfaces with a little transmission oil, then fit to the
clutch housing.
TH121141
171
Install the clutch piston wear plate onto the piston, F
then place the first belleville washer on top of the
wear plate with the large diameter downwards. Then
alternate the remaining 4 washers followed by the
snap ring retainer.
TH121142
172
Fit the 5 steel and 5 friction discs. F
Fit a steel separator disc first and then alternate the
friction and separator discs. Finish with the clutch
disc end plate.
TH121143
173
Install the end plate retaining ring. F
TH121144
174
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Install the inner thrust washer, thrust bearing and F

TH121145
175
Press the pilot bearings onto the clutch gear and hub, F
ensuring the bearings are pressed flush with the gear
face. Place the clutch gear and hub onto the shaft.
TH121146
176
Place the inner thrust washer, thrust bearing and F
TH121147
177
Using snap ring pliers, position the thrust washer F
retaining snap ring and clutch shaft locating snap
ring. Then install the gear with the conical section
downwards onto the snap ring.
TH121148
178
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Press the roller bearing inner race onto the clutch F

shaft with the bearing race shoulder down.
TH121149
179
Regulator valve disassembly
Using a suitable punch tap the valve retaining pin
from the regulator valve sleeve.
NOTE: The valve is under spring pressure.
TH121150
180
Remove the regulator valve piston and spring.
TH121151
181
Reassembly
Regulator valve reassembly is in reverse order of dis-
assembly. Clean and inspect all parts.
604.02.395.00 - 12 - 2002
Disassembly of the modulator valve

Remove the inner, middle and outer springs and stop
pin from the housing sleeve.
TH121237
182
Remove the accumulator spool.
TH121152
183
Remove the cross pin which is approximately 1/3 the
way up the housing sleeve, it should also be the
shorter of the two pins in the sleeve.
TH121153
184
Remove the regulator spool, spring retainer, spring
and spacer from the sleeve housing.
TH121154
185
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Remove the cross pin in the end of the sleeve, this

will be the longest of the two pins.
TH121155
186
Reassembly
IMPORTANT: Make sure the neck on the regulator
spool is not clogged.
Refit the shortest pin 1/3 the way up the sleeve and
fit the spring retainer, spacer, spring and regulator
spool. Compress the regulator spool by hand and
push in the end (larger) pin.
NOTE: The regulator spool can bottom out on the
spring retainer. Care should be taken to ensure the
spring retainer slides inside the spool.
TH121156
187
In the other end of the sleeve, place the accumulator
spool as shown.
TH121157
188
Then fit the outer, middle and inner springs and then
install the stop pins.
TH121158
189
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Disassembly of the manifold plate

Remove the reverse idler gear retaining nut and
washer.
TH121159
190
Then remove the end plate with dowel pin, reverse
idler gear, bearing and thrust washer.
TH121160
191
If the reverse idler shaft is to be replaced, support the
manifold plate around the idler shaft and press the
idler shaft from the plate.
TH121162
192
The stator support is kept in position by means of two
bull rings, remove the bull ring on the stator converter
side.
TH121163
193
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Push down the support into the transmission to

expose the retaining ring and make it possible to
remove it.
TH121164
194
Remove the stator support and thrust washer.
TH121165
195
Remove the stator support oil sealing ring and
expander ring.
TH121166
196
If the bushing and/or bearing need to be removed,
the bushing must be removed from the same end as
the needle bearing.
TH121167
197
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Compress the safety valve using a suitable hand tool

and remove the retaining washer. Remove the
spring, and from the other side of the manifold plate,
remove the poppet valve.
TH121168
198
Reassembly of the manifold plate
Reassemble in the reverse order of disassembly.
604.02.395.00 - 12 - 2002
Disassembly of the converter housing

From the top of the housing remove the hexagonal
head plug. Then using a small screwdriver, lever out
the check valve ball assembly and remove it from the
top of the housing.
TH121169
199
Remove the torque converter bearing.
TH121170
200
Remove the oil distributor.
TH121171
201
Remove the converter oil seal.
TH121172
202
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Remove the pressure test plug for the C clutch and

then using a suitable hexagonal wrench remove the
distributor lock screw.
TH121173
203
Using a suitable puller remove the C & D oil distributor
sleeve.
TH121174
204
Remove the F clutch pressure test point plug and using
a hexagonal wrench remove the distributor locking
screw. Then using a puller remove the E & F distributor
sleeve.
TH121175
205
Reassembly
Reassembly of the converter housing is carried out
in the reverse order of disassembly.
Ensure the chamfered end of the distributors are
upwards.
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Disassembling the transmission idler gear case

Use a percussion wrench to remove the retainer nut,
washer, O--ring and the front output flange.
TH121176
206
Remove sleeve outer “O” ring.
TH121177
207
Use an extractor to remove the outer sleeve and
inner O--ring.
TH121178
208
Remove the coupling sleeve snap ring.
TH121179
209
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Use a percussion wrench to remove the retainer nut,

washer, O--ring and the front output flange.
TH121180
210
Remove the idler gear case cover screws and
washers.
TH121181
211
Hook the (front) cover and fasten it to a hoist.
Use a lever to separate the two covers and then
remove the front one.
TH121182
212
Remove the idler gears and the shafts.
TH121183
213
604.02.395.00 - 12 - 2002
Pry the input asssembly from cover.
TH121184
214
Remove the output shaft assembly.
TH121185
215
If the bearing outer races have to be replaced,
remove the outer races.
TH121186
216
Remove the seal sleeve snap ring.
TH121187
217
604.02.395.00 - 12 - 2002
Use an appropriate driver to remove the sleeve gasket.
TH121188
218
Transfer case assembly

Reverse the disassembly procedure to carry out the
assembly.
At the end of assembly, lock the output flanges and
tighten the nuts at 339 – 407 Nm.
TH121189
219
604.02.395.00 - 12 - 2002
Transmission assembly
From the rear, install the rear bearing snap ring.
TH121071
220
Install the clutch shaft rear bearing outer races.
TH121070
221
Install the output shaft front bearing snap ring.
TH121069
222
From the front of transmission case, position the out-
put gear with the long hub of the gear towards the
front.
TH121190
223
604.02.395.00 - 12 - 2002
Install the output shaft rear bearing in case against

the locating ring.
TH121191
224
Put the output shaft in position. Align the splines on
the shaft with the splines in the output gear. Tap the
shaft into position.
TH121192
225
Install a new bore plug.
TH121193
226
Install the output shaft gear snap ring.
TH121194
227
604.02.395.00 - 12 - 2002
Install the output shaft front bearing in the case

against the locating ring.
TH121195
228
Install the front bearing snap ring.
TH121196
229
Install the coupling sleeve.
TH121061
230
604.02.395.00 - 12 - 2002
Install the forward/reverse (A/B) distributor sleeve

with the inside diameter chamfer out, and the notch
in the distributor aligned upwards with the retaining
screw hole in the housing.
TH121197
231
Apply some thread lock to the lock screw and install
it in the housing. Then install the plug.
TH121198
232
Install the modulation diverter in the housing.
TH121075
233
Install a new O--ring on the transmission valve body
bottom and then install the valves and the spring in
the transmission case.
TH121074
234
604.02.395.00 - 12 - 2002
Install the modulation valve case with the new O--ring

in the transmission case and tighten to the correct
torque.
TH121072
235
Install the forward/reverse shaft rear bearing.
TH121199
236
Install the C/D shaft rear bearing.
TH121200
237
Position the D clutch gear and shaft through the bear-
ing and onto the output flange.
TH121201
238
604.02.395.00 - 12 - 2002
Replace the O--ring gasket (2) of the oil delivery tube

(1) and install the delivery tube together with the net
filter. 1
TH121056
239
Firstly position the C/D clutch pack. Align the splines
of the D gear & hub already fitted with internal teeth
of the friction disc.
TH121202
240
Position the reverse/forward (A/B) clutch packs and
shaft. Use caution so as not to damage the shaft oil
slip rings.
TH121203
241
Install the E/F clutch pack and shaft rear roller bearing
into the casing and then fit the shaft and clutches.
TH121204
242
604.02.395.00 - 12 - 2002
Fit a new gasket to the transmission case using a

light coat of grease to hold it in position.
TH121205
243
Install the thrust washer and the pump control shaft
on the manifold plate.
Install the manifold plate onto the main transmission
housing. Use the dowel pins to locate the manifold
plate correctly. Ensure the manifold plate is tight
against the transmission case before installing the
bolts. Do not use the bolts to pull the plate to the
housing.
NOTE: Be careful not to damage the oil seals.
TH121206
244
Install the manifold plate to transmission housing bolts
and tighten to the correct torque.
Remember the hex head bolt on the other side of the
manifold plate.
TH121207
245
Position the swivel hub gear on the stator support.
TH121208
246
604.02.395.00 - 12 - 2002
Install the pump idler gear bearing on idler shaft.
TH121210
247
Install the pump idler gear on bearing.
TH121211
248
Install the idler gear thrust washer, aligning the hole
with the roll pin.
TH121212
249
With the “O”--rings in position, install the solenoid
cartridges.
TH121213
250
604.02.395.00 - 12 - 2002
Tighten the cartridges to the specified torque.
TH121214
251
With cartridge to coil “O”--rings in place, position the
solenoid coils on the cartridges.
TH121215
252
WIth new “O”--rings in position, install the coil to
cartridge nuts.
Tighten the cartridge nuts to specified torque.
TH121216
253
Install solenoid protection cover and mounting
screws.
Tighten the screws to the specified torque.
TH121217
254
604.02.395.00 - 12 - 2002
Position the manifold plate to converter housing

gasket using a light coat of grease to hold the gasket
in place.
TH121209
255
Position the converter housing onto the manifold
plate. To assist with this the transmission can be laid
on its back so the manifold plate is horizontal. The
converter housing to manifold plate bolts must not be
fitted until the two faces are tight against each other.
TH121218
256
Fit the housing bolts and tighten to the recommended
torque.
TH121219
257
Install the converter locating snap ring on the turbine
shaft.
TH121220
258
604.02.395.00 - 12 - 2002
Slide on the torque converter and fit the torque

converter snap ring.
TH121221
259
With a new ’O’ ring fitted, install the bore plug into the
converter assembly and fit the plug snap ring.
TH121222
260
Install the regulator valve using the fabricated tool
and tighten to the correct torque.
TH121223
261
Refit the filter onto the regulator valve.
TH121224
262
604.02.395.00 - 12 - 2002
With a new gasket in place, install the transmission

pump and tighten to the correct torque.
TH121225
263
Install the transfer case assembly.
TH121227
264
Install the transfer case washers and lock screws.
Tighten the screws to the correct torque.
TH121228
265
Install the drive plate onto the torque converter and
tighten the bolts to the specified torques.
TH121226
266
604.02.395.00 - 12 - 2002
SECTION 25 -- FRONT AXLE 1
SECTION 25 -- FRONT AXLE
CONTENT
25 100 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Wheel toe--in check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Component overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front axle removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Front axle overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Axle drive pinion bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Bevel gear pinion installation and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Front drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
SPECIFICATIONS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering differential with final

epicycloids reductions
Overall width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2050 mm (flange--to--flange)
Crown wheel and pinion ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 : 34
Final reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 6 (4 satellites)
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 degrees
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Without lock
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet disc with 8 discs + parking brake
with inner negative control
Steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With position sensor
NOTE: As to replacement intervals, oil and lubricant quantity and type for the front axle, refer to the OPER-
ATOR’S MANUAL.
604.02.395.00 - 12 - 2002
2 SECTION 25 -- FRONT AXLE
DESCRIPTION
Front view
Top view
TH125160
1
The axle fitted to this unit incorporates:
• Integral steering cylinder • Double reduction (crown wheel and pinion plus
• Steering sensor planetary hubs)
• Central drive • Service brakes and park brake with inner nega-
tive control
604.02.395.00 - 12 - 2002
OPERATION
Engine power (1) is transmitted from the engine

through the powershift transmission (2) and the drop
box (3) to the front axle (4) via the drive shaft (5).
1
2
3
5
4
TH125161
2
604.02.395.00 - 12 - 2002
TROUBLESHOOTING
PROBLEM CAUSE REMEDY
Same noise for engagement and 1. Hub bearings damaged Replace damaged elements
release
Higher noise during engagement 2. Low oil level Top up oil
rather than release
3. Crown wheel and pinion worn Check through the upper cover.
Replace worn crown wheel and pin-
ion
4. Crown wheel and pinion bear- Replace damaged elements
ings worn
5. Epicycloids planetary hub or Replace damaged elements
bearing worn
6. Pinion ring nut loose Check the crown wheel and pinion
and respective bearings. If they are
not damaged, tighten the ring nut
7. Only one pinion bearing worn See remedy No. 4
Noise under steering 8. Differential satellites and/or plan- Replace damaged elements
etary hubs damaged
“Stick slip” noise when changing 9. Universal joint damaged Check and replace the joint as
direction of travel. shown in the vehicle handbook
10. Wheel loose Check possible wheel hub disc and
stud bolt damages. If needed, repla--
ce damaged elements and tighten
the nuts to prescribed torque
11. Steering pin seals, axle shafts Check and replace damaged
or steering pivots damaged elements
12. Differential case satellites free Check through the upper cover.
Replace damaged elements
13. Differential adjusting bushes See remedy No. 8
worn
604.02.395.00 - 12 - 2002
WHEEL TOE--IN CHECK

When checking the toe--in, ensure the front wheels
are pointing straight ahead using the steering
position indicator lamp in the cabin.
Measure the distance between the two front wheels

at the front of the rim (A). Then measure the distance
between the front wheels at the rear of the rim (B).
The variance between A and B should be 0 – 2 mm

(0 – 0.078 in) = toe--in. 2
1
i.e.: B--A = 0 -- 2 mm
TH125162
To adjust front wheel toe--in, slacken both lock nuts 3
(2) and turn rims equally (1) in the same way.
Re--tighten both lock nuts (2).
The steering stops (1) are incorporated in the hubs
at each end of the axle. The stops are adjustable to
prevent the tyres contacting any part of the frame or
cab when on full lock and held by the locknut.
1
TH125163
4
COMPONENT OVERHAUL
Axle in situ
The following components can be overhauled with the
axle mounted on the unit.
• Planetary reduction hub assembly
• Steering knuckle
• Tie rod pins
• Axle drive shafts, seals and bushes
Axle removed
The following components can be overhauled with the
axle removed.
• Brake assemblies
• Differential assembly
• Pinion assembly
604.02.395.00 - 12 - 2002
FRONT AXLE REMOVAL PROCEDURE

• Extend the boom and lower to the ground.
• Chock the rear wheels.
• Place wooden wedges between the axles and
the frame to prevent the Telescopic Handler from
swinging.
• Jack--up the machine upper part and secure it on
suitable stands.
• Remove the front drive shaft.
TH125164
5
• Remove the wheels.
• Disconnect the steering hoses (1).
NOTE: Ensure both pipes are plugged to prevent con- 2
stant oil leaking.
• Disconnect the steering angle sensor (2).
1
TH125165
6
• Remove the power (3) and park (4) brake pipes.
3
TH125166
7
• Remove the four axle levelling cylinder fixing
screws (5).
• Support the axle and remove the four fixing
screws (6).
• Lower and remove the axle from the vehicle bot-
tom with a wheeled jack.
NOTE: Some items which require servicing after axle
removal may be more easily loosened while the axle
is in--situ, i.e. steering tie rod ends.
5 6
TH125167
8
604.02.395.00 - 12 - 2002
FRONT AXLE OVERHAUL 2

STEERING CASE REMOVAL
7
Support the axle (1) or leave it mounted and remove
the steering tie rod pins (2).
Sling the whole assembly (7) and hook it to the hoist,
slightly pulling the tie rod.
TH125001
9
Unloose and remove the fitting screws (3) from the
bottom pivot pin (4).
NOTE: Screws cannot be re--used.
TH125002
10
Remove the bottom pivot pin (4) complete with the
front sealing ring (5).
5
Remove the front sealing rings (5).
NOTE: Note down the side for assembly.
If the ball cover needs replacing, remove it from the
bottom pivot pin.
4
TH125003
11
Unloose and remove the fitting screws (3) from the
top pivot pin (6).
TH125004
12
604.02.395.00 - 12 - 2002
Using two levers, remove the top pivot pin (6) com-
plete with front seal (5). Pay attention not to damage
the surfaces.
Remove the front sealing rings (5).
NOTE: Note down the side for assembly.
If the ball cover needs replacing, remove it from the 5
bottom pivot pin.
6
TH125005
13
Remove the complete steering knuckle (7).
TH125006
14
Using a puller for inner parts, remove the top bush (8)
and the bottom ball--bush (9).
TH125007
15
604.02.395.00 - 12 - 2002
HOW TO ASSEMBLE THE COMPLETE

STEERING KNUCKLE
Lubricate the top bush (8) and the bottom ball bush
(9) and fit them into the fulcrum holes of the arm.
Use tools T3 and T4. T3
9
8 T4
TH125009
16
Lubricate the terminal of the u--joint (10) and install
the steering case (7).
Pay due attention not to damage the dust cover rings
7
and the sealing rings.
TH125006
10
17
Fit a new seal (5) onto the top pivot pin (6). Lubricate
and install the unit in the steering case. Position the
screws (3) and lightly tighten.
Check the correct assembly side of the seal (5).
TH125005
18
Fit a new seal (5) onto the bottom pivot pin (4). Lubri-
cate and fit the unit in the steering case. Position the
screws (3) and lightly tighten. 5
Check for the correct assembly side of the seal (5).
4
TH125003
19
604.02.395.00 - 12 - 2002
Tighten the new fittinig screws (3) of top and bottom

pivot pins in sequence using the cross tightening
method.
Torque wrench setting: 128÷142 Nm. 3
3
TH125010
20
Connect the steering tie rod (2) (See “STEERING
2
CYLINDER INSTALLATION”).
NOTE: Lubricate joints with Molikote.
TH125001
21
604.02.395.00 - 12 - 2002
DOUBLE UNIVERSAL JOINT REMOVAL

Loosen and remove upper and lower dowel (3) lock
nuts (2).
Remove upper and lower bush retaining dowels (3). 2
3
TH125012
22
Remove the entire u--joint (4).
NOTE: To remove the u--joint use, if necessary, a
plastic hammer or a lever.
TH125013
23
Remove the snap ring (5) from the bushing unit (9).
TH125014
24
Position the entire u--joint (4) under a press and
remove the complete bush (9).
TH125015
25
604.02.395.00 - 12 - 2002
Remove the snap ring (6) from the bearing (7).

Use a puller to remove the bearing (7) the sealing ring
(8) and the O--ring.
NOTE: Note down the assembly side of the ring (8).
7 6
7
8
TH125016
26
1 3
2
5
2
4
8
3
9
10
TH125017
27
604.02.395.00 - 12 - 2002
INSTALLATION OF U--JOINT
Using tools T5 and T6, insert the sealing ring (9) and
the bearing (8) in the bush (7).
NOTE: Carefully check the assembly side of the seal
(8). T5 T6
8 7
9
9
TH125018
28
Fit the snap ring (6) on the bearing (7).
TH125019
29
Heat the bearing in oil at an approx. temperature of
100 °C and fit the entire bush (9) on the u--joint (4).
TH125020
30
Fit the snap ring (5) on the bushing unit (9); also
install the O--ring (10).
10
5
9
TH125014
31
604.02.395.00 - 12 - 2002
Insert the u--joint and tighten the top and bottom

dowels (2).
Torque wrench setting: Max. 15 Nm.
2
NOTE: For u--joint coming with a bush, centre the
point of the check dowels in the slot..
TH125022
32
Apply Loctite 242 to the jutting parts of the dowels 3 2
(2).
Screw the check nuts (3) of the dowels (2) and lock
them using a torque wrench.
Torque wrench setting: 122 Nm.
TH125023
33
604.02.395.00 - 12 - 2002
HOW TO DISASSEMBLE THE PLANETARY

REDUCTION GEAR 1
Disconnect the tie rod from the steering knuckle.
For details, see “HOW TO REMOVE THE COM-
PLETE STEERING KNUCKLE”.
Remove the securing screws (1) from the planetary
carrier cover (2).
2
TH125024
34
Loosen the planetary carrier cover (2) from the steer-
ing knuckle (3) by alternatively forcing a screwdriver
into the appropriate slots.
2
TH125025
35
Remove the complete planetary carrier cover (2).
TH125026
36
Unloose and remove the tightening nuts (4) from the
crown flange (5).
TH125027
37
604.02.395.00 - 12 - 2002
Remove the safety flange (6).
TH125028
38
Using a puller, remove the complete crown flange (5)
by acting on the stud bolts.
5
TH125029
39
Partially extract the hub using a plastic hammer.
NOTE: Alternately hammer on several equidistant 8
points.
Remove the external bearing (8).
TH125030
40
Remove the complete hub (7) by hand.
7
TH125031
41
604.02.395.00 - 12 - 2002
Remove the pivot pins and remove the steering

knuckle (3).
For details, see “HOW TO REMOVE THE COM- 3
PLETE STEERING CASE”.
TH125032
42
Remove the snap rings (9).
TH125033
43
With the help of a puller, remove the planetary gears
(10).
NOTE: Note down the correct assembly position of 10
the planetary gears.
TH125034
44
Remove the snap ring (12) from the crown (13).
12
13
TH125035
45
604.02.395.00 - 12 - 2002
Remove the crown flange (5).
TH125036
46
Remove the sealing ring from the hub (14).
14
TH125037
47
Remove the internal bearing (15).
15
TH125038
48
Remove the external thrust blocks from the bearings
(8) and (15) forcing a pin--driver into the appropriate
slots on the hub (7).
NOTE: Hammer in an alternate way so as to avoid
seizure or deformation of the thrust blocks.
TH125039
49
604.02.395.00 - 12 - 2002
Use a puller to remove the centring ring (16), the

sealing ring (17) and the bearing (18) from the steer- 16
ing knuckle (3).
16 17 18
NOTE: Note down the orientation of both centring
ring (16) and sealing ring (17).
17
18
3
TH125040
50
604.02.395.00 - 12 - 2002
ASSEMBLING THE PLANETARY REDUCTION

GEAR 3 T7
Lubricate the bushing (18) and the seat of the steer-
ing knuckle (3).
Install the bushing (18), using tool T7.
18
TH125041
51
Lubricate the outer surface of the sealing ring (17)
and centring ring (16); fit them into their seat using
tool T8. T8
16 17
TH125042
52
Position the lower part of tool T9A and the thrust
block of the external bearing (8) under the press.
8
T9A
TH125043
53
Lubricate the seats of the bearings and position the
hub (7); on tool T9A; position the thrust block of the
internal bearing (15).
NOTE: Check that the thrust block is correctly 7
oriented.
15
T9A
TH125044
54
604.02.395.00 - 12 - 2002
Position the upper part of tool T9B and press the

thrust blocks into the hub (7) all the way down.
T9B
7
TH125045
55
Fit the bearing (15) into the internal thrust block.
15
TH125046
56
Apply a jointing compound for repositionable fixtures
to the outer surface of the sealing ring (14).
Position the sealing ring (14) in the hub (7). 14
NOTE: Check that the ring (14) is correctly oriented. 7
TH125047
57
Position tool T10 and press the sealing ring (14) into
its seat.
T10
14
TH125048
58
604.02.395.00 - 12 - 2002
Insert the flange (5) in the crown (13).
13
TH125036
59
Insert the snap ring (12) in order to fix the flange (5)
in the crown (13).
12
NOTE: Carefully check that ring (12) is properly 13
inserted in the slot of the crown (13).
5
TH125156
60
With the help of tool T11, insert the planet wheel
gears (10) into the cover (2).
T11
Accurately check the orientation.
10
TH125050
61
Lock the gears (10) into position by fitting the snap
rings (9).
TH125033
10
62
604.02.395.00 - 12 - 2002
Fit the steering knuckle (3) onto the U--joint (19) and
install the articulation pins. For pin assembly details,
see “HOW TO ASSEMBLE THE COMPLETE 3
STEERING CASE”.
19
TH125032
63
Install the hub (7).
7
TH125031
64
Install the external bearing (8).
8
NOTE: Using a plastic hammer, drive the bearing to
the limit stop by lightly hammering around the edge.
TH125030
65
Fit the complete crown flange (5).
NOTE: In order to fasten the flange (5), use a plastic 5
hammer and alternately hammer on several equidis- 6
tant points.
Apply Tecnolube Seal 101 grease to the surface of
the safety flange (6) which touches the crown flange
(5).
Fit the safety flange (6).
TH125028
66
604.02.395.00 - 12 - 2002
Apply Loctite 242 to the studs and fit in the nuts (4).
Cross tighten the nuts (4) in two stages.
Initial torque wrench setting: 120 Nm
Final torque wrench setting: 255÷285 Nm 4
TH125053
67
Fit the planetary carrier cover (2) onto the hub (3).
20 3
ATTENTION
Check that the O--ring (20) is in good condition and
in position.
2
TH125026
68
Lock the planetary carrier cover (2) by tightening the
screws (1).
Torque wrench setting for screws: 40÷50 Nm 1
TH125055
69
604.02.395.00 - 12 - 2002
HOW TO REMOVE THE STEERING CYLINDER

Remove the centring sensor (1) of the steering pis-
ton, if supplied.
1
TH125056
70
Remove the safety cotter pins (3) from the articula-
tion pins (4) of the tie rod bars (5).
ATTENTION 5
Dispose of used cotter pins.
6
Remove the castellated nuts (6) that lock the articu-
lation pins (4). 3 4
TH125057
71
Disconnect the tapered pins of the articulation (4)
from the steering knuckle (7) by means of a puller.
7
TH125058
72
If the connection of the steering bars includes a
safety collar (13), raise the border.
13
TH125059
73
604.02.395.00 - 12 - 2002
Disconnect left and right tie rods from the piston (2).
TH125060
74
Remove the securing screws (8) from the steering
cylinder (9).
Extract the cylinder (9) using a plastic hammer.
9
NOTE: For cylinder disassembly, refer to “HOW TO
DISASSEMBLE THE STEERING CYLINDER”.
8
TH125061
75
604.02.395.00 - 12 - 2002
HOW TO INSTALL THE STEERING CYLINDER

Check that the O--rings of the axle unit are in good
condition; lubricate the seats of the seals and fit the
steering cylinder (9) into its seat. 9
Lock the cylinder by cross--tightening the screws (8).
Torque wrench setting: 116÷128 Nm
8
TH125063
76
Apply Loctite 242 to the thread and connect the tie
rods by screwing the terminals onto the piston stem. 13
Torque wrench setting: 240÷270 Nm
NOTE: Versions with coupling require than the rim of
the articulation (13) is riveted onto the surface of the
piston stem.
TH125064
77
Insert the pins (4) in the steering knuckle (7) and lock
them in that position by tightening the nuts to
A
260÷290 Nm.
Find the notch position on the basis of the split pin
hole and tighten the nuts further.
ATTENTION
Check rubber guard integrity (A).
Insert split pins and bend safety stems.

7
ATTENTION
Use new split pins. TH125065
78
If fitted, insert the proximity sensor (1) to check the
piston location and tighten the screws (10).
Tightening torque: 5÷6 Nm.
10
TH125056
79
604.02.395.00 - 12 - 2002
ATTENTION
T12
Eliminate the action of the negative braken if fitted.
Apply tools T12 to the hubs and lock them.

Using a level “B”, check that tools are perfectly flat
and parallel to each other.
B
T12
TH125067
80
Connect the sensor (1) to the inspection device
according to either diagram.
TH125068
81
Sensor connection card, STANDARD version.
TH125069
82
Sensor connection card, OPTIONAL version.
TH125070
83
604.02.395.00 - 12 - 2002
Centre the piston by slowly moving it first in one = =

direction then in the other and position it half way on
the stroke, which is determined by the switching on
and off of the signal lamp of the inspection device in
the reversal stage.
TH125071
84
Inspect jut “C” on one side of the piston and note
down the size for checking later adjustments.
NOTE: If cylinders come without a sensorm the cen-
C
tring of the piston must be carried out on the basis of
the maximum stroke.
TH125072
85
Without moving the piston, check front and rear size
at the edge of tools T12.
Max. difference: 0.6÷0.7 mm
NOTE: In order to check the rear size, rotate the
bevel gear pinion and check that tools T12 are flat.
T12
TH125073
T12
86
If necessary, adjust convergency without moving the
centring of the piston and adjust the length of the tie
rods (5).
5
NOTE: With a half turn of screw, the front size is
reduced by about 3 mm, whereas the rear one is
increased by about 3 mm.
TH125074
87
604.02.395.00 - 12 - 2002
Loosen the nuts (11) and screw them onto the ball--
and--socket joints.
Hold the steering knuckles still and rotate the ball--
and--socket joints. Once the convergency has been
adjusted, lock the nuts (11). 11
Torque wrench setting for nuts: 298÷328 Nm
TH125075
88
604.02.395.00 - 12 - 2002
HOW TO DISASSEMBLE THE STEERING

CYLINDER 2
Remove the snap ring (1) from the cylinder head (2).
TH125077
89
With the help of a plastic hammer, push the head (2)
inside the cylinder (3).
NOTE: The head should line up with the edge of the
3
cylinder.
TH125078
90
With the help of a drift, apply pressure to the stop ring
(4) that is placed inside the cylinder (3) and extract
the ring using a screwdriver.
3
TH125079
91
Hammer the piston (5) up to the rear of the head (2)
using a plastic hammer.
Continue hammering until the head (2) is ejected
from the cylinder (3).
5
3
TH125080
92
604.02.395.00 - 12 - 2002
Disassemble the cylinder unit (3) by extracting first

the head (2), then the piston (5). 5
A
ATTENTION
Note down the assembly side of the piston. The 2
bevelled part “A” of the piston is oriented towards the
head (2).
3
Remove all seals, anti--extrusion rings and scraper
rings from head (2), cylinder (3) and piston (5).
NOTE: 1 -- All seals must be replaced every time the TH125081
unit is disassembled. 2 -- Particular attention must be 93
paid not to damage the seats of both seals and piston
slide.
9
2
6
7
10 8
11 4
1
8
7
6 12
13
3
TH125082
94
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HOW TO ASSEMBLE THE STEERING CYLINDER 7 8

After applying grease, install the sealing ring (6) of
the shaft, the anti--extrusion ring (7) and the scraper
ring (8) inside the cylinder (3).
ATTENTION
Thoroughly check thet positioning of the anti--extru-
sion (7).
6
TH125083
95
After applying grease, install the sealing ring (6) of
the shaft, the anti--extrusion ring (7) and the scraper 8 7 6
ring (8) in the head (2).
ATTENTION
Thoroughly check that positioning of the anti--extru-
sion (7) ring is correct.
TH125084
96
Fit the seal (9) onto the outside of the head (2).
9
ATTENTION
1 -- In order to facilitate assembly, apply grease to the
outer surface of the piston.
2 -- Do not roll the seal (9) up.
TH125085
97
Prepare the piston (5) by fitting it with the guide ring
11 10
(10), the magnetic ring (11), the O--ring (12) and the 13
seal (13).
12
ATTENTION 5
1 -- In order to facilitate assembly, apply grease.
2 -- If a centring sensor is not fitted, then the magnetic
ring (11) should be replaced by guide ring (10).
TH125086
98
604.02.395.00 - 12 - 2002
Apply tool T18 to the shaft on the opposite side of the

head and centre it on the cylinder (3) so that it fits into
the piston (5).
NOTE: Apply a little grease to seals and cylinder. 5 T18
TH125087
99
Push the piston (5) into the cylinder for 100 mm using
a plastic hammer.
5 3
TH125088
100
Remove tool T18 and apply it to the opposite side of
the piston (5).
Apply grease to head (2) seals, fit the head onto the 2
piston and push it into the cylinder (3) using a plastic
hammer.
T18
NOTE: Insert the head as to line it up with the edge
of the cylinder.
TH125089
101
Insert the stop ring (4) ensuring that it fits into the seat
of the cylinder (3). 4
TH125090
102
604.02.395.00 - 12 - 2002
Apply pressure to the head using two screwdrivers

or levers until the head is fastened onto the stop ring
(4).
TH125091
103
Fit the snap ring (1) on the head (2).
2
ATTENTION
Make sure that the snap ring (1) is securely fastened
in its seat.
If necessary, force it into its seat using a drift and a
hammer.
TH125077
104
604.02.395.00 - 12 - 2002
HOW TO REMOVE AND DISASSAMBLE

THE DIFFERENTIAL UNIT
Remove the complete arms.
For details, see “CHECKING WEAR AND REPLAC-
ING THE BRAKING DISKS”.
TH125092
105
Mark the position of the ring nuts (1).
Remove the fitting screws (3) from the ring nuts (1).
3
1
TH125093
106
Uniformly heat the ring nuts (1) up to a temperature
of 80°C.
Apply tool T13 and remove the ring nuts.
NOTE: Accurately clean the threaded portions of T13
ring nuts, body and cover.
TH125094
107
Remove the fitting screws (4) from the middle cover
(5). 4 5
4
TH125095
108
604.02.395.00 - 12 - 2002
Insert a screw--driver in the opposing slots then force

and remove the middle cover (5) and the complete 6
differential unit (6). 5
NOTE: Support the pieces using a rod.
TH125096
109
If the bearings need replacing, extract the external
thrust blocks of the bearings (7) and (8) from middle
cover (5) and central body (2). 2 8
NOTE: Accurately check the O--ring (9).
5 7
TH125097
110
Remove the fitting screws (11) from the crown (12).
11
12
TH125099
111
If the bearing need replacing, extract the bearing (7)
and remove the crown (12).
7
12
TH125100
112
604.02.395.00 - 12 - 2002
Remove the shim washer (13) and the planetary gear

(14).
13
14
TH125101
113
If the bearing need replacing, extract the bearing (8)
from the differential carrier (15).
15
TH125102
114
Remove the snap rings (16) from the two pins (17) of
the planet wheel gears (18).
17
16
TH125103
115
Insert tool T14 between the planet wheel gears (18).
T14
18 18
TH125104
116
604.02.395.00 - 12 - 2002
Force tool T14 in--between the planet wheel gears

(18) using two pin--drivers.
ATTENTION
Make sure that tool T14 is perfectly lined up with the
pins (17) when locked.
17
TH125105
117
Place the differential carrier (15) under a press, posi-
tion bush T15 and insert gudgeon T16A. Press T16A T16B
pin to limit position. T15
T16B
17
15
TH125106
118
Remove gudgeon T16A and bush T15.
NOTE: In this condition the tool T14 contains pin
(17). T16A
T15
TH125107
119
Remove tool T14 together with the pin (17) of the
planet wheel.
17
TH125105
120
604.02.395.00 - 12 - 2002
Leave the released planetary gear in position and

again lock tool T14. T14 18
Repeat the operations for the extraction of the pin of
the 2nd planet wheel.
Repeat the operations for all other pins.
18
TH125104
121
Remove tool T14 and remove the last two planet
wheel gears (18), the 2nd differential unit gear (14)
and the relative shim washer (13) from the differential 14
carrier.
13
15
TH125108
122
4
3
5 16
1
20
9 11
17
19
20
17 16
18 19
13
14
7
13
15 10
2
12 18 8
17 19
20
16 19
17
20
6
16
TH125109
123
604.02.395.00 - 12 - 2002
ASSEMBLING
Insert the shim washer (13), and the planetary gear
(14) in the differential carrier (15). 14
13
15
TH125108
124
Position the shim washer (19) and the first planet
wheel gear (18). 18
Hold them in position using bar T16C.
T16A
T16C
19
TH125110
125
With the help of gudgeon T16A, position the second
planet wheel gear (18) and the relative shim washer 18
(19).
19
T16C
TH125111
126
Insert tool T14 between the two planetary gears (18).
Line up the entire unit by pushing bar T16C all the
way down until gudgeon T16A is ejected. T14
T16C
TH125112
127
604.02.395.00 - 12 - 2002
Lock tool T14 behind the planet wheel gears (18).

After locking, remove bar T16C. T14
18 18
TH125104
128
Fit the snap rings (20) onto the pins (17).
20 17
TH125113
129
Place the differential carrier (15) under the press,
position bush T15 and insert the planet wheel pin T16B
(17). 17
Put gudgeon T16B on top of the planet wheel pin T15
(17). T16B
17
TH125114
130
Press T16B pin all the way down.
T16B
T15
T16B
15
17
TH125106
131
604.02.395.00 - 12 - 2002
Remove gudgeon T16B, bush T15 and fit the snap

ring (16) on the pin (17).
ATTENTION
Make sure that the snap ring centres the seat and 16
that it rests on the surface on the differential carrier.
Repeat the operations on the other planet wheel pin 17
or planet wheel axle.
TH125115
132
Position the second planetary gear (14) in the differ-
ential carrier (15).
14
15
TH125116
133
Position the shim washer (13) on the crown (12).
NOTE: In order to hold the shim washer (13) in posi-
tion, apply grease to it. 13
12
TH125117
134
Position the crown (12) on the differential carrier (15)
and lock it with screws (11) applied with Loctite 242. 11
12
Torque wrench setting for screws: 128÷142 Nm.
NOTE: Secure the screws using the cross--tighten-
ing method.
15
TH125118
135
604.02.395.00 - 12 - 2002
Install the bearings (7) and (8) using tool T17.
8
T17
7
T17
TH125119
136
If the bearings are replaced, insert the external thrust
blocks in the middle cover (5) and in the central body 2
(2).
TH125120
137
Position the differential unit (6) in the central body (2)
with the help of a bar and fit the middle cover (5). 1
2 9
NOTE: Thoroughly check the state of the O--ring (9) 5
and make sure that the cover is fitted with the oil dis-
charge in the lower position.
TH125121
138
Lock the middle cover (5) with screws (4).
Torque wrench setting for screw: 23.8÷26.2 Nm.
4
5
4
4
TH125122
139
604.02.395.00 - 12 - 2002
NOTE: If the ring nuts (1) are removed, spread them

with Loctite 242.
Tighten ring nuts on the crown side until clearance
T13
between pinion are crown is zero, then lock the
crown; go back 1/4÷1/2 turn.
TH125123
140
Pre--set the bearings by means of the ring nut situ-
ated on the opposite side of the crown, so as to
increase pinion torque up to 140÷210 Ncm.
ATTENTION T19
If bearings are not new, check the static torque; if
bearings are new, check the continuous torque.
TH125124
141
Introduce a dial gauge with adjustable pointer “A”
through the top plug hole.
A
Position the did sense with adjustable pointer on the 12
centre of one of the teeth of the crown (12), pre--load
to 1 mm and then reset it to zero.
TH125125
142
Manually move the crown (12) in both directions in
order to check the existing backlash between the pin- 12
ion and the crown.
TH125126
143
604.02.395.00 - 12 - 2002
Adjust the backlash between the pinion and the

crown by loosening one of the ring nuts (1) and
tightening the opposite to compensate.
Normal backlash: 0.18--0.23.
T13
Difference between MIN and MAX clearance for
whole circumference should not exceed 0.09 mm.
TH125123
144
Apply Loctite 242 to the screws (3), fit them into one
of the two holes and tighten.
Torque wrench setting: 23.8÷26.2 Nm. 3
Fit the top plug after applying repositionable jointing
compound for seals to the rims.
TH125127
145
Re--install the complete arms.
ING THE BRAKING DISKS”.
TH125092
146
604.02.395.00 - 12 - 2002
HOW TO REMOVE THE AXLE DRIVE PINION

Remove the complete arms and the differential unit.
ING THE BRAKING DISKS” and “REMOVING THE
DIFFERENTIAL UNIT”.
TH125092
147
If disassembly is awkward, heat the check nut (1) of
the flange (2) at 80°C.
NOTE: Heating is meant to loosen the setting of Loc- 2
tite on the nut (1).
1
TH125128
148
Position tool T20A (or T20B), so as to avoid pinion
rotation. T20A
Unloose and remove the nut (1); also remove the (T20B)
O--ring (3).
TH125129
149
Remove the flange (2) complete with guard (4) by
means of a puller.
TH125130
150
604.02.395.00 - 12 - 2002
Remove the swinging support (5).

5
TH125131
151
Remove the sealing ring (6).
TH125132
152
Position wrench T22 onto the ring nut (7) and apply
bar hold T21 to the pinion.
Stop wrench T22 and rotate the pinion so as to
release and remove the ring nut (7).
NOTE: If disassembly proves awkward, heat the ring 7
nut to approx. 80 ° C. T21
T22
TH125133
153
Apply blocks T23 and, with the help of a puller,
extract the pinion (8) complete with the internal bear-
ing, the distance piece and shims. T23
NOTE: The thrust blocks of the bearings remain in 8

the central body (12).
TH125134
154
604.02.395.00 - 12 - 2002
Remove the pinion (8), shims (11) and spacer (10).

10
8
11
TH125135
155
Using a puller and a press, remove the inner bearing
(9) from the pinion (8).
TH125136
156
Remove the external bearing (13) thrust block.
13
TH125137
157
Insert a drift in the appropriate holes and remove the
internal bearing (9) thrust block as well as the shim
washers (14).
14
TH125138
158
604.02.395.00 - 12 - 2002
14
10
13
6
5
11
3
7
1 4
TH125139
159
604.02.395.00 - 12 - 2002
AXLE DRIVE PINION BEARING

ADJUSTMENT 3
Use the specific tool.
Tighten the tool in a vice and insert the bearing (1) 2
from above, the spacer (2) and the other bearing (3).
1
TH125140
160
Insert the other tool elements and tighten the nut (4)
until the bearing/spacer unit is packed.
4
TH125141
161
Use a depth gauge (range 0--15 mm) to measure the
Q
Q value between the tool upper surface and the push
rod.
TH125142
162
Mount the bearing outer housing on the differential
case.
Install the bearings and the spacer in the differential
case with the tool.
Tighten the nut tool so that the bearing/ spacer unit
is packed.
TH125143
163
604.02.395.00 - 12 - 2002
Use a depth gauge(range 0--15 mm) to measure the

Q1 value between the tool upper surface and the
push rod (as it was done in the vice).
S1 = Q1--Q corresponds to the shim to be inserted
between the spacer and the bearing inner race.
TH125144
164
Check the nominal value (X) indicated on the pinion
(5) and add to it or subtract from it the Y variation indi-
cated on the pinion head in order to obtain measure-
ment Z. 5
118
E.g. X=118 mm Y=0.1 mm Z= 118--0.1=117.9 mm
X
Install tool XXXXX on the differential case and
measure the Q2 value between the flange and the
bearing inner housing. If Q2 is added to the fixed (+0.1)
value Q3=50mm (value from the theoretical starting
point of the pinion primitive generating line to the sur- Y
face measured by the tool) the W value is obtained.
TH125146
165
E.g.: Q2=68.7 mm W=68.7+50=118.7 mm
The S2 value is obtained also from W--Z correspon-

ding to the shim to be inserted between the bearing
and the pinion head.
E.g.: S2=118.7--117.9=0.8 mm
TH125145
166
604.02.395.00 - 12 - 2002
HOW TO INSTALL AND ADJUST THE AXLE

DRIVE PINION
Place the inner bearing (9), the shim “S2” previously
defined (if needed), and the pinion (8) under a press.
Force the bearing against the pinion.
TH125147
167
Fit the pinion (8), shim “S1” (11) and spacer (10) in
the main body. 10
8
NOTE: The finer shims must be placed between the
thicker ones.
11
TH125135
168
Insert the external bearing (13) in the central body in
order to complete the pack arranged as in the figure.
9 10
11 13
TH125148
169
Connect the pinion (8) to the tie rod T28A and T28B;
connect the tie rod T28C (see special tools) to the
press and block.
TH125149
170
604.02.395.00 - 12 - 2002
Apply Loctite 242 to the thread of the ring nut (7) and
screw the nut onto the pinion (8).
7
8
TH125150
171
Apply special wrench T22 to the ring nut (7) and bar--
hold T21 to the pinion (8).
Lock the wrench T22 and rotate the pinion using a
torque wrench, up to a minimum required torque set- T21
ting of 500 Nm.
T22
TH125151
172
Install the bar--hold T19 onto the pinion (8) and with
the help of a torque metre, check the rotation torque
of the pinion (8).
Torque: 120--170 Ncm.
T19
ATTENTION
If torque exceeds the maximum value, then the size
of shim “S1” (11) between the bearing (13) and the
spacer (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.
TH125124
173
ATTENTION
If torque does not reach the minimum value, then the
size of shim “S1” (11) needs to be reduced.
ATTENTION
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 rotation torque of the pinion (8).
604.02.395.00 - 12 - 2002
Lubricate the outer surface of the new sealing ring (6)

and fit it onto the central body (12) using tool T27.
6
T27 12
TH125152
174
Install the swinging support (5).
NOTE: Check that it is properly oriented. 5
TH125131
175
Fit the flange (2) complete with the guard (4) and
fasten it.
For seating the flange (2), use a plastic hammer if
necessary.
NOTE: Make sure that the guard (4) is securely fas-
tened onto the flange and that it is not deformed.
2
4
TH125153
176
Apply Loctite 242 to the threaded part of the pinion.
Position tool T20A (or T20B) and fasten it in order to
avoid rotation. Insert O--ring (3), the nut (1) and tighten
it using a torque wrench.
Torque wrench setting: 280÷310 Nm.
T20A
(T20B)
TH125154
177
604.02.395.00 - 12 - 2002
Remove blocks T23 (used for extracting the pinion)

and re--install the differential unit and the arms.
For details, see “HOW TO ASSEMBLE AND INSTALL
THE DIFFERENTIAL UNIT” and “CHECKING WEAR
AND REPLACING THE BRAKING DISKS”.
T23
TH125155
178
604.02.395.00 - 12 - 2002
FRONT DRIVE SHAFT
Specifications
Length (A) closed: . . . . . . . . . . . . . . . . . . . . 662 mm
Extension (B): . . . . . . . . . . . . . . . . . . . . . . . . 72 mm
TH125168
179
FRONT DRIVE SHAFT REMOVAL

1
ATTENTION
Support the drive shaft with suitable instruments dur-
ing removal.
Slacken the locking stud bolt (2) screws (1) to discon-

nect the drive shaft (3) front part. Carry out the same
operation for the drop box side and remove the drive
shaft (3). 3
1 2
TH125169
180
604.02.395.00 - 12 - 2002
Spider removal
1. Clean the assembly components thoroughly after
removing the drive shaft.
NOTE: Since the drive shaft is a sliding assembly, it
is recommended to mark the fork and the shaft both
sides with a piece ot chalk.
TH125170
181
2. Remove the lubricator from the spider and install
a flanged fork (1) on the vice shoes to make it
possible to extract the drive shaft spider (5).
3
3. Remove safety snap rings and hit the shaft upper
side with a hammer. 2
Remove the bearings (3) and the shaft.
1
3
TH125171
182
4. Place the spider pins on the vice shoes and beat
the flanged fork to remove the bearings.
5. Repeat the same operations on the opposite side

(only for front shaft).
TH125172
183
604.02.395.00 - 12 - 2002
Spider installation
1. Lock the flanged fork. Insert the spider in the
flanged fork following the lubricator hole direc-
tion.
Lubricator hole
TH125173
184
2. It is recommended to use a locating punch to
position the bearing correctly. In this way the
bearing can be inserted over the spider pin in the
right way.
3. Remove the locating punch and insert the sec-

Punch
ond bearing on the opposite side. Then insert
snap rings. Bearing
4. Repeat operations 2 and 3 to match the spider

and the shaft.
Locating pin
5. Fit again the lubricator. TH125174
185
6. Repeat the above mentioned operations on the
universal joint opposite side (only for front shaft).
7. Apply grease with the lubricators until it is visible

next to each bearing gasket.
604.02.395.00 - 12 - 2002
SECTION 27 -- REAR AXLE 1
SECTION 27 -- REAR AXLE
CONTENT
27 100 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Operation diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear axle removal procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering differential

with final epicycloids reductions
Overall width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2050 mm (flange--to--flange)
Crown wheel and pinion ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 : 34
Final reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 6 (4 satellites)
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 degrees
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Without lock
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet disc with 8 discs
Steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With position sensor
NOTE: For replacement intervals, oil and lubricant quantity and type for the rear axle, refer to the OPERATOR’S
MANUAL.
604.02.395.00 - 12 - 2002
2 SECTION 27 -- REAR AXLE
DESCRIPTION
Front view
TH127001
Top view
TH127002
1
The axle fitted to this unit incorporates:
• Integral steering cylinder • Double reduction (crown wheel and pinion plus
• Steering sensor planetary hubs)
• Central drive • Power brakes
604.02.395.00 - 12 - 2002
OPERATION DIAGRAM
Engine power (1) is transmitted from the engine

through the transmission (2) and the drop box (3) to
the rear axle (4) via the drive shaft (5).
1
2
TH127003
2
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REAR DRIVE SHAFT
Specifications
Length (A) closed: . . . . . . . . . . . . . . . . . . . 1347 mm
Extension (B): . . . . . . . . . . . . . . . . . . . . . . . . 72 mm
TH127005
3
ATTENTION
1 2
Support the drive shaft with suitable instruments dur-
ing removal.
Slacken the locking stud bolt (2) screws (1) to discon- 3

nect the drive shaft (3) front part. Make the same
operation on the rear side and remove the drive shaft
(3).
NOTE: Refer to Section 25 “FRONT AXLE” for drive
shaft spider removal.
TH127004
4
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COMPONENT OVERHAUL
Axle in situ
The following components can be overhauled with
the axle mounted on the unit.
• Planetary reduction hub assembly
• Tie rod pins
• Axle drive shafts, seals and bushes
Axle removed
The following components can be overhauled with
the axle removed.
• Brake assemblies
• Differential assembly
• Pinion assembly
REAR AXLE REMOVAL PROCEDURE

• Chock the front wheels.
• Place wooden wedges between the axles and
the frame to prevent the Telescopic Handler from
swinging.
• Jack--up the machine upper part and secure it on
suitable stands.
• Remove the rear drive shaft.
• Remove the wheels.
• Disconnect the steering hoses (1).
NOTE: Ensure both pipes are plugged to prevent
constant oil leaking. TH127006
• Disconnect the steering angle sensor (2). 5

• Remove the power and park brake pipes.
1 2
• Remove the four axle levelling cylinder fixing
screws.
• Support the axle and remove the four fixing
screws.
• Lower and remove the axle from the vehicle bot-
tom with a wheeled jack.
NOTE: Some items which require servicing after
axle removal may be more easily loosened while the
axle is in--situ, i.e. steering tie rod ends.
TH127007
6
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OVERHAUL
Pivot bushes
Remove the front and rear pivot casing from the axle
and lever the bushing from the casing. Inspect the
bush and pivot for wear.
TH127008
7
The axle fitted to the rear of the Telescopic Handler
is almost identical to that fitted to the front. Therefore
when overhauling the following components refer to
Section 25.
• Axle hubs
• Tie rod pins
• Axle shafts
• Axle trumpet housing
• Brake housing
• Differential crown wheel and pinion
• Steering cylinder
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SECTION 33 -- BRAKES 1
SECTION 33 -- BRAKES
CONTENT
33 000 Power brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Brake release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake disc adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Brake disc replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS
Brake operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Powered hydraulic

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet discs, piston operated
Brake discs (front axle, per side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
(rear axle, per side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
NOTE: For replacement intervals, oil and lubricant quantity and type for the brake system, refer to the OPER-
ATOR’S MANUAL.
604.02.395.00 - 12 - 2002
2 SECTION 33 -- BRAKES
POWER BRAKES
1. Brake pedal
2. Brake pump
3. Oil sump
3 4. Front axle
5. Rear axle
1
2
4 5
TH133043
1
Description and operation

The vehicle brakes on the front and rear axles. All The footbrake operates the pump which actuates the
front and rear axles are equipped with 4 + 4 discs (4 front and rear assemblies hydraulically.
for each side).
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PARKING BRAKE
PRESSURE SUPPLY
MAX 35 BAR
BRAKE RELEASE VALVE

FOR PASSIVE PARKING
TH133044
2
Description and operation
When the parking brake switch is operated (1), the
oil flows to the drain reservoir and negative brake is
actuated.
When the brake switch is released, the valve makes
the oil flow again in the system and disengages brake
discs.
1
TH133045
3
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BRAKE BLEEDING PROCEDURE
NECESSARY CONDITIONS
• Engine off.
• Two operators required.
-- 1 in the cabin to press the brake pedal and top
up the reservoir
-- 1 outside, on the axle, to open and close bleed
screws
EQUIPMENT
• Transparent flex hose (L=500 mm ∅i = 5mm)
• Oil recovery container.
BLEEDING STEPS
• Remove the upper cab instrument panel (1) (to
access the pump reservoir) 1
• Remove the chassis guard (upper side above
front axle)
TH133052
4
604.02.395.00 - 12 - 2002
• Loosen the front and rear axle (3) bleed screw

(2). Usually start with rear axle and then proceed
as follows:
-- rear right--hand side axle
-- rear left--hand side axle
-- front right--hand side axle
-- front left--hand side axle 2
• Attach the rubber hose to the end of the bleed
screw. Place the other end of the hose in the
collection container.
TH133047
5
TH133048
6
• Remove the brake pump reservoir cap (4) and fill
the reservoir with oil.
• Push the pedal repeatedly, down and up, so oil 4
circulates through the system and the air out.
• As the reservoir level drops, top up.
• When the oil starts to flow down the transparent
hose, tighten the bleed screw with the pedal still
pushed down.
• Repeat steps for each of the bleed screws in the
above mentioned order.
• Test the brakes with the engine off and the pedal
should become hard before reaching half its TH133049
downward stroke. If the pedal can be pressed
7
further or to the floor, repeat the bleeding pro-
cedure.
• Re--install front axle cover and instrument panel
inside the cabin.
604.02.395.00 - 12 - 2002
BRAKE RELEASE
In the event the brakes remain locked and it is not

possible to re--start the engine, but you wish to move
the vehicle, it is necessary to tighten the front axle
screws (1) (two for each side) after slackening the
locknut (2). When the vehicle is operative again,
slacken the screws and fasten them with the locknut.
2 1
TH133050
8
BRAKE DISC ADJUSTMENT
Perform operations on both axle arms. Remove the

oil level cap (1).
Operate the brakes and keep them pressed to check
thickness “S” between the discs with a thickness
gauge (minimum value of “S” = 4.5 mm)
ATTENTION
Replace brake discs and intermediate discs on both
sides, if needed.
1
TH133051 S
9
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TROUBLESHOOTING
Insufficient braking
Cause Remedy
1. Wrong adjustment Check the brake disc thickness. If the brake discs
can be re--used, adjust them as described in the
vehicle manual.
2. Brake discs worn Check the brake disc thickness and replace them, if
needed.
Replace all axle and main cylinder seal rings which
3. Wrong fluid in the circuit
came into contact with the wrong fluid. Replace also
the hoses.
Check and repair all outside and main circuit leak-
4. Fluid leak from brake circuit ages.
If the cause is the wrong fluid, see remedy no. 3.
If the leakage goes outwards, replace O--rings
between the central case and the intermediate cover.
If the leakage goes inwards, replace the above men-
tioned O--rings and those of the brake piston.
5. Axle overheating with fluid evaporation (brakes See problem: overheating.
return when axle cools down)
Brake pedal does not react

Cause Remedy
6. Air in braking circuit Bleed the braking circuit as described for the vehicle
manual bleeding.
Insufficient negative brake

Cause Remedy
7. Wrong adjustment See remedy no. 1.
8. Brake discs worn See remedy no. 2.
Overheating
Cause Remedy
9. Wrong oil level Discharge, wash and fill until level is reached.
10. Little clearance between brake discs Adjust the brake as described for the vehicle manual.
11. Park brake on during traction Release the brake by correcting clearance.
12. Wrong fluid in the circuit See remedy no. 3.
13. Brake circuit choked Check and repair damaged pipes.
14. Wrong lubricant Replace the brake system and pump seal rings.
Oil coming out

Cause Remedy
15. Hydraulic fluid leakage from braking system See remedy no. 2 and no. 3.
16. Hydraulic fluid leakage from differential circuit See remedy no. 3.
604.02.395.00 - 12 - 2002
BRAKE DISC REPLACEMENT
Brake and parking brake front disc removal

Connect an external pump to the negative brake pipe
union “P” and select a pressure of 15 – 30 bar to elim-
inate the Belleville washer load.
TH133001
10
Remove the steering tie rod pins from the steering
knuckle (see “STEERING CYLINDER REMOVAL”).
Sling the axle shaft to be removed (1) with a hoist.
Remove screws and nuts.
1
TH133002
11
Remove the axle shaft (1) with the brakes and the
half shaft. Place the axle shaft in vertical position.
Extract pressure.
TH133003
12
Remove the piston return springs (2).
TH133004
13
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Remove the piston drive screws (3).
ATTENTION
If the screws need to be replaced, take note of differ-
ent colours for brake clearances. 3
TH133005
14
Write down their assembly sequence and remove
the intermediate disc (4).
4
TH133006
15
Slacken and remove stud bolts.
TH133007
16
Extract the cylinder (5).
TH133008
17
604.02.395.00 - 12 - 2002
Remove Belleville washers (6) and take note of their

assembly position.
TH133009
18
Remove the piston (7) by blowing compressed air
gradually through the negative brake pipe union.
ATTENTION
Hold the piston (7) because it might be ejected
suddenly and get damaged.
Remove the O--rings from the piston (7).
NOTE: O--rings must be replaced whenever the 7

assembly is disassembled.
TH133010
19
Before removing the negative piston, mark its posi-
tion.
TH133011
20
Remove the piston (8) by blowing compressed air
gradually through the negative brake pipe union.
ATTENTION
Hold the piston (8) because it might be ejected
suddenly and get damaged.
TH133012
21
604.02.395.00 - 12 - 2002
Remove the brake discs (9) from the axle shaft and
take note of their assembly position. 9
NOTE: If the discs need to be replaced, make sure
their original position is respected.
TH133013
22
Remove the spacer (10) and the shims (11).
11
10
TH133014
23
13
7
3
8 9
5
4 11
2
9
10
1
TH133043
24
604.02.395.00 - 12 - 2002
Assembly
Install the O--rings on the piston (8).
Lubricate the piston and the O--rings, then insert the
piston in the cylinder (5).
8
NOTE: Piston “C” bleeding valve should face down-
wards.
5
TH133015
25
Hit the piston (8) with a plastic hammer to insert it in 8
the cylinder (5).
NOTE: Slightly beat in crosswise, alternate fashion
around the edge. 8
TH133016
26
Install the O--ring on the piston (7).
Lubricate the piston and the O--rings, then insert the
piston in the cylinder (5).
TH133017
27
Hit the piston (7) with a plastic hammer to insert it in
the cylinder (5).
NOTE: Slightly beat in crosswise, alternate fashion 7
around the edge.
TH133018
28
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Check the cylinder O--ring (12) conditions and posi-

tion.
12
TH133019
29
Insert the Belleville washer (6) and reattach the cylin-
der (5).
6
NOTE: Check the Belleville washer (6) assembly
direction and their location.
5
TH133020
30
Fasten the cylinder (5) by tightening the screws with
a torque wrench to a torque of 86 ÷ 89 Nm.
TH133021
31
Fill the piston chambers with the appropriate oil.
TH133022
32
604.02.395.00 - 12 - 2002
Connect an external pump to the negative brake pipe

union “A” and select a pressure of 15 – 30 bar.
TH133001
33
Insert the travel automatic adjusting springs (13) and
align them with the piston.
13
TH133023
34
Insert the intermediate disc (4).
4
TH133006
35
Reinstall the return springs (2) back on the piston.
Apply LOCTITE 270 on the piston adjusting nut
threading. 2
Tighten with a torque wrench to a torque of 10 – 15
Nm.
TH133004
36
604.02.395.00 - 12 - 2002
IMPORTANT: Screw (3) set for 1 mm clearance (y).

Tighten the drive screws (3) and make sure they all
have the same colour.
Apply LOCTITE 270 on the threading.
Tightening torque: 5 ÷ 7 Nm.
3
TH133005
37
Establish the shims to be inserted under the spacer.
With a set pressure of 30 bar, measure the distance
between the intermediate disc and the cylinder.
EXAMPLE: x = 25.4 mm
TH133024
38
Place the brake assembly fitted with the spacer
under the press, load it to 1000 Kg and measure
value “V”.
EXAMPLE: V = 40 mm
TH133025
39
Arm fixed value 68 mm.
Shims to be applied under the spacer.
S = 68 mm – (x + y + v) = Shims to be applied
TH133026
40
604.02.395.00 - 12 - 2002
Insert the previously established dimension shims

and the spacer. 11
10
TH133014
41
Slightly lubricate the brake discs (9) and install them
on the axle shaft in the correct order. They should be
positioned so that the oil circulation holes match with B
9
marks “B”.
NOTE: When steel discs are fitted, ensure the slot
next to the oil plug is free.
Check that the seal ring housing on the axle shaft is
intact. Fasten it with two opposite screws and respect-
ive washers.
Check the axle shaft flanges match with each other and
tighten the respective fastening screws and washers in 1
crosswised, alternate tightening fashion.
TH133027
Tightening torque: 298 Nm.
42
604.02.395.00 - 12 - 2002
Rear brake removal

Remove the swivel support (2).
NOTE: If the bush (1) is worn and needs to be 2
replaced, take note of the fitting “A” notch assembly 1
side.
TH133028
43
Remove the steering tie rod pins from the steering
knuckle (see “STEERING CYLINDER REMOVAL”). 6
Sling the axle shaft to be removed (3) with a hoist and 4 5
tension the hoist a little.
Slacken and remove the screws (4) and the washers
(5) fastening the axle shaft (3) to the central unit (6).
3
TH133029
44
Remove the axle shaft (3) and the brake disc unit (7).
Set the axle shaft on a bench.
3
TH133030
45
Remove the brake discs (7) and write down the
assembly order.
NOTE: 1 – If the discs do not have be replaced,
ensure their original position is maintained.
2 – Remove the double universal joint (18).
18
7
TH133031
46
604.02.395.00 - 12 - 2002
Remove the piston (9) return springs (8).

NOTE: If the springs (8) are distorted, replace them. 8
9
8
TH133032
47
Remove the piston drive pin screws (10).
ATTENTION
If the screws need to be replaced, write down colours
for brake clearances (See “BRAKING UNIT ASSEM-
BLY”).
10
TH133033
48
Slowly blow compressed air through the braking cir-
cuit attachment in order to remove the whole piston
(9).
ATTENTION
Hold the piston because it might be ejected suddenly
and get damaged.
TH133034
49
604.02.395.00 - 12 - 2002
10
15 9
6 8
7 11
14 16
3
13
12
18
TH133035
50
604.02.395.00 - 12 - 2002
Rear brake assembly

14
Clean the piston (9) and the sliding/seal housings
thoroughly. 12
Replace the O--rings (11) and (12) and the anti--ex- 11
trusion rings (13) and (14). Respect assembly direc-
tion. 13
ATTENTION
Make sure anti--extrusion rings (13) and (14) are
positioned correctly. 3
9
TH133036
51
Insert the springs (15) on the piston (9) circumfer-
ence for travel compensation.
15
9
15
TH133037
52
Lubricate the seals and install the piston (9) in the
arm (3).
A
ATTENTION
Make sure the piston housing matches with the stop
(A) inside the arm.
9
TH133038
53
Insert the piston (9) by lightly beating the circumfer-
ence with a plastic hammer.
TH133039
54
604.02.395.00 - 12 - 2002
Insert the pin screws (10) and ensure they all have
the same colour.
White: clearance 1 mm
Yellow: clearance 0.75 mm 10
Blue: clearance 0.5 mm
Apply Loctite 270 on the threading
Tightening torque: 5 ÷ 7 Nm
TH133033
55
Insert the piston (9) return springs (8).
8
ATTENTION 9
Be careful not to damage spring attachments.
8
TH133032
56
Slightly lubricate the brake discs (7) and install them
on the arm in the correct order. They should be posi-
tioned so that the oil circulation holes align with
marks “B”.
NOTE: When steel discs are fitted, ensure the slot
next to the oil plug is free. B
7
TH133040
57
Check the arm seal ring (16) integrity and location.
Install the whole arm.
Fasten it with two opposite screws.
16
TH133041
58
604.02.395.00 - 12 - 2002
Check the arm flatness and fasten them with the

screws (4) and the washers (5) in a crosswise, alter-
nate tightening fashion.
Tightening torque: 298 Nm.
4 5
TH133042
59
604.02.395.00 - 12 - 2002
SECTION 35 -- HYDRAULIC SYSTEM 1
SECTION 35 -- HYDRAULIC SYSTEM
LIST OF CONTENTS
35 000 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Parking brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Steering system hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Telescopic boom hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Component operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Delivery side divider valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure reducing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Front loader controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power steering (OSPQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Telescopic boom distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Auxiliary controls distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Boom removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
604.02.395.00 - 12 - 2002
2 SECTION 35 -- HYDRAULIC SYSTEM
TECHNICAL DATA
Hydraulic oil
Specification Ambra Hydrosystem 46 HV NH646H
International specification ISO VG 46, DIN 51524
Total system capacity 185 litres
Hydraulic oil filter change interval 250 hours
Hydraulic oil change interval 500 hours
Checking interval 10 hours
Hydraulic pump
Gear pump with built--in flow divider valve sensitive to the load and delivering priority flow to the steering
circuit.
Delivery New pump 130 lt./min @ 2500 rpm @ 230 bar
Worn pump 110 lt./min @ 2500 rpm @ 230 bar
Pressure reducing valve

Control pressure 35 bar
Relief valve pressure 45 bar
Balancing and load checking valves

Location
Lifting cylinder, piston side
Tilting cylinder, piston side
Telescopic cylinder(s), piston side
Safety valve against load peaks 350 bar
Hydraulic distributor
Multi--element distributor with open centre and individual circuit relief valves.
Power steering
Main relief valve 175 bar
Secondary relief valves 240 bar
604.02.395.00 - 12 - 2002
DESCRIPTION AND OPERATION PARKING BRAKE CIRCUIT

The machine is fitted with a parking brake mounted
INTRODUCTION on the front axle.
The hydraulic circuit includes: The parking brake works on the oil--bath multiple disk
• parking brake circuit service brakes equipping the front axle (3).
• (primary) steering circuit As a rule, the brakes are applied with the engine off.
If the parking brake is used with the engine running,
• (secondary) telescopic boom circuit
the machine can be blocked by pressing on switch
The latter also includes the system components (2) after cutting out the safety device. This activates
responsible for the selection of the stabilisers, frame the transmission block (neutral) and, by energising
levelling and rear axle lock--up. the solenoid valve (1), pressurises the oil (det. 4) in
The operating diagrams of the above--mentioned cir- the braking assemblies equipping the front axle (3).
cuits and the relative descriptions are given below; the To cut out the brake, first press on the switch (2) after
diagramsgive an overall view of the hydraulics and cutting out the safety device.
include some indications on the electrics, as needed to
provide an understanding of the system’s operating
logic.
1 4
2
6 2
TH135001
1
1. Solenoid valve 5. Pressure control tapping fitting
2. Control switch 6. Supply block
3. Front axle
4. Representation of valve with brake applied N.B.: For component location, see figure on page 9.
604.02.395.00 - 12 - 2002
STEERING SYSTEM HYDRAULIC CIRCUIT With the steering wheel stationary, the power steer-
Basic circuit operation ing distributor is in neutral and the oil can flow to the
Pump (3) takes in the oil through a 100 micron filter return path (from inlet P to outlet T). In these condi-
located in the hydraulic reservoir and delivers it tions, in the event of collisions against the wheels,
through the load sensing divider valve (2) at the back the latter are dampened by the shock--proofing
of the pump. In this manner, the oil reaches first the valves and are not transmitted to the steering wheel.
steering system circuit (primary circuit) and the rest Moreover, two anticavitation valves prevent cavita-
of the oil is transferred to the telescopic boom and the tion phenomena from occurring in the steering cylin-
auxiliary hydraulic circuits (secondary circuits) (Ref. ders chambers.
A). When the steering wheel is turned, the movement is
The flow of oil goes through the priority hole of the transferred to the distributor which gradually opens
divider valve and reaches the steering system motor the conduits to the cylinder ways, while neutral con-
(1) and then the selection valve (7) for three steering tacts close.
modes: Following wheel rotation (and the ensuing distributor
— Two steering wheels rotation) the volume of oil that goes through is directly
— Four concentric or discordant wheels proportional to the angular movement of the steering
— Four concordant or unilateral crab wheels. wheel and produces the angular movement of the
(see fig. TH135003, page 5) drive wheels.
Steering system hydraulic circuit diagram
1
2 3 4 5
8 6
7
TH135002
2
1. Power steering 7. Steering mode selection valve
2. Priority flow divider valv 8. Front axle control cylinder
3. Hydraulic pump A. Delivery line to telescopic boom circuit
4. Tank with intake filter B. Heat exchanger discharge line
5. Plug with inlet and outlet side overpressure valve C. Discharge line from telescopic boom distributor
6. Rear axle control cylinder
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STEERING VALVE
A T
The machine is equipped with two steering axles and
the related steering cylinders which provide for three
different steering modes as a function of solenoid
valve position.
B
1. two steering wheels
2. four concentric (or discordant) steering wheels
3. four unilateral (or concordant) steering wheels (crab)
If the solenoid valve (5) is not activated, steering is
achieved by means of the front axle (7) and the oil
contained in the steering cylinder chamber, which is P
not pressurised, is controlled by the same distributor
that conveys the oil to the discharge line (T) and TH135004
hence to the reservoir simultaneously with the oil 3
pressurisation command.
If the solenoid valve (5) is activated in either direction
the two steering cylinders are connected in series
and the delivery oil enters the chamber of a rear axle
cylinder (6) to return to the chamber of the other cyl-
inder.
4. Front axle solenoid valve 1 2 3

5. Rear axle solenoid valve
6. Rear axle cylinder TH135003
7. Front axle cylinder
4
A. Connection to cylinder (6)
T. Connection to cylinder (7) 5
B. Connection to cylinder (6)
P. Steering system delivery line
R. Steering system delivery line 6
TH135006
5
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STEERING SYSTEM HYDRAULIC CIRCUIT
2
4
TH135007
6
1. Hydraulic pump 4. Power steering
2. Steering cylinder on front axle 5. Steering mode selection valve
3. Reservoir 6. Steering cylinder on rear axle
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TELESCOPIC BOOM HYDRAULIC CIRCUIT

Basic circuit operation is connected to the lifting cylinder (30) and makes its
The pump (1) takes in the oil through a 100 micron possible to keep the tool (fork, bucket, etc.) in hori-
filter situated in the hydraulic tank and sends it on to zontal position during cylinder (30) lifting.
the steering circuit through line (a) in priority mode, The telescopic boom is extracted by means of an
and hence to the distributors (11) and (22) supply unstable cursor type switch located on the front of the
lines (secondary circuit). unit’s control levet handle (14). The operation is elec-
Taken as a whole, the circuit is mainly controlled by trically controlled by means of a trimmer (35), which
the operation of the control unit (14) and the push activates electrically the proportional solenoid valve
buttons (13) situated on the panel to the left of the of the distributor (22). The latter distributes the load
driver. to the lifting cylinders (27) and (28) (if fixed).
The pump delivery hydraulic oil flows to the distribu- The front part of the handle houses two switches (34)
tors that control the various hydraulic functions by for the operation of the solenoid valve equipping the
managing the flow--rate to the various actuators: the distributor (28) that supplies the cylinder (6) (OPT.).
hydraulic oil coming back from the actuators through The distributor (22) also contains, for each slide
the distributors is transmitted to the oil cooler, where valve, load sensing valves, connected to the load
it is cooled and hence returns to the hydraulic reser- sensing line G.
voir via the total capacity filter, which holds back any
impurities as may be contained in the oil returning Rear axle lock
from the actuators.
The rear axle locking cylinder uses the system’s dis-
When the oil temperature is low, oil viscosity charge line which has a pressure of 3--4 bar. Its
increases and so does the resistance to the passage activation takes place automatically during the boom
of the oil through the cooler. If the oil pressure lifting stage: at ca 15°, the sensor fitted to the boom
exceeds 5 bar, whether because of the high viscosity itself sends a signal to the control unit which activates
of the oil (thermostatic valve function) or due to radi- the valve (20).
ator clogging, the oil returns directly to the tank, by--
passing the radiator.
Auxiliary control distributor
The pump (1) supplies, in parallel with the distributor
Tool distributor
(22), the stabiliser and levelling control assembly
Stem lifting is achieved by working on the hand lever (11).
(14), which distributes the pressure load to the two
These controls are operated by means of push but-
central hydraulic (slide) valves of the distributor (22),
tons (13) which activate the distributor’s solenoid
which supply both the lifting cylinder (30) and the
valves and hence control the output pressures in the
compensation cylinder (17). The circuit of the latter
circuit itself, balanced by the load sensing line (G).
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Telescopic boom circuit components
1. Hydraulic pump with divider valve 26. Cylinder locking valve (16 m version)
2. Levelling cylinder locking valve 27. Telescopic cylinders
3. Levelling cylinder 28. Telescopic cylinder (16 m version)
4. Right stabiliser cylinder locking valve 29. Lifting cylinder blocking valve
5. Right stabiliser cylinder 30. Lifting cylinder
6. Connection to auxiliary circuit (OPT) 31. Heat exchanger
8. Left stabiliser cylinder 32. Tilt cylinder locking valve
9. Left stabiliser cylinder locking valve 33. Tilt cylinder
11. Auxiliary controls distributor 34. Push buttons for auxiliary cylinder control (OPT)
13. Unstable rocker for auxiliary controls 35. Trimmer for control unit (hand lever)
14. Control unit (hand lever) 36. Horn switch
15. Reservoir 37. ITransmission disengagement (neutral) switch
17. Compensation cylinder (pump) A. Steering circuit delivery line
19. Rear axle locking cylinder B. Steering priority flow pilot line
20. Rear cylinder locking control valve C. Horn
21. Oil filter D. Output signal for transmission locking (neutral)
22. Telescopic boom distributor E. Discharge line from transmission locking (neutral)
23. Supply locking valve for control unit and parking F. Parking brake circuit line
brake G. Stabiliser circuit line
25. Telescopic cylinder locking valve H. Power steering discharge
Components of steering system and parking brake circuits
7. Front axle steering control cylinder 16. Steering selection solenoid valve
10. Parking brake assembly 18. Rear axle steering control cylinder
12. Power steering 24. Parking brake solenoid valve
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8
5
19 20 3
4
9 34
2 11
13
35
36
30 33 27 28 37
29
25
32
6 26
17
1 14
23
31 22
15
21
TH135008
7
Telescopic boom circuit
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Arrangement of hydraulic system components, complete

with:
28 -- steering
26
-- parking brake
32
20 -- telescopic boom
27 25
33
20
24
23
29
30
31 22
1 21
20
2
19
3
18
4
17
5
16
15
14
13
12
6
C 11
34 35
10
7 14
8 36
37
9
TH135009
8
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32 33 28 27 26 25
30 29 17
5 4 2 3 11 1 16 23
31
24
22
21
14
34
35 8
36
37 19 20 18
7 10 12 13 14 15
TH135010
9
Complete topographic diagram of hydraulic circuit
604.02.395.00 - 12 - 2002
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COMPONENT OPERATION
2
Hydraulic pump
The hydraulic pump (1) is a constant flow gear pump
with a built--in divider valve (2) that divides the load
sensing line delivery flow.
The pump moves at the speed of the engine and has
a rated delivery flow of 130 lt./min at an engine speed
of 2500 rpm, at 230 bar.
It can work at temperatures ranging from -- 25°C to 3
+ 80°C.
The pump input control (3) is direct type, without idle 1
TH135011
gears.
10
Hydraulic scheme
4
1
TH135012
2
11
The hydraulic connections to the pump and flow
divider valve are: 1
1. to the hydraulic distributor
2. pump intake line
3. load sensing line
4. to power assisted circuit of steering system with 4
reducing valve
3
TH135013
12
Delivery side divider valve
The flow divider valve (2) mounted at the back of the
hydraulic pump (1) ensures that a priority flow corre- 2
sponding to the demand is always delivered to the 4
steering circuit (priority circuit), while the remaining
flow is transmitted to the telescopic boom activated
by the distributor and to the auxiliary circuits (sec-
ondary circuit).
1. Housing
2. Load sensing line connector
3. Shim 3
4. Spring
5. Pin 5
6. Plug 1 6
TH135014
13
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1 2 3 4 5 6
11 10 9 8 7
TH135015
14
Operation of the delivery side flow divider valve
To steering circuit Steering circuit load sensing signal
To tool circuit
1. Pin 7. Shim (if fitted)

2. To loader arm circuit 8. Spring
3. Hydraulic pump intake hole 9. Balancing hole
4. Steering/braking circuit 10. Hole
5. Hole 11. Plug
6. Load sensing connector
The load sensing divider valve ensures that a priority applied to the left hand side of the pin moves the pin
flow corresponding to the demand is always deliv- to the right, thereby conveying the delivery flow to the
ered to the steering circuit (priority circuit), while the loader arm circuit.
remaining flow is transmitted to the tool circuit (sec- As soon as the steering wheel is rotated, the pres-
ondary circuit). sure generated in these circuits is sensed in the load
At key--on, the pin in the load sensing valve is pushed sensing line and applied to the right hand side of the
to the left by a spring (8) enabling the pump flow to pin. When the combined effects of the load sensed
enter the valve through a hole (3) which ensures the and the force of the spring against the right hand side
delivery of the priority flow to the steering and braking of the pin exceeds the pressure applied to the left
system circuits. The pressure of the pump is also hand side of the pin, the pin moves to the left, thereby
applied to the centre of the pin and transmitted to the increasing the flow delivered to the steering circuit.
left hand side of the pin through hole (10). The bal- Since the oil in the load sensing line flows through the
ancing hole (9) senses the pressure but works as a steering motor adjustment holes before reaching the
damper to prevent the pin from moving in an irregular divider valve, the load sensing pressure is always
manner. proportional to the demand. This ensures that the
Assuming that during engine starting the braking and valve transmits only the quantity of oil necessary to
steering circuits are not used, the load sensing line the steering circuit, while the rest of the pump’s out-
opens towards the reservoir and the pump pressure put flow is routed to the loader arm circuit.
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Pressure reduction valve

Pressure reduction valve (1) regulates the pressure
at 35 bar in the portion of the circuit providing oil to
the hydraulic power assisted controls, the joystick
and the parking brake.
TH135016
15
Hydraulic diagram
1. Delivery line 1 2 3
2. Discharge for negative brake solenoid valve
3. Connection to PST of main control valve
4. Powering for joystick
5. Discharge to reservoir
5 4
TH135017
16
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TH135018
17
Pressure reduction valve
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FRONT LOADER CONTROLS

2
To lift, lower, retract and tilt the parts, move the lever 1
(1) as follows:
-- forward, to lower the arm
-- back, to lift the arm
-- to the left, to retract the front loader/tool
-- to the right, to tip the front loader/tool.
3 4
5
6
TH135020
s
18
Upper control plate
This consists of an unstable cursor type three--posi-
tion switch (2) and two buttons (3) and (4).
The cursor (2) makes it possible to pull out the tele-
scopic boom (when pushed forward) or retract its
(when pulled back).
The two buttons, buttons (3) and (4), are available for
auxiliary functions.
Under the load handling lever there are two unstable
buttons that have been assigned the following func-
tions:
5. Optional function 4 3 2 1
TH135021
6. Transmission disengagement (neutral)
19
Being unstable, button (6) keeps the transmission Hydraulic scheme
1--2 Cylinder lifting lines
disengaged until it is released.
3--4 Front loader training lines
P -- Supply line
T -- Discharge line
s
The bottom part of the power assisted control unit

includes six hydraulic connections that go to the joy-
stick as follows:
• Return to reservoir orifice (T)
• Four outlet holes (1--2--3 and 4) for proportional
pressure, each of which is connected to each
end of the slide valves of the lifting and tilting
control distributor.
• An inlet orifice for the oil supply at a pressure of
35 bar (P).
Each of the four outlet holes is equipped with small
pistons with plungers that make it possible to apply
a pilot pressure proportional to the movement of the T
joystick at the end of a pin and hence to move it by 1
the extent necessary to activate it.
The joystick is connected to a tilting plate; both the
joystick and the plate are movable above the control
unit body. 4
2 P
When the joystick is used, the tilting plate moves 3
over one of the piston and plunger assemblies to
transfer the oil to the hydraulic distributor spools. TH135022
20
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2
9
TH135024
21
Hydraulic cylinders
1. Telescopic cylinder with double balancing valve 5. Right stabiliser cylinder

(only for telescopic boom in two sections) 6. Frame levelling cylinder (front axle)
2. Telescopic cylinder 7. Lifting cylinder with balancing valve
3. Rear axle blocking cylinder 8. Compensation cylinder
4. Left stabiliser cylinder 9. Tilt cylinder with balancing valve.
The hydraulic cylinders employed to operate the tele- self--levelling of the load forks during the boom lifting
scopic boom are shown in the figure. cycle.
The telescopic cylinder (2) is housed in the boom A safety feature characterising the boom cylinders is
structure; however, when the telescopic boom is the presence of balancing valves that ensure that the
fitted with the three sections option, an additional cyl- cylinder stays locked in its position even in the event
inder (1) is mounted directly on the boom. of hydraulic pipe failure. The cylinders fitted with
The compensation cylinder (8) is connected these valves cannot be retracted if the engine is not
hydraulically to the tilt cylinder (9) and ensures the running.
604.02.395.00 - 12 - 2002
The balancing and load holding valves are mounted

on the piston side of the lifting, tilting and telescopic
extension cylinders.
Operation of balancing (load holding) valves --

See next page
The balancing (load holding) valves are mounted on
the lifting, tilting and telescopic cylinders to ensure
that the cylinder stem stays locked in its position
even in the event of hydraulic pipe failure. With this
type of load holding valves the cylinders cannot be
retracted if the engine is not running and without
operating the control valve spools. TH1350070
When the two--section telescopic boom is used, a 22
centralised double--acting balancing valve is also
provided to prevent the activation of the telescopic
Since it takes both the load sensing pressure applied
cylinder, on both the piston and the stem sides, if the
to the end of the double pilot spool and the cylinder
engine is off.
discharge pressure through orifice C2 to move the
orifice and enable the oil discharged from the cylin-
A. Extending the cylinder der to flow back into the reservoir, in the event of cyl-
When a cylinder with a balancing valve is extended, inder hose failure, the balancing valve would close
the oil flows from the control valve spool to orifice V2 due to the action of the spring, thereby preventing
and through the check valve up to orifice C2. The oil cylinder retraction. Similarly, if the engine is not run-
from the cylinder returns freely from orifice C1 to ori- ning, but the in--cab controls are moved, there will be
fice V1 and then to the reseervoir through the control no pressure at orifice V1/C1 to supplement the back
valve spool. pressure applied to orifice C2, move the pin and let
the oil flow back into the reservoir.
B. Load holding (in neutral)
When the control pin is in neutral, the back pressure D. Operation of circuit relief (shock) valve
generated in the circuit by the weight of the tele- If a cylinder is subjected to a sudden load variation,
scopic boom and the load keeps the lock holding as may be caused, for instance, by a collision against
valve in its seat and prevents cylinder retraction. a wall while driving with the telescopic boom
extended, the sudden load variation applied to the
C. Cylinder retraction cylinder is too high. In such circumstances, the pres-
sure generated at discharge orifice C2 is sufficient to
When a cylinder has to be retracted, the oil flows
move the spool against the force of the safety valve
from orifice V1 to orifice C1, but the pressure of the
spring and discharge the excess pressure into the
oil discharged from the cylinder into orifice C2 is not
reservoir via the circuit relief valve in the hydraulic
sufficient by itself to move the double pilot spool
distributor element. As soon as the pressure has
against the force of the safety valve spring and bring
been relieved, the circuit relief valve closes again
about cylinder retraction. The pressure applied to the
and holds the cylinder in its position.
cylinder through orifices V1/C1 is therefore applied
as pilot pressure also to the end surface of the pin
through the threading of the pilot screw. This pres-
sure, together with the back pressure applied to the
spool via orifice C2, moves the spool against the
action of the safety valve spring enabling the oil dis-
charged from the cylinder to flow back into the reser-
voir.
604.02.395.00 - 12 - 2002
A B
1 2 3 4
V1 V2 V1 V2
C1 C2 C1 C2
kg
C D
V1 V2 V1 V2
C1 C2 C1 C2
TH135028
23
Operation of balancing valve
Oil at pump pressure Static oil
Counter--pressure oil Return to reservoir
A. Extension 1. Pilot screw

B. Load holding 2. Double pilot spool
C. Retracting 3. Check valve
D. Circuit relief function 4. Circuit relief valve
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POWER STEERING (OSPQ)

P 1
The main components of the OSPQ are the control
valve and the rotor assembly. The control valve is a R T
revolving valve that modifies the alignment of the oil
passages as it revolves, thereby activating the steer-
ing cylinders. The rotor assembly is under the control
valve.
2
Its normal function is to work as a hydraulic motor to
perform metering operations. In an emergency, with- LS
out fluid power, it is only possible to perform short
steering manoeuvres while the vehicle continues L 3
moving over a short distance.
1. Pipe fitting flange TH135025
2. Flange to fasten the power steering 24
3. Housing for steering column
L Cylinder supply line, for rear axle
R Cylinder supply line, for front axle
P From pump
T Discharge line to reservoir
LS Load sensing line
The action generated by the steering wheel trans-

mits pressure through the LS line to the divider valve
on the pump, which, in its turn, gives priority to the
power steering P line.
The delivery flow to the motor assembly is controlled
by valve (B).
Steering lock is controlled by an anti--collision valve
(A) which redirects the oil flow to the discharge line
T.
TH135026
25
1. Pilot and flow amplification valve
2. Flow amplification circuit
3. Flow pilot circuit 1
2 3
TH135027
26
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20
14 20
5
25
6
2 3 7
4 10
12
11
26 8
15
13
19
16
9
17
24
18
21
22
23
TH135029
27
Power steering components
1. Dust guard 14. Overpressure valve

2. Power steering body 15. O--ring
3. Check ball valve 16. Distribution plate
4. Threaded bushing 17. Rotor
5. Seals 18. O--ring
6. Steering lock parts 19. Fixed ring for rotor (17)
7. Rings 20. Anti--collision valve
8. Rotary valve 21. Cover
9. Sleeve return springs (11) 22. Washers
10. Sleeve (11) driving pin and shaft (12) 23. Screw with pin
11. Valve seat sleeve (8) 24. Cover (21) fastening screws
12. Rotor (17) drive shaft 25. Pilot valve
13. O--ring 26. Spacer
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TELESCOPIC BOOM DISTRIBUTOR 2

The main distributor is a ”compensated load sensing” 1 3
type distributor that controls the lifting of the boom
and the travel and compensation effects for tool
training.
Its main components include:
• an input plate (1)
• four sections (slide valves) (2) to distribute the
flow
• a closing plate (3).
The task of each distributor section is to transfer the
hydraulic oil flow to the various user devices as a TH1350071
function of the demand communicated by the oper- 28
ator using the hand lever.
When the hand lever is set on neutral, the hydraulic When a distributor slide valve is opened by the action
oil from the pump reaches the distributor and is cut-- of the hand lever, the path of the hydraulic oil from the
off by the position of the four slide valves, after going pump to the user device is opened up. In actual prac-
through the circuit of the tool to be moved. tice, the cross--sectional area of the opening, which
Working in conjunction with the pump and the auxili- is produced by the movement of the distributor slide
ary control distributor, the distributor ensures that the valve, behaves like a calibrated restriction.
hydraulic supply is distributed independently of the Any variation in oil flow (user device movement
load applied. This system -- called ”Load Sensing” -- speed) required by the operator is reflected in pump
works to ensure that the pump delivers only the out- output through the Load Sensing signal.
put demanded.
When a single distributor slide valve is activated,
As long as the hand lever is not activated and the pump pressure is supplied to the user device and,
user devices require no flow, the Load Sensing line, through the Load Sensing line, is applied to the
and hence the ”LS” inlet of the distributor, is not pres- spring side of the Load Sensing valve (3) slide valve.
surised. In these conditions, the pump flow is routed The position of the pump plate will vary so as to
to the discharge line (T) by valve (9) (quick discharge increase flow--rate as a function of demand. When
valve). the pump’s delivery pressure exceeds the load pres-
In these conditions, the main pump delivers exactly sure, the user device begins to move and the flow of
the amount of oil needed to compensate losses from oil delivered by the pump causes a pressure drop
the system; the pressure in the pump delivery line, through the slide valve restriction. When this pres-
called ”stand--by pressure”, is ca 25 bar. sure drop corresponds to the load of the Load Sens-
ing valve calibration spring, a balance is established.
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TH135030
29
Distributor hydraulic circuit scheme
1. Input side valve -- 2. Auxiliary cylinder control On--Off solenoid valve (OPT) -- 3. Compensation valves (load sensing) -- 4.
Hydraulic (slide) valve for tool (forks) tilt cylinder control -- 5. Hydraulic (slide) valve for boom lifting cylinder control -- 6.
Telescopic boom (12 or 16 m) extension proportional solenoid valve -- 7. Distributor closing slide valve -- 8. Max. pressure
control valves -- 9. Quick discharge for flow discharge with all user devices in neutral (stand--by) -- 10. Flow regulator -- P. Pump
delivery line -- LS. Load sensing line -- T. Discharge line -- A1--B1. To compensation and tilt cylinders -- A2--B2. To telescopic
boom lifting cylinders -- A3--B3. To auxiliary cylinder -- A4--B4. To telescopic boom extraction cylinders.
1 2 3 4 3 5 3 6 9
8 7
TH135031
30
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MAIN COMPONENTS OF TELESCOPIC

BOOM DISTRIBUTOR
5
4 3
7
3
9
3
8 2
1
10
TH135032
31
N.B.: For the definition of the components shown in this diagram, see legend to Figure 30.
604.02.395.00 - 12 - 2002
AUXILIARY CONTROL DISTRIBUTOR

This is a compensated type distributor, like the main
distributor of the telescopic boom. It controls the right
and left front stabilisers and frame levelling by means
of the cylinder fitted to the front axle.
It is located in the front part of the frame, near the
front axle itself, and is connected to the main distribu-
tor of the load sensing line and the flow discharge line
(T).
It receives the flow directly from the pump and hence
from the flow divider valve. It is managed by the oper-
ator by means of unstable switches (1) located on the
control panel in front of the driver’s compartment. TH135072
32
1. Control switches
A1--B1. Connection to the right stabiliser cylinder
A2--B2. Connection to the left stabiliser cylinder
A3--B3. Connection to frame levelling cylinder on front
axle
P. Pump output flow
T. Discharge line to reservoir
LS. Load sensing line
TH135034
33
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CYLINDERS
2
9
TH135024
34
1. Outer telescopic cylinder (16 m model only) 6. Frame levelling cylinder

2. Inner telescopic cylinder 7. Compensation cylinder (mated to lifting cylinder)
3. Rear axle lock--up cylinder 8. Lifting cylinder (mated to compensation cylinder)
4. Left stabiliser cylinder 9. Tilt cylinder
5. Right stabiliser cylinder
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INNER TELESCOPIC CYLINDER
5 21 2 3
27 10 11 9 22 17 1 14 13 1 4 25 7 14 28 29 11 10
3
5 19
31 12 24
30 23 26 8 12 18 25
2 3 6 15 16 9
6 5 3
20 4
TH135051
35
Calibration of circuit relief valve on stem side (V1) = 260 bar Tightening torque
Calibration of circuit relief valve on plunger side (V2) = 160 1
bar 480-- 530 Nm
2 1070--1120 Nm
3 20-- 25 Nm
Model Stroke (C) Stroke (D)
4 380-- 430 Nm
T13 3400 mm 3350 mm
T14 3800 mm 3750 mm 5 1070--1120 Nm
T17 3650 mm 3600 mm 6 120-- 125 Nm
604.02.395.00 - 12 - 2002
1. Complete cylinder liner 17. O--ring

2. Complete cylinder liner 18. Plunger ring
3. Complete rod 19. Plunger ring
4. Complete rod 20. Plunger guide ring
5. Front bottom 21. Plunger guide ring
6. Front bottom 22. O--ring
7. Plunger 23. Plug
8. Plunger 24. O--ring
9. Guide ring 25. Anti--extrusion ring
10. Wiper ring 26. O--ring
11. Gasket 27. Rod eye
12. Dowel 28. Valve
13. O--ring 29. Screw
14. Anti--extrusion ring 30. Valve
15. O--ring 31. Piston ring
16. Anti--extrusion ring
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OUTER TELESCOPIC CYLINDER

(only 16 m model)
1 2 3 3
6 7 10 3 9 8 5 1 2 15 11 13 4 12 13 14 16 17
TH135050
36
Stroke (B): 3450 mm Calibration of circuit relief valve on rod side (V1) = 260 bar
Operating pressure: 260 bar Calibration of circuit relief valve on plunger side (V2) = 160
bar
7 Tightening torque: 550-- 600 Nm
8 Tightening torque: 1300--1350 Nm
9 Tightening torque: 20-- 25 Nm
s

2. Complete rod 11. O--ring
3. Front bottom 12. Plunger ring
4. Plunger 13. Plunger guide ring
5. Guide bush 14. Dowel
6. Wiper ring 15. Spacer
7. Gasket 16. Valve
8. O--ring 17. Screw
9. Anti--extrusion ring
604.02.395.00 - 12 - 2002
FRAME LEVELLING AND REAR AXLE

LOCKING CYLINDER
1 2 3
6 10 7 3 9 8 5 1 2 11 13 4 12 14
TH135052
37
Stroke (A): 195 mm Tightening torque
Max. retraction pressure: 180 bar 1 500-- 600 Nm
Max. operating pressure: 260 bar
2 2100--2150 Nm
3 20-- 25 Nm
s

2. Complete rod 9. Anti--extrusion ring
5. Guide bush 12. Plunger ring
6. Wiper ring 13. Plunger guide ring
7. Rod ring 14. Dowel
604.02.395.00 - 12 - 2002
SMALL STABILISER CYLINDER

(12 m and 14 m models only)
1 2 3
4 9 12 11
11
3 6 10 7 5 1 2 8
TH135053
38
Max. operating pressure: 310 bar 1 530 Nm
Circuit relief valve max. pressure: 330 bar
(*) pay attention to direction of assembly 2 1538.6 Nm
3 31.5 Nm
s

2. Complete cylinder liner 8. Plunger ring
3. Rod gasket 9. Plunger
4. Front bottom 10. Guide ring
5. O--ring 11. Grease nipple
6. O--ring 12. Dowel
604.02.395.00 - 12 - 2002
LARGE STABILISER CYLINDER

(standard on 16 m model, available on 12 m and 14 m models)
1 2 3
6 7 10 3 5 9 8 1 2 11 13 4 12 13 14
TH135054
39
Max. operating pressure: 260 bar 1 775-- 835 Nm
2 2400--2500 Nm
3 20-- 25 Nm
s

5. Guide ring 12. Plunger ring
604.02.395.00 - 12 - 2002
COMPENSATION CYLINDER
1 2 3
6 7 10 5 2 9 8 3 1 11 13 4 12 14
TH135055
40
Max. Operating pressure: 260 bar 1 300--350 Nm
2 700--750 Nm
3 20-- 25 Nm
s

604.02.395.00 - 12 - 2002
LIFTING CYLINDER
1 2 3
6 7 3 10 5 9 8 1 2 11 4 13 12 14
TH135056
41
Stroke(A): 1220 mm Tightening torque
Max. operating pressure: 260 bar 1 1500--1500 Nm
2 5500--6000 Nm
3 20-- 25 Nm
s

604.02.395.00 - 12 - 2002
TILT CYLINDER
1 2 3
6 7 10 3 5 9 8 1 2 11 4 12 13 14
TH135057
42
Stroke(A): 442 mm Tightening torque
Max. operating pressure: 260 bar 1 775-- 825 Nm
2 2500--2600 Nm
3 20-- 25 Nm
s

604.02.395.00 - 12 - 2002
BOOM REMOVAL
Description of steps
s
• Lift the boom to make the rod (1) of the lifting and
compensation cylinders accessible and remov-
able (top of engine bonnet)
• Turn off the engine
• Harness the boom (to prevent it from slipping out
or falling off) with chains or ”bands” (use the two
connecting plates equipping the boom). 1
TH135058
s
43
• Place a support under the lifting + compensation
cylinders so as to prevent them from falling and
keep them in the required position for
re--assembly.
TH135059
s
44
604.02.395.00 - 12 - 2002
• To remove the pin (1) from the lifting +

compensation cylinders, remove the static ring 2
(2) from the cab side and pull out the pin from the 1
opposite side with the aid of an extrector.
TH135060
s
45
• To remove the boom rear fastening pin (1),
unscrew screw (2) and drive out the pin with the
aid of a rubber mallet.
1
• Disconnect the hydraulic system pipes:
-- outer telescopic cylinder pipes (16 m version)
-- pipes on the boom (cab side)
• Remove the boom. 2
TH135061
s
46
604.02.395.00 - 12 - 2002
BOOM INSTALLATION
Description of steps
• Harness the boom, then lift it and place it on the
machine in the correct position
• Fit the boom fastening pin (to rear part of the

machine)
• Fit the lifting + compensation cylinders pin and

remove the support
• Connect the hydraulic system pipes:

-- outer telescopic cylinder connection pipes
(16 m version)
-- pipes on boom
• Remove che chains/bands
604.02.395.00 - 12 - 2002
BOOM DISASSEMBLY
General conditions
A. If you have to work on the machine, instead of the
inner part of the boom, or have to work on the
inner part but it is not possible to use an on--board
pump to activate the cylinders, proceed as fol-
lows:
Take down the boom assembly (see Boom

Removal and Installation procedure)
B. If you have to work on the inner part of the boom

and the engine is ON, proceed as follows:
We recommend that you remove the boom sec-

tions from the machine one at a time.
C. If you have to work on the inner part of the boom

and the engine is OFF, or it there is no on--board
pump, proceed as follows:
Take down all the boom sections simultaneously

with the aid of a crane or a hoist and do not forget
to deactivate the locking valve before removing
the individual boom sections (by fastening the 1st
on the pin side and pulling out the boom sections
from the opposite side with the aid of an over-
head crane or a lift truck).
604.02.395.00 - 12 - 2002
Description of boom disassembly procedure

(12 m + 14 m)
4 5
6
3
2
1
TH135073
47
1. First boom 4. Lifting + comp. cylinder
2. Second boom 5. Outer telescopic cylinder
3. Third boom 6. Tilt cylinder
s
s
s
s
• Pull out the third boom by ca 500 mm to make it

possible to remove pin (1) (take down the split
ring and pull out the pin). 1
TH135062
s
48
• Unscrew and remove all the mounting hardware
that fasten the shoes so as to release them (you
can unscrew these on all the sections).
TH135063
49
604.02.395.00 - 12 - 2002
• Disconnect the hydraulic pipes of the ”tilt”

cylinder and the hydraulic pipes of the auxiliary
tool system.
• Pull out the third boom section; together with this,
pull out the relative shoes.
s
• Unscrew the mounting hardware (1) for the

supports (2) of the inner telescopic cylinder pin
ar the rear and pull out the pin. 2
1
TH135064
s
50
• Take down the inner hydraulic pipes (if the
hydraulic system is not active, these pipes can
be removed at the beginning of the procedure)
• Pull out the inner telescopic cylinder from the
back of the first boom.
• Remove (pull it out from the front) the second
boom section (and together with this, remove the
accompanying shoes, the mounting hardware of
which has been removed previously).
604.02.395.00 - 12 - 2002
Description of boom disassembly procedure (16 m)
5
6 7
8
4
3 2 1
TH135073
51
1. First section 5. Outer telescopic cylinder
2. Second section 6. Lifting + compensation cylinder
3. Third section 7. Inner telescopic cylinder
4. Fourth section 8. Tilt cylinder
s
s
s
s
s
s
s
s
• Pull out the fourth section by ca 500 mm to make

it possible to take out the pin (remove the split
ring and pull out the pin). 1
TH135062
52
s
604.02.395.00 - 12 - 2002
• Unscrew and remove all the mounting hadware

fastening the shoes so as to release them (you
can unscrew this on all the sections).
TH135063
s
53
• Disconnect the hydraulic pipes of the ”tilt”
cylinder and the hydraulic pipes of the auxiliary
system tool.
• Pull out the fourth section; together with this the
accompanying shoes are also removed.
s
• To take out the pin (1) of the outer telescopic

cylinder, remove the central screw (2) and then
pull out the pin (1). 2
TH135065
54
s
• Disconnect the inner telescopic cylinder pipes.

• Remove the third and second sections (still
connected together) and pull out simultaneously
the shoes of the second section.
s
• Remove the screws (1) of the supports (2) of the

inner telescopic cylinder pin on the back of the
second section and pull out the pin.
• Pull out the inner telescopic cylinder from the 2
back of the second section.
• Remove the third section (by pulling it out from
the front end) from the second section (and the
accompanying shoes).
1
TH135064
s
55
BOOM ASSEMBLY PROCEDURE
Fit back the boom sections by repeating the same
steps in reverse order.
604.02.395.00 - 12 - 2002
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 1
SECTION 55 – ELECTRICAL SYSTEM
Chapter 1 – Electrical system general
CONTENTS
55 000 Electrical equipment specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Electrical system and fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Controls and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bulb replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
System precautions for battery charging and welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Starting the machine using jump leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Temporary wiring repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Electrical system general fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
55 000 ELECTRICAL EQUIPMENT SPECIFICATIONS
ELECTRICAL SYSTEM 88 kW
Alternator 90 amp
Battery type 12 volt negative earth
Standard 105 Ah (12v/505 A)
Battery disconnect via the isolator switch On negative/chassis cable
Regulator Transistorised
Ground (Earth) Negative
Starting motor Positive engagement, solenoid operated (3,5 kw)
Headlight bulb 40/45W H4 Halogen
Stop/Tail light bulb 5/21W Bayonet cap
Interior light bulb 5W Festoon and 10W bayonet cap
Flasher light bulb 21W Bayonet cap
Work light bulbs 55W H3 Halogen
Instrument/Warning light bulbs 1,2W Capless
Rocker switch bulbs 1,2W Capless
604.02.395.00 - 12 - 2002
2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
ELECTRICAL SYSTEM AND FUSES

The electrical system of all models consists of vari-
ous wiring harnesses, instrument clusters, and
switches. A micro--processor is also used to control
the powershift transmission.
The instrument console and warning lamps are

mounted in front of the operator, behind the steering
wheel.
The key start switch has three positions:
I OFF
II Ignition ‘ON’
III Engine start (cranking)
1
2
TH155001
1
The battery is located on the left--hand side of
engine.
The battery type is 12 volt, 105 Ah, standard or 150
Ah optional. There is an isolator switch (1) located on
the negative cable to provide a battery disconnect
facility.
1
TH155002
2
604.02.395.00 - 12 - 2002
The alternator is 12 V, 90 A.
TH155003
3
The starter is a Bosch 3.5 kW unit.
TH155004
4
Fuses and relays
The machine fuse and relay board is located in the
rear compartment, behind the driver.
The fuses are numbered and reference to Figure 5
will permit rapid identification of the circuits they pro-
tect.
NOTE: Certain optional items of equipment may not
be installed on your machine. However, the fuses are
still installed and may be used as spares.
IMPORTANT: Do not replace a blown fuse with
another of a different rating.
TH155005
604.02.395.00 - 12 - 2002
Fuse board – Fuses

Fuse No. Rating Colour Circuit Schema
F1 3A Purple Instrument + tilting prevention system 8
F2 7,5A Brown Stabilisers 3
F3 5A Orange Sensor power supply 3
F4 15A Blue Front work headlights 7
F5 15A Blue Horn 2
F6 10A Red Air conditioner recirculation motor 10
F7 15A Blue Driving switch – lights 6
F8 15A Blue Seat 9
F9 15A Blue Arm working headlights 7
F10 15A Blue Rear window wiper 8
F11 5A Orange At disposal 1
F12 10A Red Double optional 4
F13 10A Red Rexroth proportional power supply 4
F14 10A Red Optional manoeuvres 4
F15 10A Red Axle rocking lock 3
F16 10A Red Tension gauge power supply 4
F17 15A Blue Rear working headlights 7
F18 5A Orange Reversing buzzer, cabin buzzer 2
F19 3A Purple Air conditioner control unit power supply 10
F20 10A Red Rotating beacon 7
F21 7,5A Brown Axle sensor power supply + work selection control unit 3
F22 5A Orange At disposal 10
F23 15A Blue Cabin ventilation solenoid valve 9
F24 10A Red Switch lighting + instrument power supply 5
F25 15A Blue Control car power supply 8
F26 7,5A Brown At disposal 5
F27 5A Orange + 30 roof lamp + sound system 9
F28 5A Orange Micro--seat 9
F29 7,5A Brown +30 CB 9
F30 15A Blue Dipped beam headlights 6
F31 15A Blue Upper window wiper 8
F32 3A Purple + 15 sound system 9
F33 5A Orange Stop lights 6
F34 10A Red Engine shut down 1
F35 5A Orange RH side lights 6
F36 5A Orange LH side lights + number plate lights 6
F37 10A Red Transfer system 2
F38 10A Red +30 warning 6
F39 15A Blue Main beam headlights 6
F40 10A Red Air conditioner compressor 10
F41 15A Blue Fridge socket 9
F42 20A Yellow Cigar lighter 9
Relays
Relays diagram
K1 Double optional 4
K3 Optional (INI) 4
K4 Optional (OUT) 4
K5 Stabiliser power supply with low arm 3
K6 Low arm 3
K7 Transmission disconnect 2
K8 Dipped beam headlights 6
K9 Horn 2
K10 Main beam headlights 6
K11 At disposal 10
K12 Tension gauge 4
K13 Blinking 6
K14 Tilting--prevention 4
K15 Start--up consensus 1
K16 Out--low stabilisers 5
K17 Stabiliser power supply with arm in 3
K18 Aligned axle warning lamp 3
K19 Parking brake engaged 5
K20 85% slow motion 8
K21 Reversing buzzer 2
K22 Air conditioner compressor 10
K23 Air conditioner on 10
604.02.395.00 - 12 - 2002
TH155006
6
TH155007
7
604.02.395.00 - 12 - 2002
CONTROLS AND INSTRUMENTS
CONTROL PANEL TABLE
POS. PIN FUNCTION SIGNAL

L3 J1 AIR FILTER WARNING LAMP NEGATIVE
L2 J2 ENGINE OIL PRESSURE WARNING LAMP NEGATIVE
L1 J3 GENERATOR WARNING LAMP NEGATIVE
S4 J4 WATER TEMP. INSTRUMENT ohm
S1 J5 FUEL LEVEL GAUGE ohm
S2 J6 REV COUNTER INSTRUMENT Hz
+ ILL J7 NIGHT LIGHTING (+) + LIGHTS
GND J8 MASS (EARTH)
+ Ch J9 POSITIVE (+ Key)
L13 J10 FOUR WHEELS STEERING WARNING LAMP POSITIVE
L9 J11 MAIN BEAM LIGHT WARNING LAMP POSITIVE
L10 J12 DIRECTION IND. WARNING LAMP POSITIVE
L7 J13 WARNING LAMP HANDBRAKE ON NEGATIVE
L11 J14 TWO WHEEL STEERING WARNING LAMP POSITIVE
B J15 OUTER BUZZER OUTPUT (--)
L8 J16 BRAKE OIL LEVEL WARNING LIGHT NEGATIVE
L12 J17 CRAB STEERING WARNING LIGHT POSITIVE
L6 J18 TRANSMISSION OIL PRESS. WARNING LAMP NEGATIVE
L5 J19 TRANSMISSION OIL HIGH TEMP. WARNING LAMP NEGATIVE
L4 J20 GLOW PLUG PRE--HEAT. WARNING LAMP NEGATIVE
604.02.395.00 - 12 - 2002
PANEL
L1 L10 S2 L11 L12 L13
S1 S4
L1 L2 L3 L4 S3 L5 L6 L7 L8
TH155008
8
PANEL INSIDE DIAGRAM
TH155009
9
604.02.395.00 - 12 - 2002
HAND AND FOOT OPERATING CONTROLS
Shown in Figure 10 is the cabin layout of a typical IMPORTANT: When starting the engine, retract all
machine with a Powershift Transmission and Servo arm segments until the relief valve is actuated and
Controls for the Telescopic Arm. remains so for 10 seconds.
NOTE: The layout of controls in the diagram may This operation assures segment and arm pipe syn-
vary between machines, depending upon options chronisation. Failure to synchronise may damage
fitted to meet Legislation in different Countries. the pipes.
1. Hydraulic control panel and parking brake. 11. Front multi--function loader lever
2. Instruments -- telescopic arm extension/retraction
-- arm lifting and lowering
3. Steering geometry selector
-- tool tilting and return
Select all steering modes at least once a day to
-- transmission disconnect button
check correct operation.
-- horn button
4. Safety key for control mode selection -- aux 1 function button
-- jobsite -- aux 2 function button
-- road
12. Glove compartment (upon request, radio
-- people--conveyance platform
compartment)
5. Vehicle hazard light switches
13. Steering wheel
6. Engine starter key IMPORTANT: Prior to driving the vehicle, always
7. Switch panel for miscellaneous services turn the steering wheel from side to side at
8. Powershift selection lever, forward direction and engine start up, to circulate the hydraulic oil.
horn 14. Accelerator foot pedal
9. Side light and direction indicator control lever 15. Brake pedal
10. Vents 16. Tilting prevention lock force release button
17. Steering wheel height adjusting lever
18. Load handling monitor indicator
19. Climate system control panel
604.02.395.00 - 12 - 2002
3
4
5
6
7
8 9
13 10 10 11
12
17
16
14
15
5 7
19
18
TH155010
10
604.02.395.00 - 12 - 2002
ALIGNMENT OF THE WHEELS

IMPORTANT: Before selecting one of the three
possible steering positions, bring the four wheels into
alignment, that is in the straight ahead position.
A -- TWO WHEEL STEERING -- Shift the distributor A
control lever for steering selection to position ‘A’ for C B
Highway Use (two wheel steer), turn the steering
wheel to ensure engagement and monitor the illumi-
nation of lamps (rear wheels aligned).
ATTENTION
Before driving on the highway, it is essential to check
the alignment of the wheels and to drive with only two
wheels steering.
C A B
Unless otherwise stated, two wheels steering is by
the front wheel only.
B – 2+2 WHEELS STEERING -- Shift the distributor

control lever for steering selection to position ‘B’ for
wheel pair steer.
C – CROSS TRANSFER -- Shift the distributor con-
trol lever for steering selection to position ‘C’ for crab
steering.
TH155011
s
11
s
s
s
s
s
s
Check the selected steering warning lamp on the

instrument panel comes and stays on.
If the warning lamp starts flashing, make sure the A
wheel alignment reaches required alignment. Slowly B
turn the steering wheel from side to side to let the
control system reach the selected setting. C
If the warning lamps keeps on flashing, have the
vehicle checked by your dealership.
TH155012
12
604.02.395.00 - 12 - 2002
INSTRUMENT CONSOLE
IMPORTANT: Gauges and switches mounted in the
Instrument panel may vary in position from that
shown in this manual. This is dependant upon model
and options fitted. Ensure you are familiar with all the
functions before operation.
Engine coolant temperature warning gauge with

warning buzzer
The engine coolant temperature indicator responds
to a sensor fitted in the engine. During normal oper- 1
ations the indicator will tend to rise from the low point
of the green segment to the centre of the gauge.
When operating under heavy load conditions, the
indicator may continue to rise to just below the red
segment and return to a lower position when normal
machine operation is resumed.
Should the indicator rise into the red segment a warn-

ing buzzer will sound. Stop the engine immediately
and investigate the cause. Normal operations can be
resumed once the engine has cooled sufficiently or
TH155013
the cause corrected.
13
NOTE: When the key--start/stop switch is turned off
the gauge needle assumes a random position. 1
Tachometer and hour meter
The tachometer (1), graduated to 3000 rev/min, is
driven from the alternator and reflects true engine
speed.
The hour meter (2), situated in the lower half of the
tachometer, records hours of engine operation and
is driven from the alternator when running.
Fuel level gauge

TH155014
2
This gauge indicates the level of fuel in the tank on
a continuous basis but is only operative with the key-- 14
start/stop switch in the ‘ON’ position.
NOTE: When the key--start/stop switch is turned off 1
the gauge needle assumes a random position.
TH155015
15
604.02.395.00 - 12 - 2002
INDICATOR/WARNING LIGHTS – 1st Segment TH155016

1
1. Main beam headlight warning lamp 2
2. Direction indicator warning light
16
2nd
s
INDICATOR/WARNING LIGHTS – Segment TH155017

1 2
3
The show the selected steering mode:
1. 2 wheel steering (front)
2. Cross transfer (crab diagram)
3. 4 wheel steering
17
INDICATOR/WARNING LIGHTS – 3rd Segment
1. Alternator charge indicator light. The alternator
charge warning light illuminates when the key
start is turned on and will remain on until the
engine is started. Once started the battery is
being charged by the alternator and the light will
be extinguished.
2. Engine oil pressure warning light with warning
buzzer: Indicates low oil pressure and should
extinguish immediately after the engine starts.
Should the oil pressure drop below the
predetermined level, the warning light will
illuminate and an audible alarm will sound. 3
1 2 4
3. Air filter restriction light. When illuminated the
engine must be stopped as soon as possible and
the filter serviced (refer to Section 4).
IMPORTANT: If the machine is left to run with the

warning light ‘on’, engine performance and fuel con- TH155018
sumption will suffer. 18
4. Thermostart heater light. With the key start ‘ON’
this light is illuminated during the warm up period
of the thermostart heater element. It is
extinguished once steering temperature is
reached, whereupon the engine can then be
started.
604.02.395.00 - 12 - 2002
INDICATOR/WARNING LIGHTS – 4th Segment
1. Transmission oil temperature warning light

Should the transmission oil temperature exceed a
predetermined level the warning light will illuminate.
ATTENTION
If the light stays ‘on’, stop the engine as soon as
possible and investigate the cause. Do not continue
to drive the machine as failure of the transmission
could occur and result in serious injury to you or
bystanders.
2
1 3 4
2. Transmission oil pressure warning light with

buzzer
TH155019
Should the transmission oil pressure drop to a prede-
termined level the warning light will illuminate and the 19
buzzer will sound.
If the warning light illuminates, place the trans-
mission in neutral and stop the engine immediately.
Check that the oil level is correct and adjust as
required. If the transmission oil is lost or extremely
low DO NOT ATTEMPT TO DRIVE THE MACHINE.
Contact your Dealer to investigate the cause and
consult the manual as for towing the machine as
necessary.
3. Parking brake warning light
The warning light is illuminated when the parking
brake is applied and the ignition is switched ON.
ATTENTION
Do not attempt to disconnect the warning apparatus
in any way. Do not attempt to drive the machine with
the parking brake applied, as serious damage to the
machine brakes with possible failure will occur. This
could result in serious injury to you and other people.
4. Brake reservoir oil level low indicator lamp
This warning lamp illuminates when the oil level in the ATTENTION
reservoir is at a LOW LEVEL. If the lamp illuminates Corrective action must be taken immediately when
at any time stop the machine immediately and this lamp illuminates. If not, failure of the brake sys-
investigate the cause, correct and or top up with new tem could occur, resulting in serious injury to yourself
oil to the level specified. To test the warning light refer and others.
to the maintenance section of the manual.
604.02.395.00 - 12 - 2002
LOAD STATUS INDICATOR PANEL
The load status indicator warns the operator when

the Telehander reaches the maximum authorised
load condition.
s
ATTENTION
Any attempt to lift loads beyond this will result in an
unsafe and unstable situation.
s
s
s
s
s
s
s
s
s
s
s
A – TWO GREEN SIGNAL LIGHT

The two signal lights indicate decreasing stability
situations, but regular. During normal operation, the
light signal status is continuously updated and indi-
cates the current situation.
C
B – TWO YELLOW SIGNAL LIGHT B
(VISUAL ALARM)
The two signal lights indicate critical situations of A
instability. In these case the instability value is
around 100% (tilting).
DANGER
It is required another operator to solve to the situ-
ation. Try to lower the vehicle centre of gravity as
much as possible.
D
Keep on lifting in the direction of the load closest to TH155020
the vehicle centre of gravity, or retract the telescopic
arm, if extended, to move the load as closest as 20
possible to the vehicle centre of gravity.
s
s
s
s
s
s
s
s
s
s
s
s
s
s
s
s
s
s
s
s
C – RED SIGNAL LIGHT

(VISUAL ALARM AND SOUND)
This signal light illuminates, when the Telehandler
reaches 100% of its maximum authorised load
capacity. The sound alarm sounds simultaneously
with the red signal light illuminated.
When this alarm comes on, all load hydraulic handl-
ing operations, stabiliser lifting an axle tilting oper-
ations are locked.
The only function allowed is the telescopic arm
retraction, unless the function lock is forced by oper-
ating the relative button as described in the following
pages. TH155021
21
604.02.395.00 - 12 - 2002
D – TEST SWITCH
Operation of this switch tests the alarm and illumi-
nates the warning lamp to ensure all is working cor-
rectly. Check each day before commencing work and
if either are not functioning correctly, in the interests 1
of yours and bystander safety, do not attempt to use
the machine as a loader until a repair has been per-
formed.
TH155022
s
22
TILTING LOCK FORCING BUTTON
When the button is kept pressed, normal hydraulic

control functions are restored during emergency
situations.
IMPORTANT: All functions must be performed while
the button is pressed.
Corrective actions include load weight approaching
to the vehicle centre of gravity (load lifting or arm
retraction), or operations to increase the vehicle sta-
bility such as, stabiliser lowering or axle inclination
adjustment.
ATTENTION TH155023
Operate this button only if it is possible to adjust the 23
vehicle stability without retracting the telescopic arm.
TILTING DANGER!!
TH155024
24
604.02.395.00 - 12 - 2002
MULTI--FUNCTION LEVER
Direction indicator stalk
The direction (turn) indicators are operated (with the 1

key start on) by the stalk switch (1) mounted to the
right of the steering wheel.
-- When pushed FORWARD: the LEFT HAND INDI-
CATOR FLASH
-- When pulled REARWARD: from the neutral posi-
tion, the RIGHT HAND INDICATORS WILL FLASH.
The warning lamp will flash when the direction indica-
tors are flashing. TH155025
25
Main/dipped beam light selector
When the dipped beam headlights are on, push the

stalk (1) forward, compared to the central position, so
the dipped beam headlights and the relative instru-
ment panel warning lamp turn on.
When the lever is pulled inwards, the dipped beam
headlights start flashing.
Windscreen wiper
If you turn the lever, the windscreen wiper turns on

(position 1); when you turn the lever in the opposite
direction (position 0), the function is deactivated and
1
the blade reaches the neutral position.
TH155026
s
26
Windscreen washer
If you press button (1) located on the multi--function

1
lever external side, the windscreen washer is acti-
vated.
TH155027
27
604.02.395.00 - 12 - 2002
POWERSHIFT 4 X 3
Gearshift
The gearshift mounted on this vehicle is called Pow-
ershift.
The Powershift lever is mounted to the left of the
steering column and allows electronic selection of
four forward gears and three reverse gears.
TH155028
s
28
HORN
The horn is actuated when the button on the gearshift

lever tip is pressed.
DRIVING WITH THE POWERSHIFT
Neutral position A
The neutral position is selected by shifting the lever

to the centre. N
Forward gear selection

R
To select forward gear, pull the lever towards the
steering wheel and push it upwards.
TH155029
Reverse gear selection
29
To select reverse gear, pull the lever towards the

steering wheel and push it downwards.
604.02.395.00 - 12 - 2002
SWITCHES
SWITCHES (right panel)
IMPORTANT: The rocker switch positions may vary

slightly or may not be all available from that shown.
They are dependant upon the model and options
fitted to your machine,
All switches are internally illuminated with ignition

‘On’ and will become brighter when each individual
function is switch is selected.
1. Slow moving warning beacon – Depressing this

switch operates the function of the roof beacon.
1 2 3 4 5 6 7 8
2. Road lights – three--position switch
-- Off
-- Sidelights TH155030
-- Main/dipped beam headlights
Main and dipped beam headlight selection is
possible with the multifunction lever previously
described.
3. Hazard flasher switch – Selected when required
to warn of a hazard.
4. Additional lights (optional) fitted on the telescopic
arm.
5. Front work lamps (2--position switch) – When
operated the front lights are illuminated.
6. Rear work lamps (2--position switch) – When
operated the rear lights are illuminated.
7. Rear window wash and wipe. Depressing this
switch operates the relative function. Depressing
it again (temporary position) operates the rear
window washer.
8. Roof window wash and wipe. Depressing this
switch operates the roof wiper blade. The
washing function is operated depressing the
switch again.
604.02.395.00 - 12 - 2002
SWITCHES (left panel)

IMPORTANT: The rocker switch positions may vary
slightly or may not be all available from that shown.
They are dependant upon the model and options
fitted to your machine.
All switches are internally illuminated with ignition
‘On’ and will become brighter when each individual
function is switch is selected.
1. Parking brake (temporary 2--position switch with
safety catch).
Depressing the switch operates the relative
function. To unlock the vehicle, move the lever
located on the switch downwards, so that the
switch can return to its original position. The
parking brake will non be engaged if the vehicle
is moving at 5 Km/h. When the parking brake is
operated, transmission is disconnected and will
be restored only releasing the brake.
1 2 3 4
2. Left stabiliser (temporary 3--position switch). TH155031
When the switch is in central position (neutral), 30
no function is operated. Depressing the switch
upper part, the left stabiliser is lifted; depressing
the switch lower part, the stabiliser is lowered.
3. Axle levelling (temporary 3--position switch).
Depressing this switch, the axle front levelling
cylinder is operated to change the vehicle tilting
along the longitudinal axis. Press the switch
upper part for tilting on the right. Press the switch
lower part for tilting on the left.
4. Right stabiliser (temporary 3--position switch).
This switch works as switch (2), but operates the
right stabiliser. Depressing the switch upper part,
the right stabiliser is lifted; depressing the switch
lower part, the stabiliser is lowered.
ATTENTION
When the arm is lifted or removed, the right and left
stabiliser lifting function is inhibited. In such condi-
tions it is not possible to lift one or both stabilisers.
604.02.395.00 - 12 - 2002
BULB REPLACEMENT
Work lamp bulb replacement, front
To gain access to the bulb, extract the cap on the
headlight rear side. Replacement of the bulb follows
the removal procedure in reverse.
NOTE: Modern headlights and worklamps tend to
have halogen bulbs fitted. Never touch a halogen
bulb with the fingers. Natural moisture in the skin will
cause the bulb to burn out when the lamp is switched
on. Always use a clean cloth or tissue when handling
halogen bulbs.
TH155032
31
Headlight and indicator bulb replacement
To gain access to the headlight bulbs, extract the four
securing screws (1), gently remove the lens cover
and remove the plug from the rear of the bulb,
release the retaining spring and extract the bulb. The
sidelight bulb is removed by pulling the bulb carrier
out of the reflector assembly. Replacement of the 1
bulbs follows the removal procedure in reverse.
2
The headlight beam may be adjusted vertically and
laterally by adjustment of the recessed slotted
screws (3).
3
The indicator bulb can be accessed by removal of the TH155033
lens cover retaining screw (2).
32
Loader mounted work lights

To gain access to the bulb, extract the securing
screws (1), gently remove the lens cover and remove
the bulb. Replacement of the bulb follows the
removal procedure in reverse.
1
TH155034
33
604.02.395.00 - 12 - 2002
Interior lamp bulb replacement

The interior lamp bulb is accessible after removal of
the moulded plastic cover lens cover. The bulb may
be removed by exerting outward pressure on one of
the retaining tangs and sliding the opposite end of the
bulb from its retaining tang. Installation of the bulb
and lens cover follows the removal procedure in
reverse.
TH155035
34
Rear work lamps
To gain access to the bulb, extract the cap on the
headlight rear side. Replacement of the bulb follows
the removal procedure in reverse.
NOTE: Modern headlights and worklamps tend to
have halogen bulbs fitted. Never touch a halogen
bulb with the fingers. Natural moisture in the skin will
cause the bulb to burn out when the lamp is switched
on. Always use a clean cloth or tissue when handling
halogen bulbs.
TH155036
35
Rear, stop and indicator
All bulbs are accessible after the moulded plastic
lens assembly screws have been removed.
The bulbs have a bayonet cap fitting with offset pins
for the brake light bulb and parallel pins for the flasher
bulb. Both bulbs may be removed by depressing
slightly and rotating approximately 20° anti--clock-
wise.
Replacement of the bulbs follows the removal pro-
cedure in reverse, however ensure the brake light
offset pins align with the socket correctly. The lens
can be replaced after the electrics have been tested.
TH155037
36
604.02.395.00 - 12 - 2002
Reversing lamps
Where fitted the lamps can be removed after removal
of the lens cover; they are of the twist bayonet type.
TH155038
37
Rocker switch bulb replacement

The rocker switches are internally illuminated by a
bulb which can be removed from the rear of the
switch assembly (1).
To gain access to the switch remove the console
attaching screws and rotate the console. 1
The bulb is of the capless type, rated at 1.2 W and
is a push fit in the retainer. After changing the bulb,
push the retainer into the back of the switch.
TH155039
38
604.02.395.00 - 12 - 2002
PROTECTING THE ELECTRICAL SYSTEMS

DURING CHARGING OR WELDING
To avoid damage to the electronic/electrical sys- • Never allow welding cables to lay on, near or
tems, always observe the following: across any electrical wiring or electronic compo-
nent while welding is in progress.
1. Never make or break any of the charging circuit
connections, including the battery connections, 6. Always disconnect the negative cable from the
when the engine is running. batteries when charging the batteries in the
machine with a battery charger.
2. Never short any of the charging circuit compo-
nents to earth (ground).
ATTENTION
3. Do not use a slave battery of higher than 12 volt Batteries contain sulphuric acid. In case of contact
nominal voltage. with skin, flush the affected area with water for five
minutes. Seek medical attention immediately. Avoid
4. Always observe correct polarity when installing
the batteries or using a slave battery to jump start contact with the skin, eyes or clothing. Wear eye
the engine. Follow the instructions in the oper- protection when working near batteries.
ator’s manual when jump starting the machine.
Connect positive to positive and negative to
negative.
5. Always disconnect the negative cable from the
batteries before carrying our arc welding on the
machine or on any implement attached to the
machine.
• Position the welder ground cable clamp as close
to the welding area as possible. IMPORTANT: Failure to disconnect the two earth
• If welding is to be carried out in close proximity cable connection at the battery prior to charging the
to a computer module, then the module should batteries or welding on the machine or attached
be removed from the machine. It is recom- implement will result in damage to the electronic and
mended that this procedure be carried out by an electrical systems.
authorised dealer.
604.02.395.00 - 12 - 2002
STARTING THE MACHINE USING JUMP LEADS • Connect one end of the second jump leads to the
auxiliary 12 volt battery negative (--) terminal and
the other end to the machine cylinder block. Fol-
lowing this procedure will prevent sparks occur-
ring near the batteries. Follow the starting pro-
cedure previously described.
ATTENTION
Operate the starting motor only from the operator’s NOTE: When using a slave battery to start the
seat. If the neutral start switch is by--passed the engine ensure that the polarity is correct, otherwise
engine may be started inadvertently with the trans- the alternator may be damaged.
mission in gear.
• When the engine starts, allow it to run at idle

speed, turn on all electrical equipment (lights,
Wear eye protection when charging the battery or etc.) then disconnect the jump leads in reverse
starting the machine engine with a slave battery. order to the connecting procedure. This will help
protect the alternator from damage due to
If it is necessary to use jump leads from an external extreme load changes.
battery to start the engine, proceed as follows:
• Connect one end of the jump lead to the machine
12 volt battery positive (+) terminal and the other NOTE: Your machine has an electro--magnetic fuel
to the auxiliary 12 volt battery positive (+) ter- shut--off, it is therefore not possible to operate the
minal. machine without a battery installed. The machine will
shut down when the power supply to the fuel shut--off
solenoid is disconnected (battery removed).
604.02.395.00 - 12 - 2002
Temporary wiring repairs

(Op No. 55 100)
The following method to repair wiring is a temporary
expedient only. Wiring should be replaced as soon as
possible. Replacement of temporary repaired cables
with new is particularly important if the machine is to
be used for spraying as chemicals can enter the
repaired area, travel up the cable and damage elec-
trical components. Do not attempt to repair the wire
on any system sensors as these are sealed and
should only be replaced with a new component.
TH155040
39
NOTE: When conducting a cable repair it is import-
ant that only RESIN CORED SOLDER is used. Use
of other types of solder may result in further cable
damage.
To carry out a temporary repair, proceed as follows:
1. Locate damaged portion of cable then cut away
outer protective cover on both sides of the dam-
aged area, Figure 39.
2. Peel back the cable from both ends of the dam-
aged area and carefully cut away the inner cable
cover at the damaged area and strip about 13
mm (1/2 inch) of insulation from the wires. Do not
cut away any wire strands.
3. Using a suitable solvent, clean about 2 inches
(50 mm) from each cover end. Clean the grey
cable cover and the individual leads. TH155041
40
4. Twist two bare leads together for each damaged
lead, being careful to match wire colours, then
weld the leads using resin cored solder. Tape
each repaired lead with vinyl insulation tape, Fig-
ure 40.
5. Wind a layer of vinyl insulation tape up to the grey
cable cover at each end of the repaired section.
Make a paper through, Figure 41, then apply sili-
con rubber compound (non hardening sealant)
over the repaired section up to the cover ends.
Sufficient sealant must be used to fill the ends of
the cut away area.
TH155042
41
604.02.395.00 - 12 - 2002
6. Allow the compound to cure then cover the area

with insulating tape taking the tape well over
each end of the repair. An overlap of at least 2
inches (50 mm) of tape at each end is necessary,
Figure 42.
7. Check to ensure the repair is satisfactory and

secure the repaired cable, so that repeated dam-
age is avoided.
NOTE: This is a temporary repair only. Ensure the

damaged cable is replaced as soon as possible to
prevent water or chemicals from entering. TH155043
42
604.02.395.00 - 12 - 2002
ELECTRICAL SYSTEM – GENERAL FAULT FINDING
PROBLEM POSSIBLE CAUSE REMEDY
Electrical system is inoperative Loose or corroded battery Clean and tighten connections
connections
Sulphated batteries Check battery open circuit voltage
for 12.6 volts minimum. Check
electrolyte level and specific gravity
Battery isolator switch turned ‘off’ Re--instate isolator switch
Main machine fuse link blown Establish reason for failure and
replace fuse link
Starter speed low and engine Loose or corroded connection Clean and tighten loose
cranks slowly connections
Low battery output Check battery open circuit voltage
for 12.6 volts minimum.
Check electrolyte level and specific
gravity.
Incorrect viscosity engine oil Use correct viscosity oil for
temperature conditions
Starter inoperative Transmission shift lever in gear Place shift lever in neutral
Loose or corroded connections Clean and tighten loose

connections
Dead batteries Charge or repair batteries
Charge indicator lamp stays on Low engine idle speed Increase idle speed
with engine running
Loose belt Check belt tension
Malfunctioning battery Check battery open circuit voltage

gravity.
Malfunctioning alternator Check alternator
Batteries will not charge Loose or corroded terminal Clean and tighten loose
connections connections
Sulphated batteries Check battery open circuit voltage
gravity.
Loose or worn belt Check automatic belt tensioner.
Replace belt if required.
Charge indicator flashing indicat- Malfunctioning alternator Check alternator
ing excessive charging voltage
604.02.395.00 - 12 - 2002
604.02.395.00 - 12 - 2002
SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2 29
SECTION 55 -- ELECTRICAL CIRCUITS
Chapter 2 – Circuit diagrams
CONTENTS
List of connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
List of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cable key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
How to use the circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Circuit 1: Starting/Recharge/Warning lights/Indicator lights . . . . . . . . . . . . . . . . . . . . . . . . 38
Circuit 2: Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Circuit 3: Wheel alignment/Hydraulic solenoids/Brake system . . . . . . . . . . . . . . . . . . . . . 42
Circuit 4: Arm control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Circuit 5: Stabiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Circuit 6: Lights/Windscreen wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Circuit 7: Work lamps/Roof beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Circuit 8: Tilting prevention system/Roof wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Circuit 9: Sound system, heating/Electric socket/Interior lamp . . . . . . . . . . . . . . . . . . . . . 54
Circuit 10: Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
604.02.395.00 - 12 - 2002
30 SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2
604.02.395.00 - 12 - 2002
LIST OF CONNECTORS
CON. DESCRIPTION CON. DESCRIPTION

X1 3--way connector for RH stabiliser sensor X33 2--way connector for front LH work lamp
X10 2--way connector for reversing buzzer X34 2--way connector for rear RH work lamp
X100 4--way connector for inside air sensor X36 4--way connector for upper wiper
X102 2--way connector for recycle motor X37 8--way connector for tilting prevention instrument
X106 4--way connector for solenoid valve X39 4--way connector for rear wiper
X11 4--way connector for arm work lamp X40 3--way connector for roof lamp
X12 3--way connector for low arm sensor X42 4--way connector for parking brake switch
X129 8--way connector for instrument panel--air conditioner X43 2--way connector for interconnection
line X44 2--way connector for seat
X132 4--connector for heater X47 4--way connector for windscreen washer
X133 4--way connector for parking brake shunt X48 12--way connector for Telehandler
X134 17--way connector for gearshift control unit X5 2--way connector for fuel level
X137 17--way connector for work selection control unit X52 2--way connector for CB
X138 2--way connector for filter thermistor X53 2--way connector for cigar lighter
X139 2--way connector for filter pre--heating X55 8--way brown connector for sound system
X14 3--way connector for retracted arm sensor X56 8--way black connector for sound system
X16 3--way connector for pre--fitting X6 40--way connector for instrument panel--rear line
X17 6--way connector for front LH headlight X60 20--way connector for instrument
X18 6--way connector for front RH headlight X62 12--way connector for gear switch
X19 3--way connector for number plate lights X63 12--way connector for light switch
X1A2 2--way connector for A2 steering solenoid valve X65 4--way connector for micro--stop
X1B2 2--way connector for B2 steering solenoid valve X67 4--way connector for front wiper
X2 3--way connector for LH stabiliser sensor X68 2--way connector for rear LH work lamp
X201 2--way connector for LH stabiliser lowering X7 24--way connector for instrument panel--front line
X202 2--way connector for LH stabiliser raising X70 10--wa connector for thermo--starting control unit
X203 2--way connector for RH stabiliser lowering X8 3--way connector for rear axle sensor
X204 2--way connector for RH stabiliser raising X9 2--way connector for loading cell
X205 2--way connector for LH levelling solenoid valve X91 2--way connector for air conditioner pressure gauge
X206 2--way connector for RH levelling solenoid valve X92a 2--way connector for electric fan
X207 2--way connector for handbrake solenoid valve X92b 2--way connector for electric fan
X208 4--way connector for proportional solenoid valve X94 8--way connector for air conditioner control unit
X209 2--way connector for optional solenoid valve rentrée X95 9--way connector for air conditioner control unit
X21 2--way connector for hammer solenoid valve X96 2--way connector for outside temperature sensor
X210 2--way connector for optional solenoid valve sortie X97 2--way connector for mixed air sensor
X211 2--way connector for servo--control solenoid valve X98 2--way connector for tap
X212 2--way connector for tilting prevention solenoid valve X99 2--way connector for defrosting sensor
X213 2--way connector for reversing solenoid valve XA1 2--way connector for alternator
X214 2--way connector for forward gear solenoid valve XA1a 1--way connector for alternator
X215 2--way connector for gearshift solenoid valve X01 9--way connector for bridges
X216 2--way connector for 1st gear solenoid valve X02 21--way connectors for bridges
X217 2--way connector for 2nd gear solenoid valve X03 21--way connector for control unit
X23 2--way connector for double optional solenoid valve X04 18--way connector for control unit
X25 18--way connector for instrument panel--engine line X05 12--way connector for control unit
X27 9--way connector for dashboard--cabin line X06 6--way connector for control unit
X28a 2--way connector for axle lock solenoid valves X07 15--way connector for control unit
X28b 2--way connector for axle lock solenoid valves X08 21--way connector for control unit
X29 2--way connector for thermo--starting relay X09 18--way connector for control unit
X3 3--way connector for front axle sensor X13 3--way deutsch connector
X30 12 way--connector for instrument panel--engine line X15 2--way connector for clogged air filter pressure gauge
X31 17--way connector for instrument panel--cabin line
X32 2--way connector for front RH work lamp
604.02.395.00 - 12 - 2002
LIST OF COMPONENTS
COMP. DESCRIPTION DIAG. COMP. DESCRIPTION DIAG.
B Rexroth handler button 4 KC Filter pre--heating relay 1
BS1 RH loudspeaker 9 KD Unswitched circuit relay 1
BS2 LH loudspeaker 9 KT Thermo--starting relay 1
C Reset button 8 M1 Starter 1
D Rexroth handler button 4 M11 Recycling 10
D Reset button 8 M12 Tap 10
EVA Axle lock solenoid valve 3 M13 Cooling fan 10
EVA2 A2 steering solenoid valve 3 M14 Electric fan 10
EVB Axle lock solenoid valve 3 M2 Front wiper motor 6
EVB2 B2 steering solenoid valve 3 M3 Upper wiper motor 8
FG1 Main fuse 80A 1 M4 Windscreen washer pump 8
FG2 Air conditioner fuse 30A 1 M5 Rear washer motor 8
FG3 Filter pre--heating fuse 20A 1 M6 Rear window washer pump 8
FG4 Spare fuse 1 M7 Fan 9
FV1 Converter fuse 30A 10 M8 Air Conditioning fan 10
G Rexroth handler button 4 M9 Compressor 10
G1 Battery 1 P Potentiometer 4
G2 Alternator 1 R1 Available resistance – 1K0hm 1W 3
H Rexroth handler button 4 R2 Thermo--starting 1
H1 Front LH headlight 6 R3 Filter pre--heating 1
H10 Rear LH work lamp 7 RL1 Work selection control unit relay 3
H11 Rear RH work lamp 7 RL2 Work selection control unit relay 3
H12 Beacon light 7 RL3 Work selection control unit relay 3
H13 Cigar lighter lamp 9 RL4 Work selection control unit relay 3
H14 Roof lamp 9 S11 LH stabiliser switch 5
H2 Front RH headlight 6 S12 Levelling switch 5
H3 LH taillight 6 S13 RH stabiliser switch 5
H4 RH taillight 6 S15 Starting panel 1
H5 Number plate light 6 S1 Parking brake 5
H6 Arm work lamp 7 S2 Beacon light switch 7
H7 Arm work lamp 7 S3 Warning switch 6
H8 Front RH work lamp 7 S30 Battery disconnection with key 1
H9 Front LH work lamp 7 S31 Fuel level 1
HA1 Reversing buzzer 2 S32 Steering selection switch 3
HA2 Buzzer 8 S33 Rear axle sensor 3
I1 Transmission oil pressure gauge 1 S34 Front axle sensor 3
I10 Air conditioner pressure gauge 10 S35 LH stabiliser sensor 5
I11 Mixed air sensor 10 S36 RH stabiliser sensor 5
I12 Outside temperature sensor 10 S38 Low arm sensor 3
I13 Defrosting sensor 10 S39 Retracted arm sensor 3
I14 Inside air sensor 10 S4 Light switch 6
I2 Transmission oil 1 S40 Brake oil level 6
high temperature sensor S5 Front work lamp switch 7
I3a Spark plug thermistor 1 S50 Heating switch 9
I3b Engine water temperature 1 S51 4 gear switch + hobbs horn 2
transducer S52 Light--direction indicator--wiper 6
I4 Pressure gauge for engine oil 1 switch
low pressure S6 Rear work lamp switch 7
I5 Clogged air filter pressure gauge 1 S7 Arm work lamp switch 7
I6 Door micro 9 S8 Upper/front wiper switch 8
I7 Filter thermistor 1 S9 Rear wiper switch 8
I8 Parking brake pressure gauge 5 X4 Horn 2
K103 Electric fan 1st speed relay 10 X53 Cigar lighter 9
K105 Electric fan 2nd speed relay 10 X54 Fridge socket 9
K107 Electric fan 3rd speed relay 10 X65 Stop light micro 6
KA Starting relay 1 Y1 LH stabiliser lowering solenoid valve 5
KB Air conditioner relay 10
604.02.395.00 - 12 - 2002
COMP. DESCRIPTION DIAG.

Y10 Optional solenoid valve (out) 4
Y11 Servo--control solenoid valve 4
Y12 Tilting prevention solenoid valve 4
Y13 Reverse solenoid valve 3
Y14 Forward gear solenoid valve 2
Y15 Gearshift solenoid valve 2
Y16 1st gear solenoid valve 2
Y17 2nd gear solenoid valve 2
Y18 Engine stop solenoid valve 1
Y2 LH stabiliser lifting solenoid valve 5
Y20 Hammer solenoid valve 4
Y3 RH stabiliser lowering solenoid 5
valve
Y4 RH stabiliser lifting solenoid valve 5
Y5 LH levelling solenoid valve 5
Y6 RH levelling solenoid valve 5
Y7 Parking brake solenoid valve 5
Y9 Optional solenoid valve (in) 4
WIRE COLOUR KEYS WIRE KEY

KEY USE
A Azure
0XXX Mass return (earth)
B White
C Orange 1XXX Visual and sound signals
G Yellow 2XXX Work area (outside) lighting
H Grey 3XXX Side and position (outside) lighting

L Blue 4XXX Inside lighting
M Brown 5XXX Control signal sensors and transmitters
N Black 6XXX Warning signal sensors and transmitters
R Red Main power supply and non--key switched
7XXX
S Pink services
V Green Main power supply and key switched servi-
8XXX
ces
Z Purple
Electrically servo--assisted mechanical
9XXX
components
NOTE: wires with two colours have compound acro-
NAMEX
nyms, e.g.: NAMEXX Control units
G/V -- Yellow/green (cross colouring) NAMEXXX
G--V -- Yellow--Green (longitudinal colouring)
604.02.395.00 - 12 - 2002
CABLE KEY
KEY SPECIFIC FUNCTION KEY SPECIFIC FUNCTION
0001 Right loudspeaker negative 3039 Front left sidelight
0002 Left loudspeaker negative 4040 Roof lamp switch on door
0051 Solenoid valve mass (air conditioner) 4041 Roof lamp power supply (red colour)
0052 3rd speed mass (air conditioner) 4042 Multi--function instrument lighting
1002 Flickering power supply from hazard switch 4043 Cigar lighter illumination
1003 Right direction indicator (light switch) 4050 Multi--function instrument lighting
1005 Steering control unit buzzer negative 4058 Sound system lighting
1006 Left direction indicator 4059 Air conditioner control lighting
(from hazard to light switch) 4060 Switch lighting
1007 Right direction indicator 5003 Engine oil low pressure visual indicator
(from hazard to light switch) 5022 “W” rev counter signal
1009 Left direction indicator (light switch) 5029 Engine water temperature signal for
1010 Beacon light switch power supply thermo--starter control unit
1011 Side light power supply 5036 Speed sensor
(from fuse to hazard switch) 5037 Speed sensor
1012 + 15 Flashing 5043 Gearshift solenoid valve
1015 Direction indicator warning lamp 5044 Gearshift power supply
1017 Stop light pressure gauge power supply 5046 A gear solenoid valve power supply (1st speed)
(from fuse to pressure gauge) 5047 B gear solenoid valve power supply (2nd gear)
1018 Light switch power supply 5048 Solenoid valve reversing
1020 Rear left direction indicator 5049 Solenoid valve forward gear
1021 Beacon light 5052 Engine water temperature proportional instrument
1023 Front right direction indicator signal
1025 Rear right direction indicator 5059 Transmission oil temperature sensor
1029 Front left direction indicator 5068 Battery charge warning lamp from control unit
1030 Hazard light direct power supply instrument A (relay card)
(from fuse to hazard switch) 5081 Transmission oil low pressure sensor
1031 Buzzer power supply 5088 Flickering charge from direction indicator switch
1041 Thermo--starter visual indicator to hazard switch
1049 Light main switch power supply 5090 RH direction indicator
1050 Flickering charge (from hazard to direction indicator switch)
1053 + 30 Light main switch (red colour) 5093 Main beam headlight signal
1063 Reverse buzzer (from light switch to relay)
1064 Starting relay coil 5094 Dipped beam headlight signal
1066 Sidelights from main switch (from light switch to relay)
1067 Front work lamp switches 5095 Horn switch from gearshift
1068 Rear work lamp switches 5096 Retracted arm sensor power supply
1072 Rear right brake light 5097 Low arm sensor signal
1077 Rear left brake light 5098 Low arm sensor power supply
1086 Right loudspeaker positive 5099 Front axle sensor signal
1087 Left loudspeaker positive 5100 Front axle sensor positive
1088 Round steering warning lamp 5101 RH out stabiliser sensor signal from LH stab. sign.
1089 Fridge socket 5102 RH stabiliser sensor positive
1090 LH direction indicator 5103 Sensor power supply (prearrangement)
(from hazard to indicator switch) 5104 LH stabiliser sensor positive
1100 2 wheels steering warning lamp 5105 Sensor signal (prearrangement)
1101 Warning lamp main beam headlights on 5106 Spark plug thermistor
1890 Crab steering warning lamp 5107 100% cut engine signal from tilting prevention
2000 Main beam headlight control control unit to relay card
(from light switch to fuse or relay) 5108 85% cut engine signal from tilting prevention
2001 Dipped beam headlight control instrument to relay card
(from light switch to fuse or relay) 5109 Frame signal from tilting prevention instrument to
2003 Flashing power supply relay control unit
(from fuse to steering column stalk) 5110 Low stabiliser signal from relay control unit to
2006 Main/dipped beam headlight switch power supply tilting prevention instrument
2007 Sidelight switch direct power supply 5111 Limit 5 Km/h
2019 Left main beam headlight 5112 Out round signal
2021 Right main beam headlight 5113 Out grab signal
2023 Right dipped beam headlight 5114 E stab. Lowering (work selector)
2025 Rear RH work lamp 5115 Yard selection (work selector)
2026 Rear LH work lamp 5116 Signal + steering switch (steering selector)
2029 Front RH work lamp 5117 Thermo--starting kit
2030 Cabin front left headlight power supply 5118 In, optional signal
2031 Left dipped beam headlight 5119 Out, optional signal
2032 Arm work lamp 5120 Telehandler
2033 Arm light switch power supply 5120 Double optional signal
2037 Main/dipped beam headlight power supply 5121 Transmission disconnection signal
(from switch to light switch) 5122 Prop. Handler signal
2085 Main beam headlight visual indicator 5123 + 5V handler
3030 Front right sidelight 5930 Rear axle sensor signal
3031 Rear right sidelight 5940 + Rear axle sensor
3032 Rear left sidelight 5950 Retracted arm sensor signal
3035 Sidelight power supply (from switch to fuses) 6037 Battery charge warning lamp from “D+” alternator
3037 Number plate light 6061 Brake oil minimum level sensor
604.02.395.00 - 12 - 2002
KEY SPECIFIC FUNCTION KEY SPECIFIC FUNCTION

6062 Visual indicator parking brake engaged 8122 Central H stabiliser power supply, work selection
6063 Clogged air filter 9003 Engine stop solenoid valve
6094 + loading cell 9007 Start Q.A.
6095 -- loading cell 9021 Switch warning lamps power supply
7000 100 A safety remote control switch for starter 9025 Horn button power supply
7006 Heating 1st speed 9032 Seat compressor
7008 + 30 warning (red colour) 9033 Transmission disconnection signal with parking
7009 Heating 2nd speed brake engaged
7011 Heating power supply 9044 Parking brake switch power supply
7021 Cigar lighter power supply (red colour) 9045 Parking brake solenoid valve
7045 Heating 3rd speed 9049 Q.A. gear
7072 Positive after fuse link 9084 Thermo--starter relay
7077 Non protected positive from battery (red colour) 9089 Thermo--starter from relay
7084 Power supply + 30 (air conditioner control unit) 9100 Servo--control solenoid valve power supply
7095 Fuel filter heating power supply after remote 9101 Tilting prevention solenoid valve power supply
control switch 9102 Proportional solenoid valve power supply
7097 Fuel filter heating power supply before remote (telescopic arm)
control switch 9103 Solenoid valve proportional signal
7099 Sound system power supply + 30 (red colour) (telescopic arm)
7100 C.B. power supply prearrangement (red colour) 9104 + 5V proportional solenoid valve (telescopic arm)
8001 + 15 after service relay 9105 Optional solenoid valve out power supply
8004 Service relay power supply 9106 Optional solenoid valve in power supply
8009 Climate control system power supply 9107 Solenoid valve. double optional
8013 Rear wiper motor 1st speed power supply 9108 Steering A2 solenoid valve
8019 From air conditioner thermostat to air conditioner 9109 Steering A3 solenoid valve
relay 9110 Steering B2 solenoid valve
8022 Front wiper reset 9111 Steering B3 solenoid valve
8023 “53a” rear wiper motor 9112 Hammer solenoid valve power supply
8058 Instrument power supply 9113 Axle lock solenoid valve
8073 Front wiper return 9114 LH stabiliser lowering solenoid valve
8077 Rear wiper motor reset 9115 LH stabiliser lifting solenoid valve
8079 + 15 Hazard switch 9116 RH stabiliser lowering solenoid valve
8080 Front wiper switch power supply 9117 RH stabiliser lifting solenoid valve
8082 Front wiper 1st speed 9118 LH levelling solenoid valve
8085 Front washer motor (pump) 9119 RH levelling solenoid valve
8086 Rear washer motor (pump) 9120 Double speed solenoid valve
8088 Starter electric magnet power supply APC1 + gearshift (APC50 control unit)
8089 Rear window wiper switch power supply APC2 Direct mass from battery
8090 Air conditioner compressor APC10 + gearshift (APC50 control unit)
8094 Fuel filter pre--heating thermistor APC11 Direct mass from battery
8097 Fuel filter pre--heating remote control switch APC12 Forward gear signal (APC50 control unit)
power supply APC14 1st gear signal (APC50 control unit)
8099 Sound system power supply + 15 APC15 2nd gear signal (APC50 control unit)
8100 Air conditioner control unit power supply + 15 APC17 4th gear signal (APC50 control unit)
8101 From converter relay to maxi fuse APC19 Reverse signal (APC50 control unit)
(air conditioning) APC26 Neutral lock (APC50 control unit)
8102 Converter power supply from maxi fuse APC3 Start (APC50 control unit)
(air conditioning) CLIMA01 Cock motor (air conditioner control unit)
8103 No recycle motor (air conditioner) CLIMA02 Electric fan 3rd speed control
8104 No recycle motor (air conditioner) (air conditioner control unit)
8105 Upper wiper motor “53a” CLIMA03 Electric fan 2nd speed control
8106 Upper wiper motor 1st speed power supply (air conditioner control unit)
8107 Upper wiper motor reset CLIMA04 Electric fan 1st speed control
8108 Tilting prevention instrument power supply (air conditioner control unit)
8109 RH stabiliser switch power supply CLIMA05 Electric fan 4th speed control
(from work selector) (air conditioner control unit)
8110 Stabiliser power supply CLIMA06 Mixed air sensor (air conditioner control unit)
(work selector control unit) CLIMA07 Inside air sensor (air conditioner control unit)
8111 Level G power supply (work selector control unit) CLIMA08 Outside temperature sensor
8112 LH stabiliser switch power supply (air conditioner control unit)
(from work selector) CLIMA11 Air conditioner consensus
8113 Steering control unit power supply (air conditioner control unit)
8114 A shared (work selector) CLIMA12 Shared sensors (air conditioner control unit)
8115 A service relay power supply (work selector) CLIMA14 Recycle motor (air conditioner control unit)
8116 B key selector power supply (work selector) CLIMA16 Recycle motor (air conditioner control unit)
8117 Upper wiper switch power supply CLIMA17 Vane motor (air conditioner control unit)
8118 Thermo--starter control unit power supply CLIMA7006 Electric fan 1st speed
8119 Handler button power supply CLIMA7009 Electric fan 2nd speed
8120 Seat neutral lock inter. micro power supply CLIMA7045 Electric fan 3rd speed
8121 Level G power supply
604.02.395.00 - 12 - 2002
HOW TO USE THE CIRCUIT DIAGRAMS

The circuit diagrams have been drawn in a linear
format, meaning that the complete vehicle system is
drawn over a number of pages, with references to
link the pages, where applicable. The flow of power
is generally speaking, from top, positive, to bottom,
negative.
Here are a number of explanations to the layout and
references contained within the diagrams:
1. All diagrams are located on the right hand pages.
Within the diagram there are a number of
references.
1. Diagram number and electric function
2. Line reference
3. Component identification reference
4. Connector x70, connector code, 3, references (pin)
5. Numerical wire colour key
6. Fuse code. G1, fuse number, 10A, capacity
7. Line continues on another diagram. In this instance:
diagram 3 at line reference 1.
8. Alphabetical wire colour key
9. Diode
10. Component pin code
2. Each component and connector appears only
once in a set of circuit diagrams.
3. The circuit diagrams are broken up into sections.
However, where single component is used in a
number of circuits, such as a processor or multi--
function switch, it is drawn either on its own or in
the circuit which it influences the most.
604.02.395.00 - 12 - 2002
DIAGRAM 1 – STARTING/RECHARGE/WARNING LAMPS/INDICATORS

1
5
8
10
TH155044
1
604.02.395.00 - 12 - 2002
DIAGRAM 1 – STARTING/RECHARGE/WARNING /INDICATORS LIGHTS
COMPONENTS
DESCRIPTION
AND FUSES
D10 Diode
G2 Alternator
I1 Transmission oil pressure gauge
I2 Transmission oil high temp. pressure gauge
I3a Spark plug thermistor
I3b Engine water temperature transducer
I4 Pressure gauge for engine oil low pressure
I5 Clogged air filter pressure gauge
I7 Filter thermistor
K15 Relay
KA Starting relay
KC Filter pre--heating relay
KD Under key relay
KT Thermo--starter relay
M1 Starter
R2 Thermo--starting
R3 Filter pre--heating
S15 Starting panel
S31 Fuel level
Y18 Engine stop solenoid valve
F11 Spare fuse 5A
F34 Engine stop fuse 10A
FG1 Main fuse 80A
FG2 Air conditioner fuse 30A
FG3 Filter pre--heating fuse 20A
CONNECTORS DESCRIPTION
X5 2--way connector for fuel level
X6 40--way connector for instrument panel--rear line
X13 DEUTSCH 3--way connector
X15 2--way connector for clogged air filter pressure gauge
X25 18--way connector for instrument panel--engine line
X60 20--way connector for instrument
X70 10--way connector for thermo--starter control unit
X138 2--way connector for filter thermistor
X139 2--way connector for filter pre--heating
XA1 2--way connector for alternator
XA1a 1--way connector for alternator
XC1 9--way connector for bridges
XC3 21--way connector for control unit
604.02.395.00 - 12 - 2002
DIAGRAM 1 – STARTER / RECHARGE / WARNING / INDICATORS LIGHTS
TH155045
2
604.02.395.00 - 12 - 2002
DIAGRAM 2 – TRANSMISSION
COMPONENTS
DESCRIPTION
AND FUSES
D02 Diode
D03 Diode
D06 Diode
D07 Diode
D11 Diode
D12 Diode
DL1 Diode
DL2 Diode
DL3 Diode
DL4 Diode
DL5 Diode
F5 Horn fuse 15A
HA1 Reverse buzzer
K07 Relay
K09 Relay
K21 Relay
RL1 Work selection control unit relay
S51 4 gear switch + Hobbs horn
Y14 Forward gear solenoid valve
Y15 Gearshift solenoid valve
Y16 1st gear solenoid valve
Y17 2nd gear solenoid valve
F18 Reverse buzzer, cabin buzzer fuse 5A
F37 Transfer system fuse 10A
X4 Horn
X7 24--way connector for instrument panel--front line
X10 2--way connector for reverse buzzer
X23 2--way connector for double optional solenoid valve
X25 18--way connector for dashboard--engine line
X43 2--way connector for interconnection
X62 12--way connector for gear switch
X134 17--way connector for gearshift control unit
X214 2--way connector for forward gear solenoid valve
X215 2--way connector for gearshift solenoid valve
X216 2--way connector for 1st gear solenoid valve
X217 2--way connector for 2nd gear solenoid valve
604.02.395.00 - 12 - 2002
DIAGRAM -- 2 TRANSMISSION
TH155046
3
604.02.395.00 - 12 - 2002
DIAGRAM 3 – WHEEL ALIGNMENT/HYDRAULIC SOLENOIDS/BRAKE SYSTEM
COMPONENTS
DESCRIPTION
AND FUSES
DL1 Diode
DL2 Diode
DL3 Diode
DL4 Diode
DL5 Diode
EVA Axle lock solenoid valve
EVA2 A2 steering solenoid valve
EVB Axel lock solenoid valve
EVB2 B2 steering solenoid valve
K5 Relay
K6 Relay
K17 Relay
R1 Spare resistor – 1K0hm 1W
S32 Steering selector switch
S33 Rear axle sensor
S34 Front axle sensor
S38 Low arm sensor
S39 Retracted arm sensor
Y13 Reverse solenoid valve
F2 Stabiliser fuse 7.5A
F3 Sensor power supply fuse 5A
F15 Axle swinging stop fuse 10A
F21 Axle sensor power supply fuse + work selection control unit 7.5A
X1A2 2--way connector for steering solenoid valve A2
X1B2 2--way connector for steering solenoid valve B2
X3 3--way connector for front axle sensor
X8 3--way connector for rear axle sensor
X12 3--way connector for low arm sensor
X14 3--way connector for lifted arm sensor
X28a 2--way connector for axle lock solenoid valves
X28b 2--way connector for axle lock solenoid valves
X137 17--way connector for work selection
X213 2--way connector for reverse solenoid valve
604.02.395.00 - 12 - 2002
DIAGRAM 3 – WHEEL ALIGNMENT/HYDRAULIC SOLENOIDS/BRAKE SYSTEM
TH155047
4
604.02.395.00 - 12 - 2002
DIAGRAM 4 – ARM CONTROL
COMPONENTS
DESCRIPTION
AND FUSES
B Rexroth handler button
D Rexroth handler button
D4 Diode
D5 Diode
D8 Diode
D9 Diode
D13 Diode
G Rexroth handler button
H Rexroth handler button
K1 Relay
K3 Relay
K4 Relay
K12 Relay
K14 Relay
K18 Relay
P Potentiometer
Y8 Solenoid valve
Y9 Optional solenoid valve (in)
Y10 Optional solenoid valve (out)
Y11 Servo--control solenoid valve
Y12 Tilting prevention solenoid valve
Y20 Hammer solenoid valve
F12 Double optional fuse 10A
F13 Rexroth proportional power supply fuse 10A
F14 Optional handling fuse 10A
F16 Voltage indicator power supply fuse 10A
X21 2--way connector for hammer solenoid valve
X48 12--way connector for handler
X208 4--way connector for proportional solenoid valve
X209 2--way connector for optional solenoid valve in
X210 2--way connector for optional solenoid valve out
X211 2--way connector for servo--control solenoid valve
X212 2--way connector for tilting prevention solenoid valve
604.02.395.00 - 12 - 2002
DIAGRAM 4 – ARM CONTROL
TH155048
5
604.02.395.00 - 12 - 2002
DIAGRAM 5 -- STABILISER
COMPONENTS
DESCRIPTION
AND FUSES
I8 Parking brake pressure gauge
K16 Relay
K19 Relay
S1 Parking brake
S11 LH stabiliser switch
S12 Levelling switch
S13 RH stabiliser switch
S35 LH stabiliser sensor
S36 RH stabiliser sensor
Y1 LH stabiliser lowering solenoid valve
Y2 LH stabiliser lifting solenoid valve
Y3 RH stabiliser lowering solenoid valve
Y4 RH stabiliser lifting solenoid valve
Y5 LH levelling solenoid valve
Y6 RH levelling solenoid valve
Y7 Parking brake solenoid valve
F24 Switch lighting fuse + instrument power supply 10A
F26 Spare fuse 7.5A
X1 3--way connector for RH stabiliser sensor
X2 3--way connector for LH stabiliser sensor
X7 24--way connector for instrument panel--front
X16 3--way connector for pre--fitting installation
X42 4--way connector for parking brake switch
X133 4--way connector for parking brake shunt
X201 2--way connector for LH stabiliser lowering solenoid valve
X202 2--way connector for LH stabiliser lifting solenoid valve
X203 2--way connector for RH stabiliser lowering solenoid valve
X204 2--way connector for RH stabiliser lifting solenoid valve
X205 2--way connector for LH levelling solenoid valve
X206 2--way connector for RH levelling solenoid valve
X207 2--way connector for parking brake solenoid valve
604.02.395.00 - 12 - 2002
DIAGRAM 5 -- STABILISER
TH155049
6
604.02.395.00 - 12 - 2002
DIAGRAM 6 – LIGHTS/WINDSCREEN WIPER
COMPONENTS
DESCRIPTION
AND FUSES
H1 Front LH headlight
H2 Front RH headlight
H3 Rear LH headlight
H4 Rear RH headlight
H5 Number plate light
K8 Relay
K10 Relay
K13 Relay
M2 Front wiper motor
S3 Warning switch
S4 Light switch
S40 Brake oil level
S52 Light – direction indicator -- wiper switch
F7 Driving--light switch fuse 15A
F30 Dipped beam headlight fuse 15A
F33 Brake light fuse 5A
F35 RH sidelight fuse 5A
F36 LH sidelight + number plate light fuse 5A
F38 Fuse + 30 warning 10A
F39 Main beam headlight fuse 15A
X17 6--way connector for front LH headlight
X18 6--way connector for front RH headlight
X19 3--way connector for number plate light
X63 12--way connector for light switch
X65 4--way connector for micro stop
X67 4--way connector for front wiper
604.02.395.00 - 12 - 2002
DIAGRAM 6 -- LIGHTS/WINDSCREEN WIPER
TH155050
7
604.02.395.00 - 12 - 2002
DIAGRAM 7 – WORK LAMPS/ROOF BEACON LIGHT
COMPONENTS
DESCRIPTION
AND FUSES
H6 Arm work lamp
H7 Arm work lamp
H8 Front RH work lamp
H9 Front LH work lamp
H10 Rear LH work lamp
H11 Rear RH work lamp
H12 Beacon light
S2 Beacon light switch
S5 Front work lamp switch
S6 Rear work lamp switch
S7 Arm work lamp switch
F4 Front work lamp fuse 15A
F9 Arm work lamp fuse 15A
F17 Rear work lamp fuse 15A
F20 Beacon light fuse 10A
X11 4--way connector for arm work lamp
X32 2--way connector for front RH work lamp
X33 2--way connector for front LH work lamp
X34 2--way connector for rear RH work lamp
X68 2--way connector for rear LH work lamp
604.02.395.00 - 12 - 2002
DIAGRAM 7 – WORK LAMPS/ROOF BEACON LIGHT
TH155051
8
604.02.395.00 - 12 - 2002
DIAGRAM 8 – TILTING PREVENTION SYSTEM/ROOF WIPER
COMPONENTS
DESCRIPTION
AND FUSES
C Reset button
D. Reset button
HA2 Buzzer
S8 Roof/front wiper switch
S9 Rear wiper switch
K20 Relay
M3 Roof wiper motor
M4 Windscreen washer pump
M5 Rear wiper motor
M6 Rear window washing pump
F1 Instrument fuse + tilting prevention system 3A
F10 Rear wiper fuse 15A
F25 Control car power supply fuse 15A
F31 Roof wiper fuse 15A
X9 2--way connector for loading cell
X37 8--way connector for tilting prevention instrument
X39 4--way connector for rear wiper
X47 4--way connector for window washer
604.02.395.00 - 12 - 2002
DIAGRAM 8 – TILTING PREVENTION SYSTEM/ROOF WIPER
TH155052
9
604.02.395.00 - 12 - 2002
DIAGRAM 9 – HEATING/SOUND SYSTEM/ELECTRIC SOCKET/ROOF LAMP
COMPONENTS
DESCRIPTION
AND FUSES
BS1 RH loudspeaker
BS2 LH loudspeaker
H13 Cigar lighter illumination
H14 Roof lamp
I6 Micro door
M7 Fan
S50 Heating switch
F8 Seat fuse 15A
F23 Cabin ventilation solenoid valve fuse 15A
F27 Fuse + 30 roof lamp + sound system 5A
F28 Micro seat fuse 5A
F29 Fuse + 30 CB 7.5A
F32 Fuse + 15 sound system 3A
F41 Fridge socket fuse 15A
F42 Cigar lighter fuse 20A
X40 3--way connector for roof lamp
X44 2--way connector for seat
X52 2--way connector for CB
X53 2--way connector for cigar lighter
X54 Fridge socket
X55 8--way brown connector for sound system
X56 8--way black connector for sound system
604.02.395.00 - 12 - 2002
DIAGRAM 9 – HEATING/SOUND SYSTEM/ELECTRIC SOCKET/INTERIOR LAMP
TH155053
10
604.02.395.00 - 12 - 2002
DIAGRAM 10 – AIR CONDITIONER
COMPONENTS
DESCRIPTION
AND FUSES
FV1 Converter fuse 30A
I10 Air conditioner pressure gauge
I11 Mixed air sensor
I12 Outside temperature sensor
I13 Defrosting sensor
I14 Inside air temperature
K8 Relay
K9 Relay
K103 Electric fan 1st speed relay
K105 Electric fan 2nd speed relay
K107 Electric fan 3rd speed relay
K11 Relay
K22 Relay
K23 Relay
M8 Solenoid valve
M11 Recirculation
M12 Cock
M13 Cooling fan
M14 Solenoid valve
F6 Air conditioner recirculation motor fuse 10A
F19 Air conditioner control unit power supply fuse 3A
F22 Spare fuse 5A
F40 Air conditioner compressor fuse 10A
X43 2--way connector for interconnection
X91 2--way connector for air conditioner pressure gauge
X94 8--way connector for air conditioner control unit
X95 9--way connector for air conditioner control unit
X96 2--way connector for outside temperature sensor
X97 2--way connector for mixed air sensor
X98 2--way connector for cock
X99 2--way connector for defrosting sensor
X100 4--way connector for inside air sensor
X102 2--way connector for recycle motor
X129 8--way connector for instrument panel--air conditioner line
X92a 2--way connector for solenoid valve
X92b 2--way connector for solenoid valve
604.02.395.00 - 12 - 2002
DIAGRAM 10 – AIR CONDITIONER
TH155054
11
604.02.395.00 - 12 - 2002
604.02.395.00 - 12 - 2002
SECTION 55 -- ELECTRIC CIRCUITS
Chapter 3 -- Wiring list
CONTENTS
Instrument panel wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Cab wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Front wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Rear wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Engine wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
604.02.395.00 - 12 - 2002
604.02.395.00 - 12 - 2002
INSTRUMENT PANEL WIRING (1)
TH155055
1
604.02.395.00 - 12 - 2002
TH155056
2
604.02.395.00 - 12 - 2002
TH155057
3
604.02.395.00 - 12 - 2002
TH155058
4
604.02.395.00 - 12 - 2002
TH155059
5
604.02.395.00 - 12 - 2002
CAB WIRING
TH155060
6
604.02.395.00 - 12 - 2002
FRONT WIRING
TH155061
7
604.02.395.00 - 12 - 2002
REAR WIRING (1)
TH155062
8
604.02.395.00 - 12 - 2002
REAR WIRING (2)
TH155063
9
604.02.395.00 - 12 - 2002
ENGINE WIRING
TH155064
10
604.02.395.00 - 12 - 2002
COPYRIGHT BY FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A.
•
Reproduction of text or illustration,
in whole or in part, is strictly prohibited.
Print No. 604.02.395.00 -- English -- XII -- 2002

Printed by Satiz -- Turin (Italy)
Coordinamento Editoriale Satiz -- Torino
Print No. 604.02.395.00
English - Printed in Italy

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T13

Print N. 604.02.395.00 (XII -- 2002)

THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.

Model T13 T14 T17

Weight (kg) 10700 11340 12090

GENERAL LIST OF CONTENTS

Engine identification code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION 21 -- POWERSHIFT GEARBOX

SECTION 25 -- FRONT AXLE

SECTION 27 -- REAR AXLE

SECTION 35 -- HYDRAULIC SYSTEM

SECTION 55 -- ELECTRICAL SYSTEM

Electrical equipment specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SEALS FOR ROTATING SHAFTS

NOTES ON SPARE PARTS

HOW TO MOVE A VEHICLE WITHOUT BATTERIES

PAY ATTENTION TO THIS SYMBOL

AVOID ACCIDENTS ◊ Never attempt to operate the machine or its tools

STARTING HYDRAULIC SYSTEM

VEHICLE SERIAL NUMBER

SERIAL NO. OF VEHICLE

IDENTIFICATION OF FRONT AXLE

IDENTIFICATION OF 4x3 POWER SHIFT

IDENTIFICATION PLATES IN THE CAB

The data relative to the engine are indicated on the

• In the event no regulations exist, ask for specific

6. Do not unseal air conditioning system by your-

7. Repair at once any leakage or defect of the

HOSES AND STEEL PIPES

SPECIFIC SEALING COMPOUNDS

SEALANTS COMMERCIAL NAME

Anaerobic sealant LOCTITE 518 (liquid gasket)

RTV silicon sealant LOCTITE SUPERFLEX 593,595 or 596

Pipe sealant PST 592 (pipe sealant with teflon)

Locking compound for LOCTITE 271/RED (sealant/locking for threads)

TIGHTENING VALUES FOR FASTENERS

MINIMUM TIGTENING TORQUES FOR FASTENERS

M4 1.7 2.2 2.6 3.4 3.7 4.8 1.8

IDENTIFICATION OF THE MANUFACTURER

HEX NUTS AND TIGHTENING NUTS

IDENTIFICATION OF THE MANUFACTURER

COMMERCIAL CLASS MARKING

MINIMUM TIGTENING TORQUES FOR FASTENERS

INCH MEASUREMENT SCREWS AND LOCK NUTS

GRADE SAE 2 GRADE SAE 5 GRADE SAE 8

NORMAL NUTS HEX NUTS HEX NUTS

GRADE IDENTIFICATION GRADE IDENTIFICATION

Q.TY NUMBER SKETCH DESCRIPTION HOW TO USE/MODEL

Sleeve wrench for power-- For oil delivery control valve

Hydraulic clutch springs com- To press the hydraulic clutch

Tool for installation of power-- For the installation of new

FRONT AND REAR AXLES

Q.TY NUMBER SKETCH DESCRIPTION HOW TO USE/MODEL

Device for the inspection of To check the wear of brake

Tool for the installation of axle To install a new bush to be

Tool for the installation of the To install a new bush to be

Q.TY NUMBER SKETCH DESCRIPTION HOW TO USE/MODEL