NEW HOLLAND LM1340-LM1745 TELEHANDLER SERVICE MANUAL

NEW HOLLAND
SERVICE MANUAL
Telehandler
Model:
LM1340 (Turbo)
LM1343 (Turbo)
LM1345 (Turbo)
LM1443 (Turbo)
LM1445 (Turbo)
LM1743 (Turbo)
- MBI GROUP -
LM1340 TURBO
LM1343 TURBO
LM1345 TURBO
LM1443 TURBO
LM1445 TURBO
LM1745 TURBO
TELEHANDLERS
Workshop Manual
Print N. 604.13.542.01 (III -- 2006)
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 LM1340 LM1343 LM1345 LM1443 LM1445 LM1745

Stabilisers no small large small large large
Engine 88 kW (110 CV -- 118 HP) Turbo Aftercooler
Max. lifting
12.300 12.450 12.450 13.550 13.550 16.600
height (m)
Max. capacity (kg)
at 500 mm from 4000 4300 4500 4300 4500 4500
fork stop
Capacity at max.
2600 3600 4000 3000 3600 2500
height (kg)
Extension at max.
1.200 0.500 0.000 0.500 0.300 1.000
height (m)
Max. longitudinal
8.650 9.330 12.540
extension (m)
Capacity at max.
700 1700 1800 1400 1500 450
extension (kg)
Weight (kg) 10480 10780 11760
Length (m) 5.850 6.070 6.135
Workshop Manual
LM1340 TURBO -- LM1343 TURBO -- LM1345 TURBO
LM1443 TURBO -- LM1445 TURBO
LM1745 TURBO
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
SECTION 10 -- ENGINE
Description Page
Coding of engines of origin .................................................................... 3

Main specifications of engines ................................................................. 4
General engine specifications .................................................................. 5
Generalities ................................................................................. 7
Description of main mechanical components of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Fuel and mechanical injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Injectionassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Removal of engine transmission group from the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Engine overhaul on bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Replacing the injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Adjustment of valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Setting of timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Timing of the injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Data -- Mounting plays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
604.13.542.01 - 03 - 2006
2 GENERAL LIST OF CONTENTS
SECTION 21 -- POWERSHIFT GEARBOX

Description Page
Powershift Gearbox 4x4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Driving with the powershift gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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
Pressure testing clutch and high pressure circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Pressure testing torque converter and cooler circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Check points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Assembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
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 procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Front axle overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Axle drive pinion bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
How to install and adjust the axle drive pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Front drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
604.13.542.01 - 03-- 2006

GENERAL LIST OF CONTENTS 3
SECTION 27 -- REAR AXLE

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

Description Page
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Steering system hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Telescopic boom hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Delivery side divider valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure reduction valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Front loader controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Power steering (OSPQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Telescopic boom distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Auxiliary control distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Working platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Procedure for the calibration of the personnel carrier platform electronic controller . . . . . . . . . . . . . . . . . . . . . 65
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
604.13.542.01 - 03 - 2006
4 GENERAL LIST OF CONTENTS
SECTION 55 -- ELECTRICAL SYSTEM

Description Page
Chapter 1 – Electrical system general

Electrical equipment specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Electrical system and fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Controls and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Use of the tip--over prevention system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Bulb replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Protecting the electrical systems during charging or welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Starting the machine using jump leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Temporary wiring repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Electrical system--general fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Working platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Chapter 2 – Circuit diagrams

List of connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
List of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
How to use the circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Diagram 1: Starter/Recharge/Warning/Indicators lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Diagram 2: Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Diagram 3: Wheel alignment/Hydraulic solenoids/Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Diagram 4: Arm control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Diagram 5: Stabiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Diagram 6: Lights/Windscreen wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Diagram 7: Work lamps/Roof beacon light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Diagram 8: Tilting prevention system/Roof wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Diagram 9: Heating/Sound system/Electric socket/Interior lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Diagram 10: Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Chapter 3 -- Wiring list

Instrument panel wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Cab wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Front wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Rear wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Engine wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
604.13.542.01 - 03-- 2006

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.
On the other hand, spiral elastic pins do not require any installation orientation.
604.13.542.01 - 03 - 2006
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.
604.13.542.01 - 03 - 2006
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 ator co--operating in the operation to be per-

formed.
Most accidents, whether they occur in workshop, on ◊ Never attempt to operate the machine or its tools
the farm, at home or on the road, are caused by the from any position other than seated in the oper-
failure of some individuals to follow simple and fun- ator’s seat.
damental safety rules and precautions. For this rea- ◊ Never perform any intervention on the machine
son MOST ACCIDENTS CAN BE PREVENTED by with engine running unless this is prescribed.
recognising the real cause and doing something
about it before the accident occurs. ◊ Cut--off the engine and make sure that all pres-
sures in the hydraulic systems are released
Regardless of the care used in the design and con- before removing caps, covers, valves etc.
struction of any type of equipment, there are many
◊ All service interventions must be performed with
conditions that cannot be completely safeguarded the utmost care and attention.
against without hindering reasonable accessibility
and efficient operation. ◊ Shop and/or field service platforms or ladders
must be constructed and maintained in accord-
A careful operator is the best insurance against an ance with local and national regulations.
accident.
◊ Disconnect the batteries and tag all controls to
The complete observance of one simple rule would signal that an intervention is in progress. Block
prevent many serious accidents. the machine and all equipment that must be
DANGER. Never attempt to clean, lubricate or main- lifted.
tain a machine while it is in motion. ◊ Do not check nor refill fuel tanks, as well as bat-
teries, nor use starting fluid while smoking or
near open flames since these fluids are flam-
SAFETY RULES mable.
SAFETY RULES ◊ Brakes are inactive when manually released for

service interventions. Under such circum-
◊ Read and heed all safety rules before any inter- stances it is necessary to maintain the control of
vention. the machine using appropriate blocks or similar
devices.
◊ Do not wear rings, wristwatches, jewellery, and
loose or hanging apparels, such as ties, torn ◊ The fuel--filling nozzle must be kept constantly
clothing, scarves, unbuttoned or unzipped inside the filling neck. Keep this contact from the
jackets that can catch on moving parts. Wear beginning to the end of the fuelling operation to
proper safety equipment as recommended for avoid the possibility that sparks due to static
the job. Examples: hard hat, heavy gloves, ear electricity are generated.
protection, safety glasses or goggles, reflector ◊ Use only designated towing or attaching points.
vests, respirator. Consult your employer for spe- Use care in making attachments. Make sure pins
cific safety equipment requirements. and/or locks are secure before pulling. Stay clear
◊ Do not perform any service operation on the of drawbars, cables or chains under load.
machine with a person seated in the operator’s ◊ To move a disabled machine, use a trailer or a
compartment, unless he is an authorised oper- low--boy, if available.
604.13.542.01 - 03 - 2006
◊ To load/unload a machine from transporter, ◊ Do not trust worn and /or kinked chains and
choose a level surface ensuring firm support to cables: do not use them for lifting or pulling oper-
the wheels of truck or trailer. Anchor the machine ations. To handle them, always use heavy
securely to the bed of truck or trailer and block gloves.
wheels or tracks with appropriate wedges.
◊ Be sure chains and cables are anchored and the
◊ Use only approved grounded auxiliary power anchor points are strong enough to handle the
sources for heaters, chargers, pumps and simi- expected load. Keep exposed personnel clear of
lar equipment to reduce the hazards of electrical anchor points and cables or chains. No
shocks. bystanders are allowed near the hooking points,
chains or cables.
◊ Lift and handle heavy parts with a lifting device
of proper capacity. ◊ Keep the area where maintenance operations
are performed CLEAN and DRY. Eliminate
◊ Beware of bystanders. immediately all water and oil spillages.
◊ Never pour gasoline or diesel fuel into open, ◊ Do not pile up oily or greasy rags; they represent
wide and low containers. a fire hazard. Store in a closed metal container.
◊ Never use gasoline, solvent or other flammable
fluid to clean parts. Use exclusively qualified, Before starting machine, check, adjust and lock
non--flammable, non--toxic commercial sol- the operator’s seat for maximum comfort and
vents. control of the machine. Be sure exposed
personnel in the area of operation are clear of the
◊ When using compressed air for cleaning parts, machine before moving it or its attachments.
use safety glasses with side shields or goggles. Sound the horn.
◊ Limit pressure to 2.1 bar, in accordance with
local and national regulations. ◊ Do not carry loose objects in pockets that might
fall unnoticed into open compartments.
◊ Do not run the engine in closed areas without
proper ventilation to remove deadly exhaust ◊ Wear proper protective equipment such as
fumes. safety goggles or safety glasses with side
shields, hard hat, safety shoes, heavy gloves
◊ Do not smoke or permit any open flames or spark when metal or other particles are apt to fly or fall.
near when re--fuelling or handling flammable
materials. ◊ Wear welders protective equipment such as
dark safety glasses, helmets, protective cloth-
◊ Do not use an open flame as a light source to ing, gloves and safety shoes, when welding or
look for leaks or for inspection anywhere on the burning. Wear dark safety glasses near welding
machine. zones. DO NOT LOOK AT ARC WITHOUT
PROPER EYE PROTECTION.
◊ Move with extreme care when working under the
machine, its attachments and or on or near ◊ Steel cables are frayed after prolonged use;
them. Always wear protective safety equipment always wear appropriate protections (heavy
as required, such as hard hat, goggles, safety gloves, goggles etc.).
shoes, ear plugs.
◊ Handle all parts carefully. Keep hands and
◊ When performing operations requiring running of fingers away from structures, gears or moving
the engine, have a qualified operator in the oper- parts. Use and wear always the appropriate
ator’s seat at all times with the mechanic on protections, such as safety goggles, gloves and
sight. Place the transmission in neutral and set safety shoes.
the brakes and safety lock.
◊ For field service, move machine to level ground,
if possible, and block it. If work on an incline is
absolutely necessary, first block machine and its
attachments securely, than move it to level
ground as soon as possible with a certain margin
of safety.
604.13.542.01 - 03 - 2006
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
fingers, near rotating fans or belts. Be especially escaping fluid, see a doctor at once. Serious
alert near pusher fans. infection or reaction can develop if proper medi-
cal treatment 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.
604.13.542.01 - 03 - 2006
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

*FNHNH17MN6HKXXXXX*
The serial number is stamped on the front part of the
machine, on the upper side of the main frame, right
side.
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.
TH001174
1
VEHICLE IDENTIFICATION PLATE
The machine identification plate is located on the left
hand of the seat pod. Record the data of your
machine below.
TECHNICAL TYPE/MODEL
UNIT SERIAL No.
YEAR TH001078
2
604.13.542.01 - 03 - 2006
ENGINE IDENTIFICATION
The engine identification information is located on
the left--hand side of the engine block. Record the
information below for quick reference in case of
necessity.
MODEL NO.
SERIAL NO.
DATE CODE
TH001141
3
TH001142
4
FRONT AXLE IDENTIFICATION

The serial number and axle type is printed on the
plate (1) located on the front of the axle housing.
Record the information below for quick reference in
the case of necessity.
AXLE TYPE
SERIAL NO.
DATE CODE
604.13.542.01 - 03 - 2006
4x3 POWER SHIFT TRANSMISSION

IDENTIFICATION
The serial number and type is printed on the plate (1),
on the lower side of the transmission. Record the
information below for quick reference in the case of
necessity.
MODEL No.
SERIAL No.
DATE CODE
1
TH001030
5
IDENTIFICATION OF REAR
TRANSMISSION
The serial number is indicated on plate (1) secured
on the rear transmission housing. Copy here the
serial number, for a prompt consultation in case of
necessity.
AXLE TYPE
SERIAL No.
DATE CODE
IDENTIFICATION OF CAB
The cab identification plate includes the serial
number and additional data and is located on the
front side of the seat. Please copy here below the
serial number for a prompt consultation in case of ne-
cessity.
SERIAL No.
DATE CODE
TH001161
6
604.13.542.01 - 03 - 2006
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.
604.13.542.01 - 03 - 2006
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.
604.13.542.01 - 03 - 2006
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 243/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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
SILVER GOLD SILVER GOLD SILVER GOLD SILVER GOLD
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
604.13.542.01 - 03 - 2006
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 LM1340 LM1343 LM1345 LM1443 LM1445 LM1745

Stabilisers no small large small large large
Engine 88 kW (110 CV -- 118 HP) Turbo Aftercooler
Max. lifting
12.300 12.450 12.450 13.550 13.550 16.600
height (m)
Max. capacity (kg)
at 500 mm from 4000 4300 4500 4300 4500 4500
fork stop
Capacity at max.
2600 3600 4000 3000 3600 2500
height (kg)
Extension at max.
1.200 0.500 0.000 0.500 0.300 1.000
height (m)
Max. longitudinal
8.650 9.330 12.540
extension (m)
Capacity at max.
700 1700 1800 1400 1500 450
extension (kg)
Weight (kg) 10480 10780 11760
Length (m) 5.850 6.070 6.135
604.13.542.01 - 03 - 2006
TH100027
1
LM1340 TURBO -- LM1343 TURBO -- LM1345 TURBO
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 2050 mm V2 3890 mm
G 402* mm W 2445 mm
I 1100 mm
* Value measured with tyres 405/70x24
604.13.542.01 - 03 - 2006
LM1340 TURBO - LM1343 TURBO - LM1345 TURBO

(without stabilisers or with stabilisers raised and with rear axle lock)
° ° °
LM1340
° LM1343
LM1345
TH001074
2
604.13.542.01 - 03 - 2006
LM1340 TURBO - LM1343 TURBO - LM1345 TURBO

(without stabilisers or with stabilisers raised and without rear axle lock)
° ° °
LM1340
° LM1343
LM1345
TH001075
3
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LM1343 TURBO (with stabilisers lowered)
LM1343
TH00R031
4
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LM1345
TH00R032
5
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TH100027
1
LM1443 TURBO -- LM1445 TURBO
A 1200 mm K 1260 mm
B 3120 mm T 4552 mm
C 1837 mm U 2730 mm
D 6070 mm V 5390 mm
E 7270 mm V1 980 mm
F 2050 mm V2 3890 mm
G 402* mm W 2445 mm
I 1100 mm
604.13.542.01 - 03 - 2006
LM1443 TURBO -- LM1445 TURBO (with stabilisers raised and with rear axle lock)
° ° °
LM1443
LM1445
°
TH001076
2
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LM1443 TURBO - LM1445 TURBO

(with stabilisers raised and without rear axle lock)
LM1443
LM1445
TH00R033
3
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LM1443
TH00R034
4
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LM1445
TH00R035
5
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TH100027
1
LM1745 TURBO
A 1200 mm K 1260 mm
B 3120 mm T 4598 mm
C 1902 mm U 2730 mm
D 6135 mm V 5445 mm
E 7335 mm V1 980 mm
F 2050 mm V2 3890 mm
G 402* mm W 2445 mm
I 1100 mm
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LM1745 TURBO (with stabilisers raised and with rear axle lock)
LM1745
TH001025
2
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LM1745 TURBO (with stabilisers raised and without rear axle lock)
LM1745
TH001079
3
NOTE: This diagram must be considered when the rear axle lock manual control is selected.
604.13.542.01 - 03 - 2006
LM1745
TH00R036
4
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ENGINE DATA 82 kW (110 CV)

Turbo Aftercooler
Model Diesel
Number of cylinders 4 in--line
Bore mm 104
Stroke mm 132
Displacement cm3 4500
Total displacement 17 : 1
Firing order 1.3.4.2
Low idle rpm 800--900

Max. idle rpm 2300--2350
Nominal speed rpm 2200

Maximum torque 480 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
604.13.542.01 - 03 - 2006
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 Mechanical, disc on transmission
STEERING
Steering type Orbitrol

Pump type Gear
System pressure 175 bar
Wheel toe--in 0 -- 2mm
FRONT AXLE
Mounted on front frame Swinging with levelling cylinder

Differential lock No
REAR AXLE
Mounted on frame Floating with swing and automatic locking when boom
angle exceeds 10°
604.13.542.01 - 03 - 2006
HYDRAULIC SYSTEM
Gear pump Hydraulic and steering system
Hydraulic system pressure:
Main system pressure 250 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
13 metre= 10,480 kg
14 metre= 10,780 kg
17 metre= 11,760 kg
TH100028
5
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-
604.13.542.01 - 03 - 2006
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
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
LM1340 front 4.5 4650 6390
LM1343 15 5 R25
15.5
LM1345 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
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
LM1443 front 4.5 5380 7300
15 5 R25
15.5
LM1445 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
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
front 4.5 5730 7470
LM1745 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.
604.13.542.01 - 03 - 2006
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
Ambra Master Gold HSP 15W40 API CH--4 7,6 litres From –10 to +50
Ambra Master Gold HSP 10W30 ACEA -- E5 (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
AMBRA AXF 80W--90 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 180 litres From --20 to +50
ENGINE RADIATOR
Water H2O 12 litres
Ambra Agriflu 12 litres From --35 to +50
BRAKE CONTROL CIRCUIT –
OIL
Ambra Brake LHM M6C 59--A 1 litre
CRANE ARM SHOES –
GREASE
Ambra Tutela GR9 NLGI 2 As required From --40 to +50
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.
604.13.542.01 - 03 - 2006
SECTION 10 -- ENGINE 1
SECTION 10 – ENGINE
TABLE OF CONTENTS
Section Description Page

10 000 Coding of engines of origin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main specifications of engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General engine specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Generalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Description of main mechanical components of the engine . . . . . . . . . . . . . . . . . . . . . . . . 13
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Fuel and mechanical injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Injectionassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Removal of engine transmission group from the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Engine overhaul on bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Replacing the injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Adjustment of valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Setting of timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Timing of the injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Data -- Mounting plays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
604.13.542.01 - 03 - 2006
2 SECTION 10 -- ENGINE
ENGINE F4 GE 0484
TH110060
1
604.13.542.01 - 03 - 2006
CODING OF ENGINES OF ORIGIN

F 4 B E 0 4 8 4 F * D +
Level of emission
Power of homologation
Use
Fuel/injection
D = TIER 2
No. of cylinders
Configuration of cylinders:
0 = 4 stroke vertical
Engine
Type of cylinder block:

B = not structural 4 = 4 cylinders
Family of
engines
8 = Diesel turbo--
charging I.D. Intercooler
4 = Earth Moving Machinery
X Y Y Y Y Y Y Y Y
X = 6 Rotary 2--valves injection pump Production progressive number

Y = Engine variant
604.13.542.01 - 03 - 2006
MAIN SPECIFICATIONS OF ENGINES
F4GE0484
A G*D600
C 3900 cm3
82 kW
D 2200 rpm
E Direct injection
F Rotary injection pump
T.C.A.
G
(Turbocharged with aftercooler)
A Engine type
B Number of cylinders
C Total displacement
p
D Maximum power
p reallyy available
E Type of injection
F Injection system
G Ai
Air iintake
k system
604.13.542.01 - 03 - 2006
GENERAL ENGINE SPECIFICATIONS
F4GE0484
Type
G*D600
Cycle Diesel 4--stroke

Fuel Turbocharged w/aftercooler
Injection Direct
Number of cylinders 4--in--line
Bore mm 102
Stroke mm 120
Total displacement cu cm 3900
Compression ratio 17 : 1
Maximum power kW 88
(HP) 120
rpm 2200
Maximum torque Nm (kgf) --

rpm --
Engine speed at low idle rpm 800--900
Engine speed at high idle rpm 2350--2450
TURBOCHARGING W/ aftercooler
Turbocharger type: HOLSET HX25W
Forced by gear pump, pressure

LUBRICATION
relief valve, oil filter
Oil pressure with hot engin
at low idle bar 1,2
at maximum speed bar 3,8
604.13.542.01 - 03 - 2006
F4GE0484
Type
G*D600
COOLING Liquid
Water pump drive: Belt
Thermostat:
Start of opening: °C 81± 2
CAPACITIES
Total 1st filling litres --
Ambra Super Gold
15W40 kg
10W30
W -- engine sump litres --
kg
-- engine sump + filter litres 7,6
kg
FUEL
VE4 / 12 F 1100 L
Injection pump type Bosch
Pump setting 0° ± 0°,5
Beginning of delivery mm 1
Nozzles type DSLA 145 P603
Firing order 1 -- 3 -- 4 -- 2
Injection pressure bar 245 bar
604.13.542.01 - 03 - 2006
GENERALITIES
A G
F
B
C
D
TH110001
2
A. Drive belt for: water pump D. Oil pump
– alternator fan E. Belt tensioner
B. Alternator F. Rotary injection pump
C. Water pump G. Air heater for cold starting
604.13.542.01 - 03 - 2006
Upper view
D E F G
C B A
TH110002
3
A. Alternator E. Injection pump
B. Injectors F. Intake manifold
C. Turbocharger G. Fuel filter
D. Blow--by
604.13.542.01 - 03 - 2006
Front view
B
H
TH110003
4
A. Blow--by F. Poly--V belt
B. Fuel filter G. Water pump
C. Priming pump H. Alternator
D. Idle pulley I. Thermostat
E. Oil filter
604.13.542.01 - 03 - 2006
Right side view
H
F
TH110004
5
A. Blow--by F. Poly--V belt
B. Turbocharger G. Oil filter connection
C. Thermostat H. Starter motor
D. Alternator I. Oil unloading pipe from turbocharger
E. Water pump L. Exhaust manifold
604.13.542.01 - 03 - 2006
Left side view
L
A
B
I
H C
TH110005
6
A. Blow--by F. Fuel filter
B. Injector fuel lines G. Fuel heater
C. Injection pump H. Cinghia Poly -- V
D. Oil filter I. Air Heater
E. Priming pump L. Intake manifold
604.13.542.01 - 03 - 2006
Rear view
O A B C D
E
M
L
I
TH110006
7
A. Blow--by H. Starter motor
B. Injector fuel lines I. Engine flywheel
C. WASTGATE valve L. Oil filter
D. Turbocharger M. Injection pump
E. Oil unloading pipe from turbocharger N. Air heater
F. Alternator O. Intake manifold
G. Exhaust manifold
604.13.542.01 - 03 - 2006
DESCRIPTION OF MAIN MECHANICAL

COMPONENTS OF THE ENGINE
Cylinder block
Also, the ducts for the circulation of the coolant are
The cylinder block is a cast iron structure containing realised as well as the lubrication oil ducts to the
cylinder sleeves (1) main journals (5) and the seats various organs.
for: camshaft bushes (3) and tappets, water/oil heat Plate (6) mounted on the lower side of the cylinder
exchanger (7), water pump (2) and oil pump (4). block, provides higher strength to stresses.
2
7
3
TH110008
8
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Crankshaft
The steel crankshaft rests on 5 journals. They are The main journal half bearings are steel made with
induction hardened. anti friction alloy lining.
Inside, the lube oil ducts are made. The last but one journal half bearings are equipped
On the front nose the oil pump drive gear, the phonic with thrust washers to contain the axial play of the
wheel, the damper wheel and the auxiliary crankshaft.
component drive pulley are installed. Items (1, 2) are fitted with an interference on the rear
On the rear nose the camshaft drive gear and the end and are not replaceable.
engine flywheel mounting hub are installed.
TH110009
9
1. Timing drive gear 3. Oil pump drive gear
2. Hub for flywheel mounting
Crankshaft sealing rings

The front and rear sealing rings are of a box type, with
radial sealing. They require tools 380000663 and
380000665 for their extraction, whereas for the
installation, 380000664 and 380000666 are
required.
604.13.542.01 - 03 - 2006
Conrods
Steel stamped, they are of an inclined cut type, with The conrod half bearings are steel made with anti
separation of the cap obtained by a new technology friction alloy lining.
(fracture split) and not by machining.
TH110010
10
Each conrod is marked:

• On the body and cap a number indicates the
matching and the cylinder on which it is installed.
• On the conrod body, a letter indicates the weight
class of the conrod installed in production.
604.13.542.01 - 03 - 2006
Pistons
TH110011
11
On the ceiling of each piston a combustion chamber The 1st trapezoidal shape piston ring with chromium
is made. The ceiling of the piston is cooled by engine ceramic lining.
oil provided by the jet installed on the cylinder block. The 2nd rectangular taper torsional sealing ring.
There are three piston ring seats: the 1st one is The 3rd with a dual skid with inner spring.
obtained by a trapezoidal shape cast iron insert.
The i.d. numbers and manufacturing data are
The piston rings have different functions and have provided in zone 1 of the piston ceiling.
different shapes.
TH110012
12
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Camshaft
The camshaft is mounted inside the cylinder block on A. Intake valve drive
5 journals. B. Exhaust valve drive
The front and rear journals are equipped with
interference fitted steel bushes lined with anti friction The camshaft is driven directly by the crankshaft by
material. Each cylinder has 2 cams. straight gears.
TH110013
TH110014
13
604.13.542.01 - 03 - 2006
Valve drive
2
1
4
6
7
8
TH110015
14
1. Rocker arm 6. Cup
2. Shaft 7. Spring
3. Adjusting screw 8. Tappet
4. Rod 9. Camshaft
5. Half cones
604.13.542.01 - 03 - 2006
Cylinder head
The cast iron cylinder head has the seats for the Also, the heads have:
following items: • single block exhaust manifold (1);
• added valve seats (4); • intake manifold (2) with air heater seat (3) for cold
• injector (6); starting.
• hermostat (5);
TH110016
15
View of cylinder head with added valve seats
604.13.542.01 - 03 - 2006
Valves and valve seats
S
1
TH110017
16
1. Intake valve A. Intake side
2. Exhaust valve S. Exhaust side
The added seats on the cylinder head have an angle Exhaust valves (2) are different from the intake
of: valves for the presence of a single grove at the tip of
• 45 ° for the exhaust valves the stem.
• 60 ° for the intake valves
TH110018
17
Figure 17 shows the oil seals installed on the valve
stems.
604.13.542.01 - 03 - 2006
Valve guides
The valve guides are not inserted.
TH110188
18
604.13.542.01 - 03 - 2006
Engine flywheel
Flywheel (1) does not require a fixed position on the The equal distance of securing screws (2) ensures
crankshaft, since there are no references, notches an indifferent installation in all positions.
nor reference holes on it for sensors or timing.
TH110020
19
604.13.542.01 - 03 - 2006
Auxiliary organs drive The belt is tensioned through the elongated hole on
A Poly--V belt (1) drive the motion from crankshaft (4) the alternator bracket.
to water pump (3) and alternator (2).
TH110021
20
1. Poly--V belt 4. Crankshaft pulley
2. Alternator 5. Guide pulley
3. Water pump
604.13.542.01 - 03 - 2006
LUBRICATION • water/oil heater exchanger located in the engine

The forced circulation lubrication is provided by the cylinder block, with oil filter connection;
following components: • oil pressure relief vale incorporated in the oil filter
• rotor oil pump, located in the front side of the cyl- connection;
inder block, driven by a straight gear mounted on • by--pass valve cutting off the filter when clogged,
the crankshaft nose; incorporated in the oil filter connection;
• cartridge oil filter.
TH110022
21
Oil gravity return way Oil filling
Pressurised oil way
604.13.542.01 - 03 - 2006
Heat exchanger
TH110023
22
1. Heat exchanger body 4. Gasket between heat exchanger group and engine
2. Inner gasket cylinder block
3. Water oil heat exchanger 5. Oil return to filter
6. Oil inlet to filter
604.13.542.01 - 03 - 2006
Oil pump
TH110024
23
TH110025
24
1. Crankshaft (1) with oil pump drive gear
604.13.542.01 - 03 - 2006
Oil sump
Oil sump (1) is secured elastically to the cylinder This type of gasket has to be replaced only in case
block by aluminium plate (3), figure 26. of deterioration or failure and not necessarily at each
The “C” section rubber gasket (2) is mounted on the removal.
oil sump mounting profile, besides providing the
sealing, reduce the noise.
TH110026
25
TH110027
26
604.13.542.01 - 03 - 2006
Oil fume re--circulation The condensed fumes, drop for the gravity under
The re--circulation of oil fumes occurs through valve rocker arm cover (2) whereas the remaining ones are
(1) located on rocker arm cover (2). recovered by blow--by (3) and directed appropriately
to the intake.
TH110028
27
604.13.542.01 - 03 - 2006
COOLING
The engine cooling system, of a forced circulation • a water pump of a centrifugal type located in the
closed circuit type, is made of the following compo- front side of the engine cylinder block;
nents: • a thermostat regulating the flow of the coolant.
• a heat exchanger cooling the lubrication oil;
TH110029
28
Water outlet from the thermostat Water entering the pump
Water re--circulation in the engine
604.13.542.01 - 03 - 2006
Water pump
The water pump, located in a seat in the cylinder A thermostat regulates the temperature of the
block, is driven by a poly--V belt. engine.
The very limited quantity of external piping, sleeves The coolant circulates also in the oil heat exchanger.
and bands eliminates many connections, reducing
the chance of leakages.
TH110030
29
TH110031
30
604.13.542.01 - 03 - 2006
FUEL AND MECHANICAL INJECTION
Fuel filter
In support (1) are located: fuel temperature sensor 5
(5) heater resistance (2) water bleeding screw (3) 1
and filter (4).
Grade of filtration of cartridge: 6 micron.
Maximum operating pressure: 5 bar. 2
Operating temperature: from – 40 °C (--40 °F)
through + 90 °C (+ 194 °F).
TH110034
31
604.13.542.01 - 03 - 2006
MECHANICAL FUEL PUMP

Volumetric pump, installed on the left side of the
engine, has the function of supplying the injection
pump. It is driven by the camshaft.
1. Fuel outlet to filter
2. Drive lever 1
3. Fuel inlet from tank
3
TH110035
32
1. Pump
2. Drive lever 1
3. Camshaft
TH110036
33
604.13.542.01 - 03 - 2006
INJECTIONASSEMBLY
3
4
2
5
1
6
10
TH110037
34
1. Fuel line injector 1 6. Manifold for pressure measuring pipe in intake mani-
2. Fuel line injector 2 fold for LDA
3. Fuel line injector 3 7. Thermal bulb for KKSB
4. Fuel line injector 4 8. Injection pump
5. Fuel unloading line from injectors 9. Solenoid valve
10. Injector
604.13.542.01 - 03 - 2006
Injection pump IdentificazioneIdentification

The pump is of a rotary type, driven by a gear match- V = rotary distributor piston
ing the one on the camshaft. E = size of pump
4 = for 4--cylinder engine
12 = 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
35
Longitudinal section view of injection pump
1. Membrane 9. Advance variator
2. Adjusting ring nut 10. Distributor piston
3. Feeling pin 11. Delivery connection
4. Drive lever 12. Hydraulic head
5. Speed governor 13. Drive plate
6. Transfer pump 14. Regulation pin
7. Drive shaft 15. Return spring
8. Cam disc
604.13.542.01 - 03 - 2006
Description of operation
Supply phase
1
2
3
6
4
7 9
8 5
TH110039
36
1. Fuel inlet duct 6. Distributor piston
2. Solenoid valve 7. End of delivery hole
3. Axial groove 8. Slider
4. Compression chamber 9. Injector
5. Fuel duct between pumping element and injectors
Distributor piston (6) is at L.D.C. and slider (8) closes The fuel is forwarded to compression chamber (4)
end of delivery hole (7). through supply duct (1) that is kept open by solenoid
vale (2).
604.13.542.01 - 03 - 2006
Delivery phase
5 3 4
TH110040
37
1. Fuel inlet duct 4. Duct between pumping element and injectors
2. Compression chamber 5. Distributor piston
3. Distributor piston inner duct 6. Injector
Distributor piston (5) under the effect of the rotation Inner duct (3) of the distributor piston is connected to
of the cam disc, raises toward the T.D.C. and, at the duct (4) providing the delivery to injectors (6).
same time, rotates on its axis. The combination of the
two movements determines the closing of fuel inlet
duct (1) and the simultaneous compression of the
fuel in chamber (2).
604.13.542.01 - 03 - 2006
End of delivery phase
6 5 4 3
TH110041
38
1. Fuel inlet duct 4. End of delivery duct
2. Compression chamber 5. Slider
3. Delivery duct 6. Distributor piston
Distributor piston (6) during its stroke toward T.D.C. Since such pressure is insufficient to actuate the
connects the high pressure inner chamber through injector, the delivery ends.
duct (4) establishing an equilibrium between the
inner chamber of the distributor piston, the injector
delivery line and the inside of the pump.
604.13.542.01 - 03 - 2006
Engine cut--off
1
4
3
2
5
TH110042
39
1. Fuel inlet duct 4. Solenoid valve
2. Mobile plug 5. Compression chamber
3. Spring
The engine cut--off occurs when cutting--off the star- The solenoid valve, under the effect of spring (3)
ting contact. The electric power energising solenoid pushes mobile plug (2) to full stroke, obstructing fuel
valve (4) is cut--off. inlet duct (1).
L.D.A. device (delivery adjustment as a function of the load)
1
2
3
4
5
6
7
8
TH110043
40
Operation of the L.D.A. device
The L.D.A. device has the purpose of changing the The axial movement of regulation pin (4) causes the
delivery of fuel as a ratio of the air pressure in the sliding of feeling pin (6) that in turn, actuates stop
intake manifold. lever (7). Stop lever turns on its axis (8) and actuates
This air pressure actuates membrane (1) connected the drive plate so that the fuel deliveries are adjusted
to regulation pin (4). In the lower side of regulation pin to the quantity of air introduced into the cylinders.
(4) taper seat (5) is machined in which feeling pin (6)
slides.
604.13.542.01 - 03 - 2006
Starting
6
5
2 1 4
7
TH110044
41
1. Starting lever 5. Regulation sleeve
2. Leaf spring 6. Solenoid valve
4. Slider 7. Compression chamber
After energising solenoid valve (6) a passage of fuel Thus, the entire stroke of the pumping element use-
is created into compression chamber (7). Under ful for the injection is exploited.
these conditions, regulation sleeve (5) is with the
masses closed; thus leaf spring (2) pushes lever (1)
and slider (4) into supplement position.
Starting device disengaged
6
5
7 2
4
TH110045
42
1. Starting lever 5. Regulator sleeve
2. Leaf spring 6. Solenoid valve
3. Tensioner lever 7. Masses
4. Slider
Once the engine starts, regulation sleeve (5) under Under these conditions slider (4) moves determining
the effect of the centrifugal force due to the expan- maximum delivery.
sion of masses (7) starts the axial movement,
pushes starting lever (1) against tensioner lever (3)
thus compresses leaf spring (2).
604.13.542.01 - 03 - 2006
Delivery start depending upon the load

(L.F.B.)
1 2
7 8
5
TH110046
43
Structure of the regulator group with correction of the
delivery start depending upon the load
1. Regulation spring 5. Slider
2. Regulator spring 6. Distributor piston
3. Tensioner lever 7. Governor shaft
4. Starting lever 8. Centrifugal masses
Description
The correction of the beginning of the delivery as a • The governor support shaft with a longitudinal
function of the load (LFB) provides a smoother (more hole and two and crossway ones.
silent) operation of the engine. • The pump body with one hole, closed externally
The operation of the LFB device is provided by modi- by a ball communicating with the supply cham-
fying: ber.
• The regulation sleeve with a supplementary hole
to the “anti lunging” hole.
604.13.542.01 - 03 - 2006
Positioning of governor sleeve in the LFB
1 2 3 4
5 67
TH110047
44
a Sleeve in rest position 3. Cross--way hole in governor sleeve
b. Moving sleeve 4. Governor sleeve
c. Sleeve under correction conditions, inner pressure 5. Cross--way hole in governor shaft
drop 6. Edge from governor centre line
1. Longitudinal hole in governor support shaft 7. Cross--way hole in governor shaft
2. Governor shaft
Operation
Not withstanding the position of the outer throttle the transfer pressure. This is obtained by the LFB
lever, when the rpm of the governor masses device.
increase, under the effect of the centrifugal force, When regulating sleeve (4) sliding on governor sup-
move governor sleeve (4) a reduction of the delivery port shaft (2) connects hole (3) with groove (6) and
is determined. In order to obtain a smoother opera- hole (7) a portion of pressurised fuel is unloaded
tion of the engine a reduction of the advance must through duct (1 and 5) into the supply chamber, cau-
correspond to a reduction of delivery. Since in the sing a reduction of the transfer pressure inside the
rotary pump the advance device operates hydrauli- pump thus reducing the advance.
cally, to obtain a reduction it is necessary to reduce
604.13.542.01 - 03 - 2006
Cold injection advance automatic device

(KKSB)
1
TH110048
45
1. KKSB bulb
The KKSB device has the function of setting an

appropriate injection advance when the engine is
cold.
46
604.13.542.01 - 03 - 2006
REMOVAL OF ENGINE TRANSMISSION

GROUP FROM THE VEHICLE
Warnings
ATTENTION
Please comply with the following warnings prior to
perform interventions on the engine involving or inte-
resting components of the fuel system.
• The utmost clean conditions of the parts must be
ensured, during the handling and the installation
of any part (starting from the simple replacement
of filter and pre--filter), to prevent the entry of
impurities or foreign bodies. For this purpose, the
protection plugs of hydraulic parts and sensors
must be removed just before positioning the
components in their seats.
• Care must be taken ensuring the correct polarity
of electric connections.
• All threaded connections must be tightened to
the prescribed torque.
Quick release couplings for low pressure lines

A B
All connectors must be fully engaged and with
stopper (1) in locking position (see Figure 47 – A). 1
To disconnect the low pressure system pipes, press
stopper (1) (as indicated in Figure 47 – B) to release
the pipe connector from the socket.
After disconnecting it, return stopper (1) in the
locking position (Figure 47 – A) to prevent any
possible deformation.
When re--assembling the low pressure system,
press stopper (1) as indicated in Figure 47 – B and
connect the connector to the relevant socket. Return 1
TH110064
stopper (1) into locking position A to provide the
connection of the pipe to the relevant component. 47
A Connector properly locked
Failing to comply with the pipe connection procedure
B Connector released for removal – installation
can result in the sudden separation of the pipes,
when starting or during the engine operation, under
the effect of the operating pressures.
604.13.542.01 - 03 - 2006
Removal Reinstallation
Remove the engine compartment guard. To reinstall the engine, reverse the operations
described for the removal, complying with the
ATTENTION following warnings:
Prior to performing any removal/installation opera- • pay special attention to the manoeuvres required
tion, disconnect the battery cables and secure the for the installation of the engine in the engine
machine under safe conditions. compartment;
• check the conditions of the cooling system slee-
ves and pipes and the air conveyors; in the event
• Remove the batteries; they are damaged, replace them;
• drain the engine coolant into an appropriate con- • check the elastic supports of the engine and tran-
tainer, as a consequence of the separation of all smission groups; in the event they are damaged,
the cooling system pipes; replace them;
• disconnect the air and exhaust fume pipes; • check the components of the exhaust piping that
they are not deteriorated or near to deteriorate,
• disconnect all electric connections located on the as well as the elastic securing elements;
engine deriving from the frame wiring;
• tighten screws and nuts to the prescribed tor-
• disconnect all the transmission group hydraulic ques;
pipes and drain the oil into an appropriate contai-
ner; • check thoroughly that the connections of the fuel
pipes and their relevant connections are correct,
• disconnect all the electric wires present in the as specified in the notices 2main interventions on
engine compartment;
the engine installed on the vehicle”;
• disconnect the pipe to the after--cooler; • fill the cooling system with coolant and bleed the
• disconnect the intake duct; air as described in the relevant paragraphs;
• disconnect the pipes from the air conditioner
compressor; ATTENTION
• disconnect the fuel delivery pipes from the primer Prior to reusing it, check that the coolant is free from
pump and return to the tank from the injection impurities; otherwise filter it with appropriate screen
pump; filters. For any topping--up, please refer to the CAPA-
• separate from the frame the lower side of the CITIES table.
engine compartment hood;
• remove the radiator group from the engine sup-
port beam (front side); • check the engine and the transmission oil levels.
• remove the propeller shafts located under the For any topping--up, please refer to the “CAPA-
telehandler frame from the transmission drive. CITIES” table.
Install lifting device 380000216 on the engine
and using an appropriate lifting device, place the
engine under pull;
• remove the securing screws, then, paying atten-
tion to the wiring on the frame, making sure that
all components are free, lift the engine/transmis-
sion and remove it from the compartment;
• once the engine/transmission group is removed
from the frame, proceed with the removal of the
engine (please refer to the transmission section).
604.13.542.01 - 03 - 2006
Checks and inspections Air bleeding from the system

Start the engine and let it operate at a speed just • The air bleeding from the cooling system must be
above low idle and wait for the temperature of the started immediately after the filling operation.
coolant to reach the thermostat opening value, then • Start the engine letting it operate at low idle for at
check that: least five minutes.
• there is no leakage of coolant from the sleeves After this time, top--up as required.
connecting the pipes of the engine cooling • Close carefully the expansion cap and run the
system and the cab heating, tightening the secu- engine at a high speed to facilitate the warming
ring elements as required; up of the coolant, until the thermostat opens.
• there are no oil leakages of oil between the cover Note: to speed--up the operation, it is suggested
and cylinder head, between sump and cylinder that the radiator be screened placing a piece of
block, heat exchanger oil filter and relevant seats cardboard between radiator and aftercooler.
and the various pipes of the lubrication system; • Bring the temperature of the coolant to about 90
• there are no leakages of fuel from the fuel pipes; °C (195 °F) (to make sure the thermostat is open)
• make sure that the indicator lights on the instru- checking the on--board temperature gauge.
ment dashboard and the instruments that have • From the time the coolant temperature is rea-
been disconnected when removing the engine ched, it is necessary to keep the engine running
operate correctly. at high idle rpm to let the complete evacuation of
the air.
This situation can be verified checking that no air
bubbles or foam are present in the expansion
tank.
• The maximum time for a full elimination of the air
is about 15 minutes, from the time the thermostat
Filling the engine cooling system opens.
General standards Important notices

• The filling operations must be performed with • Do not open the expansion tank cap from the
engine cold. time it is closed and the engine warm--up opera-
• To prevent the formation of air pockets in the tion starts until when the engine is fully cooled--
system, the pouring of the liquid must occur off.
slowly. Consequently, any topping--up of missing coo-
• The percentage of antifreeze in the cooling liquid lant must be done when the engine is for sure
must not exceed 50%. cooled--off.
This is to prevent two possible consequences:
• Proceed with the filling in compliance with the – burns for the person performing the operation;
procedures previously described until the expan- – possible damages to the engine, since the
sion tank is filled. system is pressurised only when the coolant
warms--up from a cold engine.
604.13.542.01 - 03 - 2006
ENGINE OVERHAUL ON BENCH
Engine disassembly
Drain the engine oil by removing the sump plug and
the filler cap on the cylinder head cover.
Remove the fan group from the fan pulley.
To install bracket 380000661 to the engine to secure
it on the engine overhaul stand proceed on the left
side of the engine:
• remove oil filter (2) from support (3) using tool
380000670;
5
• remove oil pipes (1) and (4) of filter support (3);
• remove support (3);
• remove electric harness (5). 4
1
2
TH110061
48
To install bracket 380000661 on the right side of the
engine, remove: 7
• starter motor (3);
• oil return (1) securing bracket (2); 1
• oil return pipe (1) relative to the turbine;
2 6
• remove oil pipes (4) and (5) from heat exchanger
group (6).
Secure the engine to rotary stand 380000301 3
• disconnect turbine lubrication delivery pipe (7)
4 5
TH110062
49
• disconnect the engine oil fumes recovery pipe
4 3
from blow--by (1); 2
• remove rocker arm cover (4); 5
1
• remove electric harness (8);
remove fuel filter (9); 13
• 6
• remove intake manifold (3); 7 12
• remove heater (2);
11
• remove heater (5) controller; 8
• remove LDA system pipe (13);
• remove quick release pipes (7), (10), (11) and 10
(12) following the notices provided in figure 51; 9
TH110063
• remove fuel filter support (6).
50
604.13.542.01 - 03 - 2006
Actuate fork (1) as indicated in the figure (item B) and

A B
remove the connector. To prevent deformations,
once the connector is separated, return fork (1) into 1
locking position (item A).
1
TH110064
51
• Disconnect supply pipes (5) from injection pump
3 2
injectors (6); remove the securing brackets of the
pipe group (1), (2) and (3) on the cylinder head.
• Remove primer pump (4). 1
4 5 6
TH110065
52
• Remove the supply pipe group from injectors (1).
2
• Remove fuel unloading pipe (2) from the injec- 1
tors removing screw (4) and gasket (3).
TH110066
53
604.13.542.01 - 03 - 2006
• Remove screws (3) and proceed with the remo-

val of turbine (1). 1
• Remove exhaust manifold (2).
TH110067
54
• Remove auxiliary organs belt (5) moving alterna-
1 8
tor securing bracket (1).
• Remove alternator (2), water pump (4), fan pul-
ley (7) and guide pulley (6). 2 7
• Remove the support from pulley (8).
• Remove connection (3) of the engine cooling
system from the cylinder block.
6
5
TH110068
55
Install tool 380000990 (1) to the flywheel housing to
prevent the rotation of the flywheel.
TH110069
56
604.13.542.01 - 03 - 2006
Remove securing screws (1) from pulley (2).
1
TH110070
57
Seal ring removal
Install tool 380000665 (4) on the nose (2) of the
crankshaft.
Drill inner sealing ring (1) with a drill (3.5 mm diam.)
through the guide holes of tool 380000665 (4) for a
depth of 5 mm.
Secure tool 380000665 (4) on ring (1) tightening the
1
6 screws (5) provided.
Pullout ring (1) tightening screw (3). 2
3
4
5
6
TH110071
58
Install the appropriate puller (3) of tool 380000669 to
outer sealing ring (2) as indicated in the figure and 1
using lever (4) extract it from front cover (1). 2
Remove the front cover.
TH110072
59
604.13.542.01 - 03 - 2006
Remove oil gear pump (1).
ATTENTION
Oil pump (1) cannot be overhauled.
TH110073
60
Removal of the injection pump
Prior to removing the injection pump remove the
flywheel locking tool described in figure 48.
Turn the crankshaft until it is in the TDC on the 1st
cylinder.
The TDC condition of the 1st cylinder is obtained
when pushing pin (1) indicated by the arrow, it rests
in its seat drilled on camshaft drive gear (2).
2
TH110074
61
To pre--set correctly the injection pump prior to
removing it, loosen screw (2) and remove “L” spacer
(1).
Retighten screw (2) full stroke.
ATTENTION
Store “L” spacer in an appropriate manner with the
pump body.
2
1
TH110075
62
604.13.542.01 - 03 - 2006
• Remove cover (1) from gear cover (2). A B

• Lock the engine flywheel as described in figure 1
48.
• Remove nut (4) securing injection pump drive 4
gear (3).
TH110076
3
63
Remove the three nuts (2) (4) (5) securing injection
pump (1) to flywheel housing (3) and extract it from 2
its seat using tool 380000322 properly installed on 1
gear (3) of figure 63B.
5
3
4
TH110077
64
Install tool 380000990 (2) to loosen screws (1).
Remove tool 380000990 (2). 1 4
Remove screws (1) securing flywheel (4) on
crankshaft (3).
3
2
TH110078
65
Install two pins (2) of appropriate length in the holes
of crankshaft (3). 1
Extract flywheel (1) so that it is possible to sling it with
a lifter and rest it in a container.
2
3
TH110079
66
604.13.542.01 - 03 - 2006
Install tool 380000663 (3) on the rear (5) of the

crankshaft.
Drill inner sealing ring (1) with a drill (3.5 mm diam.)
for a depth of 5 mm.
Secure tool 380000663 (3) on ring (1) tightening the
6 screws (4) provided.
Pullout ring (1) tightening screw (2).
1
5
2
TH110080
67
Install the appropriate puller (3) of tool 380000669 to
outer sealing ring (2) as indicated in the figure and 1
using lever (4) extract it from flywheel housing (1). 2
TH110072
68
Remove screws (2) and remove rear cover (1).
1
ATTENTION
Record the mounting position of screws (2) since
they have different dimensions. 2
TH110081
69
604.13.542.01 - 03 - 2006
Turn the engine upside down, remove screws (2),

remove plate (3) and remove oil sump (1). 1
2
TH110082
70
Remove screws (1) and (4) and remove oil suction
strainer (5). 5
Remove screws (2) and remove stiffening plate (3). 1
2
4
TH110083
71
Remove screws (1) and gear (3) from camshaft(2).
1
TH110084
72
Removal of rocker arm group
2 1
For each cylinder, remove rocker arm group (1)
loosening adjustment nuts (3), adjusters (2) and
removing screws (4).
3
TH110057
73
604.13.542.01 - 03 - 2006
Extract injectors (2) using tool (1) 380000671.

1
TH110053
74
Remove screws (1) securing the heat to the cylinder
block.
1
TH110085
75
Attach to brackets (1) and (2) the steel cables and
remove the cylinder head from the cylinder block. 1
TH110086
76
Remove screws (2) and remove timing gear housing
(1).
1
ATTENTION
Record the mounting position of screws (2) since
they have different dimensions. 2
TH110087
77
604.13.542.01 - 03 - 2006
Remove screws (1) securing conrod caps (2) and

remove them.
Extract the pistons complete with conrods from the
top of the cylinder block.
1
ATTENTION
Keep the half bearings in the relevant seats. In the
event they are reused, they must be installed in the
same position found at the disassembly.
2
TH110088
78
Remove screws (1) and remove main journal caps
(2).
1
2
TH110089
79
The last but one main journal (1) and relevant
support have half--bearing (2) equipped with thrust
washer.
1
ATTENTION
Record the mounting positions of the upper and 2
lower half bearings, since in the event they are reu-
sed, they must be installed in the same position
found at the disassembly.
TH110090
80
Lift crankshaft (2) from the cylinder block using tool
380000262 (1).
1
TH110091
81
604.13.542.01 - 03 - 2006
Remove main journal half bearings (1).

Remove screws (2) and remove oil jets (3).
1
2
3
TH110092
82
Remove screws (1) and plate (2) retaining camshaft
(3).
ATTENTION
Record the mounting position of plate (2).
2
1
TH110093
83
Extract carefully camshaft (1) from the cylinder
block.
TH110094
84
Extract tappets (1) from the cylinder block.
TH110095
85
604.13.542.01 - 03 - 2006
REAPIR INTERVENTIONS ON THE

CYLINDER GROUP
Checks and measurements
Once the disassembly of the engine is completed,
proceed with an accurate cleaning of the 1
cylinders--cylinder block group.
Use the appropriate eyes to handle the cylinder 2
group. 1
Check accurately that the engine cylinder block is
free from cracks. 2
Check the conditions of the machining plugs.
Replace them when showing signs of rusting or there
are doubts about their sealing.
Examine the surfaces of the cylinder sleeves; they
TH110096
must be free from any sign of seizing, scratches,
out--of round, tapering or excessive wear. 86
The check of the inner diameter of the cylinder
sleeves, to verify the amount of out--of--round,
tapering and wear is made using bore gauge
380000827 (1) equipped with dial previously zeroed
on ring caliper (2) with the diameter of the cylinder
sleeve.
ATTENTION
In the event the ring caliper is not available, use a
micrometer for the zeroing.
The measurements must be made for each single

cylinder, at three different heights of the sleeve and
on two planes perpendicular between them: one
parallel to the longitudinal axis of the engine (A) and
the other perpendicular (B). On the latter and in
correspondence with the first measurement, the
maximum wear is generally found.
When an out--of round, tapering or any wear is found,
proceed with the re--boring and grinding of the
cylinder sleeves. The re--boring of the cylinder
sleeves must be performed in relation with the
diameter of pistons provided as spare parts
oversized 0.5 mm over the nominal value and with
the prescribed mounting play.
TH110097
87
604.13.542.01 - 03 - 2006
ATTENTION
In case of re--boring, all the sleeves must have the
same oversize.
Check the seats of the main journal bearings

proceeding as follows:
• install the main journal caps without the bea-
rings;
• tighten the securing screws to the prescribed tor-
que;
• using an appropriate bore dial gauge, check that
the diameter of the seats is at the prescribed
value.
In the event a higher value is found, replace the
cylinder block.
TH110098
88
Checking the head mounting face on the
cylinder block
Check that the head mounting face on the cylinder 2
block is not deformed.
This check can be made, after removing dowels (4)
using a calibrated ruler (2) and feeler gauge (3).
In the event deformations are found, grind the 3 4
mounting face. 1
The flatness error cannot exceed 0.075 mm.
ATTENTION
The grinding of the cylinder block can be performed TH110099
only after making sure that once the work is finished, 89
the protrusion of the piston from the cylinder sleeve
does exceed the prescribed value.
Check the conditions of machining plugs (1).

Replace them when showing signs of rusting or there
are doubts about their sealing.
Once the grinding is completed rework the bevel of
the cylinder sleeves as indicated in Figure 88.
604.13.542.01 - 03 - 2006
TIMING
Camshaft
TH110100
90
MAIN CAMSHAFT DATA
The data listed refer to the normal diameter of the pins.
The surfaces of the main journals and those of the

cams must be absolutely smooth. In the event they
show signs of seizing or scratches, replace the
camshaft and the relevant bushes.
Check of the cam lifting and the journals

alignment
1
Place the camshaft on centres and using a dial
gauge on the central main journal, check the
alignment deviation does not exceed 0.04 mm, 2
otherwise replace the camshaft. Also, check the cam
lifting. It must measure 7.239 mm for the exhaust
ones and 6.045 mm for the intake ones, otherwise
replace the camshaft.
Check the diameter of camshaft (2) main journals
with micrometer (1) on two axis perpendicular
between them.
TH110101
91
604.13.542.01 - 03 - 2006
BUSHES
Bushes (2) of the camshaft must be forced into the
relevant seats.
The inner surfaces must be free from any sign of
seizing or wear.
Measure with bore gauge (3) the diameter of front
and rear bushes (2) and intermediate seats (1) of the 1
3
camshaft.
The measurements must be done on two axis
perpendicular between them. 2
TH110102
92
TH110103
93
MAIN DATA OF CAMSHAFT BUSHES AND RELEVANT SEATS
* dimension to be obtained after press fitting the bushes
604.13.542.01 - 03 - 2006
Replacing the bushes

1
To replace front and rear bushes (1) use puncher
380000667 (2) and holder 380000668 (3) for the
disassembly and reassembly.
ATTENTION 2
Bushes (1) to be reassembled must be directed so
that the lubrication holes coincide with those on the
seats on the cylinder block.
3
2
TH110104
94
Tappets
MAIN DATA OF TAPPETS AND RELEVANT SEATS

ON THE CYLINDER BLOCK
TH110105
95
AInstalling the tappets – Camshaft
Lubricate tappets (1) and install them in the relevant
seats on the cylinder block.
TH110106
96
Lubricate the camshaft main journal bushes and
install camshaft (1) taking care that, during the
operation, the bushes or the support seats are not
damaged.
TH110094
97
604.13.542.01 - 03 - 2006
Position plate (1) retaining camshaft (3) with the

groove toward the upper side of the cylinder block
and the stamping directed toward the operator.
Tighten screws (2) to the prescribed torque.
TH110107
98
Check the axial play of camshaft (1). It must measure
0.23 ± 0.13 mm.
TH110108
99
Install jets (2) and tighten securing screws (1) to the
prescribed torque.
2
TH110109
100
604.13.542.01 - 03 - 2006
CRANKSHAFT
Measuring main and conrod journals
1
In the event signs of seizing, scoring or excessive
out--of round are found on the main and conrod 2
journals, it is necessary to grind them. Prior to
proceeding with the journal (2) grinding operation,
measure with micrometer (1) the journals, so as to
establish to what diameter the journals must be
undersized.
ATTENTION
It is suggested that the data measured be recorded
on a table. TH110110
See Figure 102. 101
The undersize classes are 0.250, 0.500 mm.
ATTENTION
The main and conrod journals must always be
ground to the same undersize class.
The undersize done on the main and conrod journals
must be recorded by an appropriate stamping done
on the side of the no. 1 crank.
For undersized conrod journals digit M.
For undersized main journals digit B.
For undersized conrod and main journals digits MB.
TH110111
102
DATA ON WHICH TO RECORD THE VALUES RELATIVE TO THE
MEASUREMENT OF CRANKSHAFT MAIN AND CONROD JOURNALS
* Nominal value
604.13.542.01 - 03 - 2006
* Measured on a radius exceeding 45.5 mm

** between adjacent main journals
TH110112
103
MAIN CRANKSHAFT TOLERANCES
TOLERANCES FAETURE OF THE SUBJECT OF TOLERANCE GRAPHIC SYMBOL
Roundness ○
FORM
Taper /○/
Parallelism //
ORIENTATION Perpendicularity
Straightness
POSITION Out--of--round or concentricity
Circular oscillation
OSCILLATION Total oscillation
Taper
CLASS OF IMPORTANCE GIVEN TO THE FEATURES OF THE PRODUCT GRAPHIC SYMBOL

CRITICAL 
IMPORTANT ⊕
SECONDARY ⊝
FIRST JOURNAL
FRONT SIDE
CAMSHAFT DRIVE SIDE INTERMEDIATE
MAIN JOURNAL JOURNALS
TH110113
104
604.13.542.01 - 03 - 2006
Replacement of oil pump drive gears

Check that the teeth of gear (1) are undamaged and
not worn, otherwise extract it with an appropriate
puller (2).
To reinstall a new gear warm it up for 10 minutes in 1
an oven at 180°C and install it on the crankshaft
including the key.
2
TH110114
105
Installation of main journal bearings
ATTENTION
1
In the event the replacement of the main journal
bearings is not required, it is necessary to reinstall
them in the same identical order and position found
at the disassembly.
Main journal bearings (1) are provided as spare parts

with an undersized inner diameter of 0.20 – 0.500
mm.
TH110115
ATTENTION 106
Do not adjust the fitting of the bearings.
Clean accurately main journal half bearings (1) with

the lubrication hole and install them in the relevant
seats.
The last but one main half bearing (1) is equipped
with thrust washers.
Measuring the installation play of the main

journals
Install crankshaft (1).
Check the play between crankshaft main bearings
and the relevant bearings, operating as follows.
1
TH110091
107
604.13.542.01 - 03 - 2006
• clean accurately the parts and eliminate all

traces of oil;
• place a piece of calibration wire (3) on crankshaft
main journals (4) parallel to the longitudinal axis; 1
• install caps (1) complete with half bearings (2) on
the relevant journals. 2
3
4
TH110116
108
Tighten screws (1) pre--lubricated in three
subsequent phase.
• 1st phase with torque wrench *
• 2nd phase with torque wrench *
* the value of the torque is not available.
TH110117
109
• 3rdphase with tool 380000304 (1) installed as
shown in the figure and tighten further screws (2) 1
to an angle *
* the value of the torque is not available.
TH110118
110
• remove the caps from the journals.
The play between main journal bearings and the
relevant journals is measured by comparing the with
of calibration wire (2) in the point of largest 1
deformation, with the scale printed on wrapping (1)
of the wire.
The numbers listed on the scale indicate the play in
millimetres.
When a play different from the prescribed value is
found, replace the half bearings and re--measure.
Once the correct value is obtained, lubricate the 2
main journal bearings and install permanently the
supports, tightening the securing screws as TH110119
previously described. 111
604.13.542.01 - 03 - 2006
Checking the crankshaft end play

The check of the end play is done using a magnetic
base dial gauge (2) on crankshaft (3) as indicated in
the figure. Normal end play is 0.068 ÷ 0.410 mm.
In the event an excessive play is found, replace the
half bearings of the last but one thrust rear main
journal (1) and repeat the check of the play between
crankshaft and main journal half bearings.
1
2
3
TH110120
112
CONROD--PISTON ASSEMBLY
3 4
7
5
8
1
TH110121
113
COMPONENTS OF THE CONROD PISTON ASSEMBLY
1. Circlips 5. Screws
2. Pin 6. Half bearings
3. Piston 7. Conrod
4. Piston rings 8. Bush
ATTENTION
Spare pistons oversized 0.5 mm are provided.
604.13.542.01 - 03 - 2006
Removal of piston rings (1) from piston (2) using tool

380000221 (3).
2 3
TH110122
114
Removal of piston pin (1) circlips (2) is done using
a scribing point (3).
1
2
3
TH110123
115
TH110124
116
MAIN DATA OF PISTON PINS AND PISTON RINGS
* The dimension is measured on a 99 mm diameter
604.13.542.01 - 03 - 2006
Pistons
Measurement of piston diameter
Measure with micrometer (2) the diameter of piston
(1) to determine the mounting play. 1
ATTENTION
The diameter must be measured 12 mm from the
base of the piston skirt.
2
TH110125
117
The play between piston and cylinder sleeve can
also be measured using a calliper and feeler gauge 1
(1) as indicated in the figure.
TH110126
118
Piston pins
Measurement of piston pin (1) using micrometer (2). 2
TH110127
119
Conditions for a correct pin--piston installation
Lubricate pin (1) and the relevant seats on the piston
with engine oil. The pin must enter the piston with a 1
slight finger pressure and must not come out under
the effect of gravity.
TH110128
120
604.13.542.01 - 03 - 2006
Piston rings
Check the thickness of piston rings (2) using
micrometer (1).
1
TH110129
121
Check the play between piston rings (3) of the 2nd
and 3rd seat and the relevant seats on piston (2) 1
using feeler gauge (1).
2
TH110130
122
DIAGRAM FOR THE MEASUREMENT OF PLAY
BETWEEN THE FIRST PISTON SEAT
AND TRAPEZOIDAL RING
1
Due to the peculiar shape of the first trapezoidal

section ring, the play between seat and ring must be
measured in the following manner. Have piston (1)
3
protruding from cylinder block so that ring (2) gets
about half out cylinder sleeve (3). 2
Under these conditions, use a feeler gauge to
measure play (X) between ring and seat. This play
must be within the prescribed limits.
TH110131
123
Measuring the gap between the tip of piston rings (2)
installed in cylinder sleeve (3) using feeler gauge (1). 1
3
TH110132
124
604.13.542.01 - 03 - 2006
Conrods
MAIN DATA FOR CONROD, PISTON PIN BUSH

AND HALF BEARING
* Inner diameter to be obtained after press fitting in the con-
rod small end and reboring.
** Dimension not measurable at free state.
ATTENTION
The conrod--conrod cap mounting faces are grooved
for a better fitting.
Consequently, it is recommended not to remove the
grooves.
TH110133
125
ATTENTION
Each conrod is marked:
• On the body and cap a number indicating the
match and the cylinder in which it is installed.
Thus, in case of replacement it is necessary to
renumber the new conrod with the same marking
of the previous one.
• On the conrod body a letter indicating the weight
class of the conrod installed in production:
-- V, 1820 ÷ 1860 (marked by a yellow colour);
-- W, 1861 ÷ 1900 (marked by a green sign;
-- X, 1901 ÷ 1940 (marked by a blue sign). *
Spare conrods are provided for class W colour coded
green *.
No removal of material is allowed.
TH110134
126
604.13.542.01 - 03 - 2006
Bushes
Check that the bush in the conrod small end is not
loose and it it is free from scratches or signs of
seizing, otherwise replace it.
The removal and installation are done using an
appropriate punch.
When press fitting, make absolutely sure that the oil
passage holes on the bush and conrod small
coincide. Use a boring tool to obtain the prescribed
diameter.
Checking the conrods

Check the parallelism of conrod (1) centre lines using
fixture 3800001003 (5) operating as follows:
• install conrod (1) on the mandrel of fixture
3800001003 (5) and lock it with bscrew (4);
• arrange mandrel (3) on “V” blocks resting conrod
(1) on stop bar (2).
2 5
TH110135
127
Checking the torsion
Check the torsion of conrod (5) comparing two points
(A and B) of pin (3) on the conrod centre line
horizontal plane.
Place support (1) of dial gauge (2) so that the latter 1
is preloaded ∼ 0.5 mm on pin (3) in point A and zero
dial gauge (2). Move mandrel (4) with conrod (5) and 2
compare on the opposite side (B) of pin (3) any
possible discrepancy. The difference between A and B
A
B must not exceed 0.08 mm.
3
5
4
TH110136
128
604.13.542.01 - 03 - 2006
Checking the flexion

Check the flexion of conrod (5) comparing the two
points C and D of pin (3) on the vertical centre line of 1
the conrod.
Place vertical support (1) of dial gauge (2) so that the 2
latter rests on point C of pin (3) .
Rock the conrod for and aft looking for the highest C D
position of the pin and zero dial gauge (2) in this
position.
Move the mandrel with conrod (5) and repeat on
opposite side D of pin (3) and check the highest point.
The difference between point C and point D must not 5
exceed 0.8 mm. 3
4
TH110137
129
Assembly of conrod--piston assembly
Mating of conrods-- pistons 1
The following references are stamped on the ceiling
of the piston: 2
1. Spare part number and number of engineering
modification;
2. Date of manufacturing;
3. Indication of the mounting direction in the cylin-
der sleeve. It must be directed toward the front
side of the cylinder block.
3
TH110138
130
Connect piston (2) to conrod (4) with pin (3) so that
installation reference wording (1) of piston (2) in the 1
cylinder sleeve and digits (5) stamped on conrod (4)
2
are seen as indicated in the figure.
3
TH110139
131
604.13.542.01 - 03 - 2006
Insert circlips (2) securing pin (1).
TH110140
132
Installing piston rings
To install piston rings (1) on piston (2) use pliers
380000221 (3).
The rings must be installed with the wording “TOP”
upward. Also position the ring gaps so that they are 1
placed at 120° .
2
3
ATTENTION
The piston rings are supplied as spare parts with the
following dimensions:
-- standard, marked by yellow paint;
-- oversized 0.5 mm marked by yellow/green paint.
TH110122
133
Install half bearings (1) on both conrod and cap.
ATTENTION
When the conrod bearings do not required being
replaced, they must be reinstalled in the same 1
sequence and position found during the disassem-
bly.
Do not perform any adjusting operation on the half
bearings. 1
TH110141
134
Installation of conrod piston in the
cylinder sleeves
Lubricate thoroughly the pistons, including the piston
rings and the surface of the piston sleeves.
1
Use band 38000020 (2) to help with the installation
of conrod--piston assembly (1) into the cylinder
sleeve, checking that:
• the number of each conrod corresponds to the
matcing number of the cap. 2
TH110142
135
604.13.542.01 - 03 - 2006
DIAGRAM FOR THE INSTALLATION OF

THE CONROD--PISTON ASSEMBLY INTO
THE GALLERY
• the gap of the piston rings must be 120 ° offset
among them;
• the conrod/piston assemblies must have the
same weight;
• the wording stamped on the ceiling of the pistons
must be directed toward the front side of the cyl-
inder block or the recess machined on the skirt
of the pistons corresponds to the position of the
oil jets.
TH110143
136
Measuring the installation play of the conrod
pins
1
To measure the play operate as follows:
• clean accurately the parts and eliminate all
2
traces of oil;
• place a piece of calibrating wire (2) on crankshaft
journals (1); 3
• install conrod caps (3) with the relevant half bear-
ings (4). 4
TH110144
137
• tighten screws (1) previously lubricated with
engine oil with torque wrench (2) to the pre-
scribed torque.
TH110145
138
• install tool 380000304 (1) on the socket and
tighten further screws (2) at the angle.
1
2
TH110146
139
604.13.542.01 - 03 - 2006
• remove the cap and determine the existing play

comparing the width of calibrated wire (1) with 2
the scale printed on envelope (2) containing the
wire.
TH110147
140
In the event a play different from the prescribed value
is found, replace the half bearings and repeat the
check.
Once the prescribed play is obtained, lubricate the
conrod half bearings and install them permanently
tightening the conrod cap securing screws as
described.
2
ATTENTION
Prior to the final installation of the conrod cap secur-
ing screws, check their diameter, measured at the 1
centre of the length of the thread, is not 0.1 mm
TH110148
smaller than the diameter measured at about 10 mm
from the tip of the screw. 141
Check manually that conrods (1) slide axially on the

crankshaft journals and that their axial play
measured with feeler gauge (2) is 0.10 ÷ 0.33 mm.
Checking the piston protrusion

Once the installation of the conrod--piston 1
assemblies is over, check with dial gauge 3
380000228 (1) equipped wih base 380000364 (2) the 2
protrusion of pistons (3) at T.D.C., with respect to the
upper face of the cylinder block.
It must be 0.28 ÷ 0.52 mm.
TH110149
142
604.13.542.01 - 03 - 2006
Timing
Timing gear housing
1
DIAGRAM OF THE ZONE OF APPLICATION
OF LOCTITE 5999 SEALANT
Clean accurately timing gear housing (1) and the
cylinder block.
The cleaning of the face to be sealed is necessary
and indispensable to achieve an effective sealing.
Apply sealant LOCTITE 5999 on the housing so that
it forms a strip of a few mm diameter.
It must be uniform (no lumps), free from air bubbles,
thin zones or discontinue.
Any imperfection must be corrected in the shortest
possible time.
TH110150
Prevent using material in excess to seal the joint.
143
To much sealant would escape on both sides of the
joint and clog oil passages.
After the application of the sealant is completed, the
joints require an immediate fitting (10 – 20 minutes).
DIAGRAM FOR THE TIGHTENING

OF THE REAR GEAR HOSING 1
SECURING SCREWS
Reinstall housing (1) on the engine cylinder block.
Tighten the securing screws in the position found at
the disassembly and torque the screws to the
prescribed value.
TH110151
144
Setting the timing
Using a felt pen, show the drive gear tooth (1)
installed on crankshaft (2) on the side face of which 1
the timing sign (→) is stamped.
TH110152
145
604.13.542.01 - 03 - 2006
Set crankshaft (4) and camshaft (2) so that when

installing on the latter driven gear (1) the marks
stamped on gears (1 and 3) coincide. 1
3
4
TH110153
146
Tighten screws (1) securing gear (2) to camshaft (3)
to the prescribed torque. 1
TH110154
147
Injection pump – Phase 1
Timing
Position the first piston to T.D.C. The condition
occurs when pin (1) indicated by the arrow enters the
seat on camshaft drive gear (2).
2
TH110074
148
Install injection pump (1) in the seat of gear housing
(2) and secure it with screws (3).
TH110155
604.13.542.01 - 03 - 2006
Install item (5) of tool 380000666 on the rear tip (6)

of the crankshaft securing it with screws (4) and 1 7
install on it the new sealing ring (3).
Install item (1) on item (5) tightening nut (2) until 2
sealing ring (3) is fully mounted in flywheel housing
(7).
3
4
5 6
TH110159
153
ENGINE FLYWHEEL
Check that the clutch disc contact face is free from 2
scratches, otherwise machine it. 1
ATTENTION
The nominal thickness of the engine flywheel is 37.6
mm.
Replacing the engine flywheel ring gear

Check the conditions of the teeth of flywheel ring
gear (2). When failures or excessive wear of the
TH110160
teeth are found, remove it from the flywheel (1, fig.
154) using a punch and install a new one, previously 154
warmed--up to 150 °C for about 15 – 20 minutes. The
bevel on the inner diameter of the ring gear must be
directed toward the flywheel.
Install two studs (2) of suitable length into the shaft

holes (3) and install the flywheel (1) by means of
suitable lifting slings and tackle. 1
3
TH110079
155
604.13.542.01 - 03 - 2006
Install tool 380000990 (2) on flywheel housing (1) to

prevent the rotation of engine flywheel (4). Tighten 4
1
screws (3) securing flywheel (4) on the crankshaft.
2 3
TH110161
156
Tighten screws (1) securing flywheel (2) in two
phases:
• 1st phase, tightening with torque wrench to the 1
prescribed value;
• 2nd phase, angle tightening to the prescribed
value.
ATTENTION
The angle tightening is done with tool 380000304.
2
TH110162
157
Injection pump – Phase II
Installation of injection pump – Phase II
Tighten nut (1) to torque using torque wrench (2).
TH110163
158
Apply sealant (1) as indicated in the figure and install
A B
cover (2).
1 2
TH110164
159
604.13.542.01 - 03 - 2006
Remove pin (1) from the seat of the timing gear figure
61. Remove pre--setting screw (2) and insert “L”
spacer (1). Retighten screw (2) to stroke end.
1
TH110075
160
Installing oil and water pump
Install oil pump (1).
Install securing screws (2) and tighten them to the
prescribed torque.
1
2
TH110165
161
Install a new sealing ring (2) on water pump (1).
1
2
TH110166
162
Install water pump (1).
Install screws (2) and tighten them to the prescribed
torque.
2
TH110167
163
604.13.542.01 - 03 - 2006
Remove sealing ring (2) from front cover (1). Clean

accurately the joint face and apply LOCTITE 5999
sealant on it.
TH110168
164
Clean accurately the joint face on the cylinder block
of front cover (2) and install it.
torque.
TH110169
165
Install item (4) of tool 380000666 on the front nose
(6) of the crankshaft and secure it with screws (5) and
install on it a new sealing ring (7). Place item (2) on
1
item (4), tighten nut (3) until sealing ring (7) is fully
mounted into front cover (1). 5
3
4
1
2 7
3
4
5 6
TH110170
166
604.13.542.01 - 03 - 2006
Installation of the oil sump

2
Install plate (1) strainer (2) install securing screws (3) 1
3
and tighten them to the prescribed torque.
TH110171
167
Install gasket (1) on oil sump (2).
ATTENTION
When the gasket is in good conditions it can be
reused. 1
TH110172
168
Install sump pump (1) install plate (3) on it.
Install screws (2) and tighten them to the prescribed 1
torque.
2
TH110082
169
Install pulley (1) on the crankshaft equipped with
spacer (2) and tighten the screws to torque and angle 4
using tool 3800000304.
Secure idle pulley (4) to front cover (3) with screw (3).
3
TH110173
170
604.13.542.01 - 03 - 2006
Installation of water/oil heat exchanger 1

Install a new seal (1) on the cylinder block, heat 2
exchanger (2) a new seal (3) and oil filter support (4).
3
torque. 4
5
TH110174
171
Lubricate sealing ring (1) with engine oil and install it
on oil pipe connection (2).
4
Install oil pipe connector (2) on support (4)
Install a new sealing ring (3) in the cylinder block. 1
3
2
TH110175
172
Install alternator support (1) so that pins (3 and 4) are
against the engine cylinder block. 1
3
torque. 2
4
TH110176
173
Reinstall alternator (1) on alternator support (3).
Tighten screws (2) not to torque. 1
TH110177
174
604.13.542.01 - 03 - 2006
Cylinder head
Removal of valves 1 2
The removal of the valves is performed with tools 3
380000302 (1) pressing plate (3) so that, by pressing
springs (4) it is possible to remove half--cones (2).
Then, remove plate (3) and springs (4).
Repeat the operations on all valves.
4
TH110178
175
Extract oil seals (1) installed on the valve stems.
To remove the valves, turn the head upside down.
ATTENTION
Mark the exhaust and intake valves prior to their
removal.
1
TH110179
176
Besides the dimensions of the head, the exhaust
valves differ from the intake valves for the presence
of additional groove (1) on the intake valve stem. 1
TH110180
177
Remove thermostat group (2) and brackets (1) and
(3). 1
3
TH110181
178
604.13.542.01 - 03 - 2006
Checking the cylinder head joint face

The check of cylinder head (1) mounting face to the
cylinder block is done with ruler (2) and feeler gauge 2
(3).
The deformation measured on the entire length of
the head cylinder must not exceed 0.20 mm.
When excessive values are found, grind the cylinder
head in accordance with the values and instructions
indicated in the figure to follow.
3
1
TH110182
179
Checking the sealing of the cylinder head
Check the hydraulic sealing using the appropriate
tooling.
Inject, using a pump, heated water at ∼ 90 °C and a
pressure of 2 ÷ 3 bar.
In the event leakages from plugs or cups replace
them using an appropriate tool for the
removal--installation.
ATTENTION
Prior to the installation of plugs, apply water repelling
sealant on the joint faces.
In the event leakages are found the cylinder head

must be replaced.
The nominal thickness A of the cylinder head is 95 ±
0.25 mm. The maximum amount of metal that can be
removed must not exceed thickness B equivalent to
0.13 mm.
ATTENTION
After the grinding check the recess of the valves and
regrind the valve seats as required, to provide the
prescribed recess of the valves.
TH110183
180
604.13.542.01 - 03 - 2006
VALVES
INTAKE AND EXHAUST VALVE MAIN DATA
TH110184
181
De--scaling inspection and re--grinding
of valves
Remove the carbon deposits from the valves using
an appropriate metal brush.
Check that the valves do not show signs of seizing,
cracks or burns.
Re--grind, if required, the valve seats with grinder
380000828 removing the least possible amount of
material.
TH110185
182
Use micrometer (2) to measure the stem of valves
(1): it must result 7.96 ÷ 7.98 mm.
1
TH110186
183
Checking the play between valve stem and
valve guide and valve centring
The inspections are done with magnetic base dial
gauge (1) positioned as illustrated; the mounting play 1
is 0.039 ÷ 0.079 mm.
Turning valve (2) check that the centring error does 2
not exceed 0.03 mm.
TH110187
184
604.13.542.01 - 03 - 2006
VALVE GUIDES
Use a bore gauge to measure the inner diameter of
the valve guides. The value must be as indicated in
the figure.
TH110188
185
VALVE SEATS
Re--grinding – replacing the valve seats
Check valve seats (2). When light scoring or burns
are found, re--grind with tool 380000828 (1) in
accordance with the bangle values indicated in
Figure 187.
1
2
TH110189
186
TH110190
187
604.13.542.01 - 03 - 2006
TH110191
188
MAIN DATA OF CYLINDER HEADS
In the event the valve seats are not re--workable with

a single re--grinding, it is possible to replace them
with spare parts. Use the same tool 380000828 (1,
Figure 186) and taking care to prevent grinding the
cylinder head, remove as much material from the
valve seats as possible, until it is possible to extract
them from the cylinder head with a punch.
Warm--up the cylinder head to 80 ÷ 100 °C and, using
an appropriate punch, install into it the new valve
seats previously cooled.
Then, using tool 380000828, regrind the valve seats
in accordance with the values shown in Figure 187.
After the regrinding operations, with base
380000364 (2) and dial gauge 380000228 (1) check
that the recess of valves (3) is at the prescribed
value. 1
TH110192
189
604.13.542.01 - 03 - 2006
VALVE SPRINGS
MAIN DATA FOR THE INSPECTION
OF THE INTAKE AND EXHAUST
VALVE SPRINGS
Prior to the re--installation, check the flexing of the
valve springs using tool 380000976. Compare the
load and elastic deformation data with the ones
indicated in the table here below.
Height Under a load of

mm N
H (free) 63.50 no load
TH110193
H1 49.02 P1 329 190
H2 38.20 P2 641
ASSEMBLY OF CYLINDER HEAD

Lubricate the valve stems and insert them in the
relevant valveguides in accordance with the position
marked at the disassembly.
Install sealing rings (1) on the valve guides.
1
TH110179
191
Install on the cylinder head: spring (4) and upper
plate (3). Using toll 380000302 (1) pressing spring 2
(4) and secure the parts to valve (5) using half cones
(2). 1 3
TH110178
192
604.13.542.01 - 03 - 2006
Reinstallation of cylinder head

Check that the mounting face of the cylinder head
and the cylinder block are clean.
Do not dirt the cylinder head gasket.
ATTENTION
Prior to re--using the screws securing the cylinder
head check that they do not show signs of deteriora-
tion or deformation, otherwise replace them.
TH110194
193
Install the cylinder head on the cylinder block
tightening screws (1) without torquing them.
1
TH110085
194
Before inserting the push rods check their
conservation conditions. The ball contact seats with
the rocker arm adjusting screws and the tappets
(arrows) must not show signs of seizing or wear,
otherwise replace them. The intake and exhaust
valve push rods are identical, thus they are
interchangeable.
TH110195
195
Rocker arm group
ITEMS COMPOSING THE ROCKER
ARM GROUP:
1. Support 4
1
2. Rocker arm
3. Shaft
4. Screws 2
TH110196
196
604.13.542.01 - 03 - 2006
MAIN DATA FOR SHAFT--ROCKER ARM

Check that the shaft/rocker arm mounting face do
not show signs of excessive wear or damages.
TH110197
197
Check that the tappet adjusters are loosen to prevent
the forcing them on the push rods when installing the 1
rocker arm group (1).
Then, install the rocker arm group made of rocker 2
arm support and shafts and secure them to the head
without tightening screws (2) and (3) to torque.
TH110198
198
Secure the head screws in accordance with the
prescriptions indicated in Figure 200.
TH110199
199
Diagram of the tightening sequence of the screws
securing the cylinder head *.
• 1st phase pre--tightening with torque wrench *
• 2nd phase, angle tightening *
• 3rd phase, angle tightening *
* The values of the torques and angle tightening DIAGRAM NOT AVAILABLE
and the diagram are not available.
TH110059
200
604.13.542.01 - 03 - 2006
Adjust the valve clearance using Allen wrench (1), ex

wrench (2) and feeler gauge (3). 1
The operating valve clearance is:
-- intake valve 0.25 ± 0.05 mm
-- exhaust valve 0.50 ± 0.05 mm.
ATTENTION
In order to speed--up the adjustment of the valve 2 3
clearance, proceed as follows:
-- turn the crankshaft; balance the valves of no. 1
cylinder and adjust the valves marked by an axterix
as indicated in the tables:
TH110056
cylinder no. 1 2 3 4 201
intake – – * *
exhaust – * – *
Turn the crankshaft; balance the valves of no. 4 cylin-

der and adjust the valves marked by the axterisc as
indicated in the diagram:
cylinder no. 1 2 3 4
intake * * – –
exhaust * – * –
Installation of injectors
Install a new sealing ring (2) lubricated with vaseline
and a new sealing washer (3) on injector (1).
Install the injectors in the seats on the cylinder head 1
and tighten them with a torque wrench.
TH110054
202
604.13.542.01 - 03 - 2006
Install the injector fuel lines group (1). Install fuel

unloading lines (2) from the injectors, using gaskets 2 1
(3) and tightening screws (4).
TH110066
203
Install injector fuel lines (5) of injection pump (6),
3 2
secure lines group (1), (2) and (3) brackets on the
cylinder head. 1
Install primer pump (4).
4 5
TH110065
204
• Install rocker arm cover (4) 3
• Install heater (2) 4 2
• Install the elbow of intake manifold (3) 5 1
• Install heater controller (5)
13
• Install fuel filter support (6) 6
• Install fuel filter (9) 12
• Connect the lines with quick release couplings 7
(7), (10), (11) and (12) following the recommen-
dations listed in Figure 206. 11
8
• Install electric harness (8) 10
• Install the line of the LDA system (13) 9
• Connect the engine oil fumes recovery line to
blow--by (1).
TH110063
205
604.13.542.01 - 03 - 2006
Press stop (1) in the direction of the arrow (item B)

and connect the line. Return the stop in the initial A B
1
locking position (item A).
TH110064
1
206
The intake manifold group is made of manifold (6) on
the cylinder head, cover (5) gaskets (2) and (4) cold 1
starting heater (3) and elbow (1).
Apply LOCTITE 5999 sealant between cover (5) and 2
manifold (6) and tighten the screws to the prescribed
torque. 3
TH110019
207
• Install oil filter support (3) on the cylinder block
• Install oil filter (2) on support (3)
• Connect oil lines (1) and (4) on filter (2)
• Install electric harness (5)
4
1
3
TH110061
2
208
604.13.542.01 - 03 - 2006
• Install exhaust manifold (3)

• Install turbine (1) using screws (2).
TH110067
209
• Install starting motor (3)
• Install turbine lubrication oil return line (1) with 7
the relevant securing screws (2)
• Install turbine oil lubrication delivery pipe (7) and 1
engine oil pipes (4) and (5) to water/oil heat
2 6
exchanger group (6).
5
4
TH110062
210
• Install thermostat group (1) on cylinder head (3)
tightening screws (2) to torque.
• Install coolant temperature sensor (6) tightening 6
it with a torque wrench 1
• Install fan pulley support (5) on head (3) using
screws (4) tightened to torque.
2
5
3
4
TH110031
211
Install fan pulley (2) on support (1) using screws (3)
tightened to torque.
1
TH110032
212
604.13.542.01 - 03 - 2006
Install Poly--V belt (5) on the crankshaft pulley(7), on

idle pulley (6), on water pump (4) and alternator (2); 1
stretch the belt moving bracket (1) on alternator (2).
2
5
TH110068
213
REPLACING THE INJECTORS
Removal 2
3
Place the vehicle under safe conditions.
Lift the engine compartment hood, disconnect the
battery cables and proceed as follows:
1
• disconnect engine oil fumes recovery line (2)
from the blow--by;
• remove rocker arm cover (1);
• disconnect the lines of the fuel manifolds from
injectors (3).
TH110052
214
Remove injectors (2) with tool 380000671 (1) and
extract them from the cylinder head.
2
TH110053
215
604.13.542.01 - 03 - 2006
Reinstallation
Install a new sealing ring (2) lubricated with Vaseline
on injector (3) and a new sealing washer (1).
Install the injectors in the seats on the cylinder head
using a torque wrench.
2
3
1
TH110054
216
Install new sealing rings (1) on fuel manifolds (2).
Connect the manifolds to the injectors, tightening the
securing nuts to a torque of 50 Nm.
Reinstall the rocker arm cover.
Reconnect the engine oil fumes recovery pipe to the
blow--by.
2 1
TH110055
217
604.13.542.01 - 03 - 2006
ADJUSTMENT OF VALVE CLEARANCE

Adjust the valve clearance using Allen wrench (1) 1
poly wrench (2) and feeler gauge (3).
The operating valve clearance is: 2
-- ± 0.05 mm
-- intake valve 0.25 ± 0.05 mm
-- exhaust valve 0.50 ± 0.05 mm.
ATTENTION 3
In order to speed--up the adjustment of the valve
clearance, proceed as follows:
-- turn the crankshaft; balance the valves of no. 1 TH110056
cylinder and adjust the valves marked by an asterix
218
as indicated in the tables:
intake – – * *
exhaust – * – *
Turn the crankshaft; balance the valves of no. 4 cylin-

der and adjust the valves marked by the axterisc as
indicated in the diagram:
intake * * – –
exhaust * – * –
REMOVAL/REINSTALLATION
OF ROCKER ARMS 2 1
Removal
Loosen nuts (3) securing valve clearance adjuster
and remove adjusters (2). 3
Remove screws (4) and remove rocker arm group (1)
made of rocker arm support and shafts and remove
the valves. 4
TH110057
219
Reinstallation
Check that the valve adjusters are loosen to prevent
forcing them on the pushing rods during the
reinstallation of the rocker arm group.
Then, install the rocker arm groups made of rocker
arm support and shafts and secure them to the
cylinder head tightening the securing screws to a
torque of 36 Nm.
Proceed with the adjustment of the valve clearance
as previously described.
604.13.542.01 - 03 - 2006
SETTING OF TIMING
The timing drive is provided by a straight teeth gear The timing setting is provided by matching the signs
mounted on the rear nose of the crankshaft engaging (⇐) stamped on them.
with the one mounted on the camshaft.
TH110049
220
604.13.542.01 - 03 - 2006
TIMING OF THE INJECTION PUMP The dial gauge must read a value of 1 mm, equivalent
Once the timing of the crankshaft with the camshaft to the stroke done by the pump distributor piston with
is obtained, move the first piston to T.D.C. This condi- respect to the B.D.C. in the event the prescribed
tion is obtained by turning the crankshaft until the pin value is not achieved, loosen the screws securing the
installed on the gear housing near the pump enters pump to the gear housing and through the elongated
the relevant seat on the timing gear. holes, turn the pump body until the pre--load value is
obtained.
When an injection pump is provided as spare part, it
is already pre--set, thus it is sufficient to install it on In the event the injection pump has been overhauled,
the camshaft, secure it to the gear housing and when it is installed on the engine it must be pre--
remove appropriately the seal ensuring the pre--set- loaded to 1 mm with respect to the B.D.C. of the dis-
ting of the pump blocking its shaft. tributor piston.
To check the correct timing, install dial gauge Install dial gauge 380000228 with its support
380000228 (2) and adapter 380000229 (1) on the 380000229 as in the figure here below and turn the
pump as indicated by the figure here below. pump body in the securing elongated holes until a 1
mm value is measured by the dial gauge. Secure the
Turn appropriately the crankshaft to eliminate the
pump on the gear housing and check as previously
gear backlash and return the engine under the condi-
described.
tion of T.D.C. on the first piston.
TH110050
221
604.13.542.01 - 03 - 2006
ELECTRICAL COMPONENTS Pre--post heating controller

• Pre--post heating kit (for engines P4BE0484 Controller 1 defines the time of intervention of the
G*D600 – F4BE0484 F*D601) (*). heater (pre--post heater) as a function of tempera-
ture 2 of the engine coolant.
• Coolant sensor KKSB, on injection pump.
• Oil pressure sensor piloting the oil pressure indi-
cator light on the dashboard.
(*) Controller, engine coolant temperature sensor,
heater.
Diagram of principle
TH110051
222
1. Pre--post heating controller 4. Heater
2. Coolant temperature sensor 5. Pre--heating indicator light on dashboard
3. Heater solenoid switch
604.13.542.01 - 03 - 2006
TROUBLESHOOTING
The engine fails to start

Cause Remedy
1. Batteries partially exhausted. 1. Check; recharge batteries and replace, if
required.
2. Battery terminal connections corroded or loosen. 2. Clean; check, tighten nuts and, if required,
replace excessively corroded terminals and nuts
3. Wrong timing of injection pump on the engine. 3. Set correct timing of injection pump on engine.
4. Accumulation of dirt or water in fuel lines. 4. Disconnect lines and injection pump and clean
accurately. If necessary, clean and dry fuel tank.
5. Empty fuel tank. 5. Refuel.
6. Presence of air in fuel lines. 6. Check fuel pump and replace if required.
7. No fuel supply to injection pump. 7. Check lines, connections, fuel pump, filters and
injection pump to ascertain presence of air, the
bleed the system.
8. Starter motor damaged. 8. Repair or replace starter motor.
9. Cold starting system inefficient. 9. Check or replace cold starter.
The engine stalls

Cause Rimedio
1. Low idle too low. 1. Adjust low idle.
2. Irregular deliveries by injection pump. 2. Check calibration of deliveries on bench.
3. Accumulation of dirt and water in fuel lines. 3. Disconnect lines and injection pump and clean
accurately. If necessary, clean and dry fuel tank.
4. Clogged fuel filters. 4. Replace filter integral cartridges.
5. Abnormal valve clearance. 5. Adjust valve clearance.
6. Burnt or cracked valves. 6. Replace valves.

7. Presence of air in fuel lines. 7. Check lines, connections, fuel pump, filters and
injection pump to ascertain presence of air, the
bleed the system.
8. Injection pump drive damaged. 8. Replace damaged parts.
The engine is overheating

Cause Remedy
1. Inefficient cooling system pump. 1. Overhaul pump and replace, if necessary.
2. Inefficient thermostat 2. Replace thermostat.
3. Radiator partially inefficient. 3. Eliminate possible scaling by flushing, check and

repair possible leakages from pipes.
4. Scaling in the coolant passages in cylinder head 4. Flush accurately

and cylinder block.
604.13.542.01 - 03 - 2006
The engine overheats (cont.ed)

Cause Remedy
5. Insufficient tension of centrifugal and fan drive 5. Check and adjust the belt tension.
pump.
6. Coolant (insufficient quantity). 6. Top--up level in expansion tank using the pre-
scribed liquid.
7. Wrong timing. 7. Check and adjust timing correctly.
8. Injection pump out of calibration both in excess 8. Calibrate the injection pump on bench complying
and defect with the calibration tables.
9. Clogged air cleaner. 9. Clean the group and replace filtering element as
required.
The engine lacks power and operates irregularly

Cause Remedy
1. Wrong timing of injection pump on engine. 1. Set correct timing of injection pump on engine.
2. Advance automatic variator in injection pump 2. Overhaul injection pump and calibrate it on test
damaged. bench complying with relevant calibration table.
3. Worn distributor pumping element. 3. Overhaul injection pump and calibrate it on test
bench complying with relevant calibration table.
4. Irregular deliveries by injection pump. 4. Overhaul injection pump and calibrate it on test
5. All--speed governor damaged. 5. Overhaul injection pump and calibrate it on test
6. Partially clogged or damaged injectors. 6. Clean, overhaul and calibrate the injectors.
7. Accumulation of dirt or water in fuel lines. 7. Disconnect pipes, injection pump and clean
accurately, if required, clean and dry the fuel
tank;
8. Damaged fuel supply pump. 8. Replace fuel pump.
9. Abnormal valve clearance. 9. Adjust valve clearance.
10. Insufficient cylinder compression. 10. Check compression and overhaul engine, if
required.
11. Clogged air cleaner. 11. Clean the group and replace filtering element, if
required.
12. Length of rod between throttle and injection 12. Adjust length of rod.
pump out of adjustment.
13. Injection pump with max. speed stroke end 13. Adjust maximum idle screw.
screw out of adjustment.
604.13.542.01 - 03 - 2006
The engine has abnormal knocks

Cause Remedy
1. Injectors partially clogged or damaged. 1. Clean, overhaul and calibrate correctly the injec-
tors.
2. Accumulation of dirt in fuel lines. 2. Clean pipes and replace the ones showing dents
or markings; clean injection pump, if required.
3. Wrong timing of injection pump on engine. 3. Provide correct timing of injection pump on
engine.
4. Knocks in the engine caused by excessive play 4. Grind crankshaft journals; install oversized bear-
of one or more main or conrod journals or ings and thrust bearings.
excessive end--play.
5. Unbalanced crankshaft. 5. Check alignment and balance of crankshaft;
replace if required.
6. Loosen flywheel securing screws. 6. Replace loosen screws and tighten all of them to
prescribed torque + angle.
7. Conrods with non parallel axis. 7. Straighten conrods; check parallelism of axes
and replace conrods if required.
8. Knocking piston due to abnormal wear. 8. Re--bore cylinder sleeves and install oversized
pistons.
9. Noisy piston pins for excessive play in the piston 9. Replace piston pin with oversized one; re--bore
seats and conrod bush. Free bushes in conrod seats on piston and conrod bushes. Replace
seat. bushes with new ones.
10. Ticking due to noisy timing. 10. Check that there are no broken springs, excess-
ive play between stems and guides, tappets and
seats. Adjust valve clearance.
The engine smokes in abnormal way: black or grey smoke

Cause Remedy
1. Excessive maximum delivery by injection pump. 1. Calibrate injection pump on test bench comply-
ing with relevant calibration table.
2. Injectors pump is excessively retarded or the 2. Perform the correct timing of the injection pump
automatic advance variator is damaged. on engine or check advance automatic variator.
3. The injection pump is excessively advanced. 3. Perform correct timing of injection pump on
engine.
4. Injectors partially and/or totally clogged or out of 4. Clean, overhaul and calibrate correctly the injec-
calibration. tors. Replace them, if required.
5. Clogged air cleaner. 5. Clean the group and replace filtering element, if
required.
6. Loss of compression by the engine due to: 6. Replace damaged parts and overhaul engine, if
-- Sticky piston rings required.
-- Wear of cylinder sleeves
-- Valves deteriorated or out of adjustment.
7. Damaged injection lines. 7. Check the conditions of the lines and replace
them, if required.
604.13.542.01 - 03 - 2006
Blue, grey-- blue or grey tending to white smoke

Cause Remedy
1. The injection pump is excessively retarded or 1. Perform the correct timing of the injection pump
automatic advanced variator is damaged. on engine or check advance automatic variator.
2. Seized or defective injectors. 2. Clean, overhaul and correctly calibrate the injec-
tors. Replace them, if necessary.
3. Passage of oil through piston rings caused by 3. Replace damaged parts or overhaul the engine,
sticky rings or wear of cylinder sleeves. if required.
4. Passage of oil through intake valve guides due to 4. Overhaul cylinder head.
wear of guides or valve stems.
5. The engine does not reach the operating tem- 5. Replace thermostat.
perature (damaged thermostat).
The engine does not cut--off

Cause Remedy
1. Damaged cut--off solenoid. 1. Replace the solenoid.
2. Damaged all--speed governor. 2. Overhaul the injection pump and calibrate it on
the test bench, complying with the relevant
calibration tables.
604.13.542.01 - 03 - 2006
TOOLING
TOOL no. DESIGNATION
380000216 Balanced rig for engine removal and installation
380000220 Band for piston insertion into cylinder sleeves (60--125 mm)
380000221 Pliers for piston rings removal and installation (65--110 mm)
380000228 Dial gauge (0--5 mm)
380000229 Dial gauge holder tool for rotary injection pump timing
(use w/ 380000228)
380000362 Engine crankshaft lifting tool
604.13.542.01 - 03 - 2006
380000301 Rotary stand for group overhauls (capacity 1000 daN,

torque 120 daN/m)
380000302 Engine valves removal and installation tool
380000304 Set of measuring tools for angle tightening w/ 1/2’’ and 3/4’’square
380000322 Puller for gear connecting injection pump to engine
380000661 Brackets securing engine to rotary stand 380000301
604.13.542.01 - 03 - 2006
380000663 Puller tool for crankshaft rear seal extraction
380000664 Mounting tool for crankshaft rear seal
380000665 Puller tool for crankshaft front seal extraction
380000666 Mounting tool for crankshaft front seal
380000667 Punch for removal and installation of camshaft bushes (w/

380000668)
380000668 Handle for interchangeable punches
604.13.542.01 - 03 - 2006
380000669 Seal extraction tool
380000670 Cartridge filter removal tool
380000671 Injector puller tool
604.13.542.01 - 03 - 2006
DATA – MOUNTING PLAYS
F4GE0484
Type
G*D600
CYLINDER AND CRANK ORGANS GROUP mm
Cylinder sleeves ∅1 102.01 ÷ 102.03
Pistons: supplied as spare parts

type
tipo
61
Measuring dimension X
101.777 ÷ 101.795
Outer diameter ∅1
40.006 ÷ 40.012
Pin set ∅2
Piston – cylinder sleeve 0.215 ÷ 0.253
Piston diameter ∅1 0.5
Location of pistons
0.28 ÷ 0.52
in cylinder block X
Piston pin ∅3 39.9968 ÷ 40.0032
Piston pin – pin seat 0.0028 ÷ 0.0152
Type of piston X1* 2.69

Piston ring seats X2 2.425 ÷ 2.445
X3 4.04 ÷ 4.06
* measured on ∅ di 99 mm
S1* 2.560 ÷ 2.605
Piston rings S2 2.310 ÷ 2.340
S3 3.075 ÷ 4.000
* measured on ∅ 99 mm
1 0.245 ÷ 0.265
Piston rings -- seats 2 0.085 ÷ 0.135
3 0.040 ÷ 0.985
Piston rings 0.5
604.13.542.01 - 03 - 2006
F4GE0484
Type
G*D600
Gap of piston rings in cylinder
sleeves:
X1 0.40 ÷ 0.70
X2 0.25 ÷ 0.55
X3 0.25 ÷ 0.55
Seat of bush in conrod small end ∅1 42.987 ÷ 43.013

Conrod bearing seat ∅2 77.075 ÷ 78.25
Conrod bearing seat

Outer ∅4 43.279 ÷ 43.553
Inner ∅3 40.019 ÷ 40.033
Conrod small end--seat bush 0.266 ÷ 0.566
Piston pin – bush pin 0.0158 ÷ 0.0362
Measurement dimension X --
Maximum error on parallelism

axes of conrod = --
Main journal ∅1 82.99 ÷ 83.01

Conrod journal ∅2 68.987 ÷ 69.013
Main journal half bearings S1* 2.456 ÷ 2.464
Conrod journal half bearings S2* 1.955 ÷ 1.968
* provided as spare parts
Main journal nos.:

no. 1--5 ∅3 87.982 ÷ 88.008
no. 2--3--4 87.977 ÷ 88.013
604.13.542.01 - 03 - 2006
F4GE0484
Type
G*D600
Half bearings – main journals:
no. 1--5 0.041 ÷ 0.119
no. 2--3--4 0.041 ÷ 0.103
Half bearings – conrod journals 0.033 ÷ 0.041
Main journal half bearings

+ 0.250; + 0.500
Conrod half bearings
Thrust main journal X1

37.475 ÷ 37.545
Thrust main journal support X2

25.98 ÷ 26.48
Thrust half rings X3 37.28 ÷ 37.38
Cranckshaft thrust 0.068 ÷ 0.410
604.13.542.01 - 03 - 2006
F4GE0484
Type
G*D600
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 relevant guide 0.052 ÷ 0.092
Seat on head for valve seat:

∅1 46.987 ÷ 47.013
∅1 43.637 ÷ 43.663
Outer diameter of valve seat; angle

of valve seat on cylinder head:
∅2
47.063 ÷ 47.089
α
60°
∅2
43.713 ÷ 43.739
α
45°
Recess 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 --
604.13.542.01 - 03 - 2006
F4GE0484
Type
G*D600
Valve spring height:
free length: H 63.5
under a load of:
329 N H1 49.02
641 N H2 38.20
Injector protrusion X not adjustable
Seats for camshaft bushes no. 1--5

--
Camshaft seats no. 2--3--4
--
Camshaft journals:
1⇒5 ∅
53.995 ÷ 54.045
Outer diameter of
camshaft bushes: ∅ --
Bush inner diameter ∅ 54.083 ÷ 54.147
Bushes and seats in cylinder block --
Bushes and main journals 0.038 ÷ 0.162

Cam lift:
6.045
7.239
604.13.542.01 - 03 - 2006
F4GE0484
Type
G*D600
∅1 Tappet plate seat

in cylinder block ∅1
16.000 ÷ 16.030
∅2
Outer diameter of
tappet plate:
∅3
∅2 15.929 ÷ 15.959
∅2 ∅3 15.965 ÷ 15.980
Between tappets and seats 0.020 ÷ 0.065
Tappets --
∅1
Rocker arm shaft ∅1 18.963 ÷ 18.975
Rocker arms ∅2 19.000 ÷ 19.026

∅2
Between rocker arm and shaft 0.025 ÷ 0.063
604.13.542.01 - 03 - 2006
SECTION 21 -- POWERSHIFT 1
SECTION 21 -- POWERSHIFT GEARBOX

CONTENT
21 000 Powershift Gearbox 4x4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Driving with the powershift gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
604.13.542.01 - 03 - 2006
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.
TH121230
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. TH121231
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.
604.13.542.01 - 03 - 2006
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. TH121230
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.
604.13.542.01 - 03 - 2006
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 – 24 wheels corresponding to a
wheel diameter of 1200 mm.
* Except different specifications of foreign Countries
TH121229
s
4
DISCONNECTING THE GEARBOX
Gearbox disconnection can be performed in two dif-

ferent ways:
1. Powershift speed gear lever
1
2. Push button on manipulator 2
Gearbox disconnection is a consequence of applying
the parking brake. Normal gearbox operation is
restored as soon as the brake is released.
2
TH121232
5
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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.
TH121228
8
1. The input shaft 3. The connecting sleeve
2. The output shaft
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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.
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
The transmission controls

(refer to hydraulic diagram)
The transmission is controlled by the direction and Oil sealing rings are located on the clutch shafts.
range solenoids. The solenoids are mounted on the These rings direct oil under pressure through a
left side of the transmission case. When the selected drilled passage in the shaft to the desired clutch.
direction and range solenoids are energised, oil
under pressure will flow through tubes and passages
to the selected clutch shafts.
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
604.13.542.01 - 03 - 2006
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 The other four speed clutches are not modulated
disengaged by spring. during engagement.
The forward and reverse clutch packs are Output is in the oposite direction to engine rotation.
hydraulically modulated using a mechanical valve.
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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 A, B, C, D, E and F are open to reservoir.
to the 1 solenoid and forward solenoid T.
None of the solenoids are engaged, allowing the oil
to flow through to the clutch D only.
604.13.542.01 - 03 - 2006
TRANSMISSION OPERATION FIRST GEAR ENGAGED
Operating solenoids: T, 1 and 2
TH121013
19
604.13.542.01 - 03 - 2006
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.
604.13.542.01 - 03 - 2006
TRANSMISSION OPERATION SECOND GEAR ENGAGED
Operating solenoids: T and 2
TH121015
21
604.13.542.01 - 03 - 2006
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 Modulation is controlled by the modulation valve in
valve arrives at solenoid valve 1 and at the forward 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
forward B clutch.
604.13.542.01 - 03 - 2006
TRANSMISSION OPERATION THIRD GEAR ENGAGED
Operating solenoids: T
TH121017
23
604.13.542.01 - 03 - 2006
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.
604.13.542.01 - 03 - 2006
TRANSMISSION OPERATION FOURTH GEAR ENGAGED*
Operating solenoids: T and S
TH121019
25
* Except different specifications of foreign Countries
604.13.542.01 - 03 - 2006
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.
604.13.542.01 - 03 - 2006
TRANSMISSION OPERATION REVERSE FIRST GEAR ENGAGED
Operating solenoids: R, 1 and 2
TH121021
27
604.13.542.01 - 03 - 2006
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.
604.13.542.01 - 03 - 2006
TRANSMISSION OPERATION REVERSE SECOND GEAR ENGAGED
Operating solenoids: R and 2

TH121023
29
604.13.542.01 - 03 - 2006
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.
604.13.542.01 - 03 - 2006
TRANSMISSION OPERATION REVERSE THIRD GEAR ENGAGED
Operating solenoids: R
TH121025
31
604.13.542.01 - 03 - 2006
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.
604.13.542.01 - 03 - 2006
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.
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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.
604.13.542.01 - 03 - 2006
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..
604.13.542.01 - 03 - 2006
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”.
604.13.542.01 - 03 - 2006
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).
604.13.542.01 - 03 - 2006
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 °C (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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
ASSEMBLY INSTRUCTIONS
13
T 1
10 4
7
4
6 2
7
4
11
3 R
6
10
8
5
2
TH121034
40
604.13.542.01 - 03 - 2006
20
20
20
20
20
19
TH121036
21 21
23
22
18
16
17
TH121035
41
604.13.542.01 - 03 - 2006
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.
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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 (1) O--ring (2) and
remove the supply tube and screen assembly.
1
TH121056
61
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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.
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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.
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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 and 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 and 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.
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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--ring in position, install the solenoid
cartridges.
TH121213
250
604.13.542.01 - 03 - 2006
Tighten the cartridges to the specified torque.
TH121214
251
With cartridge to coil O--ring in place, position the
solenoid coils on the cartridges.
TH121215
252
WIth new O--ring 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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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 380000258)
COMPULSORY ALL
2 380000258 Striker handle ALL
604.13.542.01 - 03 - 2006
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 procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Front axle overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Axle drive pinion bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
How to install and adjust the axle drive pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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.
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
TH125188
2
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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 service brake pipe (3).
3
TH125186
7
• Remove the four axle levelling cylinder fixing
screws (5).
• Support the axle and remove the four fixing
screws (6).
NOTE: Tightening torque screws (6) M20x1,5x200
600 Nm.
• 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
604.13.542.01 - 03 - 2006
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 (11).
11
Remove the front sealing rings (11).
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
HOW TO ASSEMBLE THE COMPLETE

STEERING KNUCKLE
Apply a thin coat of clean oil to the splined end of the 7
universal joint yoke (10) and install the trunnion
housing (7).
Be careful to prevent any damages to dust seals and
oil seals.
Prepare a shims pack of 0.85 mm to fit under the top
trunnion.
TH125006
10
15
Install a new seal (5) on the top trunnion (6); apply a
thin coat of clean oil and fit the trunnions into their
seats in the housing. Install the screws (3) and
tighten to a torque of 140 Nm.
Check if the oil seal (5) is installed in the correct way.
5
TH125005
16
Fit a new seal (11) onto the bottom pivot pin (4).
Lubricate and fit the unit in the steering case. Position
the screws (3) and lightly tighten. 11
Check for the correct assembly side of the seal (11).
4
TH125003
17
Tighten the new fittinig screws (3) of top and bottom
pivot pins in sequence using the cross tightening
method. Torque wrench setting: 140 Nm.
3
3
TH125010
18
604.13.542.01 - 03 - 2006
Use a pry to confirm there is no vertical play.

If there is some play, take the measurement of the
play and remove shims suitably.
TH125183
19
Verify the torque reaction of the trunnions, 30 ÷ 60
Nm.
If it is higher, add shims adequately.
TH125184
20
Connect the steering tie rod (2) (See “STEERING 2
CYLINDER INSTALLATION”).
NOTE: Lubricate joints with Molikote.
TH125001
21
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
INSTALLATION OF U--JOINT
Using tool (T5) P.N. 380000582 insert sealing ring (8)
into bush (9) and insert bearing (7) using a striker.
NOTE: Carefully check the assembly side of the seal
(8). T5
8 7
9
9
TH125189
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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) P.N.
380000583.
18
TH125041
51
Lubricate the outer surface of the sealing ring (17)
and centring ring (16); fit them into their seat using
tool (T8) P.N. 380000584. T8
16 17
TH125042
52
Install the outer and inner races (8--15) of the bear-
ings on sprocket hub (7) after lubricating the seats. 7
For this operation, use appropriate strikers. 8
15
TH125208
53
Fit the bearing (15) into the internal thrust block.
15
TH125209
54
604.13.542.01 - 03 - 2006
Apply a jointing compound for repositionable fixtures

to the outer surface of the sealing ring (14). 14
Position the sealing ring (14) in the hub (7).
7
NOTE: Check that the ring (14) is correctly oriented.
TH125210
55
Position tool (T10) P.N. 380000585 and press the
sealing ring (14) into its seat. T10
14
TH125211
56
Insert the flange (5) in the crown (13).
13
TH125036
57
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
58
604.13.542.01 - 03 - 2006
Using an appropriate striker (T11) insert planetary

gears (10) into cover (2).
T11
Accurately check the orientation.
10
TH125050
59
Lock the gears (10) into position by fitting the snap
rings (9).
TH125033
10
60
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
61
Install the hub (7).
7
TH125031
62
604.13.542.01 - 03 - 2006
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
63
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
64
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
65
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
66
604.13.542.01 - 03 - 2006
Lock the planetary carrier cover (2) by tightening the

screws (1).
Torque wrench setting for screws: 40÷50 Nm 1
TH125055
67
604.13.542.01 - 03 - 2006
HOW TO REMOVE THE STEERING CYLINDER

Remove the centring sensor (1) of the steering pis-
ton, if supplied.
1
TH125217
68
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
69
Disconnect the tapered pins of the articulation (4)
from the steering knuckle (7) by means of a puller.
7
TH125058
70
If the connection of the steering bars includes a
safety collar (13), raise the border.
13
TH125059
71
604.13.542.01 - 03 - 2006
Disconnect left and right tie rods from the piston (2).
TH125060
72
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
73
604.13.542.01 - 03 - 2006
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
74
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
75
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
76
If fitted, insert the proximity sensor (1) to check the
piston location and tighten the screws (10).
Tightening torque: 5 ÷ 6 Nm.
10
TH125212
77
604.13.542.01 - 03 - 2006
ATTENTION
T12
Eliminate the action of the negative braken if fitted.
Install tow drilled bars (T12) on the sprocket holder

hubs and lock them.
Using a level “B”, check that tools are perfectly flat
and parallel to each other.
B
T12
TH125067
78
Connect the sensor (1) to the inspection device
according to either diagram.
TH125213
79
Sensor connection card, STANDARD version.
TH125069
80
Sensor connection card, OPTIONAL version.
TH125070
81
604.13.542.01 - 03 - 2006
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.
TH125214
82
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
83
Without moving the piston, check the front and rear
measurement at the end of bars (T12).
Max. difference: 0.6 ÷ 0.7 mm
NOTE: To check the rear measurement, turn the
bevel pinion and check the planarity and parallelism
of bars (T12).
T12
TH125073
T12
84
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
85
604.13.542.01 - 03 - 2006
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
86
604.13.542.01 - 03 - 2006
ADJUSTMENT OF STEERING ANGLE

NOTE: Perform the same operations on both sides.
Loosen the locknut of one of the stop adjusting
screws on the cylinder side.
Steer completely until the stop screw touches the
axle stop.
TH125180
Sul
87
On the opposite side, adjust the stop screw so as to
bring it exactly in contact, without stress, with the rel-
evant axle stop.
Tighten the locknuts.
Steer completely to the opposite direction and repeat
the same procedure for the other stop screws.
TH125181
88
IMPORTANT: At steering lock position, the stop
screws must touch simultaneously the axle stops.
TH125182
89
604.13.542.01 - 03 - 2006
HOW TO DISASSEMBLE THE STEERING

CYLINDER 2
Remove the snap ring (1) from the cylinder head (2).
TH125077
90
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
91
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
92
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
93
604.13.542.01 - 03 - 2006
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 94
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
95
604.13.542.01 - 03 - 2006
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
96
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
97
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
98
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
99
604.13.542.01 - 03 - 2006
Apply tool (T18) P.N. 380001186 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
100
Push the piston (5) into the cylinder for 100 mm using
a plastic hammer.
5 3
TH125088
101
Remove tool (T18) P.N. 380001186 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
102
Insert the stop ring (4) ensuring that it fits into the seat
of the cylinder (3). 4
TH125090
103
604.13.542.01 - 03 - 2006
Apply pressure to the head using two screwdrivers

or levers until the head is fastened onto the stop ring
(4).
TH125091
104
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
105
604.13.542.01 - 03 - 2006
HOW TO REMOVE AND DISASSAMBLE

THE DIFFERENTIAL UNIT
Remove the complete arms.
For details, see “CHECKING WEAR AND REPLAC-
ING THE BRAKING DISKS”.
TH125092
106
Mark the position of the ring nuts (1).
Remove the fitting screws (3) from the ring nuts (1).
3
1
TH125093
107
Uniformly heat the ring nuts (1) up to a temperature
of 80°C.
Apply tool (T13) P.N. 380000586 and remove the ring
nuts. T13
NOTE: Accurately clean the threaded portions of
ring nuts, body and cover.
TH125094
108
Remove the fitting screws (4) from the middle cover
(5). 4 5
4
TH125095
109
604.13.542.01 - 03 - 2006
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
110
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
111
Remove the fitting screws (11) from the crown (12).
11
12
TH125099
112
If the bearing need replacing, extract the bearing (7)
and remove the crown (12).
7
12
TH125100
113
604.13.542.01 - 03 - 2006
Remove the shim washer (13) and the planetary gear

(14).
13
14
TH125101
114
If the bearing need replacing, extract the bearing (8)
from the differential carrier (15).
15
TH125102
115
Remove the snap rings (16) from the two pins (17) of
the planet wheel gears (18).
17
16
TH125103
116
Insert tool (T14) P.N. 380000587 between the planet
wheel gears (18).
T14
18 18
TH125104
117
604.13.542.01 - 03 - 2006
Force tool (T14) P.N. 380000587 in--between the

planet wheel gears (18) using two pin--drivers.
ATTENTION
Make sure that tool (T14) P.N. 380000587 is
perfectly lined up with the pins (17) when locked.
17
TH125105
118
Place differential body (15) under a press position
bush (T15) P.N. 380000588 and insert pin (T16B). T16B
Press pin (T16B) of kit T16 (T16A + T16B + T16C) T15
P.N. 380000589 full stroke. T16B
17
15
TH125106
119
Remove gudgeon (T16B) and bush (T15) P.N.
380000588.
NOTE: In this condition the tool (T14) P.N. T16A
T15
380000587 contains pin (17).
TH125107
120
Remove tool (T14) P.N. 380000587 together with the
pin (17) of the planet wheel.
17
TH125105
121
604.13.542.01 - 03 - 2006
Leave the released planetary gear in position and

again lock tool (T14) P.N. 380000587. 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
122
Remove tool (T14) P.N. 380000587 and remove the
last two planet wheel gears (18), the 2nd differential
unit gear (14) and the relative shim washer (13) from 14
the differential carrier.
13
15
TH125108
123
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
124
604.13.542.01 - 03 - 2006
ASSEMBLING
Insert the shim washer (13), and the planetary gear
(14) in the differential carrier (15). 14
13
15
TH125108
125
Position the shim washer (19) and the first planet
wheel gear (18). 18
Hold them in position using bar (T16C).
19
T16C
TH125111
126
With the help of gudgeon (T16A), position the sec-
ond planet wheel gear (18) and the relative shim 18
washer (19).
T16A
T16C
19
TH125110
127
Insert tool (T14) P.N. 380000587 between the two
planetary gears (18). Line up the entire unit by push-
ing bar (T16C) all the way down until gudgeon (T16A) T14
is ejected.
T16C
TH125112
128
604.13.542.01 - 03 - 2006
Lock tool (T14) P.N. 380000587 behind the planet

wheel gears (18). T14
After locking, remove bar T16C.
18 18
TH125104
129
Fit the snap rings (20) onto the pins (17).
20 17
TH125113
130
Place the differential carrier (15) under the press,
position bush (T15) P.N. 380000588 and insert the T16B
planet wheel pin (17). 17
Put gudgeon (T16B) on top of the planet wheel pin T15
(17). T16B
17
TH125114
131
Press (T16B) pin all the way down.
T16B
T15
T16B
15
17
TH125106
132
604.13.542.01 - 03 - 2006
Remove gudgeon (T16B), bush (T15) P.N.

380000588 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
133
Position the second planetary gear (14) in the differ-
ential carrier (15).
14
15
TH125116
134
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
135
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
136
604.13.542.01 - 03 - 2006
Using an appropriate striker (T17) install bearings (7)

and (8).
8
T17
7
T17
TH125119
137
If the bearings are replaced, insert the external thrust
blocks in the middle cover (5) and in the central body 2
(2).
TH125120
138
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
139
Lock the middle cover (5) with screws (4).
Torque wrench setting for screw: 23.8÷26.2 Nm.
4
5
4
4
TH125122
140
604.13.542.01 - 03 - 2006
NOTE: If the ring nuts (1) are removed, spread them

with Loctite 242.
Tighten ring nuts on the crown side until clearance
between pinion are crown is zero, then lock the
crown; go back 1/4÷1/2 turn.
TH125200
141
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
If bearings are not new, check the static torque; if
bearings are new, check the continuous torque.
TH125201
142
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
143
Manually move the crown (12) in both directions in
order to check the existing backlash between the pin- 12
ion and the crown.
TH125126
144
604.13.542.01 - 03 - 2006
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.
Difference between MIN and MAX clearance for
whole circumference should not exceed 0.09 mm.
TH125202
145
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
146
Re--install the complete arms.
ING THE BRAKING DISKS”.
TH125092
147
604.13.542.01 - 03 - 2006
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
148
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
149
Prevent the rotation of the pinion using a bar (T20A)
as indicated in the figure.
Unloose and remove the nut (1); also remove the T20A
O--ring (3).
TH125215
150
Remove the flange (2) complete with guard (4) by
means of a puller.
TH125130
151
604.13.542.01 - 03 - 2006
Remove the swinging support (5).

5
TH125131
152
Remove the sealing ring (6).
TH125132
153
Position wrench (T22) P.N. 380000591 onto the ring
nut (7) and apply bar hold (T21) P.N. 380000590 to
the pinion.
Stop wrench (T22) and rotate the pinion so as to
release and remove the ring nut (7). 7
NOTE: If disassembly proves awkward, heat the ring T21
nut to approx. 80 ° C.
T22
TH125133
154
Apply blocks (T23) P.N. 380000592 and, with the
help of a puller, extract the pinion (8) complete with
the internal bearing, the distance piece and shims. T23
NOTE: The thrust blocks of the bearings remain in 8

the central body (12).
TH125134
155
604.13.542.01 - 03 - 2006
Remove the pinion (8), shims (11) and spacer (10).

10
8
11
TH125135
156
Using a puller and a press, remove the inner bearing
(9) from the pinion (8).
TH125136
157
Remove the external bearing (13) thrust block.
13
TH125137
158
Insert a drift in the appropriate holes and remove the
internal bearing (9) thrust block as well as the shim
washers (14).
14
TH125138
159
604.13.542.01 - 03 - 2006
14
10
13
6
5
11
3
7
1 4
TH125139
160
604.13.542.01 - 03 - 2006
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
161
Insert the other tool elements and tighten the nut (4)
until the bearing/spacer unit is packed.
4
TH125141
162
Use a depth gauge (range 0--15 mm) to measure the
Q
Q value between the tool upper surface and the push
rod.
TH125142
163
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
164
604.13.542.01 - 03 - 2006
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
165
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 on the differential case and measure the
Q2 value between the flange and the bearing inner
housing. If Q2 is added to the fixed value Q3=50mm (+0.1)
(value from the theoretical starting point of the pinion
primitive generating line to the surface measured by Y
the tool) the W value is obtained.
TH125146
166
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
167
604.13.542.01 - 03 - 2006
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
168
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
169
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
170
Apply Loctite 242 to the thread of the ring nut (7) and
screw the nut onto the pinion (8).
7
8
TH125150
171
604.13.542.01 - 03 - 2006
Apply special wrench (T22) P.N. 380000591 to the

ring nut (7) and bar--hold (T21) P.N. 380000590 to
the pinion (8).
Stop wrench (T22) P.N. 380000591 and tighten the T21
pack using a torque wrench until the bearings are
fully seated. Then tighten the opinion to the maxi-
mum required torque of 500 Nm.
T22
TH125151
172
Install a torque meter on pinion (8) and check the roll-
ing torque of the pinion.
Torque: 120--170 Ncm.
ATTENTION T19
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
ATTENTION 173
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).
Lubricate the outer surface of the new sealing ring (6)

and fit it onto the central body (12) using tool (T27)
P.N. 380000594. 6
T27 12
TH125152
174
604.13.542.01 - 03 - 2006
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.
Prevent the rotation of the pinion using a bar (T20A)
as indicated in the figure. Install O--Ring (3) and nut
(1); tighten with a torque wrench.
Torque wrench setting: 280÷310 Nm.
T20A
TH125216
177
Remove blocks (T23) P.N. 380000592 (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
604.13.542.01 - 03 - 2006
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
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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
604.13.542.01 - 03 - 2006
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.
FRONT DRIVE SHAFT INSTALLATION

1
ATTENTION
ing installation.
1. Apply on the screws (1) Loctite 270 (271 only for

U.S.A.).
2. Insert spider on the axle flange and keep in posi-
3
tion. 1 2
3. Insert the two stud bolts (2) and tight the four TH125169
screws (1) at 34--41 Nm torque. 186
4. Repeat this operation on the other side of the
drive shaft.
604.13.542.01 - 03 - 2006
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
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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.
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
TH127011
2
604.13.542.01 - 03 - 2006
REAR DRIVE SHAFT
Specifications
Length (A) closed: . . . . . . . . . . . . . . . . . . . 1347 mm
Extension (B): . . . . . . . . . . . . . . . . . . . . . . . . 72 mm
TH127005
3
ATTENTION
1 2
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
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
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
• Axle shafts
• Axle trumpet housing
• Brake housing
• Differential crown wheel and pinion
• Steering cylinder
604.13.542.01 - 03 - 2006
SPECIAL TOOLS
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
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
604.13.542.01 - 03 - 2006
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

ringnut
2 380000591
COMPULSORY ALL
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

bearings
2 380000463
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
Adapter for the arrangement To adjust the pinion.

of axle bevel pinion
2 380000609
COMPULSORY ALL
604.13.542.01 - 03 - 2006

Tool for the installation of To install a new seal
Roto--Glyd DANFOSS seal
2 380000281
COMPULSORY ALL
Tool for the installation of To install the springs
DANFOSS rotor springs
2 380000306
RECOMMENDED ALL
Tool for the installation of To install a new seal

DANFOSS dust seal
2 380000210
COMPULSORY ALL
604.13.542.01 - 03 - 2006
SECTION 33 -- BRAKES 1
SECTION 33 -- BRAKES
CONTENT
33 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Power brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Brake disc adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Brakes disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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.
604.13.542.01 - 03 - 2006
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).
604.13.542.01 - 03 - 2006
PARKING BRAKE
PARKING BRAKE LEVER

INSTALLED IN CAB
TRANSMISSION
REAR VIEW
TH133056
2
Description and operation
When parking brake lever (1) is actuate, the brake
caliper closes on the disc mounted on the output of
the transmission shaft, blocking the movements of
the transmission itself.
NOTE: When the parking brake lever is actuated, the
transmission is cut--off. 1
TH133053
3
604.13.542.01 - 03 - 2006
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)
TH133054
4
604.13.542.01 - 03 - 2006
• 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
TH133057
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.
604.13.542.01 - 03 - 2006
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
TH133055 S
8
604.13.542.01 - 03 - 2006
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.
Parking brake inefficient

Cause Remedy
7. Incorrect adjustment Check the thickness of the parking brake disc and
brake pads to define whether they can be reused and
adjust them in accordance with the instructions
provided in the manual.
8. Brake disc/brake pads worn--out Check the thickness of the parking brake disc and
replace it when required.
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. Wrong fluid in the circuit See remedy no. 3.
12. Brake circuit choked Check and repair damaged pipes.
13. Wrong lubricant Replace the brake system and pump seal rings.
Oil coming out

Cause Remedy
14. Hydraulic fluid leakage from braking system See remedy no. 2 and no. 3.
15. Hydraulic fluid leakage from differential circuit See remedy no. 3.
604.13.542.01 - 03 - 2006
BRAKES DISASSEMBLY
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
9
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
10
Remove the axle shaft (3) and the brake disc unit (7).
Set the axle shaft on a bench.
3
TH133030
11
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
12
604.13.542.01 - 03 - 2006
Remove the piston (9) return springs (8).

NOTE: If the springs (8) are distorted, replace them. 8
9
8
TH133032
13
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
14
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
15
604.13.542.01 - 03 - 2006
10
15 9
6 8
7 11
14 16
3
13
12
18
TH133035
16
604.13.542.01 - 03 - 2006
Brakes 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
17
Insert the springs (15) on the piston (9) circumfer-
ence for travel compensation.
15
9
15
TH133037
18
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
19
Insert the piston (9) by lightly beating the circumfer-
ence with a plastic hammer.
TH133039
20
604.13.542.01 - 03 - 2006
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
21
Insert the piston (9) return springs (8).
8
ATTENTION 9
Be careful not to damage spring attachments.
8
TH133032
22
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
23
Check the arm seal ring (16) integrity and location.
Install the whole arm.
Fasten it with two opposite screws.
16
TH133041
24
604.13.542.01 - 03 - 2006
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
25
604.13.542.01 - 03 - 2006
SECTION 35 -- HYDRAULIC SYSTEM 1
LIST OF CONTENTS
35 000 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Steering system hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Telescopic boom hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Delivery side divider valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure reduction valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Front loader controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Power steering (OSPQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Telescopic boom distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Auxiliary control distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Working platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Procedure for the calibration of the personnel carrier platform electronic controller . . . . 65
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
604.13.542.01 - 03 - 2006
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.
Pressure relief valve 230--240 bar
Power steering
Main safety valve 175 bar
Secondary safety valve 240 bar
604.13.542.01 - 03 - 2006
DESCRIPTION AND OPERATION STEERING SYSTEM HYDRAULIC CIRCUIT

Basic circuit operation
INTRODUCTION Pump (3) takes in the oil through a 100 micron filter
The hydraulic circuit includes: located in the hydraulic reservoir and delivers it
through the load sensing divider valve (2) at the back
• (primary) steering circuit
of the pump. In this manner, the oil reaches first the
• (secondary) telescopic boom circuit steering system circuit (primary circuit) and the rest
The latter also includes the system components of the oil is transferred to the telescopic boom and the
responsible for the selection of the stabilisers, frame auxiliary hydraulic circuits (secondary circuits) (Ref.
levelling and rear axle lock--up. A).
The operating diagrams of the above--mentioned cir- The flow of oil goes through the priority hole of the
cuits and the relative descriptions are given below; the divider valve and reaches the steering system motor
diagramsgive an overall view of the hydraulics and (1) and then the selection valve (7) for three steering
include some indications on the electrics, as needed to modes:
provide an understanding of the system’s operating — Two steering wheels
logic. — Four concentric or discordant wheels
— Four concordant or unilateral crab wheels.
(see fig. TH135003, page 4)
Steering system hydraulic circuit diagram
1
2 3 4 5
8 6
7
TH135002
1
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
604.13.542.01 - 03 - 2006
With the steering wheel stationary, the power steer-

ing distributor is in neutral and the oil can flow to the
return path (from inlet P to outlet T). In these condi-
tions, in the event of collisions against the wheels,
the latter are dampened by the shock--proofing
valves and are not transmitted to the steering wheel.
Moreover, two anticavitation valves prevent cavita-
tion phenomena from occurring in the steering cylin-
ders chambers.
When the steering wheel is turned, the movement is
transferred to the distributor which gradually opens
the conduits to the cylinder ways, while neutral con-
tacts close.
Following wheel rotation (and the ensuing distributor
rotation) the volume of oil that goes through is directly
proportional to the angular movement of the steering A
wheel and produces the angular movement of the T
drive wheels.
B
STEERING VALVE
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:
1. two steering wheels P
2. four concentric (or discordant) steering wheels
TH135004
3. four unilateral (or concordant) steering wheels (crab)
2
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
not pressurised, is controlled by the same distributor
that conveys the oil to the discharge line (T) and
hence to the reservoir simultaneously with the oil
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- 1 2 3
inder.
TH135003
3
5
4. Front axle solenoid valve
5. Rear axle solenoid valve
6. Rear axle cylinder
7. Front axle cylinder
6
A. Connection to cylinder (6)
T. Connection to cylinder (7) 7
B. Connection to cylinder (6)
P. Steering system delivery line
R. Steering system delivery line 4
TH135006
4
604.13.542.01 - 03 - 2006
STEERING SYSTEM HYDRAULIC CIRCUIT
2
4
TH135085
5
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
604.13.542.01 - 03 - 2006
TELESCOPIC BOOM HYDRAULIC CIRCUIT

Basic circuit operation The telescopic boom is extracted by means of an
The pump (1) takes in the oil through a 100 micron unstable cursor type switch located on the front of the
filter situated in the hydraulic tank and sends it on to unit’s control levet handle (14). The operation is elec-
the steering circuit through line (a) in priority mode, trically controlled by means of a trimmer (35), which
and hence to the distributors (11) and (22) supply activates electrically the proportional solenoid valve
lines (secondary circuit). of the distributor (22). The latter distributes the load
to the lifting cylinders (27) and (28) (if fixed).
Taken as a whole, the circuit is mainly controlled by
the operation of the control unit (14) and the push The front part of the handle houses two switches (34)
buttons (13) situated on the panel to the left of the for the operation of the solenoid valve equipping the
driver. distributor (28) that supplies the cylinder (6) (OPT.).
The pump delivery hydraulic oil flows to the distribu- The distributor (22) also contains, for each slide
tors that control the various hydraulic functions by valve, load sensing valves, connected to the load
managing the flow--rate to the various actuators: the sensing line G.
hydraulic oil coming back from the actuators through
the distributors is transmitted to the oil cooler, where Rear axle lock
it is cooled and hence returns to the hydraulic reser- The rear axle locking cylinder uses the system’s dis-
voir via the total capacity filter, which holds back any charge line which has a pressure of 3--4 bar. Its
impurities as may be contained in the oil returning activation takes place automatically during the boom
from the actuators. lifting stage: at ca 15°, the sensor fitted to the boom
When the oil temperature is low, oil viscosity itself sends a signal to the control unit which activates
increases and so does the resistance to the passage the valve (20).
of the oil through the cooler. If the oil pressure
exceeds 5 bar, whether because of the high viscosity Auxiliary control distributor
of the oil (thermostatic valve function) or due to radi-
The pump (1) supplies, in parallel with the distributor
ator clogging, the oil returns directly to the tank, by--
(22), the stabiliser and levelling control assembly
passing the radiator.
(11).
These controls are operated by means of push but-
Tool distributor
tons (13) which activate the distributor’s solenoid
Stem lifting is achieved by working on the hand lever valves and hence control the output pressures in the
(14), which distributes the pressure load to the two circuit itself, balanced by the load sensing line (G).
central hydraulic (slide) valves of the distributor (22),
which supply both the lifting cylinder (30) and the
compensation cylinder (17). The circuit of the latter
is connected to the lifting cylinder (30) and makes its
possible to keep the tool (fork, bucket, etc.) in hori-
zontal position during cylinder (30) lifting.
604.13.542.01 - 03 - 2006
TH135008
6
Telescopic boom circuit
604.13.542.01 - 03 - 2006
604.13.542.01 - 03 - 2006
Arrangement of hydraulic system components, complete

with:
28 -- steering
26
-- telescopic boom
32
20
27 25
33
20
29
30
31 22
1 21
20
2
19
3
18
4
17
5
16
15
14
13
12
6
C 11
35
7 14
37
8
TH135086
7
604.13.542.01 - 03 - 2006
604.13.542.01 - 03 - 2006
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.
8
Hydraulic scheme
4
1
TH135012
2
9
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
10
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
11
604.13.542.01 - 03 - 2006
1 2 3 4 5 6
11 10 9 8 7
TH135015
12
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 As soon as the steering wheel is rotated, the pres-
flow corresponding to the demand is always deliv- sure generated in these circuits is sensed in the load
ered to the steering circuit (priority circuit), while the sensing line and applied to the right hand side of the
remaining flow is transmitted to the tool circuit (sec- pin. When the combined effects of the load sensed
ondary circuit). and the force of the spring against the right hand side
At key--on, the pin in the load sensing valve is pushed of the pin exceeds the pressure applied to the left
to the left by a spring (8) enabling the pump flow to hand side of the pin, the pin moves to the left, thereby
enter the valve through a hole (3) which ensures the increasing the flow delivered to the steering circuit.
delivery of the priority flow to the steering and braking Since the oil in the load sensing line flows through the
system circuits. The pressure of the pump is also steering motor adjustment holes before reaching the
applied to the centre of the pin and transmitted to the divider valve, the load sensing pressure is always
left hand side of the pin through hole (10). The bal- proportional to the demand. This ensures that the
ancing hole (9) senses the pressure but works as a valve transmits only the quantity of oil necessary to
damper to prevent the pin from moving in an irregular the steering circuit, while the rest of the pump’s out-
manner. put flow is routed to the loader arm circuit.
Assuming that during engine starting the braking and
steering circuits are not used, the load sensing line
opens towards the reservoir and the pump pressure
applied to the left hand side of the pin moves the pin
to the right, thereby conveying the delivery flow to the
loader arm circuit.
604.13.542.01-- 03 - 2006
Pressure reduction valve

Pressure reduction valve regulates the pressure at
35 bar in the part of the circuit that supplies oil to the
piloted hydraulic controls and the joystick.
TH135088
13
Hydraulic diagram
1. Piloting pressure pick--up
2. Connection to PST of main control valve
3. Powering for joystick
4. Discharge to reservoir
TH135087
14
604.13.542.01 - 03 - 2006
TH135089
15
Detail of ports of pressure reduction valve
604.13.542.01-- 03 - 2006
FRONT LOADER CONTROLS

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 2
-- to the left, to retract the front loader/tool 3
-- to the right, to tip the front loader/tool. 4
TH135080
s
16
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. Transmission disengagement 4 3 2 1
TH135021
17
Being unstable, button (5) keeps the transmission
disengaged until it is released. Hydraulic scheme
1--2 Cylinder lifting lines
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. TH135090
18
604.13.542.01 - 03 - 2006
2
9
TH135091
19
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.
604.13.542.01-- 03 - 2006
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 20
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.
604.13.542.01 - 03 - 2006
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
21
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
604.13.542.01-- 03 - 2006
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 22
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
23
1. Pilot and flow amplification valve
2. Flow amplification circuit
3. Flow pilot circuit 1
2 3
TH135027
24
604.13.542.01 - 03 - 2006
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
25
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
604.13.542.01-- 03 - 2006
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- 26
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.
604.13.542.01 - 03 - 2006
TH135030
27
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
TH135092
28
604.13.542.01-- 03 - 2006
MAIN COMPONENTS OF TELESCOPIC

BOOM DISTRIBUTOR
5
4 3
7
3
9
3
8 2
1
10
TH135032
29
N.B.: For the definition of the components shown in this diagram, see legend to Figure 28.
604.13.542.01 - 03 - 2006
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. TH135093
30
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
TH135094
31
604.13.542.01-- 03 - 2006
CYLINDERS
2
9
TH135091
32
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
604.13.542.01 - 03 - 2006
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
33
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
LM1340 3400 mm 3350 mm
LM1343 5
LM1345 1070--1120 Nm
LM1443 3800 mm 3750 mm 6 120-- 125 Nm

LM1445
LM1745 3650 mm 3600 mm
604.13.542.01-- 03 - 2006
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
604.13.542.01 - 03 - 2006
OUTER TELESCOPIC CYLINDER

(only 17 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
34
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
604.13.542.01-- 03 - 2006
FRAME LEVELLING AND REAR AXLE

LOCKING CYLINDER
TH135096
35
Stroke (A): 135 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
4 PS 1521--A
5 PS 1521--P
6 PS 1521--K
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
604.13.542.01 - 03 - 2006
SMALL STABILISER CYLINDER

(13 m and 14 m models only)
1 2 3
4 9 12 11
11
3 6 10 7 5 1 2 8
TH135053
36
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
604.13.542.01-- 03 - 2006
LARGE STABILISER CYLINDER

(standard on 17 m model, available on 13 m and 14 m models)
TH135095
37
Max. operating pressure: 260 bar 1 775-- 835 Nm
2 2400--2500 Nm
3 20-- 25 Nm
s

5. Guide ring 12. Plunger ring
604.13.542.01 - 03 - 2006
COMPENSATION CYLINDER
1 2 3
6 7 10 5 2 9 8 3 1 11 13 4 12 14
TH135055
38
Max. Operating pressure: 260 bar 1 300--350 Nm
2 700--750 Nm
3 20-- 25 Nm
s

604.13.542.01-- 03 - 2006
LIFTING CYLINDER
1 2 3
6 7 3 10 5 9 8 1 2 11 4 13 12 14
TH135056
39
Stroke(A): 1220 mm Tightening torque
1 1500--1500 Nm
2 5500--6000 Nm
3 20-- 25 Nm
s

604.13.542.01 - 03 - 2006
TILT CYLINDER
1 2 3
6 7 10 3 5 9 8 1 2 11 4 12 13 14
TH135057
40
Stroke(A): 442 mm Tightening torque
1 775-- 825 Nm
2 2500--2600 Nm
3 20-- 25 Nm
s

604.13.542.01-- 03 - 2006
ARMS
BOOM REMOVAL
ATTENTION
Lift and handle all heavy materials with a lifting device
with appropriate capacity.
Make sure that all items are properly secured by ap-
propriate slings and hooks. Use the lifting eyes pro-
vided for this purpose. Beware of persons standing
near the load to be lifted.
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
41
• 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.
ATTENTION
Do not allow unauthorised personnel to repair or to
maintain this machine. Read and head carefully the
Operation and Maintenance Instruction Manual prior
to starting, operating, maintaining, refuelling or re-
pairing this machine.
TH135059
s
42
604.13.542.01 - 03 - 2006
• 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
43
• 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
TH135082
s
44
604.13.542.01-- 03 - 2006
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
(17 m version)
-- pipes on boom
• Remove che chains/bands
604.13.542.01 - 03 - 2006
BOOM DISASSEMBLY
ATTENTION
ATTENTION
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).
604.13.542.01-- 03 - 2006
Description of boom disassembly procedure (13 m + 14 m)
6 4 5
3
2
1
TH35R125
45
1. First boom 4. Lifting + comp. cylinder
2. Second boom 5. Outer telescopic cylinder
3. Third boom 6. Tilt cylinder
s
s
s
ATTENTION
s

1
• Using tools 380001586 and 380001587 discon-

nect the two telescopic cylinder--feeding hoses
and connect an external hydraulic unit and feed
pressurised oil until the boom is extended 500
mm to make the removal of pivot pin (1) possible. TH135062
s
46
• Remove circlip (2) and extract pin (1).
ATTENTION 2
Handle all parts with great care.
Do not place hands or fingers between pieces. Wear
authorised protective clothing/devices such as
glasses, gloves and safety shoes.
1
TH35R126
s
47
s
604.13.542.01 - 03 - 2006
• Once the rod of the telescopic cylinder has been

freed from the boom, it is necessary to invert the 1 3
direction of the oil flow from the unit to retract the
cylinder rod inside the boom.
• Remove screws (1) of supports (2) from pin (3).
• Remove screw (4) from the bottom securing
point of the third arm.
2
4
TH35R127
s
48
• Loosen the tilt twin hose (5) from the front side of
the boom group and auxiliary hydraulic function 6
hose (6).
• Pull the two hoses from the rear side of the boom
until they come out from the respective channels.
TH35R128
s
49
• Sling the cylinder group using chains and hold it
during the backing--off operation to prevent acci-
dental falls.
ATTENTION
TH35R129
s
50
• Sling the telescopic cylinder using cables and ex-
tract it from the boom group as indicated in the
figure.
WARNING
TH35R130
51
604.13.542.01-- 03 - 2006
• Then, disconnect the inner hoses from the inner

pipes.
• Mark the various pipes to facilitate the connec-
tion during the reassembly operation.
DANGER
Fluid under pressure; prior to removing the cap or the
cover, turn them slowly to bleed internal pressures.
Please refer to the Operation and Maintenance In-
struction Manual.
TH35R131
s
52
• Pull out from the rear side of the boom all the ho-
ses present and precisely tilt twin hose (1), two 2
telescopic cylinder hoses (2) and the supple-
mentary hydraulic function twin hose (3).
3
1
TH35R132
s
53
• Remove from the boom group all the front inner
sliding pads indicated in the figure that could pre-
vent or make difficult the extraction operation of
the arms.
WARNING
TH35R133
s
54
604.13.542.01 - 03 - 2006
• Use cables to sling third arm (1) and extract it

from the second arm (2).
WARNING
Make sure that all items are properly secured by ap- 2
1
TH35R134
s
55
• Using again appropriate cables, sling second
arm (2) and extract it from the first arm (3). 2
3
TH35R135
s
56
• Remove all the outer steel pipes from the first
boom marking their position to facilitate their po-
sitioning during the reassembly.
TH35R136
s
57
DESCRIPTION OF THE INSTALLATION OF THE
BOOMS (13m + 14m)
WARNING
Prior To reinstalling the boom group, clean thorou-

TH35R137
ghly all the parts.
• Install all the outer steel pipes on the first boom. 58
604.13.542.01-- 03 - 2006
• Install the series of rear pads (1) on the second

boom using the securing screws after applying
LOCTITE 243 on the threaded part tightening
them to a torque of 40Nm.
TH35R138
59
s
• Apply grease GR9 AMBRA MULTIPURPOSE on

the outer walls of second boom (2) and the inner
walls of first boom (3) precisely along all the sli- 3
ding sections of pads (1). 2
1
TH35R139
s
60
• Use appropriate cables to sling second boom (4)
and insert it into first boom (5). 4
WARNING
5
TH35R140
s
61
• Keep the second boom slightly lifted to facilitate
the installation operation of the two lower pads
and two metal blocks (6) on the first boom using
the securing screws, applying LOCTITE 243 on
the threaded part. Tighten the screws to a torque
of 40Nm.
WARNING
authorised protective clothing/devices such as 6
glasses, gloves and safety shoes. TH35R141
62
604.13.542.01 - 03 - 2006
• Install all inner sliding pads (1) on the front side

of the first boom, following the same procedure
used fro the installation of the other pads.
TH35R142
s
63
• Install all sliding pads (2) on the rear side of the
third boom using the relevant securing screws af-
ter applying LOCTITE 243 on the threaded part.
Tighten them to a torque of 40Nm. 2
TH35R143
s
64
the outer walls of third boom (3) and the inner
walls of second boom (4) precisely along all the
sliding sections of pads.
• Use cables to sling the third boom and insert it in-
to the second one.
4
WARNING 3

propriate slings and hooks. Use the lifting eyes pro- TH35R144
vided for this purpose. Beware of persons standing 65
s
604.13.542.01-- 03 - 2006
• Following the same procedure of the previous

phases, complete the installation of all the sliding
pads in accordance with the diagram indicated in
the figure.
WARNING
Make sure that the cables are safely secured and
that the securing point is strong enough to support
the load to be applied.
Keep all persons in the vicinity away from the hook-
ing point, cables or chains.
TH35R145
s
66
• Insert hoses (2) from the front--lower side of first
boom (1).
TH35R146
s
67
• Push the hoses sliding them inside the boom
along the relevant lower channels and precisely 4
the tilt twin hose in the first channel (3), the two
telescopic cylinder hoses in channel (4) and the
supplementary hydraulic function twin hose in
the third channel (5).
5
3
TH35R147
s
68
604.13.542.01 - 03 - 2006
• Connect the inner hoses and the outer steel

pipes.
• Secure the boom outer steel pipes in the secu-
ring points provided.
TH35R131
s
69
• Insert the tilt twin hose (1) inside the relevant up-
per channel as indicated in the figure.
WARNING
1
TH35R148
s
70
• Insert supplementary hydraulic function twin ho-
se (2).
TH35R149
s
71
• Slide the hoses inside the channels until they exit
from the front side of the third boom.
• Secure the hoses.
TH35R150
72
604.13.542.01-- 03 - 2006
• Use cables to sling the telescopic cylinder and in-

sert it into the boom group.
WARNING
TH35R130
s
73
• Connect the telescopic boom to an external hy-
draulic unit to move the eye of the rod to reach
the pivot point on the third boom.
DANGER
struction Manual.
TH35R151
s
74
• Once the eye of the telescopic cylinder rod rea-
ches the pivot point on boom (1) insert the pin
and secure it with the circlip.
TH35R152
s
75
• Once the telescopic cylinder rod is secured on
the boom, it is necessary to invert the direction
of the oil flow to retract the cylinder rod inside the
boom.
TH35R153
76
604.13.542.01 - 03 - 2006
• Position the telescopic cylinder inside the boom

inserting pin (1) into the relevant seats. 3 1
• Secure pin (1) using plates (2) and screws (3).
Install screw (4) to the bottom securing point on
the third boom.
• Tighten all the screws to a torque of 300Nm.
2
4
TH35R154
s
77
• Disconnect the cylinder from the outer hydraulic 5
unit and connect two hoses (5) using tools
380001586 and 380001587.
DANGER
struction Manual.
TH35R155
s
78
604.13.542.01-- 03 - 2006
Boom disassembly description (17 m)
5
6 7
8
4
3 2 1
TH135098
79
1. First boom 5. Outer telescopic cylinder
2. Second boom 6. Lifting + comp. cylinder
3. Third boom 7. Inner telescopic cylinder
4. Fourth boom 8. Tilt cylinder
s
s
s
s
s
ATTENTION
1
• Using tools 380001586 and 380001587 discon-

nect the two inner telescopic cylinder feeling and
connect them to an external hydraulic unit send-
ing pressurised oil to extract the boom about
500mm to make the removal of pivot pin (1) pos- TH135062
sible. 80
s
• Remove circlip (2) and extract pin (1).
ATTENTION 2
glasses, gloves and safety shoes. 1
TH35R126
s
81
604.13.542.01 - 03 - 2006
• Remove screws (1) of plates (2) of the outer tele-

scopic cylinder intermediate blocking support 1
from the upper side of the boom.
2
TH35R156
s
82
• Remove screws (3) of securing plates (4) of the
outer telescopic cylinder front support. 6 3
• To remove pin (5) remove central screw (6) then
extract pin (5).
4
TH35R157
s
83
• Use cables to sling outer telescopic cylinder (7),
lift it from the upper side of the boom and rest it 7
on an appropriate support.
WARNING
TH35R158
s
84
• Once the rod of the telescopic cylinder has been
freed from the boom, it is necessary to invert the 8 10
direction of the oil flow from the unit to retract the
cylinder rod inside the boom.
• Remove screws (8) of supports (9) from pin (10).
• Remove screw (11) from the bottom securing
point of the third arm.
9
11
TH35R159
85
604.13.542.01-- 03 - 2006
• Use an external hydraulic unit to send pressuri-

sed oil to move the pin of the inner telescopic cy-
linder rod do get out from the relevant mounting
seats.
• Disconnect all the hydraulic pipes.
• Use chains to sling the cylinder group and extract
it from inside the boom, holding it with lifting ca-
bles to prevent accidental dropping.
TH35R160
s
86
• Rest the cylinder group on appropriate stands,
disconnect steel pipes (1) present on it, and two
tilt hoses (2).
• In the same manner, disconnect the supplemen-
tary hydraulic function hoses from the opposite
side.
TH35R161 1
s
87
• Remove steel pipes (1) from the inner telescopic
cylinder group by removing securing screws (3) 3
and plastic block (4).
TH35R162
s
88
• Use lifting chains to sling and disconnect cylinder
(5) from inner steel pipes. (1).
WARNING
Lift and handle all heavy materials with a lifting device 5
near the load to be lifted. 1
TH35R163
89
604.13.542.01 - 03 - 2006
• Remove from the boom group all the front inner

sliding pads indicated in the figure that could pre-
vent or make difficult the extraction operation of
the arms.
WARNING
TH35R164
s
90
• Use lifting cables to sling fourth boom (1) and ex-
tract it from inside third boom (2).
WARNING
Make sure that all items are properly secured by ap- 2 1
TH35R165
91
s
• In the same manner, extract third boom (2) from

inside second boom (3).
2
TH35R166
s
92
604.13.542.01-- 03 - 2006
• Extract second boom (1) from inside first boom

(2). 2
1
TH35R167
s
93
• Then, disconnect the inner hoses from the inner
pipes.
• Mark the various pipes to facilitate the connec-
tion during the reassembly operation.
DANGER
struction Manual.
TH35R131
s
94
• Remove all the outer steel pipes from the first
boom marking their position to facilitate their po-
sitioning during the reassembly.
TH35R168
s
95
DESCRIPTION OF THE INSTALLATION OF
BOOM 17m
WARNING
Prior To reinstalling the boom group, clean thorou-

ghly all the parts.
• Install all the outer steel pipes on the first boom. TH35R169
96
604.13.542.01 - 03 - 2006
• Install the series of rear pads (1) on the second

boom using the securing screws after applying
LOCTITE 243 on the threaded part tightening
them to a torque of 40Nm.
the outer walls of second boom (2) and the inner
walls of first boom (3) precisely along all the sli-
ding sections of pads. 1
• Use appropriate cables to sling second boom (2)
and insert it into first boom (3).
TH35R138
s
97
WARNING 3
Lift and handle all heavy materials with a lifting device 2
TH35R170
s
98
• Keep the second boom slightly lifted to facilitate
the installation operation of the two lower pads
and two metal blocks (4) on the first boom using
the securing screws, applying LOCTITE 243 on
the threaded part. Tighten the screws to a torque
of 40Nm.
4
TH35R171
s
99
• Install all inner sliding pads (5) on the front side
of the first boom, following the same procedure
used fro the installation of the other pads.
5
WARNING
TH35R172
100
604.13.542.01-- 03 - 2006
2
the outer walls of third boom (2) and the inner
1
walls of second boom (1) precisely along all the
sliding sections of pads.
• Use cables to sling the third boom and insert it in-
to the second one.
TH35R173
101
WARNING
s

1
• Following the same procedure, insert fourth 3

boom (3) into third boom (1).
TH35R174
s
102
• Complete the installation of all the sliding pads in
accordance with the diagram indicated in the fi-
gure.
WARNING
TH35R175
s
103
604.13.542.01 - 03 - 2006
• Use lifting chains to sling and position cylinder (1)

on inner steel pipes (2).
2
TH35R176
s
104
• Install steel pipes (2) on the inner telescopic cy-
linder by inserting plastic block (3) and securing 4
screws (4).
TH35R177
s
105
• Connect the two tilt hoses (5) to steel pipes (2)
(cylinder left side).
• In the same manner, connect the two supple-
mentary function hoses on the opposite side (cyl-
inder right side).
TH35R178 2
s
106
• Using chains, sling the cylinder group and insert
it into the boom, holding it with lifting cables to
prevent accidental droppings .
• Connect an external hydraulic unit to the tele-
scopic cylinder.
TH35R179
107
604.13.542.01-- 03 - 2006
• Pressure must be applied to the telescopic cylin-

der to move the rod eye reaching the pivot point
on the fourth boom (1).
1
TH35R180
s
108
• Insert (2) and secure it using circlip (3).
TH35R181
s
109
• Insert tilt twin hose (4) from the inner steel pipe
left front side in the corresponding upper channel 4
as indicated in the figure.
WARNING
TH35R182
s
110
• In the same manner, insert supplementary hy-
draulic function twin hose (5), coming from the in-
ner steel pipe right side to the other unit.
TH35R183
111
604.13.542.01 - 03 - 2006
• Once the telescopic cylinder rod is secured on

the boom, it is necessary to invert the direction
of the oil flow to retract the cylinder rod inside the
boom.
WARNING
struction Manual
TH35R184
s
112
• Connect the two tilt cylinder hoses (1) as indica-
ted in the figure through the inner steel pipe and
the two supplementary hydraulic function hose
(2).
• Connect the two hoses to inner telescopic cylin-
der (3) using tools 380001586 and 380001587.
2
1
TH35R185
s
113
• Position the telescopic cylinder inside the boom
inserting pin (1) into the relevant seats. 4
5
• Secure pin (1) using plates (2) and screws (3).
Install screw (4) to the bottom securing point on
the third boom.
• Tighten all the screws to a torque of 300Nm.
7
TH35R186
s
114
604.13.542.01-- 03 - 2006
• Using lifting cables to sling outer telescopic cylin-

der (1) and position it on the boom fro the rein- 1
stallation.
WARNING
TH35R187
s
115
• From the front side, secure the cylinder using
plates (2) and screws (3). 5 3
Tighten the screws to a torque of 110 Nm.
• Insert pin (4) and secure it with central screw (5).
2
TH35R188
s
116
• Secure the outer telescopic cylinder through the
7
intermediate side on the relevant support instal-
ling plates (6) and screws (7). 6
Tighten the screws to a torque of 110 Nm.
TH35R189
s
117
• On the rear side of the outer telescopic cylinder,
connect the connecting pipe with control valve
(8) and inner telescopic cylinder feeling pipe (9). 9
TH35R190
118
604.13.542.01 - 03 - 2006
604.13.542.01-- 03 - 2006
WORKING PLATFORM
s
The use of the working platform requires the

hydraulic system to be equipped with an hydraulic
block with proportional solenoid valve.
TH135074
s
119
Such proportional valve, indicated in the illustration,
checks the pilot oil pressure for boom lifting/tele-
scoping, allowing this manoeuvre by radio control
from the working platform.
TH135075
s
120
The electrical components of the working platform
are illustrated in SECTION 55 – ELECTRIC SYS-
TEM, in this manual.
604.13.542.01 - 03 - 2006
62
604.13.542.01-- 03 - 2006
5 7
CODE CNH--MT: 76091086
5. SHUTTLE VALVE LG 6--S--2X (40 Nm)

6 6. PRESSURE REDUCTION PROPORTIONAL VALVES 4 K1X/30AG12C4V (12 Nm + 5 Nm)
7. VALVE BLOCK
PROPORTIONAL SOLENOID VALVES PILOTING BLOCK
TH135077
121
TELEHANDLER HYDRAULIC SYSTEM

WITH WORKING PLATFORM
TH135076
122
604.13.542.01 - 03 - 2006
604.13.542.01 - 03 - 2006
PROCEDURE FOR THE CALIBRATION OF

THE PERSONNEL CARRIER PLATFORM
ELECTRONIC CONTROLLER
Memorisation of the parameters of the

controller
s
1. Connect BB3 to the 12--way connector located in

the rear side of the machine.
The connector is located in the harness con-
nected to the Rexroth controller
TH135099
123
s
2. Starting conditions:
• Starter key in ON.
• Key on radio control in position “1”
• Press button START on the radio control
3. Select F1 (Config/Cal)
to enter the change menu
TH135100
s
124
604.13.542.01 - 03 - 2006
4. Select 1 (prop + Adj)
TH135101
125
5. Scroll the display using the buttons with
symbol
TH135102
s
126
6. Select 5 (Poti Adjust)
TH135103
s
127
7. Reading 2.2 V with the joystick in NEUTRAL
TH135104
128
604.13.542.01 - 03 - 2006
8. Reading 4.0 V with the joystick full stroke in

lowering
Press ENTER
TH135105
s
129
9. Reading 0.4 V with the joystick full stroke in lifting
Press ENTER
TH135106
s
130
10. Press button Menu until the previous display
reading returns.
Select 8 (Potiadjust)
TH135103
s
131
604.13.542.01 - 03 - 2006
11. Reading 2.2 V with the joystick in neutral
TH135107
s
132
12. Reading 4.0 V with the joystick full stroke (right-
ward) in extension
Press ENTER
13. Reading 0.4 V with the joystick full stroke (left-
ward) in retract
Press ENTER
TH135108
s
133
14. Press button Menu until the previous display
reading returns.
Select 2 (settings)
TH135101
s
134
15. Scroll the display using the buttons with
TH135102
135
604.13.542.01 - 03 - 2006
16. Select 3 (Poti Mid)
TH135103
s
136
Press ENTER
TH135109
s
137
18. Select 4 (Poti mid)

Press ENTER
TH135110
s
138
604.13.542.01 - 03 - 2006
20. Press button Menu until the home display

returns.
Press TEACH Storage to enter the memorisa-
tion menu.
TH135100
s
139
21. Select 1 (SAVE PARAMS)
22. Select ENTER to memorise the data in the con-

troller.
23. At the end of the procedure, turn the key into

position OFF.
604.13.542.01 - 03 - 2006
SPECIAL TOOLS
NUMBER SKETCH DESCRIPTION HOW TO USE/MODEL
Linkage for hoses inside the arm

380001586 ALL
(32 mm)
Linkage for hoses inside the arm

380001587 ALL
(36 mm)
604.13.542.01 - 03 - 2006
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 fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Controls and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Use of the tip--over prevention system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Bulb replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Protecting the electrical systems during charging or welding . . . . . . . . . . . . . . . . . . . . . . 26
Starting the machine using jump leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Temporary wiring repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Electrical system--general fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Working platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
55 000 ELECTRICAL EQUIPMENT SPECIFICATIONS
ELECTRICAL SYSTEM 82 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
604.13.542.01 - 03 - 2006
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
TH155116
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
1
facility.
TH155106
2
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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.
TH55R059
IMPORTANT: Do not replace a blown fuse with 5
another of a different rating.
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Fuses
NOME DESCRIPTION VALUE
F1 Fuse Cold starter kit-- -- boom sensor-- -- LH stabil. sensor SX 5A 1
F2 Fuse Conditioner 3A 10
F3 Fuse radio 3A 9
F4 Fuse optional 3A 10
F5 Fuse LH stabiliser lowering SX 7.5A 3
F6 Fuse rear axle sensor 7.5A 3
F7 Fuse upper wiper 10A 8
F8 Fuse heating 15A 9
F9 Fuse front work lights 15A 7
F10 Fuse work selector 10A 3
F11 Fuse micro stop 7.5A 6
F12 Fuse sfilo/rientro 15A 4
F13 Fuse optional 5A 10
F14 Fuse warning 10A 6
F15 Fuse rotary beacon 10A 7
F16 Fuse working mode--proportional ev. 10A 10
F17 Fuse low boom sensor 10A 3
F18 Fuse horn 15A 2
F19 Fuse rear wiper 10A 8
F20 Fuse engine cut--off 10A 10
F21 Fuse option IN/OUT 10A 4
F22 Fuse boom work lights 15A 7
F23 Fuse front wiper 10A 6
F24 Fuse tail lights--plate light 5A 6
F25 Fuse optional 7.5A 10
F26 Fuse ceiling light 5A 9
F27 Fuse compressor 10A 10
F28 Engine cut--off 10A 1
F29 Fuse basket ON 15A 8
F30 Fuse momentum instrument 5A 8
F31 Fuse attachments 5A 7
F32 Fuse instrument lights 3A 5
F33 Fuse gearshift safety + parking brake 10A 2
F34 Fuse back--up buzzer 5A 2
F35 Fuse rear work lights 15A 7
F36 Fuse tail lights--cigarette lighter--radio 5A 6
F37 Fuse high beams 15A 2
F38 Fuse low beams 15A 6
F39 Fuse cigarette lighter 20A 9
Relè
NAME DESCRIPTION VALUE
K1 Relay 100% MOTION CUT 8
K2 Relay stabilizer 3
K3 Relay stabilisers 3
K4 Relay option (OUT) 4
K5 Relay gearshift safety 2
K6 Relay back--up buzzer 2
K7 Relay extraction 2
K8 Relay low beam lights 6
K9 Relay low boom sensor 3
K10 Relay levelling 3
K11 Relay steering selector 10
K12 Relay parking brake 5
K13 Relay 2nd speed 2
K14 Relay reverse 4
K15 Relay retraction 2
K16 Relay high beam 6
K17 Controller 8
K18 Flasher 6
K19 Relay engine cut--off 1
K20 Relay horn 2
K21 Relay option “IN” 4
K22 Relay 1st speed 2
K23 Forward 2
K24 Relay 4st speed 2
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TH55R059
6
TH55R058
7
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CONTROLS AND INSTRUMENTS
CONTROL PANEL TABLE
POS. PIN FUNCTION SIGNAL

L3 J1 BRAKE OIL LEVEL INDICATOR LIGHT 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 REAR WHEEL ALIGNMENT INDICATOR LIGHT POSITIVE
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
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PANEL
TH55R060
8
PANEL INSIDE DIAGRAM
FUEL LEVEL ENGINE RPM COOLANT

COUNTER TEMPERATURE
GAUGE
HOUR METER
TH55R061
9
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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.
This operation assures segment and arm pipe syn-
NOTE: The layout of controls in the diagram may chronisation. Failure to synchronise may damage
vary between machines, depending upon options the pipes.
fitted to meet Legislation in different Countries.
1. Hydraulic control panel. 11. Front multi--function loader lever

-- telescopic arm extension/retraction
2. Instruments -- arm lifting and lowering
-- tool tilting and return
3. Steering geometry selector -- transmission disconnect button
Select all steering modes at least once a day to -- horn button
check correct operation. -- aux 1 function button
-- aux 2 function button
4. Safety key for control mode selection
-- jobsite 12. Glove compartment (upon request, radio
-- road compartment)
-- people--conveyance platform
13. Steering wheel
5. Vehicle hazard light switches IMPORTANT: Prior to driving the vehicle, always
turn the steering wheel from side to side at
6. Engine starter key engine start up, to circulate the hydraulic oil.
7. Switch panel for miscellaneous services 14. Accelerator foot pedal
8. Powershift selection lever, forward direction and 15. Brake pedal

horn
16. Tilting prevention lock force release button
9. Side light and direction indicator control lever
17. Steering wheel height adjusting lever
10. Vents
18. Load handling monitor indicator
19. Climate system control panel
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3
4
5
6
7
8 9
13
10 12 11
17
16
14
15
5 7
19
18
TH55R062
10
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ALIGNMENT OF THE WHEELS

IMPORTANT: Prior to selecting one of the three
possible steering modes, verify that the rear wheels
alignment indicator light is activated and align the
wheels perfectly. A
A -- TWO WHEEL STEERING -- Shift the distributor C B
control lever for steering selection to position ‘A’ for
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
C A B
wheels steering.
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
A
B
TH55R063
12
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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
TH55R064
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

TH55R065
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.
TH55R066
15
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INDICATOR/WARNING LIGHTS – 1st Segment TH55R067

1
1. Main beam headlight warning lamp 2
2. Direction indicator warning light
16
2nd
s
INDICATOR/WARNING LIGHTS – Segment TH55R068

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. Brake reservoir oil level low indicator lamp
This warning lamp illuminates when the oil level
in the reservoir is at a LOW LEVEL. If the lamp
illuminates at any time stop the machine
immediately and investigate the cause, correct
and or top up with new oil to the level specified. TH55R069
To test the warning light refer to the maintenance 18
section of the manual.
IMPORTANT: If the machine is left to run with the
ATTENTION warning light ‘on’, engine performance and fuel con-
Corrective action must be taken immediately when sumption will suffer.
this lamp illuminates. If not, failure of the brake sys-
tem could occur, resulting in serious injury to yourself
and others.
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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.
INDICATOR/WARNING LIGHTS – 4th Segment TH55R070
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 2
bystanders. 1 3 4
2. Transmission oil pressure warning light with

buzzer
19
Should the transmission oil pressure drop to a prede-
termined level the warning light will illuminate and the
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. Rear wheels alignment indicator light
The indicator light comes ON when the rear wheels

are aligned.
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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 C
situations, but regular. During normal operation, the
light signal status is continuously updated and indi-
cates the current situation. B
B – TWO YELLOW SIGNAL LIGHT

(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.
Keep on lifting in the direction of the load closest to TH001053 D
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
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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. TH155023
ATTENTION 23
Operate this button only if it is possible to adjust the
vehicle stability without retracting the telescopic arm.
TILTING DANGER!!
TH155082
24
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USE OF THE TIP--OVER PREVENTION SYSTEM
When the equipment is started, the tip--over prevention system is activated and performs automatically the test
operation. The indication of the load conditions is activated with the state ON of the input “activation of SAR”
(pin C of the 3--way connector). This input is associated with a switch, normally located on the control board of
the equipment designated as “Working/Travel” that provides the operator, in case of substantial travelling of the
equipment, the neutralisation of the SAR and switches to mode Travel (under this mode no movements of the
arm are allowed).
The longitudinal stability conditions of the equipment is indicated by the activation/cutting--off of the leds of the
load curve. The approaching of the maximum load threshold is also indicated by a buzzer, coming ON at 90 %
and by the activation of output “travel speed reduction” (pin 6 of the 8--way connector). When the equipment is
in a pre--tipping condition, i.e. the maximum load threshold (100%) indicated by the coming ON of the last red
led of the scale is exceeded, the buzzer sounds constantly and all the leds are flashing.
Calibration
The calibration procedure of the SAR is based upon the acquisition of the two points for the determination of the
two work curves.
Preliminary conditions
The device provides an unlimited number of calibrations. However, it is necessary that, prior to staring operating
the equipment, the SAR is calibrated, complying with the following prescriptions:
• all the calibration operations must be performed under safe conditions with the vehicle not braked,
in an horizontal position on a firm surface (ex. concrete platform), with the steering straight without stabilisers
and without adverse weather conditions (i.e. wind) a for an average time not exceeding 30 mi.
• the load cell must be secured to the axle at least 12 hours prior to the calibration and subsequently
tightened
• the equipment must stay activated with the cell connected for at least 15 minutes prior to the calibra-
tion.
Calibration procedure
1. Press the test key and start the engine;
2. Keep the test key pressed (for about 5 seconds) until the ”POWER” led statrts flashing;
3. The sar enters the calibration mode: the load scale green led comes on;
604.13.542.01 - 03 - 2006
4. The memorisation of the minimum value must be made with the machine idle (unloaded), telescopic boom
fully retracted and horizontal forks just off the ground;
5. After pressing the ”test” key, the same led relative to item 3 indicating the minimum value of the load scale
starts flashing (for 6 secs) indicating that the ”MINIMUM LOAD” condition is being memorised.
6. The completion of the memorisation of the minimum load is indicated by the green led, going off and by the
buzzer sounding for 2 seconds;
7. Once the memorisation of the minimum load is over, the red led relative to the maximum load value comes
on;
8. Using a load of about 2000 kg, arrange the machine in the maximum load condition (with the boom fully exten-
ded parallel to the ground and the rear wheels at the ground lifting limit);
9. Retract the boom about 600 mm (corresponding to a reduction of the load of about 15% before beginning
the momentum);
10. Press the test key to start the memorisation procedure: the red led flashes (for 8 secs) indicating that the
”MAXIMUM LOAD” condition memorisation is in progress;
11. The completion of the memorisation of the minimum load is indicated by the red led, going off;
12. At the end of the calibration, if the procedure has been correctly performed, the only led on is the green one
”POWER ON” and the buzzer sounds continuously until the TEST key is pressed again.
Error indications
In the event the controller monitors a malfunction of the sensor, relative to installation problems, wiring or it is
unable to provide guaranteed repeatability of the measurement, the buzzer sounds constantly and all the leds
of the display flash. The typology of the malfunction monitored can be read by pressing the “Test” button providing
a diagnosis of the system from the operator’s cab.
The table of codifies of the errors is following:
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Errors when switcing on
CODE
POWER The leds are numbered from the bottom upward
Rif. Probable cause LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7
Sensor not connected or no
101 1 1 0 0 1 0 0
current < absolute Min.
Sensor shorted or no current >
102 1 1 0 0 0 1 0
from absolute Max.
103 System not calibrated 1 0 1 0 1 0 1
Green Green Green Green Yellow Yellow Red
Normal operational errors
CODE
104 Sensor not connected 1 1 0 0 1 0 0
Sensor current out of absolute
105 1 1 0 0 0 1 0
limits
106 Sensor shorted 1 1 0 0 0 0 1
Errors of calibration
CODE
Acquisition Min. current < ab-
107 1 0 1 0 1 0 0
solute Min
Acquisition Max. current > ab-
108 1 0 1 0 0 0 1
solute Max
Min. current acquired<> Max.
109 1 1 0 1 0 1 0
current acquired
0 = Led off
1 = Led on
604.13.542.01 - 03 - 2006
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. TH155109
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.
TH155110
s
26
Windscreen washer
If you press button (1) located on the multi--function

1
lever external side, the windscreen washer is acti-
vated.
TH155111
27
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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.
TH121230
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.
TH155117
Reverse gear selection
29
To select reverse gear, pull the lever towards the

steering wheel and push it downwards.
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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. Additional lights (optional) fitted on the telescopic

arm. 1 2 3 4 5 6 7 8 9
2. Attachment electric control.
3. Optional rear wiper/washer. The function is
TH155112
activated by pressing the button.
30
4. Hydraulic function cut--off (optional)
5. Slow moving warning beacon – Depressing this
switch operates the function of the roof beacon.
6. Road lights – three--position switch
-- Off
-- Sidelights
-- Main/dipped beam headlights
Main and dipped beam headlight selection is
possible with the multifunction lever previously
described.
7. Hazard flasher switch – Selected when required
to warn of a hazard.
8. Front work light (2--way switch) – The front light
comes ON when actuated
9. Rear work light (2--way switch) – The rear light
comes ON when actuated
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SWITCHES (left panel)

IMPORTANT: The rocker switch position may vary
slightly or may not be all available from that shown.
They are dependant upon the model and options
fitted to your machines.
1. This switch provides two operational modes for

the stabilisation system.
a) Switch in neutral position. When the boom
exceeds 30 degrees, the lifting of both stabilisers
is inhibited. In this position, the operator must
refer to the load capacity diagrams of section 00
“with stabilisers and axle lock”.
b) Switch pressed. This provides the actuation of
the stabilisers and the levelling of the frame with
boom exceeding 30 degrees. In this position the 1 2 3 4
operator must refer to the load capacity dia- TH155113
grams at section 00 “without stabilisers and with- 31
out axle lock.
ATTENTION
With the arm lifted over 30° the lifting function of the
right and left axle levelling stabilisers is inhibited.
Under these conditions, it is impossible to lift one or
both stabilisers or make a levelling of the frame.
2. Left stabiliser (3--position rocker switch). When

the switch is in idle position (central) no function
is activated. When the button upper side is
pressed, the left stabiliser is lifted; when the but-
ton lower side is pressed, the stabiliser is low-
ered.
3. (3--position rocker switch). This switch controls
the axle front levelling cylinder and makes it
possible to change the vehicle tilting along the
longitudinal axis. When the button upper side is
pressed, the vehicle will tilt on the right--hand
side; when the button lower side is pressed, the
vehicle will tilt on the left--hand side.
4. Right stabiliser (3--position rocker switch). This
switch works as switch (2), but controls the right
stabiliser. When the button upper side is
pressed, the right stabiliser is lifted; when the
button lower side is pressed, the stabiliser is
lowered.
604.13.542.01 - 03 - 2006
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
32
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).
33
Loader mounted work lights

To gain access to the bulb, extract the securing
screws, gently remove the lens cover and remove
the bulb. Replacement of the bulb follows the
removal procedure in reverse.
TH55R071
34
604.13.542.01 - 03 - 2006
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.
TH155114
35
Rear work light
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.
TH55R072
36
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.
TH155077
37
604.13.542.01 - 03 - 2006
Reversing lamps
Where fitted the lamps can be removed after removal
of the lens cover; they are of the twist bayonet type.
TH155115
38
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
39
604.13.542.01 - 03 - 2006
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.
604.13.542.01 - 03 - 2006
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).
604.13.542.01 - 03 - 2006
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
40
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 40.
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
41
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 41.
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 42, 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
42
604.13.542.01 - 03 - 2006
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 43.
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
43
604.13.542.01 - 03 - 2006
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
604.13.542.01 - 03 - 2006
WORKING PLATFORM
The operation of the working platform utilizes the
function of some components of the electric system:
TH135074
44
-- cable reel on the first telescopic section of the
boom, for 4x1 cable;
TH155065
45
-- electronic controller for the control of PK valves
and proportional solenoid valves for telescopic
extension;
TH135075
46
-- central processing unit complete with platform
system (inside cab);
TH155067
47
604.13.542.01 - 03 - 2006
-- wiring harness:
3
1. radio control 2 4
1
2. connections to proportional solenoid valves
3. connector to solenoid valves electronic 6
controller
4. ground on machine frame
5. connection to cab wire
6. wires to be wound to cable reel.
5
TH155068
48
RADIO CONTROL
(self--homologated for frequency and EMS)
-- 12 V radio receiver on machine frame.
TH155069
49
-- radio transmitter on working platform
TH155070
50
Read the following paragraphs for main indications
concerning the description, installation and opera-
tion of the radio control.
604.13.542.01 - 03 - 2006
RADIO CONTROL
1. Description of the radio control
2. Instructions for radio control installation
3. Transmitter unit and its operation
4. Receiver unit
5. Procedure for setting the proportional outputs
6. Radio frequency
7. Troubleshooting
8. Technical data
1. DESCRIPTION OF THE RADIO CONTROL

A radio control is utilized to control machine operation from remote position. The radio control is composed of
a portable transmitter unit which allows the operator to control the machine at some distance and a receiver unit
installed on the machine itself.
The transmitter unit sends a coded message, by radio--frequency transmission. This message contains a value
denominated “address” that allows the receiver unit to decode exclusively the messages received from the pro-
per transmitter unit (the one having the same address).
This feature excludes interferences that might operate any control. In fact, if the radio--frequency transmission
is disturbed, incorrect or interrupted, the receiver unit will autonomously stop the whole system.
2. INSTRUCTIONS FOR RADIO CONTROL INSTALLATION
The installation must be exclusively carried out by qualified personnel, according to the regula-
tions of the country where the radio control will be installed. Only correct installations can guar-
antee the required safety degree during the successive utilization of the radio control.
Main indications
Connect the Radio Control to the machine in accordance with the operational characteristics of the machine
itself: the existing safety circuits of the radio control and/or the machine, cannot be excluded.
The simple configuration adaptability of the harness of the receiver unit allows the installation of this device
without need of interventions on the machine: do not modify the electric board of the machine without
Manufacturer’s authorization.
Exclude the power supply to the receiver unit by disconnecting all electric connectors when wel-
ding operations are carried out on the machine (welding damages electronic systems permanen-
tly).
604.13.542.01 - 03 - 2006
Installation
The receiver unit must be installed in a favourable position for receiving the signals issued by the tran-
smitter unit. Therefore, the receiver unit must be installed upright (antenna pointing up). The receiver unit must
also have easy access, allowing safe conditions of operation.
If the receiver unit is covered by metallic frames or installed inside metallic boxes, use the proper extension--kit
for external antenna.
The antenna must never be in contact with metal parts.
It is forbidden to drill the receiver unit case. Drilling jeopardises weatherproof protection degree (IP65).
Always install rubber cushions to reduce the effect of machine vibrations on the receiver unit.
It is suitable positioning the receiver unit far from heat sources (exhaust pipes, alternators, etc.).
Wiring
The connection to the receiver unit, on most machines, is provided by a multiple plug which, in case of need,
can be quickly disconnected when the radio control is to be replaced by a cable control. Even when the machine
is not provided with this arrangement, it is always recommended to use this type of connection.
The installation reliability depends on the wiring quality: therefore, it is recommended to prepare it according to
the best principles utilizing multicore cable or single wires with a section adequate to the currents involved and
with characteristics against flame propagation (refer to norm EN 60204--1 for more specific data).
In case of external connections to the receiver unit, it is recommended to utilize oil--proof wires.
The mains supply of the receiver unit must obligatorily have a switch to allow power supply shut
off during operations of installation, wiring and/or maintenance.
In order to get the best operation of the radio control, connect the receiver unit immediately down-
stream from the machine master switch.
It is always opportune to check the power supply value also under maximum load so as to verify the maximum
variations (the deviations allowed limit values can be found both in the Technical Data and in the technical card
of the Radio Control).
Voltage variations of power supply to the receiver unit beyond the limit values may jeopardise
the normal operation of the radio control.
The series C26--PRO radio controls are equipped with protection circuits against accidental movements of the
actuators from their rest position (SAFETY function).
This protection is effective if in the receiver unit the movement controls common supply is obtained from the
series circuit of the STOP contact and the SAFETY contact (that is closed when a movement control is transmit-
ted).
Conversely, the selection controls common supply may not be in series with the SAFETY contact.
604.13.542.01 - 03 - 2006
Setting of proportional outputs
The Manufacturer supplies the radio control with setting values of proportional outputs already
preset. During the installation, these values must be checked and possibly modified according
to the operational necessities of the machine (refer to paragraph 5 “Procedure for setting the pro-
portional outputs”).
Checking and testing
After completing installation and wiring, it is always necessary to:
-- check that, operating the STOP push button of the radio control, the following functions take place: putting
machine into safety condition (through direct operation of the general solenoid valve of the main circuit),
possible engine stop and, if existing, opening of the main electromagnetic switch so as to cut voltage
off;
-- confirm the exact correspondence of the machine manoeuvres with the controls of the transmitter unit (this
correspondence is indicated in the technical card);
-- check the operation of the safety circuit (a simple method is to remove the fuse F3, located on the main board
of the receiver unit, and to check that in these conditions no movement control can be effected; finally, reinstall
the fuse F3 and check the correct operation).
3. TRANSMITTER UNIT AND ITS OPERATION
Switch--on and start--up
Make sure the key--switch is in position “O”, install

the battery in its seat without forcing. Check that nei-
ther the stop push button nor the actuators are ope-
rated.
Turn the key--switch to position “I” and operate the

START push button until the green LED starts fla-
shing.
⇒ The switch--on occurs only if the battery

charge is sufficient and all actuators are
cut out. TH155071
51
Controls
The machine can perform the radio--controlled manoeuvres only after having completed the radio--electric link
between transmitter and receiver units (signalled by the pilot light ENABLE existing in the receiver unit (refer to
paragraph 4 “Receiver unit”)).
Operate the actuators corresponding to the manoeuvres the operator intends to control (all movement controls
comply with the requirements of category 3 according to the norm EN 954--1). Some of the available controls
on the transmitter unit are the following:
604.13.542.01 - 03 - 2006
Change of frequency
In case of interferences or conflict with other radio systems, it is possible to change the radio frequency in opera-
tion. With transmitter unit switched on and started up, it is necessary to keep START push button actuated for
5--6 seconds: a long beep joined by the lighting up of both signalling LEDs will indicate that the change of fre-
quency has occurred. During this operation the receiver unit will switch off: the operation can be resumed pres-
sing the START push button again as the usual start--up operation.
LED signalling
Some operating conditions of the transmitter unit are pointed out by two signalling LEDs (one green and one red).
Led
Signalling pattern
green red
Slow flashing Normal operation
Warning: Warning:
Quick flashing
battery almost exhausted battery exhausted
Control connected
Light on at start--up*
during start--up
Light of both LEDs Change of frequency
is on at the same time* accomplished
* joined by a sound signal
When the battery has delivered approximately 90% of its charge, the green LED increases the flashing speed
giving a pre--alarm that battery needs charging. If the operator continues to use the radio control, approximately
3 minutes before the battery will be fully exhausted, the red LED starts flashing and at the same time a sound
alarm is activated. When this situation occurs, the machine must be put immediately in safety condition, the tran-
smitter unit must be switched off and the battery must be charged (or replaced with other full--charged battery).
Automatic switch--off
The switch--off of the transmitter unit can occur automatically when:
-- the battery is not sufficiently charged and/or;

-- the radio control has not been operated during approximately 3.5 minutes (the automatic switch--off can be
disabled).
For all instructions, warnings and technical data regarding the batteries and battery--chargers, refer to
the supplied booklet.
604.13.542.01 - 03 - 2006
4. RECEIVER UNIT
A
N
G G
B
B
C
C
H
E
I
L
F M
G
G
D
TH155072
52
A antenna B POWER signal light

B POWER signal light C ENABLE signal light
C ENABLE signal light H RI97--08 module (refer to chapter 9)
D connecting plug I F1 fuse
E identification plate L F2 fuse
F technical data plate M F3 fuse
G cover screws N inner LEDs
External signalling
The POWER signal light indicates the presence (if on) or absence (if off) of power supply into the receiver unit.
The ENABLE signal light indicates the radio--link has occurred (if on) or is missing (if off) between transmitter
and receiver units.
Therefore, with receiver unit getting power supply, the correct operation is signalled by:
-- POWER and ENABLE constantly on, with transmitter unit started up;
-- POWER constantly on and ENABLE off, with transmitter unit not started up.
604.13.542.01 - 03 - 2006
Internal signalling
The existing LEDs indicate that a relay activation has occurred: when a LED is on it indicates that the relevant
relay is activated for the control that is illustrated by the following chart (available also on the inner part of the
receiver unit cover):
53
Functions
SAFETY In order to protect the system from accidental movements due to possible failures of the radio
control, the C26 PRO series is equipped with a safety function denominated SAFETY. This func-
tion constantly monitors the rest position (neutral) of the movement actuators in the transmitter
unit and is available as output on the SAFETY relay of the receiver unit.
FLOW Operating a movement control, the FLOW function will also be activated: this function controls
the solenoid valve that puts the oil under pressure in the primary hydraulic circuit of the control
valve.
T.S. The T.S. (TIME STOP) is the control that stops the diesel engine of the machine: it remains acti-
vated for 10 seconds after activation of STOP push button.
Fuses
The three fuses installed inside the receiver unit have the following characteristics:
Fuse Function Technical features

F1 POWER SUPPLY protection 4A (32Vdc, autofuse)
F2 STOP circuit protection 10A (32Vdc, autofuse)
F3 SAFETY circuit protection 10A (32Vdc, autofuse)
604.13.542.01 - 03 - 2006
5. PROCEDURE FOR SETTING THE PROPORTIONAL OUTPUTS (REMOTE SET UP)
The procedure for setting the proportional outputs must be performed only by qualified and
trained personnel.
Information on module RI97--08
The proportional outputs of module RI97--08 are set to the values indicated in the technical card. The number
of the technical card relating to the radio control can be found on the sticker of data memory (K2).
C1 connector for proportional outputs

connector for auxiliary proportional C3 C1 C2 S L P
C2
outputs
C3 connector for power supply
C4 connector for setting key
C5 connector for connection to the board
L green LED
K1 setting key
K2 data memory K2
P reset push button C4
C5 K1
S rotary dial
TH155073
54
Never leave the setting key K1 inserted during the operation of the radio control: it is required only
during the setting stage and, when it is inserted, it gives consent to just one proportional control
at a time.
To restore the initial proportional outputs values (i.e. the values indicated in the technical card), insert the setting
key and press the restore push button P until the green LED stops flashing and remains continuously on.
In case of module replacement, the same proportional outputs values can be kept shifting the K2 data memory
from the old module to the new module.
Preparation for setting
1. Make sure the transmitter unit is switched off.

2. Disconnect power supply from the receiver unit.
3. Open the receiver unit and insert the setting key K1 into the connector C4.
4. Connect power supply to the receiver unit. WARNING: From this moment, until the setting is completed, do
not touch the receiver unit (there is a risk of losing the entered settings).
5. Turn the key--switch of the transmitter unit to position “I” and press the START push button.
6. Turn the key--switch to position “ ” (REMOTE SET UP).
604.13.542.01 - 03 - 2006
Setting
7. Select the parameters to be set by means of the selector knob S installed on module RI97--08: determine
the setting by operating the selector RPM+/− installed on the transmitter unit (where sign + is for increasing
the value to be set and the sign − is for decreasing this value).
⇒ The modules with voltage outputs can be set in positions 1, 2, 3, 4 and 5. The modules with current
outputs (PWM) can be set in positions 0, 1, 3 and 4.
⇒ During the setting, when the joystick is moved out of rest position, a blow of 0.5 seconds of horn/
alarm indicates that we are in the area of setting the minimum.
⇒ The settings must be carried out for every single position of the speed selector installed on the
transmitter unit.
Settings of modules with voltage outputs
Position 1 Turn selector knob S to position 1 to adjust the maximum and minimum voltage (or cur-
rent) values of the two semiaxis of each joystick. Proceed as follows:
1. To set the maximum value, move the joystick to maximum stroke on the semiaxis to be set.
Holding the joystick in this position, operate the selector RPM+/− installed on the transmitter
unit and set the desired value.
2. To set the minimum value, move the joystick immediately out of rest position on the semiaxis
to be set. Holding the joystick in this position, operate the selector RPM+/− installed on the
transmitter unit and set the desired value.
Position 2 Turn selector knob S to position 2 to adjust the voltage value corresponding to the rest
position of the joystick. Normally, this value should not be modified. If necessary, proceed
as follows:
-- move any joystick immediately out of rest position;
-- holding the joystick in this position, operate the selector RPM+/− installed on the transmitter
Position 3 & 4 Turn selector knob S to positions 3 and 4 to adjust the minimum and maximum voltage of
the auxiliary outputs Z8 and Z9, respectively. Proceed as follows:
1. To set the maximum value, turn the knob (installed on the transmitter unit) relevant to control
Z8 (or Z9) completely clockwise. Holding the knob in this position, operate the selector
RPM+/− installed on the transmitter unit and set the desired value.
2. To set the minimum value, turn the knob (installed on the transmitter unit) relevant to control
Z8 (or Z9) completely anticlockwise. Holding the knob in this position, operate the selector
Position 5 Turn selector knob S to position 5 to reverse the direction of the semiaxis.
Proceed as follows:
-- move the joystick relative to the axis to be reversed immediately out of rest position;
unit putting it in position + to reverse the direction of the semiaxis or in position − to restore
the direction of the semiaxis.
604.13.542.01 - 03 - 2006
Settings of modules with voltage outputs
Position 0 Turn selector knob S to position 0 to adjust the frequency of the PWM signal (current).
Normally, this value should not be modified. If necessary, proceed as follows:
-- move any joystick immediately out of rest position;
Position 1 Turn selector knob S to position 1 to adjust the maximum and minimum voltage (or cur-
rent) values of the two semiaxis of each joystick. Proceed as follows:
1. To set the maximum value, move the joystick to maximum stroke on the semiaxis to be set.
Holding the joystick in this position, operate the selector RPM+/− installed on the transmitter
2. To set the minimum value, move the joystick immediately out of rest position on the semiaxis
to be set. Holding the joystick in this position, operate the selector RPM+/− installed on the
transmitter unit and set the desired value.
Position 3 & 4 Turn selector knob S to positions 3 and 4 to adjust the minimum and maximum voltage of
the auxiliary outputs Z8 and Z9, respectively. Proceed as follows:
1. To set the maximum value, turn the knob (installed on the transmitter unit) relevant to control
Z8 (or Z9) completely clockwise. Holding the knob in this position, operate the selector
2. To set the minimum value, turn the knob (installed on the transmitter unit) relevant to control
Z8 (or Z9) completely anticlockwise. Holding the knob in this position, operate the selector
Setting storage
8. Switch the transmitter unit off to store the settings.

9. Cut out the power supply to the receiver unit.
10. Pull out the setting key K1.
11. Close the receiver unit cover and turn power supply on.
604.13.542.01 - 03 - 2006
6. RADIO FREQUENCIES
The radio frequencies programmed for the radio control pertain to the system of frequencies admitted by the
European regulations in force at the moment of the market launch.
Check if there are possible restrictions in the country where the radio control will be operated.
A radio control can be programmed in AUTOMATIC SCANNING or MANUAL SELECTION mode.
Automatic scanning
Usually, a radio control is programmed by the Manufacturer in Automatic Scanning mode: consequently, it can
be operated in any available frequency. In case of interference or conflict with other systems, this mode allows
shifting the operating frequency (refer to “Change of operating frequency”) without need of internal adjustments
neither for the transmitter unit nor for the receiver unit.
Manual selection
To set this operational mode for operating radio frequency, call the assistance of authorized per-
sonnel only.
A radio control operating in Manual Selection mode allows to operate at a specific frequency. To set this fre-
quency, it is necessary to set the dip switches installed in the transmitter and receiver modules.
604.13.542.01 - 03 - 2006
7. TROUBLESHOOTING
In case the “radio control + machine” system does not start up, it is suitable to check if it is a radio control problem
or a machine problem. Therefore, before starting any check, connect the cable control: if the machine does not
start up, it is a machine problem.
If, on the contrary, the machine starts up normally when operated by cable control only, the problem is in the radio
control. In this case, carry out the following checks.
604.13.542.01 - 03 - 2006
8. TECHNICAL DATA
General
Operating frequency
Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433,050 ÷ 434,790 MHz

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 869,7 ÷ 870 MHz
United Kingdom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458,500 ÷ 458,800 MHz
Australia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472,0125 ÷ 472,1125 MHz
USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 ÷ 470 MHz
Operative radio channels (step 25 kHz)
Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 (at 433 MHz); 12 (at 870 MHz)
United Kingdom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Australia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 groups of 128
Channalizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 kHz (optional 12.5 kHz)
Hamming distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ≥ 8
Probability of missing error detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 10-- 11
Typical operating range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 m
Operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --20º C ÷ + 70º C
Passive emergency time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,5/1,5 sec
Response time of controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 ÷ 120 ms
Response time of STOP function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 ÷ 120 ms
Transmitter unit
Number of available controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 + 2 analogic + 12 on/off + start + stop

Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . internal
Modulation type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GFSK
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 10 mW (at 433 MHz)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 5 mW (at 870 MHz)
Power supply: battery pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NiMH 7,2V -- 1,3 Ah
Shut--off voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,0 V
Autonomy with charged battery (at 20°C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ÷ 10 ms
Pre--alarm time battery almost exhausted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approximately 15 min.
Pre--alarm time battery exhausted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approximately 3 min.
Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PA6 fg 20%
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IP65
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (173 x 160 x 236) mm
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ≤ 2 kg
604.13.542.01 - 03 - 2006
Receiver unit
Power supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ÷ 30 Vdc (< 40W)

Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . external, whip type
Current carrying capacity of STOP and SAFETY relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 A (30 Vdc)
Current carrying capacity of the relays for movement controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 A (30 Vdc)
Current carrying capacity of the relays for selection controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 A (30 Vdc)
Receiver sensibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,5 mV for 20 dB SINAD
Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PA6 fg 20%
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IP65
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (180 x 230 x 95) mm
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,8 kg
Drilling template . . . . . . . . . . . . . . . . . . . A = 148 mm
B = 116 mm
C = 253 mm
D = 253 mm
TH155074
55
Battery charger and Batteries
Technical data available in specific booklet.
604.13.542.01 - 03 - 2006
SPECIAL TOOLS
NUMBER SKETCH DESCRIPTION HOW TO USE/MODEL
380001303 BB3 Diagnostic instrument ALL
380001471 Cable with adapter for BB3 ALL
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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2 47
SECTION 55 -- ELECTRICAL CIRCUITS
Chapter 2 – Circuit diagrams
CONTENTS
List of connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
List of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
How to use the circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Diagram 1: Starter/Recharge/Warning/Indicators lights . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Diagram 2: Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Diagram 3: Wheel alignment/Hydraulic solenoids/Brake system . . . . . . . . . . . . . . . . . . . 57
Diagram 4: Arm control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Diagram 5: Stabiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Diagram 6: Lights/Windscreen wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Diagram 7: Work lamps/Roof beacon light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Diagram 8: Tilting prevention system/Roof wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Diagram 9: Heating/Sound system/Electric socket/Interior lamp . . . . . . . . . . . . . . . . . . . 69
Diagram 10: Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
604.13.542.01 - 03 - 2006
48 SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2
LIST OF CONNECTORS
CON. DESCRIPTION CON. DESCRIPTION

X1 3--way connector for LH stabiliser sensor X32 1--way connector for front RH work lamp
X10 2--way connector for reversing buzzer X33 1 way connector left front work light
X100 4--way connector for inside air sensor X313 Connector 2--ways, opt. sol. valve out
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 6--way connector for instrument panel--air conditioner X43 9--way connector conditioner arrang. line
line
X68 1--way connector for rear RH work lamp
X131 Connector 4--ways, inside heating
X48 8--way connector for Telehandler
X132.1 Connector 4--ways, inside heating
X5 2--way connector for fuel level
X132.2 Connector 4--ways, inside heating
X53 2--way connector for cigar lighter
X132.3 1--way connector for heater
X55 8--way brown connector for sound system
X132.4 1--way connector for heater
X56 8--way black connector for sound system
X137 17--way connector for work selection control unit
X6 15--way connector for instrument panel--rear line
X138 2--way connector for filter thermistor
X60 20--way connector for instrument
X139 2--way connector for filter pre--heating
X62 12--way connector for gear switch
X14 3--way connector for retracted arm sensor
X63 12--way connector for light switch
X16 Engine--dashboard 6--way connector
X65 4--way connector for micro--stop
X17 6--way connector for front LH headlight
X67 4--way connector for front wiper
X18 6--way connector for front RH headlight
X69 3--way connector tip--over prevention
X1A2 2--way connector for A2 steering solenoid valve
X7 18--way connector for instrument panel--front line
X1B2 2--way connector for B2 steering solenoid valve
X70 10--way connector for thermo--starting control unit
X301 2--way connector for LH stabiliser lowering
X8 3--way connector for rear axle sensor
X302 2--way connector for LH stabiliser raising
X9 2--way connector for loading cell
X303 2--way connector for RH stabiliser lowering
X91 2--way connector for air conditioner pressure gauge
X304 2--way connector for RH stabiliser raising
X92a 2--way connector for electric fan
X305 2--way connector for LH levelling solenoid valve
X92b 2--way connector for electric fan
X306 2--way connector for RH levelling solenoid valve
X94 8--way connector for air conditioner control unit
X309 2--way connector for optional solenoid valve
X95 9--way connector for air conditioner control unit
X21 12--way connector rear line--dashboard
X99 3--vay connector thermostat
X2 3--way connector for RH stabiliser sensor
XA1.2 2--way connector for alternator
X310 3--way connector tachometer sensor
XA1.1 1--way connector for alternator
X311 2--way connector for servo--control solenoid valve
XC1 18--way connector for control unit
X213 2--way connector for reversing solenoid valve
XC2 21--way connectors for bridges
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
X218 2--way connector attachment solenoid valve
X25 21--way connector for instrument panel--engine line
X27 9--way connector for dashboard--cabin line
X15 6--way connector deutsch RH rear light
X308 2--way connector axle unlocking solenoid valve
X13 6--way connector deutsch LH rear light
X313 2--way connector axle unlocking solenoid valve
Xi3 3--way connector thermostats
X29 2--way connector for thermo--starting relay
X314 2--way connector anti momentum solenoid valve
X30 6--way way connector pre--heating arrangement
X207 1--way connection bucket
X4 2--way connector for micro--stop
X48 12--way connector Rexroth dt. joystick
X31 17--way connector for instrument panel--cabin line
604.13.542.01 - 03 - 2006
LIST OF COMPONENTS
COMP. DESCRIPTION DIAG. COMP. DESCRIPTION DIAG.
B Rexroth handler button 4 M5 Rear washer motor 8
BS1 RH loudspeaker 9 M7 Fan 9
BS2 LH loudspeaker 9 M8 Air Conditioning fan 10
EVA2 A2 steering solenoid valve 3 M9 Compressor 10
EVB2 B2 steering solenoid valve 3 S131 Heating switch 9
FG1.1 Main fuse 80A 1 S15 Rear axle unlocking switch 4
FG1.2 Main fuse 80° 1 R3 Filter pre--heating 1
FG2 Air conditioner fuse 30A 1 R2 Thermo--starting 1
FG3 Filter pre--heating fuse 20A 1 K300 Climate relay 10
FV1 Converter fuse 40A 10 K301 Thermostat relay 10
G Rexroth handler button 4 S1 Parking brake micro 5
G1 Battery 1 S11 LH stabiliser switch 5
G2 Alternator 1 S12 Levelling switch 5
H Rexroth handler button 4 S13 RH stabiliser switch 5
H1 Front LH headlight 6 S14 Attachment switch 7
H11 Rear RH work lamp 7 S15a Starting panel 1
H12 Beacon light 7 S2 Beacon light switch 7
H13 Cigar lighter lamp 9 S3 Warning switch 6
H14 Roof lamp 9 S30 Battery disconnection with key 1
H15 Lights 9 S31 Fuel level 1
H2 Front RH headlight 6 S61 Steering selection switch 3
H3 LH taillight 6 S33 Rear axle sensor 3
H4 RH taillight 6 S35 LH stabiliser sensor 5
H19 Light, licence plate 6 S36 RH stabiliser sensor 5
H6 Arm work lamp 7 S15 Road/site selection switch 4
H7 Arm work lamp 7 S38 Low arm sensor 3
H8 Front RH work lamp 7 S39 Retracted arm sensor 3
H9 Front LH work lamp 7 S4 Light switch 6
HA1 Reversing buzzer 2 S311 Speed sensor 5
HX Climate lighting 10 S64 Brake oil level 6
I1 Transmission oil pressure gauge 1 S5 Front work lamp switch 7
I10 Air conditioner pressure gauge 10 S50 Climate switch 10
I13 Thermostat 10 S51 4 gear switch + hobbs horn 2
I2 Transmission oil 1 S52 Light--direction indicator--wiper 6
high temperature thermostat switch
I3a Spark plug thermistor 1 S6 Rear work lamp switch 7
I3b Engine water temperature transduc- 1 S7 Arm work lamp switch 7
er S8 Upper/front wiper switch 8
I4 Pressure gauge for engine oil low 1 S9 Rear wiper switch 8
pressure S310 Tachometer sensor 5
I7 Filter thermistor 1 SCX Climate switch 10
I8 Parking brake pressure gauge 5 HA4 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 S65 Stop light micro 6
KA Starting relay 1 S103 Key manoeuvres resetting 8
KB Air conditioner relay 10 Y1 RH stabiliser lowering solenoid 5
KC Filter pre--heating relay 1 valve
KD Unswitched circuit relay 1 Y10 Optional solenoid valve (out) 4
KT Thermo--starting relay 1 Y11 Servo--control solenoid valve 5
M1 Starter 1 Y13 Reverse solenoid valve 2
M11 Recycling 10 Y14 Forward gear solenoid valve 2
M12 Tap 10 Y15 Gearshift solenoid valve 2
M13 Cooling fan 10 Y16 1st gear solenoid valve 2
M14 Electric fan 10 Y17 2nd gear solenoid valve 2
M2 Front wiper motor 6 Y18 Engine stop solenoid valve 1
M4 Windscreen washer pump 8 Y19 Attachment solenoid valve 7
Y2 LH stabiliser lifting solenoid valve 5
604.13.542.01 - 03 - 2006
COMP. DESCRIPTION DIAG. HOW TO USE THE CIRCUIT DIAGRAMS

Y3 RH stabiliser lowering solenoid 5
valve The circuit diagrams have been drawn in a linear
Y4 RH stabiliser lifting solenoid valve 5 format, meaning that the complete vehicle system is
Y5 LH levelling solenoid valve 5 drawn over a number of pages, with references to
Y6 RH levelling solenoid valve 5 link the pages, where applicable. The flow of power
Y28a B axle unlocking solenoid valve 3 is generally speaking, from top, positive, to bottom,
Y28b A axle unlocking solenoid valve 3 negative.
Y9 Optional solenoid valve (in) 4
Y12 Tilting prevention solenoid valve 8 Here are a number of explanations to the layout and
Y8 Proportional solenoid valve 4 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
WIRE COLOUR KEYS 2. Line reference
3. Component identification reference
4. Connector x70, connector code, 3, references (pin)
A Azure 5. Wire colour code
6. Fuse code. G1, fuse number, 10A, capacity
B White 7. Line continues on another diagram. In this instance:
diagram 3 at line reference 1.
C Orange 8. Alphabetical wire colour key
G Yellow 9. Diode
10. Component pin code
H Grey
L Blue
M Brown 2. Each component and connector appears only
once in a set of circuit diagrams.
N Black
R Red
S Pink 3. The circuit diagrams are broken up into sections.
However, where single component is used in a
V Green number of circuits, such as a processor or multi--
Z Purple function switch, it is drawn either on its own or in
the circuit which it influences the most.
NOTE: wires with two colours have compound acro-
nyms, e.g.:
G/V -- Yellow/green (cross colouring)
G--V -- Yellow--Green (longitudinal colouring)
604.13.542.01 - 03 - 2006
DIAGRAM 1 – STARTING/RECHARGE/WARNING LAMPS/INDICATORS
0 1 P
2
0 0 h
M
G
p p t t
3
U
t t
TH55R047
1
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DIAGRAM 1 – STARTING/RECHARGE/WARNING /INDICATORS LIGHTS
COMPONENTS
DESCRIPTION
AND FUSES
F1 Cold starting –boom sensor-- stabiliser sensor fuse kit
F28 Engine stop fuse 10A
FG1.1 Main fuse 80A
FG1.2 Main fuse 80A
FG2 Air conditioner fuse 30A
FG3 Filter pre--heating fuse 20A
G1 Battery
G2 Alternator
I1 Transmission oil pressure gauge
I2 Transmission oil high temperature thermostat
I3a Spark plug thermistor
I3b Engine water temperature transducer
I4 Pressure gauge for engine oil low pressure
I7 Filter thermistor
K19 Engine cut--off 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
S15a Starting panel
S30 Keyed battery cut--off
S31 Fuel level
Y18 Engine stop solenoid valve
604.13.542.01 - 03 - 2006
DIAGRAM 1 – STARTER / RECHARGE / WARNING / INDICATORS LIGHTS
p t t
TH55R048
2
604.13.542.01 - 03 - 2006
DIAGRAM 2 – TRANSMISSION
COMPONENTS
DESCRIPTION
AND FUSES
F18 Fuse horn 15A
F33 Fuse gearshift safety + parking brake 10Amp
F34 Reverse buzzer fuse 5A
F37 Main beam headlight fuse 15A
HA1 Reverse buzzer
HA4 Horn
K5 Gearshift safety relay
K6 Backup alarm relay
K7 Transmission cut--off relay
K13 2nd speed relay
K15 Retraction relay
K20 Horn relay
K22 1st speed relay
K23 Forward speed relay
K24 4th speed relay
S51 4 gear switch + Hobbs horn
Y13 Reverse solenoid valve
Y14 Forward gear solenoid valve
Y15 Gearshift solenoid valve
Y16 1st gear solenoid valve
Y17 2nd gear solenoid valve
604.13.542.01 - 03 - 2006
DIAGRAM 2 -- TRANSMISSION
1 2 3 F
4
H
N
TH55R049
3
604.13.542.01 - 03 - 2006
DIAGRAM 3 – WHEEL ALIGNMENT/HYDRAULIC SOLENOIDS/BRAKE SYSTEM
COMPONENTS
DESCRIPTION
AND FUSES
EVA2 A2 steering solenoid valve
EVB2 B2 steering solenoid valve
F5 Fuse LH stabiliser descent SX 7.5°
F6 Fuse rear axle sensor 7.5A
F10 Fuse work selector 10A
F17 Fuse low boom sensor 10A
K2 Relay stabilisers safety
K3 Relay stabilisers
K9 Relay low boom sensor
K10 Relè livellamento
S33 Rear axle sensor
S38 Low arm sensor
S39 Retracted arm sensor
S61 Steering selection switch
604.13.542.01 - 03 - 2006
DIAGRAM 3 – WHEEL ALIGNMENT/HYDRAULIC SOLENOIDS/BRAKE SYSTEM
0
1 2
TH55R050
4
604.13.542.01 - 03 - 2006
DIAGRAM 4 – ARM CONTROL
COMPONENTS
DESCRIPTION
AND FUSES
B Rexroth handler button
F12 Fuse extension/retraction 15A
F21 Fuse option IN/OUT 10A
G Rexroth handler button
H Rexroth handler button
K4 Optional relay (OUT)
K14 Relay reverse
K21 Relay option “IN”
S15 Rear axle unlocking switch
S16 Switch site/road selector
Y8 Proportional solenoid valve
Y9 Optional solenoid valve (in)
Y10 Optional solenoid valve (out)
604.13.542.01 - 03 - 2006
DIAGRAM 4 – ARM CONTROL
1 0
TH55R051
5
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DIAGRAM 5 -- STABILISER
COMPONENTS
DESCRIPTION
AND FUSES
F32 Fuse instrument light 3A
I8 Parking brake pressure gauge
K12 Relay parking brake
S1 Parking brake micro
S11 LH stabiliser switch
S12 Levelling switch
S13 RH stabiliser switch
S35 LH stabiliser sensor
S36 RH stabiliser sensor
S310 Sensor tachometer
S311 Speed 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 Solenoid valve RH levelling
Y6 Solenoid valve LH levelling
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DIAGRAM 5 -- STABILISER
1 0 2 1 0 2 1 0 2 1 0
TH55R052
6
604.13.542.01 - 03 - 2006
DIAGRAM 6 – LIGHTS/WINDSCREEN WIPER
COMPONENTS
DESCRIPTION
AND FUSES
F11 Fuse micro stop 5A
F14 Fuse warning 10A
F23 Fuse front wiper 10A
F24 Fuse tail lights + licence plate light 5A
F36 Fuse head lights – cigarette lighter -- Radio 5A
F38 Main beam headlight fuse 15A
H1 Front LH headlight
H2 Front RH headlight
H3 Rear LH headlight
H4 Rear RH headlight
H19 Light, licence plate
K8 High beam relay
K16 Low beam relay
K18 Flasher
M2 Front wiper motor
S3 Warning switch
S4 Light switch
S52 Light -- direction indicator -- wiper switch
S64 Brake oil level
S65 Stop lights micro
604.13.542.01 - 03 - 2006
DIAGRAM 6 -- LIGHTS/WINDSCREEN WIPER
1 0 0 1 2
0 1 L
0
R
TH55R053
7
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DIAGRAM 7 – WORK LAMPS/ROOF BEACON LIGHT
COMPONENTS
DESCRIPTION
AND FUSES
F9 Front work lamp fuse 15A
F15 Beacon light fuse 10A
F22 Arm work lamp fuse 15A
F31 Fuse attachments 7.5A
F35 Rear work lamp fuse 15A
H6 Arm work lamp
H7 Arm work lamp
H8 Front RH work lamp
H9 Front 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
S14 Attachment switch
Y19 Attachment solenoid valve
604.13.542.01 - 03 - 2006
DIAGRAM 7 – WORK LAMPS/ROOF BEACON LIGHT
1 0 1 0 1 0 1 0 1 0
TH55R054
8
604.13.542.01 - 03 - 2006
DIAGRAM 8 – TILTING PREVENTION SYSTEM/ROOF WIPER
COMPONENTS
DESCRIPTION
AND FUSES
F19 Rear wiper fuse 10A
F29 Fuse basket activated 15A
F30 Fuse momentum instrument 5A
K1 Relay 100% motion cut
K17 Controller
M4 Windscreen washer pump
M5 Rear wiper motor
S8 Roof/front wiper switch
S9 Rear wiper switch
S103 Key manoeuvres resetting
Y12 Momentum solenoid valve
604.13.542.01 - 03 - 2006
DIAGRAM 8 – TILTING PREVENTION SYSTEM/ROOF WIPER
I I
I 0 I 0
M M
TH55R055
9
604.13.542.01 - 03 - 2006
DIAGRAM 9 – HEATING/SOUND SYSTEM/ELECTRIC SOCKET/ROOF LAMP
COMPONENTS
DESCRIPTION
AND FUSES
BS1 RH loudspeaker
BS2 LH loudspeaker
F3 Fuse Radio 3A
F8 Seat fuse 15A
F26 Fuse ceiling light 5A
F39 Cigar lighter fuse 20A
H13 Cigar lighter illumination
H14 Roof lamp
H15 Lighting
M7 Fan
S131 Heating switch
X53 Cigarette lighter
X54 Fridge socket
604.13.542.01 - 03 - 2006
DIAGRAM 9 – HEATING/SOUND SYSTEM/ELECTRIC SOCKET/INTERIOR LAMP
1 2
0 3
TH55R056
10
604.13.542.01 - 03 - 2006
DIAGRAM 10 – AIR CONDITIONER
COMPONENTS
DESCRIPTION
AND FUSES
F2 Fuse conditioner 3A
F4 Fuse optional 3A
F13 Fuse optional 5A
F16 Fuse working -- mode – proportional solenoid valve 10A
F20 Fuse engine cut--off 10A
F25 Fuse optional 7.5A
F27 Fuse conditioner compressor 10A
FG3 Fuse filter pre--heating 20A
FV1 Converter fuse 40A
HX Climate lighting
I10 Air conditioner pressure gauge
I13 Thermostat
K11 Relay steering selector
K103 Electric fan 1st speed relay
K105 Electric fan 2nd speed relay
K107 Electric fan 3rd speed relay
K300 Relay climate
K301 Relay thermostat
KB Conditioner relay
M8 Solenoid valve
M9 Compressor
M11 Recirculation
M12 Cock
M13 Cooling fan
M14 Solenoid valve
S50 Climate switch
SCX Climate switch
604.13.542.01 - 03 - 2006
DIAGRAM 10 – AIR CONDITIONER
1 2
0 3
M M M
p
TH55R057
11
604.13.542.01 - 03 - 2006
604.13.542.01 - 03 - 2006
SECTION 55 -- ELECTRIC CIRCUITS
Chapter 3 -- Wiring list
CONTENTS
Instrument panel wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Cab wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Front wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Rear wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Engine wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
604.13.542.01 - 03 - 2006
604.13.542.01 - 03 - 2006
INSTRUMENT PANEL WIRING (1)
TH55R073
604.13.542.01 - 03 - 2006
TH55R074
604.13.542.01 - 03 - 2006
TH55R075
604.13.542.01 - 03 - 2006
TH55R076
604.13.542.01 - 03 - 2006
CAB WIRING
TH55R077
604.13.542.01 - 03 - 2006
FRONT WIRING
TH55R078
604.13.542.01 - 03 - 2006
REAR WIRING
TH55R079
604.13.542.01 - 03 - 2006
ENGINE WIRING
TH55R080
604.13.542.01 - 03 - 2006

NEW HOLLAND LM1340-LM1745 TELEHANDLER SERVICE MANUAL

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NEW HOLLAND LM1340-LM1745 TELEHANDLER SERVICE MANUAL

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NEW HOLLAND

Print N. 604.13.542.01 (III -- 2006)

THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.

Model LM1340 LM1343 LM1345 LM1443 LM1445 LM1745

GENERAL LIST OF CONTENTS

Coding of engines of origin .................................................................... 3

SECTION 21 -- POWERSHIFT GEARBOX

Powershift Gearbox 4x4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION 25 -- FRONT AXLE

604.13.542.01 - 03-- 2006

SECTION 27 -- REAR AXLE

SECTION 35 -- HYDRAULIC SYSTEM

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 1 – Electrical system general

Chapter 2 – Circuit diagrams

Chapter 3 -- Wiring list

604.13.542.01 - 03-- 2006

SEALS FOR ROTATING SHAFTS

NOTES ON SPARE PARTS

HOW TO MOVE A VEHICLE WITHOUT BATTERIES

PAY ATTENTION TO THIS SYMBOL

AVOID ACCIDENTS ator co--operating in the operation to be per-

SAFETY RULES ◊ Brakes are inactive when manually released for

STARTING HYDRAULIC SYSTEM

VEHICLE SERIAL NUMBER

UNIT SERIAL No.

FRONT AXLE IDENTIFICATION

4x3 POWER SHIFT TRANSMISSION

• 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 243/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

Model LM1340 LM1343 LM1345 LM1443 LM1445 LM1745

* Value measured with tyres 405/70x24

LM1340 TURBO - LM1343 TURBO - LM1345 TURBO

LM1340 TURBO - LM1343 TURBO - LM1345 TURBO

LM1343 TURBO (with stabilisers lowered)

LM1345 TURBO (with stabilisers lowered)

* Value measured with tyres 405/70x24

LM1443 TURBO - LM1445 TURBO

LM1443 TURBO (with stabilisers lowered)

LM1445 TURBO (with stabilisers lowered)

* Value measured with tyres 405/70x24

LM1745 TURBO (with stabilisers lowered)

ENGINE DATA 82 kW (110 CV)