Case TX130--30 Instruction manual

WORKSHOP MANUAL
PRINT No. 9--93210
TX130--30/TX130--30 turbo
TX130--33/TX130--33 turbo

AVOID ACCIDENTS
Mostaccidents andinjuriesoccurringinindustry,onthefarm,athomeorontheroad,arecaused bythe failure of
some individual to follow simple and fundamental safety rules or precautions. For this reason, MOST
ACCIDENTSCANBEPREVENTEDbyrecognizingtherealcauseandtakingthenecessaryprecautions,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.
ATTENTION
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, ad-
justing 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 suitablysupported bymeans otherthan the hydraulic lift cylinders, cable and/ormech-
anical 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 TX130--30/TX130--30 Turbo
TX130--33/TX130--33 Turbo
no stab. Small stab.
Engine Aspirated 60 kW -- 71 kW Turbo charged
Max. lifting height (m) 12,750 13.060
Max. capacity (kg) a 500 mm from fork stop 3,300 3,300
Capacity at max. height (kg) 2,500 3,300
Extension at max. height (m) 1.800 1.800
Max. longitudinal extension (m) 8.750
Capacity at max. extension (kg) 650 1,350
Weight (kg) 9,600
Length (m) 5,950

Workshop Manual
TX130--30/TX130--30 Turbo
TX130--33/TX130--33 Turbo
TELEHANDLERS
9-93210 -- 12 -- 2004
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
Main specifications of engines 2.................................................................
Troubleshooting 5.............................................................................
Generalities engine F4GE0404B*D600 21........................................................
Generalities engine F4GE0454C*D600 23........................................................
Description of main mechanical components of the engine 25.......................................
Lubrication 37................................................................................
Cooling 42...................................................................................
Mechanical injection supply system 44...........................................................
Mechanical fuel pump 45.......................................................................
Injection assembly 46..........................................................................
Removal of engine transmission group from the vehicle 56..........................................
Engine overhaul on bench 59...................................................................
Repair interventions on the cylinder group 71.....................................................
Timing 73....................................................................................
Bushes 74...................................................................................
Crankshaft 77................................................................................
Conrod--piston assembly 81....................................................................
Valves 103...................................................................................
Valve guides 104..............................................................................
Valve seats 104...............................................................................
Valve springs 106.............................................................................
Assembly of cylinder head 106..................................................................
Replacing the injectors 113.....................................................................
Adjustment of valve clearance 115..............................................................
Removal/reinstallation of rocker arms 115........................................................
Setting of timing 116...........................................................................

4GENERAL LIST OF CONTENTS
9-93210 -- 12 -- 2004
Timing of the injection pump 117................................................................
Electrical components 118......................................................................
Tooling 119...................................................................................
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.................................................................
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..............................................................................
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............................................................................
SECTION 27 -- REAR AXLE
Description Page
Specifications 1...............................................................................
Description 2.................................................................................

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GENERAL LIST OF CONTENTS 5
9-93210 -- 12 -- 2004
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 10.......................................................................
Hydraulic pump 10............................................................................
Delivery side divider valve 10...................................................................
Pressure reduction valve 12....................................................................
Front loader controls 14........................................................................
Balancing valves 16...........................................................................
Power steering (OSPQ) 18.....................................................................
Telescopic boom distributor 19..................................................................
Auxiliary control distributor 22...................................................................
Cylinders 24..................................................................................
Booms 34....................................................................................
SECTION 55 -- ELECTRICAL SYSTEM
Description Page
Chapter 1 – Electrical system general
Electrical equipment specifications 1............................................................
Electrical system and fuses 2..................................................................
Controls and instruments 6....................................................................
Procedure for the calibration of the load momentum system 17.....................................

6GENERAL LIST OF CONTENTS
9-93210 -- 12 -- 2004
Bulb replacement 22..........................................................................
Protecting the electrical systems during charging or welding 25.....................................
Starting the machine using jump leads 26.......................................................
Temporary wiring repairs 27...................................................................
Electrical system--general fault finding 29........................................................
Chapter 2 – Circuit diagrams
List of connectors 32.........................................................................
List of components 33........................................................................
How to use the circuit diagrams 34.............................................................
Diagram 1: Starting/Recharge/Warning/Indicators lights 36........................................
Diagram 2: Transmission 38...................................................................
Diagram 3: Wheel alignment/Hydraulic solenoids/Brake system 40..................................
Diagram 4: Boom control 42...................................................................
Diagram 5: Stabiliser 44.......................................................................
Diagram 6: Lights/Front wiper 46...............................................................
Diagram 7: Work lamps/Roof beacon light 48....................................................
Diagram 8: Load momentum device / Upper wiper 50.............................................
Diagram 9: Heating / Radio / Power socket / Ceiling light 52.......................................
Diagram 10: Conditioner 54....................................................................
Chapter 3 -- Wiring list
Instrument panel wiring 58....................................................................
Cab wiring 62................................................................................
Front wiring 63...............................................................................
Rear wiring 64...............................................................................
Engine wiring 65.............................................................................
SECTION 60 -- AIR CONDITIONING UNIT
Description Page
AIR CONDITIONING UNIT 2...................................................................
Operating instructions 2........................................................................
Cab climate 4.................................................................................
Cab climate controls 4.........................................................................
Air conditioning system 5.......................................................................
Service precautions 6..........................................................................
Tool connections 9............................................................................
Discharging 10................................................................................
Refrigerant charging 10........................................................................
Leak inspection 11.............................................................................
Special tools 14...............................................................................
Troubleshooting 15............................................................................

SECTION 00 -- GENERAL 1
9-93210 -- 12 -- 2004
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;
-- smearthesealinglipwithafilmoflubricant(oiltobepreferredtogrease)andfillwithgreasethegapbetween
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.
“O--RING” TOROIDAL SEALS
LubricateO--ringsbeforeinsertingthemintherelevantseatstoprevent thembecomingtwistedandrolledduring
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.

2SECTION 00 -- GENERAL
9-93210 -- 12 -- 2004
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
Thewearlimitsprovidedforsomeitemsmustbeconsideredasrecommendedvalues,butnotabsolutelybinding.
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
Thecablesoftheexternalpower supplymust beconnectedexclusivelytotherespectiveterminalsof thepositive
and negative cables of the vehicle, using efficient clamps providing adequate and safe contact. In the event it
isnecessarytochecktheoperationofthe electricalsystem 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.

SECTION 00 -- GENERAL 3
9-93210 -- 12 -- 2004
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
Most accidents, whether they occur in workshop, on
the farm, at home or on the road, are caused by the
failure of some individuals to follow simple and fun-
damental safety rules and precautions. For this rea-
son MOST ACCIDENTS CAN BE PREVENTED by
recognising the real cause and doing something
about it before the accident occurs.
Regardless of the care used in the design and con-
struction of any type of equipment, there are many
conditions that cannot be completely safeguarded
against without hindering reasonable accessibility
and efficient operation.
A careful operator is the best insurance against an
accident.
The complete observance of one simple rule would
prevent many serious accidents.
DANGER. Neverattempttoclean,lubricateormain-
tain a machine while it is in motion.
SAFETY RULES
SAFETY RULES
◊Read and heed all safety rules before any inter-
vention.
◊Do not wear rings, wristwatches, jewellery, and
loose or hanging apparels, such as ties, torn
clothing, scarves, unbuttoned or unzipped
jackets that can catch on moving parts. Wear
proper safety equipment as recommended for
the job. Examples: hard hat, heavy gloves, ear
protection, safety glasses or goggles, reflector
vests, respirator. Consult your employer forspe-
cific safety equipment requirements.
◊Do not perform any service operation on the
machine with a person seated in the operator’s
compartment, unless he is an authorised oper-
ator co--operating in the operation to be per-
formed.
◊Neverattempt tooperatethemachineor itstools
from any position other than seated in the oper-
ator’s seat.
◊Never perform any intervention on the machine
with engine running unless this is prescribed.
◊Cut--off the engine and make sure that all pres-
sures in the hydraulic systems are released
before removing caps, covers, valves etc.
◊All service interventions must be performed with
the utmost care and attention.
◊Shop and/or field service platforms or ladders
must be constructed and maintained in accord-
ance with local and national regulations.
◊Disconnect the batteries and tag all controls to
signal that an intervention is in progress. Block
the machine and all equipment that must be
lifted.
◊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-
mable.
◊Brakes are inactive when manually released for
service interventions. Under such circum-
stances it is necessary to maintain the control of
the machine using appropriate blocks or similar
devices.
◊The fuel--filling nozzle must be kept constantly
inside the filling neck. Keep this contact from the
beginning to the end of the fuelling operation to
avoid the possibility that sparks due to static
electricity are generated.

4SECTION 00 -- GENERAL
9-93210 -- 12 -- 2004
◊Use only designated towing or attaching points.
Usecareinmakingattachments.Makesurepins
and/orlocksaresecurebeforepulling.Stayclear
of drawbars, cables or chains under load.
◊To move a disabled machine, use a trailer or a
low--boy, if available.
◊To load/unload a machine from transporter,
choose a level surface ensuring firm support to
thewheelsoftruckor trailer.Anchor themachine
securely to the bed of truck or trailer and block
wheels or tracks with appropriate wedges.
◊Use only approved grounded auxiliary power
sources for heaters, chargers, pumps and simi-
lar equipment to reduce the hazards of electrical
shocks.
◊Lift and handle heavy parts with a lifting device
of proper capacity.
◊Beware of bystanders.
◊Never pour gasoline or diesel fuel into open,
wide and low containers.
◊Never use gasoline, solvent or other flammable
fluid to clean parts. Use exclusively qualified,
non--flammable, non--toxic commercial sol-
vents.
◊When using compressed air for cleaning parts,
use safety glasses with side shields or goggles.
◊Limit pressure to 2.1 bar, in accordance with
local and national regulations.
◊Do not run the engine in closed areas without
proper ventilation to remove deadly exhaust
fumes.
◊Donotsmokeorpermitanyopenflamesorspark
near when re--fuelling or handling flammable
materials.
◊Do not use an open flame as a light source to
look for leaks or for inspection anywhere on the
machine.
◊Movewith extremecarewhenworkingunderthe
machine, its attachments and or on or near
them. Always wear protective safety equipment
as required, such as hard hat, goggles, safety
shoes, ear plugs.
◊Whenperformingoperationsrequiringrunningof
the engine, have aqualified operator in the oper-
ator’s seat at all times with the mechanic on
sight. Place the transmission in neutral and set
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
groundassoonaspossiblewitha certainmargin
of safety.
◊Do not trust worn and /or kinked chains and
cables: donotuse them for lifting or pullingoper-
ations. To handle them, always use heavy
gloves.
◊Be sure chains and cables are anchored and the
anchor points are strong enough to handle the
expected load. Keep exposed personnel clear of
anchor points and cables or chains. No
bystanders are allowed near the hooking points,
chains or cables.
◊Keep the area where maintenance operations
are performed CLEAN and DRY. Eliminate
immediately all water and oil spillages.
◊Do not pile up oily or greasy rags; they represent
a fire hazard. Store in a closed metal container.
Before starting machine, check, adjust and lock
the operator’s seat for maximum comfort and
control of the machine. Be sure exposed
personnelintheareaofoperationareclear ofthe
machine before moving it or its attachments.
Sound the horn.
◊Do not carry loose objects in pockets that might
fall unnoticed into open compartments.
◊Wear proper protective equipment such as
safety goggles or safety glasses with side
shields, hard hat, safety shoes, heavy gloves
when metal or other particles are apt to fly orfall.
◊Wear welders protective equipment such as
dark safety glasses, helmets, protective cloth-
ing, gloves and safety shoes, when welding or
burning. Wear dark safety glasses near welding
zones. DO NOT LOOK AT ARC WITHOUT
PROPER EYE PROTECTION.
◊Steel cables are frayed after prolonged use;
always wear appropriate protections (heavy
gloves, goggles etc.).
◊Handle all parts carefully. Keep hands and
fingers away from structures, gears or moving
parts. Use and wear always the appropriate
protections, such as safety goggles, gloves and
safety shoes.
STARTING
◊Do not run the engine in closed areas without
proper ventilation to remove deadly exhaust fu-
mes.
◊Do not place head, body, limbs, feet, hands or
fingers, near rotating fans or belts. Be especially
alert near pusher fans.

SECTION 00 -- GENERAL 5
9-93210 -- 12 -- 2004
ENGINE
◊Loosen the radiator cap very slowly, to release
pressurefromthesystem, beforeremovingit.All
coolant level top--ups must be performed with
engine inoperative or at low idle, if warm
◊Do not run engine when refuelling and use care
if the engine is hot due to the increased possibil-
ity of a fire if fuel is spilled.
◊Never attempt to check or adjust fan belts when
engine is running. Do not adjust engine fuel
pump when machine is moving.
◊Never lubricate the machine with engine run-
ning.
◊IMPORTANT: In accordance with directives no.
2000/25/EC of the European Union and no. 40
CFR Part. 89 of the U.S.A. it is prohibited to make
any type of alteration on the engine, including un-
loading uncertified software. Any alteration made
on an engine or fuel supply system found not com-
plying with current specifications involves:
legally,that the engine is illegal in that market
and is not protected by insurance, the warranty
on the engine and supply system becomes void;
in accordance with what declared by the certifi-
cates, the customer can be confronted by elev-
ated costs for the reconditioning of the engine;
technically, possible overloads on the engine
components; possibleprematurewearof theen-
gine due to excessive load on the components
or the use of contaminated oil. Only personnel
authorised by the Manufacturer can perform re-
pairs on the fuel supply system. Repairs can be
performedonlyusingthespecificationsprovided
by the Manufacturer.
ELECTRICAL SYSTEM
◊Should booster batteries be used, remember to
connect both ends of the booster cables in the
propermanner (+) with(+)and(--)with(--).Avoid
short--circuitsoftheterminals. Followthoroughly
the instructions of this Manual.
Avoid short circuiting the terminals. BATTERY
GAS IS HIGHLY FLAMMABLE. Leave battery
boxopentoimproveventilationwhenrecharging
batteries. Never check charge by placing metal
objects across the posts. Keep sparks or open
flames away from batteries. Do not smoke near
batterytoguardagainstthepossibilityofcausing
an explosion.
◊Before any intervention, make sure that there
are no fuel or electrolyte leakages; eliminate
them before proceeding with further work.
◊When recharging batteries in closed ambient,
make sure that there is appropriate ventilation to
prevent possible accidental explosions due to
the accumulation of gases generated during the
recharge.
◊Beforeanyintervention,makesurethatthemain
switch is OFF.
HYDRAULIC SYSTEM
◊Fluid escaping under pressure from a very small
hole can be almost invisible and can have suffi-
cient force to penetrate the skin. Use a piece of
cardboardorwoodtosearchfor suspectedpres-
sure leaks. DO NOT USE HANDS. If injured by
escaping fluid, see a doctor at once. Serious
infection or reaction can develop if proper medi-
cal treatment is not administered immediately.
◊In case pressures must be measured, use
instruments of adequate capacity. Always follow
the recommended procedures.
WHEELS AND TYRES
◊Make sure that the inflation pressure of the tyres
is according to the specifications issued by the
Manufacturer and check it periodically.
◊Should the pressure be changed, stand on the
side of the tyre at a safe distance.
◊Pressure check operations must be performed
with unloaded machine and cold tyres. Never
use reconditioned tyre rims, since eventual
weldings, heat--treatments or repairs not per-
formed correctly can weaken the wheel, thus
causing subsequent damages or dangers.
◊Do not perform torch cutting or welding oper-
ations on rims with inflated tyres installed.
◊Before operating on tyres, block all wheels, front
and rear. After jacking the machine, block it with
stands according to current safety rules and
regulations.
◊Before removing objects from the tyre tread,
deflate it.
◊Never inflate tyres with flammable gas;
explosions and serious bodily injuries may
result.
REMOVALS AND INSTALLATIONS
◊Lift and handleallheavypartswithliftingdevices
of adequate capacity. Make sue that the parts
are attached to lifting devices are properly
slinged. Use the lifting eyes provided. Beware of
persons in the vicinity.
◊Handle all parts carefully. Keep hands and
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.

6SECTION 00 -- GENERAL
9-93210 -- 12 -- 2004
PRODUCT IDENTIFICATION
The Telehandlerandits main components areidenti-
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 ma-
chine.
VEHICLE SERIAL NUMBER
The serial number is stamped on the front part of the
machine, on the upper side of the main frame, right
side.
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
ashelpinidentifyingthemachineintheeventoftheft.
Keep them in a safe place.
TH001111 1
VEHICLE IDENTIFICATION PLATES
The vehicle identification plate is located on the left
side of the seat location. Record here below the data
for your machine.
TECHNICAL TYPE/MODEL
SERIAL NO. OF VEHICLE
YEAR
TH001061 2
IDENTIFICATION OF ENGINE
F4GE0404B*D600
The identification data of the engine are located on
the right side of the engine crankcase. Record the
information below for quick reference in case of ne-
cessity.
MODEL No.
SERIAL No.
DATE CODE TH00R005 3

SECTION 00 -- GENERAL 7
9-93210 -- 12 -- 2004
IDENTIFICATION OF ENGINE
F4GE0454C*D600
The identification data of the engine are located on
the right side of the engine crankcase. Record the
information below for quick reference in case of ne-
cessity.
MODEL No.
SERIAL No.
DATE CODE
TH00R010 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
4x3 POWER SHIFT TRANSMISSION
IDENTIFICATION
Theserialnumberandtypeisprintedontheplate(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
TH001030
1
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

8SECTION 00 -- GENERAL
9-93210 -- 12 -- 2004
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
necessity.
SERIAL No.
DATE CODE
TH00R016 6

SECTION 00 -- GENERAL 9
9-93210 -- 12 -- 2004
ENVIRONMENTAL CONSIDERATIONS
The following recommendations can be useful:
•Become familiar and make sure you have well
understood the relevant legislation in effect in
your country.
•In the event no regulations exist, ask for specific
information with the suppliers of lubricants, anti-
freeze and detergents regarding their effects on
humans and the environment and how to store,
handle and dispose of these substances safely.
Useful indications
1. Do not fill tanks with inadequate canisters or dis-
pensing pressurised systems that could cause
considerable spillage.
2. In general, avoid the contact of the skin with any
fuel, oil, acid, solvent etc. The majority of them
contain substance dangerous for your health.
3. Modernlubricants containadditives. Donotburn
contaminated fuels and/or wed oils in normal
heating burners.
4. Avoid spillage when draining used coolant mix-
tures, engine oils, transmission and hydraulic
fluids, brake fluid. After draining, do not mix
brake fluidorfuelwith lubricants. Store them ina
riskfreemanneruntilwhen theycanbedisposed
of in an adequate way, in accordance with local
regulations and the resources available.
5. Moderncoolingmixtures,suchasantifreezeand
other additives, must be changed every two
years. Maximum attention must be paid to pre-
ventthattheyspillovertheground.Theymustbe
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
engine cooling system or hydraulic system.
8. Do not increase the pressure of any pressurised
system,sincethiscouldcauseseriousproblems
to the components of the system.
9. Protect hoses when performing any welding,
since a splash of welding materials could pen-
etrate and burn them, causing a hole orweaken-
ing the wall with subsequent leakages of oil,
coolant etc.

10 SECTION 00 -- GENERAL
9-93210 -- 12 -- 2004
MAINTENANCE TECHNIQUES
GENERAL NOTICES
Clean the outside of all the components prior to per-
forminganytypeof repair. Dirtandabrasivedustcan
reduce the efficient life expectancy of a component
and result in expensive repairs.
The time spent in preparing and cleaning working
surfaces is giving results, making work easier and
safer, and the components overhauled will be more
reliable and operate better.
Use cleaning fluids proven to be safe. Some types of
fluidcancauseseriousproblemstoO--Ringsandirri-
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.
ReplaceO--Rings,sealingringsandsealseverytime
they are moved. Never useoldO--Rings or sealsand
new ones together, independently from their condi-
tions. Always lubricate new O--Rings and seals with
hydraulic oil before installing them.
When replacing components, always use the tooling
required by this type of work.
HOSES AND STEEL PIPES
Alwaysreplacehosesandsteel pipeswhenthetaper
end or connections are damaged.
When a new hose is installed, connect it without
tightening the ends and make sure that it is routed in
the correct manner, before tightening the ends. Fix-
tures must be tightened just enough to hold the hose
without squeezing it, avoiding rubbing as well.
After replacing a hose of moving components, make
sure that the hose is not disturbed by the movement
of the component in any position.
Make sure that all hoses installed are not choked or
bent.
If hoseconnectionsaredamaged,dented, chokedor
leaking, decrease the flow of oil and the productivity
of the relevant actuators. Connections showing
signs of displacement from their original pre--
pressed position must be considered as already
broken, since they are going to fail or separate soon.
A hose with a ragged outer sleeve allows water to
penetrate. Thus, hidden corrosion of the reinforcing
wire will develop along the entire length of the hose,
with the subsequent failure of the hose itself.
If a hoseswells,thisindicatesthat thereis aninternal
leakage due to a structural failure. This condition
deteriorates very quickly and causes the failure of
the hose.
Clogged, squeezed, excessively tensioned or
deformed hoses are generally easily subject to flow
reduction, decrement of the operationalspeed ofthe
fluid and the final failure of the hose.
Loose hoses move freely and must be prevented
from touching each other and nearby surfaces. This
causes a rubbing action shortening the useful life of
the hose.
CONNECTIONS WITH FRONT SEALING
O--RINGS
When repairing connections with front sealing
O--Rings, please comply with the following pro-
cedures.
WARNING: NEVER DISCONNECT, NOR
TIGHTEN A HOSE OR A STEEL PIPE UNDER
PRESSURE. IF IN DOUBT, MOVE THE CONTROL
LEVERS SEVERAL TIMES WITH THE ENGINE
INOPERATIVE BEFORE DISCONNECTING A
HOSE OR A STEEL PIPE.
1. Loosen the connections and separate the hose
or steel pipe, then remove and eliminate the
O--Rings from the connection.
2. Dip a new O--Ring in clean, hydraulic oil before
installing it. Install the new O--Ring in the con-
nection and, if necessary, hold it in its position
with vaseline.
3. Install a new hose or steel pipe and tighten man-
ually the connection holding, at the same time,
the pipe still to prevent it from turning.
4. Use two wrenches to tighten the connection to
the torque prescribed for its size. Please refer to
the table to follow for the tightening torques.
NOTE: to ensure that a joint does not leak, it is
important that the connections are neither
excessively tightened nor too little.

SECTION 00 -- GENERAL 11
9-93210 -- 12 -- 2004
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 587DOW CORNING SILASTIC
732 GENERAL ELECTRIC RTV 103 or 108
Pipe sealant PST 592 (pipe sealant with teflon)
Locking compound for
threads LOCTITE 271/RED (sealant/locking for threads)
TIGHTENING VALUES FOR FASTENERS
Check periodically that the fasteners are properly
tightened.
Based upon the tables to follow, determine the cor-
rect tightening torque when parts of the fastening
components are checked, adjusted or replaced.
IMPORTANT: DO NOT use the values listed in the
tables when the Manual indicates a different torque
ortighteningprocedureforaspecificapplication.The
torque values are provided for general use only.
Makesure thatthethreads of thefastenersareclean
and undamaged.
NOTE: Useatorquewrenchtotightenfastenerscor-
rectly.

12 SECTION 00 -- GENERAL
9-93210 -- 12 -- 2004
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
M102836 4356617930
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
HEX NUTS AND TIGHTENING NUTS
CLASS 05 AND HIGHER
IDENTIFICATION OF THE MANUFACTURER
MINIMUM TIGHTENING 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
NOMINAL
DIMENSION NOT PLATED PLATED
Zn/Cr NOT
PLATED NOT
PLATED
PLATED
Zn/Cr PLATED
Zn/Cr
LOCK NUT
CL. 8
with BOLT
CL. 8.8
COMMERCIAL CLASS
MARKINGCOMMERCIAL CLASS

SECTION 00 -- GENERAL 13
9-93210 -- 12 -- 2004
IDENTIFICATION
SCREWS (WITHOUT NUT) AND ROUND HEADED SCREWS
LOCK NUTS
1 289 373 742 960 1048 1356 523 739 1
7/8 193 248 495 641 698 904 350 494 7/8
3/4 198 256 306 397 432 560 217 306 3/4
5/8 112 145 174 224 244 316 122 172 5/8
9/16 81 104 125 163 176 229 88 125 9/16
1/2 57 73 87 113 123 159 61 88 1/2
7/16 37 47 57 73 80 104 41 57 7/16
3/823303546506526353/8
5/16 13 17 20 26 28 37 14 20 5/16
1/4 6,2 8,1 9,7 13 14 18 6,9 9,8 1/4
MINIMUM TIGHTENING 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
NOMINAL
DIMEN.
NOMINAL
DIMEN.
NOT
PLATED
OR
SILVER
PLATED
NOT
PLATED
OR
SILVER
PLATED
NOT
PLATED
OR
SILVER
PLATED
NOT
PLATED
OR
SILVER
PLATED
PLATED
Zn/Cr
GOLD
PLATED
Zn/Cr
GOLD
PLATED
Zn/Cr
GOLD
PLATED
Zn/Cr
GOLD
GRADE SAE 2 GRADE SAE 5 GRADE SAE 8
NORMAL NUTS HEX NUTS
GRADE SAE 5 HEX NUTS GRADE SAE 8
GRADE A. NO MARKS
GRADE B: LETTER B
GRADE C: LETTER C
GRADE IDENTIFICATION
GRADE A: NO CUTS
GRADE B: ONE PERIMETER CUT
GRADE C: TWO PERIMETER CUTS
GRADE IDENTIFICATION
GRADE A: NEW MARK
GRADE B: THREE MARKS
GRADE C. SIX MARKS
GRADE IDENTIFICATION
THE MARKS ARE NOT
COMPULSORILY LOCATED IN THE
CORNERS