— - — a I FIATALLIS FR160.2 WHEEL LOADER S/N 582101-UP SERVICE MANUAL 60402207 V/1996FR160.2 WHEEL LOADER Service Manual Print N° 604.02.207 English ‘AX Tins avert sro. SIGNALS MPORTANT MESSAGES IWOLVNG 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 word WARNING - Cautions directed to avold improper repair interventions involving potential consequences for the operator's safety. DANGER-These warnings quality 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, forthe ‘damages that may result Neither the Factory nor any Organizations in its Distribution Network, including bu not limited to national, regional or local distributors, are responsible for any lablty arising rom any damage resulting from detects caused by parts and! ‘oF components not approved by the Factory for use in mainaining andlor repainng produels manutactured of ‘merchandized by the Factory, |nany case,no warranty of anykindis made or shall imposed with espectto products manufactured or merchandlzed 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. ——— Ad worninc a ‘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 ing, adjusting and/or repairing. Ifitis 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.SUMMARY SPECIFICATIONS AND MAIN DATA FR160.2 vsnnnnmnnnnnennnnsne PAG. AC SAFETY RULES. o pag. | UNITS OF MEASURE USED IN THE MANUAL .u.ossnnnennnnnn B&Q. VEN LUBRICANTS. svn pag. XI ENGINE .... .Section 1 TRANSMISSION Section 2 AXLES .. . Section 3 BRAKES... .Section 4 STEERING SYSTEM .Section 5 EQUIPMENT HYDRAULIC SYSTEM .Section 6 BUCKET AND FRAME... .Section 7 ELECTRICAL SYSTEM.. . Section 8 CAB ... Section 9FRI60.2 TECHNICAL SPECIFICATIONS FR160.2 MAIN DIMENSIONS. ‘Study SAFETY RULES in the front ofthis manual horcughty forthe protection of machine and safety of personnelIDENTIFICATION - 2611.200.00.3 MARKING - R 160.2 ENGINE Brand and model Iveco-Fiat 8365.25.584 7308 te, 4 sok, irjcon, tubocharped Number of eylinders Bore and stroke isis em Total displacement... 8102 cucm Compression ratio... 15.821 Net power at flywhee! “191 GV 140 KW Max. torque speed. 1400 pm Max. power speed 2150 rpm Injector setting... ~ 200 + 208 bar \Valvelrocker arm clearance: intake / exhaust 03/08 Firing order 15-36-24 ENGINE SPEEDS Low idle 870 » 920 rpm MAX. ile nn 12360 + 2420 rpm Converter stall. 2210 + 2350 rpm Equipment stat. 2230 + 2370 rpm Full stall. 1680 + 1880 rpm. Minkrum starting temperature: standard version 1 18°C with cold starting version ... + 25°C Seiting of engine coolant high temperature ‘sender .. 107£3°C Seiting of engine oil low pressure switch and hourmeter drive 0.4 +0.2 bar Setting of engine oil resistor for pressure gauge .. 0+ 8 bar Engine lubrication: Normal lubrication pressure with engine max. power ‘output and stabilized temperature nn... 4+ 8 bar Stabilized engine oil temperature with engine max. power output: 95 + 105°C (203 = 220°F) + ambient temperature, ‘TORQUE CONVERTER Type single stage, single phase type Conversion ratio at stall 28721 Converter main pressure .. 25 +5.0 bar Converter safety valve pressure 8 bar FRI60.2 ‘SMISSION Down-shift device for down-shifting of speeds and use of engine brake with machine travelling down- bil Forward speed Reverse speed | Km/h r a 6.96 e = 12.46 = = 24.55, F = = With tyres . 23.5x 25 AA safety device prevents the starting of the engine with a speed engaged. ‘Transmission pump delivery. . 97 Ltrhmin (25.6 USGal/min) at 2150 r.p.m. Main pressure. 16+ 18 bar Transmission oll temperature 70 +90°C (158 « 194°) Pressure reduction valve 10 bar Transmission ol fites (qty 2) one paper and one metal. Setting distance between induction sensors on transmission and gear teeth 5+.8mm ‘Setting of transmission oil low pressure switch... 14.5 £05 bar Setting of transmission oil high temperature sensor 119 +3°C (248£3°F) Transmission oil low pressure time ....5 +7 $20.8 AXLES Front axl, rigid supportin type Reduction ratio. Rar axle, ful-foating supporting type Reduction ratio. ‘Axles complete with oll bath disc brakes. ‘Super Max-Trac selt-locking differentials, Planetary reduction gears in wheel hubs. 4:21.70 121.700 Tyres: Type 1» tubeless Radials 23.5 x 25 XHA Inflation pressure ncn nnnn nnn (bar) Operation “front: 8.00.....r@ar: 2.00 Travel front: 2.00.....r6ar: 2.00 Whee! tightening torque .. 60 dam BRAKES Brakes pump delivery . Operation pressure... Accumulators recharge starting 8.17 Lirimin (3.0 USGal) 65 bar pressure 115 +121 bar ‘Accumulators recharge ending pressure .. 150 + 160 bar ‘Accumulators precharge pressure.....60 bar (2 Ltr) ‘Accumulators precharge pressure. (0.7 Lt) ‘Study SAFETY RULES in the font ofthis manual thoroughly for he protection of machine and afety of personnelFR160.2 c Soting of brakes oillow pressure sensor... 954Sbar FLUID CAPACITIES Setting of stop lights pressure switch.......1805bar Engine: Transmission Cut-off prossUte woxronnn 181 Bar Lubrication oil sesaee 17 KQ, Setting of parking brake engaged Coolant nnn ro Lt sensor 60+5bar Fuel... 286 Lirs Setting of transmission cutoff pressure switch 15+1bar Transmission: Torque converter cil 20 Ltrs ‘STEERING SYSTEM Hydraulic system 112 Ltrs Pump delivery (at 100 rpm- 7 bar) 170 cuomturn Axles: Max. operating pressure 185 bar Front 1.99 Ltrs (10.8 USGal) cylinders — 2 Rear vsnne90 Ltrs (7-8 USGal) Bore x rod diameter x stroke. 80x 45 x 440 Emergency pump: Gear type, driven by transmission cAB Setting of priority valve 185 bar Modular type cab, elastically suspended by elastic Setting of emergency steering pump low pressure switch 0.8 +1.2bar Setting of steering main pump low pressure switch . 0.8+1.2bar Emergency steering timer T25+7 secs EQUIPMENT HYDRAULIC SYSTEM Type: Sealed with anticavitation and safety valve Pump vane, double body = delivery at 2150 engine r.p.m, 250 Ltrimin (66 USGatimin) = max. operating pressure 200 bar Control valve ' 3 spools Control “piloted, single lever Hydraulic cylinders, double-strok: = boom .. so 2 + bore x rod diameter x StrOk@..... 140 X 70 x 901 = Bucket CONtPO! nn od bore x rod diameter x stroke... 140 x 70 x 655, Egipment operation times: = raise... 6.3 sec. + lowering, 2.8 sec. = dumping 1.8 sec. Setting of ol fiter clogging sensor equipment 2+22bar Setting of oll high temperature sensor equipment 973°C ELEC" SYSTEM Operation voltage 24 Batteries, in series . oe a seen aintenance-free Starter motor with automatic engagement pinion.. 75KW ‘Altemator with voltage regulator... 5A pads, integrated with safety structure, WEIGHT ‘The weight of he machine with 23.5 x25tires and2.8 cum (3 cuyd), filled and with operator... 15730 Kg OPTIONALS Electronic Load Travel Stabilizer (LTS). The controls switch ON can have two positions. Position 0: OFF Position 1: LTS engaged for speeds over 5 km/hour (3.1 mph). Position 2: (to be used only for maintenance or repair operations) - LTS permanently ON with speeds lower than § km/hour. Study SAFETY RULES in the front of his manual heroughy forthe protection of machine and safely of personneSAFETY RULES GENERALITIES ‘Study this Manual before stating, operating, maintaining, fueling or servicing the machine. ead and heed all safety rules before any intervention. Do not allow unauthorised personnel to operate service or maintain this machine, Do not wear rings, wrist watches, jowellry, loose or hang- ing apparels, such as ties, tor clothing, scarves, unbut- toned 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, safely lasses or goggles, reflector vests, respirator. Con- sult your employer for specific safety equipment require: ments, Keep operator's compartment, stopping points, grab-ails land handles clear of foreign objects, ol grease, mud or ‘snow accumulation to minimize the danger of slipping or stumbling, Clean mud or grease from shoes before at tempting to mount or operate the machine. onotjump.on roffthe machine. Keep two hands and one foot, ortwo feet andone handin contact with step grab alls and handles at al times, Do not use controls or hoses as hand holds when climbing ‘on or of machine, Hoses and controls are movable and do ‘not provide a solid support Controls also may be inadvert- cently moved causing accidental machine or equipment movement. Never attempt to operate the machine orits tools from any position other than seated in the operator's seat. Keep head, body, imbs, hands and feet inside operator's ‘compartment at all times to reduce exposure to hazards ‘outside the operator's compartment, Be careful of sippery conditions on stepping points, hand fails, and on the ground. Wear safety boots or shoes that have a high slip resistant sole material Do not leave the machine untl itis completely stopped Check the seat safety belt atleast twice ayear. there are signs of wear or fraying or other signs of weakness that could lead to failure, replace it STARTING NEVER START OR OPERATE AN UNSAFE MACHINE. Belore operating a machine, always ensure that any un- sale condition hae boon eatistactorly remedied Check brakes, steering and attachment controls botore moving. Advise the proper maintenance authority of any malfunctioning part or system, Be sure all protective guards or panels arein place, and al safety devices provided are in place andin good operating conditions Be sure exposed personnel in the area of operation are clear of the machine before moving itor is attachments, WALK COMPLETELY AROUND the machine before ‘mounting. Sound horn, Obey flag man, safety signals and signs. Before starting machine, check, adjust and lock the opera- to's seat for maximum comfort and control ofthe machine. Fasten your seat belt (when provided) Obey al lag signals and signs. Due to the presence on the machine of flammable fluids, ever chack or fil fuel reservoirs or batteries near open flames, smoking materials or sparks. REMEMBER THAT STARTING FLUID IS FLAMMABLE, Follow recommendations printed on containers and inthe Operation and Maintenance Manual DO NOT PUNCTURE OR BURN CONTAINERS, Containers must be stored in fresh, well ventilated places, ‘ut of reach of unauthorised persons. Follow strictly the. instructions provided by the Manutacturer. Never use these preducts near open flames, smoking materials or sparks. OPERATING Check the fasteners of wheels and rims before starting a working shit. if necessary, retighten to the prescribed torque, Do not run the engine of this machine in closed areas ‘without proper ventilation to remove deadly exhaust gases, Roll Over Protective Structures are required on loaders, dozers, graders, excavators. NEVER OPERATE ma- chines without ROPS, ‘Make sure the Operator's compartment is fee of forsign ‘objects, especially if not firmly secured, Never use the ‘machine 10 transport objects, unless proper securing Points are provided. DO NOT CARRY RIDERS ON MACHINE. Study and famifarize with escape routes alternate to nor- mal ext routes. Seat belts are required to be provided with Rol Over Protection Structures or cabs. Keop safety belts fastened ‘eround you during operation, For yourpersonal protection, donotclimb on oreffmachine while machine in mation. ‘Make sure that exposed persons inthe area of operation are clear of tho machine, before stating the engine andSAFETY RULES ‘operating the equipment. Obey al indications provided by flags and signals NEVER COAST the machine down grades and slopes with the transmission in neutral or neutralized, or power shift type machines, or clutch disengaged on manually sited machines. Donot operate machinery in a condition of extreme fatigue oriliness. Be especially careful towards the end of working shit Do not operate machine with brakes out of adjustment, ‘Operate the machine at speeds slow enough to ensure ‘complete control at al times. ‘Travel slowly over rough terrain, on slopes or near drop- ‘ff, in congested areas or on ice or slippery surtaces. ‘When backing, always look to where the machine isto be ‘moved. Be alert to the position of exposed personnel. DO NOT OPERATE if exposed personnel enter the immediate Work area. STOP THE MACHINE. Maintain a safe distance from other machines, Provide sufficient clearance for ground and visibility conditions. ‘Yield rightot-way to loaded machines. Maintain clea vision of areas of travel or work. Keep cab windows clean and repaired When machines are operatingin andor, the pusher (rear) ‘must be equippedwith the appropriate deflectors protect the unin frontirom the airstream coming fromthe radiator, When pulingortowingthrough acable orchain, donotstart ‘suddenly at full thot; take-up slack carol Inspect carefully for flaws or troubles before using, Avoid kinking chains orcables, Danotpulithrough akinked chain orcable tothe high stresses and possibilty of failure ofthe kinked area. Always wear heavy gloves when har ding chains or cables Be sure chains and cables are anchored and the anchor Points are strong enough to handle the expected load Keep exposed porsonnelclearof anchor points and cables, ‘or chains, DO NOT PULL UNLESS OPERATOR's COMPARTMENT. (OF MACHINES INVOLVED ARE PROPERLY GUARDED AGAINST POTENTIAL CABLE OR CHAIN BACKLASH. Be alert to soft ground conditions close to newly con structed walls. The fil material and weight of the machine ‘may cause the wall colapse under the machine. In darkness, check area of operation carefully betoro ‘moving in with machine. Use all lights provided. Do not ‘move into area of restricted visibly engine has a tendency to stall for any reason under load ‘or idle, report this for adjustment to proper maintenance authority immediately. Dontcontinueto operate machine, Lunt condition has been corrected. ‘On machines supplied with suction radiator tans, be sureto periodically check engine exhaust parts for leaks, as ex- hhaust fumes are dangerous tothe operator, Operators must know thoroughly the performances of the ‘machine they are operating. When working on slopes or ear sudden lovel drops ofthe terrain, avoid areas where ‘ground is loose oF soft since roling-over or loss of control of machine could result Where noise exposure exceeds 90 dBA for 8 hours, wear approved ear protection |When counterweights are provided, do not work machin ifthey have been removed, “Transport a loaded bucket as fartipped-back andin as low ‘position as possible fr maximum visibilt, stability and ‘safest transport ofthe machine, Move ata proper specdifor, the load and ground conditions, ‘The bucket load must alvays be propery arranged: move with extreme care when transporting oversized loads, Use only the type of bucket recommended for the machine and the materials to be handled. Follow the recommenda tions forthe loading capacity and the arrangement of the ‘materials, the specifications of the terrain and the job tobe performed Do not it and haul loads overtioad where persons are standing or working, or downhill when working on slopes: inthelattercase the buckel must be unloaded onthe uphill side, whenever possible. ‘With a full bucket, start and stop the machine carefully: void stating without rst reducing the engine «p.m. Overtaking manoeuvres must be performed only when absolutely necessary and unavoidable. Beware of possible ‘uneven terrains, poor visibility conditions, the presence of ‘other machinery or persons out of sight. Operate the machine at a speed adequate to the working Conditions inthe site and slow enough to ensure complete ‘control at al times, Check monitoring instruments at star-up and frequently ‘during operations. Incase of abnormal condition warnings, slop immeciately the machine, Never use the bucket as a man it or to carry riders. Never use the machine as a work platform or scaffolding, ‘nor other inappropriate operations (i.e. pushing railway cars, trucks oF other machines), {Be alert of people in the operating area a! the machine, Load trucks from the divers side whenever possible. \When operating a machine, know what clearances will be encountered, overtiead doors, cables, pipes, bearing oad limitations of ground, bridges, floors or ramps.SAFETY RULES When roading, find-out what conditions are likly to be ‘encountered, clearances, trafic congestion, type of road surfacing, ete. Beware of fog, smoke or dust elements that ‘obscure visblty When crossing gullies or ditches, move at an angle with reduced speed after ensuring ground conditions willpermit a safe traverse, Explore the working area to identily potential risks such as: slopes, overhangs, pits, demotion rubble, fires, ravines, ditches, soft terrain, heavy traffic, crowded parking areas, ‘closed ambients.Insuch conditions, proceed with extrome ‘Whenever possible, avoid going over obstacles such as rough terrain, rocks, logs highly iregular ground, stops, ditches, railroad tracks. When obstructions must be crossed, do so with extreme care at an angle, i possible. Rloduce speed, shft-down. Ease up tothe break overpoint, pass the balance point slowly on the obstruction and ease ‘down on the ather side. In steep down-till operation, do not allow engine to over speed, Select proper gear before starting down grade. ‘Avoid side hill travel, whenever possible, Drive up and ‘down the slope. Should the machine slipping sideways, tum itimmediately downtil ‘The grade of slope you should attempt wil be limited by factors such as condition of the ground, load being han dled, type of machine, speed of machine and visibity. ‘Theres no substitute for good judgement when workingon slopes. Avoid operating equipment too close to an overhang or high wal, either above or below the machine. Be on the look-out for caving edges, faling objects and slides. Be ware of concealment by brush and undergrowth of these danger. ‘When pushing-over trees, the machine must be equipped with proper overhead guarding, Never allow a machine to Climb up on the root structure particularly while the tree is beingfelled. Use extreme care when pushing over any ree with dead branches. ‘Avoid brush piles, logs or rock. NEVER DRIVE OVER THEMor othersurtaceirregularties, that brake traction with the ground, especially when on slopes or near drop-off. Be alert to avoid changes in traction conditions that could cause loss of control. DO NOT DRIVE on ice or frozen ground conditions when warking the machine on steep slopes or near drop-olts. Working in vigin and rough terainsis characterizedby the presence ofall the pels and risks listed above. In these Conditions, itis emphasised the danger represented by large tree ibs (possibly faling on the machine), large roots (acting as a leverage under the machine when up- rooted causing the rol-over ofthe unt) et. STOPPING ‘When the machine is stopped for whatever reason, folow the instuctions of chapters “Stopping the machine" and “Stopping the engine” ofthe Operation and Maintenance Instruction Manual ‘Always remember to postion the transmission drive control in neutral and engage the control lock to secure the machine, ‘Set parking brake (when provided). NEVER LEAVE THE MACHINE UNATTENTED with the fengine running, Aiways betore leaving the operator's seat ‘and after making sura all people are clear of the machine, lowy lower the attachments or tools fat othe ground in a postive ground support position. Parkinanon- operating andno-tafic area orasinstructed, Park on frm level ground f possible. Where not possible, position machine ata right angle tothe slope, making sure there is no danger of uncontrolled siding movements. Set parking brake. i parking in traficlanes cannot be avoided, provide appro- priate flags, barriers, flares and signals as required, Also Provide advance warning signals in the traffic lane of approaching trafic. Keep head, body, imbs, hands and eet clear ofthe dozer, arms, bucket or ripper in ited positon. ‘Always disconnect the master switch before any interven- tion (Le. cleaning, repairing, maintaining, refueling etc.) Do the same when parking for prolonged periods oftimeto avoid accidental or unauthorized staring Never lower attachments or tools other than seated in operator's seat. Sound hom. Make sure area near the atachmentis clear Lower the attachment slowly. DO NOT USE FLOAT POSITION of hydraulic system, Secutelyblockthe machine andlockiteverytime youleave itunattended. Return keys to authorized security. Heed all shut-down operations of the Operation and Maintenance Instruction Manual are followed. Everytime you leave the ‘machine, engage parking brake (i equipping unt. MAINTENANCE, GENERALITIES Before operating or performing any intervention on the machine: + read carefully al the rules contained by this Manual; + read and obey all safety related plates and instructions located on the machineSAFETY RULES Do not allow unauthorized personnel to perform any main- tenance operation. Do not perform maintenance operation without prior authorization. Folow all commended main tenance and service procedures. Keep operator's compartment free ofall loose objects that are not property secured. Do not wear rings, wrist watches, jowellary loose or hang ing apparels, such as tes, torn clthing, scarves, unbut- toned 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 goggies, reflector vests, respirator. Con ‘sult your employer for specific safety equipment require- ments. Do not perform any service operation onthe machine with person seated in the operator's compartment, unless he is an authorized operator co-operating inthe operation to be performed, Keep operator's compartment, stopping points, grab-ral and handles clear of foreign objects, ol, grease, mud or ‘snow accumulation to minimize the danger of slipping or ‘stumbling. Clean mud or grease from shoes before at- ‘tempting to mount or operate the machine. Keep shoes ree ofmudor greasobeforeclimbing or driving the machine. Never attempt to operate the machine or its tools from any position other than seated in the operators seat. Never stand under the boom, When maintenance operations require moving hydraul- cally oporatedattachmentsby meansof machine's hydrau- lic system remember that all manoeuvres must be made only when seated in the operator's seat. Before stating ‘machine or moving attachment or tools, setbrakes , sound horn and callfor an all clear. Raise attachment lowly. ‘Alwayslockby means of outside devices the machine arms, or parts that must be lited for intervention, while your are below. Do not alow te anybody to pass near or even below the lited, and not locked device. It you are not absolutely sure about your safety, donot stay below the lied device, ‘even i itis locked, Do not place head, body, limbs, feet, hands and fingers, ‘ear rotating fans or belts, or cuting parts of the machine, Unless they are suitably and safely locked. "Never performinterventions with engine running, exceptas called for in a Manual. Do not wear loose clothing or Jewellery near moving pars. When servicing or maintenance require access to areas that cannot be reached from the ground, use a ladder or stop platform that meet local and national regulations, to reach the service point. f such ladder or platform are not available, uso the machine hand holds and steps as provided. Perform all service or maintenance careful. Shop andior field service platforms or ladders must be ‘constructed and maintained in accordance with local and national regulations. Disconnect batteries and TAG all controls according to ‘current regulations to warn that work i in progress. Block machine andall attachments that must be raised according to.currant regulations, Due to the presence of flammable fluids, never check or fil {uel tanks, batteries, nor use starting fluid near lighted ‘smoking materials or open flames, Donnot check or fuelthe tanks, batteries and accumulators, nor use the starting quid you smoke or near open flames, “These fids are flammable! BRAKES ARE INOPERATIVE when manually leased for ‘servicing. Provisions must be made to maintain contol of tho machine by blocking or other means. “The fusl fling nose mustbekept constantly inside the filing neck. Keep this contact rom the beginningtothe endotthe fueling operation to avoid the possibly that sparks due to Satie electricity ae generated. Use only designated towing or attaching points. Use care in making attachments. Make sure pins andior locks are secure before pulling. Stay clear of drawbars, cables or chains under load, ‘To move a disabled machine, use atraler or a low-boy, i available. In case towing is needed , use all necessary signals required by local and national regulations, and follow the directions provided in this Manual ‘Toload/unioad a machine from transporter, choose alevel surface ensuring firm support to the wheels of truck oF traler. Use strong access ramps, with adequate height and angle. Keep surface free of mud, ol or sippery materials ‘Anchor the machine securely to the bed of ruck or traler land block wheels or racks with appropriate wedges. Nover align holes with fingers orhands; always use appro- pate aligning tools Eliminate all sharp edges and burrs from re-worked pars Use only approved grounded auxiliary power sources for heaters, chargers, pumps and similar equipment to reduce the hazards of electrical shocks. Lift and handle heavy parts with ating device of proper ‘capacity. Be sure parts are supported by proper slings and hooks. Use liting eyes if provided. Watch-out for people in the vicinity Never pour gasoline or diesel ul into open, wide and low ‘containers. Neveruse gasoline, solventorotherllammable {luidto clean parts. Use exclusively qualified, non-lamma- ble, non-toxic commercial solvents. ‘When using compressed airforcleaningparts, used safety, lasses with side shields or goggles. Limit prossure to 2 bar, in accordance with local and national regulations.SAFETY RULES Do not run the engine in closed areas without proper Ventilation to remove deadly exhaust fumes, Do not smoke or permit any open flames or spark near ‘hen re-fueling or handling flammable materia, Donot use an open lame as a light source to lookforleaks. ‘oF for inspection anywhere on the machine. ‘Make sure that all mechanic's tools are in good conaltons.. NEVER USE tools with mushroomed heads or frayed ‘Always wear eye protections, “Move with extrome care when working under the machine, its attachments and or on or near them. Always wear Protective safety equipment as required, such as hard hat ‘goggles, safety shoes, earplugs, When performing operations requiring running of the en- gine, have a qualified operator in the operator's seat a all ‘times with the mechanic on sight Place the transmission in ‘neutral and set the brakes and safety lock. KEEP HANDS, AND CLOTHING AWAY FROM MOVING PARTS. Forfield service, move machine o level ground, tpossible, {and block it. work on an inctine is absolutely necessary, first block machine and its attachments securely, than ‘move ito level ground as soon as possible. Do not trust worn and /or kinked chains and cables: do not Use them for lting or puling operations. Te handle them, always use heavy gloves. ‘Avoid kinking chains orcables. Donotpulthrough akinked chain or cable to the high stresses and possibilty of failure ofthe kinked area. Always wear heavy gloves when han- ding chains or cables, BBe 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 andcables or chains. DONOT PULL UNLESS OPERATOR'S COMPARTMENT. ‘OF MACHINES INVOLVED ARE PROPERLY GUARDED AGAINST POTENTIAL CABLE OR CHAIN BACKLASH. Keep the area where maintenance operations are per formed CLEAN and DAY. Eliminate immediately all water and ol spillage. Donotpile oly or greasy rags; they representa fre hazard ‘Store in closed metal container. Before starting machine, check, adjust and lock the opera tor's seat for maximum comfort and control ofthe machine, Be sure exposed personnel in the area of operation are clear of the machina bafore moving it or its attachments, Sound hom, Fst inhibitors are volatile and flammable Use only in well, ventilated areas. Keep open flames away - DO NOT SMOKE - Store containers in a cool wel ventilated place, ‘secure against unauthorised personnel Do not carry loose objects in pockets that might fll unno- ticed into open compartments, \Wear proper protective equipment such as safety goggles. or safety glasses with side shields, hard hat, safety shoes, heavy gloves wien metal or other particles are aptto fly or tall. Wear welders protective equipment such as dark safely lasses, helmets, protective clothing, gloves and safely shoes, when welding or burning. Wear dark safety glasses. ‘ear welding zones. DO NOT LOOK AT ARC WITHOUT PROPER EYE PROTECTION. now yourjacking equipment andits capacity. Be-sure the Jacking point used on the machine is appropriate for the load to be applied. Be sure the support ofthe jack atthe ‘machine andunder ackis appropriate andstable, Transfer load to appropriate blocking as a safely measure, before proceeding with service ormaintenance work, accordingto local or national reguations, ‘Any equipment up on ajack is dangerous. Transfer load to ‘appropriate blocking asa safaty measure before proceed- ing with service or maintenance work according to local of national requirements. Steel cables are frayed after prolonged use: always wear appropriate protections (heavy gloves, goggles, etc). Handle all parts carefully. Keep hands and fingers away fom structures, gears or moving parts, Use and wear ‘always the appropriate protections. ‘Compressed airsystems can have water deposits created bby moisture condensation due to changes of atmospheric Conditions. If required, discharge deposits, as instructed. Before performing any maintenance or service operation, lock the frames ofthe machine wih the appropriate safety ‘ovice. Rememberto remove itatthe endo the operation, It the machine is equipped with hydraulic brakes, make ‘sure that he reservoiris always filed upto the correct level Book always all whee!s, ront and rear, before proceeding with any maintenance or service operation involving the bleeding of braking system or romoval of piping or eylin- ders. STARTING Do not run the engine in closed areas without proper Ventilation to remove deadly exhaust fumes. Donot place head, body, limbs, feet hands or fingers, ear rotating fans or belts. Be especially alert near pusher fans, REMEMBER THAT STARTING FLUID IS FLAMMABLE. Foliow recommendations printed on containers and in the ‘Operation and Maintenance ManualSAFETY RULES Containers must be storedin fresh, well ventilated places, ‘out of reach of unauthorised persons. Follow strictly the instructions provided by the Manufacturer. DO NOT PUNCTURE OR BURN CONTAINERS. ENGINE Loosen the radiator cap very slowly, to release pressure ‘rom the system, before removing it. All coolant level top- ‘ups must be performed with engine OFF. Avoid that flammable materials touch exhaust parts Should this be possible, provide the necessary protections. Do net run engine when refueling and use care if the engine is hot due to the increased possiblity ofa fire ifuel is piled ‘Never attempt to check or adjust fan belts whan engine is running. Do not adjust engine fuel pump when machine is moving Do not lubricate the machine with engine running. Do not run the engine with ar intakes, door or protections open. ELECTRICAL SYSTEM Disconnect batteries prior to any intervention on machine or electrical system (cleaning, repair, maintenance). ‘Should booster batteries be used, remember to connect ‘both ends of the booster cables in the proper manner (+) with +) and (-) with (). Avoid shor-crcuits ofthe terminals. Follow thoroughly the instructions ofthis Manual Before any intervention, make sure thatthe main switch is OFF, BATTERY GAS IS HIGHLY FLAMMABLE. Leave battery ’box open to improve ventilation when recharging batteries. Never check charge by placing metal objects across the posts, Keap sparks or opentlames away from batteries. D0 rat smoke near battery to guard against the possibilty of causing an explosion. Betore any intervention, make sure that there areno fuel or ‘lectrolyte leakages; siminate them betore proceeding with further work. HYDRAULIC SYSTEM Fluid escaping under pressure from a very small hole can be almost invisible and can have sufficient force to pen- trate the skin, Use apiece of cardboard or woodto search vl for suspected pressure leaks. DO NOT USE HANDS. It injured by escaping fluid, see a doctor at once. Serious infection or reaction can develop If proper medical treat ment isnot administered immediately. ‘Stop the engine and release all pressures in the system before removing panels, housings, plugs or covers, In case pressures must be measured, use instruments of ‘adequate capacity. Alvays follow the recommended pro- ccodures. TooLs Keep head, body, limbs, feet, fingers or hands away from ‘bucket, blade or ripper when in raised positon. Prior to any intervention, install all safety devices according to current rules and regulations. Incase equip~ ment on the machine must be operated by hydraulic systems, remember fo proceed only after seating in the ‘operators compartment. Make sure that there are no pergonsin the operating area ofthe machine. Alert people ‘afore operating using the hom and by voice. Move the ‘equipment very caretuly Do net use machine to transport loose objects, unless proper devices for this purpose are provided. Clutches and brakes of this machine and eventual ‘auxiliary equipment and attachments (such as operating cylinder orwinches controlvalves) mustahwaysbe properly ‘adjusted in accordance wit the instructions provided by the Manuals of the Manufacturer. Never perform adjust- ‘ments with engine running, except when called for by the above instructions. ‘TYRES AND WHEELS Make sure thatthe inflation pressure ofthe fyresis accord ing to the specifications issued by the Manufacturer and check t periodically. ‘Should the pressure be changed, stand on the side of the tyre ata safe distance. Pressure check operations must be performed with un- loaded machine and cold tyres. Never use reconditioned tyre rims, since eventual Wweldings, heat-tealments or repairs not performed cor. rectly can weaken the Wheel, thus causing subsequent ‘damages or dangers. Do not perform torch cutting or welding operations on rims ith inflated tyes installed ‘Spare tyres must be inflated only as farit is necessary to keep the im components assembled; remember thatwhenSAFETY RULES ‘ot installed on the disc, a tyre inflated to maximum Before removing objects from the tye tread, deflate it ressure can explode, oan cae Never inflate tyros with flammable gas; explosions and Maximum care mustbe taken when handling tyreinflated serious bodily injuries may result to maximum pressure Press When changing workshit, check hat wheelorrim securing Before operating on tyres, block all wheels, front and rear. _ screws andbrackels arenotloasen; if necessary, otghion to the prescribed torque. Alter acking the machine, block it with stands according to L 7 current safety rules and regulations A. warene (On machines having hydraulically, mechanically, and/or cable controlled equipment (such as shovels, loaders, dozers, excavators etc.) be certain the equipment is lowered to the ground before servicing, adjusting and/or ‘repairing itis necessary to have the hydraulically, mechanically, and/or eable controlled equipment partially Or fully raised to gain access to certain tems, be sure the equipments suitably supported by means other than ‘the hydraulic lit eylinders, cable and/or mechanical devices used for controlling the equipment. vilUNITS OF MEASURE ‘The units of measure used in this Manual are those adopted by the International System (I.S.) superseding those previously used by the M.K.S. system, Force: decanewton (daN), supersedes kilogram (kg) Pressure: bar, supersedes kg/sqom Torque: decanewton x meter (daN + meter), supersedes kg * m To convert the units of measure, the following table applies: muttipy | by — | toobtain Force kg 0.9807 | dan Pressure | kg/sqem | 0.9807 bar Torque kgem | 0.9807 | daNem Note - For standard repair requirements, the following equivalences can be considered appropriate: kg = daNm; Kg/sqcm = bar, Kg + m = dam. ‘Study SAFETY RULES in the font ofthis manval thoroughly forthe protection of mache and safely of personnel CLASSIFICATION OF STANDARD COMPO- NENTS TO DETERMINE THE TIGHTENING TORQUES Note - Incase, in the different sections, the tighten- ing torque is not listed, refer to the table “TIGHTE- NING TORQUES’, only after identifying exactly the ‘component, ‘The latter is identified by a coded eight digit number, allowing a complete description of the iter, Example: O@eeee oe 1+ Standard index digit, Itis always represented by the digit 4. This number indicates that the item can be fabricated in different versions differing for the material and coating. a-b-c-d-e-Standard base digits It is a number always composed of five digits identifying the dimensional specifications of the item. {Material index digit, ‘This digit indicates the material used for a defined item. Its meaning s indicated inthe table that follows. 9 Coating index digit Itindicates the coating applied to a defined item. viResistance class and material Meterial | eat UNI DIN SAE BsI BNA index (f) 0 Rao 40-48-48 1 A 42 1 R50 58-68 3 Pp 56 2 R80 8G 5 T 80 3 R100 100 10k 8 v 100 4 Brass | Brass | Messing | Brass | Brass | Lalton 5 — [Aluminium | Aluminium | Aluminium | Aluminium | Aluminium | Aluminium 6 Copper | Copper | Kupfer | Copper | Copper | Cuivre 7 Free for other metalic materials, WARNING. TORQUE TABLES + Lubricate by motor oi ll screws and bolts unti24_Ifthecorresponding torqueis notindicated, the following dia,, with grease the larger diameters. tables can aid you for this purpose. + Tolerance on torque: + 5% ~ Resistance classes R80, R100, R120 must be Understood as follows: 10.9 subsites 100 torscrows 129 azo tosibstutes Reo | toms 2" Roo COT = caded FOSF = phosphate: ZNT = zed ‘Sluty SAFETY RULES in he fet of his marual thoroughly fo the protection of machine and safety of personne amurs ex Strength grade: 10 (P80) Strength grade: 10.9(R 100) Diameter normal low type | with polyamide ring Diameter normal |sett-ocking| and pitch roma Towype] andpicn | 2nr ZN smm | datim | datvm | anim | “dam | mm | dati | danm Mex 13 | 12 Mx wf mext2s | 32 | 26 | as | a2 |maxta | 13 | a5 M10 x 1.25, 72 52 82 62 M10 x 1.25, 7 79 M10x 1.5, 65 | 5 17 6 M10x 1.5 65 7 M12 x 1.25, - 13, 87 14.5 10.2 M12 x 1.25 12.7 13.9 mexts | it [a1 | v9 | 96 |mexis| on | a maxis | 195 13 | ate 1s | maxis | 20 | 22 M14 x2 18 12.5 20 | 14.6 M14x2 | 18 19 MI6x1.5 30 7 34 - 20 M16 x 1.5 30, 33, Miex2 : wiex2 : : miexis | 45 | 25 so | 2 | mexts | a | a0 maxes | - ; ; - [urexzs | - : weoxts | oo | a5 | o4s | 05 | meoxrs | co | 5 [weox25 | 5 - | = | weoxes | - M22 x 1.5 80 at 7 - M22 x 1.5, 80 90 | mae x25 - - | - Me2 x 2.5 - - | wea xe 100 47 108 52.5 M24.x2 100 - 110 M28 x3 eax : Mer x2 33 | 404 : merx2 | wo | - | msox2 130 | 494 ; waox2 | 140 | - M8 x2 wo | - |. - [mssxe [100 | - waexs | 20 | ~— [wsexs [aa | Study SAFETY RULES inthe rot of his manual borough forthe protection of machine and salety of personnel xFLUID CAPACITIES | rem quantity] Far pRopuct | REFILL Liters Product (Intemational pe:s) Cooling system “4 PARAFLU11 | 5080 miture of water and aréstazn. The mite proves ani-xiaton,ant-corosion, ait-scalng.anffoaming and freezing protection “erc¢ar') Fuel reservoir 208 : ASTIN. 20 type TT good auay cose Engine 17K auton Engine o"COMC D4" SUPER or API CF" Service orewiL- 2108 Transmission 20 Mona Engine o"COMC D4" SUPER orsAPl CPt Service ore. 2108 TUTELAGINN() | _ ATE Type ASUFFIXA Hydraulic and 12 roRAULCAR — | Hydraute ot DIN sts24/51505/ brakes system apai.asorsi | 180VG32, 46 0r68 Grease fittings : Tureiace | Lihium-caium base grease | NLGI. 2 consistongy | SuperMax Trac antes | sa 20200 | wh ant-sck and sl front ao | Tureataansriu| [S.dves API GL-#+ | rear | (1) To be used at temperature below -20°C (-4° F). ‘The quantities of oll indicated are those required for periodic changes, following the draining and refiling directives indicated in detail for each group. ‘Study SAFETY RULES in tho font ofthis manual thoroughly for he protection of machine and safely of personne xiSECTION 1 ENGINE COMPONENTS TABLE OF CONTENTS CHAPTER TITLE PAGE GENERAL DESCRIPTION Turbo-charger.. LDA air intake device 12 DIAGNOSTIC AND TESTS wn 124 Troubleshooting vans 1.22 Tests 123 Output data on bench for 8365.25.584 engine 124 Injection pump calibration data REPAIR PROCEDURES Phasing of injection pump on engine .. Removalinstalaton of engine Turbocharger (Removal/inspection/Installation) Trouble hooting te tubo-charging sys Exhaust silencer. Ali leaner rn Starter motor (Removalinstalation) Altemator (Removalnstalaton) Drive belts (Replacement/Adjustment) Fue! reservoir (Removal/nstalation). Throtle contol inkage (Removal/nstliation and Adjustment) Fuel euof sleoid ae (erovalnsataion and Adjusmen Radiator (Removalinstallation) Cold starting (Special optional equipment). 14 ‘SPECIFICATIONS AND DATA. 1-94 14d Goneraites. 1-94 142 Standard engine speeds 1-34 18 TooLs 16 TIGHTENING TORQUES.FR1602 ENGINE 1-3 1.1 GENERAL DESCRIPTION Model FAR160.2 Is equipped with FIAT-IVECO turbo-charger engine type 8365.25.584. ‘The repair procedures as well as trouble-shooting and testing procedures are listed in the Manual print ‘no. 604,06.184, available from your local FIAT-HITACHI Dealer, LM. SIDE VIEW OF ENGINE 4. Fuel fiter 4. Engine oil dipstick 2. Starter motor. 5. Fuel priming pump, 3. Injection pump. 6. Engine breather. LH. SIDE VIEW OF ENGINE 1. Coolant fier. 4. Engine oil fiter. 2. Transmission heat exchanger. 5. Engineoilheatexchanger. 3. Turbo-charger. ‘Stuty SAFETY RULES inte front ofthis manual heroughiy fr the protection of machine and saety of personneENGINE FR160.2 1.1.1 TURBO-CHARGER The turbo-charger increases the power and the efficiency of the engine providing compressed air to the engine intake manifold. The power to drive the turbo-chargeris provided by the energy oftheexhaust gases. The turbo-charger includes a main housing and two air ducts forairand exhaust gases in aluminum alloy, housing respectively, the compressor wheel (2) and the turbine (4). Fig. 1.3 - Functional diagram of turbo-charger ‘A. Airflow through compressor intake - B. Exhaust gases flow through the turbine - 1. Compressor hou- sing - 2. Compressor wheel - 3. Turbine housing - 4. Turbine - 5. Exhaust manifold -6. Intake manifold, ‘The compressor wheel is made of aluminum alloy andis mountedon one endofthe turbine shatt. Wheel (4) located inside the turbine housing is made with high temperature resistant aluminum alloy and is, fittedto the turbine shaft. Consequentiyasolid rotating assembly is obtained. ‘When the engine is started, the exhaust gases flow, athightemperature andpressure, are directedtoward the discharge by the manifold inside housing where part of their energy is transferred to the blades of turbine (4), causing a fast rotation; subsequently, the ‘gases are sent to the silencer. ‘The rotation is transferred othe shatt of compressor is Sucks clean air from the dry type air cleaner and sends it, compressed, through the vane inside the intake ducts and then to the cylinders. The turbo-charger provides the needs of the engine, reacting, in effec, to the flow of expanding exhaust gases. With the increase of the power output of the engine, the energy provided by the exhaust gases increases proportionally. When the demand of poweris reduced Cr when the engine speed is reduced, the energy of the exhaust gases decreases, so as the turbine- compressor assembly speed. The turbo-charger is lubricated by the engine oil through an extemal piping, Effects of altitude on turbo-charger The main effect that an engine equipped with turbo- charger feels wth relation to altitude isthe increase othe exhaust gases temperature, witha subsequent increase of exhaust smoke emission The maximumattitude the machine can stand without interventions on the engine is 2,500 m (8,000 ft) above sea level At higher altitudes, to avoid an excessive increase of the exhaust gases temperature (normal operating temperature 500 + 550°C; 930 + 1020°F), it is recommended to under-calibrate the injection pump 2% of max. output every 100 m or 328 ft above 2,500 m attude. — Bd wssvneg — Avoid accelerating in the stopping stage of the engine, since there isthe risk shat the turbo-charger turbine shaft will rotate without lubrication even after the engine has stopped, due to the effect of inertia This will cause serious damage othe turbine shaft bushing, —— A wse0.ng —— Before switching off the engine, when itis hot, run at ile fora few minutes 0 allow the turbo-chargerto low-down ‘and cool gradually ‘Study SAFETY RULES in the font of tis manual oroughly forthe protection of machine and satay of personnelFR160.2 ENGINE 1-5 1.1.2 LDA AIR INTAKE DEVICE The air intake device is meant to adjust the delivery of fuel to the quantity of air (in weight) sont into the cylinders by the turbo-charger. This because in tur bo-chargedengines, alow speeds, theturbo-charging pressures too low, thus the quantity of ar (in weight) Sent ito the cylinders is insufficient. Consequently, the{ueldelivery mustbereferrediotheturbo-charging Pressure. This is obtained by the variable position stop ofthe maximum stroke of the ake actuated by the above device, starting from a pre-set turbo- charging pressure (Selected during the calibration phase). The LDA device includes housing (10, fig. 1.4) and cover (11) blocking between them, mombrane (8) that must be airtight. On the cover, connection (1) picks-up the turbo-charging pressure, whereas the membranes pushedby spring (6) posiionedagainst ring nut (8) mounted on the device cover. The latter cean change, within certain imi, the spring pre-load, thus changing the beginning o the intervention of the LDA device, that should work at 0.13 + 0.05 bar. ‘Access to adjusting ring nut (8) is gained through the threaded hole on the pump body, atter removing the relevant plug. Rod (7) is connected to the membrane through the plate and guide disc, actuating regulation rod (8) through an lever. When turbo-charging pressure increases, the mom- brane is lowered against the spring load, lowering with ithe rod, through the lever, allowing the rake to travel further. Once the turbo-charging pressure 0.31 + 0.05 bar is reached, the LDA device ends its intervention, allowing the rake to runthe whole stroke: (max. delivery). Before setting the LDA device, check that the device is free of leakages under a pressure of 0.5 bar. Fig. 1.4 Section view of LDA device 1..Connection to turbo-charged air pressure -2. Co- ver - 3. Regulation rake stroke adjusting screw - 4. Jam nut (8) - 5. Membrane - 6. Spring - 7. Rod - 8, Rake -9. Intervention adjusting ring nut - 10. LDA housing - 11. LDA cover. Study SAFETY RULES inte front ofthis manual horougy forthe protection of machine and safety of personne1-6 ENGINE FR160.2 1.2 DIAGNOSTIC AND TESTS 1.2.1 TROUBLE-SHOOTING To trouble-shoot this engine refer to Service Manual print no. 604.06.184, available from your FIAT= HITACHI Dealer. 1.2.2 TESTS For the tests not included in this Manual, refer to ‘Service Manual print no. 604.06.184, available from your FIAT-HITACHI Dealer. ‘SUMMARY TABLE OF TIGHTENING TORQUES IVECO ENGINE TYPE 8365 FLYWHEEL SECURING SCREW Screw PIN 4765553 M16 x 1.5, 1st phase, pre-torque 100 Nm 2nd phase, rotation 60° CON-ROD CAP SECURING ‘Screw PIN 4722162 M14 x 1.5 SCREW 4st phase, pre-torque 40 Nm 2nd phase, rotation 35° CRANKSHAFT CAP ‘Sorew PIN 8829588 M16 x 1.5, SECURING SCREW ‘st phase, pre-torque 55 Nm 2nd phase rotation 75° HEAD SECURING SCREW Nut P/N 8505174 for studs PIN 4707320 4st phase, pre-torque 88 Nm 2nd phase, rotation 90° 8rd phase, rotation 90° Nut P/N 8505174 for studs PN 4718322 and PIN 4718319 - 4718316 ‘1st phase, pre-torque 88 Nm 2nd phase, rotation 90° ‘3rd phase, rotation 180° ‘tut SAFETY RULES inte rot of hs manus thoroughly forthe protection of machine and safety of personnelFR160.2 1.2.3 OUTPUT DATA ON BENCH FOR 8365.25.584 ENGINE Test conditions: ENGINE ~ engine on bench without fan, air cleaner and exhaust silencer; = atmospheric pressure 740 + 5 mm Hg (986 + 7 mbar); = ambient temperature 20 + 3°C (68 + 5°F); = relative humidity 70% + 5; fuel density 830 + 10 git, Injection timing 23 + 1° BTDC, cylinder 1 on compression stroke. HThrotte contro! | Engine | Engine powerwithrun-nengine for: | Fuel fever position ‘Speed ‘consumption perhour Zhoure so hours rom total total | kw (HP) kW (HP) Kgl ber | Max power | 2160 | rasa-ten7 as+209 | ots-30 | 1481s | Max.torque | 1400 - 1045 +1155 (1425+ 1575)| 22.528 ves goeng_ | 00-240 | vin ae) | sn0- 20 ‘Study SAFETY RULES in the front ofthis manval thoroughly forthe protection of machine and salay of personnel1-8 ENGINE FR160.2 1.2.4 INJECTION PUMP CALIBRATION DATA Injection pump: PES6P110A720RS530 (BOSCH) Governor: RQV450 - 1075 PA1016 - 3 Fuel pump: FPIK22P9 Pressure piping (ENGINE): diam. 6 x diam. 1.5 length for no. 1 cylinder = $20 mm, no. 2- 3 = 340 mm, no. 4 = 420 mm, no, 5 = 490 mm, no. 6 = 565 mm, Injector setting (ENGINE): 200 + 208 bar. ‘Min. engine speed, no-load: 880 + 960 «pm. Static timing mounting 23° + 1° BTDC, plunger 1 of injection pump in beginning of fuel injection and piston no. 1 on compression stroke. Test bench with static and dynamic specifications according to ISO 4008/1 and 4008/2 standards. Piping diam. 6 x diam. 1.5 x 600 mm length (according to ISO 4093.3 standard) (Outside diameter x wall thickness x length). Injectors ISO standard (calibrated orifice), Injector setting 172 = 175 bar. ‘Test fluid according to ISO 4113 standard, temperature: 38 + 42 °C (100 + 108 °F). Feeding pressure 1.5 bar. Burette emptying time: 20 sec. Relief valve set at 1.3 » 1.8 bar. INJECTION PUMP PHASING (Spi point test - Stop block removed) Plunger itt 2.00+2.10 mm (tom 8700) (corresponding to covering of pot) Firing order -5-3-6-2-4 Rotation clockwise PUMP BASIC CALIBRATION (Stop block removed) Type of Pump rpm Postion of| ‘cucm/1000 | Max. discrepancy ] Press. on LOA. operation rake (rm) strokes, between cylinders (oa) _ 7 (cucm) : Calibration 1075 1080-1090 | 1224124 4 o7 Test 700 126+ 190 o7 Tost 500 93-95 o Test 450 60-64 17522 4 ° ‘Study SAFETY RULES in the font ofthis manual thorough forthe protacton of machine and slay of personnelFRI60.2 ENGINE 19 GOVERNOR PERFORMANCE BASIC TESTS (tp bok omoves) HIGH SPEEDS Low Pees Twtletwer | Pump pm | Rao postin | Thote lover | Pumpin | Rake ponton poston ‘rm | pooten ‘rm version | stao-1uo | a0 | eg -6 0 10620 wh enpect wn nopoct ihorsonal | r240~12r0 | ‘ohorwonit | ago omin poste poston 1480 ot soowseo | 2 PUMP FINAL CALIBRATION - WITH GOVERNOR (Win sop eck stated hora) Type ot | Pump rpm ceuemy/1000 Max. discrepancy Preseure on LDA, ereraton | vase | etooncyindestuom | "ag Gover eoting 1078 teas t28 4 o7 Minna 4 rome 4s sat 1 105.216 ‘Study SAFETY RULES in the front ofthis manuel thoroughly forthe protacton of machine and slay of pacsonnelENGINE FR1602 1.3 REPAIR PROCEDURES 1.3.1 PHASING OF INJECTION PUMP ON ENGINE — Bd wre ——— ‘Keep hands and face away from the tip of nozcles when calibrating injectors. Sprayed fuel under pressure can cause injuries and damages. Always were goggles or lasses with side panels when testing injector efficiency: Keep your hands and face away from loosen piping connections when testing fuel lines. Always were goggles ‘or glasses with side panels Position the engine so that the phasing marks are aligned with the flywheel housing, Fig. 1.5 Couple the engine and the injection pump mating the corresponding splines. Check that element 1 of the pump starts to raise, than hand-tight the securing screws. Fig. 1.6 Remove the access plug from the pump body. Helped by an assistant, rotate the engine cranking with a lever on the crankshaft pulley, to rotate both engine and injection pump. When the plunger (visable through the accessholeon the pump) starts its upward stroke, the phasing mark ‘on the flywheel starts to appear through the hole on the fiywnee! housing. Continue to rotate the engine until the phasing mark Cn the flywhee! corresponds with the pointer on the ‘lywhee! housing itself Plug the delivery port of the injection pump. ‘Mount the bleeding pipe on the high pressure outlet port of plunger no. 1 Plug the remaining ports of the pump to avoid that ‘other delivery valves of the pump open. Move the throttle lever to half stroke. Study SAFETY RULES inthe front ofthis manual thoroughly fr the protection of machine and safely of personnelFR160.2 ENGINE 1 ‘Mount the fuel delivery pipe between phasing fixture 75295704 and the inlet port of the injection pump. ‘Actuate the hand pump of the phasing fixture until a Constant flow of fuel exits the bleeding pipe. Whilstthe hand pump is actuated, rotate the injection ump body in the direction opposite to the rotation direction of the pump, to reach the closing ofthe port, 80 a8 to stop the flow. The pump pressuremust never absolutely exceed the value of 17 bar, to avoid damaging it Tighten the injection pump securing screws to the specified torque. The remaining instalation operations are the reverse of the removal procedure, Check that all screws are tightened to the specified torque. ‘Study SAFETY RULES inthe fret of his manual thoroughly forthe protection of machine and safety of personnel1.3.2 REMOVAL/INSTALLATION OF ENGINE Place the main switch in OFF position. — Ad aren — Always turn the master switch to the “OFF” position before cleaning, repaiving, servicing, or parking the unit Drain coolant fromthe engine. Tofacilitte the draining, loosen slowly the radiator filler cap (1) ———— Mowncen FLUID UNDER PRESSURE: turn cap or cover slowly to relieve pressure before removing, since the coolant could be very he thus causing bums and personal injures Fig. 1.9 Remove the ladders, rear mudguards and cab angle panels. Fig. 1.10 ENGINE tudy SAFETY FULES in the font ofthis manual thought for he rotation of mach FR160.2 Remove the side panels Remove the muffler extension pipe. Remove the nuts and washers for studs and the screw with washer securing the cowling. Three of these studs are locatedinside the radiator protection. Flomove the cowling using an appropriate hoist, Ad warn — Liftand handle ll heavy parts with equipment ofadequate parts are lifted by ‘appropriate links and hooks. Use lifting eyes provided. Watch ou for people in the vicinity ofthe load being lifted. capacity. Make sure that hea Remove the fan guards. Disconnect the breather pipe from the upper part of the radiator and the heat exchanger pipe. Remove the upper manifold between radiator and water pump. Remove the muftler. Disconn: level sensor wire Fomove the radiator upper deflector. Remove the two radiator side deflectors recarding their positions for the re-installtion. Loosen, but do not remove, the lower deflector. ect and tag the radiator = Fig. 1.11 Loosen the two clamps on the radiator lower manifold {and remove the manifold from the radiator. Disconnect and tag the back-up alarm wire Disconnect the back-up alarm, Disconnect and tag the rear light wirings. Remove the clamps securing the wiring tothe radiator, guard, re satty of personnel.FR160.2 Remove. the two starter protection fuses from the radiator guard, Fig. 1.12 Remove the nut (36 mm) securing the main switch to the support. Remove the screws securing the radiator guardtothe frame. Remove the fuel reservoirfilerneck and plugthe hole to avoid polluting the fuel Disconnect eventual wiring clamps. Remove the piping of the hydraulic oil cooler. Close the grid. Lit slowly backward so that the guard does not interfere with the fan. Make sure the wires are not caught B se201¢ —— Liftand handle all heavy parts with equipmentofadequate capacity. Make sure that heavy parts are lifted by ‘appropriate links and hooks. Use lifting eyes provided. Watch outfor people in the vicinity ofthe load being lifted. ‘Shut-off the valves and disconnect the hoses of the cab heater. Disconnect and tag the wires on the altemator. Disconnect and tag the engine oil pressure sensor. Disconnect and tag the transmission oll temperature ‘sensor and the relevant clamps. Disconnect also the twohoses between heat exchanger andtransmission housing, Disconnect the hose from the block on the tran- ‘mission heat exchanger. ENGINE 1213 Disconnect the brake power pump pipes. Disconnect the grounding plait between engine and frame, Disconnect the feeding and return fuel lines to the injection pump. Remove the brake pump from the timing housing, Disconnect the throttle linkage from the injection pump and remove the linkage support bracket on the engine block. Disconnect and tag the engine oil level sensor wire andthe delivery booster solenoid wires on the injection ump. Remove all wire clamps. Disconnect the breather pipe from the transmission cil dipstick neck and disconnect the temperature sensor wire. Disconnectandtag the fuet cut-off solenoid wiresand the starter motor wires with relevant clamps. Disconnect the engine oil drainage block from the frame, Secure thehooks ofa hoist (loadrotorP/N75292914) to the engine lifting eyes, as illustrated, to hold and balance the load of the engine, that is about 770 kg Fig. 1.13 Remove the engine brackets securing screws. Remove the flywheel inspection cover. Rotate the engine acting on the fan blades and remove the screws securing the flex-joint to the flywheel Flemove the screws securing the converter housing tothe flywheel housing. The converter tends to come ‘outwith the engine, thus some leverage is necessary to separate it from the engine, Once its separated, itecanbe keptinthe housing by securing itwith a wire. Note - To remove the upper securing screws, itis advisable to remove the various lower pipings of the hydraulic reservoir ‘Study SAFETY RULES in he font of tis manual throughly forthe protection of machine and safety of personnel1-14 Lift slowly the engine and extract it from the frame, Pulling it backward. Make sure it does not inteferes with surrounding components, in particular: converter flox-joint,hidraulic reservoir and pipes, engine pump, axle suppor, brake pipes, engine exhaust pipe and weg, — MA wse0nng —— Liftand handleall heavy parts with equipmentofadequate capacity, Make sure that heavy parts are lifted by ‘appropriate links and hooks. Use lifting eyes provided, Watch outfor peoplein the vicinity ofthe load being lifted. INSTALLATION The installation is the reversal procedure of the removal, with the following exceptions, ‘Smear the flywheel guide nose with anti-seizing lubricant. Install a driving pin (with screwdriver cut) in the converter flex-joint so that its aligned with the hole in the flywheel and the inspection hole on the housing Rotate the flywheel so that the flex-joint guide pin holes aligned with the inspection hole on the flywheel housing, Install two driving pins in the holes indicated to facilitate the alignment ofthe transmission assembly. Hook the hoist chain (PIN 75292914) to the lifting eyes of the engine as illustrated, ENGINE FR160.2 Fig. 1.15 —— & wasrncg —— Liftand handle all heavy parts with equipmentofadequate ‘capacity. Make sure that heavy parts are lifted by ‘appropriate links and hooks. Use lifting eyes provided. Watch ou for people inthe vicinity ofthe load being lifted. x Meal AWE” 5 Fig. 1.16 Rotate the engine into position checking the clearances while it is downed, Note- Incaseitis dificultto obtain correctalignment ‘engine/transmission, remove the two engine front ‘supports. Align all the driving pins, so as to ensure that the mating of the flywheel and converter is ‘smooth. (If the converter has been secured to the housing, remove the wire). Tightan the converter drive screws, Note - The tightening torques ofall nuts and screws are standardized, except when indicated differently ‘Study SAFETY RULES inte front of his manual thoroughly forthe protection of machine and safely of personnelFR160.2 ENGINE 1-15 1.3.3 TURBO-CHARGER (REMOVALIINSPECTION/INSTALLATION) A 1.3.3.1 Removal WARNING ———— Before removing the turbo-charger clean externally the group to prevent entry of dirt into the engine during the removal Normally the turbo-charger is removed from the engine for one ofthe following three reasons: inspection, repair ‘or overhaul. When the urbo-charger is removed from the ‘engine, always keep all openings ofthe intake and exhaust ‘manifoldstotallyclosed. This willpreventdirtfromentering the manifolds and damage the turbo-charger or he engine, when the latter is returning 10 operating conditions. Remove the turbo-charger and disassemble it considering fig. 1.17, Fig.1.17 - Exploded view of turbo-charger ‘A. Air intake -a. Housing (8) securing screw -b. Housing (1) securing screw -e. Compressor wheel (9) securing nut - 1. Housing, exhaust side - 2. O-Rings - 3. Thrust collar - 4. Retaining rings - §. Bushes - 6. O-Rings - 7. Intermediate plate -8. Housing, inlet side - 9. Compressor wheel - 10, Central body - 11. Cup - 12. Turbine and shaft ‘Study SAFETY RULES in th front ofthis manual horeughly forthe protection of machine an safety of personne1-16 1.3.3.2 Inspection Inspect the compressor housing, the compressor wheel, the turbine and turbine housing to find the accumulation of dirt, An excessive accumulation of dirtonthe compressor wheel ortheturbineisimpairing the perfect balancing of the mobile components. Wear found on the outer diameter of the blades of the compressor wheel or the turbine indicates an excessive wear of the bearings. Bent blades indicate the entry of foreign materials, of a certain dimension. Never attempt to straighten them; replace without hesitation damaged wheels or turbines. Check that the shaft complete with turbine (12, fig. 1.17)is not scored, out-of-round or showing other signs of damage due to bearing seizure. Check that all components are free of corrosion signs. Replace all components not in perfect conditions; clean all group components. For this purpose, it is recommended that components are dipped into the appropriate solution, slowly rinsed until all foreign ‘materials are removed and the parts are clean. All parts must be immediately dried using dry compres- sed air Fig. 1.18 - Disassembly/assembly of turbine shaft securing nut 1. Compressor wheel, ENGINE FRI60.2 — Bd sssvrg —— ‘Never use gasoline or solvents or other flammable fluid to clean parts. Use authorized commercial, non-flammable, non-toxic approved fluids ony. —— wen —— During cleaning operations, always take maximum care, ‘avoiding that the blades ofthe compressor and turbine are bent and/or damaged. ‘Check the axial play of the turbine shatt proceeding as follows: ~ place the turbo-charger group with the shaft horizontal, indicated in fig, 1.19; + securedial gauge (A) usingamagneticbase placed fn the central body taking care that the contact, Point of the gauge plunger is on the end of the shaft. (fig. 1.19); Fig. 1.19 - Check of shaft axial play ‘A. Dial gauge - 1. Shaft end. Note - The arrow indicates the direction of the move- ment to apply to the turbine shaft. ‘Study SAFETY RULES in the front ofthis manual thorough forthe protacton of machine and safety of personnel