Hidromek 102b 102s Service Manual PDF PDF Free

HMK 102 ENERGY WORKSHOP MANUAL 00
GENERAL
 00- 01 REVISION HISTORY
 00 - 02 FOREWORD
 00 - 03 SAFETY
 00 - 04 STANDARTS
01
0
REVISION HISTORY
When new or revised information is published Action
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the pages is indicated in the table. Page to be Add
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HMK ENERGY WORKSHOP MANUAL
01
SPECIFICATIONS
 01- 01 GENERAL
- Location of components
- General dimensions
- Specifications and performance data
 01 - 02 LUBRICATION CHART
01
SPECIFICATIONS 1
GENERAL
LOCATION OF COMPONENTS
1 BUCKET LOADER 7 STABILIZERS

2 LOADER ARM 8 KINGPOST CARRIAGE
3 ENGINE 9 BOOM
4 HYDRAULIC TANK 10 ARM BACKHOE
5 FUEL TANK 11 BUCKET BACKHOE
6 CAB
GENERAL VIEW OF HMK 102 ENERGY

01 HMK 102 ENERGY WORKSHOP MANUAL
01
SPECIFICATIONS
2 GENERAL
GENERAL DIMENSIONS
G1: 1780 mm
G2 : 2210 mm
GENERAL DIMENSIONS OF HMK 120 B ENERGY

01
SPECIFICATIONS
GENERAL 3
G1 : 1905 mm
G2 : 2340 mm
GENERAL DIMENSIONS OF HMK 120 S ENERGY

01
SPECIFICATIONS
4 GENERAL
MODEL : HMK 102B HMK 102S
A. OVERALL TRANSPORT LENGTH 6090 mm 6125 mm
B. TREAD WİDTH, FRONT 1920 mm 1905 mm
C. TREAD WİDTH, REAR 1780 mm 1905 mm
D. OVERALL TRANSPORT WIDTH 2440 mm 2440 mm
E. BACKHOE MAX. DIGGING DEPTH (STD. ARM) 4400 mm 4350 mm
F. BACKHOE MAX. DIGGING DEPTH (TELESCOP. ARM) 5640 mm 5590 mm
G. TRANSPORT HEIGHT (MAX.) 3530 mm 3595 mm
H. GROUND CLEARANCE, BUCKET, DRIVE POSITION 400 mm 400 mm
I. BUCKET WIDTH (STD) 2440 mm 2440 mm
J. DUMP HEIGHT (LOADER) 2610 mm 2760 mm
K. DUMP HEIGHT (BACKHOE STD.) 3700 mm 3750 mm
L.. DUMP HEIGHT (BACKHOE TELESCOP.) 4650 mm 4700 mm
M. BUCKET LOADER MAX HEIGTH 4100 mm 4165 mm
N. BUCKET LOADER LEVELLING (MINUS) 195 mm 140 mm

01
SPECIFICATIONS
HMK 102 B 5
HMK 102 S
SPECIFICATIONS AND PERFORMANCE
Item Unit Specifications
Loader Bucket Capacity
m3 1,1
(CECE) heaped
Backhoe bucket options
Attachment
350 mm m3 0,08
400 mm m3 0,09
500 mm m3 0,11
600 mm m3 0,14
700 mm m3 0,18
800 mm m3 0,22
Operating Weights (STD)
kg 8.400 / 8.700
102B / 102S
1. speed km/h 5,0
Travel 2. speed km/h 9,0
3. speed km/h 21,0
Speed
4. speed km/h 40,0
Bucket breakout force B / S kgf 7.190 / 7.155
Arm breakout force B & S kgf 6.100 / 6.260
Backhoe bucket breakout force B & S kgf 4.395
Maker - PERKINS
Model - 1104C-44T
4 cycle, 4 cylinders, in line, direct
Type - injection, water cooled diesel
engine
Rated output HP (Kw) / rpm 100 (74,5) / 2200
Maximum torque Nm (lb.ft) / rpm 415 (306,08) /1350
Bore x Stroke mm 105 x 127
Total displacement cm3 (in3) 4400 (268)
Compression Ratio - 18,2 : 1
Injection pump DELPHI
Engine
Low Idle speed (No load) rpm 950 ±50

High Idle speed
rpm 2150 ±50
(No Load)
Firing Order - 1–3–4-2
Lubricating oil pressure kgf/ cm2 (kpa) 3,0 (300)
Valve Suction 0,20 (0,008)
mm (inch)
clearance Exhaust 0,45 (0,018)
Starter V 12
Voltage V 12
Alternator
Output A 115
Turbocharger - Installed
Engine oil pan capacity l 11
Weight (dry) kg 305
01
SPECIFICATIONS
6 HMK 102 B
HMK 102 S
Type - Aluminium
Cooling
System
Radiator Air cooled

Coolant capacity l 25
Horn Type - Electric Horn
Electric system
Type - Lead-acid
Battery Capacity V/Ah 12V / 165 Ah
Voltage V 12
Light Headlight (L/H) 2 each halogen ( 55W / 60W )
Light Working lamp 1 each halogen ( 55W )
Circuit Type - FUSE
protection Number of fuses each +
Maker HEMA
Main
Flow Rate cc/rev 37/29
Pump
Type - Tandem gear pump
Brake Type - Gear pump
pump Flow rate cc/rev 4
Hydraulic System
Maker - HUSCO
Pressure bar 230
 Unloader valve function
depends upon digging &
load conditions
Main
Control  Anti-schock & anti-
Valve cavitation valves
Function -
 HSC Hydraulic Speed
Control provides more
engine power & less fuel
consumption while
driving
01
SPECIFICATIONS
HMK 102 B 7
HMK 102 S

- Anti-wear, anti oxidation, anti foam
Hydraulic
Type mineral oil for the high pressurized

hydraulic system
Oil
Grade - ISO VG 46
Kinematic Viscosity @ 40 º C cSt 47,5
Viscosity index - 158
Fuel Capacity liter 120,0
Type - Closed Type
Tank
Capacity Liter 120,0

Hydraulic
Pressure kg/cm2 0 - 0.5
Oil
Suction filter  90
Return filter  10
Maker - ITL
Transmission
Model type - PS764

Torque converter stall
- 2,52 : 1
ratio
Lubricating L 12,0
Travel System
Weight kg 258
Dimension
HMK 102 B FRONT 12.5-80/18 12PR

REAR 16,9/14x 28 12PR
Tİres
HMK 102 S ALL 4 16,9/14 x 28 12PR

Psi /
Tire Pressure front 58 /4
bar
Psi /
Tire Pressure rear 38 / 2,6
bar
Service
System
Type - Gear Pump

Brake
Brake
Pump
Flow rate cc/rev 4,0

Accumulator
Type - With diaphragm

Service Brake
Brake System
Capacity l 0,75
Gas pressure bar 16
Service brake pressure bar 210

Axle Brake Type - Disc
02
SPECIFICATIONS
LUBRICATION CHART 1
LUBRICATION CHART UNIT : liter
*Initial filling
Refill m
Ambient temperature 0
C
Store Oil capacity
HMK102
equipm. type -30 -20 -10 0 10 20 30 40 50
B-S
SAE 30
Engine oil
SAE 10W
API
Engine oil 11 SAE 10W 30
CF4/SG,
pan
CH-4, or SAE 15W 40 *
CI-4
SAE 40
Transm. CAT TO4, ZF
PS764 TE-ME 3C, 12 SAE 10 W
Allison C4
Transm. ATF Dexron

IID & III
13 ATF
Carraro
102 B
Front axle, 7,6
differantial
102 B
Rear axle
23
hubs &
differantial SAE 90 API GL4, GL5
102 S Gear oil
Front axle, 14
differantial 2 x 1,9
& 2 hubs
102 S
Rear axle, 16
differantial 2 x 1,9
& 2 hubs
ISO VG 32
Hydraulic Hydraulic
120 ISO VG 46
oil tank oil
ISO VG 68
ASTM D975 No.1

Diesel
Fuel tank 120
fuel ASTM D975 No.2, EN590
Fittings of
As
grease Grease NLGI 2, AW, EP (Li. soap or MoS2)
required
nipple
Antifreeze
Cooling & soft ASTM D4985, (antifreeze/water ratio
25 depends on temperature)
system water mix
1:1
02
GENERAL
FOREWORD 1
FOREWORD
Basically, this workshop manual contains the technical information necessary for
operations and repairs in a service workshop.
For easy understanding and using, this manual is divided into sections for each main
system of HİDROMEK 102 energy series backhoe loader.
In addition to this, the divided sections also include internal sections for better
explanation of the topics.
! SAFETY
 Improper operation and maintenance of this machine could result in serious injury
or death.
 Operation and maintenance manual must be read carefully and understood
BEFORE OPERATING THE MACHINE.
 Always keep the Operation & Maintenance Manual and Spare Parts Catalogue in
the machine.
 Precautions must be taken concerning flammable liquids, hazardous fluids, oils,
lubricants and cleaning solvents.
 To prevent injury to workers, the symbol ! is used to mark safety
precautions in this manual. The precautions accompanying this symbol should
always be followed carefully.
 The specifications contained in this manual are subject to change at any time and
without any advance notice. Contact your HİDROMEK distributor for the latest
information.
How to read this manual

Chapter and section
This manual is issued as a guide to carrying out repair and maintenance. To easily
understand this manual it is divided as follows:
Example: 10 – 01
Section number (01 : Structure and function)
Chapter number (10 : Engine)

02
2 GENERAL
FOREWORD
PAGE
Page numbering is started from each section. Therefore, revised pages can be easily
inserted. Also, additional pages and revision number can be indicated.
Example:
Chapter number (10 : Engine)
10
01 Section number (01 : Structure and function)
3
3 rd revision
For the revision status in this manual, refer to REVISION HISTORY.
SYMBOLS
SYMBOL ITEM REMARKS
Special safety precautions are

Safety necessary when performing the
work.
Caution Special technical precautions or

other precautions for preserving
standards are necessary when
performing the work
Tightening Pay attention to the tightening torque

torque during assembly.
Tool Use proper tools in assembling and

disassembling.
Adhesive Places to be applied with adhesive.
Places where oil or lubricant must be

added.
02
3
GENERAL
FOREWORD
HAZARD SYMBOL EXAMPLES

Following symbols are used to convey a better understanding.
HAZARDING ALERT SYMBOLS
Caution – Warning – dangerous

ISO 3864 – B.3.1
Caution – Warning – dangerous

AINSI Z535.4
UL 1492
Caution, flammable
ISO 3864 – B.3.2
Caution, explosion
ISO 3864 – B.3.3
Caution, risk of electric shock

ISO 3864 – B.3.6

UL 1492
Caution, hot surface

IEC 417 - 5041
Caution, rotational object

02
4
GENERAL
FOREWORD
Caution , entanglement
Design: ISO 7001-019
Oxidation
Being reviewed in ISO 3864
Corrosive
ISO 3864 (EC code by EC)
Corrosive
ANSI Z535.3 (Being reviewed in ISO TC/96)
Caution, toxic risk

ISO 3864 (EC code by EC)
Pungent, toxic
Being reviewed in ISO 3864 (EC code by EC)

ANSI Z535.3 (Being reviewed in ISO TC/96)
Hot surface
ANSI Z535.3
02
GENERAL 5
FOREWORD
Caution , hot surface

IEC 417-5041
Entanglement
AINSI Z535.3 (Being reviewed in ISO TC/96)
Pinch
Cut-sever
PROHIBITION SIGNS
Use of matches, lighters and smoking

prohibited
ISO 3864 B.1.2
Do not touch
JIS B 0139 Revised plan
Don’t use in a damp place

IEC 417-5582Pr
03
GENERAL
SAFETY 1
For safety observe the following rules.
GENERAL PRECAUTIONS
SAFETY PRECAUTIONS
 Trained and experienced personnel should carry out the repair and
maintenance works.
Before carrying out any operation or maintenance, carefully read the
OPERATING & MAINTENANCE MANUAL.
 Read all the precautions given on the decals, which are fixed on the machine.
SAFETY DEVICE
 Make sure that all guards and covers are mounted in their proper positions.
Repair or replace if damaged.
 Pay attention to the method of using any safety locking device or safety belt.
SAFETY CLOTHES AND HELMET

 Wear the specified work clothes in the correct manner.
 Use the specified protective gear (helmet, safety glasses, safety shoes, mask,
gloves). Wear goggles, gloves and helmet for guarding against injury from
flying objects. Always have a trained and experienced welder carry out any
welding work. When carrying out welding work, always wear welding gloves,
apron, glasses, cap and other suitable clothes.
00 102 ENERGY WORKSHOP MANUAL
03
2 GENERAL
SAFETY
PREPARATION FOR EMERGENCIES
 Know where fire extinguishers are

located and how to use them.
 Keep a first aid kit and an eye wash kit
near the work area.
 Obtain emergency phone numbers for
doctors, ambulance service, hospital and fire
department
HANDLE FLUIDS SAFELY AND AVOID FIRE
 Handle fuel with care. It is highly flammable

 Do not smoke when refueling and beware of
open fire or sparks from refueling area.
Engine must be stopped when refueling and
Refuel in open and well ventilated area.
 Store flammable fluids away from fire hazards.
 It is dangerous to puncture or throw
the pressurized containers in fire.
DISPOSE OF FLUIDS PROPERLY
 Improperly disposing of fluids is harmful

for environment and ecology. Before draining
any fluids, find out the proper way to dispose of
waste from your local environmental agency.
 Collect draining fuel, oil or other fluids in
Suitable containers. Do not use food or beverage
containers, that may mislead someone to drink from
them. Clean the oil spillage at once.
 Do not pour oil into the ground, sewer system,
stream of the river, pond or lake. Observe the
environmental protection regulations when disposing of oil
fuel, coolant, brake fluid, filters, batteries and other harmful waste.
03
GENERAL 3
SAFETY
AVOID HARMFUL ASBESTOS DUST
 Avoid breathing dust

containing asbestos fibers.
Inhaled asbestos fibers may cause

lung cancer.
 Illuminate working area adequately with

safety lamp. Always use a safety lamp
when working inside or under the machine.
The bulb of the safety lamp must be covered with
a hard wire cage. The bulb may break accidentally
and the hot filament can ignite the spilled fuel or oil.
CAUTION FOR USING HAND TOOLS AND STEPS
 Never jump on or off the machine.

 When you get on or off the machine, be sure
to contact at three points with the machine. The steps
and handrails must be used, and with face towards
the machine. Do not hold any control lever or hand
lever to escalate.
 Always keep the machine clean. Remove

all mud or oil from the steps. Remember that,
dirtiness is the first reason of any accident or trouble.
03
4 GENERAL
SAFETY
PREPARATIONS FOR WORK
WARN OTHERS WHEN SERVICING

 Unexpected machine movement
can cause serious injury.
 Before performing any work on
the machine, attach a
“DO NOT OPERATE” tag on the steering
wheel.
 When carrying out any operation
with two or more workers, always agree
on the operating procedure before
starting.
 Whether a “DO NOT OPERATE”
tag is attached or not, sound travel alarm
before the machine starts to move.
USE TOOLS PROPERLY
 Keep all tools in good condition and learn

how to use them.
 For keeping the tools and dismantled parts,
have an appropriate and clean area in the
workshop.
 Always keep the work area clean and be sure
that the floor is out of dirt and oil.
 Park the machine on a level and firm ground before adding oil or starting any
repair.
 Lower the machine attachments on the

ground before starting any repair work. If it is
not possible, apply safety lock or blockage
material to prevent the attachment from
falling down.
 Turn the engine “OFF”, keep the start
key with you and lock the levers to “LOCK”
position before leaving operator cab.
Otherwise the machine may suddenly operate

and cause serious injury or death.
03
GENERAL
SAFETY 5
COOLING SYSTEM SAFETY
 Hot coolant can burn you.

 When the radiator is hot,
turn the radiator cap slowly with a piece
of cloth to release the pressure.
 Do not remove the radiator cap
when the engine is overheated.
AVOID PRESSURIZED FLUIDS
 High pressurized fluids can penetrate under

the skin and cause serious injury.
 Avoid the hazards of pressurized fluids

by releasing pressure, before disconnecting the pressurized lines, like hydraulic, fuel
or etc.
 Use a piece of a cardboard when searching

for leaks. Protect your hands, eyes and body from
the high pressurized fluids.
 Be careful not to break, twist or damage the high pressurized pipes and hoses
can cause electrical ignition and fire.
HANDLING OF HEAVY OBJECTS

 Use a hoist or crane when lifting heavy components.
 Wire ropes, chains and hooks must be in good working
conditions and free of damages.
 The capacity of the lifting equipment and lifting points
must be very well known.
 Before assembling or disassembling work, support

the machine with wooden blocks, jacks or stands.
 Before starting work, lower the bucket on the ground.
 Its forbidden to work under the equipment without any support or lock.
03
6 GENERAL
SAFETY
ELECTRICAL SYSTEM
 Before welding on the machine or repairing

the electrical system, ALWAYS turn the master
switch OFF. Disconnect the negative ( - )
terminal of the battery.
 Be careful not to break or damage wiring,
when dismounting or removing components.
Damaged wires can cause short-circuit spark
and fire.
 Wear safety glasses when working with the

batteries.
 The sulfuric acid of the electrolyte is poisonous
and harmful. If it is splashed, immediately flush with
plenty of water.
 If splashed into eye, wash your eyes with plenty of water and get medical first
aid.
 To inhale the electrolyte vapor is harmful for your lungs.
 Because of explosion risk, keep away sparks,

open flame from top of the battery.
 Wear a safety mask not to inhale the vapor.
 If the terminals are short-circuited

with a metal object, the battery may explode.
Do not put any metal object or wire on the battery.
 It is important to tighten the battery terminals
properly. Otherwise, because of insufficient contact,
there will be a contact resistance and heat will be generates on the terminals. The
lead terminal abrasion will occur.
 Be careful with the polarity when connecting the
battery terminals.
 Do not wash the sensors, connectors and

instruments in the cab with water or steam. Dampness
in the electrical system can cause abnormal operation
and failure.
03
GENERAL
SAFETY 7
CAUTIONS DURING REPAIRS
 When dismounting any cover or cap under spring

tension or system pressure, be careful with removing the
bolts. Two bolts on opposite sides must be removed after
the spring tension or pressure is released.
 High pressure grease in the recoil spring adjusting

system can eject and cause injury.
Do not loosen the grease valve more then 1 turn, before the grease pressure is
released in the system.
 When assembling and disassembling parts,

always use specified tightening torques.
 Installing protective guards, cage, etc. is very important.

The rotation part’s guards must be installed and tighten correctly.
 Be careful not to let your clothes or hair loose

to be caught by rotating parts.
 Never touch or try to hold rotating parts such as

fan blades or fan belts.
 Never insert your finger or hand to align two holes.
 Be careful not to pinch your fingers in a hole,

between parts or tools.
04
GENERAL 1
STANDARTS
MEASUREMENT CONVERSIONS
LENGTH
Unit cm m km in ft yd mile
cm 1 0,01 0,00001 0,3937 0,032808 0,0109361 0,0000062
m 100 1 0,001 39,37 3,28083 1,093613 0,0006214
km 100000 1000 1 39370,078 3280,839 1093,613 0,6213712
in 2,54 0,0254 0,0000254 1 0,083333 0,027778 0,0000158
ft 30,48 0,3048 0,0003048 12 1 0,333333 0,0001894
yd 91,44 0,9144 0,000914 36 3 1 0,000568
mile 160934,4 1609,344 1,609344 63360 5280 1760 1
1 mm = 0,1 cm 1μ = 0,001 mm
AREA
Unit cm² m² km² a ft² yd² in²

cm² 1 0,0001 - 0,000001 0,0010764 0,0001196 0,155
m² 10000 1 0,000001 0,01 10,76391 1,19599 1550
km² - 1000000 1 10000 10763910,4 1195990 -
a 1000000 100 0,0001 1 1076,39 119,5990 -
ft² 929,03 0,092903 - 0,000929 1 0,111111 144
yd² 8361,27 0,8361274 - 0,0083613 9 1 1296
in² 6,4516 0,0006452 - 0,0000065 0,0069444 0,0007716 1

1 ha = 100 a, 1 mile² = 259 ha = 2,59 km²
04
2 GENERAL
STANDARTS
VOLUME
Unit cm³ = cc m³ l in³ ft³ yd³

cm³ = ml 1 0,000001 0,001 0,0610237 0,0000353 0,0000013
m³ 1000000 1 1000 61,024 35,315 1,30795
l 1000 0,001 1 61,024 0,035315 0,001308
in³ 16,387 0,0000164 0,0163871 1 0,0005787 0,0000214
ft³ 28316,84 0,0283168 28,31684 1728 1 0,037037
yd³ 764554,8 0,7645549 764,5548 46656 27 1
1 gal (US) = 3785,41 cm³ = 231 in³ = 0,83267 gal (US)
WEIGHT
Unit g kg t oz lb
g 1 0, 001 0,000001 0,035274 0,0022
kg 1000 1 0,001 35273,96 2204,62
t 1000000 1000 1 35273 2204,59
oz 28,34952 0,0283495 0,0000283 1 0,0625
lb 453,59237 0,4535924 0,0004536 16 1

1 ton (metric) =1,1023 ton (US) = 0,9842 ton (UK)
PRESSURE
Unit kgf/cm² bar Pa = N/m² kPa Lbf/in² Lbf/ft²

kgf/cm² 1 0,980665 98066,5 98,0665 14,22334 2048,161
bar 1,019716 1 100000 100 14,50377 2088,543
Pa = N/m² 0,0000102 0,00001 1 0,001 0,000145 0,0208854
kPa 0,0101972 0,01 1000 1 0,1450377 20,88543
Lbf/in² 0,070307 0,0689476 6894,7572 6,894757 1 144
Lbf/ft² 0,0004882 0,0004788 47,8802589 0,0478803 0,0069444 1
1 kgf/cm² = 735,55923 torr (mm Hg)= 0,967841 atm
04
GENERAL
STANDARTS 3
APPROXIMATE CONVERSIONS
TORQUE Conversion Conversion

factor factor
newton meter (N.m) x 10,2 = kgf.cm x 0,8664 = lb.in
newton meter (N.m) x 0,74 = lbf.ft x 1,36 = N.m
newton meter (N.m) x 0,102 = kgf.m x 7,22 = lbf.ft
PRESSURE (Pa =N/m²)

kilopascal (kPa) x 4,0 = in (water column) x 0,249 = kPa
kilopascal (kPa) x 0,295 = in (Hg column) x 3,386 = kPa
kilopascal (kPa) x 0,145 = psi x 6,894 = kPa
bar x 14,5 = psi x 0,069 = bar
kgf/cm² x 14,22 = psi x 0,070 = kgf/cm²
newton/mm² x 145,04 = psi x 0,069 = bar
megapascal (MPa) x 145 = psi x 0,00689 = MPa
POWER (W = J/s)
kilowatt (kW) x 1,359 = PS (cv) x 0,736 = kW
kilowatt (kW) x 1,34 = HP x 0,746 = kW
kilo watt (kW) x 0,948 = Btu / s x 1,055 = kW
watt (W) x 0,737 = ft.lb/s x 1,355 =W
ENERGY (J =N.m)
kilojoule (kJ) x 0,9478 = Btu x 1,055 = kJ
Joule (J) x 0,239 = calorie x 4,185 =J
VELOCITY AND
ACCELERATION
meter per sec² (m/s²) x 3,28 = ft/s² x 0,3048 = m/s²
meter per second (m/s) x 3,28 = ft/s x 0,3048 = m/s
kilometer per hour (km/h) x 0,62 = mph x 1,609 = km/h
TEMPERATURE
ºC = (ºF - 32) ÷ 1,8 ºF=(ºC x 1,8)+32
FLOW RATE
l / min (dm³/min) x 0,264 = US gal/min x 3,785 = l/min
04
4 GENERAL
STANDARTS
STANDARD TIGHTENING TORQUE
The following charts give the standard tightening torques of bolts and nuts.
Exceptions are given in chapter of “Disassembly and Assembly “
METER TABLE
Classification 4T, 5T 10T
Bolt type
Bolt size Torque kgf.m (lbf.ft) Torque kgf.m (lbf.ft)
M4 0,2 ± 0,02 (1,4±0,1) 0,4 ± 0,04 (2,9±0,3)
M5 0,3 ± 0,03 (2,2±0,2) 0,8 ± 0,08 (5,8±0,6)
M6 0,5 ± 0,05 (3,6±0,4) 1,4 ± 0,14 (10,1±1,0)
M8 1,2 ± 0,12 (8,7±0,9) 3,3 ± 0,30 (23,8±2,2)
M10 2,3 ± 0,23 (16,6±1,7) 6,5 ± 0,70 (47,0±5,0)
M12 4,0 ± 0,40 (29,0±3,0) 11,3 ± 1,10 (82,0±8,0)
<M14> 6,4 ± 0,60 (46,0±4,0) 17,9 ± 1,80 (129±13)
M16 9,5 ± 0,90 (69,0±6,0) 26,7 ± 2,70 (193±19)
<M18> 13,5 ± 1,40 (97,0±10,0) 38,0± 3,80 (274±27)
M20 18,6 ± 1,90 (134±14,0) 52,2 ± 5,20 (377±38)
<M22> 24,7 ± 2,50 (178±18,0) 69,4 ± 6,90 (500±50)
M24 32,1 ± 3,20 (232±23,0) 90,2 ± 9,00 (650±65)
M30 62,6 ± 6,30 (452±45,0) 176,1 ± 17,6 (1270±127)
M36 108,2 ± 10,80 (781±78,0) 304,3 ± 30,4 (2200±220)
M42 171,8 ± 17,20 (1240±124) 483,2 ± 48,3 (3500±350)
M45 211,3 ± 21,10 (1525±152) 594,3 ± 50,4 (4300±430)

04
GENERAL
STANDARTS 5
INCH TABLE
Classification 4T, 5T 10T
Bolt type
Bolt size Torque kgf.m (lbf.ft) Torque kgf.m (lbf.ft)
¼” 0,6 ± 0,06 (4,3±0,4) 1,7 ± 0,20 (12,2±1,2)
5/16” 1,2 ± 0,12 (8,7±0,8) 3,0 ± 0,30 (21,7±2,2)
3/8” 2,0 ± 0,20 (14,4±1,4) 5,6 ± 0,50 (40±4,0)
7/16” 3,2 ± 0,32 (23,0±2,0) 8,9 ± 0,90 (64±6)
½” 4,7 ± 0,47 (34,0±3,0) 13,4 ± 1,30 (97±10)
9/16” 6,8 ± 0,68 (50,0±5,0) 19,0 ± 1,90 (137±14)
5/8” 9,3 ± 0,93 (67,0±7,0) 26,1 ± 2,60 (190±19)
¾” 16,0 ± 1,60 (115±15) 45,1 ± 4,50 (325±33)
7/8” 25,5 ± 2,55 (185±19) 71,6± 7,20 (520±52)
1” 38,0 ± 3,80 (275±27,0) 106,9 ± 10,7 (770±77)
1 1/8” 54,1 ± 5,40 (390±39,0) 152,2 ± 15,2 (1100±110)
1 ¼” 74,2 ± 7,42 (535±54,0) 208,9 ± 20,9 (1510±151)
1 ¾” 98,8 ± 9,88 (710±71,0) 277,8 ± 27,8 (2000±200)
1 ½” 128,2 ± 12,80 (925±93,0) 360,7 ± 36,1 (2600±260)
NOTE : 1N.m ~ 0,1 kgf.m

ENGINE
 10- 01 Specifications
 10 - 02 Workshop
01
ENGINE
SPECIFICATIONS 1
INTRODUCTION
The PERKINS 1100 series engine is 4 cylinders

and RG model turbocharged.
Identification of the engine is:

1104C-44T.
The engine conforms with EEC stage 2

emmissions legislation for construction machine
application.
Gross intermittent Speed

Performance data
ISO/TR 14396 rev/min
Power output (kW) 74,5 2400
Power output (bhp) 99,5 2400
Peak torque (Nm) 372 1400
Peak torque (lbf.ft) 274 1400
01
ENGINE
2 SPECIFICATIONS
PERFORMANCE CURVE
Note: Lower speed ratings cannot be read off this curve
GENERAL DATA
Dimensions
01
ENGINE
SPECIFICATIONS 3
GENERAL DATA
Bore and stroke 105 mm x 127 mm
Number of cylinders In-line 4 cylinders
Cubic capacity 4,4 litres (269 cu.in)
Cycle 4 stroke
Aspiration Turbocharged
Combustion system Direct injection
Compression ratio 19,3 : 1
Engine rotation Anticlockwise (viewed on flywheel)
Governing All speed mechanical
Cooling system Pressurized water
Length 663 mm
Width 597 mm
Height 810 mm
Dry weight 305 kg

01
ENGINE
4 SPECIFICATIONS
GENERAL VIEW
1 Rocker cover 4 Fuel injection pump 7 Water pump
2 Oil pan breather 5 Oil filter 8 Fan pulley
3 Fuel filter 6 Crank shaft pulley 9 Thermostat

01
ENGINE
SPECIFICATIONS 5
GENERAL VIEW (cont’d)
10 Oil filling cap 13 Turbocharger 16 Crank shaft dumper
11 Exhaust manifold 14 Starter 17 Air intake
12 Charge alternator 15 Dumper housing

01
ENGINE
6 SPECIFICATIONS
18 Charge alternator 20 Turbo oil feed 22 Turbocharger
19 Fan pulley 21 Turbo oil drain 23 Exhaust manifold

01
ENGINE
SPECIFICATIONS 7
24 Fuel feed pump 27 Starter 30 Oil pan
25 Oil filling cap 28 Oil level dipstick 31 Crank shaft pulley
26 Fuel filter 29 Oil filter 32 Water pump
33 Thermostat housing
01
ENGINE
8 SPECIFICATIONS
INTAKE & EXHAUST VALVES
A : Intake valve B: Exhaust valve
ENGINE IDENTIFICATION ETHICHET

02
ENGINE
WORKSHOP 1
GENERAL INFORMATION
INTRODUCTION
This Workshop Manual has been written to provide assistance in the service and
overhaul of Perkins 1100 series 4 cylinder engines. It should be used in conjunction
with normal workshop practice and information contained in current service bulletins.
Mention of certain accepted practices therefore, has been purposely omitted in order
to avoid repetition. For overhaul procedures the assumption is made that the engine
is removed from the application.
The engine conforms with USA (EPA/CARB) stage 2 and EEC stage 2 emissions
legislation for agriculture, construction and industrial applications.
When reference is made to the “left” or “right” side of the engine, this is as seen from
the flywheel end of the engine.
“SAFETY PRECAUTIONS” are given for your protection and must be used all times.
Danger is inbdicated in the text by two methods:

Warning ! This indicates that there is a possible danger to the person.
Caution : This indicates that there is a possible danger to the engine.
Note : Is used where the information is important, but there is no a danger.
In this Workshop Manual, the Perkins 1100 series RG model turbocharged 4

cylinders engine workshop procedures are explained.
The correct identification of the engine is by the full engine number. The engine
number is stamped on a label which is fastened to the left side of the cylinder block.
If you need parts, service or information for your engine, you must give the complete
engine number to the HİDROMEK ‘s After Sales Dealers and Service.
The engine serial number plate contains the

following information:
(1) TPL number
(2) Type
(3) Serial number
(4) List number
02
ENGINE
2 WORKSHOP
SAFETY PRECAUTIONS
These safety precautions are important. You must refer also to the local
regulations in the country of use. Some items only refer to specific applications.
 Only use these engines in the type of application for which they have been
designed.
 Do not change the specification of the engine.
 Do not smoke when you fill the fuel tank.
 Clean away fuel which has been spilt. Material which has been contaminated
by fuel must be moved to a safe place.
 Do not refill the fuel tank while the engine runs (unless it is absolutely
necessary).
 Do not clean, add lubricating oil, or adjust the engine while it runs (unless you
have had the correct training; even then extreme care must be used to prevent
injury).
 Do not make adjustments that you do not understand.
 Ensure that the engine does not run in a location where it can cause a
concentration of toxic emmisisons.
 Other persons must be kept at a safe distance while the engine or auxiliary
equipment is in operation.
 Do not permit loose clothing or long hair near moving parts.
 Keep away from moving parts during engine operation.
Warning! Some moving parts cannot be seen clearly while the engine runs.
 Do not operate the engine if a safety guard has been removed.
 Do not remove the filler cap, or any component of the cooling system while the
engine is hot and while the coolant is under pressure because dangerous hot
coolant can be discharged.
 Do not allow sparks or fire near the batteries (especially when the batteries are
on charge) because the gases from the electrolyte are highly flammable. The
battery fluid is dangerous to the skin and especially to the eyes.
 Disconnect the battery terminals before a repair is made to the electrical
system.
 Only one person must control the engine.
 Ensure that the engine is operated only from the control panel or from the
operator’s position.
 If your skin comes into contact with high pressure fuel, obtain medical
assistance immediately.
 Diesel fuel and lubricating oil (especially used lubricating oil) can damage the
skin of certain persons. Protect your hands with gloves or a special solution to
protect the skin.
 The combustible material of some components of the engine (for example
certain seals) can become extremely dangerous if it is burned. Never allow
this burnt material to come into contact with the skin or with the eyes.
 Do not wear clothing which is contaminated by lubricating oil. Do not put
material which is contaminated with oil into the pockets of clothings.
 Discard used lubricating oil in a safe place to prevent contamination.
02
ENGINE
WORKSHOP 3
SAFETY PRECAUTIONS (cont’d)
 Ensure that the control lever of the transmission drive is in the “out-of-drive”
position before the engine is started.
 Use extreme care if emergency repairs must be made in adverse conditions.
 Always use a safety cage to protect the operator when a component is to be
pressure tested in a container of water. Fit safety wires to secure the plugs
which seal the hose connections of a component which is to be pressure
tested.
 Do not allow compressed air to contact your skin. If compressed air enters
your skin, obtain medical help immediately.
 Turbochargers operate at high speed and at high temperatures. Keep fingers,
tools and items away from the inlet and outlet ports of the turbocharger and
prevent contact with hot surfaces.
 Do not clean an engine while it runs. If cold cleaning fluids are applied to a hot
engine, certain components on the engine may be damaged.
 Fit only genuine Perkins parts from your HİDROMEK dealer.
ENGINE LIFT EQUIPMENT
The maximum weight of the engine without

coolant, lubricant, or a gear box fitted will
vary for different applications. It is
recommended that lift equipment of minimum
capacity is used: 600 kg (1320 lbs)
Note: Use lift equipment or obtain assistance

to lift heavy engine components.
Before the engine is lifted:

 Always use lift equipment of the
approved type and correct capacity to
lift the engine. It is recommended that
lift equipment of the type shown in the
figure is used, to provide a vertical lift
directly above the engine lift brackets
(1). Never use a single lift bracket to
raise an engine.
 Check the engine lift brackets for
damage and that they are secure
before the engine is lifted. The torque
for the setscrews for the engine lift brackets is 44 Nm (33 lbf.ft) 4,5 kgf m.
 To prevent damage to the rocker cover, ensure that there is clearance
between the hooks and the rocker cover.
02
ENGINE
4 WORKSHOP
VITON SEALS
Some seals used in engines, and in components fitted to engines, are made of Viton.
Viton is used by many manufacturers and is a safe material under normal conditions
of operation.
If Viton is burned, a product of this burnt material is an acid which is extremely
dangerous. Never allow this burnt material to come into contact with the skin or with
the eyes.
If it is necessary to come into contact with components which have been burnt,
ensure that the precautions which follow are used:
 Ensure that the components have cooled.
 Use neoprene gloves and discard the gloves safely after use.
 Wash the area with the calcium hydroxide solution and then with clean water.
 Disposal of components and gloves which are contaminated must be in
accordance with local regulations.
If there is contamination of the skin or eyes, wash the affected area with a contunious
supply of clean water or with calcium hydroxide solution for 15 - 60 minutes. Obtain
immediate medical attention.
SAFETY CAUTIONS WHEN AN ENGINE IS CLEANED
Care should be taken, when an engine is cleaned with a high pressure cleaning
system.
Cautions:
 Do not wash an engine while it runs or while it is hot. If cold cleaning fluids are
applied to a hot engine, certain components on the engine could be damaged.
 Leave the engine to cool for at least one hour and disconnect the battery
connections before cleaning.
 Do not wash any part of the fuel injection pump, cold starty device, electrical
shut off solenoid or electrical connectors.
 Ensure that the alternator, starter motor and any other electrical components
are shilded and not directly cleaned by the high pressure cleaning system.
If these cautions are ignored, the engine or certain components could be damaged,
fail to operate and also make the manufacturer’s warranty invalid.
02
ENGINE
WORKSHOP 5
BASIC ENGINE DATA
Number of cylinders ………………………. 4
Cylinder arrangement …………………….. In line
Cycle ……………………………………….. Four stroke
Direction of rotation ………………………. Clockwise from the front
Induction system ………………………….. Turbocharged
Combustion system ………………………. Direct injection
Nominal bore ……………………………… 105 mm (4.133 in)
Stroke ………………………………………. 127 mm (5.00 in)
Compression ratio ………………………… 19,3 : 1
Cubic capacity …………………………….. 4,4 liters (268 in3 )
Firing order ………………………………… 1-3-4-2
Valve tip clearances (cold)

Inlet …………………………………………. 0,20 mm (0.008 in)
Exhaust …………………………………….. 0,45 mm (0.018 in)
Lubricating oil pressure*………………... 300 kPa (43 lbf/in2 ) 3.0 kgf/cm2

* Minimum value at maximum engine speed and normal engine temperature.
02
ENGINE
6 WORKSHOP
DATA AND DIMENSIONS

Note: This information is given as a guide for personnel engaged on engine
overhauls. The dimensions which are shown are those which are mainly used in the
factory. The information applies to all engines, unless an engine type code is shown.
CYLINDER HEAD
Angle of valve seat:
Intake ………………………………………. 300 (1200 included angle)
Exhaust ……………………………………. 300 (1200 included angle)
Leak test pressure ……………………….. 200 kPa (29 lbf/in2 ) 2,04 kgf/cm2
Head thickness …………………………… 117,95/118,05 mm (4.643/4.647 in)
Rz and Rmax to be measured to DIN EN ISO 4287

Surface finish of head face for cylinder head joint ………. Rz < 15µm Rmax < 20 µm
Permissible wave depth:

Wt < 4 µm with a wave distance Wd < 2,0 mm
Diameter of parent bore for valve guide:
Intake ………………………………………. 13,000/13,027 mm (0.5118/0.5129 in)

Exhaust ……………………………………. 13,000/13,027 mm (0.5118/0.5129 in)
Min permissible thickness after head face
has been machined ………………………. 117,20 mm (4.614 in)
Max permissible distortion of cylinder

head face:
1 0,03 mm (0.0012 in)
2 0,05 mm (0.0019 in)
3 0,05 mm (0.0019 in)
4 0,03 mm (0.0012 in)

02
ENGINE
WORKSHOP 7
INTAKE AND EXHAUST VALVES:
Intake valves:
Diameter of valve stem ………………….......... 8,953/8,975 mm (0.3525/0.3533 in)
Clearance in valve guide ……………………… 0,025/0,069 mm (0.001/0.0027 in)
Max permissible clearance in valve guide:
Production limit …………………………………. 0,069 mm (0.0027 in)
Service limit ……………………………………... 0,13 mm (0.005 in)
Diameter of valve head ………………………... 46,20/46,45 mm (1.819/1.829 in)
Angle of valve face …………………………….. 300
Full length ………………………………………. 128,92/129,37 mm (5.076/5.093 in)
Stem seal with integral seating
Seal arrangement ………………………………
washer
Depth of valve head below the face of cylinder
head:
Production limits ………………………………... 1,58/1,84 mm (0.062/0.072 in)
Exhaust valves:
Diameter of valve stem ………………….......... 8,938/8,960 mm (0.3519/0.0528 in)
Clearance in valve guide ……………………… 0,040/0,84 mm (0.0016/0.033 in)
Max permissible clearance in valve guide:
Production limit …………………………………. 0,084 mm (0.003 in)
Diameter of valve head ………………………... 41,51/41,75 mm (1.634/1.644 in)
Angle of valve face …………………………….. 300
Full length ………………………………………. 128,92/129,37 mm (5.076/5.093 in)
Stem seal with integral seating
Seal arrangement ………………………………
washer
Depth of valve head below the face of cylinder
head:
Production limits ………………………………... 1,53/1,81 mm (0.060/0.071 in)
02
ENGINE
8 WORKSHOP
Dimensions of recesses for valve seat inserts:
Intake
1 10,910/11,040 mm (0.4295/0.4346 in)
2 47,820/47,845 mm (1.8827/1.8837 in)
3 Radius 0,38 mm (0.015 in) maximum
Exhaust
1 10,910/11,040 mm (0.4295/0.4346 in)
2 42,420/42,445 mm (1.670/1.6711 in)
Valve seat insert tool:

Intake
1 1,5 mm (0.06 in)
2 20 mm (0.800 in)
3 6,8/7,1 mm (0.267/0.279 in)
4 100 mm (3.940 in)
5 38,10/38,30 mm (1.500/1.507 in)
6 46,25/46,50 mm (1.820/1.830 in)
8 Radius 1,5 mm (0.06 in)
9 1,5 mm (0.06 in)
10 8,77/8,80 mm (0.345/0.346 in)
Exhaust
1 1,5 mm (0.06 in)
2 20 mm (0.800 in)
3 7,2/7,5 mm (0.283/0.295 in)
4 100 mm (3.940 in)
5 34,38/34,58 mm (1.353/1.361 in)
6 41,75/42,00 mm (1.643/1.653 in)
8 Radius 1,5 mm (0.06 in)
9 1,5 mm (0.06 in)
10 8,77/8,80 mm (0.345/0.346 in)
02
ENGINE
WORKSHOP 9
VALVE GUIDES AND VALVE SPRINGS :
Valve guides
Inside diameter of partially finished guide …. 8,25/8,35 mm (0.3248/0.3287 in)
Inside diameter of finshed guide ……………. 9,000/9,022 mm (0.3543/0.3552 in)
Outside diameter:
Intake ….………………………………………... 13,034/13,047 mm (0.5131/0.5137 in)
Exhaust …………………………………………. 13,034/13,047 mm (0.5131/0.5137 in)
Interference fit of valve guide in cylinder head. 0,007/0,047 mm (0.0003/0.0019 in)
Full length ………………………………………. 51,00/51,50 mm (2.008/2.028 in)
Protrusion from bottom of recess for valve
12,35/12,65 mm (0.486/0.498 in)
spring……………………………………………..
Valve springs
Fitted length:
Models RG ……………………………………… 34,5 mm (1.358 in)
Load fitted length:
Models RG ……………………………………… 229 N (51 lbf) 23,0 kgf
Number of active coils …………………………. 3,8
Number of damper coils ……………………….. 0
Direction of coils ………………………………... Right hand
TAPPETS, ROCKER SHAFT, ROCKER LEVERS
Tappets:
Diameter of tappet stem ……………………….. 18,987/19,012 mm (0.7480/0.7485 in)
Diameter of tappet bore in cylinder block ……. 19,050/19,082 mm (0.7500/0.7513 in)
Clearance of tappet in cylinder block ………… 0,038/0,095 mm (0.0015/0.0037 in)
Rocker shaft:
Outside diameter ……………………………….. 24,962/24,987 mm (0.9828/0.9837 in)
Rocker levers and bushes:
Diameter of parent bore for rocker lever …….. 25,013/25,051 mm (0.9848/0.9863 in)
Clearance between rocker lever bore and
0,026/0,890 mm (0.0010/0.0035 in)
rocker shaft ………………………………………
Maximum permissible clearance between
0,17 mm (0.007 in)
rocker lever bore and rocker shaft …………….
02
ENGINE
10 WORKSHOP
PISTONS AND PISTON COOLING JETS
Pistons
“Fastram” combustion bowl,
Type …………………………………………
re-entrant angle 800
Diameter of bore for gudgeon pin ……….. 39,703/39,709 mm (1.5631/1.5633 in)
Height of piston above top face of cylinder
0,21/0,35 mm (0.008/0.0137 in)
block …………………………………………
Width of groove for top ring:
Engine type RG …………………………….. Tapered
Width of groove second ring……………….. 2,54/2,56 mm (0.0999/0.1007 in)
Width of groove third ring ………………….. 3,52/3,54 mm (0.1385/0.1393 in)
Piston cooling jets
150/250 kPa (22/36 lbf/in2)
Valve opening pressure ……………………
1,5/2,5 kgf/cm2
Piston rings
Top compression ring:
Barrel face, molybdenum insert,
Engine type RG ……………………………..
keystone
Taper face, cast iron, internal bottom
Second compression ring ………………….
chamfer
Width of top ring:
Engine type RG …………………………….. Tapered
Width of second ring ……………………….. 2,47/2,49 mm (0.097/0.098 in)
Width of third ring …………………………... 3,47/3,49 mm (0,1366/0,1374 in)
Clearance of top ring in groove:
Engine type RG …………………………….. Wedge
Clearance of second ring in groove ……… 0,05/0,09 mm (0.002/0.003 in)
Clearance of third ring in groove ….……… 0,03/0,07 mm (0.0011/0.0027 in)
Gap of top ring ……………………………… 0,30/0,55 mm (0.0118/0.0216 in)
Gap of second ring …………………………. 0,70/0,95 mm (0.0275/0.0374 in)
Gap of third ring …………………………….. 0,30/0,55 mm (0.0118/0.0216 in)
02
ENGINE
WORKSHOP 11
CONNECTING RODS AND BIG END BEARINGS
Connecting rods:
Type ……………………………………… “H” shape section, wedge shape small end
Location of cap to connecting rod ……. Fracture split
Diameter of parent bore for big end ….. 67,21/67,22 mm (2.6460/2.6465 in)
Diameter of parent bore for small end .. 43,01/43,03 mm (1.693/1.694 in)
Length grade:
Length between centres (parent bores). 219,05/219,10 mm (8.624/8.626 in)
Big end bearings:
Turbocharged engines bearing cap ….. 4x steel back, tin/aluminium bearing material
Turbocharged engines bearing rod ….. 4x steel back, leaded bronze bearing material
Width …………………………………….. 31,55/31,88 mm (1.240/1.255 in)
Thickness at center of bearings ………. 1,835/1,842 mm (0.0723/0.0725 in)
Bearing clearance ……………………… 0,030/0,081 mm (0.0012/0.0032 in)
- 0,25 mm (- 0.010 in); - 0,50 mm (- 0.020 in)
Available undersize bearings ………….
- 0,75 mm (- 0.030 in)
GUDGEON PINS AND SMALL END BUSHES
Gudgeon pins:
Type …………………………………………… Fully floating
Outside diameter …………………………….. 39,694/39,700 mm (1.5628/1.5630 in)
Clearance fit in piston boss …………………. 0,003/0,015 mm (0.0001/0.0006 in)
Small end bushes:
Type …………………………………………… Steel back, lead bronze
Outside diameter …………………………….. 43,66/43,84 mm (1.7190/1.7259 in)
Inside diameter ………………………………. 39,723/39,738 mm (1.5638/1.5645 in)
Surface finish grade …………………………. Ra 0,8 µm
Cleararnce between bush in small end and
gudgeon pin ………………………………….. 0,023/0,044 mm (0.0009/0.0017 in)
02
ENGINE
12 WORKSHOP
CRANKSHAFT
Diameter of main journals ……………….. 76,159/76,180 mm (2.9984/2.9992 in)

Maximum wear and ovality on journals
and crank pins …………………………….. 0,04 mm (0.0016 in)
Width of center journal …………………… 44,15/44,22 mm (1.738/1.741 in)
Width of all other journals ………………... 39,24/39,34 mm (1.545/1.549 in)
Diameter of crank pins …………………… 63,47/63,49 mm (2.499/2.500 in)
Width of crank pins ……………………….. 40,35/40,42 mm (1.589/1.591 in)
Diameter of flange ………………………… 135,27/135,32 mm (5.3257/5.3277 in)
Depth of recess for spigot bearing ……… 46,96/46,99 mm (1.8488/1.8499 in)
Crankshaft end-float ……………………… 0,05/0,38 mm (0.002/0.015 in)
Maximum permissible end-float …………. 0,51 mm (0.020 in)
Fillet radii of journals and crank pins …… 3,68/3,96 mm (0.145/0.156 in)
- 0,25 mm (- 0.010 in);
Undersize journals and crank pins ……… - 0,51 mm (- 0.020 in);
- 0,76 mm (- 0.030 in)
Crankshaft heat treatment:
Induction hardened ……………………….. Part no: 3131D74, 4114A006
Nitrocarburized ……………………………. Part no: 3131D072, 4112A005
CRANKSHAFT OVERHAUL
Notes:
 Nitrocarburized crankshafts must be hardened again, each time they are
machined. These crankshafts must be nitrocarburized or, if this process is not
available, they can be nitrided for 20 hours. If neither process is available a
new crankshaft, or a “new for old” crankshaft must be fitted.
 Check the crankshaft for cracks before and after it is ground. Demagnetize the
crankshaft after it has been checked for cracks.
 After the crankshaft has been machined remove any sharp corners from the
lubricating oil holes.
 Surface finish and fillet radii must be maintained and require Ra 0,4 µm.
02
ENGINE
WORKSHOP 13
The finished sizes for crankshaft journals which have been ground undersize are
given in the table below:
Item 0,25 mm ( 0.10 in) 0,51 mm (0.20 in) 0,76 mm (0.030 in)
75,909/75,930 mm 75,649/75,670 mm 75,399/75,420 mm
1
(2.9884/2.9892 in) (2.9784/2.9792 in) )2.9684/2.9692 in)
63,220/63,240 mm 62,960/62,982 mm 62,708/62,728 mm
2
(2.488/2.4896 in) (2.4788/2.4796 in) (2.4688/2.4696 in)
3 39,47 mm (1.554 in) max - -
4 37,44 mm (1.474 in) max - -
5 44,68 mm (1.759 in) max - -
6 40,55 mm (1.596 in) max - -
7 Do not machine - -
8 Do not machine - -
3,68/3,69 mm
9 - -
(0.1448/0.1452 in)
Surface finish for journals, crank pins and fillet radii must be 0,4 microns (16 micro
inches). Surface finish for the seal area of the crankshaft palm must be 0,4/1,1
microns (16/43 micro inches).
02
ENGINE
14 WORKSHOP
With the crankshaft on mountings at the front and rear journals, the maximum run-out
(total indicator reading) at the journals must not be more than shown below:
Journal Maximum run-out

1 mounting
2 0,08 mm (0.0031 in)
3 0,15 mm (0.0059 in)
4 0,08 mm (0.0031 in)
5 mounting
Run-out must not be opposite. The difference in run-out between one journal and the
next must not be more than 0,10 mm (0.004 in).
Run-out on the crankshaft pulley diameter, rear oil seal diameter and the rear flange
diameter must not be more than 0,05 mm (0.002 in) total indicator reading.
MAIN BEARINGS
Type ………………………………… Steel back with, tin/aluminium bearing material
Bearing width:
All bearings …………………………. 31,62/31,88 mm (1.244/1.255 in)
Bearing thickness at center ……….. 2,083/2,089 mm (0.0820/0.0823 in)
Bearing clearance:
All bearings …………………………. 0,057/0,117 mm (0.0022/0.0046 in)
- 0,25 mm (- 0.010 in); -0,50 mm (- 0.020 in);
Available undersize bearings ……...
-0,75 mm (-0.030 in)
CRANKSHAFT THRUST WASHERS

Type ………………………………… Steel back bearing material
Position ……………………………. Each side of center main bearing
Thickness:
Standard …………………………… 2,26/2,31 mm (0.089/0.091 in)
Oversize …………………………… 2,45/2,50 mm (0.096/0.098 in)

02
ENGINE
WORKSHOP 15
Balancer unit:
Number of teeth on gear of drive shaft ………. 17
Backlash from gear of drive shaft to idler gear 0,097/0,17 mm (0.0038/0.0066 in)
Diameter of bore for idler gear ………………... 37,197/37,212 mm (1.5431/1.5437 in)
Diameter of hub of idler gear ………………….. 37,152/37,162 mm (1.4626/1.4630 in)
End-float of idler gear ………………………….. 0,12/0,27 mm (0.0047/0.0106 in)
Number of teeth on idler gear ………………… 44
Lubricating oil pump on the balancer:

Type ……………………………………………. Differential rotor, gear driven
Number of lobes:
Inner rotor ……………………………………... 4
Outer rotor …………………………………….. 5
Clearance of outer rotor to body ……………. 0,13/0,23 mm (0.005/0.009 in)
Clearance of inner rotor to outer rotor ……… 0,05/0,20 mm (0.0020/0.0079 in)
End clearance:
Inner rotor ……………………………………... 0,032/0,125 mm (0.0013/0.0049 in)
Outer rotor …………………………………….. 0,032/0,125 mm (0.0013/0.0049 in)
TIMING CASE AND DRIVE ASSEMBLY
Camshaft:
Diameter of number 1 journal ……………….. 50,711/50,737 mm (1.9965/1.9975 in)
Cam lift:
Intake for model RG ………………………….. 7,031/7,130 mm (0.2768/0.2807 in)
Exhaust for model RG ……………………….. 7,963/8,063 mm (0.3135/0.3174 in)
Maximum permissible ovality and wear on
journals ………………………………………… 0,05 mm (0.021 in)
End-float :
Production limits ……………………………… 0,10/0,55 mm (0.004/0.022 in)
Service limits ………………………………….. 0,60 mm (0.023 in)
Width of spigot for thrust washer …………… 5,64/5,89 mm (0.222/0.232 in)
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ENGINE
16 WORKSHOP
Camshaft thrust washer:
Type ………………………………………… 3600
Depth of recess in cylinder block for thrust
washer ……………………………………..... 5,54/5,64 mm (0.218/0.222 in)
Thickness of thrust washer ………………... 5,486/5,537 mm (0.216/0.218 in)
Relationship of thrust washer to front face
of cylinder block ……………………………. -0,154/-0,003 mm (-0.0006/-0.0001 in)
Camshaft gear:
Number of teeth …………………………….. 68
Diameter of bore ……………………………. 34,92/34,95 mm (1.3750/1.3760 in)
Outside diameter of the camshaft hub …… 34,90/34,92 mm (1.3741/1.3747 in)
Fuel pump gear:

Bore ………………………………………….. 36,00/36,06 mm (1.1809/1.1819 in)
Crankshaft gear:
Diameter of bore ……………………………. 47,625/47,650 mm (1.8750/1.8760 in)
Diameter of hub for gear on crankshaft ….. 47,625/47,645 mm (1.8750/1.8758 in)
Transition fit of gear on crankshaft ……….. -0,20/+0,20 mm (-0.0008/+0.0008 in)
Idler gear and hub:

Number of teeth …………………………… 73
Diameter of bore of gear ………………….. 57,14/57,18 mm (2.2495/2.2512 in)
“ - with roller bearings ………………... 72,35/72,36 mm (2.8482/2.8489 in)
Width of gear and split bush assy. (fitted) .. 30,14/30,16 mm (1.186/1.187 in)
Inside diameter of flanged bushes (fitted) .. 50,78/50,80 mm (1.999/2.000 in)
Outside diameter of hub …………………… 50,70/50,74 mm (1.9990/1.9999 in)
“ - with needle roller bearings ………... 49,975/49,988 mm (0.0016/0.0039 in)
End float of gear:
Production limits ……………………………. 0,10/0,20 mm (0.004/0.008 in)
“ - with needle roller bearings ………... 0,10/0,75 mm (0.0039/0.0295 in)
Service limit .………………………………... 0,38 mm (0.015 in)
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ENGINE
WORKSHOP 17
Timing gear backlash values
Oil pump gear (without oil pump idler) …… 0,046/0,106 mm (0.0018/0.0041 in)
Oil pump idler gear (with crankshaft gear).. 0,095/0,160 mm (0.0037/0.0063 in)
Crankshaft gear (with idler gear) …………. 0,064/0,124 mm (0.0025/0.0049 in)
Camshaft gear (with idler gear) …………... 0,052/0,107 mm (0.0020/0.0042 in)
PTO gear (with idler gear) ……………...…. 0,112/0,172 mm (0.0044/0.0068 in)

Fuel injection pump gear (with idler gear) . 0,054/0,109 mm (0.0021/0.0043 in)
Coolant pump gear (with fuel injection
pump gear) …………………………………. 0,073/0,133 mm (0.0028/0.0052 in)
CYLINDER BLOCK ASSEMBLY

Cylinder block
441,073/441,374 mm
Height between top and bottom faces…….
(17.3657/173769 in)
105,000/105,025 mm
Diameter of cylinder bore ………………….
(4.1338/4.1348 in)
105,500/105,525 mm
Diameter of first oversize cylinder bore .....
(4.1535/4.1545 in)
106,00/106,025 mm
Diameter of second oversize cylinder bore
(4.1732/4.1742 in)
Maximum permissible cylinder bore wear.. 0,15 mm (0.0059 in)
Diameter of parent bore for main bearing .. 80,416/80,442 mm (3.1660/3.1670 in)

Camshaft bore diameter
Number 1 (for bush) ……………………….. 55,563/55,593 mm (2.188/2.189 in)
Number 2 …………………………………… 50,546/50,597 mm (1.990/1.992 in)
Number 3 …………………………………… 50,038/50,089 mm (1.969/1.972 in)

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ENGINE
18 WORKSHOP
TURBOCHARGER
The make and type and part number of turbocharger fitted is marked on the
turbocharger identification plate, that is fitted to the turbocharger body.
As a general guide, the make and type of turbocharger fitted is ………Garret GT25
Waste-gate test pressure for rod movement of 1,00 mm (0.039 in)
Waste - gate pressure

Turbocharger (kPa) (lbf/in2) (kgf/cm2)
Part number (± 5) (± 0,72) (± 0,05)
2674A200 100 14.5 1,01
2674A201 110 15.9 1,12
2674A202 128 18.5 1,30
2674A209 100 14.5 1,01
2674A211 128 18.5 1,30
2674A215 128 18.5 1,30
2674A223 136 19.7 1,38
2674A224 136 19.7 1,30
2674A225 136 19.7 1,38
2674A226 100 14.5 1,01
2674A227 128 18.5 1,30
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ENGINE
WORKSHOP 19
LUBRICATION SYSTEM
Canister type oil filter

Type ………………………………………... Full flow, screw-on type canister
Pressure to open by-pass valve in filter ... 80/120 kPa (16/24 lbf/in2)
Lubricating oil pump

Type ………………………………………... Diferantial rotor, gear driven
Number of lobes:
Inner rotor ………………………………….. 5
Outer rotor …………………………………. 6
Clearance of outer rotor to body ………… 0,152/,0330 mm (0.0059/0.0129 in)
End clearance.
Inner rotor ………………………………….. 0,038/0,089 mm (0.0014/0.0035 in)
Outer rotor …………………………………. 0,025/0,076 mm (0.0010/0.0029 in)
Idler gear for lubricating oil pump

End float …………………………………… 0,050/0,275 mm (0.0019/0.0108 in)
Inside diameter of bush (fitted) ………….. 16,012/16,038 mm (0.6303/0.6314 in)
Outside diameter of idler shaft …………... 15,966/15,984 mm (0.6285/0.6292 in)
Clearance of bush of idler gear on shaft .. 0,028/0,072 mm (0.0011/0.0028 in)
Oil pressure relief valve (oil pump)
Diameter of bore for plunger ……………. 19,250/19,300 mm (0.7578/0.7598 in)
Outside diameter of plunger …………….. 19,186/19,211 mm (0.7553/0.7563 in)
Clearance of plunger in bore ……………. 0,039/0,114 mm (0.0015/0.0044 in)
Length of spring (fitted) ....……………….. 59,8 mm (2.3543 in)
Load on spring (fitted) ……………………. 121 N (27.1 lbf) 12,0 kgf
Oil pressure relief valve (balancer)
Diameter of bore for plunger ……………. 14,52/14,54 mm (0.5716/0.5724 in)
Outside diameter of plunger …………….. 14,46/14,48 mm (0.5692/0.5700 in)
Clearance of plunger in bore ……………. 0,04/0,08 mm (0.0015/0.0031 in)
Length of spring (fitted) ....……………….. 45 mm (1.77 in)
Load on spring (fitted) ……………………. 77/84 N (17.3/18.9 lbf) 7,8/8,5 kgf
02
ENGINE
20 WORKSHOP
COOLING SYSTEM
Coolant pump
Type ………………………………………. Centrifugal gear diven
Outside diameter of shaft ……………….. 21,425/21,438 mm (0.8435/0.8440 in)
Diameter of bore of drive gear ………….. 21,375/21,400 mm (0.8415/0.8425 in)
Interference fit of drive gear on shaft ….. 0,025/0,063 mm (0.0009/0.0024 in)
Diameter of bore of impeller ……………. 11,943/11,971 mm (0.4701/0.4712 in)
Outside diameter of shaft for impeller …. 11,997/12,008 mm (0.4723/0.4727 in)
Interference fit of impeller on shaft …….. 0,026/0,065 mm (0.0010/0.0025 in)
Diameter of bore for bearing ……………. 39,989/40,014 mm (1.5743/1.5753 in)
Diameter of bearing ……………………… 39,989/40,000 mm (1.5743/1.5747 in)
Interference fit of bearing in pump body
(transition fit) ……………………………… +0,025/-0,011 mm (0.0009/-0.0005 in)
Dimension of impeller boss to front face
of pump body (fitted) …………………….. 7,030/7,330 mm (0.276/0.288 in)
Dimension of gear from rear flat face of
pump body (fitted) ……………………….. 31,60/32,10 mm (1.244/1.263 in)
Fan drive housing

Bore of housing for bearing …………….. 61,986/62,005 mm (2.4403/2.4411 in)
Outside diameter of bearing ……………. 61,987/62,000 mm (2.4404/2.4409 in)
Interference fit of bearing in housing …... 0,014/-0,018 mm (0.0006/-0.0007 in)
Outside diameter of shaft ……………….. 25,002/25,011 mm (0.9843/0.9846 in)
Maximum permissible end-float of shaft . 0,200 mm (0.0079 in)
Thermostat
Type: Single wax element, by-pass blanking
Nominal
temperature “start to Minimum
“fully open”
Part number stamped on open” valve lift, fully
temperature
thermostat temperature open
by-pass valve
2485C034 82 0C 79/84 0C 93 0C 10 mm
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ENGINE
WORKSHOP 21
FUEL SYSTEM
Delphi fuel injection pump
Type …………………………………………. DP210, with a locking screw
Direction of rotation from drive end ……… Clockwise from drive end
Fuel lift pump

Type …………………………………………. Electrically operated
Method of drive …………………………….. Electric motor 12V
Green fuel filter

Type …………………………………………. Replaceable paper element
ATOMISER SERVICE SETTINGS
Colour Set and reset pressure

code Holder Nozzle atm lbf/in2 MP
Yellow 2645A321 2645A611 290 +8/-0 4262 +117.6/-0 29,4 +0,8/-0
Blue 2645A321 2645A612 290 +8/-0 4262 +117.6/-0 29,4 +0,8/-0
Red 2645A322 2645A613 290 +8/-0 4262 +117.6/-0 29,4 +0,8/-0
Black 2645A322 2645A614 290 +8/-0 4262 +117.6/-0 29,4 +0,8/-0
white 2645A322 2645A612 290 +8/-0 4262 +117.6/-0 29,4 +0,8/-0
FLYWHEEL AND HOUSING
Limits for flywheel housing run-out and alignment (total indicator reading)
Diameter of housing flange bore Maximum limit (total indicator reading)
mm in mm in
410 16.14 0,25 0.010

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ENGINE
22 WORKSHOP
ELECTRICAL EQUIPMENT
Alternators
Note: The information which follows is general and may varies with specific
applications.
Make and type …………………………….. Denso
Rating:
Denso A 115i 12V ………………………… 12V/65A, 12V/85A
Rotation ……………………………………. Clockwise from the drive end
Starter motors
applications.
Make and type …………………………….. Denso
Voltage:
Denso P95RL ……………………………... 12V 3,0 kW
Number of teeth on pinion ……………….. 10
Max starter cable resistance at 200 0C
12 V ………………………………………… 0.0017 Ω
Starter aids
applications.
Type ………………………………………... Glow plugs
Voltage …………………………………….. 12 V
THREAD SEALANT
When setscrews or studs are fitted into holes which are tapped through the cylinder
block, a suitable sealant must be used to prevent leakage.
Micro encapsulated anaerobic sealant (M.E.A.S.) fasteners have been introduced
instead of jointing compounds or other sealants when the fasteners are fitted in
through holes into oil or coolant passages. The identification of these fasteners, as
supplied, is by a red, blue, or other colour sealant around the fastener threads.
With M.E.A.S. sealed studs, the sealed end must be fitted into the cylinder head/
cylinder block etc. Ensure that the threaded holes have a 1,59 mm (0.0625 in) 45 0
chamfer, to ensure that when the new fasteners are fitted the M.E.A.S. sealant is not
removed. If the fasteners have to be removed and fitted again, the threads must be
cleaned and a suitable sealant used.
Note: New setscrews have sealant applied by the manufacturer to the first 13,0 mm
(0.50 in) of the threads. If the setscrews are to be used again, clean the old sealant
from the male and female threads and apply new sealant to the setscrews.
02
ENGINE
WORKSHOP 23
STANDARD TORQUE VALUES
Most of the torque values on the engine are standard. Special torque values are
listed in the separate special torque tables. The standard torque values listed in the
tables below can be used when a special torque is not necessary.
The torque values below apply to components lubricated with a little clean engine oil
before they are fitted.
Standard torques for setscrews and nuts
Thread Torque
size Nm lbf ft kgf m
M6 x 1,00 9 7 0,9
M8 x 1,25 22 16 2,2
M10 x 1,50 44 32 4,5
M12 x 1,75 78 58 8,0
M14 x 2,00 124 92 13,0
M16 x 2,00 190 140 19,3
Standard torques for studs (metal end)
Thread Torque
size Nm lbf ft kgf m
M6 x 1,00 5 4 4
M8 x 1,25 11 8 1,1
M10 x 1,50 18 13 1,8
M12 x 1,75 25 18 2,5
Standard torques for pipe unions, plugs, and adaptors
Thread size Torque

inches Nm lbf ft kgf m
1/8 PTF 9,5 7 0,9
¼ PTF 17 12 1,7
3/8 & ½ PTF 30 22 3,0
¾ PTF 45 33 4,6
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ENGINE
24 WORKSHOP
SPECIFIC TORQUE VALUES
The torque values below apply to components lubricated with a little clean engine oil
before they are fitted.
Special torques for setscrews and nuts
Thread Torque
Description size Nm lbf ft kgf m
Cylinder head assembly
Setscrew cylinder head See operation page
Torx screw, rocker shaft M8 35 26 3,5
Lock nut, rocker lever adjustment 3/8 UNF 27 20 2,7
Fastener, rocker cover M6 9 7 0,9
Setscrew, heatshield to cover M6 9 7 0,9
Setscrew, exhaust manifold to cylinder head M10 33 24 3,3
Piston and connection rod assemblies
Setscrew, fracture split connecting rod See operation page
Crankshaft assembly
Setscrews, main bearing 5/8 UNF 245 180 25
Setscrews, crankshaft pulley 7/16 UNF 115 85 12
Allen screws, bridge piece to cylinder block M6 16 12 1,6
Torx screw, rear end oil seal housing M8 22 16 2,2
Setscrews, balancer to cylinder block M10 54 39 5,5
Timing case and drive assembly
Setscrew, camshaft gear M12 95 70 9,7
Setscrew, PTO blanking plate plastic M10 22 16 2,2
Setscrew, plastic oil filler M8 22 16 2,2
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ENGINE
WORKSHOP 25
SPECIFIC TORQUE VALUES (cont’d)
Thread Torque
Cylinder block
Plug, compressor oil feed M10 22 16 2,2
Plug, oil rail rear face 7/8 UNF 68 50 7,0
Plug, front feed M12 46 34 4,6
Plug, turbocharger feed M10 x1 19 14 1,9
Plug, coolant drain ¼ NSPM 40 29 4,0
Fuel system
Nuts, high pressure fuel pipes M12 30 22 3,0

Setscrew, atomizer clamp M8 35 26 3,5
Nut, fuel injection pump to gear M14 88 65 9,0
Setscrew, timing case to fuel injection pump M8 25 18 2,5
Locking screw on shaft of DP210 fuel
M12 17 12 1,7
injection pump
Locking screw in run position of DP210 fuel
M12 12 9 1,2
injection pump
Lubrication system
Plug, lubricating oil sump G¾ 34 25 3,4
Oil inspection valve M10 x1 12 9 1,2
Oil inspection valve plug M10 x1 12 9 1,2
Nut, dipstick tube M16 18 13 1,8
Element, oil filter 3 ½ ACME 25 18 2,5
Cooling system
Setscrews, fan drive housing to cylinder head M10 44 32 4,5
Setscrews, fan drive pulley to hub M8 12 9 1,2
Setscrews, fan M8 12 9 1,2
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ENGINE
26 WORKSHOP
SPECIFIC TORQUE VALUES (cont’d)
Thread Torque
Flywheel and housing
Setscrews, flywheel to crankshaft ½ UNF 105 77 10,7
Setscrews cast iron flywheel housing to cylinderblock M10 44 32 4,5
Head stamped 8,8 M12 75 55 7,6
Head stamped 10,9 M10 63 46 6,4
Head stamped 10,9 M12 115 85 11,7
Setscrews, flywheel housing to cylinder block M10 70 52 7,1
Aspiration system
Nuts, turbocharger to manifold M10 47 35 4,8

Banjo bolt, turbo feed M10 x1 22 16 2,2
Fastener, breather pipe to cylinder head M6 9 7 0,9
Electrical equipment
Sensor, engine oil pressure M12 x1,5 10 7 1,0
Plug, engine oil pressure M12 x1,5 12 9 1,2
Sensor, inlet manifold temperature M18 20 15 2,0
Plug, inlet manifold temperature M18 20 15 2,0
Sensor, inlet manifold pressure M12 10 7 1,0
Plug, inlet manifold pressure M12 10 7 1,0
Sensor, coolant temperature M18 20 15 2,0
Plug, coolant temperature M18 20 15 2,0
Glow plug to cylinder head M10 18 13 1,8
Nut, bus-bar to glow plug M4 2 1 0,2
Nut, alternator pulley M16 80 59 8,1
Nut, starter motor M10 44 32 4,5
02
ENGINE
WORKSHOP 27
COMPRESSION TEST DATA
Tests have shown that many factors affected compression pressures. Battery and
starter motor condition, ambient conditions and the type of gauge used can give a
wide variation of results for a given engine.
It is not possible to give accurate data for compression pressure, but tests have
shown that the results should be within 2000/3500 kPa, (300/500 lbf/in 2),
21,0/35,0 kgf/cm2 for diesel engines.
Compression tests should only be used to compare between the cylinders of an

engine. If one or more cylinders vary by more then 350 kPa, (50 lbf/ in 2), 3,5 kgf/cm2
then those cylinders may be faulty.
Compression tests should not be the only method used to show the condition of an
engine, but they should be used together with other symptoms and tests.
How to do a compression test
Caution: Before the compression test, ensure that the battery is in good condition
and that it is fully charged. Also ensure that the starter motor is in good condition.
1. Ensure that the valve tip clearances are set correctly
2. Remove the atomizers
3. Fit a suitable gauge into the atomizer hole of the cylinder to be tested.
Warning: ensure that the engine can not start.
4. Operate the starter motor and record the pressure indicated on the gauge for
each cylinder.
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ENGINE
28 WORKSHOP
CYLINDER HEAD ASSEMBLY
General description
In a diesel engine there is little carbon deposit and for this reason th number of hours
run is no indication of when to overhaul a cylinder head assembly. The factors which
indicate when an overhaul is necessary are how easily the engine starts and its
general performance.
The cast iron cylinder head is fastened to the cylinder block by flanged head
setscrews. The cylinder head gasket is a multi-layer contruction. The individual inlet
and exhaust ports are designed to assist air swirl and improve air flow.
The intake manifold is integral within the cylinder head, and the rocker cover also
contains the engine breather pipe.
The cylinder head assembly has two overhead valves fitted for each cylinder. Each
overhead valve is held in place by a single coil spring, cap, and two collets. The face
angle of the intake and the exhaust valves are both 300. The valves move in sintered
steel valve guides which can also be renewed. The exhaust valve guides have a
counterbore to prevent seizure of the valve stem caused by a build up of carbon
under the head of the valve. Each valve stem is fitted with a synthetic rubber oil seal.
The overhead valves are operated by a rocker shaft assembly fitted to the top of the
cylinder head and under a composite rocker cover. The forged steel rocker levers are
operated by cold drawn push rods with hardened heads. The rocker shaft is secured
to the cylinder head by sintered steel brackets between each pair of valves. The
rockers and valve gear are lubricated by an oil flow from the hollow rocker shaft that
receives a reduced oil flow from the cam shaft oil feed.
Tappet adjustment is achieved by adjustment screws and locknuts at the push rod
end of each rocker lever.
02
ENGINE
WORKSHOP 29
ATOMISER COVER
To remove and to fit
To remove
Unscrew the atomizer cover
setscrews (1) and remove
the atomizer cover (2).
To fit
Fit the atomizer cover (2)
and tighten the setscrews
(1) to 9 Nm, ( 7 lbf ft),
0,9 kgf m.
ROCKER COVER
To remove
1. Remove the atomizer cover
2. Remove the breather pipe
3. Unscrew the fasteners

(number 1 to 10), remove the
rocker cover and discard the
joint.
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ENGINE
30 WORKSHOP
ROCKER COVER
To fit
1. If the rocker cover has an oil filler
cap, check the condition of the O-
ring, renew as required.
2. Ensure that the rocker cover and
the groove for the joint are clean and
free from oil and grease.
3. Fit a new joint (1) to the rocker
cover.
4. Check the condition of the fasteners, renew as required.

5. Clean the seal face of the cylinder head and fit the rocker
cover.
6. Secure the rocker cover to

the cylinder head with the
fasteners and tighten in
sequence (1 to 10) to 9 Nm,
(7 lbf ft), 0,9 kgf m.
7. Fit the breather pipe.

02
ENGINE
WORKSHOP 31
ROCKER ASSEMBLY

Special tool Part number
Rocker assembly tools 27610227
To remove
1. Remove the atomizer cover.
2. Remove the rocker cover.
3. Fit the rocker assembly tools (1) between each pair of rocker levers.
4. Release evenly and gradually the Torx screws of the rocker shaft; begin with
the end Torx screws and move toward center. Remove the Torx screws and
lift off the rocker assembly.
To fit
Note: Ensure that the machined square is facing upwards before the rocker
assembly is fitted and that the longest Torx screw (2) is fitted in.
1. Check that the push rods fit correctly in the sockets of the tappets and ensure
that the rocker assembly tools (1) are correctly fitted between each pair of
rocker levers. Fit the rocker assembly. Check that the ends of the adjustment
screws fit correctly in the sockets of the push rods.
2. Fit the Torx screws for the rocker shaft and tighten the torx screws 35 Nm,
(26 lbf ft), 3,6 kgf m; begin with the inner Torx screws and work outwards.
3. Set valve tip clearance.
4. Fit the rocker cover.
5. Fit the atomizer cover.
02
ENGINE
32 WORKSHOP
ROCKER ASSEMBLY
To dismantle and to assemble
To dismantle
1. Remove the circlips from both ends of the rocker shaft. Ensure that the ends
of the rocker shaft are not damaged.
2. Dismantle the assembly and make a note of the position of each component to
ensure that they can be assembled in the same position.
To assemble
1. Ensure that the oil holes in the rocker shaft and in the rocker levers are not
restricted.
2. Lubricate the components with clean engine lubricating oil before assembly.
Assemble the components in the correct order. Fit the circlips to the ends of
the rocker shaft.
To inspect and to correct

1. Clean and inspect all components for wear and any other damage.
2. Check the clearance of the rocker levers on the rocker shaft. If the clearance
is greater than 0,13 mm (0.005 in), renew the rocker lever and/or the rocker
shaft.
02
ENGINE
WORKSHOP 33
VALVE TIP CLEARANCES
To check and to adjust
The valve tip cleararnces are checked

between the top of the valve stem and
the rocker lever, with the engine cold.
The correct clearance for
intake valves is 0,20 mm (0.008 in)
and for
exhaust valves is 0,45 mm (0.018 in).
The valve positions are shown in the

below figure and table.
The sequence of valves from number 1
cylinder is shown below.
Note: Number 1 cylinder is the furthest cylinder from the flywheel end of engine.
Cylinder and 1 2 3 4
valve number 1 2 3 4 5 6 7 8
Valve
I = Intake I E I E I E I E
E = Exhaust
1. Rotate the crankshaft in the normal direction of rotation until the intake valve 7 of
number 4 cylinder has just opened and the exhaust valve 8 of the same cylinder has
not closed completely. Check clearances of thevalves 1 and 2 of number 1 cylinder
and adjust them, if necessary.
Note: The correct torque for the locknut on the adjusting screws is 27 Nm, (20 lbf ft),
2,8 kgf m.
02
ENGINE
34 WORKSHOP
Valve tip clearances (cont’d)
2. Rotate the crankshaft and set again

the valves 3 and 4 of number 2 cylinder,
as indicated above for number 4 cylinder.
Then check/adjust the clearances of
valves 5 and 6 of number 3 cylinder.
3. Set the valves 1 and 2 of number 1 cylinder. Then check/adjust the clearances of
the valves 7 and 8 of number 4 cylinder.
4. Set the valves 5 and 6 of number 3 cylinder. Then check/adjust the clearances of
valves 3 and 4 of number 2 cylinder.
Note: After the valve tip clearances have been adjusted, lubricate the rocker
assembly with clean engine oil. Apply particular attention to the rocker shaft bearing
surfaces, valve tips, push rod sockets and the push rods so that the oil will drain to
lubricate the cam followers.
02
ENGINE
WORKSHOP 35
VALVE SPRINGS
To change the valve springs (with cylinder head fitted)
Special tools
Valve spring compressor (1) Part No: 21825666
Setscrew adaptor used with 21825666 (2) Part No: 27610235
Note: Steps above listed refer to a change of valve spring for a single cylinder.
Warning ! Wear eye protection during this operation.

3. Rotate the crankshaft in the normal direction of rotation until the intake valve of
relevant cylinder has just opened and the exhaust valve has not fully closed. In this
position the piston will be at approximately top dead center (TDC).
4. Remove the rocker assembly.
5. Fit the valve spring compressor (1)

and the adaptor (2).
Caution: Ensure that the valve spring is
compressed squarely or damage can
occur to the valve stem.
Note: Do not over compress the valve
springs so that coils are touching.
6. Compress the valve spring and

remove the collets. Ensure that the
valve spring is compressed squarely or
damage to the valve stem can occur.
Caution: Do not rotate the crankshaft while the valve spring is removed.
7. Release the valve spring compressor and remove the valve spring, cap and valve
seal. Note: The valve stem seal must only be used once.
8. Ensure that the new valve stem seal is clean, not damaged and that the spring is
present correctly located on the seal.
9. Lubricate the valve stem with clean engine oil. Fit the valve stem seal onto the
valve guide and ensure that the seal and the seating washer are correctly located.
10. Put the new valve spring in position, ensure that the larger diameter is against the
cylinder head.
02
ENGINE
36 WORKSHOP
Valve springs (cont’d)
11. Fit the valve spring cap.

Caution:Ensure that the valve spring is compressed squarely or damage can occur
to the valve stem.
Note: Do not over compress the valve springs so that coils are touching.
12. Fit the valve spring compressor, compress the valve spring and fit the collets.
Remove the valve spring compressor.
13. Fit the rocker assembly.
14. Check the valve tip clearances.

Note: If other or all the valve springs are to be changed, they can be changed two
cylinders at a time. The sets of cylinders are 1 – 4 and 2 – 3.
If the rocker assembly has been removed, piston TDC can be found as follows:
1. Fit the valve spring compressor and

compress the valve springs to open
the valve.
2. Rotate the crankshaft, by hand, in

the normal direction of rotation until
the piston touches the valve.
Note: Ensure that the collets are fully
located before the pressure is
released on the valve spring
compressor.
3. Cotinue to rotate the crankshaft,

and at the same time, release
pressure on the valve spring
compressor until the piston is at
(TDC).
02
ENGINE
WORKSHOP 37
CYLINDER HEAD ASSEMBLY
To remove
1. Drain cooling system.
2. Disconnect the battery terminals.
3. Remove the air filter/air cleaner hose at the intake manifold.
4. Remove the boost control pipe that is fitted between the intake manifold and the
top of fuel injection pump.
5. Disconnect all connections to the turbocharger and remove the turbocharger.
6. Release the exhaust manifold

fasteners in the reverse
sequence to that shown in figure.
7. Remove the low-pressure fuel

pipes which are fitted between
the fuel injection pump and the
fuel lift pump with integral fuel
filter.
8. Remove the fuel lift pump with integral fuel filter.

Caution: Where access to the fuel injection pump outlet unions is possible, ensure
that a separate spanner is used to prevent movement of the fuel injection pump
outlets when the connections of the high-pressure pipes are released. Fit suitable
plugs to all open connections on the fuel injection pump.
10. Remove the high pressure fuel pipes.
11. Remove the atomizer leak-off hoses.
12. Remove the atomizers. Fit suitable plugs on to the nozzles and the open
connections.
13. Remove the bus-bar and glow plugs.
14. Release the setscrews of the coolant by-pass pipe at the timing case. Remove
the coolant by-pass pipe from the cylinder head.
02
ENGINE
38 WORKSHOP
Cylinder head assembly (cont’d)
15. Disconnect the coolant temperature sensor/sender unit.
18. Remove the push rods.
19. Release the cylinder head

setscrews evenly and gradually
in the reverse sequence to that
shown in the figure.
20. Check the setscrews for distortion with a

straight edge held along the setscrew. If there
is a visual reduction in the diameter of the
thread that has not been in engagement with
the cylinder block, tha setscrew must be
discarded.
Caution: Do not use a lever to separate the cylinder head fromn the cylinder block,
as this may damage the face of either the cylinder head or the cylinder block.
21. Remove the cylinder head and put it on a surface that will not damage the bottom
face of the cylinder head.
22. Remove the cylinder head gasket.

02
ENGINE
WORKSHOP 39
To fit
Special tools
Angle gauge (to tighten cylinder head screws) Part No: 21825607
1. With a suitable cleaner, clean thoroughly the bottom face of the cylinder head and
the top face of the cylinder block. Hard carbon and corrosion can be removed with a
hard plastic or hard wood scraper. Ensure that the top face of the cylinder block and
the bottom face of the cylinder head are free from scratches or other damage and
there is no debris in the cylinder bores.
Note: The engines have two

location pins (2), one at each end of
cylinder head, pressed into the
cylinder block to hold the cylinder
head and cylinder head gasket in
the correct position when the
cylinder head fitted.
Cautions: To prevent damage to

the cylinder head gasket, ensure
that the location pins are pressed in
the cylinder block before the
cylinder head is fitted. The cylinder head gasket must be fitted without jointing
compound.
2. Fit a new cylinder head gasket in the correct position.
3. To ensure the cylinder head is fitted into the correct position, fit two suitable M15
guide studs (1). Put the cylinder
head in position. Ensure that the
two location pins are fully engaged
in the cylinder head.
4. Apply a small amount of
lubricant to the threads and thrust
faces of the cylinder head
setscrews. Engage the seven short
setscrews in positions
2, 5, 6, 7, 8, 9, 10, then remove the
guide studs (1). Fit the three long
setscrews in positions 1, 3, 4.
5. Tighten the setscrews to 50 Nm,
(37 lbf ft), 5,1 kgf m in the sequence shown in the figure.
6. Tighten the setscrews to 100 Nm, (74 lb ft), 10,0 kgf m in the sequence shown in
the figure.
02
ENGINE
40 WORKSHOP
7. Tighten the setscrews, in the correct sequence, a further part of a turn according to
the length of the setscrews. Short setscrews (S) must be turned a further 225 0. Long
setscrews (L) must be turned a further 270 0. A special tool can be used for this
operation.
Fit the tool between the socket and the

handle. Position the stop (1) against a
suitable protrusion on the cylinder head
to prevent movement of the degree dial in
a clockwise direction.
Rotate the pointer to align with the
relevant angle on the degree dial for the
length of setscrew. Tighten the setscrew
until the pointer on the tool is aligned with
the zero position on the degree dial.
If no tool is available, make a suitable mark on the cylinder head in line with a corner
of each setscrew . Make another mark, at the correct angle (counter-clockwise), on
the edge of the flange of each fastener according to the length of the setscrew.
Tighten each setscrew in the correct sequence until the marks on the flange are next
to, and in line with , the marks on the cylinder head.
8. Put the push-rods in position. Ensure that the

end of each push rod fits correctly in the tappet
socket.
10. Set the valve tip clearances.
11. Fit the atomizers.

12. Fit the atomizers leak-off hoses.
13. Fit the glow plugs and bus-bar.
14. Fit the high-pressure fuel pipes; tighten the connection nuts to 22 Nm, (16 lbf ft),
2,2 kgf m.
Caution: Where access to the fuel injection pump outlet unions is possible, ensure
that a separate spanner is used to prevent movement of the fuel injection pump
outlets when the connections of the high pressure pipes are tightened.
15. Fit the fuel lift pump with integral fuel filter and the bracket. Fit the low-pressure
fuel pipes between the fuel injection pump and the fuel lift pump with integral fuel
filter.
16. Fit the coolant by-pass pipe.
02
ENGINE
WORKSHOP 41
17. Fit the two suitable temporary studs

(1) then fit the exhaust manifold joint (2).
Caution: Damage to the exhaust
manifold can occur if not aligned and
tightened correctly.
18. Fit the exhaust manifold and the

fasteners, lightly tighten the fasteners 1
and 2.
19. Remove the two temporary studs, fit

the remaining fasteners and lightly
tighten.
20. Evenly and gradually tightem the

exhaust manifold fasteners to 33 Nm,
(24 lbf ft), 3,4 kgf m in the sequence
shown in the figure.
21. Fit the turbocharger.
22. Connect the electrical connection to the cold start device.
23. Fit the boost control pipe between the intake manifold and the top of the fuel
injection pump.
24. Fit the electrical connection to the coolant temperature sensor/sender unit.
25. Connect the coolant outlet and the hoses for the cab heater. Tighten the clips.
26. Fill the cooling system.
28. Connect the battery.
29. Bleed air from the fuel system.
30. Start the engine and run it at low speed. Check that oil flows from the holes in
the rocker levers. If the oil flow is correct, fit the rocker cover.
Note: It is not necessary to tighten the cylinder head setscrews again with the engine
hot or after limited period in service.
02
ENGINE
42 WORKSHOP
VALVE AND VALVE SPRINGS
To remove
Special tools
Valve spring compressor Part No: 21825666
Setscrew adaptor used with 21825666 Part No: 27610235
1. Remove the cylinder head.

2. Clean the bottom face of the cylinder head and check the depth of the heads
of the valves below th face of the cylinder head.
3. Make a suitable mark on the heads of the valves to ensure that the valves can
be fitted in their original
positions, if they are to be
used again.
Caution: Ensure that the valve
springs are compressed squarely or
the valve stem can be damaged.
Note : Do not over compress the
valve springs so that coils are
touching.
4. Use the valve spring

compressor and the relevant
adaptor to compress the valve
spring (3) and remove the
collets (1).
5. Release the valve spring
compressor and remove the
valve spring cap (2), valve
spring and valve stem seal
(4).
6. Repeat steps 4 and 5 for the
other valves.
02
ENGINE
WORKSHOP 43
Valve and valve springs (cont’d)
To fit
Special tools
Valve spring compressor Part No: 21825666
Setscrew adaptor used with 21825666 Part No: 27610235
Cautions:
 Valves must not be lapped, as the special heat resistant layer on the face of
the valve will be destroyed.
 If inlet valves are badly worn or damaged they must be replaced.
Note: The intake valve has a larger diameter head than the exhaust valve.
1. Lubricate the valve stem (5) with

clean engine oil and fit the valves
in their respective guides.
Note: The valve stem seal must
only be used once.
2. Fit new valve stem seals (4) on

the valve guides.
3. Put the valve springs in position,

ensure that the larger diameter is
against the cylinder head. Fit the
valve spring cap (2).
Caution: Ensure that the valve
spring is compressed squarely or
damage can occur to the valve
stem.
4. Use the valve spring compressor

and the relevant adaptor to
compress the valve spring (3) and
fit the collets (1).
02
ENGINE
44 WORKSHOP
Valve and valve springs (cont’d)
Special tools
Gauge, valve depth Part No: 21825496
Dial gauge for use 21825496 Part No: 21825617
1. Ensure that the heads of the valves

and the bottom face of the cylinder head
are clean.
2. Put the valve depth gauge on the face

of the cylinder head and zero the dial
gauge.
3. Carefully put the valve depth gauge in

position over the head of each valve and
make a note of the measurement. The
maximum depth, in service, is given in the relevant data and dimensions for the
“Intake & exhaust valves”.
4. If a valve is below the depth limit, check the valve depth with a new valve in
position. If the valve depth is still below the limit the valve seat insert must be
renewed.
5. Check the valves for cracks. Check the stems of the valves for wear and for
correct fit in their valve guides.
Cautions:
 Valves must not be lapped, as the special heat resistant layer on the face of
the valve will be destroyed.
 If inlet valves are badly worn or damaged they must be replaced.
6. Check that the seat faces of the valves are not badly burnt or damaged. Seat
faces of valves which are damaged can be ground on a special machine.
When new valves are fitted, the valve depyhs must be checked after the valve
springs are fitted.
7. Check that the load on the valve springs is correct at their fitted length, refer to the
relevant data and dimensions for the “Valve guides and valve springs”. Fit new valve
springs at every complete engine overhaul.
02
ENGINE
WORKSHOP 45
VALVE GUIDES
To inspect
To check the valve guides for wear.

The maximum permissible clearance
(5) with a valve lift of 15,0 mm (0.6
in), between the valve stem and the
bore of the guide is 0,22 mm (0.009
in) for intake valves, and 0,25 mm
(0.010 in) for exhaust valves. If the
clearance, with a new valve fitted, is
more than the limit, than a new valve
guide (4) must be fitted.
It is recommended that the
procedure given below is used to check the valve guide clearance:
1. Put a new valve in the valve guide.
2. Put a dial test indicator with a magnetic base (1) onto the face of the cylinder head.
3. With the valve lifted 15,0 mm ( 0.6 in) and the gauge (2) in contact with the edge of
the level head (3), move the valve radially away from the gauge. With the valve held
in this position, set the gauge to zero.
4. Move the valve radially across the axis of the cylinder head towards the gauge.
Make a note of the reading on the gauge. If the reading is equal to or greater than the
data given above, a new valve guide (4) must
be fitted.
To remove
Special tools
Remover / replacer for valve guides Part No: 21825478

Adaptor used with 21825478 Part No: 21825479
1. Fit the adaptor (4) into the remover/

replacer tool (3).
2.With the adaptor fitted to the tool, put the
spacer (5) in position on the tool. Pass the
adaptor (4) through the valve guide (6) and
put the spacer and tool in position on the
valve seat.
3. Fit the attachment (7) to secure the
adaptor to the valve guide.
4. Hold the top handle (1) and turn the
bottom handle (2) clockwise to pull the valve
guide out of the cylinder.
02
ENGINE
46 WORKSHOP
To fit
Special tools
Remover / replacer for valve guides Part No: 21825478
Adaptor used with 21825478 Part No: 21825479
Adaptor used with 21825478 and 21825479 Part No: 27610234
Note: The partially finished valve guides are reamed and the valve seats are cut in
one operation with a special tool. The valve seat and the guide are cut in one
operation to ensure the concentricity of the valve seat to the valve guide. This will
ensure a good seal between the guide and its seat. New valves and new valve seat
inserts must be fitted each time a new valve guide is fitted. Valves must not be
lapped. If all or most of the original valve guides need to be renewed it may be cost
effective to overhaul or exchange the cylinder head.
1. Clean the parent bore in the
cylinder head for the valve guide.
2. Lubricate the outer surface of the

new valve guide (6) with clean
engine lubricating oil.
3. Fit the adaptor (5) into the

remover/ replacer tool (3).
4. With the adaptor fitted to the tool,

put the spacer (4) in position on the
tool. Pass the adaptor through the
cylinder head and put the spacer
and tool assembly in position on the
valve seat.
5. Put the valve guide in position on

the adaptor and fit the adaptor (7).
Fit the attachement (8) to secure the
valve guide to the adaptor.
6. Hold the top handle (1) and turn

the bottom handle (2) clockwise to
pull the valve guide until the
distance piece contact the cylinder
head.
7. When the valve guide is fitted correctly, the top of the valve guide will have a
protrusion (9) of 12,35 / 12,65 mm (0.486/0.498 in) above the valve spring
seat.
8. Ream the valve guide to the finished size.
02
ENGINE
WORKSHOP 47
1. Remove the cylinder head assembly.

2. Remove the thermostat housing.
3. Inspect the cylinder head for signs of gas or coolant leakage.
4. Remove the valve springs and valves.
5. Clean the face of the cylinder head and the passages for coolant and for
lubricating oil. The coolant jacket can be cleaned with a special solvent which
must be used in accordance with the manufacturer’s instructions.
6. Test the cylinder head for leaks at the pressure given in the relevant data and
dimensions for the “Cylinder head”.
7. When the cylinder head is throughly clean, check it for cracks. Inspect
carefully the areas around the valve seats and around the holes for the
atomizer nozzles.
Caution: Remove only the minimum material and ensure that the thickness of
the cylinder head will not be less than 117,20 mm (4.614 in) after the cylinder
has been machined.
8. The bottom face of the cylinder head can be machined if there is a distortion,
or deep scratches.
9. Use a straight edge and feeler gauges to check the cylinder head for
distortion. Refer to relevant data and dimensions for the “Cylinder head”.
Cautions:
 After the cylinder head has been machined the valve seats must be
corrected to give the correct valve head depth.
 Work to the minimum limit to allow for later wear.
10. Check the valve seats for wear and for damage.
11. Before any work is done on the valve seats, new valve guides must be fitted.
12. Badly damaged valve seats can be corrected by use of the cutter tool or new
inserts can be fitted.
Special tools
Cutter 300 for inlet & exhaust valve seats and valve
Part No: 27610030
guide reamer
Caution: Valves must not be lapped.

02
ENGINE
48 WORKSHOP
To inspect and to correct (cont’d)
Note: The partially finished valve guides

are reamed and the valve seats are cut in
one operation with a special tool. The
valve seat and the guide are cut in one
operation to ensure the concentricity of
the valve seat to the valve guide. This will
ensure a good seal between the guide
and its seat. New valves and new valve
seat inserts must be fitted each time a
new valve guide is fitted. Valves must not
be lapped. If all or most of the original
valve guides need to be renewed it may
be cost effective to overhaul or exchange
the cylinder head.
1. Before any work is done on the valve

seats, new valve guides must be fitted.
Cautions:
 Ensure that the correct cutter is
fitted, for 300 valve seats.
 Ensure that the valve seat cutter is
not allowed to fall onto the seat as
this can damage the blades.
Note: The intake valve has a larger
diameter head than the exhaust valve.
2. Select the relevant valve seat cutter, 300 (2) and the valve guide reamer (1). Set
the blades of the cutters to the diameter of the valve seat to be cut. (see “Intake &
exhaust valves”)
Note: The blades of the reamer must not cut the valve guide when the seat is cut.
3. Fit the cutter onto the reamer and push the handle fully onto the reamer. Ensure
that the flat part of the reamer shank is towards the allen screw. Tighten the allen
screw to secure the reamer to the handle.
4. Fit the reamer / cutter assembly into the valve guide. Ensurethat the valve seat
cutter is not allowed to fall onto the seat as this can damage the blades. Carefully
turn the handle in a clockwise direction (3) and gradually move the reamer into the
valve guide until the valve guide is reamed to the finished size. A lubricant is not
necessary.
5. Contunue to turn the handle in a clockwise direction to cut the valve seat. Remove
only the minimum material to ensure a good valve seat. Keep the seat as narrow as
possible.
02
ENGINE
WORKSHOP 49
To inspect and to correct (cont’d)
6. When the seat is cut, remove the reamer/cutter assembly. Remove any debris
from the area of the valve guide, valve seat and port.
7. Fit the valve.
8. Check that the valve depth is within limits, refer to relevant data and dimensions
for the “Intake and exhaust valves”.
Note: If a valve seat has become too damaged or too worn to correct, a valve seat
insert can be fitted. If all or most of the original valve seat inserts need to be renewe it
may be cost effective to overhaul or exchange the cylinder head.
To fit valve seat inserts
1. Remove the valve guide, and clean the bore into which the guide is to be
fitted.
2. Fit new partially finished valve guide.
3. With the bore of the new partially finished valve used as a pilot, machine the
recess in the cylinder head to the dimensions shown in “Dimensions of
recesses for valve seat inserts”, or machine out the old insert. Remove all
debris and clea the insert recess.
4. If the bottom face of the cylinder head has been machined, the insert will have
to be surface ground on the back face to ensure that there is no protrusion of
the insert above the bottom faceof the cylinder head. After the back of the
insert has been ground, ensure that the outer edge of the back face has a
0,9 / 1,3 mm (0.035 / 0.051 in) chamfer at 300 to the vertical.
5. With the bore of the new, partially finished, valve guide used as a pilot, and
with the rear face of the insert towards the cylinder head, press in the insert
with the valve seat insert tool, see “Valve seat insert tool”.
Caution: Do not use a hammer on the insert and do not use lubrication.
Use a hydraulic press or a hand press in one continuous movement. Ensure
that the bottom of the insert is in contact with the bottom of the recess.
6. Ream the valve guide and cut the valve seat at an included angle of 120 0 for
300 valve seats.
Ensure that the depth of the valve head below the face of the cylinder head is within
the production limits, refer to the relevant data and dimensions for the “Intake and
exhaust valves”.
Note: Work as near as possible to the minimum value to allow for future wear on the
valve seat.
02
ENGINE
50 WORKSHOP
PISTON AND CONNECTING ROD ASSEMBLIES
General description
The pistons that are used in the engine have a combustion chamber in the top of the
piston. The combustion chamber is designed to give an efficient mix of fuel and air.
The pistons and connecting rods are matched to the
relevant cylinder.
The pistons have two compression rings and an oil
control ring. The groove for the top ring has a hard metal
insert to reduce wear of the groove. The piston skirt has
a layer of graphite to improve the wear characteristics.
Axial location of the fully floating gudgeon pin is by
circlips. The gudgeon pin is off-centre to reduce the noise
level.
Piston cooling jets are fitted in the cylinder block to spray
lubricating oil onto the inner surface of the pistons.
The correct piston height is important to ensure that the
piston does not contact the cylinder head and to ensure
the efficient combustion of fuel.
The piston height is controlled by the length of the connecting rod. There are six
length grades of connecting rods used to obtain the correct piston height.
To obtain the different grades, the small-end bush is machined off-centre. The
amount that the bush is off-centre gives the different length grades.
In service, a partially finished small-end bush

is available, which can be fitted to the original
connecting rod and machined to obtain the
correct length grade. Specialist equipment
and personnel with the correct training are
neede to machine the partially finished
small-end bush. Connecting rod kits are also
available with the small end bush fitted and
machined to obtain the correct connecting
rod grade.
Notes:
 If the crankshaft of the cylinder block is to be renewed, it may be necessary to
change the grade of the connecting rods. This will occur if the correct piston
height above the cylinder block face cannot be maintained with the original
connecting rod assemblies.
 Always use the engine identification number to order new parts.
The connecting rod is a one-piece forging that is fractured hydraulically to split the big
end cap from the connecting rod. This process produces rough but accurately
matched surfaces (1).
02
ENGINE
WORKSHOP 51
BIG END BEARING
To remove
1. Drain the engine lubricating oil.

2. Remove the lubricating oil
sump.
3. Remove the lubricating oil
oilpump.
4. Unscrew the fasteners ((4) and
remove the bearing cap(3).
Caution: Do not stamp or
punch the connecting rod
assembly, as this cause a
fracture.
5. Mark the bearing cap and the
connecting rod with the cylinder number to ensure correct assembly.
Caution: Ensure that the relevant shell bearing is kept with the correct cap or
connecting rod.
6. Rotate the crankshaft until the relevant connecting rod as its lowest position.
7. Remove the shell bearing (5) from the cap (3). Keep the bearing with cap.
8. Carefully push the connecting rod up the cylinder bore just enough to allow
access to the upper half of the shell bearing. Remove the shell bearing (6)
from the connecting rod (1). Keep the bearing with the connecting rod.
Caution: Do not allow the connecting rod to hit the piston cooling jet.
To fit
1. Clean the bearing faces of the connecting rod and the crank pin.
Cautions:
1. Ensure that the relevant shell bearing is kept with the correct cap or
connecting rod.
2. Do not stamp or punch the connecting rod assembly, as this could cause a
fracture.
2. Clean the complete bearing and lubricate the

bearing surface and the crank pin with clean engine
lubricating oil.
3. Fit the upper half of the shell bearing to the
connecting rod; ensure that the bearing shell is fitted
centrally (1).
02
ENGINE
52 WORKSHOP
4. Fit the connecting rod to the

crank pin. Ensure that the
forged marks (1) to the front
of the engine.
Note: The fasteners used
with these connecting rods
must only be used once.
5. Clean, lubricate and fit the
lower half of the shell bearing
into the cap; ensure that the
bearing shell is fitted centrally.
Fit the new connecting rod
fasteners. Fit the cap to the connecting rod. Ensure thet the assembly has
both of the forged marks on the same side (1).
6. Tighten the new fasteners to an initial torque of 18 Nm (13lbf ft), 1,9 kgf m.
7. Tigten the new fasteners to 70 Nm, (52 lbf ft), 7,1 kgf m. The fasteners must
be tightened a further 1200.
8. Ensure that the crankshaft rotates freely.
9. Fit the lubricating oil pump.
10. Fit the lubricating oil sump and fill the sump to the correct level with lubricating
oil.
To inspect
Check the bearings and the crank pin for wear or other damage
02
ENGINE
WORKSHOP 53
PISTON AND CONNECTING RODS
To remove
1. Drain the lubricating oil and the cooling system.
2. Remove the cylinder head assembly.
3. Remove all carbon from the top of the boresof the cylinders.
4. Remove the lubricating oil sump.
5. Remove the lubricating oil pump.

Cautions:
 Do not stamp or punch the connecting rod assembly, as this could cause a
fracture.
 The pistons and connecting rods are matched to the relevant cylinder. Mark each
connecting rod and piston with the cylinder number to ensure correct assembly.
6. Remove the big end caps and the big end bearings from the connecting rods.
Caution: Do not allow the connecting rods to hit the piston cooling jets. If a cooling
jet is hit, renew it if necessary.
7. Rotate the connecting rods 900 to prevent contact with the cooling jets. Push the
pistons and the connecting rods out through the top of the cylinder liners. Keep the
bearings and caps together to ensure that they can be fitted in their original positions.
8. Inspect the crank pins for damage.
To fit
Special tools
Piston replacer tool Part No: 21825491
1. Ensure that the piston, the cylinder bore, the crank pin and the big end of the
connecting rod are clean. Lubricate the piston and the cylinder bore with clean
2. Rotate the crankshaft until the relevant crank pin is at its lowest position.
Lubricate the crank pin with clean engine lubricating oil.
3. Fit the upper half of the shell bearings to the connecting rod. Ensure that the
bearing shell is fitted correctly. Lubricate the bearing with clean engine
lubricating oil.
02
ENGINE
54 WORKSHOP
To fit (cont’d)
4. Put the piston replacer tool in position at

the top of the relevant cylinder. The tool
has a tapered bore to compress the
piston rings when the piston and
connecting rod assembly is fitted. Ensure
that the smaller end of the tapered bore is
towards the face of the cylinder block.
5. Arrange the piston ring gaps 1200 apart.
Pass the connecting rod through the
piston replacer tool and allow the piston to
enter the tool.
The arrow mark on the top of
the piston must be towards
the front of the engine.
Caution: Ensure that the
connecting rod will not hit the
piston cooling jet as the
connecting rod assembly is
fitted.
6. Push the piston and
connecting rod assembly
through the piston replacer
tool and onto the crank pin.
The piston and connecting rod assembly must be rotated to ensure that the
connecting rod will not hit the piston cooling jet as the assembly is fitted. When
the connecting rod has passed the piston cooling jet, rotate the connecting rod
until the arrow mark on top of the piston is towards thefront of engine.
7. Clean the connecting rod cap and the lower half of the bearing. Fit the bearing
to the cap; ensure that the bearing is fitted correctly. Lubricate the bearing with
clean engine lubricating oil. Fit the cap and ensure that the assembly number
is the same as that on the connecting rod and that the numbers are on the
same side. Tighten the fasteners gradually and evenly.
8. Check the crankshaft will rotate freely.
9. Check the piston height above the top face of the cylinder block.
11. Fit the lubricating oil sump.
12. Fit the cylinder head assembly.
13. Fill the sump to the correct level with lubricating oil.
02
ENGINE
WORKSHOP 55
To check the piston height above the cylinder block
Special tools
Piston height tool Part No: 21825496
Dial gauge for use with 21825496 Part No: 21825617
Caution: If the correct piston height above the cylinder block is not obtained, damage
to the engine can occur and the engine not be emissions compliant.
Put the piston height tool on the face of the cylinder block and rotate the gauge dial
to the zero position. Rotate the crankshaft until the piston crown is approximately at
top dead center (TDC). Carefully put the tool over the top of the piston with the
plunger of the aguge in contact with the piston above the axis of the gudgeon pin.
Rotate the crankshaft to ensure that the piston is at the highest position and make a
note of the gauge indication.
The piston height above the top face

of the cylinder block should be
0,21/0,35 mm (0.008/0.014 in)
Notes:
 The top of the piston should not be machined.
 If the original piston is used, ensure that it is assembled to the correct
connecting rod and is used in the original cylinder.
If any of the components listed below are renewed; refer to the relevant operation:
 The dconnecting rod.
 The small end bush.
02
ENGINE
56 WORKSHOP
PISTON RINGS
To remove
Note: The pistons have two compression rings and an oil control ring. All the piston
rings are above the gudgeon pin. To ensure that the correct type is obtained always
use the engine identification number to order new parts.
Caution: Only expand the ring gaps enough to ensure that the ends of the rings do
not damage the piston when the ring is removed or put into position.
1. Fit the spring of the oil control

ring in the bottom groove with the
latch pin (1) inside both ends of
the spring. Fit the oil control ring
over the spring. Ensure that the
ring gap is at 1800 to the latch
pin.
2. Fit the cast iron ring with the
taper face into the second
groove.
3. The second ring has a green
identification mark which must be
on the left of the ring gap when
the ring is fitted and the piston is upright, with the word “TOP” towards the top
of the piston.
4. The first ring has red identification mark which must be on the left of the ring
gap when the ring is fitted and the piston is upright.
5. Ensure that the ring gaps are 1200 apart.
02
ENGINE
WORKSHOP 57
PISTON AND CONNECTING ROD ASSEMBLY
To dismantle
Caution: The pistons and connecting rods are matched to the relevant cylinder. Note
the position of each
connecting rod and piston for
correct assembly.
1. Remove the piston

rings.
2. Remove the circlips
which retain the
gudgeon pin.
Caution: Do not
scratch, etch or stamp
the piston surface.
3. Put a temporary mark on the piston to indicate the cylinder number as shown
on the connecting rod. Put the temporary mark on the piston on the same side
as the mark on the big end to ensure that they are assembled correctly.
4. Push the gudgeon pin out by hand. If the gudgeon pin is tight, heat the piston
to 40 / 50 0C (100/120 0F) for easy removal of the gudgeon pin.
5. Inspect the piston and connecting rod assembly.
To assemble
1. Clean the bore of the small end

bush and lubricat it with clean
2. Fit a new circlip in the circlip
groove of one of the gudgeon
pin bosses. Ensure that it fits
correctly in the groove.
3. With the piston upside down,
put the connection rod in
position with the forged mark
(1) on the same side as the recess in the gudgeon pin boss (2). If the original
piston is used, ensure that it is assembled to the correct connecting rod and is
used and is used in the original cylinder.
4. Lubricate the gudgeon pin bosses with clean engine lubricating oil and push in
the gudgeon pin towards the circlip. If the gudgeon pin is a tight fit in the piston
heat the piston to 40 / 50 0C (100/120 0F) before the gudgeon pin is fitted.
5. Fit a new circlip in the groove in the other gudgeon pin boss. Ensure that it fits
correctly in the groove.
6. Fit the piston rings.
02
ENGINE
58 WORKSHOP
To check the length of a connecting rod
A partially finished small end bush, which can be fitted to the original connecting rod
and machined to obtain the correct length grade is available. Specialist equipment
and personnel with the correct training are needed to machine the partially finished
small end bush.
Connecting rod kits are also available with the small end bush fitted and machined to
obtain the correct connecting rod grade.
Cautions:
 It is important that the piston does not contact the cylinder head. Ensure that
the piston height above the cylinder block is correct.
 Ensure that the connecting rods are fitted in the correct cylinder. Record the
position of the connecting rod and its relevant cylinder when it is removed from
the engine.
To ensure that the piston height above the cylinder block is correct, the engine may
have up to six length grades (F to L) of connectin rods fitted.
Identification of the length grade is by a letter or color which is marked on the side of
each connecting rod (1). The letter F is the longest grade of connecting rod and letter
L is the shortest grade. The difference between grades is 0,046 mm (0.0018 in).
The dimensions for each grade are listed below:
Grade letter Color code Length (mm)

F Red 165,728 / 165,761
G Orange 165,682 / 165,715
H White 165,637 / 165,670
J Green 165,591 / 165,624
K Purple 165,545 / 165,578
L Blue 165,499 / 165,532
If the grade letter or coulor on the side of the connecting rod cannot be seen, the
length can be checked by the
measurement of the dimension (X).
Before the length of the connecting
rod is measured, ensure that the
bores of the big end and the small
end are square and parallel. The
length is checked with the big end
bearing removed and the original
small end bush fitted.
02
ENGINE
WORKSHOP 59
PISTON AND PISTON RINGS
To inspect
1. Check the piston for wear and other damage.

2. Check that the piston rings are free to move in their grooves and that
the rings are not broken.
3. Remove the piston rings and clean the piston ring grooves and the
piston rings.
Note: The pistons have a tapered top groove and the piston ring is
wedge shaped. The top piston ring clearance cannot be checked by this
method.
4. Fit new piston rings in the
grooves and check for wear of
the grooves with feeler gauges.
Compare the piston ring
clearance in the groove to that
given for new components in the
relevant data and dimensions for
the “Pistons and piston cooling
jets” and renew the piston if
necessary.
5. Clean all carbon deposits from
the top of the cylinder bore. Fit each piston ring in the top part of the
cylinder bore and measure the ring gap with gauges. The coil spring
must be removed from the oil control ring when the gap of this piston
ring is measured.
The piston ring ring gaps for

new components are given in
the relevant data and
dimensions for the “Piston
rings”.
02
ENGINE
60 WORKSHOP
CONNECTING ROD
To inspect
1. Check the small end bush for wear or for other damage and renew it, if
necessary.
Note: Connecting rod kits are available with a new small-end bush fitted and
finished to the correct grade to identify the correct connecting rod grade.
A partially finished small-end bush, which can be fitted to the original
connecting rod and machined to obtain the correct length grade is also
available.
2. Check the connecting rod for distortion. Refer the relevant data and
dimensions for the “Connecting rods and big end bearings” to identify the
correct mandrel size.
Note: The large and small end bores must be square and parallel with each
other within the limits of ± 0,25 mm (0.010 in) measured 127 mm (5.0 in) each
side of the connecting rod axis on the test mandrel. With the small-end bush
fitted, the limits are reduced to ± 0,06 mm (0.0025 in).
3. Check the fit of the gudgeon pin in the small-end bush and check the gudgeon
pin for wear, refer to the relevant data and dimensions for the “Gudgeon pins
and small-end bushes”.
PISTON COOLING JETS
To remove
Release the setscrew (1) and

remove the piston cooling jet
assembly.
Note: The crankshaft is removed to
show clearly the piston cooling jet.
To fit
1. Check that the spring loaded valve moves freely against spring pressure in the
valve assembly and that the jet tube is not damaged. Renew piston cooling
jets as necessary.
2. Fit the piston cooling jet; ensure that the valve is fitted correctly in the locating
hole in the cylinder block.
3. Fit the setscrew (1) and tighten to 9 Nm, (17 lbf ft), 0,9 kgf m.
02
ENGINE
WORKSHOP 61
To check the jet alignment
Note: Ensure thjat the end of a 1,70

mm, (0.067 in), diameter rod, of 300
mm (11.8 in) in length, into the jet. If
a suitable rod is not avaible, reduce
the end of a thicker rod to 1,70 mm
(0.067 in) diameter for a length of
16,00 mm (0.630 in).
When the rod is inserted into the jet

it must extend out of the top of the
cylinder within the, are shown in the
figure.
Replace the piston cooling jet, as
necessary.
CRANKSHAFT ASSEMBLY
General description
The crankshaft is forged from chromium molybdenum steel and has five main
journals. There is a large flange at the rear of the crankshaft to which the flywheel is
fitted.
End-float and thrust movements are controlled by two split 3600 thrust washers on
both sides of the center main bearing.
The main bearings have steel backs with an aluminium / tin bearing material, and
main bearing caps are made of cast iron or spheroidal graphite iron.
The timing ring is an interference fit onto the machined surface of the web. The timing
ring is fitted behind the crankshaft palm and is located by a dowel.
The rear end oil seal is made from a PTFE material and is an integral part of the
pressed steel housing, which is fitted to the cylinder block.
The crankshaft pulley (2) is held in position by a plain thrust block (3) and three
setscrews (4). The nose (1) of the crankshaft and the pulley is serrated for location.
02
ENGINE
62 WORKSHOP
To remove
1. Remove the fan drive belts.

2. Remove the three setscrews (4) which hold the pulley and remove the
setscrews, the thrust block (3) and the pulley (2).
3. Clean the components and check for damage. Renew damaged components
as required.
4. Check the area of the seal contact on the pulley for wear. If there is excessive
wear, a wear sleeve can be fitted.
To fit
1. Put the pulley (2) in position on the crankshaft nose (1). Lubricate lightly the
threads of the setscrews (4) with clean engine lubricating oil. Fit the thrust
block (3) and the setscrews to 115 Nm, (85 lbf ft), 11,8 kgf m.
2. Check each setscrew again to ensure that they are still to the correct torque.
3. Fit the drive belts.
02
ENGINE
WORKSHOP 63
REAR END OIL SEAL ASSEMBLY
To remove and to fit the rear end seal oil seal assembly
Caution: The new rear end oil seal assembly includes a plastic protection sleeve (2)
that is fitted to the inside of the seal. This sleeve is to protect the oil seal from
damage when it is fitted to the crankshaft palm (1). The plastic sleeve must remain
inside the seal until the assembly is fitted. When the assembly is fitted, the plastic
sleeve will be pushed out of the oil seal and assembly. The plastic sleeve must be
discarded after the assembly is fitted. The seal of the new rear end oil seal assembly
is pre-waxed, there is no need to lubricate the palm or the seal before it is fitted.
Notes:
 The oil seal for the rear end oil seal assembly cannot be renewed, if the seal is
faulty, the complete assembly must be renewed.
 If the crankshaft palm has a wear groove caused by the old oil seal assembly,
a wear sleeve must be fitted to the crankshaft palm before the new assembly
is fitted.
 An alignment tool is needed to fit therear end oil seal assembly.
 Therear end oil seal cannot be used again and must be replaced if removed.
To remove
1. Remove the drive components from the rear end of the engine.
2. Remove the flywheel and the flywheel housing.
3. Remove the Torx screws from the rear end oil seal housing and remove the
assembly.
02
ENGINE
64 WORKSHOP
To fit
Caution: To prevent contamination of the oil seal surface, keep the new seal
assembly packed until required for use.
Note: The rear end oil seal cannot be used again and must be replaced if removed.
1. Ensure that the crankshaft palm (1), the rear face of the cylinder block and the
bridge piece are dry, free from dirt, and that there are no rough metal edges.
Do not use a lubricant on either the crankshaft palm, or on the rear end oil
seal, as the seal is pre-waxed.
2. Remove the new rear end oil seal assembly (3) from its pack. Ensure that the
plastic sleeve (2)supplied with
the rear end oil seal is square
within the rear end oil seal. The
plastic protection sleeve must
be in place when the seal is
fitted to the crankshaft palm,
this will prevent the seal being
damaged when fitted.
3. Place the rear end oil seal over
the crankshaft palm and
engage the plastic protection
sleeve (1) onto the crankshaft
palm.
4. With the plastic protection sleeve
engaged on the crankshaft palm,
push the rear end oil seal
assembly evenly and smoothly
onto the crankshaft palm until it
is against the cylinder block. The
plastic protection sleeve will be
pushed out of the assembly.
02
ENGINE
WORKSHOP 65
To fit (cont’d)
5. Discard the plastic sleeve.

6. Rotate the rear end oil seal (3) to align the holes in the rear end oil seal
assembly with the holes in the cylinder block rear face and the cylinder block
bridge piece.
7. Losely fit the Torx screws (5).
8. Place the seal alignment tool (4) onto the crankshaft palm and over the rear
end oil seal housing to align the rear end oil to crankshaft palm.
Notes:
 Ensure that the two rubber locating pins are correctly located into the cylinder
block.
 Ensure that there is no distortion of the rubber dust lip and that is in full contact
with crankshaft palm. If there is distortion, discard the seal and replace with a
new seal.
9. Tighten setscrews 1,2,3,4,5,6,7
and 10 in the sequence to 22
Nm, (16 lbf ft), 2,2 kgf m.
10. Remove the alignment tool and
the remaining Torx screws 8 and
9 in sequence to 22 Nm, (16 lbf
ft), 2,2 kgf m.
11. Fit the flywheel and flywheel
housing.
12. Fit the drive components to rear
end of the engine.
02
ENGINE
66 WORKSHOP
Alignment tool
The alignment tool must be manufactured locally to the following specifications:
1. Outer surface (1) to be knurled

2. Remove all sharp edges
3. To be made from material EN 32, harden 0,5 mm deep.
Note: All dimensions are in millimeters.
To remove and to fit a wear sleeve
Special requirements
Powerpart liquid gasket Part No: 21820518
To remove
1. Remove the rear end oil seal.

2. With a sharo tool mark a deep line along the length of the sleeve.
3. Insert a suitable thin blade between the crankshaft palm and the sleeve next to
the marked line. The wear sleeve will separate along the marked line.
4. Remove the wear sleeve. Use a suitable cleaner to remove any sealant from
the crankshaft palm.
02
ENGINE
WORKSHOP 67
Wear sleeve
To fit
1. Ensure that the crankshaft palm is dry and free from oil, dirt and sealant.
2. Remove any rough areas from the crankshaft palm surface.
3. Apply a small continuous bead of sealant (2), that does not harden, to the
inner surface of the wear sleeve 5,0 mm (0.197 in) from the flange end of the
sleeve (1).
Caution: The wear sleeve must be fitted
within five minutes of applying the sealant.
4. Ensure that the crankshaft is

fully forward in the engine.
5. Place the wear sleeve onto

the crankshaft palm (3), use
the tool (1) tha is supplied
with the new wear sleeve and
suitable hammer, to force the
wear sleeve (2) over the
crankshaft palm leaving a gap (5) of 0,4 / 0,6 mm (0.016/0.024 in).
6. Remove the tool and measure the gap (5) between the wear sleeve flange and
the cylinder block in two places 1800 apart. The correct gap is 0,4 / 0,6 mm
(0.016/0.024 in).
7. After the wear sleeve has been fitted, check and remove any rough metal
edges from the crankshaft palm and the wear sleeve.
8. Fit a new rear end oil seal.

02
ENGINE
68 WORKSHOP
To check crankshaft end-float
The axial movement of the crankshaft

is controlled by thrust washers fitted
both sides of the center main bearing.
The end-float can be checked with a

feeler gauge between a thrust washer and the crankshaft or wit a dial test indicator
on one end of the crankshaft to check the movement.
If the end-float is more than the tolerance given in the relevant data and dimensions
for the “Crankshaft”, thrust washerswhich are 0,019 mm (0.0075 in) oversize can be
fitted.
The oversize thrust washers can be fitted to one or to both sides of the main bearing.
They are fitted instead of the standard size washer, to reduce the end-float to the
factory tolerances.
02
ENGINE
WORKSHOP 69
Thrust washers
To remove
1. Drain the lubricating oil and remove the lubricating oil sump.
2. If necessary, remove the lubricating oil pump, or remove the balancer unit.
3. Release the setscrews of the center main bearing and remove the main
bearing cap complete with the lower halves of the thrust washers.
4. Use a suitable tool (1) made of a

soft material to push each of the
upper halves of the thrust washers
from their recesses. Where
necessary, move the crankshaft to
the front or to the rear to loosen a
tight washer.
To fit
1. Lubricate the thrust washerswith clean engine lubricating oil.

Caution: Factory built engines have an upper shell bearing that has an lubricating oil
slot (1) that is fitted to the number one crankshaft journal. The remaining upper shell
bearings have two lubricating oil holes (2). For service all upper shell bearings will be
replaced with bearings that have the lubricating oil slot (1).
2. Slide each of the upper halves of the

thrust washers into their recess in the
cylinder block. Ensure that the sides of
the thrust washers that have the grooves
(1) are against the crankshaft.
3. Fit the lower half thrust washers to

the main bearing cap with the location
tags in their recesses.
02
ENGINE
70 WORKSHOP
To fit (cont’d)
4. Ensure that the location thimbles (2)

are fitted correctly in the main bearing
cap or in the cylinder block.
5. Ensure that the bearing is fitted

correctly in the cap and that the
bearing and the crankshaft
journal are clean. Lubricate the
bearing with clean engine
lubricating oil.
6. Fit the cap with the location tags of both halves of the shell bearings to the
same side (1), ensure that the plain bearing shell is fitted to the lower bearing
cap.
7. Tighten the main bearingsetscrews to 245 Nm, (181 lbf ft), 25,0 kgf m.
8. Ensure that the crankshaft turns freely. If the thrust washers have been
removed and fitted, check the crankshaft end-float.
9. If necessary, fit the lubricating oil pump or fit the balancer unit.
10. Fit the lubricating oil sump, and fill the sump to the correct level with
lubricating oil of an approved grade.
02
ENGINE
WORKSHOP 71
MAIN BEARINGS
To remove (with the crankshaft in position)
Caution: Ensure that the tops of the main bearing caps are stamped with their
relevant position number. Keep the bearings with their relevant caps.
Notes:
 If more than one set of main bearings are to removed than identify, and keep
each pair as a set.
 If the rear main bearing cap is to be removed with thecrankshaft in position,
The flywheel, the flywheel housing, the rear end oil seal assembly and the
bridge piece will have to be removed.
1. Drain the lubricating oil and remove the sump.

2. Remove all necessary components to get access to the specific bearing cap.
3. Release the setscrews of the bearing cap and remove the bearing cap.
Remove the lower half of the shell bearing from the cap.
4. With a suitable tool (1), push the
upper half of the shell bearing
from the side opposite to the
location tag (2) to remove the
bearing tag from its recess (3) in
the bering housing.Carefully
rotate the crankshaft to release
the bearing from its housing.
To fit (with the crankshaft in position)
1. Clean the upper half of the shell bearing and lubricate the bearing surface with
clean engine lubricating oil.
Caution: Only the upper half of the bearing has lubrication holes and must be
fitted to the cylinder block.
2. Fit the plain end of the upper half of the bearing between the crankshaft
journal and the side of the bearing housing which has the recess for the
location tag. Slide the bearing into its housing until the tag on the bearing is
fitted correctly in its rscess in the housing.
3. Clean the lower half of the bearing and cap, lubricate the bearing surface with
02
ENGINE
72 WORKSHOP
To fit (cont’d)
4. Fit the bearing into the cap with

tag of the bearing fitted
correctly in the recess in the
cap.
5. Ensure that the location
thimbles (2) are fitted correctly
to the cap or to the cylinder
block. Fit the bearing cap with
the location tags of both
bearings an the same side (1).
6. Inspect the setscrews for
damage and for distortion and
renew them if necessary. Lightly lubricate the setscrew threads with clean
engine lubricating oil. Fit the setscrews and tighten the setscrews to 245 Nm,
(181 lbf ft), 25,0 kgf m.
7. Ensure that the crankshaft turns freely. If the thrust washers have been
removed and fitted, check the crankshaft end-float.
8. Fit all the components which were removed for access to the main bearing
cap.
9. Fit the lubricating oil sump, and fill the sump to the correct level with lubricating
oil of an approvedgrade.
02
ENGINE
WORKSHOP 73
CRANKSHAFT
To remove
Note: If the crankshaft is to be renewed, it may be necessary to change the grade of

the connecting rods. This will occur if the correct piston height above the block face
cannot be maintained with the original piston and connecting rod assemblies.
Warning: Use the lift equipment or obtain assistance to lift heavy engine components
such as the flywheel, flywheel housing and the crankshaft.
1. Before the engine is removed from the machine, drain the lubricating oil and
the coolant.
3. Remove the fan, the drive belts, the fan drive pulley and housing, and the
coolant pump.
4. Remove the fuel fuel injection pump.
5. Remove the crankshaft pulley.
6. Remove the alternator and its mounting bracket.
7. Remove the exhauster.
8. Remove the timing case cover.
9. Remove the timing gears and the timing case.
10. Remove the flywheel and flywheel housing.
11. Remove the rear end oil seal housing.
12. Remove the lubricating oil pump, remove the balancer unit.
13. Remove the bridge piece.
Warning: The engine should be upside down before the fasteners for the
crankshaft are removed. If the engine cannot be turned upside down support
thr crankshaft before the fasteners are removed.
14. Remove the caps of the connecting rods. Keep the bearings and caps
together. Remove the bolts of the connecting rods and carefully push the
pistons towards the top their bores.
15. Ensure that the tops of the main bearing caps are stamped with their relevant
position number. Remove the main bearing caps, the lower half of the shell
bearings and the upper and lower thrust washers. Keep the bearings with their
relevant caps.
16. Lift out the crankshaft. Remove the upper half of the bearings and keep each
bearing with its relevant lower half and cap.
Caution: If a timing ring is fitted to the crankshaft ensure that is protected from
damage and is correctly stored.
02
ENGINE
74 WORKSHOP
To fit
Powerpart silicone adhesive Part No: 21826038
1. Ensure that all lubricating oil passages are clean and free from restriction.
2. Clean the main bearing housings and the upper half of the bearings. Fit the
shell bearings with the location tags fitted correctly in their recesses. Lubricate
the bearings with clean engine lubricating oil.
3. Ensure that the main journals of the crankshaft are clean. Put the crankshaft in
position on the upper bearings.
4. Clean and lubricate the upper halves of the thrust washers and slide them into
their recesses on both sides of the bearing housing. Ensure that the slotted
sides of the thrust washers are towards the crankshaft.
5. Clean the bearing caps and the lower half of the bearings. Fit the bearings to
the caps with the location tags fitted correctly in their recesses. Lubricate the
bearings with clean engine lubricating oil.
6. Clean the lower halves of the thrust washers and lubricate them with clean
engine lubricating oil. Fit the thrust washers on both sides of the bearing cap
for the center main bearing.
7. Check that the location thimbles for the main bearing caps are fitted correctly
in the caps or in the cylinder block. Fit the bearing caps in their correct
positions with the location tags of the bearings on the same side.
8. Fit the setscrews to the main bearing caps and tighten them to 265 Nm,
(196 lbf ft), 27,0 kgf m.
9. Clean the bridge piece and the location areas for the bridge piece in the
cylinder block. Use a straight edge (2) to ensure that the bridge the bridge
piece is in line with
the rear face of the
cylinder block.
Tighten the bridge
piece cap screws (1)
to 16 Nm, (12lbf ft),
1,6 kgf m.
02
ENGINE
WORKSHOP 75
To fit (cont’d)
Note: The maximum protrusion for the

bridge piece (2) to the cylinder block (1) is
0 / -0,075 mm, (0-0.0029 in) (3).
10. When the bridge piece is in position, inject powerpart silicone adhesive into
the groove (2) at each end of the bridge piece. Continue to inject adhesive
until the groove is completely full and the adhesive leaves the lower groove (1)
at the front and rear of the
bridge piece.
11. Fit the connecting rod caps.
13. Fit the rear end oil seal
housing.
14. Fit the flywheel housing and
the flywheel.
15. Fit the timing case and the
timing gears, timing case and
drive assembly.
16. Fit the timing case cover.
17. Fit the exhauster.
18. Fit the alternator amd its mounting bracket.
19. Fit the crankshaft pulley.
20. Fit the fuel injection pump.
21. Fit the coolant pump, the fan drive pulley and housing, the drive belts, and the
fan.
23. After the engine has been installed, fill the lubricating oil sump to the correct
level with an approved oil.
To inspect
Check the crankshaft for wear and other damage. The maximum permissible wear
and ovality on the crankshaft journals and crank pins is 0,04 mm (0.0016 in).
The main journals and the crank pins of standard size cranshafts can be machined to
0,25 mm (0.010 in), 0,50 mm (0.020 in), or 0,75 mm (0.030 in) undersize diameter.
Special undersize bearings are available.
02
ENGINE
76 WORKSHOP
CRANKSHAFT TIMING RING
To remove
Warning: Ensure that suitable protective clothing is worn.

Cautions:
 Apply heat to timing ring only to reduce the risk of damage to the crankshaft.
 Carefully remove the timing ring, do not damage the crankshaft palm oil seal
face.
1. Remove the crankshaft from the cylinder block.

Note: If a “speedi sleeve” (wear sleeve) has been fitted to service the
crankshaft palm seal diameter, the shoulder of ths sleeve must be removed to
give clearance for the timing ring.
2. Support the crankshaft in a vertical position with the crankshaft palm at bottom
3. Apply heat to the timing ring (1) with a flame. The temperature of the timing
ring must not exceed 270 0C (518 0F). When heat is applied to the timing ring,
the ring will fall off the crankshaft web.
4. Discard the old timing ring after it has been allowed to cool safely.
5. Do not remove the timing ring locating dowel (2) from the crankshaft web
unless the locating dowel is
damaged.
To fit
Warning: Ensure that suitable protective

clothing is worn.
Cautions:
 Apply heat to timing ring only to
reduce the risk of damage to the
crankshaft.
 Carefully remove the timing ring, do not damage the crankshaft palm oil seal
face.
1. Ensure that the timing ring bore, and the crankshaft timing ring location
shoulder, are both clean and free from any rough metal edges.
2. If the locating dowel (2) was removed press a new dowel into the hole in the
crankshaft web. Ensure that the locating dowel is at the bottom of the hole.
3. Support the crankshaft in a vertical position with the crankshaft palm at the
top.
4. Heat the timing ring (1) in an oven to a temperature 207 0/2500 C (4050/4820F).
With the timing ring bore chamfer and relief groove towards the crankshaft
web, and the dowel hole aligned with the dowel, immediately fit the timing ring.
Ensure that the timing ring is fitted fully against the crankshaft web shoulder.
5. Allow the timing ring to cool safely.
6. Fit the crankshaft to the cylinder block.
02
ENGINE
WORKSHOP 77
BALANCER UNIT
Timing pin Part No: 27610225
To remove
1. Drain the lubricating oil from the sump and remove the sump.
2. Set the piston of the number 1 cylinder to TDC.
3. Insert the timing pin (1) into the balancer, ensure that the timing pin is fully
located in the drive shaft.
Warning: The weight of the unit is
approximately 25 kg (55 lb).
4. Provide a support for the balancer unit
before release of the setscrews from the
engine.
5. Release the setscrews and carefully
remove the balancer unit.
To fit
1. Ensure that the contact faces of the cylinder block and of the balancer unit are
clean and the thimble (1) and the dowel (2) are fitted correctly to the cylinder
block or to the balancer unit.
2. Set the piston number 1 cylinder to
TDC.
3. Fit two suitable M10 guide studs into
position (1).
02
ENGINE
78 WORKSHOP
BALANCER UNIT
To fit (cont’d)
4. Insert the timing pin (1) into balancer,

ensure that the timing pin is fully located
in the drive shaft and that the balancer
weights are pointed away from the
cylinder block.
5. Carefully fit the balancer unit onto the two

M10 guide studs in the cylinder block,
check that the balancer unit is fitted
correctly on the thimble and the dowel.
Ensure that the idler and crankshaft gears are in mesh. Fit two setscrews in
the center positions of the balancer frame, then tighten the setscrews to
54 Nm, (40 lbf ft), 5,5 kgf m.
6. Remove the two M10 guide studs and fit the four remaining setscrews in their
correct position.Tighten the setscrews to 54 Nm, (40 lbf ft), 5,5 kgf m.
7. Rotate the crankshaft through two turns to ensure that it is free to rotate.
8. Fit the lubricating oil sump, and fill the sump to correct level with lubricating oil
of an approved grade.
02
ENGINE
WORKSHOP 79
OIL PUMP
To dismantle
1. Remove the balancer from the engine.

2. To prevent movement of the drive shaft, put a suitable flat distance piece in
position between the balancer weights.
3. Release the setscrew and remove the idler gear assembly.
Note: Keep the components together as an assembly.
4. Release the nut of the lubricating oil pump gear and remove the nut. Using a
suitable two legged puller (2), locate the puller arms on the back of the gear
(1) and remove the lubricating oil pump gear from the shaft.
5. Release the four setscrews (1)

from the lubricating oil pump
cover plate and remove the
cover.
6. Inspect the lubricating oil

pump.
7. Dismantle the lubricating oil
relief valve.
02
ENGINE
80 WORKSHOP
Oil pump
To assemble
Powerpart Threadlock and nutlock Part No: 21820117
1. Assemble the lubricating oil relief

valve.
2. Fit the four setscrews (1) to the
lubricating oil pump cover plate
and tighteh to 26 Nm, (19 lbf ft),
2,6 kgf m.
3. Fit the lubricating oil pump gear and nut

(1), gradually tighten to 95 Nm, (70 lbf ft),
9,7 kgf m.
Note: Ensure that the flats on the thrust
washer (2) are aligned.
4. If necessary, renew the idler gear. Lubricate the bush with clean engine
lubricating oil. Fit the hub into the bush and fit the thrust washer onto the rear
of hub. Ensure that the threads of the setscrew are clean and dry. Fit the
setscrew through the assembly and apply a small amount of Threadlock and
Locknut to the thread. Fit the assembly to the front of the balancer unit.
Tighten the setscrew to 26 Nm, (19 lbf ft), 2,6 kgf m.
5. Check the end-float of the idler gear with a feeler gauge between the front
race of the idler gear and the hub. Check the backlash between the idler gear
and the drive shaft gear. Refer to the data and dimensions for “Balancer unit”.
6. Fit the suction tube and the joint and tighten the setscrews.
7. Remove the distance piece from the balancer weights.
8. Fit the balancer to engine.
02
ENGINE
WORKSHOP 81
Oil pump
To inspect
Note: If any part is worn enough to have an effect on the performance of the oil
pump, the complete oil pump must be renewed.
1. Remove the setscrews and remove the cover of the oil pump.
2. Remove the outer rotor and clean thoroughly all the parts. Check for cracks
and any other damage.
3. Fit the outer rotor and check the outer rotor to

body clearance, refer to the data and
dimensions for the “Lubricating oil pump”.
4. Check the inner rotor to outer rotor clearance, refer to data and dimensions for
the “Lubricating oil pump.
5. Check the rotor end-float with a straight

edge and a feelr gauge. For all above
clearances, refer to the data and
dimensions for the “Lubricating oil
pump”.
6. Lubricate the inner and outer rotor with clean engine lubricating oil. Clean the
top face of the oil pump and the inner face of the cover. Fit the cover. Tighten
the setscrews to 28 Nm, (21 lbf ft), 2,9 kgf m.
02
ENGINE
82 WORKSHOP
TIMING CASE AND DRIVE ASSEMBLY
General description
The timing case is made of either aluminium or cast iron.
The cast iron timing case is used to mount two power take-off units.
The timing gears are made of steel. There are two different types of steel camshaft
gear and upper idler gear. One is for
heavy duty and one for light duty. A
power take-off is available on either the
left hand side or the right hand side or on
both sides of the timing case. Some
engines have an idler gear with a roller
bearing.
The drive from the crankshaft gear
passes through an idler gear to the
camshaft gear and to the gear of the fuel
injection pump. The drive from the
crankshaft gear also passes a lower idler
gear to the gear of the lubricating oil
pump. The coolant pump isdriven by the
gear of the fuel injection pump. The
camshaft and the fuel injection pump run
at half the speed of the crankshaft.
The timing case contains the front oil seal.
To remove
Notes:
 To assist with access to the timing case cover, the fan drive can be removed.
 The timing case cover can be removed with the crankshaft pulley fitted.
1. Remove the coolant pump.
2. Remove the setscrews and the cover (1)

together with the joint.
3. Remove the joint from the cover and

discard the joint.
02
ENGINE
WORKSHOP 83
Timing case and drive assembly
To fit
1. Clean the joint faces of the timing case

and cover.
2. The new joint must be aligned by the

three joint dowels (1). The joint dowels
are a push fit into the cover (2).
3. Fit the two temporary studs (1)

through the timing case and into the
cylinder block.
4. Remove the timing pins.

5. Fit the cover to timing case and
loosly fit the setscrews.
6. Loosely fit the coolant pump.
7. Tighten the cover setscrews (2)

and coolant pump fasteners (1)
together to 22 Nm, (16 lbf ft),
2,2 kgf m.

10. Fit the fan drives.
02
ENGINE
84 WORKSHOP
FUEL PUMP GEAR
To remove
Special tools
Crankshaft timing pin Part No: 27610211
Rocker assembly tools Part No: 27610227
Camshaft timing pin Part No: 27610212
Cautions:
 These procedures must only be carried out by a person with the correct
training.
 Fuel injection pump nut (1) is loosened before the fuel pump timing is set and
the pump locked, the fuel
injection pump timing will be
lost and the fuel injection pump
will have to be removed and
sent to dealer to be reset.
 The timing pins are a push fit.

Do not use excessive force to fit
the pins.
 The engine is pin timed at TDC,
do not use the pins as a locking
device when repairs are carried
out on the engine.
Notes:
 The fuel pump gear can be removed with the crankshaft pulley fitted.
 It is recommended to help rotate the crankshaft, that the glow plugs are
removed.
1. Rotate the crankshaft to TDC.

Caution: The backlash must be
removed from all the gears before the
fuel injection pump is locked. Failure
to do so will make the fuel pump
timing incorrect.
3. Apply pressure counterclockwise by
hand to the fuel pump gear (2), to
remove back lash from the gears (1),
than lock the fuel injection pump.
02
ENGINE
WORKSHOP 85
To remove (cont’d)
4. To lock the pump shaft, ensure the backlash is removed. Loosen the locking
screw (1) and move the
washer (2). Tighten the
locking screw (1) to
17 Nm, (12 lbf ft), 1,7 kgf m.
The washer (2) can now
rotate around the locking
screw (1) with the pump shaft
locked.
5. Release the nut (2) and fit a suitable two legged puller (3). Tighten the puller
until the gear is released.
6. Remove the puller (3) and the

nut (2). Remove the gear (1).
02
ENGINE
86 WORKSHOP
Fuel pump gear
To fit
Special tools
Cautions:
 These procedures must only be carried out by a person with the correct
training.
 The drive shaft of the pump must not be turned without the locking screw
released, as this will damage be the drive shaft.
 The engine is pin timed at TDC, do not use the pins as a locking device when
repairs are carned out on the
engine.
1. Clean and check the fuel pump

gear and renew if damaged.
Clean the fuel injection pump
tapered shaft (1).
2. Check the engine is set to TDC.
3. Fit the gear (2) onto the tapered
shaft (1). Check that the fuel
pump gear is correctly in mesh
with the idler gear.
4. Fit the washer and nut (1) and tighten
by hand.
Caution: The backlash must be
removed before the fuel injection
pump is released. Failure to do so will
make the fuel pump timing incorrect.
5. Apply pressure counter clockwise by

hand to the fuel pump gear to remove
the backlash from all gears (shown in
side figure 1). Tighten the nut (1) to
24 Nm, (18 lbf ft), 2,4 kgf m.
02
ENGINE
WORKSHOP 87
Fuel pump gear
To fit (cont’d)
6. Release the locked fuel pump

shaft.
 To release the pump shat, ensure
that the backlash is removed.
Loosen the locking screw (1) and
move the washer (2). Tighteh the
locking screw (1) onto the washer
to 12 Nm, (9 lbf ft), 1,2 kgf m.
7. Tighten the nut of the fuel pump

gear to
88 Nm, (65 lbf ft), 9,0 kgf m.
8. Remove the two timing pins.
9. Check the fuel injection pump gear end-float (1) and the backlash (1).
10. Lightly lubricate each gear with clean engine lubricating oil.
12. Fit the glow plugs.
02
ENGINE
88 WORKSHOP
IDLER GEAR HUB
To remove
Notes:
 The idler gear hub is bushed.
 This gear is the heavy duty idler
gear. To remove the heavy duty idler
gear assembly, the plate (2) is
removed and fitted as part of the
gear assembly.
 When the idler gear is to be
removed, it is good to practice to
mark the plate (2) and the idler gear,
to help align the parts when they are
to be assembled.
1. Remove the fuel pump gear.

3. Remove the three setscrews (1) and the plate (2) from the idler gear.
4. Remove the gear and the hub assembly (1) from the recess (1) in the cylinder
block. The hub assembly must be moved forward and lifted over the front oil
seal housing (2).
5. Slide the hub (2) out of gear (1).

02
ENGINE
WORKSHOP 89
Idler gear
To fit
Special tools
Fuel pump timig pin Part No: 27610032
Cautions:
 The hub assembly must be aligned correctly to the plate (2) and the cylinder
block to allow the gear to be lubricated.
 The marked teeth (2) on the idler gear must be assembled to the hub so that
they face to front.
 The marked teeth (2) on the
idler gear must not be used as
timing marks.
 The engine is pin timed at TDC,

do not use the pins as a locking
device when repairs are carried
out on the engine.
Note: To fit the heavy duty idler gear

assembly the plate (upper fig.shown 2)
is fitted as part of the gear assembly. The plate will be marked with the word “TOP”,
ensure this facing the front of the engine this is to allow the gear assembly to be fitted
correctly.
02
ENGINE
90 WORKSHOP
Idler gear
To fit (cont’d)
1. Clean and check the hub and gear for damage, renew if necessary.
2. Check the engine timing.
3. Lubricate the hub with clean
lubricating engine oil and fit
thegear to hub. Rotate the hub in
the gear to align the oil way to the
top.
4. Fit the hub assembly (1) over the

front oil seal housing (2) and into
mesh with crankshaft gear and
camshaft gear.
5. Check that the hole (1) is towards the

cylinder head.
6. Align the plate (2) to the three holes in

the hub. Fit secrews (3). With the hub
assembly fitted, tighten evenly

the three setscrews (3) to 44
Nm, (32 lbf ft), 4,5 kgf m.
7. Check the end float (1) and
backlash, see “Timing case and
drive assembly”.
8. Fit the fuel pump gear.
02
ENGINE
WORKSHOP 91
Idler gear bushes
To remove and fit
Caution: If the bushed in the idler gear are to be renewed, the backlash between the
camshaft gear and the idler gear, and between the idler gear and the fuel pump gear
must be accurate.
If the bushes are to be changed, remove them with a suitable puller. If a puller is not
available, machine off the face of one of the bushes and press them out.
Press in new bushes and machine the bores to get the correct clearance on the hub.
The gear must have the correct backlash. Machine the faces to get the correct end
clearance.
When assembled, the idler gear backlash between the crank gear and idler gear
must be checked in four positions. Rotate the crankshaft clockwise viewed from the
front, and check the backlash between the two gears every 90 0, see “Timing case
and drive assembly”.
02
ENGINE
92 WORKSHOP
CAMSHAFT GEAR
To remove
Caution: The engine is pin timed at TDC, do not use the pinsas a locking device
when repairs ae carried out on the engine.
1. Remove the idler gear.

2. Remove the camshaft timing
pin.
3. Remove the setscrew (1), with
its washer, and remove the
gear from the camshaft. Ensure
that the key in the camshaft is
not lost.
To fit
Note: The camshaft timing pin is a push fit into the timing case. The camshaft gear
will rotate a small amount when the pin is fitted. This is to allow the assembly of the
gears and removal of the backlash from the gears when needed, with the timing pin
fitted.
1. Clean and check the camshaft gear and camshaft key for wear and damage,
renew if necessary.
2. Ensure that the camshaft key is fitted correctly.
3. Fit the camshaft gear to the camshaft with the marked teeth towards the front
and the keyway correctly aligned with the key. If necessary, lighly hit the gear
with a soft face hammer to engage the key into the keyway. Fit the camshaft
timing pin. If the camshaft needs to be rotated, remove the rocker assembly.
4. Fit the washer and setscrew to the gear and tighten the setscrew to
95 Nm, (70 lbf ft), 9,7 kgf m.
5. Fit the idler gear.
02
ENGINE
WORKSHOP 93
FRONT OIL SEAL
To remove
Special tools
Three legged puller Part No: 27610230
To remove the oil seal from timing case fitted to the engine
Warning! The oil seal housing must not be damaged when the oil seal is removed.

2. Thoroughly clean the area around the oil seal housing.
3. Fit the legs (2) of the puller under the oil seal and lock into position.
4. Fit a suitable distance piece (1)
between the crankshaft and the
puller.
5. Remove the oil seal from the

housing.
6. Discard the oil seal.
Note: If the timing case is removed from the engine, the seal can be removed from
the timing case. Use a suitable adaptor to press the seal out of the timing case.
Ensure that the timing case is supported correctly, and that excessive pressure is not
used to remove the seal, this can damage or distort the case.
To fit
Special tools
Crankshaft front oil seal replacer Part No: 21825577
Fastener plate for use with 21825577 Part No: 21825580
Pressure plate for use with 21825577 Part No: 21825578
Adaptor for use with 21825577 Part No: 27610217
02
ENGINE
94 WORKSHOP
Front oil seal
To fit (cont’d)
To fit the oil seal from timing case fitted to the engine
Warning! The oil seal (6) is made of “VİTON”, see the safety precautions for “Viton
seals”
Cautions:
 New timing case oil seals have a sleeve (5) fitted to protect the oil seal. Do not
remove the sleeve until the crankshaft pulley is to be fitted. Discard the new oil
seal if the sleeve (5) is not fitted.
 Damage may be done to the seal if the correct tool is not used.
 It is important that only genuine spare parts are used. The use of a seal that is
not a genuine part, may damage the engine and will affect the warranty.
 Do not lubricate the oil seal or the oil seal housing.
1. Clean the oil seal housing and check for damage, renew if necessary.
2. Check the crankshaft pulley seal face for wear.
3. Assemble the oil seal tool. Fit the fastener plate (7) to the front of the
crankshaft.
4. Assemble the nut (1) and the pressure plate (2) onto the threaded bar (3).
5. Align the seal (6) and the sleeve (5) to the front of the oil seal housing (8).
6. Fit the adaptor (4) onto the sleeve (5).
7. Put the pressure plate assembly onto the adaptor (4) and tighten the threaded
bar (3) onto thefastener plate (7). Check the alignment of assembly and the oil
seal to the oil seal housing.
8. Fit a rod through the hole in the end of the threaded bar to prevent movement
of the bar when the nut is tightened. Tighten the nut (1) to push the seal into
the housing. Tighten until contact is made with the bottom face of the oil seal
housing.
9. Removethe replacer tool.
10. Turn and pull the sleeve (5) counter clockwise, to remove the sleeve from the
oil seal.
11. Fit the crankshaft pulley immediately.
02
ENGINE
WORKSHOP 95
Front oil seal
To fit (cont’d)
To fit the oil seal from timing case removed
1. Clean the oil seal housing and check for damage, renew if necessary.
2. Check the crankshaft pulley for damage, repair if is necessary.
3. Check that the new oil seal has the sleeve protector fitted.
4. Align the oil seal housing. Do not lubricate the oil seal or the housing.
5. With a suitable tool, press the oil seal into the housing until contact is made
with the bottom face of the housing.
6. Fit the timing case.
7. When the front timing case cover is fitted, turn and pull the sleeve protector
counter clockwise, to remove the sleeve from the seal.
8. Fit the crankshaft pulley immediately.
To fit a wear sleeve
To renew a worn or damaged crankshaft pulley, a wear sleeve (2) is fitted over the
spigot (1).

Note: Full instructions and a
special tool to fit the wear sleeve
are in each service kit.
2. Fit the wear sleeve, in
accordance with the
manufacturer’s instructions. It is
not necessary to remove the
flange (3) of the wear sleeve after
it has been fitted. A new front oil
seal (4) must be used when a wear sleeve is fitted.
02
ENGINE
96 WORKSHOP
TIMING CASE
To remove
Special tools
Note: It is not necessary to remove the alternator, if the belts and the link setscrew
are removed. The alternator can be rotated away from the timing case.
1. Drain the lubricating oil and coolant.

2. Remove the fan drive.
4. If required remove the alternator.
6. Remove the fuel injection pump.
7. Remove the coolant by-pass.
8. Remove the crankshaft timing pin
and the camshaft timing pin.
9. Remove the camshaft gear.
10. Remove the timing case oil seal if a
new oil seal is to be fitted.
11. Remove internal setscrews (1) and
the outer setscrews (2) of the timing
case.
12. Remove the timing case from the cylinder block. Remove the upper joint (1)
from the timing case, and the lower joint from the cylinder block.
13. Discard all old joints.

02
ENGINE
WORKSHOP 97
Timing case
To fit
Special tools
Alignment tool Part No: 27910216
Powerpart retainer Part No: 21820608
Note: If a new timing case is to be fitted, it may be necessary to fit blanking plugs.
Apply powerpart retainer P/N: 21820608 to the blanking plug bore. This plug must be
fitted into the timing case before the case is fitted to the engine.
1. Clean and check the timing case for damage, renew if necessary.
2. Check that the camshaft
thrust washer is fitted
correctly. Fit the lower
timing case joint (1) onto the
cylinder block.
3. Fit wo temporary studs (2)
to the cylinder block.
4. Fit the upper timing case joint (1) to the timing case (2).
02
ENGINE
98 WORKSHOP
Timing case
To fit (cont’d)
5. Fit the alignment tool (2) into the

block and secure in place.
6. Fit the timing case (1) over the

alignment tool (2) and onto the
cylinder block. Fit the setscrews
into the timing case and tighten
by hand.
7. Align the timing case (5) to the

cylinder block (4).
Note: To seal the lubricating oil
sump joint, ensure that the bottom of
the timing case is correctly aligned
with the bottom of the cylinder block
before the setscrews are tightened.
The alignment of the bottom face of
the timing case (5) and the cylinder
block (4) must not exceed ± 0,05
mm (0.002 in).
8. Tighten the setscrews to 22 Nm, (16 lbf ft), 2,2 kgf m And check the alignment
(3) of the timing case face to the cylinder block face , adjust if necessary.
9. Fit the coolant by-pass.
11. Fit the camshaft gear.
12. Fit the idler gear.
13. Fit the fuel injection pump.
15. Fit the coolant pump. Note: The coolant pump setscrews should be tightened
together with the timing case cover setscrews.
16. Fit a new oil seal to the timing case.
18. Fit the alternator.
19. Fit the fan drive.
20. When the engine is fitted into the application, fill the lubricating oil sump to the
correct level and with the correct grade of engine lubricating oil. Fill the cooling
system to the correct level and with the recommended antifreeze.
02
ENGINE
WORKSHOP 99
CRANKSHAFT GEAR
To remove
1. Remove the timing case.

2. The crankshaft gear is a transition fit on the crankshaft. It may slide off easily
or, if it is a tight fit and the gear is to be renewed. It may be necessary to
remove the crankshaft, to remove the gear safely.
To fit
Caution: Do not use a flame to heat gear, as this can cause local damage.
1. The gear (1) can fit easily, or it may be necessary to heat the gear before it will
fit onto the crankshaft. If the gear is
to be heated, heat the gear in an
oven to not more than 200 0C (392
0
F). If an oven is not available, heat
the gear in coolant which is at its
boiling point.
2. Align the keyway in the gear to the
key in the crankshaft.
3. Fit the gear (1) with the shoulder
(2) facing outward.
02
ENGINE
100 WORKSHOP
CAMSHAFT AND TAPPETS
To remove
1. Remove the timing case.

3. Remove the rocker assembly and the push rods.
4. With the engine upside down, remove the camshaft thrust washer (1) and
carefully remove the the cam shaft.
5. Remove the tappets.

6. Inspect the camshaft and the tappets for wear and other damage, also inspect
the camshaft bush. Renew the components as necessary.
To fit
1. Ensure that all components are clean and are lubricated with clean engine
lubricating oil.
2. With the engine upside down, fit
the tappets into position.
3. Carefully fit the camshaft.
4. Fit the camshaft thrust washer (2).
Ensure that it is fitted correctly onto
the hollow dowel (1).
5. Turn the engine the right way up.
7. Check that the camshaft end-float
is within the limits.
8. Fit the push rods.
10. Adjust the valve tip clearance.
02
101
ENGINE
WORKSHOP
CYLINDER BLOCK ASSEMBLY
General description
The cylinder block is made of high duty cast iron with an integral crankcase. The
sides of the cylinder block extend below the crankshaft center line to give added
strength. The cylinder block provides full length support for the cylinder bores.
All bores are honed with silicon carbide tools to a controlled finish to ensure long life
and low oil consumption. A bush is fitted in the cylinder block for the front camshaft
journal and the other camshaft journals run directly in the block.
To dismantle
Notes:
 If the cylinder block is to be renewed, it may be necessary to change the grade
of the connecting rods. This will occur if the correct piston height above the
block face cannot be maintained with the original piston and connecting rod
assemblies.
 All of the components that need to be removed for access to the cylinder block
are referred to in the procedure below. As a result some of the stages within
operations may be repeated.
1. Ensure that all engine fluids are drained.
2. Remove the the wiring harness, and the speed and timing sensor.
3. Remove the VLPM.
4. Remove the lubricating oil cooler.
5. Remove the lubricating oil filter head.
6. Remove the cylinder head.
7. Remove the crankshaft.
8. Remove the piston and the connecting rod assemblies.
9. Remove the camshaft.
10. Remove the piston cooling jets.
To assemble
Special requirement
Powerpart threadlock & nutlock Part No: 21820117
1. Clean througly the new cylinder block. Ensure that all the oil passages are
clean and free from debris.
2. Remove the threaded plugs from the old cylinder block and clean the threads.
Seal the threads with Powerpart threadlock & locknut, and fit the threaded
plugs into the new cylinder block.
3. Fit the piston cooling jets.
02
102
ENGINE
WORKSHOP
Cylinder block assembly
To assemble (cont’d)
4. Fit the crankshaft.

5. fit the piston and connecting rod assemblies.
6. Fit the camshaft.
7. Fit the lubricating oil filter housing.
8. Fit the lubricating oil cooler.
9. Fit the ECM, the wiring harness, and the speed and timing sensor.
10. Fit the VLPM.
11. Install the engine into the machine.
13. Fill the lubricating oil sump to the correct level with an approved lubricating oil.
14. Bleed air from the fuel system.
To inspect
1. Clean the internal passages for the coolant and the oil.
2. Check the cylinder block for craks and for other damage.
3. Check the camshaft bush for wear. If the bush is to be renewed, use a suitable
adaptor to press it out of the bore. Ensure
that the lubricating oil hole in the new bush
(1) will be towards the front of the engine
when fitted. Press in the new bush with the
oil hole on the same side and aligned with
the oil hole in the block until the front end of
the bush is aligned with the face of the
recess.
02
103
ENGINE
WORKSHOP
CYLINDER BORE
To inspect
To ensure the best performance during the life of the engine it is important that worn
or damaged cylinder bores are re-bored and re-honed.
The condition of a cylinder bore is decided by:

 The amount and location of any polished areas
 Wear
 Damage to the bore wall
Note: It will not be necessary to re-bore / re-hone if:
 The honed finish can still be clearly seen.

 The engine performance and oil consumption are acceptable.
To check the condition of a cylinder bore
1. Inspect the bore surface for cracks and deep scratches.

2. Check the bore wall for areas where the honed finish has been polished away.
Check especially the area around the top of the bore just below the carbon
ring. In this area, thrust from the top piston ring is at its maximum.
Cautions:
 Do not use “Flex-hone” to repair cylinder bores.
 New oversized piston and rings must be fitted when the cylinder bore is
re-bored / re-honed.
 An engine can have high oil consumption with very little wear of the
bores, if the surfaces of the bores are glazed.
 Specialist training and equipment are needed to machine the finish of a
cylinder bore.
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ENGINE
WORKSHOP
ENGINE TIMING
General description
To ensure that 1100 series 4 cylinder engines have an accurate system of timing, the
engines are pin timed.
This system will set the engine so that number 1 piston is at top dead center (TDC)
on the compression stroke.
To reach the accurate fuel injection needed for engines to conform to emission
legislation, the latest fuel injection pumps operate at a static timing of TDC.
It is important that fuel injection timing is accurate to conform to emission legislation.

Always use operation to obtain TDC on the compression stroke of number 1 cylinder.
Cautions:
 The hub nut (1) must not be released
until TDC on the compression stroke is
set, the backlash is removed from the
fuel injection pump gear and the fuel
pump shaft is locked. If the nut (1) is
loosened before TDC on the
compression stroke is set and the fuel
pump shaft is locked the fuel pump
timing will be lost. The pump will have to
be removed and sent to be reset.
To set number 1 piston to TDC on the compression stroke
Special tools
Cautions:
 This procedure must only be carried out by a person with the correct training.
 The timing pins are a push fit. Do not use excessive force to fit the pins.
 Do not use the pins as a locking device when repairs are carried out on the
engine.
 The timing pins must be removed before the timing case cover is fitted. Failure
to do so will damage the engine.
02
 The marks on the timing gears are not to be use as timing marks. The marks
indicate the front of the gear only. 105
ENGINE
WORKSHOP
To set number 1 piston to TDC on the compression stroke (cont’d)

2. Remove the glow plugs.
3. Remove the timing case cover.
Note: The crankshaft timing pin can be inserted with the crankshaft pulley still
fitted.
4. To set the No 1 piston to TDC on
the correct stroke, rotate the
crankshaft in the normal direction
of rotation until the intake valve
(7) of number 4 cylinder has just
opened and the exhaust valve (8)
of the same cylinder has not
closed completely.
5. Carefully rotate the crankshaft in the normal direction of rotation. Align the hole
in the crankshaft with the hole in
the cylinder block and the timing
case (1). Insert the crankshaft
timing pin through the timing case
and the cylinder block. Push the
pin fully into the hole in the
crankshaft web.
6. Insert the camshaft timing pin,
through the hole in the camshaft
gear (2) and into the body of the
timing case. With the two timing
pins fitted the engine is set at TDC
No 1 on the compression stroke.
Note: The camshaft timing pin is a
push fit into the timing case. The camshaft gear can rotate a small amount
when the pin is fitted. This is to allow the assembly of the gears and removal
of the backlash from the gears, with the timing pins fitted.
7. Remove the timing pin from each gear.
Caution: The fuel pump timing of the injection pump must not be checked or
adjusted. If the fuel pump timing is lost, the pump must be removed and sent to the
dealer to be reset.
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ENGINE
WORKSHOP
To check the valve timing
Note: Do not fit the timing case cover, the glow plugs or the rocker cover at this
stage.
1. Set the piston of No 1 cylinder to TDC on the compression stroke.

2. Mark the pulley at TDC, set a temporary pointer to the mark.
3. Set the valve tip cleararace of No 1 cylinder intake valve to 1,220 mm
(0.048 in) and No 1 exhaust valve to 1,302 mm (0.051 in).
4. Rotate the crankshaft, clockwise from the front, until the push rod of No 1
cylinder intake valve is just loose and push rod for No 1 cylinder exhaust valve
is equally loose. In this position, check if the mark on the crankshaft pulley or
damper is within ± 2,50 of the temporary pointer. Use the formula below to find
the measurement which is equal to 2,5 0 on the pulley or damper.
CxP C : circumference of pulley or damper P: 2,5 degrees

360
5. If the timing is more than 2,50 out of position , the timing gears are likely not to
be in correct mesh.
Notes:
 One tooth on the camshaft gear is equivalent to 18 mm (0.70 in) at the
circumference of a pulley of 200 mm (7.87 in) diameter.
 One tooth on the camshaft gear is equivalent to 16 mm (0.62in) at the
circumference of a pulley of 170 mm (6.69 in) diameter.
6. Rotate the crankshaft clockwise from the front, until the intake valve of the rear
cylinder has just opened and the exhaust valve has just closed. Set the valve
tip clearance of the intake valve No 1 cylinder to 2,20 mm (0.008 in). Set the
valve tip clearance of the exhaust valve of No 1 cylinder to 0,45 mm (0.018 in).
7. Fit the timing case front cover.
10. Remove the temporary pointer from the timing case and the timing mark from
the pulley.
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ENGINE
WORKSHOP
ASPIRATION SYSTEM
General description
Warning! Turbochargers operate at high speed and high temperatures. Keep fingers,
tools and debris away from the inlet and outlet ports of the turbocharger and prevent
contact with hot surfaces.
The turbocharger is
fitted between the
exhaust and intake
manifold and is
driven by exhaust
gas. The
turbocharger passes
air to the engine at
more than
atmospheric
pressure. It is
lubricated by oil from
the main gallery. The
oil enters through the
bearing housing of
theturbocharger and
returns to the cylinder
block. From there it is
returned to the
lubricating oil sump.
All turbochargers that are fitted with a

waste-gate unit (1), which is controlled by
boost pressure from the inlet manifold,
will allow some of the exhaust gases to
by-pass the turbine rotor at higher engine
speeds. With this arrangement the
turbocharger can be designed to be more
effective at lower engine speeds.
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108
ENGINE
WORKSHOP
Aspiration system
To remove and to fit an exhaust elbow
To remove
1. Remove the two setscrews (3) from the exhaust elbow (1).
2. Pull the exhaust elbow (1) from the adaptor (4).
To fit
1. Ensure that all the component faces are clean and free of damage, renew if
necessary.
2. Push the exhaust elbow (1) onto the adaptor (4).
3. Align the exhaust elbow (1) to the support bracket (5) and the exhaust pipe of
the application.
4. Fit the setscrews (3) and tighten to

44 Nm, (33 lbf ft), 4,5 kgf m.
Note: If the support bracket (5) is to
be removed and fitted, remove the
exhaust elbow, and remove the
three setscrews that hold the
support bracket. To fit the bracket,
align the support bracket to the
cylinder block. Fit the top setscrews
(2) to align the bracket, then fit the
two remaining setscrews. Tighten to 44 Nm, (33 lbf ft), 4,5 kgf m.
5. Connect the exhaust elbow to the application.
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109
ENGINE
WORKSHOP
TURBOCHARGER
Warnings!
 The sealing washers used on the lubricating oil pipe (6) contain Viton. Read
the safety precautions for Viton
seals.
 Discard old lubricating oil in a safe
place and in accordance with local
regulations.
Caution: Ensure that the turbocharger

waste-gate and the actuator rod of the
waste-gate are not used to lift or move the
turbocharger. This could damage the
waste-gate and effect the calibration.
To remove
1. Througly clean the turbocharger.

2. Remove the air cleaner hose at the compressor inlet.
3. Put a suitable container under the oil drain pipe.
4. Disconnect the exhaust pipe for the application and remove the exhaust elbow
from the turbocharger.
5. Remove the three nuts (2) of the
adaptor plate (3) and remove the
adaptor plate.
6. Release the hose clip of the
compressor outlet. Remove the
setscrews of the crossover pipe.
Remove the crossover pipe
complete with the old gasket and
hose. Discard the gasket.
7. Removethe banjo bolts (5) and
the sealing washers. Remove the
pipe and discard the old sealing
washers.
8. Remove the setscrews (4) from the bottom flange of the oil drain pipe.
9. Remove the nuts (1) at the turbocharger to exhaust manifold flange. Remove
the turbocharger and the gasket with the drain pipe. Remove the bottom joint
of the drain pipe.
10. Remove the setscrews from the top of the oil drain pipe and remove the pipe
joint from the turbocharger. Discard all old joints and gaskets. Cover the open
ports in the manifold, the turbocharger and te pipes to ensure that dirt will not
enter.
11. Check the air hoses and the oil drain pipe for damage, renew if necessary.
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110
ENGINE
WORKSHOP
Turbocharger
To fit
Warning! The sealing washers used on the

lubricating oil pipe (5) contain Viton. Obey to
the safety precautions.
Cautions:
 The compressor inlet hose has a heat
shild material that partly covers the
hose. When a new hose fitted, the
hose must be correctly aligned to the
exhaust to protect the hose from
theheat.
 When a new compressor inlet hose is
to be fitted, use a water and 5% soap
solution to fit the hose into position. Do not use oil or grease.
 The reflective heat shield of the inlet hose must be kept clean and free from
dust, oil or paint. If the surface of the heat shield is not shiny, the part that is
protected by the heat shield could be damaged.
1. Remove the covers from the pipes, manifold and turbocharger.

2. Check that the turbocharger inlet and outlet ports are clean and free from
restriction and that the turbocharger shaft rotates freely. Also check that the
open ports in the intake crossover pipe and the exhaust pipe are clean and
free from restriction.
3. Fit loosely the drain pipe (2)
and its new joint to
turbocharger (1).
Note: The turbocharger drain
pipe has different size
setscrews. The top flange has 6
mm setscrews and the bottom
flange has 8 mm setscrews.
4. Fit a new gasket (4) to the
exhaust manifold flange. If the
original nuts are to be used,
ensure that the threads of the
studs are clean. Apply a suitable compound to the studs to prevent seizure.
Note: The threads of new nuts are phosphated to prevent seizure.
5. Fit the turbocharger (1). Fit the nuts (5) and tighten them to 47 Nm, (34 lbf ft),
4,8 kgf m.
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ENGINE
WORKSHOP
Turbocharger
To fit (cont’d)
6. Fit the bottom flange of the pipe (2) together with a new joint and tighten the
flange setscrews to 22 Nm, (16 lbf ft), 2,2 kgf m. Tighten the top flange
setscrews to 9 Nm, (7 lbf ft), 0,9 kgf m.
7. Lubricate the bearing housing of the turbocharger with clean engine lubricating
oil. Fit loosely the pipe (3) and new sealing washers. Tighten both banjo bolts
to 22 Nm, (16 lbf ft), 2,2 kgf m.
Note: Ensure that the lubricating oil pipe (3) does not come in contact with
other components.
8. Fit the adaptor plate (9) to the turbocharger and fit loosely the three nuts.
9. Fit the exhaust elbow to the
adaptor.
10. With the elbow secure, tighten the
nut (6) by hand, then (7) and (8).
Tighten the nuts in the same
sequence to 25 Nm, ( 18 lbf ft),
2,5 kgf m.
11. Connect the exhaust pipe for the

application to the exhaust elbow.
12. Fit the crossover pipe and hose to
the turbocharger. Tighten the setscrews to 22 Nm, (16 lbf ft), 2,2 kgf m.
13. Check that there is no restriction in the hose from the air filter to the
turbocharger. Fit the hose and tighten the clip to 5 Nm, (4 lbf ft), 0,5 kgf m.
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ENGINE
WORKSHOP
Turbocharger
To check the operation of the waste-gate
If the waste-gate valve does not operate at the correct pressure, it can affect the
engine performance.
If the valve opens at a low pressure, this can cause black exhaust smoke and loss of
power at lower engine speeds.
1. Disconnect the actuator hose (2) at the actuator. Connect to the actuator an
air supply which can be adjusted accurately and is fitted with an accurate
gauge.
2. Fasten a dial test indicator
(1) to the turbocharger with
its plunger in contact with
the end of the actuator rod
(3) to measure axial
movement of the rod.
Caution: Do not apply an
air pressure of more than
205 kPa, (30 lbf/in2),
2,1 kgf/cm2 to the actuator.
Higher pressures may
damage the actuator.
3. Slowly apply air pressure. Check that the pressure necessary to move the rod
1,00 mm, (0.039 in), is within limits, refer to the data and dimensions for
“Turbocharger”. Ensure that the pointer returns to zero when the pressure is
released. Repeat the test several times to ensure that an accurate reading is
obtained. It may be necessary to lightly hit the turbine housing with a soft
hammer during the test operation.
4. Consult your nearest dealer if the operation of the waste-gate is not correct.
5. if the air pressure is correct, release the air pressure, remove the test
equipment and connect the actuator.
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ENGINE
WORKSHOP
TURBOCHARGER FAULTS
Caution: If the turbocharger or waste-gate is found to be damaged or faulty, a new

turbocharger must be fitted.
The chart below is given to assist in the correct diagnosis of turbocharger faults.
Problems Possible causes code numbers

1,4,5,6,7,8,9,10,11,18,20,21,22,25,26,27,28,35,
No enough power 36
1,4,5,6,7,8,9,10,11,18,20,21,22,25,26,27,28,35,
Black smoke 36
Blue smoke 1,2,4,6,8,9,17,19,20,21,22,30,31,32
High lubricating oil consumption 2,8,15,17,19,20,28,29,31,32
Too much lubricating oil at turbine end 2,7,8,17,19,20,22,28,30,31,32
Too much lubricating oil at compressor end 1,2,4,5,6,8,19,20,21,28,31,32
Not enough lubrication 8,12,14,15,16,23,24,29,32,33,37,38
Lubricating oil in the exhaust manifold 2,7,17,18,19,20,22,28,31,32
Inside of the intake manifold wet 1,2,3,4,5,6,8,10,11,17,18,19,20,21,28,32
Damaged compressor impeller 3,4,6,8,12,15,16,20,21,23,24,29,32,33,37,38

7,8,12,13,14,15,16,18,20,22,23,24,25,27,29,32,
Damaged turbine rotor 33,37,38
3,6,7,8,12,13,14,15,16,18,20,21,22,23,24,29,32,
Rotating assembly does not turn freely 33,37
Worn bearings, bearing bores, journals 6,7,8,12,13,14,15,16,23,24,29,33,37,38
1,3,4,5,6,7,8,9,10,11,12,13,14,15,16,18,20,21,2
Noise from turbocharger 2,23,24,29,32,33,37,38
Sludge or carbon deposit in bearing housing 2,11,13,14,15,17,18,24,29,33,37,38
List of possible causes
1 Element of the air filter dirty.

2 Restricted crankcase breather.
3 Element of the air filter not fitted, or not sealing correctly. Loose connection to
turbocharger.
4 Internal distortion, or restriction in pipe from air filter to turbocharger.
5 Damaged/restricted crossover pipe, turbocharger to intake manifold.
6 Restriction between air filter and turbocharger.
7 Restriction in exhaust system.
8 Turbocharger loose or clamps/setscrews loose.
02
9 Intake manifold crossover pipe has cracks, is loose, or has flange distortion.
114 10 Exhaust manifold has cracks, is loose, or has flange distortion.
ENGINE
WORKSHOP
List of possible causes (cont’d)
11 Restricted exhaust system.

12 Delay of lubricating oil to turbocharger at engine start.
13 Insufficient lubrication.
14 Dirty lubricating oil.
15 Incorrect lubricating oil.
16 Restricted lubricating oil supply pipe.
17 Restricted lubricating oil drain pipe.
18 Turbine housing damaged or restricted.
19 Leakage from turbocharger seals.
20 Worn turbocharger bearings.
21 Excessive dirt in compressor housing.
22 Excessive carbon deposit behind turbine rotor.
23 Engine speed raised too rapidly at initial start.
24 Insufficient engine idle period.
25 Faulty fuel injection pump.
26 Worn or damaged atomizers.
27 Valves burned.
28 Worn piston rings.
29 Lubricating oil leakage from supply pipe.
30 Excessive preservation fluid (on initial engine start).
31 Excessive engine idle period.
32 Restriction in turbocharger bearing housing.
33 Restriction in lubricating oil filter.
35 Waste-gate actuator faulty or damaged.

36 Waste-gate valve not free.
37 Engine stopped too soon from high load.
38 Insufficient lubricating oil.
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ENGINE
WORKSHOP
LUBRICATION SYSTEM
General description
Pressure lubrication is supplied by a rotor type pump which is driven through an idler
gear from the crankshaft gear. The pump has an inner rotor and outer rotor which are
off-set to each other. There is an interference fit between the inner rotor and the drive
shaft. When the pump rotates because the space between the lobes which are in
mesh, increases to cause a suction to fill the space and a decrease to create a
pressure increase.
Lubricating oil from the sump passes through a strainer and pipe into the suction side
of the pump. The pump delivers the oil to the cylinder block via oil cooler. The oil is
transferred by the oil pump frame to the oil filter passage in the cylinder block.
Then relief valve is integral with the pump and re-circulates the excess oil directly
back to oil pump inlet.
The lubricating oil passes through the oil filter and directly back to the mainpressure
rail which drilled the full length of the left side of the cylinder block.
From the pressure rail, lubricating oil passes to the main bearings of the crankshaft
and through passages in the crankshaft to the big end bearings. The pistons and the
cylinder bores by the oil jets which are attached the main pressure rail.
Lubricating oil passes from the main bearings through passages in the cylinder block
to the journals of the camshaft. The front camshaft bearings feeds oil through a
drilling in the cylinder block and cylinder head to the rocker shaft. The oil passes
through the center of the rocker shaft to the rocker levers. The rocker pads, valve
stems, cam lobes and the tappetsare splash lubricated.
The hub of the idler gear is lubricated by oil from the end pressure rail and the timing
gears are splash lubricated.
The lubricating oil for turbochargers is delivered by an external pipe from a tapping
on the side of the cylinder block above the right hand side of filter face. The oil
returns from the turbocharger down another extended drain pipe into the side of the
cylinder block, or filter head, through an external pipe to the turbocharger. The oil
passes through the turbocharger and returns through a pipe to the sump.
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ENGINE
WORKSHOP
LUBRICATION SYSTEM
1: Suction pressure to the oil pump 2: Main engine oil press. 3: Reduced pressure
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117
ENGINE
WORKSHOP
Oil filter (canister type)
To renew
Warning! Discard the used canister, and lubricating oil in a safe place and in
accordance with local regulations.
Cautions:
 The canister contains a valve and a special tube to ensure that lubricating oil
does not drain from the filter, when the lubricating oil is changed. Ensure that
the genuine spare canister is used.
 Ensure that the application is on a level surface to ensure an accurate reading
on dipstick.
1. Put a suitable container below the lubricatingoil filter.

2. Remove the filter canister with a strap wrench. Ensure that the adaptor is
secure in the filter head. Discard the canister.
3. Clean the filter head.
4. Lubricate the top of the canister seal (1) with
5. Fit the new canister and tighten by hand only. Do
not use a strap wrench.
6. Remove the container and discard the old
lubricating oil.
7. Start the engine and check for leakage from the
filter. When the engine has cooled, check the
engine oil level on the dipstick and add more oil
into the sump, as necessary.
Filter head
To remove
1. Put a tray under the filter head

to contain split lubricating oil.
2. Remove the filter canister.
3. Remove the setscrews and
remove the filter head (2) from
the cylinder block. Discard the
joint (1).
4. Clean the joint face (1) of the
filter head and the cylinder
block.
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ENGINE
WORKSHOP
Filter head
To fit
1. Ensure that all joint surfaces are clean and free from damage.
2. Fit a new joint to the filter head, the joint is fitted dry.
Note: The setscrews for securing the filter head have a sealant (MEAS)
applied by the manufacturer to the first 13,0 mm (0.50 in) of the threads. If the
setscrews are used again, the sealant must be removed from the male and
female threads and Threadlock & locknut P/No:21820117 applied to the first
13,0 mm (0.050 in) of the setscrews threads.
3. Fit the filter head to the cylinder block. Gradually and even tighten the
setscrews.
4. Fit the new filter canister.
Sump
To remove
Warnings!
 Discard the used lubricating oil in a safe place and in accordance with local
regulations.
 Before the sump is removed, ensure that the sump is fully supported before
the setscrews removed.
1. Operate the engine until it is warm.

2. Stop the engine, remove the sump
drain plug (1) and its O-ring , and drain
the oil. Where necessary, remove the
dipstick and the dipstick tube.
3. Provide a support for the sump and
remove the setscrewsand, if relevant,
the two nuts which fasten the sump to
the timing case. Lower the sump and
remove and discard the joint.
4. Wash the sump with an approved cleaning fluid, ensure all the cleaning fluid is
removed. Clean the flange face of the sump and of the cylinder block.
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119
ENGINE
WORKSHOP
Sump
To fit
Powerpart threadlock & nutlock Part No: 21820117
Powerpart silicone rubber sealant Part No: 1861108
Notes:
 If either the cylinder block bridge piece and/or the timing case, have just been
fitted then fit the sump before any bridge piece/timing case sealant has been
allowed to cure.
 If the sump only is to be fitted, then any old surface sealant from either the
cylinder block bridge piece, and /or the timing case, should be removed and
renewed.
1. Remove any old sealant from the cylinder block bridge piece, timing case, and
cylinder block joint surfaces.
2. Ensure that the joint faces of the cylinder block and the sump are both free
from dirt and damage.
3. Insert four alignment studs into
holes (1).
4. Apply a bead of silicone rubber
sealant to the joints between the
cylinder block and the timing
case (3), and the cylinder block
and the bridge piece (2).
Note: Handle the sump joint with
care as rubber-sealing bead can
be easily damaged.
02
5. Place the joint onto the cylinder block over the alignment studs and ensure
120 that all of the fixing holes align correctly.
ENGINE
WORKSHOP
Sump
To fit (cont’d)
6. Place the sump onto the cylinder block over the alignment studs.
Note: The setscrews for securing the sump have sealant (MEAS) applied by
the manufacturer to the first 13,0 mm (0.050 in) of the threads. If the setscrews
are used again, the sealant must be removed from the male and female
threads and threadlock & nutlock applied to the first 13,0 mm (0.050 in) of the
setscrew threads.
7. Loosely fit the setscrews into all of the available holes by hand.
8. Remove the alignment studs and fit the remainder of the setscrews.
9. Tighten the four setscrews (4) to 22 Nm, (16 lbf ft), 2,2 kgf m.
10. Tighten the remainig setscrews (4) to 22 Nm, (16 lbf ft), 2,2 kgf m.
11. Fit the drain plug (1), if necessary fit a new O-ring, and tihten to 34 Nm, (25 lbf
ft), 3,5 kgf m.
12. Fill the sump to the mark (2) on the

dipstick with new engine lubricating oil
of an approved grade.
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ENGINE
WORKSHOP
Oil strainer and suction pump
The oil strainer is an integral part of the suction pipe. No regular service is necessary.
But wash the strainer when it is removed.
To remove
1. If not already removed; remove the lubricating oil sump.

2. Remove the setscrews from the flange of the suction pipe. Remove the
suction pipe and strainer. Remove the old joint. Clean the flange face of the oil
pump and suction pipe.
To fit
1. Fit the suction pipe to the oil pump together with a new joint. Tighten the
setscrews (1).
1. Wash the assembly in an approved cleaning fluid and dry it thoroughly.

2. Check the pipe, the strainer and the welded joints for craks and other damage.
3. If a component is damaged, renew as necessary.
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ENGINE
WORKSHOP
LUBRICATING OIL PUMP ASSEMBLY
To remove
Warning! Discard the used lubricating oil in a safe place and in accordance with local
regulations.
1. If not already removed; remove the lubricating oil sump.

2. Remove the setscrews (1) and remove the oil pump assembly.
To fit
1. Fill the oil pump assembly with

clean engine lubricating oil. Fit
the oil pump assembly to the
cylinder block., ensure that the
dowel (1) and the thimble (2)
are correctly located, then
tighten the setscrews to
22 Nm, (16 lbf ft), 2,2 kgf m.
2. Check the idler gear for wear
and other damage. If the gear is
damaged, it must only be

renewed as an assembly. The
assembly consists of an idler
gear, an idler shaft and a front
plate.
3. Check that there is backlash
between the oil pump
02
idlergear and the crankshaft gear.
123
ENGINE
WORKSHOP
Lubricating oil pump assembly
To inspect
Note: For all the clearances, refer to the data and dimensions for the “Lubrication
system”
1. Remove the setscrews and remove the cover of the oil pump.
2. Remove the outer rotor and clean all the parts. Check for craks and any other
damage.
3. Fit the outer rotor, and check the outer rotor to body clearance.
4. Check the inner rotor to outer rotor to clearance.
5. Check the rotor end –float with a

straight edge and a feeler gauge.
6. Lubricate the inner and outer rotor
with clean engine lubricating oil.
Clean the top face of the oil pump
and the inner face of the cover. Fit
the cover. Tighten the setscrews to
28 Nm, (21 lbf ft),2,9 kgf m.
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ENGINE
WORKSHOP
Relief valve
To remove the relief valve of the balancer
1. Remove the plug that retains the relief valve (1). Remove the spring and valve.
To fit
1. Ensure the relief valve is clean.
2. Place the relief valve and spring into the balancer.
3. Tighten the plug for the relief valve (1) to 22 Nm, (16 lbf ft), 2,2 kgf m.
To remove the relief valve of the lubricating oil pump
Caution: Do not change the operation pressure of the relief valve by a method other
than the installation of new components.
1. Remove the plug which fastens the relief valve (2), and remove the spring and
valve.
To fit
1. Ensure the relief valve is clean.
2. Place the relief valve and spring into the lubricating oil pump.
3. Tighten the plug for the relief valve (2) to 22 Nm, (16 lbf ft), 2,2 kgf m.
02
ENGINE
WORKSHOP 125
FUEL SYSTEM
General description
Cautions:
 There are no adjustments that can be carried out on the fuel pump. The fuel
injection equipment must only be checked by personnel who have had the
correct training.
 If a fuel injection pump is returned for repair, or under warranty, then all of the
fuel ports must be closed with a plastic blanking
cap to prevent the entry of water and dirt into the
pump. If blanking caps are not fitted then the
warranty will be affected.
The fuel injection pump comforms to emission legislation.
Cold start advance unit (KSB)
The fuel pump has a cold start advance unit that holds the timing of the pump in an
advanced position when the engine is cold.
Caution: It is important that the electrical connections to the sender unit are
connected correctly. Failure of the KSB to operate correctly could result in damage to
the engine as the timing will be fully advanced for normal operation.
The sender unit is on the rear of the timing case on the left side of the engine.
With the engine cold, the sender unit energises to advance the pump timing for the
cold start operation of the fuel injection pump.
To ensure that the engine conforms to

emissions legislation, it is important that
the electrical connections of the engine
cold start advance unit are fitted
correctly before the engine is operated.
02
ENGINE
126 WORKSHOP
Fuel system
Wiring diagram for the cold start advance unit fitted to injection pump is shown below,
on the illustration. For easy identification the cables are shown in circles on the
illustration.
The amperage of each of the cables listed in the cable identification table below. The
identification numbers for the electrical components are shown in triangles. Refer to
the component identification list to find a component.
Cable identification
Cable number Current (Amperes)
1 3
2 3
3 6
Component identification
Component Description
1 Fuel injection pump
2 Engine stop solenoid
3 Sender unit
4 Start switch
5 Cold start advance unit
02
ENGINE
WORKSHOP 127
Typical Fuel system
Fuel from the tank, passes to the electric lift pump / filter (4).
Fuel leaves the lift pump (3) under pressure to the fuel injection pump (6).
The fuel injection pump has a self-vent pipe to remove air from the fuel system back
into the fuel tank through a connection on the connector block. The fuel in the
injection pump also lubricates and cools the pump.
The fuel injection pump increases the fuel pressure and injects high-pressure fuel at
the correct time and sequence through pipes to the atomizers (1).
02
ENGINE
128 WORKSHOP
FUEL FILTER ASSEMBLY
To renew
Warnings!
 The combustible material of some components of the engine can become
extremely dangerous if it is burned. Never allow this burnt material to become
into contact with the skin or with the eyes.
 Discard the used element and fuel oil in a safe place in accordance with local
regulations.
 If the fuel level in the tank is higher than the fuel lift pump, the supply and
return fuel line valves must be turned off before servicing or repairs are made.
If the fuel line valves are not turned off, fuel will flow through the system.
 Ensure that the starter switch is in the OFF position before any service or
repairs are made to the fuel system. If the lift pump has power, fuel will be
released.
Cautions:
 It is important that only genuine spare parts are used. The use of an element
that is not a genuine part may damage the fuel injection pump.
 The pre-filter canister and main filter elements must be renewed at the same
time.
 Do not allow dirt to enter the fuel system. Before a connection is disconnected,
clean the area around the connection. After a component has been
disconnected, fit a suitable cover to all open connections.
1. Place a suitable container below the fuel filter assembly to retain spilled fuel
oil.
2. Througly clean the outside surfaces of the fuel filter assembly. Open the drain
tap (1) at bottom of of the filter
casing to drain the fuel from the
filter.
3. Use a strap wrench to loosen

the filter casing. Remove the
casing and element from the
fuel filter head.
02
129
ENGINE
WORKSHOP
Fuel filter assembly
To renew (cont’d)
4. To remove the filter element from the casing; press down on the filter element
(1), against the spring
pressure, and rotate the
element to the left to release it
from the filter casing (4).
5. Put the new filter element
inside the casing and press
the element down against the
spring pressure. Rotate the
element to the right to lock the
element into the casing.
6. Fit a new seal (3) to the
casing and lightly lubricate the
seal face with clean fuel oil.
7. Check the thread (2) on the
inside of the element is not
damaged.
8. Fit the filter assembly to the fuel filter head and tighten by hand until the filter
assembly contacts the filter head. Tighten the assembly a further 1/8 of a turn
by hand. Do not use strap wrench.
9. Close the drain tap and remove the container.
02
130
ENGINE
WORKSHOP
ATOMIZERS
To identify a faulty atomizer
Regular maintenance of the atomizers is not necessary. The atomizer should be

renewed and not cleaned, and renewed only if an atomizer fault occurs. The major
problems that may indicate that new atomizers are needed listed below:
 Engine will not start or is difficult to start
 Not enough power
 Engine misfires or runs erratically
 High fuel consumption
 Black exhaust smoke
 Engine knocksor vibration
 Excessive engine temperature
Warnings!
 If your skin comes into contact with high-pressure fuel, obtain medical
assistance immediately.
 Keep away from moving parts during engine operation. Some moving parts
cannot be seen clearly while the engine runs.
To find the defective atomizer, release

the atomizer cover setscrews (1) and
remov the atomizer cover (2), run the
engine at fast idle.
Release and tighten the union nuts (3)

of the high-pressure fuel pipe at each
atomizer, one at a time. Do not loosen
the union nut more than half a turn.
When the union nut of the defective
atomizer is released, it has a little or
no effect on the engine speed.
02
131
ENGINE
WORKSHOP
Atomizers
To remove
Cautions:
 Atomizers must be removed and fitted by a person with the correct training.
 Do not allow dirt to enter the fuel system. Before a connection is disconnected,
clean thoroughly the area around the connection. After a component has been
disconnected, fit a suitable cover to
all open connections.
1. Release the atomizer cover

setscrews (1) and remove the
atomizer cover (2).
2. Remove the fuel leak-off pipe from

the connection (5).
3. Remove the union nuts of the

high-pressure pipe from the
atomizer (4) and from the fuel
injection pump. Do not bend
the pipe. If necessary, remove
the pipe clamps. Fit a plastic
cap to cover the fuel inlet
connection.
4. Remove the setscrew (6) from
the clamp (7) and remove the atomizer and its seat washer from the recess in
the cylinder head.
Caution: Remove and discard the

seat washer (3). If the original seat
washer remains in the recess for the
atomizer, the nozzle protrusion will
be incorrect when a new seat
washer is added.
02
132 ENGINE
WORKSHOP
Atomizers
To fit
1. Put a new seat washer (3) into

the seat recess in the cylinder
head.
2. Ensure that the atomizer seal (1)
is not damaged. Apply a small
amount of clean engine oil to the
seal.
Caution: The atomizer must be
fitted so that the two leak-off
connections (5) point away from
the cylinder head towards the
intake manifold.
3. Place the atomizer (4) into the
recess in the cylinder head.
4. Fit the clamp (7), tighten the
setscrew (6) for the clamp to
27 Nm, ( 20 lbf ft), 2,8 kgf m.
Caution: Do not tighten the union
nuts ofth high-pressure pipes to
more than the recommended torque
value. If there is a leakage from the
union nut, ensure that the pipe is
correctly aligned with the atomizer
inlet. Do not tighten the atomizer
union nut more, as this can cause a restriction at the end of the pipe. This can
affects the fuel delivery.
5. Remove the plastic cap and fit the high-pressure fuel pipe. Tighten the union
nuts to 27 Nm, (20 lbf ft), 2,8 kgf m.
6. Fit the high pressure fuel pipe clamps.
7. Fit the fuel leak-off pipes to the connectors (5).
8. Operate the engine and check for leakage of fuel and that there is no air in the
system.
9. Stop the engine. Refit the atomizer cover and tighten the setscrews.
02
ENGINE 133
WORKSHOP
Fuel lift pump and filter assembly
Caution: Do not allow dirt to enter the fuel system. Beforea connection is
disconnected, clean thoroughly the area around the connection. After a component
has been disconnected, fit a suitable cover to all open connections.
To remove
1. Disconnect the fuel pipes from the electric fuel lift pump and filter assembly.
2. Drain the electric fuel lift pump and filter assembly.
3. Remove the setscrew (2) and the spacer from the support bracket (3) for the
fuel pipes.
4. Remove the setscrews (1) and rubber washers. Remove the electric fuel lift
pump and filter assembly.
To fit
Note: Ensure that new rubber washers are fitted to the setscrews and the cylinder
block before the electric fuel lift pump and filter assembly is fitted.
1. Fit the setscrews (1) and new rubber washers to the fuel lift pump and filter
assembly.
2. Fit the spacer and setscrew (2) to the support bracket (3) for the fuel pipe.
3. Fit the fuel pipes to the fuel lift pump and filter assembly.
4. Eliminate any trapped air from the fuel system.
system.
02
134 ENGINE
WORKSHOP
Fuel lift pump and filter assembly
To test
1. Remove the two outlet fuel pipes from the electric fuel lift pump and filter
assembly, make note of the location of the pipes to ensure that the pipes are
fitted correctly.
2. Connect two suitable rubber hoses to the outlet pipes (feed to fuel injection
pump and return to the fuel tank), and place into a three liters measuring
cylinder.
3. Operate the engine until a consistent flow of fuel is running from the outlet pipe
of the fuel injection pump.
Note: The return pipe to the fuel tank will have a slower flow than the feed
pipe from the fuel injection pump.
4. The combined flow of both pipes should be at a rate of two liters/per minute as
a minimum.
5. If the flow is less than two liters/per minute, replace the electric fuel lift pump
and filter assembly.
6. Connect the electric fuel lift pump outlet pipes in the correct position.
system.
To test pressure regulator
1. Remove the fuel lift pipe from the fuel injection pump, fit a suitable pipe with a
pressure test point and connect a 0-80 kPa (0-12 lbf/in2 ), 0-0,8 kgf/cm2
pressure gauge.
2. Operate the engine at idle for two minutes to allow any trapped air to be
removed.
3. The reading on the pressure gauge should be 27,5 kPa, (3,98 lbf/in 2), 0,28
kgf/cm2 at idle., and rated speed 28 kPa, (4.06 lbf/in 2), 0,28 kgf/cm2.
4. The combined flow of both pipes should be at a rate of 2 liters/per minute as a
minimum.
5. Connect the fuel lift pipe to the fuel injectiom pump. Operate the engine at idle
for two minutes.
Note: If the fuel lift pump and filter assembly does not meet the above
specifications check for the following; that all the electrical connections are
fitted, there are no leaks in the pipes and connections, that the seal on the
drain tap does not leak and that the O-ring for the canister to the lift pump
does not leak.
02
ENGINE 135
WORKSHOP
Air in the fuel system
If air enters the fuel system, it must be removed before the engine can be started.
Air can enter the system if:

 The fuel tank is drained during normal operation
 The low-pressure fuel pipes are disconnected
 A part of the low-pressure fuel system leaks during engine operation
 A fuel system componet such as a filter element, or a fuel pump, has been
installed during a service
 The high-pressure fuel pipes have been disconnected.
To eliminate air from the fuel system
Cautions:
 Do not operate the engine until the air is eliminated from the fuel injection
pump.
 After the air is eliminated, operate the engine at low idle for two minutes.
The fuel injection pump will eliminate air automatically when the start key is turned to
the RUN position for three minutes.
1. Release the atomizer cover setscrews and remove the atomizer cover.
2. Turn the start key to the RUN position for three minutes then return the key to
the OFF position.
3. Loosen the high-pressure pipes (1) at the atomizers.
4. Operate the starter

motor until fuel free from
air comes from the
connections.
5. Tighten the connections
to 30 Nm, (22 lbf ft),
3,0 kgf m.
6. Start the engine and
check for leaks.
7. Fit the atomizer cover and tighten its setscrews.
02
136 ENGINE
WORKSHOP
FUEL INJECTION PUMP
General description
Cautions:
 If the fuel injection pump is removed from the engine it will need to be returned
to nearest dealer for the pump timing to be checked or reset.
 Do not unlock the shaft of the fuel injection pump until the fuel pump gear is
fitted.
 A new fuel injection pump will be supplied with the pump shaft in the locked
position. The drive shaft of the pump must not be turned without the spacer (2)
in position under the locking screw (1).
The fuel injection pump has a drive gear fastened to the shaft of the pump.
An O-ring (3) is fitted instead of a joint between the pump flange and the timing case.
02
ENGINE 137
WORKSHOP
Fuel injection pump
To remove
1. Disconnect the battery.

2. Set the engine to TDC No: 1 cylinder compression stroke.
3. Lock the pump shaft; to lock the fuel injection pump shaft loosen the locking
screw (2) and rotate the washer (1). Tighten the locking screw (2) to 17 Nm,
(12 lbf ft), 1,7 kgf m.
Caution: Use a second spanner to prevent movement of the high-pressure
outlet on the pump when the union nut for each high pressure pipe is
released.
4. Remove the low-pressure and the high-pressure fuel pipes from the pump.
Caution: Do not rotate the crankshaft when the pump is not on the engine.
5. Remove the fuel pump gear.
6. Remove the setscrew from the fuel pump support bracket (4).
7. Remove the setscrews and washers that secure the fuel pump and remove
the pump.
8. Discard the fuel pump O-ring

(3).
02
138 ENGINE
WORKSHOP
Fuel injection pump
To fit
Cautions:
 The engine must be set to TDC No 1 cylinder, compression stroke before the
pump is fitted.
 Do not unlock the shaft of the fuel ijection pump until the fuel pump gear is
fitted.
 A new fuel injection pump will be supplied with the pump shaft in the locked
position. The drive shaft of the pump must not be turned without the spacer (2)
in position under the locking screw (1).
1. Fit a new O-ring (3) to the pump flange.

Lightly lubricate the O-ring with clean engine
lubricating oil.
2. Fit the pump into position in the timing case, fit the three washers and
setscrews, then tighten the setscrews to 25 Nm, (18 lbf ft), 2,5 kgf m.
02
ENGINE 139
WORKSHOP
Fuel injection pump
To fit (cont’d)
3. Loosely fit the setscrew (4) of the support bracket. Ensure that force is not
applied to the fuel pump.
4. Fit the fuel pump gear.
Caution: The fuel pump gear must be fitted to the engine before the
crankshaft is rotated.
6. Tighten the setscrew (4) of the

support bracket to 44 Nm, (32
lbf ft), 4,4 kgf m. Ensure that
force is not applied to the fuel
pump.
Cautions:
 Do not tighten tighten the union
nuts of the high-pressure pipes
more than the recommended
torque tension. If there is a leakage from the union nut, ensure that the pipe is
correctly aligned with the pump outlet. Do not tighten the pump union nut more, as
this can cause a restriction at the end of the pipe. This can affect the fuel delivery.
 Use a second spanner to prevent movement of the high-pressure outlet on the
pump when the union nut for each high-pressure outlet on the pump when the
union nut for each high-pressure pipe is tightened.
7. Fit the low-pressure and the high-pressure fuel pipes to the pump. Tighten the
high-pressure pipe union nuts to 27,5 Nm, (21 lbf ft), 2,8 kgf m.
9. Eliminate air from the fuel system.
system.
02
140 ENGINE
WORKSHOP
COOLING SYSTEM
General description
Coolant from the bottom of the radiator passes through the centrifugal coolant pump
that is fitted onto the front of the timing case, to assist the flow of the coolant through
the system.
The coolant pump is gear driven by the fuel injection pump gear.
An integral oil cooler, has an aluminium cover with a five or seven plate element. The
oil cooler has no external pipes and is fitted to the left side of the cylinder block.
From the pump, the coolant passes through a passage in the timing case to the
coolant jacket in the top left side of the cylinder block. The coolant continues to the
rear of the cylinder block where some of the coolant passes into the lubricating oil
cooler. Some of the coolant passes around the element of the integral cooler and
then to the rear of the cylinder block.
The coolant then passes from the rear of the cylinder block and into the cylinder
head. The coolant
leaves the cylinder
head at the front
and passes into the
thermostat housing.
If the thermostat is
closed, the coolant
goes directly
through a by-pass
to the inlet side of
the coolant pump. If
the thermostat is
open, the
thermostat closes
the by-pass and the
coolant passes to
the top of the
radiator.
02
141
ENGINE
WORKSHOP
THERMOSTAT
To remove
Special tools
Thermostat tool Part no: 27610226
Note: Engines are fitted with a single thermostat. Identification of the thermostat is by
the nominal temperature which is stamped on the by-pass valve.
1. Drain the coolant in the cooling system to a level below the thermostat
position and disconnect the top hose from the coolant outlet connection.
2. Release the two setscrews (1) and remove the thermostat housing from
the cylinder head.
3. Remove the O-ring and
discard.
4. Press down on the thermostat using the thermostat tool (3) and rotate the
thermostat to release it from the housing (2).
5. Remove the thermostat from the

housing.
02
142
ENGINE
WORKSHOP
Thermostat
To fit
Thermostat tool Part no: 27610226
Powerpart red rubber grease Part no: 21820221
1. Clean the thermostat housing. Ensure that the grooves for the spring retainers
and the seat for O-ring are free of debris.
2. Ensure that the jiggle pins (1) in the thermostat are both free to move.
3. Lubricate a new O-ring (4) with

powerpar red rubber grease before it
is fitted. Fit O-ring. Place the
thermostat (5) in position in the
housing (7).
4. Use the thermostat tool (3) to

push and rotate the thermostat
to engage the spring retainers
into the grooves in thehousing
(6) and (8).
5. Fit the thermostat assembly to

the cylinder head and tighten the
setscrews.
02
6. Connect the top hose and fill the cooling system.
143
ENGINE
WORKSHOP
Thermostat
To test
Note: Do not remove the thermostat from the housing to test.
1. Place the thermostat and the housing in a suitable container filled with coolant.
2. Heat the coolant gradually. Use a thermometer to check the temperature at
which the valve starts to open and at which it is fully open. For the correct
operating temperatures, refer to the data and dimensions for Thermostat”.
Caution: If the thermostat does not operate correctly, it must be renewed. Do
not try to adjust the settings.
COOLANT PUMP
Note: Identification of the coolant pump is by the part number that is cast onto the
coolant pump body.
To remove
1. Drain the cooling system and disconnect the hose at the inlet connection of
the coolant pump.
2. Remove the nine setscrews in which retain the coolant pump and remove the
coolant pump.
3. Remove and discard the joint.
02
144
ENGINE
WORKSHOP
COOLANT PUMP
To fit
Special requirement
Powerpart threadlock & nutlock Part no: 21820117
1. Ensure that all joint faces are clean.

2. Check the drive gear of the coolant pump for wear or other damage. If the
gear is damaged, the pump must be renewed.
3. Fit two suitable guides (10), fit a new joint (11).
4. Fit the pump (12) onto the guides and into the timing case cover with its gear
in mesh with the gear of the fuel injection pump.
Note: The setscrews that retain the coolant pump have a sealant (MEAS)
applied by the manufacturer to the first 13,0 mm (0.50 in) of the threads. If the
setscrews are used again, the sealant must be removed from the male and
female threads and threadlock & nutlock applied to the first 13,0 mm (0.050 in)
of the setscrew threads.
5. Fit and lightly tighten the seven sescrews which retain the pump to the cover
of the timing case. The pump is a tight fit in the cover, but can be pulled into
position if the setscrews for the pump are gradually and evenly tightened.
6. Remove the guides and fit the
remaining setscrews.
7. Tighten all the setscrews (1-9) on the
coolant pump to
22 Nm, (16 lbf ft), 2,2 kgf m.
8. Connect the hose to the inlet
connection of the coolant pump and fill
the cooling system.
02
9. Operate the engine and check for leakage.
145
ENGINE
WORKSHOP
Coolant pump
To dismantle
1. Remove the setscrews (1) the cover and the joint. Discard the joint.
2. To remove the impeller (3) from the pump

shaft; drill twelwe 6,35 mm (0.25 in) holes
between the existing holes at equal
distance around the impeller. Drilling these
holes will brak pieces off the impeller (3)to
allow the 2 legged puller to be correctly
fitted.
3. The impeller can be removed

by using a suitable two legged
puler attached to the back of
the impeller (4). Tighten the
center setscrew (2) of the puller
until the impeller is removed.
Discard the impeller.
Caution: Do not damage the
sealing face of the coolant seal
housing during removal of the seal.
4. To remove the coolant seal (8), it
will be necessary to break the
seal and use an extractor to
remove the center sleeve of the
seal from the body of the shaft.
This will loosen the grip of the
seal on the shaft. To remove the
body of the seal, drill three 3,175
mm (0.125 in) holes through the
top of the coolant seal 1200
apart. Fit three 25,4 mm (1.00 in)
self-tapping screws. Insert a
suitable lever through the
coolant inlet of the pump body
and gradually and evenly apply
the lever under head of each
02
self-taping screw to remove the seal. Discard the seal. Caution: Do not
146 damage the sealing face of the oil seal housing during removal of the seal.
ENGINE
WORKSHOP
Coolant pump
To dismantle (cont’d)
5. Remove and discard the circlips (9) (10).
6. Put the impeller end of the pump

body face down on a suitable
press. Press the drive gear end
of the shaft through the gear (13)
and the pump body until the shaft
(7)and ball bearing assembly (11)
are released from the pump.
Discard the bearing and the
shaft. The gear will also be
released through the side of the
housing.
7. Inspect the gear for wear or other
damage and renew it, if
necessary.
8. Put the impeller end of the pump
body face down on a press and
use a suitable mandrel to engage
the outer face of the oil seal (14).
Press out the oil seal and discard
it.
9. With the impeller end of the
pump body face down on a
press, use a suitable to engage
the outer race of the needle roller bearing (12). Press out the bearing and
discard it.
02
147
ENGINE
WORKSHOP
Coolant pump
To assemble
Caution: It is important that all of the components in the kit for the coolant pump are
used.
1. Clean thoroughly the inside of the pump body, the bearing bores and the
counterbore for the coolant
seal. These bores and their
chamfers must be clean and
free of corrosion.
2. Put the gear end of the pump
body face down on a press.
Use a suitable mandrel to
engage the outer face of the oil
seal and press in until the
bottom face of the oil seal is
level with the face of the gear
housing.
3. With the gear end of the pump
body face down a press,
position the drive gear into the
correct position. Use a suitable
adaptor to press the drive shaft
through the oil seal and into
drive gear so that there is a
1,5 mm (0.060 in) gap between
the drive gear and the top face
of the drive gear pocket.
4. Use a suitable adaptor to press
the bearing (11) onto the drive
shaft, until it is against its
shoulder.
5. Put the impeller end of the pump body face down on a press. Fit the new
circlip (9), with the bevel edge away from the oil seal to retain the bearing
assembly in the body of the pump. Fit the circlip (10) to the drive shaft to retain
the bearing assembly to the drive shaft of the pump.
02
148
ENGINE
WORKSHOP
Coolant pump
To assemble (cont’d)
6. Turn the pump over and press the needle roller bearing (12) into the bearing
housing until the end of the bearing is level with or 0,5 mm (0.020 in) below
the top of the housing.
Caution: Do not lubricate the coolant seal (8). The coolant seal must not be
contaminated with oil or grease. If the coolant seal is held by the edge of the
outside flange. A tool can be manufactured to press the new seal into position.
The tool should be made of a suitable material to the dimensions shown as:
A 54,00 mm (2.125 in)
B 6,00 mm (0.236 in)
C 10,00 mm (0.393 in)
D 48,00 mm (1.889 in)
E 44,00 mm (1.732 in)
F 18,00 mm (0.708 in)
G 54,00 mm (2.125 in)
7. Turn the pump over onto thegear end and with the widest end of the coolant
seal towards the oil seal, push the seal onto the shaft util it is in contact with
the coolant seal counterbore. Ensure that the seal is square with the bore and
with a suitable adaptor press the seal into the counterbore, until the outer
flange is in contact with the pump body. Continue to apply force for
approximately ten seconds to ensure that the seal remains in position.
8. Press the impeller onto the shaft so that it is level with the top of the drive
shaft.
9. Fit a new cover joint and fit the cover. Fit the setscrews and tighten to
22 Nm, 816 lbf ft), 2,2 kgf m.
02
149
ENGINE
WORKSHOP
FAN
To remove
Remove the locknuts and remove the fan from the studs. The fan extension and the
pulley can now be removed from the studs.
To fit
Clean thoroughly the rear of the fan where the fan fits onto the fan extension. Ensure
that all paint is removed from this area. Fit the pulley onto the studs, and fit the fan
extension. Clean the front face of the fan extension. Fit the fan and the locknuts, refer
to the data and dimensions for “Special torques for setscrews and nuts”.
FAN DRIVE
To remove
1. Loosen the pivot fasteners of the alternator and the fasteners of the alternator
adjustment link. Remove the drive belts.
2. Release the locknuts and remove the fan, fan extension and the pulley.
3. Check the end-float of the drive shaft. If it is more than 0,25 mm (0.010 in), the
fan drive assembly must be renewed.
4. Release the setscrews and remove the fan drive.
To fit
1. Fit the fan drive and tighten the setscrews to 44 Nm. (33 lbf ft), 4,5 kgf m.
2. Fit the fan.
3. Fit the belts and adjust the tension.
02
150
ENGINE
WORKSHOP
LUBRICATING OIL COOLER
To remove
1. Drain the cooling system.

2. Place a suitable container under
the oil cooler.
Note: Do not remove setscrews
(1), as these setscrews hold the
oil cooler element to the cover.
3. Release the setscrews that retain
the oil cooler to the cylinder
block.
4. Remove the oil cooler and the
joint.
To fit
1. Renew the joint, ensure that all the joint faces are clean.
2. Fit the oil cooler.
3. Fit all the setscrews and tighten to the correct torque.
5. Check the oil level on the dipstick (2). Refill to the correct level with new
lubricating oil of an approved grade.
6. Operate the engine and check for leakage of coolant or oil.
02
151
ENGINE
WORKSHOP
Lubricating Oil cooler
To dismantle
1. Remove the oil cooler from the cylinder block.

2. Remove the four setscrews (1) from the oil cooler and remove the cooler
element.
Warning! Do not allow
compressed air to contact your
skin. If compressed air enters your
skin, obtain medical help
immediately.
3. Clean the element and check for
cracks. If a solution is used to
clean the outside of the element,
ensure that this does not enter the
element.Check that there are no
restrictions to the flow of lubricating
oil through the element of the oil cooler. If the inside of the element needs to
be cleaned, use a solvent which is suitable for copper. Dry the element with
low pressure air and then flush it with clean engine lubricating oil.
To assemble
1. Renew the joints (2) on the flanges

of the element.
2. Fit the element to the cover and
tighten the setscrews (1) to the
correct torque.
3. Fit the oil cooler.
02
152
ENGINE
WORKSHOP
Coolant by-pass pipe
Powerpart red rubber grease Part no: 21820221
To remove
1. Remove the two setscrews (1).
2. Carefully pull the coolant by-

pass pipe from the cylinder
head.
3. Remove and discard the O-
rings.
To fit
1. Fit new O-rings (3) and (2) and lubricate with red rubber grease.
2. Carefully fit by-pass pipe into the cylinder head, ensure that the O-ring is
correctly fitted.
3. Fit the two setscrews (1) and tighten to the correct torque.
02
153
ENGINE
WORKSHOP
FLYWHEEL AND HOUSING
General description
The flywheel is fitted with a hardened starter ring. The starter rings have either 115 or
126 teeth.
The flywheel housing is made of cast iron.
Flywheel
Warning! The flywheel is heavy. Use lift equipment or get help to assist with the lift
operation before removal of the flywheel fasteners.
To remove
1. Remove two opposite setscrews from the flywheel. Fit temporarily two guides
to ensure that the flywheel can be removed and fitted safely.
2. Remove the reminder of the setscrews and washers and remove the flywheel.
3. Check the flywheel and ring gear for damage and renew.
To fit
1. Ensure that the location faces of the crankshaft and the flywheel are clean and
free from damage.
2. Fit a hardened steel washer to each of ten setscrews. Fit the flywheel over the
guide studs and secure in place with eight of the setscrews. Do not fully
tighten the setscrews. Tighten the setscrews referring to “Specific torque
values”.
3. Remove the temporary studs and fit the remaining two setscrews. Tighten the
setscrews referring to “Specific torque values”.
4. Check the flywheel run-out with a dial test indicator. This must be less than
0,30 mm (0.012 in) total indicator reading.
02
154
ENGINE
WORKSHOP
Flywheel
To fit (cont’d)
5. Check the alignment of the flywheel face. The error in alignment must not be
more than 0,03 mm (0.001 in) total indicator reading for every 25 mm (1.0 in)
of the flywheel radius from the crankshaft axis to the indicator plunger. During
this check, keep the crankshaft pressed toward the front of the engine to
remove the effect of crankshaft end-float.
Ring gear
To remove
Warning: Wear eye protection and suitable protective clothing during this operation.
Before the ring gear is removed, check the position of the chamfer on the teeth. To
remove the ring gear use a hammer and chisel to break the ring. Ensure that the
flywheel is not damaged during this operation.
To fit
The ring gear is heated onto the flywheel. When a new gear is to be fitted, ensure
that it is not heated to more than 250 0C (480 0F). ensure that the chamfer on the
teeth of the gear is in the correct direction.
02
155
ENGINE
WORKSHOP
Flywheel housing
Warning! The flywheel housing is heavy, use a lift equipment or get help to assist
with the lift operation before removal of the flywheel housing fasteners.
To remove
1. Remove the starter, and the flywheel.

2. Release the housing setscrews and with a soft face hammer, hit carefully the
housing to remove it from the dowels.
To fit
1. Ensure that the rear face of the cylinder block and the faces of the housing are
clean and free from damage. Ensure that the location dowels are fitted
correctly.
2. Fit the housing onto the dowels and lightly tighten the setscrews.
3. Check the housing concentricity with a dial test indicator. The run-out limit is
given in the relevant data and
dimensions for the “Flywheel and
housing”. If any adjustment is
necessary, it must be made on the
housing and concentricity checked
again.
4. Tighten the setscrews to the
recomended torque value refer to
“Specific torque values”.
5. Check the housing alignment. The

maximum tolerance is given in the
relevant data and dimensions for the
“Flywheel and housing”. Any necessary
adjustment must be made on the
housing and not on the cylinder block.
6. Fit the flywheel and the starter motor.

02
156
ENGINE
WORKSHOP
ELECTRICAL EQUIPMENT
ALTERNATOR
General description
The alternator is driven from the crankshaft pulley by double belts. The diodes,
resistors and brushes are fitted inside a cover to protect them against dirt and
moisture. Fan is included within the alternator casing to cool and protect the
alternator.
This alternator has solid state regulator fitted within the rear cover. The regulators are
sealed and repair is not possible.
For any repairs to the alternator consult your dealer.
Cautions:
 Do not disconnect the battery while the engine is in operation. This will cause
a voltage surge in the alternator charge system which will immediately cause
damage to the diodes or to the transistors.
 Do not disconnect an electrical wire before the engine is stopped and all
electrical switches are in the “OFF” position.
 Do not cause a short circuit by the connection of electrical wires to the wrong
terminals. The correct electrical wire must be connected to the correct
terminal. A short circuit or wrong connection, which gives reverse polarity, will
immediately cause permanent damage to the diodes and to the transistors.
 Do not connect a battery into the system until it has been checked for the
correct polarity and voltage.
 Do not check for current flow with a spark contact as damage can be caused
to the transistors.
To check the belts
1. Check the belts for wear and damage and renew, if necessary in pairs.
2. Check the belt tension. Check
/ adjust the tension on both
belts. To ensure maximum
belt life, it is recommended
that a belt tension gauge
used. Fit the gauge (1) at the
center of the longest free
length and check the tension.
If a Burroughs gauge is used,
the correct tension is 535 N,
(120 lbf ), 54 kgf. Adjust belts
if necessary.
02
157
ENGINE
WORKSHOP
Alternator
To adjust drive belt tension
1. Loosen the pivot fastener (1) of the alternator and the fasteners of the
adjustment link (2) and (3).
2. Change the position of the alternator to give the correct tension. Tighten the
adjustment link fasteners, and then tighten the pivot link fasteners. First tighten
the front and then the rear fastener in sequence.
3. Check the belt tension again to ensure that it is still correct.
To remove the drive belts
Note: The drive belts are supplied as a set and must be renewed as a set.
1. Loosen the pivot fastener (1) of the alternator and the adjustment link
fasteners (2) and (3).
2. Release all of the tension from the belts and remove the belts.
3. Fit the new belts and adjust the tension. The belt tension must be checked
again after the first 20 hours of operation.
02
158
ENGINE
WORKSHOP
Alternator
To remove
Warning! Ensure that the battery earth connection has been removed before any
alternator connection is removed.
1. Disconnect the electrical connection.

2. Release all the belt tension and remove the belts.
3. Remove the adjustment link from the alternator and remove the pivot bolts.
Make a note ot the position of the washers and distance pieces to ensure that
they are fitted correctly. Remove the alternator.
To fit
1. Put the alternator in position and assemble loosely the pivot fasteners and the
adjustment link and its fasteners. Ensure that the washers and the distance
pieces are fitted in their correct positions and that the alternator pulley is
aligned to the crankshaft pulley within ± 2,4 mm (0.094 in)
2. Fit the drive belts and adjust the drive belt tension.
3. Connect the electrical connection.
4. If all of the work is complete, connect the battery earth connection.
To maintain
1. Ensure that the drive belts are not worn and that the belt tension is correct.
2. Keep the alternator clean. To clean the alternator, use a material which is
damp with kerosene or a special fluid used for this purpose. Ensure that the
fluid does not enter the cover of the alternator.
3. Ensure that air can pass easily over the casing to keep it cool.
Fault diagnosis for the alternator
The alternator is designed in such a way that a flow of current shows that the system
is in correct operation. If the system is in correct operation, no open circuit, voltage or
current output checks need to be done on the installation unless:
 The warning lamp does not show when the alternator is stationary and the
switch is in the “ON” position, or it shows a light when the alternator is in
operation.
02
159
ENGINE
WORKSHOP
Alternator
Fault diagnosis (cont’d)
 No charge current is shown on the ammeter

 The battery is discharged
 The battery is hotter than normal, which is indication of loss of voltage control.
If one or more of the above sysmptoms occur, the procedure indicated below should
be applied.
Normal operation:
1. Ensure that the engine has stopped nd that the ignition switch is in the “OFF”
position.
2. Check that the battery voltage is correct; either 12V to 12,8V. Check the
condition of the battery if the voltage is not correct.
3. Turn the ignition switch to the “ON” position and checkthat the ignition warning
lamp is illuminated.
4. Start the engine and operate it at a fast idle. Check that the ignition warning
lamp is now extinguished.
5. Switch on an electrical load, such as the vehicle lights, and increase the
engine to its maximum speed.
6. The battery voltage should now rise to 13,5 V.
7. Switch off the applied electrical load and the battery voltage should rise to
14 V.
If the warning lamp is not illuminated when the ignition switch is in the “ON” position:
1. Check that the battery voltage is correct, with the ignition switch in the “OFF”
position.
1: Applied electrical load. 2: Battery. 3: Ignition switch 4: Ignition warning light

02
5: Alternator terminal “D+” 6: Alternator terminal “W” 7. Alternator. 8: Alternator
160 terminal B+”.
ENGINE
WORKSHOP
Alternator
If the warning lamp is not illuminated when the ignition switch is in the “ON” position
(cont’d):
2. Start and run the engine at a fast idle speed. Measure the voltages between
the alternator terminal “B+” (8) and earth, and between alternator terminal “D+”
(5) and earth. The voltages should be between 13 V to 15V. If the voltages are
not within this range then the alternator is faulty. Renew the alternator.
3. Increase the engine to its maximum, switch on an electrical load (1) such as
the vehicle lights, and measure the voltages between the alternator terminal
“B+” (8) and earth, and the alternator terminal “D+” ((5) and earth. The
voltages should be between 13V to 15V. If these values are correct then the
fault is within the charging system circuit. Check that the cables and
connections are all correct. If the voltages are still incorrect then the alternator
is faulty. Renew the alternator.
Starter motor
The starter motor is operated by a solenoid and has roller clutch drive. The solenoid
engages the starter drive in two operations to ensure that the motor gets its
maximum torque only when the starter motor is engaged fully with the flywheel. The
clutch prevents rotation of the armature at high speed if the starter is held in the
engaged position.
Warning: Always disconnect the battery terminals before the removal of any
component of the electrical system.
02
161
ENGINE
WORKSHOP
Starter motor
To remove
1. Disconnect the starter motor cables.

2. Remove the fasteners and remove the starter motor.
To fit
1. Check that the starter is free from faults, oil and grease.
2. Clean the flange face of the starter motor and the face of the flywheel housing.
3. Fit the starter motor and tighten the M10 setscrews to a torque of 44 Nm,
(33 lbf ft), 4.5 kgf m.
4. Connect the starter motor cables.
To maintain the brush gear and the commutator
Repairs to the starter motor are not recommended. Your dealer’s aftersales
department has specialist equipment and personnel with the correct training to repair
your starter motor.
To test on the engine
Ensure that the battery is fully charged.

Turn on the lights and operate the starter switch.
If the starter does not operate but the lights keep their power, or there is no voltage
drop across the battery, check the switch and all the connections and wires. Slow
action of the starter can be caused by faulty connections.
02
162
ENGINE
WORKSHOP
STARTING AID
The starting aid consists of a set of glow plugs, one on each cylinder. The glow plugs
are fitted in the cylinder head near the atomizers. The tip of the glow plugs reaches
into the combustion chamber in the piston crown.
The glow plugs are operated electrically, usually through the the start switch. When
the glow plugs are energized, their tips become very hot and improve the combustion
process during cold start conditions.
To remove
1. Disconnect the glow plugs power supply cable.

2. Remove the four nuts (1) that fasten the bus-bar, remove the bus-bar.
3. With a suitable socket, loosen then remove the glow plugs.
To fit
1. Ensure that the threads of the glow plugs and the cylinder head holes are
clean.
2. Fit the glow plugs into the correct holes in the cylinder head, then gradually
tighten to 18 Nm, (13 lbf ft), 1,8 kgf m.
3. Fit the bus-bar and the four nuts, tighten the nuts to 2 Nm, (1.5 lbf ft), 0,2 kgf
m.
4. Connect the glow plugs power supply cable.
02
163
ENGINE
WORKSHOP
Starting aid
To check the glow plug’s power supply continuity
1. Disconnect the glow plug’s power supply cable and the bus-bar.
2. Apply one probe af a multimeter, that can check continuity, to the terminal of
the glow plug and apply the other probe to a suitable earth. If the continuity is
correct the multimeter will give an audible signal. If there is no audible signal,
renew the glow plug. Repeat this check for all of the glow plugs.
Note: If a multimeter is not available the following procedure can be used.
1. Connect a 12V test lamp between the positive ( +) terminal of the battery and
earth to check that the lamp will light.
2. Connect the test lamp between the terminal of the glow plug, that is furthest
away from the power supply and earth.
3. Operate the control switch than the test lamp should be illuminated if the
power supply is correct.
4. Disconnect the cables at each glow plug.
5. Connect the test lamp to the positive terminal of the battery and to the terminal
of a glow plug. The lamp will be illuminated if the continuity is correct. If thetest
lamp is not illuminated, renew the glow plug.
6. When all of the glow plugs have been checked, connect the bus-bar to the
glow plugs and reconnect the power supply cable.
To check the operation of the glow plug
1. Disconnect the glow plug’s power supply cable and the bus-bar.
2. Connect a 50-0-50 ammeter between the power supply cable and the terminal
of a glow plug.
3. Connect a voltameter between the glow plug terminal and the earth.
4. Engage the control switch and check the readings of the ammeter and the
voltmeter: With a 12V supply, there is an immediate initial current of 30
amperes, that becomes approximately 21 amperes for each glow plug. This
will reduce to approximately 14 amperes after 8 seconds, 10 amperes after 20
seconds and reach 9 amperes after 60 seconds.
Note: If the ammeter reading is low, or there is no reading, renew the glow plug. If
there is no voltmeter reading, check the switch and the power supply cable.
When all of the glow plugs have been checked, remove the ammeter and the
voltmeter and connect the power supply cable. Check that the glow plugs are
correctly fitted.
02
164
ENGINE
WORKSHOP
Pressure sensor
Warning! The O-ring (2) fitted to the oil pressure sensor is made of “Viton”.
There is a pressure sensor fitted to the oil filter head (1) for the oil pressure.
To remove
1. Disconnect the electrical connector from the sensor.

2. With a suitable spanner, loosen, then remove the sensor from the oil filter
head (1).
3. Discard O-ring (2).
To fit
1. Ensure that the threads of the sensor are clean and free from damage.
2. Fit a new O-ring (2) to the sensor.
Note: The O-ring for the oil pressure sensor’s color is brown, for temperature
sensor is black.
Caution: Do not use air operated tools to fit sensors as these may damage
the sensor.
3. Fit and tighten the sensor to 10 Nm, (7 lbf ft), 1,0 kgf m.
4. Check that the connector seal is in place, that it is clean and not damaged.
Renew the seal if it is damaged.
5. Carefully fit the electrical connector to the sensor.
6. Lightly pull the harness connector to ensure that it is locked to the sensor
connector.
02
ENGINE 165
WORKSHOP
Temperature sensor
A temperature sensor is fitted to the cylinder head (1) for the coolant temperature.
To remove
Caution: Before the coolant temperature sensor is removed from the cylinder head,
ensure that the coolant is drained to a level that is below the sensor or cylinder head.
1. Disconnect the connector from the sensor.

2. With a suitable spanner, loosen then remove the sensor from the cylinder
head.
3. Discard O-ring.
To fit
1. Ensure that the threads of the sensor are clean and free from damage.
2. Fit a new O-ring (2) to the sensor. Note that the O-ring color is black.
3. Fit the sensor to the cylinder head and
tighten to 20 Nm, (15 lbf ft), 2,1 kgf m.
4. Check that the connector seal is in
place, that it is clean and not
damaged. Renew the seal if it is
damaged.
5. Carefully fit the electrical connector to
the sensor.
6. Lightly pull the harness connector to
ensure that it is locked to the sensor
connector.
02
166 ENGINE
WORKSHOP
List of special tools
Part number Description Illustration
Remover / replacer for

21825478
valve guides (main tool)
Adaptor for use with

21828479
21825478
Inlet and outlet valve

27610234 guide adaptor for use with
21825478
Gauge for piston height,

valve depth and cylinder
21825496
liner flange; for use with
21825617
Fastener plate for use

21825580
with 21825577
Replacer tool for seal of

21825577 timing case cover (main
tool)
02
ENGINE 167
WORKSHOP
List of special tools (cont’d)
Part number Description Illustration
Pressure plate for use with

21825578
21825577
Adaptor for front seal for

27610217
use with 21825577
21825491 Replacer tool for pistons
Dial gauge for use with

21825617
21825496
21825666 Valve spring compressor
Stud adaptor for use with

21825931
21825666
HMK 102 ENERGY SERVİS EL KİTABI 20
ELEKTRİK SİSTEMİ
 20-01 Genel, özellikler

01
ELECTRICAL
DATA 1
TECHNICAL DATA
GENERAL
SYSTEM TYPE: 12 VOLT, negative earth
BATTERY : 1 unit 165 Ah heavy duty
- COLD CRANK amps for 1 minute to 1.4 volts per cell at -18 °C ( O °F)
550
- RESERVE CAPACITY ( minutes) for 25 amp load 220
ALTERNATOR
4WS 65 amp nominal output
FUSE IDENTIFICATION & LAYOUT TABLE

01
2
Spare Spare Spare
Spare Spare Spare
ELECTRICAL
DATA
FUSE IDENTIFICATION
COLUMN A FUSE RATING
1. Gearbox control ,transmission 10 Amp
2. Stop solenoid 5 Amp
3. Gauges, instrument cluster 3 Amp
4.Braking lights 5 Amp
5. Wiper rear 10 Amp
6. Working lights, rear, inner 15 Amp
7. Working lights, rear, outer 15 Amp
8. Steering system 7,5 Amp
9. Hydraulic breaker 5 Amp
COLUMN B
1. Starter 20 Amp
2. Soft drive system (optional) 7,5 Amp
01
3. Clamp-shovel 7,5 Amp
4. Heater, fan 10 Amp 3
5. Wiper, front 15 Amp
6. Air-condition compressor 20 Amp
7. Return to dig & unloader 5 Amp
8.Signals 7, 5 Amp
9. Head lights 15 Amp
COLUMN C
1. Parking & tail lamps 5 Amp
2. Interior lighting 3 Amp
3. Hazard warning lights 10 Amp
4. Lighter 10 Amp
5. Beacon 7,5 Amp
6. Horn 10 Amp
7. Working lights , front 15 Amp
8. Long beam 15 Amp
9. Radio (optional) 5 Amp
ELECTRICAL
DATA
BULBS RATING
Head lights-main/dipped 60 W / 55 W
Work lights ( rear & front) 55 W HALOGEN
Side lights, front 2W
Cab interior lighting 5W
Brake lights 21 W
Direction turn indicators 21 W
Interior lighting 5W
Beacon 55 W HALOGEN
Instruments-gauges 1.2 W
RELAYS
01
4 The relays and fuses are located on the base underneath the cover in the front
console. Note that the relays for steering and gears are not explained here.
RELAY IDENTIFICATION
The number of terminals of the relays are fully explained on the base illustration
given.
The location of the relays on the relay base:

A. Breaker valve relay (optional)
B. Headlight, main - dipped relay
C. Stabilizer warning
D. Horn relay
E. Intermittent wash / wiper
F. Flasher(for hazard warning light)
ELECTRICAL
DATA
CIRCUIT DIAGRAM
01
5
01
6 ELECTRICAL
DATA
Electric Diagram Identification
Item Item
no Description no Description
A1 Intake heater A2 Battery
B1 Stop solenoid B2 Starter motor
C1 Lighter C2 Starter relay
D1 Clamping solenoid valve D2 Forward low& high
E1 Steer mode solenoid valve E2 Main shaft& lay shaft
F1 Wiper assy, front F2 Reverse low& high
G1 Wash assy, front G2 Buzzer, reverse gear
H1 Timer relay H2 Transmission main board
J1 Column switch J2 4WD solenoid valve
K1 Switch, fan K2 Horn relay
L1 Fan, air condition L2 Horn
M1 Column sw. gear& direction M2 Horn switch
N1 Horn switch, lever N2 Brake relay
O1 Switch, air-condition O2 Brake press. warning switch
P1 Compressor, air-condition P2 Gauge, coolant temp.
R1 Switch, air-condition press. R2 Switch, coolant temp.
S1 Thermostat S2 Gauge& sensor, fuel level
T1 Gear selection T2 Switch, park brake
U1 Dump switch U2 Sensor, coolant indicator
V1 Stop light switch V2 Switch, transmission oil temp.
X1 Front working lamps X2 Switch, engine oil pressure
Y1 Buzzer for indicators Y2 Switch, transmission oil press.
Z1 Turn indicators Z2 Switch, air filter clogged
ZA Hazard lights Z2A Switch, indicator switch
ZB Wiper assy, rear screen Z2B Gauge, engine R.P.M.
ZC Wash assy, rear screen Z2C Alternator
ZD Main beam Z2D Switch, hazardous light
ZE High beam Z2E Flasher
ZF Rear working lights, outer Z2F Column switch, turn indicator
ZG Rear working lights, inner Z2G Switch, park &headlights
ZH Park lights Z2H Selector, main &high beam
X1 Interior light switch Z2J Relay, main &high beam
X2 Interior light Z2K Indicators, side panel
Y1 Beacon switch
Y2 Beacon
Y3 2WD / 4WD switch
01
ELECTRICAL 7
DATA
POWERSHIFT TRANSMISSION
MAINBOARD
01
8 ELECTRICAL
DATA
CONNECTIONS BETWEEN T/M CARD AND ITS SOCKETS

Term No
Color Cross section Connector No Terminal (Pin) Connecting Point
FR darkblue 0,75 mm 1 9 From Brake Switch
4WD+ blue-white 0,75 mm 1 7 .+ 12 V to 2x4 Switch
4WD purple-black 0,75 mm 1 8 From 2x4 Switch
R green-white 1 mm 1 6 From Direction Select Lever - Reverse
FR yellow 1 mm 1 5 From Direction Select Lever - Forward
S4WD blue-white-black 1 mm 2 6 To 2x4 Solenoid
no connection
.+12V red 1,5 mm 1 1
.+12V red 1 mm 1 12
.+12V no connection
GVK yellow-blue 0,75 mm 1 13 .+ 12 V to Back Up Alarm
S6 orange 1 mm 2 7 To Solenoid No. 6
S5 white 1 mm 2 8 To Solenoid No. 5
S3 green 1 mm 2 2 To Solenoid No. 3
S4 red-white 1 mm 2 1 To Solenoid No. 4
M white-red 1 mm 1 11
S1 pink 1 mm 2 4 To Solenoid No. 1
S2 brown 1 mm 2 3 To Solenoid No. 2
no connection
2V green 0,75 mm 1 2 From Direction Select Lever - 2nd Gear
3V yellow-black 0,75 mm 1 3 From Direction Select Lever - 3rd Gear
4V grey 0,75 mm 1 4 From Direction Select Lever - 4th Gear
DP no connection
DP+ orange 1 mm 1 10 From Dump Switch
GROUND black 1,5 mm 1 14
GROUND black 1,5 mm 2 5
GROUND no connection
01
ELECTRICAL 9
DATA
FORWARD/REVERSE GEAR SELECTION LEVER

ON THE LEVER ON THE HARNESS
Term. No Function
Color Cross section Color Cross section
1 N/A N/A
2 N/A N/A
3 N/A 0,75 mm N/A
4 blue-yellow 0,75 mm white 0,75 mm Forward Gears selected
5 yellow 0,75 mm grey 0,75 mm 3rd Gear selected
6 green-red 0,75 mm dark blue 0,75 mm Neutral Possition selected
7 red 0,75 mm red 1,00 mm +' to FR/RV selection
8 black 0,75 mm pink 0,75 mm +' for Horn
9 white-green 0,75 mm green 0,75 mm Reverse Gears selected
10 green 0,75 mm blue 0,75 mm 2nd Gear selected
11 black 0,75 mm pink 0,75 mm Horn
12 white 0,75 mm N/A 1st Gear selected
13 grey 0,75 mm purple 0,75 mm 4th Gear selected
14 blue 0,75 mm red 1 mm +' for Gear selections
SIGNAL LEVER
ON THE LEVER ON THE HARNESS
Term. No Function
Color Cross section Color Cross section
1 black-purple 1,50 mm green-white 1,00 mm Wiper Motor 2nd speed
2 black-green 1,00 mm grey 0,75 mm Wiper intermittent
3 red-white 2 mm white 0,75 mm +' to Wiper Motor
4 black 1 mm dark blue 0,75 mm Flashing
5 N/A N/A
6 grey 1 mm blue 0,75 mm Washing Motor/Front
7 blue 1 mm grey 0,75 mm Wiper Motor 1st speed
8 black-green 1 mm green 0,75 mm Turning Signal/RH
9 black-white 1 mm yellow 0,75 mm Turning Signal/LH
10 yellow 2 mm dark blue 2 mm Short Lights
11 white-black 1.5 mm dark blue 2 mm Lights Common Pin
12 black-green 1 mm N/A Automatic Stop - Wiper
13 white 1.5 mm purple 0,75 mm Long Lights
14 black-white-green 1 mm blue-white 1 mm Turning Signal common Pin
01
10 ELECTRICAL
DATA
TRANSMISSION MAIN BOARD SCHEMATIC
01
ELECTRICAL 11
DATA
4 WHEEL STEERING MAINBOARD AND ITS RELAYS

This main board is only fitted to S machines just near to the transmission main board.
This card energizes the coil of solenoids by means of relays on the steering system.
CHASSIS : Neutral
( +12V ) : Positive connection point of main board feed line.
(D) : Positive end of coil in valve D (relay 1)
(C) : Positive end of coil in valve C (relay 2)
(B) : Positive end of coil in valve B (relay 3)
(A) : Positive end of coil in valve A (relay 4)
( A1 ) : To warning light 2 WD mode
( C1 ) : To warning light CRAB STEER mode
( D1 ) : To warning light 4 WD mode
(3) : Outlet to terminal NO 3 STEER MODE selector
The relays and the solenoid valves according to the steer mode selected
Steer mode Relays in contact Valves in contact

2WD 4-5 A
CRAB STEER 2-3 B-C
4WD 1-3 B-D
01
12 ELECTRICAL
DATA
STEERING MODE MAINBOARD ( continuously energized)
RL, RA, RB, RC, RD : 10 Amp 12V relay in the diagram,

the mode is selected as 2WS.
If 470N condensator is fitted, every mode can be selected directly. If not, there is no
possibility of choosing any mode without selecting 2WS first and the lights for both
modes are illuminated, meaning that incorrect mode is selected.
01
ELECTRICAL 13
DATA
THE TRANSMISSION GEARBOX SOLENOID VALVES
The solenoid valves are located on the transmission gearbox seen as below.
Ts : Forward Low ratio Us : Forward High ratio Ws : Reverse Low ratio

Vs : Reverse High ratio Ss : 2 / 4 WD clutch Ys : Main Clutch
Zs : Lay-shft clutch
Solenoid energizing combination is shown below table, on which gear is selected.
Gear
Forward Reverse Forward 4WD Reverse 4WD
selection
1 Ts, Zs Ws, Zs Ts, Zs, Ss Ws, Zs, Ss
2 Us, Zs Vs, Zs Us, Zs, Ss Vs, Zs, Ss
3 Ts, Ys Ws, Ys Ts, Ys, Ss Ws, Ys, Ss
01
14 4 Us, Ys Vs, Ys Us, Ys, Ss Vs, Ys, Ss

ELECTRICAL
SPECIFICATIONS
ELECTRICAL TROUBLE SHOOTING
The aim of this section is to identify the basic electric failures and their causes.
To inspect the electric circuit, please refer to the diagram of electrical system.
PROBLEM 1
UNABLE TO CHOOSE STEERING MODES
SOLUTION
STEP 1. Check fuse B1
If it is failed, replace by the new one.
If not, refer to step 2.
STEP 2. CHECK IF PROXIMITY SWITCH IS ENERGISED OR NOT.

If not, check wires and sockets.
If energized, refer to step 3.
STEP 3. CHECK WHETHER ADJUSTMENT GAP IS CORRECT OR NOT.

If not, adjust it until signal comes.
If correct, refer to step 4.
STEP 4. CHECK WHETHER SIGNAL COMES FROM PROXIMITY TO SWITCH OR

NOT.
If not, check wires.
If signal comes, refer to step 5.
STEP 5. CHECK WHETHER ENDS OF THE PROXIMITY SWITCH ARE WELL OR

NOT.
If not, replace the switch.
If it is well, refer to step 6.
STEP 6. CHECK WHETHER INLET OF THE COIL IN STEERING MODE

MAINBOARD ARE OKEY OR NOT.
If not, check the main-board and if necessary replace it.
If it is O.K., refer to step 7.
STEP 7. CHECK WHETHER THE RELAY TERMINALS ON THE MAINBORD ARE

OKEY OR NOT.
If not, replace the relevant faulty relay.
If O.K., refer to step 8.
STEP 8. CHECK WHETHER THE OUTPUT TERMINAL OF THE SOLENOID VALVE

IS OKEY OR NOT.
If not, check the wiring harness and sockets.
If O.K.., refer to step 9.
01
15
ELECTRICAL
SPECIFICATIONS
PROMLEM 1 SOLUTION (cont’d)
STEP 9. CHECK WHETHER SOLENOID VALVE IS OKEY OR NOT.

Check whether solenoid valve is faulty or not, and whether the plunger of the
solenoid is O.K. or not.
PROBLEM 2 :
STARTER SWITCH DOES NOT WORK (NO START).
SOLUTION
STEP 1. CHECK WHETHER PARKING BRAKE IS APPLIED OR NOT.
If it is, release it.
STEP 2. CHECK WHETHER A GEAR IS SELECTED THROUGH THE COLUMN

SWITCH OR NOT.
If it is so, shift to neutral.
STEP 3. CHECK WHETHER THE BATTERY TERMINALS ARE LOOSE AND

OXIDISED OR NOT.
If they are loose, tighten them. If they are oxidized, clean them with hot water or
oxidation solvent.
STEP 4. CHECK WHETHER CONTACTS OF THE STARTER SWITCH ARE OKEY

OR NOT.
If not, replace the contacts or starter switch.
STEP 5. CHECK WHETHER STARTER SOLENOID IS ENERGIZED OR NOT.

If not, check the wiring harness, sockets and terminals.
If it is energized, refer to step 6.
STEP 6. CHECK WHETHER STARTER SOLENOID IS OKEY OR NOT.

If not, replace the starter solenoid.
STEP 7. CHECK WHETHER FUSE A1 IS OKEY OR NOT.

If not, replace it. (In the case that machine is not moving but starter is working
properly.)
01
16
ELECTRICAL
SPECIFICATIONS
PROBLEM 5:
MACHINE IS MOVING ALTHOUGH HAND BRAKE IS APPLIED (HAND BRAKE IS
NOT WORKING).
SOLUTION
STEP 1. Check whether fuse B7 is O.K. or not.
If it is not, replace it.
STEP 2. CHECK WHETHER HAND BRAKE SWITCH IS WORKING PROPERLY OR

NOT.
STEP 3. CHECK WHETHER THE WIRING HARNESS IS OKEY OR NOT.

If not, check the wiring harness and sockets again; repair or replace faulty parts.
PROBLEM 6:
NO 4 WHEEL DRIVE.
SOLUTION
STEP 1. Check whether fuse A1 is O.K. or not.
STEP 2. CHECK WHETHER 4WD SELECTOR IS WORKING PROPERLY OR NOT.


STEP 4. CHECK WHETHER THE 4WD SOLENOID IS ENERGIZED OR NOT.

If it is not, check the wiring harness, sockets as well as terminals.
STEP 5. CHECK WHETHER 4WD SOLENOID VALVE IS WORKING PROPERLY

OR NOT.
If not, replace its coil and the plunger if it is blocked; or replace it completely.
If O.K., refer to step 6 .
STEP 8. CHECK FOR MECHANICAL OR SIMILAR FAILURE IN THE GEARBOX.

( See transmission section, fault finding title )
01
17
ELECTRICAL
SPECIFICATIONS
PROBLEM 7:
NO 4WD AND NO BRAKING LIGHT IS ILLUMINATED ( IN 4WD).
SOLUTION
STEP 1. CHECK WHETHER BRAKE SWITCH IS O.K. OR NOT.

STEP 3. CHECK WHETHER BRAKING LIGHTS ARE OKEY OR NOT.

Check whether they are energized and if necessary replace the relevant faulty bulb.
PROBLEM 8:
BRAKING PRESSURE WARNING LIGHT DOES NOT ILLUMINATE.
SOLUTION
STEP 2. CHECK WHETHER THE BULB IS OKEY OR NOT.

STEP 3. CHECK WHETHER THE ACCUMULATOR LOW PRESSURE SWITCH IS

ADJUSTED CORRECTLY OR NOT.
If it is not, adjust it . If the problem can not be solved by adjusting, replace it.
PROBLEM 9:
BATTERY (CHARGE) WARNING LIGHT DOES NOT ILLUMINATE.
SOLUTION
STEP 1: CHECK THE FAN BELT WHETHER IT IS LOOSE OR NOT.
If it is loose, try to tighten it.
If it not, refer to step 2.
STEP 2: CHECK WHETHER THE HARNESS FROM ALTERNATOR SIGNAL IS

OKEY OR NOT.
If it is O.K., refer to step 3.
STEP 3: CHECK WHETHER THE ALTERNATOR IS WORKING PROPERLY OR

NOT.
If the alternator is not working properly, repair it. If necessary, replace by a new
one.
01
18
ELECTRICAL
SPECIFICATIONS
PROBLEM 10:
THE HAZARD WARNING LIGHT DOES NOT ILLUMINATE.
SOLUTION
STEP 1. CHECK WHETHER FUSE C3 IS OKEY OR NOT.
STEP 2. CHECK WHETHER THE FLASHER IS WORKING PROPERLY OR NOT.
If okey, refer to step 4.
STEP4. CHECK WHETHER THE HAZARD WARNING LIGHT BUTTON IS
WORKING PROPERLY OR NOT.
PROBLEM 11:
NO TURN SIGNAL INDICATORS.
SOLUTION
STEP 1. CHECK WHETHER FUSE B2 IS OKEY OR NOT.
STEP 2. CHECK WHETHER THE COLUMN SWITCH IS WORKING PROPERLY
OR NOT.
STEP 3. CHECK WHETHER THE WIRE HARNESS IS OKEY OR NOT.
If not,check the wiring harness and sockets again; repair or replace faulty parts.
STEP 4. CHECK WHETHER THE HAZARD WARNING LIGHT BUTTON IS
WORKING PROPERLY OR NOT.
STEP 5.CHECK WHETHER THE BULBS ARE WORKING PROPERLY OR NOT.
If they are not working properly, replace the faulty bulbs.
PROBLEM 12:
NO 2WD.
SOLUTION
STEP 1. CHECK WHETHER FUSE B3 IS OKEY OR NOT.
01
STEP 3. CHECK WHETHER 4WD BUTTON IS WORKING PROPERLY OR NOT.
If it is not, replace it. 19
ELECTRICAL
SPECIFICATIONS
PROBLEM 13:
WARNING LIGHT FOR AIR FILTER DOES NOT ILLUMINATE.
SOLUTION
STEP 1. CHECK WHETHER THE AIR FILTER IS WORKING PROPERLY OR NOT.
If not, check the wiring harness and sockets again; repair or replace the faulty parts.
STEP 3. CHECK WHETHER VACUUM SENSOR SWITCH IS WORKING
PROPERLY OR NOT.
PROBLEM 14:
THERE IS FUEL IN THE TANK BUT NO LEVEL CAN BE SEEN ON THE GAUGE.
SOLUTION
STEP 2. CHECK WHETHER THE FLOAT IS WORKING PROPERLY OR NOT.
PROBLEM 15:
NO INSTRUMENT PANEL LIGHT IS ILLUMINATED
SOLUTION
STEP 1. CHECK WHETHER FUSE A4 IS OKEY OR NOT.
STEP 3. CHECK WHETHER THE BULBS ARE WORKING PROPERLY OR NOT.
PROBLEM 16:
WHEN TEST BUTTON IS APPLIED, ONE OF THE LIGHTS IN THE INSTRUMENT
PANEL DOES NOT ILLUMINATE*
*( for example: transmission oil pressure or engine oil pressure light)
SOLUTION
STEP 2. CHECK WHETHER THE BULBS ARE WORKING PROPERLY OR NOT.
01
20
ELECTRICAL
SPECIFICATIONS
BATTERY
WARNING
Batteries give off an explosive gas. Do not smoke when handling or working on
the battery. Keep the battery away from sparks and flames.
Battery electrolyte contains sulphuric acid. It may burn you if it touches your
skin or eyes. Wear safety goggles. Handle the battery carefully to prevent
spillage. Keep metallic items (watches, rings, zips etc.) away from the battery
terminals. Such items could short the terminals and burn you.
Set all switches in the cab to off before disconnecting and connecting the
battery. When disconnecting the battery, take off the ground ( - ) lead first.
When reconnecting, fit the positive ( +) lead first.
Re-charge the battery away from the machine, in a well-ventilated area. Switch
the charging circuit off before connecting or disconnecting the battery. When
you install the battery on the machine, wait five minutes before connecting it
up.
01
21
ELECTRICAL
SPECIFICATIONS
MAINTENANCE
The following steps should be
followed in order to provide
optimum performance from the
battery :
1 Make sure that the battery
terminals are clean and tight.
smear petroleum jelly on the
battery terminals to prevent
corrosion.
2 When applicable – never allow the electrolyte level to fall below the
recommended level – 10 mm (0,4 in) above the plates. use only distilled water for
topping up.
3 Keep the battery at least three quarters charged. Otherwise, the plates may
become sulphated (hardened) – this condition makes recharging the battery very
difficult.
Extra precautions must be taken when bench charging the maintenance free
batteries because they are more prone to be damaged by overcharging than
the standard type of battery:
- Never boost-charge a maintenance free battery.
- Never charge a maintenance free battery at a voltage exceeding 15.8 volts.
- Never continue to charge a maintenance free battery after it begins to generate
gas bubbles.
TESTING – SPECIFIC GRAVITY

The specific gravity of the electrolyte gives an idea of the state of charge of the
battery. Readings should be taken using a hydrometer, when the electrolyte
temperature is 15 ºC (60 ºF). If the battery has recently been on charge, Wait
approximately one hour (or slightly discharge the battery) to dissipate the surface
charge before testing.
Readings should be as tabulated and should not vary between cells by more than
0.04. A greater variation indicates an internal fault on that particular cell.
If the electrolyte temperature is other than 15 ºC (60 ºF) a ‘correction factor’ must be
applied to the reading obtained. Add 0,07 per 10 ºC (18 ºF) If the temperature is
higher than 15 ºC (60 ºF) and subtract the same if the temperature is lower.
SPECIFIC GRAVITY AT 15 ºC (60 ºF)

FULLY SEMI FULLY
CHARGED CHARGED DISCHARGED
Ambient
temperature 1,270 – 1,290 1,190 – 1,210 1,110 – 1,130
up to 27 ºC (80 ºF)
above 1,240 – 1,260 1,170 – 1,190 1,090 – ,1110
01
22 27 ºC (80 ºF)
ELECTRICAL
SPECIFICATIONS
BATTERY TESTING
This test is to determine the

electrical condition of the
battery and to give an indication
of the remaining useful ‘life’.
Before testing, ensure that the
battery is at least 75 % charged
(Specific gravity of 1.23 to 1.25
for ambient temperature up to
27 ºC ).
Ensure that the battery is

completely disconnected from
the vehicle.
Connect up the battery tester (part no. 993/85700) as follows:
1. Set the check/load switch A to OFF.

2. Set rocker switch B to the battery voltage (12 V).
3. Connect the red flying lead to the battery positive (+) terminal and the
black flying lead to the battery negative (-) terminal.
4. Set the check/load switch a to check to read the battery no-load
voltage, which should be at least 12.4 volts.
5. Set the check/load switch a to load and hold down for 5 – 10 seconds until
the meter reading stabilizes. The reading should be at least 9 volts.
NOTE: Do not hold the switch in the load position for more than 10 seconds.
6. If the foregoing tests are unsatisfactory, consult fault diagnosis on the

following:
FAULT DIAGNOSIS
BATTERY TESTER READINGS REMEDY
1 Check : 0 – 12.6 volts Renew battery.

Load : less than 6 volts
2 Check: 6 – 12.4 volts Recharge and re-test. If tests still yellow

Load: less than 9 volts and zone.
falls unsatisfactory Renew battery.
3 Check: less than 10 volts. Indicates battery has been over-discharged

load: less than 3 volts. and unlikely to recover.
Renew the battery.
01
4 Check: more than 11 volts Charge battery, which will probably recovers.
Load: 6 – 10 volts steady 23
ELECTRICAL
SPECIFICATIONS
STARTER MOTOR
01
24
ELECTRICAL
SPECIFICATIONS
STARTER MOTOR
REMOVAL AND REPLACEMENT
Disconnect cables and remove battery. Remove cables from main starter terminal
and solenoid terminal. using special tool 825/00410 (and adapter 825/99833 if
required) unscrew three securing nuts and remove starter motor. Replace by
reversing the removal sequence.
DISMANTLING
NOTE: Dismantle only to item 34 unless the field windings are to be renewed. Test
the windings electrically before removing them from the motor yoke 15.
Using a slotted steel tube, displace ring 23 to permit withdrawal of ring 22.
Allow brake shoes 28 to remain in the end plate 11 unless requiring renewal.
SERVICING AND RENEWAL

Renew brushes 14 and 14A if their length is less than 8 mm (0.3 in.).
Clean the commutator A. if individual copper bars are burned or eroded, the armature
has broken windings and must be renewed. otherwise, polish with fine grade glass
paper (not emery). Renew armature if commutator diameter is 38 mm (1.5in.) or less.
Check the field windings for open circuits by connecting a multimeter set to measure
resistance between the stud terminal B and each positive brush 14A in turn. A high
or infinity reading indicates an open circuit. Similarly, connect the meter between
brushes 14A and the motor yoke 15. any reading other than infinity indicates a short
circuit between the coils and the yoke. renew the coils as necessary removing screws
36 with a pole shoe screwdriver C50 (obtainable from Lucas dealers).
Check bronze bushes 32 and 34 for wear
ASSEMBLY
Align cross pin c with the notches
in the brake shoes 28 before
assembling brush carrier and back
plate to motor yoke. Ensure that
brushes 14A are correctly located
in the insulated brush boxes.
smear drive shaft splines and
operating collar-bearing surface
with grease before assembly.
Assemble operating fork 19 with
curved face forward the armature.
set the movement of drive pinion
24 by connecting a 6v battery and switch as shown. operate switch and check
dimension D. Adjust to 0.13-1.14 mm (0.005-0.045 in.) by slackening locknut 17 and
rotating eccentric pin 18 as necessary. Re-tighten locknut.
01
25
ELECTRICAL
SPECIFICATIONS
ALTERNATOR
01
26
ELECTRICAL
SPECIFICATIONS
GENERAL DESCRIPTION
The alternator is a three-phase generator having a rotating field winding and static
power windings.
When the starter switch is turned on, current from the battery flows by way of the ‘NO
CHARGE’ warning light to the field winding. This creates a magnetic field, which
supplements the residual magnetism in the rotor poles. As the engine is started, the
fan belt drives the rotor and alternating current is generated in the power windings as
they are cut by the rotating magnetic field. Output is controlled by a solid-state
regulator, which varies the field current in accordance with electrical demand.
Servicing is restricted to periodic inspection of slip ring brushes. Bearings are sealed
for life.
SERVICE PRECAUTIONS
A. Ensure that the battery negative terminal is connected to the earth cable.
B. Never disconnect connections to the battery or alternator, or any part of the

charging circuit whilst the engine is running. Disregarding this instruction will
result in damage to the regulator or rectifying diodes.
C. Main output cables are ‘live’ even when the engine is not running. take care
not to earth connectors in the moulded plug if it is removed from the alternator.
D. During arc welding on the machine, protect the alternator by removing the
moulded plug (or if separate output cables fitted, remove the cables).
E. If jump starting is necessary; connect the second battery in parallel without

disconnecting the vehicle battery from the charging circuit. The booster battery
may then be safely removed after a start has been obtained. Take care to
connect batteries positive-to-positive, negative-to-negative.
01
27
ELECTRICAL
SPECIFICATIONS
ALTERNATOR REMOVAL & REPLACEMENT
01
28
ELECTRICAL
SPECIFICATIONS
Disconnect cables from rear of alternator, remove bolts A, B and C and withdraw
unit from machine.
Replace by reversing the removal sequence. Position the alternator until belt
deflection is approximately 10 mm (3/8 in) before tightening bolts B and C. It may be
necessary to slacken bolt d to allow full movement of alternator. Tighten bolt A last of
all.
DISMANTLING AND ASSEMBLY

DISMANTLING
Remove suppressor 2 (if fitted) by removing nut 1 and disconnecting lead E from
terminal F.
Unscrew bolts 3 and disconnect lead G from terminal H to remove the brush box and
regulator assembly 4. If the brush length is less than 5 mm (0.2 in.), new length 17
mm (0.67 in), or if spring pressure is less than 1.3 N the brush box and regulator
assembly must be renewed.
Remove nuts and washers 5, bolts 6 and nuts 7. Remove slip ring end bracket 8.
Carefully remove rectifier 10 and stator 11 as an assembly. Unsolder the inter-
connecting wires at X, Y and Z only if renewing either of these components.
Remove nut and washer 12 using an 8 mm allen key in the shaft hexagon hole to
prevent rotation. If necessary, use a press to remove rotor 19 from the drive end
bracket 17.
Check the rotor poles and the inner faces of the stator for signs of rubbing, which
indicates worn bearings. The drive end bearing is part of bracket 17 and cannot be
removed separately. if requiring renewal, needle roller bearing 20 should be pressed
out in the direction of the arrow.
ASSEMBLING
Reverse the dismantling procedure, but note the following data:
Ensure that spacers 14, 16 and 18 are correctly positioned as shown.

Ensure that the slip rings J are clean and smooth, using extra fine glass paper to
rectify slight imperfections.
Ensure that insulation bushes 9 and washers 5 are positioned as shown.
Take care not to damage the brushes when fitting the brush box and regulator
assembly.
TORQUE SETTINGS
ITEM Nm kgf.m lbf.ft

3 2.7 0.28 2.0
5 4.1 0.41 3.0
6 3.4 0.35 2.5
7 5.4 0.55 4.0
12 60.0 6.10 44.2
01
29
ELECTRICAL
SPECIFICATIONS
HARNESS WIRE SPECIFICATIONS
Code Color Code Color

R RED B BLUE
Pk PINK V VIOLET
Br BROWN Gr GREY
O ORANGE Bl BLACK
Y YELLOW W WHITE
G GREEN Db DARK BLUE
ISO 6722 Class C
Conductor std: DIN72551, P6, type B-FLR9Y. R.
Ambient temperature: +125°C. -40°C.

01
30
ELECTRICAL
SPECIFICATIONS
SENSORS & SWITCHES
No: Description Part Number Color Type Setting Connection

T/M Oil Pressure
1 515/23140 Brown ON/OFF At 40 Psi M12 x 1
Switch
T/M
2 Oil Temperature 515/23148 White ON/OFF At 110 º C ¼” -19 BSP
Switch
01
31
ELECTRICAL
SPECIFICATIONS
Sensors & switches (cont’d)
1. Temperature Sensor (Temperature Gauge)

2. Temperature Switch (Warning Light)
01
32
ELECTRICAL
SPECIFICATIONS
Sensors & switches (cont’d)
No: Description Part No Color Setting Connection

E/N Temperature
1 515/26020 Yellow M18
Sensor
E/N Temperature On/Off Temperature
2 515/22160 Grey M18
Switch 110° C
E/N Oil Pressure On/Off Pressure at
3 515/23003 Pink M12 X 1,5
Switch 40 Psi
Air Filter Clogged On/Off UnderPressure
4 515/22800 Orange
Sensor at 0,55 mbar
On/Off Temperature
5 Cold Start Switch 515/23003
40 ° C
5. Cold start advance
3. Engine oil pressure

01
33
ELECTRICAL
SPECIFICATIONS
4 WHEEL STEERING VALVE
SV2 SV3
SV1 – S1 SV1 – S2
01
34
ELECTRICAL
SPECIFICATIONS
TRANSMISSION SELECTION LEVER POSITIONS
NEUTRAL POSITION
1ST GEAR FORWARD SELECTED

01
ELECTRICAL
SPECIFICATIONS 35
TRANSMISSION SELECTION LEVER POSITIONS (cont’d)
2ND GEAR FORWARD SELECTED
3RD GEAR FORWARD SELECTED

01
36 ELECTRICAL
SPECIFICATIONS
4TH GEAR FORWARD SELECTED

01
ELECTRICAL 37
SPECIFICATIONS
1ST GEAR REVERSE SELECTED
2ND GEAR REVERSE SELECTED

01
38 ELECTRICAL
SPECIFICATIONS
3RD GEAR REVERSE SELECTED
4TH GEAR REVERSE SELECTED

01
ELECTRICAL
SPECIFICATIONS 39
2WD (2TH GEAR FORWARD SELECTED)
PARK BRAKE OR TX DUMP APLLIED (1ST GEAR FORWARD SELECTED)

01
40 ELECTRICAL
SPECIFICATIONS
SERVICE BRAKE APPLIED
3RD GEAR FORWARD SELECTED

HYDRAULIC
 30- 01 Hydraulic system general
 30- 02 Hydraulic system service
 30- 03 Brake system

01
HYDRAULIC
GENERAL 1
GENERAL INFORMATION
OIL TYPE : ISO VG 46 HVI

OIL CAPACITY (HYDRAULIC TANK) : 120 L
OIL CAPACITY (FULL SYSTEM) : 160 L
OIL CHANGE INTERVAL : EVERY 1.000 HOUR*
CHANGE INTERVAL OF RETURN FILTER : FIRST 50 HOUR /
EVERY FOLLOWING 500*
PUMP CAPACITY (P1 + P2)
STANDARD BOOM+BREAKER LINE : 37 CC/REV + 29 CC/REV
TELESCOPIC ARM+BREAKER LINE : 46 CC/REV + 23 CC/REV
MAX. SYSTEM PRESSURE : 230 BAR @ 1500 RPM / 40-50˚C
UNLOADER VALVE PRESSURE (SECOND PUMP) : 210 BAR @

1500 RPM / 40-50˚C
STEERING SYSTEM PRESSURE

HMK102B : 125 BAR
HMK102S : 140 BAR
NOTE:
• THE FILTER AND OIL CHANGE INTERVALS SHOULD BE
SHORTENED DOWN TO 2/3 OF THE STANDARD SERVICE
LIFE WHEN HYDRAULIC BREAKER IS USED.
01
2 HYDRAULIC
GENERAL
General Hydraulic circuit’s block diagrams are shown below.
STANDART BOOM CIRCUIT

01
HYDRAULIC
GENERAL 3
STANDART BOOM & BREAKER CIRCUIT
STANDART BOOM & BREAKER CIRCUIT (ELECTRICAL VALVE)

01
4 HYDRAULIC
GENERAL
TELESCOPIC ARM
TELECOPIC ARM & BREAKER CIRCUIT

01
HYDRAULIC
GENERAL 5
TELESCOPIC ARM & BREAKER LINE , BUNCHER HDS

01
6 HYDRAULIC
GENERAL
HYDRAULIC SYSTEM OPERATION PRINCIPLE
When the control valve lever is pressed down the spool moves downward too. The
neutral cave is cut, respectively the oil flow to tank is obstructed. At the same
moment pressure pump line is connected to the piston side of the cylinder while the
rod chamber is connected to the tank.
Because of the pressure difference created between piston and rod chambers of the
piston, the latter starts to move in the shown direction.
When the control lever is pressed up and the spool moves upward too. So before
mentioned operation is functioning reverse side.
01
HYDRAULIC
GENERAL 7
HYDRAULIC SYSTEM FUNCTIONS
01
8 HYDRAULIC
GENERAL
HYDRAULIC SYSTEM FUNCTIONS (cont’d)
01
HYDRAULIC
GENERAL 9
01
10 HYDRAULIC
GENERAL
01
HYDRAULIC
GENERAL 11
01
12 HYDRAULIC
GENERAL
01
HYDRAULIC
GENERAL 13
01
14 HYDRAULIC
GENERAL
01
HYDRAULIC
GENERAL 15
01
16 HYDRAULIC
GENERAL
01
HYDRAULIC
GENERAL 17
01
18 HYDRAULIC
GENERAL
01
HYDRAULIC
GENERAL 19
01
20 HYDRAULIC
GENERAL
01
HYDRAULIC
GENERAL 21
01
22 HYDRAULIC
GENERAL
01
HYDRAULIC
GENERAL 23
01
24 HYDRAULIC
GENERAL
UNLOADER VALVE CROSS SECTION VIEW
Selenoid
The gallery that
coil for
two pumps
unloader
combine
valve
P1 inlet
Main Relief
Valve
Tank
P2 inlet
Line
LOAD HOLDING CHECK VALVE
Anti shock valves
Load Holding
Check valve
Tank line
Pressure line to from the
the cylinder cyl.
01
HYDRAULIC
GENERAL 25
STEERING SYSTEM 2WS
The steering function occurs by hydraulic flow from pump P 1. Depend upon steering
wheel turning right or left, oil flows to the steering cylinder’s (8) piston or rod side via
control valve (LS).
01
26 HYDRAULIC
GENERAL
STEERING SYSTEM 4WS
There is two steering cylinder, front and rear axle mounted.

The steering function occurs by energizing solenoid valves combination.
For example:
2WS MODE (NON ANY SOLENOID ENERGIZED)
FRONT
F1 F2
S2 S1
SV
SV2 1
SV3
R2
R1
REAR
01
HYDRAULIC
GENERAL 27
CRAB MODE (SOLENOID SV1, SV2, SV3 & COIL S1 ENERGIZED)
FRONT
F1 F2
S2 S1
SV1
SV2 SV3
R2
R1
REAR
TURN MODE (SOLENOID SV1, SV2, SV3 & COIL S2 ENERGIZED)
FRONT
F1 F2
S2 S1
SV1
SV2 SV3
R2
R1
REAR
01
28 HYDRAULIC
GENERAL
CLAMPING SYSTEM
Our machine has a specially designed backhoe attachment locking position for
transport purposes. In this way, any load that
may appear is distributed in the correct way.
Otherwise, all the excessive forces that will
appear during the riding will be beared by the
metal frame. Also, it should be noted that the
hydraulic system pressure is low while riding.
This event affects negatively the clamping
pressure, hence increases the possibility of
impacts on the metal frame.
The correct operation of the clamping system could

be checked by performing of so-called pressure
loss test. It is simply required to put a “T”-connector
on the clamping line and to install a 300 or 400 bar
pressure gauge.
With the system installed, when clamped, the
pressure should be above 180 bar even when the
oil called. Additionally, the mentioned above
pressure should not drop more than 20 – 30 bar
within 20 min interval.
DO NOT LUBRICATE the carrier rail

flat surfaces (where the blockage
pistons work on). As the side-shifter
lock relies on the natural friction
between the lock pistons and the
carrier rails, any lubricant on the
surfaces will affect the lock
performance significantly. Thin layer of
grease is allowed on the top surface of
the rail only.
02
HYDRAULIC
SERVICE 1
TECHNICAL DATA
THESE DATA ARE VALID FOR BOTH HMK 102B & HMK 102S MODELS.
HYDRAULIC PUMP
MODEL Double pump
ROTATION (VIEWED FROM DRIVESHAFT END) Anti-clockwise

MOUNTING Coupled on the transmission
THEORETICAL DISPLACEMENT cc/rev

PUMP SECTION 1 (mounting flange end) 46
PUMP SECTION 2 23
FLOW AT 2200 rev/min AND SYSTEM PRESSURE

( 95% DISPLACEMENT )
PUMP SECTION 1 (mounting flange end) 81,4 lt /min
PUMP SECTION 2 64,0 lt/ min
MAXIMUM SYSTEM PRESSURE 230 bar ( 3335 PSI )
AUXILARY RELIEF VALVE
RELIEF VALVE OPERATING PRESSURES bar PSI
TELESCOPIC DIPPER RAM HEAD SIDE 210 3045

TELESCOPIC DIPPER RAM ROD SIDE 210 3045
JAW BUCKET RAM HEAD SIDE 248 3600
JAW BUCKET RAM ROD SIDE 248 3600
DIPPER RAM HEAD SIDE 248 3600
DIPPER RAM ROD SIDE 248 3600
SLEWING RAM HEAD SIDE 158 2300
SLEWING RAM ROD SIDE 158 2300
BOOM RAM HEAD SIDE 248 3600
BOOM RAM ROD SIDE 310 4500
SHOVEL CROWD RAM HEAD SIDE 158 2300
SHOVEL CROWD RAM ROD SIDE 248 3600
MAIN RELIEF VALVE 230 3335
HYDRAULIC FILTER ELEMENT

RELIEF VALVE OPERATING PRESSURES
BY-PASS PRESSURE 2 29
02
2 HYDRAULIC
SERVICE
TECHNICAL DATA
LOADER VALVE
ITEM DESCRIPTION
4J ARMS LIFT SERVICE
4K SHOVEL SERVICE
4L CLAM SHOVEL SERVICE
1H PUMP SECTION 1- INLET
2H PUMP SECTION 2- INLET
4A PRESSURE TEST PORT
4B CLAMSHOVEL RELIEF
VALVE
4F UNLOADER RELIEF
VALVE
4E UNLOADER SOLENOID
4M AUXILIARY RELIEF VALVE
4N AUXILIARY RELIEF VALVE
1H+2H CARRY-OVER PORT
1D TANK PORT
P SERVICE PORTS
Y DATA PLATE
4G,4H LOAD HOLD CHECK
VALVES
RELIEF VALVE OPERATING PRESSURES bar PSI

MAIN RELIEF VALVE (1500 rpm) (M.R.V) 227 3300
UNLOADER VALVE 207 3000
CLAM SHOVEL RELIEF VALVE 217 3150
02
HYDRAULIC
SERVICE 3
TECHNICAL DATA
BACKHOE VALVE
ITEM DESCRIPTION ITEM DESCRIPTION

SERVICE PORT Stabilizer left
P1+P2 CARRY OVER from loader valve 10
side, head side
SERVICE PORT Stabilizer right
5C DIPPER 3
side, rod side
SERVICE PORT Dipper arm rod SERVICE PORT Stabilizer right
6 9
side side, head side
SERVICE PORT Dipper arm
12 5G SLEW
head side
5J A.R.V. Dipper arm rod side 5T A.R.V. Bucket crowd ram
5X A.R.V. Dipper arm head side 5S A.R.V. Bucket crowd ram
SERVICE PORT Head side of
5D BUCKET CROWD 2
right ram, rod side of left ram
SERVICE PORT Bucket crowd SERVICE PORT Rod side of right
5 8
ram head side ram, head side of left ram
SERVICE PORT Bucket crowd
11 5H BOOM
ram rod side
5L A.R.V. slew head side 5V A.R.V. Boom head side
5K A.R.V. slew rod side 5U A.R.V. Boom rod side
5E STABILIZER Left side T1 ,T2 TANK PORTS
5F STABILIZER Right side 5R, 5Q, 5P, 5O, 5N, 5M
SERVICE PORT Stabilizer left ARE LOAD HOLD CHECK
4
side, rod side VALVES
02
4 HYDRAULIC
SERVICE
TECHNICAL DATA
RELIEF VALVE OPERATING PRESSURES Bar PSI
JAW BUCKET RAM HEAD SIDE 248 3600

JAW BUCKET RAM ROD SIDE 248 3600
DIPPER RAM HEAD SIDE 248 3600
DIPPER RAM ROD SIDE 248 3600
SLEWING RAM HEAD SIDE 158 2300
SLEWING RAM ROD SIDE 158 2300
BOOM RAM HEAD SIDE 248 3600
BOOM RAM ROD SIDE 310 4500
SHOVEL CROWD RAM HEAD SIDE 158 2300
SHOVEL CROWD RAM ROD SIDE 248 3600
HYDRAULIC CONTAMINATION
HYDRAULIC FLUID QUALITY

Construction machinery uses different types of fluids in the hydraulic system for
power transmission, equipment lubrication, and rust prevention. Seventy two percent
( 72 %) of the causes of problems in hydraulic equipment are related to the
inadequate maintenance of the quality of the hydraulic fluid therefore, control of the
quality of the hydraulic fluid minimizes hydraulic equipment problems and improves
safety as well as reliability.
EFFECTS OF CONTAMINATION
Contamination greatly effects the performance and the life of the hydraulic
equipment. for example , if there is a contaminant in a hydraulic pump, it develops
internal wear to cause leakage and hence lower delivery output. The particles worn
will cause further deterioration in the performance of the hydraulic system.
Contaminants also enter principal sliding sections of the equipment causing
temporary malfunction, scuffing, rubbing, sticking, chaffing and leakage and can lead
to major problems seriously.
THE CONTAMINANTS ARE CLASSIFIED AS FOLLOWS:

1. SOLID PARTICLES:
Sand, fibres, metallic particles, welding scale, sealing materials and wear
particles.
2.LIQUID:
Usually water and inadequate oils and greases.
3.GASES:
Air, sulphur dioxide etc. that cause corrosive compounds if dissolved in the fluid.
02
HYDRAULIC
SERVICE 5
HYDRAULIC CONTAMINATION
FIGURE: SUDDEN FAILURE FIGURE: BROKEN PUMP

DRIVE SHAFT
Big metal particles are The pump drive shaft is broken by

squeezed in the tooth of the effects of contaminants such
the gear pump. as blocking A. R. V. and leading to
occur of peak pressure.
FIGURE: SCRATCHED RAM

FIGURE : RUST FORMATION
You can see a scratched rod of a ram
damaged by contaminants entering through You can see the results of the
the end cap of the ram. These scratches can hydraulic contamination as rust
cause greater problems by allowing more formation on the samples given.
contaminant in.
02
6 HYDRAULIC
SERVICE
CONTAMINATION STANDARDS
Contamination that damages the hydraulic system can be seen too small to be
identified visually. The particle is in micron size.
1 MICRON (µ) = 0.001 mm (0.0000394 in)
Listed below are a few typical comparisons:
Red blood cells : 8µ

Human hair : 72 µ
Smallest particle that may be identified visually is 40 microns, normally.
FILTERS
The filter assembly fitted to HMK 102 B and

HMK 102 S are designed to filter all the
contamination that is rated to the required
level of cleanliness. It must be serviced
according to the requirements given in the
Operation & Maintenance manual. All data
is given in this manual on specifications &
periodical maintenance of the filters.
02
HYDRAULIC 7
SERVICE
TROUBLE SHOOTING
The aim of this section is to shoot the trouble when you face with a failure in a faulty
unit such as valves, rams and pumps etc.. If you trace a failure in a faulty unit, refer
to dismantling, inspecting and test instructions given in the following sections in this
manual. It is very important to refer to hydraulic circuit diagrams and relevant
sections to identify the failure.
TO SHOOT THE TROUBLE:
1. READ THE RELEVANT SAFETY INFORMATIONS.

2. MAKE SIMPLE CHECKS AND BEGIN TO FIND THE CAUSE OF FAILURE
FROM SIMPLE TO COMPLEX.
3. MAKE SURE THAT THE HYDRAULIC FLUID IS AT CORRECT OPERATING
TEMPERATURE AND MAKE SURE THAT THE TEMPERATURE IS NOT
OVER 80°C MAXIMUM.
4. CHECK THE CONDITION OF THE HYDRAULIC FLUID AND IF NECESSARY
DRAIN & REPLACE IT.
5. MAKE RELEVANT ELECTRICAL CHECKS BEFORE WORKING ON
HYDRAULICS.
6. REMOVE ALL CONTAMINATION AND IDENTIFY THE ORIGIN OF
CONTAMINATION.
7. REMOVE AND DISCARD ALL SEALS SUCH AS ‘O-RINGS’ AND REPLACE
THEM BY NEW ONES BEFORE ASSEMBLING A HYDRAULIC
COMPONENT.
FAULT 1 : LACK OF POWER IN ALL HYDRAULIC FUNCTIONS

PROBABLE CAUSE ACTION
INSUFFICIENT HYDRAULIC FLUID Check for leaks and top up fluid as required.
LEAKAGE IN HYDRAULIC SYSTEM Check the hoses for leakage.
ENGINE PERFORMANCE Check the engine performance.
MAIN RELIEF VALVE (M.R.V) Check and adjust as required.

SETTING IS INCORRECT
LOW PUMP FLOW Check pump flow, if required replace it.
TANK FILTER BY-PASS VALVE Check the condition of hydraulic filter.
UNLOADER VALVE PRESSURE Check pressure setting of the un-loader

SETTING IS TOO HIGH valve.
02
8 HYDRAULIC
SERVICE
FAULT 2: RAMS ARE OPERATING SLOWLY
LOW PRESSURE LINES ARE BLOCKED, Check pipe lines and replace the
DAMAGED OR LEAKING failed one.
LOW PUMP FLOW Check pump flow
PRIORITY VALVE Check priority valve if it is sticking,

rectify as required.
(M.R.V) SETTING INCORRECT Check and adjust as required
UNLOADER VALVE Check whether un-loader valve sticking

or not.
TANK FILTER BY-PASS VALVE Check condition of hydraulic filter.
HYDRAULIC TANK BREATHER Check pressure setting of the un-loader

valve.
FAULT 3 :ONE HYDRAULIC SERVICE IS OPERATING SLOWLY OR NOT

OPERATING
SERVICE PIPE LINES ARE BLOCKED Check pipe lines hoses and replace
OR DAMAGED the failed ones. Check ram.
RAM IS LEAKING Identify leak origin and if required

replace the seals.
A.R.V. SETTING IS INCORRECT Check & adjust it.
VALVE BLOCK SECTION IS LEAKING Check for leaks and rectify as required.
Make sure the associated load hold
check valve is operating.
Check the relevant control lever and
linkages. Check whether spool is sticking
or not.
CHECK VALVE IF MALFUNCTIONING Test the check valve.
PISTON ROD IS BENT OR WORK IN Replace piston rod, check A.R.V,

ECCENTRICITY A.R.V. & M.R.V. pressure settings
check the grease in pins.
02
HYDRAULIC
SERVICE 9
FAULT 4 : A SPOOL IS STICKING IN LOADER VALVE OR BACKHOE VALVE.
OIL TEMPERATURE IS TOO HIGH Check for correct fluid. Refer Operation
and Maintenance manual. Check oil cooler
and front grill for blockage.
THE HYDRAULIC FLUID IS Check the hydraulic filter and strainer.

CONTAMINATED If they are clogged badly, draiın and flush
the hydraulic system effectively.
Refill the hydraulic system.
SERVICE PIPE CONNECTIONS Check tightening torque for

AND ADAPTERS over- tightening.
THE VALVE HOUSING IS TWISTED Loosen retaining bolts and tighten to

BOLTS OR RETAINING ARE NOT correct torque value.
WELL TIGHTENED
PRESSURE IS TOO HIGH Check system pressure.
LINKAGE IS BENT OR BROKEN Renew the failed one.
A SPOOL IS BENT OR SCRATCHED Dismantle and control the valve and

replace the spool.
A RETURN SPRING OR GLAND Remove the end cap, check spring is

MISALIGNED in correct position, dismantle the gland
assy. and check whether there is a failed
part or not.
02
10 HYDRAULIC
SERVICE
FAULT 5 : OIL SEALS IN THE CONTROL VALVE ARE LEAKING.
PAINT OR DIRT ON THE SEAL FACE Remove the seal & clean, if necessary
replace it.
THE BACK PRESSURE IN THE Check circuit pressures and adjust.

VALVE CIRCUIT IS EXCESSIVELY
HIGH
SPOOL IS DAMAGED Dismantle it for inspection. Renew if

necessary.
THE SEAL IS NOT SECURED WELL. Clean the seal and tighten the retaining
bolts to the correct torque.
THE SEAL IS CUT OR DAMAGED Fit a new seal.
FAULT 6 : RAM IS CREEPING.
RAM OR PIPE LINES MAY BE Check & rectify as required.

LEAKING.
CHECK VALVE MALFUNCTIONING. Test check valve ,rectify .
VALVE SECTION SPOOLS ARE Check for contamination.

LEAKING.
A.R.V. IS LEAKING. Check for contamination.

02
HYDRAULIC
SERVICE 11
FAULT 7: HYDRAULIC OIL BECOMES TOO HOT.

OIL COOLER OBSTRUCTED Remove debris from cooler
RESTRICTION IN NEUTRAL Check hoses

CIRCUIT LINES
HYDRAULIC FILTER CLOGGED Change hydraulic filter

AND BY-PASS VALVE NOT WORKING
FAULT 8 :THE ENGINE TENDS TO STALL WHEN HYDRAULICS ARE UNDER

LOAD.
M.R.V. SETTING INCORRECT Check and adjust .
POOR ENGINE PERFORMANCE Check engine performance, see

transmission workshop manual
UNLOADER VALVE PRESSURE Check pressure setting of the

SETTING IS TOO HIGH un-loader valve.
FAULT 9: STEERING FAILS TO RESPOND SELECTED MODE.

SELECTOR SWITCH FAULTY Check selector switch
PROXIMITY SWITCHES ARE NOT Check it’s setting, reset or replace

OPERATING PROPERLY.
STEER MODE VALVE IS NOT Check whether spools are sticking or not.
OPERATING PROPERLY. Replace if required.
LEAKS IN THE RELEVANT HOSES OR Check hoses and connections.

COMPONENT CONNECTIONS
ELECTRICAL FAILURE Check relevant electrical connectors, if

problem still persists, check the wiring
continuity on relevant circuits.
02
12 HYDRAULIC
SERVICE
HYDRAULIC CIRCUIT DIAGRAM HMK 102 B
02
HYDRAULIC
SERVICE 13
1. Hydraulic tank (0.3 bar inlet 5C. Control valve, dipper

pressure) 5D. Control valve, slew
1A. Suction strainer 5E,5F Control valve, stabilizers
P1+P2. Pump section P1& P2 5G Control valve, bucket crowd
P1A. Pressure test port for P1 5H Control valve, boom
P2A. Pressure test port for P2 5Ii,5J A.R.V. dipper (248 bar)
1H. Pressure line for P1 5K,5L A.R.V. slew (158 bar)
2H. Pressure line for P2 5S,5T A.R.V. bucket crowd (248 bar)
1H+2H. High pressure carry-over line 5U,5V A.R.V. boom
2. Priority valve (5U:310 bar,5V:248 bar)
3H. Steering feed line 6. Throttle valve, return line of
LS. Steering load sensing line loader lift
1T. pressure test port for aux. val. 7, 8. Rams, loader lift
3. Auxiliary valve assy. 9,10. Rams, shovel
3A. M.R.V. (250 bar),auxiliary valve 11,12. rams, clam shovel
3D. Auxiliary valve 13,14.Rams, hydraulic clamps
3B,3C. Relief valve (180 bar for 15. Ram, dipper
breaker) (210 bar for extradig dipper) 16. Ram, bucket crowd
4. Loader valve block 17,18. Rams, stabilizers
4A. Pressure port for hydraulic 19,20 Cushion valve, slew rams
system 21,22 Rams, slew
4B. M.R.V.( 230 bar) 23. Throttle valve, return line of
4C. Check valve boom ram.
4D. Spool, un-loader valve 1D Return line, loader valve
4E. H.S.C. solenoid valve 2D Return line, backhoe valve
4F. Un-loader valve (210 bar) 24. Ram, boom
4G,4H,4I Load hold check valves 4J. Control valve, loader lift
4K. Control valve, shovel 25. Oil cooler, hydraulic fluid.
4L. Control valve ,clam shovel 26. Filter assembly, return line
4M,4N A.R.V. shovel (bypass valve:2 bar)
(4N:248 bar,4M:158 bar) 26A Filter element, return line
4O Parallel gallery 27. Ram, telescopic dipper
5. Backhoe valve block 28. Hydraulic breaker (optional)
5A. Clamping solenoid valve 29. Steering ram
5B. Make-up check valve 30. Steering unit
02
14 HYDRAULIC
SERVICE
HYDRAULIC CIRCUIT DIAGRAM HMK 102 S
FRONT
REAR
02
HYDRAULIC
SERVICE 15
1. Hydraulic tank 5C. Control valve, dipper

(0.3 bar inlet pressure) 5D. Control valve, slew
1A. Suction strainer 5E,5F Control valve, stabilizers
P1+P2. Pump section P1&P2 5G Control valve, bucket crowd
5H Control valve, boom
P1A. Pressure test port for P1 5I,5J A.R.V, dipper (248 bar)
P2A. Pressure test port for P2 5K,5L A.R.V., slew (158 bar)
1H. Pressure line for P1 5S,5T A.R.V., bucket crowd (248 bar)
2H. Pressure line for P2 5U,5V A.R.V, boom
2. Priority valve (5U:310 bar,5V:248 bar)
3H. Steering feed line 6. Throttle valve, return line of
LS. Steering load sensing line loader lift
1T. Pressure test port for aux. val. 7, 8. Rams, loader lift
3. Auxiliary valve assy. 9,10. Rrams, shovel
3A. M.R.V. (250 bar),auxiliary valve 11,12. Rams, clam shovel
3D. Auxiliary valve 13,14. Rams, hydraulic clamps
3B,3C. Relief valve 15. Ram, dipper
(180 bar for breaker) 16. Ram, bucket crowd
(210 bar for telescopic dipper) 17,18. Rams, stabilizers
4. Loader valve block 19,20 Cushion valve, slew rams
4A. Pressure port for hydraulic 21,22 Rams, slew
system 23. Throttle valve, return line of
4B. M.R.V.( 230 bar) boom ram.
4C. Check valve 1D Return line, loader valve
4D. Spool, un-loader valve 2D Return line, backhoe valve
4E. H.S.C. solenoid valve 24. Ram, boom
4F. Un-loader valve (210 bar) 25. Oil cooler, hydraulic fluid.
1H+2H. High pressure carry-over line 26. Filter assembly, return line
4J. Control valve, loader lift (bypass valve:2 bar)
4K. Control valve, shovel 26A Filter element, return line
4L. Control valve ,clam shovel 27. Ram, telescopic dipper
4M,4M A.R.V.,shovel 28. Hydraulic breaker (optional)
(4N:248 bar,4M:158 bar) 29. Front steering cylinder
4O parallel gallery 30. Rear steering cylinder
4G,4H,4I Load hold check valves 31. Steering solenoid valve
32. Steering solenoid valve
5. Backhoe valve block 33. Steering unit
5A. Clamping solenoid valve
5B. Make-up check valve
02
16 HYDRAULIC
SERVICE
DESCRIPTION OF NEUTRAL CIRCUIT

02
HYDRAULIC
SERVICE 17
NEUTRAL CIRCUIT RETURN
02
18 HYDRAULIC
SERVICE
DESCRIPTION OF NEUTRAL CIRCUIT
When the hydraulic system of the machine is operated under neutral position, the
hydraulic pump ( tandem, two sections, P1 & P2) receives the hydraulic fluid from the
hydraulic tank and feeds this oil to the hydraulic circuit.
The tandem pump is driven directly by a drive shaft.
The oil fed by pump section P1, is delivered to priority valve 2. Then hydraulic oil
passes to auxiliary valve 3 over priority valve. Since the auxiliary valve is in neutral
position, the hydraulic oil enters loader valve block 4 through auxiliary valve.
Pump section P2, feeds oil directly to loader valve. Thus, the oil fed by P1 & P2
comes together ( confluxes ) in the neutral gallery of the loader valve block and then
passes to backhoe valve 5 block through high pressure carry-over line. Since the
backhoe valve block is neutral position, the hydraulic fluid passes through the neutral
gallery to collector over return line T4.
The oil that is collected in the collector goes to oil cooler thorough pipe 4 and hose 3.
then, after the cooled fluid is strained by return filter, it returns to hydraulic tank via
pipe 6 and hose 8. (refer to page ’NEUTRAL CIRCUIT RETURN’)
02
HYDRAULIC
SERVICE 19
DESCRIPTION OF PUMP
The basic principle of the gear pump depends on the meshing of two spur gears,
one of which is engine–driven while the other is an idler.
Oil is picked up by the gear teeth on the suction side of the pump and carried out
between the teeth and the pump body. As the gears come into mesh, the space
carrying the oil is filled by a gear tooth on the mating gear, forcing the oil out of the
space and through the pump inlet.
PUMP FLOW TESTING

Before removing the pump, it is necessary to determine the source of any problem by
measuring the output flow at system pressure at both of the pump outlet ports.
To check flow it is necessary to fit a flow meter into the output line of each pump
section in turn. Make sure the flow meter is installed with its arrow pointing away from
the pump and, if possible, located between pump and loader valve.
WARNING
HYDRAULIC FLUID AT SYSTEM PRESSURE MAY INJURE YOU. BEFORE
FITTING OR DISCONNECTING HYDRAULIC HOSES, STOP THE ENGINE AND
RELEASE PRESSURE TRAPPED IN THE HOSES BY OPERATING CONTROL
LEVERS A FEW TIMES. TAKE CARE NOT TO START THE ENGINE WHILE THE
HOSE ENDS ARE OPEN WITHOUT ANY PLUG OR CAP.
02
20 HYDRAULIC
SERVICE
FITTING / REMOVING A FLOW METER AND LOAD VALVE
Before removing / fitting a flow meter and load valve, switch off the machine and
operate the loader / excavator control levers a few times to release the system
pressure.
FITTING
1 a. Open the test plug on the pump section P1 line. Fit the flow meter.
b. Open the test plug on the pump section P2 line. Fit the flow meter.
REMOVAL
Removal is the reverse of fitting.
CHECK FLOW
1. Check the setting of the main relief valve (M.R.V.) as described in LOADER
VALVE, PRESSURE TESTING. Adjust if necessary.
2. a. USING A LOAD VALVE: Fit a flow meter and a load valve to each pump
each turn.
Fit a 0-400 bar pressure gauge to the load valve pressure test connector.
b. IF NO LOAD VALVE IS AVAILABLE: Fit a flow meter to each pump output
plugs each turn.
3. START THE ENGINE AND ALLOW TO RAISE THE HYDRAULIC OIL

TEMPERATURE UP TO THE OPERATING TEMPERATURE. SET THE ENGINE
SPEED TO 2000 rpm.
4. a. USING A LOAD VALVE, Adjust the load valve so that pressure gauge
reading is just below the M.R.V. setting.
b. IF NO LOAD VALVE IS AVAILABLE, Raise or lower the loader arms until

the ram’s stroke end. Continue to operate the raise/lower, control so that system
pressure builds up. Observe the flow meter and note its reading at the moment of the
M.R.V. operates.
02
HYDRAULIC
SERVICE 21
LOADER VALVE
02
22 HYDRAULIC
SERVICE
LOADER VALVE DESCRIPTION
The loader valve is mounted on the chassis frame, right hand side (when viewed
from rear). Standard equipment includes loader lift spool (4J), shovel spool (4K) and
un-loader valve assembly (4D). Clam shovel spool (4L) is optional. Linkage rods
connect the spool ends to the control levers.
OPERATION
In neutral circuit hydraulic oil from pump section P2 enters the loader valve via a
steering priority valve. On entering the valve block, oil flows around the waist section
of the un-loader valve 3L, past a check valve and joins flow from pump P1.
Oil from pump section P1 enters the loader valve as shown.
Combined oil from P1 and P2 passes the main relief valve (M.R.V.- not shown) and
fills the parallel gallery (1H+2H). From the parallel gallery the oil flows around the
waist central portions of spools 4J, 4K and 4L (all in neutral position) and flows on to
feed the excavator valve via high pressure carry over line 1B.
The exhaust gallery T is connected to the tank return line.
COMPONENT KEY
4 LOADER VALVE BLOCK
4C LIFT RAM SPOOL
4K SHOVEL RAM SPOOL
4L CLAM SHOVEL SPOOL
4D UNLOADER VALVE SPOOL
4F UNLOADER PILOT VALVE
WARNING
MAKE THE MACHINE SAFE BEFORE WORKING UNDERNEATH IT. PARK THE
MACHINE ON LEVEL GROUND, LOWER THE ARMS. APPLY THE PARKING
BRAKE, PUT THE TRANSMISSION IN NEUTRAL AND STOP THE ENGINE.
CHOCK BOTH SIDES OF ALL FOUR WHEELS.
DISCONNECT THE BATTERY, TO PREVENT THE ENGINE BEING STARTED
WHILE YOU ARE BENEATH THE MACHINE.
02
HYDRAULIC
SERVICE 23
LOADER VALVE REMOVAL & INSTALLATION
REMOVAL
1. Operate the valve block levers back and forth to release residual pressure.
2. Remove clevis pins A to disconnect the control levers from the spools of valve
block.
3. Disconnect all hydraulic hoses from the valve block and plug all orifices to
prevent ingress of dirt. Label each hose before disconnecting, this will
ensure correct position when refitting.
4. Loosen and remove nuts and bolts 2, 4 and spacing washers 3.
INSTALLATION
Installation is the reverse of removal sequence.
After installation, check the main relief valve (M.R.V.) and auxiliary relief valve
(A.R.V.) pressure settings.
NOTE:
All hydraulic adapters that are installed together with a sealing washer must also
have sealant applied to the threads of the adapter.
02
24 HYDRAULIC
SERVICE
LOADER VALVE CUTOFF VIEW

02
HYDRAULIC
SERVICE 25
ASSEMBLE
1. Lay out valve components on a

clean, flat working surface.
The inlet assembly will include
an O-ring and the spool includes
an O-ring, a load check poppet
and a load check spring. Tools
required for basic valve assembly
include ¾ “ and 11/16” open or
box end wrenches and a torque
wrench with thin wall sockets.
2. Assemble tie rod nuts to one end

of each tie rod with one or two
threads showing. Insert tie rods
through tie rod holes of inlet (larger
tie rod at top). Lay inlet on end with
tie rods up, place O-ring into position.
3. Place first spool section (O-ring side up)

on inlet section, position O-ring and
insert load check poppet (nose down)
and spring (behind poppet) into load
check cavity as shown. Repeat this
procedure for each spool section ;
the load check springs are compressed
by the following sections during assembly.
02
26 HYDRAULIC
SERVICE
4. Position end section on last spool section

as shown and hand tighten tie rod nuts.
The end section on picture is a “turn
around” section without ports. Universal
outlet/power beyond section and power
beyond and closed center sections are
also used as end sections.
These end sections do not have O-ring
grooves.
5. Position valve assembly with the mounting pads of the end sections on a flat
surface.
To obtain proper alignment of end
sections relative to the spool sections
apply downward pressure to the end
sections; snug tie rod nuts to about
10 ft.lbs.
Final torque the two 11/16” nuts to

48 ± 5 ft.lbs; final torque the ¾” nut
to 74 ± 8 ft.lbs. Check for proper
spool movement.
6. Install auxiliary valves and plugs and

torque to proper specifications.
General assembly notes:

A. Lever assemblies can be installed on section before or after complete valve
assembly.
B. The load check and spring may be omitted from assembly in certain circuit
conditions.
02
HYDRAULIC
SERVICE 27
AUXILIARY RELIEF VALVE

A.R.V.’s are positioned on the excavator valve block in order to relieve excessive
pressure in the services.
1. VALVE AT REST
Below figure shows the service in neutral with no forces acting on the
equipment.
The force of spring D acting through collar C keeps poppet B firmly held on its
seat. Chamber J is connected to exhaust gallery via small drilled holes H, this
means the pressure in the chamber will always be at the exhaust side. The A.R.V.
pressure setting is adjustable by means of spring D and adjusting screw E.
Turning the screw clockwise compresses the spring and therefore increases the
pressure setting. Turning the screw anti-clockwise conversely, releases the spring
which decreases the pressure setting.
2. POPPET OPENS
If the pressure in the service gallery A has reached the setting of the A.R.V.,
the pressure on the service side of the poppet is high enough to overcome the force
of spring D so poppet B lifts off its seat. Oil in chamber J is displaced through small
drilled holes H. Service pressure at A is now released to exhaust gallery K.
02
28 HYDRAULIC
SERVICE
OPERATION OF ANTI-CAVITATION
When the service gallery is cavitating, the A.R.V. anti-cavitation operation allows oil
from the exhaust gallery to supplement the cavitating service line.
1. OPERATION 1
When the A.R.V. is subjected to normal operating pressure in service gallery A, the
force of spring F and pressure in the service gallery acting on the bottom face of
anti-cavitation cone G keep the cone held firmly on its seat.
2. OPERATION 2
Whenever the service gallery is cavitating, the pressure in the exhaust gallery K is
sufficient to overcome the force of spring F. The cone and the assembly move down
allowing oil in the exhaust gallery and limit the effects of cavitation.
LOAD HOLD CHECK VALVES

The following text describes how the load hold check valve works on the arms raise
service.
OPERATION 1
The weight of the loaded shovel produces
a higher pressure in service line P than in
parallel gallery 4O. This pressure differential
causes load hold check valve 4G to close,
thus preventing the load from dropping.
OPERATION 2
As the neutral circuit has been blocked by the
central area of the selected spool, the
pressure in parallel gallery 4O increases until it
is greater than that in service line P. At this
point, load hold check valve 4G opens,
allowing oil to flow from the parallel gallery into
service line and operate the lift rams.
02
HYDRAULIC 29
SERVICE
AUXILIARY RELIEF VALVE & LOAD HOLD CHECK VALVE
02
30 HYDRAULIC
SERVICE
AUXILIARY RELIEF VALVE (A.R.V) & LOAD HOLD CHECK VALVE (L.H.C.V.)
DISMANTLING & ASSEMBLY

The numerical sequence shown on the illustration is intended as a guide to
dismantling.
For assembly, the sequence should be reversed.
The following points must be avoided when dismantling and assembling the valve:
CONTAMINATION
DAMAGE TO SPOOL
DAMAGE TO SEAL GROOVES
All or any of the above points may result in possible problems with the valve. The Aux
Relief Valves are identical in design but have different pressure settings.
L.H.C.V., the load hold check valves are also identical.
WHEN DISMANTLING
When removing the O-rings and seals, use an appropriately rounded tool that will
not cause any damage to the seal grooves. Discard all O-rings and back-up rings.
DO NOT use worn or damaged items. Dismantle sub-assembly 14 from item 1 using
a special tool (see service tools) the special spanner locates in cross holes B.
Make sure that small drilling A is not blocked. Ensure good condition of sealing faces
on poppet 18 and on the mating face of the valve block. Inspect the valve
components for scratches, nicks or any other kind of damage, replace with new if
required.
WHEN ASSEMBLING
Renew all O-rings and back-up rings. Coat the parts with hydraulic fluid before
assembling. Make sure that all the parts move freely. Fit back-up ring 13 on the
upper side of O-ring 12. Fit the face of sleeve 9 against shoulder of poppet 10.
Torque tighten item 14 using the special tool (see service tools) until its shoulder
seats firmly against item 1. Pressure test the relief valves using the procedure
described.
TORQUE SETTING
ITEM Nm kgf m
1 65 6,6
3 24 2,5
15 81 8,3
02
HYDRAULIC
SERVICE 31
UNLOADER VALVE ASSEMBLY
Un-loader spool operation avoids overloading the engine if a service is being worked
particularly hard, for example when using the excavator to tear out. It does this by
dumping the oil from pump section P2 to tank, allowing engine power to be applied
fully to the main pump section P1.
The un-loader is operated automatically when the system pressure reaches 210 bar.
The un-loader is operated manually. This is referred to as HYDRAULIC SPEED
CONTROL (HSC).
The main applications for manual operation are:
1. More traction force is made available to the loader end when entering a stock
pile.
2. More power from the engine is made available while traveling on the
highway, providing improved fuel economy.
3. Reduced backhoe speed when placing objects. (sensitivity)
02
32 HYDRAULIC
SERVICE
SYSTEM OPERATION
Pressure in the inlet gallery C rises to the setting of pilot valve 4f via the bore of the
spool 4D. At pressure below the setting of the un-loader valve, both pilot valve 4F
and the spool 4D remain closed.
If the pressure in the inlet gallery C rises to the setting of pilot valve 4F, this valve will
open, allowing oil in spring cavity 3P to escape more quickly than it can be replaced
by oil entering through the small drilling D.
This creates a pressure differential between the spring cavity 3P and gallery C.
Higher pressure in gallery C acts on the face of spool 4D causing the spool to be
moved off its seat. Oil entering the valve block from pump P2 now flows directly to
tank (T).
High pressure in gallery C also holds check valve 4C firmly closed, preventing oil of
pump P1 from being dumped too.
When pressure in the inlet gallery C falls, for example if the excavator has stopped
tearing out, pilot valve 4F will be at the same pressure as oil in gallery C, spring
pressure will move spool 4D back onto its seat, closing pump P2 connection to tank.
HYDRAULIC SPEED CONTROL (HSC)
Solenoid valve 4e is connected between

the un-loader valve chamber 3P and the
return to tank circuit.
When the solenoid is de-energized spring
force acting on the end of the spool keeps
the connection from chamber 3P to tank
closed. When the solenoid is energized
by the switch in the cabin manually, the
spool moves causing a connection from
the un-loader spool chamber 3P to the
hydraulic tank via valve block internal
galleries and service hoses.
Because the un-loader chamber is now
connected to the tank and so at exhaust
pressure, pressure in gallery C acts on
the face of un-loader spool 4D causing
the spool to be moved off its seat. Oil
entering the valve block from pump
section P2 now flows directly to tank.
Therefore, hydraulic oil flow in the system
can be decreased manually whenever
required.
02
HYDRAULIC
SERVICE 33
UNLOADER VALVE ASSEMBLY

02
34 HYDRAULIC
SERVICE

The numerical sequence given on the illustration is intended as a guide to
dismantling.
CONTAMINATION
DAMAGE TO SPOOL
All or any of the above points may result in problems with the valve possibly. The
A.R.V.s are identical in design but have different pressure settings. the L.H.C.V.s are
also identical.
WHEN DISMANTLING
Use an appropriately rounded tool when removing O-rings and seals that will not
cause any damage to the seal grooves. Discard all O-rings and back up rings.
Do not use worn or damaged items. Use a nylon rod to push out spool assembly
item 23 , do not damage spool bore.
Inspect the valve components for scratches, nicks or any other type of damage,
replace with new if necessary.
WHEN ASSEMBLING
Renew all O-rings and back-up rings. Coat parts with hydraulic fluid before
assembling. Make sure that all the parts move freely. Ensure that the small drilling
through the centre of item 23 is clean.
Shims 21 are intended to limit the maximum pressure setting the specified pressure
setting is achieved by adjusting cap nut 15. If the specified pressure can not be
achieved under test, it is permissible to add shims as required. There must be at
least one hardened shim next to the spring item 22.
Check pressure setting after refitting. Check the operation of the ‘Hydraulic Speed
Control’.
WARNING
DO NOT OVERTIGHTEN THE SOLENOID ASSEMBLY, OTHERWISE THE

SOLENOID VALVE CAN BE DAMAGED OR THE OPERATION OF THE SOLENOID
MAY BE EFFECTED, USE OF THE SPANNER FLATS AND TORQUE TIGHTEN TO
FIGURE INDICATED IN THE TABLE BELOW.
Torque settings
ITEM Nm kgf.m
1 6,7 0,7
5 27 2,8
8 81 8,3
12 81 8,3
16 45 4,6
19 34 3,5
02
HYDRAULIC
SERVICE 35
STANDARD SPOOL
02
36 HYDRAULIC
SERVICE
dismantling.
CONTAMINATION
DAMAGE TO SPOOL
All or any of the above points may result in problems with the valve possibly.
WHEN DISMANTLING
When removing O-ring’ and seals, use an appropriately rounded tool that will not
cause any damage to the seal grooves, for instance item 3 which is a wiper seal and
is a press fit in the counter bore.
Care must be taken to ensure that the spool 8 is not damaged when removing it from
the valve block. Hold the spool in clamp, unscrew bolt 9 and remove spring 12,
spacer 10 and cups 11 and 13.
Check for surface contamination on the under side of the seal plates 2 and 14. Clean
if necessary. Check for the flatness of the seal plate. If found not to be bent-replace
with a new one.
WHEN ASSEMBLING
Renew seal 3 and O-rings 4 and 15. Make sure that the O–rings and wiper seals are
not trapped or damaged.
When fitting bolt 9 , clean the threads through using a cleaning solvent, leave it for 10
minutes then apply a small quantity of lock & seal compound to the threads of the
spool.
Make sure that all the parts move freely, check that item 10 does not interfere with
item 13.
Re-connect lever mechanism to the lever end of the spool.
run the engine and inspect the valve for external leaks.
Torque settings
Item Nm kgf.m
1 5,4 0,6
5 9,5 0,96
9 9,5 0,96
02
HYDRAULIC
SERVICE 37
FLOAT SPOOL
02
38 HYDRAULIC
SERVICE
dismantling.
CONTAMINATION
DAMAGE TO SPOOL
WHEN DISMANTLING
Use an appropriately rounded tool that will not cause any damage to the seal
grooves when removing O-rings and seals. For instance item 3 which is a wiper seal
and is a press fit in the counter bore.
Care must be taken to ensure that the spool 15 is not damaged when removing it
from the valve block. Remove collar 11 and collect detent balls 12 carefully. Using
tool to hold the spool, remove circlip 18, plug 19, ball 20 and spring 21. Unscrew
detent pin 22 and remove spring 24 and cups 23 and 25.
Check for surface contamination on the under side of the seal plates 2 and 16.
Clean if necessary. Check for the flatness of the seal plate. If found not to be bent-
replace with the new one.
WHEN ASSEMBLING
Renew seal 3 and O-rings 4, 6 and 17. Make sure that the O–rings and wiper seals
are not trapped or damaged.
When fitting detent pin 22, clean the threads through using a cleaning solvent, leave
it for 10 minutes then apply a small quantity of lock & seal compound to the threads
of the spool.
Make sure that all the parts move freely, apply grease balls 12, this will help to hold
the balls in position while assembling.
Re-connect lever mechanism to the lever end of the spool.
Run the engine and inspect the valve for external leaks.
Torque settings
Item Nm kgf.m
1 9,5 0,96
5 9,5 0,96
8 9,5 0,96
02
HYDRAULIC
SERVICE 39
MAIN RELIEF VALVE
1. VALVE AT REST
Main relief valve (M.R.V.) 4B is positioned

in the loader valve block in order to relieve
excessive pressure in the hydraulic system.
When the hydraulic system is in neutral or
under light load and there are no excessive
forces acting on the equipment, hydraulic
system pressure that enters chamber D
through the small drilling e will not be
sufficient to move the main plunger a off its
seat B. The force of spring g is adjustable
to suit the relevant service by means of
adjuster at the top of the valve.
As long as the pressure does not continue
to rise, plunger a will remain on its seat.
2. PILOT VALVE OPENS
as the system pressure increases sufficient

to force the pilot valve f that moves against
spring G, the pressurized oil in chamber D
is allowed to escape into cavity K and to
pass down the sides of sleeve J into the
exhaust gallery H.
3. MAIN VALVE OPENS
as system pressure reaches the setting of

the valve, pressure in chamber D can not
rise because the seat orifice of pilot valve f
is larger than small drilling e and oil is can
not fil the chamber as fast as it is being
exhausted.
Pressure acting on the lower faces of main
plunger A is obviously greater than the combined force of both spring C and the
pressure in chamber D. then, the plunger moves off its seat, allowing pressure to be
vented into the exhaust gallery H.
As the system pressure decreases, the pilot valve can close and pressure in
chamber D helps spring C to push the main plunger a back to its seat.
02
40 HYDRAULIC
SERVICE
LOAD HOLD CHECK VALVES
the following text describes how the load hold

check valve works in the arms raise service.
OPERATION 1
The weight of the loaded shovel produces a
higher pressure in service line P than in
parallel gallery 4O. This pressure differential
causes load hold check valve 4G to close,
thus preventing the load from dropping.
OPERATION 2
As the neutral circuit has been blocked by the
central area of the selected spool, the
pressure in parallel gallery 4O increases until
it is greater than that in service line P. At this
point, load hold check valve 4G opens,
allowing oil to flow from the parallel gallery
into service line and operate the lift rams.
02
HYDRAULIC
SERVICE 41
MAIN RELIEF VALVE
02
42 HYDRAULIC
SERVICE

dismantling.
 CONTAMINATION
 DAMAGE TO SPOOL
 DAMAGE TO SEAL GROOVES
DISMANTLING
Use an appropriately rounded tool when removing O-rings and seals that will not
cause any damage to the seal grooves.
Discard all ‘o-ring’s and back up rings. do not use worn or damaged items.
Inspect the valve components for scratches, nicks or any other type of damage,
replace with new if required.
ASSEMBLING
Renew all O-rings and back-up rings.
Coat parts with hydraulic fluid before assembling. Make sure that all the parts move
freely.
Make sure that the O-rings and back-up rings are fitted in the correct order, items 10
and 11.
Adjust pressure setting as required.
Torque settings
Item Nm kgf.m lbf.ft
3 5,4 0,6 4
02
HYDRAULIC
SERVICE 43
LOADER VALVE PRESSURE TESTING
MAIN RELIEF VALVE
Make sure that the hydraulic oil is at normal operating temperature, ie.50°C (122° F).
Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine;
operate the control levers to release residual hydraulic pressure.
1. Connect a 0-400 bar ( 0 - 6000 lbf / in2 ) pressure gauge to pressure test
connector A on the loader valve, (see service tools )
2. With the engine running at 1500 revs./min., check M.R.V. pressure by raising
or lowering the loader arms until the rams are fully open or closed and noting the
maximum gauge reading.
CAUTION: Do not select ‘FLOAT’. The maximum pressure should be as stated in
technical data.
NOTE:
The rams must be ‘held’ open or closed when reading gauge.
3. If the pressure is not correct, loosen locknut D and adjust screw C. Turn it
clockwise to increase pressure and anti-clockwise to decrease the pressure.
When the pressure is correct, tighten the locknut.
02
44 HYDRAULIC
SERVICE
UNLOADER VALVE PRESSURE TESTING
Make sure that the hydraulic oil is at normal operating temperature, ie. 50°C (122°F).
Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine;
operate the control levers to release residual hydraulic pressure.
Make sure that the hydraulic speed control facility is not switched on, otherwise the
correct un-loader valve pressure cannot be obtained.
1. Connect a 0-400 bar ( 0 - 6000 lbf/in2 ) pressure gauge to pressure test

connector P2A plug.
2. With the engine running at 1500 revs./min., slowly operate arms raise or lower.
NOTE 1:
The loader lift arms raise or lower service is specified because it has no auxiliary
relief valve (A.R.V.). Selecting this service ensures that the pressure is released
through the un-loader valve and not through an A.R.V.
3. When the service reaches full travel, the gauge reading should rise slowly to
unloading pressure then fall back to zero. The maximum reading should be as
specified in technical data.
4. If the pressure is not correct, slacken locknut E and adjust cap F. Turn it
clockwise to increase pressure and anti-clockwise to decrease the pressure.
When the pressure is correct, tighten the locknut.
If the correct pressure cannot be achieved, add or subtract shims as required, see
un-loader valve assembly - dismantling and assembly.
02
HYDRAULIC
SERVICE 45
UNLOADER VALVE TESTING

02
46 HYDRAULIC
SERVICE
HYDRAULIC SPEED CONTROL (H.S.C.) TESTING
The following procedure can be used to establish if the hydraulic speed control facility
operates correctly.
1. Connect a 0-400 bar (0 - 6000 lbf/in2) pressure gauge to pressure gauge to

pressure test connector P2 A plug.
2. With the engine running at maximum speed, slowly operate lift arms raise,
raise the pressure to 210 bar approximately.
3. Then, the pressure gauge reading should drop to zero, automatically.
4. Repeat the above procedure once more. The pressure gauge reading should
drop to zero again (or near zero).
5. if there is no pressure drop at steps 3 and 4, then check the H.S.C. hydraulic
and electrical circuits for any faults.
02
HYDRAULIC
SERVICE 47
REMOVAL & INSTALLATION
WARNING
MAKE THE MACHINE SAFE BEFORE WORKING

UNDERNEATH IT. Park the machine on level ground, lower the arms. apply the
parking brake, put the transmission in neutral and stop the engine. Chock both sides
of all four wheels.
Disconnect the battery, to prevent the engine being started while you are beneath the
machine.
Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting
hydraulic hoses, stop the engine and operate the controls to release pressure
trapped in the hoses. Make sure that the engine cannot be started while the hoses
are out without any plugs or caps.
BACKHOE VALVE
CAUTION : This component is heavy. Do not attempt to remove it unless its

weight is held by a sling. Make sure that the sling is attached to a proper
lifting equipment.
REMOVAL
1. Operate the valve block levers back and forth to

release residual pressure.
2. Remove the rear valance.
3. Remove clevis pins a to disconnect the control
levers from the spools of valve block.
4. Disconnect all hydraulic hoses from the valve block
and plug all orifices to prevent ingress of dirt. Label
each hose before disconnecting, this will ensure
correct positioning when refitting.
5. Loosen nuts 3 - do not remove the retaining nuts
completely.
6. Wrap a suitable sling around the valve, make sure that the weight of the valve
is supported by the sling.
7. Remove nuts 2 and lower the valve block to the ground.
INSTALLATION
Installation is the reverse of removal sequence.

Hoses and pipes must be re-connected and phased in same position as removal.
After installation, check the auxiliary relief valve (A.R.V.) pressure settings.
NOTE:
All hydraulic adapters that are installed together with a sealing washer must also
have sealant applied to the threads of the adapter.
02
48 HYDRAULIC
SERVICE
BACKHOE VALVE
02
HYDRAULIC
SERVICE 49
BACKHOE VALVE DISMANTING AND ASSEMBLY

dismantling.
For assembly the sequence should be reversed.
CHECK VALVES
Each of the identical load hold check valves can be removed as shown. Make-up
check valve 5B is smaller in size but otherwise identical.
Ensure good condition of seating faces on poppets 4 and 8 and on the mating faces
in the valve block.
SPOOLS
Spools 5C, 5D, 5E, 5F, 5G are identical but must not be interchanged as they are
matched to their bores. Stabilizer spools 5E and 5F are identical to each other but
different from the excavator spools.
All spools have the same centering and sealing components (items 9 to 21).
Follow the sequence 9 to 21 to dismantle a spool completely. To prevent spool
rotation when turning screw 15, hold a rod through the eye end of the spool.
If only renewing the seals, dismantle as far as cap 14. Then, remove items 15 to 22
as an assembly.
Coat new seals with hydraulic fluid and take care to prevent them from being
damaged by the sharp edges of the spool.
Apply lock and seal compound to threads of screw 15.
RELIEF VALVES
Relief valves 4H to 4P appear identical but have various pressure settings (see
technical data). ensure that they are correctly adjusted and fitted in their specified
positions.
relief valve dismantling and assembly procedures are detailed separately.
NOTE: All hydraulic adapters that are installed together with a bonded sealing
washer must also have sealant applied to the threads of the adapter.
Torque settings
Item Nm kgf.m lbf.ft

1 122 12,4 90
5 80 8,3 60
13 7 0.7 5
15 11 1,1 8
23 95 10,0 70
02
50 HYDRAULIC
SERVICE
AUXILIARY RELIEF VALVE
A.R.V.’s are positioned on the excavator
valve block in order to relieve excessive
pressure in the services.
1. VALVE AT REST
Figure shows the service in neutral with
no forces acting on the equipment.
The force of spring D acting through collar C
keeps poppet B firmly held on its seat.
Chamber J is connected to exhaust gallery
via small drilled holes H, this means the
pressure in the chamber will always be at
exhaust.
The A.R.V. pressure setting is adjustable by
means of spring D and adjusting screw E.
Turning the screw clockwise compresses
the spring and therefore increases the
pressure setting. Conversely, turning the
screw anti-clockwise, releases the spring
which decreases the pressure setting.
2. POPPET OPENS
If the pressure in the service gallery A has
reached the setting of the A.R.V., the
pressure on the service side of the poppet is
high enough to overcome the force of spring
D so poppet B lifts off its seat.
ANTI-CAVITATION OPERATION
When the service gallery is cavitating, the A.R.V. anti-cavitation operation allows oil
from the exhaust gallery to supplement the cavitating service line.
OPERATION 1:
When the A.R.V. is subjected to normal operating pressure in service gallery A, the
force of spring f and pressure in the service gallery acting on the bottom face of anti-
cavitation cone G keep the cone held firmly on its seat.
OPERATION 2:
When the service gallery is cavitating, the pressure in exhaust gallery k is sufficient to
overcome the force of spring F. The cone and its assembly move down allowing oil in
the exhaust gallery to enter the service gallery and limit the effects of cavitation.
When the service gallery is no longer cavitating, compressed spring f will return to its
relaxed position and thus bring the anti-cavitation cone back onto its seat.
02
HYDRAULIC
SERVICE 51
AUXILIARY RELIEF VALVES
02
52 HYDRAULIC
SERVICE
DISMANTING AND ASSEMBLY

Eight A.R.V’s are fitted at positions 5X TO 5V. These are identical in design but have
various pressure settings (see technical data).

dismantling.
For assembly the sequence should be reversed.
DISMANTING
Dismantle sub-assembly 14 from item 1 using a special tool . The special spanner
locates in cross holes B.
Dismantle sub-assembly 14 into its parts. Make sure that small drilling A is not
blocked. discard old and worn ‘o-ring’s and back-up rings.
ASSEMBLING
Renew all O-rings and back-up rings.
Coat O-rings and back-up rings with hydraulic fluid.
Fit back-up ring 13 on the upper side of O-ring 12 as shown in the inset.
Fit flat face of sleeve 9 against shoulder of poppet 10.
Torque tighten item 14 using the special tool see service tools until its shoulder seats
firmly against item 1.
Pressure test the valve using the procedure described in backhoe valve pressure
testing.
Torque settings
Item Nm kgf.m lb.ft

1 65 6.6 48
3 24 2.5 18
02
HYDRAULIC
SERVICE 53
HYDRO-CLAMP OPERATION (SIDESHIFT MACHINES)
When the backhoe is being used for excavation, the kingpost assembly must be
‘clamped’ to the side-shift rear frame.
The hydro-clamp control valve assembly (items G,D and C) is positioned in the inlet
end of the excavator valve block and is connected directly to the parallel gallery B.
The valve operates in conjunction with solenoid valve E housed in the side of the
excavator valve block.
1. CLAMPS PRESSURIZED
When the hydro-clamp control lever is pushed downwards the hydro-clamp valve is
closed. The control lever of jaw bucket is hold steadily until M.R.V. relieves pressure
fully. this situation builds maximum pressure in parallel gallery. In this case, hydro-
clamp check valve opens and let the maximum pressure enter to hydro-clamp piston
when the lever of jaw bucket is released, the hydro-clamp check valve takes its
position and let the oil blocked in pistons. In other words pistons are blocked in
pressurized condition and clamps are pressurized.
2. CLAMPS RELEASED
When hydro-clamp lever is pulled upwards the hydro-clamp valve housing is being
turned clockwise and begin to spin until check valves stand to H. Then, the check
valve takes off its position. In this case, the pressurized oil in hydro-clamp circuit is
released to tank from the clearance that is formed by check valve. This means, the
clamps are released.
3. CLAMPS LOCKED UP
If no service is being operated, pressure in the parallel gallery falls to that of the
neutral circuit and the force of spring G is sufficient to keep the poppet seated.
Therefore, pressure is trapped in the line to the clamps, keeping the excavator end in
a securely clamped condition.
02
54 HYDRAULIC
SERVICE
HYDRO-CLAMP OPERATION (SIDE SHIFT MACHINES)
5 : BACKHOE VALVE BLOCK

5A : HYDRO-CLAMP VALVE
5B : MAKE-UP CHECK VALVE
HYDRO-CLAMP ASSY.
02
HYDRAULIC
SERVICE 55
SIDE SHIFT VALVE – HOSE & PIPES (ISO PATTERN)
1 SERVICE PORT, BOOM RAM, HEAD SIDE

2 SERVICE PORT,BUCKET CROWD RAM, HEAD SIDE
3 SERVICE PORT, STABILIZER, LEFT SIDE, ROD SIDE
4 SERVICE PORT, STABILIZER, RIGHT SIDE, ROD SIDE
5 SERVICE PORT, SLEWING, HEAD SIDE OF RIGHT RAM,
ROD SIDE OF LEFT RAM
6 SERVICE PORT, DIPPER RAM, ROD SIDE
7 SERVICE PORT, BOOM RAM, ROD SIDE
8 SERVICE PORT, BUCKET CROWD RAM, ROD SIDE
9 SERVICE PORT, STABILIZER,LEFT SIDE, HEAD SIDE
10 SERVICE PORT, STABILIZER, RIGHT SIDE, HEAD SIDE
11 SERVICE PORT , SLEWING, ROD SIDE OF RIGHT RAM,
HEAD SIDE OF LEFT RAM
12 SERVICE PORT, DIPPER RAM, HEAD SIDE
02
56 HYDRAULIC
SERVICE
HYDRAULIC TANK
2 TANK
3 HYDRAULIC RETURN FILTER ASSEMBLY
3A ELEMENT, RETURN FILTER
3B CLOGGING & CONTAMINATION INDICATOR
7 FILLER CAP
8 TEMPERATURE& OIL LEVEL INDICATOR
9 SUCTION STRAINER
13 DRANING PLUG
02
HYDRAULIC
SERVICE 57
DESCRIPTION
Hydraulic tank stores hydraulic fluid. There is a special valve in the filler cap 7
mounted on tank that forms a 0.3 bar inlet pressure in the tank to improve pump
suction. The suction strainer in the tank 9 is 90 micron type. The return filter element
fitted on the return line of the tank is 10 micron type.
When the return line filter is clogged, we can only determine it by looking at its
contamination indicator. The by-pass pressure rate of the return line filter is 2 bar.
MAINTENANCE
Hydraulic system oil change interval: 1000 operating hours
Suction strainer flushing interval:1000 operating hours.
Return line filter element change interval: first at 100 operating hours, Then at every
500 operating hours.
NOTE:
If suction strainer is found to be damaged, immediately replace it with a new one.
DIMENSIONS
LOADER RAMS
Diameter Ø mm Stroke mm
LOADER LIFT 90 725
SHOVEL 80 735
SHOVEL CLAM 80 255
EXCAVATOR RAMS
SLEW 115 203
BOOM 115 985
DIPPER 100 820
BUCKET CROWD 90 725
EXTRADIG DIPPER 70 1228
02
58 HYDRAULIC
SERVICE
PRIORITY VALVE
TOOLS
1. Open end spanner

2. Nylon pin
3. Hexagon socket spanner
insert 8 mm
4. Torque wrench
5. Socket spanner 22 mm
6. Allen key 8mm
02
HYDRAULIC
SERVICE 59
1. Screw out the pp plug using the

8mm allen key.
Remove the seal ring.(alu.)
2. Loosen the is plug using the 22 mm

open-end spanner
3. Pull out the plug with seal ring (alu.) and

spring
02
60 HYDRAULIC
SERVICE
4. Press out spool using the nylon pin.
5. Dismantled OLS 80
02
HYDRAULIC
SERVICE 61
REASSEMBLY
6. Guide the spool into bore.

Use the nylon pin to centre the spool in the
bore.
7. Put in the PP plug. Remember the seal ring.
8. Guide the spring and LS plug

into the bore. Remember the seal ring.
02
62 HYDRAULIC
SERVICE
9. Tighten the LS-plug with torque wrench using

a 22 socket spanner insert.
10. Tighten the PP plug with a torque wrench

using a 8 mm hexagon socket spanner insert.
Tightening torque: 5+-1 daNm

(442 lbf in ± 88 lbf in)
11. The OLS 80 is now reassembled.

02
HYDRAULIC
SERVICE 63
EXPLODED VIEW OLS 80
1. INTERNAL PP-PLUG
2. O-RING
3. ORIFICE SCREW
5. SPOOL
6. HOUSING
7. SPRING(7 BAR)*
8. INTERNAL LS –PLUG
9. NAME PLATE
10. DRİVE SCREW
02
64 HYDRAULIC
SERVICE
VIEW WITH ADAPTERS
1. PRIORITY VALVE ASSEMBLY

2. PRIORITY VALVE
3. WASHER
4. ADAPTER-S
5. ADAPTER -S
6. WASHER
7. ADAPTER
8. ADAPTER -S
02
HYDRAULIC
SERVICE 65
OPERATING INSTRUCTIONS FOR CAST IRON TYPE

HYDRAULIC GEAR PUMP
1. BEFORE ASSEMBLY OF THE NEW PUMP YOU HAVE TO FOLLOW BELOW

PROCEDURE
a) Discharge hydraulic tank hydraulic oil, main hoses and its connections. As little
and harmful metal particles which comes from old pump can have got into in
your hydraulic components and it causes big problem for your system. Therefore
you must clean it carefully.
b) Disassemble to the valves which are out of order previously in your hydraulic
system. And then check these valves. İf necessary repair it.
c) Discharge all hydraulic oil which is used by hydraulic components from whole
system,
d) Renew connection and old hydraulic hoses in your system. Especially renew
suction hydraulic hoses which lost quality. In order to succeed that touch it and
check to the softness of the hose.
e) Before assembly of the gear pump to the machine you must open to the
pressure relief valve, valve groups. And check to the spring and spool holes.
Renew conic elements spool and faulty or break spring.
f) Adjust set pressure of the pump pressure relief valve to the zero position.
g) Throw out of the old filter which is used in pressure line, suction line and return
line of the system. And then you must use new filter which is suggested by
machine manufacturer .These new filters must have original filtering degree.
h) Disassemble of the suction line strainer and clean it. During this cleaning
operation if necessary disassemble of the connection hoses and then clean and
dry to the tank entirely.
i) Connect to the clean connection hoses and pipe connections. Close valve of the
tank and fill up with proper hydraulic oil till maximum level of the indicator on the
tank.
j) Check drive shaft and coupling which is in the motor and gearbox. Broken or out
of order shafts must be changed. Otherwise pump gears, parallel shaft spline
and shaft bearings can be damaged easily.
02
66 HYDRAULIC
SERVICE
ASSEMBLY OF THE PUMP TO THE MACHINE
a) Install pump shaft to the setting place. Mounting flange must be seat to the
assembling place where on the drive shaft hole. And then mounting flange
connection bolts and nuts must be tightened. These bolts and nuts must have
8.8 quality. Last tightening process must be done with torque-meter. Using
torque-meter equalize axial load on every bolts.
b) Fill up to the suction hoses with hydraulic oil and connect to the suction port
flange with bolts. Hose flange or coupling O-ring must be installed properly.
c) Check pressure line hoses, O- ring and these hoses must be tightened to the
pressure line of the pump. Especially in multiple pumps connection of the
pressure line hoses must be checked. As pressure line hoses can be tightened
wrong pump.
MOST IMPORTANT; Disassemble hoses must be checked because some piece of

clothes can got into disassemble hoses .Therefore these hoses must be checked
manually
d) After completing to the hoses connections and checking to the valve. Tank
valves must be opened and decreasing of the oil level must be observed and
completed.
e) Suction port flange bolts must be loosened slightly. Till hydraulic oil appears .As
soon as hydraulic oil appears these bolts must be tightened again. These
process must be made perfectly. As while operating of the system .Pump musn’t
be sucked air for any reason
3-START UP TO THE HYDRAULIC GEAR PUMP

a) Before starting up to the machine while all valves in neutral position. Revolve
shaft one or more revolution finally start up to the motor which operates to the
pump on neutral and unloading position
b) During operating of the motor. You must listen to the hydraulic equipments and
region where the pump is in .In addition to this new pump must start up
between 10 and 15 minutes
c) During this 10-15 minutes hydraulic oil level in the tank hydraulic hoses must be
checked due to leakage of from hydraulic hoses
02
HYDRAULIC
SERVICE 67
ASSEMBLY OF THE PUMP TO THE MACHINE (cont’d)
d) During above procedure if you didn’t any improper function. Pressure relief
valve of the pump must be adjusted from hydraulic diagram During start up of
the hydraulic equipments (motor,pump,lift etc ) you must not adjust pressure
relief valve because;
e) Pressure relief valve operates when hydraulic components comes to at the end
of the stroke.
f) After you adjust to the pressure relief valve .if your hydraulic circuit contains
shock valve you must adjust shock valve .Shock valve set pressure always set
to the over % 15 of the operating pressure of the system.
g) Check oil level of the hydraulic equipments,
h) Adjust to the level of hydraulic oil in the tank while maximum hydraulic oil out of
the tank
i) Check temperature indicator on the tank .Temperature must not pass to the
85 C. During initial start up of the pump you must check that pump frequently in
first 5 hours manually,
j) If you observe overheated in your system you must check radiator absolutely
your radiator may have dirt .If your radiator contains fan ,Fan motor maybe
breakdown,
k) You don’t start up new pumps on overheated and over operating pressure
Otherwise you faced with some problems like that fire, cutting shaft, bearing
failure and body crack,
4 . In order to do not faced with any problem you must obey to the periodic care
rules which are given to you by machine manufacturer. If you don’t have you must
follow these procedure,
a) You must check hydraulic oil leakage ,hydraulic oil level and dirty-ness condition
of the system once every 50 hours ,
b) You must check hydraulic filters and oil level in the tank once every 250 hours,
c) Renew hydraulic filters once 500 hours ,

d) Change hydraulic oil once 1500-2000 hours. During changing operation of the
hydraulic oil from the tank. Check air ventilation of the tank and Check tightening
of the connection bolts and nuts to the pump
e) You must make maintenance of your hydraulic gear pump every 600 hours,
02
68 HYDRAULIC
SERVICE
PUMP VIEW
03
HYDRAULIC
BRAKE SYSTEM 1
GENERAL INFORMATIONS
OIL TYPE : ISO VG 46 HVI
OIL CHANGE INTERVAL : Every 1000 hours
BRAKE PUMP CAPACITY : 4 cc / rev
MAX ALLOWED ON-BRAKE PRES. : 90 bar
CUT-IN / CUT-OUT PRESSURE

SINGLE BRAKE PEDAL : 50/60 bar
DOUBLE BRAKE PEDAL : 130/155 bar
“WARNING LIGHT ON” PRESSURE

SINGLE BRAKE PEDAL : 25 bar
DOUBLE BRAKE PEDAL : 70 bar
BRAKE LIGHT ON (4x4 CUT-IN) PRESSURE : 3 – 5 bar
ACUMULATOR CHARGING PRESSURE

SINGLE BRAKE PEDAL : 16 bar
DOUBLE BRAKE PEDAL : 45 bar
03
2 HYDRAULIC
BRAKE SYSTEM
ACCUMULATOR & CHARGING VALVE
Single or double brake system main operation principal:
Brake pump suction hydraulic oil is from the hydraulic oil tank.
Accumulator charges and keeps hydraulic pressure for braking while the engine is
stopped.
In case of emergency, it is possible to brake.

03
HYDRAULIC
BRAKE SYSTEM 3
SINGLE PEDAL BRAKE
NEUTRAL CIRCUIT
25 BARS
3-5 BARS
ACUMULATOR CHARGING
25 BARS
3-5 BARS
03
4 HYDRAULIC
BRAKE SYSTEM
SINGLE PEDAL BRAKE
PRESSURE NEARLY 60 BARS
25 BARS
3-5 BARS
PRESSURE ABOVE 60 BARS
25 BARS
3-5 BARS
03
HYDRAULIC
BRAKE SYSTEM 5
SINGLE PEDAL BRAKE
25 BARS
3-5 BARS
25 BARS
3-5 BARS
03
6 HYDRAULIC
BRAKE SYSTEM
BRAKE PEDAL VALVE
ACCUMULATOR CHARGING VALVE
N
P
03
HYDRAULIC
BRAKE SYSTEM 7
DOUBLE BRAKE SYSTEM
Double brake system acts as to break separately to the left or right rear axle hub of
the machine.
03
8 HYDRAULIC
BRAKE SYSTEM
DOUBLE BRAKE SYSTEM
NETURAL CIRCUIT
70 BARS
3-5 BARS
PRESSURE NEARLY 90 BARS
70 BARS
3-5 BARS
03
HYDRAULIC
BRAKE SYSTEM 9
DOUBLE BRAKE SYSTEM
70 BARS
3-5 BARS
PRESSURE ABOVE 90 BARS APPLIED

ON RIGHT PEDAL
70 BARS
3-5 BARS
03
10 HYDRAULIC
BRAKE SYSTEM
BRAKE PISTON & DISCS
PARKING BRAKE
01
CHASSIS
TRANSMISSION 1
ITL PS 760
UNIT IDENTIFICATION
Powershift serial plate
The powershift serial number is stamped on a plate which is mounted to the rear of
the unit as shown.
1. When replacement parts are required,
always ensure that the correct parts are
obtained. e.g. in the case of gear
replacements, always check the part
number stamped on the gear and the
number of teeth.
2. When ordering replacement parts, quote

the details on the serial plate shown.
3. It is essential that all gaskets and seals

removed while dismantling, should be
renewed on reassembly.
4. On reassembly care should be taken

that all parts are correctly replaced since
any component omitted or incorrectly
assembled can lead to a complete failure.
5. Lubricants should comply with the

recommended list as provided in this
manual. It is important to adhere to the
oil changing procedure.
6. It is advisable to lightly lubricate with a recommended lubricant, parts such as

gears, shafts, thrust washers and oil seals during reassembly.
01
2 CHASSIS
TRANSMISSION
Torque settings
Use only where no torque setting is specified in the text. Values are for dry threads
and may be within three per cent of the figures stated. For lubricated threads the
values should be REDUCED by one third.
Note : All bolts used on Powershift gearboxes are high tensile and must not be
replaced by bolts of lesser tensile.
01
CHASSIS
TRANSMISSION 3
Service tools
01
4 CHASSIS
TRANSMISSION
01
CHASSIS
TRANSMISSION 5
01
6 CHASSIS
TRANSMISSION
Powershift gearbox support plates for use with hydraulic jack. Plates should be
locally manufactured from 5 mm thick mild steel plate
01
CHASSIS
TRANSMISSION 7
Powershift assembly Cradle

Note: Support legs will also be required. These must be locally manufactured so that
the gearbox can be supported as shown at A.
01
8 CHASSIS
TRANSMISSION
Powershift gearbox – hydraulic pump removal tools

The tools detailed below enable the pump to be removed with the torque onverter
housing in place.
1 : Reaction bar. Locally manufacture from mild steel bar. Drill the 2 holes through
the bar as shown.
2 : Two of lengths of M10 x 1,5 threaded rod 250 mm (10 in) long.
3 : Two of M10 x 1,5 nuts.
A set of M10 x 1,5 taps will also be required.

01
CHASSIS
TRANSMISSION 9
Torque converter alignement tool
(For 12” and W300 torque converters)

01
10 CHASSIS
TRANSMISSION
01
CHASSIS
TRANSMISSION 11
Sealing and Retaining Compounds
A medium strength sealant suitable for all sizes of gasket

Loctite 574
flanges and for hydraulic fittings of 25-65 mm diameter.
For all sizes of flange where the strength of the joint is
Loctite 275
important.
Loctite 932 For all retaining parts which are likely to be dismantled.
A medium strength locking fluid foe sealing and retaining nuts,
Loctite 242 bolts and screws up to 50 mm diameter, and for hydraulic
fittings up to 25 mm diameter.
A medium strength fluid similar to Loctite 242 but with greater
Loctite 243
resistance to thread contamination.
Loctite 648 For retaining parts which are unlikely to be dismantled.
Loctite 577 A medium strength thread sealing compound.
A clearing primer which speeds the curing rate of anaerobic
Loctite Activator
products.
Cleaner / For degreasing components prior to use of anaerobic adhesives
Degreaser and sealants.
Loctite 509 Flange sealant, medium strength
Note : The above list is the range of Sealants and Retaining Compounds available.
Lubricants & Capacities
INTENATIONAL
ITEM CAPACITY LUBRICANT
SPECIFICATION
15,5 lt dry TO4, Q8 EL4117 SAE 10W
Powershift 4 speed
11,0 lt wet Q8 EL 4118 SAE 30
Note: The figure quoted is TOTAL system capacity and only intended as a guide.
Use the MIN and MAX marks on the dipstick when filling the system. Use the dipstick
on all occasions when filling.
Note: EL4117 (SAE 10W)- This product is for use in Transmissions where the
ambient temperature range is -32 0C to 40 0C
EL4118 (SAE 30)- This product is for use in Transmissions where the ambient
temperature range is -5 0C to 46 0C
01
12 CHASSIS
TRANSMISSION
01
CHASSIS
TRANSMISSION 13
01
14 CHASSIS
TRANSMISSION
01
CHASSIS
TRANSMISSION 15
01
16 CHASSIS
TRANSMISSION
01
CHASSIS
TRANSMISSION 17
01
18 CHASSIS
TRANSMISSION
01
CHASSIS
TRANSMISSION 19
01
20 CHASSIS
TRANSMISSION
Hydraulic and Electrical Operation

01
CHASSIS
TRANSMISSION 21
01
22 CHASSIS
TRANSMISSION
01
CHASSIS 23
TRANSMISSION
01
24 CHASSIS
TRANSMISSION
Drive paths 4 speed FORWARD

01
CHASSIS
TRANSMISSION 25
Powershift Gearbox
Drivepaths 4 speed REVERSE
01
26 CHASSIS
TRANSMISSION
Drivepaths 4 speed REVERSE

01
CHASSIS
TRANSMISSION 27
01
28 CHASSIS
TRANSMISSION
Clutch Operation FORWARD , REVERSE
01
CHASSIS
TRANSMISSION 29
01
30 CHASSIS
TRANSMISSION
01
CHASSIS
TRANSMISSION 31
Torque Converter
01
32 CHASSIS
TRANSMISSION
TROUBLE SHOOTING
01
CHASSIS
TRANSMISSION 33
01
34 CHASSIS
TRANSMISSION
01
CHASSIS
TRANSMISSION 35
01
36 CHASSIS
TRANSMISSION
01
CHASSIS
TRANSMISSION 37
01
38 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 1
ITL PS 760
TEST PROCEDURES
02
2 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 3
02
4 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 5
02
6 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 7
02
8 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 9
02
10 CHASSIS
TRANSMISSION
02
CHASSIS 11
TRANSMISSION
02
12 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 13
02
14 CHASSIS
TRANSMISSION
02
CHASSIS 15
TRANSMISSION
02
16 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 17
HAND BRAKE
02
18 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 19
02
20 CHASSIS
TRANSMISSION
COLUMN CONTROL LEVER

PS760 gearbox speed selector is manually selectable foe each of the 4 gears.
02
CHASSIS
TRANSMISSION 21
02
22 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 23
02
24 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 25
02
26 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 27
02
28 CHASSIS
TRANSMISSION
THIS PAGE IS
INTENTIONNALLY LEFT BLANK

02
CHASSIS
TRANSMISSION 29
REMOVAL AND REPLACEMENT

02
30 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 31
02
32 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 33
02
34 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 35
02
36 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 37
02
38 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 39
02
40 CHASSIS
TRANSMISSION
INSPECTION
02
CHASSIS
TRANSMISSION 41
02
42 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 43
02
44 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 45
02
46 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 47
02
48 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 49
02
50 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 51
02
52
CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 53
02
54 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 55
02
56 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 57
02
58 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 59
02
60 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 61
02
62 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 63
02
64 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 65
02
66 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 67
02
68 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 69
02
70 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 71
02
72 CHASSIS
TRANSMISSION
02
CHASSIS
TRANSMISSION 73
02
74 CHASSIS
TRANSMISSION
01
CHASSIS
AXLES 1
01
2 CHASSIS
AXLES
01
CHASSIS
AXLES 3
01
4 CHASSIS
AXLES
01
CHASSIS
AXLES 5
01
6 CHASSIS
AXLES
01
CHASSIS
AXLES 7
01
8 CHASSIS
AXLES
01
CHASSIS
AXLES 9
01
10
CHASSIS
AXLES
TECHNICAL DATA
STEERING (SD55 FRONT AXLE)
RELIEF VALVE PRESSURE AT 1500 rpm
SHOCK VALVE PRESSURE
STEERING CYLINDER SIZE
BORE Diameter Ø 70 mm (2,75 in)

ROD Diameter Ø 30 mm (1,18 in)
TORQUE SETTINGS
PISTON HEAD 405 Nm 41 kgf.m 300 lbf.ft

END CAP 678 Nm 69 kgf.m 500 lbf.ft
NOTE: the above data refers to HİDROMEK steering cylinders. Please check the
type of steering cylinder that is fitted on your machine before any operation to apply.
01
CHASSIS 11
AXLES
01
12
CHASSIS
AXLES
01
CHASSIS 13
AXLES
01
14 CHASSIS
AXLES
Steering System – Bleeding

Procedure
1
Whenever any hydraulic steering
component is disconnected or
removed the system must be
bled in accordance with the
below given procedure.
NOTE: This procedure must be

carried out in the correct order
that is pre-determined with the
engine running. You must not
change the order of operations.
1. Start the engine.

2. Lower the stabilizers fully.
3. Lower the loader attachment
and press
2
the shovel to the ground to
lift the
machine up.
4. Turn the steering wheel to left
3
fully.
5. Turn the steering wheel to
right fully.
Please repeat to turn the steering

wheel to left and right
sequencely for 10 times.
5 4
The air blocked in the cylinder
will be released to tank after this
procedure is carried out.
01
CHASSIS
AXLES 15
SD55 / ST AXLE
TYPE Spiral bevel input with epicyclic hub reduction
DESIGNATION SD55 / ST AXLE
INTALLATION CENTRE PIVOT
NO. OF STEER
1
CYLINDER
WEIGTH (Dry, no steer
330 kg (728 lbs) approximately
cylinder & wheels)
RATIOS
OVERALL 16,2 : 1
CROWNWHEEL & PINION 3:1
NO. OF TEETH
CROWNWHEEL 33
PINION 11
HUB REDUCTION 5,4 : 1
INPUT TYPE YOKE
TOE-IN 00
CASTOR ANGLE 00
CAMBER ANGLE 10
KINGPIN INCLINATION 00
01
16 CHASSIS
AXLES
SD55 / ST AXLE – OFFSET DRIVE HEAD (STEER CYLINDER NOT SHOWN)
01
CHASSIS 17
AXLES
01
18 CHASSIS
AXLES
REMOVAL & REPLACEMENT
BOTTOM VIEW
01
CHASSIS
AXLES 19
Pay extra attention to re-install pivot

pin retaining bolt F and Nylock nut E to
their correct locations, respectively.
Always install a new Nylock nut E. Do
not fit the Nylock nut that was removed
before.
01
20 CHASSIS
AXLES
01
CHASSIS 21
AXLES
01
22 CHASSIS
AXLES
DRIVE HEAD – ASSEMBLY (cont’d))
01
CHASSIS 23
AXLES
01
24 CHASSIS
AXLES
01
CHASSIS
AXLES 25
01
26 CHASSIS
AXLES
AXLE HUB & DRIVESHAFT - DISMANTLING
01
CHASSIS
AXLES 27
01
28 CHASSIS
AXLES
AXLE HUB & DRIVE SHAFT - ASSEMBLY
01
CHASSIS 29
AXLES
01
30 CHASSIS
AXLES
01
CHASSIS
AXLES 31
PD70 / PT AXLE CENRAL DRIVE HEAD (INBOARD BRAKES)
3 pieces, spiral bevel input with epicyclic hub

TYPE
reduction & inboard brakes.
DESIGNATION PD 70 AXLE
INTALLATION RIGID PAD MOUNT
NO. OF STEER CYLINDER 1 (DOUBLE ROD)
WEIGTH (Dry & without

wheels)
HALF (AXLE) SHAFT

5 FRICTION PLATE, 6 COUNTER PLATE (EACH
BRAKING / TYPE
HALF SHAFT)
INPUT TYPE YOKE
OSCILLATION (PIN OR
± 50
TRINNION MOUNT)
RATIOS OVERALL 15.78 : 1
NUMBER OF TEETH
CROWNWHEL 38
PINION 13
01
32 CHASSIS
AXLES
CUT A WAY OF AXLE (CENTRAL DRIVE HEAD)
01
CHASSIS
AXLES 33
CUT A WAY OF AXLE CENTRAL CASING
01
34 CHASSIS
AXLES
CUT A WAY OF AXLE ARM
01
CHASSIS
AXLES 35
REMOVAL & REPLACEMENT
01
36 CHASSIS
AXLES
01
CHASSIS
AXLES 37
01
38 CHASSIS
AXLES
01
CHASSIS
AXLES 39
01
40 CHASSIS
AXLES
01
CHASSIS
AXLES 41
01
42 CHASSIS
AXLES
01
CHASSIS
AXLES 43
01
44 CHASSIS
AXLES
01
CHASSIS
AXLES 45
01
46 CHASSIS
AXLES
01
CHASSIS
AXLES 47
01
48 CHASSIS
AXLES
01
CHASSIS
AXLES 49
01
50 CHASSIS
AXLES
01
CHASSIS
AXLES 51
01
52 CHASSIS
AXLES
SD 80 AXLE
01
CHASSIS
AXLES 53
01
54 CHASSIS
AXLES
TECHNICAL DATA
STEERING (SD55 FRONT AXLE)
RELIEF VALVE PRESSURE AT 1500 rpm
SHOCK VALVE PRESSURE
STEERING CYLINDER SIZE
BORE Diameter Ø 90 mm (3,54 in)

ROD Diameter Ø 50 mm (1,96 in)
NOTE: the above data refers to HİDROMEK steering cylinders. Please check the
type of steering cylinder that is fitted on your machine before any operation to apply.
01
CHASSIS
AXLES 55
01
56 CHASSIS
AXLES
LINK ARMS Removal & Replacement

01
CHASSIS
AXLES 57
01
58 CHASSIS
AXLES
CYLINDER Dismantling & Assembly
01
CHASSIS
AXLES 59
01
60 CHASSIS
AXLES
Steering System – Bleeding Procedure
Whenever any hydraulic steering

component is disconnected or removed
the system must be bled in accordance
with the below given procedure.
NOTE: This procedure must be carried

out in the correct order that is pre-
determined with the engine running and
the machine raised up by lowering
loader attachment of which shovel
should be pressed to the ground and
pushing the stabilizers to the ground
fully as well.
The air blocked in the cylinders will be

released to tank after this procedure is
carried out.
1 Select 2 Wheel Steer
(a) Turn steering wheel to left,

1
until front wheels are fully locked
to left.
(b) Turn steering wheel to right,
until front wheels are fully locked
to right.
a b
01
CHASSIS
AXLES 61

a
(a) Turn steering
wheel to left, until
2
front wheels are
fully locked to left.

a
(a) Turn steering
wheel to full right
limit.
3
(b) Turn steering
wheel to full left
c
limit.
(c) Turn steering
wheel to full right b
limit.
wheel to
Select 4 Wheel Steer
(a) Turn steering
left, until
4 a
front wheels are

(a) Turn steering
wheel to full right limit.
5 a
(b) Turn steering
wheel to full left
limit.
(c) Turn steering
b c
wheel to full right limit.
01
62 CHASSIS
AXLES

a
(a) Turn steering
front wheels are
6
7
Steer
Select 2 Wheel
7 a
(a) Turn steering
wheel to full right
limit.
(b) Turn steering
b c
wheel to full left
limit.
(c) Turn steering
wheel to full right
limit.
8
Steer
Select 4 Wheel
8 a
(a) Turn steering
front and rear
wheels are fully
locked.
01
CHASSIS
AXLES 63
1
THE REMAINING AIR IN THE STEERING SYSTEM
MAY CAUSE THE BLOCKAGE OF THE STEERING
SYSTEM. Below given operations should be done in
order to release the air blocked in the system:
(1) Select 2 Wheel Steer (Position 2 on the instru-

ment panel in the operator cabin). When a thin
piece of metal B like a feeler gauge etc. is
placed in front of the proximity switch A of
rear axle, rear steering is blocked. Turn steer-
ing wheel to left and right, until front wheels
are fully locked.
(2) Select 4 Wheel Steer (Position 1 on the instru-

ment panel in the operator cabin). Place a thin
piece of metal B like a feeler gauge etc. in
front of the proximity switch A of front axle.
Front steering will be blocked. Turn steering
wheel to left and right, until rear wheels are
locked fully.
Repeat this procedure until the

steering system is free of air.
After the steering system is bled;

- Select 2 Wheel Steer
(Position 2 on the instrument
panel in the operator cabin).
- Bring the wheels to
straight ahead driving
position by turning the steering
wheel. Rear
axle steering system should
be blocked in
straight forward drive position
after this operation. The
middle of proximity switch
of rear axle steering should stay in
line with
the target disc exactly.
01
64 CHASSIS
AXLES
01
CHASSIS
AXLES 65
SD80 AXLE CENTRAL DRIVEHEADS (INBOARD BRAKES)
3 pieces, spiral bevel input with epicyclic hub

TYPE
reduction & inboard brakes.
DESIGNATION SD 80 AXLE
INTALLATION RIGID PAD MOUNT
NO. OF STEER CYLINDER 1 (DOUBLE ROD)
WEIGTH (Dry & without

wheels)
HALF (AXLE) SHAFT

5 FRICTION PLATE, 6 COUNTER PLATE (EACH
BRAKING / TYPE
HALF SHAFT)
INPUT TYPE YOKE
OSCILLATION ± 50
KINGPIN INCLINATION 00
TOE-IN 00
CASTOR ANGLE 00
CAMBER ANGLE 10
RATIOS
OVERALL 15.78 : 1
CROWNWHEEL & PINION 2,923 : 1
NUMBER OF TEETH
CROWNWHEL 38
PINION 13
01
66 CHASSIS
AXLES
CUTAWAY OF SD80 AXLE
01
CHASSIS
AXLES 67
OFFSET DRIVE HEAD Removal & Replacement

01
68 CHASSIS
AXLES
01
CHASSIS
AXLES 69
Pay extra attention to re-install pivot pin

retaining bolt A and Nylock nut to their
correct locations, respectively. Always
install a new Nylock nut. Do not fit the
Nylock nut that was removed before.
01
70 CHASSIS
AXLES
PROXIMITY SWITCH SETTING
PROCEDURE
When fitted, the proximity switch setting

procedure
is the same for both off-set (front)
and central
(rear) drive head axles.
The illustration shows a central drive head

axle.
- Park the machine on a level

ground.
- Lift the machine sufficient enough
the raise the wheels off the ground.
- Perform the Steering System

Bleeding Procedure if any steering
cylinder is dismantled for servicing
before.
- Align the wheels in the straight
ahead position. Check if straight
ahead by measuring X and Y at the
given illustration. The
measurement X should be equal to
the measurement Y. See Link Arms
Removal and Replacement,
Section:Replacement for correct
wheel alignment on page E5-16.
- Remove the proximity switch cover

C.
- Loosen the bracket fixing bolts E
and slide the assembly just in line
with the target disc A for lateral
adjustment.
- With the starter switch on, loosen

the proximity switch lock nut D.
Make sure the light emitting diode
(L.E.D.) is not illuminated (if it is so
then screw the proximity switch
out). Now, screw the proximity
switch towards the target disc A
until the light emitting diode
(L.E.D.) on the proximity switch
illuminates. Add a further 1 to 1,5
turns. Tighten the locknut.
NOTE: Take care not to overtighten the

locknuts. Otherwise, the threads on
the proximity switch may be
damaged.
8 Refit the proximity switch cover C.

01
CHASSIS
AXLES 71
01
72 CHASSIS
AXLES
01
CHASSIS
AXLES 73
01
74 CHASSIS
AXLES
01
CHASSIS
AXLES 75
01
76 CHASSIS
AXLES
01
CHASSIS
AXLES 77
01
78 CHASSIS
AXLES
01
CHASSIS
AXLES 79
OFFSET DRIVE HEAD - DISMANTLING
01
80 CHASSIS
AXLES
01
CHASSIS
AXLES 81
01
82 CHASSIS
AXLES
DRIVE HEAD – ASSEMBLY (cont’d )

01
CHASSIS
AXLES 83
01
84 CHASSIS
AXLES
01
CHASSIS
AXLES 85
01
86 CHASSIS
AXLES
01
CHASSIS
AXLES 87
PROXIMITY SWITCH SETTING PROCEDURE
The proximity switch setting procedure for the

Central Drive Head axles (rear) is identical to the
Off-set Drive Head (front). Please refer to
PROXIMITY SWITCH SETTING PROCEDURE
.
PROPSHAFTS
REMOVAL and REPLACEMENT
The removal and replacement propshafts of the Central

Drive Head axles (rear) is identical to the Off-set Drive
Head (front). Please, refer to PROPSHAFTS
REMOVAL and REPLACEMENT
HUB and DRIVESHAFT-
DISMANTLING and ASSEMBLY
Dismantling and assembly of the Central Drive Head axle

(Rear) hub and driveshaft is the same as for the Off-set
Drive Head axle (Front) hub and driveshaft.
01
88 CHASSIS
AXLES
The procedure for renewing the Central

Drive Head axle (Rear) pinion oil seal is the
same as for the Off-set Drive Head axle
(Front) pinion oil seal. Please, refer to
pages E5-33 and E5-34 for a complete
description of the procedure.
01
CHASSIS
AXLES 89
01
90 CHASSIS
AXLES
01
CHASSIS
AXLES 91
01
92 CHASSIS
AXLES
01
CHASSIS
AXLES 93
01
94 CHASSIS
AXLES
01
CHASSIS
AXLES 95
01
96 CHASSIS
AXLES
01
CHASSIS
TRANSMISSION 1
CARRARO
GENERAL SPECIFICATIONS
The transmission is a component that transmits the power from the engine to the
wheels with an assigned transmission ratio.
PRODUCT IDENTIFICATION PLATE

01
2 CHASSIS
TRANSMISSION
TECHNICAL SPECIFICATIONS
Code : CA643171
Model : TLB2 UP/CD-4WD
DESCRIPTION Values
Dry weight 248 kg
Speed n0 4
Forward Transmission ratio
1st speed 5.533
2nd speed 3.360
3rd speed 1.532
4th speed 0.810
Reverse Transmission ratio
1st speed 5.533
2nd speed 3.360
3rd speed 1.532
4th speed 0.810
Max engine power 81 kW at 2200 rpm
Max input speed to transmission 3000 rpm
Torque Converter type W 300 SACHS
Converter stall torque ratio 3.01
Oil capacity (without converter & cooler) 13 liters
Oil specification ATF Dexron II-D & Dexron III
Suction oil filter capacity 250 µm
Delivery oil filter capacity & type 10 µm – AGV BETA 2.2
Engine flange type SAE 3
Front & rear output flange type END YOKE 1410
PTO flange type SAE C 127-2 BOLT
Rear PTO/ Front PTO ratio 1.044
01
CHASSIS
TRANSMISSION 3
DIMENSIONS
Rear view
01
4 CHASSIS
TRANSMISSION
DIMENSIONS
Left side view

01
CHASSIS
TRANSMISSION 5
MAIN POINTS NOMENCLATURE
FRONT VIEW
1: Spin-on filter (10 µm)
2: Oil pump group

(Acceptance criteria on bench
test:
19 lt/min pump flow
at 900 rpm measure before
spin-on filter)
22: Pipe oil fill interface and

dipstick fitting hole
RIGHT SIDE VIEW
5: Breather plug
6: Oil thermostat
(115 ± 3 0C)
7: Oil inlet port from cooler
13: Magnetic oil drain plug

(SW ½” )
18: Boom lock oil return
19: Boom lock oil pressure

port (14.0 ÷ 17.0 bar)
(measure at 900÷2200 engine rpm
with oil temperature 80 0C)
20: Brakes oil pressure port

(14.0 ÷ 17.0 bar)
21: Oil out/inlet port to

hydraulic differential lock
(14.0 ÷ 17.0 bar)
01
6 CHASSIS
TRANSMISSION
MAIN POINTS NOMENCLATURE (cont’d)
REAR VIEW
25: ON / OFF solenoid valve
26: FWD / RVS proportional

pressure reducing valves
27: Pressure sensor

(setting value
9 ÷ 11bar)
LEFT SIDE VIEW
3: Torque converter SACHS

W300
4: SAE 3 torque converter

housing
9: Torque converter inlet

pressure check port
(3.0 ÷ 9.0 bar)
12: Suction filter (250 µm)
17: Brakes oil return

01
CHASSIS
TRANSMISSION 7
MAIN POINTS NOMENCLATURE (cont’d)
TOP VIEW
8: Oil outlet port to cooler
10: FWD clutch pressure check point (13.5 ÷ 16.5 bar)

max pressure in NEUTRAL (0.3 bar)
(measure at 900÷2200 engine rpm with oil temperature 80 0C)
11: RVS clutch pressure check point (13.5 ÷ 16.5 bar)

max pressure in NEUTRAL (0.3 bar)
(measure at 900÷2200 engine rpm with oil temperature 80 0C)
15: Holes eyebolt threads for lifting
16: Lubrication pressure check port (from cooler) oil outlet port to brake tank
23: Control valve supply pressure check port (14.0 ÷ 17.0 bar)
24: Gears pressure check port (13.5 ÷ 16.5 bar)

01
8 CHASSIS
TRANSMISSION
FILLING AND CHECKS
The oil quantity for the correct operation of the transmission is obtained by combining
one volume check and level check.
Correct determination of oil on the machine (first filling)
Carry out the following instructions:

 Fill the transmission with a measured volume W of oil, about 19,5 liters.
 Apply the parking brake.
 Keep the shuttle shaft control in the NEUTRAL position.
 Start the engine by keeping the slow running of 800 ÷ 1000 rpm for about one
minute.
 Stop the engine.
 Drain the oil from the transmission by unscrewing the oil drain plug. Let drip for
some minutes.
 Measure the oil
discharged quantity Z
liters.
 Calculate the X
quantity of oil to fill the
first installation where
X = W – Z liters.
 Screw again oil drain
plug.
 Fill the transmission
with the oil volume
suggested of 13 liters.
 Start the engine by
keeping the slow
running of 800 ÷ 1000
rpm until an oil
temperature higher
than 25 0C is obtained.
 Check that the
transmission oil level is
230 mm from the
transmission inlet axis.
 If necessary, top up
with oil to keep to the
previous reference
value.
01
CHASSIS
TRANSMISSION 9
Scheduled maintenance filling
Carry out the following instructions:
 Fill the transmission with a volume of oil of about 13 liters.

 Apply the parking brake.
 Keep the shuttle shaft control in NEUTRAL range.
 Start the engine by keeping the slow running of 800 ÷ 1000 rpm until an oil
temperature higher than 25 0C is obtained.
 Check that the transmission oil level is 230 mm from the transmission inlet
axis.
 If necessary, top up with oil to keep to the previous reference value.
1: Pipe oil fill interface and dipstick fitting hole
2: Oil drain port
3: Breather
01
10 CHASSIS
TRANSMISSION
SERVICE SCHEDULE
Specified lubrication intervals are for standard-duty use.

Severe operating conditions require shorter intervals.
Maintenance
Ordinary First
Operation performing
maintenance maintenance
personnel
Seasonally or every Initial 100
Only trained
Oil changing 1000 hours of hours of
personnel
operation (1) operation
Only trained
Oil filter replacement 500 hours of hours of
personnel
Every 500 hours of Initial 50 hours Only trained
Oil level check
operation (2) of operation (3) personnel
Couplings and
tightening torques Only authorized
1000 hours of hours of
( flanges, threaded parts ) personnel
checks
Hydraulic parts (torque Seasonally or every Initial 100
converter, oil pump, Only authorized
manifold, pipe
1000 hours of hours of
personnel
connections) checks operation (1) operation
Electric and electronic Seasonally or every Initial 100
Only authorized
parts ( connections, 1000 hours of hours of
personnel
wirings, controls ) checks operation (1) operation
(1)
Which both of conditions comes first
(2)
250 hours for severe operating conditions
(3)
At the season end if you have not reached the indicated operating hours
LUBRICATION alternative approved oil
Petrol Ofisi (TR) MOBIL Specifications

Correspond to
ATF-DEXRON IID and
PO ATF 2 Mobil fluid 424
ATF-DEXRON III
specifications
01
CHASSIS
TRANSMISSION 11
Sealing compounds and adhesives
Apply contact surface or on bolts sealing compound / adhesives shown below
Apply on the contact surface Loctite 510 or equivalent
Apply bolts thread / on pins Loctite 270 or equivalent

01
12 CHASSIS
TRANSMISSION
TIGHTENING TORQUES
01
CHASSIS
TRANSMISSION 13
TIGHTENING TORQUES ( cont’d )

01
14 CHASSIS
TRANSMISSION
TIGHTENING TORQUES ( cont’d)

01
CHASSIS
TRANSMISSION 15
HYDRAULIC COMPONENTS
Hydraulic scheme
01
16 CHASSIS
TRANSMISSION
HYDRAULIC COMPONENTS
Hydraulic components (in scheme)

1 Suction filter (250 µm )
2 Transmission oil pump ( 36 cc / rev.)
3 Oil filter relief valve
4 Spin-on delivery filter ( 10 µm )
5 Torque converter SACHS W300-204-2.64
6 Oil cooler
7 Torque converter pressure relief valve
8 Oil flow divider / pressure regulator valve
9 Air breather
10 FORWARD clutch pressure check port
11 REVERSE clutch pressure check valve
12 FORWARD clutch
13 REVERSE clutch
14 4WD engagement / disengagement
15 Ramp valve
16 Input shaft lubrication (axis A )
17 Brake oil port return to sump
18 Transport lock oil port return to sump
19 Oil outlet port to boom lock
20 Oil outlet port to brakes
21 Hydraulic differential lock engagement / disengagement
22 1st gear clutch
23 2nd gear clutch
24 3rd gear clutch
25 4th gear clutch
26 Primary shaft lubrication (axis B )
27 Output shafts lubrication (axis C / E )
28 Oil cooler back temperature thermostat port
29 Control valve unit
01
CHASSIS
TRANSMISSION 17
MAIN HYDRAULIC COMPONENTS

01
18 CHASSIS
TRANSMISSION
OIL PUMP
TECHNICAL DATA
Delivery pressure and flow At Engine r.p.m.

13.0 ÷ 14.5 bar 26 lt / min 900 rpm
14.0 ÷ 15.5 bar 60 lt / min 2200 rpm
01
CHASSIS
TRANSMISSION 19
CONTROL VALVE UNIT
ON / OFF VALVE DATA
Nominal voltage : 12 V DC
Power consumption : 19,8 W (20 0C)
IP rating : IP 69
PROPORTIONAL VALVE DATA
Coil resistance : 7,25 Ω (20 0C)

Power consumption : 19,8 W (20 0C)
IP rating : IP 69
CONTROL VALVE SCHEME ( next figure)
TS Proportional pressure reducing valve

SV 2 / 3 directional valve
RMP Ramp valve
PS Supply pressure check port
PS1 Supply pressure check port
TP Supply clutch pressure check port
P Oil outlet port to boom lock
X Oil outlet port to brakes
HDL Hydraulic differential lock engagement / disengagement
01
20 CHASSIS
TRANSMISSION
Hydraulic control valve scheme

01
CHASSIS
TRANSMISSION 21
KINEMATIC SCHEME
01
22 CHASSIS
TRANSMISSION
TROUBLE SHOOTING
This list of possible failures and remedies provides no more than an indication of
what the problem might be and how to fix it.
It should be remembered that problems are not caused by just one part, but by the
part’s interaction with other elements; accordingly, additional action over and above
the steps described is frequently required.
This list may not cover all possible problems and remedies.
Specialist personnel must identify the problem and its cause and the n proceed with
the necessary repairs.
Warning ! All checks and tests must be performed with the oil at working
temperature : 80 ± 2 0C
CHECKS & TESTS
Transmission oil check

Always check the correct oil level and correct oil specifications.
Pressure check
Several transmission breakdowns can be identified by running pressure checks.
Irregular measurements might indicate that there is a problem, which specialist
personnel must identify.
Stall test
In order to create ideal conditions for troubleshooting, the converter stall procedure
must be performed first. The purpose of this test is to determine whether the torque
converter and hydraulic clutch units are operating correctly.
This operation will also bring the oil up to its working temperature 80 ± 2 0C, allowing
any problems in the engine, converter or transmission to be identified.
Proceed as follows:
 Check the oil level.
 Activate the parking brake to block the wheels.
 Start the engine and keep it ticking over at idle speed (800 – 1000 rpm).
 Put the gear lever into 4th.
 Put the reverser in the FORWARD position.
 Rev the engine for short periods to a maximum of 1500 – 1700 rpm, to bring
the oil up to working temperature.
Important : The converter stall test must not exceed a maximum duration of 30
seconds each time. After this 30 seconds period, put the reverser in NEUTRAL for 15
seconds, then repeat the procedure.
Warning ! Failure to keep to these test periods may result in the oil overheating and
attendant damage to the clutches, filter, converter and seals.
 Gradually reduce the engine revs to minimum.
 Put the reverser in NEUTRAL.
01
CHASSIS
TRANSMISSION 23
GUIDE TO PROBLEMS
Mechanical problems
 Check that all of the transmission’s internal and external mechanical parts are
correctly fitted.
 Check the efficiency of the parking brake.
 Check that the cooling system is in good operating condition.
 Check the efficiency of the engine. Make sure that the engine’s idling speed is
set correctly and that it complies with the maximum speed specifications under
loadless conditions.
Hydraulic problems
 Check the transmission oil level.
 Use the specified oils.
 Check that the hydraulic system is correctly filled.
 Check the efficiency of the hydraulic system. Check for oil leaks.
 Check the efficiency of the transmission’s hydraulic components (converter, oil
pump, filter, connections, hoses)
Electrical problems
 Check the efficiency and correct installation of the machine battery.
 Check the efficiency and correct installation of all electrical components
outside the transmission (wiring, cables, alternator, battery etc.)
 Check the efficiency and correct installation of all transmission electrical
components (wiring, sensors, solenoid valves etc.)
01
24 CHASSIS
TRANSMISSION
TROUBLESHOOTING OF TRANSMISSION
The next table lists problems, possible causes and recommended corrective action.
Problem Cause Action

Check / replace
Faulty supply to solenoid valves Repair / replace
Damaged wiring connections between
transmission and machine Clean
Oxidized contacts in electrical wiring Replace
Break in electric cable Replace
Damaged solenoids Replace
Damaged sensors Check / replace fuses
Short circuits or false contacts Top up
Incorrect oil level Repair / top up
Check for leaks Clean
Machine does not move Blocked intake filter Replace
Damaged oil pump Replace oil pump
Damaged oil pump relief valve Replace
Blocked / damaged transmission filter Replace
Damaged / jammed control valve Replace
Damaged converter Wait for oil to reach
Oil temperature below 0 0C working temperature
Replace
Damaged rotary seals Repair
Blocked reverser lever Replace / repair clutch
Worn clutch unit Check / repair /
No drive transmission (broken gears, replace
shafts, bearings etc.)
Irregular functioning of electronic gear Replace EGM / ECU

management EGM / ECU
01
CHASSIS
TRANSMISSION 25
TROUBLESHOOTING OF TRANSMISSION (cont’d)

Incorrect oil temperature Wait for oil to reach
working temperature
Transmission oil overheating Restore acceptable
temperature values
Incorrect operating pressure Check hydraulic circuit
and replace (oil pump,
Machine has reduced filters, control valve)
power transmission
Damaged converter Replace
Incorrect oil level Top up
Worn clutch unit Replace / repair
4WD clutch failure Repair / replace 4WD
shaft group
Overheating solenoids Replace
Damaged transmission & machine Repair / replace
wiring connections
Damaged sensors Replace
Damaged EGM / ECU logic Replace EGM / ECU
Damaged hydraulic cooling system Repair

Dirty heat exchanger Clean
Parking brake inadvertently activated Release
Excessive dirt on axle wheel hubs Clean
Seizing (broken gears, shafts, bearings Check / repair/
etc.) replace
Overheating Braking force outside transmission : Check / repair axle

irregular axle operation
Clutch plate drag Repair / replace
Damaged oil thermostat Replace
Worn oil pump Replace
01
26 CHASSIS
TRANSMISSION
TROUBLESHOOTING OF TRANSMISSION (cont’d)
Clutch plate drag Repair / replace

Low oil temperature ( high oil viscosity) Wait for oil to reach
Wheels rotate when working temperature
machine is raised
Incorrect oil specifications Replace oil & filters
Damaged control valve Replace
Faulty reverser locking Repair / replace
Seizing (broken gear, shafts, bearings ) Replace
Noise Worn clutch plates Replace

Worn synchronizer actuation unit Replace
Worn 4WD clutch Replace
Electrical system fault Repair / replace
Worn clutch plates Replace
Irregular actuation Low oil temperature (high oil viscosity) Wait for oil to reach
working temperature
Overheating See “ overheating”
Faulty EGM / ECU operation Replace EGM / ECU
Damaged hydraulic system Repair / replace
Damaged/ jammed shuttle-shaft lever Repair / replace
Electrical system fault Repair / replace
Gear remains engaged
Damaged hydraulic system Repair / replace
Damaged clutch unit Repair / replace
Irregular EGM / ECU operation Replace EGM / ECU
02
CHASSIS
AXLES 1
AXLE SETTING STAMP
02
2 CHASSIS
AXLES
02
CHASSIS
AXLES 3
02
4 CHASSIS
AXLES
02
CHASSIS
AXLES 5
02
6 CHASSIS
AXLES
02
CHASSIS
AXLES 7
02
8 CHASSIS
AXLES
02
CHASSIS
AXLES 9
02
10 CHASSIS
AXLES
02
CHASSIS
AXLES 11
02
12 CHASSIS
AXLES
02
CHASSIS
AXLES 13
02
14 CHASSIS
AXLES
02
CHASSIS
AXLES 15
02
16 CHASSIS
AXLES
02
CHASSIS
AXLES 17
02
18 CHASSIS
AXLES
02
CHASSIS
AXLES 19
02
20 CHASSIS
AXLES
02
CHASSIS
AXLES 21
02
22 CHASSIS
AXLES
02
CHASSIS
AXLES 23
02
24 CHASSIS
AXLES
02
CHASSIS
AXLES 25
02
26 CHASSIS
AXLES
02
CHASSIS
AXLES 27
02
28 CHASSIS
AXLES
02
CHASSIS
AXLES 29
02
30 CHASSIS
AXLES
02
CHASSIS
AXLES 31
02
32 CHASSIS
AXLES
02
CHASSIS
AXLES 33
02
34 CHASSIS
AXLES
02
CHASSIS
AXLES 35
02
36 CHASSIS
AXLES
02
CHASSIS
TRANSMISSION 1
CARRARO
PLUGS AND FİLTERS DISASSEMBLY & ASSEMBLY OPERATIONS
Some of the following pictures could not show exactly your transmission, but the
indicated operations are correct anyway.
02
2 CHASSIS
TRANSMISSION
DISASSEMBLY
Remove the drain plug (1) and drain the oil

from the transmission.
Remove the two cap screws (2) which fasten

the cover for the oil screen.
Remove the cover (3).
Filter handling and wash according to the rules in

force. In case of replacement, use only authorized
disposal procedures. In case of doubt, refer to
authorized bodies.
Remove the oil screen (4) and the O-ring (5).
02
CHASSIS
TRANSMISSION 3
DISASSEMBLY (cont’d)
Unscrew the oil filter (6).

Note: Filter handling and disposal according to the
rules in force. Use only authorized disposal procedures.
In case of doubt, refer to the authorized bodies.
If necessary, remove the connector (7) for the oil

filter (6).
Unscrew and remove the oil filter protection valve (8).
Check the valve (8) condition.

Clean with care the valve and replace the
O-ring (9) and (10) if necessary.
02
4 CHASSIS
TRANSMISSION
Remove the breather (11) from the transmission

housing only if this part is leaking or damaged.
To check the FORWARD clutch pressure,

remove the plug (12).
To check the REVERSE clutch pressure,

remove the plug (13).
To check the lubrication pressure, remove

the plug (14).
02
CHASSIS
TRANSMISSION 5
Remove the speed sensor (15).
Remove the thermostat (16).
Remove the pressure switch (17).

02
6 CHASSIS
TRANSMISSION
ASSEMBLY
Assemble the pressure switch (17) to the prescribed

torque.
Assemble the speed sensor (15) to the

prescribed torque.
Assemble the thermostat (16) to the prescribed torque.
Assemble the plugs (12), (13) and (14) to

prescribed torque after the pressure check.
Assemble by hand the breather (11) to the

transmission housing and tighten it strongly.
02
CHASSIS
TRANSMISSION 7
ASSEMBLY (cont’d)
Clean with care the oil filter protection valve (8).

Assemble the new O-ring (9) and (10).
Assemble the oil filter protection valve (8).

Tighten the valve (8) to the prescribed torque.
Assemble the connector (7) for the oil filter (6)

then tighten it to the prescribed torque.
Assemble new oil filter (6).

Note: Put a thin coat of oil or grease on the filter
gasket, turn clockwise until the gasket makes
contact with the base, continue to turn the filter
2/3 turn.
02
8 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Assemble new O-ring (5) to the filter (4). Insert the

filter (4) with O-ring (5) and assemble the cover (3).
Assemble the two cap screws (2) and tighten

at prescribed torque to fasten the cover (3).
Assemble the drain plug (1) to the prescribed

torque.
02
CHASSIS
TRANSMISSION 9
TORQUE CONVERTER AND OIL PUMP DISASSEMBLY & ASSEMBLY

OPERATIONS
02
10 CHASSIS
TRANSMISSION
DISASSEMBLY
Drain oil transmission hydraulic circuit.

Remove the torque converter (1) from the
transmission housing.
Remove screws (2).

Warning: Make reference mark on the pump
and bell housing before unscrewing the bolts.
Extract the pump (3) by means of two levers.
Remove the oil pump (3).

Note: Destructive operation for the O-ring
(4).
02
CHASSIS
TRANSMISSION 11
Remove O-ring (4).

Warning: Do not open/disassemble the pump
or its operation may be compromised. Special
tools from manufacturer are required for
reassembly.
If replacement is necessary, remove the seal ring

(5).
Note: Destructive operation for the seal ring (5).
02
12 CHASSIS
TRANSMISSION
ASSEMBLY
Assemble new seal ring (5) on the oil pump (3).
Assemble new O-ring (4).
Warning: Before a new pump assembly,

check that oil passage holes between pump
and half-case or the visual marks coincide.
Grease the ring (5) to keep it centered / coaxial

with respect to the shaft slot center line and make
the introduction onto the pump easier.
02
CHASSIS
TRANSMISSION 13
ASSEMBLY (cont’d)
Apply a thin film of grease on the coupling seat with

the transmission housing (6).
Assemble the oil pump (3).
Assemble the screws (2) to prescribed torque.

Warning: Check that reference marks made on
the oil pump and on the bell housing coincide.
In order to avoid damage to the pump seal ring,

it is recommended to fit the converter on the TLB
transmission by hand (the two teeth of the pump
driving converter can cut the seal ring lip).
Match the transmission and the converter the
engine flywheel with the screws of the converter
driving disc of engine SAE3 bell housing.
Fit the converter (1). Turn the torque converter
until engaging the relative splined shafts.
02
14 CHASSIS
TRANSMISSION
HYDRAULIC CONTROL VALVE DISASSEMBLY & ASSEMBLY OPERATIONS
02
CHASSIS
TRANSMISSION 15
DISASSEMBLY
Drain oil from transmission hydraulic circuit,

disconnect all electrical connections. Remove bolts
(1).
Lift the control valve (2).
Remove gasket (3).
Place the control valve unit on a clean workbench.

Remove fastening screws (4) from the valves (5)
and (6).
02
16 CHASSIS
TRANSMISSION
Extract with care the valves (5) and (6) with a

screwdriver.
Remove the valves (5) and (6).
Check the valves (5) and (6) condition.
Unscrew and remove the valve (7).

02
CHASSIS
TRANSMISSION 17
Unscrew and remove the oil filter protection valve (8).

Clean with care the valve and replace the O-ring
(9) and (10) if necessary.
ASSEMBLY
Clean with care the oil filter protection valve (8).

Assemble the new O-ring (9) and (10).
Tighten the valve (8) to the prescribed torque.

02
18 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Assemble the on/off valves (6) and proportional valves

(5) respecting the indicated position.
Assemble the valve fastening screws (4) to the prescribed torque.

02
CHASSIS
TRANSMISSION 19
ASSEMBLY (cont’d)
Assemble the new gasket (3).
Assemble the control valve unit (2) to the

transmission (11).
Tighten the bolts (1) to the prescribed

torque.
02
20 CHASSIS
TRANSMISSION
HYDRAULIC SYSTEM PIPES
02
CHASSIS
TRANSMISSION 21
DISASSEMBLY
Drain oil from the transmission hydraulic circuit.

Unscrew the connections of pipe (1) (shaft
lubrication) and remove the pipe (1).
Remove the pipe (2) ( 1st speed) unscrewing

related connections.
Remove the pipes (3) (3rd speed)- (4) ( 2nd

speed) and (5) (4th speed) unscrewing related
connections
Collect connection gaskets.
Remove the pipe (6) (4WD) unscrewing related

connections.
02
22 CHASSIS
TRANSMISSION
ASSEMBLY
Assemble the pipe (6).

Tighten the connections to the prescribed torque.
Assemble the connections of pipe (1).

Tighten the connections to the prescribed
torque.
Assemble the connections of the pipe (2).

Tighten the connections to the prescribed
torque.
Assemble the pipes (3), (4) and (5) then

tighten related connections to the
prescribed torque.
02
CHASSIS
TRANSMISSION 23
TRANSMISSION HOUSING
02
24 CHASSIS
TRANSMISSION
DISASSEMBLY
Drain oil from transmission.

Unscrew flange (2) fastening bolt (1).
If necessary use a screwdriver and two

screws to stop flange rotation.
Collect the washer (3).
Remove flange (2) and O-ring (4).

Note: This is a destructive operation for the
O-ring.
02
CHASSIS
TRANSMISSION 25
Remove seal ring (5).

Note: This is a destructive operation for
the O-ring.
Remove the fastening screws (6) from the

flange (7).
Remove flange (7).
Extract transmission shaft PTO (8).

02
26 CHASSIS
TRANSMISSION
Remove the Teflon seal ring (9) by cutting it to

replace.
Remove snap ring (10).
Extract bearing (11) with tool.
Unscrew flange (13) fastening bolt (12).

Use a screwdriver and two screws to
stop flange rotation.
02
CHASSIS
TRANSMISSION 27
Remove the bolt (12) and washer (14).
Remove flange (13) and O-ring (15).

O-ring.
Remove seal ring (16).

the seal ring.
Remove the bearing snap ring (17).

02
28 CHASSIS
TRANSMISSION
Remove fastening bolts (18) from the rear

(19) and front (20) half housings.
Insert a lever in the special slot to detach

the cover.
Note: The surfaces have been attached
with a sealant.
Lift the front half housing (20) by means of

two hooks.
Remove the three O-rings (21).

02
CHASSIS
TRANSMISSION 29
ASSEMBLY
Assemble three O-rings (21) to the rear half

housing.
Note: Accurately remove from mating
surfaces any residual of sealant and clean
them with a detergent.
Assemble all the transmission internal parts.

Apply a thin film of prescribed sealant on the
edge of rear half-housing.
Install the front half housing (20) on the rear

half-housing. Make sure that the bearings
on the shafts go straight into the bores in
the front half housing. Push the front half
housing all the way down on the rear half
housing.
Assemble fastening bolts (18) to the rear

(19) and front half (20) housings. Tighten the
bolts to the prescribed torque.
02
30 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Assemble snap ring (17).
Assemble seal ring (5) on front shaft

output.
Assemble flange (2) and new O-ring (4).
Assemble the washer (3) and bolt (1).

02
CHASSIS
TRANSMISSION 31
ASSEMBLY (cont’d)
Tighten the bolt (1) to the prescribed torque.

Use a screwdriver and two screws to stop
flange rotation.
Assemble seal ring (16) on rear shaft

output.
Assemble flange (13) and new O-ring

(15).
Assemble the washer (14) and bolt (12).

02
32 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Tighten the bolt (12) to the prescribed

torque.
Use a screwdriver and two screws to stop
flange rotation.
Assemble bearing (11) on

transmission shaft PTO (8).
Assemble Teflon seal ring (9) as

mentioned in following section “Shafts
assembly”.
02
CHASSIS
TRANSMISSION 33
ASSEMBLY (cont’d)
Insert transmission shaft PTO (8) to the end

of stroke.
Apply a thin film of prescribed

sealant to flange (7).
Warning: The two holes for oil
passage (A) should overlap during
flange assembly.
Assemble screws (6) to the prescribed

torque.
02
34 CHASSIS
TRANSMISSION
SHAFTS A - D
02
CHASSIS
TRANSMISSION 35
DISASSEMBLY
Grasp with pliers the input shaft assembly A.

Remove with shaft assembly D and lift.
Remove the Teflon seal ring (1) to replace.
Remove the snap ring (2).

02
36 CHASSIS
TRANSMISSION
Install a bearing separator under the gear as

shown (do not install the bearing separator
between the gear and the bearing).
Use a puller on the bearing separator and insert a
shaft protector between the puller and the end of
of the input shaft.
By means of puller which operates between
bearing separator and shaft protector pull only until
the bearing is free. Pulling any farther can damage
the parts.
Remove bearing (3).
Remove spacer (4).

02
CHASSIS
TRANSMISSION 37
Remove gear (6).
Remove needle cage (7).
Remove thrust washer (8).
Remove split pin (9).

02
38 CHASSIS
TRANSMISSION
Remove lock ring (10).
Use prybars to lift and to remove the

thrust plate lock ring (11) evenly.
Remove the clutch plates (18) and the clutch

drive plates (17).
Place a mark below the groove on the

friction bell.
02
CHASSIS
TRANSMISSION 39
Place a mark on each thrust plate lock ring (11),

clutch plate (18) and clutch drive plate (17).
These marks will be used for reference during the
reassembly procedure.
Lower the spring (15) lock washer (13).
Loosen the handles of the threaded rods to

release the tension from the spring. Remove
the top piece of the special tool.
02
40 CHASSIS
TRANSMISSION
Remove lock spring cover (13) and spring (15).
Remove sleeve (5).
Remove clutch piston (19) by blowing in

compressed air through the delivery hole.
Remove the Teflon seal ring and relevant

inner O-ring (20) from outer seat of piston
and Teflon seal ring and relevant inner O-
ring (21) from inner piston. To remove the
rings it is necessary to cut them.
02
CHASSIS
TRANSMISSION 41
Turn the shaft. Remove Teflon seal rings (22)

by cutting them.
Remove bearing (24).
Remove bearing (24) and thrust washer

(25).
02
42 CHASSIS
TRANSMISSION
Remove gear (26) and needle cage (12).
For disassembly of the other parts,

repeat the necessary operations
before done.
Check the sealing ring grooves (large and small) for wear and damage if necessary.
Use new parts as required.
Check on the output shaft for wear and damage.

Check oil passages in the output shaft to be sure that the passages are open and
free of foreign material.
Check the ball bearings and the needle bearings for flat areas, pitting, and other
damage.
02
CHASSIS
TRANSMISSION 43
If the clutch discs are to be used again,

keep the clutch packs in the same previous
assembly order separate and record which
clutch pack goes with each clutch.
At each disassembly, verify with a

caliper that the total thickness of the
clutch kit is within the wear limit (see
table next page). If not -, replace the
clutch kit (18) with a new one. Verify
that all the clutch plates do not appear
burned or that the friction material is
not damaged and that splines are well
traced.
Verify also that all the clutch drive plates

(17) are perfectly plane and inspect for
pitting or scoring.
In the case that at least one of the
above problems occurs, replace the
complete clutch kit with a new one.
If using a new clutch kit, soak the clutch

plates in clean transmission oil for at
least an hour before assembly.
In any case lubricate the contact
surfaces of clutches drive plates with
clean transmission oil before assembly.
02
44 CHASSIS
TRANSMISSION
Inspect the bore of the shaft in the input shaft housing for damage that will cause
leakage when the clutch is assembled.
Check the slots in the side of the input shaft housing for damage from the tangs on
the steel discs.
Use new parts as required during assembly.
FORWARD -REVERSE GEAR CLUTCH

Number of clutch plate (each side) 6
Number of clutch steel plate (each side) 6
Nominal clutch plate thickness 2,40 ± 0,05 mm
Nominal clutch kit thickness * 29,00 ~ 29,20 mm
Maximum clutch plate wear (each side) 0,25 mm
Maximum clutch kit wear 1,5 mm
* Under load of 163 kg.
Remove bearing (16) of shaft D by means of

an extractor.
Remove bearing (37) of shaft D by means

of an extractor.
02
CHASSIS
TRANSMISSION 45
ASSEMBLY
Assemble new Teflon ring (20) and relevant

inner O-rings (20), new Teflon ring (21) and
relevant inner O-rings (21) respectively into the
piston outer and inner seats.
Apply a thin film of grease on the sealing rings

just inserted.
Insert clutch piston (19) with special tool

(a) as protection of seal rings (21).
Assemble sleeve (5).
Assemble spring (15) and washer (13).

02
46 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Lower the spring (15) lock washer (13) by using

tool.
Insert snap ring (14).

Note: Ensure that the snap ring (14) is
well fitted.
Loosen the handles of threaded rods to release

the tension from the spring. Remove the top piece
of the special tool.
02
CHASSIS
TRANSMISSION 47
ASSEMBLY (cont’d)
Remove tool and assemble the split pin

(9).
Insert thrust washer (8).
Insert needle cage (7).
To assemble the clutch pack, start

with the gear (6) on the bench. Install
the thrust plate (11) so that the
reference mark on top of the plate
made during disassembly is facing
towards the gear.
02
48 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Assemble clutch plates (18) and clutch drive

plates (17) on the gear (6).
The assembled clutch pack must contain seven
clutch drive plates and six clutch plates.
Locate the pack assembly by

means of two screwdrivers.
Assemble lock ring (10).

02
CHASSIS
TRANSMISSION 49
ASSEMBLY (cont’d)
Assemble washer (4).
Heat the bearing (3) to 80 ~ 100 0C

(176 ~ 212 0F )
Assemble bearing (3) using tool.
Install the snap ring (2).

Note: For clarity of the Teflon sealing ring
installation procedure the following photos do
not show the clutch pack, gear, spacer,
bearing, and snap ring installed on the input
shaft.
Insert the Teflon seal ring (1) as follows.

02
50 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Install the spacer onto the input shaft with

the chamfered end facing in.
Slide the expander/protector onto the

input shaft and over the spacer. The
expander/protector will stop in the
correct position to install the seal ring in
the groove.
Heat the Teflon seal ring to 60 ~ 80 0C

(140 ~ 176 0F) for 5 minutes. Install the
Teflon seal ring onto the
expander/protector.
Install the pusher over the

expander/protector and slide the seal ring
until it reaches the groove in the shaft.
Remove the pusher, expander/protector,
and spacer from the shaft.
02
CHASSIS
TRANSMISSION 51
ASSEMBLY (cont’d)
Install the end of the seal compressor with

the deep chamfer onto the shaft and over
the seal ring.
Use a back and forth twisting motion to
allow the seal compressor to slip over the
top of the sealing ring and seat the sealing
ring into the groove. Be careful not to
damage the sealing ring. After the sealing
ring is seated in the groove, remove the
seal compressor from the shaft.
Turn the seal compressor around and

slide the end with the narrow chamfer
over the shaft and over the seal ring.
Leave the seal compressor in place for
15 minutes until the sealing ring has
cooled and is properly sized and seated
in the groove. After the seal ring has
cooled, remove the seal compressor
from the shaft.
Measure the clutch discs clearance for

each clutch assembly. The thrust plate lock
ring must be all the way up against the lock
ring.
Use a feeler gauge to measure the distance
between the thrust plate lock ring and the
first clutch drive plate. The distance must
be 1,6 to 2,45 mm.
If the distance is not within specification, the
clutch is probably assembled wrong.
02
52 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Note: Overturn the shaft and execute the

operations from the sequence before
applied. Use clean transmission oil to
lubricate the thrust washer (25).
Install the thrust washer so that the notch in
the inner edge fits over the pin.
Make sure that the side with the oil grooves
is down.
Heat the bearing (24) 80 ~ 100 0C

(176 ~ 212 0F )
Use driver to drive the bearing (24) onto
the input shaft until the bearing makes
contact with the thrust washer.
Assemble the Teflon seal rings (22) as

follows :
Place the spacer into the
expander/protector.
02
CHASSIS
TRANSMISSION 53
ASSEMBLY (cont’d)
Slide the expander/protector and the spacer

onto the shaft. The expander/protector will
stop in the correct position to install the seal
ring in the groove.
Heat the Teflon seal ring to 60 ~ 80 0C

(140 ~ 176 0F) for 5 minutes. Install the
Teflon seal ring onto the
expander/protector.
Install the pusher over the expander/protector

and slide the seal until it reaches the groove
in the shaft. Remove the pusher,
expander/protector, and spacer from the
shaft.
Install the end of the seal compressor

with the deep chamfer onto the shaft
and over the seal ring.
Use a back and forth twisting motion
to allow the seal compressor to slip
over the top of the sealing ring and
seat the sealing ring into the groove.
Be careful not to damage the sealing
ring. After the sealing ring is seated in
the groove, remove the seal
compressor from the shaft.
02
54 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Turn the seal compressor around and

slide the end with the narrow chamfer
over the shaft and over the seal ring.
Leave the seal compressor in place for
15 minutes until the sealing ring has
cooled and is properly sized and seated
in the groove. After the seal ring has
cooled, remove the seal compressor
from the shaft.
For the introduction of the other three (2 nd, 3rd, 4th ) Teflon rings, repeat the
operations from sequence before applied.
1 Lubrication oil passage 5 Forward clutch pack

2 Forward clutch oil passage 6 Reverse clutch pack
3 Reverse clutch oil passage 7 Reverse gear
4 Forward gear 8 Input shaft
02
CHASSIS
TRANSMISSION 55
ASSEMBLY (cont’d)
Apply compressed air of approximately 6 bar to the forward clutch passage. Listen to
hear the forward piston moving to lock the forward clutch pack.
Try to move the forward gear. The forward gear must not turn on the input shaft. Try
to move the reverse gear. The reverse gear must turn freely on the input shaft. If the
clutches do not work correctly, disassemble the clutches to find the problem.
Apply compressed air of approximately 6 bar to the reverse clutch passage. Listen to
hear the reverse piston moving to lock the reverse clutch pack. Try to move the
reverse gear. The reverse gear must not turn on the input shaft. Try to move the
forward gear. The forward gear must turn freely on the input shaft. If the clutches do
not work correctly, disassemble the clutches to find the problem.
Assemble D shaft bearing (16).
Assemble D shaft bearing (37).
Lubricate with oil the shaft seat A.
Fit the shaft assembly D and shaft

assembly A. the operation is correct only
if the two shafts are fitted at the same
time.
02
56 CHASSIS
TRANSMISSION
AXIS B
02
CHASSIS
TRANSMISSION 57
DISASSEMBLY
Lift the three shafts B-C-E, at the same time by

using tool.
Remove seals (1) and (2).

Teflon seal rings.
By means of an extractor remove bearing (3) and

gear (4).
Remove the bearing (3) and the gear (4).

02
58 CHASSIS
TRANSMISSION
Remove the lock ring (5).
Remove the washer (6).
Remove the spring pin (23).
Remove gear (8).

02
CHASSIS
TRANSMISSION 59
Remove roller retainers (7) and washer (13).
Remove spring pin (24) and spacer

(14).
Slightly press thrust plate (10).
Remove lock ring (9).

02
60 CHASSIS
TRANSMISSION
Remove thrust plate (10) by means of two

screwdrivers.
Remove disc (11) and counter-discs (12)

pack.
Lower the spring (17) retaining washer (16) by

using tool.

02
CHASSIS
TRANSMISSION 61

release the tension from the spring.
Remove the top piece of the special tool.
Remove the washer (16) and spring (17).
Remove sleeve (18).
Remove clutch piston (19) by blowing

in compressed air through the delivery
hole.
02
62 CHASSIS
TRANSMISSION
Remove Teflon seal ring (20) and relevant

inner O-ring from outer seat of piston and
Teflon seal rings (21) and relevant inner O-
ring from inner of piston. To remove the
rings it is necessary to cut them.
Remove the Teflon seal ring (26).
Remove bearing (25) by means of an

extractor.
02
CHASSIS
TRANSMISSION 63
Check the sealing ring grooves (large and small) for wear and damage if necessary.

damage.
If clutch discs are to be used again, keep the

clutch packs in the same previous assembly
order separate and record which clutch pack
goes with each clutch.
At each disassembly, verify with a caliper that the

total thickness of the clutch kit is within the wear
limit (see table on the next page). If not, replace
the clutch kit (11) with a new one.
Verify that all the clutch plates do not appear

burned or that the friction material is not
damaged and that splines are well traced.
Verify also that all the clutch drive plates (12)
are perfectly plane and inspect for pitting or
scoring.
In the case that at least one of the above
problems occurs, replace the complete clutch
kit wit a new one.
02
64 CHASSIS
TRANSMISSION
If using a new clutch kit soak the clutch plates in clean transmission oil for at least an
hour before assembly.
In any case lubricate the contact surfaces of clutch drive plates with clean
transmission oil before assembly.
Inspect the bore of the shaft in the input shaft housing for damage from the tangs on
the steel discs.
2nd GEAR CLUTCH

Number of clutch plate 8
Number of clutch steel plate 8
Maximum clutch plate wear 0,20 mm

02
CHASSIS
TRANSMISSION 65
ASSEMBLY
Assemble new Teflon seal ring (26).

For the introduction of the Teflon ring,
repeat the operations from sequence
before applied using spacer ring.

inner O-ring, new Teflon ring (21) and relevant
inner O-rings respectively into the piston outer
and inner seats.
Apply a thin film of grease on the seal

rings just inserted.
02
66 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Insert clutch piston (19) with tool (a) as

protection of seal rings (21).
Assemble the sleeve (18).
Assemble spring (17) and washer (16).
By using tool lower spring (16) lock washer (17).

02
CHASSIS
TRANSMISSION 67
ASSEMBLY (cont’d)

Note: Ensure that the snap ring (15) is well
fitted.
Loosen the handles of the threaded rods to release

the tension from the spring. Remove the top piece of
the special tool.
Assemble clutch pack to shaft (22).
Assemble spacer (14) and spring pin

(24).
02
68 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Insert washer (13) and roller bearing (7).
Assemble thrust plate (10) and press it

against the clutch pack.
Assemble retaining ring (9).
Apply compressed air at low

pressure in hole in order to push the
thrust plate (10) against the retaining
ring (9), then align the clutch plate
(11) spline.
02
CHASSIS
TRANSMISSION 69
ASSEMBLY (cont’d)
Assemble gear (8) paying attention it completely fit

in its seat.
Assemble spring pin (23).
Assemble the washer (6) and lock ring (5).

each clutch assembly. The clutch plate
lock ring must be all the way up against
the lock ring. Use a feeler gauge to
measure the distance between the
clutch plate lock ring and the first clutch
plate (11). The distance must be 2,20
to 3,05 mm. if the distance is not within
specification. The clutch is probably
assembled wrong.
02
70 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Assemble gear (4) taking care to orientate the shelf

facing the clutch and bearing (3) by using tool.
1 Lubrication oil passage 4 2nd speed clutch pack

2 2nd speed clutch oil passage 5 Input shaft
3 2nd speed gear
02
CHASSIS
TRANSMISSION 71
ASSEMBLY (cont’d)
See illustration.
Try to rotate the 2 nd speed gear. The 2 nd speed gear must turn freely on the input
shaft.
Apply compressed air of approximately 6 bar to the 2 nd speed gear clutch oil
passage. Hear the 2 nd speed gear piston moving to lock the 2 nd speed gear clutch
pack.
Try to move the 2 nd speed gear. The 2 nd speed gear must not turn on the input shaft.
If the clutch does not work correctly, disassemble the clutch to find the problem.
Insert Teflon seal (1) and (2).

For the introduction of the rings, repeat
the operations from sequence before
applied by using special tools.
Lift the three shafts B-C-E at the same time

and insert into the half-housing using tool.
02
72 CHASSIS
TRANSMISSION
AXIS C
02
CHASSIS
TRANSMISSION 73
DISASSEMBLY
Lift the three shafts B-C-E at the same time.
By means of an extractor remove bearing (58).
Remove bush (57).
Remove the gear (54) with its inner parts.

02
74 CHASSIS
TRANSMISSION
Overturn the group.

Push down the thrust plate (39).
Remove the thrust plate (39) by means of

two screwdrivers.
Remove clutch kit (40).

02
CHASSIS
TRANSMISSION 75
Push down the thrust washer (42) to allow lock

ring removal (41) by using special tool.
Loosen the handles of threaded rods to

Remove the lock ring (41), the thrust washer

(42) and spring (43).
Remove clutch piston (44) by blowing in

compressed air through the delivery hole.
02
76 CHASSIS
TRANSMISSION
Remove the Teflon seal ring (45) and

relevant timer O-ring from outer seat of
piston (44).

relevant inner O-ring from seat of gear
(54).
Remove gear (37) with an extractor.

Remove bushing (47) and (56), roller bearing (46)
and (55) and spacer (50).
Check the condition of removed parts

(46), (47), (50), (55) and (56).
02
CHASSIS
TRANSMISSION 77
Remove the O-rings (48) and (53) from

the bush (50).
Note: Destructive operation for the seal
rings.
Check the wear condition of the Teflon

seal rings (49) and (51). If replacement is
necessary, cut the Teflon seal rings (49)
and (51) to remove them from the bush
(50).
Note: Destructive operation for the seal
rings.
Remove gear (35).
Remove roller retainer (36).

02
78 CHASSIS
TRANSMISSION
Remove the thrust washer (31).
Push down the counter-disc (33) to set free

the lock ring (34).

two screwdrivers.
02
CHASSIS
TRANSMISSION 79
Remove the clutch kit (32).
Remove spring pin (22).

tool.

02
80 CHASSIS
TRANSMISSION
Loosen the handless of the threaded rods to release the

tension from the spring. Remove the top piece of the
special tool.
Remove the lock ring (30), the thrust

washer (29) and spring (28).
Extract clutch piston (26) from its seat by

blowing in compressed air through the
delivery hole.
Remove the bush (27) and clutch piston

(26).
02
CHASSIS
TRANSMISSION 81
Remove the Teflon seal ring (25) and relevant

inner O-ring from outer seat of piston and Teflon
seal rings (24) and relevant inner O-ring from
inner of piston. To remove the rings it is
necessary to cut them.
Overturn the shaft (23).

Cut and remove the seal rings (16),
(17), (18) and (19).
By means of an extractor remove bearing (1).
Remove the thrust washer (2).

02
82 CHASSIS
TRANSMISSION
Remove gear (3).
Remove the roller retainer (7) and

thrust washer (8).
Remove spring (21).
Push down the thrust plate (5) to set free the

lock ring (4).
02
CHASSIS
TRANSMISSION 83

two screwdrivers.
Remove the clutch kit (6).
Lower the spring (11) lock washer (10) by using tool.

02
84 CHASSIS
TRANSMISSION

release the tension from the spring. Remove the
top piece of the special tool.
Remove the lock ring (9), the thrust washer (10)

and spring (11).
Extract clutch piston (13) from its seat

by blowing in compressed air through
the delivery hole.
02
CHASSIS
TRANSMISSION 85
Remove the bush (12) and clutch piston (13).

relevant inner O-ring from outer seat of
piston and Teflon seal rings (14) and
relevant inner O-ring from inner of piston.
To remove the rings it is necessary to cut
them.
Check the sealing ring grooves (large and small) for wear and damage.
If necessary use new parts as required.

damage.
02
86 CHASSIS
TRANSMISSION
If the clutch discs are to be used again, keep the


limit. If not, replace the clutch kit B wit a new one.
Verify that the all clutch plates do not appear burned or that the friction material is not
damaged and the splines are well traced.
Verify also that all the clutch drive plates (A) are
perfectly plane and inspect for pitting or scoring.

problems occurs, replace the complete clutch kit
with a new one.
If using a new clutch kit soak the clutch plates in
clean transmission oil for at least an hour before
assembly.
02
CHASSIS
TRANSMISSION 87
the steel discs.
1d GEAR CLUTCH
3nd GEAR CLUTCH

4nd GEAR CLUTCH


02
88 CHASSIS
TRANSMISSION
ASSEMBLY

inner O-ring on gear (54) using special tool.
Assemble O-ring (52).
Calibrate the Teflon ring (53) using

special tool.
Assemble new Teflon ring (45) with

relative O-ring on clutch piston (44).
Apply a thin film of grease on the outer

edge and in the inner part of clutch piston
(44) and assemble in gear (54).
02
CHASSIS
TRANSMISSION 89
ASSEMBLY (cont’d)
Insert spring (43), thrust washer (42) and snap ring

(41).
Lower the spring (43) lock washer (42) by

using tool.

Note: Ensure that the snap ring (41) is well
fitted.

02
90 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Insert clutch kit (40) and thrust plate (39) into

the gear (54).
Assemble retaining ring (38) making

sure it is correctly seated.

each clutch assembly. The thrust plate
lock ring must be all the way up against
the lock ring. Use a feeler gauge to
measure the distance between the thrust
plate lock ring and the first clutch plate
(40). The distance must be 1,725 to
2,375 mm. If the distance is not within the
specification, the clutch is probably
assembled wrong.
02
CHASSIS
TRANSMISSION 91
ASSEMBLY (cont’d)
Assemble new Teflon ring (25) and relevant inner

O-ring, new Teflon ring (24) and relevant inner O-
rings respectively into the piston (26) outer and
inner seats.

Insert clutch piston (26) with the special tool (a)

as protection of seal rings (24).

02
92 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Assemble spring (28) and retainer washer (29).

tool.

well fitted.
Loosen the handles of the threaded rods to release

the tension from the spring. Remove the top piece of
the special tool.
02
CHASSIS
TRANSMISSION 93
ASSEMBLY (cont’d)
Remove tool and assemble spring pin (22).
Insert the thrust washer (31) into the shaft

(23).
Apply a thin film of grease under washer
(31) to avoid its failing when overturning
the shaft.
Assemble the washer (31) on the pin

(22).
Insert clutch kit (32) on main shaft (23).

02
94 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Insert the roller bearing (36) and thrust plate (33).
Assemble the lock ring (34).
Apply compressed air at low pressure in

hole (a) in order to push the thrust plate
(33) against retaining ring (34), then align
the clutch plate (32) spline.
Measure the clutch discs clearance. The

thrust plate lock ring must be all the way
up against the lock ring. Use a feeler
gauge to measure the distance between
the thrust plate lock ring and the first
clutch plate (32). The distance must be
1,50 to 1,95 mm. If the distance is not
within specification, the clutch is probably
assembled wrong.
02
CHASSIS
TRANSMISSION 95
ASSEMBLY (cont’d)
Insert the roller retainers (36) paying attention it

completely fit in its seat.
Insert gear (37) on the shaft (23).
Assemble the gear assembly (54) on

main shaft (23).
Assemble the bush (47) and needle

bearing (46) with special tool.
02
96 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Assemble the new O-rings (48) and (52) to

the bush (50).
Assemble the new seal rings (49) and (51) to the bush (50) with the special tools.
Note: For correct assembly of seal rings follow operations before mentioned.
Assemble the bush (50) on main shaft

(23) with special tool.
Warning: The reference mark must be on
the top surface.
02
CHASSIS
TRANSMISSION 97
ASSEMBLY (cont’d)
Assemble the bush (56) and needle

bearing (55) with special tool.
Assemble the bush (57).
Turn the shaft.

Assemble new O-ring with relative Teflon ring
(14) into the piston (13) outer seat.
Assemble new O-ring with relative Teflon ring
(15) into the piston (13) inner seat.
02
98 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)

Insert the clutch piston (13) with the

special tool as protection of seal rings
(15).
Assemble spring (11) and thrust washer (10).

02
CHASSIS
TRANSMISSION 99
ASSEMBLY (cont’d)
Lower the spring (11) lock washer (10) by using tool.

well fitted.
Loosen the handles of the threaded rods to release the

tension from the spring. Remove the top piece of the
special tool.
Assemble spring pin (21).

02
100 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Insert clutch kit (6) on main shaft (23).
Assemble thrust plate (5).
Apply compressed air at low pressure in

hole in order to push the thrust plate (5)
against the retaining ring (4), then align the
clutch plate (6) spline.
02
CHASSIS
TRANSMISSION 101
ASSEMBLY (cont’d)
Measure the clutch discs clearance.

The thrust plate lock ring must be all the way up
against the lock ring.
Use a feeler gauge to measure the distance
between the thrust plate lock ring and the first clutch
plate (32). The distance must be 2,20 to 3,05 mm. if
the distance is not within specification, the clutch is
probably assembled wrong.
Assemble the thrust washer (8) and roller bearing

(7).
Assemble the gear (3).
Assemble the thrust washer (2).

02
102 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Assemble bearing (1) with the special tool.
Assemble Teflon seals (16), (17),

(18) and (19) using special tools.
02
CHASSIS
TRANSMISSION 103
ASSEMBLY (cont’d)
1: 1st clutch oil passage

4: 3rd gear
5: 3rd gear clutch pack
6: 4th gear clutch pack
7: 4th gear
8: 1st gear
9: 1st gear clutch pack
10: Main shaft
11: Lubrication oil passage
See figure above.

Verify that all the gears can freely rotate on the main shaft.
02
104 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Apply compressed air of approximately 6 bar to the 1 st speed gear clutch passage.
Hear the 1st speed gear piston moving to lock the 1st speed gear clutch pack.
Try to move the 1st speed gear. The 1st speed gear must not turn on the input shaft.
Apply compressed air of approximately 6 bar to the 3 rd speed gear clutch passage.
Hear the 3rd speed gear piston moving to lock the 3rd speed gear clutch pack.
Try to move the 3 rd speed gear. The 3 rd speed gear must not turn on the input shaft.
Apply compressed air of approximately 6 bar to the 4th speed gear clutch passage.
Hear the 4th speed gear piston moving to lock the 4th speed gear clutch pack.
Try to move the 4th speed gear. The 4th speed gear must not turn on the input shaft.
Hook the three shafts B-C-E using the special

tool.
Lift the shafts B-C-E at the same time and
insert the unit into the half housing using tool.
02
CHASSIS
TRANSMISSION 105
AXIS E
02
106 CHASSIS
TRANSMISSION
DISASSEMBLY
Lift the three shafts B-C-E at the same time.
Remove seals (22) and (23).

seal rings.
By means of an extractor, remove

bearings (21) and (1).
Remove spacer (20).
Remove gear (18).

02
CHASSIS
TRANSMISSION 107
Remove roller bearing (19).
Overturn the shaft (12).

Press the spring washers (5) and remove
retaining ring (2) by using tool.
Danger: Springs can cause damages to
persons if removed incorrectly.
Remove the shims (3) and washer (4).
Remove the spring washers (5) and

spacer (6).
02
108 CHASSIS
TRANSMISSION
Remove the thrust plate (16) and clutch kit (15).
Remove brake counter disc (14).
Extract piston (8) using pins (10) as pusher.

02
CHASSIS
TRANSMISSION 109
Remove O-rings, inner (7) and outer (9).

the O-rings.
Remove the O-rings (11) from pins (10).

Note: This is a destructive operation for the O-
rings.
If the clutch discs are to be used again, keep the


limit. If not, replace the clutch kit B wit a new one.
02
110 CHASSIS
TRANSMISSION
Verify that the all clutch plates do not appear burned or that the friction material is not
damaged and the splines are well traced.
Verify also that all the clutch drive plates (A) are
perfectly plane and inspect for pitting or scoring.

problems occurs, replace the complete clutch kit
with a new one.
If using a new clutch kit soak the clutch plates in
clean transmission oil for at least an hour before
assembly.
the steel discs.
4WD GEAR CLUTCH

* Under load of 163 kg

02
CHASSIS
TRANSMISSION 111
ASSEMBLY
Insert inner (7) and outer (9) O-rings on clutch

piston (8).
Insert O-rings (11) on the relative pins (10).
Insert pins (10) on clutch piston (8).
Apply a thin film of grease on O-rings and position

the pins on clutch piston (8) in correspondence with
the holes on output shaft.
02
112 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Overturn the shaft (12) and fully insert the

clutch piston (8).
Insert brake counter-disc (14) on shaft (12)

with tapered edge facing down.
Mount the clutch kit (15) starting with a

drive plate (A) followed by a clutch plate
(B).
Mount thrust plate (16) on shaft (12).

02
CHASSIS
TRANSMISSION 113
ASSEMBLY (cont’d)
Assemble gear (18).
Assemble roller bearing (19) and spacer

(20).
Assemble bearing (21) using special tool.

02
114 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Turn shaft (12). Make sure that the disc/ counter-disc pack
and the piston are correctly seated.
Preassemble spacer (6), washer (4) and lock

ring (2).
Using a thickness gauge measure quote X

between washer (4) and lock ring (2).
Subtract from quote X fixed quote S1 ( S1 = 1,80
mm ).
The result S is the thickness of shims (3) which
has to be insert to between washer (4) and locking
(2).
S = X – S1 = X – 1,80 mm
02
CHASSIS
TRANSMISSION 115
ASSEMBLY (cont’d)
Select the shim (3) of thickness value ( S ) among the

range available shims.
Thickness of shims are: 0,1 mm, 0,3 mm, 0,5 mm.
Note: Choose the shim (3) so that is guaranteed a stroke

of 1,70 ~ 1,90 mm.
Disassemble the washer (4) and lock ring

(2).
Insert spring washer (5).

Warning: Check the spring washer (5)
orientation.
Mount washer (4) and shims (3) with

thickness S defined before.
02
116 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
Lower spring washers (5) and assemble

retaining ring (2) by using tool.
Danger: Springs can cause damages to
persons if the snap ring is not assembled
correctly.
Assemble Teflon seals (22) and (23) by

using special tools.
02
CHASSIS
TRANSMISSION 117
ASSEMBLY (cont’d)
Use tool for piston operation check and correct

adjustment check.
In order to verify the seal rings (7) and (9)

feed the piston chamber with oil at 10 bar
and check with a dial gauge located as
shown in the photo.
Real stroke is included between 2,3 and 2,4 mm.

02
118 CHASSIS
TRANSMISSION
ASSEMBLY (cont’d)
1: 4WD oil passage 2: 4WD gear 3: 4WD lubricant oil passage

4: Shaft 5: Spring washers
Apply compressed oil pressure of approximately 10 bar to the 4WD clutch passage.
Listen to hear the piston moving to unlock the clutch pack. The spring washers
compresses. Try to move the 4WD gear. The 4WD gear must turn freely on the shaft.
If clutch does not work correctly, disassemble the clutch to find the problem.
Lift the three shafts B-C-E at the same time

and insert the unit into the half housing by
using tool.
02
CHASSIS
TRANSMISSION 119
TROUBLESHOOTING
This list of possible failures and remedies provides no more than an indication of
what the problem might be and how to fix it.
It should be remembered that the problems are not caused by just one part, but by
part’s interaction with other elements. Accordingly, additional action over and above
the steps described is frequently required.
This list may not cover all possible problems and remedies.
Specialist personnel must identify the problem and its cause and then proceed with
the necessary repairs.
Warning: All checks and tests must be performed with the oil at working temperature
80 ± 2 0C.
CHECKS AND TESTS
Transmission oil check

Always check the correct oil level and correct oil specification.
Pressure test
Several transmission breakdowns can be identified by running pressure checks.
Irregular measurements might indicate that there is a problem, which specialist
personnel must identify.
Stall test
In order to create ideal conditions for troubleshooting, the converter stall procedure
must be performed first. The purpose of this test is to determine whether the torque
converter and hydraulic clutch units are operating correctly.
This operation will also bring the oil up to its working temperature of 80 ± 2 0C,
allowing any problems in the engine, converter or transmission to be identified.
Proceed as follows:
 Check the oil level.
 Apply the parking brake to block the wheels.
 Start the engine and keep it ticking over at idle speed (88-00-1000 rpm).
 Put the gear lever into 4th.
 Put the reverser in the FORWARD position.
 Rev the engine for short periods to a maximum of 1500-1700 rpm, to bring the
oil up to working temperature.
Important: The converter stall test must not exceed a maximum duration of 30
seconds each time. After this 30 sec period, put the reverser in NEUTRAL for
15 seconds than repeat the procedure. Warning: Failure to keep to these test
periods may result in the oil overheating and attendant damage to the
clutches, filter, converter and seals.
 Gradually reduce the engine revs to minimum.
 Put the reverser in NEUTRAL.
02
120 CHASSIS
TRANSMISSION
GUIDE TO PROBLEMS
Mechanical problems
 Check that all of the transmission’s internal and external mechanical parts are
correctly fitted.
 Check the efficiency of the parking brake.
 Check that the cooling system is in good operating condition.
 Check the efficiency of the engine. Make sure that the engine’s idling speed is
set correctly and that it complies with the maximum speed specifications under
no load conditions.
Hydraulic problems
 Check the transmission oil level.
 Use the specified oils.
 Check that the hydraulic system is correctly filled.
 Check the efficiency of the hydraulic system. Check for oil leaks.
 Check the efficiency of the transmission’s hydraulic components (converter, oil
pump, filter, connections, hoses)
Electrical problems
 Check the efficiency and correct installation of the vehicle battery.
 Check the efficiency and correct installation of all electrical components,
outside the transmission (wiring, cables, alternator, battery, et.).
 Check the efficiency and correct installation of all transmission electrical
components (wiring, sensors, solenoid valves, EGM/ECU, etc.).
02
CHASSIS
TRANSMISSION 121
TROUBLESHOOTING OF TRANSMISSION
The next table lists problems, possible causes and recommended corrective action.
Problem Probable Cause Remedy
Faulty supply to solenoid valves Check/Replace

MACHINE DOES
NOT MOVE Damaged wiring connections between Repair/Replace
transmission and machine
Oxidized contacts in electrical wiring Clean
Break in electric cable Replace
Damaged solenoids Replace
Short circuits or false contacts Check/Replace fuses
Irregular functioning of electronic gear Replace EGM/ECU

management (EGM/ECU)
Check for leaks Repair/Top up
Blocked suction strainer Clean
Damaged oil pump Replace
Damaged oil pump relief valve Replace oil pump
Blocked/damaged transmission oil filter Replace
Damaged/jammed control valve Replace
Oil temperature below 0 0C Wait for oil to reach

working temperature
Damaged rotary seals Replace

02
122 CHASSIS
TRANSMISSION

Incorrect oil temperature Wait for oil to reach
working temperature
Transmission oil overheating Restore acceptable

MACHINE HAS temperature values
REDUCED
POWER Incorrect operating pressure Check hydraulic circuit
TRANSMISSION and replace (oil pump,
filter, control valve)
Worn clutch unit Replace/Repair
4WD clutch failure Repair/Replace 4WD

shaft group
Overheating solenoids Replace
Damaged transmission and machine Repair/Replace

wiring connections
Damaged EGM/ECU logic Replace EGM/ECU
Damaged hydraulic cooling system Repair
Dirty heat exchanger Clean

OVERHEATING
Parking brake inadvertently applied Release
Excessive dirt on axle wheel hubs Clean
Seizing (broken gears, shafts, bearings, etc.) Check/Repair/Replace
Braking force outside transmission: Check/Repair/Replace

irregular axle operation
Clutch plate drag Repair/Replace

02
CHASSIS
TRANSMISSION 123
OVERHEATING Damaged converter Replace
Damaged oil thermostat Replace
Worn oil pump Replace
WHEELS Clutch plate drag Repair/Replace

ROTATES WHEN
MACHINE IS Low oil temperature (high oil viscosity) Wait for oil to reach
RAISED working temperature
Incorrect oil specifications Change oil and filters
Faulty reverser locking Repair/Replace
NOISE Damaged converter Replace
Seizing (broken gears, shafts, bearings, etc.) Check/Repair/Replace
Worn synchronizer actuation unit Replace
Worn 4WD clutch replace
IRREGULAR Damaged control valve Replace

ACTUATION
Electrical system fault Repair/Replace
Low oil temperature Wait for oil to reach

working temperature
02
124 CHASSIS
TRANSMISSION
IRREGULAR Overheating See “overheating”

ACTUATION
Faulty EGM/ECU operation Replace EGM/ECU
Damaged hydraulic system Repair/Replace
GEAR REMAINS Damaged/jammed shuttle shaft lever Repair/Replace

ENGAGED
Damaged clutch unit Repair/Replace
Irregular EGM/ECU operation Replace EGM/ECU
NO 4WD POWER Damaged 4WD clutch Replace

TRANSMISSION
Hydraulic system fault Repair/Replace
Faulty brake sensor Check/Replace
Faulty EGM/ECU operation Replace EGM/ECU
GEAR SHIFT Damaged clutch unit Repair/Replace

WON’T ENGAGE
Damaged pressure sensor Check/Replace
Irregular EGM/ECU operation Replace EGM/ECU

02
CHASSIS
TRANSMISSION 125
SPECIAL TOOLS
Description CARRARO Part No: Figure
Handle CA119033
Driver CA715004
Driver CA7150046
Driver CA715149
Calibrator CA715356
Clutch
CA715358
assemble/disass.
02
126 CHASSIS
TRANSMISSION
SPECIAL TOOLS (cont’d)
Axe B,C,E
CA715750
rising tool
Driver CA715409
Check CA715494
Protection +
CA715495
shims
Pusher CA715497
Protection CA715499
02
CHASSIS
TRANSMISSION 127
Driver CA715501
Driver CA715623
Protection + shims CA715743
Protection + shims CA715744
Calibrator CA715745
Pusher CA715746
Calibrator CA715747
02
128 CHASSIS
TRANSMISSION
Pusher CA715748
Calibrator CA716009
Protection CA716010
Protection + shim CA716018
Pusher CA716019
Calibrator CA716020
Extractor CA716021
01
TIRE
GENERAL 1
Proper tire care and safety is simple and easy. The Rubber Manufacturers
Association (RMA) recommends getting in the habit of taking five minutes every
month to check your tires, including the spare.
It's important to have the proper air pressure in your tires, as under inflation may lead
to tire failure. The right amount of air for your tires is specified by the vehicle
manufacturer and is shown on the vehicle door edge, door post, glove box door or
fuel door. It is also listed in the owner's manual.
1. When you check the air pressure, make sure the tires are cool - meaning they are
not hot from driving even a mile. (NOTE: If you have to drive a distance to get air,
check and record the tire pressure first and add the appropriate air pressure when
you get to the pump. It is normal for tires to heat up and the air pressure inside to go
up as you drive. Never "bleed" or reduce air pressure when tires are hot.)
2. Remove the cap from the valve on one tire.
3. Firmly press a tire gauge onto the valve.
4. Add air to achieve recommended air pressure.
5. If you overfill the tire, release air by pushing on the metal stem in the center of the
valve with a fingernail or the tip of a pen. Then recheck the pressure with your tire
gauge.
6. Replace the valve cap.
7. Repeat with each tire, including the spare. (NOTE: Some spare tires require higher
inflation pressure.)
8. Visually inspect the tires to make sure there are no nails or other objects
embedded that could poke a hole in the tire and cause an air leak.
9. Check the sidewalls to make sure there are no gouges, cuts, bulges or other
irregularities. NOTE: Air pressure in a tire goes up (in warm weather) or down (in cold
weather) 1-2 pounds for every 10 degrees of temperature change.
01
2 TIRE
GENERAL
Misalignment of wheels in the front or rear can cause uneven and rapid tread
wear and should be corrected by a tire dealer. Front-wheel-drive vehicles, and those
with independent rear suspension, require alignment of all four wheels. Have your
alignment checked periodically as specified by the vehicles' owners manual or
whenever you have an indication of trouble such as "pulling" or vibration.
Also have your tire balance checked periodically. An unbalanced tire and wheel
assembly may result in irregular wear.
Sometimes irregular tire wear can be corrected by rotating your tires. Consult
your vehicle's owners manual, the tire manufacturer or your tire dealer for the
appropriate rotation pattern for your vehicle. NOTE: If your tires show uneven wear,
ask your tire dealer to check for and correct any misalignment, imbalance or other
mechanical problem involved before rotation.
Before rotating your tires, always refer to your car's owner's manual for rotation
recommendations. If no rotation period is specified, tires should be rotated
approximately every 6,000 miles
Tires must be replaced when the tread is worn down to 1/16 of an inch in order to
prevent skidding and hydroplaning. An easy test: place a penny into a tread groove.
If part of Lincoln's head is covered by the tread, you're driving with the proper amount
of tread. If you can see all of his head, you should buy a new tire.
Built-in tread wear indicators, or "wear bars," which look like narrow strips of smooth
rubber across the tread will appear on the tire when the tread is worn down to one-
sixteenth of an inch. When you see these "wear bars," the tire is worn out and should
be replaced.
Visually check your tires for signs of uneven wear. You may have irregular tread wear
if there are high and low areas or unusually smooth areas. Consult your tire dealer as
soon as possible.
01
TIRE
SPECIFICATIONS 3
TIRE SIZE
HMK 102 B front 12,5/80 x 18 12 ply rating TUBELESS
HMK 102 B rear 16,9/14 x 28 12 ply rating TUBELESS
HMK 102 S front & rear 16,9/14 x 28 12 ply rating TUBELESS
INFLATION PRESSURE
Size psi bar
12,5/80 x 18 58 4
16,9/14 x 28 38 2,6
12,5/80 x 18 16,9/14 x 28 16,9/14 X 28
FRONT TIRES REAR TIRE

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HMK 102 ENERGY WORKSHOP MANUAL 00

 00- 01 REVISION HISTORY

Revision Revision Revision

1 BUCKET LOADER 7 STABILIZERS

GENERAL VIEW OF HMK 102 ENERGY

GENERAL DIMENSIONS OF HMK 120 B ENERGY

GENERAL DIMENSIONS OF HMK 120 S ENERGY

MODEL : HMK 102B HMK 102S

A. OVERALL TRANSPORT LENGTH 6090 mm 6125 mm

B. TREAD WİDTH, FRONT 1920 mm 1905 mm

C. TREAD WİDTH, REAR 1780 mm 1905 mm

D. OVERALL TRANSPORT WIDTH 2440 mm 2440 mm

E. BACKHOE MAX. DIGGING DEPTH (STD. ARM) 4400 mm 4350 mm

F. BACKHOE MAX. DIGGING DEPTH (TELESCOP. ARM) 5640 mm 5590 mm

G. TRANSPORT HEIGHT (MAX.) 3530 mm 3595 mm

H. GROUND CLEARANCE, BUCKET, DRIVE POSITION 400 mm 400 mm

I. BUCKET WIDTH (STD) 2440 mm 2440 mm

J. DUMP HEIGHT (LOADER) 2610 mm 2760 mm

K. DUMP HEIGHT (BACKHOE STD.) 3700 mm 3750 mm

L.. DUMP HEIGHT (BACKHOE TELESCOP.) 4650 mm 4700 mm

M. BUCKET LOADER MAX HEIGTH 4100 mm 4165 mm

N. BUCKET LOADER LEVELLING (MINUS) 195 mm 140 mm

Low Idle speed (No load) rpm 950 ±50

Radiator Air cooled

Item Unit Specifications

Type mineral oil for the high pressurized

Capacity Liter 120,0

Model type - PS764

HMK 102 B FRONT 12.5-80/18 12PR

HMK 102 S ALL 4 16,9/14 x 28 12PR

Type - Gear Pump

Flow rate cc/rev 4,0

Type - With diaphragm

Gas pressure bar 16

Service brake pressure bar 210

Transm. ATF Dexron

ASTM D975 No.1

How to read this manual

Section number (01 : Structure and function)

Chapter number (10 : Engine)

For the revision status in this manual, refer to REVISION HISTORY.

SYMBOL ITEM REMARKS

Special safety precautions are

Caution Special technical precautions or

Tightening Pay attention to the tightening torque

Tool Use proper tools in assembling and

Adhesive Places to be applied with adhesive.

Places where oil or lubricant must be

HAZARD SYMBOL EXAMPLES

HAZARDING ALERT SYMBOLS

Caution – Warning – dangerous

Caution – Warning – dangerous

Caution, risk of electric shock

Caution, risk of electric shock

Caution, hot surface

Caution, rotational object

Caution, toxic risk

Caution, risk of electric shock

Caution , hot surface

Use of matches, lighters and smoking

Don’t use in a damp place

For safety observe the following rules.

SAFETY CLOTHES AND HELMET

PREPARATION FOR EMERGENCIES