Training Manual

TELEHANDLER TIER 3
1. General information
2. Walk around
Telehandler Tier 3
3. Engine
4. Controls and instruments
5. Telescopic arm assembly
6. Transmission
7. Transmission disassembly
8. Hydraulic system
9. Steering system
10. Brake system
11. Electrical system
12. Front axle disassembly
13. Man Platform
14. Accessories Technical Training Manual
Lecce Training Centre – November 2008 (made by S. Spedicato) 1

Telehandler - General Information
GENERAL
INFORMATION
1
‘HEAVY’
‘HEAVY’ MODELS
MODELS
LM1340 - LM1343 LM1443 - LM1445 LM1745

LM1345 TURBO TURBO TURBO
IVECO NEF TIER III MECHANICAL TURBOCHARGED WITH AFTERCOOLER

ENGINE
88 kW (120 HP) @ 2200 RPM
HYDRAULIC LOAD SENSING PRESSURE COMPENSATING

SYSTEM (1 FIXED DISPLACEMENT GEAR PUMP)
POWERSHIFT by DANA
TRANSMISSION
(4 SPEED FORWARD + 3 SPEED REVERSE)
SPEEDMETER + HOURMETER + ANTITIPPING DISPLAY (with safety

DASHBOARD
hydraulic lockout)
OPTIONAL
MANDATORY
LM1340 -> WITHOUT MANDATORY
STABILIZERS LM1443 -> NARROW
LM1343 -> NARROW HEAVY
LM1445 -> HEAVY
LM1345 -> HEAVY
REAR AXLE
OPTIONAL MANDATORY
LOCKING SYSTEM
2
‘LIGHT’
‘LIGHT’ MODELS
MODELS
LM1330 - LM1333
LM732 LM1133
TURBO
IVECO NEF TIER III MECHANICAL TURBOCHARGED

ENGINE
74 kW @ 2200 RPM
LOAD SENSING PRESSURE COMPENSATING

HYDRAULIC SYSTEM
(1 FIXED DISPLACEMENT GEAR PUMP)
POWERSHIFT by DANA
TRANSMISSION
(4 SPEED FORWARD + 3 SPEED REVERSE)
SPEEDMETER + HOURMETER + ANTITIPPING DISPLAY (without

DASHBOARD
safety hydraulic lockout)
OPTIONAL
MANDATORY
STABILIZERS NOT LM1330 -> WITHOUT
(NARROW)
LM1333 -> NARROW
REAR AXLE LOCKING
NOT
SYSTEM
3
LM
LM 13
13 45
45
MAX HEIGHT
MAX ALLOWED
WITH BOOM
WEIGHT (4,5 TON)
ALL EXTENDED
4
MAX
MAXHEIGHT
HEIGHTWITH
WITHBOOM
BOOMALL
ALLEXTENDED
EXTENDED
5
LM1133
LM1133
SAFE
SAFE WORKING
WORKING
LOAD
LOAD DIAGRAM
DIAGRAM
(WITH
(WITHSTABILIZERS
STABILIZERS
RAISED)
RAISED)
6
LM1745
LM1745
SAFE
SAFE WORKING
WORKING
LOAD
LOAD DIAGRAM
DIAGRAM
(WITH
(WITHSTABILIZER
STABILIZER
LOWERED)
LOWERED)
7
SAFETY
SAFETY WORKING
WORKING LOAD
LOAD DIAGRAM
DIAGRAM
(Ref.
(Ref. Normative
Normative :: UNI
UNI EN
EN 1459)
1459)
Machine must be placed on support having 7° of slope.
Load 800 Kg ÷ 4500 Kg.
Rear wheel must be parallel to support axle
(as showed below)
Front wheel must be all steered.
Rise the boom and try to extend it at max height.
7°
7°
8
Telehandler - Walk Around
WALK
AROUND
1
LEFT
LEFT SIDE
SIDE
HYDRAULIC
FUEL TANK OIL TANK
(135 Litres) (185 litres)
2
LEFT
LEFT SIDE
SIDE
DOOR
LOCK
3
DOOR
LOCK
4
DOOR
RELEASE
LEVER
5
HAND
HAND BRAKE
BRAKE
WINDSCREEN
WASHER TANK
6
LEFT
LEFTSIDE
SIDE
REMOVE THIS
PANEL TO
CLEAN THE
HYDRAULIC
TANK
7
REAR
REARVIEW
VIEW
REAR
WINDOW
LOCK
ROTARY
BEACON
SUPPLY
8
REAR
REARVIEW
VIEW
Max opening : 150 mm.

In case of emergency
you have to remove
the red pin to open
fully the window
9
REAR
REAR AXLE
AXLE LOCKING
LOCKING CYLINDER
CYLINDER
10
REAR
REAR AXLE
AXLE LOCKING
LOCKING CYLINDER
CYLINDER
REAR AXLE LOCKING VALVE.
LIFTING THE BOOM, WHEN
ANGLE WITH GROUND PLANE
REACH ≈ 30 °
REAR AXLE WILL BE LOCKED
11
REAR
REARVIEW
VIEW
REAR AXLE
LOCKING
ACTIVATED NOT ACTIVATED
PROXIMITY
SWITCH
THIS PROXIMITY SWITCH WHEN NOT ACTIVATED, (BOOM RAISED) DOESN’T LET THE
STABILISERS TO MOVE UP AND DOESN’T ALLOW THE OPERATOR TO USE FRAME
LEVELLING CYLINDER
12
COUNTERWEIGHTS
COUNTERWEIGHTS
ON LM1340/43/45 ARE INSTALLED a + b
ON LM1330/33 LM1443/45 and LM1745 ARE INSTALLED a + b + c
600 kg 600 kg
(a) (b)
300 kg
(c)
13
NARROW
NARROWSTABILIZER
STABILIZER
WELDED
ON FRAME
Inside machine shape

14
HEAVY
HEAVYSTABILIZER
STABILIZER
15
FRAME
FRAMELEVELLING
LEVELLINGCYLINDER
CYLINDER
16
FRAME
FRAMELEVELLING
LEVELLINGCYLINDER
CYLINDER
ANTIDROP
VALVE
17
STABILIZER
STABILIZER CYLINDER
CYLINDER
ANTIDROP
VALVE
18
MACHINE’S
MACHINE’S CYLINDERS
CYLINDERS
External
boom
Cylinder
Tilt Telescopic
Lift and
Cylinder Cylinder
compensation
Cylinder
Frame
levelling
Cylinder
Rear axle
Stabilizer locking
Cylinders Cylinder
19
PILOT
PILOT SUPPLY
SUPPLY AND
AND STABILIZER
STABILIZER
SOLENOID
SOLENOID GROUP
GROUP
20
TRANSFER
TRANSFER BOX
BOX
HAND
BRAKE
DISK
FRONT
FRONT SIDE
SIDE 21
TRANSMISSION
TRANSMISSION
22
TRANSMISSION
TRANSMISSION
FRONT MACHINE
HAND
BRAKE
CALIPER
23
STEERING
STEERING SOLENOID
SOLENOID VALVE
VALVE
24
PIPING LAY
Telehandler - WalkOUT
PIPING LAY OUT Around
25
TILT
TILT CYLINDER
CYLINDER
ANTI DROP
VALVE
26
BOOM
BOOM LIFT
LIFT CYLINDER
CYLINDER
ANTI DROP
VALVE
COMPENSATION
CYLINDER
27
COMPENSATION
CYLINDER BOOM LIFT
CYLINDER
28
BOOM LIFT COMPENSATION

CYLINDER CYLINDER
STEERING
SOLENOID
VALVE
29
30
31
32
33
FRONT
FRONT CAB
CAB VIEW
VIEW
BEHIND THIS
PLASTIC COVER
THERE ARE
HYDRAULIC OIL
FLEX HOSES AND
ELECTRIC WIRES 34
FRONT
FRONT CAB
CAB VIEW
VIEW
Bulkhead
Connector
35
GUIDE WITH PLASTIC

PAD TO REDUCE
MOVEMENT OF BOOM IF
MACHINE HAVE TO
WORK AS A WHEEL
LOADER
PLASTIC PAD USED

LIKE BOOM END
STROKE
36
ENGINE
RADIATORS
RADIATORS GROUP
GROUP
WATER TRANSMISSION
RADIATOR RADIATOR
AFTERCOOLER
RADIATOR
HYDRAULIC
OIL
RADIATOR
37
HYDRAULIC
HYDRAULIC PUMP
PUMP
38
HYDRAULIC
HYDRAULIC PUMP
PUMP
PRIORITY
VALVE STEERING
PRESSURE
PORT
STEERENIG
L.S.
39
REAR
REAR VIEW
VIEW
PROSSIMITY
SENSOR
HYDRAULIC
FILTER
MAIN
CONTROL
VALVE
40
REAR
REAR VIEW
VIEW
HYDRAULIC
FILTER ON
RETURN LINE
AND BYPASS
41
MAIN
MAINCONTROL
CONTROLVALVE
VALVE
42
LM1330/33
LM1330/33MAIN
MAINDIFFERENCES
DIFFERENCES
MAN PLATFORM
BOOM WITH
NOT AVAILABLE NEW JOYSTICK
INTERNAL CHAIN
WITH BOOM EXTENSION
ON / OFF
OVERLOAD
INDICATION ONLY
(NO LOCKUP FACILITY)
NO REAR
AXLE LOCK
NEF ENGINE
60 kW Natural Aspirated
320 Nm @ 1400 rpm
71 kW Turbo without aftercooler
400 Nm @ 1400 rpm
DIFFERENT
NARROW STAB COUNTERWEIGHTS
43
LM1330/33
LM1330/33COUNTERWEIGHTS
COUNTERWEIGHTS
44
LM1333
LM1333NARROW
NARROWSTABILIZERS
STABILIZERS
45
JOYSTICK
JOYSTICKLM1333
LM1333
BOOM EXTENSION /
RETRACTION BUTTONS
AUX FUNCTION
BUTTON
46
LM1333
LM1333BOOM
BOOMWITH
WITHCHAINS
CHAINS
47
LM1333
LM1333BOOM
BOOMWITH
WITHCHAINS
CHAINS
48
LM1330/33
LM1330/33HYDRAULIC
HYDRAULICMAIN
MAINVALVE
VALVE
SPOOL FOR
BOOM
EXTENSION
49
LM732
LM732––LM1133
LM1133
FUEL TANK
(143 Litres)
50
Battery
BatteryCompartment
Compartment
Capacity: 95 Ah
Max current: 900 A
51
REAR
REARSIDE
SIDE
A.C. Condenser
Rear
Window
Opening
Hydraulic Oil
Reservoir
(110 litres) 52
REAR
REAR SIDE
SIDE
HYDRAULIC OIL
FILLER CAP
Hydraulic oil
reservoir with
level indicator
53
COUNTERWEIGTHS
COUNTERWEIGTHS(LM1133)
(LM1133)
200 kg 200 kg
54
Stabilizer
StabilizerCylinder
Cylinder(LM1133)
(LM1133)
Load Holding
Valve
55
Transfer
Transfer Box
Box
Hyd. Oil
Filter on
Return
Line
Parking
Brake Disc
56
TRANSMISSION
TRANSMISSION
Parking
Pinza freno
Brake
di
parcheggio
Caliper
57
Steering
Steering Solenoid
Solenoid Valve
Valve
58
HYDRAULIC
HYDRAULIC MAIN
MAIN CONTROL
CONTROL VALVE
VALVE
Hydraulic Main
Valve
Stabilizers
Control & Pilot
Supply Unit
59
PIPING
PIPINGLAY-
LAY-OUT
OUT
60
LIFT
LIFT &
& COMPENSATION
COMPENSATION CYLINDERS
CYLINDERS
COMPENSATION
CYLINDER
LOAD
HOLDING
VALVE
61
COMPENSATION
CYLINDER
LIFT CYLINDER
62
ENGINE
ENGINESIDE
SIDE
63
Rain
RainCup
CupAir
AirCleaner
Cleaner
(standard)
(standard)
Cyclonic
CyclonicAir
AirCleaner
Cleaner
(optional)
(optional)
64
RADIATORS
RADIATORS GROUP
GROUP
ENGINE
COOLANT
RADIATOR
TRANSMISSION
OIL COOLER
HYDRAULIC
OIL COOLER
65
HYDRAULIC
HYDRAULIC GEAR
GEAR PUMP
PUMP (MADE
(MADEBY
BYCASAPPA)
CASAPPA)
66
Telehandler - Engine Tier 3
ENGINE
TIER III
1
Side
SideMounted
MountedEngine
Engine
2
Side
SideMounted
MountedEngine
Engine
3 point engine mount for vibration free performance
Tier 3 Mechanical Engine

Model F4GE9484J*J600C
kW/hp @ rpm 88/120 @ 2200
Max Torque Nm @ rpm 525 @ 1400
Turbo & Intercooler TI
Bore - mm 104
Stroke - mm 132
Capacity cc 4485
Compression Ratio 17.5:1
Firing order 1-3-4-2
Valves /Cylinder 2
Fuel Injection System Mechanical
High Idle rpm 2450
26% increased in power Rated Speed rpm 2200
32% increase in torque
22 % increase in power to weight ratio Low Idle rpm 1000
3
Engine
EngineIdentification
Identification
Engine Type
88 kW (120 hp) : F4GE9484J*J600
74 kW (100 hp) : F4GE9484F*J600
Engine Specification Decal on Sump or Timing Gear Housing
4
IDENTIFICATION
IDENTIFICATIONPLATE
PLATE
5
ENGINE
ENGINEIDENTIFICATION
IDENTIFICATIONCODE
CODE
F 4 G E 9 4 8 4 J ∗ J
Emission level
Approved rating
Use
Feeding / Injection
J = TIER 3
Cylinder no.
Cylinder pattern:
9 = 4 strokes, vertical
Engine
Type of crankcase: 4 = 4 cylinders

Group G = non--structural
Engines
8 = Direct Injection, Turbo,

Diesel, Intercooler
4 = Earthmovers
6
Engine
EngineInstallation
Installation
7
Engine
EngineCooling
Cooling
COOLANT
LIQUID
RADIATOR
AFTERCOOLER
RADIATOR
8
Engine
EngineCooling
Cooling
Steel Airflow Grill

9
Diesel
DieselFuel
FuelSystem
System
Fuel Tank located

under cab.
Capacity 135 l
10
Diesel
DieselFuel
FuelInjection
InjectionPump
Pump
Bosch VE Type Fuel Injection Pump: Mechanical Governor
11
ENGINE
ENGINE –– TURBO
TURBO SIDE
SIDE
TURBOFAN
EXHAUST ALTERNATOR
MANIFOLD
WATER
PUMP
STARTER
MOTOR
UNION FOR
OIL FILTER
12
THERMOSTAT
VALVE
ALTERNATOR
POLY – V
BELT
WATER
PUMP 13
ENGINE
ENGINE –– INJECTION
INJECTION SIDE
SIDE
INJECTION
FUEL PUMP
FILTER
ENGINE OIL
FILTER
14
ENGINE
INJECTION SIDE
SIDE
DISTRIBUTOR FUEL
PUMP (VE TYPE)
COLD START AUTOMATIC

INJECTION SYSTEM
(ADVANCE TIMING) WITH
WATER TEMPERATURE
UNDER 60° ÷ 70 °
15
ENGINE
INJECTION SIDE
SIDE
TEMPERATURE SWITCH
FOR COLD START SYSTEM
(AT LOW TEMPERATURE IS
NORMALLY CLOSED)
16
ENGINE
INJECTION SIDE
SIDE
FUEL
FILTER
FUEL ENGINE OIL

PUMP PRESSURE SWITCH
17
ENGINE
ENGINE –– TOP
TOP VIEW
VIEW
BLOW - BY
WATER
TEMPERATURE
SENSOR (FOR
INDICATION IN CAB)
18
WASTEGATE
WASTEGATE
(*)
(*) WASTEGATE is a device that control the intake air pressure at about 1,2 bar.
In case this pressure is going to rise, the wastegate start to open and let to exhaust
gas to go directly to muffler.
19
WASTEGATE
WASTEGATE
20
E.G.R.
E.G.R.––Exhaust
ExhaustGas
GasRecirculation
Recirculation
In general on tier 3 engines has been
developed a new system called E.G.R in order
to reduce the pollution.
EGR stand for Exhaust Gas Recirculation.
Practically part of exhaust gas is introduced in
the cylinders in order to reduce the combustion
temperature.
In fact, the exhaust gas doesn’t contain
oxygen, practically are neutral and are as
obstacle to heat propagation.
Since the production of oxide of nitrogen
(pollution) is directly proportional to
combustion temperature, it means that if we
reduce the combustion temperature, we reduce
pollution.
IVECO NEF got the EGR just modifying the
cams shaft.
So when the gas is going outside of cylinder,
part re-enter in the same cylinders.
Note: in the picture there is a solution adopted by Isuzu.
21
E.G.R.
E.G.R.––Exhaust
ExhaustGas
GasRecirculation
Recirculation
On NEF engines an extra lobe on the cam

shaft let to get the exhaust gas recirculation
during the intake cycle by keeping the
exhaust valve open for a short time.
B
A
22
E.G.R.
E.G.R.––Exhaust
ExhaustGas
GasRecirculation
Recirculation
23
CYLINDER
CYLINDERHEAD
HEAD
300 450
24
LUBRICATION
LUBRICATIONFLOW
FLOW
25
ENGINE
ENGINEOIL
OILCOOLER
COOLER
26
OIL
OILVAPOR
VAPORRECIRCULATION
RECIRCULATION
1. Valve
2. Tappet cap
3. Breather pipe
27
Cooling
CoolingSystem
System
28
MECHANICAL
MECHANICALFUEL
FUELPUMP
PUMP
1. Priming pump
2. Drive lever
3. Camshaft.
29
INJECTION
INJECTIONPUMP
PUMP
30
Engine
EngineTiming
Timing
2
5
4
3 1. Pump Drive Gear
2. Timing Gear Housing
3. Gasket
4. Bosch Fuel Injection Pump
5. Hole to accept Timing Pin
6. Hole in Timing Gear Housing
31
Engine
EngineTiming
TimingTool
Tool
p/n 99360616
To determine TDC No 1 Cylinder, remove the sealing plug and engage the turning tool
with the flywheel teeth.
Remove the cap from the support and insert timing pin tool and press lightly towards the
flywheel
Slowly turn the engine until the pin engages into pump drive gear hole
32
FINDING
FINDINGTDC
TDC
Remove the first injector, fit the tool 380000977 (2)

and the relevant dial gauge 380001005 (1) and
remove the tappet cover (3).
Rotate the engine drive shaft until cylinder #1 is at

TDC.
The condition of 1st cylinder to TDC at end of

compression phase is obtained when the dial gauge
pointer reaches maximum value and suction and
exhaust valves are both closed.
33
SETTING
SETTINGPUMP
PUMPTIMING
TIMING
- With the ignition pump fitting into its housing
and with loosened fastening screws, remove
the closure cap placed over the pump cover.
- Fit the dial gauge 380000228 (2) and the

relevant tool 380001084 (1), pre--loading the rod
by 2.5 mm.
- Rotate the engine drive shaft in order to have

the condition of the first cylinder to TDC end of
compression phase. Reset the dial gauges and
rotate the engine drive shaft into the
anticlockwise direction until the relating value
of presetting (0.80 ± 0.05 mm) should be read
on the dial gauge.
- Rotate the pump in anti--clockwise direction if

the stroke is shorter or in clockwise direction if
the stroke is longer, until obtaining the stroke
prescribed.
- Checking these conditions, lock the pump by

tightening the relevant nuts to the prescribed
pair.
34
TABLE
TABLEOF
OFPRE-DELIVERY
PRE-DELIVERYVALUES
VALUESFOR
FORBOSCH
BOSCHINJECTION
INJECTIONPUMPS
PUMPS
NOTE: INJECTION PUMP CALIBRATION

Overhaul and calibration interventions are up to BOSCH assistance network.
The contract technical specification containing the data to calibrate the pump at the bench is identified by
the code shown on injection pump body and is available at BOSCH technical assistance network.
Otherwise, refer to CNH Technical Assistance Service.
35
Telehandler - Controls and Instruments
CONTROLS
AND
INSTRUMENTS
1
TOP
TOP VIEW
VIEW
2
SIDE
SIDE VIEW
VIEW
3
TRANSMISSION
TRANSMISSION CONTROL
CONTROL
HORN
GEAR UPSHIFTING AND

DOWNSHIFTING ARE
CONTROLLED ONLY BY
THIS SELECTOR
4
LEFT
LEFTSIDE
SIDEDASHBOARD
DASHBOARD––HEAVY
HEAVYMODELS
MODELS
FRONT
FRAME
LEVELLING
REAR AXLE LEFT RIGHT

UNLOCK SWITCH STABILIZER STABILIZER
5
LEFT
LEFTSIDE
SIDEDASHBOARD
DASHBOARD––LIGHT
LIGHTMODELS
MODELS
ROAD / WORKING MODE

SWITCH
6
RIGHT
RIGHT HAND
HAND MANIPULATOR
MANIPULATOR
OTOR
E RM
WI P
KNOB TO SELECT:
- LOW BEAM / HIGH BEAM -
DIRECTIONAL LIGHT
- WIPER
7
Telehandler - ControlsROAD POSITION
and Instruments
MAN PLATFORM
ALL HYDRAULIC FUNCTIONS ARE DISCONNECTED
TELESCOPIC ARM (BOOM, STABILIZER, AND FRAME LEVELLING)
CONTROLS ARE
PLACED OUTSIDE
THE CAB
(PLATFORM)
WORKING
POSITION
WORKING
KEY IGNITION
KEY
8
1 2 3 4 5 6 7 8 9
1 - Working lights on boom switch 6 - Road lights switch

2 - Optional solenoid valve switch (winch) 7 - Emergency
3 - Wiper switch 8 - Working lights on cab switch (front side)
4 - Joystick AUX buttons supply switch 9 - Working lights on cab switch (rear side)
5 - Revolving beacon switch
9
INSTRUMENT
INSTRUMENTCLUSTER
CLUSTER
Warning Buzzer
1. Low Battery Charging 5. Transmission Oil Pressure Low

2. Low Engine Oil Pressure 6. Rear Wheel Alignment Indicator
3. Brake Fluid below Minimum Level 7. Engine Pre-heat Indicator
4. Transmission Oil Temperature High 8. Parking brake ‘ON’ indicator
10
AUXILIARY
FUNCTION
BOOM IN
EXTENSION
ROTATIVE SLIDER
TO CONTROL
TELESCOPIC BOOM
BOOM IN
RETRACTION
11
TRANSMISSION
DECLUTCH
BUTTON
REAR VIEW
12
AUXILIARY
AUXILIARY CONTROL
CONTROL
1 - FLEX HOSES TO SUPPLY LOCK CYLINDER ON QUICK COUPLER.
USING THE HYDRAULIC ATTACHMENTS (p.e. BUCKET CONCRETE MIXER), YOU

HAVE TO REMOVE THE FLEX HOSES AND CONNECT THEM TO HYDRAULIC MOTOR.
13
BUBBLE’S
BUBBLE’S INCLINOMETER
INCLINOMETER
I
When bubble is at end stroke,

angle is about ± 10°.
Our machine reach ± 8°.
±8° ±8°
14
HEATING/A.C.
HEATING/A.C.CONTROLS
CONTROLS
AIR CONDITIONING
SWITCH
15
JOYSTICK
JOYSTICK‘ON
‘ON––OFF’
OFF’
BOOM EXTENSION /
RETRACTION BUTTONS
AUX FUNCTION
BUTTON
16
ANTI-TIPPING
ANTI-TIPPING SYSTEM
SYSTEM
ANTI-TIPPING
DISPLAY
LOAD CELL
(tighten torque 65 Nm
and apply Loctite 638)
17
ANTI
ANTI –– ROLLING
ROLLING SYSTEM
SYSTEM
B
1 - “ON” indicator : Led become ON when key ignition is turned in ON position;
2 - Load indicator : there are 6 leds (3 green, 2 yellow, 1 red) ;
3 - TEST push button : - allows to check all the antirolling system lamps.
When pushed, all leds will come ON for 2 second and buzzer will sound
for 2 second.
- used during the calibration procedure
- allows to display the error codes through the led ON
18
ANTI
ANTI –– ROLLING
ROLLING SYSTEM
SYSTEM CONNECTOR
CONNECTOR
Connector 8 pin Deutsch DT 04-8P C015

Connector pin Description Type Status ON Status OFF
1 V BATT - Input 0V Open circuit
2 SENSOR - Input / output - -
3 HYDRAULIC Output 12V Open circuit
4 V BATT + Input 12V Open circuit
5 SENSOR + Input / output - -
6 “SLOW MOTION” FUNCTION Output 0V Open circuit
7 “MAN-BASKET” Input Open circuit 12V
8 STABILIZERS LOWERED Input 12V Open circuit
19
ANTI
ANTI –– ROLLING
ROLLING SYSTEM
SYSTEM
When the starter key is in ON position, the anti-rolling system is activated and performs the self test
operation in automatic and all leds will come ON together to buzzer for 2 seconds.
The condition of longitudinal stability of machine is showed by leds of the load curve.
During work condition leds will come ON depending of load on fork and arm extension.
In case we are near to maximum load allowed, there will be a buzzer activated to the 5th led .
If suppose to extend the arm, the buzzer will sound in continuous and all the leds will flash.
Now all hydraulic function are not allowed.
Only retraction arm is permitted.
Calibration - Preliminary conditions:
The device allows to make a lot of number of calibrations; it is nevertheless necessary that, before
beginning to work, the anti-rolling system must be setted in accordind to following prescriptions:
- All the operations of calibration must be perform under safety conditions with the machine not braked,
in horizontal position on flat area , with all wheel straight on , without stabilizers.
- Load cell must have been fixed on axle at least 12 hours before the calibration;
- Starter key have to remain turned in ON position (in order to have the electric connection with the
anti-rolling system) for at least 15 minutes before the calibration.
20
NORMAL
NORMALCONDITION
CONDITIONOF
OFWORK
WORK
Rear axle = beam
Load
cell
IN THIS CONDITION WE HAVE TO CARRY OUT

ZERO SETTING (MINIMUM LOAD)
21
ROLLOVER
ROLLOVER CONDITION
CONDITION
Load
cell
SIGNAL FROM LOAD CELL IS ABLE TO LOCK ALL HYDRAULIC

FUNCTION EXCEPT TO RETRACT TELESCOPIC ARM
22
CALIBRATION
CALIBRATION PROCEDURE
PROCEDURE
1 - PRESS AND KEEP PRESSED TEST SWITCH;

2 - START ENGINE;
3 - CONTINUE TO KEEP PRESSED TEST SWITCH UNTIL POWER LED START TO FLASH;
4 - NOW THE SYSTEM IS IN CALIBRATION MODE : FIRST GREEN LED ON DISPLAY
WILL COME ON;
NOTE : IF YOU DON’T RELEASE THE TEST SWITCH IN TIME, THE SYSTEM
WILL WORK WITH THE VALUES OF PREVIOUS CALIBRATION
23
CALIBRATION
CALIBRATION PROCEDURE
PROCEDURE
5 - MINIMUM LOAD HAVE TO BE STORAGED WITH NO LOAD ON FORK, ARM COMPLETELY
RETRACTED AND FORK IN ORIZZONTAL POSITION NEAR TO GROUND (ABOUT 20 MM);
6 - PRESS “TEST SWITCH”, THE FIRST LED BEGINS TO FLASH (FOR 8 SECONDS)
INDICATING THAT THE STORAGE OF “MINIMUM LOAD” IS IN PROGRESS.
AS SOON AS THIS OPERATION IS COMPLETED, THE LED WILL COME “OFF” AND THE
BUZZER WILL SOUND FOR 2 SEC.
7 - AUTOMATICALLY LAST RED LED (INDICATING MAX ALLOWED LOAD) WILL COME “ON”;
8 - LOAD 2000 ÷ 3000 Kg ON FORK AND TRY TO EXTEND THE ARM UP TO BACK SIDE OF
MACHINE TEND TO RISE FROM THE GROUND;
9 - RETRACT TELESCOPIC BOOM ABOUT 600 MM (WHICH MEANS A LOAD REDUCTION OF
ABOUT 15 % BEFORE ROLLOVER);
10 - PRESS “TEST SWITCH”, TO START THE PROCEDURE OF
STORAGE : THE RED LED WILL FLASH FOR 8 SEC.
INDICATING THAT THE STORAGE OF “MAXIMUM LOAD”
IS IN PROGRESS.
11 - AS SOON AS THIS OPERATION IS COMPLETED, THE LED
WILL COME “OFF” AND THE BUZZER WILL SOUND.
PRESS AGAIN THE “TEST SWITCH” TO COME OUT OF THE
PROCEDURE.
24
ANTI
ANTI –– ROLLING
ROLLING SYSTEM
SYSTEM
ERROR INDICATION
If ECU detect some problem on sensor (load cell), the buzzer will sound with continuity and all leds
of display will start to flashing. Pressing “Test” button the problem can be showed through leds on
display in according to following error codes.
00 == Led
Led OFF
OFF
ERRORS
ERRORS WHEN
WHEN STARTING
STARTING 11 == Led
Led ON
ON
25
ERRORS
ERRORS IN
IN OPERATING
OPERATING MODE
MODE
ERRORS
ERRORS IN
IN CALIBRATION
CALIBRATION MODE
MODE
26
STEERING WHEEL
ANGLE ADJUSTING
LEVER
• PUSH BUTTON TO DISCONNECT

SANTI – ROLLING SYSTEM (RESET).
• IMPROVES DIGGING PERFORMANCE
27
Telehandler - Telescopic Boom
TELESCOPIC
BOOM
1
TELESCOPIC BOOM
7 m – 2 Section Boom 11 m – 3 Section Boom
Single Internal Cylinder External Cylinder & chain
operated 3rd section
2
TELESCOPIC BOOM
13 m Light – 3 Section Boom 13 m Heavy – 3 Section Cylinder
Internal cylinder & chain operated Internal dual piston cylinder
3d section
3
TELESCOPIC BOOM
14 m – 3 Section Boom 17 m – 4 Section Boom
Internal dual piston cylinder Internal dual piston cylinder & External single
cylinder operated 2d section
4
Telescopic
p boom & Cylinders
y
Inner and outer boom overlap has been increased to provide maximum
boom rigidity
Boom Overlap Dimensions
7 m LM 732 : 1200 mm
11 m LM 1133
1st – 2nd Section : 1100 mm
2nd – 3rd Section : 1220 mm
5
Telescopic
p boom & Cylinders
y
New Boom Design
Improved production process

ensures rectangular & parallel
boom sections
Reinforcement
R i f t plates
l t on the
th
points of high stress make the
boom both strong and light
Better load distribution

between inner and outer boom
sections
Optimised placement of the

wear pads in the outer corners
of the
o t e boo
boom
Wear pad size increased to

reduce friction
6
Telescopic
p boom & Cylinders
y
7 metre boom
6 & 7 m Booms have single

internal boom cylinder
The Load Holding Valve is
located at the rear of the
boom
7
Telescopic
p boom & Cylinders
y
Wear Pad Locations 7m Booms
Outer Section - Rear
8
Telescopic boom & Cylinders
Wear Pad Locations 7m Booms
O t & IInner Section

Outer S ti
9
Telescopic boom & Cylinders
11 metre boom
F R
The 3
3-section
section boom has a single external cylinder
The cylinder is attached at the rear (R) to the outer section and at the front (F) to the centre
section The third section is chain operated by twin upper chains and a single lower chain
As the boom extends, the upper chains pull the third section outwards as the cylinder and the
second section extend.
As the boom retracts, the lower chain retracts the third section as the cylinder and second
section retract. The chains have adjustable tensioners:
Tightening Torques: Top Adjusters (2) 35 Nm; Bottom Adjuster 70 Nm .
10
HOW THE BOOM WITH CHAINS WORKS
THE CYLINDER ROD IS FIXED ON THE FIRST ARM,, THE BOTTOM SIDE ON THE
SECOND ARM. WHEN WE EXTEND THE BOOM, THE CYLINDER PUSH OUT THE
SECOND ARM.
THE UPPER CHAINS ARE FIXED TO THE FRONT SIDE OF THE FIRST ARM ON THE
ONE HAND, TO THE REAR SIDE OF THE THIRD ARM ON THE OTHER HAND AND
ROTATE ON A PULLEY FIXED ON THE FRONT SIDE OF THE SECOND ARM. WHEN THE
SECOND ARM IS EXTENDED BY THE CYLINDER,
CYLINDER THE PULLEY PUSH OUT THE
CHAINS WHICH DRAG IN EXTENSION THE THIRD ARM.
BUT, IF THE SYSTEM WORK IN THIS WAY ONLY, WHEN WE RETRACT THE SECOND
ARM, THE THIRD WILL PULL DOWN ONLY BY ITS OWN WEIGHT.
SO THERE IS A LOWER CHAIN WHICH IS FIXED TO THE FRONT INTERNAL SIDE OF

THE FIRST ARM ON THE ONE HAND,
HAND TO THE REAR SIDE OF THE THIRD ARM ON
THE OTHER HAND AND ROTATE ON A PULLEY FIXED TO THE REAR DOWN SIDE OF
THE SECOND ARM. WHEN THE SECOND ARM IS RETRACTED BY THE CYLINDER,
THIS CHAIN DRAG IN RETRACTION THE THIRD ARM.
11
Telescopic
p Boom & Cylinders
y
3 2 1
12
Telescopic
p boom & Cylinders
y
11 metre boom
Upper Chains & Tensioners
13
Telescopic
p Boom & Cylinders
y
11 metre boom
Front View Rear View
Lower Chain & Tensioners
Arrow indicates external access aperture for chain tensioning
14
Lift, Tilt & Compensating Cylinders
Cylinder: Diameter - Stroke (mm) LM 732 LM 1133

Lift 140/70 - 1213
Tilt 130/70 – 342
Compensating 60/35 -1213
Extension 95/65 - 2835 (Internal) 95/65 – 2835 (External)
C li d
Cylinders are common to
t 7 & 11 m units,
it exceptt ffor th
the boom
b extension
t i cylinder
li d
15
Telescopic
p Boom & Cylinders
y
13 metre ‘light’ boom
FIRST
ARM
SECOND
ARM
THIRD
ARM
16
S h
Schematic
ti diagram
di off cylinder
li d and
d chains
h i layout.
l t
17
Schematic diagram of chains layout

layout.
18
Telescopic
p Boom & Cylinders
y
13 metre ‘heavy’ & 14 metre : 3 section boom
The boom has an internal dual

piston telescopic cylinder: the
two rods are extended or
retracted on opposite side at
same time (synchronized).
The load holding valve is
mounted on ppiston,, rear side of
machine.
19
Telescopic
p Boom & Cylinders
y
13 metre ‘heavy’ & 14 metre boom : cylinders & hydraulic pipes layout
AUXILIARY FLEX
HOSES
TILT FLEX HOSES
20
•Two guides per corner
•Two bolts for every guide
•Only 3 different guides in total
21
PADS THICKNESS
12 mm 15 mm
19 mm
15 mm
25 mm
12 mm (steel)
12 mm
25 mm
15 mm
(steel)
15 mm
19 mm
12 mm
12 mm
When pads have to be replaced (about 1000 - 1500 hours) , don’t need to
di
disassembly
bl the
th ttelescopic
l i bboom
22
REAR VIEW
GUIDE
CHANNEL
INSIDE THIRD
ARM
TILT FLEX
HOSES AUX FLEX
HOSES
23
TEST OF TELESCOPIC ARM MOVEMENT
24
Telescopic
p Boom & Cylinders
y
17 metre : 4 section boom
The 17 m boom has an internal dual piston cylinder and an external single
cylinder connected in a series hydraulic circuit.
The load holding valve is mounted on rear side of external cylinder.
25
Telescopic
p Boom & Cylinders
y
17 metre boom : cylinders & hydraulic pipes layout
26
27
17 metre boom : cylinders & hydraulic pipes layout
28
29
12 mm 15 mm
19 mm LM1745
PAD’S
THICKNESS
15 mm
25 mm
12 mm (steel)
12 mm
25 mm
(steel) 15 mm 15 mm
19 mm
12 mm 12 mm
12 mm 15 mm
15 mm
12 mm
12 mm
30
Telescopic
p Boom & Cylinders
y
17 metre boom : cylinders synchronisation procedure, to do

everyday morning before to start to work.
N.B. (Only for LM1745) In order to have a correct working of the

external cylinder it’s necessary to retract fully the boom keeping the
joystick in rear position for some seconds
seconds. Then
Then, extend the boom
for 40 - 50 cm and retract fully again. Repeat this operation of
synchronization for 7 - 8 time.
31
Telehandler - Powershift Transmission
POWERSHIFT
TRANSMISSION
1
TRANSMISSION
TRANSMISSIONSPECIFICATIONS
SPECIFICATIONS
Hydraulic oil: Ambra Hydropower 10W

Pump flow rate: 53 litres @ 2000 rpm
Total system capacity: 12.9 litres + 5 litres in exchange line

Tranfer box: 0.75 litres
Change interval: Every 1000 hours
(1st change 100 hours)
Oil filter change: Every 1000 hours

(1st change 100 hours)
Pressure: 15 ÷19 bar
Transmission Stall: 1890 ÷1990 rpm
2
Powershift
PowershiftTransmission
Transmission
Powershift transmission
Speeds with wheels 19,5”
24 TI 05.
4 x 3 Transmission Speeds @ 2200 rpm

Torque Converter:
280 mm / 11” in Diameter
Ratio 1.84:1
Max Push in F1 = 8.8 t
3
Transmission
Transmissionby
byDANA
DANASPICER
SPICER mod.
mod.T12000
T12000
4
T12000
T12000DANA
DANASPICER
SPICERTransmission
Transmission
Transmission Identification Decal
5
Transmission
TransmissionOil
OilCooler
Cooler
Main radiator assembly is

combined engine coolant &
transmission oil cooler
6
LAY-OUT
LAY-OUT
TRANSMISSION
TRANSMISSION
7
LAY-OUT
LAY-OUT
TRANSMISSION
TRANSMISSION
8
REVERSE
FORWARD
SPLITTER
B
9
SOLENOID SOLENOID
DIRECTIONAL CLUTCH SPEED CLUTCH
GEAR REVERSE FORWARD SPLITTER A B
IF X X X
II F X X
III F X
IV F X X
IR X X X
II R X X
III R X
IF WE ENERGISE . . . .
10
Disengaged TRANSMISSION
TRANSMISSION -- neutral
neutral
Disengaged
Disengaged Disengaged
clutch
carrier
engaged
with
shaft
clutch
carrier clutch
engaged carrier
with engaged
shaft with
shaft
Disengaged
Disengaged
Fixed on shaft 11
Idler gear
(disengaged) INPUT
TRANSMISSION
TRANSMISSION
(1st
(1st FORWARD)
FORWARD)
Disengaged
Disengaged ENGAGED
Disengaged
ENGAGED
Fixed on shaft 12
(ENGAGED) INPUT
TRANSMISSION
TRANSMISSION (1st (1st FORWARD)
FORWARD)
OUTPUT
13
INPUT
14
NEUTRAL
Safety valve
8 ÷ 10 bar
Pressure
Forward
regulator solenoid Splitter Reverse
solenoid solenoid
16.5 – 19.3 A B
solenoid
bar solenoid
1st 2nd 3rd 4th Forward Reverse

clutch clutch clutch clutch clutch clutch
15
FORWARD 1st SPEED
Reverse
solenoid
A
solenoid B
Splitter
solenoid Forward
solenoid
solenoid

16
FORWARD 2nd SPEED
Reverse
solenoid
A
B Splitter
solenoid Forward
solenoid solenoid
solenoid

17
FORWARD 3th SPEED
Reverse
solenoid
A
B Splitter
solenoid Forward
solenoid solenoid
solenoid

18
FORWARD 4th SPEED
Reverse
solenoid
A
B
solenoid Forward Splitter
solenoid
solenoid solenoid

19
TRANSMISSION
TRANSMISSION
(4
(4th
th FORWARD)
FORWARD)
ENGAGED
Disengaged Disengaged
Disengaged
Disengaged
Fixed on shaft 20
(ENGAGED) INPUT
REVERSE 1st SPEED
Reverse
solenoid
A
B Splitter
solenoid Forward
solenoid solenoid
solenoid

21
22
BREATHER
OIL
DIPSTICK
DRAIN
23
REVERSE
FORWARD
SPLITTER
A
B
24
TO COOLER
MODULATION
VALVE FOR
FORWARD AND
FROM REVERSE
COOLER
25
MODULATION
MODULATION VALVE
VALVE
26
CHECK
CHECK POINT
POINT
OIL
FILLING
CLUTCH
PRESSURE
PORT (IS
MOUNTED A
PRESSURE
SWITCH
SETTED 14 BAR
(INDICATION IN
THE CAB)
CONVERTER
OUTPUT
PRESSURE
PORT
TOP VIEW
27
TRANSMISSION
PRESSURE
SWITCH
28
CHECK
CHECK POINT
POINT
BREATHER
PRESSURE
PORT FROM
COOLER
OIL
DIPSTICK
TOP VIEW
29
OIL LEVEL
DRAIN
30
BREATHER
OIL
FILLER
OIL LEVEL
INDICATOR
31
DRAIN
DRAIN
32
CHECK
CHECK POINT
POINT
FORWARD
CLUTCH REVERSE
PRESSURE CLUTCH
PORT PRESSURE
PORT
BOTTOM VIEW
33
FORWARD
CLUTCH REVERSE
PRESSURE CLUTCH
PORT PRESSURE
PORT
34
1st CLUTCH
PRESSURE
PORT
2nd CLUTCH
PRESSURE
PORT
CONVERTER
TEMPERATURE
PORT
3rd CLUTCH
PRESSURE
PORT
4th CLUTCH
PRESSURE
PORT 35
CONVERTER
TEMPERATURE
SWITCH
36
1st CLUTCH
PRESSURE
PORT
2nd CLUTCH
PRESSURE
PORT
CONVERTER
TEMPERATURE
3th CLUTCH
PRESSURE
PORT
4th CLUTCH
PRESSURE PORT
37
Telehandler - Transmission Disassembly
TRANSMISSION
DISASSEMBLY
1
2
Remove
snap ring
3
Remove cover
(using a screw driver)
4
5
6
Remove
snap ring
7
Remove the
converter
8
9
Remove the
snap ring
10
Position of two snap rings.

Position of
ThesePosition
two snapofring
two snap
keep torque
two snap rings
converter in this position
rings
11
Remove the
transmission
oil filter
12
PRESSURE
REGULATOR
13
SPECIAL TOOL
TO REMOVING
PRESSURE
REGULATOR
14
SPECIAL TOOL TO
REMOVING
PRESSURE
REGULATOR
(tighten 65 Nm)
15
PRESSURE
REGULATOR
16.5 – 19 Bar
TRANSMISSION
OIL FILTER
16
Remove the
hydraulic
pump cover
17
Remove the
transmission
pump.
Pump flow:
53 l/min
@ 2000 rpm
18
Unscrew all the bolts
19
Remove the
converter
housing
20
21
22
TO
COOLER
SAFETY VALVE
setting to
8 – 10 Bar
Remove
impeller hub
gear
23
PRESSURE
REGULATOR
16.5 – 19 Bar
SAFETY VALVE
setting to
8 – 10 Bar
24
PRESSURE
REGULATOR
16.5 – 19 Bar
25
Remove the
solenoids
protection
cover
26
Remove the
solenoid coil
(R ≈ 10 Ω)
27
Remove all
valve
cartridge
28
Remove bolts
and washer
29
Using tool to
remove plate
30
Remove
plate
31
PRESSURE
REGULATOR
16.5 – 19 Bar
32
PRESSURE
REGULATOR
TRANSMISSION
PUMP
IDLER
GEAR
33
DELIVERY
LINE
TRANSMISSION
SUCTION PUMP
LINE
(ORBITAL TYPE)
34
1st / 2nd FORWARD

CLUTCH REVERSE
CLUTCH
3rd and 4th

clutch
35
Removing
bolts
36
Using a chain to
support the
transfer box and
loosen bolts
37
Remove the transfer box

from transmission
housing using tools
38
Coupling
sleeve
39
Remove
coupling sleeve
40
snap
ring
41
Remove the
snap ring
42
USING A PULLER
TO REMOVE THE
BEARING
43
44
Snap ring in
Snap ring in contact with
contact with sprocket
bearing wheel
45
Remove the snap

ring in contact with
sprocket wheel
46
From the rear,

remove cover
47
48
49
Position of Position of
snap ring in snap ring in
contact with contact with
sprocket bearing
wheel
50
Sprocket
wheel
51
Using a air gun to

loosen flange nut
52
Output flange, “O”

ring, washer and
nut removed
53
Use air gun to

loosen flange nut
54
Output flange,
“O” ring, washer
and nut removed
55
Remove sleeve
outer “O” ring
56
Using a puller to
remove pilot
sleeve
57
Pilot sleeve and

inner “O” ring
removed
58
Remove
snap ring
59
Remove front to rear

cover screws and
lockwashers
60
Use a chain to
separate front
and rear cover
61
Front cover
removed
62
Remove idle
shaft and
gear
63
Telehandler - Hydraulic System
HYDRAULIC
SYSTEM
1
TECHNICAL
TECHNICALSPECS
SPECS
Hydraulic Oil: Ambra Hydrosystem 46 HV NH646H
Casappa Gear Pump:

Flow Rate: 130 litres/min @ 2200 rpm
Displacement: 56 cc/rev
Oil Reservoir Capacity: 115 litres (7 & 11 m) – 185 litres (13 ÷ 17 m)
Oil Change Interval: Every 2000 hours or after 2 years
Oil Filter Change: Every 500 hours or after 6 months
Max Working Pressure: 240 ÷ 245 bar
Pilot Pressure: 35 bar
System Type: Load Sensing flow sharing

Close Centre Control Valve
2
LM 732
Gear Pump & ‘ON – OFF’ Main Control Valve
Component Review with Reference to Circuit Diagrams
3
1 Gear
GearType
TypePump
Pump
Powershift Transmission
Casappa Pump
130 l/m
4
2 Steering
SteeringMotor
Motor
240b
175b
Rexroth-Bosch: 250 cc/rev

5
3 3-Way
3-WaySteering
SteeringValve
Valve
Provides 2-wheel, 4-wheel & Crab steering modes
Steering Mode selected by 3-

position switch. 2WS centre
position has lock for road work.
Mode selected indicated by

dash panel indicator lights
6
4 Compensation
CompensationCylinder
Cylinder
7
5 Tilt
TiltCylinder
Cylinder 6 Load
LoadHolding
HoldingValve
Valve
8
7 Lift
LiftCylinder
Cylinder 8 Load
LoadHolding
HoldingValve
Valve
9
9 Telescopic
TelescopicBoom
BoomCylinder
Cylinder
7 Metre Boom
10 Load
LoadHolding
Holding
Valve
Valve
10
11 Hydraulic
HydraulicControl
Control--Joystick
Joystick
Lift & Tilt Cylinders are servo controlled by the joystick, other functions
are electrically controlled:
A. Boom extend & retract switch
B. Boom Aux Hydraulics switch
C. Lock out switch for Boom Auxiliary Buttons for Safety &
highway operations
11
12 Pressure
PressureReducing
ReducingValve
Valve
Provides 35 bar pressure output for Joystick Servo Control Valve

12
13 Main
MainControl
ControlValve
Valve
(ON
(ON––OFF
OFFtype)
type)
Control Valve Sections
13B 13A
13A. Dump Valve 15bar
13C
13B. Boom Telescopic
Solenoid Operation: ’ON/OFF’
13E
13C. Boom Aux Hydraulic
13D Solenoid Operation: ’ON/OFF’
13F
13D. Lift - Servo Control **
13E. Tilt – Servo Control**
** Joystick Operation
13F. Steering Priority Valve
Load Sensing Relief Valve &
Flow Regulator
13
14 15 16 Main
MainControl
ControlValve
ValveRelief
ReliefValves
Valves
Cylinder Relief Valves

14A. Rod End – 200bar
14B
14B. Piston End - 275bar
Main Relief Valve

15. Sensing Line Relief - 240bar
16. Sensing Line Flow Regulator
Metered sensing line return flow to
14A relieve sensing line pressure in
Neutral
15
16
14
17 Oil
OilCooler
Cooler&&Bypass
BypassValve
Valve
15
18 Return
ReturnFilter
Filter
16
19 Reservoir
Reservoir&&Breather
Breather
4
1
Oil Reservoir: 185 litres

1. Cover 3. Filler 3
2. Level Indicator 4. Breather
17
LM 1133
Component Differences to 7 m
18
9 11
11mmTelescopic
TelescopicBoom
BoomCylinder
Cylinder
External Cylinder with chain operation
of the Centre Boom Element
10
Load Holding
Valve
19
20 Stabilizer
StabilizerCylinders
CylindersControl
ControlValve
Valve
C
B A D
A + B: Electro-Hydraulic Control Valve for right + left stabilizer;

C: Pressure Reducing Valve mounted adjacent; D: not used
20
21 Stabilizer
StabilizerCylinder
Cylinder&&Load
LoadHolding
HoldingValve
Valve
21
Hydraulic
HydraulicSystem
SystemPressure
PressureTesting
Testing––Servo
ServoPressure
Pressure
A
2200
55-60oC
35 bar
Start & run engine

Check pressure
Adjust if required (A)
LM 732
22
Hydraulic
HydraulicSystem
SystemPressure
PressureTesting
Testing––Servo
ServoPressure
Pressure
2200
55-60oC
35 bar
Start & run engine

Check pressure
Adjust if required
LM 1133
23
Hydraulic
HydraulicSystem
SystemPressure
PressureTesting
Testing––System
SystemPressure
Pressure
2200
55-60oC
245 bar
Start & run engine

Operate boom auxiliary
button
Check pressure
Adjust System Relief
Valve if required
LM 732
24
Hydraulic
HydraulicSystem
SystemPressure
PressureTesting
Testing––System
SystemPressure
Pressure
245 bar
2200
55-60oC
Start & run engine

Operate boom auxiliary
button
Check pressure
Adjust System Relief
Valve if required
LM 1133
25
System
SystemPressure
PressureRelief
ReliefValve
Valve
26
13, 14 & 17 Metres

Main component differences to 7 and 11 m
27
HYDRAULIC
HYDRAULICCOMPONENTS
COMPONENTS LOCATION
LOCATION
HYDRAULIC MAIN
PUMP CONTROL
VALVE
HYDRAULIC
FILTER
STEERING
VALVE
STABILIZER PILOT
SOLENOID AND VALVE
SUPPLY UNIT
28
Telehandler - Hydraulic System 9. Hydraulic system
PIPING
PIPING LAY-OUT
LAY-OUT
29
HYDRAULIC
HYDRAULICPUMP
PUMP
PRIORITY
VALVE SUCTION
LINE
30
CONTROL
CONTROLVALVE
VALVE
FLOW ELETTRO-
BALANCING PROPORTIONAL
VALVE VALVE
L.S. PRESSURE
RELIEF VALVE
FLOW
REGULATOR
VALVE
31
MAIN
MAIN CONTROL
CONTROL VALVE
VALVE
LIFTING
SPOOL
TELESCOPIC
PROPORTIONAL
UNIT
AUXILIARY TILT
PORT SPOOL
32
MAIN
MAIN CONTROL
CONTROL VALVE
VALVE
PRESSURE
PORT:
240 bar
FLOW
BALANCING
VALVE
L.S. RELIEF
VALVE
FLOW
REGULATOR
33
COMPENSATION
HOSES
TILT
SPOOL
34
HYDRAULIC
HYDRAULICSYSTEM
SYSTEMOPERATION
OPERATION
35
LOAD
LOADSENSING
SENSINGSYSTEM
SYSTEM
Suppose two or more hydraulic circuits are working at

different pressure of working.
In a traditional circuit what happen ?
Oil prefer to go in the circuit with low pressure, so the speed

of the cylinder will move faster than other cylinder at high
pressure
We can not control speed of cylinder because speed

depend of the load
Target of LS system is speed of cylinder not depending by

the load. If we keep constant pressure drop across orifice
of spool , we get speed of cylinder independent by load
36
One way LS line Pressure compensator

valve
Spool
37
FLOW
FLOW RATE
RATE THROUGH
THROUGH AA ORIFICE
ORIFICE
OIL P1 P2 Q
A
Q = A .α . 2∆P
ρ
α = GEOMETRICAL CHARACTERISTIC OF ORIFICE (CONSTANT)

ρ = DENSITY (CONSTANT)
IF ∆P = CONSTANT Q = CONSTANT
38
LOAD
LOAD SENSING
SENSING SYSTEM
SYSTEM
Restriction
on control
valve betwen ∆P = 15 bar ∆P = 60 bar
control valve 40 bar
e spool)
100 bar PRESSURE
COMPENSATOR
115 bar
100 bar 100 bar
∆P = 15 bar
LS
TOTAL SETTING : 240 bar
15 bar 1 FLOW BALANCING VALVE
225 bar 0,7 l/min 2 L.S. RELIEF VALVE

1
2 3 FLOW REGULATOR
3
39
LOAD
LOADSENSING
SENSINGCONTROL
CONTROLVALVE
VALVE
The load sensing relief valve don’t let that

pressure in main circuit is bigger than 240 bar.
The load sensing flow regulator allows load

sensing pressure to vent to reservoir in order to
have no pressure il LS line when all hydraulic
circuits are in neutral.
40
Control
Control Valve
Valve Section
Section
P LS
LS
Pressure
compensator
OVER
LOAD
VALVE
Spool
41
CONTROL VALVE
VALVESECTION
CONTROL
Centralising SECTION
Spool cap spring Spool Plug Spring Check valve
Wiper
Plate
O Ring seal
Valve
section
Pressure
Overload compensator Plug
relief valve
42
Neutral
Neutral
Load sensing
Load check line Pressure Compensating Valve
valve
Spool
43
Neutral
Neutral
Load sensing
line
44
ONE
ONE HYDRAULIC
HYDRAULIC CIRCUIT
CIRCUIT OPERATING
OPERATING
When a single hydraulic circuit is operated the spool in

the control valve section is moved allowing oil to flow
past the lands of the spools and apply pressure to the
metering element of the pressure compensator valve.
The metering element moves upwards to allow oil to

flow to the load check valve and at the same time
uncovers the drilling in the spool portion of the
pressure compensator valve enabling operating
pressure to be sensed in the load sensing gallery.
45
One
One spool
spool operated
operated
One way LS line Pressure compensator
valve
Spool
PRESSURE OIL CAN MOVE UP THE

EXTERNAL (METERING) ELEMENT OF
COMPENSATOR
46
One
One spool
spool operated
operated
LS line
47
TWO
TWO OR
OR MORE
MORE HYDRAULIC
HYDRAULIC CIRCUITS
CIRCUITS OPERATING
OPERATING
When two spools are operated simultaneously, the

pump pressure is applied to the metering element of
the pressure compensator valve in both valve sections.
Pump pressure, and load sensing line pressure as well,
will rise until it overcomes the pressure behind the load
check valve of the heaviest loaded circuit.
The load sense pressure moves the metering element
of the pressure compensator valve in the lower loaded
circuit downwards and restricts the flow to the circuit.
Now the two spools work under the same pressure
drop ensuring flow distribution is load independent.
48
Two
Two spools
spools operated
operated
LS line
49
SECOND
SECONDSPOOL
SPOOLWITH
WITHLIGHT
LIGHTLOAD
LOAD
One way
valve LS line Pressure compensator
Spool
Two
spools
operated
50
LOAD
LOAD SENSING
SENSING CONTROL
CONTROL VALVE
VALVE
The flow balancing valve controls the flow of oil from the
hydraulic pump and send excess flow back to reservoir.
The valve also mantains a back pressure of about 20 bar

in the circuit when all spools are in neutral and engine
speed is 1000 rpm.
Back pressure will increase to about 20 bar at an engine

speed of 2100 rpm.
51
LOAD
LOAD SENSING
SENSING
CONTROL
CONTROL VALVE
VALVE
LS
1 2 3
T
T1
1 Flow balancing valve

2 Flow regulator
3 LS pressure relief valve 52
CONTROL
CONTROLVALVE
VALVE
FLOW
REGULATOR
VALVE
FLOW L.S. PRESSURE
BALANCING RELIEF VALVE
VALVE
LOAD SENSING
LINE
53
LOAD
LOADSENSING
SENSINGREGULATOR
REGULATOR--Neutral
Neutral
Load Sensing Load Sensing
flow regulator pressure relief valve
To
reservoir
LS line
From
pump
To telehandler Flow balancing valve

control valve (setting 15 bar)
54
LOAD
LOADSENSING
SENSINGREGULATOR
REGULATOR--Light
Lightload
load
To
reservoir
LS line
From
pump
To telehandler
control valve Flow balancing valve
55
LOAD
LOADSENSING
SENSINGREGULATOR
REGULATOR--Heavy
Heavyload
load
To
reservoir
LS line
From
pump
To telehandler
control valve Flow balancing valve
56
REAR LOCK ANTIDROP
STEERING AXLE VALVE
VALVE Telehandler - HydraulicVALVE
System
HYDRAULIC
SUPPLY
UNIT
STABILIZER ANTIDROP
CONTROL VALVE VALVE
ORBITROL
JOYSTICK
HYDRAULIC
PUMP
MAIN
VALVE
57
Steering
Steeringpriority
priorityvalve
valve
STEERING L.S.
TO HYDRAULIC
SYSTEM
OIL FROM PUMP
TO STEERING
SYSTEM
58
STEERING
STEERINGSYSTEM
SYSTEM
THIS ORBITROL IS AT
DOUBLE DIPLACEMENT.
WHEN DRIVER IS
STEERING WITH
STEERING SPEED MORE
THAN 10 turns/min,
DISPLACEMENT OF
ORBITROL WILL
CHANGE FROM
160 cc/rev TO
250 cc/rev
FEED DIRECTLY
STEERING CYLINDER
THROUGH ORBITROL
NORMAL
WORKING
LINE
59
STABILIZER AND SUPPLY

CONTROL UNIT
LS
MAIN VALVE
60
STABILIZER
STABILIZER AND
AND SUPPLY
SUPPLY CONTROL
CONTROL UNIT
UNIT
5 6
4
7
1 2 3
1 – Right stabilizer control valve

2 – Left stabilizer control valve
3 – Frame leveling control valve
4 – Pressure reducing valve (35 bar)
5 – Pressure relief valve (45 bar)
6 – Solenoid valve to supply telescopic spool
7 – Solenoid valve to supply pilot valve
61
STABILIZER
STABILIZER AND
AND SUPPLY
SUPPLY CONTROL
CONTROL UNIT
UNIT
Supply
Supply to
to
telescopic
telescopic
spool
spool
Supply
Supply to
to pilot
pilot
valve
valve
P
P
62
STABILIZER
STABILIZER AND
AND SUPPLY
SUPPLY CONTROL
CONTROL UNIT
UNIT
LS
LS
Supply
Supply to
to
telescopic
telescopic
spool
spool
Supply
Supply to
to pilot
pilot
valve
valve
TT
63
STABILIZER
STABILIZER SOLENOID
SOLENOID GROUP
GROUP
TO
OIL FROM
HYDRAULIC
PUMP
TANK
LOAD
SENSING
LINE
FRONT FRAME LEFT STABILIZER

LEVELLING SUPPLY PORT
SUPPLY PORT RIGHT
STABILIZER
SUPPLY PORT
64
STABILIZER
STABILIZER AND
AND SUPPLY
SUPPLY CONTROL
CONTROL UNIT
UNIT
PRESSURE
PORT:
13 ÷ 15 bar (*)
33 ÷ 35 bar(**)
BOTH SOLENOID
VALVE ARE
ENERGIZED BY
WORKING KEY IN
THE CAB
SOLENOID VALVE TO SUPPLY

TELESCOPIC SPOOL.
SOLENOID VALVE TO
SUPPLY PILOT VALVE. THIS SOLENOID VALVE IS
ENERGIZED AND DE-
THIS SOLENOID VALVE IS ENERGIZED BY WORKING KEY
ENERGISE BY WORKING IN THE CAB (Y11)
KEY AND DE-ENERGIZED
BY ELECTRONIC UNIT IN (*) with manipulator in neutral 65
CASE OF ROLLING (Y12) (**) with manipulator end stroke
MAIN
MAIN CONTROL
CONTROL VALVE
VALVE
LS P
ELECTRIC PILOT SIGNAL

SIGNAL FROM FROM
MANIPULATOR MANIPULATOR
66
LOCK
LOCK VALVE
VALVE ON
ON TELESCOPIC
TELESCOPIC BOOM
BOOM
Lock valve con pilot ratio 1:8.

This valve has got 2 different
pilot area : one is bigger 8
times than the other one .
This means that the valve start
to open when pilot pressure
reach 250 bar / 8 ( ≈ 30 bar).
From control valve

67
LOCK
LOCK VALVE
VALVE ON
ON TELESCOPIC
TELESCOPIC BOOM
BOOM
At low temperature, oil

will prefer to go through
the by-pass valve instead
across the orifice.
When the oil temperature
became warmer, oil will
prefer to go across the
orifice.
The orifice work to
modulate (more
graduality) the movement
of telescopic boom.
From control valve

68
OPERATION
OPERATION :: LOWERING
LOWERING BOOM
BOOM
In case of boom lowering (very

slow), pilot oil of valve (1) , pass to
through a small valve (normally
open).
In case of fast boom lowering, and
the temperature of oil is cold, pilot
oil will switch the valve (2).
So the pilot oil will pass through
the orifice to open with graduality
the valve (1).
(1)
(2)
69
OPERATION:
OPERATION: TILT
TILT DUMP
DUMP
70
LM1333
LM1333 HYDRAULIC
SYSTEM
MAIN
MAIN DIFFERENCES:
DIFFERENCES:
-REAR
-REAR AXLE
AXLE LOCK
LOCK N.A.
N.A.
-TELESCOPIC
-TELESCOPIC PROP.
PROP. UNIT
UNIT N.A.
N.A.
-MAN
-MAN PLATFORM
PLATFORM N.A.
N.A.
71
LOCK
LOCKVALVE
VALVE
Oil in V2 push against a

green poppet (that is the
one way valve on the
hydraulic diagram so will let
the passage of oil toward C2.
Same oil passing through a
orifice, go to move the
second spool , that allow
the passagge of oil to tank.
72
TELESCOPIC
TELESCOPICPROPORTIONAL
PROPORTIONALUNIT
UNIT
“P” “T”
port port
73
TELESCOPIC
PROPORTIONALUNIT
UNIT SPOOL
POSITION’S
FEED BACK
ELECTRONIC
SIDE “T”
port
“P”
port
PROPORTIONAL PISTON TO
SOLENOID MOVE THE
VALVE SPOOL
74
TELESCOPIC
PROPORTIONALUNIT
UNIT
THREADED SIDE
PROPORTIONAL TO FIX SPOOL
SOLENOID
VALVE
75
TELESCOPIC
PROPORTIONALUNIT
UNIT
76
TELESCOPIC
PROPORTIONALUNIT
UNIT
77
TELESCOPIC
PROPORTIONALUNIT
UNIT
PROPORTIONAL
VALVE
78
TELESCOPIC
PROPORTIONALUNIT
UNIT
UNDER MAGNETIC FIELD THIS

ELEMENT PUSH AGAINST VALVE
PLUNGER TO CLOSE
PROPORTIONALLY THE WAY OUT 79
TELESCOPIC
PROPORTIONALUNIT
UNIT
OIL TO
RETRACT
TELESCOPIC
BOOM
SPOOL
POSITION’S
FEED BACK
SPOOL
OIL TO
EXTEND PISTON TO
TELESCOPIC MOVE
BOOM SPOOL 80
TELESCOPIC
PROPORTIONALUNIT
UNIT
81
TELESCOPIC
PROPORTIONALUNIT
UNIT
SPOOL
POSITION’S
FEED BACK
OIL TO
OIL TO
EXTEND
RETRACT
TELESCOPIC
TELESCOPIC
BOOM
BOOM 82
TELESCOPIC
PROPORTIONALUNIT
UNIT
Voltage comparator receive
signal S1 from Joystick and
feed-back signal S2 from
electro-proportional valve.
S1 Voltage
Voltage Voltage comparator will
Joystick
Joystick compare both signal S1 with S2
comparator
comparator
If there is not difference
(between S1 and S2), the signal
from Voltage comparator will be
S2 zero , so the electro-proportional
valve will stay close.
If there is difference, the signal

from Voltage comparator S3 will
S3
control the electro-proportional
valve (increasing or decreasing
passage of oil through the valve).
Electro-proportional
Electro-proportional
valve
valve
83
TELESCOPIC
PROPORTIONALUNIT
UNIT
PLUG
84
TELESCOPIC
PROPORTIONALUNIT
UNIT
LED COMES “ON”

WHEN ZERO SETTING
IS PERFORMED
THROUGH TRIMMER
(WITH ENGINE NO
RUNNING)
TRIMMER
IF ZERO SETTING IS NOT CORRECT, WE COULD SEE THE TELESCOPIC

ARM GOING TO RETRACT OR EXTEND WITH TELESCOPIC CONTROL IN
NEUTRAL
85
TELESCOPIC
PROPORTIONALUNIT
UNIT
CABLE NUMBER CABLE COLOUR SIGNAL

1 BLUE + BATTERY
2 YELLOW / GREEN - BATTERY
3 BROWN JOYSTICK
86
4 BLACK + 5 V JOYSTICK
Telehandler - Steering System
STEERING
SYSTEM
1
STEERING
STEERINGSYSTEM
SYSTEM
Rexroth Steering Motor
Steering Motor Displacement: 160 cc /Turn

Steering Motor Relief Valve: 175 bar
Cylinder Relief Valves: 240 +/- 5 bar
2
STEERING
STEERINGMOTOR
MOTOR
3
STEERING
STEERINGSYSTEM
SYSTEM
4
STEERING
STEERINGMODE
MODESWITCH
SWITCH
2WS
4WS
2WS position lock for highway operation

Indicator light shows mode selected
Crab Steer Rear axle alignment indicator light
5
STEERING
STEERINGMODE
MODESWITCH
SWITCH
Before to select a steering mode, you need to check the rear wheels are aligned. This is
very easy to do, only checking when the indicator lamp on the cluster switch on.
In fact on the rear axle is mounted a proximity switch, this provide to close the electric
circuit of the indicator lamp when rear wheels are aligned.
If the indicator lamp is off, you need to select 4 WS or Crab Steering mode in order to
align the rear wheels.
After that, you can select the steering mode you like.
IMPORTANT: during transfer on the road, for safety, use only the 2WS mode.
For this reason, check the indicator lamps relevant rear wheels
aligned and 2WS mode are ON.
6
STEERING
STEERINGSWITCH
SWITCH
7
2WS
8
4WS
9
4WS
4WS
3890 mm
10
Crab Steer
11
33-way
-way Steering
SteeringSolenoid
SolenoidValve
Valve
12
Steering
SteeringCylinder
CylinderSensor
Sensor
The steering sensor (1) is located in the centre of the

rear steering cylinder.
The steering cylinder magnetic piston ring registers with
the steering sensor in the straight ahead position,
illuminating the instrument panel warning light
13
77&&11
11M
M::Steering
SteeringSystem
SystemPressure
PressureTesting
Testing
Warning
Do Not Touch
10-15 bar Steering wheel if low
pressure gauge
fitted
1000
60o- 70oC
Steering System Standby Pressure Test 14

77&&11
11M
M::Steering
SteeringSystem
SystemPressure
PressureTesting
Testing
2000
60o - 70oC
175 bar
15
Steering Motor Max Pressure Test
13,
13,14
14&&17
17M
M::Steering
SteeringSystem
SystemPressure
PressureTesting
Testing
STEERING VALVE PRESSURE PORT:

170 ÷ 180 bar (for all models)
13 ÷ 15 bar (stand by pressure)
60o- 70oC
16
Steering
SteeringCylinder
CylinderCentring
Centring
Ensure the steering cylinder is

central by positioning the cylinder
with equal rod protrusion (C) each
side.
Adjust both track rods equally until

the hubs are parallel to each other.
Use two straight edges and a
measuring tape to check .
Max difference: 0,6 - 0,7 mm
17
Steering
SteeringSwivel
SwivelHousing
HousingStops
Stops
The rear stops control the

minimum turning circle.
The front stops should be

set to prevent the tyres
touching the machine on
full lock, left and right,
with the axle fully
oscillated.
18
Telehandler - Axles & Brakes
AXLES & BRAKES
1
Axles
Axles&&Driveline
Driveline
• Unique power transfer from engine to axles with in-line NH

patented configuration
2
Axles
Axles&&Driveline
Driveline
Transfer Gear
Components
3
Axles
Axles&&Driveline
Driveline
Dana Spicer
Front Axle LSD 212/678
Rear Axle 212/679
4
Axles
Axles&&Driveline
Driveline
Axle Ratios
Crown Wheel & Pinion 3.77:1
Hub Reduction 6:1
Total reduction 22.66:1
Front Axle
Limited Slip Diff lock (45%)
Rear Axle
No Diff Lock
5
Axle
AxleMounting
Mounting
Rear Axle
Pivot Mount: 8O Oscillation
Front Axle
Rigid Mount
Axle Width 1920 mm flange to flange

Steering Angle : 40 O
6
Axles
Axles&&Driveline
Driveline
4
5
1
3
1. Main Drive Pinion

2. Differential Assembly
3. Wet Disc Brakes
4. Drive Shaft Double UJ
5. Final Planetary Reduction Gear
7
Axles
Axles&&Driveline
Driveline
Front Axle Differential Cross

Section
1. Planetary Gear Shaft

2. Thrust Washer
3. Planetary Gear
4. Side Gear Plate
5. End Plate
6. Friction Discs
7. Separator Plates
8. ‘O’ Ring Oil Seal
9. Differential Casing
10. Crown Wheel Bolts
11. Differential Bearings
12. Side Gear
13. End Plate
8
Axles
Axles&&Driveline
Driveline
Axle Oil Seal Locations
9
Axles
Axles&&Driveline
Driveline
Axle Mounting Bolts - Tightening Torques – 600 Nm
Front Axle Mounting
Rear Axle Mounting 10

Toe-in
Toe-inCheck
Check
Check the track width at hub height at the front and rear of the rim, the
correct toe in is 0-2 mm.
11
Braking
BrakingSystem
System
12
Braking
BrakingSystem
System
Brakes Wet discs, piston operated

Bracke discs 4 for each side on both axles
Parking brake Mechanical operated
Brake fluid LHM - green
13
BRAKE
PEDAL 1. Brake Pedal
2. Master Cylinder
3. Fluid Reservoir
4. Rear Axle Disc Brakes
5. Front Axle Disc Brakes
14
Brake
BrakeFluid
FluidReservoir
Reservoir
Use LHM brake fluid
To test the Low Fluid Warning Light

& circuit, depress blue rubber test switch.
15
1. Master cylinder
2. Brake lights switch
16
Braking
BrakingSystem
SystemLayout
Layout
3
1. Master Cylinder
2. Front Axle Disc Brakes
3. Rear Axle Disc Brakes
Maximum Pressure 60 bar
17
Front
Front&&Rear
RearBrake
BrakeComponents
Components
1. End Plate
2. Friction Discs (4) 201.5 mm Diameter
3. Separator Plates (4)
4. Brake Piston
1 5. Brake Piston Seals
6. Brake Piston Seals
7. Wear Compensator Sleeve & Pins
2
5
6
18
Braking
BrakingSystem
System
A B
A. Brakes Released B. Brakes Applied

19
Braking
BrakingSystem
SystemBleeding
Bleeding
Ensure the brake fluid reservoir

is topped up with LHM fluid
before attempting to bleed the
system.
B Suggested sequence:-
Rear Axle - right hand side
- left hand side
Front Axle - right hand side
- left hand side
20
Parking
ParkingBrake
Brake
Parking brake consists

of a mechanically
operated calliper disc
brake, mounted on the
transfer box output
shaft.
Provides 4 wheel
braking
21
Telehandler - Front Axle Disassembly
FRONT AXLE
DISASSEMBLY
1
FRONT
FRONT AXLE
AXLE
2
FRONT
FRONT AXLE
AXLE
BLEED
SCREW
SERVICE
BRAKE
BREATHER
STEERING
CYLINDER
AXLE OIL
FILLING
3
FRONT
FRONTAXLE
AXLETOP
TOPVIEW
VIEW
BLEED
SERVICE SCREW
BRAKE BREATHER
BLEED
SCREW SERVICE
BRAKE
4
FRONT
FRONT AXLE
AXLE
BRAKE OIL
LEVEL AND
CHECK BRAKE
WEAR 5
CHECK
CHECK BRAKE
BRAKE WEAR
WEAR
APPLY THE BRAKES

AND KEEP THEM
UNDER PRESSURE.
CHECK THE LINING
DISTANCE “S”
BETWEEN THE DISK.
6
MINIMUM : 4.5 MM
AXLE
AXLE DISASSEMBLY
DISASSEMBLY
REMOVE THE ARTICULATION PIN
7
AXLE
AXLE DISASSEMBLY
DISASSEMBLY
USING A PULLER, DISCONNECT PIN OF THE

ARTICULATION FROM THE STEERING CASE
8
AXLE
AXLE DISASSEMBLY
DISASSEMBLY
DISJOINT THE PLANET CARRIER COVER (2) FROM THE

STEERING CASE (3) USING A SCREWDRIVER
9
AXLE
AXLE DISASSEMBLY
DISASSEMBLY
REMOVE THE COMPLETE PLANET CARRIER COVER (2)

10
AXLE
AXLE DISASSEMBLY
DISASSEMBLY
LOOSE AND REMOVE THE NUTS (4)
11
AXLE
AXLE DISASSEMBLY
DISASSEMBLY
REMOVE THE SAFETY FLANGE (6)
12
AXLE
AXLE DISASSEMBLY
DISASSEMBLY
USING A PULLER, REMOVE THE PLANET CARRIER (5)
13
AXLE
AXLE DISASSEMBLY
DISASSEMBLY
USING A PLASTIC HAMMER

14
AXLE
AXLE DISASSEMBLY
DISASSEMBLY
REMOVE THE EXTERNAL BEARING (8)

15
AXLE
AXLE DISASSEMBLY
DISASSEMBLY
BY HAND REMOVE THE COMPLETE HUB (7)
16
AXLE
AXLE DISASSEMBLY
DISASSEMBLY
REMOVE THE SNAP RINGS (9)

17
AXLE
AXLE DISASSEMBLY
DISASSEMBLY
USING A PULLER, REMOVE THE PLANET WHEEL GEARS (10)
18
AXLE
AXLE DISASSEMBLY
DISASSEMBLY
LOOSEN AND REMOVE BOLTS FROM THE

TOP OF ARTICULATION PIN
19
AXLE
AXLE DISASSEMBLY
DISASSEMBLY
USING TWO LEVERS, REMOVE THE TOP

ARTICULATION PIN (6)
20
AXLE
AXLE DISASSEMBLY
DISASSEMBLY
REMOVE THE COMPLETE STEERING

CASE (7)
21
AXLE
AXLE DISASSEMBLY
DISASSEMBLY
USING A PULLER, REMOVE THE TOP BUSH (8)

AND THE BOTTOM BALL-BUSH (9)
22
AXLE
AXLE DISASSEMBLY
DISASSEMBLY
23
AXLE
AXLE DISASSEMBLY
DISASSEMBLY
24
AXLE
AXLE DISASSEMBLY
DISASSEMBLY
CHECK
BRAKE
WEAR
25
Use a tool to remove the disk
26
BRAKE
BRAKE AUTOMATIC PISTON
STROKE
COMPENSATION
BRAKE
RETURN
SPRING
27
AUTOMATIC
AUTOMATIC STROKE
STROKE COMPENSATION
COMPENSATION
Expansion
bushing
In case of brake disk wear, the brake piston stroke will be a little
longer, the expansion bushing will then extend to compensate.
28
44 BRAKE
BRAKE DISK
DISK FOR
FOR EACH
EACH SIDE
SIDE
29
DIFFERENTIAL
DIFFERENTIAL BODY
BODY
30
LOCK
BOLT
SPECIAL TOOL TO
ADJUST THE
BACKLASH BETWEEN
PINION AND BEVEL
GEAR THROUGH THE
RING NUT
31
LOOSEN THESE FOUR BOLTS TO REMOVE THE PLATE.

BEHIND THIS PLATE THERE IS THE BEVEL GEAR 32
USE TWO LEVERS TO REMOVE THE PLATE

33
BEVEL
GEAR
34
35
BEVEL
BEVEL GEAR
GEAR
36
PINION
37
REMOVE THE SEALING RING

38
RING
NUT
39
SPECIAL TOOL USED TO LOOSEN THE RING NUT

40
DIRECTION TO
LOOSEN THE
RING NUT
41
RING NUT LOOSEN

42
USING A HAMMER TO REMOVE THE PINION

43
SPACER
TRACK OF
BEARING
44
HOW
HOW TO
TOADJUST
ADJUST
Telehandler THE
THE
- Front Axle BEVEL
BEVELSET
Disassembly SET
1st STEP : CALCULATE “S1”
Nominal Size.
To calculate the real
size, you have to add
or subtract the
tolerance printed on
the top of the pinion.
S1
Shims
D Fixed dimension
118
with high
precision
149 + 0.03
Thickness of
bearing 45
S1 = 149 – 118(+ tolerance) – D
HOW
HOW TOTOADJUST
ADJUSTTHE THEBEVEL
BEVELSETSET
Real size = 118 + 0.1 = 118.1
Calculate (shims) “S” as follow :

S1 = 149 –118.1 – D =
Suppose D = Overall thickness of bearing = 30.2 mm
S1 = 0.7 mm
46
HOW
HOW TO
TOADJUST
ADJUSTTHE
THEBEVEL
BEVELSET
SET
Fixed
measurement
D
USING A DIAL GAUGE TO

MEASURE OVERALL
THICKNESS “D”
47
HOW
HOW TO
TOADJUST
ADJUSTTHE
THEBEVEL
BEVELSET
SET
2nd STEP : CALCULATE “S2”
spacer
S2
S2 = Shims between spacer and internal track of bearing 48

HOW
HOW TO
TOADJUST
ADJUSTTHE
THE
BEVEL
BEVELSET
SET
Insert a dial
gauge and
measure “A”
SPECIAL TOOLS
(TO ASSEMBLY Manually tightening
BEARING AND
SPACER )
49
HOW
HOW TO
TOADJUST
ADJUSTTHE
THE
BEVEL
BEVELSET
SET
SPACER
50
HOW
HOW TO
TOADJUST
ADJUSTTHE
THE
BEVEL
BEVELSET
SET
FAKE
PINION
INSERT TOOLS IN
THE BODY OF AXLE
AND MANUALLY
TIGHTENING
51
HOW
HOW TO
TOADJUST
ADJUSTTHE
THE
BEVEL
BEVELSET
SET
Insert dial
gauge and
measure
“B”
52
HOW
HOW TO
TOADJUST
ADJUSTTHE
THE
BEVEL
BEVELSET
SET
SHIMS
SHIMS (S
(S22 )) == B
B –– A
A
53
HOW
HOW TO
TOADJUST
ADJUSTTHE
THEBEVEL
BEVELSET
SET
DIRECTION OF
TIGHTENING
APPLY MINIMUM REQUIRED TORQUE TO THE RING

NUT BY SPECIAL TOOLS : 500 Nm
54
(Range is 500 Nm ÷ 570 Nm)
HOW
HOW TO
TOADJUST
ADJUSTTHE
THEBEVEL
BEVELSET
SET
NEED TO INCREASE THE TORQUE ON THE RING NUT UNTIL

ROLLING TORQUE OF THE PINION IS BETWEEN :
120 Ncm ÷ 170 Ncm
55
HOW
HOW TO
TOADJUST
ADJUSTTHE
THEBEVEL
BEVELSET
SET
POSITIONING OF DIAL GAUGE TO

MEASURE THE BACKLASH 56
HOW
HOW TO
TOADJUST
ADJUSTTHE
THEBEVEL
BEVELSET
SET
INSERT A DIAL GAUGE WITH A ROTARY KEY ON RING NUT.

MANUALLY MOVE THE PINION IN BOTH DIRECTION IN ORDER TO
CHECK THE EXISTING BACKLASH BETWEEN PINION AND BEVEL
GEAR.
THE BACKLASH SHOULD BE : 0.20 ÷ 0.25 mm 57
HOW
HOW TO
TOADJUST
ADJUSTTHE
THEBEVEL
BEVELSET
SET
ADJUST THE BACKLASH BETWEEN THE PINION AND THE

BEVEL GEAR BY LOOSING OR TIGHTENING THE RING NUT
58
BRAKE
BRAKEDISK
DISKSHIMMING
SHIMMING
CORRECT POSITION
OF BRAKE DISK
(ONLY ONE HOLE
IS OVAL)
59
60
Telehandler - Electrical System
ELECTRICAL
SYSTEM
1
7 & 11 M BATTERY
Capacity: 95 A/h – Cranking o

Capacit output:
tp t 900A
Twin batteries: Optional
Battery Isolator Switch: Optional
2
13, 14 & 17 M BATTERY
95Ah BATTERY
MASTER
SWITCH
3
Bosch Alternator 90A Bosch Starter Motor 3.5kW
4
CONNECTORS IDENTIFY
5
CONNECTORS IDENTIFY
FILTER
TEMPERATURE
SWITCH
FILTER
PREHEATING
6
CONNECTORS IDENTIFY
7
Electric Modules in Engine Compartment
RELAY AND
FUSES INSIDE
THE ENGINE
SPACE
8
Electric Modules in Engine Compartment
STARTER
RELAY KA
LINK FUSES
80 A
9
7 & 11 M : Electric Modules in Engine Compartment
10
Electric Circuit Board
Fuse & Relays

located behind
operators seat
11
ELECTRIC BOARD
FUSES
FLASHER
VOLTAGE
COMPARATOR
K17
RELAYS
MAN PLATFORM
PROVISION
CONNECTOR
CONNECTORS 12
ELECTRIC BOARD
VOLTAGE
COMPARATOR K17 FLASHER
13
Cab Bulkhead Connectors
14
Instrument Panel & Controls
15
Indicator & Warning Lights
Warning Buzzer
1. Low Battery Charging 5. Transmission Oil Pressure Low

2. Low Engine Oil Pressure 6. Rear Wheel Alignment Indicator
3. Brake Fluid below Minimum Level 7. Engine Pre-heat Indicator
4 Transmission Oil Temperature High
4. 8 Parking brake ‘ON’
8. ON indicator
16
L9 L10 S2 L11 L12 L13
S1 S4
L1 L2 L3 L4 L5 L6 L7 L8
POS. PIN FUNCTION POS. PIN FUNCTION

L3 J1 Brake oil level L9 J11 High beam
L2 J2 Engine oil pressure L10 J12 Direction indicator light
L1 J3 Alternator L7 J13 Parking brake
S4 J4 Engine water temperature L11 J14 2 wheel steering
S1 J5 Fuel level indicator B J15 Buzzer
S2 J6 Speed meter L8 J16 Rear wheels aligned
+ILL J7 Light L12 J17 Crab steering
GRND J8 Ground L6 J18 Transmission oil pressure
+ Ch J9 + (under key ) L5 J19 Transmission oil temperature
L13 J10 4 wheel steering L4 J20 Preheating
17
Right Hand Panel Switches
1 2 3 4 5 6
1. Isolates Boom Auxiliary Buttons on Joystick

2 Beacon
2.
3. Side & Headlights (Main beam & Dip on Indicator Turn Lever)
g
4. Hazard Lights
5. Front Worklights
6. Rear Worklights
18
Electrical Wiring Schematic
Explanation
1 – ELECTRIC DIAGRAM IS DIVIDED IN

TABLE (OR PAGE)
2 – EACH ABLE HAS A GRID AS

REFERENCE WITH DIFFERENT
COLOUMN
19
Electrical Wiring Schematic Explanation
1. X51 = code to identify the

connector
t on the
th identification
id tifi ti chart
h t
2. N1 = wire colour ((N=black)) and

wire core cross sectional area in mm2
3. Z/B1 = wire with more than one colour and wire core cross sectional
3
area. Z/B = Z main colour with a B tracer running through it. Z-B = Z
main colour with bands of B running along it
4. The wire Z/B1 continues on circuit 2, grid reference 8

Z = VIOLET
B = WHITE
5. The symbol describing the type of component
6 S30 = code
6. d tto id
identify
tif the
th componentt on the
th identification
id tifi ti chart
h t
20
Component
p Codes
COMPONENT LETTER
CONNECTORS X
MODULES A
LIGHTS E
FUSES F
CHARGING G
WARNING LIGHTS H
RELAYS K
MOTORS/BUZZERS M
SWITCHES S
DIODES V
SOLENOIDS Y
21
Wire Colours
LETTER COLOUR
A LIGHT BLUE
B WHITE
C ORANGE
G YELLOW
H GREY
L BLUE
M BROWN
N BLACK
R RED
S PINK
V GREEN
Z VIOLET
R-Z Is a cable with 2 color (Red is a basic color, Violet are longitudinal lines)
R/Z Is
I a cable
bl with
ith 2 color
l (R(Red
d iis a b
basic
i color
l and d violet
i l t are vertical
ti l lilines))
22
WIRE COLOR
23
Telehandler - Man Platform
MAN
PLATFORM
1
MAN PLATFORM
Radio-control
Swing fixing
Selector
Auxiliary hoses
fixing point
to supply swing
cylinder
Platform
swing
i
cylinder with
antidrop valve
2
SWING SELECTOR
Main relief
valve setting
to 100 bar
3
CONNECTION BETWEEN AUX AND SWING CYLINDER

Antidrop
valve
Swing
selector
T P
Platform swing
c linder
cylinder
Auxiliary hoses
4
LOAD LIMITING SYSTEM
A e B are 2 hinge point of the man

platform.
platform
In particular, the B hinge point has a slot
that, in case of overload, permit to platform
to perform a little movement (rotation)
going to press some springs.
Due to this, a microswitch will cut off
possibility to control the man platform by
radiocontrol.
Max load allowed is 400 Kg ± 20%.
B
5
“ On “ “ Off “
A = Hinge point
B = Slot
6
Microswitch
Guide with
slot
7
PERFORMANCE
- Platform can swing up to 180° (± 90°).

- Dimensions : 2300 x 1000 x 1000 mm extendable up to 4450 mm
with 2 sliding element on both side.
- Weight : 750 Kg
- Capacity : 400 Kg ± 20% (personnel and material);
- Co
Controls:
o s co
controllable
o ab e by radio-control
ad o co o from
o p
platform.
a o
8
Use of the platform requires the modification of the hydraulic and electric systems of the
machine.
HYDRAULIC SYSTEM
Addition of hydraulic block with proportional solenoid valve, providing the electro-hydraulic
piloting
il ti off th
the spooll off th
the b
boom cylinder.
li d
ELECTRIC SYSTEM
The following components must be added:

- Radio-control on the platform
- Receiver
R i on th
the machine
hi fframe
- ECU (made by REXROTH) to control the electro-proportional valve
- ECU (made by CIAM) to control the entire system
- Cable reel to supply
pp y the micro-switch on pplatform
- n. 2 proximity switch (fixed on stabilizers)
- n.1 supplementary cab harness
- n.1 supplementary frame harness
9
ECU by
REXROTH
Hydraulic block
Receiver
Radio control
- Proportional
P ti l solenoid
l id valve
l on - Platform installed and locked
main control valve
- Stabilisers fully lowered
(retract/extend telescopic boom)
OUTPUT INPUT
- Connection with Rexroth’s ECU - Working key on platform position
- Electric board of machine - Antirolling system not in alarm
ECU by CIAM 10
CONNECTION BETWEEN SUPPLEMENTARY FRAME

HARNESS AND CABLE REEL
Cables of frame harness (X202) have to be connected to cable reel as showed in the photos
11
CABLE REEL
12
SENSORS FIXED ON STABILISERS
Welded
plate
l t
STABILISERS IN UP POSITION STABILISERS FULLY LOWERED
When stabilisers are fully lowered, the welded plate will be located in front of the sensors, so they will
enable the electric system to work.
13
HOW USE THE PLATFORM
T use the
To th platform
l tf is
i necessary tto satisfy
ti f 4 conditions:
diti
- The platform have to be installed and locked on mechanical or hydraulic quick coupler
- Stabilisers fully lowered
- Working key in Platform position (*)
- Anti-rolling system not in alarm condition
If only one of these conditions is not satisfied, the platform control electronic
system doesn’t work.
(*) the key can be removed and all hydraulic controls are transferred on platform.
14
STABILIZERS AND SUPPLY

CONTROL UNIT
Emergency hand
pump to lower
boom in case of
engine failure.
HYDRAULIC BLOCK
FOR TELESCOPIC
BOOM CONTROL BY
RADIO CONTROL
15
EMERGENCY HAND PUMP
16
HYDRAULIC BLOCK WITH PROPORTIONAL SOLENOID VALVE
CPU
(by REXROTH)
to control
the proportional
solenoid valve
Hydraulic block
with proportional
solenoid valve
17
FRAME HARNESS DETAIL
Red Led Green Led

in case of failure will (CPU supply)
blink ((error code))
Connector
(used for connection
to electronic
instrument “BB3”
18
RADIO CONTROL ON PLATFORM
Boom Lowering
Joystick
Man on board
push button.
button
Keep it in
ON position Boom retraction Boom extension
when use
joystick
Boom Lifting Auxiliary control

((Platform’s swingg
by radiocontrol)
19
RADIOCONTROL FIXING PLATE
20
Horn.
To be press
Radio transmission before start
powering key engine
21
Engine
starter Emergency button
button to stop immediately
the engine
22
ELECTRIC BOARD
MAN PLATFORM
ANTIROLLING CONTROL
SYSTEM UNIT (by CIAM)
CONNECTORS
(X27 - X31)
Bulkhead
Connector
23
Location
of CIAM
CPU
24
HOW TO USE BB3
In case of normal operation by radio-control, if boom movement (lift or lower) looks too fast or too
slowly, is necessary to check by BB3 the following parameters stored in the memory of REXROTH
CPU.
Must be :
Imin 1 = 400 mA (lift)
Imax 1 = 1100 mA (lift)
Imin 2 = 400 mA (lowering)
Imax 2 = 1050 mA (lowering)
Imin1 and Imin 2 are the minimum current to control the proportional solenoid valves (one for lift function
and the other one for the lowering function).
400 mA correspond to a pilot pressure of 6 bar.
Springs centering have the same equivalent pressure of 6 bar.
So this pilot pressure represent the minimum pressure to move the lift / lowering spool.
25
HOW TO USE BB3
Imax1 and Imax 2 are the maximum piloting current of both proportional solenoid valve.
Since 2000 mA correspond to pilot pressure of 35 bar, 1100 mA will correspond to 17 bar.
Current limiting have as consequence to reduce the boom speed in lift and lowering operation for
safety reason.
Since Imax1 e Imax2 have practically the same value (unless of 50 mA), the speed of arm lowering /lift
is the same.
But during lowering operation, due to weight of arm, we can see the speed is a little higher than the
speedd iin lift operation.
ti
In conclusion parameters have to be verified:

- in case of arm movement is too higher or too lower
- in case of REXROTH CPU replacement
26
BB3
27
Telehandler
HOW TO- USEMan Platform
BB3
1 - Connect BB
BB-33 to diagnostic connector
placed behind the power supply.
2 - Turn ignition key in ON
3 - Select F1 (CONFIG/CAL)
28
HOW TO USE BB3
4 - Select 1 (PROP + ADJ)
5 - To
T modify
dif lift parameter,
t select
l t 2 (I
(Imax 1)
To modify lower parameter select 4 (Imax 2)
6 - Pressing CLEAR to delete the

actual parameter storage in CPU
29
HOW TO USE BB3
7 - Insert new parameter .

T increase
To i th
the movementt off speed,
d need
d tto increase
i th
the piloting
il ti current.
t
8 - Select ENTER
9 - Pressing MENU to come back to previous page
10 - Select TEACH (STORAGE)
30
HOW TO USE BB3
11 - Select 1 (SAVE PARAMS)
12 - Select ENTER to storage new parameter
13 - Turn ignition key in OFF
31
HOW USE BB3
If the following message is shown on BB3
“ BB3 NOT RECEIVED ”
after connection to BB3 to REXROTH connector and keyy ignition

g in ”ON” p
position,,
will be necessary to exchange pin 7 with pin 12 of connector connected to BB3.
P/n (CNH) : 380001303 (BB3)

380001471 (cable)
32
DIAGNOSTICS
In error condition is possible to detect the type of error looking the blinking frequency of red Led on
REXROTH CPU CPU.
NUMBER OF
POSSIBLE CAUSE REMEDY
BLINKING
1 Failure in extension joystick Check wiring, joystick switch, remote ctr
2 Failure in lift joystich Check wiring, joystick switch, remote ctr
3 Failure in lift proportional sol. valve Check wiring, plug connection, magnet
4 Failure in lower proportional sol. valve Check wiring, plug connection, magnet
5 Failure in lift - lower potentiometer Check wiring, lift-lower potent., remote ctr
6 Failure in extention - retract potentiometer Check wiring, ext.- retr. potent., remote ctr
33
Telehandler - Accessories
ACCESSORIES
1
BUCKET
BUCKET WITH
WITH BOLTED
BOLTED TEETH
TEETH
Is not requested to make any modification on electric / hydraulic system
2
44 IN
IN 11 MULTIPURPOSE
MULTIPURPOSE BUCKET
BUCKET
If the machine is equipped with AUX hoses, is only requested to add 2 flex hoses
3
MANUALLY EXTENDABLE CRANE JIB
4
BUSKET MATERIAL HANDLING
5
LOG
LOG FORK
FORK
6
MAN
MAN PLATFORM
PLATFORM SWING
SWING AND
AND EXTENDIBLE
EXTENDIBLE
Is requested to make modification on electric / hydraulic system
7
FIXED
FIXED MAN
MAN PLATFORM
PLATFORM
Is requested to make modification on electric / hydraulic system unless

of platform swing cylinder
8
HOOK
HOOK FORK,
FORK, SIDE
SIDE SHIFT
SHIFT CARRIAGE
CARRIAGE
9
FIXED
FIXED FORK
FORK
10
FORK
FORK EXTENSION
EXTENSION
11
LIFTING
LIFTING HOOK
HOOK ON
ON CARRIAGE
CARRIAGE FORK
FORK
12
CRANE
CRANE JIB
JIB WITH
WITH WINCH
WINCH
13
CRANE
CRANE JIB
JIB WITH
WITH WINCH
WINCH
1 Switch (located in the cab) to enable
an electric soket on boom
(AUX)
2 Lift limiting switch
3 Lower limiting switch
NEUTRAL
NEUTRAL
3
1 + -
14
CRANE
CRANE JIB
JIB WITH
WITH WINCH
WINCH
1 Switch (located in the cab) to enable
an electric soket on boom
(AUX)
LIFTING
LIFTING
3
1 + -
15
CRANE JIB WITH WINCH
1 Switch
1 (located in the
Int. Presa cab) to sul
di corrente enable
braccio
(AUX) an electric soket on boom
2 Fine corsa in salita
3 Fine corsa in discesa
LIFTING
LIFTING
STROKE
STROKE END
END
2
1 + -
3
16
1 Switch
1 (located in the
di corrente enable
braccio
LIFTING
LIFTING
2
1 + -
3
17
1 Switch
1 (located in the
di corrente enable
braccio
LIFTING
LIFTING
STOP
STOP 2
1 + -
3
18
CRANE
CRANE JIB
JIB WITH
WITH WINCH
WINCH
To fix the crane jib with winch on machine is necessary to carry out the following operations:
1 - Add an external harness to be fixed on boom (see photo 1 ).

One extremity of this harness (where there are 2 connectors) will be connected to connectors on
machine harness (X23 ed X218) (see photo 2).
They are located near the proximity switch used to lock the rear axle.
The opposite extremity of harness (in photo 1) will be joint to cable reel.
Photo
Photo 11 Photo
Photo 22
19
CRANE
CRANE JIB
JIB WITH
WITH WINCH
WINCH
The wire is clamped along steel hoses
20
CRANE
CRANE JIB
JIB WITH
WITH WINCH
WINCH
This switch allows to supply the cable reel
21
CRANE
CRANE JIB
JIB WITH
WITH WINCH
WINCH
2 - Add a switch on dashboard (it will be connected

to connector S14 of machine harness)
3 - Add a cable reel (fixed on telescopic arm)
4 - Add a supplementary harness to be fixed on

quick coupler to connect both solenoid valves
and both limiting switches.
1
1 Connection to solenoid valves

2 Connection to limiting switches
3 2
Connection to electric socket of cable reel
3 22
LIFT
LIFT // LOWER
LOWER LIMITING
LIMITING SWITCHES
SWITCHES ADJUSTING
ADJUSTING
3
4 2
After replace the cover, is possible to recognize the following components:

1 - Adjusting locking screw
2 - Lower limiting switch adjusting
3 - Lift limiting switch adjusting
4 - Connector
23
LIFT
LIFT // LOWER
LOWER LIMITING
LIMITING SWITCHES
SWITCHES ADJUSTING
ADJUSTING
To adjusting the lift / lower limiting switch is necessary to carry out :

1 - Unscrew the adjusting locking screw 1 ;
2 - Roll up the steel cable up to the hook of winch is hardly out of metallic structure of crane jib;
3 - Adjust the lower limiting switch 2 (use a screwdriver) making plastic cam 5 to rotate
up to push the plastic tooth (yellow color) into connector body;
4 - To roll down all the steel cable unless of about 2 meters;
5 - Adjust the lift limiting switch 3 (use a screwdriver) making plastic cam to rotate
up to push the plastic tooth (yellow color) 6 5
into connector body;
6 - Lock the adjusting locking screw 1
7 - Check the system
24
LIFT
LIFT // LOWER
LOWER LIMITING
LIMITING SWITCH
SWITCH CONNECTION
CONNECTION
Connection
Connection X220
X220
Cable 5038
Cable 5038
Connection
ConnectionX220
X220 Connection
Connection X220
X220
Cable 9121
Cable 9121 Cable
Cable 5039
5039
25
CRANE
CRANE JIB
JIB WITH
WITH WINCH
WINCH
Solenoide
valves
Connection
to AUX hoses
Limiting
switches
26
LIMITING
LIMITING SWITCHES
SWITCHES FIXING
FIXING DETAIL
DETAIL
27
DETAIL
DETAIL BRACKET
BRACKET FIXING
FIXING
28
HYDRAULIC
HYDRAULIC LIFTING
LIFTING WINCH
WINCH ON
ON RAFT
RAFT
Is requested to make modification on electric / hydraulic system.

This modification are the same to “CRANE JIB WITH WINCH”
29
HYDRAULIC
HYDRAULIC LIFTING
LIFTING WINCH
WINCH ON
ON RAFT
RAFT
((SOLENOID
SOLENOID VALVE
VALVE CONNECTION)
CONNECTION)
YY14
14aa
DIN
DINconnector
connector
11==black
black
22==5038
5038
YY14
14bb
DIN
DINConnector
Connector
11==black
black
22==5039
5039
30
CRANE
CRANE JIB
JIB WITHOUT
WITHOUT WINCH
WINCH
31
LIFTING
LIFTING HOOK
HOOK ON
ON RAFT
RAFT
32
CONCRETE
CONCRETE MIXING
MIXING BUCKET
BUCKET
33
CONCRETE
CONCRETE MIXING
MIXING BUCKET
BUCKET
(AUX)
1 Solenoid valve
2 Cylinder to open the
small window on bucket
1 so concrete can come
out
3 Safety valve
(stop hydraulic motor
in case somebody open
the protection grid)
2 4 Hydraulic motor
5 Switch located in the cab
- +
5
In
In case
case of
of
operator
operator have
have 3
to
to discharge
discharge 4
the
the material
material
from
from the
the
bucket
bucket
34
CONCRETE
CONCRETE MIXING
MIXING BUCKET
BUCKET
(AUX)
1 Solenoid valve
out
3 Safety valve
2 4 Hydraulic motor
- +
5
In
In case
case of
of
operator
operator have
have 3
to
to discharge
discharge 4
the
the material
material
from
from the
the
bucket
bucket
35
CONCRETE
CONCRETE MIXING
MIXING BUCKET
BUCKET
(AUX)
1 Solenoid valve
out
3 Safety valve
2 4 Hydraulic motor
- +
5
4 3
In
In case
case of
of
somebody
somebody
open
open the
the
protection
protection grid
grid
36
CONCRETE
CONCRETE MIXING
MIXING BUCKET
BUCKET
(AUX)
1 Solenoid valve
2 Cylinder for material

discharging’s window
1
3 Safety valve
4 Hydraulic motor
2
- +
5
3
STOP
STOP In
In case
case of
of
somebody
somebody
open
open the
the
protection
protection grid
grid
37
CONCRETE
CONCRETE MIXING
MIXING BUCKET
BUCKET
To fix the crane jib with winch on machine is necessary to carry out the following operations:
1 - Add an external harness to be fixed on boom (see photo 1 ).

One extremity of this harness (where there are 2 connectors) will be connected to connectors on
machine harness (X23 ed X218) (see photo 2).
They are located near the proximity switch used to lock the rear axle.
The opposite extremity of harness (in photo 1) will be joint to cable reel.
Photo
Photo 11 Photo
Photo 22
38
CONCRETE
CONCRETE MIXING
MIXING BUCKET
BUCKET
The wire is clamped along steel hoses
39
CONCRETE
CONCRETE MIXING
MIXING BUCKET
BUCKET
2 - Add a switch on dashboard (it will be connected

to connector S14 of machine harness).
This switch will allows to supply the solenoid
valve through the cable reel.
3 - Add a cable reel (fixed on telescopic arm)
40
Solenoid
valve
Hydraulic
motor
Connection
to AUX hoses
Cylinder to open
Discharge window for
material material
window discharging
41
Normally the safety valve is kept shifted by pin connected

to hinge in order to cut oil to hydraulic motor in case
the operator try to open the safety grid.
Safety
valve
Safety
grid
42

Training Manual

Uploaded by

Copyright:

Available Formats

Training Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Training Manual

Uploaded by

Copyright:

Available Formats

TELEHANDLER TIER 3

4. Controls and instruments

5. Telescopic arm assembly

10. Brake system

11. Electrical system

12. Front axle disassembly

13. Man Platform

14. Accessories Technical Training Manual

Lecce Training Centre – November 2008 (made by S. Spedicato) 1

LM1340 - LM1343 LM1443 - LM1445 LM1745

IVECO NEF TIER III MECHANICAL TURBOCHARGED WITH AFTERCOOLER

HYDRAULIC LOAD SENSING PRESSURE COMPENSATING

SPEEDMETER + HOURMETER + ANTITIPPING DISPLAY (with safety

IVECO NEF TIER III MECHANICAL TURBOCHARGED

LOAD SENSING PRESSURE COMPENSATING

SPEEDMETER + HOURMETER + ANTITIPPING DISPLAY (without

Max opening : 150 mm.

Inside machine shape

BOOM LIFT COMPENSATION

GUIDE WITH PLASTIC

PLASTIC PAD USED

Tier 3 Mechanical Engine

Engine Specification Decal on Sump or Timing Gear Housing

Type of crankcase: 4 = 4 cylinders

8 = Direct Injection, Turbo,

Steel Airflow Grill

Fuel Tank located

Bosch VE Type Fuel Injection Pump: Mechanical Governor

COLD START AUTOMATIC

FUEL ENGINE OIL

Note: in the picture there is a solution adopted by Isuzu.

On NEF engines an extra lobe on the cam

Remove the first injector, fit the tool 380000977 (2)

Rotate the engine drive shaft until cylinder #1 is at

The condition of 1st cylinder to TDC at end of

- Fit the dial gauge 380000228 (2) and the

- Rotate the engine drive shaft in order to have

- Rotate the pump in anti--clockwise direction if

- Checking these conditions, lock the pump by

NOTE: INJECTION PUMP CALIBRATION

GEAR UPSHIFTING AND

REAR AXLE LEFT RIGHT

ROAD / WORKING MODE

1 - Working lights on boom switch 6 - Road lights switch

1. Low Battery Charging 5. Transmission Oil Pressure Low

1 - FLEX HOSES TO SUPPLY LOCK CYLINDER ON QUICK COUPLER.

USING THE HYDRAULIC ATTACHMENTS (p.e. BUCKET CONCRETE MIXER), YOU

When bubble is at end stroke,

2 - Load indicator : there are 6 leds (3 green, 2 yellow, 1 red) ;

Connector 8 pin Deutsch DT 04-8P C015

Calibration - Preliminary conditions:

Rear axle = beam

IN THIS CONDITION WE HAVE TO CARRY OUT

SIGNAL FROM LOAD CELL IS ABLE TO LOCK ALL HYDRAULIC

1 - PRESS AND KEEP PRESSED TEST SWITCH;

• PUSH BUTTON TO DISCONNECT

Boom Overlap Dimensions

Improved production process

Better load distribution

Optimised placement of the