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0-30

InTroduCTIon

0.4 - TIghTEnIng TorquEs for nuTs and bolTs of ElECTrICal ConnEC-

TIons

Tighten all nuts and bolts of wiring harnesses, leaving the battery negative cable until last.

For closing torque, where not specified use class 9 N.93810

0.4.1 - standard tightening torques

Table 26

gEnEral TablE

pITCh

TorquE

6x1

5.5

8x1

14.4

8x1.25

13.4

10x1

29.5

10x1.5

26.5

12x1.25

12x1.75

14x1.5

Table 27

gEnEral TablE

pITCh

TorquE

14x2

16x1.5

121

16x2

113

Tolerance ±20%

0.4.2 - battery terminal tightening torques

Fig. 2

Содержание R3 EVO 85

Страница 1: ...Workshop manual R3 EVO 85 16001 R3 EVO 85 20001 R3 EVO 100 16001 R3 EVO 100 20001 R3 EVO 110 1001 R3 EVO 110 5001...

Страница 2: ...Find manuals at https best manuals com...

Страница 3: ...for nuts and bolts of electrical connections 0 30 0 4 1 Standard tightening torques 0 30 0 4 2 Battery terminal tightening torques 0 30 0 4 3 Starter motor tightening torques 0 31 0 4 4 Alternator tig...

Страница 4: ...lary utility distributor 4 way version R3 EVO 100 16001 R3 EVO 100 20001 R3 EVO 110 5001 R3 EVO 85 16001 R3 EVO 85 20001 10 144 10 4 11 Remote control valve 6 way version R3 EVO 100 16001 R3 EVO 100 2...

Страница 5: ...3 11 Renewal of the engine ECU Calibration of the accelerator pedal 20 45 20 3 12 Renewal of the engine ECU Calibration of the hand throttle lever 20 48 20 4 ECU alarms 20 51 20 4 1 Key to the ECU ala...

Страница 6: ...bly of the gear case cover 30 135 30 3 37 Assembly and disassembly of the camshaft 30 139 30 3 38 Check the camshaft 30 143 30 3 39 Removal and refitting of the rotation device 30 144 30 3 40 Removing...

Страница 7: ...y of the forward drive clutch assembly R3 EVO 110 1001 30 268 30 5 9 Disassembly of the reverse drive clutch assembly R3 EVO 110 1001 30 272 30 5 10 Gearbox and Hi Lo assembly R3 EVO 110 1001 30 277 3...

Страница 8: ...rential disassembly R3 EVO 110 1001 30 392 30 7 11 Differential unit adjustment R3 EVO 110 1001 30 394 30 7 12 Bevel gear pair R3 EVO 110 1001 30 397 30 7 13 Adjustment of the bevel gear pair R3 EVO 1...

Страница 9: ...110 1001 30 459 30 9 H0 Hydraulic system 30 463 30 9 1 Pump for hydraulic lift and auxiliary services R3 EVO 110 1001 30 463 30 9 2 Power steering valve H0 02 01 R3 EVO 110 1001 30 464 30 9 3 Power s...

Страница 10: ...hanics 2 2 40 7 40 1 4 Electrical and electronic components 1 2 40 13 40 1 5 Electrical and electronic components 2 2 40 21 40 2 Components 40 26 40 2 1 A Starting and charging R3 EVO 100 20001 R3 EVO...

Страница 11: ...10 5001 R3 EVO 85 16001 40 165 40 2 31 M Electrical electronic devices flasher units and timers R3 EVO 100 20001 R3 EVO 110 1001 R3 EVO 85 20001 40 166 40 2 32 M Electrical electronic devices flasher...

Страница 12: ...342 40 3 14 S004D Accessories and diagnostics Version with high visibility cab Version with digital instrument panel R3 EVO 100 16001 R3 EVO 110 5001 R3 EVO 85 16001 40 354 40 3 15 S005 Instrument pan...

Страница 13: ...0001 R3 EVO 110 1001 R3 EVO 85 20001 40 593 40 3 37 S012A Heating Version with standard cab Version with digital instrument panel R3 EVO 100 16001 R3 EVO 110 5001 R3 EVO 85 16001 40 611 40 3 38 S012D...

Страница 14: ...ith standard cab Version with digital instrument panel R3 EVO 100 16001 R3 EVO 110 5001 R3 EVO 85 16001 40 890 40 3 60 S020 Windscreen wipers Version with high visibility cab R3 EVO 100 20001 R3 EVO 1...

Страница 15: ...panel R3 EVO 100 16001 R3 EVO 110 5001 R3 EVO 85 16001 40 1139 40 3 84 S029 Brakes U S A R3 EVO 100 20001 R3 EVO 110 1001 R3 EVO 85 20001 40 1153 40 3 85 S029D Brakes U S A Version with digital instru...

Страница 16: ...1220 40 4 32 0 016 0484 4 60 Central U S A 40 1221 40 4 33 0 016 0664 4 Front lights 40 1225 40 4 34 0 016 0865 4 10 Cab roof Version with standard cab R3 EVO 100 20001 R3 EVO 110 1001 R3 EVO 85 20001...

Страница 17: ...XVII CONTENTS 40 4 50 04411923 4 RH lower headlights 40 1250 40 4 51 04411923 4 LH lower headlights 40 1251...

Страница 18: ...XVIII CONTENTS PAGE LEFT INTENTIONALLY BLANK...

Страница 19: ...0 1 0 Introduction...

Страница 20: ...controls l Before starting work clean the machine thoroughly to remove mud dust and gravel Also clean the cab thoroughly to remove all residue of oil snow or ice from the steps handles and grips norm...

Страница 21: ...moval or assembly operations clean it as soon as possible to avoid operators slipping and possible fires l If electrical cables or wires are removed make sure that they are reassembled with their orig...

Страница 22: ...ted in the cooling system and then top up l When the hydraulic equipment has been disassembled add oil up to the indicated level Start the engine and let the oil circu late in the hydraulic circuits a...

Страница 23: ...with threading spread with anaerobic threadlock The values indicated refer to tightening on steel or cast iron material for soft material such as aluminium copper or plastics plated or panels the tor...

Страница 24: ...exagonal head plugs Socket head threaded plugs Thread Spanner Torque Nm 10 Spanner Torque Nm 10 MET RIC M6x1 10 10 M8x1 13 12 M10x1 13 14 5 14 M10x1 25 13 14 M10x1 5 13 14 M12x1 25 17 30 M12x1 5 17 30...

Страница 25: ...washers Table 5 One way pipe unions Three way pipe unions Four way pipe unions Thread Spanner Torque Nm 10 Spanner Torque Nm 10 Spanner Torque Nm 10 M8x1 12 14 M8x1 25 13 14 M10x1 14 20 14 20 M10x1 2...

Страница 26: ...t anaerobic product suitable for sealing between metallic surfaces can be used to eliminate traditional gaskets since it can fills gaps up to 0 4 mm Since it does not settle the torque does not need t...

Страница 27: ...ings etc Loctite 638 Colour fluorescent green Fast curing anaerobic structural adhesive with very high me chanical resistance suitable for fastening non ferrous alloy freely moving cylindrical couplin...

Страница 28: ...si x 0 070 kg cm lb Imp gall x 0 100 kg lb US gall x 0 120 lb cu ft x 16 21 kg m lb ft x 1 356 Nm psi x 1 379 bar Conversion from metric to imperial units Table 8 mm x 0 0394 inch m x 3 281 foot m x 1...

Страница 29: ...e fitting clothing goggles and gloves suitable for the operation to perform cleaning draining fluids repairs Do not go near moving parts with long hair that has not been tied back hair can get caught...

Страница 30: ...ecting the pipes of the hydraulic system and fuel supply system fit the caps to prevent impurities from entering l Use a container with sufficient capacity to recover oil coolant or fuel l Before remo...

Страница 31: ...METAL CABLES standard S or Z twisted type POLYESTER BELTS with slots simple cable mm Capacity kg Width mm Capacity kg 60 90 60 90 8 650 620 500 25 500 400 860 700 10 1000 1740 1420 50 1000 800 1730 1...

Страница 32: ...stics plated or panels the torques need to be reduced by 50 See para 0 3 Tightening torques page 0 20 Unions The indicated torques refer to fitting unions on any material Table 10 MET RIC Unions with...

Страница 33: ...lugs Socket head threaded plugs Thread Wrench Torque Nm 10 Wrench Torque Nm 10 MET RIC M6x1 10 10 M8x1 13 12 M10x1 13 14 5 14 M10x1 25 13 14 M10x1 5 13 14 M12x1 25 17 30 M12x1 5 17 30 6 30 M12x1 75 17...

Страница 34: ...g washers Table 13 One way pipe unions Three way pipe unions Four way pipe unions Thread Wrench Torque Nm 10 Wrench Torque Nm 10 Wrench Torque Nm 10 M8x1 12 14 M8x1 25 13 14 M10x1 14 20 14 20 M10x1 25...

Страница 35: ...st anaerobic product suitable for sealing between metallic surfaces can be used to eliminate traditional gaskets since it can fills gaps up to 0 4 mm Since it does not settle the torque does not need...

Страница 36: ...ings etc Loctite 638 Colour fluorescent green Fast curing anaerobic structural adhesive with very high me chanical resistance suitable for fastening non ferrous alloy freely moving cylindrical couplin...

Страница 37: ...si x 0 070 kg cm lb Imp gall x 0 100 kg lb US gall x 0 120 lb cu ft x 16 21 kg m lb ft x 1 356 Nm psi x 1 379 bar Conversion from metric to imperial units Table 16 mm x 0 0394 inch m x 3 281 foot m x...

Страница 38: ...and used by trained personnel B Torque angle con trol tightening with manual or auto matic tools subject to monitoring and or with certification and used by trained personnel Torque control tight enin...

Страница 39: ...4 3 8 3 2 5 3 0 3 3 7x1 00 1 4 9 6 0 6 7 2 4 6 5 6 6 3 3 4 0 5 0 5 6 8x1 00 1 7 8 9 7 10 9 2 7 3 9 1 10 2 3 6 5 8 0 9 0 8x1 25 1 7 3 9 0 10 0 2 6 9 8 4 9 4 3 6 1 7 4 8 3 10x1 00 1 15 9 20 0 22 5 2 14...

Страница 40: ...349 Tightening torques for 5 8 UNI EN ISO 898 1 screws and 5 UNI EN ISO 898 1 nuts Table 21 Thread Category Coefficient of friction 0 10 VI 0 14 VII 0 17 II Cs nom Nm Cs nom Nm Cs nom Nm 4x0 70 1 1 1...

Страница 41: ...77 95 107 2 72 89 100 3 63 79 88 18x1 50 1 117 148 168 2 110 139 157 3 97 123 139 18x2 50 1 106 131 146 2 99 122 137 3 88 108 121 20x1 50 1 163 207 234 2 152 194 219 3 135 171 194 20x2 00 1 156 196 2...

Страница 42: ...13 5 15 1 2 10 3 12 6 14 1 3 9 1 11 2 12 5 10x1 00 1 23 9 30 0 33 8 2 22 3 28 1 31 6 3 19 8 24 8 28 0 10x1 25 1 22 8 28 4 31 8 2 21 3 26 5 29 7 3 18 9 23 5 26 3 10x1 50 1 21 7 26 7 29 8 2 20 3 25 0 2...

Страница 43: ...ws and 8 UNI EN ISO 898 1 nuts Table 23 Thread Category Coefficient of friction 0 10 VI 0 14 VII 0 17 II Cs nom Nm Cs nom Nm Cs nom Nm 4x0 70 1 1 8 2 2 2 4 2 1 7 2 1 2 3 3 1 5 1 8 2 0 5x0 80 1 3 5 4 3...

Страница 44: ...42 159 3 101 126 141 18x1 50 1 188 237 268 2 175 222 251 3 155 196 222 18x2 50 1 170 210 234 2 159 196 219 3 140 173 194 20x1 50 1 261 331 375 2 244 310 350 3 216 274 310 20x2 00 1 250 314 354 2 234 2...

Страница 45: ...9 5 2 20 1 24 7 27 6 3 17 8 21 9 24 4 10x1 00 1 46 8 58 8 66 2 2 43 7 55 0 61 9 3 38 7 48 6 54 8 10x1 25 1 44 7 55 6 62 3 2 41 8 51 9 58 2 3 36 9 46 0 51 5 10x1 50 1 42 5 52 4 58 4 2 39 7 48 9 54 6 3...

Страница 46: ...2 UNI EN ISO 898 1 nuts Table 25 Thread Category Coefficient of friction 0 10 VI 0 14 VII 0 17 II Cs nom Nm Cs nom Nm Cs nom Nm 4x0 70 1 3 1 3 8 4 2 2 2 9 3 5 3 9 3 2 6 3 1 3 5 5x0 80 1 6 1 7 5 8 3 2...

Страница 47: ...7 244 274 3 174 216 242 18x1 50 1 323 408 461 2 302 381 431 3 267 337 381 18x2 50 1 291 360 402 2 272 337 376 3 241 298 333 20x1 50 1 448 569 644 2 419 532 602 3 371 471 533 20x2 00 1 430 540 608 2 40...

Страница 48: ...ive cable until last l For closing torque where not specified use class 9 N 93810 0 4 1 Standard tightening torques Table 26 General table Pitch Torque 6x1 5 5 8x1 14 4 8x1 25 13 4 10x1 29 5 10x1 5 26...

Страница 49: ...0 31 Introduction 0 4 3 Starter motor tightening torques Fig 3 0 4 4 Alternator tightening torques Fig 4...

Страница 50: ...27 6 kgm 5 2 0399 129 6 Screw M18x1 5 10 9 395 Nm 40 3 kgm 5 2 0399 140 6 Screw M18x1 5 10 9 395 Nm 40 3 kgm 5 2 0399 003 6 10 Screw M20x1 5 10 9 550 Nm 56 kgm 5 2 1011 308 6 Nut M14x1 5 8 120 Nm 12 2...

Страница 51: ...ispensing nozzle The use of open containers or brushes is not permissible 3 Screw the solenoid valves and cartridge valves into the relative seats by hand engaging at least one turn of the thread Powe...

Страница 52: ...6 3 Cartridge valve tightening torques Table 30 Type of valve Threads p n Tightening torque A Nm Fig 10 M18X1 5 2 3729 686 0 XX 35 40 2 3719 760 0 XX Fig 11 3 4 16 UNF 2 3729 691 0 XX 35 40 Fig 12 M2...

Страница 53: ...tion 0 7 Installation of quick couplers 0 7 1 Table of tightening torques Table 31 Type of quick coupler Threads p n Tightening torque A Nm Fig 14 M22X1 5 0 010 8473 0 XX 60 66 Fig 15 M22X1 5 0 010 98...

Страница 54: ...0 36 Introduction PAGE LEFT INTENTIONALLY BLANK...

Страница 55: ...10 1 10 Technical characteristics...

Страница 56: ...Table 33 2012 2013 2012 Series 2013 Series Table 34 L04 L06 L In series 04 Number of cylinders 06 Number of cylinders Table 35 2V 2V Number of valves Table 36 m m Mechanical injection system Nozzle li...

Страница 57: ...17 Engine number The engine number D is punched on the crankcase arrow and on the model plate Fig 18 Cylinder numbering Cylinder layout The cylinders are numbered progressively from 1 from the flywhee...

Страница 58: ...View from right hand side example Fig 20 Key 1 Crankcase breather 2 Lubricant oil filler cap 3 Injection pump 4 Lubricant oil dipstick 5 Lubricant oil radiator 6 Lubricant oil cartridge filter 7 Lubr...

Страница 59: ...10 5 Technical characteristics View from left hand side example Fig 21 Key 1 Combustion air intake 2 Coolant outlet 3 Coolant inlet 4 Supply air radiator connections 5 Exhaust gas outlet 6 Starter...

Страница 60: ...elief valve TD TCD 2013 4 Lubricant oil radiator 5 Check valve TD TCD 2012 6 Bypass valve 7 Bypass valve 8 Pressure regulator valve 9 Lubricant oil filter 10 Primary lubricant oil channel 11 Piston co...

Страница 61: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com...

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