Ad 25

WORKSHOP MANUAL
ADT 25
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25 INTRODUCTION I
WORKSHOP MANUAL
ADT 25
IIą INTRODUCTION ADT 25
ASTRA VEICOLI INDUSTRIALI

Product Service
Via Caorsana, 79 - 29100 PIACENZA (Italy)
Tel. 0523/5431 - Fax 0523/597068 - Telex 530148 ASTRA I
Publication no. A3000021

First edition APRIL 2001
Second edition MARCH 2002
Prepared by SIPAL S.p.A. - TORINO (Italy)
Complete or partial copying of the text and illustrations herein is prohibited.
ADT 25 INTRODUCTION III
Figure 1
174CU01
IVą INTRODUCTION ADT 25
Page left intentionally blank
ADT 25 INTRODUCTION V
SECTIONS
TITLE SECTION PAGES
INTRODUCTION from I to VIII
CONDITIONS OF USE 1.1 from 1 to 16
SAFETY INSTRUCTIONS 1.2 from 1 to 18
GENERAL SPECIFICATIONS 2 from 1 to 28
ENGINE 3 from 1 to 52
AUTOMATIC TRANSMISSION 7 from 1 to 82
PROPELLER SHAFT 10 from 1 to 10
FRONT AXLE 12.1 from 1 to 50
INTERMEDIATE AXLE 12.2 from 1 to 58
REAR AXLE 12.3 from 1 to 48
BRAKES 13.1 from 1 to 20
WHEELS AND TYRES 13.2 from 1 to 8
SUSPENSION 14 from 1 to 10
STEERING SYSTEM 15 from 1 to 6
HYDRAULIC SYSTEM 16 from 1 to 44
ELECTRICAL SYSTEM 17 from 1 to 30
CAB AND CHASSIS 18 from 1 to 24
BODY 20 from 1 to 4
VIą INTRODUCTION ADT 25
PARTS
Figure 2
1 3 2
4 6 9 5 7 10 8
174CU02
1. Cab
2. Body
3. Central joint
4. Engine
5. Transmission
6. Front axle
7. Intermediate axle
8. Rear axle
9. Suspension cylinder
10. Tipper cylinder
ADT 25 INTRODUCTION VII
Main vehicle assemblies production numbers

You are advised to make a note of the model and serial The plate location is shown in Section 2-GENERAL
number (PN) and/or production code (PIN) of the main SPECIFICATIONS.
vehicle assemblies written on the respective plates This will ensure faster identification of the parts
applied to the assembly. required for partial or total replacement.
engine
automatic transmission
front axle
intermediate axle
rear axle
suspension cylinder
tipper cylinder
VIIIą INTRODUCTION ADT 25
SECTION 1.1
CONDITIONS OF USE
ADT 25 SECTION 1.1 CONDITIONS OF USEą1
CONTENTS
Page Page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 WARRANTY AND LIABILITY OF THE

MANUFACTURER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CONFORMITY MARKING . . . . . . . . . . . . . . . . . . . . . 4
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INFORMATION ON THIS HANDBOOK . . . . . . . . . 5
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warranty coupons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Purpose of this handbook . . . . . . . . . . . . . . . . . . . . . . 6
GENERAL OPERATION RULES . . . . . . . . . . . . . . . 10
To whom this handbook is addressed . . . . . . . . . . . 6
Pre-disassembly preparation . . . . . . . . . . . . . . . . . 10
Safekeeping of this handbook . . . . . . . . . . . . . . . . . . 6
During disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Updates to this handbook . . . . . . . . . . . . . . . . . . . . . . 6
After disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Units of measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
During assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SCHEDULED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Interchangeable parts . . . . . . . . . . . . . . . . . . . . . . . . 13
VEHICLE REPAIR SERVICEMEN . . . . . . . . . . . . . . . 7
Welding on the chassis . . . . . . . . . . . . . . . . . . . . . . . 15
WASTE DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SCRAPPING THE VEHICLE . . . . . . . . . . . . . . . . . . . 8
2ąCONDITIONS OF USE SECTION 1.1 ADT 25
INTRODUCTION
This technical handbook contains a series of repair
procedures relating to the articulated dump trucks.
Read this handbook carefully before carrying out any
repairs on the vehicle.
Scrupulous observance of the rules and instructions
herein will ensure that repairs are carried out safely and
efficiently.
Copyright
The copyrights of this handbook belong to the vehicle
manufacturer.
The text, drawings and illustrations contained in this
handbook cannot be circulated or given to third
parties, totally or partially, without the written consent
of the vehicle manufacturer.
CONFORMITY MARKING
This vehicle was made in compliance with Community Figure 1
Directive 98/37/EEC and amendments (Machinery
Directive).
All parts of the vehicle comply with the aforesaid
directive, as shown by the CE marking.
The plate is located in the position shown in the figure
and must be legible at all times.
LEVEL OF NOISE
Noise outside the vehicle:
Lwa = 108 dB (A)
174CU01A
Noise at driver's seat:
Lpa = 76 dB (A)
Figure 2
measured on identical vehicle, in accordance with
Directive 86/662/EEC.
VIBRATIONS TRANSMITTED TO OPERATOR

Acceleration transmitted to the operator's arms:
weighed average quadratic level
< 2.5 m/s2 (8.2 ft/s2)
Acceleration transmitted to the operator's body:

weighed average quadratic level
< 0.5 m/s2 (1.6 ft/s2)
Measured by means of accelerometer on identical

vehicle running on medium unsurfaced terrain.
Figure 3
174CU02
174CU03
INFORMATION ON THIS HANDBOOK

Definitions Symbols
Handbook is this WORKSHOP MANUAL. You will find the following symbols highlighting parts of
Vehicle is the machinery described in this manual. the handbook. Their meaning is:
Manufacturer is the company manufacturing the
vehicle. procedures, technical information and
Dealership is the company or organisation officially precautions which, if not respected and/or
representing the Manufacturer. incorrectly carried out, could cause injury to
Supplier is any company supplying components users (safety symbol, also see SECTION
and/or consumable material used by the vehicle. 1.2-SAFETY INSTRUCTIONS).
User is the person directly or indirectly involved in
repairing the vehicle. procedures, technical information and
precautions which, if not respected and/or
Contents incorrectly carried out, could damage the
vehicle.
This manual contains the repair instructions
for all the vehicle parts. procedures, technical information and
precautions which, if not respected and/or
Some devices described in this handbook incorrectly carried out, could pollute the
may not be fitted in your vehicle, according environment.
to the outfit and the market for which the
vehicle was made.
. very important procedures, technical
This handbook is organised in several sections, which information and precautions.
are organised in chapters and, where required,
paragraphs to ensure rapid and easy retrieval of
information.
Refer to the general list of contents at the beginning of
this Handbook for further information on how the
various topics are set out.
Purpose of this handbook

Purpose of this handbook is to allow users to get to
know the vehicle and repair it as specified, in a safe and
long-lasting fashion, taking the required actions and
arranging human and material resources as needed.
To whom this manual is addressed

This manual is addressed to those persons who need
to and/or have been delegated to carry out repairs on
the vehicle and/or whose job it is to give instructions on
how to carry out such repairs.
These persons are:
D operative units/site/department managers;
D users directly concerned in vehicle maintenance.
Safekeeping of this handbook

This handbook must be kept inside the vehicle, in a dry
place, and must be readily available for consultation.
You are advised to file a copy.
Keep the handbook for the entire life of the vehicle, until
it is scrapped. Users are required to purchase a new
copy if the handbook is either lost or damaged. Copies
must be exclusively ordered from the manufacturer.
Updates to this handbook

The information, descriptions and illustrations in this
handbook reflect the state of the art at the time of
marketing of the vehicle.
The manufacturer reserves the right to implement
changes to vehicles, for technical or marketing
reasons, at any time. The manufacturer will not be
obliged either to implement such changes in the
vehicles marketed before or to consider this handbook
obsolete.
Any additional information which the manufacturer
may deem suitable to provide at a later time will be kept
with the handbook as an integral part of the publication.
Units of measure
International System (SI) units of measure as used in
this handbook.
Imperial System values are expressed in brackets.
SCHEDULED USE VEHICLE REPAIR SERVICEMEN

The vehicle described in this handbook was designed Any repairs to the vehicle must be carried out
and made for the following use: exclusively by qualified repair servicemen with the
D to haul excavation material in general; necessary ability and technical knowledge.
D to haul material resulting from interventions on Vehicle servicemen must:
industrial or civilian artefacts in general; D have the operative skills required for construction
D to haul material required to make infrastructures site vehicle maintenance;
and/or industrial or civilian artefacts in general. D be sensitised to respect and adopt safety
The vehicle must be used for such purposes. instructions and precautions.
The vehicle must be in proven and checked conditions The servicemen must be put in the condition to be able
of efficiency for said use, fully respecting the envisaged to work in total safety by means of suitable training
criteria and restrictions of use. periods or courses, so that they are fully aware of the
Specific care must be paid to the following aspects: rules of professional demeanor that must be followed
D do not exceed the payloads specified by the during repairs to the vehicle.
manufacturer; The direct reporting manager must ensure respect of
D do not exceed the gradients specified by the general safety instructions, specifically those
manufacturer; contained in this handbook.
D do not drive the vehicle on loose terrain which can The manager will also ascertain suitability of operating
compromise stability; personnel, in terms of technical skills and
D do not use the vehicle to remove objects or psychological-physical conditions.
products;
D use the vehicle paying special care to the safety
instructions and specifications;
D carry out the ordinary maintenance interventions
specified by the manufacturer;
D carry out the extraordinary maintenance
interventions which are required, specifically those
related to safety of use.
. The manufacturer declines liability for injury

to persons and for damage to the vehicle
and/or to the transported goods in the event
of other use or use in other conditions than
those specified.
WASTE DISPOSAL SCRAPPING THE VEHICLE

Collect and properly dispose of replaced material The vehicle must be scrapped according to the laws in
(brake pads, filters, etc.) and waste material, resulting force, at the end of the vehicle's working life.
from maintenance operations and repairs (material Recycle and demolish the vehicle according to the laws
soaked in fuel, oil, powder, etc.) according to the laws in force.
in force, separately from normal waste. The vehicle must be demolished by expert personnel
Collect and dispose of used lubricants and fluids, using suitable working tools to ensure the required
according to the laws in force. safety conditions.
Collect and dispose of used batteries according to the Demolish the vehicle by separating and collecting the
laws in force. various materials by type to allow recycling and
Drain and recharge the air conditioning system using disposal.
the specific devices, according to the laws in force. Please note that it is forbidden to abandon an obsolete
Furthermore, you are advised to separate ferrous vehicle at a quarry, building site, dump or in the
materials, light alloys and waste plastic materials for environment.
separate recycling. Specific attention must be devoted to certain
components and substances which can pollute the
environment and/or cause injuries, i.e.:
D presence of fuels, coolant fluids, hydraulic oil and
lubricating oils on board;
D presence of batteries and respective electrolyte;
D presence of pressurised gas (tyres, suspension
components, air conditioner);
D presence of solid polluting materials (tyres, brake
pads, plastic parts, filters) or hazardous materials
(glass, windows).
Dispose of these materials according to the laws in
force.
WARRANTY AND LIABILITY OF THE SERVICE

MANUFACTURER
Warranty coupons
Warranty conditions The manufacturer provides a warranty card to the user
The user must scrupulously observe the precautions with each vehicle.
illustrated in this handbook to ensure validity of the You are advised to use the coupon during the first hours
contractual warranty. Specifically, the user will: of operation of the vehicle.
D respect restrictions of use specified by the
manufacturer; Warranty coupon: after 250 hours of work.
D not implement changes or variants to the vehicle
without the manufacturer's written approval; . Different warranty conditions are valid only
D always carry out the maintenance interventions; if stated on the vehicle purchasing contract.
D always use genuine spare parts;
D ascertain that the personnel called to use the Service
vehicle have the necessary requirements in terms of
Dealerships are available for all types of interventions.
skills and training.
Equipment and expert personnel are available for
The contractual warranty will not be applicable if the
overhauling and repairing operations.
aforesaid conditions are not respected, even in part.
Dealerships can provide information and advice to
ensure the best use of the vehicle.
Liability
The manufacturer declines all direct or indirect Spare parts
liabilities deriving from:
Use genuine spare parts for replacements which can
D disrespect of the instructions contained in this
be ordered from dealers and authorised workshops.
handbook;
Please remember that the following information will be
D use of the vehicle by untrained or unauthorised
required to order spare parts:
personnel;
D vehicle type;
D use non complying with the regulations in force in
D chassis number;
the country where the vehicle was marketed;
D reference and catalogue numbers shown in the
D unauthorised changes and/or repairs;
Spare Parts Catalogue.
D use of other than genuine spare parts.
If the part belongs to a main assembly (engine,
transmission, axles, motors, etc.), you will also need to
specify the assembly model and serial number.
GENERAL OPERATION RULES

Pre-disassembly preparation D All units, especially those which look alike, should
be placed in order and tagged or marked when
Cleaning before bringing the vehicle into service shop necessary.
Remove mud and dirt completely before bringing the D Standard parts such as nuts and bolts are to be
vehicle into the service shop. Carrying mud and dirt into kept, noting the assembly position and the quantity.
the service shop impedes cleaning operations when D Shims and washers used to adjust clearances are
disassembling and increases the possibility of to be kept so they can be re-assembled in the
contamination of parts during reassembly. same conditions.
D During disassembly, carefully inspect for any
Preliminary survey before disassembly seizure, interference or contact with moving parts to
find the cause of the problem.
Before disassembly, make an accurate preliminary
D When measuring, record all the values, such as end
survey and make a note of the results. This will save
clearances, backlash or projection which only have
unnecessary labour and component costs and will be
significance if measured during disassembly.
useful to give advice to the user to prevent problems in
D Keep the same adjustment values of the rods as far
the future.
as possible. If it is necessary to disassemble
In particularly:
adjustment devices, measure the length before
D Check the type and number of the machine and
disassembly and make a note of the value so as to
service meter reading.
be able to reassemble in the identical condition.
D Check the reason for disassembly.
D If tapered or fitted parts that should fit tightly come
D Check the symptom, location and cause of the
off easily, inspect the parts involved to find the cause
problem and make another visual check if
so that the same problem does not occur again
necessary.
when reassembling.
D Check the contamination of the air cleaner and air
leakage. Figure 4
D Check the characteristics of the fuel being used,
contamination of the fuel filter and for any water in
the fuel, loss of fuel, deformed pipes.
D Check the oil level, oil contamination (viscosity,
colour and impurity) presence of water in the oil, oil
leakage and clogged oil filter.
D Check the tension of the V belts;
D Check for any faulty components or loosened
connections.
Disassembly preparation
To save unnecessary labour, make sure that the
equipment, area and space on the shelves is available,
according to the specific type of disassembly to be 1730101
carried out, and clean the area beforehand.
D Use an appropriate jig and do not try to force them.
During disassembly
Removal of parts
D Before removing parts, check the assembly
conditions and front/rear, left/right and up/down
relations and the removal procedures
D Make sure there are the relevant mating marks
indicating the mounting positions and if necessary
mark clearly to avoid errors during reassembly.
D Use the special disassembly tools where specified.
D If it is difficult to remove a part even after the
mounting screws have been removed, do not force
it, but check the part to find where the problem lies.
Disconnecting hydraulic lines After disassembly
Operate each control lever several times to When using detergents, make sure you fully
relieve any pressure in the lines to be understand the use instructions and take
removed. care not to bring them into contact with the
Open the air bleeder cap of the hydraulic eyes or skin. Dispose of used detergents
tank. correctly.
Figure 5 Cleaning
D Clean the disassembled parts and arrange them in
order. Completely remove sludge and dust from the
oil ports of each part.
D To clean more efficiently, divide the detergent into
two containers; one to remove the dirt and one for
finishing. When cleaning more important parts,
divide the containers further to avoid using dirty
detergent.
D When cleaning large castings, such as the cylinder
head or block, , immerse them in a container for 5
to 10 minutes with a pH 10-12 detergent, at a
temperature of 50 °C and 70 °C (122Ą÷Ą158 °F),
then rinse thoroughly.
1730102
D To disconnect a rigid tube from another one, or a Rust and dust prevention
rigid tube from a hose, grasp the male end with a D Cover clean parts to avoid rusting.
wrench and loosen the female nut side. D Place caps on the ends of tubes and hoses.
D Plug the end of the removed tube or hose and the D If it will be some time before assembly, use rust
oil port on the part, to prevent foreign matter from inhibitor.
entering.
D Since the tube or hose to be removed contains oil, During assembly
pour this off into a suitable container.
D Clean up any oil spills in the working area. Installing the parts
D Attach a tag with an appropriate marking to each D Before starting to assemble, clean all the
tube, hose and hydraulic component line components and repair any damage. Dirt and dust
connection for easier reassembly. have adverse effects on moving parts and can
shorten the machine life, so take all precautions to
limit their penetration.
D Before assembly, remove the layer of rust inhibitor
if present on new parts.
D Parts with mating marks are to be mounted so that
the marks are correctly aligned.
D Use a press and appropriate tools when installing
bearings, bushings, oil gaskets etc. When
mounting special parts, use the specific special
tools.
D Coat the surface of press-fit parts with
molybdenum disulphate grease or other specific
lubricant, where prescribed.
Screw and nut tightening Connecting hydraulic lines

D Clean all rigid tubes with a suitable detergent and
Figure 6 blow dry with compressed air.
D Do not use coupling liquids (three components).
D When installing high pressure hoses, do not allow
any torsion. Avoid that other parts interfere with the
hoses if they have no protective spring.
D Install correctly, checking the tags on each rigid
tube or hose and on hydraulic component
connections.
Figure 8
1730103
D Tighten nuts and bolts alternately so that average

torque can be applied evenly. The numbers on the
figure indicate the order of tightening.
D Unless indicated otherwise, apply lubricant to the
threaded part of the bolts, so as to obtain even
tightening.
Figure 7
1730105
D When connecting the lines, slightly tighten the nuts

at both ends, then tighten alternately.
D After completing the line connections, run the
engine at low speed and from the operator's seat
move each hydraulic component through the
control levers. Make a further inspection then top up
the oil in the hydraulic tank
D Points such as end clearances, end plates,
projections, steps and backlash that cannot be
checked except during the assembly process, are
to be checked and measured before passing on to
the next step.
D Shims and washers used to adjust clearances are
to be refitted in the same condition as they were
before disassembly, unless worn or damaged.
D After reassembly, check the adjustment values.
D Assemble the linkage with the rod adjustment value
1730104
identical to that before disassembly.
a: correct assembly D If parts fitted by pressure are easily inserted, check
b: incorrect assembly the insertion dimensions again and correct any
flaws before assembling.
D The nuts and bolts that cannot be inspected
externally, or those for more important parts are to
be installed and locked with an appropriate device
to prevent loosening (lock wire, split pin, bent
washer).
D Bolts on which a thread stop has been applied
(residue can be seen when removed) are to be
cleaned with light oil and dried before tightening.
Apply 2 or 3 drops of thread stop to the threaded
part of the bolts, then tighten.
Interchangeable parts
Figure 10
Gaskets
D As a rule, replace all gaskets with new ones.
D Apply sealing liquid to the sealing gaskets of certain
parts.
D Remove all flaws, dust, paint, oil or previously used
seal liquids.
D Apply an even coating of the specified sealing liquid
and allow to dry for a few minutes.
D When the liquid is dry to the touch, mate the
gaskets.
O-rings
D If the O-rings have become hardened after long
1730107
storage, discard them even if they have never been
used. D When assembling oil seal gaskets, apply some
D Use only the O-rings indicated in the spare parts grease to prevent initial dry friction.
lists. For the engine, in particular, O-rings of
special material, like silicone rubber are used for a. Single lip type oil seal gasket
their resistance to heat and deterioration. Do not Apply the grease evenly over the entire external
use substitutes. border of the side opposite to the sealing part of
D Before installation, apply a coating of oil to the the lip (arrow), taking care that there is no build
O-ring to prevent cracking. Silicone rubber tears up.
easily and must therefore be handled with care. b. Double lip type oil seal gasket
Apply grease to 40-60% of the external border of
Oil seal gaskets (oil seal rings) the section between the lips (arrow).
Figure 9 D Make sure that the contact surface (shaft area) of

the oil seal gasket is free of dust, cracks or rust and
apply lubricant to facilitate the installation.
Figure 11
1730106
A: inner side (possible pressure)

B: outer side
a: main lip (seal)
1730108
b. dust protection lip
D To install, use a guide and an assembly jig to avoid
D Pay attention to the direction of the oil seal gasket damaging the oil seal gasket lip.
lips. D After inserting the oil seal gasket and pushing it into
D Take care that no dust settles on the oil seal gasket, its seat, the gasket should have no inclination.
and ascertain that there is no rust or cracking
(especially on the lip surfaces).
D When an adhesive product is applied to the external D Bearings to be mated with large interference values
part of the gasket, take care that none drops onto are to be inserted by shrink fitting. To avoid
the lip surfaces. Since the adhesive remaining on damaging the heat treatment hardening, keep the
the assembly tools could easily pass onto the lips, temperature below 120 °C (248 °F).
use clean guides and assembly jigs.
Figure 13
Bearings
D Since dust adversely affects bearing wear, when
disassembling and reassembling, care must be
taken to protect them from dust.
D Handle the bearings with care when cleaning and
do not allow them to spin in compressed air.
D When installing, do not knock on the bearing inner
or outer ring, as this could cause indentations on
the rolling surfaces.
Figure 12
1730110
D Non-separating bearings that require interference

on both inner and outer rings are to be inserted
using an appropriate assembly jig.
Snap rings (seeger rings)

D To insert and remove snap rings, use snap ring
pliers taking care not to widen excessively.
D After installation, make sure the snap rings are
completely fitted into their groove.
1730109
D If interference is required on the inner ring, push it

in using an appropriate assembly jig.
Welding on the chassis D turn over and weld as specified in the previous step;
Before starting these operations, disconnect the allow the side members to cool slowly and evenly;
negative terminal of the battery and connect the welder do not use jets of air or other methods, immediately
earth directly onto the piece to be welded. remove excess material by grinding;
Work on plastic tubes is only to be carried out by skilled
Figure 15
experts, using the appropriate equipment and
performed with perfect workmanship.
Figure 14
1730112
A = 0.3 H
1730111 B = H .175 mm (7 in)
S = (0.8 ć 1) S1
Remove the paint and any oxidation from the parts to
be welded. On the yield point, on the internal part of the D apply internal corner reinforcements in steel having
side member and along the entire length of the part the same characteristics as the chassis (minimum
involved, make a 60° chamfer. indicative dimensions are shown on the figure);
D they should be fixed only to the vertical rib of the side
Cuts on the side member are not allowed
member and welding beads can be used. The
that correspond to the stress variation section and length of the weld bead is to be
zones, furthermore the line of separation is adequate to transmit the section bending and
not to involve the existing holes on the side cutting moments.
member. D After welding the part involved is to be efficiently
The operating instructions for correct welding follow protected with a rust inhibitor.
below:
D heat all around the zone to be welded; make the arc
welding passing several times using carefully dried
basic tips , or MIG-MAG procedures with a suitable
filling material; avoid current overloads; the welding
is to be free of border incisions and spatter;
SECTION 1.2
SAFETY INSTRUCTIONS
ADT 25 SECTION 1.2 SAFETY INSTRUCTIONSą1
CONTENTS
Page Page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 WORKING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . 9
SAFETY INFORMATION AND SYMBOLS . . . . . . . 3 TOWING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . 11
GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 4 REPLACING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . 11
PREVENTING FIRES . . . . . . . . . . . . . . . . . . . . . . . . . . 5 MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . 12
USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 PREVENTING INJURIES . . . . . . . . . . . . . . . . . . . . . . 13
STARTING AND STOPPING . . . . . . . . . . . . . . . . . . . . 8 PREVENTING INTOXICATION AND

CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DRIVING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . 9
PREVENTING BURNS AND ELECTROCUTION . . 16
2ąSAFETY INSTRUCTIONS SECTION 1.2 ADT 25
INTRODUCTION
The instructions and warnings given in this handbook
illustrate the fundamental safety principles for
operating articulated dump trucks.
Figure 1
156NS01
These instructions are not comprehensive. They do not

illustrate all the potential hazards which may arise.
Operators must be aware of all the procedures
described in this handbook. The procedures advise
against adopting work methods which could cause
injuries and/or affect integrity of the vehicle.
The procedures are not comprehensive. The
Manufacturer cannot account for all the possible
methods of use and operation, nor evaluate all the
possible consequences.
Consequently, operators must be responsible and
careful at all times, to prevent hazardous situations for
themselves and others.
Use of the vehicle is subjected to respecting the
specifications contained in this manual and safety
regulations set forth by the law in the country where the
vehicle is used. Knowledge of local legislation is
mandatory for all vehicle users.
Read this manual carefully. Contact an expert or call the
Manufacturer if in doubt.
Safety information and symbols

Figure 1 shows a safety symbol which is used to attract
the operator's attention to safety relevant matters. Pay
the utmost care when you see this symbol on the
vehicle or in this handbook.
Always follow the recommended safety instructions.
Always read the safety related adhesive labels.
Replace the labels if they are damaged.
Safety plates and labels on the vehicle are illustrated in
Section 2 - GENERAL SPECIFICATIONS.
General instructions
Arrange a first aid kit in the vehicle. Check and Figure 3
replenish regularly (Figure 2).
Figure 2
156NS03
Standard safety equipment includes:

156NS02
D helmet
D goggles or face mask
Arrange a plate providing emergency telephone
D protective earphones
numbers. Keep it up-to-date.
D thick gloves
Vehicle personnel should be aware of basic first aid
D suitable clothes
procedures to be applied in the event of an accident or
D safety boots.
casualty.
Keep children away from the vehicle, the equipment
and the materials used.
Keep unauthorised persons away from the vehicle, the
equipment and the materials used.
The vehicle can only be driven by qualified personnel,
who is authorised to do so by the legislation in force.
Drivers must be in suitable psychological and physical
(tiredness, effect of alcohol, drugs, etc.).
Furthermore, drivers must be familiar with the position
and operation of all controls, instruments, gauges and
warning lights in the vehicle. The driver must also be
able to evaluate, in principle, failures which may occur
and adopt the required precautions.
Do not allow unqualified or unsuitable personnel to use
the vehicle.
Maintenance and repair operations must be carried out
by qualified personnel, who are familiar with the
arrangement and operation of assemblies and
workshop tools.
Do not allow unqualified personnel to carry out
maintenance or repair operations on the vehicle.
Do not wear rings, wristwatches or loose and hanging
clothes when carrying out maintenance and repair
operations on the vehicle.
Do not use radio or personal stereo headphones
during operations to avoid distractions.
Personnel will use the vehicle safety features (seat
belts) and personal protection devices during vehicle
use and maintenance (Figure 3).
PREVENTING FIRES
Keep a suitably sized fire extinguisher in the vehicle. Stop the engine before refuelling. Do not refuel in
Check it regularly (Figure 4). closed places.
Check for leakage or residues of fuel, lubricants and
Figure 4 fluids which could cause minor fires before starting the
engine.
Short circuits can cause fires (Figure 7).
Figure 7
174NS09
The portable fire extinguisher can only be used by
skilled personnel.
Vehicle personnel must be familiar with the basic
156NS07
techniques for dealing with fire.
Fuel and most lubricants and fluids are flammable Regularly check conditions of battery terminals, wires
(Figure 5). and electrical devices.
Do not store flammable substances in places which are
Figure 5 not suitable for the purpose. Do not pierce or burn
pressurised container or cylinders. Do not pile up
materials soaked in flammable substances.
Be careful where you leave rags and/or replaced
materials which may contain flammable residues.
156NS05
Do not smoke while refuelling or topping up fluids. Do

not refuel or top up near naked flames. Do not handle
fuel (Figure 6).
Figure 6
156NS06
Put out all smouldering materials and naked flames Stay away from the vehicle if a small fire occurs in the
before starting any maintenance operation. brake or tyre areas. The tyres could explode.
Do not smoke during maintenance operations Never stand in front of the sidewall. Keep a safety
(Figure 8). distance of at least 15 metres (16,5 yd) from the thread
(Figure 10).
Figure 8
Figure 10
156NS08
Do not use petrol, solvents or other flammable or toxic

fluids to clean mechanical parts. Use non-flammable,
non-toxic, type-approved products on the market.
Do not weld near tanks, pipes, reservoirs, electric wires
or flammable materials in general.
Protect flammable parts with suitable guards when
welding.
Stay away from the vehicle and call a fire-fighting
expert team in the event of a large-scale fire (Figure 9).
Figure 9
156NS10
Stay away from the vehicle for a few hours after putting
out the fire to allow the tyres to cool down. Approach
the vehicle protected by a crawler loader bucket, for
example.
156NS09
OVERTURNING ACCIDENTS 1
Prevention
Always check the limits for height and width during all
stages of loading/unloading, and make sure they are
within the prescribed limits (1).
Keep the wheels perpendicular to the slope when
driving up or down a gradient.
Do not make a U-turn on a gradient to prevent turning
over.
Respect the transverse gradient permitted for the
loaded and unloaded vehicle. 156NS19
Respect the values for maximum slope when unloaded
and loaded (2).
Check that the hammer for breaking the specially 2
treated glass is always kept in the cab.
In the event of overturning

Make sure that the personnel trained to use the vehicle
know where the emergency exits are and the location
of the special glass breaking tool.
The following emergency exits can be used to abandon
the vehicle (3):
D door (open);
D front right window (smash).
156NS20
Use the special tool (4), located at the bottom of the
window to break the specially treated glass
3
174NS07
174NS08
INSTRUCTIONS FOR USE

Cab With the vehicle stationary and the parking brake
Use the steps and handles to get on and off (Figure 11). applied, before setting off, check position of the seat,
the steering wheel and the rearview mirrors to ensure
Figure 11 maximum driving comfort and control accessibility
(Figure 12).
Figure 12
156NS12
Make these adjustments each time the driver is

changed.
Drivers should be able to fully press the pedals and
operate the controls correctly without lifting their backs
174NS01A from the backrest.
Do not adjust the seat, the steering wheel or the
Keep the steps and handles clean to avoid slipping.
rearview mirrors while driving or in any other way than
Do not use flexible parts or controls as handles. They
specified.
could break or get damaged.
Always wear seat belts (Figure 13).
Face the vehicle while you are getting on and off. Have
three points of contact (steps and handles) at any time. Figure 13
Do not jump on or off the vehicle.
Do not get on or off while the vehicle is moving.
Keep the floor clear from fragments, tools or other
objects which could interfere with the pedals.
Keep the pedals clean (mud or grease).
Eliminate anything which can reduce visibility or
distract the driver.
Keep windows and rearview mirrors clean.
156NS13
The webbing must not be twisted. The belt should wrap

around your hips, not your abdomen, to prevent the
risk of slipping forwards.
Replace the seat belt being worn in an accident of a
certain severity even if it does not appear damaged.
Do not make changes which can decrease
functionality of the seat belt.
Starting and stopping

Before starting off, check the vehicle exterior for Do not smoke or use naked flames near the batteries
problems, such as flat tyres, fluid leakage, broken (Figure 15).
parts.
Make sure no-one is near the vehicle when starting the Figure 15
engine.
Sound the horn before starting the engine (Figure 14).
Figure 14
156NS15
In the event of contact with electrolyte, wash the

affected part for at least 15 minutes and call a doctor.
Do not run the engine in closed places without a
suitable ventilation system for disposing of harmful
exhaust in the air (Figure 16).
Figure 16
156NS14
Start the engine while you are sitting in the driver's seat.
Do not start the engine by short-circuiting the starter
motor wires.
Two people are required to start the engine with a
battery charger or auxiliary battery: one person will sit
in the driver's seat and the other person will stand near
the battery charger or auxiliary battery.
Do not carry out this operation if the flat battery is 156NS16
frozen. It could explode.
Respect cable connection procedure and polarity to Never leave the vehicle with the engine running.
prevent the risk of the batteries exploding or projecting Do not park with the parking brake applied and the
electrolyte. gear engaged, also if you are sitting in the driver's seat.
Always wear gloves and protective glasses when Before leaving the vehicle parked in a suitable area
approaching the batteries. where it is not a hindrance, make sure that the parking
brake is applied and that the keys have been removed
from the control panel.
Always apply the parking brake in the following cases:
D when the vehicle is parked for a long or short time;
D when loading/unloading the vehicle.
Driving the vehicle

Make all the necessary adjustments (seat, steering Never travel with the transmission in neutral.
wheel, rearview mirrors) before setting off. Do not use the parking brake for slowing down or
Check that the engine warning lights are OK. stopping the vehicle.
Sound the horn before starting off (Figure 17).
Working the vehicle
Figure 17
Do not use the vehicle for purposes other than those
described by the Manufacturer.
1 Always check height and width during the various
loading/unloading operations. Make sure they fall
within the specified limits (Figure 19).
Figure 19
156NS17A
Check that no-one is standing near the vehicle before

starting off.
Be very careful when steering: the front part of the
vehicle can move also when the vehicle is stationary.
This can be very dangerous for persons standing near 156NS19
the vehicle (Figure 18).
Figure 18 Beware of overhead obstacles, such as bridges,

cables and wires. Make sure that the load does not
knock into them.
Keep the wheels perpendicular to the slope when
driving up or down a gradient.
Do not make a U-turn on a gradient to prevent rolling
over.
Respect the transverse gradient permitted for the
loaded and unladen vehicle.
Respect the maximum possible gradient for the loaded
and unladen vehicle (Figure 20).
Figure 20
156NS18
Check the ground surrounding the vehicle before
reversing to make sure there are no people or
obstacles.
Do not transport people in the cab or in other parts of
the vehicle, with exception of the emergency seat.
Respect signs, especially speed limits. Never exceed
the speed limit.
Never drive at speeds which are forbidden and
dangerous for yourself or others.
Switch the lights on at night and when visibility is poor
(dust, fog, rain). Slow down. 156NS20
Look out for people when reversing and changing

direction.
Ideally, a person should be asked to signal when No-one should ever stand in the loading and
reversing. This person will be able to observe the unloading area of the vehicle (Figure 22).
approach from a more favourable position with respect
to the driver. Figure 22
Do not move the vehicle to loading position while the
bucket of loader or excavator is moving overhead.
Stay inside the cab while loading the vehicle.
Make sure that the maximum capacity of the vehicle is
not exceeded during loading operations (Figure 21).
Figure 21
156NS22
When unloading by means of the external control, the

operator must never leave the control, which is located
in a safe position, and must wear all the required
personal protection devices.
156NS21 Never start off during loading or unloading operations.
Do not get on or off the vehicle during loading and
Make sure that the load is well arranged and will not fall unloading operations.
out of the body during transportation. When crossing another vehicle, the unladen vehicle
Check the area before unloading. Look out for should give way to the loaded vehicle and the vehicle
hazardous points: loose terrain, ditches, humps and driving downhill should give way to the vehicle running
fencing. uphill.
Beware of icy ground: it may become weak and If other vehicles and/or other machines are used in the
slippery when the temperature rises. working area, appoint a person in charge of signalling
Avoid loading and unloading on steep slopes: the and use signals which can be understood by all drivers
vehicle could roll over. (Figure 23).
Be very careful of unbalancing the vehicle by the
movement of material out of the body during unloading Figure 23
operations.
Check that the body is in the correct position before
starting off after unloading.
156NS23
In this case, all personnel will follow the instructions

provided.
Towing the vehicle Replacing a wheel

Use the specific hitches provided for this purpose to The wheel replacement operation requires the utmost
tow the vehicle. care. The operation must be carried out by at least two
Do not use cables, belts or chains to have the vehicle experts, using a hoist or a crane to handle the wheel.
towed or to tow another vehicle: they could break. Stop the possibly unladen vehicle in a flat area, apply
Do not use cables, belts or chains to have the vehicle the parking brake and remove the key from the panel.
towed or to tow another vehicle if the braking system Make sure that the ground is adequately firm for the
of the vehicle being towed does not work. load to be supported. If in doubt, use plates and
Always use a stiff, suitably dimensioned bar platforms to prevent sinking.
(Figure 24). Only use the lifting points shown.
Make sure that the lifting device is suitable to carry out
Figure 24 the operations and respect safety requirements.
Do not use wheels or fasteners other that those
1 originally provided.
Excessive tightening may be dangerous: Do not use
tubes or extensions other than those provided to
tighten the wheel nuts.
Check that the wheel nuts are tight after two or three
hours of vehicle operation.
Check wheel nut tightness regularly.
156NS24
A user must always be aboard the vehicle being towed.

Do not stand near vehicles being towed.
The parking brake will not work if the output propeller
shaft is removed from the rear gearbox and/or the
transfer cases and/or the drive axles.
In this case, arrange suitable wedges under the wheels
in both directions of travel to prevent uncontrolled
vehicle movements.
MAINTENANCE INSTRUCTIONS
Introduction
Personnel in charge of repairs must be aware of all the Always lock the tipped body (Figure 26) when
procedures described in this handbook. The operating in such conditions.
procedures advise against adopting work methods
which could cause injuries and/or affect integrity of the Figure 26
vehicle.
The procedures are not comprehensive. The
Manufacturer cannot account for and evaluate all the
possible methods of operation or the possible
consequences.
Keep the place of work clean and dry. Do not smoke
during the operations. Wear all the required personal
protection devices before starting maintenance
operations.
Carry out the scheduled maintenance operations.
Carry out all the operations which are required for
correct and safe use of the vehicle.
Always apply notice boards warning that operations
are being carried out on the vehicle.
Do not allow unqualified personnel to carry out
maintenance or repair operations on the vehicle.
Carry out maintenance and repair operations with the
utmost care.
Only use the specific tools or wrenches expressly
specified for replacement, checking and maintenance
operations. 174NS02
Never tamper with valves, regulators or other devices, Proceed as follows:
unless specified in the handbook, to prevent damage a. fully tip the body and remove the pin;
to vehicle components and consequent hazards for b. turn the tie-rod forwards;
persons. c. insert the pin in the slot on the rear chassis.
Always lock joint (Figure 25); in safety position unless
otherwise specified.
Figure 25
156NS25
Proceed as follows:
a. align the vehicle and remove the pin
b. turn the tie-rod forwards;
c. insert the pin in the slot on the front chassis.
Make absolutely sure that the electrical power is Use the specific steps and handles for getting on and
disconnected before working directly or indirectly on off the side platform (Figure 29).
electrical system parts by operating the battery
disconnect switch (Figure 27). Figure 29
Figure 27
174NS03A
174NS05
Proceed as follows: Keep the steps and handles clean to avoid slipping.
a. to connect power: turn switch to vertical position; Do not use flexible parts or controls as handles. They
b. to disconnect power: turn switch to horizontal could break or get damaged.
position. Face the vehicle while you are getting on and off. Have
three points of contact (steps and handles) at any time.
Preventing injuries Do not jump on or off the vehicle.
Use the specific steps and handles for getting on and Do not get on or off while the vehicle is moving.
off the front platforms (Figure 28).
Figure 28
174NS04
All checking, bleeding, topping-up, maintenance and Figure 32

replacement operations must be carried out with the
vehicle stationary, on level ground, in a well lit and
ventilated area. Apply the parking brake, arrange
wedges under the wheels and remove the keys from
the ignition switch, unless otherwise specified in the
handbook (Figure 30).
Figure 30
156NS31
Warn people who are near the vehicle before starting

the engine (e.g. for a test).
Wait for at least four hours after stopping the vehicle
before conducting maintenance operations to avoid
contacts with hot parts. Be very careful of the cooling
fan which could start up suddenly.
Do not work over or under the vehicle propped up on
156NS29
jacks or other lifting devices which are not suitable to
Make sure that no-one is sitting in the driver's seat.
ensure safety (Figure 33).
Use portable lamps when the lighting is not adequate
and to illuminate working areas which cannot easily be Figure 33
accessed otherwise.
Use a ladder or platform with steps compliant with
safety regulations to carry out repairs and maintenance
operations in areas which cannot be reached from the
ground.
Keep hands and clothes away from moving parts when
carrying out operations with the engine running.
Never put your head or other parts of your body (feet,
hands) near turning belts or fans, when the engine is
running (Figure 31).
Figure 31
156NS32
Unload the vehicle before jacking it up. Only use the

lifting points shown.
Make sure that the lifting device is suitable to carry out
the operations and respect safety requirements.
After jacking up the vehicle, prop it up before carrying
out operations underneath.
Fully deflate the tyre before carrying out any type of
operation on tyres or rims.
Never stand in front of the sidewall while you are
inflating a tyre.
Never weld rims with tyres fitted to prevent explosions
156NS30 and fire.
Only use the expressly specified tools for inflating the
Do not put your head or other parts of your body (feet, tyres with nitrogen.
hands) near shafts or turning parts when the engine is
running (Figure 32).
Preventing intoxication and contamination

Do not run the engine in closed places without a Be very careful: drained oil and fluids, as well as filters
suitable ventilation system for disposing of harmful and surrounding parts, could be very hot (Figure 36).
exhaust in the air (Figure 34).
Figure 36
Figure 34
156NS35
156NS33
Ensure adequate ventilation to prevent the
Avoid prolonged, repeated contacts of fuel, lubricant accumulation of toxic vapours while cleaning and
and fluids with skin to prevent skin problems and other replacing filters.
syndromes (Figure 35). Do not weld in closed areas or areas which are not
suitably ventilated.
Figure 35 Do not weld on or near painted surfaces to prevent
developing toxic vapours.
Remove the paint with suitable products, wash the
surfaces and leave to dry.
Do not breathe dust and toxic residues while grinding
and sand-blasting. Protect your eyes with masks and
goggles.
Use a suitable vacuum cleaner to remove dusty
residues from the vehicle or place of work.
Do not play with compressed air. Keep compressed air
guns away from people.
Wear protective goggles with side guards and a mask
when using compressed air to clean filters, to prevent
injury caused by particles of dust. You are advised to
carry out the cleaning operations in a ventilated area.
Be very careful before removing caps or covers from
reservoirs, radiators or cylinders: turn the part slowly to
discharge any residual pressure.
Stand at a side during bleeding operations and always
wear protective goggles. Loosen the bleeder slowly by
a few turns to let out condense and fluid.
156NS34
Discharge pressure from the circuits before carrying
Do not swallow fuel, lubricant or fluids. In the event of out operations.
accidental contact with eyes, wash the concerned part Never use your hands to feel for leakage of pressurised
thoroughly with water. fluid.
Pressurised fluid leakage can penetrate under the skin
and in the eyes, causes very severe injuries.
Never use naked flames to feel for leakage of air
conditioning system. It could generate phosgene, a
very dangerous gas.
Preventing burns and electrocution

Be very careful of all parts of the vehicle which could In the event of contact with electrolyte, wash the
present high operating temperatures: engine, affected part for at least 15 minutes and call a doctor.
radiators, heat exchangers, exhaust pipe, gearbox, Do not charge a frozen battery. It could explode.
axles, brake discs, hubs (Figure 37). Respect cable connection procedure and polarity to
prevent the risk of the batteries exploding or projecting
Figure 37 electrolyte.
Do not smoke or use naked flames near the batteries
(Figure 39).
Figure 39
156NS15
Ensure adequate ventilation to prevent the

156NS36 accumulation of explosive gas while recharging the
battery.
Do not loosen the radiator cap when the engine is hot. Do not charge batteries near the workshop air
Let the coolant cool down before removing the cap. In compressor intake.
any case, remove the cap very carefully. Loosen the Arrange the air compressor away from the area where
cap slowly to release the pressure and remove it. paint, fuel and batteries are stored to prevent taking in
Do not place sources of heat near pressurised fluid vapours.
tubes to prevent sudden failures. Do not open the camera box or the monitor. Live parts
Protect tubes and electrical wires with suitable guards inside.
for welding. All operations must be carried out by skilled, suitably
Batteries contain sulphuric acid: always wear gloves equipped personnel.
and protective glasses when approaching the batteries
(Figure 38).
Figure 38
156NS37
SECTION 2
GENERAL SPECIFICATIONS
ADT 25 SECTION 2 GENERAL SPECIFICATIONSą1
CONTENTS
Page Page
VEHICLE COMPOSITION . . . . . . . . . . . . . . . . . . . . . 3 CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 PLATES APPLIED TO THE VEHICLE . . . . . . . . . . 16
WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 EUROPEAN VERSION . . . . . . . . . . . . . . . . . . . . . . . . 16

Inside engine hood plate . . . . . . . . . . . . . . . . . . . . . . 19
HORIZONTAL CENTRE OF GRAVITY . . . . . . . . . . . 5
Inside cab plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECURING POINTS FOR TRANSPORTATION
ON TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 U.S.A. VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Inside engine hood plate . . . . . . . . . . . . . . . . . . . . . . 23
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inside cab plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PERFORMANCE ALIGNMENT CHART . . . . . . . . . 8
MEASURES (INTERNATIONAL SYSTEM) . . . . . . 26
VEHICLE IDENTIFICATION DATA . . . . . . . . . . . . . . 9
STANDARD TIGHTENING TORQUES . . . . . . . . . . 27
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Screws and nuts with metric thread . . . . . . . . . . . . 27
POSITION OF IDENTIFICATION DATA ON
MAIN GROUPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gear shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Drive axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Front suspension cylinder . . . . . . . . . . . . . . . . . . . . . 11
MAIN GROUP CHARACTERISTICS . . . . . . . . . . . 12

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . 13
Front drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Intermediate and rear drive axles . . . . . . . . . . . . . . . 13
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Tipping system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2ąGENERAL SPECIFICATIONS SECTION 2 ADT 25
VEHICLE COMPOSITION
GROUPS DESCRIPTION
ENGINE
CUMMINS 6CTA8.3 - C260 (Turbo - 6 Cylinders)
GEARBOX
ÊÊ
ZF 6 WG 210
FRONT AXLE
ZF AP9
INTERMEDIATE AXLE
ZF AP9
REAR AXLE
ZF AP9
LAYOUT
TRANSMISSION
DIMENSIONS [mm (ft)]
174DT01A
A Wheel base 5183 (16.99)

B Front track 2795 (9.16)
C Rear track 2795 (9.16)
D Front overhang 2317 (7.60)
E Rear overhang 1258 (4.12)
F Overall length 9608 (31.50)
G Maximum width of body 2605 (8.54)
H Maximum height of unladen vehicle 3517 (11.53)
I Minimum height from the ground (ground clearance) 481 (1.58)
L Loading height 2696 (8.84)
M Maximum height with raised body 6394 (20.96)
N Maximum tipping angle 67°
Turning radius between kerbs 4362 (14.30)
Turning radius between walls 8182 (26.83)
Allowed tolerance "3%
WEIGHTS [kg (US ton) (lb)] (Allowed tolerance ±3%)

kg US ton lb
Vehicle tare in full running order: 17500 (19.20) (38581)
Tare weight distribution
front axle: (51.4%)
( ) 9000 ((9.92)) (19842)
( )
rear axle: (48.6%) 8500 (9.37) (18739)
Total weight: 40500 (44.64) (89287)
Maximum allowed weight
front axle: (34.6%)
( ) 14000 (15.43)
( ) (30865)
( )
rear axle: (65.4%) 26500 (29.21) (58422)
Capacity: 23000 (25.35) (50706)
HORIZONTAL CENTRE OF GRAVITY (during transport with unladen vehicle) [mm (ft)]
2665 (8.74)
174DT02
SECURING POINTS FOR TRANSPORTATION ON TRAILER
174DT15
A: Front securing points

B: Rear securing points
C: Central securing points
PERFORMANCE
Type of tyres 23.5 R 25
Axle reduction ratio 1 : 21.85 LOCK-UP
Gear Gearbox ratio Total ratio Speed km/h (mph) Max. gradient
(*) (%)
1st gear 1 : 5.562 121.530 5.2 (3.2) 35.0
2nd gear 1 : 3.615 78.988 8.1 (5.0) 21.0
3rd gear 1 : 2.255 49.272 12.9 (8.0) 12.0
4th gear 1 : 1.466 32.032 19.9 (12.4) 5.0
5th gear 1 : 0.943 20.605 30.9 (19.2) 4.0
6th gear 1 : 0.613 13.394 47.6 (29.6) 2.0
1st Reverse gear 1 : 5.274 115.237 5.5 (3.4) 33.0
2nd Reverse gear 1 : 2.138 46.715 13.6 (8.5) 11.0
3rd Reverse gear 1 : 0.894 19.534 32.6 (20.3) 2.0
(*) speed that can be reached with engine running at 2200 rpm and tyre rolling circle of 4.825 mm (189.96 in).
Minimum speed at maximum torque in 1st gear: 3.3 km/h (2.0 mph)
Max. speed (theoretical): 47.6 km/h (29.6 mph)
Maximum gradient in 1st gear (theoretical): 35%
Maximum gradient in 1st gear (with converter on-theoretical) 50%
Weight/power ratio: 155.769 kg/CV (347.9 lb/HP)
PERFORMANCE ALIGNMENT CHART

To use the alignment chart (see diagram below) plot a vertical line starting from TOTAL GROSS WEIGHT (G.V.W.)
(A) to meet the advance TOTAL RESISTANCE curve (GRADE) sum of the rolling resistance as a function to ground
conditions (see table below) and the slope of the route (B).
Follow a horizontal line to meet the highest speed allowed curve (C).
Continuing horizontally from this point up to the y-axis determines the traction force (RIMPULL) (D) required,
whereas continuing vertically downwards to the x-axis determines the SPEED (E) that can be obtained under
the set conditions.
Rolling resistance
Ground conditions kg for each ton of gross weight %
asphalt - concrete 15 1.5
hard packed soil 20 2.0
soft soil 30 3.0
mud on packet soil 40 4.0
packed snow 25 2.5
soft snow 45 4.5
sand - gravel 100 10.0
SPEED (Km/h)
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
600
G 130
500 R 60 110
400 A 50 100
D 40 90
R 80
I 300 E
30 70
M
P (%) 60
U 50
200
L 20
L 40 R
I
(kN) 30 M
P
100 U
90 1st 10
L
9 20
80 8 L
70 100 2nd 7
60 80 (lbf x
6 1000)
50 60 3rd 5
10
40 4 9
40
4th 8
30 3 7
6
5th
20 5
20 2
4
6th
C B
D 7th
3
10 10 1
9 9 2
8 8 8th
7 7
6 6
5 5
1
4 4 0.9
0.8
3 3 0.7
0.6
G 0.5
2 2 R
A 0.4
D
E 0.3
1 1 (%)
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 SPEED
(Km/h)
G.V.W.
(Kg x 1000) 10
0 5 10
20
15
E 20 30
25
40
30
50
35
60 70
40
80 90
45
100
SPEED
(mile/h)
G.V.W. 22 30 40 50 60 70 80 90 100 110 120 140 160 180 200 220
(lb x 1000)
A
VEHICLE IDENTIFICATION DATA

The chassis type and number of the articulated truck is the vehicle identification data.
Figure 1
The chassis number is punched on the right-hand side of the vehicle (Arrow).
Chassis number
1. International manufacturer identification

2. Type of vehicle, (AD = articulated dumper)
3. Capacity:
25
4. Version:
TP = Tipper
5. Data of manufacture
6. Data of manufacture
7. Chassis progressive number.
POSITION OF IDENTIFICATION DATA ON MAIN GROUPS

All the main vehicle groups are identified with a serial Engine
number to be found on the actual group, in the
positions shown below. Figure 4
The group identification number is always to
be indicated when ordering spare parts.
Cab
Figure 2
The type of engine and the serial number are indicated

on a plate on the engine.
Gear shift
Figure 5
The cab number is indicated on a plate in the cab on

the right.
Chassis
Figure 3
The type of gearbox and the serial number are

indicated on a plate on the gearbox.
The chassis number is stamped on the right side of the

vehicle.
Drive axles Front suspension cylinder
Figure 6 Figure 8
FRONT
INTERMEDIATE
The type and serial number are indicated on a plate on

the cylinder casing.
REAR
The type of axle and the serial number are indicated on

a plate on the axle housing.
Tipper cylinder
Figure 7
The type and serial number are indicated on a plate on

the cylinder casing.
MAIN GROUP CHARACTERISTICS
Engine
6CTA 8.3 - C260
Main characteristics:
Number of cylinders 6 in-line
Bore mm (in) 114 (4.49)
Stroke mm (in) 135 (5.32)
Displacement cm3 ( in3) 8270 (504.5)
Compression ratio 16.5 : 1
Cycle: Diesel 4 timing
Turbocharger type: fixed geometry
Power type: Aftercooler
Power data (SAE J1995):
Maximum power output kW (CV) 194 (264)

kW (BHP) 194 (260)
running at approx. rev/min (rpm) 2200
Maximum torque Nm (lb ft) 1123 (828.3)
running at approx. rev/min (rpm) 1300
Injection system:
Type of injection direct
Injection system distributor pump in line
Ignition order 1-5-3-6-2-4
Adjustments:
Cold tappet clearance adjustment
Intake valves mm (in) 0.30 (0.012)
Exhaust valves mm (in) 0.61 (0.024)
Automatic transmission Brakes

Completely hydraulic braking system with separate
ZF 6WG210 circuits for front and rear brakes: braking pump
Gearbox with 6 forwards gears and 3 reverse. controlled by engine and hydraulic pressure
Single stage torque converter with lock-up in all gears. accumulators.
Service brake
Stall ratio: 1.77 : 1 Disk brake with two callipers per axle, each with four
Incorporated third differential lockable by tooth pistons.
engagement between front axle and intermediate and Braking pressure: 150 bar (2176 psi)
rear axles.
Parking brake
Gear ratios Disk brake with double calliper and hydraulic spring
release activation acting on rear propeller shaft.
Gear Normal
1st 5.562 Wheels and tyres
2nd 3.615 Five-piece rims on six wheels.
Steel rims
3rd 2.255 Rims: 19.5 - 25
4th 1.466 Tyres: 23.5 R 25 (standard).
5th 0.943
Suspension
6th 0.613 Front
1st RG 5.274 Two hydro-pneumatic cylinders (air-oil) for variable
flexibility and damping.
2nd RG 2.148
Working pressure (static load): 130 bar (1886 psi)
3rd RG 0.894 Rear
Double rigid rocker distributing the load on the two
RG= Reverse gear
intermediate and rear axles with rod able to absorb the
torque reaction under the different use conditions.
Front drive axle
Steering
ZF AP9
Rigid type axle with side pinion reduction on hubs; Orbitrol
differential with limited stroke.
Hydraulically controlled steering with flow amplifier by
Centre bevel reduction ratio: 3.44
means of two double action hydraulic cylinders on
Epicyclical final reduction ratio
articulated joint between frames.
in wheel hubs: 6.35
System fitted with main gear pump controlled from
Total reduction ratio: 21.85
gearbox and electrically controlled emergency pump
(see hydraulic system).
Intermediate and rear drive axles
Steering angle: 45° both directions
ZF AP9 Hydraulic system

Rigid type axle with side pinion reduction on hubs; The hydraulic system is made up of three hydraulic
differential with limited stroke. pumps:
The differential on the intermediate axle distributes the Main pump
torque between the intermediate and rear axle. Can be (steering and tipping): 117 cm3/rev (7.13 cu in/rev)
locked through the specific control in the cab. steering emergency pump: 19 L/min - 24 V d.c.
Centre bevel reduction ratio: 3.44 (4.17 Imp gpm)
Epicyclical final reduction ratio Brakes pump: 19.5 cm3/rev (1.18 cu in/rev)
in wheel hubs: 6.35 175 bar (2539 psi)
Total reduction ratio: 21.85
All the circuits (steering, tipping, braking) use the same

hydraulic oil tank.
An oil filter, housed in the tank on the intake manifold
and two high pressure filters, located on the pump
delivery line, are used to filter the oil well.
An air-oil heat exchanger is used to cool the hydraulic
circuit and maintain an optimal temperature.
Tipping system
System with gear pump controlled from gearbox (see
Hydraulic system).
Two multi-stage, double acting hydraulic cylinders
mounted on ball joints inside the chassis to allow body
tipping and return.
Tipping angle: 68°
Body
Flat bottom steel structure with box type stiffening, with
supporting flexible pads. Walls and bottom in high
abrasion resistance steel.
Capacity:
- straight (SAE 1:1): 10.6 m3 (13.9 yd3)
- heaped to brim (SAE 2:1): 13.3 m3 (17.4 yd3)
Electrical system
Voltage: 24 V
Alternator: 28 V 70 A
Starter motor: 4.8 kW
Batteries (n. 2): 12 V 140 Ah
(connected in series)
Chassis
The chassis consists of two independent structures
jointed together in the middle.
The front and rear parts of the chassis are connected
with a central bearing and a heavy duty pin joint and
taper roller bearings that allow the parts to rotate and
oscillate.
It is built of boxed parts made of highly-resistant steel
(Hardox 400), and plates that weld them together.
CAPACITIES
Capacity Required
Parts to be supplied
l (US Gal) kg (Ib) specifications
Engine
ACEA E3
SAE 15W40 oil 22 (5.8) 19.2 (42.7) MIL L 2104E lev.
API GF 4
Engine cooling
Protective anti-freeze
anti freeze Engine only
9 8 (2
9.8 (2.6)
6) 9 8 (21
9.8 (21.6)
6) ASTM D336
mixture/water Complete circuit
Bonnet lifting circuit
Hydraulic fluid 2 (0.5) 1.7 (3.8) ATF DEXRON II
Fuel tank
Diesel 325 (85.8) 260 (573.2) ASTM D-975
Gear shift
ACEA E3
SAE 15W40 oil 26 (6.8) 22.8 (50.7) MIL L 2104E lev.
API GF 4
Axles + final reduction
Front
20 (5.3) 17.5 (38.9)
Intermediate MIL L 2105D
SAE 85W140 oil 21.5 (5.7) 18.8 (41.8)
API GL 5
Rear
20 (5.3) 17.5 (38.9)
Suspension
Hydraulic fluid 1.6 (0.4) 1.4 (3) ATF DEXRON II
Hydraulic circuit
ISO VG 46
Hydraulic fluid 250 (65
(65.8)
8) 218 8 (486
218.8 (486.2)
2)
DIN 51524/51525
Climate control system
Refrigerant fluid R134a
Greasing
Lubricating grease (lithium base) - - N.L.G.I. 2
PLATES APPLIED TO THE VEHICLE

The adhesives and plates applied on the vehicles may the adhesives and plates on a 25 model, indicating the
vary according to the market and local requirements of position where they are located.
the country. These pages contain a brief description of
5 1
7 6 3
4
8 9
18
13 14 17
12 15
19 1
7
11
5
10
16 17
9 6 8
EUROPEAN VERSION
Pos. 1 Towing eye plate Pos. 2 Battery throw off plate
Pos. 3 Fuel filler Pos. 7 Crushing hazard warning plate
Pos. 4 Danger of burns warning plate
Pos. 8 Vehicle tie-down plate
Pos. 5 Keep clear of prop shaft plate
Pos. 9 Safety warning plate
Pos. 6 Warning plate
Pos. 10 Hydraulic oil filler plate
Pos. 11 Maintenance plate
Pos. 12 CE plate
Pos. 17 Grease point centralized plate
Pos. 13 Inside noise plate
Pos. 18 Test point plate
Pos. 14 Outside noise plate
Pos. 15 Crushing hazard warning plate
Pos. 19 Warning plate INSIDE CAB PLATE
Cargo body tipping control plate
Warning plate
INSIDE ENGINE HOOD PLATE
Warning plate
Emergency exit
Warning plate
Gear selector plate
Danger of burns warning plate
Lock differential gear plate Parking brake control plate
Warning plate Voltage rating plate
Tyre inflation pressure plate

Voltage rating plate
Lubrication plate
U.S.A. VERSION
Pos. 1 Towing eye plate Pos. 5 Keep clear of prop shaft plate
Pos. 2 Battery throw off plate

Pos. 3 Fuel filler
Pos. 4 Wheel nuts torque plate
Pos. 8 Vehicle tie-down plate Pos. 12 CE plate
Pos. 13 Inside noise plate

Pos. 9 Safety warning plate
Pos. 10 Hydraulic oil filler plate

Pos. 14 Outside noise plate
Pos. 11 Maintenance plate
Pos. 16 Warning plate Pos. 19 Warning plate
Pos. 17 Grease point centralized plate INSIDE ENGINE HOOD PLATE
Warning plate
Pos. 18 Test point plate
Warning plate
Danger of burns warning plate
INSIDE CAB PLATE
Cargo body tipping control plate
Lock differential gear plate
Warning plate
Parking brake control plate
Emergency exit
Warning plate
Gear selector plate
Tyre inflation pressure plate
Lubrication plate
MEASURES (INTERNATIONAL SYSTEM)

Force in N (Newton) Pressure in kPa (kilopascal)
Other units in use:
Conversion: kg/cm 2 (kilogram per square centimeter)
1N = 0.1019 kg Atm (Metric atmosphere)
1 kg = 9.81 N psi (Pound per square inch)
Conversion:
Power in kW (kilowatt) 1 kg/cm2 = 1 Atm
Other units in use: 1 kg/cm2 = 98.1 kPa
CV (Metric Horsepower) 1 kg/cm2 = 0.981 bar
HP (Horsepower) 1 kg/cm2 = 1 bar *
1 kg/cm2 = 14.22 psi
Conversion: 1 bar = 100 kPa
1 kW = 1.36 CV 1 bar = 1.02 kg/cm2
1 kW = 1.34 HP 1 bar = 14.51 psi
1 CV = 0.736 kW 1 psi = 6.9 kPa
1 CV = 0.986 HP 1 psi = 0.069 bar
1 HP = 0.746 kW 1 psi = 0.0703 kg/cm2
1 HP = 1.014 CV 1 kPa = 0.145 psi
1 kPa = 0.0102 kg/cm2
1 kPa = 0.01 bar
Torque in Nm (Newton meter)
Conversion: Conversion values for British units

1 Nm = 0.1019 kg 1 mm = 0.039 inch
1 kgm = 9.81 Nm 1m = 3.281 ft
1 kgm = 10 Nm * 1 km = 0.621 miles
1 cm3 = 0.061 cu in
1l = 1.759 pts (0.88 Imp. qts)
Specific consumption in g/kWh (grams per 1 bar = 14.5038 psi
kilowatthour) 1g = 0.035 oz. (0.564 dr)
Other unit in use: 1 kg = 2.205 Ibs
g/CVh (grams per Horsehour) 1t = 1.102 short ton (0.9842 long ton)
Conversion: Temperature conversion:

1 g/kWh = 0.736 g/CVh (°F * 32)
°C +
1 g/CVh = 1.36 g/kWh 1.8
°F = (°C x 1.8) + 32
(*) Nm and bar are converted according to the ratios

10:1 and 1:1
Standard tightening torques
Screws and nuts with metric thread
Maximum tightening torque for metric threads in daNm
Diameter SCREW - CLASS SCREW - CLASS SCREW - CLASS

x 8.8 10.9 12.9
Pitch
dxp DAĆ DAĆ DAĆ
PHOSĆ PHOSĆ PHOSĆ
(mm) UNĆ CROMET CADMIUM PHATE UNĆ CROMET CADMIUM PHATE UNĆ CROMET CADMIUM PHATE
COATED GALVAĆ PLATED COATED COATED GALVAĆ PLATED COATED COATED GALVAĆ PLATED COATED
NISED NISED NISED
3 x 0.5 0.12 0.12 0.11 0.09 0.17 0.16 0.15 0.13 0.21 0.19 0.18 0.15
4 x 0.7 0.28 0.26 0.24 0.20 0.39 0.37 0.34 0.29 0.47 0.44 0.41 0.35
5 x 0.8 0.56 0.52 0.48 0.40 0.79 0.74 0.67 0.57 0.94 0.88 0.80 0.68
6x1 1.0 0.9 0.8 0.7 1.3 1.3 1.2 1.0 1.6 1.5 1.4 1.2
8 x 1.25 2.3 2.2 2.0 1.7 3.3 3.1 2.8 2.3 3.9 3.7 3.3 2.8
8x1 2.5 2.4 2.1 1.8 3.5 3.3 3.0 2.5 4.3 4.0 3.6 3.0
10 x 1.5 4.7 4.4 4.0 3.3 6.5 6.1 5.6 4.7 7.9 7.4 6.7 5.6
10 x 1.25 5.0 4.7 4.2 3.5 7.0 6.5 5.9 4.9 8.4 7.9 7.1 5.9
12 x 1.75 8.0 7.5 6.8 5.7 11.3 10.6 9.6 8.0 13.6 12.7 11.5 9.6
12 x 1.25 9.0 8.4 7.5 6.2 12.6 11.8 10.6 8.7 15.1 14.1 12.7 10.4
14 x 2 12.8 12.0 10.9 9.1 18.0 16.9 15.3 12.8 21.6 20.2 18.4 15.3
14 x 1.5 14.1 13.1 11.9 9.7 19.8 18.5 16.7 13.6 23.8 22.2 20.0 16.4
16 x 2 19.8 18.5 16.8 13.9 27.9 26.1 23.6 19.5 33.5 31.3 28.3 23.4
16 x 1.5 21.5 20.0 18.0 14.6 30.2 28.2 25.3 20.6 36.3 33.8 30.4 24.7
18 x 2.5 27.2 25.4 23.1 19.2 38.2 35.8 32.4 27.0 45.8 42.9 38.9 32.4
18 x 1.5 31.4 29.2 26.2 21.1 44.1 41.1 36.8 29.7 53.0 49.3 44.2 35.7
20 x 2.5 38.4 36.1 32.7 27.0 54.3 50.8 46.0 38.0 65.2 61.0 55.2 45.6
20 x 1.5 43.9 40.9 36.5 29.4 61.7 57.5 51.4 41.3 74.1 68.9 61.6 49.5
22 x 2.5 53.9 49.0 44.6 36.2 75.9 68.8 62.8 51.0 91.0 82.6 75.3 61.1
22 x 1.5 59.0 54.8 48.9 39.1 82.9 77.1 68.8 55.0 99.5 92.5 82.6 66.1
24 x 3 66.7 62.4 56.4 46.6 93.8 87.7 79.3 65.5 112.5 105.2 95.2 78.6
24 x 2 74.2 69.1 61.9 50.0 104.4 97.2 87.1 70.3 125.3 116.7 104.5 84.4
27 x 3 98.7 92.2 83.1 68.2 138.8 129.6 116.9 95.9 166.5 155.5 140.2 115.0
27 x 2 108.4 100.8 90.1 72.4 152.4 141.8 126.7 101.8 182.9 170.2 152.1 122.2
30 x 3.5 133.7 124.9 112.7 92.8 188.0 175.6 158.5 130.5 225.6 210.7 190.2 156.5
30 x 2 151.6 141.0 125.8 100.6 213.2 198.2 176.9 141.5 255.9 237.9 212.2 169.8
Maximum tightening torque for metric threads in lb ft
Diameter SCREW - CLASS SCREW - CLASS SCREW - CLASS

x 8.8 10.9 12.9
Pitch
dxp DAĆ DAĆ DAĆ
PHOSĆ PHOSĆ PHOSĆ
(mm) UNĆ CROMET CADMIUM PHATE UNĆ CROMET CADMIUM PHATE UNĆ CROMET CADMIUM PHATE
COATED GALVAĆ PLATED COATED COATED GALVAĆ PLATED COATED COATED GALVAĆ PLATED COATED
NISED NISED NISED
3 x 0.5 0.88 0.88 0.81 0.66 1.25 1.18 1.10 0.96 1.55 1.40 1.33 1.11
4 x 0.7 2.06 1.92 1.77 1.47 2.88 2.73 2.51 2.14 3.47 3.24 3.02 2.58
5 x 0.8 4.13 3.83 3.54 2.95 5.83 5.46 4.94 4.20 6.93 6.49 5.90 5.01
6x1 7.37 6.64 5.90 5.16 9.59 9.59 8.85 7.37 11.80 11.06 10.32 8.85
8 x 1.25 16.96 16.22 14.75 12.54 24.34 22.86 20.65 16.96 28.76 27.29 24.34 20.65
8x1 18.44 17.70 15.49 13.27 25.81 24.34 22.12 18.44 31.71 29.50 26.55 22.12
10 x 1.5 34.66 32.45 29.50 24.34 47.94 44.99 41.30 34.66 58.26 54.57 49.41 41.30
10 x 1.25 36.87 34.66 30.97 25.81 51.62 47.94 43.51 36.14 61.95 58.26 52.36 43.51
12 x 1.75 59.00 55.31 50.15 42.04 83.34 78.17 70.80 59.00 100.30 93.66 84.81 70.80
12 x 1.25 66.37 61.95 55.31 45.72 92.92 87.02 78.17 64.16 111.36 103.99 93.66 76.70
14 x 2 94.4 88.50 80.39 67.11 132.75 124.64 112.84 94.40 159.30 148.97 135.70 112.84
14 x 1.5 103.99 96.61 87.76 71.54 146.02 136.44 123.16 100.30 175.52 163.72 147.50 120.95
16 x 2 146.02 136.44 123.90 102.51 205.76 192.49 174.05 143.81 247.06 230.84 208.71 172.57
16 x 1.5 158.56 147.50 132.75 107.67 222.72 207.97 186.59 151.92 267.71 249.27 224.20 182.16
18 x 2.5 200.60 187.32 170.36 141.60 281.72 264.02 238.95 199.12 337.77 316.39 286.89 238.95
18 x 1.5 231.57 215.35 193.22 155.61 325.24 303.11 271.40 219.03 390.87 363.59 325.97 263.29
20 x 2.5 283.20 266.24 241.16 199.12 400.46 374.65 339.25 280.25 480.85 449.87 407.10 336.30
20 x 1.5 323.76 301.64 269.19 216.82 455.03 424.06 379.07 304.59 546.49 508.14 454.30 365.06
22 x 2.5 397.51 361.37 328.92 266.97 559.76 507.40 463.15 376.12 671.12 609.17 555.34 450.61
22 x 1.5 435.12 404.15 360.64 288.36 611.39 568.61 507.40 405.62 733.81 682.19 609.17 487.48
24 x 3 491.91 460.20 415.95 343.67 691.77 646.79 584.84 483.06 829.69 775.85 702.10 579.67
24 x 2 547.22 509.61 456.51 368.75 769.95 716.85 642.36 518.46 924.09 860.66 770.69 622.45
27 x 3 727.91 679.97 612.86 502.97 1023.65 955.80 862.14 707.26 1227.94 1146.81 1033.97 848.12
27 x 2 799.45 743.40 664.48 533.95 1123.95 1045.77 934.41 750.77 1348.89 1255.22 1121.74 901.22
30 x 3.5 986.04 921.14 831.16 684.40 1386.50 1295.05 1168.94 962.47 1663.80 1553.91 1402.72 1154.18
30 x 2 1118.05 1039.87 927.77 741.92 1572.35 1461.72 1304.64 1043.56 1887.26 1754.51 1564.97 1252.27
SECTION 3
ENGINE
ADT 25 SECTION 3 ENGINEą1
CONTENTS
Page Page
EXTERNAL VIEW OF ENGINE . . . . . . . . . . . . . . . . . 3 ENGINE - ADJUSTMENTS AND CHECKS . . . . . 32
ENGINE AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . 5 Preliminary operations . . . . . . . . . . . . . . . . . . . . . . . . 32

Valves clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
ENGINE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . 6
Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
ENGINE FUEL SUPPLY SYSTEM . . . . . . . . . . . . . . . 7
Climate control compressor drive belt . . . . . . . . . . . 36
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . 8
Intake manifold pressure check . . . . . . . . . . . . . . . . 37
Thermostat operation and system layouts . . . . . . . . 8
Intake manifold temperature check . . . . . . . . . . . . . 37
COOLANT CIRCULATION INSIDE THE
ENGINE - PARTIAL REMOVAL-REFIT . . . . . . . 38
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Preliminary operations . . . . . . . . . . . . . . . . . . . . . . . . 38
SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . 10
Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . 20 Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Coolant thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
ENGINE REMOVAL-REFIT . . . . . . . . . . . . . . . . . . . 21 Tightener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Fuel feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Checks and inspections . . . . . . . . . . . . . . . . . . . . . . 25 Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
RADIATOR REMOVAL-REFIT . . . . . . . . . . . . . . . . 26 Intake manifold cover and gasket . . . . . . . . . . . . . . 46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Aftercooler and gasket . . . . . . . . . . . . . . . . . . . . . . . . 46
Refit and circuit refill . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Anti-freeze percentage check . . . . . . . . . . . . . . . . . 28 Exhaust manifold and gaskets . . . . . . . . . . . . . . . . . 48

Lubrication oil pressure regulator, valve and
WATER-LUBRICANT EXCHANGER
spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
REMOVAL-REFIT ON AUTOMATIC
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Lubrication oil thermostat . . . . . . . . . . . . . . . . . . . . . 49
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Lubrication oil heat exchanger element and
gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
ENGINE - PERIODICAL REPLACEMENT . . . . . . 30
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Engine oil replacement . . . . . . . . . . . . . . . . . . . . . . . 30
Engine oil filter replacement . . . . . . . . . . . . . . . . . . . 31
2ąENGINE SECTION 3 ADT 25
EXTERNAL VIEW OF ENGINE
Figure 1
1730301C
Left-hand side (intake side)

1. Fan
2. Injection pump
3. Brake solenoid valve
4. Engine oil filler cap
5. Spare
6. Fuel feed system air bleeder screw
7. Fuel separator filter
8. Engine oil pressure sensor
9. Engine oil drainage cap
10. Fuel supply pump
11. Engine oil pressure warning light
12. Braking system delivery pump
13. Braking system intake pump
Figure 2
1730302B
Right-hand side (exhaust side)

1. Engine coolant temperature sensor
2. Air inlet from filter (engine intake)
3. Turbo assembly
4. Exhaust gas outlet toward silencer (engine exhaust)
5. Coolant filter
6. Coolant inlet from tank
7. Coolant outlet toward radiator (thermostat outlet)
8. Alternator
9. Coolant inlet for heater
10. Coolant outlet from tank
11. Coolant inlet from radiator (pump intake)
12. Engine oil filter
13. Engine oil dip stick
14. Coolant outlet for heater
15. Starter motor
ENGINE AIR INTAKE SYSTEM
Figure 3
17303160
1. Air intake
2. Air cleaner
3. Sleeve between cleaner and fuel tank
4. Piping inside fuel tank
5. Sleeve between fuel tank and turbo charger
6. Intake manifold
7. Turbo charger to exhaust gas
8. Intake valve
ENGINE EXHAUST SYSTEM
Figure 4
17303161
1. Exhaust valve
2. Exhaust manifold
3. Turbo charger to exhaust gas
4. Piping between turbo charger and muffler
5. Muffler
6. Piping between muffler and exhaust pipe
7. Exhaust pipe
ENGINE FUEL SUPPLY SYSTEM
Figure 5
17303162
1. Fuel arrival from tank

2. Fuel return to tank
3. Fuel supply pump
4. Fuel filters
5. Delivery pipes to pump (low pressure)
6. Delivery pipes to injectors (high pressure)
7. Return pipe from injectors
8. Injector
9. Distributing pump
ENGINE COOLING SYSTEM
Thermostat operation and system layouts
Figure 6
17303163
1. Engine
2. Thermostat
3. Pump
4. Radiator
5. Operator compartment heater
6. Gearbox oil exchanger
7. Expansion tank
A: thermostat closed: the cold coolant is completely returned into the engine without passing through the radiator.
B: thermostat in intermediate position: part of the coolant is sent to the radiator and the other part is taken in by
the pump and then sent into the engine.
C: thermostat open: the hot coolant is sent to the radiator, the cold coolant is taken in by the pump and sent into
the engine.
COOLANT CIRCULATION INSIDE THE ENGINE
Figure 7
17303164
1. Coolant arrival from radiator (pump inlet)

2. Water pump
3. Coolant delivery to engine oil exchanger
4. Coolant outlet from engine oil exchanger to upper manifold
5. Coolant delivery in upper manifold
6. Coolant delivery to cylinder head
7. Engine coolant return from cylinder head
8. Coolant circulation in cylinder head
9. Engine oil exchanger
10. Coolant delivery to radiator (thermostat outlet)
11. Coolant inlet from upper manifold to thermostat
SPECIFICATIONS AND DATA

Engine type Cummins 6CTA 8.3-C260
Cycle Diesel 4 stroke direct injection
Number of cylinders 6 in line
Bore 114 mm 4.49 in
Stroke 1135 mm 5.32 in
Total displacement 8270 cm3 504.5 in3
Piston type Articuled
Injection order 1-5-3-6-2-4
Compression ratio 16,5 : 1
Max Power 194 kW 260 HP
Engine speed at rated power 230 rad/sec 2200 rpm
Max engine speed-unloaded 257.5 rad/sec 2460 rpm
Minimum speed 52.3 rad/sec 500 rpm
Peak Torque 1123 Nm 828.3 lb ft
Engine speed at peak torque 136 rad/sec 1400 rpm
Emission according to Tier 1 EPA-CARB.
Engine Weight (With standard accessories)
637 kg 1404 lb
(Dry Weight)
Engine Min. cranking speed 15.7 rad/sec 150 rpm
Timing check
Intake valve lash 0.30 mm 0.012 in
at cold engine
Exhaust valve lash 0.61 mm 0.024 in
Fuel system PUMP in line
Fuel injection Direct
Turbocharging
Turbocharger type Fix geometry
Intercooled/aftercooled Aftercooled
Lubrication
at 1200 rpm or peak Torque 2.07 bar 30 psi
Low idle (min. allowable) 0.69 bar 10 psi
Cooling system
Capacity engine only 10.9 liters 2.4 Imp gal
Opening start 81 °C 178 °F
Max. opening 95 °C 203 °F
DIAGNOSTIC
1. The engine does not start
2. The engine either does not crank or cranks slowly
3. The engine starts and then stops
4. The engine either stops suddenly or when decelerating
5. The engine does not reach nominal ratio
6. The engine does not stop
7. Excessive engine vibrations
8. Excessive engine noise
9. Excessive engine noise - Knock
10. Poor engine power
11. Irregular engine operation when idling and misfiring
12. The alternator either does not charge or charges insufficiently
13. Coolant leakage - External
14. Excessive coolant temperature - Gradual overheating
15. Excessive coolant temperature - Sudden overheating
16. Coolant temperature too cold
17. Excessive gas in crankcase (blow-by)
18. Poor acceleration or slow engine response
19. The engine decelerates slowly
20. Excessive fuel consumption
21. Fuel in coolant
22. Fuel in lubricant oil
23. Excessive air temperature in intake manifold
24. Pressure in intake manifold (turbo) too low
25. Excessive lubricant oil consumption
26. Contaminated lubricant oil
27. Excessive lubricant oil pressure
28. Low lubricant oil pressure
29. Too much sludge in lubricant oil in crankcase
30. Excessive lubricant oil temperature
31. Lubricant oil in coolant
32. Excessive black smoke in exhaust
33. Excessive white smoke in exhaust
Trouble Cause Corrective action
The engine does not start Battery connections deteriorated Clean, check and fasten terminal
and/or disconnected nuts and/or replace them, if they are
damaged
Flat battery Recharge the battery and replace it,

if required
The starter motor turns but the enĆ Check integrity of electrical system
gine does not start (according to wiring diagram)
Thermal starter faulty (where fitted) Restore
Injection pump not timed Check timing
Injectors dirty and/or obstructed Check operation, clean and reĆ

place, if required
Water in the fuel feed circuit Check and bleed water in the sysĆ
tem
Air in the fuel feed circuit Check and bleed air in the system
Compression ratio non correct Either overhaul engine or work on

concerned parts only (valves, gas
rings, etc.)
Fuel filters obstructed Replace the filters
Stop device ineffective Check and replace damaged parts
The engine either does not crank Battery wires and/or connections Check efficiency of battery wires
or cranks slowly loose, broken or corroded and connections
(excessive resistance)
Lubricant oil temperature too low Fit an oil sump heater and fill the sysĆ
tem with hot oil
Lubricant characteristics are not Change oil and filters

suitable for conditions of operation
of the engine
The engine starts and then stops Low fuel level in tank Fill the fuel tank. See the service
manual
Air in fuel feed circuit Check for air in the feeding circuit.
Fasten or replace connections,
pipes, primer pipe and fuel filters, as
required
Fuel filter or fuel intake manifold obĆ Replace the fuel filter. Check fuel inĆ
structed take manifold for obstructions
Fuel starts congealing due to the Check the fuel heater, where fitted.
cold temperature A fuel heater may be required in
certain climates
Fuel intake obstructed Eliminate obstructions from fuel inĆ

take manifold
Fuel switch off valve closed Check for disconnected wires

Check whether fuel switch off valve
solenoid is powered
Exhaust system obstructed Eliminate obstructions from exhaust

system
The engine starts and then stops Poor quality fuel or fuel unsuitable Feed engine from a high quality fuel
(Cont.d) for the application tank
The air intake system is excessively Clean or replace air cleaner and inĆ
restricted take pipe, as required
Engine brake incorrectly adjusted Adjust engine brake
The engine either stops suddenly Fuel intake obstructed Eliminate obstructions from fuel inĆ
or when decelerating take manifold
required
Battery voltage low Check batteries and battery power

circuit (not switched)
Fuel switch off valve (FSOV) closed Check for disconnected wires.
Check whether fuel switch off valve
solenoid is powered
Poor quality fuel or fuel unsuitable Feed engine from a high quality fuel
for the application tank
The engine does not reach Excessive load with reference to Reduce vehicle load or shift to a
nominal ratio nominal engine power lower gear
Rpm counter incorrectly calibrated Compare rpm counter reading with

or faulty a portable rpm counter or electronic
analyser. Calibrate or replace rpm
counter, as required

take manifold
Incorrect head unit adjustment Gauge and adjust valves and injecĆ
tors
The engine does not stop Ignition key circuit failure Check ignition key circuit
Fumes are taken into the engine Check air intake manifolds. Locate
through the air vents and isolate source of fumes. Repair,
as required
Excessive engine vibrations Low fuel level in tank Fill the fuel tank
required
Fuel starts congealing due to the Check the fuel heater, where fitted.
cold temperature A fuel heater may be required in
certain climates
Fuel intake obstructed Check fuel intake manifold for obĆ

structions
Excessive engine vibrations Fuel switch off valve closed Check for disconnected wires.
(Cont.d) Check whether fuel switch off valve
solenoid is powered
Excessive engine noise Lubricant oil pressure too low Check oil pressure. If low, see Low
lubricant oil pressure"
Degraded or diluted lubricant oil Check lubricant oil specifications.

See Contaminated lubricant oil"
Excessive coolant temperature See Excessive coolant temperaĆ

ture - Gradual overheating" or ExĆ
cessive coolant temperature -
Sudden overheating"
Accessory belt too taut or offset Check the belt
Damper damaged Inspect the damper
Engine mounts worn, damaged or Check engine mounts. Replace, if

of the incorrect type required
Excessive engine noise - Knock Engine is running in a cold environĆ Check shutter, choke and air vent
ment under the bonnet
Poor engine power The altitude is high Engine power decreases at higher
altitudes
The air intake system is excessively Clean or replace air cleaner and inĆ
restricted take pipe, as required
Intake or exhaust leakage Check for loose or damaged pipes

or missing caps. Check turbo comĆ
pressor and exhaust manifold
fastening
Turbo compressor faulty Replace the turbo compressor, if reĆ

quired
Lubricant oil level over specified Check oil level. Check dipstick caĆ
level libration and sump capacity. Fill
system to the specified level
required
Fuel exhaust pipe obstructed Clean or replace fuel pipes, check

valves and tank breathers, as reĆ
quired
Excessive air temperature in intake See Excessive air temperature in

manifold intake manifold"
Poor engine power (Cont.d) Excessive fuel temperature at pump Fill fuel tank, either switch or cut off
intake fuel heaters and check fuel cooling
device
Irregular engine operation when Engine mounts worn, damaged or Check engine mounts
idling and misfiring of the incorrect type
Fuel leakage Check fuel pipes, connections and

filters for leakage. Check delivery
pipes to fuel feed tanks
pipes, primer pipe and filters
for the application tank. Use fuel, as required
tors

take manifold
The alternator either does not Alternator belt loose Check alternator belt tension
charge or charges insufficiently
ins fficiently
Battery wires or connections loose, Check battery wires and connecĆ
broken or corroded (excessive reĆ tions
sistance)
Batteries flat Check batteries. Replace, if reĆ

quired
Open" electrical circuit (blown Check fuses, wires and connections

fuses, broken wires or loose conĆ
nections)
Alternator pulley on shaft loose Fasten the pulley
Coolant leakage - External Coolant level exceeding specificaĆ Check coolant level
tions
External coolant leakage Check for engine leakage from

hoses, drain taps, coolant manifold,
union pipes, expansion caps, pipes,
fittings, radiator head, compressor
seals, head, oil heat exchanger,
coolant pump seal and components
fitted by the manufacturing containĆ
ing coolant
Radiator cap of the incorrect type, Check radiator pressure cap

faulty or providing low pressure
index
Filling pipe or breather pipe either Check breather pipe and filling pipe
partially or completely obstructed, for correct arrangement and obĆ
or arranged incorrectly structions
Coolant filling pipe either partially or Check whether the coolant filling
completely obstructed pipe is either partially or completely
obstructed
Engine overheating See Excessive coolant temperaĆ

ture"
Excessive coolant temperature - Coolant level lower than specified Check engine and cooling system
Gradual overheating for external leakage of coolant. ReĆ
pair, if required. Top up coolant
Intercooler air cooling radiator fins, Check intercooler, air conditioner

radiator fins or air conditioner conĆ condenser and radiator fins.
denser fins damaged or obstructed. Clean, if required
Coolant system hose either broken, Inspect radiator hoses

obstructed or leaking
Accessory belt loose Check belt tension and adjust, if reĆ

quired
Lubricant oil level over or under Check oil level. Remove or add oil,
specified level. if required

index
Coolant level over than specified or Check level. Check antifreeze conĆ
excessive antifreeze concentration centration
Excessive coolant temperature - Coolant level lower than specified Check engine and cooling system
Sudden overheating for external leakage of coolant. ReĆ
pair, if required. Top up coolant
Intercooler air cooling radiator fins, Check intercooler, air conditioner

radiator fins or air conditioner conĆ condenser and radiator fins.
Coolant system hose either broken, Inspect radiator hoses

obstructed or leaking
Accessory belt broken Replace the belt

index
Filling pipe or breather pipe either Check breather pipe and filling pipe
partially or completely obstructed, for correct arrangement and obĆ
or arranged incorrectly structions
Coolant temperature too cold Coolant temperature gauge or senĆ Check operation of gauge and senĆ
sor faulty sor. Repair or replace, if required
Excessive gas in crankcase Crankcase ventilation system obĆ Check and clean breather and
(blow-by) structed crankcase ventilation tube
Poor acceleration or slow engine Engine is running in a cold environĆ Warm the engine up before deĆ
response ment manding power

fastening
Excessive fuel temperature Fill the fuel tank. Either switch or cut
off the fuel heater, where fitted
Poor acceleration or slow engine Poor quality fuel or fuel unsuitable Feed engine from a high quality fuel
response (Cont.d) for the application tank
Engine is running in a warm environĆ Feed external air to the turbo comĆ
ment pressor at high temperatures
The engine decelerates slowly Accelerator pedal jammed Release the accelerator pedal
Excessive fuel consumption Mechanical and environmental Consider environmental temperaĆ

conditions effect fuel consumption ture, wind, tyre size, axle alignment,
type of terrain and spoilers when
evaluating fuel consumption
Lubricant oil level over specified Check oil level. Check dipstick caĆ
level libration and sump capacity. Fill sysĆ
tem to the specified level
The air intake system is excessively Check air intake manifold for obĆ
restricted. structions. Clean or replace air
cleaner and intake pipe, as reĆ
quired.
Fuel leakage Check fuel pipes, connections and

filters for leakage. Check delivery
pipes to fuel feed tanks
Incorrect use See instructions
Wheel rpm counter or kilometre Check wheel rpm and kilometre

counter incorrectly calibrated counter calibration. Calibrate or reĆ
place wheel rpm counter or kiloĆ
metre counter, if required. Check
fuel consumption with new odoĆ
meter readings
Fuel in coolant Coolant feed contaminated Check coolant feed. Drain coolant
and change it using non contamiĆ
nated fluid. Replace the coolant
filters
Fuel heater faulty (where fitted) Check fuel heater and replace it, if
required
Fuel in lubricant oil Oil feed contaminated Check oil feed. Drain oil and change
it using non contaminated oil. ReĆ
place the oil filters
Excessive engine idling time Excessively long idling time (over 10

minutes) may be caused by excessĆ
ively cold oil and coolant temperaĆ
ture. Stop the engine instead of idĆ
ling it for a long time. Increase idling
speed, if the engine must stay on
Excessive air temperature in inĆ The vehicle speed is too low to allow Reduce engine load. Increase enĆ
take manifold adequate cooling with respect to the gine ratio (fan) by shifting down
engine load
Either fan box damaged or missing Inspect box and recirculation flaps.
or air recirculation flaps damaged or Repair, replace or install, if required
missing
Accessory belt broken or loose Check the belt. Replace the belt, if
required
Excessive air temperature in Intercooler air cooling radiator fins, Check intercooler, air conditioner
intake manifold (Cont.d) radiator fins or air conditioner conĆ condenser and radiator fins.
Pressure in intake manifold Turbo compressor faulty Replace the turbo compressor
(turbo) too low
fastening
Air compressor connection loose or Check connection between maniĆ

damaged fold and compressor. Repair or adĆ
just, as required
Excessive lubricant oil consump- Check actual oil consumption Check amount of oil added with reĆ
tion spect to distance driven
Lubricant oil leakage (external) Check for leakage of oil from the enĆ
gine. Fasten the bolts, pipe caps
and fittings. Replace the seals, if reĆ
quired
Oil change frequency inadequate Check correct oil change frequency
Lubricant characteristics are not Change oil and filters. Use oil of the
suitable for conditions of operation specified type
of the engine
Crankcase ventilation system obĆ Check and clean breather and

structed crankcase ventilation tube
Contaminated lubricant oil Identify source of oil contamination Analyse the oil to determine the conĆ
taminating substances
Oil feed contaminated Check oil feed. Drain oil and change
it using non contaminated oil. ReĆ
Too much sludge in lubricant oil See Too much sludge in lubricant
oil in crankcase"
Fuel in lubricant oil See Fuel in lubricant oil"
Excessive lubricant oil pressure Pressure switch, lubricating oil Check operation and position of
gauge or sensor failure or incorrectĆ pressure switch, gauge and sensor
ly positioned
Coolant temperature too cold See Coolant temperature too cold"
of the engine
Low lubricant oil pressure Lubricant oil level over or under Check oil level. Remove or add oil,
specified level. if required
Lubricant oil leakage (external) Check for leakage of oil from the enĆ
gine. Fasten the bolts, pipe caps
and fittings. Replace the seals, if reĆ
quired
Pressure switch, lubricating oil Check operation and position of

gauge or sensor failure or incorrectĆ pressure switch, gauge and sensor
ly positioned
Low lubricant oil pressure Lubricant characteristics are not Change oil and filters. Use oil of the
(Cont.d) suitable for conditions of operation specified type
of the engine
Lubricant oil contaminated by Contact the dealer

coolant or fuel
Oil filter obstructed Change oil and filters. Change oil

more frequently
Engine worn Overhaul the engine
Too much sludge in lubricant oil in Oil feed contaminated Check oil feed. Drain oil and change
crankcase it using non contaminated oil. ReĆ
of the engine
Oil change frequency inadequate Check correct oil change frequency.
Lubricant oil contaminated by See Coolant leakage - Internal"

coolant
Crankcase ventilation system obĆ Check and clean breather and

structed crankcase ventilation tube
Excessive lubricant oil temperaĆ Lubricant oil level over or under Check oil level. Remove or add oil,
ture specified level if required
Excessive coolant temperature See Excessive coolant temperaĆ

ture - Gradual overheating" or ExĆ
cessive coolant temperature -
Sudden overheating"
Lubricant oil temperature switch, Check operation and position of oil

gauge or sensor faulty or incorrectly temperature switch, gauge and senĆ
positioned sor
Lubricant oil in coolant Coolant contaminated Drain coolant and change it using
non contaminated fluid. Replace the
coolant filters
Excessive black smoke in Turbo compressor impeller out of Check bearing radial play and end
exhaust specifications play. Inspect the turbo compressor.
Replace the turbo compressor, if reĆ
quired

fastening
Fuel exhaust pipe obstructed Check turbo compressor and exĆ

haust manifold fastening
Excessive white smoke in Cold engine Warm the engine up to normal

exhaust working temperature
Coolant temperature too cold See Coolant temperature too cold"
tors
TIGHTENING TORQUE
Fastening screws front engine supports Ą65 Nm (48 lb ft)
Fastening screws rear engine supports Ą80 Nm (60 lb ft)
Rocker arm adjustment valves lock nut Ą24 Nm (18 lb ft)
Engine idle adjustment screw lock nut ĄĄ8 Nm ( 5.9 lb ft)
Turbocharger mounting nut Ą45 Nm (33 lb ft)
Injection pump control gear mounting nut 105 Nm (77 lb ft)
Fuel high pressure line unions Ą24 Nm (18 lb ft)
Fuel exhaust manifold on injectors union ĄĄ9 Nm ( 6.6 lb ft)
Turbo charger oil delivery union on exchanger Ą15 Nm (11 lb ft)
Turbocharger oil delivery union on turbine Ą35 Nm (26 lb ft)
Injection pump timing pin cap Ą15 Nm (11 lb ft)
Engine oil pressure regulator cap Ą80 Nm (60 lb ft)
Engine oil thermostat Ą50 Nm (37 lb ft)
Tappets cover screw Ą24 Nm (18 lb ft)
Aftercooler mounting screw Ą24 Nm (18 lb ft
Intake manifold cover mounting screw Ą24 Nm (18 lb ft)
Injector brackets mounting screw Ą24 Nm (18 lb ft)
Belt tightener mounting screw Ą43 Nm (32 lb ft)
Alternator lower mounting screw Ą43 Nm (32 lb ft)
Injection pump front mounting screws Ą43 Nm (32 lb ft)
Exhaust manifold mounting screws Ą43 Nm (32 lb ft)
Oil-water exchanger cover mounting screws Ą24 Nm (18 lb ft)
Turbocharger to turbine body mounting screws Ą11 Nm ( 8 lb ft)
Starter motor mounting screws Ą43 Nm (32 lb ft)
Water pump mounting screws Ą24 Nm (18 lb ft)
Thermostat mounting screws Ą24 Nm (18 lb ft)
Turbocharger oil discharge line mounting screws Ą24 Nm (18 lb ft)
Alternator lower mounting screws Ą24 Nm (18 lb ft)
Injection pump rear mounting screws Ą24 Nm (18 lb ft)
Alternator upper mounting screws Ą43 Nm (32 lb ft)
Fuel supply pump unions mounting screws/nuts Ą24 Nm (18 lb ft)
SPECIAL TOOLS
Gear for manual engine rotation 3824591
ENGINE REMOVAL-REFIT
. Before starting any type of operation make Figure 9
sure all the necessary safety precautions
have been taken and fully explained to those
involved in the operations.
Read the relevant instructions in SECTION
1.2 of this manual.
If in doubt, contact someone with more exĆ
perience.
Always observe all the general recommenĆ
dations to carry out maintenance jobs corĆ
rectly.
Removal
To remove proceed as follows: 1730304
D bring the vehicle onto a suitable flat, solid surface,
D disconnect the propeller shaft as described in SECĆ
switch off the engine, remove the ignition key, enĆ
TION 10;
gage the parking brake and apply the warning signĆ
D bring the heater tap to maximum, then open the filler
boards.
cap on the reservoir;
D cut off the battery isolator switch or disconnect the
D prepare a suitable container, then remove the
terminals from the battery to avoid the risk of short
sleeve from the exchanger to the intake pump and
circuits;
drain off the coolant;
D lock knuckle with the steering lock bar following the
instructions in SECTION 1.2; Never dispose of residual coolant in unauĆ
thorised dumps or by pouring it into the
Figure 8 sewers.
Figure 10
174CU01
D remove the engine cowl and the cab as described

in SECTION 18; 1730305
D remove the radiator coolant as indicated in the
The cab is to be removed by experts proĆ
Chapter RADIATOR REMOVAL-REFIT;
vided with the necessary equipment.
D prepare a suitable container, then drain off the hyĆ D appropriately shape and prepare a rear hooking
draulic fluid as described in SECTION 16; bracket (7) and mount it in the holes provided;
D using suitable lifting equipment apply the chains to
Never dispose of residual fluid in unauthoĆ
the assembly brackets (7) and (8) and take up the
rised dumps or by pouring it into the sewers.
slack, checking that the load is evenly balanced;
D remove the bolts that secure the front (5) and rear
Figure 11 (6) engine mountings from both sides;
D check very carefully:
- that all electrical connections have been disconĆ
nected;
- all the piping has been disconnected;
- all the securing straps have been released;
D lift the assembly with care, taking it out from above.
1730306
D Disconnect the hydraulic system return pipes and

remove the flanged coupling from the hydraulic sysĆ
tem tank;
. The subsequent operations relate to the folĆ

lowing figures
D disconnect and plug the fuel delivery (11) and return
(12) pipes;
D disconnect the accelerator control cable (9);
D disconnect the hydraulic fluid delivery (13) and reĆ
turn (14) pipes from the brake master cylinder;
D remove the air line (15) from the air cleaner to turbo
assembly;
D remove the exhaust piping (16) from turbo assemĆ
bly to exhaust pipe;
D disconnect these electric connections:
- from the starter motor (20);
- from the alternator (22);
- from the coolant temperature gauge (23);
- from the engine oil temperature gauge (24);
- from the engine oil pressure indicator (25);
- from the climate control compressor (26);
- from the diesel pump delivery shut off solenoid
valve (27);
- from the chassis earth point (28);
Figure 12
1730307C
Figure 13
1730308B
Refit Checks and inspections

To refit carry out the same operations in reverse order, Start the engine and when at steady state check:
paying particular attention to: D there is no coolant loss from the engine cooling or
D check the engine flexible mountings: if they are in cab heating system sleeves: if leaks are found,
bad condition replace them; tighten the connections or replace the faulty parts;
D check that the exhaust and intake pipes with their D there is no hydraulic fluid loss from pipes that were
connections are perfectly intact; previously disconnected: if leaks are found, tighten
D check that the fuel intake and return pipes with the the connections or replace the faulty parts;
associated unions are perfectly intact; D there is no lubricant leakage between cover and cylĆ
D check that the engine cooling and cab heating sysĆ inder head, sump and crankcase, the filter and its
tems with the associated connections are perfectly seat or from any of the system pipes: if leaks are
intact; found tighten the connections or replace the faulty
D check the engine oil level and if necessary top up or parts;
fill (see USE AND MAINTENANCE MANUAL); D there is no fuel loss from the feed system pipes or
D bleed the fuel supply circuit (see USE AND MAINĆ unions: if leaks are found tighten the connections or
TENANCE MANUAL); replace the faulty parts;
D fill the engine coolant circuit following the instrucĆ D there are no air leaks from intake pipes or gas leaks
tions in the Chapter RADIATOR REMOVAL-REFIT; from exhaust pipes: if leaks are found tighten the
D fill the hydraulic circuit following the instructions in connections or replace the faulty parts;
SECTION 16. D the accelerator control makes the complete stroke
in both directions of the flow adjustment rod;
D the engine braking device is operating correctly;
D the warning lights and temperature and pressure
gauges that were disconnected are operating corĆ
rectly.
RADIATOR REMOVAL-REFIT
. Before starting any type of operation make D remove the engine cowl as described in SECTION
18;
D bring the heater tap to maximum, then open the filler
cap on the reservoir;
D prepare a suitable container, then remove the
sleeve connecting the exchanger to the pump inĆ
1.2 of this manual.
take (4) and drain off the coolant;
perience. Never dispose of residual coolant in unauĆ
Always observe all the general recommenĆ thorised dumps or by pouring it into the
dations to carry out maintenance jobs corĆ sewers.
rectly.
D disconnect /remove the following engine coolant piĆ
pes:
Removal - from engine to radiator (2);
- from radiator to exchanger (5);
Wait until the engine temperature drops - bleeder from radiator to reservoir (7);
below 50 °C (122 °F) before starting this
operation. During these operations some coolant may
spill out.
To remove proceed as follows:
boards.
circuits;
instructions in SECTION 1.2;
Figure 14
7 2
4 5 4
1730309
Figure 15 Figure 17
1730312
1730310
D unlock the mounting screws and move aside the D unlock the mounting screws and remove the fan
water-hydraulic fluid exchanger, taking care not to guards;
bend the pipes;
Figure 18
Figure 16
1730313
1730311
D use suitable equipment to support the radiator, unĆ
D unlock the upper mounting screws, turn over the lock the tie-rod and pad mounting screws and reĆ
conditioner radiator, release it from the lower pins move the radiator;
and move it aside taking care not to bend the pipes; D handle the radiator with care, without putting presĆ
sure on the radiator core fins as they could easily beĆ
come damaged.
Refit and circuit refill Anti-freeze percentage check

To refit follow the removal operations in reverse order. To protect the system from corrosion a 50-50 mixture
Fill the circuit as follows: of water and the specific anti-freeze fluid is required.
D under the vehicle front wheels place a layer of resisĆ The minimum percentage of anti-freeze depends on
tant material about 4.5 cm (17.5 in) thick, having a the environment temperature where the vehicle is in
slope of about 10%; use.
Figure 19 Figure 20
156NM61
174NM01B
ÄÄÄ
water
D prepare a mixture with 50% water and 50% of the
anti-freeze
specific anti-freeze fluid then slowly pour the mixĆ
ture through the filler cap. Do not close the cap;
Check the percentage of anti-freeze in the engine
D start the engine and leave it idling, at the same time
coolant using an appropriate refractometer.
pour in the mixture until the circuit is completely de-
aerated, continuing this operation for at least 15
minutes;
. A densimeter should not be used since it is
not sufficiently accurate.
D close the filler cap.
If special additives are used, always comply
Check that the pressure control valve in the to the mixing instructions of the Supplier.
cooling system incorporated in the cap is
working. If it is not, replace the cap.
WATER-LUBRICANT EXCHANGER REĆ Figure 21

MOVAL-REFIT ON AUTOMATIC TRANSĆ
MISSION
. Before starting any type of operation make
1.2 of this manual.
perience.
rectly.
Removal
Wait until the engine temperature drops

below 50 °C before starting this operation.
boards.
terminals from the battery to avoid the risk of short 1730314
circuits;
D lock knuckle with the steering lock bar following the D disconnect the coolant outlet hose (4);
D prepare a suitable container, then empty the engine During these operations some coolant may
cooling circuit as described in the Chapter spill out.
RADIATOR REMOVAL-REFIT; D disconnect the automatic transmission inlet (2) and
Never dispose of residual coolant in unauĆ outlet (3) hoses;
During these operations some lubricant
sewers.
may spill out.
D prepare a suitable container pour off the automatic
transmission lubricant as described in SECTION 7; D use an appropriate fixture to support the exchanger
(1), unlock the mounting screws and remove it.
Never dispose of residual fluid in unauthoĆ
rised dumps or by pouring it into the sewers. Refit
Refit by reversing the removal sequence.
D Fill the engine cooling circuit as shown in the
RADIATOR REMOVAL-REFIT chapter;
D Fill the automatic transmission lubricating circuit asĆ
shown in SECTION 7 .
ENGINE - PERIODICAL REPLACEMENT Figure 23

1.2 of this manual.
perience.
rectly.
156NM21
Engine oil replacement
D clean the filler cap area, then fill up with the required
Collection and disposal of lubricant oils and quantity of the recommended lubricant through the
waste fluids are to be carried out in comĆ filler cap;
pliance with current legislation in force. D close the filler cap and return the dip stick to its houĆ
Proceed as follows: sing;
D shut off the hot engine and wait until the temperaĆ D start the engine and bring it to running temperature,
ture of the coolant reaches 60 °C (140 °F); then shut off and wait a few minutes;
D open the engine cowl;
D prepare a container with an appropriate capacity, Figure 24
then take out the dip stick;
Figure 22
156NM11
D out the dip stick and check that the level is between
156NM20 the two marks H (maximum) and L (minimum) enĆ
graved on the stick. If necessary top up.
D clean the cap area, unscrew the drainage cap and Do not use the vehicle if the level is not withĆ
drain out all the oil, leaving it sufficient time to empty; in the correct range;
Too much or too little lubricant can damage
Do not unscrew the side cap as this will not
the engine.
allow the sump to empty completely.
D clean the thread, close the discharge cap and
tighten to the specified torque;
Engine oil filter replacement Figure 27
. Collection and disposal of lubricant oils and

waste fluids are to be carried out in comĆ
pliance with current legislation in force.
Do not postpone oil filter replacement over

the indicated time interval. If it becomes
clogged the by-pass valve allows engine
lubrication, but the lubricant circulating is
no longer filtered.
Proceed as follows:
156NM26
D shut off the hot engine and wait until the temperaĆ
ture of the coolant reaches 60 °C (140 °F);
D screw down the cartridge by hand until the gasket
D open the engine cowl;
comes into contact with the support, then tighten
Figure 25 further by 3/4 of a turn;
Do not lock the cartridge too tightly as this

will damage the gasket. Always attain to the
instructions of the Supplier.
D start up the engine for a few minutes and check
there is no lubricant leakage;
D check and if necessary top up the engine oil level.
156NM24
D unscrew the filter cartridge with the appropriate

wrench, then carefully clean the seat on the supĆ
port;
Figure 26
156NM25
D fill the new cartridge with the specified lubricant and

spread some also on the gasket;
ENGINE - ADJUSTMENTS AND CHECKS

. Before starting any type of operation make Proceed as follows:
sure all the necessary safety precautions Figure 29
1.2 of this manual.
perience.
rectly.
Preliminary operations
switch off the engine, remove the ignition key, enĆ 1730316
boards; D Remove the air intake sleeve.
terminals from the battery to avoid the risk of short Figure 30
circuits;
D open the engine cowl (see USE AND MAINTENĆ
ANCE MANUAL).
Valves clearance
Valve adjustment is to be carried out with the

engine cold, and the coolant at a stabilised
temperature less than 50 °C (122 °F).
Figure 28
1730317
D Remove the securing straps, remove the wastegate

signal pipe, remove the crankcase breather pipe
and any other components that impede the removal
of the tappets cover.
Figure 31
1730315
Looking at the engine from the timing system side, the

crankshaft rotates clockwise.
The cylinders are numbered starting from the timing
gearbox cover.
Order of injection: 1-5-3-6-2-4.
1730318
D Unlock the mounting screws and remove the

tappets cover and gasket.
Figure 32 Figure 34
1730319 1730321
D Check/adjust the valves shown in the figure followĆ

D Insert tool 3824591 (gear for manual rotation) into ing the indications below (step A, I = intake; E =
the flywheel box and engage the flywheel crown exhaust).
gear.
D Using tool 3824591 find the top dead centre (TDC) Make sure that the engine timing pin is disĆ
of cylinder no. 1 slowly turning the crankshaft clockĆ engaged to avoid damaging it.
wise and at the same time pressing the engine timĆ
ing pin.
Figure 35
Figure 33
1730322
D Make a reference mark on the damper and turn the

crankshaft 360 degrees (one full turn).
Figure 36
1730320
D When the engine timing pin (a) engages in the timĆ

ing shaft gear cavity, (b) cylinder no. 1 is at TDC of
the compression stroke.
After finding the TDC, disengage the timing
pin to avoid damaging it.
1730323
D Check/adjust the valves shown in the figure followĆ

ing the indications below (step B, I = intake; E = exĆ
haust).
Figure 37 . If the timing system cover gasket is still in

good condition it can be re-used.
. Do not stretch the rubber gasket.

If the gasket overlay zone is longer than that
shown in the figure, shorten it to have the
correct overlay.
Figure 39
1730324
D Insert the prescribed thickness gauge between the

valve and the rocker pad.
D Tighten the adjusting screw until slight resistance is
felt on the thickness gauge.
D Tighten the lock nut to the specified torque, keeping
the adjustment screw in the position obtained.
D After tightening the lock nut to the specified torque,
check that it is possible to slide the thickness gauge
backwards and forwards between the valve and the
rocker with only a slight resistance. 1730326
Try inserting a thickness gauge that is 0.03 D Install the new O-rings on the bolts.
mm (0.001 in) thicker between the valve and D Refit the disassembled components working in reĆ
the rocker pad. If this is possible there is too verse order.
much valve clearance. D Tighten the cover mounting screws to the tightening
torque.
D After all the operations are finished, restore the veĆ
Figure 38
hicle to operating condition.
1730325
D Install the rubber gasket in the groove of the tappets

cover, starting from the overlay zone shown in the
figure.
Belts Belt replacement

Proceed as follows:
D remove the belt protection grid; Figure 42
Tension check
Figure 40
174NM08
D using a square wrench turn the tightener clockwise

to loosen the belt tension;
174NM06
Do not turn the tightener anti-clockwise as
D pressing with the hand on the longer branch (arrow) this could damage the internal loading
check that the belt sag is within the prescribed vaĆ spring.
lues;
Figure 43
Figure 41
174NM09
174NM07
D remove the belt;
D If in doubt as to the actual belt tension, use the D fit the new belt, then release the tightener;
special measuring equipment and the relevant tenĆ
sioning table. Never turn a belt on the pulley to fit it into the
groove, nor prise it with a tool (such as a
screwdriver). This could cause damage and
premature breakage;
The belts have not to touch the bottom of the
grooves or rub against adjacent parts.
D start the engine running for ten minutes, shut off,
wait for it to cool down, then check the belt tension.
New belts always lengthen after the first

working period, therefore the tension must
be checked again.
Climate control compressor drive belt Replacement

Proceed as follows:
Check D open the engine lid;
Proceed as follows: D with the engine off and cold, release the pin nut and
D open the engine lid; the securing nut, then remove the belt;
D with the engine off and cold, check that the belt is D fit the new belt and adjust the tension.
not frayed or cracked (small crosswise cracks are
allowed);
. Take the same precautions specified for the
accessories drive belts.
Figure 44 D run the engine for ten minutes, switch it off and wait
for it to cool down, then check the belt tension.
174NM72
D manually press the longer stretch (1) and check that
the yield is within the specified range.
yield: 9.5P12.5 mm (0.37P0.49 in)
Adjusting the tension

Proceed as follows:
D open the engine lid;
Figure 45
174NM73
D with the engine off and cold, release the pin nut and
the securing nut, then adjust the compressor (2) to
regulate the tension;
D tighten both the nuts to the specified tightening torĆ
que.
Intake manifold pressure check Intake manifold temperature check
These checking operations require the use These checking operations require the use
of the vehicle: be very cautious and observe of the vehicle: be very cautious and observe
general safety conditions. general safety conditions.
Proceed as follows: Proceed as follows:
Figure 46 Figure 47
B
1730328
D Install a temperature gauge in the intake manifold.

D Ensure that the fan is always working.
D Measure the environment temperature and make a
note of it.
1730327 D Start up the vehicle and bring the engine to nominal
rpm and load, making a note of the readings on the
D connect a gauge on the union (A) at the turboĆ temperature gauge.
charger outlet; D Check that the thermal differential is within the preĆ
D connect another gauge in the intake manifold (B); scribed values:
set the gauges so that they can be read from the Maximum thermal differential 7 °C (45 °F)
driver's cab; D If the value is not correct, check the air heat exĆ
D start up the vehicle and bring the engine to nominal changer and act accordingly.
rpm and load, making a note of the readings on the
two gauges;
D check that the differential pressure is within the preĆ
scribed values:
Maximum differential pressure 21 kPa (3 psi)
D If the value is not correct, check the air heat exĆ
changer and act accordingly.
ENGINE - PARTIAL REMOVAL-REFIT

Before starting any type of operation make Figure 49
1.2 of this manual.
perience.
rectly.
1730330
switch off the engine, remove the ignition key, enĆ D unlock the mounting screws and remove the pump
gage the parking brake and apply the warning signĆ from the crankcase.
boards.
Refit
terminals from the battery to avoid the risk of short To refit carry out the same operations in reverse order,
circuits; paying particular attention to:
D open the engine cowl (see USE AND MAINTENĆ D clean the sealing surface of the monobloc.
ANCE MANUAL).
Figure 50
Water pump
operation.
Removal
Proceed as follows:
D drain off the engine cooling circuit as described in
the Chapter RADIATOR REMOVAL-REFIT;
Never dispose of residual coolant in unauĆ
sewers. 1730331
D remove the belt as described in the relevant ChapĆ D install a new O-ring in the water pump groove.
ter;
Figure 51
Figure 48
1730332
1730329 D install the water pump and alternator support and
D unlock the mounting screw and move aside the alĆ tighten the mounting screws to the specified torque.
ternator supporting bracket; D assemble the belt as described in the relevant
Chapter.
Coolant thermostat
Figure 54
operation.
Removal
Proceed as follows:
D remove the belt as described in the relevant paraĆ
graph;
D drain off about 2 litres of engine coolant following
the instructions in the Chapter RADIATOR REĆ
MOVAL-REFIT;
thorised dumps or by pouring it into the 1730335
sewers.
D Remove the thermostat body / tightener assembly.
Figure 52 Figure 55
1730333
1730336
D Unlock the alternator upper and lower mounting D Remove the thermostats and clean the gasket surĆ
screws and lower it. faces.
D Remove the flexible sleeve from the radiator output
union. When cleaning the gasket surfaces, take
care that dirt does not fall into the thermostat
Figure 53 cavity.
1730334
D Unlock the mounting screws from the thermostat

body and the water outlet union and remove the
water outlet union.
Refit D Install the flexible sleeve.

To refit carry out the same operations in reverse order, D Assemble the alternator and then the belt.
paying particular attention to: D Fill the engine cooling circuit as described in the
Chapter RADIATOR REMOVAL-REFIT;
Figure 56 D After all the operations are finished, restore the veĆ
Tightener
Proceed as follows:
D open the engine cowl (see USE AND MAINTENĆ
ANCE MANUAL);
D remove the belt as described in the relevant ChapĆ
ter;
Figure 59
1730337
D Install new thermostats in the thermostat body.
D Fit a new gasket on the thermostats.
Figure 57
1730340
D unlock the mounting screw and remove the tighĆ

tener from the bracket.
To refit carry out the same operations in reverse order,
paying particular attention to tighten the mounting
screws to the specified torque.
1730338
D Position the thermostat body / tightener on the therĆ
mostats and on the gasket, insert the mounting
screws and tighten them by hand.
Figure 58
1730339
D Assemble the water outlet union.

D Insert the mounting screws and tighten all the
screws to the specified torque.
Fuel feed pump Injectors

Proceed as follows:
Removal
Figure 60 Proceed as follows:
D Thoroughly clean the area around the injectors.
Figure 62
1730341
D Disconnect the fuel delivery pipe from the supply

pump and the fuel filter.
. Use two wrenches to disconnect the duct 1730343

from the supply pump. D Disconnect the high pressure fuel ducts.
Figure 61
. Protect the injector inlets and delivery valves
from the entry of dirt.
Figure 63
1730342
D unlock the mounting screws and remove the supply

pump.
1730344
Clean the mating surfaces of the fuel D Disconnect the fuel exhaust manifold.
transfer pump on the monobloc.
Install a new gasket and the fuel transfer Figure 64
pump.
paying particular attention to tighten the mounting
screws and nuts to the specified torque.
1730345
D Unlock the mounting screw and remove the whole

injector.
Refit Injection pump

Proceed as follows:
Removal
Figure 65 Proceed as follows:
D Thoroughly clean the area around the pump.
Figure 67
1730346
D Lubricate the sealing surfaces of the injector sleeve

with an anti-seize paste (a). Assemble the injector,
the injector sleeve, a new copper sealing washer (b) 1730343
and the retaining bracket (c). D Disconnect all the high pressure fuel ducts.
D Remove the control knuckle.
Use only one washer. D Remove the fuel on-off solenoid valve.
A thin film of clean engine oil between the D Remove the booster signal.
washer and the injector can serve to prevent D Remove the oil regulator duct.
the washer from falling while installing.
Figure 68
D Install the assembly in the injector hole.
The injector fuel return connection is to face
toward the tappets cover.
D Insert the injector retaining screws and tighten to

the specified torque.
D Refit the fuel exhaust manifold and tighten the screw
to the specified torque.
Figure 66
1730349
D Insert tool 3824591(gear for manual rotation) into

the flywheel box and engage the flywheel crown
gear.
D Using tool 3824591 find the top dead centre (TDC)
of cylinder no. 1 slowly turning the crankshaft clockĆ
wise and at the same time pressing the engine timĆ
ing pin.
After finding the TDC, disengage the timing
pin to avoid damaging it.
1730347
D Refit the high pressure fuel ducts and tighten the
unions to the specified torque.
Figure 69 Refit
The fuel injection pump has a timing pin loĆ

cated in the regulator box, that serves to
place the pump shaft in the position that
corresponds to the TDC of cylinder no. 1.
Once the fuel injection pump has been inĆ
stalled, remove the timing pin, turn it upside
down and insert it in its seat.
Proceed as follows:
D Make sure that cylinder no. 1 is at TDC.
Figure 72
1730350
D Remove the gearbox cover access cap.

D Remove the nut and washer from the fuel injection
pump shaft.
D Use an extractor to loosen the fuel injection pump
driving gear from the shaft.
Figure 70
1730353
D Remove the cap giving access to the timing pin.

D Remove the timing pin (A), then reverse the position
of timing pin (B) so that the pin groove fits into the
timing tooth in the injection pump.
D If the timing tooth is not aligned with the timing pin
hole, turn the shaft until the alignment of the timing
tooth is obtained.
1730351
Figure 73
D Remove the nuts that fasten the injection pump to
the monobloc.
D Remove the injection pump support bracket mountĆ
ing screws.
Figure 71
1730354
D Install and fasten the timing pin with the access cap.
1730352
D Remove the fuel injection pump.
Figure 74 Figure 76
1730355 1730357
D Check that the filler hole (A) and flange (B) O-rings D Install the injection pump retaining nut and washer.
are mounted correctly on the injection pump and D For the moment tighten the mounting nut to a torque
that they are not damaged. of 15 Nm (11 ft lb).
If the O-ring on flange (B) is marked by a Figure 77

coloured stripe, change it. When the new
O-ring with coloured stripe has been fitted,
lubricate only the seat of the gearbox, not
the O-ring.
D Lubricate the mounting flange with engine oil.
D Clean and dry the mating surfaces between the inĆ
jection pump driving gear (inner diameter) and the
shaft (outer diameter).
To clean the mating surfaces, use a petroĆ
leum free detergent. If this precaution is not
taken, the gear could slip in relation to the
shaft.
1730358
Figure 75 D Disengage the engine timing pin.
Figure 78
1730356
D Insert the pump shaft in the driving gear and place 1730359
the pump flange on the mounting stud bolts.
D Tighten the mounting nuts to the specified torque. D Remove the pump timing pin cap and install the pin,
D Tighten the support bracket screws to the specified the sealing washer and the cap, tightening to the
torque. specified torque.
Figure 79 Injection pump purging
After installation the pump has to be purged.
Proceed as follows:
D Loosen the purging screw near the front panel from
the side nearest the engine.
D Start up the engine and let it run to bleed the air from
the fuel injection pump, then tighten the purging
screw.
D Purge all the high pressure lines.
Injection pump minimum adjustment

1730360
The minimum is adjusted by means of the
D Tighten the injection pump shaft nut to the specified minimum adjustment screw.
torque.
D Tighten the gearbox cover access cap by hand. Proceed as follows:
D Install the high pressure ducts on the fuel pump.
D Install the fuel delivery and return ducts. Figure 81
D Tighten the unions to the specified torque.
D Check that the high pressure ducts have no contact A
with each other or with other components.
Figure 80
1730361
D If a new or repaired pump has been installed, fill the

regulator box with the required amount of oil before
starting up the engine.
Lack of lubricant in the regulator can cause
damage to the pump camshaft and to the flyĆ
wheel counterweight of the regulator. 1730362A
D Loosen the lock nut;

D Turn the minimum adjustment screw:
A. anticlockwise to raise the minimum;
B. clockwise to lower the minimum.
D Tighten the lock nut to the specified torque.
Intake manifold cover and gasket Figure 83
Removal and refit

Proceed as follows:
D Remove the auxiliary cold start device, if installed.
D Remove the air intake sleeve.
D Remove the fuel high pressure lines as described in
the relevant paragraph.
Figure 82
1730364
D Remove the coolant delivery pipe (a) and return

pipe (b).
Figure 84
1730363
D Unlock the mounting screws and remove the intake

manifold cover and gasket.
Plug the air inlet with a clean cloth to avoid
dirt entering into the intake system.
D Clean the sealing surface.

D Install a new gasket and the intake manifold cover,
tightening the screws to the specified torque. 1730365
D Assemble the high pressure fuel ducts and tighten D Remove the aftercooler box and its gasket.
the unions to the specified torque.
D Assemble the removed components working in reĆ Plug the air inlet with a clean cloth to avoid
verse order to the removal. dirt entering into the intake system.
hicle to operating condition. D Clean the sealing surface.
D Install a new gasket and the aftercooler box, tightenĆ
Aftercooler and gasket ing the screws to the specified torque.
D Install the coolant delivery pipe (a) and return pipe
Removal and refit (b) and tighten the securing straps.
Proceed as follows: D Assemble the high pressure fuel ducts and tighten
D Remove the auxiliary cold start device, if installed. the unions to the specified torque.
D Remove the air intake sleeve. D Assemble the removed components working in reĆ
D Remove the high pressure fuel lines as described in verse order to the removal.
the relevant paragraph. D Fill the engine cooling circuit as described in the
D Drain off about 2 litres of engine coolant, following Chapter RADIATOR REMOVAL-REFIT.
the instructions in the Chapter RADIATOR REĆ D After all the operations are finished, restore the veĆ
MOVAL-REFIT; hicle to operating condition.
sewers.
Turbocharger Figure 87
Removal
Proceed as follows:
D Remove the air intake sleeve and the exhaust pipe.
D Disconnect the wastegate actuator signal pipe.
Figure 85
1730368
D Unlock the mounting nuts and remove the turboĆ

charger and its gasket.
Plug the discharge flange with a clean cloth
to avoid dirt entering in the manifold.
1730366 Figure 88
D Remove the oil return duct from the turbocharger

assembly.
Figure 86
1730369
D Clean the sealing surface.

D Inspect the sealing surface and the stud bolts for
any damage.
1730367 Refit
Proceed as follows:
D Remove oil delivery duct to the turbocharger asĆ
sembly. Figure 89
1730370
D Install a new gasket and apply an anti seize paste

to the stud bolts.
D Install the turbocharger and tighten the mountĆ D Install the lubricant delivery duct and tighten the uniĆ
ing nuts to the specified torque. ons to the specified torque.
The oil delivery duct must not come into
Figure 90
contact with the turbine body, otherwise it
could burn and cause serious injury or damĆ
age.
D Assemble the removed components working in reĆ
verse order to the removal.
Start up the engine and check there are no leaks.
After all the operations are finished, restore the veĆ
Exhaust manifold and gaskets
Removal
Proceed as follows:
1730371
D Remove the air intake sleeve and exhaust pipe
D If necessary, loosen the turbine body bolts and posiĆ D Remove the turbocharger as described in the relĆ
tion the bearing housing so that the turbocharger oil evant paragraph.
discharge pipe can be installed.
Figure 92
D Install the flexible hose and straps onto the turboĆ
charger oil discharge pipe without tightening them,
then refit the oil discharge pipe and the gasket on
the turbocharger;
D tighten the screws to the specified torque, then
tighten the straps;
D If previously loosened, tighten the turbine body
bolts to the specified torque;
Figure 91
1730373
D unlock the mounting nuts and remove the exhaust

manifold with its gaskets.
Refit
Proceed as follows:
Figure 93
1730372
D Pour 50-60 cm3 (3.05-3.67 in3) of the specified enĆ

gine oil into the oil delivery union, then turn the turĆ
bine impeller to allow the lubricant to enter into the
bearing housing.
To avoid internal damage, new turboĆ
chargers are to be pre-lubricated before
starting up the engine.
1730374
D Clean the sealing surfaces of the exhaust manifold.
Figure 94 Lubrication oil pressure regulator, valve and spring
Removal and refit

Proceed as follows:
Figure 96
1730375
D Apply an anti-seize paste to the exhaust manifold

mounting screws.
D Install the exhaust manifold with new gaskets and
safety plates.
1730377
Figure 95
D Remove the regulator cap, spring and valve.
D Clean and inspect the regulator hole and valve beĆ
fore reassembling.
The valve must move freely in the hole.
D Install the regulator, the spring and the cap and

tighten to the specified torque.
Lubrication oil thermostat
Removal and refit

1730376
Proceed as follows:
Figure 97
D Tighten the mounting screws in the order indicated
verse order to the removal.
D Start up the engine and check there are no leaks.
1730378
D Remove the lubrication oil thermostat.
D Clean and inspect the lubrication oil thermostat hole
before reassembling.
D Install the lubrication oil thermostat and tighten to
Lubrication oil heat exchanger element and gasket D Clean the sealing surfaces of the oil heat exchanger.
Figure 100
Removal and refit
Proceed as follows:
D drain off the engine cooling circuit as described in
the Chapter RADIATOR REMOVAL-REFIT;
sewers.
D Remove the lubrication oil filter.
Figure 98
1730381
D Assemble the oil heat exchanger gasket, the elĆ

ement, the heat exchanger cover gasket, the lubriĆ
cating oil thermostat and the oil heat exchanger
cover on the monobloc.
Remove the protective caps from the new

heat exchanger element.
1730379 verse order to the removal.
D Remove the turbocharger oil delivery duct from the Figure 101
head of the oil filter.
Figure 99
156NM26
D Fit a new oil filter following the instructions in the relĆ

evant paragraph.
1730380 D Fill the engine cooling circuit as described in the
D Remove the oil heat exchanger, element and Chapter RADIATOR REMOVAL-REFIT;
gaskets. D After all the operations are finished, restore the veĆ
The heat exchanger contains about 0.7 hicle to operating condition.
litres of lubrication oil, which will spill out
when removing from the engine.
Starter motor Alternator
Removal and refit Removal and refit

D Remove the control belt as described in the relevant
Figure 102 paragraph.
Figure 104
1730382
D Disconnect the battery cable from the solenoid. 1730384
Figure 103 D Remove the bolt (A) from the alternator knuckle.
D Remove the bolt (B) from the support bracket.
Figure 105
1730383
1730383
D Unlock the mounting screws and remove the starter

motor and the spacer.
1730385
D Install the starter motor working in reverse order.
D Tighten the mounting screws to the specified D Remove the alternator mounting bolts and nuts.
torque. D Remove the alternator.
D Fit the alternator on the bracket and secure it,
tightening the mounting bolts by hand.
D Connect the knuckle to the alternator, screwing the
bolt by hand.
Check that the alternator knuckle is posiĆ

tioned to have correct belt alignment.
D Tighten the alternator mounting bolts to the speciĆ
fied torque.
D Fit the control belt as described in the relevant paraĆ
graph.
SECTION 7
AUTOMATIC TRANSMISSION
ADT 25 SECTION 7 AUTOMATIC TRANSMISSIONą1
CONTENTS
Page Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Converter counter pressure valve . . . . . . . . . . . . . . 37

Oil pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
AUTOMATIC TRANSMISSION SECTION . . . . . . . 4
Differential lock control . . . . . . . . . . . . . . . . . . . . . . . . 38
AUTOMATIC TRANSMISSION . . . . . . . . . . . . . . . . . 5
Drive input shaft (PTO shaft) . . . . . . . . . . . . . . . . . . 39
BASIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . 6
Gearbox cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Output shaft [AB] and differential lock . . . . . . . . . . 40
Lock-up clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Shafts and clutches . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CLEANING, INSPECTING AND CHECKING . . . . 43
Central splitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cleaning components . . . . . . . . . . . . . . . . . . . . . . . . 43
AUTOMATIC GEARBOX CONTROL SYSTEM . . . . 9
Inspecting and checking . . . . . . . . . . . . . . . . . . . . . . 43
Gearbox control system block diagram . . . . . . . . . . 9
GENERAL ASSEMBLY INSTRUCTIONS . . . . . . . 44
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Lubricants used for assembly . . . . . . . . . . . . . . . . . . 44
GEARBOX OIL COOLING SYSTEM . . . . . . . . . . . . 19 Clutches and pistons . . . . . . . . . . . . . . . . . . . . . . . . . 44
SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . 20 Lip seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Roller bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . 24 Shrink-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 SUBASSEMBLY DISASSEMBLY AND

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
REMOVAL-REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
KV and KR clutch disassembly . . . . . . . . . . . . . . . . . 45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
KV and KR clutch assembly . . . . . . . . . . . . . . . . . . . 46
Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Axial play test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
SPECIFIC MAINTENANCE OPERATIONS . . . . . 29 Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 K1, K2 and K3 clutch disassembly . . . . . . . . . . . . . 50
Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 K1, K2 and K3 clutch assembly . . . . . . . . . . . . . . . . 51
Replacing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Axial play test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . 31 Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
ELECTRONIC-HYDRAULIC CONTROL UNIT . . 31 K4 clutch disassembly . . . . . . . . . . . . . . . . . . . . . . . . 56
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 K4 clutch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Converter clutch valve (lock-up) . . . . . . . . . . . . . . 32 Axial play test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Input shaft disassembly . . . . . . . . . . . . . . . . . . . . . . . 61
GEARBOX AND GEAR DISASSEMBLY . . . . . . . . 35
Input shaft re-assembly . . . . . . . . . . . . . . . . . . . . . . 61
Preliminary operations . . . . . . . . . . . . . . . . . . . . . . . . 35
Differential disassembly . . . . . . . . . . . . . . . . . . . . . . . 62
Sensors and transmitters . . . . . . . . . . . . . . . . . . . . . 36
Differential re-assembly . . . . . . . . . . . . . . . . . . . . . . 63
Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2ąAUTOMATIC TRANSMISSION SECTION 7 ADT 25
Page Page
Differential lock disassembly . . . . . . . . . . . . . . . . . . . 64 Box cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Differential lock re-assembly . . . . . . . . . . . . . . . . . . 66 Drive input shaft (PTO shaft) . . . . . . . . . . . . . . . . . . . 75
Oil pressure pump disassembly . . . . . . . . . . . . . . . . 69 PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Oil pressure pump re-assembly . . . . . . . . . . . . . . . 69 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Gearbox cover preparation . . . . . . . . . . . . . . . . . . . . 70 Converter counter pressure valve . . . . . . . . . . . . . . 78
GEARBOX AND GEAR ASSEMBLY . . . . . . . . . . . . 71 Oil pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Oil pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Drive input shaft (AN) and clutches . . . . . . . . . . . . . 71 Sensors and transmitters . . . . . . . . . . . . . . . . . . . . . . 82
Box cover side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Drive output shaft (AB) . . . . . . . . . . . . . . . . . . . . . . . . 73
DESCRIPTION
The ZF 6WG210 automatic transmission consists of Clutches: each shaft has a hydraulically controlled
these main parts: multiple disk clutch.
Torque converter: the torque converter has three Oil pressure pump: clamped onto the pump shaft, it
parts: the pump, the turbine and the stator. The pump is of the gear type and ensures the pressure required
is the input element and is controlled by the engine. for lubrication and hydraulic operation.
The turbine is the output element and is hydraulically Hydraulic assembly: this consists of a set of solenoid
controlled by the pump. The stator is the reaction eleĆ valves controlled by the gearbox control unit, and a seĆ
ment (torque multiplier). ries of channels to transmit the oil pressure in the apĆ
Lock up clutch: this is installed between pump and turĆ propriate points.
bine: when transmission reaches the turbine speed, it Power take-off activation. The power take-off conĆ
is close to that of the pump, the lock-up clutch beĆ trolled by the pump shaft (thus by the engine flywheel)
comes engaged so that the engine driving torque is is mounted on the rear side of the transmission case.
sent direct to the transmission with a ratio of 1:1. Gearbox control unit and wiring: the control unit reĆ
Shafts and gears: the forward gear ratios and the reĆ ceives the input signal and controls the output, so as
verse gear ratio are obtained by six shafts, each of to ensure correct transmission operation.
which has two or three helical tooth gears always enĆ
gaged.
Figure 1
1730710
AUTOMATIC TRANSMISSION SECTION

a. reversing shaft KR i. gearbox oil pressure pump
b. driving torque input shaft AN j. driving torque input flange
c. forward gear shaft clutch KV k. torque converter
d. 2nd gear shaft K2 l. lock-up clutch WK
e. 3rd gear shaft K3 m. input shaft speed sensor
f. driving torque output flange, rear n. 4th gear shaft K4
g. driving torque output flange, front o. converter safety valve
h. driving torque output shaft AB (without splitter) p. 1st gear shaft K1
Figure 2
1730711
AUTOMATIC TRANSMISSION
a. reversing shaft KR k. torque converter
b. driving torque input shaft AN l. lock-up clutch WK
c. forward gear shaft KV m. not used
d. 2nd gear shaft K2 n. 4th gear shaft K4
e. 3rd gear shaft K3 o. not used
f. not used p. 1st gear shaft K1
g. not used q. power take-off
h. driving torque output shaft Ab with splitter IN: motion input direction of rotation
i. gearbox oil pressure pump OUT A: forward travel direction of rotation
j. not used. OUT B: reverse output direction of rotation
Figure 3
1730712
BASIC COMPONENTS
Torque converter
The function of the torque converter is to hydraulically a multiplication ratio that ranges from a maximum of
transmit the engine driving torque to the gearbox, with approx. 2.5:1 to a minimum of 1:1 (top gear).
Figure 4
1730713
The torque converter consists of three parts: pump P, Figure 5

turbine T and stator S. The pump is the input element
and is controlled by the engine. The turbine is the outĆ
put element and is hydraulically controlled by the
pump. The stator is the reaction element (torque multiĆ
plier) and is mounted on a free wheel that allows rotaĆ
tion only in the same direction as the pump.
The assembly is enclosed in a box full of a specific oil.
The assembly is completed by a lock-up clutch WK
that stiffens the pump-turbine connection under cerĆ
tain conditions.
Operation
The pump is connected to the engine, and when it roĆ
tates, it transmits its energy to the oil. The centrifugal
force projects the oil toward the perimeter of the pump,
where it flows at high speed to the turbine. Here the kiĆ
nematic energy of the oil impresses a rotary motion to
the turbine, in the same direction as the pump.
At the turbine outlet the oil is deviated by the stator so
1730714
that its direction is the same as that of the turbine
blades. In this way the stator, which under normal conĆ The ratio between the torque acting on the turbine and
ditions is prevented from rotating by the free wheel, the driving torque is called the converter multiplication
supplies a torque reaction that is added to that of the ratio, and is proportional to the difference in speed beĆ
turbine. tween pump and turbine.
In detail: Clutch engaged (lock-up)

D With the vehicle wheel stationary this ratio is approx. The control unit pilots a solenoid valve that determines
1:2.5 (condition A, maximum flow); an increase in pressure in rear zone a As a conseĆ
D Converter timing conditions (flow ≠ 0) this ratio lowĆ quence, piston (1) slides and locks clutch (2). In this
ers to intermediate values (condition B); way turbine T is integral with pump P and the relevant
D With similar pump speed and turbine speed, the raĆ flow is eliminated.
tio is almost 1:1 (flow ≈ 0).
The flow condition = 0 is never reached Clutches
completely, except by means of the lock- The clutches prevent rotation between the hub and the
up clutch (condition C). bell when they are engaged. They are appropriately
controlled to obtain the forward and reverse gear raĆ
When the speeds of the pump and the turbine are alĆ
tios.
most the same, a flow of oil hits the stator and causes
this to rotate in the same direction as the turbine, withĆ Figure 7
out reaction torque, and the converter becomes a simĆ
ple hydraulic joint.
Lock-up clutch
The lock-up clutch WK is a device that makes a meĆ
chanical coupling between pump and converter turĆ
bine when it is engaged.
With the lock-up clutch engaged there is no flow beĆ
tween pump P and turbine T, thus changing the gearĆ
box to a mechanical transmission, with the relevant reĆ
duction in friction loss in the converter and
consequently reduction in fuel consumption.
Figure 6
1730716
The multiple disk clutches (3), are hydraulically locked,

sending oil under pressure behind the control piston
(1) by suitable solenoid valves, while they are released
by the mechanical action of a helical spring (2) that acts
on the piston in the opposite direction to the oil presĆ
sure.
1730715
Clutch disengaged (converter timing)

The oil circulating inside the converter operates with
the same pressure on rear a and front b of the engagĆ
ing piston (1) of the clutch (2): turbine T is free to rotate
in relation to pump P.
Central splitter
The lockable central splitter has the purpose of dividing linkages are manually locked when there is a risk of
the driving torque between the two sides, unless the slipping on one of the two sides.
Figure 8
1730717
1. front side output shaft Operation

2. sliding sleeve to lock splitter Under normal conditions (position A) the driving torque
3. hollow shaft coming from gear shaft K3 is distributed in this way: 2/3
4. shaft gear K3 through the train carrier (6) to the rear output shaft (7)
5. external planet gear and 1/3 through the sun gear to the front output shaft
6. train carrier (1).
7. rear side output shaft If the splitter is locked (position B), the sliding sleeve (2)
8. sun gear makes the hollow shaft (3), which is in its turn integral
9. crown gear with the train carrier, integral with the front output shaft,
10. internal planet gear i.e. with the sun gear.
11. sliding sleeve control lever The driving torque is therefore equally distributed on
the two sides, since the assembly has become a single
A: disengaged position (splitter free) unit with the crown gear (9).
B: engaged position ( splitter locked)
AUTOMATIC GEARBOX CONTROL SYSTEM

The control system consists of a gearbox control unit Gearbox control system block diagram
EST37, a set of sensors and electrical connections to 1. Electric power supply
the control unit that transmit the information required to 2. Input angular speed (pump)
detect the operating conditions, and a set of solenoid 3. Turbine angular speed
valves that, controlled by the control unit according to 4. Internal angular speed
the strategies contained in it, control the hydraulic 5. Output angular speed
valves in the hydraulic assembly to obtain the required 6. Selector lever
gearbox operation. 7. Clutch disengaged signal
The control system also manages the self diagnostics 8. Bin-up
and the dialogue with the external diagnostic equipĆ 9. Retarder request (if installed)
ment. 10. Splitter lock request
11. Kick-down
12. Engine load sensor
13. CAN interface
14. Converter oil temperature
15. Pressure pump oil temperature
16. Solenoid valves
17. Diagnostics interface
18. Speedometer
19. Display
20. Gearbox fault warning light
21. Retarder (if installed)
22. Lock-up clutch
23. Splitter lock
Figure 9
13
14
12
15
I I
11
Y6 10
Y5 9
Y4
16 Y3
8
7
Y2
Y1 -
B2/T-
17 EST-37 B1/T+
6
18 R
19 N
F
I I I I
5
4
20
21 3
22 2
23
1730718
1
OPERATION
1st forward gear: ratio 1:5.562

Clutches Free Locked The driving torque passes from input shaft AN through
the associated clutch to shaft KV, then to shaft K2, to
KV X
shaft K4, to shaft K1 and then, through the associated
KR X clutch, to shaft K3 and finally to output shaft AB, that
K1 X turns the same direction as shaft AN.
K2 X
K3 X
K4 X
Figure 10
1730719
2nd forward gear: ratio 1:3.615

Clutches Free Locked The driving torque passes from input shaft AN to shaft
K4, and through the associated clutch, to shaft K1,
KV X
then, through the associated clutch, to shaft K3 and fiĆ
KR X nally to output shaft AB, that turns in the same direction
K1 X as shaft AN.
K2 X
K3 X
K4 X
Figure 11
1730720
3rd forward gear: ratio 1:2.255

the associated clutch to shaft KV, to shaft K2, then,
KV X X
through the associated clutch, to shaft K3 and finally to
KR X output shaft AB, that turns in the same direction as
K1 X shaft AN.
K2 X
K3 X
K4 X
Figure 12
1730721
4th forward gear: ratio 1:1.466

K4, and through the associated clutch, to shaft K2,
KV X
then, through the associated clutch, to shaft K3 and fiĆ
KR X nally to output shaft AB, that turns in the same direction
K1 X as shaft AN.
K2 X
K3 X
K4 X
Figure 13
1730722

the associated clutch to shaft KV, to shaft K2, then to
KV X
shaft K3 and finally, through the associated clutch, to
K1 X shaft AN.
K2 X
K3 X
K4 X
Figure 14
1730723

K4, through the associated clutch to shaft K2, then to
KV X
shaft K3 and finally through the associated clutch to
K1 X shaft AN.
K2 X
K3 X
K4 X
Figure 15
1730724
1st reverse gear: ratio 1:5.274

the associated clutch to shaft KR, to shaft K4, shaft K1
KV X
and then through the associated clutch to shaft K3 and
KR X finally to output shaft AB, that turns in the opposite diĆ
K1 X rection to shaft AN.
K2 X
K3 X
K4 X
Figure 16
1730725
2nd reverse gear: ratio 1:2.138

KV X
and then, through the associated clutch, to shaft K3
KR X and finally to output shaft AB, that turns in the opposite
K1 X direction to shaft AN.
K2 X
K3 X
K4 X
Figure 17
1730726
3rd reverse gear: ratio 1:0.894

KV X
and then through the associated clutch, to shaft K3 and
KR X finally to output shaft AB, that turns in the opposite diĆ
K1 X rection to shaft AN.
K2 X
K3 X
K4 X
Figure 18
1730727
GEARBOX OIL COOLING SYSTEM

The gearbox fluid (1) is cooled by an oil-water heat exĆ
changer (2) located in the front of the vehicle. A: gearbox fluid inlet-outlet unions.
The fluid circulates driven by the oil pressure pump inĆ B: heat exchanger fluid inlet-outlet unions.
side the gearbox.
Figure 19
1730728
Figure 20 Figure 21
A B
1730729 1730730
TORQUE CONVERTER
Max input power 210 kW 280 HP
Max turbine torque -input- 1150 Nm 849 lb ft
Max turbine torque -output- 1650 Nm 1218 lb ft
Stall torque ratio 1.77 : 1
Element phases 2
Stator Fix wheel (blade)
Lock-up cluch All gears
GEARBOX
Type Full power shift
Gear/clutch configuration Countershaft
Gear number - Front/rear 6 forward/3 reverse
PTO units speed 1.0 engine speed
Oil capacity approx. 26 liters 5.7 Imp gal
Weight (without oil) 470 kg 1037 lb
Oil level cold check temperature 15-45 °C 59-113° F
Oil level hot check temperature 80-104 °C 176-220 °F
Rolling bearing mounting maximum temperature 90 °C 194 °F
Interference mounting pieces maximum temp. 140° 284 °F
RATIOS
Forward
1st gear 5.562
2nd gear 3.615
3rd gear 2.255
4st gear 1.466
5st gear 0.942
6st gear 0.613
Reverse
1st gear 5.274
2nd gear 2.138
3nd gear 0.894
POWER TAKE-OFF
Available output 2
Max. torque 800 Nm 590 lb ft
Total weight - dry (kg) 590 kg 1330.8 lb
DIAGNOSTIC
a. Automatic transmission shifts at excessively fast speed
b. Automatic transmission shifts at excessively slow speed
c. Low main pressure in all gears
d. Main low pressure in one gear (normal in other gears)
e. The vehicle moves fast in first and reverse gear
f. Low lubrication pressure
g. Oil leakage from converter box (without PTO controlled by engine)
h. Transmission overheats in all gears
i. No transmission response when gear stick is shifted
j. Problematic gear shifts
k. Dirty oil
l. Leakage of oil from output shaft
m. Engine pick-up speed high with vehicle not moving
n. Engine pick-up speed high with vehicle not moving
o. Clutch slips in all forward gears
p. One specific gear slips
q. Oil leakage from filler pipe
r. Vibration or noise
Automatic transmission shifts at Regulator box jammed Clean or replace the regulator
excessively fast speed
Control valve spring excessively Adjust the spring
loaded
Valves do not work freely Overhaul the regulator
Automatic transmission shifts at Regulator box jammed, weak Clean or replace the regulator
excessively slow speed springs
Control valve spring setting excessĆ Adjust the spring

ively weak
Low main pressure in all gears Oil missing Top up oil
Oil filter obstructed Replace the filter
Oil intake tube leaking or missing Overhaul the damaged parts
Main pressure adjustment valve Replace the spring

spring stretched
Distributor leaking Replace or overhaul the distributor
Valves jammed (main pressure Overhaul the distributor and the

dampers, relays and regulating main pressure regulating valve
valve)
Oil pump damaged or worn Replace or overhaul the oil pump
Main low pressure in one gear Loss of clutches of a certain gear in Replace or overhaul the distributor
(normal in other gears) actuating circuits
Excessive clutch piston seal leakĆ Overhaul the clutch and replace the
age for a certain gear seals
The vehicle moves fast in first and Engine idling speed too fast Adjust engine idling speed
reverse gear
Low lubrication pressure Oil missing Restore level
Excessive internal oil leakage Check distributor assembly screws,

lubrication valve housing and
spring; low main pressure
Exchanger pipes leaking or obĆ Restore or replace, if required

structed
Lubrication valve spring weak Replace the valve spring
Oil leakage from converter box Converter pump hub seal worn Replace the seal
Converter pump hub worn in seal Replace the pump hub

area
Oil intake tube leaking or missing Overhaul the damaged parts
Transmission overheats in all Oil missing Restore level

gears
Excessive oil Restore level
No circulation of engine coolant in Restore level

heat exchanger.
Heat exchanger obstructed (oil side Eliminate obstructions

or coolant side)
No transmission response when Gear stick electrical connection Restore connections

gear stick is shifted and/or control unit damaged and/or
disconnected
Main pressure missing See point 3
Problematic gear shifts Modulator valve jammed; spring set Repair or replace the valves; loosen
excessively tight spring setting
Distributor valves jammed Replace or overhaul distributor

valve
Dirty oil Oil not changed at specified freĆ Change oil, fit new filtering element
quency
Oil filter damaged Replace the filter
Clutch faulty Overhaul the gearbox
Leakage of oil from output shaft Output shaft flange seal worn or Replace the seal
damaged
Seal resting surface of flange worn Replace the flange
Engine pick-up speed high with Oil missing Top up oil level
vehicle not moving
Clutch pressure missing See point 4
Forward gear clutch slips Overhaul forward gear
Engine pick-up speed low with Poor engine performance (not due Adjust or overhaul the engine
vehicle not moving to altitude)
Poor operation of converter compoĆ Replace the converter

nents
Clutch slips in all forward gears Oil missing Top up oil level
Clutch pressure (main) missing See point 3
Forward gear clutch slips Overhaul forward gear and replace

piston seals
Front mount hub segments worn or Replace the segments

broken
One specific gear slips One specific clutch slips Overhaul the concerned parts
Forward gear clutch does not disenĆ Overhaul forward gear

gage (forward gear)
Reverse gear clutch does not disenĆ Overhaul reverse gear

gage (reverse gear)
Oil leakage from filler pipe Level gauge clearance Fasten cap and replace it, if required
Oil level too high Remove the required amount of oil

to restore the correct level
Breather valve obstructed Clean or replace breather valve
Vibration or noise Transmission bent or incorrectly balĆ Clean the transmission. Check conĆ
anced tact with surrounding elements. ReĆ
place the transmission if offset or
deformed. Remove and dynamiĆ
cally balance the transmission if it
does not work correctly (it vibrates).
Transmission loose at fork/flange Check blind screw fastening transĆ

mission. If loose, replace and
tighten new screws at specified
torque
Worn or dry mounts Test transmission manually. ReĆ

place all transverse units with the
mounts if loose
TIGHTENING TORQUE
Screws fastening gearbox mounts to chassis 200 Nm 147 lb ft
Screws fastening front and rear cradle to gearbox 400 Nm 295 lb ft
Pipe plate differential pressure switch 30 Nm 22 lb ft
Screws fastening pipe plate to gearbox 23 Nm 17 lb ft
Screws fastening hydraulic control unit to gearbox 11 Nm 8 lb ft
M5 screws fastening converter clutch valve to mount 5.5 Nm 4 lb ft
Screws fastening converter clutch valve mount to plate 9.5 Nm 7 lb ft
Screw retaining converter clutch valve plate 18 Nm 13 lb ft
Converter clutch valve threaded sleeve 46 Nm 34 lb ft
Screws fastening converter clutch valve mount to bracket 23 Nm 17 lb ft
Screws fastening converter clutch valve bracket to gearbox 46 Nm 34 lb ft
M12 screws fastening hose fittings to gearbox 45 Nm 33 lb ft
M8 screws fastening hose fittings to gearbox 35 Nm 26 lb ft
Hose fastening to fittings 35 Nm 26 lb ft
Screws fastening filter head to pipe plate 23 Nm 17 lb ft
Gearbox cover M8 studs 9 Nm 6.6 lb ft
Gearbox cover M12 studs 23 Nm 17 lb ft
Gearbox threaded sleeve 46 Nm 34 lb ft
Gearbox threaded bushing 80 Nm 59 lb ft
KR/KV shaft stud 17 Nm 12.5 lb ft
K1/K2/K3/K4 shaft stud 17 Nm 12.5 lb ft
Differential cover fastening screws 68 Nm 50 lb ft
Differential guard fastening screws 23 Nm 17 lb ft
Gearbox cover fastening screws 46 Nm 34 lb ft
Oil delivery cover fastening nuts 23 Nm 17 lb ft
PTO box fastening nuts 79 Nm 58 lb ft
Screws fastening flange to rear output shaft 46 Nm 34 lb ft
Differential lock control cover fastening screws 23 Nm 17 lb ft
Differential lock engagement fork fastening pins 9.5 Nm 7 lb ft
Differential lock control switch 30 Nm 22 lb ft
Screws fastening bushing to front output shaft 32 Nm 23.5 lb ft
Screws fastening differential lock device to gearbox 79 Nm 58 lb ft
Oil pressure pump fastening screws 46 Nm 34 lb ft
Oil pressure pump M10 fastening screws 34 Nm 25 lb ft
Oil pressure pump M8 fastening screws 23 Nm 17 lb ft
Screws fastening converter bell to gearbox 68 Nm 50 lb ft
Screws fastening input shaft to membrane 115 Nm 85 lb ft
Screws fastening membrane to converter 115 Nm 85 lb ft
Screws fastening flange to input shaft 34 Nm 25 lb ft
Screws fastening converter cover to bell 46 Nm 34 lb ft
Cover fastening screws (emergency steering pump) 23 Nm 17 lb ft
Tachometer signal transmitter 30 Nm 22 lb ft
Sensors 30 Nm 22 lb ft
Sensor fastening screws 23 Nm 17 lb ft
Breather 12 Nm 9 lb ft
TOOLS
5870 350 000 assembly trolley unit with tipping mechanism
5870 350 063 bars (to be used with 5870 350 000)
5870 350 090 retainers (to be used with 5870 350 000)
5870 350 000 assembly trolley unit with tipping mechanism
5870 350 089 box cover fastening brackets (to be used with 5870 350 000)
5870 260 010 handles for fastening shafts to box cover
5873 001 000 base for removing KR/KV/K4 shaft taper roller bearings
5873 001 057 gripper (to be used with 5873 001 000)
5870 100 043 pressing tool (to be used with 5873 001 000)
5873 001 000 base for removing K1/K2/K3shaft taper roller bearings
5873 002 001 base for removing K1/K2/K3 shaft taper roller bearings
5870 100 043 pressing tool (to be used with 5873 001 000)
5870 345 088 clutch compression spring pre-load ring
5873 001 000 input shaft taper roller bearing removal base
5870 001 006 bushing (to be used with 5873 350 000)
5870 600 003 oil pipe assembly tool
5870 345 089 shaft manual rotation sleeve
5870 280 007 shaft manual rotation handwheel
5870 048 237 seal assembly pad
5870 506 142 rear output flange screws retainer plate assembly pad
5870 204 011 oil pressure pump box assembly guide screw
5870 058 023 differential output shaft roller bearing assembly guide bushing
5870 260 002 pads (to be used with 5870 350 000)
REMOVAL-REFIT
Before starting any type of operation make Figure 23
1.2 of this manual.
perience.
rectly.
Removal
1730701
D disconnect propeller shafts: (A) from the engine to
the gearbox, (B) from the gearbox to the front axle
and (C) from the gearbox to the intermediate mountĆ
boards;
ing following the instructions in SECTION 10;
D prepare a suitable container and drain off the hyĆ
draulic fluid as described in SECTION 16.
circuits;
D lock knuckle with the steering lock bar following the Never dispose of residual fluid in unauthoĆ
instructions in SECTION 1.2; rised dumps or by pouring it into the sewers.
Figure 22
1730303A
D remove the engine cowl and cab as described in

SECTION 18;
The cab is to be removed by experts proĆ
vided with the necessary equipment.
D Disconnect the electrical connections: D Remove the exhaust mufflers (8) and the respective
a. engine speed partition.
b. rotator speed D Use a suitable lifting device, apply chains to the asĆ
c. turbine speed sembly brackets and pull them, making sure that
d. lock-up clutch solenoid valve the weight is equally divided and that the assembly
e. electrical hydraulic control unit does not slant excessively to the side.
f. filter and oil circuit obstruction sensors D Remove the front and rear gearbox rubber mount
g. differential lock control. fastening screws (6) from both sides.
D Disconnect the pipes: D Check that all connections and pipes have been disĆ
- delivery (10) from main pump connected and that all the fastening clips have been
- suction (12) from hydraulic reservoir released.
- lubricant delivery from heat exchanger (1) D Lift the assembly carefully upwards.
- lubricant return from heat exchanger (5) D Remove the brackets supporting the front and rear
- differential lock control (16). gearbox.
D Remove the suction pipe (12) from hydraulic reserĆ
voir.
Figure 24
1730707A
Figure 25
1730706
Refit
paying particular attention to:
D check the gearbox flexible mountings: if they are
damaged, replace them;
D check that the connecting pipes and associated
unions are perfectly intact;
D check the gearbox oil level and if necessary top up
or fill (see OPERATION AND MAINTENANCE
MANUAL).
SPECIFIC MAINTENANCE OPERATIONS
Checking oil level

The correct oil level is essential for good operation of Figure 27
the transmission. Insufficient oil can cause irregular opĆ
eration and damage the converter. Excessive oil can
cause the formation of foam and overheat the transmisĆ
sion.
Figure 26
156NM76
Hot check (80-100 °C) (176-212 °F) (Figure 27)

Proceed as follows:
D run a certain distance to warm up the transmission;
D let the engine idle with the gearshift in Neutral posiĆ
156NM75 tion;
D clean the filler area, loosen the handle by two or
Cold check (15-45 °C) (59-113 °F) (Figure 26)
three turns and remove the dipstick built into the fillĆ
Proceed as follows: er. Check that the oil level in the transmission is withĆ
D start the engine and let it idle with the gearshift in in the HOT reference range;
Neutral position for approximately one minute; D either top up or drain the oil to reach the specified
D clean the filler area, loosen the handle by two or level and reposition the dipstick by refastening the
three turns and remove the dipstick built into the fillĆ handle;
er. Check that the oil level in the transmission is not
under the COLD reference (minimum level); Figure 28
D top up, if required. Do not drain any oil in excess, reĆ
position the dipstick by refastening the handle;
D do a hot check as soon as possible.
174NM32
D Check that breather (Figure 28) is perfectly clean

and working.
Changing oil
Collect and dispose of used lubricants and D fill the new cartridge with the specified lubricant and
fluids according to the laws in force. apply the same lubricant to the seal (Figure 31);
Figure 31
Proceed as follows:
D take a suitably sized container, clean the filler area,
loosen the handle by two or three turns and remove
the dipstick;
D remove both drain caps (Figure 29) and fully drain
the oil;
D clean the drain cap. Check that the threading is in
good condition. Apply sealing paste and close at
the specified torque;
drain cap: 140 Nm (103 lb ft)
D pour in the specified amount of lubricant through
the filler and reposition the dipstick by refastening
the handle;
D check the level again after a test drive. 156NM25
Figure 29 D fasten the cartridge by hand until the seal comes

into contact with the housing, then turn by another
3/4th of a turn (Figure 32);
Figure 32
156NM77
Replacing oil filter

La sostituzione del filtro deve esser eseguita
in concomitanza alla sostituzione dell'olio
lubrificante. 156NM42
Proceed as follows:
D with a cold engine, loosen the filtering cartridge Do not fasten the cartridge excessively. This
(Figure 30) using the specific tool and accurately could damage the seal. Observe the specifiĆ
clean housing and engine cations provided by the supplier.
Figure 30 D run the engine for a few minutes and check for leakĆ
age.
D check engine oil level and top up, if required.
156NM78
REPAIR OPERATIONS
Check that all precautions have been taken D Loosen the fastening screws and separate the filter
head from the pipe plate.
and that all aspects concerning safety of
personnel involved in the operations have Figure 35
been explained before started any operaĆ
tion.
Read the instructions provided in SECTION
1.2 of this manual.
In doubt, consult an expert.
Follow all the general recommendations for
correctly performing maintenance operaĆ
tions.
ELECTRONIC-HYDRAULIC CONTROL UNIT
Removal
Proceed as follows:
1730743
Figure 33
D Remove the differential pressure switch (obstrucĆ
tion indicator).
Figure 36
1730741
D Remove the transmission oil filter using tool 5870

105 005.
1730744
Figure 34
D Remove the piston and the compression spring (byĆ
pass valve).
Figure 37
1730742
1730745
D Remove the hoses.
D Loosen the fastening screws and separate the hyĆ
draulic control unit from the pipe plate.
Figure 38 Converter clutch valve (lock-up)
Figure 41
1730746
D Loosen the fastening screws and separate the pipe 1730749
plate from the gearbox.
D Fit the converter clutch solenoid valve and fasten
Figure 39 the screws at the specified torque.
Figure 42
1730747
D Extract the converter safety valve from the hole in

1730750
the box.
D Fit the converter valve components in the order
Figure 40 shown and fasten the threaded sleeve at the speciĆ
fied torque.
1. Valve support
2. Piston
3. Scraper rings
4. Compression spring
5. Retainer
6. O-ring
7. Threaded sleeve
Fit a new o-ring (6).
The control pressure of the converter clutch
(15 + 1 bar) (218 + 15 psi) is determined by
the scraper rings (3): tentative value, 3 eleĆ
ments, 0.5 mm (0.02 in) thick each.
1730744 Fit the retainer (5) with the flat thrust side
D Loosen the fastening screws and remove the plate facing the compression spring.
with converter clutch valve support. D Fit the converter valve support on the plate placing
D Disassemble the converter clutch valve. the seal in between.
Assembly Figure 45
Proceed as follows:
Figure 43
1730753
D Fit the seal.
1730751
Lubricate the seal to facilitate assembly.
D Fit the following components in the order shown:
1 = compression spring
2 = piston Figure 46
3 = Differential pressure switch (obstruction indiĆ
cator).
Lubricate the o-ring (arrow).
D Fasten the pressure switch at the specified torque.
Figure 44
1730754
D Fasten the pipe plate and fasten the screws at the
specified torque.
Figure 47
1730752
D Fit the converter safety valve in its housing.
1730755
D Fit two guide screws 5870 204 063 and fit the inner
seal.
Figure 48 Figure 51
1730756
1730759
D Pay attention to the correct component assembly D Fit the hydraulic control unit and fasten the screws
sequence: at the specified torque.
1. Inner seal
Figure 52
2. Intermediate sheet
3. Outer seal
Figure 49
1730760
D Fit the seal.
D Fit the plate with converter clutch valve on the box
1730757 and fasten the screws at the specified torque.
D Fit the intermediate shim sheet.
Figure 53
Figure 50
1730761
1730758 D Fit the hoses (arrow) and fasten the fittings and the
D Fit the outer seal. screws at the specified torque.
D Remove the guide screws. Fit new seals.
Figure 54 GEARBOX AND GEAR DISASSEMBLY

Proceed as follows:
Figure 56
1730762
D Fit the o-rings (arrows) in the circular grooves on

the filter head.
Figure 55
1730764
D Fasten the transmission to the supporting tools:
assembly trolley 5870 350 000
bars 5870 350 063
retainer 5870 350 090.
D Drain all lubricant oil.
D Remove the hoses, the filter unit, the hydraulic conĆ
trol unit, the pipe plate and the converter clutch
valve, as shown above.
Figure 57
1730763
D Fit the pipe plate head and fasten the screws at the
specified torque.
D Lubricate the filter seal.
D Fasten the filter until it comes into contact with the
seal surface and tighten it manually by 3/4 of a turn.
1730765
D Remove the PTO engagement box.
Sensors and transmitters Converter
Figure 58 Figure 60
1730768
1730766
D Remove the input flange fastening screws.
Figure 59 D Remove the input flange with an extractor.
Figure 61
1730767
1730769
1. Tachometer signal transmitter
2. Output shaft speed sensor D Mark the relative position of the cover on the gearĆ
3. Turbine shaft speed sensor box.
4. Internal input speed sensor D Loosen the connection screws.
5. Crankshaft shaft speed sensor
Figure 62
D Remove the tachometer signal transmitter (1).
D Loosen the fastening screws and remove the senĆ
sor (2).
D Remove the sensors (3), (4) and (5).
1730770
D Remove the converter and cover from the gearbox

with a suitable lifting device.
Figure 63 Figure 65
1730773
1730771
D Use a press to extract the input shaft and the conĆ D Remove the snap ring and remove the bearing from
verter from the gearbox cover. the cover.
D Remove the input shaft speed sensor.
Figure 64
Figure 66
1730774
D Loosen the fastening screws and remove the conĆ

verter bell.
Converter counter pressure valve
Figure 67
1730772
D Loosen the fastening screws and remove the memĆ

brane from the converter.
D Turn the membrane, loosen the fastening screws
and remove the membrane from the input shaft.
1730775
D Pre-load the compression spring, remove the safeĆ

ty plate and remove the single components.
Oil pressure pump Figure 71
Figure 68
1730779
D Loosen the fastening screws and remove the cover.
1730776
D Loosen all the fastening screws and remove both Differential lock control
the oil delivery flange and the oil pressure pump
from the gearbox. Figure 72
Figure 69
1730780
1730777 D Loosen the fastening screws and detach the differĆ
ential lock control by means of suitable levers.
D Detach the oil pressure pump from the oil delivery
flange. Figure 73
Figure 70
1730781
D Remove the snap ring and remove the shim and the
1730778 grooved gear.
D Remove the stator shaft.
Drive input shaft (PTO shaft) Gearbox cover
Figure 74 Figure 77
1730782 1730785
D Turn the unit upside-down. D Remove both cylindrical pins (arrow).

D Loosen the fastening screws and remove the output
flange, then push the shaft seal out of the hole on Figure 78
the box.
Figure 75
1730786
D Loosen the screws fastening the box to the cover.
1730783 Figure 79
D Remove the shaft from the housing hole.
Figure 76
1730787
D Lift the cover from the gearbox with a suitable lifting
device and eyebolts.
1730784
D Remove the retainer snap ring and remove the four

contact ball bearing with a press.
D Remove the piston ring (arrow).
Output shaft [AB] and differential lock Shafts and clutches
Figure 80 Due to the specific installation conditions, it

is very difficult to remove each clutch withĆ
out using special tool 5870 260 010.
Be very carefully of sharp corners and
edges.
Figure 83
1730788
D Remove the output shaft.
Figure 81
1730791
D Remove the oil pipes and the piston rings (arrow).
Figure 84
1730789
D Loosen the fastening screws and remove the upper

metal guard.
Figure 82
1730792
D Fit the cover on the gearbox with a suitable lifting deĆ

vice and eyebolts.
D Fit the handles 5870 260 010 onto all the shafts so
to secure the shafts to the cover.
1730790
D Lift the differential from the housing.

D Remove the lower metal guard.
Figure 85 Figure 88
1730793 1730796
D Lift the cover with shafts and respective clutches The figure shows the arrangement of the clutches in the
from the gearbox. box cover.
AN = Input
Figure 86 KV = Forward gear clutch
KR = Reverse gear clutch
K1 = 1st gear clutch
K2 = 2nd gear clutch
K3 = 3rd gear clutch
K4 = 4th gear clutch
Figure 89
1730794
D Fasten the cover by means of the supporting tools:
- assembly trolley 5870 350 000
- retainer 5870 350 089.
Figure 87
1730797
The various clutches can be recognised by the 10 digit
ZF catalogue part number.
The part number is engraved on the front end of the reĆ
spective clutch shaft (arrow).
…. 371 … = K1
…. 372 … = K2
…. 373 … = K3
…. 374 … = K4
…. 375 … = KV
…. 376 … = KR
1730795 Follow the sequence below to remove the
clutches:
D Turn the box cover by 180°. K1; K2; K3; K4; KV, KR and AN (together).
D Remove the handles.
Figure 90 Figure 93
1730798
17307101
D Lift clutch K4 by means of suitable levers and reĆ D Lift the clutches KV and KR and remove the clutch
move the clutch K1. K4.
Figure 91 Figure 94
17307102
1730799
D Remove the clutch K2. D Remove the clutches KV, KR and the input shaft AB
at the same time.
Figure 92
Figure 95
17307100
17307103
D Remove the clutch K3.
D Remove the bearing outer rings from the box and
the cover (arrow).
The outer ring and inner ring mating must be
at least ensured by means of a suitable
marking when the taper roller bearings are
not replaced.
CLEANING, INSPECTING AND CHECKING

Cleaning components Inspecting and checking
All components must be clean to allow an efĆ

Guards and machined surfaces
fective inspection. During assembly, do not
let dust and foreign bodies inside the transĆ Inspect borings and assembly surfaces for traces of
mission. Even the smallest particles can wear, scratches and grooves:
damage accurately mated components. D Eliminate scratches and burring with sandpaper.
Use petroleum based solvents for cleaning Replace deeply scratched or grooved parts.
only, with the exception of benzene and deĆ D Check all oil pipes. Eliminate obstructions with eiĆ
rivatives. Solvents such as trichlorethylene, ther a jet of compressed air or by passing a smooth
benzol, acetone and all aromatic products wire in both direction of the pipe. Rinse with cleanĆ
may damage polyacrylic rubber seals. ing solvent.
D Check threading, rectify damaged threads with a
Accurately clean all removed parts. Follow the precauĆ used tap of the required size.
tions below: D Replace boxes or other castings which are cracked
D Accurately clean the guards, inside and out, to allow or grooved due to excessive wear.
checking and to prevent dirt from penetrating inĆ D Check all oil circuits in the control distributor and
side. main casing, looking for porosity, broken seats,
D Use solvent only to clean the clutch plates. Clean cracks, deposits of dirt and surface defects.
all other metal transmission components perfectly D Check seal resting surfaces for deformation or surĆ
with solvent or steam. Do not use caustic soda face defects.
based solutions for steam cleaning.
D Dry all components with compressed air, except for Bearings and axial shims
the bearings. Apply grease to steam cleaned comĆ Check all bearings for notches, pricking, scratches or
ponents immediately after drying. excessive wear. Replace the parts which are faulty or
D Clean oil pipes by passing a piece of soft wire in which operation is irregular after cleaning and lubricaĆ
both direction and washing with solvent. Dry the tion:
pipes with compressed air. D Inspect the bearings which present notches, burĆ
Never dry the bearings by turning them with ring, ovalisation, sharp edges or traces of overheatĆ
compressed air. A bearing which turns fast ing. Replace the damaged components.
without being adequately lubricated may D Inspect the end of stroke shims which may be deĆ
deteriorate very quickly. formed, scratched, worn or burred. Replace any
faulty or worn parts.
D Used bearings must be perfectly washed with solĆ
vent. If the bearing is very dirty or full of hardened O-rings and seals
grease, submerge in solvent before cleaning.
D Clean bearings correctly during disassembly/asĆ Check the piston rings and the lip seals for notches,
sembly for maximum duration. cuts, tears, cracks or deformation:
D A deteriorated seal may indicate the presence of
faults in piston grooves or corresponding surface.
These faults will damage the new seal.
D Replace the seals and the o-rings.
Gears, grooves and threaded parts

Check gears for localised wear, pricking, burring or
broken teeth:
D Replace the gear if faults are found;
D Check that the grooves are not deformed, chipped
or burred. Replace the gear if faults are found;
D Check for burring and damaged threads: replace
the damaged parts.
Rings and springs

Check for pricking, deformation or excessive wear on
rings. Replace the snap ring if any fault is found:
D Seek traces of overheating, permanent set or wear
due to friction on parts next to the springs. Replace
the spring if any fault is found.
Clutch plates GENERAL ASSEMBLY INSTRUCTIONS

Check the plates looking for encrusted metallic parĆ
ticles, very pricked, excessively worn, excessively taĆ Lubricants used for assembly
pered, cracked, deformed or damaged grooves. ReĆ Hold parts provisionally in place during assembly by
place the damaged plates. means of low fusion point oil soluble grease (Vaseline).
Dimensional checks Never use fibrous, insoluble or vegetable
Carry out all dimensional checks before refitting and based products in any point of the transmisĆ
check compliance. sion.
Clutches and pistons

Soak each clutch plate in transmission fluid for at least
two minutes.
Before final assembly, apply plenty of transmission fluid
in the piston cavity.
Fit the clutch plates so that they are all directed the
same way.
Lip seals
Make sure that the spring lip side is actually on the side
of the oil to be contained (towards the inside of the box):
apply high temperature resistant grease inside the seal
to protect it during shaft assembly and ensure lubricaĆ
tion at the beginning of operation.
Roller bearings
Heat the bearing on an electrical radiating plate or in an
oil bath (maximum temperature of approximately 90°C
(194°F)) to fit it on the shaft. Fit the bearing at the press.
Warm the bearings for a suitable time to obĆ
tain adequate dilatation.
Heating time depends of the dimensions of
the bearings. Approximately 45 minutes are
sufficient for the larger bearings.
Shrink-fitting
Shrink-fitting can be carried out by respectively heatĆ
ing and cooling the two parts. The female part can be
heated in an oven or oil bath (maximum temperature of
approximately 140°C (284°F), with the exception of
bearings) and the male part can be cooled in dry ice.
SUBASSEMBLY DISASSEMBLY AND ASSEMBLY

KV and KR clutch disassembly Figure 98
. The procedures for KV clutch are illustrated

below. Proceed in a similar way for the KR
clutch.
Proceed as follows:
Figure 96
17307106
D Remove the snap ring.

D Remove the terminal flange and the plate set.
Figure 99
17307104
D Replace the snap ring;

D Remove both taper roller bearing inner rings with
the specific tools:
- insert (bearing 2700) 5873 001 057
- insert (bearing 33800) 5873 001 059
- base 5873 001 000
- pressure element 5870 100 043.
Figure 97
17307107
D Use tool 5870 345 088 to load the reaction spring,

remove the snap ring, relieve the springs and reĆ
move the individual components.
Figure 100
17307105
D ðthe snap ring.

D Use an extractor to remove the plate holder drum
from the shaft.
17307108
D Use compressed air to lift the piston and remove it.

D Remove the inner and outer piston o-rings.
Figure 101 D Fit both o-rings (1) and (2) in the piston grooves
and lubricate them.
D Check operation of the drain valve (arrow). The ball
should never be jammed.
Figure 104
17307109
D Use a press to push the clutch shaft out of the interĆ

mediate gear.
Figure 102 17307112
D Fit the piston to the point of contact.

D Fit the shim, the compression spring and the resting
ring.
Fit the resting ring with the groove facing upĆ
wards.
Figure 105
17307110
D Remove the snap ring and remove the ball bearing.
KV and KR clutch assembly
. The procedures for KV clutch are illustrated

below. Proceed in a similar way for the KR
clutch.
Proceed as follows:
Figure 103
17307113
D Use tool 5870 345 088 to load the reaction spring
and insert the snap ring in the plate holder ring
shaped groove (arrow).
17307111
Figure 106
KV and KR clutches
17307114
D Fit the plates in the order shown, without lubricating them.

D Fit the first outer clutch plate (3) so that the uncoated surface is facing the piston.
D Fit the terminal flange and lock it with the snap ring (6), choosing a tentative shim.
. The drawing shows the clutch components and the respective installation position.
The components of the KV and KR clutch plates are identical.
Pos. Description Quantity Remarks

1 Plate holder drum 1
2 Piston 1
3 Outer clutch plate 1 Coated on one side
4 Outer clutch plate 10 Coated on both sides
5 Inner clutch plate 10
6 Snap ring 1 Available thickness from 2.1 to 4.2 mm
(0.08 - 0.16 in)
7 Terminal flange 1
D Play between plates: 2.7 - 2.9 mm (0.105 - 0.115 in)
. The play between plates is defined by the thickness of the snap ring (6).
Axial play test Figure 109

Proceed as follows:
Figure 107
17307117
D Refit the pawl with calibrated hole, if removed.

17307115 D Refit the stud (1) and fasten at the specified torque,
if removed.
D Arrange a dial gauge with probe on the terminal D Fit the roller bearing (2).
flange.
D Exert a force of approximately100 N (22.5 lb) on the Figure 110
flange and reset the gauge.
D Use compressed air to move the piston so that the
flange moves against the snap ring and check that
the play between plates (gauge reading) is within
the specified range.
Play between plates: 2.7-2.9 mm (0.105ć0.115 in)
D If this is not so, use a different sized snap ring.
. Available thickness of rings from 2.1 to 4.2

mm (0.08ć0.16 in).
D After checking and restoring the play between
plates, remove the plates and apply the specified luĆ
17307118
bricant. Refit the plates.
Completion D Fit the ball bearing and fasten it with the snap ring.
Proceed as follows: Figure 111
Figure 108
17307119
17307116
D Use a press to fully fit the intermediate gear.
D Align and centre the plate set with the intermediate
gear to simplify plate holder drum assembly.
D Remove the intermediate gear.
Figure 112 Figure 114
17307120 17307122
D Heat the inner hole of the plate holder drum to D Check operation of the clutch with compressed air.
approximately 120 °C (248 °F).
D Fit the previously assembly plate holder drum fully. . The opening and closing of the clutch
should be clearly heard if the components
Figure 113 are fitted correctly.
D Fit both taper roller bearing inner rings.
17307121
D Fasten the plate holder drum by means of the snap

ring.
K1, K2 and K3 clutch disassembly Figure 117
. The procedures for K3 clutch are illustrated

below. Proceed in a similar way for the K1
and K2 clutches.
Figure 115
17307125
D Lift the intermediate gear (1) by extracting it from the

clutch.
D Remove the radial roller bearing (2) and the axial
roller bearing (two ring cage).
17307123 Figure 118

the specific tools:
- insert (bearing 33800) 5873 001 059
- insert (bearing 39500) 5873 001 057
- base 5873 001 000
- base 5873 002 000
- pressure element 5870 100 043
Figure 116
17307126

from the shaft.
Figure 119
17307124
D Remove the axial roller bearing (two ring cage).
17307127
D Remove the snap ring

D Remove the terminal flange and the plate set.
17307128 17307129
D Use tool 5870 345 088 to load the reaction spring, D Fit the piston to the point of contact.
remove the snap ring, relieve the springs and reĆ D Fit the cup springs and the resting ring.
move the individual components. D Fit the resting ring with the groove facing upwards.
D Use compressed air to lift the piston and remove it. D Fit the cup spring as shown in the figure.
D Remove the inner and outer piston o-rings.
Figure 123
K1, K2 and K3 clutch assembly
. The procedures for K3 clutch are illustrated

below. Proceed in a similar way for the K1
and K2 clutches.
Proceed as follows:
Figure 121
17307130
17307111
D Fit both o-rings (1) and (2) in the piston grooves shaped groove (arrow).
and lubricate them.
Figure 124
K1 clutch
17307131


2 Piston 1
(0.08 - 0.16 in)
7 Terminal flange 1
Actual number of clutch surfaces: 18
D Play between plates: 2.4 -2.6 mm (0.095-0.105 in)
Figure 125
K2 and K3 clutches
17307132

The components of the K2 and K3 clutch plates are identical.

2 Piston 1
(0.08 - 0.16 in)
7 Terminal flange 1
D Play between plates: 1.8 -2.0 mm (0.070ć0.080 in)
Axial play test Completion

17307115 17307133
D Arrange a dial gauge with probe on the terminal D Refit the pawl with calibrated hole, if removed.
flange.
D Exert a force of approximately 100 N (22.5 lb) on the . The pawl only needs to be fitted on the K1
flange and reset the gauge. clutch shaft. K2 and K3 clutch shafts are not
D Use compressed air to move the piston so that the provided with a pawl.
D Refit the stud and fasten at the specified torque, if
removed.
Play between plates: Figure 128
K1 clutch: 2.4 -2.6 mm (0.095ć0.0105 in)
K2 and K3 clutches: 1.8 -2.0 mm (0.070ć0.080 in)

mm (0.08ć0.16 in).
17307134
D Heat the inner hole of the plate holder drum to

approximately 120 °C (248 °F).
D Fit the previously assembly plate holder drum fully.
Figure 129 Fit ring (1) with chamfer facing the cage.
All plates inside clutch K3 are certainly in
place only when the bearing ring is in conĆ
tact with the shaft collar.
Figure 132
17307135
D Fit the axial roller bearing - ring (1), cage (2) and
ring (3).
Fit ring (1) with chamfer facing the cage.
17307138
Figure 130 D For K1 and K2 clutches only: fasten the intermediate

components by means of the snap ring.
Figure 133
17307136
D Fit the intermediate gear so that all inner clutch
plates are in the correct position. 17307139
D Fit the radial roller bearing (2). D Check operation of the clutch with compressed air.
Figure 131
. The opening and closing of the clutch
are fitted correctly.
17307137
D Fit the axial roller bearing - ring (1), cage (2) and
ring (3).
K4 clutch disassembly Figure 136

Proceed as follows:
Figure 134
17307106

17307140 D Remove the terminal flange and the plate set.
D Remove the snap ring; Figure 137

the specific tools:
- insert (bearing 2700) 5873 001 057
- insert (bearing 33800) 5873 001 059
- base 5873 001 000
- pressure element 5870 100 043
Figure 135
17307107
D Use tool 5870 345 088 to load the reaction spring,

remove the snap ring, relieve the springs and reĆ
move the individual components.
Figure 138
17307141

from the shaft.
17307108
D Use compressed air to lift the piston and remove it.
17307142 17307143
D Remove the intermediate gear. D Fit the piston to the point of contact.
The shaft cannot be separated from the gear D Fit the cup springs and the resting ring.
(forced shrink-fitting). Fit the resting ring with the groove facing upĆ
wards.
K4 clutch assembly Fit the cup spring as shown in the figure.
Proceed as follows:
Figure 142
Figure 140
17307111
D Fit both o-rings (1) and (2) in the piston grooves

and lubricate them.
17307130

shaped groove (arrow).
Figure 143
K4 clutch
17307132


2 Piston 1
(0.08ć0.16 in)
7 Terminal flange 1
D Play between plates: 1.4-1.6 mm (0.055ć0.065 in).
. The clearance between plates is defined by the thickness of the snap ring (6).
Axial play test D Align and centre the plate set with the intermediate
Proceed as follows: gear to simplify plate holder drum assembly.
D Remove the intermediate gear.
Figure 144
Figure 146
17307115
17307146
D Arrange a dial gauge with probe on the terminal
flange. D Refit the stud and fasten at the specified torque, if
D Exert a force of approximately 100 N (22.5 lb) on the removed.
flange and reset the gauge.
Figure 147
D Use compressed air to move the piston so that the
Play between plates:
1.4-1.6 mm (0.055ć0.065 in)

mm (0.08ć0.16 in).
17307147
Completion
D Fit the axial roller bearing (two ring cage).
Proceed as follows:
Figure 145
. The two rings are interchangeable.
17307145
17307148
17307151
D Fit the radial roller bearing. D Fasten the plate holder drum by means of a snap
D Fit the intermediate gear. ring.
17307149
17307152
D Fit the axial roller bearing - ring (1), cage (2) and D Check operation of the clutch with compressed air.
ring (3).
Fit ring (1) with chamfer facing the cage.
. The opening and closing of the clutch
are fitted correctly.
Figure 150 D Fit both taper roller bearing inner rings.
17307150
D Heat the inner hole of the plate holder drum to

approximately 120°C (248 °F).
D Fit the previously assembly plate holder drum fully.
Input shaft disassembly Input shaft re-assembly

17307153 17307155
D Refit the o-ring from the lower ring groove (internal

D Remove the snap ring;
diameter) and lubricate it.
the specific tools: Figure 156
- press insert 5873 011 014
- base 5873 001 000
- bushing 5870 001 006
Figure 154
17307156
D Insert a snap ring in the ring groove of the turbine

shaft (arrow).
D Fit the turbine shaft so that the snap ring engages
the input shaft dent.
17307154
D If required, use a press to push the turbine off the Figure 157
input shaft.
. The turbine shaft is fastened axially by

means of a snap ring which will break during
disassembly.
D Remove the o-ring from the lower ring groove (inĆ
ternal diameter).
. The shaft cannot be separated from the gear

(forced shrink-fitting).
17307157

D Clip on the seals.
Differential disassembly Figure 161

Proceed as follows:
Figure 158
17307161
D Push the roller bearing out of the cover.

17307158
Figure 162
the specific tools:
- press insert: 5873 002 038
- base device: 5873 002 001
Figure 159
17307162
D Remove the external gear set holder.
Figure 163
17307159
D Loosen the fastening screws and remove the cover.
Figure 160
17307160 17307163
D Remove the snap ring. D Push the rubber pins away from the planet gears.
D Remove each planet gear shaft, retrieving rollers
and shims.
D Remove the sun gear and the respective shims.
Differential re-assembly Figure 166

Proceed as follows:
Figure 164
17307166
D Arrange the previously assembled planet gear set

17307164
to align and centre.
D Fit the planet gear set shaft with a press.
D Arrange the upper shim (1) (larger internal diameĆ
ter), the sun gear (2) and the upper shim (3) (smaller Pay attention to the assembly position of the
internal diameter). planet gear set shaft.
Align the rubber pin guide holes (1).
Fit the shim (3) facing the longer side of the
Align the central oil hole (2).
hub (arrow).
Figure 167
Figure 165
17307165 17307167
D Fasten the sun gear set shaft by means of the rubĆ

D Assemble the rollers and the shims on the planet
ber pin.
gear.
1 = shim (interchangeable) Insert the rubber pin to centre the respective
2 = roller shaft (arrow).
3 = planet gear
Use lubricant grease to hold the rollers in D Fit the other planet gear sets in the same way.
place.
Figure 168 Differential lock disassembly

Proceed as follows:
Figure 171
17307168
D Fit the gear set in the external gear with the long hub
side facing upwards. 17307171
Figure 169 D Loosen the fastening screws and remove the output
flange.
Figure 172
17307169
D Fit the roller bearing completely and fasten it by

means of the snap ring. 17307172
Figure 170 D Remove the shaft seal and remove the snap ring.
Figure 173
17307170
D Apply LOCTITE thread locker to the cover fastening 17307173

screws.
D Fasten the differential cover and fasten the screws D Remove the output shaft using a plastic hammer.
at the specified torque.
17307177
17307174
D Push the ball bearing out of the shaft with a press. D Loosen the fastening screws and remove the pins
and the control fork.
Figure 175
Figure 178
17307175
17307178
D Push the oil delivery ring out of the shaft with a
press. D Remove the switch and the lock pin.
17307179
17307176
D Loosen the fastening screws and remove the conĆ
D Remove the sliding sleeve. trol device components.
Differential lock re-assembly Figure 182

Proceed as follows:
Figure 180
17307182
D Fit the seal.

17307180 D Fit the cylinder completely.
D Fasten the screws at the specified torque.
D Fit the spring cup and the compression spring.
Figure 183
Figure 181
17307181 17307183
D Refit the o-ring in the switch ring groove and lubriĆ
D Refit the o-ring in the piston ring groove and lubriĆ cate it
cate it. D Fit the switch and the lock pin. Fasten the screw at
D Fit the piston. the specified torque.
Pay attention to the radial position of the pisĆ Figure 184
ton. The lock pin contact surface must face
the guide hole (arrow).
17307184
D Refit the o-ring in each pin ring groove and lubriĆ

cate it.
D Fasten the transmission fork by means of the pins
and fasten the screws at the specified torque.
17307185 17307188
D Fit both sliding rebounds (arrow) and fit the sliding D Fit the output shaft (fitting the sliding sleeve at the
sleeve. same time) then fit it completely.
17307186
D Push the oil delivery ring in completely.
Figure 187
17307189
D Fasten the output shaft by means of the snap ring.

Be very careful to the radial position of the
seal.
The oil hole (arrow) must be free.
17307187
D Push the ball bearing in completely.
17307190
17307193
D Fit the bushing and the intermediate washer.
D Blow compressed air to move the sleeve: the resistĆ
Figure 191 ance value (measured with a multimeter) should
change if the switch is intact.
Figure 194
17307191
D Apply LOCTITE thread locker to the fastening

screws. 17307194
D Fasten the bushing arranging the washers in beĆ
tween and fasten the screws at the specified torque. D Insert the membrane in the guide hole (arrow) and
install the metal mesh filter.
Figure 192 1 = membrane
2 = metal mesh filter
Figure 195
17307192
D Use pad 5870 048 237 to fit the shaft seal with the
lip (detail) facing inwards. 17307195
Different seals can be used according to the
version: D Lubricate the o-ring and fit it in the ring groove (arĆ
- rubber coated external diameter: dampĆ row).
en with alcohol.
- metallic external diameter: apply LOCĆ
TITE 574 sealant.
Oil pressure pump disassembly Oil pressure pump re-assembly

17307196
D Loosen both fastening screws and remove the cam

plate.
Replace the pump unit if signs of wear apĆ
pear.
Figure 197
17307198
D Fit the roller bearing components in the order

shown.
D bearing front ring and external ring.
Figure 199
17307197
D Remove the snap ring (1) and remove the seal (2)
and the roller bearings (3).
17307199
D Carefully fit the seal completely, with the lip facing

downwards, then fasten it with the snap ring.
Dampen the external diameter of the seal
with alcohol.
17307200 17307203
D Fit the o-ring in the ring groove (shown by the arĆ

D Fit the external rotor.
row) and apply oil to it.
The chamfer (arrow) should be facing
downwards. Gearbox cover preparation
Figure 204
Figure 201
17307201
17307204
D Fit the internal rotor.
D Fit M8 and M12 studs applying LOCTITE 243 thread
The dent (arrow) should be facing upwards. locker if removed and fasten at the specified torque.
Figure 205
Figure 202
17307202 17307205
D Fit the cam plate and fasten it in radial direction by D Fit new o-rings on the threaded sleeve (1) and on
means of two screws. the threaded bushing (2), then fasten at the speciĆ
Do not tighten the screws. Fasten them by fied torque.
hand until they come into contact and loosĆ
en them by approximately half a turn.
Respect the assembly position of the cam
plate shown in the figure.
GEARBOX AND GEAR ASSEMBLY

Proceed as follows: The outer ring and inner ring mating must be
at least ensured when the taper roller bearĆ
Oil pipes ings are not replaced.
Respect the marking made during disasĆ
Figure 206 sembly.
Figure 207
17307207
Gearbox side
Figure 208
17307206
D Fit the oil pipe using the following special tools:

Tool: 5870 600 003
Tool: 5870 600 004
Tool: 5870 600 005
1 = oil intake
2 = pressurised oil delivery
3 = lubrication oil delivery
Drive input shaft (AN) and clutches

D Fit the external rings of all taper roller bearings in
17307208
their housings on both halves of the box.
D Refer to the following figures for the fitting position.
AN = Input Box cover side
KV = Forward gear clutch
KR = Reverse gear clutch Follow the sequence below to refit the
K1 = 1st gear clutch clutches:
K2 = 2nd gear clutch KV, KR and AN (together), K4, K3, K2, K1.
K3 = 3rd gear clutch
K4 = 4th gear clutch
AB = output
17307209 17307212
D Fit the box cover, the KR clutch, the AN input shaft D Arrange the K2 clutch.
and the KV clutch at the same time.
Figure 213
Figure 210
17307213
17307210
D Lift the K4 clutch and arrange the K1clutch.
D Lift the AN input shaft and position the K4 clutch. D Install, lubricate and align the seals.
17307211
17307214
D Refit the K3 clutch. D Fit the handles 5870 260 010 onto all the shafts so
to secure the shafts to the cover.
17307217
17307215
D Fit the previously assembled differential in the exterĆ

D Turn the box cover upside-down.
nal bearing ring.
D Use a suitable lifting device and eyebolts to fit the
cover on the box making the shaft bearings come Figure 218
into contact with the respective external rings.
D Remove the handles.
D Remove the cover from the gearbox with a suitable
lifting device and ey.
Drive output shaft (AB)
Figure 216
17307218
D Fit the upper metal guard and fasten both guards by

tightening the screws at the specified torque.
Box cover
Figure 219
17307216
D Fit the lower metal guard.
17307219
D Fit the new o-rings in the ring grooves of both oil

pipes.
D Fit both oil pipes in the gearbox (arrow).
D Install, lubricate and align the seals.
17307220 17307223
D Check smooth gear mechanism operation with the
D Apply LOCTITE 574 sealant on the assembly surĆ
hub 5870 345 089 and the handle 5870 280 007.
face making sure it is applied inside the holes (deĆ
tail). Correct interference of mobile parts (for exĆ
ample on the guard or on the oil pipes).
Figure 221
D Repeat the operation on all clutch shafts.
Figure 224
17307221
D Use a hoist to carefully fit the box cover on the gearĆ
box putting the parts into contact. 17307224
Make sure both oil pipes are aligned with the
holes on the gearbox cover. D Fasten the box cover and fasten the screws at the
specified torque.
Figure 222 Pay attention to the assembly position of the
fastening plate and clutch converter valve
support bracket (arrow).
17307222
D Fit both cylindrical pins in central position on the asĆ

sembly face (arrow).
Drive input shaft (PTO shaft) Figure 227
Figure 225
17307227
D Fit the pump shaft until it comes into contact.
17307225
Figure 228
D Push the internal bearing half ring in completely.
The ball bearing presents four contact
points.
D Fit the outer ring and cage.

D Push the internal bearing half ring in completely.
Figure 226
17307228
D Fasten the pump shaft by means of the snap ring.
Figure 229
17307226
D Fasten the bearing by means of the snap ring.

D Check that the axial play of the bearing is within the
specified range:
axial play 0.0-0.05 mm (0.0ć0.002 in)
D Use a ring with a different thickness if this is not so.
D Install, lubricate and align the seals (arrow).
17307229
D Fit the o-ring (arrow) in the oil delivery cover
groove.
D Fit the oil delivery covers fastening the nuts at the
specified torque.
PTO Figure 233
Figure 230
17307233
D Push the ball bearing in completely with a press.

17307230
Figure 234
D Apply grease to the o-ring and fit it.
Figure 231
17307234
17307231 D Fit the output shaft until it comes into contact.
Figure 235
D Fit the PTO box and fasten the nuts at the specified
torque.
Differential
Figure 232
17307235
D Fasten the output shaft by means of the snap ring.
17307232
D Use pad 5870 058 023 and extension 5870 260 002
to carefully push the roller cage into the output shaft
completely.
D Lubricate the cage.
17307238
17307236
D Use pad 5870 048 237 to fit the shaft seal with the D Insert the output flange until it comes into contact.
lip facing the oil sump.
Figure 239
. Different seals can be used according to the
version:
- rubber coated external diameter: dampĆ
en with alcohol.
- metallic external diameter: apply LOCĆ
TITE 574 sealant.
Figure 237
17307239
D Fit the o-ring (arrow) in the space between the outĆ

put flange and the shaft.
Figure 240
17307237
D Insert the fastening seals and fit the retainer plate by

pressing on it with tool 5870 506 142.
17307240
D Fasten the output shaft by means of the washer (1)

and tightening the fastening screws (2) at the speciĆ
fied torque.
D Then fasten the screws by means of the safety
washer.
17307244
D Fit the previously assembled differential lock control
Converter counter pressure valve
17307241 Figure 245

D Align both thrust washers of the sun gear set so that
they are centred.
Figure 242
17307245
D Fit each component in the order and direction
shown and fasten them by means of the safety
plate.
17307242 Fit the pressure plate (arrow) with the 6 mm
D Fit the hollow shaft completely. (0.235 in) diameter part facing the safety
plate.
Figure 243
17307243
D Fit the previously assembled differential lock control
Oil pressure pump Figure 249
Figure 246
17307249
D Fit the previously assembled pump completely usĆ

17307246 ing the three fastening screws.
D Fit two guide screws 5870 204 011 and fit the seal. Pay attention to the radial position.
Use lubricating grease to facilitate assemĆ
bly. D Remove the fastening screws.
17307247
D Fit the oil pressure pump housing.
Figure 248
17307250
D Fit new o-rings in the fastening screws (arrow) and

lubricate them.
D Fasten the oil pressure pump to the gearbox fastenĆ
ing the screws at the specified torque.
D Fasten the oil pressure pump housing to the gearĆ
box fastening the screws at the specified torque.
17307248
D Fit the two guide screws and fit the stator shaft.
Pay attention to the radial position.
Converter Figure 253
Figure 251
17307253
17307251 D Fit the ball bearing and fasten it by means of the

seal.
D Fasten the converter bell to the gearbox fastening
Figure 254
the screws at the specified torque.
Figure 252
17307254
D Arrange the box cover on the converter and push it

in completely.
Figure 255
17307252
D Fasten the membrane to the input shaft fastening
D Apply LOCTITE 262 thread locker.
D Fasten the membrane to the converter and fasten
17307255
D Insert the input flange until it comes into contact.

D Fasten the shaft by means of the washer (1) and
tightening the fastening screws (2) at the specified
torque.
D Then fasten the screws by means of the safety
washer.
17307256
17307258
D Install, lubricate and align the seal (arrow). D Fit the seal.
D Fit the cover and fasten the screws at the specified
Figure 257 torque.
17307257
D Use a suitable lifting device to install the converter

so that the cover fits completely on the converter
bell.
Respect the markings made during disasĆ
sembly (arrow).
D Fasten the cover to the converter bell fastening the
bolts at the specified torque.
Sensors and transmitters Figure 261
Figure 259
17307261
D Fit the breather (arrow) if removed and tighten at the

17307259
specified torque.
D Fill the gearbox with the specified amount of lubriĆ
cant to the oil gauge level.
Figure 260 D Use a suitable lifting tool to remove the gearbox
from the supporting equipment and arrange it on a
suitable platform.
17307260
1. Tachometer signal transmitter

2. Output shaft speed sensor
3. Turbine shaft speed sensor
4. Internal input speed sensor
5. Crankshaft shaft speed sensor
D Fit new o-rings on the sensors and lubricate them.

D Fasten the sensor (2) and fasten the screws at the
specified torque.
D Tighten the sensors (3), (4) and (5) at the specified
torque.
D Apply LOCTITE 574 thread locker and fasten the
tachometer signal transmitter (1) at the specified
torque.
SECTION 10
PROPELLER SHAFT
ADT 25 SECTION 10 PROPELLER SHAFTą1
CONTENTS
Page Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Shaft disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Crosshead disassembly . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . 5
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL-REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL-REFIT INTERMEDIATE SHAFT . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIFIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . 9
General the propeller shaft joints . . . . . . . . . . . . . . . . 9
2ąPROPELLER SHAFT SECTION 10 ADT 25
DESCRIPTION
The vehicle transmission line consists of the following: The shafts are all of the telescopic type, with a shank
A. a propeller shaft between the engine and the that has a grooved coupling that slides in the seat inĆ
gearbox side the actual shaft: this permits a certain variation in
B. a double universal joint between the gearbox and the length of the shaft, caused by the movement of the
the front axle movement output and input units.
C. a propeller shaft between the gearbox and interĆ Furthermore, each shaft has two universal joints inĆ
mediate axle, divided into three sections and fitted stalled one on each end, that allow the rotation of the
with two intermediate supports ends with a certain degree of inclination and ensure the
D. a propeller shaft between the intermediate axle homogeneity of the rotation (no angular speed pulsing)
and the rear axle between the movement input and output.
Figure 1
1 2
A
4
B
3 C
C
5 D 6
1731009
1. engine
2. gearbox
3. front differential
4. transfer
5. intermediate differential
6. rear differential
DIAGNOSTIC
1. Vibration or noise
2. Excessive wear of mounts
Vibration or noise Deformed drive shafts Clean the transmission. Check conĆ
tact with surrounding elements. ReĆ
place propeller shaft if deformed
Incorrectly balanced drive train Remove transmission and dynamiĆ

cally balance unit
Mounts worn Replace all transverse units with the

mounts if loose
Insufficient part lubrication Lubricate by means of the specific

grease dispensers
Excessive wear of mounts Deformed drive shafts Clean the transmission. Check conĆ
tact with surrounding elements. ReĆ
place propeller shaft if deformed
Flange fork badly aligned and/or Check alignment, offset and balĆ
fork offset ance of fork/flange. Repair or reĆ
place, if required
Transmission not balanced Check transmission and replace it if

it is worn; check balance of unit and
balance it, if required
TIGHTENING TORQUE
Screws fastening CV joint to propeller shaft-gearbox (A): 67 Nm ( 49 lb ft)
Propeller shafts CV joint plate fastening screws
(excluding propeller shaft-gearbox) (B): 155 Nm (114 lb ft)
Intermediate shaft journal fastening nuts (C): 600 Nm (442 lb ft)
Screws (A) and (B): apply Loctite thread locker 242

Screws for nuts (C): apply Loctite thread locker 270
Figure 2
B C B
A
B C B
A B C
1731007
REMOVAL-REFIT
Before starting any operation, make sure Figure 3
that all necessary precautions have been
taken and all aspects have been made clear
regarding the safety of those involved in the
operation.
1.2 of this handbook.
If in doubt consult someone with more exĆ
perience.
Removal
For the removal proceed as follows:
switch off the engine, remove the ignition key, enĆ 1731002
boards. D unscrew the two screws that fasten the universal
joint crosshead plate to the shaft on both sides of
The disassembly of the transmission line beĆ
the joint;
tween the gearbox and the intermediate axle
D repeat the operation from the other side of the shaft,
renders the parking brake out of action.
then withdraw the shaft, cautiously lowering the liftĆ
In his case place suitable chocks under the
ing unit;
wheels in both travel directions to avoid unĆ
controlled movement of the vehicle during Figure 4
the disassembly operations.

battery terminals to avoid any risk of short circuits;
D use a suitable hydraulic jack to support the shaft to
be removed;
D make a reference mark on the parts to be removed;
1731003
D if necessary remove the two screws from the reĆ

maining sides of the joint that fasten the universal
joint crosshead securing plate.
Refit
To refit follow the removal operations in reverse:
. Check that the reference marks made beĆ

fore removal match perfectly.
Shaft disassembly Checks

When overhauling it is advisable to make a static and
Figure 5 dynamic check on the propeller shaft as follows:
D place the propeller shaft on the equipment to check
the centring;
D rotate the shaft, and using a zeroed centesimal dial
gauge, check that in the centre part the eccentricity
is within the specified values:
maximum eccentricity: 0.5 mm (0.02 in)
D if this is not the case, have the shaft straightened
with the specific specialised equipment.
Figure 7
1731000
D disassemble the shaft into the two parts and take off
the sealing gasket.
Crosshead disassembly
Figure 6
1731006
D Use a ruler to check that the alignment of the crossĆ

head mounting plate seats alignment is within the
specified values:
maximum misalignment: 0.2 mm (0.01 in)
D Do not remove the plates welded onto the shaft: if
they are removed or missing have the shaft balĆ
anced by means of the specific specialised equipĆ
ment.
D Check that the shaft grooves have no signs of
1731005
knocks, deformation or wear.
D Check that the crosshead is intact and that the cage
D Remove all the plates and remove the crosshead.
tracks are not scored.
D Remove the stop rings and take out the roller cages
from the crosshead. Do not use damaged or unbalanced shafts
which would cause dangerous vibrations for
Reassembly the vehicle and to avoid the breaking of the
D Reassemble in the reverse order to the disassemĆ shaft, which is also a personal hazard.
bly.
D Carefully lubricate all the roller bearings before asĆ
sembling.
D Lubricate the grooved coupling of the shaft.
REMOVAL-REFIT INTERMEDIATE SHAFT

Before starting any operation, make sure D cut off the battery isolator switch or disconnect the
that all necessary precautions have been battery terminals to avoid any risk of short circuits;
taken and all aspects have been made clear D lock knuckle with the steering lock bar following the
regarding the safety of those involved in the instructions in SECTION 1.2;
operation. D use a suitable hydraulic jack to support the shaft to
Read the relevant instructions in SECTION be removed;
1.2 of this handbook. D make a reference mark on the parts to be removed;
If in doubt consult someone with more exĆ D Loosen the two screws fastening the CV joint spider
perience. to the shaft on both sides of the input joint (1) and
lower the extremity of the input shaft.
Removal D Repeat the operation on the output joint side (2).
D Remove the nuts fastening the front (3) and rear (4)
For the removal proceed as follows: intermediate shaft journal and remove the shaft by
D bring the vehicle onto a suitable flat, solid surface, lowering it carefully with the lifting device.
gage the parking brake and apply the warning signĆ Refit
boards.
To refit follow the removal operations in reverse:
The disassembly of the transmission line beĆ
Check that the reference marks made beĆ
tween the gearbox and the intermediate axle
fore removal match perfectly.
renders the parking brake out of action.
In his case place suitable chocks under the
wheels in both travel directions to avoid unĆ
controlled movement of the vehicle during
the disassembly operations.
Figure 8
1 3 4 2
1731010
SPECIFIC MAINTENANCE
Greasing the propeller shaft joints . Two or three shots are sufficient to guaranĆ
The cardan joints and the supports are fitted with greaĆ tee proper lubrication.
sers.
Proceed as follows:
Remove the pebble guard cover to get at the lower part
D clean the relevant union;
of the gearbox output shaft and its supports (detail).
D inject the specified grease into the unions indicated.
Only use a hand pump for greasing, never a high presĆ
sure greaser.
Figure 9
174NM75
SECTION 12.1
FRONT AXLE
ADT 25 SECTION 12.1 ąFRONT AXLEą1
CONTENTS
Page Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Axle-hinge strip down . . . . . . . . . . . . . . . . . . . . . . . . 16
First reduction: bevel gear pair . . . . . . . . . . . . . . . . . . 4 Re-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Second reduction: hub and epicyclic train . . . . . . . . 8 SPECIFIC MAINTENANCE . . . . . . . . . . . . . . . . . . . 18
SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . . 9 Checking axle/transfer case oil level . . . . . . . . . . . . 18

Changing axle/transfer case oil . . . . . . . . . . . . . . . . 19
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
EPICYCLICAL REDUCTION GEAR . . . . . . . . . . . . 20
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
EPICYCLICAL REDUCTION GEARS . . . . . . . . . . . . 12
Checking the dismantled parts . . . . . . . . . . . . . . . . . 24
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Re-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
EPICYCLICAL REDUCTION GEARS . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
AXLE REMOVAL-REFIT . . . . . . . . . . . . . . . . . . . . . 13
Break-down drawing of self-locking differential . 37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Break-down drawing of pinion . . . . . . . . . . . . . . . . 38
Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Re-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Knuckle hinge strip down . . . . . . . . . . . . . . . . . . . . . 15
Re-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2ąFRONT AXLE SECTION 12.1 ADT 25
DESCRIPTION
The axle is a dual reduction bearing type. mountings to connect to the chassis and housings for
It consists of a box type structure that contains the the bearings, as well as the brake calliper mounting
bevel gear pair with the differential, the axle shafts and flange.
hubs with the end reduction. The structure has
Figure 1
1891201
1. Axle
2. Suspension cylinder attachments 1891201
3. Driving torque input flange
4. Brake calliper
5. Swivel hinge support
6. Swivel pipe
7. Support securing bracket on axle
First reduction: bevel gear pair

The first reduction is obtained by the pinion -ring bevel The differential gear box with ring bevel gear is
gear assembly (bevel gear pair) inside the differential. supported by two taper roller bearings mounted in O
The pinion is supported by two taper roller bearings arrangement with the pre-load and axial position that
mounted in X arrangement with the pre-load and axial can be adjusted by two opposed ring nuts.
position that can be adjusted by shims.
Figure 2
3
4
16
5 A
15 6
13
B
12 11 10 9 8
1.731.213A 1.731.213B
1. Input flange 11. Differential gear carrier shaft

2. External taper roller bearing 12. Side pinion
3. Internal taper roller bearing 13. Crown wheel
4. Bevel pinion 14. LH adjustment ring nut
5. Ring bevel gear 15. LH taper roller bearing
6. RH taper roller bearing 16. Differential gear box (version A)
7. RH adjustment ring nut 17. Adjustment shim for pinion axial position
8. Differential gear box (version B) 18. Pinion bearings pre-load adjustment ring
9. Multi-disk clutch
10. Pressure plate (version B) A: differential standard version
B: differential self-locking version
The differential is self-locking. coefficient and thus holds the braking torque constant
It has a multiple disk clutch inserted between the for the whole useful life of the differential.
differential gear box (train carrier) and the crown The thrust on the disks is ensured by the sloped
wheels on each side. contact between the shaft and the pressure plate:
The multiple disk clutch includes the external disks therefore a greater radial peripheral thrust on the train
connected to the differential gear box and internal carrier shaft (from the ring bevel gear) will cause a
disks connected to the crown wheel gears by greater axial thrust on the disks.
appropriate pressure plates. The thrust on the disks generates a stall torque that
The internal disk friction surfaces have a patented acts on the crown wheel.
molybdenum coating that ensures a constant friction
Figure 3
1731214
1. Crown wheel
2. Differential gear box
3. Differential cover
4. Crown wheel gear
5. Side pinion
6. Differential gear carrier shaft
7. Bevel pinion
8. Pressure plate (quantity: 2)
9. Multiple disk clutch ć external disk
10. Multiple disk clutch ć internal disk
11. Shoulder
12. Pressure plate rings sloped surfaces
Operation Under these conditions there is no relative motion

The driving torque coming from the propeller shaft is between the two crown wheels and therefore the side
transmitted by a universal joint to the bevel pinion. pinions do not turn around their shaft which is integral
From here the torque passes to the ring bevel gear, to the differential gear box.
which is integral to the differential gear box. When the resistance of one wheel is greater than that
The differential is a gear for which the box represents of the other, or when the speed of the two wheels is not
the train carrier, that carries the differential gear carrier the same (vehicle on a road with bends) the crown
shafts and receives the driving torque, whereas the two wheel gears have a different rotation speed: the
side gears, which represent the crown wheels, both of relevant motion is permitted by the side pinions, that
which rotate, receive the driving torque and transmit it now turn around their shafts in directions opposite to
to the axle shafts. each other.
When both wheels are subject to the same stall torque Obviously at a lower crown wheel rotation speed the
or have the same speed (vehicle being driven on a transmitted driving torque is greater, and vice versa.
straight road), the ring bevel gear and the differential Therefore when the differential is operating, the wheel
gear box rotate as one, transmitting the torque in equal with a lower speed can transmit a greater torque,
parts to the two crown wheels, and from here to the two whereas the wheel with a higher speed can transmit a
axle shafts, that rotate at the same speed: the wheels lower torque.
transmit the same driving torque. Under certain conditions it may happen that the slower
wheel loses its grip completely, since the torque is
Figure 4 exceeded that can be transmitted to the ground, and
therefore meets practically no resistance: in this case,
the standard differential causes the wheel that slips to
freewheel, and stops the wheel that still has grip: the
axle traction is reduced to nothing.
To avoid this problem the self-locking differential is
used, which can generate a stall torque on each crown
wheel, which is no longer free to rotate in relation to the
differential gear box, but is braked in proportion to the
torque that the differential is to transmit.
This stall torque , that depends on the thrust applied to
the multiple disk clutch, always has a fixed ratio with the
input torque, that is called the locking ratio".
The locking ratio is the maximum difference between
the transmittable torque on the two axle shafts, in
percentage.
1731215
Right wheel with road grip the same as the left one
IN: driving torque input

DX: RH side: torque delivered 50% of total
SX: LH side: torque delivered 50% of total
If the two wheels do not have the same grip, the stall In fact, the multiple disk clutches automatically
torque generated by the multiple disk clutches partially compensate the grip variations of the wheels from the
locks the crown wheel on the side with less grip and left and right sides of the vehicle, without the need of
increases the torque delivered by the crown wheel on any operation on the part of the driver. It is therefore
the side with stronger grip. In other words, the braking possible to apply a much higher driving force during
torque replaces the reaction torque that is lacking on the use of the vehicle, and avoid slipping when one of
the side of the wheel with less grip. the wheels runs on a surface with poor grip.
In this way, looking at the example given beforehand of For example, with a locking ratio of 45%, 72.5% of the
a wheel that loses grip, this can no longer freewheel driving torque may be transferred to a rear axle shaft
and therefore the other wheel will still be able to (instead of 50% as in normal cases), whereas the other
transmit part of the driving torque, ensuring at least in axle shaft only receives 27.5%.
part the axle traction. The differential effect produced when steering the
vehicle is caused by an overlay of the effect coming
Figure 5 from the difference in the wheel speeds at the locking
action depending on the load.
1731216
Right-hand wheel with less grip than the left one

(example)

DX: RH side: torque delivered 27,5% of total
SX: LH side: torque delivered 72,5% of total
Second reduction: hub and epicyclic train

The second reduction is obtained by an epicyclical The hub is supported by two taper roller bearings
reduction unit with cylindrical wheels contained in the mounted in O arrangement with a pre-load that can be
wheel hub. adjusted by a ring nut. The side pinion gears rotate on
pivoting roller bearings.
Figure 6
8 9 10 12 15
6 4 3 2
1.731.217A 1731217B
1. Axle Operation
2. Hub support The driving torque coming from the differential is
3. Internal taper roller bearing transmitted through a floating axle shaft to the crown
4. External taper roller bearing gear by means of a grooved shank.
5. Wheel mounting bolt
The four side pinion gears rotate in the opposite
6. Epicyclic train crown gear
direction to the crown gear, whereas the crown wheel
7. Pivoting roller bearing
is integral to the hub support and therefore does not
8. Epicyclic train carrier
9. Epicyclic train side pinion gear turn. This makes the train carrier turn in the opposite
10. Epicyclic train crown gear direction to the side pinions, therefore in the same
11. Grooved shank connecting axle shaft-crown direction as the axle shafts.
wheel Since the train carrier is integral to the wheel hub, the
12. Hub wheel turns in the same direction as the axle shaft.
13. Brake disk
14. Seal ring
15. Axle shaft

AXLES ZF AP9 / HK
Drive wheel configuration 6x6
Type Bearing with double reduction
Transversal differential lock-type Slip limited
Locking factor 100%
Axle shaft type Full floating
Bearings for bevel pinion 2, with taper rollers
Bearings pinion 2, with taper rollers
Reduction ratio 1 : 3.44
Epicyclic reduction gear ratio on the wheels 1 : 6.35
Total reduction ratio (differential + hub) 1 : 21.85
Bevel pinion bearings rolling torque adjustement 1.5-2.3 Nm 1.1-1.7 lb ft
Differential housing bearing rolling torque 0.3-0.4 Nm 0.22-0.3 lb ft
Backlash adjustments Through ring nuts
Backlash between pinion and crown wheel 0.25-0.30 mm 0.0098-0.0090 in
DIAGNOSTIC
1. Vibrations
2. Continuous noise
3. Noise when accelerating
4. Noise when decelerating
5. Noise when cornering
6. Harsh knocks when accelerating or decelerating
7. Lubricant leakage
Vibrations Broken and/or damaged gear Replace damaged gear and gear
teeth meshing with it
Wheels not fitted correctly Remove wheels and refit them corĆ
rectly
Satellite gear set or flange box exĆ Remove, repair or replace the
cessively offset faulty component
Continuous noise Missing lubrication Restore level
Differential/hub/wheel bearing Replace damaged and/or worn

worn components
Broken and/or damaged gear Replace damaged gear and gear

Noise when accelerating Pinion-crown clearance not corĆ Adjust

rect
Noise when decelerating Pinion-crown clearance not corĆ Adjust

rect (excessive)
Bearings damaged Replace bearings
Satellite gear set axial backlash exĆ Adjust

cessive
Noise when cornering Incorrect operation of self-locking Use suitable oil with anti-slipping
differential additives
Satellite gear set or planet gear set Replace the gears

worn
Satellite gear set axis worn and/or Replace satellite gear set
damaged
Harsh knocks when accelerating Imperfect gear adjustment Adjust

or decelerating
d l ti
Anchoring structure pin clearance Replace the parts
excessive
Structure anchoring to chassis Fasten the screws at the specified

loose torque
Lubricant leakage Oil seals worn Replace seals
Nuts or bolts loose Fasten the nuts or bolts at the

specified torque
Box cracked Repair or replace the box
TIGHTENING TORQUES
AXLE
1. Nut fastening bracket to rocker arm and to axle 470 Nm (346 lb ft)
2. Side vertical screws fastening rocker arm to axle 600 Nm (442 lb ft)
3. Rotating hinge cap fastening nuts 525 Nm (387 lb ft)
4. Journal bushing guide sleeve fastening screws 115 Nm ( 85 lb ft)
5. Screws fastening reaction arm pin to chassis 255 Nm (188 lb ft)
6. Screws fastening reaction arm pin to axle 255 Nm (188 lb ft)
7. Short horizontal screws fastening rocker arm to axle 600 Nm (442 lb ft)
8. Long horizontal screws fastening rocker arm to axle 530 Nm (391 lb ft)
1891205
1891207
1891203
EPICYCLICAL REDUCTION GEARS

Hub support mounting screws: 460 Nm (338 lb ft)
Brake disk mounting screws: 295 Nm (217 lb ft)
Ring nut securing internal toothed wheel flange: see values given for the different versions
in the reduction unit overhaul chapter
Oil drainage/level cap: 150 Nm (110 lb ft)
Differential gear carrier plate mounting screws 190 Nm (140 lb ft)
Brake calliper mounting screw: 295 Nm (217 lb ft)
DIFFERENTIAL
Motion input flange mounting nut: 600 Nm (441 lb ft)
Bolts securing ring bevel gear to differential half-box: 125 Nm ( 92 lb ft)
Calibrated bolts securing differential half-boxes: 110 Nm ( 81 lb ft)
Screws securing differential bearing support caps: 295 Nm (217 lb ft)
Oil level cap 150 Nm (110 lb ft)
Oil drainage cap 150 Nm (110 lb ft)
TOOLS

5870 350 000: assembly trolley
5870 350 055: securing equipment
5870 656 005: Wrench for crown nut on hub support.
5870 912 012: Reaction brackets (to be used with 5870 656 005)
5870 610 001: Wheel fastening stud assembly (to be used with 5870 610 002)
5870 610 002: Wheel fastening stud assembly
5870 050 009: Hub bearing outer ring assembly pad on wheel side
5870 050 003: Hub bearing outer ring assembly pad on axle side
5870 260 004: Guiding handle for pads
DIFFERENTIAL
5870 024 004: Extractor to remove differential bearing inner track (differential side)
5870 024 005: Extractor to remove differential bearing inner track (crown side)
5870 405 003: Riveting kit complete
to use only with drill 5870 101 007
5870 240 002: Pinion motion input flange locking tool.

5870 026 000: Basic kit to remove inner track of internal bearing from bevel pinion
to be used with extractor 5870 026 014
5870 500 001: Pinion axial position measuring shaft

5870 500 006: Pinion axial. position measuring flange o.d. 120 mm (4.72 in).
5870 058 073: Internal pinion external bearing track assembly plug
5870 340 001: Thickness gauge ring to measure pinion bearing preload spacer
5870 055 074: Pinion seal ring assembly plug
AXLE REMOVAL-REFIT
. Before starting any type of operation make D disconnect the central lubrication system unions
(arrow);
D raise the vehicle to have the wheels off the ground,
then place two supporting trestles under the front
chassis, without touching the axle (1);
D remove both wheels following the instructions in
1.2 of this manual.
SECTION 13.1;
If in doubt, contact someone with more
D put under the front axle place an appropriate
experience.
hydraulic jack that allows lowering at removal;
Always observe all the general
recommendations to carry out maintenance
jobs correctly. Figure 7
Removal
switch off the engine, remove the ignition key,
engage the parking brake and apply the
maintenance in progress" signboards.
circuits;
1891208
D remove the double transmission joint (10) as

described in Section 10;
D disconnect the braking system hydraulic union (20);
D unlock the bolts (a) of both suspension cylinders
(15) put aside the washers (12), bushings (13) and
pin (14);
D unlock the mounting screws (b) on both sides and
remove the pin (16) that connects the ball joint to the
rotation hinge mounting;
D very carefully lower the axle with the knuckle hinge.
Refit
To refit follow the removal operations in reverse order.
Figure 8
1731203
Figure 9
1731204A
Knuckle hinge strip down

To strip down, proceed as follows: Re-assembly
D place the axle with the knuckle hinge on an To reassemble follow the removal operations in reverse
appropriate stand, order.
D support the knuckle hinge (2) with a suitable
device;
D unlock the two pairs of mounting nuts (c), remove
the hinge cap (4), the bushing (5) and associated
rings, then take out the hinge;
Figure 10
1731205
Axle-hinge support strip down Re-assembly

To strip down, proceed as follows: To reassemble follow the removal operations in reverse
D loosen the screws (1) securing bracket (21) to order.
rotating hinge support (3);
D loosen the screws (m) securing the suspension
cylinder attachments (22) and remove the
attachments;
D loosen the screws (d) securing the rotating hinge
support (3) and the axle (1) and remove the support
from the axle;
D loosen the securing screws (h) and remove the
bushing guide pipe (23) from the support (3);
D on both sides unscrew the securing screws (e) of
the pin (7) that connects the ball joint to the chassis.
Remove both chassis-support connecting rods
(6). Put aside the bushings (8);
D remove the spring washers (f) and take out the ball
joints (9) from both ends of each connecting rod;
D unscrew the securing screws (g) and remove the
flanges (24) from the chassis..
Figure 11
1891210
Figure 12
1891211
SPECIFIC MAINTENANCE
Checking axle/transfer case oil level Figure 15
Proceed as follows:
D move the reference mark of a hub to the horizontal
position;
Figure 13
156NM81
D check that breather (3) is perfectly clean and

working.
156NM80B
D clean the cap area and open cap. Lubricant should
drip out of the hole;
D if necessary, top up the level as indicated in the next
paragraph;
D close the filler cap and fasten at the specified
torque;
. Simply check one of the transfer cases on

each axle.
Figure 14
156NM80A
. Do not use the centre cap on the differential

(2) for the check.
Changing axle/transfer case oil Filling
Collect and dispose of used lubricants and Figure 18

fluids, according to the laws in force.
. It might make operations easier to remove

both wheels from the axle involved.
Proceed as follows:
Dumping
Figure 16
156NM123
D fill partially with the specified lubricant until it
overflows from the filler cap hole (b), then replace
the seal, apply sealant paste on the cap and tighten
it to the specified torque;
Figure 19
156NM82A
D transfer cases: take the drain cap on one hub to the
lowest position;
D arrange a suitably sized container, clean the cap
areas and remove the cap; drain all the lubricant;
D repeat the procedure on the other hub;
Figure 17
156NM80B
D bring the reference mark on a hub to the horizontal
position, fill with the remaining amount of lubricant
until it overflows from the cap hole;
D Close the cap, do a test run and recheck the level,
topping up if necessary until it overflows;
D Replace the seal, apply sealant paste on the cap
and tighten it to the specified torque.
156NM83
D axle: arrange a suitably sized container, clean the
cap areas and remove the filler cap (b) and the drain
cap (a), drain all the lubricant;
D clean the drain caps. Check that the threading is in
good condition. Apply sealant to both caps and
close them at the specified torque.
20ąąFRONT AXLE SECTION 12.1 ADT 25
EPICYCLICAL REDUCTION GEAR

Figure 22
Before starting any type of operation make
1.2 of this manual.
If in doubt, consult an expert.
correctly performing maintenance
operations.
Removal
Proceed as follows:
Figure 20
1891240
D Loosen the mounting screws and remove the brake

caliper.
Figure 21
1891250
The hub may be fitted with three different solutions for
locking the bearings.
VERSION A
1. lock nut
2. stop plate
3. pre-load adjustment spacer
1891241
VERSION B
D Loosen the screws securing the hub to the axle. 1. lock nut
Then use a suitable lifting device and remove the 2. counter lock nut
hub by sliding it carefully from the axle to avoid 3. pre-load adjustment spacer
damaging the axle shaft.
VERSION C
1. pre-load adjustment ring nut
2. counter lock nut
(spacer not included)
Disassembly
Figure 26
Figure 23
1891245
1891242 D Remove the differential gear carrier plate assembly
D Fasten the unit to the supporting tools: and take it to the work bench.
- retainer 5870 350 055. Figure 27
Figure 24
1891246

1891243
D Loosen all the hexagonal head screws. Figure 28
Figure 25
1891247
D Use a suitable extractor to remove the pinion gears.

1891244
D Mark the matching positions of the differential gear
carrier plate and the hub (arrow).
D Using appropriate extractor screws, remove the
differential gear carrier plate from the hub.
Figure 29 Figure 31
1891251
1891248
D version A loosen the fastening screw and remove D Versions A and B: remove the spacer.
the stop plate.
Figure 32
Figure 30
1891252
1891249
D Remove the crown gear from the grooved bushing.
D Version A using tools 5870 656 005 and 5870 912
012, remove the ring nut securing the inner toothed Figure 33
gear wheel.
The ring nut is locked with thread locker.
Heat the threading to about 120 °C before
unscrewing to avoid damage.
D Versions B and C: using tools 5870 656 005 and
5870 912 012, remove both ring nuts securing the
inner toothed gear wheel.
1891253
D Remove the inner toothed gear wheel from the hub.
Figure 34 Figure 36
1731228 1731231
D Remove the retaining snap ring and separate the D Remove the sealing ring from the hub support.
gear wheel from its flange. D Remove the taper roller bearing inner track , axle
side.
Figure 35
Figure 37
1731232
D Using a universal extractor, remove the outer tracks

of the taper roller bearings from the hub.
1891254 Figure 38
D Using a suitable lifting device, carefully remove the
hub complete with brake disk from the hub support
and take it to the work bench.
D Recover the taper roller bearing inner ring on the
wheel side.
1891255
D Lock the hub in a press, then remove the screws

securing the brake disk.
Checking the dismantled parts

Figure 39
Wheel hub
D check the bearing housings to ensure there are no
signs of strain and/or ovalising;
D check the condition of the bearings, replace them
if they have blue contours, cracks and/or signs of
wear;
Axle shafts
D check the condition of the axle shafts, replace them
if there are signs of strain on the end grooves and/or
over the whole length;
Final reductions
1891256
D check the condition of the gear teeth: replace if
D Using a suitable plug and a press, remove the brake there are signs of pitting, cracks and/or sinking;
disk from the hub. D check that the side pinions and needle bushings
D If necessary remove the stud bolts that fasten the function correctly;
wheels from the hub, using a press. D check the thread on the bearing lock ring nut:
ensure there is no denting, strain and/or seizure;
Figure 40
Re-assembly
. When reassembling, bear in mind the

following general rules:
D heat the bearings and gears that are
pressure-assembled in an oven at 90°C;
D accurately centre the sealing rings and
bearings and use the specific tool or
hammer to assemble them;
D lubricate ring nuts and bearings.
Proceed as follows:
1891257 Figure 41
D Remove the grooved bushing (1) and the spacer
ring (2) from the hub.
. Take care not to lose the two dowels.

D Remove the hub from the supporting equipment.
1891260
D If they have been removed, refit the wheel stud bolts
on the hub, using tools 5870 610 001 and 5870 610
002.
Figure 42 Figure 44
1891263
D Fit the brake disk on the hub and centre it using the
double dowel pins.
D Fit the bolts without tightening.
The pins must be fitted with the cut
1891261 positioned as shown in the figure (cuts
D If they have been removed, refit the two dowels staggered by 180° and positioned along the
(detail). circumference).
D Fit the spacer ring in the hub.
Figure 45
Centre the spacer ring on the two dowels.
Figure 43
1891264
D Block the hub with a press and tighten the bolts to
1891262
D Fit the grooved bushing.

D Fit the hub on the supporting equipment.
Figure 46 Figure 48
1891267
D Using tools 5870 260 004 and 5870 051 029 fit the
sealing ring.
Apply sealant on the outer diameter of the
sealing ring.
Respect the positioning of the ring shown in
the figure.
The use of the tool makes it possible to fit the
ring in the correct axial position.
Figure 49
1891265
D Using the tools 5870 260 004 and 5870 050 003 or
5870 050 009 fit respectively the outer ring of the
taper roller bearing on the axle side (A) and the
wheel side (B).
Figure 47
1891268
D Use appropriate lifting equipment to support the
hub assembly and ensure it is centred correctly,
then slide it gently to the end of the hub support.
1891266
D Fit the inner ring of the taper roller bearing on axle

side (A) on the hub support;
To determine the hub bearing pre-load

Figure 50
Proceed as follows:
Figure 53
1891269
D Install the inner track of the taper roller bearing on

1731271
wheel side (B) so that it comes into contact with the
hub. D Apply MOLYKOTE to the thread of the hub support
and on the thread and contact area of the ring nut
Figure 51 (version A) or on the internal ring nut (versions B and
C).
D Manually fit the ring nut without tightening.
Figure 54
1731242
D Insert the gear wheel flange onto the inner toothed

gear wheel and secure it with a snap ring.
1891272
Figure 52
D Using a cable and a commercial dynamometer
measure and record the rolling torque of the sealing
ring Mtring.
1891270
D Fit the complete inner toothed gear wheel onto the

grooved hub support.
Versions A and B
Figure 57
Figure 55
1891273
1891273
D Using tools 5870 656 005 and 5870 912 012 tighten
D Bed in the hub bearings as follows: the lock nut to the specified tightening torque, and
- using tools 5870 656 005 and 5870 912 012 simultaneously turn the hub forwards and
tighten the lock nut to the specified bedding-in backwards, while hitting it with a plastic hammer to
torque of 500 Nm; bed in the bearings:
- simultaneously turn the hub forwards and bearing lock nut: 1000 Nm
backwards while hitting it with a plastic hammer
to bed in the bearings; Figure 58
- bring the hub to the horizontal position, then
loosen and remove the ring nut.
Figure 56
1891272
D Using a cable and a commercial dynamometer,

measure the total rolling torque of the hub Mttotal.
D Determine the rolling torque of the hub bearings
1891274 Mtpre-load with the following formula:
Mtpre-load = Mttotal - Mtring
D Measure the distance D between the ring nut
D Check that the hub bearings rolling torque
contact surface and spacer contact surface.
Mtpre-load is within the specified values:
D Select a spacer with thickness S calculated from the
Mtpre-load new bearings 9.0 - 12.0 Nm
following formula:
Mtpre-load reused bearings 7.0 ć 9.0 Nm
S = D ć 0.25 mm
D If it is not, use a spacer with a different thickness.
D Fit the spacer selected and refit the lock nut.
Version C
Figure 59
Figure 61
1891275 1891273
D version A: after adjusting the bearing pre-load, D Bed in the hub bearings as follows:
lock the ring nut with the plate and locking screw. - using tools 5870 656 005 and 5870 912 012
tighten the adjustment nut to the specified
Figure 60
bedding-in torque of 500 Nm;
- simultaneously turn the hub forwards and
backwards, while hitting it with a plastic hammer
to bed in the bearings;
loosen the ring nut.
Figure 62
1891276
D version B: after adjusting the bearing pre-load,
lock the ring nut by tightening the counter ring nut
to the specified tightening torque:
bearing counter lock nut: 400 Nm
D secure the ring nuts with the stop tabs.
1891276
the adjustment nut to the specified tightening
torque, and simultaneously turn the hub forwards
and backwards, while hitting it with a plastic
hammer to bed in the bearings:
bearing lock nut: 100 Nm
To determine the crown wheel gear-differential gear

Figure 63 carrier plate axial clearance
Proceed as follows:
Figure 65
1891272
Using a cable and a commercial dynamometer,

1731277
Mtpre-load with the following formula: D With a plug and a press, fit the side pinions with the
Mtpre-load = Mttotal - Mtring relative pins.
Mtpre-load is within the specified values: Figure 66
Mtpre-load new bearings 7.0ć9.0 Nm
D If it is not, alter the adjustment ring nut tightening
torque.
Figure 64
1731278
D Fit the snap ring.
Figure 67
1891276
D after adjusting the bearing pre-load, lock the ring
nut by tightening the counter ring nut to the
specified tightening torque:
1731279
D Install the thrust spacer in the differential gear

carrier plate.
Figure 68 Figure 69
1731250 1731251
D Determine distance between the differential gear D Determine distance b between the hub surface and
carrier plate surface and the installed thrust spacer: the crown wheel gear surface.
. Make sure that the axle shaft is correctly

locked in the axial teeth of the differential.
Check that the difference (a - b) is within the specified
values.
axial clearance: 0,30 ć 0,50 mm.
Example:
dimension a
straightedge 100.00 mm
value measured 85.10 mm
distance a 14.90 mm.
dimension b
distance b 14.60 mm.
Difference (a - b) = 0.30 mm (axial clearance)

If it is not so, apply a spacer:
D oversized to reduce the clearance
D undersized to increase the clearance.
. The spacers are available in thicknesses of

0.30/0.50/1.00/3.00 mm.
Figure 70 Figure 72
1891280 1891281
D Fit the crown wheel. D Apply sealant to the contact surfaces, fit the unit to
the axle ensuring that the axle shaft correctly mates
Figure 71 with the grooves of the grooved bushing.
D Tighten the screws to the specified torque.
Figure 73
1891282
1731252 D Assemble the brake calliper and tighten the screws

D Apply sealant to the contact surfaces, fit the
D Check the clearance between the brake disk and
differential gear carrier plate assembly in the hub
brake pad guide pins following the instructions in
and tighten the securing screws to the specified
torque.
D Fill the hub with the specified quantity of the
D Remove the unit from the support trolley.
specified lubricant, up to the marked oil level.
Comply to the references marked at
disassembly.
Pay attention to the radial position of the oil
drainage cap.
DIFFERENTIAL
Before starting any type of operation make D Using appropriate lifting equipment support the
sure all the necessary safety precautions differential external box assembly, and with a
have been taken and fully explained to those suitable screw extractor remove the assembly from
involved in the operations. the axle.
Read the relevant instructions in SECTION D Place the assembly on a supporting stand with the
1.2 of this manual. appropriate adjusting elements.
experience. Figure 76
jobs correctly.
Removal
Proceed as follows:
D Remove the axle shafts from the axle as described
in the previous paragraph.
Figure 74
1731255
D Remove the safety wire from the cap support
mounting screws and the ring nut locking plates.
D Remove the locking plates from both bearing
pre-load adjustment ring nuts.
1731254
D Loosen the screws that secure the differential
external box to the axle.
mark the position between box and axle
(arrow).
Figure 75
1731255
Figure 77 Differential disassembly

Proceed as follows:
Figure 79
1731257
D Loosen both bearing pre-load adjustment ring

nuts.
Figure 78
1731259
D Using special tools 5870 024 005 and 5870 002 404
1731258
remove the taper roller bearing outer track from the
D Loosen the mounting screws and remove both differential half-boxes on the crown wheel side (C)
support caps. and side pinion side (D).
mark each support cap and corresponding
Figure 80
external box (arrows).
D Remove both adjustment ring nuts.

D Using appropriate lifting equipment remove the
differential assembly from the external box and take
it to the work bench.
1731260
D Loosen all the mounting screws and remove the
differential half-box.
Mark both differential half-boxes before
this operation (arrows).
Figure 81 Figure 83
1731261 1731263
D remove the thrust ring, the driven /driving disks, the D Remove the crown wheel gear, the crown wheel
crown wheel backing plate and the crown wheel backing plate, the driven and driving disks and the
gear. thrust ring.
Do not invert the position of the disks. Do not invert the position of the disks.
Figure 82 D If necessary, separate the bevel ring gear from the

differential half-box, using a suitable tool to remove
the rivets.
D Knock lightly to separate the crown wheel from the
Pinion disassembly
Proceed as follows:
Figure 84
1731262
D Remove the side pinions group.
1731264
D Remove the split pin and loosen the crown nut with
tool 587024002.
D Remove the flange using a commercial extractor.
Figure 85 Checking the dismantled parts
Bearings
- check the condition of the bearings replace them
wear;
Crow wheel gear

- check the state of the teeth: replace if there are
signs of pitting, cracks and/or sinking;
Side pinions
1731265
- check the mating surfaces with the pins;
D Remove the oil seal ring from its housing. Even if only one element is found damaged,
the complete gears assy must be replaced.
Figure 86
Crosshead pins
- check the mating surfaces with the side pinions.
Thrust rings
- check the state of the rings: replace them if they
have blue contours, cracks and/or signs of wear;
Bevel gear pair

- check that the teeth of the crown and the pinion are
worn evenly over the whole working band of the
tooth: replace the bevel pair if there are signs of
pitting, cracks and/or sinking;
1731266
Irregular wear may indicate incorrect
D With a plug and a press extract the pinion from the adjustment of the bearings: check they are
external box. intact before reassembling.
D Remove the inner ring of the external bearing (A).
Figure 87 Even if only one element is found damaged,

the complete pair must be replaced.
- When installing the new bevel pair assembly, check
that the wheel and pinion have the same coupling
numbers.
- check the bearing housings: to ensure there are no
Ring nuts
- check the thread on the bearing locking ring nut:
ensure there is no denting, strain and /or seizure:
there must be no denting, strain and/or seizure;
External box
1731267
D Using 587002600+5870026014 remove the inner signs of strain and/or ovalising;
ring of the pinion internal bearing (B). - check that the sealing surfaces and threads are
D Remove both outer tracks of the taper roller intact and are not dented or damaged.
bearings from the external box.
Figure 88
1731268
Break-down drawing of self-locking differential
1. Ring bevel gear and differential half-box
2. Thrust ring
3. Driving disks (internal grooving)
4. Driven disks (external grooving)
5. Crown wheel backing plate
6. Crown wheel
7. Side pinions shaft
8. Side pinion
9. Differential half-box
10. Mounting screw
Figure 89
1731269
Break-down drawing of pinion
1. Split pin
2. Notched nut
3. Washer
4. Motion transmission flange
5. Protection ring
6. Seal ring
7. External taper roller bearing (B)
8. Bearing pre-load spacer S2
9. Pinion
10. Internal taper roller bearing (A)
11. Pinion axial position spacer S1
12. External box
Re-assembly Figure 90
When reassembling, bear in mind the
- heat the bearings and gears that are
assembled by pressure in an oven at
905C (194 °F);
- accurately centre the seal rings and
- lubricate ring nuts and bearings.
Carry out all the indicated measuring

procedures with maximum precision.
Imprecise measurements leave a bad
contact pattern and make it necessary to 1731270
repeat the procedure.
Finding the thickness of spacer S1 for pinion axial
position
Proceed as follows:
D Fit both differential bearing support caps, attaining
to the reference marks made when disassembling.
Figure 91
1731271
First operation
D Insert tools 5870500001 + 5870500006 the Example:
differential support seats and tools 5870351000 + dimension a+b: 191.80 mm (7.55 in)
5870351005 in the pinion seats.
dimension b is to be found using a thickness
D Determine distance H between the resting surfaces
gauge
of internal bearing (A) and centre of the differential
support. dimension c: 15.00 mm (15.24 mm)
(1/2 diameter of measuring shaft)
dimension H= a+b+c: 206.80 mm (8.15 in)
Figure 92 D Remove the differential bearings support caps.
Figure 94
1731272
1731274
Second operation
D Fit correctly sized spacer S1 in the box as previously
D Find thickness S of the internal taper roller bearing described.
(A).
Example: Figure 95
Dimension d: 90.00 mm (3.54 in)
Value measured e: 43.90 mm (1.72 in)
Bearing thickness S=d - e: 46.10 mm (1.82 in)
Figure 93
1731273
Third operation
D Find the required value depending on pinion
assembly dimension X
D Read value V engraved on the surface of the pinion
(arrow) and add it to thickness S of the bearing.
Example:engraved value V 159.90 mm (6.30 in)
Bearing thickness S 46.10 mm (1.8 in)
dimension X =V+S: 206.00 mm (8.11 in)
Calculation of thickness for spacer S1 1731275

D The thickness required for the spacer is found by
the difference between dimension H measured on D With the aid of tool 5870058073, insert the outer
the differential external box and the required track of bearing (A) in the differential box.
dimension X. D Turn the box and fit the outer track of bearing (B) in
Example: its seat.Finding the thickness of spacer S2 for
Thickness of spacer S1= H ć X: 0.80 mm (0.0314 in) bearings pre-load and pinion assembly.
D Remove the special tools used for the
measurements.
Figure 96 Figure 98
1731278
1731276
Proceed as follows: D Position measuring tool 5870034001 on the pinion
shoulder.
Figure 97
The spring pins are to face the grooved part
of the pinion (arrow).
Make sure that the pins protrude sufficiently
so that the overall thickness of the tool is
more than the presumed thickness of
spacer S2 to be found.
Figure 99
1731277
D Heat the inner track of bearing (A) to about 90°C
(194 °F) and fit it on the pinion. Make sure it is up
against the shoulder of the pinion.
1731279
D Place the pinion assembled in this manner on a

spacer pipe. Lift the differential box and carefully
position it over the pinion, so that the weight of the
box packs down the pinion bearings
D Heat the bearing inner track to about 90°C (194 °F)
and fit it on the pinion.
1731280 1731282
D Lock the control flange on the pinion groove. D Remove and measure the thickness of the
D Fit the slashed nut and tighten it to the specified measuring tool 587034001 using a micrometer.
torque using tool 5870240002 D The thickness found will be that for spacer S2.
Figure 101 Crown wheel assembly ć riveted.

Proceed as follows:
D Heat the inner diameter of the crown wheel to about
90°C (194 °F) and insert the crown wheel against
the differential half-box surface to have full contact.
D Using tool 5870405003 rivet the crown wheel onto
the differential half-box.
For this cold riveting operation a press of at
least 30 t (66225 lb) is necessary.
Use only the riveting kit 5870405003
supplied as spare part.
The riveting is to be carried out with extreme
precision so that the crown wheel rotates
without eccentricity.
1731281
D Using suitable tools, check that the rolling torque is
within the specified values.
pinion rolling torque :
1.5P2.3 Nm (1.1P1.7 lb ft)
D The rolling resistance can be corrected by
loosening or tightening the slashed nut.
Make a note of the torque value, as this will
be needed in the next stage.
D Remove the slashed nut, take out the control flange,
remove the inner ring of bearing (B) and withdraw
the pinion from the differential box.
Crown wheel assembly ć bolted. Complete self-locking differential assembly.

As an alternative it is possible to bolt the crown wheel Proceed as follows:
to the differential half-box.
Figure 104
Figure 103
1731284
D Heat the taper roller bearing inner track to about
90°C (194 °F) and fit it tightly onto the differential
half-box.
Figure 105
1731283
Proceed as follows:
D Check that the contact area between crown wheel
and differential half-box is clean and free of grease.
Use only original components supplied as
spare parts.
1731285
D Tighten the bolts to the specified torque.
D At the end of the operations temporarily assemble D Position the shoulder ring with the grooved surface
the other half-box, arrange the group between the facing downwards (arrow).
two points and with a dial gauge, check that the
eccentricity is within the specified values.
1731288
D Fit a crown wheel gear onto the shoulder plate

Make sure that the crown wheel is locked
inside the two internally grooved plates.
Figure 109
1731286
D Fit an externally grooved disk (driven disk) and an

internally grooved disk (driving disk) in alternation
until all the disks have been mounted.
The last disk is a driving disk.
Figure 107
1731289
D Assemble the shafts and side pinion gears and fit
them on the crown wheel gear.
Figure 110
1731287
D Fit the crown wheel shoulder plate with the flat side
downwards on the top of the internally grooved
disk.
1731290
D Fit the other crown wheel gear onto the side pinion
gear assembly.
Figure 111 Finding the disk pack axial clearance

Proceed as follows:
Figure 113
1731291
D Fit the other crown wheel gear backing plate with

the flat side upwards.
1731293
Figure 112
First operation
D Find the value a between the box mounting plane
and the internally grooved plate.
Figure 114
1731294
1731292
Second operation
D Fit an internally grooved disk (driving disk) and an D Find dimension b between box and cover mounting
externally grooved disk (driven disk) alternately until plane
all the disks have been mounted. Example:
The first disk is a driving disk. dimension a: 6.00 mm (0.236 in)
dimension b: 5.80 mm (0.228 in)
Difference a ć b: 0.20 mm (0.0078 in)
(disk axial clearance)
D Check that it is within the specified values.
disk pack axial clearance
0.20P0.80 mm (0.0078P0.031 in)
D the clearance can be corrected by installing disks of
different thicknesses, providing the thickness of the
disk pack is the same on both sides.
It is recommended to keep as close as

possible to the lowest value.
Figure 115 Pinion assembly

Proceed as follows:
Figure 117
1731295
D Position the shoulder ring with the grooved surface

facing upwards (arrow). 1731297
Figure 116 D Position spacer S2 onto the pinion shoulder, then fit
the assembled pinion in the differential box.
D Fit the bearing inner ring (B).
Figure 118
1731296
90Ă°C (194Ă°F) and position it against the differential
half-box until it comes into contact.
1731298
D Apply LOCTITE thread stop to the calibrated bolts.
D Join the two half-boxes and tighten the calibrated D Apply LOCTITE sealant on the outer diameter of the
bolts to the specified torque. seal ring
D Using tool 5870055074 insert the seal ring into the
Use only new calibrated bolts. differential box.
The seal ring lip is to face inwards.
1731299 17312101
D Mount the flange onto the pinion. D Apply MOLYKOTE to the thread of the adjustment
D Position the washer and tighten the slashed nut to ring nut.
the specified torque using tool 587024002. D Tighten both ring nuts by hand.
D Lock the slashed nut in its seat with a split pin.
Figure 122
Finding the differential bearing pre-load
Proceed as follows:
Figure 120
17312102
D Align the markings and fit the bearing support caps.

D Fit the washers and cap mounting screws and
17312100 tighten to the specified torque.
D Position the outer tracks of the taper roller bearings
on both ends of the differential.
D Using suitable lifting equipment, assemble the
crown wheel group in the differential box.
Figure 123 Checking the pinion-crown wheel backlash

Proceed as follows:
Figure 125
17312103
D Tighten both adjustment ring nuts to obtain the

specified distance between the supports,
measured diagonally.
distance for supports:
340.00P340.30 mm ( 13.4 in)
Figure 124
17312104
D Assemble a dial gauge at a right angle to the outer

diameter of the crown wheel flank and sway the
crown forwards and backwards taking care not to
move the pinion.
D Check that the backlash between crown and pinion
is within the specified values.
crown-pinion backlash:
0.25P0.35 mm (0.0098P0.014 in)
Figure 126
1731281
total rolling torque:
1.8P2.7 Nm (1.3P2 lb ft)
The rolling torque measured includes the
torque of the pinion bearings.
D The rolling torque can be corrected by varying the
two adjustment ring nuts by the same number of
notches.
D In detail: 17312105
- loosen the ring nuts to decrease the rolling
torque;
- tighten the ring nuts to increase the rolling
torque;
D If this is not the case, adjust by means of the Figure 128

adjustment ring nuts.
D the backlash can be adjusted without altering the
bearings pre-load, by unscrewing one adjustment
ring nut by a certain number of notches and then
screwing the opposite adjustment ring nut by the
same number of notches.
D In detail:
- tighten ring nut (C) and loosen ring nut (D) to
reduce the backlash
- tighten ring nut (D) and loosen ring nut (C) to
increase the backlash
Checking the contact pattern area of the crown-pinion

Proceed as follows:
17312107
Figure 127
- Once all the adjustments and configurations are
correct, fix the locking plates of both adjustment
ring nuts with screws and safety wire.
- Lock the mounting screws of both bearing support
caps with safety wire.
Figure 129
17312106
D cover about a dozen crown teeth with Prussian blue,
lubricated red lead or other paint or marking that
can easily be removed.
D Rotate the crown by hand in the direction shown in
the figure.
D When the teeth mesh, the paint is sent out by the
17312111B
contact of the teeth, leaving an exposed zone with
the exact dimension, shape and location of the D Support the complete external box suitable lifting
contact area (see figure on next page). equipment.
D Apply LOCTITE sealant along the joining surfaces.
D Mount the complete external box assembly onto the
axle attaining to the reference marks made when
disassembling.
D Tighten the mounting screws and lock to the
specified torque.
D Fill the axle with the indicated quantity of prescribed
lubricant up to the control oil level.
Figure 130
a a a
b b b
1 2 3
1731208 1731209 1731210
Shape and position of contact area Figure 131

1. correct pinion position.
2. pinion positioned too far back: reduce the
distance between pinion and crown axis using a
thinner S1 spacer.
3. pinion positioned too far forward: reduce the
thicker S1 spacer.
a. driven flank (concave)

b. driving flank (convex)
156NM123
SECTION 12.2
INTERMEDIATE AXLE
ADT 25 SECTION 12.2 INTERMEDIATE AXLEą1
CONTENTS
Page Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Changing axle/transfer case oil . . . . . . . . . . . . . . . . 19
First reduction: bevel gear pair . . . . . . . . . . . . . . . . . . 4 EPICYCLICAL REDUCTION GEAR . . . . . . . . . . . . 21

Second reduction: hub and epicyclic train . . . . . . . . 8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Transfer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Checking the dismantled parts . . . . . . . . . . . . . . . . . 25

Re-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . 13
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 DIFFERENTIAL AND SPLITTER . . . . . . . . . . . . . . . 34
Epicyclical reduction gears . . . . . . . . . . . . . . . . . . . . 14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Lockable splitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Epicyclical reduction gears . . . . . . . . . . . . . . . . . . . . 14
Self-locking differential . . . . . . . . . . . . . . . . . . . . . . . 42
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Location of spacers/adjustment ring nuts and
AXLE REMOVAL-REFIT . . . . . . . . . . . . . . . . . . . . . 15 relative bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Re-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Finding the thickness of spacer S1 for pinion
Axle-rocker arm support-parking brake axial position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
strip down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Pinion bearing axial pre-load: nil . . . . . . . . . . . . . . 48
SPECIFIC MAINTENANCE . . . . . . . . . . . . . . . . . . . 18 Shape and position of contact area . . . . . . . . . . . . . 58
Checking axle/transfer case oil level . . . . . . . . . . . . 18
2ąINTERMEDIATE AXLE SECTION 12.2 ADT 25
DESCRIPTION
The axle is a dual reduction bearing type. the bearings, as well as the brake caliper mounting
It consists of a box type structure that contains the flange.
bevel gear pair with the differential, the axle shafts and The axle also includes a trasnfer unit upstream of the
hubs with the end reduction. The structure has differential.
mountings to connect to the chassis and housings for
Figure 1
1891213
1. Axle
2. Axle support
3. Transfer unit
4. Brake caliper
5. Tie rod fastening bracket
6. Rocher lever fastening bracket

The first reduction is obtained by the pinion ćring bevel The differential gear box with ring bevel gear is
Figure 2
A B
1891230A 1891230B
1. Taper roller bearing 9. Differential gear carrier shaft

2. Gear transmitting movement to pinion 10. Side pinion
3. Taper roller bearing 11. Crown wheel
4. Bevel pinion 12. RH taper roller bearing
5. Ring bevel gear 13. Pre-load adjustment ring nut
6. Pre-load adjustment ring nut 14. Differential gear box (version B)
7. LH taper roller bearing 15. Multi-disk clutch
8. Differential gear box (version A) 16. Pressure plate (version B)
A: differential standard version

Figure 3
1731214
1. Crown wheel
4. Crown wheel gear
5. Side pinion
7. Bevel pinion
11. Shoulder
Operation
The driving torque coming from the propeller shaft is Under these conditions there is no relative motion
transmitted by a universal joint to the bevel pinion. between the two crown wheels and therefore the side
From here the torque passes to the ring bevel gear, pinions do not turn around their shaft which is integral
which is integral to the differential gear box. to the differential gear box.
The differential is a gear for which the box represents When the resistance of one wheel is greater than that
the train carrier, that carries the differential gear carrier of the other, or when the speed of the two wheels is not
shafts and receives the driving torque, whereas the two the same (vehicle on a road with bends) the crown
side gears, which represent the crown wheels, both of wheel gears have a different rotation speed: the
which rotate, receive the driving torque and transmit it relevant motion is permitted by the side pinions, that
to the axle shafts. now turn around their shafts in directions opposite to
When both wheels are subject to the same stall torque each other.
or have the same speed (vehicle being driven on a Obviously at a lower crown wheel rotation speed the
straight road), the ring bevel gear and the differential transmitted driving torque is greater, and vice versa.
gear box rotate as one, transmitting the torque in equal Therefore when the differential is operating, the wheel
parts to the two crown wheels, and from here to the two with a lower speed can transmit a greater torque,
axle shafts, that rotate at the same speed: the wheels whereas the wheel with a higher speed can transmit a
transmit the same driving torque. lower torque.
Under certain conditions it may happen that the slower
Figure 4 wheel loses its grip completely, since the torque is
exceeded that can be transmitted to the ground, and
percentage.
1731215

1731216

(example)


Figure 6
8 9 10 12 15
6 4 3 2
1.731.217A 1731217B
1. Axle Operation
5. Wheel mounting bolt The four side pinion gears rotate in the opposite
6. Epicyclic train crown gear direction to the crown gear, whereas the crown wheel
7. Pivoting roller bearing is integral to the hub support and therefore does not
8. Epicyclic train carrier turn. This makes the train carrier turn in the opposite
9. Epicyclic train side pinion gear direction to the side pinions, therefore in the same
10. Epicyclic train crown gear direction as the axle shafts.
11. Grooved shank connecting axle shaft-crown Since the train carrier is integral to the wheel hub, the
wheel wheel turns in the same direction as the axle shaft.
12. Hub
13. Brake disk
14. Seal ring
15. Axle shaft
Transfer unit
The divider unit consists of a hollow shaft" differential The output shaft from the transfer transmits the motion
and a pair of cylindrical wheels. to the rear axle, whereas the pair of wheels (with ratio
1:1) transmit the motion to the differential pinion.
Figure 7
1891231A
1. Drive input flange 11. Motion output shaft flange to rear axle
2. Drive input shaft/splitter carrier 12. Taper roller bearing
3. Bearing 13. Gear transmitting movement to pinion
4. Drive output shaft from splitter to rear axle 14. Taper roller bearing
5. Toothed coupling locking splitter 15. Crown wheel (splitter motion output to
6. Pinion taper roller bearing intermediate axle)
7. Gear transmitting movement to pinion 16. Splitter locking device
8. Pinion taper roller bearing 17. Differential gear carrier shaft
9. Bevel pinion 18. Side pinion
10. Bearing 19. Crown wheel (splitter motion output to rear axle)
Transfer unit - section (see previous page for key)
Figure 8
1891231B
Operation
The driving torque coming from the propeller shaft is When the resistance of one axle is more than that of the
transmitted by means of a universal joint to the input other, or when the speed of the two axles is no longer
shaft. the same (vehicle on a road with bends) the side gears
From here the torque passes to the transfer box. have a different rotation speed: as a consequence at a
The divider is a wheelwork in which the box is the lower side gear rotation speed a greater driving torque
train-carrier that carries the differential gear carrier is transmitted, and vice-versa.
shafts and receives the driving torque, whereas the two Therefore, when the differential is operating, the axle
side gears represent the crown wheels, both of which that has less speed can transmit a higher torque,
rotate, receive the driving torque and transmit it to the whereas that with a higher speed transmits a lesser
coaxial axle shafts. torque.
The operation is exactly the same as that of a To avoid the possibility that with a loss of grip one of the
differential between the wheels. two axles freewheels, cancelling the traction of both
When both axles are subject to the same stall torque or axles, there is a locking device of the transfer that can
have the same speed ( vehicle being driven on a be engaged.
straight road), the transfer distributes the driving torque With this device engaged, the box is integral with the
in equal parts between the axles. external side gear: in this way the entire box - side
gears - side pinions assembly rotates as a single unit
and the torque is by force divided equally between the
axles.
DIAGNOSTIC
1. Vibrations
2. Continuous noise

rectly
worn components
rect
rect (excessive)
cessive
worn
damaged
or decelerating
d l ti
excessive
loose torque
specified torque
TIGHTENING TORQUES
AXLE
1. Hex head screws securing tie rod anchoring plate on axle 380 Nm (280 ft lb)
2. Allen screws securing tie rod anchoring plate on axle 580 Nm (428 ft lb)
3. Screws securing support and rocker bracket on axle 600 Nm (443 ft lb)
4. Rocker joint pin nut 1000 Nm (738ft lb)
5. Nut securing rocker securing bracket 600 Nm (443 ft lb)
6. Screws securing tie rod to bracket 600 Nm (443 ft lb)
Figure 9
1891215

Internal crown wheel flange mounting ring nut: see values given for the different versions
Brake caliper mounting screw: 295 Nm (217 lb ft)
DIFFERENTIAL AND SPLITTER

Bevel pinion bearing lock nut 750 Nm
Screws securing housing on box 160 Nm
Splitter bearing lock nut 550 Nm
Differential lock control cover fastening screws 42 Nm
Splitter half cases securing screws 120 Nm
Screws securing pinion lock nut cover 50 Nm
Screws securing bevel crown gear to differential 120 Nm
Screws securing differential cap on crown wheel side 245 Nm
Axle oil level cap 150 Nm
Axle oil drainage cap 150 Nm
Splitter oil level cap 70 Nm
Splitter oil drainage cap 150 Nm
TOOLS

5870 610 001: Wheel fastening stud assembly (to be used with 5870 610 002)
5870 610 002: Wheel fastening stud assembly
DIFFERENTIAL
5870 000 065: Extractor bevel pinion flange support
5870 027 000: Extractor base to remove bevel pinion bearing inner track
5870 027 004: Extractor to remove bevel pinion bearing inner track (to be used with 5870 027 000)
5870 500 021: Pinion axial position measuring flange
AXLE REMOVAL-REFIT
. Before starting any type of operation make D disconnect the central lubrication system unions
(arrow);
then place two supporting trestles under the rear
chassis, without touching the axles;
D remove both wheels following the instructions in
1.2 of this manual.
SECTION 13.1;
D under the intermediate and rear axles place an
experience.
appropriate hydraulic jack that allows lowering at
removal, so that at this stage the two axles remain
more or less horizontal;
jobs correctly.
D disconnect hydraulic union of the service (30) and
parking (31) brake system;
Removal D disconnect the hydraulic (32) and electrical (35)
To remove proceed as follows: connections of the distributing differential lock
D bring the vehicle onto a suitable flat, solid surface, between the axles;
switch off the engine, remove the ignition key, D remove the input (10) and output (not shown)
engage the parking brake and apply the propeller shafts as described in Section 10;
maintenance in progress" signboards. D loosen the screws (a) securing the bracket to the tie
D cut off the battery isolator switch or disconnect the rod (2);
terminals from the battery to avoid the risk of short D on both sides, remove the split pin (b) and loosen
circuits; the fastening nut (5) of the rocker arm pin;
D lock knuckle with the steering lock bar following the D remove the rocker arm pin (4), picking up the
instructions in SECTION 1.2; washers and the bushings (6), then remove the
bearing (7), clearing the rocker arm from the axle;
D very carefully lower the axle(1) and remove it from
the vehicle.
Refit
Figure 10
1891216
Axle-rocker arm support-parking brake strip down

To strip down, proceed as follows: D loosen the fastening nuts (e) of the bracket rocker
D loosen the fastening screws (c) and (d) and remove arms support (13); remove bracket;
tie-rod fastening plate (12); D remove the parking brake calipers (8) and disk (9)
D loosen the fastening screws (e) of the rocker arms following the instructions in SECTION 13.2.
support (13);
D remove the rocker arms support (11) from the axle
(1) using a suitable lifting mean;
Figure 11
1891218
SPECIFIC MAINTENANCE Figure 14
Checking axle/transfer case oil level

Proceed as follows:
position;
Figure 12
156NM81
D check that breather is perfectly clean and working.
156NM80B
paragraph;
torque;
each axle.
Figure 13
156NM80A

(2) for the check.
Changing axle/transfer case oil Figure 17

Collect and dispose of used lubricants and

Proceed as follows:
Dumping
Figure 15
156NM120A
D clean the differential cap area and remove the cap

(b) and the drain cap (a); drain all the lubricant;
156NM82A
lowest position;
Figure 16
156NM83
D axle: arrange a suitably sized container, clean the
Filling Figure 20
Figure 18
156NM80B
156NM123 D bring the reference mark on a hub to the horizontal

D axles : fill partially with the specified lubricant until position, fill with the remaining amount of lubricant
it overflows from the filler cap hole (b), then replace until it overflows from the cap hole;
the seal, apply sealant paste on the cap and tighten D close the cap, do a test run and recheck the level,
it to the specified torque; topping up if necessary until it overflows;
D replace the seal, apply sealant paste on the cap and
Figure 19 tighten it to the specified torque.
156NM120A
D fill with approximately 1.5 litres of the specific
lubricant through the differential cap hole (b), then
replace the seal, apply sealant paste on the cap and
tighten it to the specified torque;

Figure 23
1.2 of this manual.
operations.
Removal
Proceed as follows:
Figure 21
1891240

caliper.
Figure 22
1891250
VERSION A
1. lock nut
2. stop plate
1891241
VERSION B
VERSION C
2. counter lock nut
Disassembly
Figure 27
Figure 24
1891245
Figure 25
1891246

1891243
Figure 26
1891247

1891244
Figure 30 Figure 32
1891251
1891248
the stop plate.
Figure 33
Figure 31
1891252
1891249
gear wheel.
1891253
Figure 35 Figure 37
1731228 1731231
side.
Figure 36
Figure 38
1731232

1891254 Figure 39
wheel side.
1891255


Figure 40
Wheel hub
wear;
Axle shafts
Final reductions
1891256
Figure 41
Re-assembly

Proceed as follows:
1891257 Figure 42

1891260
002.
Figure 43 Figure 45
1891263
double dowel pins.
Figure 46
Figure 44
1891264
1891262

Figure 47 Figure 49
1891267
sealing ring.
sealing ring.
the figure.
Figure 50
1891265
wheel side (B).
Figure 48
1891268
1891266


Figure 51
Proceed as follows:
Figure 54
1891269

1731271
C).
Figure 55
1731242

1891272
Figure 53
ring Mtring.
1891270

Versions A and B
Figure 58
Figure 56
1891273
1891273
Figure 57
1891272

following formula:
S = D ć 0.25 mm
Version C
Figure 60
Figure 62
1891275 1891273
Figure 61
Figure 63
1891276
1891276

Proceed as follows:
Figure 66
1891272

1731277
torque.
Figure 65
1731278
Figure 68
1891276
1731279

carrier plate.
Figure 69 Figure 70
1731250 1731251

values.
Example:
dimension a
dimension b


0.30/0.50/1.00/3.00 mm.
Figure 71 Figure 73
1891280 1891281
Figure 74
1891282

torque.
disassembly.
drainage cap.
DIFFERENTIAL AND SPLITTER Disassembly

Proceed as follows:
Read the instructions provided in Section
1.2 of this manual.
correctly performing maintenance operaĆ
tions.
Removal
Proceed as follows:
D Follow the instructions described in the relevant
chapter, and remove the final reduction units from
the axle, then the axle shafts. 1891291
Figure 75 D Separate the differential box housing from the

adapter box.
Figure 77
1891292
D Remove the cylindrical pin and lift the differential

1891290 box housing.
D Loosen the screws that secure the differential exterĆ
nal box to the axle.
. Mark the matching positions of the box and

the axle (arrows).
D Using a suitable lifting device, support the differenĆ
tial-splitter unit, then use suitable extractor screws
to remove the assembly from the axle.
D Position the assembly on the stand, using suitable
adapters.
Differential disassembly
Figure 78
Proceed as follows:
Figure 80
1891293
D Remove the split pins and the bearing pre-load adĆ

justment ring nuts.
Figure 79
1731259
D Use the special tools 5870024005 and 587002404

to extract the taper roller bearing inner track from
1891294 the differential half-boxes on the crown gear side
D Loosen the screws securing the cap on the crown (C) and on the side pinions side (D) respectively.
gear side, and remove the cap.
Figure 81
. The cap cannot be disassembled on the
other side as it is part of a casting.
D Using appropriate lifting equipment remove the difĆ
ferential assembly from the external box and take it
to the workbench.
1731260
D Loosen all the securing screws and remove the difĆ
ferential half-box.
. Before performing this operation mark both

differential half-boxes (arrows).
Figure 82 Figure 84
1731261 1731263
D Remove the thrust ring, the driven/driving disks, the D Remove the crown wheel gear, the crown wheel
crown wheel backing plate, and the crown wheel. backing plate, the driven and driving disks and the
thrust ring.
. Do not invert the position of the disks.
. Do not invert the position of the disks.
Figure 83 D If necessary, remove the hex-head screws securĆ
ing the crown gear.
D Knock lightly to separate the ring bevel gear from
Splitter disassembly
Proceed as follows:
Figure 85
1731262
1891295
D Remove the splitter locked indicator.

D Loosen the hex-head screws and remove the
splitter locking device cover.
Figure 86 Figure 89
1891296
D Loosen the central lock nut and remove the flange.
Figure 87
1891299
D Make a reference mark on the splitter half-boxes.
D Loosen the securing screws, separate the two
splitter half-boxes and remove the components:
(1) carrier with side pinions and thrust washers (2)
crown wheel (3) with thrust washer.
Figure 90
1891297
D Loosen the securing screws and remove the cover.

D Remove the seal from the cover.
Figure 88
18912100
D On both sides, loosen securing screw (1) and reĆ

move pin (2) of gearbox fork.
1891298
D Remove the splitter assembly from the adapter box.
D Remove the support flange complete with bearing
from the splitter.
Figure 91 Figure 93
18912101
18912103
D Remove the gearbox fork and the control rod.
D Remove the taper roller bearing inner ring (1) and
. During this operation, push the control rod spacer (2).
gently downwards to disengage the fork.
Figure 94
D Remove the sliding collar.
Figure 92
18912104
D Remove the crown wheel complete with inner

spacer and taper roller bearing from the housing.
18912102
D Turn the box over, then use a punch to block gear
rotation and remove the lock nut.
Figure 95 Figure 97
18912107
D Loosen the securing screws and remove the cover
on the bevel pinion securing nut.
18912105 Figure 98
D Loosen the internal (detail) and external securing
screws and separate the adapter box from the difĆ
ferential box housing.
Figure 96
18912107A
D Loosen the nut securing the bevel pinion.
Figure 99
18912106
D Remove the driving spur gear.
18912108
D Using tool 5870 000 065, extract the support flange
complete with bevel pinion from the box.
Controllo delle parti smontate

Figure 100
Bearings
- check the state of the bearings: replace them if they
Crown wheels
Side pinions
Damage to even one element means that the
18912109 whole gear assembly must be replaced.
D Recover the taper roller bearing inner ring (1) and
spacer (2). Crosshead pins
Figure 101 - check the mating surfaces with the side pinions;
Thrust rings
Bevel gear pair

- check that the teeth of the crown gear and the pinion
are worn evenly along the tooth working area: reĆ
place the bevel pair if there are signs of pitting,
cracks and/or sinking;
Irregular wear may indicate incorrect adjustĆ
ment of the bearings: check adjustment is
correct before refitting.
18912110 Damage to even one element means that the
D Using a press, remove the bevel pinion from the whole bevel gear pair must be replaced.
support flange. - When installing the new bevel pair assembly, check
Figure 102
numbers.
- check the bearing seats: to ensure there are no
Ring nuts
- check the thread on the bearing lock nut: there must
be no denting, strain and/or seizure;
External box
- check the bearing seats: to ensure there are no
- check that the sealing surfaces and threads are inĆ
tact and are not dented or damaged.
18912111
D Using the tool 5870 027 000 and 5870 027 004, exĆ
tract the taper roller bearing inner ring from the
bevel pinion.
D Remove both outer tracks of the taper roller bearĆ
ings from the external box.
Lockable splitter
Figure 103
1. Motion input flange 14. Driving spur gear
2. Ball bearing support flange 15. Splitter support outer bearing (F)
3. Ball bearing 16. Splitter bearings lock nut
4. Differential half-box 17. Bevel pinion bearing lock nut
5. Crown wheel 18. Bevel pinion outer bearing (B)
6. Side pinion 19. Splitter box
7. Side pinion shaft 20. Driven spur gear
8. Splitter lock control fork 21. Bevel pinion bearing support flange
9. Splitter lock control device 22. Bevel pinion inner bearing (A)
10. Splitter lock sliding sleeve 23. Bevel pinion
11. Crown wheel (shaft) 24. Motion output flange ball bearing
12. Splitter support inner bearing (E) 25. Seal
13. Splitter housing 26. Motion output flange shaft
18912112
Self-locking differential
Figure 104
1. Differential half-box 10. Securing screw
2. Thrust ring 11. Differential carrier
3. Driving disks (internal splines) 12. Ring bevel gear
4. Driven disks (external splines) 13. Differential bearing on crown gear side (C)
5. Crown wheels backing plate 14. Adjustment ring nut
6. Crown wheel 15. Differential bearing on side opposite crown gear
7. Side pinions shaft (D)
8. Side pinion 16. Support cap
18912113
Location of spacers/adjustment ring nuts and relative bearings
Figure 105
S1 spacer for bevel pinion axial position A. Bevel pinion inner bearing
S2: spacer for bevel pinion taper roller bearing B. Bevel pinion outer bearing
pre-load C. Differential bearing crown gear side
S3: spacer for splitter taper roller bearing pre-load D. Differential bearing on side opposite crown
S4: spacer for splitter end play gear
GH: ring nuts for taper roller bearing pre-load/ring E. Splitter support inner bearing
bevel gear axial position F. Splitter support outer bearing
18912114
Re-assembly D Use tools 5870 500 001 and 5870 500 021 to
measure the distance A from the differential axis to
When reassembling, bear in mind the followĆ the flange surface.
ing general rules: D Measure distance B from the flange surface to the
D heat the bearings and gears that are presĆ bearing contact surface.
sure-assembled in an oven at 90°C; D Measure bearing width C.
D accurately centre the sealing rings and D Calculate distance X between pinion and differential
bearings, and fit them with the specific tool axis by using the following formula:
or hammer; X = A+B-C
D lubricate ring nuts and bearings. D Read value V cut in the pinion surface (arrow).
D Calculate the thickness of spacer S1 by using the
following formula:
Carry out all the measuring procedures indiĆ S1 = X - V
cated with the utmost precision.
Incorrect measurements can lead to poor Example:
functioning of the unit.
Distance A 164.20 mm
Distance B 25.75 mm
Finding the thickness of spacer S1 for pinion axial Bearing width C 37.05 mm
position Gives X = A+B-C = 152.90 mm
Proceed as follows: Value V 151.80 mm
D Fit the differential bearing support cap according to Gives S1 = X-V = 1.10 mm
the reference marks made during disassembly.
Figure 106
18912115
18912116 18912118
D Install shim S1, determined according to the forĆ D Fit the bearing pre-assembled support on the
mula, and the outer track of bearing (A) in the supĆ bevel pinion.
port flange.
Wear protective gloves when handling hot
Figure 108 components.
D Heat the driven spur gear and fit it.
Position the gear with the chamfered side
facing the pinion.
Figure 110
18912117

components.
D Heat the inner ring of bearing (A) and fit it on the
bevel pinion.
1891236
D Install the pre-assembled bevel pinion and insert
it completely into the housing.
Finding the thickness of spacer S2 for the pinion bearĆ

ings axial pre-load Figure 113
. Since the pre-load value is very small, it is

very difficult to measure it with a dynamomeĆ
ter and therefore we recommend you proĆ
ceed as indicated.
Proceed as follows:
Figure 111
18912121
D Measure the end play G of the bevel pinion with a
dial gauge.
D Find the thickness S2 definitive of the spacer by apĆ
plying the following formula:
S2definitive= S2trial ć (G + 0.02/0.04) mm
to obtain the value of the specified axial pre-load:
18912119 Pinion bearing axial pre-load: 2ć3 Nm
D Fit the selected spacer, then tighten the hexagonal
D Install the pre-load adjustment spacer (1) with
nut to the specified torque.
thickness S2trial so as to give a certain end play.
Splitter assembly
components. Proceed as follows:
D Fit both outer rings of bearings (E) and (F) in the
D Heat the inner ring (2) of bearing (B) and fit it. housing.
18912120 18912122
D Fit the hexagonal nut and tighten it to the specified D Insert the driving spur gear with the long hub facing
torque. downwards.
Position the gear with the long hub facing
downwards - output flange side.
Finding the thickness of spacer S3 for splitter bearing

Figure 115 axial pre-load
. Since the pre-load value is nil, we recomĆ

mend you proceed as indicated.
Proceed as follows:
Figure 117
18912123
D Apply sealant to the mounting surface taking care
to apply it to the outside of the holes. 18912125
D Install the housing on the box. D Install the pre-load adjustment spacer (1) with
D Tighten the outer and inner (detail) securing screws thickness S3trial so as to give a certain end play.
to the specified tightening torque.
Apply thread-lock to the securing screws. Wear protective gloves when handling hot
components.
Figure 116 D Heat the inner ring (2) of bearing (F) and fit it.
Figure 118
18912124
18912126
components. D Fit the hexagonal nut and tighten it to the specified
torque.
D Heat the inner ring of bearing (E) and fit it on the
crown wheel (shaft).
D Fit the crown wheel (shaft) and mate with driving
gear.
Splitter completion
Figure 119
Proceed as follows:
Figure 120
18912127
D Measure the end play G of the bevel pinion with a

dial gauge. 18912128
D Find the thickness S3definitive of the spacer with the
D Insert the collar on the crown wheel (shaft).
following formula:
S3definitive = S3trial ć G mm Figure 121
to obtain the specified value of the axial pre-load.
Pinion bearing axial pre-load: nil
The splitter bearings must have no play and

not be pre-loaded.
D Fit the selected spacer, then tighten the hexagonal
nut to the specified torque.
18912129
D Fit the gearbox fork inserting the sliding pads in the
gearbox collar.
Figure 122
18912130
D Fit a new O-ring on the control rod.

D Assemble the control rod and mesh with the gearĆ
box fork.
18912100
D Insert the pin (2) of the gearbox fork on both sides.
. Slightly lower the gearshift rod to make this

operation easier.
D Tighten the screw (1) securing the pin on both sides.
18912132
Figure 124 D Fit the following components in the splitter half-box

in the order given: (1) thrust washer (2), crown
wheel (3), carrier with side pinions and thrust
washers.
Take care that the thrust washers of the indiĆ
vidual side pinions are positioned correctly.
Figure 126
18912131
D Fit a new O-ring on the cover.

D Fit the control rod.
D Fit the cover and tighten the securing screws to the
specified tightening torque.
18912133
D Check that the play for the side pinion group is withĆ
in the specified values.
Side pinion group play: 0.15 - 0.20 mm.
D If it is not, use thrust washers with a suitable thickĆ
ness.
D Observing the reference marks made during disasĆ
sembly, refit the second splitter half-box and
tighten the securing screws to the specified torque.
Finding the thickness of spacer S4 for splitter end

play Figure 128
Proceed as follows:
D Fit the ball bearing in the support flange.
Figure 127
18912134
D Using a press, fit the support flange complete with

bearing on the splitter.
D Install the group in its housing.
18912135
D Measure distance A between the cover resting
surface and the bearing shoulder.
D Measure distance B between the flange resting
surface and the bearing side.
D Find the thickness of spacer S4 with the following
formula:
S4 = A ć B - 0.20 mm
to obtain the specified value of the end play.
Splitter end play: 0.20 mm
Example:
Distance A 6.5 mm
Distance B 5.0 mm
Gives S4 = A-B-0.20 mm = 1.30 mm
18912140 18912142
D Install the seal on the cover using a suitable pad in D Fit the differential lock adjustment screw.
the direction indicated. D Activate the lock with compressed air and simultaĆ
neously tighten the adjustment screw until contact
Figure 130 is made with the control rod. From this point, tighten
the adjustment screw another 1/3 of a turn, approx.
and lock it with a lock nut.
Apply thread-lock to the adjustment screw.
Figure 132
S4
18912141
D Insert spacer S4, selected previously, in the cover.
D Install the cover according to the reference marks
and tighten the securing screws.
18912143
D Fit the splitter lock enabled indicator.
Fitting the complete self-locking differential.

Figure 134
Proceed as follows:
Figure 133
1731284
D Heat the inner track of the taper roller bearing at apĆ
18912144
prox. 90°C and fit it completely in the differential
Proceed as follows: half-box.
D Check that the contact area between gear wheel
and differential half-box is clean and free of grease. Figure 135
D At the end of the operations temporarily fit the other
half-box, arrange the group between the two
points and with a dial gauge, check that the eccenĆ
tricity is within the specified values.
maximum eccentricity: 0.08 mm
1731285
D Position the thrust ring with the splined surface
facing downwards (arrow).
1731288
D Fit a crown wheel gear onto the backing plate.

Make sure that the crown wheel is fitted inĆ
side the two internally splined plates.
Figure 139
1731286
D Fit an externally splined disk (driven disk) and an inĆ
ternally splined disk (driving disk) alternately until all
the disks have been mounted.
Figure 137
1731289
them on the crown wheel.
Figure 140
1731287
D Fit the crown wheel backing plate with the flat side
downwards on the top of the internally splined disk.
1731290
gear group.
Finding the disk pack end play

Figure 141
Proceed as follows:
Figure 143
1731291
D Fit the other crown wheel backing plate with the flat
side upwards. 1731293
Figure 142 D Measure distance a between box attachment surĆ

face and internally splined plate.
Figure 144
1731294
D Measure distance b between the box and the cover
attachment surface
1731292 Example:
distance a: 6.00 mm
D Fit an internally splined disk (driving disk) and an exĆ distance b: 5.80 mm
ternally splined disk (driven disk) alternately until all Difference a ć b: 0.20 mm (disk end play)
the disks have been mounted. D Check that the end play is within the specified vaĆ
lues.
The first disk is a driving disk.
disk pack end play: 0.20-0.80 mm
D the play can be corrected by installing disks of differĆ
ent thicknesses, providing the thickness of the disk
pack is the same on both sides.
It is recommended to keep as close as possĆ
ible to the lowest value.
Adjusting differential bevel gear pair

Figure 145
Proceed as follows:
Figure 147
1731295
D Position the thrust ring with the splined surface 18912145

facing upwards (arrow).
D Temporarily join the adapter box and the differential
Figure 146 box casing.
Figure 148
1731296
D Heat the inner track of the taper roller bearing at apĆ 18912146
prox. 90°C and move it towards the differential
half-box until it comes into contact. D Position both outer tracks of the taper roller bearing.
D Apply LOCTITE thread-lock to the calibrated bolts. D Fit the differential in the relative box.
D Join the two half-boxes and tighten the calibrated
Figure 149
bolts to the specified torque.
Use only new calibrated bolts.
18912147
D Apply MOLYKOTE to the threading of the adjustĆ
ment ring nuts.
D Tighten both adjustment ring nuts by hand.
18912150
18912148
D If this is not the case, adjust by means of the adjustĆ
D Align the reference marks and fit the bearing supĆ ment ring nuts.
port cap on crown gear side. D ù The play can be adjusted without altering the
D Tighten the securing screws to the specified torque. bearings pre-load, by unscrewing one adjustment
Figure 151
In particular:
- to decrease the play tighten the ring nut (GH1)
and loosen the ring nut (GH2);
- to increase the play loosen the ring nut (GH1)
and tighten the ring nut (GH2).
D Tighten the adjustment ring nut by two notches on
the side opposite the crown gear in order to apply
a pre-load of 3 - 4 Nm.
D The pre-load can be corrected by adjusting both
adjustment ring nuts by the same number of
notches.
In particular:
18912149
- to decrease the pre-load loosen the ring nuts;
- to increase the pre-load tighten the ring nuts.
D Fit a dial gauge at a right angle to the outer diameter
of the crown gear flank and sway the crown forĆ
wards and backwards taking care not to move the
pinion.
D Check that the play between crown and pinion is
crown-pinion play: 0.25-0.35 mm

Figure 154
Proceed as follows:
Figure 153
18912152
18912151 D Apply LOCTITE sealant along the joining surfaces.
D cover a dozen teeth of the crown gear with Prussian D Fit the cover of the nut securing the pinion and
blue, lubricated minium or any other paint or dye tighten the securing screws to the specified torque.
that is easily removable.
Figure 155
the figure.
D When the teeth mesh, the paint is expelled by the
the exact dimension, shape and location of the conĆ
tact area (see figure on next page).
D Once all the adjustments and configurations are
correct, secure both adjustment ring nuts.
D Lock the screws securing the bearing support cap
with safety wire.
18912153
D Support the complete external box with suitable liftĆ
ing equipment.
axle keeping to the reference marks made when
disassembling.
D Tighten the securing screws and tighten to the
specified torque.
Figure 156
Shape and position of contact area

Figure 157
2. pinion positioned too far back: reduce the disĆ
tance between pinion and crown axis using a
thinner S1 spacer.
3. pinion positioned too far forward: reduce the disĆ
tance between pinion and crown axis using a
thicker S1 spacer.
18912154
SECTION 12.3
REAR AXLE
ADT 25 SECTION 12.3 REAR AXLEą1
CONTENTS
Page Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIFIC MAINTENANCE . . . . . . . . . . . . . . . . . . . 16

First reduction: bevel gear pair . . . . . . . . . . . . . . . . . . 4 Checking axle/transfer case oil level . . . . . . . . . . . . 16
Second reduction: hub and epicyclic train . . . . . . . . 8 Changing axle/transfer case oil . . . . . . . . . . . . . . . . 17
SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . . 9 EPICYCLICAL REDUCTION GEAR . . . . . . . . . . . . 18
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . 11
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Re-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Break-down drawing of self-locking
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
AXLE REMOVAL-REFIT . . . . . . . . . . . . . . . . . . . . . 13 Break-down drawing of pinion . . . . . . . . . . . . . . . . 36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Re-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Axle-knuckle hinge strip down . . . . . . . . . . . . . . . . 15
2ąREAR AXLE SECTION 12.3 ADT 25
DESCRIPTION
The axle is a dual reduction bearing type. mountings to connect to the chassis and housings for
It consists of a box type structure that contains the the bearings, as well as the brake calliper mounting
bevel gear pair with the differential, the axle shafts and flange.
hubs with the end reduction. The structure has
Figure 1
1891221
1. Axle
2. Axle support
3. Driven torque input flange
4. Brake caliper
5. Tie rod fastening bracket
6. Rocher lever fastening bracket

The first reduction is obtained by the pinion ćring bevel The differential gear box with ring bevel gear is
Figure 2
3
4
16
5 A
15 6
13
B
12 11 10 9 8
1731213A 1731213B
1. Input flange 11. Differential gear carrier shaft

2. External taper roller bearing 12. Side pinion
3. Internal taper roller bearing 13. Crown wheel
4. Bevel pinion 14. LH adjustment ring nut
5. Ring bevel gear 15. LH taper roller bearing
6. RH taper roller bearing 16. Differential gear box (version A)
7. RH adjustment ring nut 17. Adjustment shim for pinion axial position
8. Differential gear box (version B) 18. Pinion bearings pre-load adjustment ring
9. Multi-disk clutch
10. Pressure plate (version B) A: differential standard version
Figure 3
1731214
1. Crown wheel
4. Crown wheel gear
5. Side pinion
7. Bevel pinion
11. Shoulder
Operation Under these conditions there is no relative motion

The driving torque coming from the propeller shaft is between the two crown wheels and therefore the side
transmitted by a universal joint to the bevel pinion. pinions do not turn around their shaft which is integral
From here the torque passes to the ring bevel gear, to the differential gear box.
which is integral to the differential gear box. When the resistance of one wheel is greater than that
The differential is a gear for which the box represents of the other, or when the speed of the two wheels is not
the train carrier, that carries the differential gear carrier the same (vehicle on a road with bends) the crown
shafts and receives the driving torque, whereas the two wheel gears have a different rotation speed: the
side gears, which represent the crown wheels, both of relevant motion is permitted by the side pinions, that
which rotate, receive the driving torque and transmit it now turn around their shafts in directions opposite to
to the axle shafts. each other.
When both wheels are subject to the same stall torque Obviously at a lower crown wheel rotation speed the
or have the same speed (vehicle being driven on a transmitted driving torque is greater, and vice versa.
straight road), the ring bevel gear and the differential Therefore when the differential is operating, the wheel
gear box rotate as one, transmitting the torque in equal with a lower speed can transmit a greater torque,
parts to the two crown wheels, and from here to the two whereas the wheel with a higher speed can transmit a
axle shafts, that rotate at the same speed: the wheels lower torque.
transmit the same driving torque. Under certain conditions it may happen that the slower
wheel loses its grip completely, since the torque is
Figure 4 exceeded that can be transmitted to the ground, and
percentage.
1731215

1731216

(example)


Figure 6
8 9 10 12 15
6 4 3 2
1731217A 1731217B
1. Axle Operation
5. Wheel mounting bolt The four side pinion gears rotate in the opposite
6. Epicyclic train crown gear direction to the crown gear, whereas the crown wheel
7. Pivoting roller bearing is integral to the hub support and therefore does not
8. Epicyclic train carrier turn. This makes the train carrier turn in the opposite
9. Epicyclic train side pinion gear direction to the side pinions, therefore in the same
10. Epicyclic train crown gear direction as the axle shafts.
11. Grooved shank connecting axle shaft-crown Since the train carrier is integral to the wheel hub, the
wheel wheel turns in the same direction as the axle shaft.
12. Hub
13. Brake disk
14. Seal ring
15. Axle shaft

AXLES ZF AP9 / HK
Drive wheel configuration 6x6
Type Bearing with double reduction
Transversal differential lock-type Slip limited
Locking factor 100%
Axle shaft type Full floating
Bearings for bevel pinion 2, with taper rollers
Bearings pinion 2, with taper rollers
Reduction ratio 1 : 3.44
Epicyclic reduction gear ratio on the wheels 1 : 6.35
Total reduction ratio (differential + hub) 1 : 21.85
Bevel pinion bearings rolling torque adjustement 1.5-2.3 Nm 1.1-1.7 lb ft
Differential housing bearing rolling torque 0.3-0.4 Nm 0.22-0.3 lb ft
Backlash adjustments Through ring nuts
Backlash between pinion and crown wheel 0.25-0.30 mm 0.0098-0.0090 in
DIAGNOSTIC
1. Vibrations
2. Continuous noise

rectly
worn components
rect
rect (excessive)
cessive
worn
damaged
or decelerating
d l ti
excessive
loose torque
specified torque
TIGHTENING TORQUES
AXLE
1. Hex head screws securing tie rod anchoring plate on axle 380 Nm (280 ft lb)
2. Allen screws securing tie rod anchoring plate on axle 580 Nm (428 ft lb)
3. Screws securing support and rocker bracket on axle 600 Nm (443 ft lb)
4. Rocker joint pin nut 1000 Nm (738 ft lb)
5. Nut securing rocker securing bracket 600 Nm (443 ft lb)
6. Screws securing tie rod to bracket 600 Nm (443 ft lb)
Figure 7
1891223

Ring nut securing internal toothed wheel flange: see values given for the different versions
Brake calliper mounting screw: 295 Nm (217 lb ft)
DIFFERENTIAL
Motion input flange mounting nut: 600 Nm (441 lb ft)
Bolts securing ring bevel gear to differential half-box: 125 Nm ( 92 lb ft)
Calibrated bolts securing differential half-boxes: 110 Nm ( 81 lb ft)
Screws securing differential bearing support caps: 295 Nm (217 lb ft)
Oil level cap 150 Nm (110 lb ft)
Oil drainage cap 150 Nm (110 lb ft)
TOOLS

5870 610 001: : Wheel fastening stud assembly (to be used with 5870 610 002)
5870 610 002: : Wheel fastening stud assembly
DIFFERENTIAL
5870 405 003: Riveting kit complete
to use only with drill 5870 101 007
5870 240 002: Pinion motion input flange locking tool.

5870 026 000: Basic kit to remove inner track of internal bearing from bevel pinion
to be used with extractor 5870 026 014

5870 058 073: Internal pinion external bearing track assembly plug
5870 340 001: Thickness gauge ring to measure pinion bearing preload spacer
5870 055 074: Pinion seal ring assembly plug
AXLE REMOVAL-REFIT
. Before starting any type of operation make D remove both wheels following the instructions in
SECTION 13.1;
D under the front axle place an appropriate hydraulic
jack that allows lowering at removal;
D disconnect the braking system hydraulic union (30);
D remove the propeller shaft (10) as described in
1.2 of this manual.
Section 10;
D loosen the screws (a) securing the bracket to the tie
experience.
rod (2);
D on both sides, remove the split pin (b) and loosen
the fastening nut (5) of the rocker arm pin;
jobs correctly.
D remove the rocker arm pin (4), picking up the
washers and the bushings (6), then remove the
Removal bearing (7), clearing the rocker arm from the axle;
To remove proceed as follows: D very carefully lower the axle(1) and remove it from
D bring the vehicle onto a suitable flat, solid surface, the vehicle.
switch off the engine, remove the ignition key,
engage the parking brake and apply the warning Refit
signboards. To refit follow the removal operations in reverse order.
circuits;
D disconnect the central lubrication system unions
(arrow);
then place two supporting trestles under the front
chassis, without touching the axle (1);
Figure 8
1731209
Axle-knuckle hinge strip down

To strip down, proceed as follows: D remove the rocker arms support (11) from the axle
D loosen the fastening screws (c) and (d) and remove (1) using suitable lifting equipment;
tie-rod fastening bracket (12); D loosen the nuts (e) securing the rocker support
brackets (13) and remove the brackets.
D loosen the fastening screws (e) securing rocker
support (11) and rocker support bracket (13) to the
axle;
Figure 9
1891226
SPECIFIC MAINTENANCE Figure 12
Checking axle/transfer case oil level

Proceed as follows:
position;
Figure 10
156NM81
D check that breather is perfectly clean and working.
156NM80B
paragraph;
torque;
each axle.
Figure 11
156NM80A

(2) for the check.
Changing axle/transfer case oil Figure 15

Collect and dispose of used lubricants and

Proceed as follows:
Dumping
Figure 13
156NM120A
D clean the differential cap area and remove the cap

(b) and the drain cap (a); drain all the lubricant;
156NM82A
lowest position;
Figure 14
156NM83
D axles: arrange a suitably sized container, clean the
18ąąREAR AXLE SECTION 12.3 ADT 25

Figure 18
1.2 of this manual.
operations.
Removal
Proceed as follows:
Figure 16
1891240

caliper.
Figure 17
1891250
VERSION A
1. lock nut
2. stop plate
1891241
VERSION B
VERSION C
2. counter lock nut
ADT 25 SECTION 12.3 ąREAR AXLEą19
Disassembly
Figure 22
Figure 19
1891245
Figure 20
1891246

1891243
Figure 21
1891247

1891244
Figure 25 Figure 27
1891251
1891248
the stop plate.
Figure 28
Figure 26
1891252
1891249
gear wheel.
1891253
Figure 30 Figure 32
1731228 1731231
side.
Figure 31
Figure 33
1731232

1891254 Figure 34
wheel side.
1891255


Figure 35
Wheel hub
wear;
Axle shafts
Final reductions
1891256
Figure 36
Re-assembly

Proceed as follows:
1891257 Figure 37

1891260
002.
Figure 38 Figure 40
1891263
double dowel pins.
Figure 41
Figure 39
1891264
1891262

Figure 42 Figure 44
1891267
sealing ring.
sealing ring.
the figure.
Figure 45
1891265
wheel side (B).
Figure 43
1891268
1891266


Figure 46
Proceed as follows:
Figure 49
1891269

1731271
C).
Figure 50
1731242

1891272
Figure 48
ring Mtring.
1891270

Versions A and B
Figure 53
Figure 51
1891273
1891273
Figure 52
1891272

following formula:
S = D ć 0.25 mm
Version C
Figure 55
Figure 57
1891275 1891273
Figure 56
Figure 58
1891276
1891276

Proceed as follows:
Figure 61
1891272

1731277
torque.
Figure 60
1731278
Figure 63
1891276
1731279

carrier plate.
Figure 64 Figure 65
1731250 1731251

values.
Example:
dimension a
dimension b


0.30/0.50/1.00/3.00 mm.
Figure 66 Figure 68
1891280 1891281
Figure 69
1891282

torque.
disassembly.
drainage cap.
DIFFERENTIAL
Before starting any type of operation make D Using appropriate lifting equipment support the
sure all the necessary safety precautions differential external box assembly, and with a
have been taken and fully explained to those suitable screw extractor remove the assembly from
involved in the operations. the axle.
Read the relevant instructions in SECTION D Place the assembly on a supporting stand with the
1.2 of this manual. appropriate adjusting elements.
experience. Figure 72
jobs correctly.
Removal
Proceed as follows:
D Remove the axle shafts from the axle as described
in the previous paragraph.
Figure 70
1731255
D Remove the safety wire from the cap support
mounting screws and the ring nut locking plates.
D Remove the locking plates from both bearing
pre-load adjustment ring nuts.
1731254
D Loosen the screws that secure the differential
external box to the axle.
mark the position between box and axle
(arrow).
Figure 71
1731255
Figure 73 Differential disassembly

Proceed as follows:
Figure 75
1731257
D Loosen both bearing pre-load adjustment ring

nuts.
Figure 74
1731259
D Using special tools 5870 024 005 and 5870 002 404
1731258
remove the taper roller bearing outer track from the
D Loosen the mounting screws and remove both differential half-boxes on the crown wheel side (C)
support caps. and side pinion side (D).
mark each support cap and corresponding
Figure 76
external box (arrows).
D Remove both adjustment ring nuts.

D Using appropriate lifting equipment remove the
differential assembly from the external box and take
it to the work bench.
1731260
D Loosen all the mounting screws and remove the
Mark both differential half-boxes before
this operation (arrows).
Figure 77 Figure 79
1731261 1731263
D remove the thrust ring, the driven /driving disks, the D Remove the crown wheel gear, the crown wheel
crown wheel backing plate and the crown wheel backing plate, the driven and driving disks and the
gear. thrust ring.
Do not invert the position of the disks. Do not invert the position of the disks.
Figure 78 D If necessary, separate the bevel ring gear from the

differential half-box, using a suitable tool to remove
the rivets.
D Knock lightly to separate the crown wheel from the
Pinion disassembly
Proceed as follows:
Figure 80
1731262
1731264
D Remove the split pin and loosen the crown nut with
tool 587024002.
D Remove the flange using a commercial extractor.
Figure 81 Checking the dismantled parts
Bearings
- check the condition of the bearings replace them
wear;
Crow wheel gear

Side pinions
1731265
D Remove the oil seal ring from its housing. Even if only one element is found damaged,
the complete gears assy must be replaced.
Figure 82
Crosshead pins
- check the mating surfaces with the side pinions.
Thrust rings
Bevel gear pair

- check that the teeth of the crown and the pinion are
worn evenly over the whole working band of the
tooth: replace the bevel pair if there are signs of
pitting, cracks and/or sinking;
1731266
Irregular wear may indicate incorrect
D With a plug and a press extract the pinion from the adjustment of the bearings: check they are
external box. intact before reassembling.
D Remove the inner ring of the external bearing (A).
Figure 83 Even if only one element is found damaged,

the complete pair must be replaced.
- When installing the new bevel pair assembly, check
numbers.
Ring nuts
- check the thread on the bearing locking ring nut:
ensure there is no denting, strain and /or seizure:
there must be no denting, strain and/or seizure;
External box
1731267
D Using 587002600+5870026014 remove the inner signs of strain and/or ovalising;
ring of the pinion internal bearing (B). - check that the sealing surfaces and threads are
D Remove both outer tracks of the taper roller intact and are not dented or damaged.
bearings from the external box.
Figure 84
1731268
Break-down drawing of self-locking differential
11. Ring bevel gear and differential half-box
12. Thrust ring
13. Driving disks (internal grooving)
14. Driven disks (external grooving)
15. Crown wheel backing plate
16. Crown wheel
17. Side pinions shaft
18. Side pinion
20. Mounting screw
Figure 85
1731269
Break-down drawing of pinion
13. Split pin
14. Notched nut
15. Washer
16. Motion transmission flange
17. Protection ring
18. Seal ring
19. External taper roller bearing (B)
20. Bearing pre-load spacer S2
21. Pinion
22. Internal taper roller bearing (A)
23. Pinion axial position spacer S1
24. External box
Re-assembly Figure 86
When reassembling, bear in mind the
- heat the bearings and gears that are
assembled by pressure in an oven at
905C (194 °F);
- accurately centre the seal rings and
Carry out all the indicated measuring

procedures with maximum precision.
Imprecise measurements leave a bad
contact pattern and make it necessary to 1731270
repeat the procedure.
Finding the thickness of spacer S1 for pinion axial
position
Proceed as follows:
D Fit both differential bearing support caps, attaining
to the reference marks made when disassembling.
Figure 87
1731271
First operation
D Insert tools 5870500001 + 5870500006 the Example:
differential support seats and tools 5870351000 + dimension a+b: 191.80 mm (7.55 in)
5870351005 in the pinion seats.
dimension b is to be found using a thickness
D Determine distance H between the resting surfaces
gauge
of internal bearing (A) and centre of the differential
support. dimension c: 15.00 mm (15.24 mm)
(1/2 diameter of measuring shaft)
dimension H= a+b+c: 206.80 mm (8.15 in)
Figure 88 D Remove the differential bearings support caps.
Figure 90
1731272
1731274
Second operation
D Fit correctly sized spacer S1 in the box as previously
D Find thickness S of the internal taper roller bearing described.
(A).
Example: Figure 91
Dimension d: 90.00 mm (3.54 in)
Value measured e: 43.90 mm (1.72 in)
Bearing thickness S=d - e: 46.10 mm (1.82 in)
Figure 89
1731273
Third operation
D Find the required value depending on pinion
assembly dimension X
D Read value V engraved on the surface of the pinion
(arrow) and add it to thickness S of the bearing.
Example:engraved value V 159.90 mm (6.30 in)
Bearing thickness S 46.10 mm (1.8 in)
dimension X =V+S: 206.00 mm (8.11 in)
Calculation of thickness for spacer S1 1731275

D The thickness required for the spacer is found by
the difference between dimension H measured on D With the aid of tool 5870058073, insert the outer
the differential external box and the required track of bearing (A) in the differential box.
dimension X. D Turn the box and fit the outer track of bearing (B) in
Example: its seat.Finding the thickness of spacer S2 for
Thickness of spacer S1= H ć X: 0.80 mm (0.0314 in) bearings pre-load and pinion assembly.
D Remove the special tools used for the
measurements.
Figure 92 Figure 94
1731278
1731276
Proceed as follows: D Position measuring tool 5870034001 on the pinion
shoulder.
Figure 93
The spring pins are to face the grooved part
of the pinion (arrow).
Make sure that the pins protrude sufficiently
so that the overall thickness of the tool is
more than the presumed thickness of
spacer S2 to be found.
Figure 95
1731277
D Heat the inner track of bearing (A) to about 90°C
(194 °F) and fit it on the pinion. Make sure it is up
against the shoulder of the pinion.
1731279
D Place the pinion assembled in this manner on a

spacer pipe. Lift the differential box and carefully
position it over the pinion, so that the weight of the
box packs down the pinion bearings
D Heat the bearing inner track to about 90°C (194 °F)
and fit it on the pinion.
Figure 96 Figure 98
1731280 1731282
D Lock the control flange on the pinion groove. D Remove and measure the thickness of the
D Fit the slashed nut and tighten it to the specified measuring tool 587034001 using a micrometer.
torque using tool 5870240002 D The thickness found will be that for spacer S2.
Figure 97 Crown wheel assembly ć riveted.

Proceed as follows:
D Heat the inner diameter of the crown wheel to about
90°C (194 °F) and insert the crown wheel against
the differential half-box surface to have full contact.
D Using tool 5870405003 rivet the crown wheel onto
For this cold riveting operation a press of at
least 30 t (66225 lb) is necessary.
Use only the riveting kit 5870405003
supplied as spare part.
The riveting is to be carried out with extreme
precision so that the crown wheel rotates
without eccentricity.
1731281
pinion rolling torque :
1.5P2.3 Nm (1.1P1.7 lb ft)
D The rolling resistance can be corrected by
loosening or tightening the slashed nut.
Make a note of the torque value, as this will
be needed in the next stage.
D Remove the slashed nut, take out the control flange,
remove the inner ring of bearing (B) and withdraw
the pinion from the differential box.
Crown wheel assembly ć bolted. Complete self-locking differential assembly.

As an alternative it is possible to bolt the crown wheel Proceed as follows:
to the differential half-box.
Figure 100
Figure 99
1731284
90°C (194 °F) and fit it tightly onto the differential
half-box.
Figure 101
1731283
Proceed as follows:
D Check that the contact area between crown wheel
and differential half-box is clean and free of grease.
Use only original components supplied as
spare parts.
1731285
D At the end of the operations temporarily assemble D Position the shoulder ring with the grooved surface
the other half-box, arrange the group between the facing downwards (arrow).
two points and with a dial gauge, check that the
eccentricity is within the specified values.
1731288
D Fit a crown wheel gear onto the shoulder plate

Make sure that the crown wheel is locked
inside the two internally grooved plates.
Figure 105
1731286
D Fit an externally grooved disk (driven disk) and an

internally grooved disk (driving disk) in alternation
until all the disks have been mounted.
Figure 103
1731289
them on the crown wheel gear.
Figure 106
1731287
D Fit the crown wheel shoulder plate with the flat side
downwards on the top of the internally grooved
disk.
1731290
gear assembly.
Figure 107 Finding the disk pack axial clearance

Proceed as follows:
Figure 109
1731291
D Fit the other crown wheel gear backing plate with

the flat side upwards.
1731293
Figure 108
First operation
D Find the value a between the box mounting plane
and the internally grooved plate.
Figure 110
1731294
1731292
Second operation
D Fit an internally grooved disk (driving disk) and an D Find dimension b between box and cover mounting
externally grooved disk (driven disk) alternately until plane
all the disks have been mounted. Example:
The first disk is a driving disk. dimension a: 6.00 mm (0.236 in)
dimension b: 5.80 mm (0.228 in)
Difference a ć b: 0.20 mm (0.0078 in)
(disk axial clearance)
D Check that it is within the specified values.
disk pack axial clearance
0.20P0.80 mm (0.0078P0.031 in)
D the clearance can be corrected by installing disks of
different thicknesses, providing the thickness of the
disk pack is the same on both sides.
It is recommended to keep as close as

possible to the lowest value.
Figure 111 Pinion assembly

Proceed as follows:
Figure 113
1731295
D Position the shoulder ring with the grooved surface

facing upwards (arrow). 1731297
Figure 112 D Position spacer S2 onto the pinion shoulder, then fit
the assembled pinion in the differential box.
D Fit the bearing inner ring (B).
Figure 114
1731296
90Ă°C (194Ă°F) and position it against the differential
half-box until it comes into contact.
1731298
D Apply LOCTITE thread stop to the calibrated bolts.
D Join the two half-boxes and tighten the calibrated D Apply LOCTITE sealant on the outer diameter of the
bolts to the specified torque. seal ring
D Using tool 5870055074 insert the seal ring into the
Use only new calibrated bolts. differential box.
The seal ring lip is to face inwards.
1731299 17312101
D Mount the flange onto the pinion. D Apply MOLYKOTE to the thread of the adjustment
D Position the washer and tighten the slashed nut to ring nut.
the specified torque using tool 587024002. D Tighten both ring nuts by hand.
D Lock the slashed nut in its seat with a split pin.
Figure 118
Finding the differential bearing pre-load
Proceed as follows:
Figure 116
17312102
D Align the markings and fit the bearing support caps.

D Fit the washers and cap mounting screws and
17312100 tighten to the specified torque.
D Position the outer tracks of the taper roller bearings
on both ends of the differential.
D Using suitable lifting equipment, assemble the
crown wheel group in the differential box.
Figure 119 Checking the pinion-crown wheel backlash

Proceed as follows:
Figure 121
17312103
D Tighten both adjustment ring nuts to obtain the

specified distance between the supports,
measured diagonally.
distance for supports:
340.00P340.30 mm ( 13.4 in)
Figure 120
17312104
D Assemble a dial gauge at a right angle to the outer

diameter of the crown wheel flank and sway the
crown forwards and backwards taking care not to
move the pinion.
D Check that the backlash between crown and pinion
is within the specified values.
crown-pinion backlash:
0.25P0.35 mm (0.0098P0.014 in)
Figure 122
1731281
total rolling torque:
1.8P2.7 Nm (1.3P2 lb ft)
The rolling torque measured includes the
torque of the pinion bearings.
D The rolling torque can be corrected by varying the
two adjustment ring nuts by the same number of
notches.
D In detail: 17312105
- loosen the ring nuts to decrease the rolling
torque;
- tighten the ring nuts to increase the rolling
torque;
D If this is not the case, adjust by means of the Figure 124

adjustment ring nuts.
D the backlash can be adjusted without altering the
bearings pre-load, by unscrewing one adjustment
D In detail:
- tighten ring nut (C) and loosen ring nut (D) to
reduce the backlash
- tighten ring nut (D) and loosen ring nut (C) to
increase the backlash

Proceed as follows:
17312107
Figure 123
- Once all the adjustments and configurations are
correct, fix the locking plates of both adjustment
ring nuts with screws and safety wire.
- Lock the mounting screws of both bearing support
caps with safety wire.
Figure 125
17312106
D cover about a dozen crown teeth with Prussian blue,
lubricated red lead or other paint or marking that
can easily be removed.
the figure.
D When the teeth mesh, the paint is sent out by the
17312111B
the exact dimension, shape and location of the D Support the complete external box suitable lifting
contact area (see figure on next page). equipment.
axle attaining to the reference marks made when
disassembling.
D Tighten the mounting screws and lock to the
specified torque.
Figure 126
a a a
b b b
1 2 3
1731208 1731209 1731210
Shape and position of contact area Figure 127

2. pinion positioned too far back: reduce the
thinner S1 spacer.
3. pinion positioned too far forward: reduce the
thicker S1 spacer.

156NM123
SECTION 13.1
BRAKES
ADT 25 SECTION 13.1 BRAKESą1
CONTENTS
Page Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE BRAKE PADS REPLACEMENT . . . . . . 12

Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Running in the service brake pads . . . . . . . . . . . . . 13
SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . . 5 SERVICE BRAKE DISK REMOVAL-REFIT . . . . . 14
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . 7
PARKING BRAKE CALIPER
SERVICE BRAKE CALIPER
REMOVAL-REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL-REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Refit and air bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PARKING BRAKE DISK REMOVAL-REFIT . . . . 20
BRAKE CALIPER OVERHAUL . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Dismantled parts check . . . . . . . . . . . . . . . . . . . . . . . 11
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2ąBRAKES SECTION 13.1 ADT 25
DESCRIPTION
Principle
The vehicle is fitted with the following braking systems, The parking brake consists of a disk mounted on a the
all hydraulically controlled: rear propeller shaft with two reverse hydraulic control
D service brake with disk brakes on all the wheels; calipers.
D parking brake with disk brake on the transmission, The fluid required to activate the actuators is obtained
The service brake consists of disk brakes fitted with from the single hydraulic system of the vehicle.
floating calipers with two pistons.
Figure 1
2 3
1
9 6
11
5
7
10 10
8
12 13
1891301
1. front axle service brake calipers 7. brake pump

2. intermediate axle service brake calipers 8. filter
3. rear axle service brake calipers 9. tank (single)
4. parking brake calipers 10. service brake pressure accumulation tank
5. service brake distributor 11. parking brake pressure accumulation tank
6. parking brake distributor 12. start-up exhaust valve
13. accumulator recharge valve
Operation
Service brake Parking brake
Figure 2 Figure 4
1731317 1731319
With the brake pedal released, the pressure does not With the parking brake control released, the pressure
operate on the pistons (Figure 2). Therefore the disks operates on the internal piston (Figure 4) compressing
are free to rotate as they are not pressed by the brake the spring and freeing the pad from the brake.
pads.
Figure 5
Figure 3
1731320
1731318
When the control is activated, the parking brake disĆ
With the pedal pressed, pressure is sent by the disĆ tributor discharges the pressure, so that the spring can
tributor to the pistons (Figure 3) that compress the operate on the pads (Figure 5) and lock the disk.
pads pressing the disk. To allow a correct distribution of the braking force on
The amount of braking action depends on how hard the the two sides of the disk, the caliper is of the floating
driver presses on the brake pedal. type, with a piston on one side only.
As there are pistons on both sides of the caliper, both
the disk and the caliper are the fixed type.
System circuit Indip. circuits for front and rear brakes
Brake type Disc - outboard
Control Fully hydraulic
Specifications and data
Service brake calipers Fixed
calipers per wheel 1
Cylinders per caliper diameter 2
Brake disc outside diameter 476.3 mm 18.7 in
standard 15.88 mm 0.625 in

Brake disc thickness
min. admitted 14 mm 0.55 in
Parking brake callipers Floating
Park brake disc thickness standard 12.7 mm 0.5 in
Number calipers (park brake) 2
Number cylinders per caliper 1
Park brake disc outside diameter 390 mm 15.35 in
Park brake disc inside diameter 175 mm 6.89 in
DIAGNOSTIC
1. Brakes either do not work or do not develop much braking power
2. Uneven brake action
3. Brakes are jammed
Brakes either do not work or do Pads worn Replace the pads

not develop much braking power
Brake discs worn Replace brake discs
Lubricant on brake discs Clean brake discs. Seek source of

lubricant and repair, as required
Hydraulic pipes damaged Check integrity of pipes and reĆ

place, if required
Fittings loose Tighten fittings and replace, if damĆ

aged
Pump intake pipe leakage Check for leakage and replace pipe,
if required
Hydraulic pump not working and/or See hydraulic system troubleshootĆ

worn ing - Slow hydraulic functions
Uneven brake action Brake disc scratched Replace brake discs
Presence of grease or oil on pads Remove and refit correctly

and discs
Brake caliper incorrectly adjusted Adjust
Brake pads not genuine Replace the pads
Brakes are jammed Brake caliper incorrectly adjusted Adjust brake calipers
Jammed control units Replace faulty parts
TIGHTENING TORQUE
Screws fastening service brake caliper to axle: 295 Nm (217 lb ft)
Service brake centring pin fastening screws: 25 Nm ( 18 lb ft)
Hub support fastening screws: 460 Nm (339 lb ft)
Service brake disc fastening screws: 295 Nm (217 lb ft)
Parking brake caliper fastening screws: 120 Nm ( 88 lb ft)
SERVICE BRAKE CALIPER REMOVAL-REFIT

. Before starting any type of operation make D cut off the battery isolator switch or disconnect the
circuits;
D remove the wheel relating to the brake involved in
1.2 of this manual.
the operation as described in SECTION 13.2;
D prepare a suitable container, disconnect the hyĆ
perience.
draulic union (2) from the caliper (1) and seal it herĆ
metically;
D suitably sustain the caliper (1), unlock the front and
rectly.
rear screws (3) securing it to the axle and remove
the caliper with the pads.
Removal
boards;
Figure 6
1731301A
Refit and air bleed

D To refit follow the removal operations in reverse D press the brake pedal down fully, keeping it in this
order. position;
D Subsequently bleed off the air from the circuit proĆ D loosen the valve to send out the oil and air bubbles,
ceeding as follows. then close it after a few seconds;
D if the end of the transparent hose remains immersed
Figure 7 in the vessel it is not necessary to close the valve;
D release the brake pedal completely;
D repeat the operation until oil with no air bubbles
comes out of the breather valve;
D refit the cap and repeat the operation for all the veĆ
hicle braking units;
D at the end of the operation check the oil level in the
tank and top up if necessary.
1731302A
D remove the dust cover cap, then insert a transparent
section of hose onto the breather valve and dip one
end of the pipe into a vessel containing a certain
quantity of oil;
BRAKE CALIPER OVERHAUL
Disassembly
D Proceed as follows:
Figure 9
Figure 8
1731304
D unlock the mounting screws (2) and remove the

plate (1);
Figure 10
1731303
D unlock both mounting screws (2) and remove both

larger diameter indexing pins (4);
D remove both pads (1) from the caliper (3);
D unlock both mounting screws (5) and remove both
smaller diameter indexing pins (6);
1731305
D remove the cover (1) and the gasket (2), then presĆ
sing on the inner side of the caliper, remove the pisĆ
ton (3), after which remove the dust cover (4), the
gasket (5) and the shoulder ring (6) from the caliper.
D repeat these operations for all the caliper pistons.
Dismantled parts check

Proceed as follows: Figure 12
D use a metal brush to remove the dirt from the caliper
body, then remove the residue with a brush and
thoroughly clean the piston seats;
D remove the breather valves, then using comĆ
pressed air carefully clean all the internal channels;
D with a cloth dipped in propyl alcohol or an
equivalent, carefully clean the piston sliding surĆ
faces;
D check the pistons and their seats for wear: if wear
or damage is found, replace;
D insert the pistons into their seats by hand and check
they slide smoothly: if they do not, replace them;
D check the condition of the pad guiding pins.
If damage is found, replace.
1731307
Always replace gaskets, seal rings and dust
covers even if they seem to be intact. D fit the piston (1) in its seat fitting the dust cover in the
At reassembly lubricate all the internal comĆ piston groove, then mount the seal gasket (2) and
ponents with the prescribed hydraulic fluid. the cover (3). Repeat these operations for all the
caliper pistons;
Reassembly
Proceed as follows:
. To make the operation easier, turn the piston
slightly when inserting.
Figure 11
Figure 13
1731306
1731308
D mount the shoulder ring (1), gasket (2) and dust
cover (3) in the seat on the caliper; D refit the plate (1) and tighten the mounting screw (2)
to the specified torque;
D fit the new pads working in reverse order to the disĆ
assembly.
SERVICE BRAKE PADS REPLACEMENT
Replacement
To replace, proceed as follows: Figure 15
Figure 14
1731310
D fit the new pads, inserting them from the caliper end
without indexing pins, sliding them along the disk
surface and fitting them onto the smaller diameter
indexing pins (arrow);
1731309
D unlock both mounting screws (2) and partially bring

out the two larger diameter indexing pins (4) so as
to leave the pad eyelet (1) free;
D connect a hose to the breather valve (5) e prepare
an appropriate container to collect the fluid coming
out;
D with a lever or large screwdriver prise both pads
from the brake disk to bring the barrels as far as
possible into the seats;
D disconnect the hose from breather valve and close
it;
D remove both the pads (1) withdrawing them from
the end of the caliper without indexing pins (3);
Figure 16 Running in the service brake pads

To run in proceed as follows:
. During this procedure it is usual to note the

emission of vapours and unpleasant smells
coming from the pad abrasive material.
D run at a moderate speed (10÷20 km/h (6.2÷12.4
mph)) with an extremely slight braking pressure
until the surface temperature of the disk reaches
315÷370 °C (599÷698 °F);
Find the disk temperature by stopping the
vehicle and measuring with a pyrometer
touching the disk.
D allow the disk to cool to a temperature of about
95Ą°C (203 °F), then repeat the heating operation
as before;
D allow the disk to cool to a temperature of about
10Ą°C (50 °F) over the environment temperature,
then test the brakes: if the result is not satisfactory,
repeat the whole procedure.
1731311
D insert the indexing pins in their seats, checking that

the clearance between the indexing pins and the
disk (detail), is within the specified values:
1.5 >h > 2.0 mm (0.06 > h > 0.08 in)
D if necessary adjust the position of the pins, then
tighten the screws to the specified torque.
SERVICE BRAKE DISK REMOVAL-REFIT

. Before starting any type of operation make Figure 18
1.2 of this manual.
perience.
rectly.
Removal
D Mark the reciprocal positions of the gear carrier
plates and the hub (arrows).
D Using the appropriate screw extractor remove the
boards;
gear carrier plate from the hub.
terminals from the battery to avoid the risk of short Figure 19
circuits;
D remove the caliper associated to the brake being
serviced following the instructions in the relevant
Chapter;
D drain off the lubricant oil as described in the relevant
paragraph;
Figure 17
1731222
D Remove the gear carrier plate assembly.
Figure 20
1731220
D Loosen all the hexagon head screws.
1731224
D Remove the crown wheel gear from the grooved
bushing.
Figure 21 Figure 24
1731226 1731230
D Unscrew the mounting screws, remove the locking D Support the hub with the brake disk by means of
plate, then remove the internal toothed ring nut suitable lifting equipment and knocking it lightly,
using tool 5870656005. cautiously withdraw it from the hub support. Take it
to the work bench.
Figure 22 D Remove the seal ring from the hub support.
Figure 25
1731227
D Remove the internally toothed wheel from the hub
by hand. 1731233
Figure 23 disk.
1731229
D Remove the outer bearing inner track (B) from the
hub support.
Refit
Figure 28
. Bear in mind the following during the refit:
- heat the bearings and gears to be thrust
into place in an oven at a temperature of
90°C (194 °F);
- accurately centre the seal rings and bearĆ
ings, using the special tool or a hammer
to assemble them;
Proceed as follows:
Figure 26
1731240
D Suitably support the hub assembly, so as to ensure
correct centring, the gently slide it on the end of the
hub support until it comes up against the internal
bearing.
Figure 29
1731237
D Fit the brake disk on the hub and tighten the screws
B
Figure 27
1731241
D Install the external bearing inner track to come into
contact.
A
1731239
D Use a suitable plug to assemble the seal ring then
the bearing inner ring onto the hub support.
seal ring.
The lip of the seal ring is to face inwards.
Figure 30 Figure 32
1731243 1731247
D Slide the complete toothed wheel with internal
D Using a cable and a commercial torque wrench
toothing onto the hub support groove.
check that the rolling torque of the hub bearings
D Assemble the crown wheel gear.
(pre-load) is within the specified values.
To determine the hub bearing pre-load Rolling torque:
re-used bearings 6.0 to 9.0 Nm (4.4 to 6.63 lb ft)
D Proceed as follows:
D Otherwise change the tightness of the ring nuts.
Figure 31
Figure 33
1731246
1731248
D Apply MOLYKOTE to the hub support thread and to
D After adjusting the bearing pre-load lock the ring
the thread and contact area of the ring nut.
nut with the plate and locking screws.
D Assemble the locking ring nut and tighten to the
specified torque using tool 5870656005.
Figure 34 Figure 35
1731225
D Assemble the brake caliper tightening the mountĆ
ing screws to the specified torque.
1731252 the pad guide pins, following the instructions in the
relevant paragraph.
D Apply sealant to the contact surfaces, assemble the D Continue by connecting the hydraulic coupling and
differential gear carrier plate assembly into the hub bleeding the air from the circuit as described in the
and tighten the mounting screws to the specified relevant paragraph.
torque. D Fill the hub with the required quantity of specified luĆ
bricant up to the oil check level.
. Match the reference made at disassembly.
drainage cap.
PARKING BRAKE CALIPER REMOVAL-REFIT

1.2 of this manual.
perience.
rectly.
. To make the illustrations clearer, the calliper

protection plate has been removed.
Removal 1731313
To remove proceed as follows: D unscrew the mounting screws and remove the caliĆ
D bring the vehicle onto a suitable flat, solid surface, per with the bracket from the housing on the axle
switch off the engine, remove the ignition key, enĆ taking care not to bend the pipe;
boards. . When handling the caliper never put your
fingers or hand in the space between the
Apply suitable chocks to the wheels to avoid pads.
uncontrolled vehicle movement when the
calipers are removed. D place a piece of hard wood 10-12 mm (0.39-0.47
in) thick between the pads to simulate the presence
D cut off the battery isolator switch or disconnect the of the disk, then discharge the hydraulic pressure,
terminals from the battery to avoid the risk of short disconnect the manual pump coupling and free the
circuits; caliper;
D lock knuckle with the steering lock bar following the D if necessary dismantle the caliper from its bracket;
instructions in SECTION 1.2; D repeat the operation for the other caliper.
Figure 36
Refit
To refit reverse the removal operations.
Continue bleeding off the air in the circuit as indicated
in the Chapter HYDRAULIC OIL REPLACEMENT.
1731312
D disconnect the hydraulic coupling and appropriateĆ

ly plug the pipe;
D connect the coupling to a manual pump and use the
pump to obtain the hydraulic pressure needed to
disengage the pads;
PARKING BRAKE DISK REMOVAL-REFIT

circuits;
D Loosen the securing screws and remove the upper
1.2 of this manual.
brackets (4) securing the calliper protection plate;
D remove the parking brake calipers as described in
perience.
the relevant chapter;
D remove the propeller shaft (3) from the parking
brake side following the instructions in SECTION
rectly.
10;
D remove the radial centring splines (2) located beĆ
Removal tween the joint fork and the disk;
To remove proceed as follows: D appropriately support the disk (1), and using a soft
D bring the vehicle onto a suitable flat, solid surface, hammer knock the disk to remove it from the flange.
gage the parking brake and apply the warning signĆ Refit
boards; Refit following removal operations in reverse.
Bleed the air from the circuit as described in the
Apply suitable chocks to the wheels to avoid
Chapter HYDRAULIC OIL REPLACEMENT.
uncontrolled vehicle movement when the
calipers are removed.
Figure 38
1891302
SECTION 13.2
WHEELS AND TYRES

ADT 25 SECTION 13.2 WHEELS AND TYRESą1
CONTENTS
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . . 4
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . 4
COMPLETE WHEEL REPLACEMENT . . . . . . . . . . . 5

Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2ąWHEELS AND TYRES SECTION 13.2 ADT 25
DESCRIPTION
The vehicle is fitted with tubeless tyres mounted on removable rims.
Figure 1
1731321
The rim is the rigid structure of the wheel and consists The tyre has to perform these tasks
of the following parts: D absorb the impacts caused by rough ground;
1. side flanges D transmit the engine driving torque to the ground;
2. rim (channel) D transmit the braking force applied to the brakes to
3. retaining ring the ground;
4. O-ring D ensure side grip round bends
5. inflation valve unit
Also the tyre is identified by these dimensions (in inĆ
It has the following dimensions (in inches): ches):
D keying diameter, measured on the base of the cirĆ D keying diameter, measured on the base of the cirĆ
cumference groove (the resting surface of the tyre cumference groove (the resting surface of the tyre
bead); bead);
D width of sipe (distance between the flange side surĆ D tyre width (distance between the tyre sidewalls).
faces).

Five-pieces rims on six wheels
Rims: 19.5 - 25
Tyres: 23.5 R 25 (s)
Inflation pressure
Front wheels 2.9 bar (42 psi)
Rear wheels 2.9 bar (42 psi)
DIAGNOSTIC
1. Air leakage from tyre
Air leakage from tyre Valve faulty Fasten components. Replace damĆ
aged and/or worn components
Rim or welding cracked Replace faulty components. Do not
attempt to repair
O-ring deformed and/or damaged Replace o-ring
Cuts and grooves in tyre Repair the tyre and replace it, if reĆ
quired
Holes punched in bead area Replace the tyre
Bead cover leakage Clean the rim and check if leakage
persists. Change tyre, if required
TIGHTENING TORQUE
Nuts fastening wheels to hub: 590 Nm (435 lb ft)

Screws fastening service brake calliper to axle: 295 Nm (218 lb ft)
Service brake centring pin fastening screws: 25 Nm ( 19 lb ft)
Hub support fastening screws: 460 Nm (340 lb ft)
Brake disc fastening screws: 295 Nm (218 lb ft)
Parking brake calliper fastening nuts: 120 Nm ( 88 lb ft)
COMPLETE WHEEL REPLACEMENT

. Utmost care must be taken when replacing Figure 4
a wheel. At least two experts are to carry out
the operation using a crane for lifting and a
trolley or other suitable equipment to handle
the wheel.
Proceed as follows:
Disassembly
D bring the vehicle (preferably unladen) onto a flat surĆ
face, switch off the engine and engage the parking
brake;
Figure 2
174NU57A
Figure 5
174NU60
174NU58A
D work on the valve making sure that the wheel to be
replaced is completely deflated;
D The vehicle can be lifted by a crane or an overhead
Figure 3 travelling crane or other appropriate lifting equipĆ
ment using suitable steel cables hooked to the slots
provided for the purpose.
A. lifting points/front hooking
B. lifting points/rear hooking
D hook the wheel to a crane or other lifting equipment
and position the lifting trolley under the wheel;
Figure 6
174NU61
D loosen the wheel mounting nuts but do not remove

them;
D lift the vehicle until the wheel is off the ground, then
insert suitable safety chocks under the axle;
174NU62
D undo the mounting nuts completely and remove

them, then take off the wheel taking care not to
damage the stud bolt threads, lower it onto the
trolley and take it away.
Assembly Checks
D clean the threads of the nuts and bolts and the rim
and hub seatings; Tyre
Make these checks periodically:
Figure 7 D check the external surface of the tyre looking for
deep cuts or breaks that could jeopardise the road
grip;
D remove any stones lodges in the tread;
D in the case of disassembly and reuse of the tyre;
check the condition of the bead and remove any
foreign matter from the tyre;
D check the inflation pressure.
The inflation pressure is to be check with the
tyres cold.
Keep the pressure at the specified values.

Insufficient pressure heats the tyre and causes side
174NU63A wear on the tread; over time this situation could destroy
D assemble the new wheel bringing it in place with a the tyre with very serious consequences for the vehicle
trolley and lifting it with a crane. Take care not to and for the driver.
damage the stud bolt threads; Excessive pressure causes abnormal stress on the tyre
D tighten the nuts slightly so that the wheel is coupled carcass and wear on the centre of the tread.
correctly to the hub;
D inflate the tyre to a pressure of about 1.5 bar (22 psi);
Figure 8
5 1
11 9
3 8
7 4
10 12
2 6
174NU64
D lower the vehicle and finish tightening the nuts to the

specified torque;
D bring the inflation pressure to the specified value.
Rim
Make these checks periodically:
D check the entire circumference of the rim and the
disk, paying special attention to the zone where it is
secured to the hub;
D check there are no signs distortion, wear, corrosion
or breaks: if there are, replace;
D check that the seal rings and valves are in good
condition;
D if necessary, touch up the paint, first removing the
previous coat and any oxidising, and applying a
suitable ground coat;
. Small repairs are allowed to remove

scratches or small dents.
Repairs on the rims are never allowed by
means of welding or the recovery of
geometry using inserts.
Never mix rim components from different
manufacturers.
Always observe the rim manufacturer specĆ
ifications for the assembly and coupling.
The use of damaged or badly assembled
rims can cause the explosion of the tyre.
SECTION 14
SUSPENSION
ADT 25 SECTION 14 SUSPENSIONą1
CONTENTS
Page Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIALISED MAINTENANCE . . . . . . . . . . . . . . . . 7

Hydro-pneumatic element . . . . . . . . . . . . . . . . . . . . . 4 Inflation equipment for front suspension
elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . . 5
Equipment connection diagram . . . . . . . . . . . . . . . . . 7
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Suspension element pressure check . . . . . . . . . . . . 7
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . 5 Suspension element inflation . . . . . . . . . . . . . . . . . . . 8
SUSPENSION CYLINDER REMOVAL-REFIT . . . 6 Suspension element oil replacement . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2ąSUSPENSION SECTION 14 ADT 25
DESCRIPTION
The front suspension consists of a pair of hydro-pneuĆ The axle can sway around its longitudinal axis (x-x),
matic elements (2) pivoted below onto the front axle (1) whereas the connecting rods absorb the longitudinal
and fixed above to the vehicle chassis. thrust, and the centre knuckle the transverse and vertiĆ
The axle in its turn is articulated to the chassis by two cal thrusts.
longitudinal reaction connecting rods (3).
The axle is rigidly restrained to a supporting structure
with a circular knuckle (4) in the centre position.
Figure 1
1891402
1. Front axle
2. Hydro-pneumatic elements
3. Longitudinal reaction connecting rods
4. Support with central knuckle
x-x. front axle longitudinal axis
Hydro-pneumatic element
The hydro-pneumatic element consists of a co-axial the return stroke, whereas the pneumatic chamber,
shock absorber with a pneumatic chamber. filled with nitrogen, acts as the flexible suspension
The hydraulic shock absorber uses the hydraulic fluid element during the compression stroke.
contained in the cylinder for hydraulic braking during
Figure 2
1731403
1. Outer cylinder body

2. Inner cylinder body
3. Load valve
4. Plug
5. Upper gaskets
6. Lower gaskets

Work pressure 130 bar (1885 psi)
DIAGNOSTIC
1. Suspension often reaches end of stroke
Suspension often reaches end of Nitrogen or oil pressure loss Check tightness of seals under caps
stroke and valves; restore pressure; reĆ
store oil level
Nitrogen pressure low and/or miniĆ Restore pressure; restore oil level
mum oil level
TIGHTENING TORQUE
Nuts fastening wheels to hub: 590 Nm (435 lb ft)
Upper bolt fastening cylinder 80 Nm ( 59 lb ft)
Lower bolt fastening cylinder 80 Nm ( 59 lb ft)
SUSPENSION CYLINDER REMOVAL-REFIT

. Before starting any type of operation make D lock knuckle with the steering lock bar following the
D using appropriate means of support, lift the chassis
until the wheels are off the ground, so that the cylinĆ
der is fully extended;
D remove the wheel involved following the instructions
1.2 of this manual.
in SECTION 13.1;
D disconnect the central lubrication system unions;
perience.
D unlock the mounting screws (2) and remove the
lower guiding pin (3), then release the cylinder from
the mounting on the axle;
rectly.
D suitably sustain the cylinder (1), then unlock the
mounting bolt (4) and remove the upper guide pin
Removal (5). Free the cylinder from the mounting on the chasĆ
To remove proceed as follows: sis and remove it;
D bring the vehicle onto a suitable flat, solid surface, D if necessary remove the bushings from the seats on
switch off the engine, remove the ignition key, enĆ the chassis (6) and the front axle (7).
boards. Refit
D cut off the battery isolator switch or disconnect the To refit follow the removal operations in reverse order.
circuits;
Figure 3
1731401
SPECIALISED MAINTENANCE
. The operations described are to be carried Figure 5
out by experts using the appropriate equipĆ
ment.
Use only and exclusively the specific equipĆ
ment essentially required for the suspenĆ
sion inflation operations.
The operations described are to be carried
out on both suspension elements in parallel.
Figure 4
174NM35
174NM36
Inflation equipment for front suspension elements

Equipment connection diagram
A: checking tool
B: inflation equipment (a) suspension element
C. copper gasket (b) nitrogen bottle
D: copper gasket A: checking tool
E: gauge (0 - 100 bar) (0 - 1451 psi) B: inflation equipment
F: flexible hose E: gauge (0 - 100 bar) (0 - 1451 psi)
G: transparent hose
H: flexible hose IN: nitrogen inlet tap to suspension
I: coupling for nitrogen bottle OUT: nitrogen bleed tap from suspension
L: hose tail fitting
Suspension element pressure check
. This check is to be made after a pause of at

least one hour.
Proceed as follows:
D lift the vehicle with suitable lifting equipment until the
wheels are off the ground, to fully extend the susĆ
pension;
Figure 6 Suspension element inflation

Proceed as follows:
Figure 8
174NM37
D unscrew the protection cap on the element; 174NM37
Figure 7
D unscrew the protection cap on the element;
Figure 9
174NM36
D assemble the checking tool (A) into the seat, then
connect the inflation equipment (B) to the checking
174NM36
tool (A);
D assemble the checking equipment (A) into the seat,
D check that both the inlet tap IN and the bleed tap
then connect the inflation equipment (B) to the
OUT on the inflation equipment (B) are both well cloĆ
checking tool (A);
sed;
D check that both the inlet tap IN and the bleed tap
D slowly tighten the knurled flywheel of the checking
OUT on the inflation equipment (B) are both well cloĆ
tool (A) and check that the pressure on the gauge
sed;
(E) is within the specified values:
suspension element pressure:
68+2 bar (957 to 1015 psi)
D loosen the flywheel of the checking tool (A) and reĆ
move all the equipment, then close the protection
cap.
D slowly tighten the knurled flywheel of the checking Suspension element oil replacement
tool (A) and read the pressure on the gauge (E); The oil replacement is carried out after removing the
D open the nitrogen bottle tap (b) then the inlet tap IN element from the vehicle.
to allow the nitrogen to enter the suspension elĆ Proceed as follows:
ement (a); D place the element on the work bench, and secure
D introduce nitrogen up to a pressure of about 75-80 it;
bar (1088-1161 psi), then close the inlet tap IN then
the bottle tap; Figure 10
D adjust the suspension element pressure to the
specified value using the bleed tap OUT:
suspension element pressure:
68+2 bar (957 to 1015 psi)
D close the bleed tap OUT, loosen the checking tool
flywheel (A) and remove all the equipment, then
close the protection cap.
1891403
D unscrew the protection cap on the element;
D assemble the checking tool (A) into the seat on the
element;
D slowly tighten the checking tool knurled flywheel
and allow the nitrogen to discharge outwards;
. Keep clear of the trajectory of the dischargĆ

ing gas.
Wear all the personal protection devices.
D loosen the checking tool flywheel and remove all the
equipment;
D turn the element over supporting it with appropriate
lifting equipment and allow the oil to drain for at least
30 minutes;
To facilitate the exit of the oil, gradually
squeeze the element.
D straighten the element, fully extend it and using a
pump introduce the required quantity of the speciĆ
fied oil, then inflate the element as described in the
relevant paragraph. Close the protection cap.
. After reassembling the element on the veĆ

hicle check the gas pressure again.
SECTION 15
STEERING SYSTEM
ADT 25 SECTION 15 STEERING SYSTEMą1
CONTENTS
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2ąSTEERING SYSTEM SECTION 15 ADT 25
DESCRIPTION
Principle
The vehicle steering is obtained by directing the front The fluid needed to activate the actuators is obtained
part of the vehicle in relation to the rear part, around the from the only hydraulic system on the vehicle.
vertical axis found by the steering pins through two The steering circuit diagram consists of these compoĆ
double action hydraulic cylinders mounted sideways to nents:
the rear chassis.
Figure 1
1731501A
1. tank
2. main pump
3. high pressure filter
4. steering valve
5. hydraulic cylinders
6. flow amplifier
7. emergency pump
8. emergency pump switch
DX: Right-hand steering

SX: Left-hand steering
Operation
The steering wheel operates on a steering valve that supplies the hydraulic fluid under pressure to the cylinders.
Figure 2
SX DX
1731502
Right-hand steering
The oil under pressure flows out from the steering valve (R), reaches the flow amplifier and continues to the
chambers:
- rear left-hand cylinder (sx) ⇒ the cylinder lengthens
- front right-hand cylinder (dx): ⇒ the cylinder shortens.
Figure 3
SX DX
1731503
Left-hand steering
The oil under pressure flows out from the steering valve (L), reaches the flow amplifier and continues to the
chambers:
- front left-hand cylinder (sx): ⇒ the cylinder shortens
- rear right-hand cylinder (dx): ⇒ the cylinder lengthens.
As the cylinders are double action, the oil returning from the chambers not involved with the pressure returns to
the tank through the steering valve.
Figure 4 The steering wheel, when turned, moves the rod that,
by means of appropriately arranged channelling, alĆ
lows the oil to flow into the cavity where the lobe gears
are housed.
The rotation of the rod also pulls with it the camshaft
where the internal gear is clamped. As this turns eccenĆ
trically it pushes the oil under pressure toward the delivĆ
ery duct, according to the direction of rotation given by
the steering wheel:
- duct R for right-hand steering;
- duct L for left-hand steering.
Right and left are intended as seen from the
vehicle driver's seat.
When the swerve is released, a set of springs inside the

valve return the sleeve to neutral position, thus closing
the channels. In this situation the vehicle holds the
steering angle reached, without changing it.
To straighten up, manoeuvre the steering wheel in the
opposite direction.
1731504
The steering valve consists of an external casing (1), a

rod (2) integral with the steering column and inserted
inside a sleeve (3), a camshaft (4) and a concentric lobe
gear pair (5) and (6) (Eaton type).
DIAGNOSTIC
1. The steering wheel is not centred
2. Apparent impossibility to steering when the steering wheel is turned slowly
3. Slow/hard steering
4. Opposite steering
5. The steering wheel rocks backwards and forwards
6. The steering wheel keeps turning
The steering wheel is not centred Steering column valve seizure Align
Centring springs broken Replace the parts
Burring on tie-rod or stem Replace the centring springs, bleed

and wash the system
Apparent impossibility to steering Presence of dirt in system Bleed and wash the system. Fill with
when the steering wheel is turned clean oil
slowly
Slow/hard steering Steering cylinder seized Replace the cylinder
Excessive wear between sleeve and Replace sleeve and stem

stem
Excessive wear of internal gear Replace internal gear
Opposite steering Pipes incorrectly fastened Check and connect tubes correctly
Internal gear and control directed Realign

wrongly
The steering wheel keeps turning Burring on tie-rod or stem Remove and repair. Replace the
damaged components, if required
Presence of dirt in system Bleed and wash the system. Fill with
clean oil
Centring springs broken Replace the centring springs, bleed

and wash the system
Sleeve and stem jammed together Remove and repair. Replace the
damaged components, if required
SECTION 16
HYDRAULIC SYSTEM
ADT 25 SECTION 16 HYDRAULIC SYSTEMą1
CONTENTS
Page Page
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 3 CHECKS AND VERIFY . . . . . . . . . . . . . . . . . . . . . . . 30
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 HYDRAULIC PRESSURE TEST POINT . . . . . . . . . 30
MAIN HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . 4 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Front lay-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 MAIN PRESSURE TEST POINT . . . . . . . . . . . . . . . 31
STEERING-TIPPING . . . . . . . . . . . . . . . . . . . . . . . . . 4 Steering pressure test point . . . . . . . . . . . . . . . . . . . 32

6WD pressure test point . . . . . . . . . . . . . . . . . . . . . . 33
MAIN HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . 5
Rear lay-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 MAIN PUMP REMOVAL - REFITTING . . . . . . . . . 34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
STEERING-TIPPING . . . . . . . . . . . . . . . . . . . . . . . . . 5
Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
DESCRIPTION OF COMPONENTS . . . . . . . . . . . . . 6
BRAKE PUMP REMOVAL - REFITTING . . . . . . . 35
MAIN HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
General lay-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PUMP REMOVAL-REFITTING . . . . . . . . . . . . . . . . 36
DESCRIPTION OF COMPONENTS . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Hydraulic system diagram . . . . . . . . . . . . . . . . . . . . . 24
RATE OF FLOW AMPLIFIER REMOVAL-
SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . 26 REFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Main hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . 26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Brake hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . 26 Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Steering emergency electro-pump . . . . . . . . . . . . 26 STEERING VALVE REMOVAL - REFITTING . . . 39
Tipper cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Tipper control distributor . . . . . . . . . . . . . . . . . . . . . . 26 Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 TILT VALVE REMOVAL - REFITTING . . . . . . . . . . 40
Counterbalancing valve . . . . . . . . . . . . . . . . . . . . . . . 26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Flow amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 STEERING CYLINDER REMOVAL - REFITTING 41
Changing hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . 27 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Replacing pressurised oil filter (pump outlet) . . . . 27 Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Replacing inner hydraulic oil filter (intake) . . . . . . . 28
TILT CYLINDER REMOVAL - CYLINDER . . . . . . 42
Changing hydraulic brake oil filter . . . . . . . . . . . . . . 28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Checking fitting and pipe tightness . . . . . . . . . . . . . 28
Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Bleeding the hydraulic system . . . . . . . . . . . . . . . . . 29
2ąHYDRAULIC SYSTEM SECTION 16 ADT 25
HYDRAULIC SYSTEM
DESCRIPTION
The system is divided into three main hydraulic systems; steering, tipping and braking system. The groups operĆ
ate with the same hydraulic fluid, coming from a single tank that serves them all.
Figure 1
1731601
1. Hydraulic oil tank

2. Steering emergency electro-pump
3. Main hydraulic pump
4. Brakes hydraulic pump
5. Steering hydraulic system
6. Tipping hydraulic system
7. Brakes hydraulic system
MAIN HYDRAULIC SYSTEM
Front lay-out
STEERING-TIPPING
Figure 2
C K
D J
E
I
H
G
1891610
A. Steering emergency electro-pump
B. Oil filter inside tank
C. Hydraulic oil tank
D. Flow amplifier
E. Cargo body tipping control distributor
F. System pressure control intakes
G. High pressure oil filter
H. Connection plate
I. Main hydraulic pump
J. Differential locking control electro- distributor
K. Power steering
L. Heat exchanger
Rear lay-out
STEERING-TIPPING
Figure 3
O
M
1731611
M. Steering cylinder
N. Tipping cylinder
O. Rear chassis connection group (with counterbalancing valve)
DESCRIPTION OF COMPONENTS
A.ąSTEERING EMERGENCY ELECTRO-PUMP
Figure 4
2
1
1731604
1. Delivery pipe to one-way valve

2. Intake pipe from T union on brake pump
B.ąOIL FILTER INSIDE TANK
Figure 5
2
3
4
1731605
1. Oil intake pipe

2. Hole housing oil filler sleeve
3. Filtering element
4. Hydraulic oil tank
C.ąHYDRAULIC TANK
Figure 6
1731606
1. Filler cap
2. Oil level gauge
3. Inspection cover
D.ąFLOW AMPLIFIER
Figure 7
6 5 4 3 2
A B
7 8 9 10 1
1891612
Figure 8 Figure 9
VIEW A VIEW B
1731608 1731609
1. Delivery from check valve

2. Delivery to tipping control valve (P)
3. Power steering blow-by
4. RH steering control to slave cylinders
5. Power steering return (T)
6. LH Power steering (L)
7. Return to tank
8. RH Power steering (R)
9. Delivery to hydraulic steering
10. LH steering control to slave cylinders
E.ąTIPPING CONTROL DISTRIBUTOR
Figure 10
2
1
4 3
1731610
1. Tipping control lever

2. Delivery pipe from Flow Amplifier (EF)
3. Tipper up command
4. Electro-distributor supply for differential lock
5. Tipper down command
6. Pressure control tap connection pipe
7. Tank-heat exchanger return pipe
G.ąHIGH PRESSURE OIL FILTER

Figure 11
3 2 1 4
1731611
1. Delivery pipe from main pump

2. Delivery pipe from emergency pump
3. Delivery pipe from flow amplifier (EF)
4. Pressure sensor for steering emergency
H.ąCONNECTION PLATE
Figure 12
1 2 3 4 5 6 7
1. Tipping up pipe from control valve (B)

2. LH steering control pipe
3. RH steering control pipe
4. Park brake control pipe
5. Rear brakes control pipe
6. Differential locking control pipe
7. Tipping down pipe from control valve (A) 1891613
I.ąMAIN HYDRAULIC PUMP
Figure 13
1
1731613
1. Intake pipe from tank

2. Delivery pipe to high pressure filter
J.ąDIFFERENTIAL LOCK CONTROL ELECTRO-DISTRIBUTOR
Figure 14
5 3
4
2
1731614
1. Oil return pipe to tank

2. Rear longitudinal differential lock control
3. Front longitudinal differential lock control
4. Supply line from tipping control valve (N)
5. Pressure control tap connection pipe
K.ąPOWER STEERING
Figure 15
2 1 3 4 5
1891614
1. Blow-by pipe from flow amplifier (LS)

2. RH steering control from flow amplifier (R)
3. Flow amplifier delivery pipe (P)
4. Return pipe to flow amplifier (T)
5. LH steering control from flow amplifier (L)
L.ąHEAT EXCHANGER
Figure 16
1 2
1731616
1. Arrival pipe from tipping control valve

M.ąSTEERING CYLINDER
Figure 17
1 2
1731617
LH CYLINDER: RH CYLINDER:
1. LH steering control pipe 1. RH steering control pipe
2. RH steering control pipe 2. LH steering control pipe
N.ąTIPPING CYLINDER
Figure 18
2
1731618
1. Tipper down control pipe

2. Tipper up control pipe
O.ąREAR CHASSIS CONNECTION GROUP ASSEMBLY
Figure 19
1891615
1. Tipper down control pipe
2. Tipper down RH cylinder control pipe
3. Tipper down LH cylinder control pipe
4. Tipper up RH cylinder control pipe
5. Tipper up LH cylinder control pipe
6. LH steering control pipe
7. RH steering control pipe
8. Tipper up control pipe
9. Parking brake control pipe
10. Rear brakes control pipe
11. Differential lock control pipe
12. Rear brakes pressure point
General lay-out
BRAKES
Figure 20
1891616
A. Brakes pump
B. Oil filter (brake system)
C. Accumulators
D. Parking brake electro-distributor
E. Recharging valve
F. Brakes control valve
DESCRIPTION OF COMPONENTS
A.ąBRAKE PUMP
Figure 21
2 3 1731621
1. Oil intake pipe from tank

2. Intake pipe to steering emergency pump
3. Delivery pipe to high pressure filter
B.ąBRAKE OIL FILTER
Figure 22
1
1891617
1. Solenoid valve
2. Return pipe to tank
3. Delivery pipe to accumulators recharging valve
4. Delivery pipe dalla pump
C.ąACCUMULATORS
Figure 23
1 7 2 3 4 5 6
1891618
1. Parking brake electro-distributor supply line
2. Supply line from one-way valve on recharging valve
3. Supply line from tap A1 of accumulator recharging valve
4. Supply line to tap P (upper) of modulator
5. Supply line from tap A2 of accumulator recharging valve
6. Supply line to tap P (lower) of modulator
7. Check valve
D.ąPARKING BRAKE ELECTRO-DISTRIBUTOR
Figure 24
4 1891619
1. Supply line from accumulator for parking brake
2. Parking brake control pipe
3. Return pipe to tank
4. Control valve
5. Pressure sensor
E.ąRECHARGING VALVE
Figure 25
A 6
1731625
1. Oil discharge pipe to tank (drive circuit)

2. Parking brake accumulator S3 supply line
3. Oil return pipe to tank (main circuit)
4. Rear brakes accumulator S2 supply line
5. Low pressure gauge
6. Supply line from pump recirculation electro-distributor
7. Front brakes accumulator S1 supply line
F.ąBRAKE CONTROL VALVE
Figure 26
1891620
1. Supply line from recharging valve (A1)

2. Supply line from recharging valve (A2)
3. Front axle brakes control pipe
4. Rear axle brakes control pipe
5. Rear brakes return pipe to tank
6. Front brakes return pipe to tank
DIAGNOSTIC
1. Slow hydraulic functions
2. Hydraulic system oil overheats
3. Emulsified oil
4. Low or missing oil pressure
5. No hydraulic function (noisy pumps)

Slow hydraulic functions Oil level low Fill the reservoir to the full level
Oil cold Wait a few minutes with the engine
running before using the vehicle
Oil not correct The oil used is not suitable. Drain
the reservoir and use oil of the corĆ
rect type
Engine ratio too low Increase engine rpm
Pump worn Replace the pump
Pump intake pipe squeezed Check integrity of tubes and replace
them in the event of damage and/or
squeezing. Do not repair
Hydraulic system oil overheats Oil not correct The oil used is not suitable. Drain
rect type
Air leakage into pump intake pipe Check integrity of tubes and replace
Oil level low Fill the reservoir to the indicated
level
Filters clogged up Replace with new filters
Pump worn Replace the pump
Oil radiator obstructed Clean and straighten fins, if bent
Pressure relief valve Check operation of valve and reĆ
place it, if required
Contaminated oil Drain the reservoir and use oil of the
correct type
Hydraulic components not adjusted Check correct adjustment of hyĆ
correctly draulic components
Emulsified oil Air leakage into pump intake pipe Check integrity of tubes and replace
Oil pipes twisted or damaged Arrange pipes correctly and check
that they are not damaged. Replace
the seals, if required Do not repair
Oil not correct The oil used is not suitable. Drain
rect type
Water in oil Change the oil
Oil level either high or low Restore correct oil level by adding or
removing oil
Low or missing oil pressure Oil not correct The oil used is not suitable. Drain
rect type
Hydraulic components not adjusted Check correct adjustment of hyĆ

correctly draulic components
No oil in system Add oil to reach indicated level
Worn cylinder seal Replace the seals
Pressure relief valve incorrectly caliĆ Check operation of valve and reĆ
brated place it, if required
No hydraulic function (noisy Hydraulic pump not working and/or Replace the pump
pumps) worn
No oil in system Add oil to reach indicated level
Intake pipes damaged Replace the pipes
Intake filter obstructed Clean filter and replace, if required
HYDRAULIC SYSTEM DIAGRAM

Ref. Description
1 Emergency steering pump (19 L/min - 24V d.c.) (4.17 imp gpm)
2 Main hydraulic pump (117 cm3/rev) (7.13 cu in/rev)
3 Hydraulic braking pump (19.5 cm3/rev) (1.18 cu in/rev)
4 Orbitrol steering valve
5 Flow amplifier
6 Tipping valve
7 Counterbalancing valve
8 Parking brake control valve
9 6x6 valve
10 Directional valve
11 Intake oil filter (125 µm)
12 Accumulators recharge valve
13 Brake modulation valve
14 Hydraulic oil heat exchanger
15 Oil under pressure filter (25 µm)
16 Check valve
17 Steering pressure emergency switch
18 Choker (ø 13 mm)
19 Steering cylinders
20 Tipping cylinders
21 Hydraulic accumulators (1.4 Litres - 65 bar)
22 Check valve
23 Accumulators pressure switch
24 Stop lights switch
25 Parking brake pressure switch
26 Brake system filter (20 µm)
27 Front axle brake calliper
28 Intermediate axle brake callipers
29 Rear axle brake callipers
30 Parking brake callipers
31 ZF gearbox locking cylinder
32 Intermediate differential locking cylinder
a Steering control hydraulic pressure test point
b Hydraulic tilt pressure test point
c Locking control hydraulic pressure test point
d Counter-balancing pressure test point
e Hydraulic brake pressure test point
SPECIFICATIONS AND TECHNICAL DATA
. the values indicated below are specific to the individual components (plate data)
Main hydraulic pump

Max. rpm 314 rad/sec (3000 rpm)
Displacement 117 cm3/rev (7.14 in3/rev)
Max. delivery at engine full speed (2100 rpm) 248 l/min (54.5 Imp gal/min)
Max. pressure 245 bar (3553 psi)
Brake hydraulic pump

Max. rpm 314 rad/sec (3000 rpm)
Displacement 19.5 cm3/rev (1.9 in3/rev)
Max. delivery at engine full speed (2100 rpm) 30 l/min (6.6 Imp gal/min)
Steering emergency electro-pump

Displacement 5.8 cm3/rev (0.35 in3/rev)
Max. delivery 19 l/min (4.1 Imp gal/min)
DC power supply voltage 24 V
Tipper cylinders
Length of stroke, extension 1736 mm (68.34 in)
Length of stroke, withdrawal 930 mm (36.61 in)
Tipper control distributor

Damping valve withdrawal pressure 50 bar (725 psi)
Damping valve extension pressure 225 bar (3265 psi)
Oil delivery class, Tap P 300 l/min (65.9 Imp gal/min)
Delivery class, Tap A/B 210 l/min (46.1 Imp. gal/min)
Power steering
Displacement 200 cm3/rev (43.9 cm3/rev)
Counterbalancing valve
Pressure setting 100 bar (1451 psi)
Capacity 240 l/min (52.7 Imp gal/min)
Flow amplifier
Nominal capacity 400 l/min (87.9 Imp gal/min)
Drive pressure relief pressure 185 bar (2684 psi)
Damping valves relief pressure 230 bar (3482 psi)
MAINTENANCE
Changing hydraulic oil Replacing high pressure oil filter (pump outlet)
Proceed as follows:
Collect and dispose of used lubricants and D drain the reservoir as shown in the respective paraĆ
fluids, according to the laws in force. graph;
D with the engine stopped, loosen the filtering carĆ
Proceed as follows:
tridge (Figure 29) with a hexagonal wrench and
D take a suitably sized container, clean the filler cap
accurately clean the housing;
and drain cap areas and remove the filler cap
(Figure 27); Figure 29
Figure 27
156NM90
156NM88 D replace the filtering element with seals fitted in the

cartridge (Figure 30);
D remove the drain cap (Figure 28) and fully drain the
fluid; Figure 30
Figure 28
156NM91
156NM89 D fill the new cartridge with the specified fluid and
apply the same fluid to the seals;
D clean the drain cap. Check that the threading is in
D fasten the cartridge by hand until the seal comes
good condition. Close at the specified torque;
drain cap: 100 Nm (73 lb ft)
3/4th of a turn;
D pour in the specified amount of fluid through the filler
and close it; Do not fasten the cartridge excessively. This
D bleed the system. could damage the seal. Observe the specifiĆ
cations provided by the supplier.
D fill the reservoir as shown in the specific paragraph;

D run the engine for a few minutes and check for leakĆ
age;
D bleed the system.
Replacing inner hydraulic oil filter (intake) Changing hydraulic brake oil filter
D drain the reservoir as shown in the respective paraĆ D drain the reservoir as shown in the respective paraĆ
graph; graph;
D remove the flange (Figure 31); D with the engine stopped, loosen the filtering carĆ
tridge (Figure 33) and accurately clean the housing;
Figure 31
Figure 33
156NM92
174NM33
D loosen the cartridge removing it from the flange
housing (Figure 32); D fill the new cartridge with specific fluid and apply
fluid to the seals;
Figure 32 D fasten the cartridge by hand until the seal comes
3/4th of a turn;
Do not fasten the cartridge excessively. This
could damage the seal. Observe the specifiĆ
D run the engine for a few minutes and check for leakĆ
age.
D bleed the system.
Checking fitting and pipe tightness

Visually check tightness of system and respective
174NM83
pipes.
In the event of faults or leakage concerning
D fasten the cartridge by hand until the seal comes the hydraulic system, repairs must be carĆ
into contact with the housing, then turn by another ried out before using the vehicle again.
3/4th of a turn; Check by implementing all the specific
Do not fasten the cartridge excessively. This safety precautions.
could damage the seal. Observe the specifiĆ
D refit the flange;

D bleed the system.
Bleeding the hydraulic system

. The vehicle is equipped with a single hyĆ Steering system
draulic system split into three systems Proceed as follows:
D braking system D start the engine, steer slowly and fully to the right
D steering system and then to the left;
D tipping system D repeat the operation a few times to eliminate the air
Bleed each of the three systems separately. bubbles in the circuit;
D at the end of the operation, check the oil level in the
reservoir and top up if required.
Braking system
Proceed as follows: Tipping system Tipper
D press the brake pedal fully and hold it pressed;
Proceed as follows:
D remove the dust boot, then fit a clear tube on the
D start the engine, either tip the bucket to fill the circuit;
breather valve (1). Submerge one end of the tube in
D take the bucket back to home position;
a bowl containing a certain amount of oil;
D repeat the operation several times to eliminate the
D loosen the valve letting out the oil and the air
bubbles in the cylinders;
bubbles. Close it after a few seconds.
Figure 34 reservoir and top up, if required.
1731302A
. Close the valve if the end of the clear tube is

not submerged.
D fully release the brake pedal;

D repeat the operation until oil without bubbles is let
out of the breather valve;
D fit the cap and repeat the operation on the other
braking units of the vehicle;
reservoir and top up if required.
CHECKS AND VERIFY
HYDRAULIC PRESSURE TEST POINT
Description
A Main pressure test point

B Steering pressure test point
C Central differential lock pressure test point
D Rear brakes pressure test point
Figure 35
1891601
MAIN PRESSURE TEST POINT (A)

Unless otherwise stated, the numbers in brackets refer The pressure gauge should show 145±5 bar
to Figure 35. (2030 to 2174 psi).
A specific adjustment device is used to adjust the main 5. There is an adjustment device (1) on the main
pressure. valve block. To increase pressure, turn adjustĆ
1. Position the vehicle on a solid, level concrete surĆ ment device clockwise. To decrease pressure,
face with the engine running. turn adjustment device anticlockwise.
2. Raise the rear body to its full extent.
3. Connect a suitable pressure gauge to the main . The pressure must never exceed 150 bar in
system test point (A). all conditions.
4. With rear body raised to full extent and control
lever operated, rev the engine to its full capacity.
Figure 36
1731629F
STEERING PRESSURE TEST POINT (B)

1. Position the vehicle on a solid, level concrete surĆ
face with the engine running.
. The steering pressure adjustment device is
located on the flow amplifier, 2.
2. Turn the steering wheel to the left until you reach
full lock and maintain a full lock until the adjustĆ
You are advised not to change the original
ment is complete.
setting.
3. Connect a suitable pressure gauge to the steering
pressure test point (B).
4. With the steering wheel still at full lock, rev the enĆ
gine to its full capacity. The pressure gauge
should show 185 bar (2684 psi).
Figure 37
1731630F
6WD PRESSURE TEST POINT (C)

1. Position the vehicle on a solid, level concrete surĆ The adjustment device is located on the reĆ
face with the engine running.
ducing valve (3) situated near the flow amĆ
2. Connect a suitable pressure gauge to the 6WD
plifier.
pressure test point (C). The pressure gauge
should show a value in the range from 5.5 to 6 bar
(80 to 87 psi). . The pressure must not exceed 6 bar. This is
the maximum required pressure. Higher vaĆ
lues could damage the cylinder.
Figure 38
3
1731630F
MAIN PUMP REMOVAL-REFITTING D lock knuckle with the steering lock bar following the
. Before starting any type of operation make D drain the hydraulic fluid from the reservoir into a suitĆ
sure all the necessary safety precautions able receptacle as specified in the appropriate paraĆ
have been taken and fully explained to those graph;
involved in the operations. D disconnect the intake union (2) and the delivery
Read the instructions provided in SECTION union (3) from the pump by loosening the securing
1.2 of this manual. screws and removing the O-rings;
Hydraulic fluid may leak out during these
correctly performing maintenance operĆ operations.
ations. D support the pump (1) adequately; loosen the securĆ
ing screws then remove the pump and its gasket.
Removal Refitting
To remove proceed as follows: To refit follow the removal operations in reverse order.
D position the vehicle on a flat surface, switch the enĆ Fill the hydraulic oil reservoir as indicated in the apĆ
gine off, remove the ignition key, apply the parking propriate paragraph.
brake and attach the warning notices. Bleed the air in the circuit as described in the appropriĆ
D cut off the battery isolator switch or disconnect the ate paragraph.
circuits;
Figura 39
2 3
1731636
BRAKE PUMP REMOVAL-REFITTING D lock knuckle with the steering lock bar following the
involved in the operations. D disconnect the intake union (2) and the delivery
Read the instructions provided in SECTION union (3) from the pump by removing the O-rings;
1.2 of this manual.
Hydraulic fluid may leak out during these
Follow all the general recommendations for operations.
correctly performing maintenance operĆ D support the pump (1) adequately, loosen the securĆ
ations. ing screws and remove the pump.
Refitting
Removal To refit follow the removal operations in reverse order.
To remove proceed as follows: Fill the hydraulic oil reservoir as indicated in the apĆ
D position the vehicle on a flat surface, switch the enĆ propriate paragraph.
gine off, remove the ignition key, apply the parking Bleed the air in the circuit as described in the appropriĆ
brake and attach the warning notices. ate paragraph.
circuits;
Figura 40
1731637
EMERGENCY STEERING PUMP REĆ D cut off the battery isolator switch or disconnect the
MOVAL-REFITTING terminals from the battery to avoid the risk of short
circuits;
. Before starting any type of operation make D access the front left mudguard compartment housĆ
ing the pump;
D disconnect the electrical power supply connections
(4) and the control relay (5);
D disconnect the intake union (2) and the delivery
union (3) from the pump by removing the O-rings;
1.2 of this manual.
If in doubt, consult an expert. Hydraulic fluid may leak out during these
operations.
correctly performing maintenance operĆ
ations. D loosen the securing screws and remove the pump
(1).
Refitting
Removal
Fill the hydraulic oil reservoir as indicated in the apĆ
D position the vehicle on a flat surface, switch the enĆ
propriate paragraph.
gine off, remove the ignition key, apply the parking
Bleed the air in the circuit as described in the appropriĆ
brake and attach the warning notices.
ate paragraph.
Figura 41
5
2
1731638
RATE OF FLOW AMPLIFIER REMOVAL- D disconnect all the unions from the valve (1) and reĆ
REFITTING move the O-rings and gaskets:
. Before starting any type of operation make (2)

(3)
return to reservoir
delivery from single-acting valve
(4) hydraulic steering right-hand drive
(5) left-hand steering to cylinders
(6) right-hand steering to cylinders
(7) hydraulic steering return
1.2 of this manual.
(8) hydraulic steering left-hand drive
(9) seepage to hydraulic steering
(10) delivery to the single-acting valve
(11) delivery to the tilt valve
ations.
(12) not connected
Removal It is good practice to mark the unions to

To remove proceed as follows: make reassembly easier.
D position the vehicle on a flat surface, switch the enĆ D support the valve (1) adequately, loosen the securĆ
gine off, remove the ignition key, apply the parking ing screws and remove the valve.
brake and attach the warning notices.
D cut off the battery isolator switch or disconnect the Refitting
circuits;
D drain the hydraulic fluid from the reservoir into a suitĆ
ate paragraph.
able receptacle as specified in the appropriate paraĆ
graph;
3
4
5
8 6
7
10
11
12
1731639
STEERING VALVE REMOVAL-REFITTING D lock knuckle with the steering lock bar following the
involved in the operations. D diconnect all the unions from the valve and remove
Read the instructions provided in SECTION the gaskets
1.2 of this manual. (2) return to the reservoir
If in doubt, consult an expert. (T) return to the flow amplifier
Follow all the general recommendations for (L) left-hand steering control
correctly performing maintenance operĆ (P) delivery from flow amplifier
ations. (R) right-hand steering control
D working from inside the cab, loosen the screw seĆ

curing the valve (1), then remove it from the bottom.
Removal
To remove proceed as follows: Refitting
D position the vehicle on a flat surface, switch the enĆ To refit follow the removal operations in reverse order.
gine off, remove the ignition key, apply the parking Fill the hydraulic oil reservoir as indicated in the apĆ
brake and attach the warning notices. propriate paragraph.
D cut off the battery isolator switch or disconnect the Bleed the air in the circuit as described in the appropriĆ
terminals from the battery to avoid the risk of short ate paragraph.
circuits;
Figura 42
T
L
P
R
1731640
TILT VALVE REMOVAL-REFITTING D drain the hydraulic fluid from the reservoir into a suitĆ
. Before starting any type of operation make graph;
sure all the necessary safety precautions D disconnect all the unions from the valve (1) and reĆ
have been taken and fully explained to those move the O-rings and gaskets;
involved in the operations. (2) return to the reservoir
Read the instructions provided in SECTION (3) down tilt control
1.2 of this manual. (4) up tilt control
If in doubt, consult an expert. (5) delivery to the flow amplifier
Follow all the general recommendations for (6) power supply for differential lock distributor
correctly performing maintenance operĆ pressure check socket connection
ations. D adequately support the valve (1), loosen the securĆ
ing screws and remove it.
Removal Refitting
To remove proceed as follows: To refit follow the removal operations in reverse order.
D position the vehicle on a flat surface, switch the enĆ Fill the hydraulic oil reservoir as indicated in the apĆ
gine off, remove the ignition key, apply the parking propriate paragraph.
brake and attach the warning notices. Bleed the air in the circuit as described in the appropriĆ
D remove the protective bulkhead on the left-hand ate paragraph.
side;
D if deemed necessary to aid operations, remove the
front left wheel as described in the relevant Section;
Figura 43
4 3 2
5
8
7
1731641
STEERING CYLINDER REMOVAL-REFITĆ D prepare a suitable receptacle, disconnect the hyĆ

TING draulic unions (7) from the cylinder and plug them
hermetically to prevent the circuit emptying;
. Before starting any type of operation make D loosen the rear securing bolt (4), remove the lower
guide pin (5) and put the washers on one side;
D adequately support the cylinder (1), then free the
cylinder from the rear chassis attachment;
D loosen the front securing bolt (2), remove the upper
guide pin (3) and put the washers on one side;
1.2 of this manual.
D free the cylinder (1) from the chassis attachments
and remove it;
D if necessary, remove the bushes (6) from the seats
on the chassis.
ations.
Then check the hydraulic fluid level in the
reservoir and top up if necessary.
Removal
To remove proceed as follows: Refitting
D disconnect the central lubrication system unions
(arrow);
D turn the steering wheel to the right and then left as
far as possible to release the hydraulic pressure in
the cylinders;
ate paragraph.
Figura 44
6
4
1 6
3
6
7 5
1731642
TILT CYLINDER REMOVAL-REFITTING

Figura 45
1.2 of this manual.
ations.
a b
Removal
1731902
To remove proceed as follows: D position a suitable receptacle, disconnect the two
D disconnect the central lubrication system unions unions, fluid input (a) and output (b), then plug them
(arrow); appropriately to prevent the circuit emptying;
D turn the steering wheel to the right and then left as
far as possible to release the hydraulic pressure in Figura 46
the cylinders;
D drain the hydraulic fluid from the reservoir into a suitĆ
graph;
1731903
D support the cylinder (1) with suitable lifting equipĆ
ment, loosen the upper securing bolt (4) and reĆ
move the guide pin (5), then lower the cylinder and
free it from the bucket attachment;
Figura 47
1731904
D unscrew the lower securing bolt (2) and extract the

pin (3), then free the cylinder from the chassis atĆ
tachment and remove it
Refitting
ate paragraph.
SECTION 17
ELECTRICAL SYSTEM
ADT 25 SECTION 17 ELECTRICAL SYSTEMą1
CONTENTS
Page Page
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 PRACTICAL HINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INTERNATIONAL SYSTEM UNITS (S.I.) . . . . . . . . 3 CABLE COLOUR CODES . . . . . . . . . . . . . . . . . . . . 10
MAIN ELEMENTS - RESISTIVITY AND IDENTIFICATION OF THE ELECTRIC

TEMPERATURE COEFFICIENT . . . . . . . . . . . . . . . . 4 FUNCTION BY THE CABLE COLOUR CODE . . . 11
RESISTOR COLOUR CODES . . . . . . . . . . . . . . . . . . 4 CONTROL UNITS LOCATION . . . . . . . . . . . . . . . . . 12
GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 5 TRANSMISSION CONTROL UNIT . . . . . . . . . . . . . 12
GENERAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . 5 INTERCONNECTION CONTROL UNIT . . . . . . . . . 13
GENERAL PRECAUTIONS FOR FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

ELECTRONIC COMPONENTS . . . . . . . . . . . . . . . . . 6
TELERUPTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
THE CONCEPT OF EARTH AND
ELECTROMAGNETIC COMPATIBILITY . . . . . . . . . 7 LAY-OUT ELECTRICAL SYSTEM . . . . . . . . . . . . . 18
2ąELECTRICAL SYSTEM SECTION 17 ADT 25
TECHNICAL DATA
International System Units (S.I.)
Value Symbol Unit Symbol

plane angle radian rad
solid angle steradian sr
LENGTH L, l meter m
area, surface S, s squared meter m2
volume V cubic meter m3
TIME t second s
angular velocity w radian per second rad/s
frequency İ hertz Hz
spinning frequency n (second)-1 s-1
velocity v meter per second m/s
acceleration g, g meter per squared second m/s2
MASS M, m kilogram kg
volume mass , kilogram per cubic meter kg/m 3
force F newton N
moment of a force/torque M, T newton-meter Nm
energy, work W joule J
power P watt W
pressure p pascal Pa, N/m2
TEMPERATURE (thermodynamic) , T kelvin K
Celsius temperature , t Celsius degree °C
temperature range ,
kelvin K
heat quantity W joule J
mass heat capacity c joule per kilo-kelvin J/kg @ k
CURRENT INTENSITY I ampere A
quantity of electricity Q coulomb C
electric field E volt per meter V/m
voltage, d.d.p., f.e.m. U, E volt V
capacity C farad F
current density J ampere-squared meter A/m2
resistance R ohm
conductance G siemens S, A/V
resistivity ohm-meter Ωm
magnetic excitation H ampere per meter A/m
magnetic field B tesla T
magnetomotive force F ampere (turn) A
magnetic moment M ampere-squared meter Am2
magnetic flux , weber b
inductance L, M henry H
LUMINOUS INTENSITY I candle cd
luminous flux E lumen lm
irradiance F lux lux
Main elements - Resistivity and temperature coefficient

Substance ( @ m) (°C)-1
Conductors
Aluminium 2.83 x 10-8 0.0039
Copper 1.69 x 10-8 0.00393
Gold 2.44 x 10-8 0.0034
Iron (0 °C) 8.85 x 10-8 0.0050
Nickel 7.24 x 10-8 0.006
Silver (0 °C) 1.47 x 10-8 0.0038
Mercury 95.8 x 10-8 0.00089
Tungsten 5.51 x 10-8 0.0045
Costantan (60% Cu, 40% Ni) 44.0 x 10-8 0.0000
Nichrome 100.0 x 10-8 0.0004
Semiconductors
Germanium (pure) 0.450 -0.048
Germanium (5 ppm As) 0.011
Silicon (pure) 640.0 -0.075
Silicon (100 ppm As) 0.003
NaCl (saturated solution) 0.044 -0.005
Insulators
Amber 5.0 x 1014
Glass 1010 ÷ 1014
Mica 1011 ÷ 1015
Quartz 7.5 x 1017
Wood 108 ÷ 1011
Resistor colour codes

brown black red gold
Colour code 1st ring 2nd ring 3rd ring Multiplier Tolerance
Silver ± 10%
Gold ± 5%
Black 0 0 1 ± 20%
Brown 1 1 1 10 ± 1%
Red 2 2 2 102 ± 2%
3 3 3 103
Orange
4 4 4 104
Yellow
5 5 5 105
Green
6 6 6
Blue 7 7 7
Violet 8 8
Grey 9 9
White
GENERAL INSTRUCTIONS
General precautions
Never disconnect the batteries or open the D Never connect or disconnect cable connector from
knife switch with the external-combustion electronic control modules with powered supply.
engine started. D Remove the electronic control modules when operĆ
never start up the engine without having ations involve temperatures exceeding 80 °C (176
connected the batteries PERMANENTLY. °F) (drying oven).
D During the connection stage, screw connector flap
D Before carrying out any servicing operation on the
nuts (temperature and pressure sensors, etc.) to
vehicle, chock the wheels securely to prevent the
the prescribed torque only.
truck from moving on its own.
D Measurements on electronic modules controlling
D Starting from the engine compartment should only
plugs, plug connections and electrical component
be performed with the cab securely fixed in its maxiĆ
connections can be only performed on suitable test
mum opening position, parking brake on, transĆ
lines with proper plugs and bushes.
mission in neutral, wheels properly chocked.
Never use improper tools such as metallic wires,
D Avoid aiming water/other fluid jets at the rear bulkĆ
screwdrivers, clips and equivalent.
head junction block.
Short circuits can occur and plug connections could
D Do not use quick charging devices to start the enĆ
be damaged causing successive contact troubles.
gine. Engine starting should be performed only by
means of separate batteries or a suitable trolley. Always disconnect the batteries and conĆ
D While performing electrical welding on the chassis, nectors from electronic control modules
disconnect connectors from electronic control modĆ when performing electric welding operĆ
ules and disconnect the terminals from the battery. ations on the vehicle.
D In case of fuse change, in order to avoid damages
to electric plant of the vehicle, use fuses only of the Before replacing a fuse, check always the
same power as indicated by the producer.
cause of its blowout. Circuit operation can
D Check for exact battery terminal polarity during start
be reset only after having removed the fault.
up from auxiliary truck.
D When disconnecting the batteries from the system,
always disconnect first the chassis ground cable of
the negative battery terminal.
D Check system perfect insulation before disconnectĆ
ing the batteries.
D Incorrect supply voltage polarisation of the elecĆ
tronic control modules (e.g. incorrect battery polaĆ
risation) can cause module breakage.
D Add a fly-fuse between the negative battery terĆ
minal and the chassis ground cable during troubleĆ
shooting of a circuit fault (main current switch conĆ
nected).
D Disconnect the ground cable from the negative batĆ
tery terminal before removing electronic compoĆ
nents.
D Electrical measurements on electronic components
must be performed using suitable instruments only.
D Do not power electronic control unit components
with vehicle voltage rating.
D Ensure that electronic device wirings (length, type
of wire, location, shielding continuity, if required,
grounding, etc.) comply with the manufacturer sysĆ
tem and that wirings are suitably reset after overĆ
hauling or repair operations.
D Disconnect the batteries from the system during reĆ
charging with external equipment.
D Disconnect the external battery charger from the
civil network before removing its plug-in contacts
from the battery terminals.
General precautions for electronic components
Figure 1 Figure 3
D Insulate the system before disconnecting the conĆ D Do not fit tester prods into electronic module conĆ
nector from an electronic module. nector plugs.
D Never cause sparks to check if the circuit is powĆ D Measurements shall be performed with multimeter.
ered. D Do not install additional electric and/or electronic
D Do not touch connector plugs of electronic modules equipment not provided by manufacturer or by the
with your hands. local laws.
D Do not connect negative components of additional
Figure 2 equipment to negative components of electronic
modules.
Figure 4
D Never use a test lamp to check circuit continuity, use

suitable testers only.
D Do not power electronic control unit components
with vehicle voltage rating. D When performing electric welding on the vehicle,
D Ensure that electronic device wirings (length, type disconnect electronic modules and/or disconnect
of wire, location, shielding continuity, if required, the power cable from positive battery terminal and
grounding, etc.) comply with the manufacturer sysĆ connect it to chassis ground.
tem and that wirings are suitably reset after overĆ D Remove electronic components and modules for
hauling or repair operations. painting baking.
D To avoid damage to electronics on board the veĆ
hicle, ensure the wiring pertaining to additional
equipment follows a different route.
D Use manufacturer original spare parts only.
THE CONCEPT OF EARTH AND ELECTROMAGNETIC COMPATIBILITY

The standard system is traditionally a singIe-pole system. The body, chassis, metal container of eledromechaniĆ
cal components act as equipotential return condudor to the generator, since any point of the metal structure or
any unisolated negative terminal is at the same potential or EARTH. This is why the earth has been chosen as
the reference for the entire system, conventionally giving it a rating of 0.
For obvious constructive reasons, different earth points scattered over the vehicle according to the location of the
components, influence the system in the negative network.
Ideally, all the equipment should be connected to only one earth point to warrant a clearly defined earth reference,
especially for the electronic devices.
Due to the above-mentioned reasons, the supply earth or system earth characterised by strong direct current inĆ
tensity (> I A for electromechanical components) must be distinguished from the analogue earth characterised by
wave shapes at determinate frequencies and with very small current intensities (mA, A) of the electronic/numeriĆ
cal systems.
The definition of signal earth or analogue earth depends on the sensitivity of the electronic systems to EMC (elecĆ
tromagnetic compatibility) since parasite signals induce malfunctioning and/or deterioration of the actual systems
(as they are emitted by systems on board and/or outside the vehicle).
In order to minimise continuous or transient disturbances or interferences caused by parasite radiations, it is of
the utmost importance to follow the warnings given on next page, always bearing in mind that the soundness of
the reference plan or system earth depends on the excellent conduction features (contact resistance tending to
zero) in each of its connecting points.
To sum up we can say that earth intended as equipotential electric conductor, i.e. as potential reference of all the
electric/electronic components on board, is subdivided into system earth and analogue earth.
The earth points in this system are estabìished by the manufacturer. They must obviously be free from paint, oxidaĆ
tion, traces of grease or dust etc. Particular attention should be paid to the efficiency of battery and starter motor
earth points.
Figure 5
EARTH POINTS AND CONTACT EFFICIENCY
A. Efficient earth point - B. Inefficient earth point - C. Fastening sequence

1. Nut - 2. Washer - 3. Wire terminal - 4. Screw
Practical hints
Connection between a component and an earthing
point must be as short as possible. Conductors
converging in an earthing point (cab and/or chassis)
must be star-connected between themselves
accurately avoiding overlappings in order to minimise
contact resistance (Figure 6, ref. B).
As regards eledronic components, the

following instructions must be strictly
observed.
D The electronic control modules/units fitted with a

metal casing are to be connected to the system
earth by means of a screw or bolt (Figure 6, ref. A).
D Conductors related to analogue earth must have
optimum isolation characteristics both between
themselves and as regards the system earth.
D Negative conductors isolated from control units
must be connected to a system earth point (set be
the manufacturer) and to the battery negative terĆ
minal. Avoid serial or chain connections (Figure 6,
ref. B).
D Each end of the braided wire must make electric
contact with the system components. Only one of
the braided wire ends is connected to the system
earth. The unbraided section (Figure 6, d dimenĆ
sion in ref. C) (cable connectors) must be as short
as possible.
D Cable looms must be parallel to the reference plane,
that is to say attached to the chassis/cab structure.
D Bodybuilders installing auxiliary systems must take
great care when performing connections to the sysĆ
tem earth. The new wires must not run alongside the
wiring system already installed on the vehicle.
Figure 6
FASTENING CONTROL UNIT BY MEANS OF A SCREW
STAR CONNECTION OF NEGATIVE CABLES TO M SYSTEM EARTH
SHIELDING OF THE CABLE OF AN ELECTRONIC COMPONENT BY MEANS OF A BRAIDED WIRE – C. CONNECTOR – d. GAP ³ 0
CABLE COLOUR CODES
Figure 7
Left rear indicator bulb

Right front indicator bulb
Right side indicator lights
Right rear indicator bulb
CODE COLOUR BASIC FUNCTION To enable its practical application, the wiring system
1111 Light blue Optical and audible signals has been split into ten main funcions (associated with
2222 White Illumination by headlights ten cable colours), each of them including more speĆ
3333 Yellow Parking lights/side marker
cific functions. Each function is identified by a four-figĆ
lamps ure code number.
4444 Grey Internal lighting Obviously, each function includes more specific sub-
functions.
The first number indicates the basic function of the
cable and identifies always the basic colour of the cable
(the matching of number and colour is indicated in the
table on the side).
The other numbers identify the specific function of the
cable.
Summing up, we can say that:
D a number consisting of four identical figures indiĆ
cates a main function and a single-colour cable;
D a number consistin of four partially or totally different
figures indicates a specific function.
IDENTIFICATION OF THE ELECTRIC FUNCTION BY THE CABLE COLOUR CODE
No. Code Colour Function
1 1111 Light blue Optical and audible signals
2 2222 White Illumination by headlights
3 3333 Yellow Parking lights/side marker lights
4 4444 Grey Internal lighting
5 5555 Orange Optical signals, engine operation and measuring instruments
6 6666 Violet Optical signals
7 7777 Red Main supply and pertaining accessories not excluded by the ignition
switch
8 8888 Green Secondary supply and pertaining accessories not excluded by the igniĆ
tion switch
9 9999 Pink Electrically-operated mechanical components
10 0000 Brown Earth
CONTROL UNITS LOCATION

Figure 8
INTERCONNECTION
CONTROL UNIT
TRANSMISSION
CONTROL UNIT
TRANSMISSION CONTROL UNIT

Figure 9
VIEW A"
RIGHT BACK CAB
(TOP VIEW)
CONTROL UNIT HOUSING
E.C.U.
Gear shift
INTERCONNECTION
VIEW A"
E.C.U.: Electronic Control Unit
INTERCONNECTION CONTROL UNIT
Figure 10
SIDE INSTRUMENT
PANEL
DRIVER SEAT
CENTRAL HOUSING
INTERCONNECTION
CONTROL UNIT
41
42
43
44
46
45
Fu s
Fu s
Fu s
Fu s
Fu s
Fu s
FUSES
174DT17
Fuse Amp. User Fuse Amp. User

1 7,5 Position lights ć instrument board light 31 7.5 LH side wipers
2 7,5 Position lights - warning light 32 7.5 RH side wipers - side window washer
3 3 Main beam lights on - dipped headĆ pump
lights off with main beams on 33 7.5 Parking brake - body control
4 7,5 LH dipped-beam lights 34 10 Potential divider 24/12V (Radio-CB -
services 12V)
5 7,5 RH dipped-beam lights
35 7.5 Power socket 12V
6 7,5 RH ć LH main beam ć warning light
36 10 Bonnet lifter addition
7 Not used
8 20 Front work light (75W x 4) Rif. Amp. User
9 5 Rear fog light 41 7.5 Gearbox fuse 2 (+15)
10 Not used 42 7.5 Emergency pump (Relay-Buzzer on)
11 10 Horns 43 Not used
12 7,5 Coil relay - mirrors motor - heating 44 7.5 Gearbox fuse 1 (+30)
- bonnet lifter
45 7.5 Differential and splitter lock - EmerĆ
13 5 Instruments - CCTV telecamera gency pump buzzer (safety device)
14 3 Warning lights 46 Not used
15 7,5 Windscreen wiper - washer
16 10 Hazard lights
17 7,5 Direction indicator lights
18 7,5 Brake lights - Reversing light - enĆ
gine stop
19 7,5 Electro-pneumatic seat - Low temĆ
perature startup - Counter
20 3 Speedometer
21 10 Cigar lighter - ceiling lamp
22 7,5 Rotating lights
23 10 Climate control (compressor)
24 20 Climate control (ventilation control)
TELERUPTORS
Figure 11
1731704Z
Type Relay User

E1 Not used
N E2 Headlamps circuit (dipped, main)
N E3 Ignition key services 20A (not during ignition)
N E4 Flashing
S E5 Parking brake
N E6 Stop lights
S E7 Not used
E8 Not used
X E9 Intermittent wiper
S E10 Dipped headlights - Main-beam headlights
N E11 Front headlights (20 A)
N E12 Horn
S E13 Not used
S E14A Ejector (Only version ADT 30 Ejector)
E14B Not used
E15 Not used
TELERUPTORS
Figure 12
1731705Z1
Type Relay User

S E17 Body Hoist x gearshift signal
S E18 K2 relay gearbox in reverse
S E19 Steering emergency pump
S E20 K1 relay gearbox in idle
E21 Not used
E22 Not used
S E23 Park brake (idle)
S E24 Torque splitter
S E25 Emergency pump safety
E26 Not used
Z D1 Emergency pump - emergency pump safety
(buzzer)
Z D3 Park brake warning light - body up
TELERUPTORS
Figure 13
1731706Z
Type Relay User

S E27 LH side wipers
S E28 RH side wiper
S E29 Hour meter operation with D+
S E30 Side window washer/wiper pump
S E31 Climate control
S E32 Telecamera
S E33 Bonnet lifter
T T1 Timer heater
LAYOUT ELECTRICAL SYSTEM
Legend
001 12 V batteries
002 Isolator
003 Alternator
004 Starter motor
005 Ignition switch
006 Fuse holder and relay control unit
007 Starter relay
008 Emergency steering pump
009 Emergency steering pump relay
010 Emergency steering pressure switch
011 Current general relay
012
013
014 Park brake switch
015 Idling switch
016
017 Outside lights switch
018 Stalk unit ć flashing lever
019 Stalk unit ć traffic beam ć main beam lever
020 Stalk unit ć turn lights lever
021 Stalk unit ć windscreen wiper lever
022 Stalk unit ć window washer button
023 Stalk unit ć horn button
024 Side and overall lights
024/c Front LH light
024/b
024/c RH side light
024/d
024/e
024/f
024/g RH taillight
025 Side and overall lights
025/c Front RH light
025/b
025/c LH side light
025/d
025/e
025/f
025/g LH taillight
026 LH traffic beam
027 RH traffic beam
028 LH main beam
029 RH main beam
030 Rear fog light switch
031 Reversing switch
032 Brake lights switch
033 Rotating lamps switch
034 Hazard lights switch
035 Lamps test button
036
037 LH map lights switch
038 RH map lights switch
039 Turn light flashing
040 Rear fog light
041 Reversing light
042 Brake lights
043 Turn lights
legend
044 Turn lights
045 Turn lights
046 Turn lights
047 LH adjustable map light
048 RH adjustable maplight
049 Rotating lamps
050 Horns
051 Frame with 10 visual indicators
054
055 Speedometer
056 Rev. counter
057 Engine water temperature gauge
058 Diesel level gauge
059 Engine oil pressure gauge
060 Gearbox oil temperature gauge
061 Hour counter
062 Buzzer
063 Cigar lighter
064 Windscreen wiper
065 Window washer pump
066 Heater unit
067
068 Impulse sender on engine flywheel
069
070 Impulse sender for speedometer
071
072 Engine water high temperature switch
073 Engine water thermostat
074 Engine oil gauge sender
075 Engine oil low temperature switch
076 Fuel level sender
077 Gearbox oil thermostat
078 Clogged brake oil filter vacuum switch
079 Clogged air cleaner vacuum switch
080
081 Accumulator pressure
082
083
084 Parking brake activation pressure
085 Rear differential lock pressure
086 Park-brake pressure (enable idling gear)
087
088
089
090 Cargo body raised microsw.
091
092
093 Heated mirrors switch
094 RH heated mirror
095 LH heated mirror
096
097 Bonnet opening button (chassis)
098 Bonnet opening electric pump
099
100
101 Starting brake oil drainage sol. valve
102 Motor driven mirrors control
legend
103 LH motor driven mirror
104 RH motor driven mirror
105 ć
106 ć
107 Idling gear relay
108
109
110 D+ signal relay
111 Horns relay
500 Automatic transmission electronic control unit
501 Kick down switch
502 Park brake solenoid valve
503 Jake brake switch (retarder 6WG 260 ZF)
504 Transfer locking switch
505 Jake brake (solenoid A - ADT 30)
506 Jake brake (solenoid B - ADT 30)
507 Park brake switch
508 Gearbox oil high temperature warning light
509 Retarder switch
510 Gearbox oil temperature gauge
511 Retarder solenoid valve
512
513
514 Front work light switch
515 Front work lights
516 ć
517 Oil high temperature warning buzzer
518 Gearbox oil high temperature switch
519 Side window washer/wiper pump
520 LH side wiper
521 RH side wiper
522 Side wiper button
523 Side window washer button
524 Tip-up control lever
525 Cargo body tip-up solenoid valve
526 Switch control lever (ejector)
527 Solenoid valve (ejector side board)
528 Cargo body up end-of travel switch
529 Fuel pump switch
530 24/12 V voltage reducer
531 Additional 12 V current tap
532 Air conditioner switch
533 Air conditioner switch
534 Air conditioner compressor
535 Transfer lock switch
536 TV monitor
537 TV switch
538 ZF display
539 Low temperature start button
540 Low temperature start relay
541 Heater
542 Presetting Tip-up timer
543 24/12 V voltage reducer
544 Additional 12 V current tap
Legend
1. Batteries
2. General switch
3. Generator
4. Starter motor
5. Starter relais
6. Emergency pump
7. Emergency pump relais
8. Fuel gauce
9. Horn
10. RH headlight
11. LH headlight
12. Washer
13. Washer (Lateral wiper)
14. Switch kick-down
15. Front diff. lock (Light)
16. Switch tip (Optional)
17. Junction box
18. Reverse
19. Rearfog
20. RH rearlight
21. External buzzer
22. LH rearlight
23. Conn. rear articulation
24. Conn. front articulation
25. Switch tip
26. Intermediate axle
27. Water temperature
28. Engine oil press. (Light)
29. Engine oil pressure
30. Switch park-brake
31.
32. Air cond. (Switch)
33. Solenoid starter
34. Air cond. (Compressor)
35. Transmission temperature
36. E.V. park-brake
37. Stop sender
38. Accumulator sender
39. Emergency switch
40. Pwg tail
41. Push or body
42. Axle disconnect
43. Park-brake solenoid
44. Brake oil filter (light)
45. Tachometer
46. RH intermediate light
47. LH intermediate light
48. Braking oil outlet (Start)
49. Bonnet tipping pump (Opt.)
50. Bonnet tipping switch (Opt.)
51. Low temperature start engine (Opt.)
52. Low temperature start relay (Opt.)
Legend
1. Relay body hoist
2. Relay EMG
3. Relay reverse
4. Diode
5. Relay start
6. Body tipping timer (Opt.)
7. Relay park-brake (Neutral)
8. Buzzer front diff. lock & emg. pump
9. Air filter
10. E.C.U. Astra
11. Tipping
12. Fuses
13. Fuses (Transmission)
14. Lighter
15. Radio 12 V
16. LCD TV
17. R-work-light
18. L-work-light
19. Beacon
20. Lateral wiper motor
21. Wiper motor
22. Switch (Lat. wiper)
23. Switch (Lat. washer)
24. Switch (Heated mirror opt.)
25. Switch (Hazard)
26. Switch (Beacon)
27. Switch (Fwk lights)
28. Switch (Test)
29. Switch (Rearfog)
30. Switch (Tv)
31. Switch (Park-brake)
32. Switch (Lights)
33. Switch (Differential lock)
34. Switch (Jake-brake or retarder)
35. Relay Jake-brake A
36. Relay Jake-brake B
37. Ejector
38. Converter 24/12
39. Flash module
40. Internal light
41. Relay hour meter
42. Relay RH lat. wiper
43. Relay LH lat. wiper
44. Relay lat. washer
45. Relay TV
46. Relay air cond.
47. El. seat
48. Hour meter
49. Coupling air cond.
50. -
51. Tachometer
52. Engine speed indicator
53. Instrument board
54. Warning lights
55. Plug 12 V
56. Remote control mirrors
57. -
58. Steering column switch
59. Ignition switch
60. Cab/transmission interface
61. -
62. RH heated-motorized mirror
63. LH heated-motorized mirror
64. RH heated mirror
65. LH heated mirror
66. Bonnet tipping relay (Opt.)
67. Low temp. start timer (Opt.)
68. Low temp. start switch (opt.)
69. -
70. Relay jake brake-retarder
71. Relay diff. long. lock
72. Relay emg. pump (Buzzer)
SECTION 18
CAB AND CHASSIS

ADT 25 SECTION 18 CAB AND CHASSISą1
CONTENTS
Page Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . 18

Central bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
BONNET TIPPING SYSTEM . . . . . . . . . . . . . . . . . . . 5 Straightening the chassis . . . . . . . . . . . . . . . . . . . . . 18
CENTRALISED GREASING DISPENSER CAB REMOVAL-REFIT . . . . . . . . . . . . . . . . . . . . . . 19

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Front centralised dispenser . . . . . . . . . . . . . . . . . . . . . 6 Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Rear centralised dispenser . . . . . . . . . . . . . . . . . . . . . 9
CAB SUPPORT SILENT-BLOCK
CENTRAL BEARING REMOVAL-REFIT . . . . . . . 12 REMOVAL-REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Reassembly and knuckle bearings adjustment . . . 14 ENGINE HOOD REMOVAL-REFIT . . . . . . . . . . . . 23

Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TESTS AND CHECKS . . . . . . . . . . . . . . . . . . . . . . . . 16 Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Chassis lateral bending check . . . . . . . . . . . . . . . . . 16

Finding chassis bending up and down . . . . . . . . . . 17
Finding chassis twist . . . . . . . . . . . . . . . . . . . . . . . . . 17
2ąCAB AND CHASSIS SECTION 18 ADT 25
DESCRIPTION
Central bearing
The vehicle has a central articulation of the chassis, ots on taper roller bearings for movement around the
consisting of a large size central bearing for the moveĆ vertical axis.
ments around the horizontal axis, and two rotating pivĆ
Figure 1
1731801
This central articulation allows the front part of the veĆ

hicle to move in relation to the rear part:
A around the horizontal axis;

B around the vertical axis.
Figure 2
1731802
1. ball bearing centre plate 6. pivot mounting screw

2. supporting ring with hubs 7. rear chassis
3. upper pivot 8. lower pivot
4. upper pair of taper roller bearings 9. lower pair of taper roller bearings
5. thrust washer 10. front chassis
The articulation around the horizontal axis is obtained In this way the position between the supporting ring
by the use of a large diameter bearing (ball bearing hub and the forked end of the rear chassis is vertically
centre plate) with the outer ring flanged to the front part restrained.
of the chassis. The bearings of the upper pivot, also mounted in X arĆ
Onto the inner ring of the ball bearing centre plate a rangement are axially free in relation to the supporting
supporting ring is flanged. This ring has two hubs - ring hub, to avoid overloading by thermal expansion
lower and upper- into which two pivots are inserted by Both pairs of bearings are pre-loaded to ensure the
means of two adjustable taper roller bearings for each necessary inflectional stiffness of the chassis.
pivot. The latter are integral with the fork shaped end The tightness against dust and water is ensured by
of the rear part of the chassis. special sliding gaskets.
The bearings of the lower pivot are mounted in X arĆ
rangement: both the outer rings are fitted up against a
fixed shoulder inside the hub.
BONNET TIPPING SYSTEM

1. Hand pump 3. Anti-emptying valve
2. Electric pump (if present) 4. Tilt cylinder
1891801
CENTRALISED GREASING DISPENSER SYSTEM

The vehicle is equipped with two centralised grease
dispensers for the front (A) and rear part (B), respecĆ
tively.
Front centralised dispenser (A)
Figure 3
1731823
Circuit Grease application point Circuit Grease application point

A1 Left suspension mount bearing A10 Right rear arm pin
A2 Right suspension mount bearing A11 Left shock absorber upper joint
A3 Left suspension mount bushing A12 Right suspension mount bearing
A4 Right front arm pin A13 Central bearing
A5 Left front arm pin A14 Central bearing
A6 Right shock absorber upper joint A15 Central bearing
A7 Left shock absorber lower joint A16 Central bearing
A8 Right shock absorber lower joint A17 Central bearing
A9 Left arm rear pin A18 Central bearing
Figure 4
1731824
Figure 5
1731825
Rear centralised dispenser (B)
Figure 6
1731826
Circuit Grease application point Circuit Grease application point

B1 Lower central bearing hinge B8 Rear suspension left rocker arm
B2 Right steering cylinder front joint B9 Right tipper cylinder upper joint
B3 Right steering cylinder rear joint B10 Rear suspension right rocker arm
B4 Left steering cylinder front joint B11 Left body tipper pin
B5 Left steering cylinder rear joint B12 Left tipper cylinder lower joint
B6 Upper central bearing hinge B13 Right body tipper pin
B7 Left tipper cylinder upper joint A14 Right tipper cylinder lower joint
Figure 7
1731827
Figure 8
1731828
CENTRAL BEARING REMOVAL-REFIT

. Before starting any type of operation make D prepare appropriate means of support for the rear
part of the chassis, and prepare a lifting trolley of adĆ
equate capacity under the front part of the chassis;
D disconnect the fittings of the central lubrication sysĆ
tem;
D disconnect the knuckle hinge (1) both steering conĆ
1.2 of this manual.
trol cylinders (5) and the telescopic protections as
indicated in the Chapter REMOVAL-REFIT STEERĆ
perience.
ING CYLINDER and rotate it against the rear chasĆ
sis;
D remove the propeller shaft (6) between the gearbox
rectly.
and the intermediate shaft as described in SECĆ
TION 10;
Removal D unscrew the mounting screws (3) and disconnect
To remove proceed as follows: the thrust bearing (2) from the front chassis;
D bring the vehicle onto a suitable flat, solid surface, D with utmost caution, move the front part of the veĆ
switch off the engine, remove the ignition key, enĆ hicle away to disengage the thrust bearing;
boards; Do not move further away than 0.5 m (1.7 ft)
D cut off the battery isolator switch or disconnect the to avoid damaging the electrical and hydrauĆ
terminals from the battery to avoid the risk of short lic connections.
circuits; D unscrew the mounting screws (4) and remove the
thrust bearing (2) from the knuckle hinge (1);
Figure 9
1731803A
D suitable support the knuckle hinge (1), then workĆ D working from above (3) unscrew the mounting
ing from below (2) unscrew the mounting screw (a) screws (a) and remove the spacer (b),the adjustĆ
and remove the spacer (b), the adjustment shims ment shims (c) and the pivot (d);
(c) and the pivot (d); D remove the knuckle hinge from the rear chassis (4);
Figure 10
1731804
Disassembly Reassembly and knuckle bearings adjustment

Figure 11 Figure 13
1731806 1731808
D remove the seal rings (3) and bearings (1) and (2) D assemble the seal rings (3), the taper roller bearings
from the lower seat of the knuckle hinge; (1) and (2) and the spacer (4) from the upper seats
of the knuckle hinge;
Figure 12
. The spacer (4) is fitted between the two
bearings.
Figure 14
1731807
D remove the seal rings (3), bearings (1) and (2) and
the spacer (4) from the upper seat of the knuckle
hinge;
1731809
D assemble the seal rings (3) and the taper roller

bearings (1) and (2) from the lower seat of the
knuckle hinge;
Figure 15
1731810
D from below assemble the pivot (d), then insert (arĆ D select from the available spare parts, the adjustĆ
row) a piece of copper wire, assemble the stop ring ment shims (c) with a thickness S that ensures the
(b) without adjustment shims and tighten the specified bearing pre-load:
screw (a) to the specified torque; S = X ć 0.12 mm (0.005 in)
D remove the screws and the stop ring and measure
thickness X of the copper wire;
Figure 16
1731811
D assemble the selected adjustment shims (c) and Refit

the stop ring (b) and tighten the screw (a) to the speĆ Assemble the hinge onto the chassis following the reĆ
cified torque; moval operations in reverse.
D repeat in exactly the same way for the upper operaĆ
tion.
TESTS AND CHECKS

The chassis transmits load weight and component Chassis lateral bending check
weight to springs and axles. It absorbs the stresses
produced during running, e.g. flexure, thrust and torĆ Figure 17
sional force, tensile stress and vibrations.
Chassis conditions are therefore essential for vehicle
operation. Inspect the chassis at regular intervals to
check that chassis and members thereof are free from
cracks or damages, that bolts and rivets are well tightĆ
ened especially in the areas submitted to stress, i.e. on
leaf spring supports, on drive support, on cross memĆ
bers and tow hook.
Every crack or distortion of the chassis seriously imĆ
pairs chassis resistance to operating stress.
The negative consequences often result in an axial disĆ
placement which has negative effects on the driving
performances and causes earlier tyre wear.
1731830
Any additional hole drilled inadequately in the connecĆ
tion points with other components can be the starting
cause of serious damages to the chassis.
Chassis lateral bending admitted: a=3 mm (1.2 in)
This also applies to any interference with other parts or
to pits due to rust, since these can increase notch senĆ Chassis side bending measurement procedure.
sitivity and favour crack formation. Proceed as follows:
Proceed as follows:
Figure 18
D Visually check the chassis controlling the
alignment.
If deformations can be seen, free the relevant part
of the chassis for easier measurement.
. Before checking, ascertain that all members

that could, with their imperfections,
influence the exact measurement readings
(for example, tyre inflation pressure, weak
or broken leaf springs and so forth) are
efficient.
D Carefully check the entire chassis for cracks paying
special attention to highly stressed coupling points
1731931
between chassis cross members, brackets, leaf
spring supports and chassis side members.
D To find the chassis lateral bending plumb the bearĆ
ing surfaces starting from the two side members at
intervals of approx. 1 m (3 ft).
D The points obtained must be carefully marked on
the floor.
Figure 19 D Use two shims (1) of the same thickness and of a size
that permits a cord to be stretched throught the straight
length of the lower or upper edge plate of the side
member.
D Measure the distance of the side member from the
cord at 1 metre intervals.
D Different cord distance shows position and entity of
actual side member bending
Finding chassis twist
Figure 22
1731932
D In order to use the plumbed points, stretch a cord

through the aligned points marked.
D The points that are not aligned indicate the beginĆ
ning and the entity of the actual strain.
Finding chassis bending up and down
Figure 20
1731835
Bending up and down admitted on chassis: c=1 mm

(0.4 in)
Slight torsion may only be detected with the cab and
mechanical units removed. To make the check, proĆ
ceed as follows:
Proceed as follows:
Figure 23
1731833
Vertical bending admitted: b=1 mm (0.4 in)

Method for measuring chassis bending downwards or
upwards.
Proceed as follows:
Figure 21
1731836
D place the chassis on two stands;

D fasten one side of the chassis to the stand with two
clamps;
D set the other side of the chassis on the knee of an
L" iron (1) in central position under the rear cross
member;
D place a ruler in cross position and a spirit level (2)
on the ruler and check the readings.
1731934
The same value should result at each check point,
otherwise the chassis is deformed.
REPAIR OPERATIONS
Figure 26
Precautions
Figure 24
1731839
Straighten chassis lateral bending by wedge heating

the upper and lower edge of the chassis length conĆ
1731837
cerned.
When welding, drilling, grinding or cutting near the The wedge point must in the desired bending direcĆ
pipes of the braking system, especially near plastic tion.
parts or electrical wiring, take adequate precautions to If the base (a) of the two wedges is on the upper edge
protect them, and if necessary, remove them. plate of the side member, the plate must also be
All parts of the chassis that are reconditioned are to be heated, but last.
protected from oxidation and corrosion
Protection and painting operations are to be carried out Figure 27
accurately on all the parts involved, following any instrucĆ
tions, methods, and preventive precautions indicated by the
paint manufacturers
Straightening the chassis
Figure 25
1731840
Straighten the chassis up or down bending by wedge

heating the upper edge plate of the side member.
When bending down, the base of the wedge (a) is
down, for up bending the base is up.
The relevant lower or upper edge plate of the side
member is to be heated last in the area where the
1731838 wedge base lays.
The chassis reconditioning is obtained by wedge heatĆ
ing the part concerned with a torch. . For greater information on chassis welding,
During this operation the metal must become cherry see SECTION 1.2 - Use.
red coinciding with a temperature ranging between
600-680°C (1112-1256 °F).
The points already heated must not be re-heated.
Let the heated points cool slowly without using water, comĆ
pressed air or other cooling agents.
CAB REMOVAL-REFIT Figure 29

1.2 of this manual.
perience.
rectly.
Removal
D bring the vehicle onto a suitable flat, solid surface, D Remove conditioner unit compressor connecting
switch off the engine, remove the ignition key, enĆ pipes;
gage the parking brake and apply the warning signĆ D unlock the mounting screws and move aside the
boards. coolant reservoir (7) without overturning it;
D cut off the battery isolator switch or disconnect the D disconnect the engine coolant inlet pipes and the
terminals from the battery to avoid the risk of short cab heating outlet pipes (8);
circuits;
D lock knuckle with the steering lock bar following the . During these operations some coolant may
instructions in SECTION 1.2; spill out.
Figure 28 D from inside the cab, partially remove the rubber mat,
loosen the fastening screws and carefully lower the
pedal board (3) on the chassis, being careful not to
damage the wiring or the pipes;
D raise the boot, loosen the fastening screws and
carefully lower the steering valve (4) on the chassis,
being careful not to damage the pipes;
D remove the hydraulic fitting plate (5) fastening bolts
from the respective silent-block mounts and lower
then plate on the chassis, being careful not to damĆ
age the pipes;
D remove the pipe (6) connecting the engine exhaust
to the exhaust muffler;
D disconnect the electrical connections:
1731812 - chassis-utility connection
D remove the engine hood as described in the ChapĆ - automatic gearbox connection
ter ENGINE HOOD REMOVAL-REFIT; - engine-gearbox connection
D discharge the air conditioning system as described - cab power wire.
in the Chapter AIR CONDITIONER SYSTEM;
Do not discharge R134a into the atmoĆ
sphere. Even if its ozone impoverishment
property is zero, it still has overall heating
properties.
Recovery and recycling are legally conĆ
trolled.
Always use type tested coolant recovery and
recharging equipment.
Never mix different types of coolants in the
same equipment.
Figure 30
1891803
D using appropriate lifting equipment apply the Refit

chains to the cab (1) inserting suitable material to To refit follow the removal operations in reverse order.
protect from rubbing where this could occur and reĆ Bleed air from the hydraulic circuit as shown in Section
move the slack, ensuring that the load is evenly balĆ 16.
anced; Check engine coolant level as shown in Section 3.
Figure 31
1731815
D remove the screws securing the front (2) and rear

(3) flexible mountings;
D check very carefully that:
- all the electrical connections have been disconĆ
nected
- all hoses have been disconnected;
- all securing straps have been released;
D very cautiously lift the assembly.
CAB SUPPORT SILENT-BLOCK REMOVAL-REFIT

circuits;
D remove the cab as described in the relevant ChapĆ
1.2 of this manual.
ter;
D unscrew the mounting screws and remove the siĆ
perience.
lent-block.
rectly.
. In the case of intervention, all four silent
blocks (A), (B), (C) and (D) are to be reĆ
placed.
Removal
To remove proceed as follows: Refit
Refit operating in reverse to the removal.
Carry out all the operations indicated in the chapter REĆ
MOVAL - REFIT CAB to restore the original conditions.
boards.
Figure 32
1731821
ENGINE HOOD REMOVAL-REFIT

circuits;
D open the hood (1) following the instructions in the
1.2 of this manual.
USE AND MAINTENANCE MANUAL;
D support the hood with cords and a suitable lifting
perience.
unit: Disconnect the rods (2) from both bonnet tip
over cylinders;
D unscrew the mounting screws, disconnect the
rectly.
hinge mountings (3) from the chassis and remove
the hood.
Removal
To remove proceed as follows: Refit
D bring the vehicle onto a suitable flat, solid surface, To refit follow the operations in reverse to the removal.
switch off the engine, remove the ignition key, enĆ Run some opening and closing cycles and if necessary
gage the parking brake and apply the warning signĆ adjust the hinges to have correct closing.
boards. Check that the hood closing warning light is functioning
properly.
Figure 33
1731822
SECTION 20
BODY
ADT25 SECTION 20 BODYą1
CONTENTS
Page Page
SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . . 3 REMOVAL AND REFITTING . . . . . . . . . . . . . . . . . . . 4

Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dimensions and capacity . . . . . . . . . . . . . . . . . . . . . . 3 Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2ąBODY SECTION 20 ADT25
ADT25 SECTION 20 BODYą3

Body
Structure with flat steel bottom with boxed parts Walls and bottom are made of high abrasion resistance
strengthening subframes and flexible support pads. steel.
Dimensions and capacity
Figure 1
174DT01
E Rear overhang 1284 mm (4.21 ft)

G Width 2500 mm (8.20 ft)
L Loading height 2648 mm (8.69 ft)
M Maximum height with raised body 6140 mm (20.14 ft)
N Maximum tipping angle 68°
Capacity:
- flush (SAE 1:1): 10,6 m3 (13.9 yd3)
- full (SAE 2:1): 13,3 m3 (17.4 yd3)
4ąBODY SECTION 20 ADT25
REMOVAL AND REFITTING

. Before starting any type of operation make gage the parking brake and apply the warning signĆ
boards;
D Cut off the parking brake isolator switch or disconĆ
nect the terminals from the battery to avoid the risk
of short circuits;
D Lock knuckle with the steering lock bar following the
1.2 of this manual.
D Support the cylinder (4) with suitable lifting equipĆ
perience.
ment, then loosen the upper securing bolt (5) on
both sides. Remove the guide pin (6), then lower the
cylinder and free it from the body attachment;
rectly.
D Adequately support the body (1) with a crane, then
loosen the securing screws (3) and remove the
jointing pins (2) on both sides. Lift the body and rest
Removal it on a suitable working surface.
D bring the vehicle onto a suitable flat, solid surface, Refitting
switch off the engine, remove the ignition key, enĆ To refit, reverse the removal operations.
Figura 34
1731901

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WORKSHOP MANUAL

ASTRA VEICOLI INDUSTRIALI

Publication no. A3000021

Prepared by SIPAL S.p.A. - TORINO (Italy)

Complete or partial copying of the text and illustrations herein is prohibited.

Page left intentionally blank

TITLE SECTION PAGES

INTRODUCTION from I to VIII

CONDITIONS OF USE 1.1 from 1 to 16

SAFETY INSTRUCTIONS 1.2 from 1 to 18

GENERAL SPECIFICATIONS 2 from 1 to 28

AUTOMATIC TRANSMISSION 7 from 1 to 82

PROPELLER SHAFT 10 from 1 to 10

FRONT AXLE 12.1 from 1 to 50

INTERMEDIATE AXLE 12.2 from 1 to 58

REAR AXLE 12.3 from 1 to 48

BRAKES 13.1 from 1 to 20

WHEELS AND TYRES 13.2 from 1 to 8

STEERING SYSTEM 15 from 1 to 6

HYDRAULIC SYSTEM 16 from 1 to 44

ELECTRICAL SYSTEM 17 from 1 to 30

CAB AND CHASSIS 18 from 1 to 24

Main vehicle assemblies production numbers

Page left intentionally blank

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 WARRANTY AND LIABILITY OF THE

SCRAPPING THE VEHICLE . . . . . . . . . . . . . . . . . . . 8

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VIBRATIONS TRANSMITTED TO OPERATOR

Acceleration transmitted to the operator's body:

Measured by means of accelerometer on identical

INFORMATION ON THIS HANDBOOK

Purpose of this handbook

To whom this manual is addressed

Safekeeping of this handbook

Updates to this handbook

SCHEDULED USE VEHICLE REPAIR SERVICEMEN

. The manufacturer declines liability for injury

WASTE DISPOSAL SCRAPPING THE VEHICLE

WARRANTY AND LIABILITY OF THE SERVICE

GENERAL OPERATION RULES

Disconnecting hydraulic lines After disassembly

Screw and nut tightening Connecting hydraulic lines

D Tighten nuts and bolts alternately so that average

D When connecting the lines, slightly tighten the nuts

Figure 9 D Make sure that the contact surface (shaft area) of

A: inner side (possible pressure)

D Non-separating bearings that require interference

Snap rings (seeger rings)

D If interference is required on the inner ring, push it

Page left intentionally blank

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 WORKING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . 9

SAFETY INFORMATION AND SYMBOLS . . . . . . . 3 TOWING THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . 11

GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 4 REPLACING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . 11

PREVENTING FIRES . . . . . . . . . . . . . . . . . . . . . . . . . . 5 MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . 12

CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 PREVENTING INJURIES . . . . . . . . . . . . . . . . . . . . . . 13

STARTING AND STOPPING . . . . . . . . . . . . . . . . . . . . 8 PREVENTING INTOXICATION AND

Page left intentionally blank

These instructions are not comprehensive. They do not

Safety information and symbols

Standard safety equipment includes:

Do not smoke while refuelling or topping up fluids. Do

Do not use petrol, solvents or other flammable or toxic

In the event of overturning