Komatsu Telescopic Handlers WH609, WH613, WH713, WH714, WH714H, WH716 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Telescopic Handlers WH609, WH613, WH713, WH714, WH714H, WH716, WH609-E0, WH613-E0, WH713-E0, WH714H-E0, WH716-E0, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Telescopic Handlers WH609-1, WH613-1, WH713-1, WH714-1, WH714H-1, WH716-1, WH609-1E0, WH613-1E0, WH713-1E0, WH714H-1E0, WH716-1E0 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,261 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
WEAM005900 - Telescopic Handler WH609-1, WH613-1, WH713-1, WH714-1, WH714H-1, WH716-1 Operation & Maintenance Manual.pdf
WEBM005700 - Telescopic Handler WH609-1, WH613-1, WH713-1, WH714-1, WH714H-1, WH716-1 Shop Manual.pdf
WEBM008500 - WH609-1E0, WH613-1E0, WH713-1E0, WH714H-1E0, WH716-1E0 Telescopic Handler Shop Manual.pdf
MAIN SECTIONS
CONTENTS...3
REVISED PAGES...5
k SAFETY...7
FOREWORD...9
HOW TO READ THE SHOP MANUAL...10
HOISTING INSTRUCTIONS...11
STANDARD TIGHTENING TORQUE...12
COATING MATERIALS...14
ELECTRIC...15
WEIGHT TABLE...16
TABLE OF OIL AND COOLANT QUANTITIES...17
CONVERSION TABLE...19
10 STRUCTURE AND FUNCTION...27
ENGINE-TRANSMISSION COUPLING...28
POWER TRAIN...29
TRANSMISSION...31
FRONT AXLE...57
REAR AXLE...61
BRAKE PUMPS...65
STEERING SYSTEM (4WS)...66
STEERING UNIT...70
HYDRAULIC DIAGRAM...71
HYDRAULIC PUMP...72
CONTROL VALVE...76
PPC VALVE...77
SOLENOID VALVES...80
SAFETY VALVES...86
CYLINDERS...93
AIR CONDITIONING SYSTEM...100
CLIMATE CONTROL SYSTEM OPERATION...101
20 TESTING AND ADJUSTMENTS...103
STANDARD SPECIFICATIONS...105
INTRODUCTION...135
VALVE LASH ADJUSTMENT...137
CHECKING ENGINE SPEED...138
TENSIONING THE AIR CONDITIONER COMPRESSOR BELT...141
ADJUSTING ACCELERATOR CABLE LENGTH...142
ADJUSTING BRAKE PEDAL TRAVEL AND POSITIONING THE STOP LAMP MICROSWITCHES...143
ADJUSTING THE PARKING BRAKES...145
BLEEDING AIR FROM CIRCUITS...147
PREPARING THE MACHINE READY FOR HYDRAULIC PRESSURE CHECK AND CALIBRATION...149
CHECKING AND CALIBRATING WORK EQUIPMENT HYDRAULIC PRESSURES...150
CALIBRATING THE PRESSURE OF THE STEERING SYSTEM...156
INSPECTING THE OPERATION OF THE UNLOADING VALVE...157
CHECKING AND CALIBRATING THE DR VALVE (PUMP FLOW VARIATION)...158
CHECKING THE DYNAMIC PUMP DP VALUE...159
CHECKING PUMP FLOW...160
BRAKE SYSTEM CHECKS...161
TRANSMISSION (POWER SHIFT) CHECKS...164
TRANSMISSION ASSEMBLY PRESSURE CHECKS...166
CHECKING THE SPEED OF THE TRANSMISSION SHAFTS RESPONSIBLE FOR TRANSLATION (CARDAN SHAFTS)...169
LEVEL CALIBRATION...170
CHECKING LOAD CELL CALIBRATION...171
CALIBRATING THE OVERTURN PREVENTION SYSTEM (STANDARD)...172
CALIBRATING THE OVERTURN PREVENTION (ASM) CONTROL UNIT...177
CHECKING LED CALIBRATION (version with ASM)...179
CHECKING SLIDING PADS CLEARANCE...180
CHECKING BOOM SIDE ALIGNMENT...182
BOOM CHAINS...184
CHAIN TENSIONING...186
CHECKING FOR BLOW-BY...191
ANALYSIS OF THE CAUSES RESPONSIBLE FOR HYDRAULIC DRIFT...194
EQUALIZING STABILIZER SPEED...203
AIR CONDITIONING SYSTEM MAINTENANCE...204
CHECKING THE A/C SYSTEM?S OPERATING TEMPERATURE...205
30 REMOVAL AND INSTALLATION...207
HOW TO READ THE MANUAL...211
PRECAUTIONS TO BE TAKEN WHEN WORKING...212
SPECIAL TOOLS...213
ENGINE HOOD...221
Removal...221
Installation...222
RADIATOR HOOD...223
Removal...223
Installation...223
AIR FILTER...224
Removal...224
Installation...224
TURBOCOMPRESSOR...225
Removal...225
Installation...226
EXHAUST PIPE...227
Removal...227
. 1st Length...227
. 2nd Length...227
Installation...228
BELT, FAN...229
Removal...229
Installation...230
RADIATOR-EXCHANGER ASSEMBLY...231
Removal...231
Installation...233
INTERCOOLER...234
Removal...234
Installation...236
MUFFLER...237
Removal...237
Installation...237
BATTERY - BATTERY TRAY...238
Removal...238
. Battery...238
. Battery tray...238
Installation...239
CYLINDER HEAD...240
Removal...240
Installation...241
INJECTORS...242
Removal...242
Installation...242
INJECTION PUMP...243
Removal...243
Installation...243
HYDRAULIC PUMP...244
Removal...244
Installation...245
COMPLETE ENGINE- SHIFT ASSEMBLY...246
Removal...246
Installation...255
ENGINE-TRANSMISSION...256
Detachment...256
Joining...257
CONTROL VALVE ASSEMBLY...258
Removal...258
Installation...261
BRACKET CONTROL, EQUIPMENT LOCK, AND FRAME LEVELLING SOLENOID VALVES...262
Removal...262
Installation...262
AIR CONDITIONER COMPRESSOR (only if equipped)...263
Removal...263
Installation...264
COMPRESSOR BELT...265
Removal...265
Installation...267
SERVO-CONTROL FEED VALVE...268
Removal...268
Installation...268
STEERING SELECTION SOLENOID VALVE ASSEMBLY...269
Removal...269
Installation...269
FRONT AXLE...270
Preparation...270
. Machine with outriggers...270
. Machine without outriggers...270
Removal...270
Installation...272
REAR AXLE...273
Preparation...273
. Machine with outriggers...273
. Machine without outriggers...273
Removal...273
Installation...275
TELESCOPIC BOOM...276
Removal...276
Installation...279
LIFT AND OFFSET CYLINDERS...283
Removal...283
Installation...284
INTERMEDIATE AND TOP BOOM...285
Removal...285
Installation...289
EXTENSION CYLINDER...290
Removal...290
Installation...291
BOOM SLIDING PADS...292
Replacement...292
1. Lower sliding pads for intermediate and top booms...292
2. Upper sliding pads for intermediate boom...293
3. Side sliding pads for intermediate and top boom...294
4. Upper sliding pads for top boom...294
5. Rear upper sliding pads for intermediate boom...296
6. Rear upper sliding pads for top boom...297
7. Rear lower sliding pads for intermediate and top boom...298
EXTENSION AND RETRACTION CHAINS (Versions with 3-section boom)...301
Removal...301
Installation...303
CHAIN RETURN PULLEY PINS AND BUSHINGS...304
RETRACTION CHAIN PULLEY...304
Removal...304
Installation...305
EXTENSION CHAIN PULLEYS...306
Removal...306
Installation...307
LOAD CELL...308
Installation...308
CONTROL UNIT...311
Removal...311
Installation...311
BALLAST...312
Removal...312
Installation...312
ENGINE LINE CENTRE...313
Removal...313
Installation...313
ACCELERATOR CABLE...314
Removal...314
Installation...315
SHIFT-REVERSING GEAR LEVER ASSEMBLY...316
Removal...316
Installation...316
STEERING COLUMN SWITCH UNIT - DIPSWITCH...317
Removal...317
Installation...317
STEERING UNIT...318
Removal...318
Installation...320
Disassembly...321
. Removing the seals...323
. Removing the wiper ring...323
Assembly...324
. Installing the inner seal (15)...324
. Installing the control valve...324
. Completing the installation procedure...325
STEERING COLUMN...328
Removal...328
Installation...328
BRAKE PUMPS...329
Removal...329
Installation...330
PPC VALVE...331
Removal...331
Installation...332
LEVEL...333
Removal...333
Installation...333
WIPER MOTORS...334
Removal...334
. Front wiper motor...334
. Rear wiper motor...335
. Upper wiper motor...336
Installation...336
PARKING BRAKE CABLE...337
Removal...337
Installation...338
DASH / INSTRUMENT PANEL...339
Removal...339
Installation...339
CONTROL PANEL...340
Removal...340
Installation...340
FUSE AND RELAY CENTRE...341
Removal...341
Installation...341
PROPELLER SHAFT...342
Removal...342
. Front cardan shaft...342
. Rear cardan shaft...342
Installation...343
FUEL TANK...344
Removal...344
Installation...345
HYDRAULIC OIL TANK...346
Removal...346
Installation...347
FRAME LEVELLING CYLINDER...348
Removal...348
Installation...348
FRAME SWING LOCKING ROD (WH609 and WH613 only)...349
Removal...349
Installation...349
AXLE LOCKING CYLINDER...350
Removal...350
Installation...350
STABILIZER CYLINDERS (If equipped)...351
Removal...351
Installation...352
EQUIPMENT HOLDER...354
Removal...354
Installation...355
EQUIPMENT MOTION CYLINDER...356
Removal...356
Installation...357
CYLINDERS...358
Disassembly...358
Assembly...359
EQUIPMENT QUICK-LOCK ASSEMBLY...363
Removal...363
Installation...363
AIR CONDITIONER FANS...364
Removal...364
Installation...364
AIR CONDITIONER CONDENSER ASSEMBLY...365
Removal...365
Installation...366
DEHUMIDIFYING FILTER...367
Removal...367
Installation...368
AIR CONDITIONING SYSTEM PRESSURE SWITCH...369
Removal...369
Installation...369
CAB...370
Removal...370
Installation...374
TRANSMISSION...375
TRANSMISSION ASSEMBLY...375
Disassembly...375
Assembly...386
1st CLUTCH...387
Disassembly...387
Assembly...390
2nd CLUTCH...391
Disassembly...391
Assembly...395
4th CLUTCH...396
Disassembly...396
Assembly...399
3rd CLUTCH...400
Disassembly...400
Assembly...403
REVERSE CLUTCH...404
Disassembly...404
Assembly...406
FORWARD CLUTCH...408
Disassembly...408
Assembly...411
PRESSURE REGULATOR VALVE...412
Disassembly...412
Assembly...412
MODULATED VALVE...413
Disassembly...413
Assembly...414
SPACER PLATE...417
Disassembly...417
Assembly...421
CONVERTER HOUSING...422
Disassembly...422
Assembly...424
DROP BOX ASSEMBLY...425
Disassembly...425
. Complete drop box assembly...425
. Input shaft...427
Assembly...427
. Input shaft...427
. Complete drop box assembly...427
AXLES...436
Disassembly...436
. Planetary reduction...436
. Steering case...440
. Cardan shaft...443
. Brakes...445
. Parking brake assembly (front axle)...447
. Removal of steering cylinder...449
. Disassembly of steering cylinder...451
. Differential...452
. Bevel pinion...457
Assembly...460
. Bevel pinion...460
. Differential...468
. Steering cylinder...474
. Steering cylinder...477
. Convergency adjustment...480
. Parking brake assembly (front axle)...480
. Brakes...482
. Cardan shaft...485
. Steering case...486
. Planetary reduction...488
!!! new_index = 1
!!! num_start = 1
!!! num_style = Arabic
1.1 FOREWORD.....3
1.2 INFORMATION ON SAFETY.....4
1.3 INTRODUCTION.....6
1.3.1 INTENDED USES.....6
1.3.2 IMPROPER OR UNAUTHORIZED USE.....6
1.3.3 MAIN CHARACTERISTICS.....7
1.3.4 RUNNING-IN.....7
1.4 PRODUCT IDENTIFICATION.....9
1.4.1 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN).....9
1.4.2 MACHINE IDENTIFICATION PLATE.....10
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE.....11
1.4.4 FRONT AXLE SERIAL NUMBER.....11
1.4.5 REAR AXLE SERIAL NUMBER.....12
1.4.6 TRANSMISSION SERIAL NUMBER.....12
1.4.7 CAB SERIAL NUMBER.....12
1.4.8 SERIAL NUMBERS AND DEALER?S ADDRESS.....13
TABLE OF CONTENTS.....14
2.1 SAFETY, NOISE AND VIBRATION PLATES.....22
2.1.1 POSITION OF THE SAFETY PLATES.....22
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS.....26
2.1.3 POSITION OF THE NOISE PLATES.....34
2.2 GENERAL PRECAUTIONS.....35
2.2.1 GENERAL SAFETY RULES.....35
2.2.2 SAFETY DEVICES AND GUARDS.....35
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS.....35
2.2.4 UNAUTHORIZED MODIFICATIONS.....36
2.2.5 LEAVING THE OPERATOR?S SEAT.....36
2.2.6 GETTING ON AND OFF THE MACHINE.....37
2.2.7 CHECKING THE REAR-VIEW MIRRORS.....37
2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL.....38
2.2.9 PREVENTING BURNS.....38
2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER.....39
2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT.....39
2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT.....40
2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE.....40
2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT.....40
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING WORK.....41
2.3.1 SAFETY ON THE WORKSITE.....41
2.3.2 FIRE PREVENTION.....41
2.3.3 PRECAUTIONS CONCERNING THE DRIVING POSITION.....41
2.3.4 ROOM VENTILATION.....42
2.3.5 PRECAUTIONS CONCERNING THE LIGHTS.....42
2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS- CHECKING THE WINDSHIELD WIPER BLADES.....42
2.4 PRECAUTIONS TO BE TAKEN DURING WORK.....43
2.4.1 WHEN STARTING THE ENGINE.....43
2.4.2 RULES FOR TRAVELLING ON ROADS.....43
2.4.3 CHECKS FOR TRAVELLING IN REVERSE.....44
2.4.4 MOVING THE MACHINE.....44
2.4.5 MOVING ON SLOPES.....45
2.4.6 WORKING ON SLOPES.....46
2.4.7 UNAUTHORIZED OPERATIONS.....46
2.4.8 WORKING IN WINDY WEATHER CONDITIONS.....47
2.4.9 MAIN OPERATING MODES.....48
2.4.9.1 LOADING THE MATERIAL.....48
2.4.9.2 UNLOADING THE MATERIAL.....50
2.4.10 PREVENTING ELECTROCUTION.....52
2.4.11 VISIBILITY.....52
2.4.12 WORKING ON ICY OR SNOW-COVERED SURFACES.....52
2.4.13 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT.....53
2.4.14 WORKING ON LOOSE GROUND.....53
2.4.15 PARKING THE MACHINE.....54
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES.....55
2.5.1 LOADING AND UNLOADING THE MACHINE.....55
2.5.2 THE ROUTE.....55
2.6 BATTERY.....56
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES.....56
2.6.2 STARTING WITH BOOSTER CABLES.....56
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY.....57
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE.....58
2.8.1 WARNING PLATES.....58
2.8.2 TOOLS.....58
2.8.3 PERSONNEL.....58
2.8.4 EQUIPMENT.....59
2.8.5 WORKING UNDER THE MACHINE.....59
2.8.6 KEEPING THE MACHINE CLEAN.....59
2.8.7 USE OF THE ENGINE DURING MAINTENANCE.....60
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY.....60
2.8.9 RULES TO BE FOLLOWED WHEN REFUELLING OR ADDING OIL.....60
2.8.10 CHECKING THE COOLANT LEVEL IN THE RADIATOR.....61
2.8.11 USING LAMPS.....61
2.8.12 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR.....61
2.8.13 PRECAUTIONS CONCERNING THE STARTER.....62
2.8.14 PRECAUTIONS CONCERNING THE GEAR LEVER.....62
2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES AND FUEL PIPES.....63
2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH- PRESSURE SYSTEMS.....63
2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES.....63
2.8.18 COOLING FAN AND FAN BELT.....64
2.8.19 WASTE MATERIALS.....64
2.8.20 PRECAUTIONS CONCERNING TECHNOPOLYMERS AND ELASTOMERS.....64
2.8.21 PRECAUTIONS TO BE TAKEN WHEN INFLATING TYRES.....65
2.8.22 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL TYPE ?HEES?.....65
3.1 GENERAL VIEWS.....68
3.1.1 RIGHT SIDE VIEW.....68
3.1.2 LEFT SIDE VIEW.....68
3.1.3 CAB INSIDE GENERAL VIEW.....69
3.2 INSTRUMENTS AND CONTROLS.....70
3.2.1 INSTRUMENTS.....70
3.2.2 WARNING LIGHTS.....72
3.2.3 SWITCHES AND PUSH BUTTONS.....77
3.2.4 ELECTRIC ACCESSORIES.....84
3.2.5 MACHINE CONTROLS.....85
3.3 LIFTING LOADS.....107
3.3.1 READING THE LOAD CHARTS.....107
3.3.1.1 DESCRIPTION OF THE LOAD CHARTS.....107
3.3.1.2 USING THE CHARTS.....109
3.4 FUSES AND RELAYS.....114
3.4.1 CENTRAL UNIT FUSES AND RELAYS.....114
3.4.1.1 CENTRAL UNIT FUSES.....115
3.4.1.2 CENTRAL UNIT RELAYS.....117
3.4.2 ENGINE LINE FUSES AND RELAYS.....118
3.4.2.1 ENGINE LINE FUSES.....118
3.4.2.2 ENGINE LINE RELAYS.....119
3.5 GUARDS, CAB AND DRIVER?S SEAT.....120
3.5.1 ENGINE HOOD.....120
3.5.2 CAB.....121
3.5.3 EMERGENCY EXIT.....122
3.5.4 VENTILATION AND HEATING.....123
3.5.5 AIR CONDITIONER (optional).....125
3.5.6 SEAT.....126
3.5.6.1 STANDARD SEAT.....126
3.5.6.2 OPTIONAL SEAT.....127
3.5.7 STEERING WHEEL.....128
3.5.8 SAFETY BELT.....128
3.5.9 WINDOW SHADE.....129
3.5.10 TECHNICAL DOCUMENTATION.....129
3.5.11 FIRE EXTINGUISHER.....130
3.6 USE OF THE MACHINE.....131
3.6.1 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE.....131
3.6.1.1 VISUAL CHECKS.....131
3.6.1.2 DAILY CHECKS.....131
3.6.1.3 OPERATIONAL CHECKS.....132
3.6.2 STARTING THE ENGINE.....133
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES.....133
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES.....134
3.6.3 WARMING THE ENGINE.....135
3.6.4 HEATING THE HYDRAULIC OIL.....135
3.6.5 HOW TO MOVE THE MACHINE.....136
3.6.5.1 MOVING ON SLOPES.....137
3.6.5.2 MAXIMUM IMMERSION DEPTH.....138
3.7 PARKING THE MACHINE.....139
3.7.1 PARKING ON LEVEL GROUND.....139
3.7.2 PARKING ON SLOPES.....140
3.8 STOPPING THE ENGINE.....141
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES.....142
3.9.1 LOADING AND UNLOADING THE MACHINE.....142
3.9.2 TRANSPORT.....143
3.9.3 LIFTING THE MACHINE.....143
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON AND IN COLD PLACES.....144
3.10.1 FUEL AND LUBRICANTS.....144
3.10.2 ENGINE COOLANT.....144
3.10.3 BATTERY.....144
3.10.4 OTHER PRECAUTIONS.....145
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK.....145
3.11 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON.....146
3.12 EQUIPMENT.....147
3.12.1 INSTALLING EQUIPMENT WITH HYDRAULIC QUICK COUPLING.....147
3.12.2 INSTALLING EQUIPMENT WITH MANUAL COUPLING.....149
3.12.3 INSTALLING EQUIPMENT REQUIRING HYDRAULIC POWER (4X1 BUCKET - FORKS - ROUND BALE GRIPPERS, ETC.).....149
3.12.4 ORGANIZING THE WORK AREA.....150
3.12.5 OPERATING THE EQUIPMENT.....150
3.12.6 OPERATING THE MACHINE FITTED WITH FORKS.....151
3.12.6.1 FORKING A LOAD.....151
3.12.6.2 TRANSPORTING THE LOAD.....153
3.12.6.3 STACKING THE LOAD.....153
3.12.7 PREPARING THE MACHINE FOR TRAVELLING ON ROADS.....155
3.12.8 USING THE MACHINE AS A LOADER.....156
3.12.8.1 ORGANIZING THE WORK AREA.....156
3.12.8.2 LOADING HEAPED AND LEVEL MATERIAL.....156
3.13 LONG PERIODS OF INACTIVITY.....158
3.13.1 PREPARING THE MACHINE FOR A LONG PERIOD OF INACTIVITY.....158
3.13.2 PREPARING THE ENGINE FOR A LONG PERIOD OF INACTIVITY.....159
3.13.3 MAINTENANCE DURING A PERIOD OF INACTIVITY.....159
3.13.4 RESTARTING THE ENGINE.....160
3.13.5 AFTER A LONG PERIOD OF INACTIVITY.....160
3.14 OPERATIONS IN CASE OF FAILURE.....161
3.14.1 IF THE ENGINE BREAKS DOWN WITH BOOM LOADED, LIFTED AND EXTENDED.....161
3.14.2 REMOVING THE MACHINE IN CASE OF FAILURE.....162
3.14.3 IF THE FUEL HAS RUN OUT.....162
3.14.4 IF THE ENGINE FAILS TO START BECAUSE THE BATTERY HAS RUN DOWN.....163
3.14.4.1 STARTING WITH BOOSTER CABLES.....164
3.14.5 OTHER TROUBLES.....165
3.14.5.1 ELECTRIC CIRCUIT.....165
3.14.5.2 HYDRAULIC SYSTEM.....165
3.14.5.3 BRAKING SYSTEM.....166
3.14.5.4 CONVERTER.....166
3.14.5.5 ENGINE.....167
4.1 GUIDE TO MAINTENANCE.....170
4.2 MAINTENANCE NOTES.....172
4.2.1 NOTES REGARDING THE ENGINE.....172
4.2.1.1 ENGINE OIL.....172
4.2.1.2 COOLANT.....172
4.2.1.3 FUEL.....173
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM.....173
4.2.3 NOTES REGARDING THE ELECTRIC SYSTEM.....174
4.2.4 NOTES REGARDING LUBRICATION.....174
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING.....175
4.3 FUEL, COOLANT AND LUBRICANTS.....176
LUBRICATION WITH GREASE.....176
4.3.1 HOMOLOGATED SYNTHETIC BIODEGRADABLE LUBRICANTS ?HEES?.....178
4.4 DRIVING TORQUES FOR SCREWS AND NUTS.....179
4.4.1 STANDARD DRIVING TORQUES.....179
4.4.2 SPECIFIC DRIVING TORQUES.....179
4.5 LUBRICATION.....180
4.5.1 LUBRICATION DIAGRAM (2-SECTION BOOM).....180
4.5.2 LUBRICATION DIAGRAM (3-SECTION BOOM).....181
4.6 PERIODICAL CHANGE OF THE SAFETY-RELATED COMPONENTS.....182
4.6.1 CRITICAL PARTS FOR SAFETY.....183
4.6.1.1 FUEL SUPPLY SYSTEM.....183
4.6.1.2 DELIVERY HYDRAULIC SYSTEM.....184
4.6.1.3 CONTROL VALVE HYDRAULIC SYSTEM.....185
4.6.1.4 BOOM HYDRAULIC SYSTEM.....186
4.7 MAINTENANCE PLAN.....187
4.7.1 WHEN REQUIRED.....191
4.7.1.a CHECKING THE BATTERY ELECTROLYTE LEVEL - INSPECTING TERMINALS AND CABLES.....191
4.7.1.b CHECKING, CLEANING OR CHANGING THE ENGINE AIR CLEANERS.....192
4.7.1.c CHECKING AND CLEANING THE CAB AIR FILTER.....194
4.7.1.d FUSES AND RELAYS - CHECK AND CHANGE.....195
4.7.1.e CHECKING THE WINDSHIELD WASHER FLUID LEVEL.....195
4.7.1.f CHECKING THE WINDSHIELD WIPER BLADES.....196
4.7.1.g LUBRICATING THE CAB DOOR AND ENGINE HOOD HINGES.....196
4.7.1.h LUBRICATING THE FORK SUPPORT ROD.....196
4.7.1.i CHECKING THE FUEL LEVEL.....196
4.7.1.j TOPPING UP THE BRAKING SYSTEM OIL RESERVOIR.....197
4.7.2 MAINTENANCE EVERY 10 HOURS OF OPERATION OR EVERY DAY.....198
4.7.2.a VARIOUS CHECKS.....198
4.7.2.b CHECKING THE ACOUSTIC ALARMS, WARNING LIGHTS AND INSTRUMENTS.....198
4.7.2.c CHECKING THE ENGINE COOLANT LEVEL.....199
4.7.2.d CHECKING THE RADIATOR FLUID LEVEL.....199
4.7.2.e CHECKING THE ENGINE OIL LEVEL.....200
4.7.2.f CHECKING THE TYRE PRESSURE.....200
4.7.2.g CHECKING THE SERVICE BRAKES.....201
4.7.2.h CHECKING AND ADJUSTING THE PARKING BRAKE.....201
4.7.3 MAINTENANCE EVERY 50 HOURS OF OPERATION OR EVERY 2 WEEKS.....202
4.7.3.a LUBRICATING THE ARTICULATED JOINTS AND THE PADS.....202
4.7.3.b LUBRICATING THE CHAIN GEAR SHAFTS (Only for 3-section boom version).....204
4.7.3.c DRAINING THE WATER SEPARATOR.....204
4.7.3.d LUBRICATING BOOM.....205
4.7.4 MAINTENANCE EVERY 100 HOURS OF OPERATION.....206
4.7.4.a LUBRICATING THE DRIVE SHAFTS.....206
4.7.4.b LUBRICATING THE FRONT AND REAR AXLE SWING JOINT.....207
4.7.4.c LUBRICATING THE WHEEL HUB JOINTS.....207
4.7.5 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION.....208
4.7.6 MAINTENANCE EVERY 250 HOURS OF OPERATION OR EVERY 3 MONTHS.....208
4.7.6.a LUBRICATING THE ARTICULATED JOINTS.....208
4.7.6.b LUBRICATING THE BOOM INNER HOSES, ROLLERS AND GUARD.....209
4.7.6.c CHECKING THE AXLE OIL LEVEL (FRONT AND REAR AXLE).....210
4.7.6.d CHECKING THE TRANSMISSION OIL LEVEL.....211
4.7.6.e CLEANING THE OUTSIDE OF THE RADIATOR AND OF THE HEAT EXCHANGER.....212
4.7.6.f CHECKING THE ALTERNATOR-FAN BELT.....212
4.7.6.g CHECKING AND ADJUSTING THE A/C COMPRESSOR BELT TENSION (Optional).....213
4.7.6.h CHECKING THE ADJUSTMENT OF THE PARKING BRAKE.....214
4.7.6.i CHECKING THE ELECTROLYTE LEVEL.....214
4.7.7 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil HEES is used).....215
4.7.8 MAINTENANCE EVERY 500 HOURS OF OPERATION OR EVERY 6 MONTHS.....216
4.7.8.a CHANGING THE FUEL FILTER.....216
4.7.8.b DRAINING THE FUEL TANK.....217
4.7.8.c CHECKING THE HYDRAULIC OIL LEVEL.....217
4.7.8.d CHANGING THE HYDRAULIC OIL DRAIN FILTER.....218
4.7.8.e DRAINING CONDENSATE FROM THE OIL TANK (Only for machines in which synthetic biodegradable oil HEES is used).....219
4.7.8.f CHANGING THE ENGINE OIL.....220
4.7.8.g CHANGING THE ENGINE OIL FILTER.....221
4.7.8.h CHECKING THE CHAINS FOR OXIDATION (Only for the 3-section boom version).....222
4.7.8.i CHECKING AND TIGHTENING THE BOOM CHAINS (Only for the 3-section boom version).....223
4.7.8.j CHECKING THE LENGTH OF THE CHAINS (Only for the 3-section boom version).....228
4.7.8.k LUBRICATING THE EXTENSION CHAINS (Only for the 3-section boom version).....229
4.7.8.l CHECKING THE CLEARANCE OF THE CHAIN DRIVING GEAR BUSHINGS (Only for the 3-section boom version).....230
4.7.8.m CHECKING THE SLIDING BLOCK CLEARANCE.....230
4.7.8.n CHECKING THE WHEEL NUT DRIVING TORQUE.....230
4.7.9 MAINTENANCE EVERY 1000 HOURS OF OPERATION OR EVERY YEAR.....231
4.7.9.a CHANGING THE FRONT AND REAR AXLE OIL.....231
4.7.9.b CHANGING THE HYDRAULIC TRANSMISSION OIL.....232
4.7.9.c CHANGING THE HYDRAULIC TRANSMISSION FILTER.....233
4.7.9.d CHECKING THE ENGINE COOLANT LEVEL AND TOPPING UP.....233
4.7.10 MAINTENANCE EVERY 2000 HOURS OF OPERATION OR EVERY 2 YEARS.....234
4.7.10.a CHECKING THE ALTERNATOR AND THE STARTER.....234
4.7.10.b CHANGING THE ALTERNATOR BELT.....234
4.7.10.c CHANGING THE COOLANT.....234
4.7.10.d CHANGING THE BRAKING SYSTEM OIL.....235
4.7.10.e CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER.....237
4.7.11 MAINTENANCE EVERY 3 YEARS.....238
4.7.11.a CHANGING THE SAFETY BELT.....238
4.7.12 MAINTENANCE EVERY 3000 HOURS OF OPERATION OR EVERY 3 YEARS.....238
4.7.12.a CHANGING THE ENGINE THERMOSTATIC VALVE.....238
4.7.12.b CHECKING THE ENGINE ANTIVIBRATION AND RETAINING SCREWS.....238
4.7.12.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE AND THE INJECTION TIMING ADVANCE.....238
5.1 TECHNICAL DATA.....240
5.1.1 DIMENSIONS WITH FORKS.....240
5.1.2 TECHNICAL CHARACTERISTICS.....242
5.1.2.1 TECHNICAL CHARACTERISTICS WH609 (Aspirated engine).....242
5.1.2.2 TECHNICAL CHARACTERISTICS WH609 (Turbo engine).....243
5.1.2.3 TECHNICAL CHARACTERISTICS WH613 (Aspirated engine).....244
5.1.2.4 TECHNICAL CHARACTERISTICS WH613 (Turbo engine).....245
5.1.2.5 TECHNICAL CHARACTERISTICS WH713.....246
5.1.2.6 TECHNICAL CHARACTERISTICS WH714.....247
5.1.2.7 TECHNICAL CHARACTERISTICS WH714H.....248
5.1.2.8 TECHNICAL CHARACTERISTICS WH716.....249
5.1.3 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED.....250
5.1.4 LOAD DISTRIBUTION ON THE AXLES.....250
5.1.5 OPERATING PERFORMANCE.....251
5.1.5.1 OPERATING PERFORMANCE WITH FORKS (ON WHEELS).....251
5.1.5.2 OPERATING PERFORMANCE WITH FORKS (ON STABILIZERS).....252
