Genie Agrilift Service Manual

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WORKSHOP MANUAL

Code 57.4400.9200 - 1

Edition 11/2005

Agricultural machinery

AGRILIFT 737 - 1037

English

Edition

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WORKSHOP MANUAL

Code 57.4400.9200 - 1

Number: ....................................

Consigned to: ................................................................................................................................

Edition 11/2005

DECLARATION

I, the undersigned..............................................................................................................................

declare that I have received the Workshop manual for TEREXLIFT agricultural machinery

series Agrilift 737 - 1037.

Copies consigned: n° ...... on paper

n° ...... on CD-Rom

The undersigned is obliged to use the manual in their workshop, without disclosing the information

in the same in any way, to unauthorised workshops and third parties in general, and not to

photocopy or reproduce this manual or parts of the same in any way without the prior written

authorisation of TEREXLIFT to do so.

If business relations between the undersigned and TEREXLIFT should come to an end, the

undersigned is obliged to return the copies received without charges for TEREXLIFT.

Yours sincerely

Date ............................

For acceptance

The consignee Company stamp

and signature of the Legal representative

...........................................

Copy to return stamped and signed for acceptance by the

Legal representative of the company receiving the copies of the manual.

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WORKSHOP MANUAL

Code 57.4400.9200 - 1

Number: ....................................

Consigned to: ................................................................................................................................

Edition 11/2005

DECLARATION

I, the undersigned..............................................................................................................................

declare that I have received the Workshop manual for TEREXLIFT agricultural machinery

series Agrilift 737 - 1037.

Copies consigned: n° ...... on paper

n° ...... on CD-Rom

The undersigned is obliged to use the manual in their workshop, without disclosing the information

in the same in any way, to unauthorised workshops and third parties in general, and not to

photocopy or reproduce this manual or parts of the same in any way without the prior written

authorisation of TEREXLIFT to do so.

If business relations between the undersigned and TEREXLIFT should come to an end, the

undersigned is obliged to return the copies received without charges for TEREXLIFT.

Yours sincerely

Date ............................

For acceptance

The consignee Company stamp

and signature of the Legal representative

...........................................

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LIST OF REVISED PAGES

Revision Revised Issued

No. date pages Notes by

1 11-2005 Publication

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GENERAL INDEX

MANUAL CONTENTS

INTRODUCTION

Sect. 1 SAFETY RULES

Sect. 2 TECHNICAL SPECIFICATIONS

Sect. 3 SCHEDULED MAINTENANCE INSPECTIONS

Sect. 4 SCHEDULED MAINTENANCE PROCEDURES

Sect. 5 TROUBLESHOOTING

Sect. 6 SCHEMES

Sect. 7 REPAIR PROCEDURES

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SERIAL NUMBER IDENTIFICATION

Machine denomination Literature valid up to serial number

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INTRODUCTION

Important

Read, understand and obey the safety rules and operating instructions in the Agrilift 737 - 1037 Operator's Handbook before attempting any maintenance or repair procedure. This manual provides the machine owner and user with detailed information on the scheduled maintenance. It also provided qualified service technicians with infromation on troubleshooting and repair procedures. Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, as well as specific tools and equipment. In these instances, we strongly recommend letting service and repair the machine at an authorized TEREXLIFT service center.

INTRODUCTION

Technical Publications

No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means without prior written permission from TEREXLIFT srl. In pursuing a policy of constant quality improvement, TEREXLIFT srl reserves the right to make changes at any time and without undertaking to give prior notice; therefore, also this publication may be subject to modifications.

http://www.terexlift.it e-mail: info@terexlift.it

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DESCRIPTION OF THE MACHINE OPERATION

The source of mechanical energy of this machine is a Deutz turbo-compressed diesel engine (pos. 1), model BF4M2012, with a max torque of 390 Nm at 1500 rev/ min. and a power rating of 74.9 kW at 2300 rev/min. The VDT12000 "power shift" mechanical transmission (pos. 2) produced by Dana is fitted to the flywheel side of the engine, and connected to this engine by a Technodrive coupler with elastic joint and with a 1-to-1 ratio. This transmission has 4 "forward" speed ratios and 3 "reverse" speed ratios. The torque transmission between engine and drive is controlled by a Dana hydrodynamic torque converter. On the special power takeoff (PTO) lodged in the transmission housing (pos. 2) there is a Casappa openloop gear pump (with fixed displacement) (pos. 3) with priority valve integrated in the housing. The displacement of this pump is 43 cm3. Its function is to provide hydraulic power, under form of pressure and capacity, to the steering cylinder of the machine (priority side) and to the telescopic boom cylinder (secondary side). The diesel engine to pump revs ratio is 0.971:1, thus the pump turns just a bit faster than the engine. A second Casappa open-loop gear pump (with fixed displacement) (pos. 4) with a displacement of 25 cm3, is installed on the power takeoff (PTO) of the engine, on the distribution side. This pump feeds the servo-assisted braking system (pos. 28), the (optional) distributor (pos.

22) operating the frame levelling and the rear (optional) hydraulic sockets, and the oil-dynamic circuit of the (optional) three-point hitch (pos. 26). The suction lines of the open-loop pumps (pos. 3) and (pos. 4) are protected by an immersed filter (pos. 5), placed inside the 85-lt. hydraulic fluid tank (pos. 6). The mechanical torque at the VDT12000 transmission output (pos. 2) is transmitted to the front axle (pos. 30) and the rear axle (pos. 29), both model 212 manufactured by Dana, through Cardan shafts. The hydraulic drive (pos. 7) of the “load sensing” type with a displacement of 315 cm3, receives oil from the priority line of the pump (pos. 3) in relation to the “load sensing” signal sent by the hydraulic drive and connected to such pump with function of pilot signal. In this way, the input flow to the hydraulic drive will be exactly the one needed for the instantaneous steering functions; any excess flow of the pump will be used for the operation of the telescopic boom. The steering circuit is protected against input overpressures by a pressure reducing valve set at 140 bar. On the two delivery lines, there are other two reducing valves with anti-shock function set at 200 bar. The function of these two valves is limiting possible shocks on the steering wheel in case of overstress on the steering cylinders.

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The three pressure reducing valves are installed in the hydraulic drive (pos. 7) and cannot be regulated from the outside. The steering circuit is completed by the front steering cylinder (pos. 9), the rear steering cylinder (pos. 10) [these cylinders being integral part of the front axle (pos.

30) and the rear axle (pos. 29) respectively] and by a 4- way/3-position solenoid valve (pos. 8) for the selection of the three different steer modes (rear wheels straight, co-ordinate front/rear steering and independent front/ rear steering). When the solenoid valve (pos. 8) is not energised, the front steering cylinder is fed by the hydraulic drive and the rear cylinder is blocked. When one magnet or the other of the solenoid valve (pos. 8) is energised, the chambers of the cylinders are connected in a different manner thus causing the desired steering effect. The Bucher/Tecnord electro-proportional modular distributor (pos. 11), with 5 sections, receives oil from the secondary line of the pump (pos. 3) and feeds all of the movements of the telescopic boom, as well as the rear (optional) power takeoff. This distributor consists of an input head with a 3-way pressure compensator used as a flow regulator for the user which works at max load (load sensing), and as a discharge valve when the pump flow is not used for the boom movements, and of 5 modules, each of them controlling a specific movement of the telescopic boom (4 in total, that is lifting/lowering, attachment holding plate rotation, boom extension/retraction, attachment locking/unlocking) and the rear (optional) power takeoff. In the head there is a pressure relief valve set at 270 bar which, acting on the line of the “load sensing” signal, limits the maximum pressure at the inlet of the distributor through such 3-way compensator. On the main inlet head of the distributor, there is the pilot line head which includes an inlet safety filter, a pressure relief valve acting on the pilots line, and a safety solenoid valve which, when de-excited, discharges the input pilot pressure, thus preventing the distributor from working. This solenoid valve is used as a “dead man” control and is activated by the relevant button on the joystick in the driving cab. The pilot head delivers oil at pressure to the 5 pilot modules of the distributor which are used to operate the relevant main sliders in relation to the command signal they receive from the joystick via the control unit. Module 1 of the distributor controls the telescopic boom lifting cylinder (pos. 13). This cylinder has one singleacting compensation valve with safety function. The pilot module of this element of the distributor is the electroproportional type with electrical feed-back and integrated electronics. The 0.35-lt. accumulator prefilled at 50 bar (pos. 14) and located on the line of the differential chamber of the lifting cylinder (pos. 13), allows damping the boom swings when the same boom

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is moved down. Module 2 of the distributor controls the cylinder operating the attachment holding plate of the telescopic boom (pos. 15). This cylinder is equipped with a double- acting compensation valve with safety function. Paralleled to this cylinder there is the fork levelling (or balancing) cylinder (pos. 16) equipped with a special double-acting compensation valve. Inside this valve, the one-way valves are installed in a reverse manner with respect to the normal position to avoid the pressurisation of the cylinder when the rotation command of the attachment holding plate is operated. Again inside this valve, there are other two one-way valves set at 5 bar with anti-cavitation function. These are used to deliver oil, sucked from the low pressure line coming from the pressure relief valve (pos. 12), to the fork levelling compensation circuit, when such circuit cannot do it alone. The pilot module of element 2 of the distributor is the electro-proportional type with electrical feed-back and integrated electronics. On the two control lines of the cylinder (pos. 15), and integral to module 2, there are two pressure relief valves set at 290 bar which protect the automatic levelling system of the forks when the boom is moved up and down and in case of overload on the attachment holding plate (ex. use of the bucket). Module 3 of the distributor controls the extension cylinder of the telescopic boom (pos. 17). This cylinder is equipped with a double-acting compensation valve with safety function. The pilot module of this element of the distributor is the electro-proportional type with electrical feed-back and integrated electronics. On the control line of the circular chamber of the cylinder (pos. 17) and integral to module 3, there is a pressure relief valve set at 150 bar which limits the load when the boom is extended in those working zones where the electronic overload warning system cannot detect overload conditions with respect to the load chart of the machine. Module 4 of the distributor controls the attachment locking cylinder (pos. 18). This cylinder has a double one-way valve with hydraulic release and safety function. The control module of this element of the distributor is the ON/OFF electrical type with integrated electronics. On the feeding lines of this cylinder, there are two quickfit connectors (pos. 19) for the connection of the hydraulic lines to the optional attachments which need hydraulic power for their operation (ex. hydraulic winch and maintenance jib, mixing bucket, etc.). Module 5 of the distributor controls the rear (optional) power takeoff (PTO) of the machine. This device is driven by a Casappa oil-dynamic gear motor (pos. 20) for open loop circuits of the reversible type with a displacement of 38 cm3. The motor is flanged to a

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mechanical reduction gear (pos. 21) with an output shaft conform to the agricultural regulations for the operation of different implements. A speed sensor senses the rotation speed of the PTO and sends a signal to the electronic control unit of the distributor (pos. 11) which keeps such speed constant regardless of the loads absorbed by the implement operated by the PTO. Inside module 5 of the distributor, there are two anticavitation valves which are necessary for the operation of the oil-dynamic motors. The pilot module of the 5th element of the distributor is of the electro-proportional type with electrical feed-back and integrated electronics. The pressure relief valve (pos. 12) set at 25 bar is located upstream of the pressure port of the distributor (pos.

11). This valve supplies oil at low pressure (25 bar) to the anti-cavitation circuits of the automatic levelling system of the forks and to feed the pilot valves line of the same distributor (pos. 11). The SAFIM S6 servo-assisted braking system with pedal (pos. 28) receives oil from the pump (pos. 4) and uses this oil to pressurise 2 hydraulic accumulators connected to this system. The oil at pressure contained in these accumulator is then used to operate the service brakes located inside the two axles (pos. 29) and (pos.

30). The fill valve inside the braking system receives the flow from the feeding line until the pressure in the line of the accumulators reaches the calibration value of the cutout valve set at 150 bar. When this pressure is reached, the valve gradually releases all the flow to line B for other uses. The brake pedal located in the driving cab, which is an integral part of the S6 braking system, is connected to two proportional sliders which control the two separated lines of the service brake, one for each axle. In relation to the stroke of these sliders, a gradual communication between the feeding line, connected to two accumulators which, at their turn, are connected to ports R1 and R2 (the accumulators have a 0.5-lt. capacity and a fill pressure of 50bar), and the service brake lines is established so the flow is distributed to such lines and the discharge line increasing, in this way, the pressure (and as a result the braking force) on the lines of the service brakes. When the sliders are in the rest position, the lines of the service brakes are connected to the discharge. The pressure switch set at 2-10 bar and connected in parallel to one of the two lines of the service brake, sends an electrical signal when the service brake is activated. The pressure switch set at 70 bar and connected to port F sends an electrical signal when the pressure inside the feeding circuit of the brake lines is not enough to guarantee the minimum breaking capacity.

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The Bucher electro-hydraulic modular distributor of the ON/OFF type for open loops (pos. 22) (on request) controls the frame levelling and supplies oil at pressure to the two additional rear oil-dynamic sockets equipped with quick-fit hydraulic connections (pos. 23) and (pos.

24). It receives oil from port B of the braking system (pos. 28) and uses this to operate the cylinder controlling

the frame levelling (pos. 25), equipped with doubleacting compensation valve which also acts as a safety valve, as well as the additional rear hydraulic sockets configured with quick-fit connections (pos. 23) and (pos.

24). On the inlet head of this distributor there is a pressure relief valve set at 220 bar. The oil flow which is not used by the distributor to operate the outriggers and the frame levelling function, is sent to the (optional) three-point hitch (pos. 26) for the operation of the lifting arms and the controlled effort device. Finally, the excess oil which is not used by the hitch is sent back to the tank (pos. 6). The heat exchanger (pos. 27) is divided into three sectors; one absorbs heat from the cooling circuit of the diesel engine, the second cools down the hydraulic circuit of the torque converter of the power shift transmission and the third one cools down the hydraulic circuit of the machine. The flow of the pump (pos. 3) is conveyed to this third sector. The oil cooled down by the heat exchanger is sent back to the tank (pos. 6).

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Hydraulic scheme

N’

Tp1

Tp2

T1’

T2’

150 bar

270 bar

290 bar

FLT

RPM

Ev13

MPR

220 bar

150 bar

Ev3

Ev4

Ev7

Ev8

Ev9

Ev10

Ev 11

Ev12

Pv1

Pv2

Pv3

Pv5

Pv4

180 bar

200 bar

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SAFETY

Section 1

SAFETY INFORMATION

SECTION INDEX

1.1 Safety rules .......................................................................................... page 2

1.1-1 Personal safety ............................................................................................. 2

1.1-2 Workplace safety.......................................................................................... 2

1.2 General remarks........................................................................................... 4

1.3 Servicemen's requisites .............................................................................. 4

1.3-1 Personal protective equipment................................................................... 5

1.4 General safety precautions ......................................................................... 5

1.4-1 Working areas ............................................................................................... 5

1.4-2 Precautions during work ............................................................................. 5

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1.1 SAFETY RULES

1.1-1 Personal Safety

In this manual, any important information is preceded by a SPECIAL SYMBOL. All operators who work or service the machine must know the exact meaning of these safety symbols.

There are six special (or safety) symbols in this manual, always combined with keywords that class the situations according to their danger degree. The symbols are always followed by a text explaining the situation taken into account, the attention to be paid to such situation, the method and the behaviour to be adopted. When necessary, it stresses prohibitions or supplies instructions to prevent dangers. Sometimes, it can be followed by illustrations.

We list below the special (or safety) symbols according to the relative seriousness of the hazard situation:

SAFETY

Draws the attention to important technical information or practical advice that allows for a safer and more efficient use of the machine.

Draws the attention to important environment-related information.

Be sure to wear protective eye wear and other protective clothing if the situation warrants it.

Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steeltoed shoes.

Draws the attention to situations that involve your own as well as the others’ safety and that can result in serious or lethal injury.

Draws the attention either to situations that involve your own as well as the others’ safety and that can result in minor or moderate injury or to situations that involve the machine efficiency.

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1.1-2 Workplace Safety

Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach.

Be sure that all tools and working areas are properly maintained and ready for use. Keep work surfaces clean and free of debris that could get into machine components and cause damage.

Be sure that your workshop or work area is properly ventilated and well lit.

Be sure any forklift, overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted. Use only chains or straps that are in good condition and of ample capacity.

AGRILIFT 737 - 1037

SAFETY

Be sure that fasteners intended for one time use (i.e., cotter pins and self-locking nuts) are not reused. These components may fail if they are used a second time.

Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe.

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1.2 GENERAL REMARKS

Most accidents occurring while working, servicing or maintaining operation machines, are caused by not complying with the basic safety precautions. Therefore, it is necessary to pay steady attention to the potential hazards and the effects that may come of operations carried out on the machine.

If you recognise hazardous situations, you can prevent accidents!

For instance, this handbook makes use of special safety symbols to highlight potentially hazardous situations.

The instructions given in this handbook are the ones established by TEREXLIFT. They do not exclude other safe and most convenient ways for the machine commissioning, operation and maintenance that take into account the available spaces and means.

If you decide to follow instructions other than those given in this manual, you must:

• be sure that the operations you are going to carry out are not explicitly forbidden;

• be sure that the methods are safe and in compliance with the indications given in this section;

• be sure that the methods cannot damage the machine directly or indirectly or make it unsafe;

• contact TEREXLIFT Assistance Service for any suggestion and the necessary written permission.

SAFETY

1.3 SERVICEMEN'S REQUISITES

The operators who use the machine regularly or occasionally (e.g. for maintenance or transport) shall have the following requisites:

health:

before and during any operation, operators shall never take alcoholic beverages, medicines or other substances that may alter their psycho-physical conditions and, consequently, their working abilities.

physical:

good eyesight, acute hearing, good co-ordination and ability to carry out all required operations in a safe way, according to the instructions of this manual.

mental:

ability to understand and apply the rules, regulations and safety precautions. They shall be careful and sensible for their own as well as for the others’ safety and shall desire to carry out the work correctly and in a responsible way.

emotional:

they shall keep calm and always be able to evaluate their own physical and mental conditions.

training:

they shall read and familiarise with this handbook, its enclosed graphs and diagrams, the identification and hazard warning plates. They shall be skilled and trained about the machine use.

It is recommended to take part in at least one technical training course organised by TEREXLIFT Assistance Office.

Do not hesitate to pose questions if you are in doubt! Contact TEREXLIFT: the assistance service is at your disposal. Addresses, phone and fax numbers are given in the cover and in the title-page of this manual.

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Ordinary and extraordinary maintenance of the machineare quite complex from a technical point of view and should be performed by an authoirsed service centre.

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SAFETY

1.3-1 PERSONAL PROTECTIVE EQUIPMENT

During work, but especially when maintaining or repairing the machine, operators must wear suitable protective clothing and equipment:

• Overalls or any other comfortable garments. Operators should wear neither clothes with large sleeves nor objects that can get stuck in moving parts of the machine

•Protective helmet when working under or in the vicinity of suspended load

•Protective gloves

•Working shoes

•Breathing set (or dust mask)

• Ear-protectors or equivalent equipment

• Goggles or facial screen.

Use only type-approved protective equipment in good condition.

1.4 SAFETY PRECAUTIONS

Read and understand the following safety instructions before servicing the machine. The following list contains safety rules which must absolutely be obeyed to prevent accidents and injuries.

1.4-1 WORKING AREA

• Make sure the area all around the machine is safe. Always be aware of potential risks.

• During work, keep the working area in order. Never leave objects scattered: they could hinder the machine movements and represent a danger for personnel.

1.4-2 PRECAUTIONS DURING WORK

• Do not walk or stop under raised loads or machine

parts supported by hydraulic cylinders or ropes only.

•Keep the machine handholds and access steps always clean from oil, grease or dirt to prevent falls or slips.

•When entering/leaving the cab or other raised parts, always face the machine; never turn the back.

• When carrying out operations at hazardous heights (over 3 meters from the ground), always use type- approved safety belts or fall preventing devices.

• Do not enter/leave the machine when it is running.

• Before servicing the engine, let its parts cool down.

• Do not leave the driving place when the machine is running.

• Neither stop nor carry out interventions under or between the machine wheels when engine is running. When maintenance in this area is needed, stop the engine, engage the parking brake and chock the wheels to prevent accidental movements.

• Do not carry out maintenance or repair works without a sufficient lighting.

• When using the machine lights, the beam should be oriented in order not to blind the personnel at work.

• Before applying voltage to electric cables or components, ensure they are properly connected and efficient.

• Do not carry out interventions on electric components with voltage over 48V.

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• Do not connect wet plugs or sockets.

• Signs and stickers shall never be removed, hidden or become unreadable.

• Except for maintenance purposes, do not remove safety devices, covers, guards,. Should their removal be necessary, stop the engine, remove them with the greatest care and always remember to refit them before starting the engine and using the machine again.

• Aleays stop the engine and disconnect the batteries before maintenance or service.

• Do not lubricate, clean or adjust moving parts.

• Do not carry out operations manually when specific tools are provided for this purpose.

• Absolutely avoid to use tools in bad conditions or in an improper way.

• Before carrying out operations on hydraulic lines under pressure (hydraulic oil, compressed air) and/ or before disconnecting hydraulic components, ensure the relevant line has been previously depressurised and does not contain any hot fluid.

SAFETY

Treatment and disposal of used oils is subject to federal, national and local laws and regulations. Collect and deliver these wastes to authorised centres.

• Use the assistance of a second person to handle loads weighing 30 to 50 kg.

• For loads over 50 kg, the use of special hoisting equipment in good condition and equipped as per enforced regulations is mandatory.

Any intervention on the hydraulic or pneumatic circuit must be carried out by authorised personnel. Before any operation on lines under pressure, release any residual pressure from the circuit. Do not use your fingers to check for pressure leaks. Fine jets of air, oil or fuel can injure you.

• Neither smoke nor use open flames if there is a risk of fire or close to fuel, oil or batteries.

• Do not leave fuel cans or bottles in unsuitable places.

• Do not empty catalytic mufflers or other vessels containing burning materials without taking the necessary precautions.

• Carefully handle all flammable or dangerous substances.

• After any maintenance or repair work, make sure that no tool, cloth or other object has been left within compartments with moving parts or in which suction and cooling air circulates.

• Never give orders to several people at a ime. Instructions and signs must be given by one person only.

•Always pay the due attention to the instructions given by the foreman.

• Never distract the operator during working phases or crucial manoeuvres.

• Do not call an operator suddenly, if unnecessary.

• Do not frighten an operator or throw objects by no means.

• After work, never leave the machine under potentially dangerous conditions.

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TECHNICAL SPECIFICATIONS

Section 2

TECHNICAL SPECIFICATIONS

SECTION INDEX

2.1 Main dimensions ................................................................................. page 2

2.2 Tyres .............................................................................................................. 2

2.3 Limit of use ................................................................................................... 3

2.4 Weight ........................................................................................................... 3

2.5 Speed ............................................................................................................ 3

2.6 Payload and reach ....................................................................................... 3

2.7 Forks (floating type) ..................................................................................... 4

2.8 Diesel engine ................................................................................................ 4

2.9 Electrical system .......................................................................................... 4

2.10 Machine sound levels .................................................................................. 4

2.11 Vibration levels ............................................................................................. 5

2.12 Refuelling ...................................................................................................... 5

2.13 Tightening torques ....................................................................................... 6

2.14 Drill diameters for threads .......................................................................... 8

2.15 Standard tightening torques for fitting seals............................................. 9

2.16 Locking material .......................................................................................... 11

2.17 Hoisting instructions.................................................................................... 12

2.18 Advice to renew flexible hoses ................................................................... 13

2.19 Lists of recommended spare parts ............................................................ 14

2.20 Machine paint colour ................................................................................... 20

2.21 Checking the cylinder movement times .................................................... 21

2.22 Hydraulic settings ........................................................................................ 23

2.23 Checking the TECNORD control unit ......................................................... 29

2.24 DLE system ................................................................................................... 37

2.25 Rear three-point hitch ................................................................................. 55

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TECHNICAL SPECIFICATIONS

2.1 MAIN DIMENSIONS

E F

AGRILIFT 737 1037

A Overall height mm 2445 2445

B Overall width mm 2325 2325

C Cab width mm 850 850

D Track mm 1920 1920

E Wheel-base mm 2850 2850

F Length to the front tyres mm 3760 3760

G Length to the attachment holding plate mm 4695 4875

G1 Length to towing hook mm - -

G2 Length to arms of the rear lifter mm 5371 5551

H Ground clearance mm 445 445

• Internal steering radius mm 1175 1175

• External steering radius mm 3500 3500

B D

2.2 TYRES

AGRILIFT 737 1037

- Dimensions (front and rear) 405/70-24 405/70-24

-P.R. (or load index) 14 pr 152B 14 pr 152B

- Rim 13x24 13x24

- Wheel disc 8 holes DIN 70361 8 holes DIN 70361

-Pressure bar/Psi 4.5/65.2 4.5/65.2

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TECHNICAL SPECIFICATIONS

2.3 LIMIT OF USE

AGRILIFT 737 1037

• Angle of approach 90° 90°

• Departure angle (without rear lifter) 90° 90°

• Departure angle (with rear lifter fully up) 38° 38°

• Min/max ambient temperature °C -20°/+45° -20°/+45°

2.4 WEIGHT

AGRILIFT 737 1037

•Weight in working order kg 7100 ~ 8000 lbs

2.5 SPEED

AGRILIFT 737 1037

-Working speed km/h 8 8

-Travel speed km/h 37 35

- Max. slope with full load % 144 144

2.6 PAYLOAD AND REACH

AGRILIFT 737 1037

- Max lifting height mm 6950 9825

- Reach at max height mm 320 1300

- Max reach forward mm 3760 6630

- Attachment holding plate rotation 130° 130°

- Maximum payload kg 3700 3700

- Payload at max height kg 3000 -

- Payload at max reach kg 1300 -

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INDEX

Page 26

AGRILIFT 737 - 1037

TECHNICAL SPECIFICATIONS

2.7 FORKS

AGRILIFT 737 1037

- Dimensions mm 1200x120x45 1200x120x45 ft

-Weight kg 58 58

lbs

- Fork holding frame - class FEM III FEM III

2.8 DIESEL ENGINE

AGRILIFT 737 1037

- Make DEUTZ DEUTZ

- Model/Type BF4M2012 BF4M2012

- Features: Diesel Diesel

cylinders in line

4 strokes 4 strokes

direct injection direct injection

- Bore x Stroke mm 101 x 126 101 x 126 ft

-Total displacement cc 4038 4038

- Power at 2300 giri/min kW 74,5 74,5

cylinders in line

2.9 ELECTRICAL SYTEM

AGRILIFT 737 1037

-Voltage V 12 12

- Battery Ah 100 100

2.10 MACHINE SOUND LEVELS

AGRILIFT 737 1037

- Guaranteed sound power level

(in accordance with the Directive 2000/14/CE)dB Lwa = ... Lwa = …

- Measured sound pressure level

(in accordance with the Directive 98/37/CE)dB Lpa = ... Lpa = ...

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AGRILIFT 737 - 1037

TECHNICAL SPECIFICATIONS

2.11 VIBRATION LEVELS

AGRILIFT 737 1037

- Mean assessed vibration level transmitted to arms m/s

- Mean assessed vibration level transmitted to body m/s

Values calculated in accordance with standard prEN13059

This is a Class A device. In a residential environment, such device can cause radio disturbance. In such cases, the operator is required to take suitable measures.

< 2.5 < 2.5

< 0.5 < 0.5

2.12 REFUELLING

AGRILIFT 737 1037

- Diesel engine l 13 13

- Engine cooling system l 22 22

- Fuel tank l 150 150

- Hydraulic system tank l 100 100

- Gearbox l 20 20

- Differential gears l 8,7 8,7

- Wheel reduction gears l 0,75 0,75

- PTO reduction gear l 1 1

Products:

Engine oil: SHELL RIMULA SAE 15W-40 (API CH-4/ CG-4/ CF-4/CF, ACEA E3, MB 228.3)

Power divider-Differential gears-Reduction gears-PTO reduction gear: FUCHS TITAN GEAR LS 85 W-90 (API GL-5 LS / GL-5)

Hydraulic system and brakes: SHELL TELLUS T 46 (DENISON HF-1 DIN 51524 part. 2 e 3)

Gearbox

: ESSOLUBE HYDRAULIC 10W (API CD/SF VICKERS 35VQ25)

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INDEX

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AGRILIFT 737 - 1037

TECHNICAL SPECIFICATIONS

2.13 TIGHTENING TORQUES

Thread Pitch Wrench measure Tightening torques

diameter mm Material class

UNI UNI UNI Normal Galvanized Normal Galvanized Normal Galvanized

mm mm

5931/32 5933÷36 5923÷30

4 0.7 7 3 2.5 2 3.2 2.8 4.4 3.9 5.3 4.8

5 0.8 8 4 3 2.5 6.1 5.5 8.7 7.8 10.3 9.3

61 10 5 4 3 10.6 9.5 14.8 13.3 17.8 16.0

8 1.25 13 6 5 4 25.1 22.5 35.4 31.8 42.5 30.2

113654 26.5 23.8 37.3 33.5 44.7 40.3

10 1.5 17 8 6 5 51.1 46.0 71.9 64.7 86.3 77.6

1.25 17 8 6 5 53.4 48.1 75.1 67.5 90.2 81.1

12 1.75 19 10 8 6 86.5 77.8 121.4 109.2 145.9 131.3

1.25 19 10 8 6 92.4 83.2 129.5 116.6 156.1 140.5

8.8

Nm Nm Nm Nm Nm Nm

10.9

12.9

14 2 22 12 10 6 137.7 123.9 193.8 174.4 232.6 209.3

1.5 22 12 10 6 145.9 131.3 206.1 185.5 246.9 222.0

16 2 24 14 10 8 209.1 188.2 293.8 264.4 353.0 317.7

1.5 24 14 10 8 218.3 196.5 308.1 277.3 369.3 332.4

18 2.5 27 14 12 8 288.7 259.8 406.1 365.5 487.7 436.9

1.5 27 14 12 8 314.2 282.8 442.8 398.5 530.6 477.5

20 2.5 30 17 12 10 408.1 367.3 573.4 516.1 687.7 618.9

1.5 30 17 12 10 439.7 395.8 619.3 557.4 742.8 662.5

22 2.5 32 17 - 12 542.3 488.5 763.2 686.9 915.3 823.7

1.5 32 17 - 12 582.6 524.3 819.3 737.4 983.6 885.3

24 3 36 19 - 12 705.1 634.5 990.8 891.7 1193.3 1074.4

23619-12 745.3 671.3 1051.0 945.9 1255.1 1129.5

27 3 41 19 - - 1036.0 927.5 1448.9 1304.0 1734.6 1561.2

24119- -1091.8 982.6 1530.6 1377.5 1836.7 1653.0

30 3.5 46 22 - - 1307.9 1258.1 1989.3 1772.4 2357.1 2121.4

24622- -1510.2 1359.1 2122.4 1910.2 2540.8 2286.7

33 3.5 50 24 - - 2000.0 1800.0 2800.0 2520.0 3400.0 3060.0

25024- -1610.0 1450.0 2300.0 2070.0 2690.0 2420.0

36 4 55 27 - - 2600.0 2340.0 3700.0 3330.0 4300.0 3870.0

35527- -2800.0 2520.0 3900.0 3510.0 4600.0 4140.0

39 4 60 27 - - 3400.0 3060.0 4800.0 4320.0 5600.0 5040.0

36027- -3600.0 3240.0 5100.0 4590.0 5900.0 5310.0

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INDEX

Page 29

AGRILIFT 737 - 1037

TECHNICAL SPECIFICATIONS

Thread Pitch Standard nuts Low nuts

diameter

Nm Nm Nm Nm

4 0.7 5.5 3.5

5 0.8 5.5 3.5

61 9.5 13.0 6.0 8.0

8 1.25 23.0 32.0 14.0 20.0

1 25.0 35.0 16.0 22.0

10 1.5 46.0 64.0 29.0 40.0

1.25 49.0 68.0 31.0 42.0

12 1.75 80.0 110.0 50.0 69.0

1.25 88.0 125.0 55.0 78.0

14 2 125.0 180.0 78.0 110.0

1.5 140.0 195.0 88.0 120.0

16 2 195.0 275.0 120.0 170.0

1.5 210.0 295.0 130.0 185.0

18 2.5 270.0 390.0 170.0 245.0

1.5 305.0 425.0 190.0 265.0

20 2.5 305.0 540.0 190.0 340.0

1.5 425.0 600.0 260.0 375.0

22 2.5 510.0 720.0 320.0 450.0

1.5 570.0 800.0 360.0 500.0

24 3 660.0 930.0 410.0 580.0

2 720.0 1000.0 450.0 630.0

27 3 980.0 1400.0 610.0 880.0

2 1050.0 1500.0 660.0 940.0

30 3.5 1350.0 1850.0 850.0 1160.0

2 1450.0 2050.0 910.0 1280.0

33 3.5 1650.0 2310.0 1050.0 1470.0

2 1980.0 2770.0 1270.0 1780.0

36 4 2120.0 2970.0 1360.0 1900.0

3 2550.0 3570.0 1630.0 2280.0

39 4 2730.0 3820.0 1750.0 2450.0

3 3250.0 4550.0 2080.0 2910.0

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INDEX

Page 30

AGRILIFT 737 - 1037

TECHNICAL SPECIFICATIONS

2.14 DRILL DIAMETERS FOR THREADS

Thread DRILL DIAMETER DRILL BIT

x pitch LIMITS DIAMETER

max min

M 4 x 0.7 3.42 3.24 3.30

x 0.5 3.60 3.46 3.50

M 5 x 0.8 4.33 4.13 4.20

x 0.5 4.60 4.46 4.50

M 6 x 1 5.15 4.92 5.00

x 0.75 5.38 5.19 5.20

M 8 x 1.25 6.91 6.65 6.80

x 1 7.15 6.92 7.00

M 10 x 1.5 8.87 8.38 8.50

x 1.25 9.38 9.19 9.20

M 12 x 1.75 10.44 10.10 10.20

x 1.5 10.68 10.38 10.50

M 14 x 2 12.21 11.83 12.00

x 1.5 12.68 12.38 12.50

M 16 x 2 14.21 13.84 14.00

x 1.5 14.68 14.38 14.50

M 18 x 2.5 15.74 15.29 15.50

x 1.5 16.68 16.38 16.50

M 20 x 2.5 17.74 17.29 17.50

x 1.5 18.68 18.38 18.50

M 22 x 2.5 19.74 19.29 19.50

x 1.5 20.68 20.38 20.50

M 24 x 3 21.25 20.75 21.00

x 2 22.21 21.83 22.00

M 27 x 3 24.25 23.75 24.00

x 2 25.21 24.83 25.00

M 30 x 3.5 26.77 26.21 26.50

x 3 27.25 26.75 27.00

M 33 x 3.5 27.77 29.21 29.50

x 2 31.21 30.83 31.00

M 36 x 4 32.27 31.65 32.00

x 3 33.25 32.75 33.00

M 39 x 4 35.27 34.67 35.00

x 3 36.25 35.75 36.00

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Page 31

AGRILIFT 737 - 1037

TECHNICAL SPECIFICATIONS

2.15 STANDARD TIGHTENING TORQUES FOR

FITTING SEALS

■ 60° CONICAL SEALS

Thread TIGHTENING

diameter TORQUES (0+10%)

60° CONICAL

inc. mm Nm

G 1/8" 15

G 1/4" M 10 x 1 20

9/16"-18 25

11/16"-16 40

13/16"-16 55

3/4"-16 62

1"-14 80

7/8"-14 80

1.1/16"-12 110

1.3/16"-12 115

1.5/16"-12 160

SEALS

■ FRONT O-LOK (Parker) SEALS

Thread TIGHTENING

diameter TORQUES (0+10%)

FRONT O-LOK

(Parker) SEALS

inc. mm Nm

9/16"-18 25

11/16"-16 40

13/16"-16 55

1"-14 80

1.3/16"-12 115

1.7/16"-12 130

1.11/16"-12 190

2"-12 245

1.7/16"-12 130

1.11/16"-12 190

1.5/8"-12 225

1.7/8"-12 270

2"-12 245

2.1/4"-12 360

■

37° COUNTER-SUNK CONICAL SEALS (JIC)

Thread TIGHTENING

diameter TORQUES (0+10%)

37° CONICAL

SEALS (JIC)

inc. mm Nm

7/16"-20 M10x1 15

1/2"-20 M12x1.5 20

9/16"-18 M14x1.5 28

M16x1.5 62

3/4"-16 M18x1.5 62

7/8"-14 M22x1.5 80

1.1/16"-12 M27x2 110

1.3/16"-12 141

1.5/16"-12 M33x2 160

1.5/8"-12 M42x2 225

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1.7/8"-12 M48x2 270

2.1/4"-12 M10x1 360

INDEX

Page 32

AGRILIFT 737 - 1037

■ SEALS WITH GRIP-RING

Thread TIGHTENING

diameter TORQUE

Fitting Pipe ø GRIP-RING

inc. mm Series mm Nm

G 1/8" M10x1 LL 4 10

G 1/8" M10x1 LL 6 10

G 1/8" M10x1 L 6 25

G 1/4" M12x1.5 L 8 50

G 1/4" M14x1.5 L 10 50

G 1/8" M20x1.5 L 12 130

G 1/8" M20x1.5 L 15 190

G 1/8" M20x1.5 L 18 245

G 1/8" M20x1.5 L 22 130

G 1/8" M20x1.5 L 28 190

G 1/8" M20x1.5 L 35 245

G 1/8" M20x1.5 L 42 245

G 1/4" M12x1.5 S 6 50

G 1/4" M14x1.5 S 8 50

G 3/8" M16x1.5 S 10 80

G 3/8" M18x1.5 S 12 80

G 1/2" M22x1.5 S 16 105

G 3/4" M27x2 S 20 220

TECHNICAL SPECIFICATIONS

■ FITTING ASSEMBLY

Thread TIGHTENING

diameter TORQUES (0+10%)

(0+10%)

SEALS

WITH

inc. mm Nm Nm

G 1/8" M10x1 25 12

M12x1.5 30 18

G 1/4" 40 18

M14x1.5 50 20

M16x1.5 60 35

M18x1.5 80 50

G 3/8" 95 40

M20x1.5 140 60

G 1/2" M22x1.5 140 75

M26x1.5 220 85

G 3/4" 250 110

M27x2 250 100

G 1" 400 190

M33x2 400 150

G 1.1/4" 600 240

M42x2 600 260

G 1.1/2" 800 300

M48x2 800 350

JOINTS AB

G 1" M33x2 S 25 370

G 1.1/4" M42x2 S 30 500

G 1.1/2" M48x2 S 38 600

Document 57.4400.9200 - 1

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A B

A Male face

Mechanical seal or copper washer

B Male face

Soft seal with O-ring

INDEX

Page 33

AGRILIFT 737 - 1037

TECHNICAL SPECIFICATIONS

2.16 LOCKING MATERIAL

THREAD LOCKERS

Product APPLICATION Characteristics Locking Resistance

Temp. °C Thread speed

Loctite 290 Thread locking to 150° M 12 Rapid Medium

Loctite 222 Thread locking to 150° M 20 Moderate Low

Loctite 243 Thread locking to 150° M 20 Rapid Medium

Loctite 262 Thread locking to 150° M 20 Moderate High

Loctite 270 Thread locking to 150° M 20 Moderate Very high

Loctite 277 Thread locking to 150° M 36 Slow High

Loctite 272 Thread locking to 200° M 36 Slow High

THREAD SEALANT For hermetic sealing. Not suitable for thermoplastic materials

Product APPLICATION Characteristics Locking

max Thread speed difficulty °C max type

Disassembly

Loctite 511 Fitting sealant 150° M80 Con./Cyl. Rapid Low

Loctite 542 Fitting sealant 150° M36 Con./Cyl. Rapid Moderate

Loctite 545 Fitting sealant 150° M36 Con./Con. Moderate Low

Loctite 565 Fitting sealant 150° M80 Con./Cyl. Instantaneous Low

Loctite 572 Fitting sealant 150° M80 Con./Cyl. Moderate Low

Loctite 577 Fitting sealant 150° M80 Con./Cyl. Rapid Moderate

GASKETS Total sealing in 24-72 hours

Product APPLICATION Characteristics Formation Resistance

max Play time to fluids °C max mm

Loctite 518 Formed-in-place gasket 150° 0,5 Moderate Excellent

Loctite 509 Formed-in-place gasket 150° 0,2 Moderate Excellent

Loctite 573 Formed-in-place gasket 150° 0,2 Slow Excellent

Loctite 574 Formed-in-place gasket 150° 0,5 Rapid Excellent

Loctite 510 Formed-in-place gasket 200° 0,2 Moderate Excellent

Loctite 5699 Formed-in-place gasket 200° 6,0 Rapid Excellent

Loctite 5999 Formed-in-place gasket 200° 6,0 Instantaneous Excellent

Loctite 5910 Formed-in-place gasket 200° 6,0 Rapid Excellent

Loctite 5900 Formed-in-place gasket 200° 6,0 Instantaneous Excellent

Loctite 5920 Formed-in-place gasket 250° M 36 Slow Good

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AGRILIFT 737 - 1037

TECHNICAL SPECIFICATIONS

2.17 HOISTING INSTRUCTIONS

All parts weighing more than 25 kg MUST COMPULSORILY be handled with suitable hoisting means. In the Disassembly and Assembly section there is a clear indication of the weight of the part to handle, while chapter A.12 contains a summary table with the weight of the single components.

Before removing parts of the machine, make sure that:

• all fixing bolts have been removed

• all hydraulic and electrical parts have been disconnected

• the part to be removed is not blocked.

STRANDED ROPES

• Use ropes or other hoisting accessories suitable to

the weight of the part to be handled. For ropes, refer to the following table:

STRANDED ROPES

Rope diameter Max admissible load

mm kg

10 1000

11.2 1400

12.5 1600

14 2200

16 2800

18 3600

20 4400

22.4 5600

30 10000

40 18000

50 28000

60 40000

• Attach the load to the natural seat of the hook. Attaching a load to an end can cause the load to fall down during raising and result in serious injury.

P P P P P

100% 88% 79% 71% 41%

• Do not attach a heavy load to ropes forming a wide suspension angle. The total capacity of the ropes reduces proportionally to the angle as shown in the following chart.

2000

1500

1000

500

30° 60° 90° 120° 150°

The value of the admissible load has been considered as equal to 1/6 the rope breaking load.

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INDEX

Page 35

AGRILIFT 737 - 1037

TECHNICAL SPECIFICATIONS

2.18 ADVICE TO RENEW FLEXIBLE HOSES

Before disconnecting a hydraulic pipe, place containers of suitable size underneath to prevent oil spillage.

Plug all disconnected parts to prevent dust or impurities from entering the circuit. They can cause serious damage.

Before disconnecting the hydraulic pipe, check that there is no residual pressure. In case, eliminate the pressure operating the control levers with the engine stopped. In any case, disconnect the hydraulic pipe with extreme caution and always wear suitable personal protection equipment -e.g. goggles, gloves, facial screen, etc. Wrap up the end of the pipe to be disconnected with some rags and slowly loosen the pipe connector so that air comes out as slow as possible.

1 Before disconnecting or refitting a flexible hose,

carefully clean the area all around.

2 Blow some compressed air to remove any impurity.

3 For an easier renewal of the hoses, whose run is not

clearly visible, proceed as follows:

- disconnect the hose to be replaced from both sides

- tie a cord to one end of the hose

-remove the hose pulling the cord until it comes out completely

- untie the cord and tie it to the new hose

- pull the cord from the other side to refit the hose until reaching the connecting point to the line.

Useful advice for mounting flexible hoses:

YES

YESNO

YES

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INDEX

Page 36

AGRILIFT 737 - 1037

TECHNICAL SPECIFICATIONS

2.19 LISTS OF RECOMMENDED SPARE PARTS

Agrilift 737

Code Description Q.ty

02.0117.0101 Grease nipple 2

04.0605.0293 Flexible hose 1

04.0605.0294 Flexible hose 1

05.4329.0000 Accumulator 1

05.4329.0001 Pressure switch 1

05.4329.0002 Pressure switch 1

07.0700.0020 Fuel prefilter 1

07.0703.0029 Starting switch 1

07.0703.0069 Fuse 4

07.0703.0125 Key 1

07.0703.0192 Relay 1

07.0703.0193 Fuse 5A 5

07.0703.0384 Bulb 2

07.0703.0425 Indicator 1

07.0703.0433 Switch 1

07.0703.0435 Switch 1

07.0703.0485 Relay 4

07.0703.0486 Relay 1

07.0703.0487 Relay 1

07.0703.0492 Proximity switch 1

07.0703.0494 Switch 1

07.0703.0535 Relay 1

07.0703.0571 Rear socket 1

07.0703.0577 Switch 1

07.0703.0584 Turn signals lever 1

07.0709.0584 Oil filter cartridge 2

07.0709.0678 Solenoid 1

07.0709.0686 Solenoid valve 1

07.0709.0705 Gasket kit 1

07.0728.0006 Gasket kit 1

07.0728.0007 Solenoid 1

07.0738.0000 Star wheel 1

07.0740.0002 Grease nipple 4

07.0740.0029 Handle 1

07.0740.0041 Glass 1

07.0740.0050 Handle 1

07.0740.0051 Lever-fitted lock 1

07.0740.0054 Stop belt 1

07.0740.0066 Filter 2

07.0740.0087 Glass 1

07.0740.0088 Wiper arm 1

07.0740.0089 Wiper blade 1

07.0740.0097 Support 1

07.0740.0104 Handle lock 1

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Page 37

AGRILIFT 737 - 1037

TECHNICAL SPECIFICATIONS

Code Description Q.ty

07.0740.0119 Heater 1

07.0740.0157 Wiper blade 1

07.0740.0192 Lock 1

07.0740.0218 Tap 1

07.0741.0000 Solenoid 1

07.0741.0004 Modulus 1

07.0741.0006 Solenoid 1

07.0741.0009 Push button 1

07.0741.0011 Push button 1

07.0741.0015 Gasket kit 1

07.0741.0016 Gasket kit 1

07.0741.0019 Cap 1

07.0741.0020 Cap 1

07.4501.0070 Oil filter 2

07.4501.0071 Fuel filter 2

07.4501.0084 Cartridge 2

07.4501.0085 Air filter 2

07.4529.0071 Seal 2

07.4529.0072 Seal 2

07.4529.0073 Seal 2

07.4529.0096 Cylinder gasket kit 1

07.4529.0097 Gasket kit 1

07.4529.0098 Seal 1

07.4529.0099 Seal 2

07.4529.0100 Gasket kit 1

09.0610.0972 Cylinder 1

09.0802.0018 Load cell 1

09.0803.0017 Hose 1

09.0805.0014 Rubber hose 1

09.0805.0037 Rubber hose 1

09.4604.0004 Oil filter 2

09.4604.0046 Oil filter 2

09.4645.0000 Gas lever cord 1

09.4645.0003 Cable 1

09.4661.0014 Plug 1

09.4670.0006 Insulator 4

53.3301.0002 Seal 1

54.0001.0001 Pin 2

54.0200.0000 Bushing 6

54.0201.0012 Bushing 2

54.0702.0000 Sliding guide 4

54.0702.0005 Sliding guide 2

54.0702.0006 Sliding guide 4

56.0005.0001 Fuse 4

56.0009.0002 Horn 1

56.0010.0005 Pivoting beacon 1

56.0010.0034 Light 1

56.0010.0035 Light 1

56.0010.0036 Light 1

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INDEX

Page 38

AGRILIFT 737 - 1037

TECHNICAL SPECIFICATIONS

Code Description Q.ty

56.0010.0037 Light 1

56.0012.0009 Microswitch 1

56.0013.0000 Transmitter 1

56.0013.0001 Fuel level indicator 1

56.0013.0028 Level indicator 1

56.0016.0022 Display 1

56.0016.0033 Control lever 1

56.0016.0034 Speed lever 1

56.0021.0040 Relay 1

56.0021.0061 Tecnord control unit 1 634972 Fuse 7,5 A 5 634973 Fuse 15 A 5 634974 Fuse 10 A 5 636455 Gasket kit 1 637650 Fuse 3 A 5 638004 Gasket kit 1 639395 Gasket kit 1 640270 Gasket kit 1 640536 Gasket kit 1 640591 Bushing 1

Document 57.4400.9200 - 1

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INDEX

Page 39

AGRILIFT 737 - 1037

TECHNICAL SPECIFICATIONS

Agrilift 1037

Code Description Q.ty

02.0117.0101 Grease nipple 2

04.0605.0374 Flexible hose 1

04.0605.0376 Flexible hose 1

05.4329.0000 Accumulator 1

07.0700.0000 Cartridge 1

07.0700.0020 Cartridge 1

07.0703.0029 Starting switch 1

07.0703.0069 Fuse 2

07.0703.0096 Removing battery 1

07.0703.0125 Key 1

07.0703.0192 Relay 1

07.0703.0193 Fuse 5

07.0703.0321 Bulb 1

07.0703.0384 Bulb 2

07.0703.0425 Indicator 1

07.0703.0429 Selector 1

07.0703.0431 Switch 1

07.0703.0433 Switch 1

07.0703.0435 Switch 1

07.0703.0485 Relay 5

07.0703.0486 Relay 1

07.0703.0487 Relay 2

07.0703.0494 Switch 1

07.0703.0532 Contact 1

07.0703.0535 Relay 1

07.0703.0569 Switch 1

07.0703.0571 Socket 1

07.0703.0572 Switch 1

07.0703.0576 Control board 1

07.0703.0578 Switch 1

07.0703.0584 Turn signals lever 1

07.0709.0584 Gearbox filter 1

07.0709.06181 Seal 2

07.0709.0678 Solenoid 2

07.0709.0679 Seal 2

07.0709.0680 Seal 2

07.0709.0682 Seal 2

07.0709.0705 Gearbox gasket kit 1

07.0712.0087 Plug 1

07.0728.0006 Gasket kit 1

07.0728.0007 Solenoid 2

07.0738.0000 Star wheel 2

07.0740.0029 Handle 1

07.0740.0041 Glass 1

07.0740.0050 Handle 1

07.0740.0051 Lever-fitted lock 1

07.0740.0054 Stop belt 1

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INDEX

Page 40

AGRILIFT 737 - 1037

TECHNICAL SPECIFICATIONS

Code Description Q.ty

07.0740.0058 Seal 1

07.0740.0066 Cab air filter 1

07.0740.0072 Wiper motor 1

07.0740.0076 Handle 2

07.0740.0087 Glass 1

07.0740.0088 Wiper arm 1

07.0740.0089 Wiper blade 1

07.0740.0098 Tank 1

07.0740.0135 Steering wheel 1

07.0740.0157 Wiper blade 1

07.0740.0202 Driving mirror 1

07.0740.0218 Tap 1

07.0740.0104 Handle lock 1

07.0741.0004 Modulus 1

07.0741.0005 Modulus 1

07.0741.0006 Solenoid 1

07.0741.0007 Cartridge 1

07.0741.0011 Push button 2

07.0741.0012 Push button 2

07.0741.0015 Gasket kit 1

07.0741.0016 Gasket kit 1

07.0741.0019 Cap 2

07.0741.0020 Cap 2

07.4501.0070 Oil filter 1

07.4501.0071 Fuel filter 1

07.4501.0084 Air filter cartridge 1

07.4501.0085 Air filter 1

07.4529.0072 Seal 4

07.4529.0097 Gasket kit 1

07.4529.0100 Gasket kit 1

09.0802.0018 Load cell 1

09.0803.0177 Left mud-guard 2

09.0803.0178 Right mud-guard 2

09.4604.0004 Oil filter 1

09.4605.0009 Fan 1

09.4610.0002 Driving mirror 1

09.4635.0033 Cardan 1

09.4635.0035 Cardan 1

09.4645.0000 Gas lever cord 1

09.4645.0000 Gas lever 1

09.4645.0003 Manual gas lever cord 1

09.4645.0022 Cable 1

09.4661.0014 Plug 1

53.3001.2000 Manifold 1

54.0001.0001 Pin 2

54.0200.0000 Bushing 8

54.0200.0001 Bushing 8

54.0702.0000 Sliding guide 4

54.0702.0000 Sliding guide 2

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TECHNICAL SPECIFICATIONS

Code Description Q.ty

54.0702.0004 Sliding guide 2

54.0702.0005 Sliding guide 2

54.0702.001 Sliding guide 4

56.0005.0001 Fuse 2

56.0009.0002 Horn 1

56.0009.0003 Horn 1

56.0010.0005 Pivoting beacon 1

56.0010.0034 Light 1

56.0010.0035 Light 1

56.0010.0036 Light 1

56.0010.0037 Light 1

56.0012.0009 Limit switch 1

56.0013.0001 Fuel level indicator 1

56.0013.0028 Level indicator 1

56.0016.0022 Display 1

56.0016.0033 Handlever 1

56.0016.0034 Speed lever 1

56.0021.0040 Relay 1

56.0021.0061 Tecnord control unit 1

56.0021.0064 Card 1 632023 Nut 8 633179 Wheel stud 8 634972 Fuse 5 634973 Fuse 5 634974 Fuse 5 635455 Gasket kit 1 637650 Fuse 5 638004 Brake pump gasket kit 1 639395 Gasket kit 1 640101 Gasket kit 1 640102 Gasket kit 1 640270 Gasket kit 1 640536 Gasket kit 1 640594 Valve 2

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TECHNICAL SPECIFICATIONS

2.20 MACHINE PAINT COLOUR

STANDARD machines

GREY RAL 7012

WHITE RAL 1013

MAT BLACK RAL 9005 (from June 2004 for cylinders)

AUSA machines

ORANGE RAL 2004

GENIE machines

BLUE MERCEDES 5928

MZ IMER machines

ORANGE RAL 2010

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TECHNICAL SPECIFICATIONS

2.21 CHECKING THE CYLINDER MOVEMENT TIMES

The check of the movement times of the cylinders shall be done with the hydraulic oil at a temperature of 60°.

BOOM LIFTING/LOWERING

Agrilift 737 Time (s)

up down

Max engine speed 16” 12”

Min. engine speed 33” 27”

Agrilift 1037 Time (s)

up down

Max engine speed 16” 12”

Min. engine speed 33” 27”

BOOM EXTENSION/RETRACTION

Agrilift 737 Time (s)

out in

Max engine speed 9” 5”

Min. engine speed 21” 11”

To check the engine speed, the area easy to reach is the external pulley of the output shaft.

Lift

Lower

Retract

Extend

Agrilift 1037 Time (s)

out in

Max engine speed 19” 12”

Min. engine speed 33” 22”

ATTACHMENT DUMPING

Agrilift 737 Time (s)

dumping roll-back

Max engine speed 5” 4”

Min. engine speed 14” 9”

Agrilift 1037 Time (s)

dumping roll-back

Max engine speed 5” 4”

Min. engine speed 14” 9”

Roll-back

Dump

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AGRILIFT 737 - 1037

Push

TECHNICAL SPECIFICATIONS

MACHINE SWAY

Agrilift 737 Time (s)

right to left left to right

Max engine speed 8” 8”

Min. engine speed 13” 13”

Agrilift 1037 Time (s)

right to left left to right

Max engine speed 8” 8”

Min. engine speed 13” 13”

LIFTING/LOWERING OF THE REAR THREE-POINT HITCH (if any)

Agrilift 737 Time (s)

up down

Max engine speed 3” 12”

Min. engine speed 5” 12”

Agrilift 1037 Time (s)

up down

Max engine speed 3” 12”

Min. engine speed 5” 12”

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TECHNICAL SPECIFICATIONS

2.22 HYDRAULIC SETTINGS

1. PRELIMINARY OPERATIONS

Warm up the hydraulic oil to 60°C by keeping one of the elements of the boom distributor to full stroke under pressure. To reach this temperature in a faster way, cover the oil core of the radiator with a carton in the case of a wateroil combined cooler, or the oil radiator if the machine is equipped with a separate oil radiator.

2. CALIBRATING THE BOOM DISTRIBUTOR

Find the mini-socket for pressure gauge ref. A inside the frame, under the boom.

2.1 CALIBRATING THE DISTRIBUTOR PRESSURE CONTROL VALVE

Let the diesel engine run at max speed, then move the boom fully up to end of stroke. Calibrate valve B of the distributor to 280 bar while keeping the lifting cylinder at end of stroke and under pressure and the diesel engine fully accelerated. In order to check the setting of the safety valve of the bucket tilting cylinder C (annexes 1), proceed as follows:

• By means of valve B set the distributor pressure to

300 bar while moving one of the cylinders to stroke end.

• With the engine running at maximum speed, tilt the

forks to one direction by means of the joystick and act on one of the two valves C until reaching a pressure of 290 bar.

•Proceed in calibrating the second valve C by tilting

the forks to the opposite direction.

• When both fork inclination safety valves have been

calibrated, reset the pressure control valve B to 280 bar by adjusting the register.

Connect a 0-400 bar pressure gauge to the mini-socket ref. A. Extend the boom to end of stroke with the diesel engine fully accelerated and check that the pressure on the pressure gauge connected to socket A is 150 bar. Otherwise, act on valve X (annexes 4).

3. CALIBRATING THE BLOCK VALVES OF THE FORK BALANCE CYLINDER (annexes 2)

• Loosen the lock nuts of the valve and tighten the two

registers of cartridges D.

• Re-loosen of one turn and a half both valves and re-

tighten the lock nuts.

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TECHNICAL SPECIFICATIONS

4. CALIBRATING THE LEVELLING DISTRIBUTOR AND THE REAR SOCKET

• Disconnect pipe E (annexes 3) and fit a tee-joint

complete with mini-socket for the pressure gauge.

• Connect a 0-400 bar pressure gauge to the mini-

socket.

• Start the diesel engine and let it run at max speed,

then operate the balancing movement of the element which the pressure gauge is fitted to.

• Check the pressure reaches 180 bar. Otherwise act

on valve F.

6. CALIBRATING THE BOOM VALVE

• If the boom movement is slow or discontinuous and unsmooth, act on valves L.

• Also check that the times for executing the different movements correspond to the data in paragraph 2.21 "Cylinder movement times".

5. CALIBRATING THE PRESSURE REDUCING VALVE

• Connect a 0-400 bar pressure gauge to the mini-

socket G.

• Start the diesel engine and let it run at idle, then check

that the pressure is between 25 and 30 bar.

• If the pressure value isn't correct, act on valve H.

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TECHNICAL SPECIFICATIONS

HYDRAULIC SYSTEM - LIFTING annex 1

B C

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TECHNICAL SPECIFICATIONS

HYDRAULIC SYSTEM - FORK BALANCE

annex 2

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TECHNICAL SPECIFICATIONS

HYDRAULIC SYSTEM - LEVELLING annex 3

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TECHNICAL SPECIFICATIONS

HYDRAULIC SYSTEM - BOOM EXTENSION

annex 4

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TECHNICAL SPECIFICATIONS

2.23 CHECKING THE TECNORD CONTROL UNIT

To check the operation data of the TECNORD control unit, proceed as follows:

- Go to the driving place and remove the cover located at the left bottom with respect to the steering wheel.

-Prepare the electrical cable code 55.0602.0203.

- Find socket X90 for the control unit of boom and PTO.

Yellow

Light blue -

Black

X90

Light

blue

- Find socket X91 for the control unit of the automatic levelling (behind the driver's seat).

White

TX232

Black

Light blue -

Black

X91

RX232

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TECHNICAL SPECIFICATIONS

- Remove the socket's protection cap and connect the end of the cable for the connection of the PC.

- Connect the other end of the cable to the special socket on the PC.

-Proceed with the checks and settings using the control and management program.

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TECHNICAL SPECIFICATIONS

POWER UNIT CHARACTERISTICS

The electronic power unit is turned on by turning the ignition key to ON.

It reads the following analog signals:

- X-axis position of the cab joystick

-Y-axis position of the cab joystick

- Position of the proportional pushbutton located on the handle of the cab joystick

- Position of the joystick on the platform buttons panel used for the control of the boom movement

- Position of the joystick on the platform buttons panel used for the control of the boom telescopes

It reads the following ON/OFF buttons:

- Dead man on the handle of the cab joystick

- Activation button for the locking/unlocking function

- Left sway activation button

- Right sway activation button

- PTO activation button

It reads the following alarm and state signals:

- Overturning moment

- Boom up

It drives the following outputs:

- ON/OFF solenoid valve for left sway

- ON/OFF solenoid valve for right sway

- ON/OFF solenoid valve for locking function

- ON/OFF solenoid valve for unlocking function

- Activation of the control module for the boom movement

- Activation of the control module for the boom telescopes movement

- Activation of the control module for the forks movement (up/down pitching)

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TECHNICAL SPECIFICATIONS

The control unit also supplies the 5VDC power signal to the joystick/proportional button (+/- 5%).

When the joystick/proportional button is in the central neutral position, the relevant analog signal is 50% of the power signal.

The dynamics of the joystick signal changes from max 87.5% (joystick/pushbutton to one end) to min. 12.5% (the opposite end) for the joystick installed in the driving cab, and from max 90% to min. 10% for the joystick installed on the platform's buttons panel (the percentages are referred to the power signal of the joysticks/proportional button).

During normal operation (no anomalous condition detected), the red LED of the control unit flashes with a sequence of 3 seconds ON and 0.25 seconds OFF (say it switches off for a short instant every 3 seconds).

The control unit can detect the following malfunctions:

- Joystick and/or proportional button not in the central neutral position when the Jobsite/OFF/Platform selector

is on Jobsite or Platform (Alarm code 1)

- ON/OFF buttons in the ON position when the Jobsite/OFF/Platform selector is on Jobsite or Platform (Alarm

code 1)

Such conditions would activate the manoeuvres associated to the button without control if the signal were not OFF when the Jobsite or Platform mode is selected. Therefore,until the control unit does not detect a neutral position, the function is inhibited and the malfunction is signalled.

- Joystick and/or proportional button with analog signal below the minimum threshold (this case also includes

the disconnection of the joystick/porportional button connection or the short circuit to ground of the proportional signal or the short circuit to ground of the power signal of the joysticks/proportional button) (Alarm code 2)

- Joystick and/or proportional button with analog signal above the maximum threshold (this case includes the

short circuit to VBATT of the power signal or the ground disconnection in the joystick or proportional button connector) (Alarm code 3)

The malfunctions detected by the power unit are signalled by the red LED which remains OFF for about 2 seconds then flashes for a number of times equal to the code number associated to the detected alarm. The more the LED flashes, the more serious is the alarm and serious alarms have priority with respect to the "soft" alarms. In presence of more alarms, the most serious one is displayed first and, as soon as this is solved, the next one (whose seriousness was lower) is displayed.

Alarm code 1

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TECHNICAL SPECIFICATIONS

Alarm code 2

Alarm code 3

The analog command signals of the control modules of the boom, telescopes and inclination movements are signals between 0.9V (-84.2%) and 4.1V (+84.2%) with rest position at 2.5V (0%).

Corsa distributore

Corsa massima FW

MAX BW

-87

MIN BW

REMARK

- PERC_cmd = (Vcontrol – 2.5)/1.9

- Corsa MASSIMA FW e BW mean the maximum stroke in one direction and the maximum stroke in the opposite drection

- With the calibration program, you can change the piloting percentages of MAX FW, min FW, MAX BW and min BW for the three proportional manoeuvres.

MIN FWZero

Corsa massima BW

MAX FW

PERC_cmd

(%)

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TECHNICAL SPECIFICATIONS

DIAGNOSTIC CONTROL PROGRAM

Starting the application, you'll find the following window and a dialog box which says to push the CONNECT button after choosing a serial port.

Please note that this software doesen't work in offline.

In fig.1 you can see the setting windows. In the "movements selector" box you can choose the movement you want to set among "braccio" (boom raising and lowering), "telescopico" (boom extension and retraction) and "movim. forche" (fork forward/back pitching).

Once you’ve chosen the movement, you can set in the "MIN" and "MAX" boxes the value (in percentage) of the movement speed you desire: MIN means the minimum speed you can have for that movement MAX means the maximum speed.

Fig. 1

"RAMP UP" and "RAMP DOWN" represent the acceleration in increasing and decreasing the movement speed.

As you can see from the pictures, using the man platform you can set different values from standard use in jobsite.

The "LOAD SETTINGS FROM FILE" is the button used to load in the machine a previous setting configuration saved in the PC and "STORE SETTINGS INTO FILE" button is the button used to save the current machine configuration in the PC.

Fig. 2

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TECHNICAL SPECIFICATIONS

In fig. 4 you’ll find the window showed when you push the "DIAGNOSTICA" button.

In this page you’ll find the system signals diagnostic. The graduated bars show you the movements of the boom and forks in real time, according to their effective speed.

The joystick control button and the 4th function button become ON and OFF depending if they are pushed or not.

The same is for outriggers and leveling UP and DOWN movements.

Regarding the Alarms, CHIUSO means OFF, APERTO means ON, in fig.4 you have, for example, an overload alarm while the outriggers are down.

Fig. 4

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TECHNICAL SPECIFICATIONS

PTO CALIBRATION PTO DIAGNOSTIC

LEVELLING CALIBRATION LEVELLING DIAGNOSTIC

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2.24 DLE SYSTEM

INSTALLING THE EXTENSIMETRIC CELL

1 = Strain cage 2 =Washer ø 10 3 = Fastening screw M10x40 cl. 10.9

AGRILIFT 737 - 1037

TECHNICAL SPECIFICATIONS

Machine side

(strain cage cable output)

Axial plane

Ground and unpainted area

In order to get the best results and avoid damaging the strain cage, follow these precautionary measures:

1 - PREPARATION:

- Thoroughly clean the whole tightening system,

especially the ground and unpainted area.

2 - ASSEMBLY:

- Apply the strain cage with its resinated side facing

the axle and holding the cable(s) toward the machine.

- Tighten the two screws with a torque wrench at 70

N/m.

- Mark the position of the screws with paint in order to

make possible loosening visible to the eye.

Wheel side

Resin side view

for strain cage support

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+12V

TECHNICAL SPECIFICATIONS

Visualizzatore 3B6

3B6 Display

X2 - 3B6

exit

X25 - CIAM

Load cell

Pin 18 + GND = 12V in work condition

0V in overload condition

Pin 7 + GND = re-reading ok (12V)

Pin 9 positive Pin10 = boom retracted with forks in

horizontal position, without load:

1.3÷1.4 mV

= boom extended with forks in

horizontal position, without load:

1.0÷1.2 mV

CONNECTOR X1 FOR CHECKS WITH TESTER

Electrical power to control unit (DLE)

Pin 1: 12 V Pin 2: ground

SHLD

BLACK (-REF1)

BLUE (-IN1)

GREEN (+OUT1)

YELLOW (-OUT1)

RED (+IN1)

WHITE (+REF1)

Pin 1 Pin 8

Overload signal (12V generated by the DLE)

Pin 18: 12 V normal conditions, 0 V alarm overload Pin 7: re-reading overload signal

Electrical power to load cell equal to 5 V

Channel 1: Pin 16: positive Pin 17: negative

Load cell signal in range 0,1 - 2,5 mV

Channel 1: Pin 10: positive Pin 9: negative

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TECHNICAL SPECIFICATIONS

2.23 CALIBRATING THE DLE LOAD LIMITER

• During the calibration mode the limiter device

doesn’t block any manoeuvres so the calibration can be done.

•We recommend having the known load in the

range of action of the machine.

• The calibration of the machine should be done

after a few minutes of use, in other words with the machine “warm”.

1 2 3

- Enter the calibration mode:

Within 5 seconds from when the instrument is activated (even if the display is still off) you should press the keys on the front panel in the right sequence. The keys to use and the relevant meaning are shown below:

Press to enter number 0

Press to enter number 1

Press to confirm the sequence entered.

The access code currently used is 1001. Therefore you should enter the following sequence:

1 0 0 1 CONFIRM

5 6 7 8

- Description of the controls:

1 Calibration selection button 2 Display 3 Stability indicator with LED-bar 4 Green light - power OK 5 Yellow light - calibration mode 6 Calibration confirmation button 7 Not used 8 Red light - outrigger position 9 Buzzer ON/OFF pushbutton

10 Red light - overload pre-alarm / alarm

The digit on display 2 shows the selected attachment. The user can choose among:

If the sequence is correct the confirmation of the instrument functioning in the calibration

mode is given by the LED near lighting with a fixed light.

The display shows a number that ISN’T blinking, starting from “0”.

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The system recognises the attachment fitted to the machine automatically.

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DISPLAY FUNCTION

0 The LED bar indicates the type of machine in use:

0 LEDs on - Agrilift 737/1037

Press or to select the machine to calibrate.

If you are doing the first calibration, press to reset the system and load the default

parameters of the selected machine. If you are re-calibrating the instrument, skip the previous point.

Press to proceed to the next point (1).

1 Fully close the boom and hold it slightly above the horizontal with respect to the ground.

DON’T lift loads.

Press to confirm the EMPTY calibration of the machine.

Press to proceed to the next point (2).

2 Place a load on the forks with a weight corresponding to the table below - in relation to

the model -, extend the boom while holding it horizontal till reaching the overturning limit (ex: Agrilift 737: 1600 kg a 3,04 m referred to the front part of the wheels).

TECHNICAL SPECIFICATIONS

Press to confirm the LOADED calibration of the machine and check that the alarm

triggers.

Press to proceed to the next point (F).

F Press to exit calibration and SAVE the changes made (the zero flashes).

The limiter is no longer in the calibration mode. The LED is not lit fixed any more. You should turn the machine off and then on again.

Now you can start working.

activation of

load (kg) the overload warn. system (m)

Agrilift 737 1600 3,04

Agrilift 1037 2000 3,40

To test the machine with different weights after a calibration, strictly respect the values shown on the load diagram (the latter are the distance between the front part of the wheels and the centre of the load on the forks).

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AGRILIFT 737 WITHOUT SELF-LEVELLING

AGRILIFT 737 - 1037

TECHNICAL SPECIFICATIONS

20°

10°

40°

30°

1300 kg

60°

50°

1600 kg

70°

2500 kg

3700 kg

3000 kg

D C

6950 mm

4740 mm

0°

1234

1440 mm

3760 mm

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AGRILIFT 737 WITH SELF-LEVELLING

60°

50°

40°

30°

TECHNICAL SPECIFICATIONS

70°

D C

3000 kg

3700 kg

6950 mm

20°

10°

0°

1600 kg

1300 kg

3760 mm

4740 mm

00 kg

1234

1440 mm

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AGRILIFT 737 - 1037

TECHNICAL SPECIFICATIONS

70°

50°

40°

30°

20°

10°

00 kg

60°

00 kg 10

00 kg

00 kg 25

9780

4850

0°

87 6 5 4321

6950

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TECHNICAL SPECIFICATIONS

SETTINGS

FUNCTION DISPLAY

A Display of the value read by the ADC converter-cell channel 1 (A) and cell 2 (B).

This diagnosis function allows you to check proper reading of the load cell. As you move the boom, you can see the LEDs of the load bar progressively go on/off (valid if calibration has already been done). Position the machine for a calibration without load. If function A is activated and the LED is completely ON or OFF, there could be a problem with the connection or in the cell thereof; if it is partly lit but there is no movement in the boom, make sure the cell is fixed.

C Digital Inputs display: this function allows you to see if the following signals are properly

delivered to the DLE device according to the lighted LEDs of the load bar: LED3: lit when the overload warning system disconnect key is turned. LED4: ON if the interlock relay is active (machine safe without alarms).

D Software version existing in the DLE unit: this function allows you to see the software

version included in the DLE unit according to the lighted LEDs of the load bar No LED: software 0 One LED: software 1…… Four LEDs: software 4

E No function.

F Press to escape from the calibration and SAVE all changes.

(the buzzer and the LED activate to confirm storage). The limiter has now escaped from the calibration mode. The LED is no longer ON steadily. It is necessary to turn off and turn on the machine to eliminate all alarm messages (display flashing).

ALARM CODES

Alarm code ................ 1

Description ................ E2PROM Error. Internal comparison of data read from E2PROM failed.

Action ......................... Switch off and switch on the machine. If the alarm continues, recalibrate the machine,

otherwise replace DLE.

Alarm code ................ 2

Description ................ CELL 1 reading out of range.

Action ......................... Check if the load cell is fixed well.

Check the connection between DLE and sensor for short circuits or signal interruptions due to a broken cable. Check the DLE connector for signs of oxidation, short circuits or absence of electrical contact in some pins. If the alarm persists, check if the cell is intact.

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TECHNICAL SPECIFICATIONS

Alarm code ................ 4

Description ................ Block Relay check error during work. Check through.re-reading of the block output

of the congruence with the current state of the limiter.

The alarm triggers even in the absence of malfunctions if the load limiter cutout key is usedo.

Action ......................... The relay or the cable can be shorted; check.

The limiter's outputs do not deactivate. Switch off and on the machine and run a complete test of the outputs. If the alarm persists, replace the DLE.

Alarm code ................ 5-8

Description ................ Block Relay check error at start. When the instrument is started, the re-reading of the

block output is always OFF except when the two outputs of the DLE are connected in series.

5 - DLE output 0V or low voltage - 12V re-reading 8 - DLE output 12V - ow voltage or 0V re-reading

The alarm triggers even in the absence of malfunctions if the load limiter cutout key is used when the instrument is started.

Action ......................... The relay or the cable can be shorted; check.

The limiter's outputs do not deactivate. Switch off and on the machine and run a complete test of the outputs. If the alarm persists, replace the DLE.

Alarm code ................ A

Description ................ RAM data error. Checks that the parameters load in the RAM at start-up remain

unaltered.

Action ......................... Switch off and on the limiter.

Alarm code ................ C

Description ................ A.D.C. reading control error. If the analog/digital converter works fine after special re-

reading of the DLE board.

Action ......................... Switch off and on the limiter.

If the alarm continues, replace DLE.

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PC CONNECTION (WINSCOPE)

TECHNICAL SPECIFICATIONS

Pict. 1

Pict. 2

Pict. 3

07.0736.0014

Pict. 5 Pict. 6

If you want to check or save the system parameters and variables, you have to open the relevant windows and check the values contained in these.

Pict. 4

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TECHNICAL SPECIFICATIONS

SAVING OR UPLOADING SETTINGS WITH WINSCOPE

When you launch the program the first time, you have to configure some options to guarantee a correct dialogue with the hardware (the machine) used.

Turn on the board to connect the PC and the unit aboard the machine. From the “Utils” menu, select “Prj Selection”.

Type in the correct path of file CFG.IT or look for the same in the Windows folders suing the "Browse" function. The file must not necessarily be in the path shown in the following example as it is at the user's discretion. It contains the menus and the name of the parameters corresponding to the hardware (and therefore to the machine) in use.

Press OK to close the window.

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TECHNICAL SPECIFICATIONS

Now highlight “Hardware Configuration” in the “Utils” menu.

The following window will appear:

For each type of machine, you must select adequate parameters, that is:

DLE (version _01 or higher)

• Hardware Type RS232

• Port COM1 (usually this is the port, but it can change in relation to the connected PC)

• Baudrate 19200

If these parameters are wrongly configured, it won't be possible to connect the units. Press OK to confirm and close the window. Now close and re-open the program.

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TECHNICAL SPECIFICATIONS

Check that the PC is correctly connected to the relevant serial port and to the DLE unit with the special cord A (code 07.0736.0014), and that the unit is supplied with power. In the "File" menu, select "Salva" (Save) if you want to download a setting of the machine onto a PC or "Carica" (Load) if you want to transfer a setting saved in the PC into the machine.

The following window will be displayed so you can type in the password. For any changes, you must enter the following data: User Name: ...(contact the TEREXLIFT Service Centre to get your ID-code)

Password: ....(contact the TEREXLIFT Service Centre to get your ID-code)

Enter the correct data and press OK. If you have selected "Salva" (Save), the following window will be displayed:

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Choose the folder where to save the setting and save the file with a name showing the serial number of the machine (e.g. T3713 SX sn 10578). Press the Save button.

If you have chosen to upload a setting previously saved in memory, select the "Carica" (Load) command from the File menu. The following window will be displayed:

Choose the setting file you want to upload on the machine and press "Apri" (Open). Save the setting as explained below:

DLE

• If you want to save the setting, contact the TEREXLIFT Service Centre to get more information and be registered as an authorised user of the system.

•To gain access to the parameters and variables, no password is needed. All you have to do is connecting the DLE display with the power cord supplied by TEREXLIFT (code 07.0736.0014) and proceed as explained below.

• Connect the DLE connecting cable to the electrical system of the machine - see Pict. 1.

• Connect the PC power cord to the DLE and the computer - see Pict. 2 – 3 – 4

•Turn the ignition key of the machine to position I "board ON" and launch the Winscope program (see Pict. 5). If this is the very first time you use the system, follow the instructions described from the first page of this document. If you want to upload or download the setting from/to the machine DLE, you need a password which must be asked to TEREXLIFT (to avoid any tampering with the system). TEREXLIFT has also a database with all the values of the settings saved ordered by serial numbers which can be provided at any time for comparson purposes.

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DISPLAYING/CHANGING THE PARAMETERS

A window appears (pict. 7) with the parameters within which the machine can work.

Pict. 7 Pict. 8

If you want to check the variables on the machine, open the "variables" window as shown in picture 8. Clicking with the mouse, another window opens (see picture 9) which will display the real variations on the machine so you can compare the same with the parameters.

Pict. 9

If, during work, the variables keep within the limits set by the calibration parameters, the system is in efficient order; otherwise, an error message with the relevant identification code is displayed by the DLE.

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DLE - MONITORING WITH 3B6 WINSCOPE - PARAMETERS

Displaying the parameters

Simulation of the variables

load % calculated in relation to the

calibration

value of the analog signal read and converted into

bits

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LIST OF THE DLE PARAMETERS

N° Winscope Name Description

00 C1cellaVuoto Value saved in analog channel 1 - calibration with unloaded machine (best setting

around 700).

01 C1cellaCarico Value saved in analog channel 1 - calibration with loaded machine (best setting

around 300).

02 C1cellaMin Min admissible value for analog channel 1 reading (if actual value is below: alarm

2) (value set at 10 roughly).

03 C1cellaMax Max admissible value for analog channel 1 reading (if actual value is above: alarm

2) (value set at 1010).

04 C2cellaVuoto Value save in analog channel 2 - calibration with unloaded machine (best setting

around 300).

05 C2cellaCarico Value save in analog channel 2 - calibration with loaded machine (best setting

around 700).

06 C2cellaMin Min admissible value for analog channel 1 reading (if actual value is below: alarm

3) (value set at 10 roughly).

07 C2cellaMax Max admissible value for analog channel 1 reading (if actual value is above: alarm

3) (value set at 1010). 08 Filter Number of filter samples, with mobile mean. Load cell reading . Max 5. 09 paCellaUnica Sets to 1 automatically (during the machine selection) when the DLE is used in

single channel mode.

10 Celle_MaxDelta Max admissible delta between readings of analog channels 1 and 2, expressed

as a %. Default value 10 (current 20).

11 SpanForche Limiter intervention percentage in case of work with stabilised machine and forks.

Default: 100 (as per calibration).

12 SpanNavicella Limiter intervention percentage in case of work with stabilised machine and

platform (changed by the relevant procedure during calibration). When the platform is selected, the limiter uses this % (default 110% - load increase of 10%) instead of the SpanForche datum (current value 125).

13 DeltaSpanGomme Limiter intervention percentage in case of work with non-stabilised machine

(changed by the relevant procedure during calibration). % value that adds to the calibration with forks and outriggers (SpanForche).

14 OffSet0 Command given to the digital potentiometer for cell 1 (value from 0 to 255) to set

the reading scale during calibration with unloaded machine to a certain pre-set value (about900 bit ADC - C1cellaVuoto) (about 700).

15 OffSet1 Command given to the digital potentiometer for cell 2 (value from 0 to 255) to set

the reading scale during calibration with unloaded machine to a certain pre-set value (about 200 bit ADC - C2cellaVuoto) (about 300).

16 paIsteresiSblocco Load % for the reset of the movements once the block condition has been rectified

(default 5% = 95%).

17 paRitardoSblocco Value expressed in tenths of second corresponding to the time that must elapse

between the block condition and the movement reset (default 10 = 1 second).

20 C1NavicellaVuoto Parameters 20, 21, 22 and 23 are usually equivalent to parameters 0, 1, 4 and 5,

and they are used when the platform must be calibrated regardless of the calibration done with the forks.

Value saved in analog channel 1 during calibration with empty machine 21 C1NavicellaCarico Value saved in analog channel 1 during calibration with loaded machine 22 C2NavicellaVuoto Value saved in analog channel 2 during calibration with empty machine 23 C2NavicellaCarico Value saved in analog channel 2 during calibration with loaded machine 24 CurMacchina Machine selected on point "0" of the calibration 28 VersioneSW Software version 29 WPsum Parameters CHECKSUM used by the safety functions

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LIST OF THE DLE VARIABLES (useful for the diagnosis)

N° Winscope Name Typical Description

value

05 PCorder 0 You can save changes effected to the parameters by setting this variable

to "1". The variable will return to 0 once the value has been saved.

10 C1swl - Load percentage of cell 1 (0% = calibration without load; 100% =

calibration under load).

13 C1adcFilter - Current value of cell 1 (analog, converted into bits 0 - 1023).

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2.25 REAR THREE-POINT HITCH

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TECHNICAL SPECIFICATIONS

• OPERATION OF THE THREE-POINT HITCH

1 - Arms lifting phase

The lever of the distributor shaft (pos. 1 tab. 7) lets the oil coming from the pump reach the rear part of the pilot valve (pos. 23 tab. 7) through a transversal hole inside the distributor body. As the upper surface of this valve is greater than the lower one, the thrust upwards prevails and the valve remains closed. The oil at pressure can therefore flow into the cylinder through the valve (pos. 9 tab. 7) and push the piston (pos. 10 tab. 2) inside the cylinder (pos. 6 tab. 2), thus resulting in the arms lifting.

2 - Neutral phase (arms stop)

The shaft of the distributor moves to such a position that the oil at pressure acting on the pilot valve (pos. 23 tab. 7) and keeping the same closed, is drained through a longitudinal groove located in the distributor body. In this way, the oil coming from the pump exerts a thrust on the rear part of the valve which opens and lets the fluid flow toward the internal body of the hitch, and not toward the cylinder.

3 - Arms lowering phase

By operating the lever (pos. 3 tab. 7), the shaft of the distributor connected to same, opens the drain valve (pos. 14 tab. 7) and, thanks to the action of the hitch piston, allows the oil to flow to the drain line. The pressure relief valve (pos. 7 tab. 1), placed on the body of the hitch, is calibrated at a pressure of 200 210 bar, that is some 20 bar higher than the one of the pressure relief valve of the hydraulic circuit of the machine.

• ADJUSTING THE SENSITIVITY

For an efficient control of the position of the implement, the sensitivity of reaction of the distributor shaft should be adjusted at best. Such sensitivity depends on the position of the cam on the distributor shaft with respect to the cap of the drain valve (pos. 14 tab. 7). Such position can be changed using the external adjustment ring nut (pos. 21 tab. 7) as follows:

- Undo the screw (pos. 17 tab. 7) and remove the external lever (pos. 19 tab. 7).

- Fit the implement you want to use to the three-point linkage system of the machine.

- Start the engine and let it run at normal speed, then lift the implement.

- Screw down the adjustment ring nut (pos. 21 tab. 7) until the load jumps slightly.

- Unscrew the ring nut so the movement stops.

- Refit the external lever (pos. 19 tab. 7) in the position shown by the relevant screw.

During work, adjust the sensitivity (if necessary) using the external ring nut.

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• WORK IN CONTROLLED POSITION

The controlled position is used for any kind of labour, and especially for ploughing, as it adjusts and keeps the traction effort of the machine constant in relation to the type and condition of the ground being worked. By partially lowering the external lever (pos. 12 tab. 5) operating the controlled position, the internal levers connected to it, make the distributor shaft (pos. 1 tab.

7) rotate. This rotation opens the oil drain ducts from the cylinder and causes the arms to move down (draining phase). The proportionality between stroke of the external control lever (pos. 12 tab. 5) and stroke of the lifting arms is automatic, as the rotation of the arms supporting shaft (pos. 1 tab. 2) connected to the control levers, causes the distributor shaft to rotate. With the oil flowing through the special openings during rotation, the initial conditions are restored and the shaft moves back to the neutral position.

• WORK WITH CONTROLLED EFFORT

This function is used to move the implement to a fixed depth regardless of the ground conditions and the traction effort exerted by the machine. Lowering the external lever of the controlled effort (pos. 6 tab. 5) makes the distributor shaft (pos. 1 tab. 7) rotate. Inside the end of the shaft, there is an eccentric pin supporting the control lever. This lever, the internal ones connected it and the eccentric pin, make the distributor shaft rotate clockwise, thus resulting in an oil discharge and the consequent lowering of the arms. The lowering phase is continuous and total, unless an external cause (load reaction) intervenes which, by pressing on the feeler pin (pos. 13 tab. 6), directly connected to the third point of the system (leaf springs) of the machine causes the internal lever to move which, being connected to the distributor shaft, make it rotate and, as a result, make the arms lift. In this way, an adjustment action of the lifting arms occurs in relation to the effort of reaction exerted by the implement fitted to the three-point linkage system of the tractor.

The control lever of the controlled position can only be operated with the controlled effort lever fully up.

The control lever of the controlled effort can only be operated with the controlled position lever fully up.

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BOX Tab. 1

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4 21

5 16

TECHNICAL SPECIFICATIONS

HITCH Tab. 2

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10 9

11 2 13

6 17

TECHNICAL SPECIFICATIONS

INTERNAL CONTROLS Tab. 3

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3 7

TECHNICAL SPECIFICATIONS

TIE-RODS Tab. 4

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14 15

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CONTROL LEVERS Tab. 5

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10 11

7 8

TECHNICAL SPECIFICATIONS

SENSITIVE PARTS Tab. 6

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1918

30 29

25 24

TECHNICAL SPECIFICATIONS

REGULATOR DISTRIBUTOR Tab. 7

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Intentionally blank page

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Section 3

SCHEDULED MAINTENANCE

INSPECTIONS

SECTION INDEX

3.1 Introduction ......................................................................................... page 2

3.2 About this section ........................................................................................ 3

3.3 Maintenance table ....................................................................................... 4

3.4 Maintenance inspection report ................................................................... 7

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3.1 INTRODUCTION

• Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine.

• Scheduled maintenance must be carried out at the intervals indicated in the MAINTENANCE REPORT.

Failure to properly complete each inspection when required may cause death, serious injury or substantial machine damage.

• Immediately tag and remove from service a damaged or malfunctioning machine.

• Repair any machine damage or malfunction before operating machine.

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3.2 ABOUT THIS SECTION

Intervention times

Maintenance interventions have been divided into 6 different groups in relation to the time at which they must be carried out, say daily, weekly, monthly, every 6 months, yearly or every two years. For ease of use, the service intervals have been grouped in different tables, as explained below:

Inspection Table

Daily A

Weekly A+B

Monthly A+B+C

Six month A+B+C+D

Yearly A+B+C+D+E

Two years A+B+C+D+E+F

Maintenance table

The maintenance table contains general information on the type of intervention to be carried out at a certain interval. For the explanation of the maintenance jobs to be done, please refer to chapter 4 "Maintenance Procedures".

Maintenance inspection report

The maintenance report summarises all of the interventions to be carried at a given interval and lets the maintenance technician note the result of the check or intervention carried out. This card can be photocopied to be used at the different service intervals and to keep a trace of all interventions carried out.

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3.3 MAINTENANCE TABLE

TABLE A

During the first 10 working hours:

A-1 Check the oil level within reduction gears, power divider and differential gears.

A-2 Check the tightening of the wheel bolts.

A-3 Check the tightening of all bolts and nuts.

A-4 Check the couplings for oil leaks.

A-5 Check the oil level of the gearbox.

Every 10 working hours or daily:

A-6 Inspect the Operator Manual.

A-7 Inspect the decals and placards.

A-8 Check the engine oil level.

A-9 Clean the air suction filter.

A-10 Check the engine coolant level.

A-11 Check and clean the radiator.

A-12 Check the hydraulic oil level in the tank.

A-13 Check the greasing of the boom section pads.

A-14 Grease the attachment holding frame.

A-15 Grease all joints of the boom, the rear axle shaft joint, the transmission shafts, the front and rear axles and

any equipment of the machine.

A-16 Check the efficiency of the overload warning system.

A-17 Check the efficiency of the lighting electric system.

A-18 Check the efficiency of braking system and parking brake.

A-19 Check the efficiency of the steering selection system.

A-20 Check the efficiency of the fork balancing system.

A-21 Make sure the safety devices installed are in efficient working order.

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TABLE B

Within the first 50 working hours:

B-1 Change the engine oil and renew the fuel filter.

B-2 Check the oil level of the PTO reduction gear.

Every 50 working hours or weekly:

B-3 Check the tension of the alternator belt.

B-4 Check the tyre inflation.

B-5 Check the tightening of the wheel nuts.

B-6 Check the tightening of the cardan shaft screws.

B-7 Clean the radiator fins.

TABLE C

Within the first 250 working hours:

C-1 Change the oil in the PTO reduction gear.

Every 250 working hours or monthly:

C-2 Change the engine oil and relevant filter.

C-3 Check the oil level in the front and rear differential gears.

C-4 Check the oil level in the four wheel reduction gears.

C-5 Check the main filtering element of the engine air filter. Replace, if necessary.

C-6 Check the clamping of the cableheads to the battery terminals.

C-7 Check the air suction hose between engine and filter.

C-8 Check the cylinder chromium-plated rods.

C-9 Check the hydraulic lines are not worn because of rubbing against the frame or other mechanical

components.

C-10 Check the electric cables do not rub against the frame or other mechanical components.

C-11 Check the wear of the sliding pads of the boom sections.

C-12 Adjust the play of the sliding pads of the boom sections.

C-13 Remove any grease from the boom, then re-grease the sliding parts of the boom sections.

C-14 Check the level of the battery electrolyte.

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TABLE C

Every 250 working hours or monthly:

C-15 Check the oil level of the gearbox.

C-16 Check the oil level of the PTO reduction gear.

TABLE D

Every 500 working hours or every six months:

D-1 Visually check the smoke quantity evacuated from the engine exhaust.

D-2 Check the tightening of the engine fixing screws.

D-3 Check the tightening of the cab fixing screws.

D-4 Check the backlash between pins and bushings in all joints.

D-5 Change the hydraulic oil filter on the intake line.

D-6 Have the hydraulic system checked by a skilled technician.

D-7 Change the main cartridge of the engine air filter.

D-8 Renew the cartridge of the engine oil filter and the fuel filter.

D-9 Change the oil of the front and rear differential casings.

TABLE E

Every 1000 working hours or yearly:

E-1 Change the safety element of engine air filter.

E-2 Change the oil of the gearbox.

E-3 Change the oil in the four wheel reduction gears.

E-4 Change the hydraulic oil.

E-5 Change the oil in the PTO reduction gear.

E-6 Change the hydraulic oil filter in the tank.

E-7 Change the gearbox oil filter.

Every 2000 working hours or every two years:

F-1 Change the engine coolant.

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3.4 MAINTENANCE INSPECTION REPORT

AGRILIFT 737 - 1037

Model

Serial number

Date

Hour meter

Machine owner

Inspected by

Inspector signature

Inspector title

Inspector company

Instructions:

- Make copies of this page to use for each inspection.

- Select the appropriate checklist(s) for the type of inspection to be performed.

Every 10 hours: A

Every 50 hours: A+B

Every 250 hours: A+B+C

Every 500 hours: A+B+C+D

Every 1000 hours: A+B+C+D+E

Every 2000 hours: A+B+C+D+E+F

- Place a check in the appropriate box after each inspection procedure is completed.

- Use the maintenance tables in this section and the step-by-step procedures in section 4 to learn how to perform these inspection.

- If any inspection receives an "N", tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the "R" box.

Legend:

Y = yes, acceptable

N = no, remove from service

R = repaired.

Table A YNR

During the first 10 working hours:

A-1 Check the oil level within

reduction gears, power divider and differential gears.

A-2 Check the tightening of the

wheel bolts.

A-3 Check the tightening of all bolts

and nuts.

A-4 Check the couplings for oil leaks. A-5 Check the oil level of the gearbox.

Every 10 working hours:

A-6 Inspect the Operator Manual. A-7 Inspect the decals and placards. A-8 Check the engine oil level. A-9 Clean the air suction filter. A-10 Check the engine coolant level. A-11 Check and clean the radiator. A-12 Check the hydraulic oil level in

the tank.

A-13 Check the greasing of the boom

section pads.

A-14 Grease the attachment holding

frame.

A-15 Grease all joints of the boom,

the rear axle shaft joint, the transmission shafts, the front and rear axles and any equipment of the machine.

A-16 Check the efficiency of the

overload warning system.

A-17 Check the efficiency of the

lighting electric system.

A-18 Check the efficiency of braking

system and parking brake.

A-19 Check the efficiency of the

steering selection system.

A-20 Check the efficiency of the fork

balancing system.

A-21 Make sure the safety devices

installed are in efficient working order.

Table B YNR

Within the first 50 working hours:

B-1 Change the engine oil and renew

the fuel filter.

B-2 Check the oil level of the PTO

reduction gear.

Table B YNR

Every 50 working hours:

B-3 Check the tension of the

alternator belt.

B-4 Check the tyre inflation. B-5 Check the tightening of the

wheel nuts.

B-6 Check the tightening of the

cardan shaft screws.

B-7 Clean the radiator fins.

Table

C YNR

Within the first 250 working hours:

C-1 Change the oil in the PTO

reduction gear.

Every 250 working hours:

C-2 Change the engine oil and

relevant filter.

C-3 Check the oil level in the front

and rear differential gears.

C-4 Check the oil level in the four

wheel reduction gears.

C-5 Check the main filtering element

of the engine air filter.

C-6

Check the clamping of the cableheads to the battery terminals.

C-7 Check the air suction hose

between engine and filter.

C-8 Check the cylinder chromium-

plated rods.

C-9 Check the hydraulic lines. C-10 Check the electric cables do not

rub against the frame or other mechanical components.

C-11 Check the wear of the sliding

pads of the boom sections.

C-12 Adjust the play of the sliding

pads of the boom sections.

C-13 Remove any grease from the

boom, then re-grease the sliding parts of the boom sections.

C-14 Check the level of the battery

electrolyte.

C-15 Check the oil level of the

gearbox.

C-16 Check the oil level of the PTO

reduction gear.

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Model

Serial number

Date

Hour meter

Machine owner

Inspected by

Inspector signature

Inspector title

Inspector company

Instructions:

- Make copies of this page to use for each inspection.

Table D YNR

Every 500 working hours:

D-1 Visually check the smoke

quantity evacuated from the engine exhaust.

D-2 Check the tightening of the

engine fixing screws.

D-3 Check the tightening of the cab

fixing screws.

D-4 Check the backlash between

pins and bushings in all joints.

D-5 Change the hydraulic oil filter

on the intake line.

D-6 Have the hydraulic system

checked by a skilled technician.

D-7 Change the main cartridge of

the engine air filter.

D-8 Renew the cartridge of the

engine oil filter and the fuel filter.

D-9 Change the oil of the front and

rear differential casings.

- Select the appropriate checklist(s) for the type of inspection to be performed.

Every 10 hours: A

Every 50 hours: A+B

Every 250 hours: A+B+C

Every 500 hours: A+B+C+D

Every 1000 hours: A+B+C+D+E

Every 2000 hours: A+B+C+D+E+F

- Place a check in the appropriate box after each inspection procedure is completed.

- Use the maintenance tables in this section and the step-by-step procedures in section 4 to learn how to perform these inspection.

- If any inspection receives an "N", tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the "R" box.

Legend:

Table E YNR

Every 1000 working hours

E-1 Change the safety element of

engine air filter.

E-2 Change the oil of the gearbox. E-3 Change the oil in the four wheel

reduction gears.

E-4 Change the hydraulic oil. E-5 Change the oil in the PTO

reduction gear.

E-6 Change the hydraulic oil filter in

the tank.

E-7 Change the gearbox oil filter.

Table F YNR

Every 2000 working hours

F-1 Change the engine coolant.

Y = yes, acceptable

N = no, remove from service

R = repaired.

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Section 4

SCHEDULED MAINTENANCE

PROCEDURES

SECTION INDEX

4.1 Introduction ......................................................................................... page 2

4.2 About this section ........................................................................................ 3

4.3 TABLE A procedures .................................................................................... 3

4.4 TABLE B procedures .................................................................................... 24

4.5 TABLE C procedures.................................................................................... 29

4.6 TABLE D procedures.................................................................................... 42

4.7 TABLE E procedures .................................................................................... 48

4.8 TABLE F procedures .................................................................................... 55

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SCHEDULED MAINTENANCE PROCEDURES

4.1 INTRODUCTION

• Maintenance inspections shall be completed by a

person trained and qualified on the maintenance of this machine.

• Scheduled maintenance must be carried out at

the intervals indicated in the MAINTENANCE REPORT.

Failure to properly complete each inspection when required may cause death, serious injury or substantial machine damage.

• Immediately tag and remove from service a

damaged or malfunctioning machine.

• Repair any machine damage or malfunction before

operating machine.

• Unless otherwise specified, perform each

procedure with the machine in the following configuration:

- machine parked on a flat level surface;

- boom in the stowed position;

- key switch in the OFF position with the key removed.

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4.2 ABOUT THIS SECTION

This section describes the maintenance interventions to be carried out on the machine according to the indications of the maintenance inspection report (see chapter 3).

Safety symbols:

Draws the attention to situations that involve your own as well as the others’ safety and that can result in serious or lethal injury.

Draws the attention either to situations that involve your own as well as the others’ safety and that can result in minor or moderate injury or to situations that involve the machine efficiency.

Draws the attention to important technical information or practical advice that allows for a safer and more efficient use of the machine.

Draws the attention to important environment-related information.

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4.3 TABLE A PROCEDURES

A-1 CHECK THE OIL LEVEL WITHIN

REDUCTION GEARS, POWER DIVIDER AND DIFFERENTIAL GEARS

To check the oil level within the wheel reduction gears:

- Stop the machine on a level ground and ensure the parking brake is engaged and plug A finds on the horizontal axis.

- Clean the plug all around, then remove it and check if oil is level with the hole.

- If necessary, add new oil through hole A until it is level.

- Refit the plug.

Place a container of suitable size under the plug.

To check the oil level in the front and rear differential gears:

- Stop the machine on a level ground and engage the parking brake.

- Loosen level plug A and check if oil is level with the hole.

- If necessary, top-up through hole B until oil comes out from hole A.

- Refit and tighten plugs A and B.

Place a container of suitable size under the plug.

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INDEX

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AGRILIFT 737 - 1037

SCHEDULED MAINTENANCE PROCEDURES

A-2 CHECK THE TIGHTENING OF THE WHEEL

BOLTS

If you have to check the tightening of the wheel bolts or replace a wheel, proceed as follows:

- Raise the machine using a hydraulic jack.

- Remove the wheel rolling it on the ground.

- Line up the wheel with the axle and fit the 8 nuts.

- Tighten the nuts following the alternate sequence shown in the picture with a pneumatic screwdriving machine.

- Lower the machine to the ground.

Re-tighten all nuts to a torque 308 Nm.

Check the tightening of wheels one hour after the job. They might get loose until they do not stay correct.

On new machines, and when a wheel has been disassembled or replaced, check the nut torque of the wheels every 2 hours until they stay correct.

Always use tyres having the dimensions indicated in the vehicle registration card.

Agrilift 737 Agrilift 1037

Dimensions (front and rear) 405/70-24 405/70-24

STANDARD

P.R. (or load index) 14 PR 152 B 14 PR 152 B

Rim 13x24 13x24

Wheel disc 8 holes DIN 70361 8 holes DIN 70361

Pressure (bar/Psi) 4.5/65.2 4.5/65.2

Document 57.4400.9200 - 1

Edition 11/2005

INDEX

Page 100

AGRILIFT 737 - 1037

SCHEDULED MAINTENANCE PROCEDURES

A-3 CHECK THE TIGHTENING OF ALL BOLTS

AND NUTS

Before starting your daily work, proceed with a random check of the bolts.

For the correct tightening torques, please refer to par.

2.13 in section 2 “Technical Specifications”.

A-4 CHECK THE COUPLINGS FOR OIL LEAKS

Before starting your work, do a walk-around inspection and check for oil leaks.

If you find them, rectify before starting using the machine.

A-5 CHECK THE OIL LEVEL OF THE GEARBOX

To check the oil level of the gearbox:

- Stop the machine on a level ground and make sure the parking brake is engaged.

- Clean the area all around dipstick A.

- Remove the dipstick and check that oil is between the min mark and the max marks.

- If necessary, add new oil through the hole of the dipstick.

- Refit and tighten the dipstick.

Document 57.4400.9200 - 1

Edition 11/2005

INDEX

Genie Agrilift Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual