New Holland W130, W130TC Workshop Manual

Download

Page 1

W130/W130TC

WHEEL LOADER

Workshop Manual

Print N° 604.13.492.00 English II - 2005

THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.

Read and heed carefully the safety instructions listed and follow the precautions recommended to avoid potential risks and to safeguard your health and your safety.

You will find this symbol in the text of this Manual referred to the following key words:

WARNING

Cautions directed to avoid improper repair interventions involving potential consequences for the operator’s safety.

DANGER

These warnings qualify specifically potential dangers for the safety of the operator or other persons directly or indirectly involved.

IMPORTANT NOTICE

All maintenance and repair interventions explained in this Manual must be performed exclusively by the Service Organization of the Manufacturer, observing strictly the instructions explained using, whenever necessary, the recommended specific tools. Whoever performs the operations reported without following exactly the precautions is responsible on his own, for the damages that may result.

Neither the Factory nor any Organizations in its Distribution Network, including but not limited to national, regional or local distributors, are responsible for any liability arising from any damage resulting from defects caused by parts and/or components not approved by the Factory for use in maintaining and/or repairing products manufactured or merchandized by the Factory. In any case, no warranty of any kind is made or shall be imposed with respect to products manufactured or merchandized by the Factory, when failures are caused by the use of parts and/or components not approved by the Factory.

Page 2

AVOID ACCIDENTS

Most accidents and injuries occurring in industry, on the farm, at home or on the road, are caused by the failure of some individual to follow simple and fundamental safety rules or precautions. For this reason, MOST ACCIDENTS CAN BE PREVENTED by recognizing the real cause and taking the necessary precautions, before the accident occurs. Regardless of the care used in design and construction of any type of equipment, there may be conditions that cannot be completely safeguarded against without interfering with reasonable accessibility and efficient operation. A careful operator is the best insurance against accidents. The complete observance of one simple rule would prevent many thousands serious injuries each year. This rule is: Never attempt to clean, lubricate or adjust a machine while it is in motion.

WARNING

On machines having hydraulically, mechanically and/or cable controlled equipment (such as showels, loaders, dozers, scrapers etc.) be certain the equipment is lowered to the ground before servicing, adjusting and/or repairing. If it is necessary to have the equipment partially or fully raised to gain access to certain items, be sure the equipment is suitably supported by means other than the hydraulic lift cylinders, cable and/or mechanical device used for controlling the equipment.

Page 3

SUMMARY

GENERALITIES.................................................... Section 0

ENGINE ................................................................ Section 1

TRANSMISSION................................................... Section 2

BRAKE SYSTEM.................................................. Section 3

STEERING SYSTEM ............................................ Section 4

BUCKET BOOMS AND FRAME .......................... Section 5

EQUIPMENT HYDRAULIC SYSTEM ................... Section 6

ELECTRICAL SYSTEM........................................ Section 7

CAB ...................................................................... Section 8

Page 4

Page 5

SECTION 0

GENERALITIES

INDEX

SUBJECT PAGE

SAFETY RULES ........................................................................................................................................... 0-1

SPECIFICATIONS........................................................................................................................................ 0-8

DIMENSIONS AND WEIGHT .......................................................................................................................0-19

TABLE OF FLUID CAPACITIES ...................................................................................................................0-20

UNITS OF MEASURE .................................................................................................................................0-21

STANDARD TORQUE SPECIFICATION .......................................................................................................0-23

LOCTITE PRODUCT CHART.......................................................................................................................0-27

Page 6

Page 7

GENERALITIES

SAFETY RULES

0 - 1W130/W130TC

GENERALITIES

Read this Manual carefully before starting, operating, maintaining, fuelling or servicing the machine.

Read and comply with all safety precautions before any intervention.

Do not allow unauthorised personnel to operate or service this machine.

Do not wear rings, wrist watches, jewellery, loose or hanging garments, such as ties, torn clothing, scarves, unbuttoned or unzipped jackets that can get caught in moving parts. Wear certified safety clothes such as: hard hat, noslip footwear, heavy gloves, ear protection, safety glasses, reflector vests, respirators. Ask your employer about specific safety equipment requirements.

Keep the operator’s compartment, step plates, grab-rails and handles clean and clear of foreign objects, oil, grease, mud or snow to minimize the danger of slipping or stumbling. Remove mud or grease from your shoes before attempting to mount or operate the machine.

Do not jump on or off the machine. Always keep both hands and one foot, or both feet and one hand in contact with steps and grab rails.

Do not use controls or hoses as hand holds when climbing on or off the machine. Hoses and controls are movable parts and do not provide solid support. Besides, controls may be inadvertently moved and cause unexpected movement of the machine or its attachments.

Never operate the machine or its attachments from any position other than sitting in the driver’s seat.

Keep head, body, limbs, hands and feet inside the operator’s compartment at all times to reduce exposure to external hazards .

Be careful of possible slippery conditions of the steps and hand rails as well as of the ground around the machine.

Do not leave the machine until it is has come to a complete stop.

Check the seat safety belt at least twice per year and replace it if it shows signs of wear, fraying or other weakness that could lead to failure.

STARTING

NEVER START OR OPERATE A FAILED MACHINE. Before operating the machine, always ensure that any unsafe condition has been satisfactorily corrected.

Check brakes, steering and attachment controls before moving off. Report any malfuctioning part or system to the maintenance managers for proper action.

Ensure all protective guards and panels as well as all safety devices provided are in place and in good operating condition.

Ensure that nobody is in the machine operating range before moving off or operating the attachment. WALK COMPLETELY AROUND the machine before mounting. Sound the horn.

Before starting machine, check, adjust and lock the driver's seat for maximum comfort and control of the machine.

Fasten your seat belts(when fitted). Obey all flag signals and signs. Due to the presence of flammable fluids on the machine,

never check or fill fuel tanks or accumulator batteries near fires, open flames, or sparks.

REMEMBER THAT SPECIAL STARTING FLUIDS ARE FLAMMABLE. Scrupolously follow recommendations printed on the containers and in this Manual.

DO NOT PUNCTURE OR BURN CONTAINERS. Containers must be stored in fresh, well ventilated places

and out of the reach of unauthorised persons. Strictly follow the instructions provided by the Manufacturer.

Never use these products near fires, open flames, or sparks.

OPERATING

Check wheel and rim retainers before each working shift. If necessary, tighten to the torque specified.

Do not run the engine of this machine in closed buildings without proper ventilation capable to remove harmful exhaust gases.

Roll Over Protective Structures (ROPS) are required on wheel or crawler loaders, dozers, or graders. NEVER OPERATE the machine if such protective structure is removed.

Keep the operator’s compartment free of foreign objects, especially if not firmly secured. Never use the machine to transport objects, unless proper securing points are provided.

DO NOT CARRY RIDERS ON THE MACHINE Study and familiarize with escape routes alternate to

normal exit routes. According to law provisions, seat belts must be fitted with

Roll Over Protection Structures or cabs. Keep safety belts fastened during operation.

For your personal safety, do not climb on or off the machine while it is in motion.

Make sure that bystanders are clear of the machine operating range before starting the engine and operating the attachment. Sound the horn. Obey all indications provided by flags, signs and signals.

DO NOT COAST OR FREEWHEEL down hills. Engage the most suitable gear speed to keep the machine under control.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 8

0 - 2 W130/W130TC

GENERALITIES

SAFETY RULES

Do not operate the machine if you are extremely tired or feel ill. Be especially careful towards the end of the working shift.

Do not operate a machine with misadjusted brakes. Operate the machine at low speed which can ensure

complete control at all times. Travel slowly over very rough terrain, slopes or near drop-

offs, in congested areas or on frozen or slippery surfaces. When backing, always look to where the machine is to be

moved. Be alert of the position of bystanders. Should someone enter the work area, STOP THE MACHINE.

Maintain a safe distance from other machines or obstacles to ensure required visibility conditions. Give way to loaded machines.

Maintain a clear vision of the surroundings of the travel or work area at all times. Keep cab windows clean and repaired.

When machines are operating in tandem, the pusher (rear) must be equipped with the appropriate deflectors to protect the front unit driver against the air stream coming from the blower fan.

When pulling or towing through a cable or chain, do not start suddenly at full throttle. Take-up slack carefully.

Carefuly inspect the towing items for flaws or problems before proceedig.

Avoid kinking or twisting chains or cables. Do not pull through a kinked chain or cable as the high stresses existing in this condition may induce failures. Always wear heavy gloves when handling chains or cables.

Chains and cables should be securely anchored. Anchor points should be strong enough to withstand the expected load. Keep anyone clear of anchor points and cables or chains.

DO NOT PULL UNLESS THE OPERATOR’S COMPARTMENTS OF THE MACHINES INVOLVED ARE PROPERLY PROTECTED AGAINST POSSIBLE BACKLAS IN CASE OF CABLE OR CHAIN FAILURE OR DETACHMENT.

Be alert of soft ground conditions close to newly constructed walls. The fill material and machine weight may cause the wall to collapse.

In darkness, check area of operation carefully before moving in with the machine. Use all lights provided. Do not move into low visibility areas.

If the engine tends to stall for whatever reason under load or at idle, immediately report this problem to the maintenance managers for proper action. Do not operate the machine until this condition has been corrected.

On machines fitted with suction radiator fans, regularly check the engine exhaust system for leaks, as exhaust fumes expelled towards the operator are toxic.

Operators must know thoroughly the performances of the machine they are driving.

When working on slopes or near sudden level drops in the terrain, avoid areas where ground is loose or soft since overturn or loss of machine control could result.

If noise level is high and continuosly exceeds 90 dBA over 8 hours at the operator's ear, wear approved ear protection in compliance with local regulations.

Where counterweights are provided, do not operate the machine if they have been removed.

When transporting a loaded bucket, keept it as rolled-back and low as possible for maximum visibility, stability and safety of there machine. Ground speed should be adequate to the load and ground conditions.

The load must always be properly arranged in the bucket; move with extreme care when transporting oversize loads.

Use only the type of bucket recommended for the machine and the materials to be handled. Follow the recommendations concerning loading capacity, arrangement of the materials, characteristics of the ground and job to be performed.

Do not lift and move loads overhead where persons are standing or working, nor downhill when working crosswise on slopes. In this case, the bucket should be unloaded on the uphill side, whenever possible.

Start and stop the machine carefully when the bucket is full. Do not move off without first reducing engine speed.

Overtaking manoeuvres should be performed only when absolutely necessary and unavoidable. Beware possible uneven terrains, poor visibility, presence of other machinery or persons out of sight.

Operate the machine at a speed adequate to the working site conditions and in any case slow enough to ensure complete control at all times.

Check instruments at start-up and frequently during operation. Stop the machine immediately should any malfunction be signalled.

Never use the bucket as a man lift or to carry riders. Never use the machine as a work platform or scaffolding,

nor for other improper use (such as pushing railway cars, trucks or other machines).

Pay attetion to people within the machine operating range. Load trucks from the driver’s side whenever possible.

Prior to operating the machine, check which obstacles and/or difficulties you will encounter, such as narrow streets, overhead doors, cables, piping, as well as ground, bridges, paving and ramps bearing load limitations.

In case of road transfers, find out beforehand what conditions are likely to be encountered, such as size restrictions, heavy traffic, paving type, etc.. Beware fog, smoke or dust that obscure visibility.

When crossing gullies or ditches, move at an angle with reduced speed after ensuring ground conditions will permit a safe traverse.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 9

GENERALITIES

SAFETY RULES

0 - 3W130/W130TC

Always inspect the working area to identify potential risks such as: inclines, overhangs, trees, demolition rubble, fires, ravines, steep slopes, rough terrain, ditches, crowns, ridge trenches, heavy traffic, crowded parking and service areas, closed ambients. In such conditions, proceed with extreme care.

Whenever possible, avoid going over obstacles such as very rough terrain, rocks, logs, steps, ditches, railroad tracks. When obstructions must be crossed, do so with extreme care and at an angle, if possible. Slow down and select a lower gear. Ease up to the break-over point, pass the balance point slowly and ease down the other side.

In steep down-hill operation, do not allow the engine to over-speed. Select the proper gear before starting down grade.

Avoid crosswise hill travel, whenever possible. Drive up and down the slope. Should the machine start slipping sideways when going uphill, steer and turn machine front immediately downhill.

The gradient you may attempt to overcome is limited by factors such as ground conditions, load being handled, machine type and speed, and visibility.

There is no substitute for good judgement and experience when working on slopes.

Avoid operating the attachment too close to an overhang or high wall, either above or below the machine. Beware of caving edges, falling objects and landslips. Remember that such hazards are likely to be concealed by bushes, undergrowth and such.

When pushing-over trees, the machine must be equipped with proper overhead guards. Never drive a machine up the roots, particularly while the tree is being felled. Use extreme care when pushing over any tree with dead branches.

Avoid faggots, bushes, logs and rocks. NEVER DRIVE OVER THEM, nor over any other surface

irregularities that discontinue adherence or traction with the ground, especially near slopes or drop-offs.

Be alert to avoid changes in traction conditions that could cause loss of control. AVOID driving on ice or frozen ground when working on steep slopes or near drop-offs.

Working in virgin rough terrains is characterized by the presence of all the perils and risks listed above. In these conditions, it is emphasised the danger represented by large tree limbs (possibly falling on the machine), large roots (which may act as a leverage under the machine when up-rooted and cause the unit to overturn), etc.

STOPPING

When the machine is to be stopped for whatever reason, do so following the instructions given in chapters “Stop- ping the machine” and “Shutting off the engine" in the Operation and Maintenance Instruction Manual.

Always remember to move the gearshift lever to the neutral position and engage the control lever lock for safety purposes.

Apply the parking brake (if fitted). NEVER LEAVE THE MACHINE UNATTENDED with the

engine running. Prior to leaving the operator’s seat,and after making sure

that all people are clear of the machine, always slowly lower the attachment until resting it safely to the ground

Park the machine in a non-operating and no-traffic area. Park on firm level ground. If this is not possible, position the machine at a right angle to the slope, making sure there is no danger of uncontrolled sliding. Apply the parking brake.

If parking in traffic lanes cannot be avoided, provide appropriate flags, barriers, flares and signals as required to adequately warn the oncoming drivers.

Keep head, body, limbs, hands and feet clear of the dozer, arms, bucket or ripper when raised.

Always switch off the battery isolator switch before servicing the machine in whatever manner (i.e., cleaning, repairing, maintaining, etc.). Do the same when the machine is to remain parked for prolonged periods of time to avoid accidental or unauthorized starting.

Never lower the attachments other than sitting in the operator’s seat. Sound the horn. Make sure that nobody is within the machine operating range. Lower the attachment slowly. DO NOT USE FLOAT POSITION in case of hydraulic controls.

Securely block the machine and lock it every time you leave it unattended. Return keys to authorized security. Perform all necessary operations as detailed in the Operation and Maintenance Instruction Manual. Apply the parking brake (if fitted) every time you leave the machine.

MAINTENANCE

GENERALITIES

Before operating or performing any intervention on the machine:

- carefully read all the norms contained in this Manual;

- read and observe all safety plates and instructions located on the machine.

Do not allow unauthorized personnel to service the machine. Do not carry out any maintenance work without prior authorization. Follow all recommended maintenance and service procedures.

Keep the operator’s compartment free of loose objects that are not properly secured.

Do not wear rings, wrist watches, jewellery, loose or hanging garments, such as ties, torn clothing, scarves,unbuttoned or unzipped jackets that can get caught in moving parts.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 10

0 - 4 W130/W130TC

GENERALITIES

SAFETY RULES

Wear certified safety clothes such as: hard hat, no-slip footwear, heavy gloves, ear protection, safety glasses, reflector vests, respirators. Ask your employer about specific safety equipment requirements.

Never service the machine with someone sitting in the driver's seat, unless this person is an authorized operator assisting in the maintenance being carried out.

Keep the operator’s compartment, step plates, grab rails and handles clear of foreign objects, oil, grease, mud or snow to minimize the danger of slipping or stumbling.

Clean mud or grease from your shoes before climbing on the machine or driving it.

Never attempt to operate the machine or its attachments from any position other than sitting in the operator’s seat.

Never stand under the boom. Should it be necessary to move the attachment through the

hydraulic controls for maintenance purposes, remember that this should be done while sitting in the operator’s seat. Before starting the machine or moving its attachment, apply the brakes, sound the horn and call that you are about to manoeuvre. Raise the attachment slowly.

Always lock machine arms or any other parts that must be lifted for maintenance purposes using adequate external means. Do not allow anyone to pass near or even below a raised yet unlocked attachment. If you are not absolutely sure about your safety, do not stay under a raised attachment, even if it is locked.

Do not place body, limbs, or fingers near articulated cutting edges of uncontrolled machine parts or deprived of the necessary guards, unless they are suitably and safely locked.

Never perform any work on the machine with the engine running, except when this is specifically required. Do not wear loose clothing, jewellery or such near moving parts.

When service or maintenance require access to areas that cannot be reached from the ground, use a ladder or step platform conforming to regulations in force. If such means are not available, use machine grab rails and steps. Always perform all service or maintenance work with the greatest care and attention.

Shop and/or field service platforms or ladders should be manufactured in accordance with safety regulations in force.

Disconnect batteries and label all controls to warn that service work is in progress. Block the machine and all attachments to be raised.

Do not check or fill fuel tanks, batteries and accumulators, nor use the starting liquid if you are smoking or near open flames. These fluids are flammable!

BRAKES ARE INOPERATIVE when manually released for servicing. Provisions must be made to maintain control of the machine using suitable blocks or other means.

The fuel filler pipe nozzle must be constantly kept in contact with the filler neck. Keep this contact from the beginning to the end of the fuelling operation to avoid possible generation of sparks due to static electricity.

Tow the machine only from the attaching points provided. Use care in making connections and ensure pins and/or bolt are firmly secured before pulling. Stay clear of drawbars, cables or chains under load.

To move a failed machine, use a trailer or a low platform truck, if available. In case towing is needed, use all necessary signals required by local regulations, and follow directions provided in this Manual.

Load/unload the machine from transporter on firm level ground providing safe support to the wheels of the truck or trailer. Use strong access ramps, with adequate height and angle. Keep the loading platform free of mud, oil or slippery materials.

Tie the machine securely to the platform of the truck or trailer and opportunely wedge machine wheels or tracks as required.

Never align holes or slots using your fingers; always use appropriate aligning tools.

Remove all sharp edges and burrs from re-worked parts. Use only approved and effectively grounded auxiliary

power sources for heaters, battery chargers, pumps and similar equipment to reduce electrical shock hazard.

Lift and handle heavy components using hoisting devices of appropriate capacity. Ensure the sling has been correctly applied. Use lifting eyes if provided. Pay attention to bystanders.

Never pour gasoline or diesel fuel into open, wide and low containers. Never use gasoline, solvents or other flammable fluids to clean parts. Use proprietary certified nonflammable, non-toxic solvents only.

When using compressed air to clean parts, wear safety glasses with side shields. Limit pressure to max 2 bars, in accordance with local safety regulations in force.

Do not run the engine in closed buildings without proper ventilation capable to remove lethal fumes.

Do not smoke, use open flames or produce sparks nearby while refuelling the unit or handling highly flammable materials.

Do not use any flame as a light source during maintenance work or to look for leaks anywhere on the machine.

Make sure that all tools provided are in good condition at all times. NEVER USE tools with mushroomed or damaged heads. Always wear eye protections.

Move with extreme care when working under the machine, its attachments, and even on or near them. Always wear protective safety equipment as required, such as hard hat, goggles, safety shoes, and ear plugs.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 11

GENERALITIES

SAFETY RULES

0 - 5W130/W130TC

In case tests during which the engine should be kept runinng, a qualified operator must sit in the driver’s seat with the mechanic in sight at all times. Place the transmission in neutral, apply and lock the brakes. KEEP HANDS OFF MOVING PARTS.

In case of field service, move machine to level ground, if possible, and block it. If work on an incline cannot be advised, block the machine and its attachments securely. Move damaged to level ground as soon as possible.

Do not trust worn and/or kinked chains and cables. Never use them for lifting or pulling. Always wear heavy gloves to handle chains or cables.

Be sure chains and cables are firmly fastened and that anchor points are strong enough to withstand the expected load. Nobody should stay near the anchor points, cables or chains. DO NOT PULL OR TOW UNLESS THE OPERATOR’S COMPARTMENTS OF THE MACHINES INVOLVED ARE FITTED WITH THE PROPER GUARDS AGAINST BACKLASH IN CASE OF CABLE OR CHAIN FAILURE OR DETACHMENT. Keep the area where maintenance is carried out CLEAN and DRY at all times. Clean immediately all water and oil spillages.

Do not pile up oily or greasy rags as they represent a major fire hazard. Always store them in closed metal containers.

Before starting the machine or its attachment, check, adjust and lock the operator’s seat. Also ensure that nobody is within the machine operating range. Sound the horn.

Rust inhibitors are volatile and flammable. Use them only in well ventilated areas. Keep open flames away - DO NOT SMOKE - Store containers in a cool well ventilatedplace where they could not be reached by unauthorised people.

Do not carry loose objects in your pockets that might fall unnoticed into open compartments.

Wear safety glasses with side shields, hard hat, safety shoes, heavy gloves when metal particles or similar may be ejected and hit you.

Metal cables get frayed after prolonged use. Always wear appropriate protections (heavy gloves, goggles, etc.) while handling them.

Handle all parts carefully. Keep hands and fingers away from gaps, gears, and similar. Always use and wear the appropriate protections.

Water can build up in pneumatic systems from condensate moisture due to changes in atmospheric conditions. If necessary, drain such deposits following instructions.

Before carrying out any maintenance work or service, lock the machine articulated frame modules using the appropriate safety device. Remember to remove and store it properly at the end of work.

If the machine is equipped with hydraulic brakes, make sure that the reservoir is always filled up to the correct level.

Always block all wheels, front and rear, before bleeding the braking system or disconnecting control hoses and/or cylinders.

STARTING

Do not run the engine in closed buildings without proper ventilation capable to remove lethal exhaust fumes.

Do not place head, body, limbs, feet, hands or fingers near rotating fans or belts.

Be especially careful near blower fans. REMEMBER THAT THE STARTING FLUID IS HIGHLY

FLAMMABLE. Follow recommendations provided in this Manual and printed on the containers. Containers must be stored in a cool, well ventilated place out of the reach of unauthorised persons. DO NOT PUNCTURE OR BURN CONTAINERS.

Wear appropriate protective equipment such as dark safety glasses, hard hat, protective clothing, special gloves and footwear while welding. Nearby persons should also wear dark safety glasses even if they are not welding. DO NOT LOOK THE WELDING ARC WITHOUT PROPER EYE PROTECTION.

Become acquainted with all your jacking equipment and its capacity. Remember that the jacking point on the machine should be appropriate for the load applied. Also, be sure the support area of the jack at the machine and on the ground is appropriate and stable.

Any load supported by a jack represents a possible hazard. Always transfer the load onto appropriate support means according to local or national safety requirements before proceeding with service or maintenance work.

ENGINE

Loosen the radiator cap very slowly to relieve system pressure before removing it. Always top-up coolant level with the engine off.

Avoid that flammable materials could touch exhaust parts. If not possible, provide necessary protections.

Do not refuel with the engine running, especially if hot, as this increases fire hazard.

Never attempt to check or adjust fan belt tensions when the engine is running.

Do not adjust the fuel pump when the machine is motion. Do not lubricate the machine with the engine running. Do not run the engine with air intakes, door or guards open.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 12

0 - 6 W130/W130TC

GENERALITIES

SAFETY RULES

ELECTRICAL SYSTEM

Always disconnect the batteries prior to any intervention on the machine or its electrical system (cleaning, repair, maintenance).

Should booster batteries be used, remember to connect ends of the booster cables in the proper manner: (+) to (+) and (-) to (-). Do not short-circuit terminals. Thoroughly follow instructions given in this Manual.

Before any intervention, make sure that the battery isolator switch is off.

BATTERY GAS IS HIGHLY FLAMMABLE. Leave the battery compartment open during recharging to improve ventilation. Never check battery charge by placing metal objects across the posts. Keep sparks or open flames away from batteries. Do not smoke near the battery to prevent explosion hazard.

Before any intervention, make sure that there are no fuel or electrolyte leakages. If any, correct prior to proceeding with further work. Do not recharge batteries in confined spaces. Ensure proper ventilation is provided to avoid accidental explosions due to build-up of gas released during charging.

HYDRAULIC SYSTEM

Pressure fluid escaping from a very small hole can be almost invisible and still have sufficient force to penetrate the skin. Always check any suspected pressure leaks using a piece of cardboard or wood. DO NOT USE HANDS. If injured by escaping fluid, obtain medical attention immediately or serious infection or reaction may develop.

Stop the engine and relieve all system pressure before removing panels, housings, caps, plugs or covers.

Always use gauges of adequate capacity (end-of-scale reading) and follow recommended procedures.

Do not use the machine to transport loose objects, unless proper devices to this purpose are provided.

Clutches and brakes of this machine as well as auxiliary devices and attachments (such as drive cylinder or winch control valves) should always be properly adjusted in accordance with the instructions provided by the Manufacturer. Never perform adjustments with the engine running, except when this is specifically required by the relevant procedures.

TYRES AND WHEELS

Make sure that the tyre inflation pressure corresponds to specifications issued by the Manufacturer. Regularly check inflation pressure.

Should pressure be changed, do this while staying on the tyre side and at a safe distance.

Pressure checks should always be carried out with the machine unloaded and cold tyres.

Never use reconditioned tyre rims, since possible weldings, incorrect heat-treatments or repairs can weaken the wheels and cause damages or failures.

Do not cut, nor weld rims with inflated tyres installed. The spare tyre should be inflated only enough to keep the

rim components assembled. Remember that when not installed on the disc, a tyre inflated to maximum pressure can explode.

Therefore, maximum care must be taken when handling a fully inflated tyre.

Before servicing tyres, block all wheels, front and rear. After jacking up the machine, block it in the raised position using suitable stands conforming to current safety regulations.

Deflate the tyre before removing objects from the tyre tread. Never inflate tyres with flammable gas: explosions and

severe bodily injuries may result. When starting your work shift, check for loose wheel or rim

bolts and brackets and retighten to correct torque as necessary.

TOOLS

Always keep head, body, limbs, feet, or hands away from bucket, blade, or ripper when in the raised position. Prior to any intervention, install all safety devices according to current regulations. In case the attachment is to be operated through the machine hydraulic system for maintenance purposes, remember to do so only while sitting in the driver's seat. Make sure that nobody is within the machine operating range. Before operating the attachment, alert people by sounding the horn and by voice. Raise the attachment slowly.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 13

GENERALITIES

SAFETY RULES

DECOMMISSIONING THE MACHINE

For the decommissioning of the machine, the availability of particular tooling (hoists, hydraulic presses. containers for liquids etc.) is required as well as specific tools listed in the Repair Manuals, available from FIAT KOBELCO Dealers. This has the purpose of avoiding that during disassembly operations, dangerous situations may arise both for the personnel involved and the environment.

In the machine are present:

•

Fluids under pressure (hydraulic system, cooling system etc.)

•

Gases (air conditioning system and accumulator, if installed)

•

Mechanical devices mounted under pressure (track tensioner etc.)

•

Heavy machine components (frames, blades, buckets etc.)

0 - 7W130/W130TC

WARNING

• The decommissioning of the machine must be

performed exclusively by personnel trained, qualified and authorised to perform such operation.

• Start the disassembly of hydraulic components

only after the same, the hydraulic oil and lubricants have fully cooled-off and after all residual pressures have been released, as described by the Repair Instruction Manual.

• Prior to proceeding with disassembly opera-

tions, comply with the

RULES

chine filled with fluids, both in the reservoirs and the relevant systems.

and drain each components of the ma-

GENERAL SAFETY

WARNING

Ensure that the attachment is safely resting on to the ground before repairing,adjusting, or servicing machines fitted with hydraulically, mechanically or cable controlled attachments (such as excavators, loaders, dozers, scrapers, etc.). Should it be necessary to partially or fully raise the hydraulically, mechanically, or cable controlled attachment to gain access to certain items, make sure the attachment is adequately retained in the raised position by means other than the hydraulic lift cylinders, cable and/or mechanical devices used for controlling it.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 14

0 - 8 W130/W130TC

GENERALITIES

SPECIFICATIONS

ENGINE - EMISSION

Model F4GE0684F Fuel #2 Diesel (#1 & 2 Mixture Permitted For Cold

Temperature) Number of Cylinders 6 Bore and Stroke 4.09" (104 mm) x 5.20" (132 mm) Displacement 409 in3 (6.7 Liters) Electrical System 24 Volts Batteries (2) 12 Volts Alternator 70 Amp Compression Ratio 17.5 to 1 Fuel Pump Air Cleaner Dry Type Elements With Warning Restriction Indicator Oil Filter Full Flow Replaceable Cartridge Lubrication Positive Pressure Cooling System Air/Water with Lube Oil Cooler Power

- Gross (per SAE J1995) 148 hp (111 kW) @ 2000 RPM

- Net (per SAE J1349) 136 hp (101 kW) @ 2000 RPM

- Gross (per SAE J1995) 149 hp (111 kW) @ 1800 RPM

- Net (per SAE J1349) 139 hp (103 kW) @ 1800 RPM Torque, Max.

- Gross (per SAE J1195) 509 lb-ft (690 Nm) @ 1200 RPM

- Net (per SAE J1349) 495 lb-ft (671 Nm) @ 1200 RPM

Governor Complies with 1996 US EPA and CARB Heavy Duty Non-Road Emissions for 100-750 hp (75-560 kW) engines.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 15

GENERALITIES

POWER TRAIN

TRANSMISSION

Make ZF Model 4WG160

0 - 9W130/W130TC

Radio 1

Forward 4.012 2.024 1.088 0.619 Reverse 3.804 1.919 1.031 -

TORQUE CONVERTER

Make ZF Model 06.013.08

Stall Ratio 2.66:1

SPEEDS: mph (km/h)

(17.5 x 25 L3 Tires)

- Forward 4.0 (6.4) 7.8 (12.5) 13.8 (22.3) 22.5 (36.2)

- Reverse 4.2 (6.8) 8.2 (13.2) 14.5 (23.4) (20.5 x 25 L3 Tires)

- Forward 4.3 (6.9) 8.4 (13.5) 14.9 (23.9) 24 (38.6)

- Reverse 4.5 (7.3) 8.8 (14.2) 15.6 (25.0)

AXLES Front Rear

- Differential Ratio 3.1 8 3.1 8

- Planetary Ratio 6.4 0 6.4 0

- Final Axle Ratio 20.36 20.36 Make ZF

Model Front - MTL 3075

Rear - MTL 3065

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 16

0 - 10 W130/W130TC

GENERALITIES

BRAKES

Hydraulic, wet four-wheel disc. One brake pedals, both pedals apply brakes and electrically neutralilzes power flow to wheels with transmission disconnect switch activated. Both pedals apply brakes only when transmission disconnect switch is not activated. Hydraulic brake valve for front and rear split system. Spring applied/hydraulic released disc parking brake on transmission output shaft neutralizes power flow to wheels engaged.

Brake Area of Service Brakes 355.28 in2 (0.229 m2)/Hub Brake Area of Parking Brake 9.0 in2 (58 cm2) Brake Pressure Front: 1305 psi (8998 kPa)

(@ 2 sec. Setting method)

Rear : 1275 psi (8791 kPa)

ACCUMULATOR DATA

Cut In 2275 psi (15686 kPa) Cut Out 2800 psi (19305 kPa) Low Pressure Warning 1500 psi (10342 kPa) Transmission Declutch 350 psi (2413 kPa) Charge Pressure (N2) 800 psi (5516 kPa)

TIRES

20.5 R 25 XTLA TL★ 50 psi Front 40 psi Rear

(345 kPa) (275 kPa)

20.5 R 25 XHA TL★ 50 psi Front 40 psi Rear

(345 kPa) (275 kPa)

20.5 R 25 XLD-D2 ★ 50 psi Front 40 psi Rear

(345 kPa) (275 kPa)

20.5 R 25 GP-2B ★ 50 psi Front 40 psi Rear

(345 kPa) (275 kPa) 550/65 R 25 XLD ★ 50 psi Front 40 psi Rear

(345 kPa) (275 kPa)

17.5 R 25 XTLA TL★ 50 psi Front 40 psi Rear

(345 kPa) (275 kPa)

17.5 R 25 XHA TL★ 50 psi Front 40 psi Rear

17.5 R 25 GP-2B ★ 50 psi Front 40 psi Rear

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

(345 kPa) (275 kPa)

Page 17

GENERALITIES

0 - 11W130/W130TC

HYDRAULICS AND STEERING

Reservoir: Filtered vent with relief on hydraulic reservoir main-

tains 3-5 psi (20-34 kPa) on reservoir. Full time 10 micron return filters furnish only clean oil to all components of the system.

Valves: Closed-center, load sensing circuit, positive low pres-

sure regeneration for bucket dump. Remote control hydraulic power assit with electromagnet detents.

Inlet section gives steering priority with maximum pressure of 3500 psi (24132 kPa). Bucket section gives bucket priority. Relief valve provides maximum loader pressure of 3625 psi (25,000 kPa).

Loader control valve section contains float circuitry. Senses steering demand to control oil flow to loader

valve or steering valve as required by steering demand.

System: A variable displacement piston pump is used to sup-

ply oil to the integrated loader and steering hydraulic system.

Pump displacement 5.49 in3/rev (90 cc/rev).

45.2 GPM @ 2000 RPM @ 3600 psi (171.0 l/min @ 2000 RPM @ 24822 kPa)

Steering Section

Center pivot articulated steering - front and rear wheels always track. Two hydraulic cylinders controlled by a hydrostatic steering gear and a priority valve.

The steering Orbitrol provider 3.8 turns lock-to-lock. Lock-to-lock time at high idle is 2.2 sec.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 18

0 - 12 W130/W130TC

GENERALITIES

Hydraulic Cylinder:

Dump:

(Z-Bar, XR) 5.00 dia x 24.40 stroke x 3.00 rod

(127.0 mm dia x 619.7 mm stroke x 76.2 mm rod)

(TC) 4.13 dia x 37.57 stroke x 2.25 rod

(104.8 mm dia x 954.4 mm stroke x 57.2 mm rod)

Lift: 4.50 dia x 31.00 stroke x 2.50 rod

(114.3 mm dia x 787.6 mm stroke x 63.5 mm rod)

Steer: 2.75 dia x 18.21 stroke x 1.50 rod

(69.9 mm dia x 462.5 mm stroke x 38.1 mm rod)

Diameter of Hydraulic Inlet and Outlet Ports:

One Inlet 2" Split Flange (50.8 mm) One Outlet 1.25" ORB (31.7 mm)

- Steering Section 1.0" ORB (25.4 mm)

Maximum Oil Velocity at Hydraulic Pump @ 2000 RPM:

Outlets - Implement Section 11.8 ft/sec (3.60 m/sec)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 19

GENERALITIES

CAPACITIES

Cooling System:

6.3 US/gal (24.0 liters) to fill system Gallons Ethylene Glycol (Prestone) required:

2.2 US/gal (8.5 liters) for 0 °F

2.7 US/gal (10.4 liters) for -20 °F

3.4 US/gal (12.8 liters) for -40 °F

Fuel Tank:

50.0 US/gal (189 liters) Usable Fuel

Engine:

Crankcase Only 16 quarts (15.1 liters) Crankcase and Filter 17 quarts (16.1 liters)

Transmission: 6.87 US/gal (26 liters) initial capacity

0 - 13W130/W130TC

5.0 US/gal (18.9 liters) service (w/filter)

Axles: Front/Rear

Total/Axle 23.2 quarts (22 liters)

Hydraulic Reservoir:

Reservoir, oil only 15.0 US/gal (56.8 liters) Reservoir, oil plus air 23.8 US/gal (90.1 liters)

Total System 30.0 US/gal (113.6 liters)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 20

0 - 14 W130/W130TC

GENERALITIES

SOUND LEVEL DATA

Emission Engine w/o Enhanced Sound Package Sound Level (Arithmetic Average) dBA

Cab Closed

Exterior Sound Level @ 15 meters per SAE J88 SEP80

Stationary - Rated Speed 7 1.4 Test Average 72.6

Operator's Station Sound Level per SAE J919 JUN86

Stationary - Rated Speed 7 0.5 Test Average 69.8

Sound levels per (in dB(A)) 2000/14/EC 98/37/EC (ISO 6395, 6396, 3744)

Interior LpA Exterior LwA Combined Dynamic (Test Average) 71.2 106.2 Decal Value 71 107

The option w Enhanced Sound Package will be developed at the begin of March. The standard machine will be w/o Enhanced Sound Package.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 21

GENERALITIES

Emission Engine w/o Enhanced Sound Package Sound Level (Arithmetic Average) dBA

Cab Closed

Exterior Sound Level @ 15 meters per SAE J88 SEP80

Stationary - Rated Speed Test Average -

Operator's Station Sound Level per SAE J919 JUN86

Stationary - Rated Speed Test Average

Sound levels per (in dBA) 2000/14/EC 98/37/EC (ISO 6395, 6396, 3744)

Interior LpA Exterior LwA

0 - 15W130/W130TC

Combined Dynamic (Test Average) - Decal Value - -

Note –

Rated speed of engine is 2000 rpm and High - Idle is 2160 - 2220 rpm.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 22

0 - 16 W130/W130TC

GENERALITIES

COMPONENT SPECIFICATIONS

ITEM MODEL SIZE

Injector Pump VE6/12F1000 Primary Fuel Filter 43.061.000.53 Engine oil filter LF16015 JD Air filter assembly G100376 10 in. Diameter Starter EV 24 volt 4 kw Alternator NCB1 24 v, 70 amp Hydraulic Pump A10V085 5.19 cu. In./rev

(85 cc/rev) Hydraulic Oil Filter HM K013582, Assembly HM K0531170 w/ride

control Head Assy. P178778 Element P165823 Hyd. control P/N C0640-10014

2 Lever Hyd. control 4TH6F

Joystick P/N 08-350-759 Hyd. control C0640-10013 3 Lever

Hyd. control 4TH6F+2TH6 Joystick + 1 Lever P/N 08-350-759 +

P/N 08-350-766 Loader Control Valve - M6-1044-00/2M6-15

2 Spool ZB Loader Control Valve - M6-1047-00/2M6-15

2 Spool TC Loader Control Valve - M6-1045-00/3M6-15

3 Spool ZB Loader Control Valve - M6-1048-00/2M6-15

3 Spool TC

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 23

GENERALITIES

ITEM MODEL SIZE

Loader Control Valve - M6-1046-00/4M6-15 4 Spool ZB

Loader Control Valve - M6-1049-00/M6-15 4 Spool TC

Cab Heater/def/AC 441407913 12kW heater Blower Motor (006-B39/I 22-24 V) 8 kW evaporator Core (combination) air flow 850 m3/h @

40 mm H2O

441407913

Cab heater defroster (006-B39/I 22-24 V) blowe motor Core

Condenser 383912A1 4R/9F 19.84"x11" Compressor 4611-6000

0 - 17W130/W130TC

Front Wiper 441411772 24 V

(150.208) 35 min-1/55 min

-1

60° Sweep

Rear Wiper 441412334 24 V

-1

45 min 175° sweep

Cab Filter 441407125 Front Recirculation surface: 90 x 470 mm

Flow 1500 l dm

-2

Cab Filter 241405799 Front External air surface: 445 x 114 mm

Flow 830 l s-1 m

-2

Steering valve and 236-4008-002 orbital pump

Cooling Fan 832059 28.0" (711 mm)

Diameter

Standard M080425 Horizontal round Muffler

Battery 548.450.1ES Cap. 100 Ah

12 V 450 Amp

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 24

0 - 18 W130/W130TC

GENERALITIES

ITEM MODEL SIZE

Trasmission 8605271

WG 160 Hyd. oil cooler 7A8 02 59 01C Air-to-Oilm 9 fins/in Beacon 35.205.000.14 Halogen 24 V

Rotary Lamp Front axle MT3075 Rear axle MT3065 Service Brakes Pump WQ09A1 Accumulators

19184-OPA3

Brake Modulation Valve Secondary steering - 02433A00

electric pump and motor Engine drive shaft 04085418 Front drive shaft 04085422 Center drive shaft 04085423 Rear drive shaft 04085424 Bucket teeth 87408033 Information Center 11000-MM3600

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 25

50˚

GENERALITIES

DIMENSIONS AND WEIGHT

0 - 19W130/W130TC

40˚

3828

44˚

380

Operating weight: 11.758 kg

Note –

Type of bucket

Machine arranged with 2.1 cu m bucket, tyres 20.5x25 filled and operator.

3290

2900 2425

With teeth and segments With suppl. cutting edge

1850

W130M0001

Dimensions in mm

* Please refer to the table

Bucket capacity m Bucket weight kg 888 935 895 942 Bucket width mm 2540 2540 2500 2500 Dumping height at 45° m m 2761 2680 2794 2713 Dumping reach at 45° m m 1029 1118 991 1080 Max. length

(w/ bucket on ground) m m 7054 7179 7005 7129 Max. height

(w/ bucket raised) m m 5030 5039 5030 5039 Turning radius

(in transportation position) m 11.5 11.56 10.4 11.5

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2.1 2.3 2.1 2.3

Page 26

0 - 20 W130/W130TC

–30 to 20 °C (-22 to 68 °F)

–10 to 50 °C (14 to 122 °F)

15W-40 –10 to 50 °C (14 to 122 °F)

GENERALITIES

– –20 to 50 °C (-4 to 122 °F)

–40 to 50 °C (-40 to 122 °F)

Spec. B-27

Grade 251H-EP

API CH-4

ACEA E2

API CF-4/SG

ACEA E3

TABLE OF FLUID CAPACITIES

Mastergold HSP*

LITRES (USG) SPECIFICATIONS (SAE) OF REFERENCE (°C)

ACEA E2

API CF-4/SG

ISO VG 46, DIN 51524

Item 1 and 2, QFH583/HD

TRX API GL4 SAE 80W-140 –20 to 50 °C (-4 to 122 °F)

rear 22

front 22

4.7 SC 35 – – –

0.2 (0.05) L BAR 134 – – –

ITEM QUANTITY FLUIDS OR LUBRICANT CLASSIFICATION VISCOSITY OUT DOOR TEMPERAT.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

ENGINE + OIL FILTER 12. 5 Super Gold MIL-L-2104E 15W-40

RADIATOR 22 Agriflu ASTM D-5345 – –35 to 50 °C (-31 to 122 °F)

TRANSMISSION + FILTER 18. 5 Super Gold MIL-L-2104E 10W-30 –30 to 20 °C (-22 to 68 °F)

HYDRAULIC SYSTEM 63 (114 TOT.) HITECH 46

FUEL TANK 18.3 – – – Diesel fuel ASTM no. 2D

AXLES

GREASE FITTINGS – MG-2 –

COMPRESSOR

WINDSHIELD WASHER

AIR CONDITIONER

FLUID

In the event engine oil with "CH4" classification is used, the change interval can be prolonged to 500 hours providing that the outer temperature of operation

Oil quantities indicated are those required for periodical changes following the draining and filling procedures indicated in detail for each group.

does not exceed 38 °C (100 °F) and that the percentage of sulphur in the fuel does not exceed 0.5 %.

In the event of really heavy duty conditions, reduce the greasing intervals.

Page 27

GENERALITIES

UNITS OF MEASURE

CONVERSION FACTORS

Metric to U.S.

MULTIPLY BY TO OBTAIN

Area: sq. meter 10.763 91 square foot

hectare 2.471 05 acre

Force: newton 3.596 942 ounce force

newton 0.224 809 pound force

Length: millimeter 0.039 370 inch

meter 3.280 840 foot kilometer 0.621 371 mile

Mass: kilogram 2.204 622 pound

Mass/Area: kilogram/hectare 0.000 466 ton/acre

0 - 21W130/W130TC

Mass/Energy: g/kW/hr. 0.001 644 lbs/hp/hr.

Mass/Volume: kg/cubic meter 1.685 555 lb/cubic yd.

Power: kilowatt 1.341 02 horsepower

Pressure: kilopascal 0.145 038 lb/sq. inch

bar 14.50385 lb/sq. inch

Temperature: degree C 1.8 x C +32 degree F

Torque: newton meter 8.850 748 lb/inch

newton meter 0.737 562 lb/foot

Velocity: kilometer/hr. 0.621 371 miles/hr.

Volume: cubic centimeter 0.061 024 cubic inch

cubic meter 35.314 66 cubic foot cubic meter 1.307 950 cubic yd.

milliliter 0.033 814 ounce (US fluid) litre 1.056 814 quart (US liquid) litre 0.879 877 quart (Imperial) litre 0.264 172 gallon (US liquid) litre 0.219 969 gallon (Imperial)

Volume/Time: litre/min. 0.264 172 gallon/min. (US liquid)

litre/min. 0.219 969 gallon/min. (Imperial)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 28

0 - 22 W130/W130TC

GENERALITIES

U.S. to Metric

MULTIPLY BY TO OBTAIN

Area: sq. foot 0.092 903 square meter

acre 0.404 686 hectare

Force: ounce force 0.278 014 newton

pound force 4.448 222 newton

Length: inch 25.4 * millimeter

foot 0.304 8 * meter mile 1.609 344 * kilometer

Mass: pound 0.453 592 kilogram

ounce 28.35 gram

Mass/Area: ton/acre 2241 702 kilogram/hectare

Mass/Energy: lb/hp/hr 608.277 4 gr/kW/hr

Mass/Volume: lb/cubic yd. 0.593 276 kg/cubic meter

Power: horsepower 0.745 700 kilowatt

Pressure: lbs/sq. in. 6.894 757 kilopascal

lbs/sq. in. 0.069 bar lbs/sq. in. 0.070 303 kg/sq. cm

Temperature: degree F 1.8 F - 32 degree C

Torque: pound/inch 0.112 985 newton meter

pound/foot 1.355 818 newton meter

Velocity: miles/hr. 1.609 344 * kilometer/hr.

Volume: cubic inch 16.387 06 cubic centimeter

cubic foot 0.028 317 cubic meter cubic yard 0.764.555 cubic meter

ounce (US fluid) 29.573 53 milliliter quart (US liquid) 0.946 353 litre quart (Imperial) 1.136 523 litre gallon (US) 3.785 412 litre gallons (Imperial) 4.546 092 litre

Volume/Time: gallon/min. 3.785 412 litre/min.

* = exact

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 29

GENERALITIES

STANDARD TORQUE SPECIFICATION

0 - 23W130/W130TC

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Use the torques in this chart when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphitiesm Molydisulfide greases, or other extreme pressure lubricants are used.

Grade 5 Bolts, Nuts, and Studs

Size

1/4 inch 108 to 132 12 to 15 5/1 6 204 to 252 23 to 28 3/8 inch 420 to 504 48 to 57

Size 7/16 inch 54 to 64 73 to 87

Pound- Newton Inches metres

Pound- Newton

Feet metres

Grade 8 Bolts, Nuts, and Studs

Size

1/4 inch 144 to 180 16 to 20 5/1 6 288 to 348 33 to 39 3/8 inch 540 to 648 61 to 73

Size 7/16 inch 70 to 84 73 to 87

1/2 inch 110 to 132 149 to 179 9/16 inch 160 to 192 217 to 260 5/8 inch 220 to 264 298 to 358 3/4 inch 380 to 456 515 to 618 7/8 inch 600 to 720 814 to 976

1.0 inch 900 to 1080 1220 to 1465

Pound- Newton Inches metres

Pound- Newton

Feet metres

1/2 inch 80 to 96 109 to 130 9/16 inch 110 to 132 149 to 179 5/8 inch 150 to 180 203 to 244 3/4 inch 270 to 324 366 to 439 7/8 inch 400 to 480 542 to 651

1.0 inch 580 to 696 787 to 944 1-1/8 inch 800 to 880 1085 to 1193 1-1/4 inch 1120 to 1240 1519 to 1681 1-3/8 inch 1460 to 1680 1980 to 2278 1-1/2 inch 1940 to 2200 2631 to 2983

1-1/8 inch 1280 to 1440 1736 to 1953 1-1/4 inch 1820 to 2000 2468 to 2712 1-3/8 inch 2380 to 2720 3227 to 3688 1-1/2 inch 3160 to 3560 4285 to 4827

Note –

Use thick nuts with Grade 8 bolts.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 30

0 - 24 W130/W130TC

GENERALITIES

TORQUE SPECIFICATIONS - METRIC HARDWARE

Use the following torques when specifications are not given.

These values apply to fasteners with coarse threads as received from supplier, plated or unplated, or when lubricated with engine oil. These values do not apply if graphite or Molydisulfide grease or oil is used.

Grade 8.8 Bolts, Nuts, and Studs

8.8

Size

Pound- Newton

Inches metres M4 24 to 36 3 to 4 M5 60 to 72 7 to 8 M6 96 to 108 11 to 12 M8 228 to 276 26 to 31 M1 0 456 to 540 52 to 61

Grade 10.9 Bolts, Nuts, and Studs

10.9

Size

Pound- Newton

Inches metres M4 36 to 48 4 to 5 M5 84 to 96 9 to 11 M6 132 to 156 15 to 18 M8 324 to 384 37 to 43

Size

Pound- Newton

Feet metres

M1 0 54 to 64 73 to 87 M1 2 93 to 112 125 to 150 M1 4 149 to 179 200 to 245 M1 6 230 to 280 310 to 380 M2 0 450 to 540 610 to 730

Size

Pound- Newton

Feet metres

M1 2 66 to 79 90 to 107 M1 4 106 to 127 144 to 172 M1 6 160 to 200 217 to 271 M2 0 320 to 380 434 to 515 M2 4 500 to 600 675 to 815 M30 920 to 1100 1250 to 1500 M36 1600 to 1950 2175 to 2600

M24 780 to 940 1050 to 1275 M30 1470 to 1770 2000 to 2400 M36 2580 to 3090 3500 to 4200

Grade 12.9 Bolts, Nuts, and Studs

12.9

Usually the torque values specified for grade 10.9 fasten can be used satisfactorily on grade 12.9 fasteners.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 31

GENERALITIES

0 - 25W130/W130TC

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

Tube OD Thread Pound- Newton Hose ID Size Inches metres

37 Degree Flare Fitting

1/4 inch 7/ 16-20 72 to 144 8 to 16

6.4 mm 5/16 inch 1/2-20 96 to 192 11 to 12

7.9 mm 3/8 inch 9/ 16-18 120 to 300 14 to 34

9.5 mm 1/2 inch 3/4-16 180 to 504 20 to 57

12.7 mm 5/8 inch 7/8-14 300 to 696 34 to 79

15.9 mm

Tube OD Thread Pound- Newton Hose ID Size Inches metres

3/4 inch 1-1/16-12 40 to 80 54 to 108

19.0 mm 7/8 inch 1-3/16-12 60 to 100 81 to 135

22.2 mm

1.0 inch 1-5/16-12 75 to 117 102 to 158

25.4 mm 1-1/4 inch 1-5/8-12 125 to 165 169 to 223

31.8 mm 1-1/2 inch 1-7/8-12 210 to 250 285 to 338

38.1 mm

Tube OD Thread Pound- Newton Hose ID Size Inches metres

Straight Threads with O-ring

1/4 inch 7/1 6- 20 144 to 228 16 to 26

6.4 mm 5/16 inch 1/2-20 192 to 300 22 to 34

7.9 mm 3/8 inch 9/1 6- 18 300 to 480 34 to 54

9.5 mm 1/2 inch 3/4-16 540 to 804 57 to 91

12.7 mm

Tube OD Thread Pound- Newton Hose ID Size Inches metres

5/8 inch 7/8-14 58 to 92 79 to 124

15.9 mm 3/4 inch 1-1/16-12 80 to 128 108 to 174

19.0 mm 7/8 inch 1-3/16-12 100 to 160 136 to 216

22.2 mm

1.0 inch 1-5/16-12 117 to 187 159 to 253

25.4 mm 1-1/4 inch 1-5/8-12 165 to 264 224 to 357

31.8 mm 1-1/2 inch 1-7/8-12 250 to 400 339 to 542

38.1 mm

Split Flange Mounting Bolts

Size

5/16-18 180 to 240 20 to 27 3/8-16 240 to 300 27 to 34 7/16-14 420 to 540 47 to 61

Size 1/2-13 55 to 65 74 to 88

5/8-11 140 to 150 190 to 203

Pound- Newton Inches metres

Pound- Newton

Feet metres

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 32

0 - 26 W130/W130TC

GENERALITIES

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

Nom SAE Dash Size Inches metres Size Inches metres

Tube OD

Thread Pound- Newton Thread Pound- Newton

Size

O-ring Face Seal End

O-ring Boss End

Fitting or Lock Nut

-4 1/4 inch 9/16-18 120 to 144 14 to 16 7/16-20 204 to 240 23 to 27

6.4 mm

-6 3/8 inch 11/16-16 216 to 240 24 to 27 9/16-18 300 to 360 34 to 41

9.5 mm

-8 1/2 inch 13/16-16 384 to 480 43 to 54 3/4-16 540 to 600 61 to 68

12.7 mm

Thread Pound- Newton Size Inches metres

-1 0 5/8 inch 1-14 552 to 672 62 to 76 7/8-14 60 to 65 81 to 88

15.9 mm

Nom 1-1/16/12 85 to 90 115 to 122 SAE Dash Size Inches metres

Tube OD

Thread Pound- Newton

1-3/16-12 95 to 100 129 to 136

Size

-1 2 3/4 inch 1-3/16-12 65 to 80 90 to 110 1-5/16-12 115 to 125 156 to 169

19.0 mm

-1 4 7/8 inch 1-3/16-12 65 to 80 90 to 110 1-5/18-12 150 to 160 203 to 217

22.2 mm

-1 6 1.0 inch 1-7/16-12 92 to 105 125 to 140 1-7/8-12 190 to 200 258 to 271

25.4 mm

-2 0 1-1/4 inch 1-11/16-12 125 to 140 170 to 190

31.8 mm

-2 4 1-1/2 inch 2-12 150 to 180 200 to 254

38.1 mm

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 33

GENERALITIES

LOCTITE PRODUCT CHART

0 - 27W130/W130TC

Form a Gasket (works with oil,

fuel or grease) Pliable

Primer Description

Fixture/Full Cure

(Steel/Steel) Time

Working

Temperature

Range-Farenheit

Low Strength Threadlocker

(Small Screws)

Surface Insensitive Gen

Instant Adhesive

Similar Gap Strength

Products (In Inches) (Steel/Steel)

Product Color

80 Yellow Fast N/A Weatherstrip Adhesive

#3 Dark Brown 24 hr N/A

123 Clear N/A N/A Parts Cleaner Fluid

220 Blue 2 9 0 0.003 57/143 in lbs -65 to +250 6 min/24 hrs 7 47 Wicking Threadlocker

221 Purple 2 2 2 0.005 75/44 in lbs -65 to +300 2 min/24 hrs 74 7 Low Strength Threadlocker

222 Purple 0.005 53/30 in lbs -65 to +300 20 min/24 hrs 76 4

225 Brown 2 2 2 0.010 45/25 in lbs -65 to +300 7 min/24 hrs 74 7 Low Strength Threadlocker

242 Blue 0.005 80/50 in lbs -65 to +300 10 min/24 hrs 76 4 Medium Strength Threadlocker

262 Re d 271 0.005 160/190 in lbs -65 to +300 5 min/24 hrs 74 7 High Strength Threadlocker

270 Green 271 0.007 160/320 in lbs -65 to +300 3 min/24 hrs 74 7 High Strength Threadlocker

271 Re d 262 0.007 160/320 in lbs -65 to +300 10 min/24 hrs 76 4 High Strength Threadlocker

272 Re d 620 0.007 180/220 in lbs -65 to +450 30 min/24 hrs 76 4 High Temperature, High Strength

275 Green 277 0.010 210/300 in lbs -65 to +300 3 min/24 hrs 74 7 High Strength Threadlocker

277 Re d 0.010 225/300 in lbs -65 to +300 60 min/24 hrs 76 4 High Strength Threadlocker

290 Green 0.003 85/350 in lbs -65 to +300 6 min/24 hrs 76 4 Wicking Threadlocker

*404 Clear 495 0.006 3200 psi -65 to +180 30 sec/24 hrs NA Instant Adhesive

*406 Clear 0.004 3200 psi -65 to +180 15 sec/24 hrs N/A Surface Insensitive Adhesive

*409 Clear 454 0.008 2500 psi -65 to +180 50 sec/24 hrs N/A Gap Instant Adhesive

*414 Clear 0.006 2500 psi -65 to +180 30 sec/24 hrs N/A Instant Adhesive

*415 Clear 454 0.010 2500 psi -65 to +180 50 sec/24 hrs N/A Gap Filling Instant Adhesive (Metals)

*416 Clear 454 0.010 2500 psi -65 to +180 50 sec/24 hrs N/A Gap Filling Instant Adhesive (Plastics)

*420 Clear 0.002 2500 psi -65 to +180 15 sec/24 hrs N/A Wicking Instant Adhesive

*422 Clear 454 0.020 2800 psi -65 to +180 60 sec/24 hrs N/A Gap Filling Instant Adhesive

*430 Clear 0.005 2500 psi -65 to +180 20 sec/24 hrs N/A Metal Bonding Adhesive

*445 White/Black 0.250 2000 psi -65 to +180 5 min/24 hrs N/A Fast Setting 2 Part Epoxy

*454 Clear 0.010 3200 psi -65 to +180 15 sec/24 hrs N/A

*495 Clear 0.004 2500 psi -65 to +180 20 sec/24 hrs N/A General Purpose Instant Adhesive

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

50 4 Brt Orange 515 0.030 750 psi -65 to +300 90 min/24 hrs Non e Rigid Gasket Eliminator

50 9 Light Blue 0.020 750 psi -65 to +320 6 hr/72 hrs 764 Flange Sealant

*496 Clear 0.005 2500 psi -65 to +180 20 sec/24 hrs N/A Metal Bonding Adhesive

510 Re d 0.020 1000 psi -65 to +400 30 min/24 hrs 76 4 High Temperature, Gasket Eliminator

515 Purple 0.010 750 psi -65 to +300 1 hr/24 hrs 7 6 4 Gasket Eliminator 515

* Products 404-496 (except for #445) are all instant adhesives (super glues) they differ mostly in viscosity

Page 34

0 - 28 W130/W130TC

GENERALITIES

Primer Description

Fixture/Full Cure

(Steel/Steel) Time

Working

Temperature

Range-Farenheit

Low Strength Pneumatic/Hydraulic

Sealant

High Temperature Retaining

Compound

Similar Gap Strength

Products (In Inches) (Steel/Steel)

518 Re d 515 0.030 500 psi -65 to +300 1 hr/24 hrs 7 64 Gasket Eliminator 518 for Aluminum

Product Color

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

545 Purple N/A 25/20 in lbs -65 to +300 4 hrs/24 hrs 74 7

542 Brown 569 N/A 132/92 in lbs -65 to +300 2 hrs/24 hrs 74 7 Hydraulic Sealant

549 Orange 5 0 4 0.020 2500 psi -65 to +300 2 hrs/24 hrs 747 Instant Seal Plastic Gasket

554 Re d 277 0.015 240/240 in lbs -65 to +300 2 to 4 hrs/24 hrs 764 Refrigerant Sealant

567 White 592 N/A 500 psi -65 to +400 4 hrs/24 hrs 76 4 Pipe Sealant for Stainless Steel

568 Orange 2 7 7 0.015 2500 psi -65 to +300 12 hrs/24 hrs 76 4 Plastic Gasket

569 Brown 545 0.010 40/25 in lbs -65 to +300 1 hr/24 hrs 764 Hydraulic Sealant

570 Brown 592 N/A 25/40 in lbs -65 to +300 6 hrs/72 hrs 7 6 4 Steam Sealant

571 Brown 592 0.015 40/20 in lbs -65 to +300 2 to 4 hrs/24 hrs 764 Pipe Sealant

572 White 578.575 N/A 80/27 in lbs -65 to +300 24 hrs/72 hrs N on e Gasketing

592 White 0.020 500 psi -65 to +400 4 hrs/72 hrs 736 Pipe Sealant with Teflon

593 Black 0.250 400 psi -95 to +400 30 min/24 hrs N/A RTV Silicone

601 Green 609 0.005 3000 psi -65 to +300 10 min/24 hrs 764 Current PIN #609

609 Green 0.005 3000 psi -65 to +300 10 min/24 hrs 76 4 General Purpose Retaining Compound

620 Green 640 0.015 3000 psi -65 to +450 30 min/24 hrs 747

635 Green 680 0.010 4000 psi -65 to +300 1 hr/24 hrs 74 7 High Strength Retaining Compound

638 Green 680 0.015 4100 psi -65 to +300 10 min/24 hrs 7 47 High Strength Retaining Compound

640 Green 620 0.007 3000 psi -65 to +400 1 hr/24 hrs 747 High Temperature Retaining Compound

660 Silver 0.020 3000 psi -65 to +300 20 min/24 hrs 764 Quick Metal

675 Green 609 0.005 3000 psi -65 to +300 20 min/24 hrs 7 47 General Purpose Retaining Compound

680 Green 635 0.015 4000 psi -65 to +300 10 min/24 hrs 7 47 High Strength Retaining Compound

706 Clear 7 55 N/A N/A N/A N/A N/A Cleaning Solvent

70 7 Ambe r N/A N/A N/A N/A N/A Activator for Structural Adhesives

73 6 Amb er N/A N/A N/A N/A N/A Primer NF

73 8 Ambe r N/A N/A N/A N/A N/A Depend Activator

747 Yellow N/A N/A N/A N/A N/A N/A Primer T

751 Clear N/A N/A N/A N/A N/A Activator for Structural Adhesives

755 Clear N/A N/A N/A N/A N/A Cleaning Solvent

764 Green N/A N/A N/A N/A N/A Primer N

767 Silver N/A N/A -65 to +1600 N/A N/A Anti-Seize Lubricant

Page 35

SECTION 1

ENGINE

INDEX

PARAGRAPH SUBJECT PAGE

1.1 GENERAL FEATURES ......................................................................................... 1-1

1.2 DESCRIPTION OF MAIN GROUPS ..................................................................... 1-3

Cylinder head.................................................................................................... 1-8

Valves and valve seats..................................................................................... 1-9

Valve guides ..................................................................................................... 1-10

Engine flywheel ................................................................................................ 1-11

1.3 LUBRICATION ...................................................................................................... 1-13

1.4 OPERATION DESCRIPTION FUEL SYSTEM ...................................................... 1-15

1.5 TROUBLESHOOTING GUIDE .............................................................................. 1-25

1.6 ENGINE OVERHAUL ON BENCH......................................................................... 1-39

Disassembly of engine ..................................................................................... 1-39

Removal of injection pump................................................................................ 1-42

Removal of rocker arm group............................................................................ 1-44

Repair interventions on cylinder group .............................................................. 1-47

Timing .............................................................................................................. 1-49

Bushes ............................................................................................................. 1-50

Tappets............................................................................................................. 1-51

Crankshaft........................................................................................................ 1-52

Conrods ............................................................................................................ 1-60

Setting the timing ............................................................................................. 1-65

Engine flywheel ................................................................................................ 1-67

Replacing the injectors ..................................................................................... 1-81

Adjusting the valve clearance ........................................................................... 1-82

1.7 TOOLING.............................................................................................................. 1-85

Page 36

Page 37

ENGINE

1.1 GENERAL FEATURES

Type F4GE0684F

Cycle Diesel 4-stroke Intake Turbocharged w/aftercooler Injection Direct

Number of cylinders 6 in-line

Bore mm 104

Stroke mm 13 2

1 - 1W130/W130TC

+++..=

Total displacement cm

∂

Compression ratio 17 : 1

Maximum power kW 111

Maximum torque (kgm) Nm 690

Engine low idle @ rpm 1020 to 1080

Engine high idle @ rpm 2060 to 2180

Maximum speed hydraulic stall

(HP) 148

@ rpm 2000

@ rpm 1200

@ rpm 1925 to 2085

6700

Maximum speed transmission stall

Maximum speed total stall (hydr. + transmission)

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

@ rpm 1925 to 2085

@ rpm 1340 to 1650

Page 38

1 - 2 W130/W130TC

ENGINE

Type F4GE0684F

TURBOCHARGING w/ AFTERCOOLER CHARGING PRESSURE 1.10 ± 0.1 bar Turbocharger type: HOLSET HX35W LUBRICATION Forced by gear pump,

pressure relief valve,

Oil pressure oil filter

bar

with hot engine: at low idle bar 1.2 at high idle ba r 3.8 COOLING Liquid Water pump drive: Belt Thermostat starts opening at: °C (°F) 81 ± 2 (178 ± 3.6)

INJECTION type Bosch

VE4/ 12F 1100

Injector nozzles type DSLA 145 P603

Firing ord e r 1 - 3 - 4 - 2

bar

Injection pressure bar 24 5

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 39

Upper view

ENGINE

1.2 DESCRIPTION OF MAIN GROUPS

D E F G

1 - 3W130/W130TC

Upper view

A. Alternator - B. Injectors - C. Turbocharger - D. Blow-by - E. Injection pump - F. Intake manifold - G. Fuel filter.

WARNING

Due to application requirements, some auxiliary groups can be located in different positions with respect to what illustrated in this section of the manual.

C AB

W110R0096

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 40

1 - 4 W130/W130TC

ENGINE

Front view

A. Blow-by - B. Fuel filter - C. Fuel pump - D. Idle pulley - E. Oil filter - F. Poly-V belt - G. Water pump - H. Alternator - I. Thermostat.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W110R0097

Page 41

Right side view

ENGINE

1 - 5W130/W130TC

W110R0098

Right side view

A. Blow-by - B. Turbocharger - C. Thermostat - D. Alternator - E. Water pump - F. Poly-V belt - G. Oil filter connection - H. Starter motor - I. Oil discharge pipe from turbocharger - L. Exhaust manifold.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 42

1 - 6 W130/W130TC

ENGINE

Left side view

A B

W110R0099

Left side view

A. Blow-by - B. Injector fuel piping - C. Injection pump - D. Oil filter - E. Fuel pump - F. Fuel filter - G. Fuel heater - H. Poly-V belt - I. Air heater (optional) - L. Intake manifold.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 43

Rear view

ENGINE

1 - 7W130/W130TC

O A B C D

Rear view

A. Blow-by - B. Injector fuel piping - C. WASTGATE valve - D. Turbocharger - E. Oil discharge pipe from turbocharger - F. Alternator - G. Exhaust manifold - H. Starter motor - I. Engine flywheel - L. Oil filter - M. Injection pump - N. Air heater

(Optional) - O. Intake manifold.

W110R0100

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 44

1 - 8 W130/W130TC

ENGINE

Cylinder head

On the cast iron made cylinder head, the seats of the following components are made:

• added valve seats 4;

• injector 6;

• thermostat 5.

Also on the heads are fitted

• single block exhaust manifold 1;

• intake valve 2 with seat for cold starting air heater

(OPTIONAL)

Detail of cylinder heads with added valve seats

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W110R0101

Page 45

Valves and valve seats

ENGINE

1 - 9W130/W130TC

A. Intake side - S. Exhaust side - 1. Intake valve - 2. Exhaust valve.

The valve seats added on the cylinder heads have an angle of:

- 45° for exhaust valves

Exhaust valves 2 differ from the intake valves for the presence of a single groove at the tip of the stem.

- 60° for intake valves

W110R0102

The figure indicates the oil seals installed on the valve stems.

W110R0103

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 46

1 - 10 W130/W130TC

ENGINE

Valve guides

The valve guides are not machined.

8.019 mm

8.039 mm

INTAKE EXHAUST

W110R0104

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 47

ENGINE

1 - 11W130/W130TC

Engine flywheel

Flywheel 1 does not require a set mounting on the crankshaft, since it has no etching, mark or reference holes for sensors or timing.

The same mounting distance of securing holes 2 allows a random installation.

W110R0105

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 48

1 - 12 W130/W130TC

ENGINE

NOTES:

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 49

ENGINE

1.3 LUBRICATION

1 - 13W130/W130TC

The forced circulation lubrication is provided by the following components:

• rotor oil pump, located in the lower side of the cyl-

inder block, driven by a straight teeth gear mounted on the nose of the crankshaft;

• water/oil heat exchanger located on the cylinder

block, with connection for oil filter;

• oil pressure relief valve incorporated in the oil filter connection;

• by-pass valve cutting off a clogged filter, incorporated with the oil filter connection;

• cartridge oil filter.

Oil natural return ducts

Oil pressure ducts

Oil filling

W110R0106

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 50

1 - 14 W130/W130TC

ENGINE

NOTES:

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 51

ENGINE

1.4 OPERATION DESCRIPTION FUEL SYSTEM

Supply phase Delivery phase

1 - 15W130/W130TC

1. Fuel inlet duct - 2. Solenoid valve - 3. Axial groove -

4. Compression chamber - 5. Duct between pumping ele-

ment and injectors - 6. Distribution piston - 7. Delivery cutoff hole - 8. Sliding element - 9. Injector.

W110R0107

534

1. Fuel inlet duct - 2. Compression chamber - 3. Distribu-

tion piston inner duct - 4. Fuel duct between pumping element and injectors - 5. Distribution piston - 6. Injector.

W110R0108

Distribution piston (6) is at B.D.C. and sliding element (8) closes delivery cut-off hole (7). The fuel is forwarded to compression chamber (4) through supply duct (1) kept open by solenoid valve (2).

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 52

1 - 16 W130/W130TC

ENGINE

Distributor piston (5) under the defect of the rotation of the cam disc, moves toward the T.D.C. and at the same time, rotates on its own axis. The combination of the two movements determines the shutting-off of fuel inlet duct (q) and at the same time, the compression oof fuel in chamber (2). Inner duct (5) of the distributor piston is connected to duct (4) providing the delivery to injectors (6).

End of delivery phase

654 3

1. Fuel inlet duct - 2. Compression chamber - 3. Delivery

duct - 4. End of delivery phase - 5. Sliding element - 6. Distributor piston.

W110R0109

Distributor piston (6) when moving toward the T.D.C. connects the high pressure inner chamber through duct (1) providing a pressure equilibrium between the inner chamber of the distributor piston, the delivery piping to the injectors and the inside of the pump body. Since this pressure is lower the value activating the injector, the delivery ends.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 53

ENGINE

1 - 17W130/W130TC

Engine cut-off

4 3

1. Fuel inlet duct - 2. Mobile plug - 3. Spring - 4. Solenoid

valve - 5. Compression chamber.

L.D.A. device (delivery adjustment as a function of the load)

1 2

3 4

5 6

7 8

W110R0111W110R0110

Operation of the L.D.A. device

The engine cut-off is provided by the cutting-off of the starter contact. The electric power actuating solenoid valve (4) is cut-off. The solenoid valve, under the effect of spring (3) pushes mobile plug (2) to stroke end determining the closing of fuel inlet duct (1).

The L.D.A. device has the purpose of changing the fuel delivery as a ratio of the air pressure monitored in the intake manifold. This air pressure actuates membrane (1) fitted on governor pin (4). In the lower side of governor pin (4) a taper seat (5) is made on which sensor pin (6) slides. The axial movement of governor pin (4) moves sen- sor pin (6) that in turn actuates cut-off lever (7). The cut-off lever turns on its axis (8) and actuates the control plates so that the fuel deliveries are adjusted to the quantity of air introduced into the cylinders.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 54

1 - 18 W130/W130TC

ENGINE

Starting

2 1

1. Starting lever - 2. Leaf spring - 4. Sliding element - 5.

Governor sleeve - 6. Solenoid valve - 7. Compression chamber.

W110R0112

Starting device disengaged

W110R0113

1. Starter lever -2. Leaf spring - 3. Tension lever - 4. Sliding element - 5. Governor sleeve - 6. Solenoid valve -

7. Masses.

After energising solenoid valve (6) fuel enters compression chamber (7). Under these conditions, governor sleeve (5) has the masses closed, thus leaf spring (2) moves lever (1) and sliding element (4) into supplement position. Thus the entire stroke of the pumping element is used as delivery for the injection.

Once the engine is started, governor sleeve (5) under the effect of the centrifugal force caused by the expansion of masses (7) starts moving axially, pushing starter lever (1) against tension lever (3) thus presses leaf spring (2). Under these conditions, sliding element (6) moves determining minimum delivery.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 55

Beginning of delivery depending upon the load

(L.F.B.)

ENGINE

1 - 19W130/W130TC

5 6

W110R0114

Structure of the governor group with correction of the beginning of delivery depending upon the load

1. Governor spring - 2. Governor sleeve - 3. Tension lever

- 4. Starter lever - 5. Sliding element - 6. Distributor piston

- 7. Regulator shaft - 8. Centrifugal masses.

Description

The correction of the beginning of the delivery as a function of the load (LFB) provides a "smoother" (less noisy) operation of the engine. The arrangement of the LFB device is obtained modifying:

• The governor sleeve has a hole supplementary to the "anti lunging" hole.

• The governor support shaft with one longitudinal hole and two cross-way holes.

• The body pump with one hole, closed from the outside by a ball communicating with the supply chamber.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 56

1 - 20 W130/W130TC

ENGINE

Position of the governor sleeve in the LFB

12 3 4

W110R0115

a. Sleeve in rest condition - b. Moving sleeve - c. Sleeve under correction condition, drop of internal pressure - 1. Longitudinal hole in the governor support shaft - 2. Governor shaft - 3. Governor sleeve cross-way hole - 4. Governor sleeve - 5. Governor shaft cross-way hole - 6. Edge of governor shaft - 7. Governor shaft cross-way hole.

Operation

Notwithstanding the position of the outer throttle lever, when, under the increase of the rpm the governor masses due to the centrifugal force, move governor sleeve (4) a reduction in the delivery of fuel is determined. To provide a smoother operation of the engine diminishing delivery a reduction of the advance must correspond. Since in a rotary pump the advance device is hydraulically controlled, to reduce it a transfer pressure decrement is required: this is provided by the LFB device. When governor sleeve (4) sliding on governor support shaft (2) connects hole (3) with groove (6) and hole (7) a portion of the fuel under pressure is discharged through duct (1 and 5) in the supply chamber, causing a drop of the transfer pressure inside the pump, thus decreasing the advance.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 57

ENGINE

Cold injection automatic advance device (KKSB)

W110R0116

1. KKSB bulb.

The KKSB device has the function of setting an appropriate injection advance on a cold engine.

1 - 21W130/W130TC

Starting with KKSB

Advance degrees

0 500 1000 1500

Starting without KKSB

RPM

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 58

1 - 22 W130/W130TC

ENGINE

Timing

The timing drive is provided by a straight teeth gear mounted on the rear tip of the crankshaft driving the gear mounted on the camshaft.

The timing is provided by coinciding marks (⇐) etched on them.

W110R0117

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 59

Timing of the injection pump

To set the timing of the crankshaft with the camshaft, move the first piston to T.D.C. This condition is obtained by turning the crankshaft until the pin on the gear housing near the injection pump enters the relevant seat of the camshaft gear.

When a spare injection pump is supplied as spare part, it is already pre-set, thus it is sufficient to install it on the timing gear, mount it on the gear housing and remove appropriately the seal ensuring the pre-setting of the pump by locking its shaft.

To check the correct timing, place a dial gauge 380000228 (2) and adapter 99395100 (1) on the pump, as indicated in the figure.

ENGINE

1 - 23W130/W130TC

W110R0118

Turn appropriately the crankshaft to eliminate the gear backlash and return the engine under the conditions of first piston at T.D.C. The dial gauge reads the desired pre-load value (see Repair Manual). If the prescribed value is not obtained, loosen the screws securing the pump to the gear housing and slide the pump body on the slots until the correct pre-load value is obtained.

When the injection pump is overhauled. it is not preset, thus it is necessary to install it when the first piston is at T.D.C. and proceed with the setting of the pre-load value, installing the dial gauge and adapter sliding it on the slots and secure it to the gear housing. Proceed with the check as described here above.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 60

1 - 24 W130/W130TC

ENGINE

Electrical components

• Pre-post heater kit

• KKSB water temperature sensor on injection pump

• Oil pressure sensors piloting the oil pressure indicator light on instrument dashboard

• Thermal bulb for KKSB on injection pump

(*) Controller, engine coolant temperature sensor,

heater.

Principle diagram

Pre-post heater controller

Controller 1 establishes the time of intervention of the heater (pre-post heating) as a function of the signal received from engine coolant temperature sensor 2.

W110R0119

1. Pre-post heating controller - 2. Coolant temperature sensor - 3. Heater solenoid switch - 4. Heater - 5. Preheating

dashboard indicator light.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 61

REMEDIES

Check, recharge the batteries and replace them if

ENGINE

1.5 TROUBLESHOOTING GUIDE

required.

Clean, inspect, tighten fixtures and replace exces-

sively corroded terminals and nuts, if required.

Have a correct timing of the injection pump on the

engine.

Disconnect pipes, injection pump and clean them

accurately and if required, clean and dry the fuel

tank.

Refill.

Check fuel pump and replace it, if required.

1 - 25W130/W130TC

Check pipes, connections, fuel pump, filters and

injection pump to make sure they are free from air

then bleed the system.

Repair or replace the starter motor.

Check or replace cold starter.

POSSIBLE CAUSES

or loosen.

1. Partially discharged batteries.

TROUBLES

The engine fails to start

2. Connections to the battery terminals corroded

pipes.

3. Wrong timing of injection pump on engine.

4. Accumulation of sediments and water in the fuel

5. Tank out of fuel.

6. No supply to injection pump.

7. Presence of air in the fuel system.

8. Starter motor damaged.

9. Cold starting device inefficient.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 62

1 - 26 W130/W130TC

ENGINE

REMEDIES

Adjust low idle.

Re-calibrate on bench.

Disconnect pipes, injection pump and clean them

accurately and if required, clean and dry the fuel

tank.

Replace the filter cartridges.

Adjust valve clearance.

Replace valves.

Check pipes, connections, fuel pump, filters and

injection pump to make sure they are free from air

then bleed the system.

Replace damaged parts.

POSSIBLE CAUSES

1. Low idle too low.

2. Irregular deliveries of injection pump.

3. Accumulation of sediments and water in fuel

TROUBLES

The engine dies

pipes.

4. Fuel filters clogged.

5. Abnormal valve clearance.

6. Valves burnt or cracked.

7. Presence of air in the fuel system.

8. Injection pump controls damaged.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 63

REMEDIES

Overhaul the injection pump and replace it, if re-

quired.

Replace the thermostat.

Eliminate any scaling by flushing. Check and re-

pair any leakage from the tubes.

Flush accurately.

Check and adjust the belt.

ENGINE

Top-up level in the expansion tank using prescribed

liquid.

Check and re-set timing.

Calibrate injection pump on bench complying with

the calibration tables.

Clean the group and, if required, replace filtering

the element.

1 - 27W130/W130TC

POSSIBLE CAUSES

1. Cooling centrifugal pump inefficient.

2. Thermostat inefficient.

TROUBLES

The engine overheats

cylinder block.

3. Radiator partially inefficient.

4. Scaling in the coolant ducts in cylinder head and

fan belt.

5. Insufficient tension of centrifugal pump drive and

6. Coolant insufficient (quantity).

and defect.

7. Wrong timing.

8. Injection pump out of calibration both in excess

9. Air cleaner clogged.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 64

1 - 28 W130/W130TC

ENGINE

REMEDIES

Have the injection pump correctly timed on the en-

gine.

Overhaul the injection pump and calibrate it on test

bench complying with the relevant calibration table.

Overhaul the injection pump and calibrate it on test

bench complying with the relevant calibration table.

Overhaul the injection pump and calibrate it on test

bench complying with the relevant calibration table.

Overhaul the injection pump and calibrate it on test

bench complying with the relevant calibration table.

Clean, overhaul and calibrate correctly the injectors.

Check pipes, connections, fuel pump, filters and in-

jection pump to make sure they are free from air

then bleed the system.

Replace fuel pump.

Adjust valve clearance.

Check compression and overhaul the engine, if re-

quired.

Clean the group and replace filtering element, if

rquired.

Adjust the length of the linkage.

Adjust high idle screw.

POSSIBLE CAUSES

damaged.

1. Wrong timing of injection pump on engine.

2. Advance automatic variator on injection pump

TROUBLES

The engine is under powered and

operates irregularly

pipes.

3. Distributor pumping element worn.

4. Injection pump deliveries irregular.

5. Governor damaged at all speeds.

6. Injectors partially clogged or damaged.

7. Accumulation of sediments or water in fuel

8. Fuel pump damaged.

9. Valve clearance abnormal.

tion pump to be adjusted.

10. Compression in cylinders insufficient.

11. Air cleaner clogged.

12. Length of linkage between throttle and injec-

justment.

13. Injection pump with high idle screw out of ad-

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 65

REMEDIES

Clean, overhaul and correctly calibrate the injec-

ENGINE

tors.

Clean the pipes and replace those with consider-

able dents. Clean injection pump, if required.

Have the injection pump on the engine correctly

timed.

Regrind the crankshaft journals, install oversized

bearings and thrust bearings.

Check the alignment and balance of the crankshaft

and replace it, if required.

Replace loosen screws and tighten all of them to

the prescribed torque + angle.

Straighten the con-rods, check the parallelism of

the centre lines and replace them, if required.

Regrind the cylinder sleeves and install oversized

pistons.

Replace the piston pin with an oversized one, re-

bore the seats on the piston and the conrod bushes.

Replace the bushes with new ones.

Check that there are no broken springs, there is no

excessive play between stems and guides, tap-

pets and seats. Adjust valve clearance.

1 - 29W130/W130TC

POSSIBLE CAUSES

1. Injectors partially clogged or damaged.

2. Accumulation of sediments in fuel pipes.

TROUBLES

The engine has abnormal knockings

play of one or more crankshaft or conrod jour-

nal bearings or thrust bearings.

3. Wrong timing of injection pump on engine.

4. Engine crankshaft knocking due to excessive

5. Crankshaft out of balance.

6. Flywheel securing screws loosen.

7. Conrod axes out of line.

tween piston seat and conrod bushing. Bush-

ing floating in conrod seat.

8. Pistons knocking due to abnormal wear.

9. Piston pins noisy due to excessive play be-

10. Rattling due to noisy timing.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 66

1 - 30 W130/W130TC

ENGINE

REMEDIES

Calibrate the injection pump on bench complying

with the calibration table.

Have the injection pump correctly timed on the

engine and check the automatic advance variator.

Have the injection pump correctly timed on the

engine.

Clean, overhaul and correctly calibrate the injec-

tors. replace them, if required.

Clean the group and replace the filtering element, if

required.

Replace damaged parts and overhaul the engine,

if required.

Check the conditions of the pipes.

POSSIBLE CAUSES

the automatic advance variator is damaged.

1. Maximum delivery of injection pump excessive.

2. The injection pump is excessively delayed or

TROUBLES

The engine smokes abnormally:

black or dark grey smoke

calibration.

3. The injection pump is excessively advanced.

4. Injectors partially and7or fully clogged or out of

5. Air cleaner clogged.

- Sticky piston rings;

- Worn cylinder sleeves;

- Valves deteriorated or out of adjustment.

6. Loss of compression on engine due to:

7. Injection pumps damaged.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 67

REMEDIES

Have the injection pump correctly timed on the

ENGINE

engine and check the automatic advance variator.

Clean, overhaul and correctly calibrate the injec-

tors. replace them, if required.

Replace damaged parts and overhaul the engine,

if required.

Overhaul cylinder head.

Replace the thermostat.

Replace the solenoid valve.

Overhaul injection pump and calibrate it on test

1 - 31W130/W130TC

bench complying with the relevant calibration ta-

ble.

POSSIBLE CAUSES

the automatic advance variator is damaged.

1. The injection pump is excessively delayed or

2. Injectors seized or defective.

TROUBLES

Blue, grey-blue or grey tending to white

smoke

sticky rings or wear of cylinder sleeves.

3. Passage of oil through piston rings caused by

due to wear of guides or valve stems.

4. Passage of oil through the intake valve guides

ture (thermostat damaged)

5. The engine does not reach operation tempera-

1. Cut-off solenoid valve damaged.

2. Governor at all speeds damaged.

Engine does not cut-off

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 68

1 - 32 W130/W130TC

ENGINE

NOTES:

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 69

DATA - MOUNTING PLAYS

ENGINE

Type F4GE0484E

1 - 33W130/W130TC

CYLINDERS AND CRANKING COMPONENTS GROUP

Ø 1

Cylinder sleeves Ø 1 102.01 to 102.03

Pistons: supplied as spares

Ø 1

parts type Position of measurement X 61

Outer diameter Ø 1 101.777 to 101.795

Ø 2

Pin seat Ø 2 40.006 to 40.012

Piston - cylinder sleeve 0.215 to 0.253

Diameter of pistons Ø 1 0.5

Position of pistons in cylinder block X 0.28 to 0.52

Ø 3

S1 S2 S3

Piston pin Ø 3 39.9968 to 40.0032

Piston pin - pin seat 0.0028 to 0.0152

Type of piston

Piston rings seat X2* 2.425 to 2.445

X1* 2.69

X3* 4.04 to 4.06

* measured on the 99 mm diameter

S1* 2.560 to 2.605

Piston rings S2* 2.310 to 2.340

S3* 3.075 to 4.000

* measured on the 99 mm diameter

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 70

1 - 34 W130/W130TC

ENGINE

Type F4GE0484E

CYLINDERS AND CRANKING COMPONENTS GROUP

Piston rings - seats 2 0.085 to 0.135

Piston rings 0.5

X1 X2 X3

Ø 1

Gap and end of piston rings in the cylinder sleeves:

Conrod small end bush seat Ø 1 42.987 to 43.013

Ø 2

Ø 4

Conrod large end bearing seat Ø 2 77.075 to 78.25

1 0.245 to 0.265

3 0.040 to 0.985

X1 0.40 to 0.70 X2 0.25 to 0.55 X3 0.25 to 0.55

Ø 3

Diameter of conrod small end bush Outer Ø 4 43.279 to 43.553 Inne r Ø 3 40.019 to 40.033

Conrod half bearings 1.955 to 1.968

Conrod small end bush - seat 0.266 to 0.566

Piston pin - bush 0.0158 to 0.0362

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 71

ENGINE

Type F4GE0484E

1 - 35W130/W130TC

CYLINDERS AND CRANKING COMPONENTS GROUP

Position of measurement X -

Maximum error on parallelism of conrod axes = -

Ø 2Ø 1

Main journals Ø 1 82.99 to 83.01 Conrod journals Ø 2 68.987 to 69.013 Main journal half bearings S1* 2.456 to 2.464

S1 S2

Conrod half bearings S2* 1.955 to 1.968

* supplied as spare part

Main journal no.:

Ø 3

no. 1 - 5 Ø 3 87.982 to 88.008 no. 2-3-4 Ø 3 87.977 to 88.013

Half bearings - main journals: no. 1-5 0.041 to 0.119 no. 2-3-4 0.041 to 0.103

Half bearings - conrod journals 0.033 to 0.041

Main journal half bearings

+ 0.250; + 0.500

Conrod journals bearings

Thrust main journal X1 34.475 to 37.545

Main journal for thrust bearing X2 25.98 to 26.48

Thrust half rings X3 37.28 to 37.38

Crankshaft thrust 0.068 to 0.41

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 72

1 - 36 W130/W130TC

ENGINE

Type F4GE0484E

CYLINDER HEAD - TIMING

Ø 1

Valve guide seat on cylinder head Ø 1 8.019 to 8.039

Ø 4

Valves:

Ø 4 7.96 to 7.98

α 60°

Ø 4 7.96 to 7.98

α 45°

Valve stem and relevant guide 0.052 to 0.092

Seat on cylinder head for valve seat:

Ø 1 46.987 to 47.013

Ø 1

Ø 1 43.637 to 43.663

Ø 2

Valve seat outer diameter; angle of valve seats on cylinder head: Ø 2 47.063 to 47.089

α 60°

Ø 2 43.713 to 43.739

α 45°

Recess X 0.356 to 1.102

X 0.104 to 0.84

Between valve seat 0.050 to 0.102 and head 0.050 to 0.102

Valve seats - -

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 73

ENGINE

Type F4GE0484E

1 - 37W130/W130TC

CYLINDER HEAD - TIMING

Height of valve spring: free length H 63.5

under a load of:

329 H1 49.02 641 H2 38.2

Protrusion of injectors X not adjustable

Camshaft bushes

ØØØ

1 2 3 4 5

no. 1-5

Camshaft seats no. 2-3-4

Camshaft support journals:

Ø 3Ø 1

1 ⇒ 5 Ø 53.995 to 54.045

Camshaft bushes outer diameter Ø -

Bushes inner diameter Ø -

Bushes and seats in cylinder block -

Bushes and journal 0.038 to 0.162

Cam lifting:

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 74

1 - 38 W130/W130TC

ENGINE

Type F4GE0484E

Ø 1

Ø 2

CYLINDER HEAD - TIMING

Seat of tappet plate in cylinder block Ø 1 -

Outer diameter tappet plate:

Between tappets and seats 0.025 to 0.070

Tappets -

Rocker arm shaft Ø 1 18.963 to 18.975

Rocker arms Ø 2 19.000 to 19.026

Ø 2 15.929 to 15.959 Ø 3 15.965 to 15.930

Between rocker arm and shaft 0.025 to 0.063

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 75

ENGINE

1.6 ENGINE OVERHAUL ON BENCH

1 - 39W130/W130TC

Disassembly of engine

W110R0120

Drain the engine oil by removing the sump plug and the engine oil filler neck from the cylinder head cover. Remove the fan group from the fan pulley. In order to install the stand mounting bracket 75301886 to the engine cylinder block, it is necessary to operate on the left side of the engine as follows:

- remove electric harness (1).

4 5

13 12

11 10

W110R0122

- remove engine oil fume recovery pipe from blowby (1);

- remove rocker arm cover (4);

- remove electric harness (8);

- remove fuel filter (9);

- remove intake manifold (3);

- remove heater (5);

- remove LDA system (13);

- remove quick release coupling pipes (7), (10), (11) and (13);

- remove fuel filter support (6).

W110R0121

To install bracket 75301886 on the right side, remove:

- starter motor (3);

- securing bracket (2) of oil return pipe (1);

- the oil return piping (1) relative to the turbine;

- remove oil pipes (4) and (5) from heater exchanger (6).

Install the engine on rotary stand 75296375.

- disconnect turbine lube oil delivery (7);

W110R0123

Move fork (1) as indicated in the figure (item A) and remove the connection. To prevent deformations when the connection is removed, return fork (1) into the locking position (item B).

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 76

1 - 40 W130/W130TC

ENGINE

3 6

W110R0124 W110R0127

- Disconnect supply pipes (5) of injectors (5) from injection pump (6). Remove pipe groups securing brackets on the cylinder head (1) (2) and (3).

- Remove fuel pump (4).

- Remove belt tensioner (4).

- Remove auxiliary organs belt (6) moving bracket (1) securing the alternator.

- Remove alternator (2) water pump (5) fan pulley (8) and guide pulleys (7).

- Remove pulley support (9).

- Remove engine cooling system connection (3) from the cylinder block.

W110R0125

- Remove injector supply pump group (1) from the injectors.

- Remove fuel return pipe (2) from the injectors removing screws (4) and gasket (3).

1 2

W110R0128

Install tool (1) 380000144 on the flywheel housing to block the flywheel.

- Remove screws (3) and remove turbine (2).

- Remove exhaust manifold (2).

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W110R0126

Page 77

ENGINE

1 - 41W130/W130TC

W110R0129

Remove securing screws (1) from pulley (2).

Replacing the seal

3 4

W110R0130

Install tool (4) 380000665 on nose (2) of the crankshaft. Drill inner seal ring (1) with a drill (3.5 mm diam.) through the holes of tool 380000665 (4) for a depth of 5 mm. Install tool 380000665 (4) on ring (1) tightening the 6 screws (5) provided. Pullout ring (1) tightening screw (3).

1 2

W110R0131

Install the appropriate puller (3) of tool 380000669 to outer seal (2) as described in the figure and pull it out from front cover (1) using lever (4). Remove the front cover.

W110R0132

Remove oil gear pump (1). Important –

Oil pump (1) cannot be overhauled.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 78

1 - 42 W130/W130TC

ENGINE

Removal of injection pump

1 2

W110R0133

Prior to removing the injection pump and the flywheel locking tool. Turn the crankshaft until the 1st cylinder is at T.D.C. The condition of cylinder no. 1 in T.D.C. is obtained when pushing pin (1) indicated by the arrow enters its seat located on camshaft drive gear (2).

W110R0135

- Remove cover (1) from gear housing (2).

- Lock the engine flywheel.

- Remove nut (3) securing the injection pump drive gear (4).

W110R0134

To pre-set correctly the injection pump, loosen screw (2) and remove (1) "L" spacer. Retighten screw (2) to contact.

Important –

Keep the "L" spacer appropriately with

the pump body.

W110R0136

Remove the three nuts (2) (4) (5) securing injection pump (1) to flywheel housing (3) and pull-it out from its seat using tool 75295944.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 79

ENGINE

1 - 43W130/W130TC

2 3

W110R0137

W110R0139

Install tool 380000144 (2) to loosen screws (3). Remove tool 380000144 (2). Remove screws (3) securing engine flywheel (4) to the crankshaft.

W110R0138

Install two pins (2) of appropriate length into the holes of crankshaft (3). Extract engine flywheel (1) so that it is possible to sling it with a hoist and place it in an appropriate container.

Install tool 380000663 (3) on rear nose ( 5) of the crankshaft. Drill inner seal ring (1) with a drill (3.5 mm diam.) through the holes of tool 380000663 (4) for a depth of 5 mm. Install tool 380000663 (3) on ring (1) tightening the 6 screws (4) provided. Pullout ring (1) tightening screw (2).

1 2

W110R0140

Install the appropriate puller (3) of tool 380000669 to outer seal (2) as described in the figure and pull it out from front cover (1) using lever (4).

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 80

1 - 44 W130/W130TC

ENGINE

W110R0141

Remove screws (2) and remove rear cover (1).

Important –

Record the mounting position of screws

(2) since the are dimensionally different.

W110R0145

Remove screws (1) and gear (3) from camshaft (2).

Removal of rocker arm group

W110R0142

Turn the engine upside down, remove screws (2) plate (3) and remove oil sump (1).

W110R0143

W110R0146

For each cylinder, remove rocker arm group (1) loosening setting nuts (3), loosen adjusters (2) and remove screws (4).

Remove screws (1) and (4) and remove oil suction strainer (5). Remove screws (2) and stiffening plate (3).

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 81

ENGINE

1 - 45W130/W130TC

W110R0147 W110R0150

Pullout injectors (2) using tool (1) 3800001099.

W110R0148

Remove screws (2) and remove timing gears cover (1).

Important –

Record the mounting position of secur-

ing screws (2) since they have different dimensions.

Remove screws (1) securing the cylinder head to the cylinder block.

W110R0149

Hook the cables to brackets (1) and (2) and lift to separate the cylinder head from the cylinder block.

W110R0151

Remove screws (1) securing conrod (2) caps and remove the caps. Pullout the pistons complete with conrods from the top of the cylinder block.

Important –

Keep the half bearings in the relevant seats, since, in case of their re-use, they must be reinstalled in the position found at the disassembly.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 82

1 - 46 W130/W130TC

ENGINE

W110R0152

Remove screws (1) and remove main journal caps (2).

W110R0155

Remove main journal half bearings (1). Remove screws (2) and remove oil nozzles (3).

W110R0153

The last but one main journal (1) and relevant support have a half bearing (2) equipped with thrust washer

Important –

Record the installation position of the lower and upper half bearings, since in case of their reinstallation, they must be located in the same position found at the disassembly.

W110R0154

W110R0156

Remove screws (1) and plate (2) securing camshaft (3).

Important –

Record the installation position of plate

(2).

W110R0157

Extract carefully the camshaft from the cylinder block.

Use tool 75301429 (1) to lift crankshaft (2) from the cylinder block.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 83

ENGINE

1 - 47W130/W130TC

W110R0158 W110R0160

Extract (1) from the cylinder block.

Repair interventions on cylinder group

Inspections and measurements

Once the disassembly of the engine is over, clean accurately the cylinder-cylinder block group. To handle the cylinder group use appropriate eyes. Check accurately that the cylinder block is free from cracks. Check the conditions of the machining plugs. Should they be found rusty or their sealing is in doubts, replace them. Inspect the surface of the cylinder sleeves. They must be free from signs of seizing, scratches, out-of-round, tapering or excessive wear.

1 2

The measurements must be done on each single cylinder, at three different heights of the sleeve and on two planes perpendicular between them: one parallel to the longitudinal axis of the engine (A) the other one perpendicular (B). The maximum wear is normally found on the latter plane and in correspondence with the first measurement In the event an out-of round, tapering or any wear is found, re-bore and re-grind the cylinder sleeves. The reboring of the cylinder sleeves must be done in relation with the diameter of spare pistons oversized

0.5 mm with respect to the nominal size and the prescribed installation clearance.

The measurement of the inner diameter of the cylinder sleeves, the amount of any out-of-round, tapering or wear is done with bore gauge 99395687 (1) equipped with a dial gauge previously zeroed on caliper ring (2) with the correct diameter of the cylinder sleeve.

Note –

Should the ring caliper be unavailable, use a

micrometer to zero the dial gauge.

W110R0159

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 84

1 - 48 W130/W130TC

ENGINE

Checking the mating face of the cylinder head on the cylinder block

1,25 ± 0,25 mm Rz 12,0 ISO CUT OFF 2,5

3 1

W110R0162

Check that the mating face of the cylinder head on the cylinder group does not show any deformation. This check can be done, after removing dowels (4) using a calibrated ruler (2) and feeler gauge (3). After identifying any zone of deformation, grind the mating face using an appropriate grinding machine. The planarity discrepancy must not exceed 0.075 mm.

W110R0161

Important

– In case of re-boring, all the cylinder

sleeves must have the same oversizing (0.5 mm).

Check the seats of the main journal bearings, proceeding as follows:

- install the main journal caps without bearings;

- tighten the securing screws to the prescribed

torque;

- using an appropriate bore gauge, check that the

diameter of the seats has the prescribed value.

Should a higher value be measured, replace the cylinder block.

Note –

the grinding of the cylinder block can be done only when it is ascertained that, once the work is done, the protrusion of the piston from the cylinder sleeve does not exceed the prescribed value.

Check the conditions of machining plugs (1) of the cylinder group. Should they be found rusty or their sealing is in doubts, replace them. Once the grinding is over, remake the bevel of the cylinder sleeves.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 85

ENGINE

Timing

Camshaft

53.995 mm

54.045 mm

Camshaft main data

The data provided refer to the normal diameter of the journals.

1 - 49W130/W130TC

W110R0163

The surfaces of the camshaft journals must be extremely smooth. Should they show any trace of seizure or scratches, it is advantageous to replace the camshaft and relevant bushes.

Checking the cam lifting and journals alignment

Place the camshaft on centres and using a centesimal dial gauge located on the central journal, check that the alignment error does not exceed 0.04 mm, otherwise, replace the camshaft. Also, check the cam lifting. It must result 7.239 mm for the exhaust cams and 6.045 mm for the intake ones. Should different values be measured, replace the camshaft.

W110R0164

Check the diameter of camshaft journals (2) using micrometer (1) on two axes perpendicular between them.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 86

1 - 50 W130/W130TC

ENGINE

Bushes

Camshaft bushes (2) must be tight mounted into their seats. The inner surfaces must be free from traces of seizure or wear. Measure the diameter of the camshaft front and rear bushes (2) and intermediate seats (1) using bore gauge

(3). The measurements must be taken on two axes perpendicular between them.

Sect. A-A

W110R0165

54.089 mm

54.139 mm

59.222 mm

59.248 mm

54.083 mm

54.147 mm

Main data of bushes for camshaft and relevant seats

* Dimension to be obtained after press fitting the bushes.

W110R0166

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 87

ENGINE

1 - 51W130/W130TC

Replacing the bushes

W110R0167

Use punch 75301885 (2) and handle 380000668 (3) to remove and install front and rear bushes (1).

Important -

When installing bushes (1), place the so that the lubrication holes coincide with the holes on the cylinder block seats.

Tappets

Installing the tappets -Camshaft

W110R0168

Lubricate tappets (1) and install them into the relevant seats on the cylinder block.

16.000 mm

16.030 mm

15.929 mm

15.959 mm

15.965 mm

15.980 mm

15.929 mm

15.959 mm

W110R0169

Main data of tappets and relevant seats on the cylinder block

W110R0170

Lubricate the camshaft journals and install the camshaft, paying attention that, during this operation, the bushes and the journals are not damaged.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 88

1 - 52 W130/W130TC

ENGINE

Crankshaft

Measuring main and conrod journals

W110R0171

Place plate (1) securing camshaft (3) with the slot directed toward the upper side of the cylinder block

W110R0174

and the stamping toward the operator, tighten screws (2) to the prescribed torque.

Should excessive traces of seizing, scratches or out of round be found, it is necessary to re-grind the journals. Prior to grinding journals (2) measure the crankshaft journals with micrometer (1) and define to what diameter the journals must be undersized.

Check the axial play of camshaft (1).

W110R0172

Note –

It is recommended to record the values meas-

ured on a table.

Install nozzles (2) and tighten securing screws (1) to the prescribed torque.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

W110R0173

Page 89

ENGINE

1 - 53W130/W130TC

The undersizing classes are 0.250; 0.500 mm.

Important –

The main and conrod journals must always be reground to the same undersize class. The undersizing performed on the main and conrod journals, must be identified by an appropriate stamping on the side of crank no. 1.

82.99 mm

83.01 mm

For undersized conrod journals by letter M. For undersized main journals by letter B. For undersized main and conrod journals by letters

MB.

68.99 mm

69.01 mm

W110R0175

Data on which to record the values relative to the measurement of crankshaft main and conrod journals

* Nominal value.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 90

1 - 54 W130/W130TC

ENGINE

W110R0176

Main crankshaft tolerances

Tolerances Features of the subject of tolerance Symbol

Shape

Roundness O Cilindricity /O/ Parallelism //

Direction

Perpendicularity ⊥ Straightness —

Position

Concentricity or radial run-out " Circular oscillation !

Oscillation

Total oscillation !! Tapering

Class of importance given to the feature of the product Symbol

Critical Important Secondary

⊕

–

Journal

timing side

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Intermediate

journals

First journal

upper side

W110R0177

Page 91

ENGINE

1 - 55W130/W130TC

Replacing the oil pump drive gears

W110R0178

Check that the teeth of gear (1) installed on crankshaft (2) are undamaged and free from wear; otherwise pull them using puller (3). When installing a new gear, it is necessary to warm it up for 10 minutes in an oven at a temperature of 180 °C (355 °F) and install it on the crankshaft, mounting the key as well.

Measuring the main journal mounting clearance

W110R0180

Install crankshaft (1) on which gears (2) and (3) are mounted.

Installing the main journal bearings

W110R0179

Important –

When it is found that the main journal bearings must not be replaced, they are reinstalled in the same sequence and position they were before the disassembly.

Main journal bearings (1) are supplied as spare parts undersized 0.250 to 0.500 mm on the inner diameter.

Important –

Do not attempt adapting the bearings.

2 3

W110R0181

Check the clearance between main journal of the crankshaft and the relevant bearings, operating as follows:

- clean accurately the components and eliminate all races of oil;

- place a piece of calibrated rod (3) on crankshaft main journals (4) parallel to the longitudinal axis;

- install caps (1), complete with half bearings (2) on the relevant supports.

Clean accurately main journal half bearings (1) having the lube hole and install them in the relevant seats. The last but one main half-bearing (1) is equipped with thrust half rings.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 92

1 - 56 W130/W130TC

ENGINE

W110R0182

W110R0184

Tighten screws (1) pre-lubricated and tighten them in three subsequent phases.

-1st phase with torque wrench to 50 ±6 Nm.

-2nd phase with torque wrench to 80 ± 6 Nm.

W110R0183

-3rd phase with tool 75301460 (1) installed as indicated in the figure and tighten screws (2) further to an angle of 60 ± 5°.

- remove the caps from the supports. The play between main journal bearings and the rel-

evant journals is measured by comparing the width taken by calibrated wire (2) in the point of maximum squeezing, with the scale provided on wrapping (1) containing the wire. The numbers listed by the scale indicate the clearance in mm of the match. Should a clearance different from the prescribed value be measured, replace the half bearings and repeat the measurement. Once the prescribed clearance is achieved, lubricate the main journal bearings and install definitely the supports, tightening the securing screws, as previously described.

Checking the crankshaft thrust clearance

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

2 3

W110R0185

The measurement of the thrust clearance is made by placing a dial gauge (2) with a magnetic base on crankshaft (3) as indicated in the figure. Normal mounting clearance is 0.068 to 0.410 mm. Should a higher clearance be measured, replace the half bearings on the rear last but one main journal (1) equipped with thrust washer and repeat the check of the clearance between crankshaft journals and half bearings.

Page 93

Conrod - Piston assembly

ENGINE

1 - 57W130/W130TC

Parts making up the conrod piston assembly

W110R0186

1. Circlips - 2. Pin - 3. Piston - 4. Piston rings - 5. Screws - 6. Half bearings - 7. Conrod - 8. Bush.

Note –

0.5 mm oversized pistons are supplied as spare parts.

2 3

W110R0187

Disassembly of piston rings (1) from piston (2) using pliers 380000221.

The disassembly of piston pin (1) circlips (2) is done using scriber (3).

W110R0188

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 94

1 - 58 W130/W130TC

ENGINE

2.560 mm

2.605 mm

2.310 mm

2.340 mm

3.075 mm

4.000 mm

Piston main data

Pistons

2.69 mm

40.0060 mm

40.012 mm

2.425 mm

2.445 mm

39.9968 mm

40.0032 mm

4.040 mm

4.060 mm

W110R0189

Measuring the piston diameter

W110R0190

Measurement of the diameter of piston (1) using micrometer (2) to determine the mounting clearance.

Note –

The diameter must be measured at 61 mm

from the skirt of the piston.

W110R0191

The clearance between piston and cylinder sleeve can be measured also using feeler gauge (1) as indicated in the figure.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 95

ENGINE

1 - 59W130/W130TC

Piston pins

W110R0192

Measuring the diameter of piston pin (1) using micrometer (2).

Conditions for a correct pin-piston matching

W110R0195

Check the clearance between piston ring (3) of the 3rd groove and the relevant seat on piston (2) with feeler gauge (1).

W110R0193

Lubricate pin (1) and the relative seats on the piston bosses with engine oil. The pin must slide in under a light finger pressure and must not come-out under its own weight.

Piston rings

W110R0194

W110R0196

Diagram for the measurement of clearance X Trapezoidal rings

Due to the particular shape of the first trapezoidal piston ring, the clearance between seat and the ring itself is measured in the following manner: have piston (1) protruding from the cylinder block so that ring (2) involved protrudes about half from cylinder sleeve (3). Under these condition, use a feeler gauge to measure clearance (X) between ring and seat. Such clearance must be of the prescribed value.

Check the thickness of piston rings (2) using micrometer (1).

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 96

1 - 60 W130/W130TC

ENGINE

∗

W110R0197

CONROD BODY

Measuring the clearance between the tips of piston rings (2) installed into cylinder sleeve (3) using feeler gauge (1).

Conrods

42.987 mm

43.013 mm

43.279 mm

43.553 mm

77.075 mm

78.250 mm

40.019 mm

40.033 mm

1.955 mm

1.968 mm

39.9968 mm

40.0032 mm

W110R0198

Main data for conrod, piston pin bush and half bearings

* Dimension of inner diameter to be obtained after press fitting into the bush conrod big end and re-boring.

CONROD

No.

CONROD No. YEAR DAY

Important –

WEIGHT

CONROD CAP

W110R0199

Each conrod is marked: On the body and cap, by a number indicating their matching and the cylinder in which it is installed. Thus, in case of replacement, it is necessary to proceed with the numbering of the new conrod with the same number of the one replaced. On the conrod body, a letter indicates the weight class of the conrod installed in production:

- V, 1820 to 1860 (identified by a yellow mark);

- W, 1861 to 1900 (identified by green mark),

- X, 1901 to 1940 (identified by blue mark). Spare conrods are supplied under class W and marked green*. Non removal of material is allowed.

** Dimension not measurable under free state. Important –

The conrod-conrod cap matching surfaces are knurled to improve the fitting. Consequently, it is recommended not to remove the knurling.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 97

ENGINE

1 - 61W130/W130TC

Bushes

Check that bush in the big end of the conrod is not free and that is free from scratches or seizing. Otherwise, replace it. The disassembly and reassembly are done using an appropriate punch. During the press fitting make sure scrupulously that the oil passage holes on the bush and the conrod big end coincide. Use a boring machine to re-bore the bush, so that the prescribed diameter is obtained.

Checking the conrod

1 2

W110R0200

Check the parallelism of the conrod (1) axes using device 75301461 (5) operating as follows:

- install conrod (1) on the mandrel of tool 75301461 (5) and secure it with screw (4);

Check of torsion

1 2

W110R0201

Check the torsion of conrod (5) comparing two points (A and B) of pin (3) on the horizontal plane of the conrod axis. Place support (1) of dial gauge (2) so that the latter is pre-loaded ~ 0.5 mm on pin (3) in point (A) and zero dial gauge (2). Move mandrel (4) with conrod (5) and compare on the opposite side (B) of pin (3) for any discrepancy: the difference between (A and B) must not exceed 0.08 mm.

1 2

- place mandrel (3) on “V” blocks resting conrod (1) on stopping bar (2).

W110R0202

Checking the flexion

Check the flexion of conrod (5) comparing two points (C and D) of pin (3) on the vertical plane of the conrod axis. Place vertical support (1) of dial gauge (2) so that the latter rests on pin (3) point (C). Oscillate the conrod for and back searching for the highest position of the pin and under this condition, zero the dial gauge (2). Move the mandrel with conrod (5) and repeat on the opposite side (D) of pin (3) the check of the highest point. The difference between point (C) and point (D) must not exceed 0.08 mm.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 98

1 - 62 W130/W130TC

ENGINE

Installing the conrod-piston assembly Conrods-bearing matching

FRONT

W110R0203

The following references are etched on the ceiling of the piston:

1. Spare part number and number of the engineering modification;

2. Date of manufacture

3. Wording indicating the mounting sign of the piston into the cylinder sleeve. It must be directed toward the front side of the cylinder block.

FRONT

Installing the piston rings

W110R0206

To install piston rings (1) on piston (2) use pliers

380000221. The rings must be installed with the wording “TOP”

upward. Also arrange the ring gaps so that they offset 1200° among them.

Important –

Piston rings are supplied as spare parts

in the following dimensions:

- standard, identified by yellow paint;

- oversized 0.5 mm marked by yellow/green paint.

W110R0204

Connect piston (2) to conrod (4) with pin (3) so that reference marking (1) for the installation of piston (2) into the cylinder sleeve and digits (5) stamped on conrod (4) are seen as indicated in the figure.

W110R0205

W110R0207

Install half bearings (1) both on the conrod and the cap.

Important –

In the event the conrod bearing do not need replacement, they must be reinstalled in the identical order and sequence found at the disassembly. Do not attempt any adjusting operation.

Insert circlips (2) securing pin (1).

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 99

ENGINE

1 - 63W130/W130TC

Installation of conrod/piston assemblies into the cylinder sleeves

W110R0208

Lubricate well the pistons, including the piston rings and inside the cylinder sleeves. Using band 380000220 (2) install conrod-piston assemblies (1) into the cylinder sleeves, checking that:

- the number of each conrod corresponds to the matching number on the cap;

Measuring the mounting clearance of the conrod journals

3 4

W110R0210

To measure the clearance, operate as follows:

- clean accurately the parts and eliminate all traces of oil;

- place a piece of calibrated wire (2) on conrod journals (1);

- install conrod caps (3) with relevant half bearings (4).

FRONT

W110R0209

Mounting diagram of conrod-piston assembly in the tunnel

- the gaps of the piston rings are offset 120° among them;

- the conrod-piston assemblies are all of the same weight;

- the wording stamped on the top of the pistons is directed toward the front side of the cylinder block or the indent on the skirt of the piston corresponds to the position of the oil nozzles.

W110R0211

- tighten screws (1) previously lubricated with engine oil using torque wrench (2) to the prescribed torque.

W110R0212

- install tool 75301460 (1) on the socket wrench and tighten screws (2) to the angle.

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)

Page 100

1 - 64 W130/W130TC

ENGINE

Checking the piston protrusion

W110R0213

- remove the cap and determine the clearance by comparing the width of calibrated wire (1) with the values of the scale provided on wrapping (2) containing the wire.

W110R0215

Once the installation of the conrod-piston assemblies is completed, check the protrusion of pistons (3) at T.D.C. with respect to the upper face of the cylinder block, using dial gauge 380000228 (1) equipped with base 380000364 (2). It must be 0.28 to 0.52 mm.

Timing Timing gear housing

W110R0214

If the clearance is not as prescribed, replace the half bearings and repeat the check. Once the prescribed clearance is obtained, lubricate the conrod half bearings and install them permanently tightening the screws securing the conrod caps, as prescribed.

Important –

Prior to the final installation of the conrod

securing screws, check that their diameter measured the centre of the threaded length is not smaller than

0.1 mm of the diameter measured about 10 mm from

the tip of the screws.

Check manually that conrod (1) slide axially on the crankshaft and that the axial play measured with feeler gauge (2) is 0.10 to 0.33 mm.

W110R0216

Diagram for the application of sealant Loctite 5999

Clean accurately timing gear housing (1) and the engine cylinder block. The cleaning of the surface to be sealed is required and indispensable to provide an effective sealing. Apply sealant Loctite 5999 on the housing so as to form a bead a few mm diameter. It must result uniform (no lumps) free from air bubbles, thin zones or discontinuities. Any imperfection must be corrected as soon as possible. Avoid using material in excess to seal the joint. Excessive sealant could escape on both sides of the joint and clog lube passages. After completing the application of the sealant, the joints require an immediate installation (10 to 20 minutes).

Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)