WORKSHOP MANUAL

ADT 25-30 TIER3

USA
ADT 25-30 TIER3 INTRODUCTION I

WORKSHOP MANUAL

ADT 25-30 TIER3

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
II INTRODUCTION ADT 25-30 TIER3

ASTRA VEICOLI INDUSTRIALI reserves the right to make any changes to the vehicle at any time for technical or
commercial reasons. The information, descriptions and illustrations to be found in this publication are updated
up to the moment of the approval to press.

ASTRA VEICOLI INDUSTRIALI

Product Service
Via Caorsana, 79 --- 29100 PIACENZA (Italy)
Tel. 0523/5431 --- Fax 0523/543459

Publication no.: A3501011

First edition: June 2006
Second edition: April 2007

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

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

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ADT 25-30 TIER3 INTRODUCTION III

Figure 1

276R0M01T

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IV INTRODUCTION ADT 25-30 TIER3

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ADT 25-30 TIER3 INTRODUCTION V

SECTIONS

TITLE SECTION PAGES

INTRODUCTION from I to VIII

CONDITIONS OF USE AND

SAFETY INSTRUCTIONS 1 from 1 to 34

TECHNICAL DATA -- ADT 25 2 from 1 to 34

TECHNICAL DATA -- ADT 30 2 from 1 to 34

FAULT CODES 3 from 1 to 46

ENGINE 4 from 1 to 160

AUTOMATIC TRANSMISSION 5 from 1 to 120

FRONT AXLE -- DISC BRAKES 6.1 from 1 to 78

FRONT AXLE -- WET OIL 6.1 from 1 to 76

INTERMEDIATE AXLE -- DISC BRAKES 6.2 from 1 to 72

INTERMEDIATE AXLE -- WET OIL 6.2 from 1 to 70

REAR AXLE -- DISC BRAKES 6.3 from 1 to 66

REAR AXLE -- WET OIL 6.3 from 1 to 54

DRIVELINE 7 from 1 to 18

SUSPENSIONS 8 from 1 to 42

WHEELS AND TIRES 9 from 1 to 12

HYDRAULIC SYSTEM 10 from 1 to 152

ELECTRICAL SYSTEM 11 from 1 to 112

PNEUMATIC SYSTEM 12 from 1 to 20

GREASE SYSTEM 13 from 1 to 22

AIR CONDITIONING SYSTEM 14 from 1 to 28

CAB 15 from 1 to 22

CHASSIS 16 from 1 to 26

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VI INTRODUCTION ADT 25-30 TIER3

PARTS

Figure 2

276CRM001

1. Engine
2. Suspension cylinder
3. Front axle
4. Transmission
5. Articulation joint
6. Intermediate axle
7. Dumper cylinder
8. Rear axle
9. Body
10. Cab

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ADT 25-30 TIER3 INTRODUCTION VII

Main vehicle assemblies production numbers

You are advised to make a note of the model and serial The plate location is shown in Section 2---TECHNICAL
number (PN) and/or production code (PIN) of the main DATA.
vehicle assemblies written on the respective plates This will ensure faster identification of the parts
applied to the assembly. required for partial or total replacement.

engine

automatic transmission

front hubs

intermediate axle

rear axle

chassis

cab

suspension cylinder

tipper cylinder

steering cylinders

hydraulic system pump

brake cooling system pumps

(wet brakes models only)

radiator fan system pump

radiator fan system motor

tipper valve

steering valve

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VIII INTRODUCTION ADT 25-30 TIER3

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 SECTION 1

CONDITIONS OF USE
AND
SAFETY INSTRUCTIONS
 ADT 25-30 TIER3 SECTION 1
CONTENTS
Page
CONDITIONS OF USE . . . . . . . . . . . . . . . . 3
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INFORMATION ON THIS HANDBOOK . . . . . . . . . . 6
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Purpose of this handbook . . . . . . . . . . . . . . . . . . . . . . 7
To whom this manual is addressed . . . . . . . . . . . . . . 7
Safekeeping of this handbook . . . . . . . . . . . . . . . . . . 7
Updates to this handbook . . . . . . . . . . . . . . . . . . . . . . 7
Units of measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SCHEDULED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
VEHICLE OPERATORS . . . . . . . . . . . . . . . . . . . . . . . 8
WASTE DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SCRAPPING THE VEHICLE . . . . . . . . . . . . . . . . . . . 9
WARRANTY AND LIABILITY OF THE
MANUFACTURER . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
After sales service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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CONDITIONS OF USE 1
Page
SAFETY INSTRUCTIONS . . . . . . . . . . . . . 11
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety information and symbols . . . . . . . . . . . . . . . . 13
General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PREVENTING FIRES . . . . . . . . . . . . . . . . . . . . . . . . . 15
ROLLOVER ACCIDENTS . . . . . . . . . . . . . . . . . . . . . 17
Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
What to do if the vehicle rolls over . . . . . . . . . . . . . . 17
Structure of the cab . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTRUCTIONS FOR USE . . . . . . . . . . . . . . . . . . . 19
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Starting and stopping . . . . . . . . . . . . . . . . . . . . . . . . . 20
Driving the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Working the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Towing the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Replacing a wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Power supply disconnection . . . . . . . . . . . . . . . . . . . 26
Safety locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Preventing injuries . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Preventing intoxication and contamination . . . . . . . 32
Preventing burns and electrocution . . . . . . . . . . . . . 33
2 CONDITIONS OF USE SECTION 1 ADT 25-30 TIER3

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ADT 25-30 TIER3 SECTION 1 CONDITIONS OF USE 3

CONDITIONS OF USE

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4 CONDITIONS OF USE SECTION 1 ADT 25-30 TIER3

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ADT 25-30 TIER3 SECTION 1 CONDITIONS OF USE 5

INTRODUCTION
This technical handbook contains a series of repair pro-
cedures relating to the articulated dump trucks.
This handbook is an integral part of the vehicle. It is pro-
vided with the vehicle and must be kept with the vehicle
for future reference until scrapping.
Read this handbook carefully before using the vehicle.
Safe running and long life of your vehicle will depend
on the observance of the rules suggested in this issue.

Copyright
The copyrights of this handbook belong to the vehicle
manufacturer.
The text, drawings and illustrations contained in this
handbook cannot be circulated or given to third parties,
totally or partially, without the written consent of the ve-
hicle manufacturer.

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6 CONDITIONS OF USE SECTION 1 ADT 25-30 TIER3

INFORMATION ON THIS HANDBOOK

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

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ADT 25-30 TIER3 SECTION 1 CONDITIONS OF USE 7

Purpose of this handbook

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

To whom this manual is addressed

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

Safekeeping of this handbook

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

Updates to this handbook

The information, descriptions and illustrations in this
handbook reflect the state of the art at the time of
marketing of the vehicle.
The manufacturer reserves the right to implement
changes to vehicles, for technical or marketing rea-
sons, at any time. The manufacturer will not be obliged
either to implement such changes in the vehicles mar-
keted before or to consider this handbook obsolete.
Any additional information which the manufacturer
may deem suitable to provide at a later time will be kept
with the handbook as an integral part of the publication.

Units of measure
International System (SI) units of measure as used in
this handbook.
Imperial System values are expressed in brackets.

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8 CONDITIONS OF USE SECTION 1
SCHEDULED USE
The vehicle described in this handbook was designed
and made for the following use:
D to haul excavation material in general;
D to haul material resulting from interventions on in-
dustrial or civilian artefacts in general;
D to haul material required to make infrastructures
and/or industrial or civilian artefacts in general.
The vehicle must be used for such purposes.
The vehicle must be in proven and checked conditions
of efficiency for said use, fully respecting the envisaged
criteria and restrictions of use.
Specific care must be paid to the following aspects:
D do not exceed the payloads specified by the
manufacturer;
D do not exceed the gradients specified by the
manufacturer;
D do not drive the vehicle on loose terrain which can
compromise stability;
D do not use the vehicle to remove objects or prod-
ucts;
D use the vehicle paying special attention to the safety
instructions and specifications;
D carry out the ordinary maintenance requirements
specified by the manufacturer;
D carry out the extraordinary maintenance require-
ments which are required, specifically those related
to safety of use.
. The manufacturer declines liability for injury
to persons and for damage to the vehicle
and/or to the transported goods in the event
of other use or use in other conditions than
those specified.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
VEHICLE OPERATORS
The vehicle can be driven exclusively by qualified per-
sonnel with the necessary skills and suitable technical
knowledge.
Vehicle drivers must:
D have the skills required to drive the vehicle in all envi-
ronmental and weather conditions;
D be psychologically and physically fit;
D be very responsible and respect the safety instruc-
tions.
Vehicle maintenance personnel must:
D have the operative skills required for construction
site vehicle maintenance;
D be sensitised to respect and adopt safety instruc-
tions and precautions.
Vehicle operators must be in condition to work in total
safety, also by means of suitable training periods or
courses, to acquire full knowledge of instructions for
vehicle use.
The direct reporting manager must ensure respect of
general safety instructions, specifically those con-
tained in this handbook.
The manager will also ascertain suitability of operating
personnel, in terms of technical skills and psychologi-
cal---physical conditions.
ADT 25-30 TIER3 SECTION 1
WASTE DISPOSAL
Collect and properly dispose of replaced material
(brake pads, filters, etc.) and waste material, resulting
from maintenance operations and repairs (material
soaked in fuel, oil, powder, etc.) according to the laws
in force, separately from normal waste.
Collect and dispose of used lubricants and fluids, ac-
cording to the laws in force.
Collect and dispose of used batteries according to the
laws in force.
Drain and recharge the air conditioning system using
the specific devices, according to the laws in force.
Furthermore, you are advised to separate ferrous mate-
rials, light alloys and waste plastic materials for sepa-
rate recycling.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
CONDITIONS OF USE 9
SCRAPPING THE VEHICLE
The vehicle must be scrapped according to the laws in
force, at the end of the vehicle’s working life.
Recycle and demolish the vehicle according to the laws
in force.
The vehicle must be demolished by expert personnel
using suitable working tools to ensure the required
safety conditions.
Demolish the vehicle by separating and collecting the
various materials by type to allow recycling and dispos-
al.
Please note that it is forbidden to abandon an obsolete
vehicle at a quarry, building site, dump or in the environ-
ment.
Specific attention must be devoted to certain compo-
nents and substances which can pollute the environ-
ment and/or cause injuries, i.e.:
D presence of fuels, coolant fluids, hydraulic oil and lu-
bricating oils on board;
D presence of batteries and respective electrolyte;
D presence of pressurized gas (tires, suspension
components, air conditioner);
D presence of solid polluting materials (tires, brake
pads, plastic parts, filters) or hazardous materials
(glass, windows).
Dispose of these materials according to the laws in for-
ce.
10 CONDITIONS OF USE SECTION 1
WARRANTY AND LIABILITY OF THE
MANUFACTURER
Warranty conditions
The user must carefully observe the precautions illus-
trated in this handbook to ensure validity of the contrac-
tual warranty. Specifically, the user will:
D respect restrictions of use specified by the manufac-
turer;
D not implement changes or variants to the vehicle
without the manufacturer’s written approval;
D always carry out the maintenance interventions;
D always use genuine spare parts;
D ascertain that the personnel called to use the ve-
hicle have the necessary requirements in terms of
skills and training.
The contractual warranty will not be applicable if the
aforesaid conditions are not respected, even in part.
Liability
The manufacturer declines all direct or indirect liabili-
ties deriving from:
D disrespect of the instructions contained in this
handbook;
D use of the vehicle by untrained or unauthorized per-
sonnel;
D use non complying with the regulations in force in
the country where the vehicle was marketed;
D unauthorized changes and/or repairs;
D use of other than genuine spare parts.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
SERVICE
After sales service
Dealerships are available for all types of interventions.
Equipment and expert personnel are available for over-
hauling and repairing operations.
Dealerships can provide information and advice to en-
sure the best use of the vehicle.
Spare parts
Use genuine spare parts for replacements which can
be ordered from dealers.
Please remember that the following information will be
required to order spare parts:
D vehicle type;
D chassis number;
D reference and catalogue numbers shown in the
Spare Parts Catalogue.
If the part belongs to a main assembly (engine, trans-
mission, axles, motors, etc.), you will also need to spec-
ify the assembly model and serial number.
ADT 25-30 TIER3 SECTION 1 SAFETY INSTRUCTIONS 11

SAFETY INSTRUCTIONS

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12 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS ADT 25-30 TIER3

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ADT 25-30 TIER3 SECTION 1 SAFETY INSTRUCTIONS 13

INTRODUCTION
1
The instructions and warnings given in this handbook
illustrate the fundamental safety principles for operat-
ing construction site dump trucks.
They do not illustrate all the potential hazards which
may arise.
Operators must be aware of all the procedures de-
scribed in this handbook. The procedures advise
against adopting work methods which could cause in-
juries and/or affect integrity of the vehicle.
The procedures are not comprehensive. The Manufac-
turer cannot account for all the possible methods of use
156NS01
and operation, nor evaluate all the possible conse-
quences.
Consequently, operators must be responsible and
careful at all times, to prevent hazardous situations for
themselves and others.
Use of the vehicle is subjected to respecting the specifi-
cations contained in this manual and safety regulations
set forth by the law in the country where the vehicle is
used. Knowledge of local legislation is mandatory for all
vehicle users.
Read this manual carefully. Contact your dealer.

Safety information and symbols

Figure 1 shows a safety symbol which is used to attract
the operator’s attention to safety relevant matters. Pay
the utmost care when you see this symbol on the ve-
hicle or in this handbook.
Always follow the recommended safety instructions.
Always read the safety related adhesive labels. Re-
place the labels if they are damaged.
Safety plates and labels on the vehicle are illustrated in
TECHNICAL DATA.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
14 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS ADT 25-30 TIER3

General instructions
1
Arrange a first aid kit in the vehicle. Check and replen-
ish regularly (Fig. 1).
Arrange a plate providing emergency telephone num-
bers. Keep it up---to---date.
Vehicle personnel should be aware of basic first aid
procedures to be applied in the event of an accident or
casualty.
Keep children away from the vehicle, the equipment
and the materials used.
Keep unauthorized persons away from the vehicle, the
equipment and the materials used. 156NS02
The vehicle can only be driven by qualified personnel,
who is authorized to do so by the legislation in force.
Drivers must be physically and psychologically fit (not 2
tired, under the influence of alcohol or drugs, etc.).
Furthermore, drivers must be familiar with the position
and operation of all controls, instruments, gauges and
warning lights in the vehicle. The driver must also be
able to evaluate, in principle, failures which may occur
and adopt the required precautions.
Do not allow unqualified or unsuitable personnel to use
the vehicle.
Maintenance and repair operations must be carried out
by qualified personnel, who are familiar with the ar-
rangement and operation of assemblies and workshop 156NS03
tools.
Do not allow unqualified personnel to carry out mainte-
nance or repair operations on the vehicle.
Do not wear rings, wristwatches or loose and hanging
clothes when carrying out maintenance and repair op-
erations on the vehicle.
Do not use radio or personal stereo headphones dur-
ing operations to avoid distractions.
Personnel will use the vehicle safety features (seat
belts) and personal protection devices during vehicle
use and maintenance (Fig. 2).
Standard safety equipment includes:
D helmet
D goggles or face mask
D protective earphones
D thick gloves
D suitable clothes
D safety boots

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 1 SAFETY INSTRUCTIONS 15

PREVENTING FIRES
1
Keep a suitably sized fire extinguisher in the vehicle.
Check it regularly (Fig. 1).
The portable fire extinguisher can only be used by
skilled personnel.
Vehicle personnel must be familiar with the basic tech-
niques for dealing with fire.
Fuel and most lubricants and fluids are flammable (Fig.
2).
Do not smoke while refuelling or topping up fluids. Do
not refuel or top up near open flames. Do not handle
fuel (Fig. 3).
174NS09
Stop the engine before refuelling. Do not refuel in
closed places.
Check for leakage or residues of fuel, lubricants and 2
fluids which could cause minor fires before starting the
engine.
Short circuits or sparks can cause fires (Fig. 4).
Regularly check conditions of battery terminals, wires
and electrical devices.
Do not store flammable substances in places which are
not suitable for the purpose. Do not pierce or burn pres-
surised containers or cylinders. Do not store up materi-
als soaked in flammable substances.
Be careful where you leave rags and/or replaced mate-
rials which may contain flammable residues. 156NS05

156NS06

156NS07

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
16 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS ADT 25-30 TIER3

Put out all smouldering materials and flames before

starting any maintenance operation.
1
Do not smoke during maintenance operations (Fig. 1).
Do not use gasoline, solvents or other flammable or tox-
ic fluids to clean mechanical parts. Use non---flam-
mable, non---toxic, type---approved products on the
market.
Do not weld near tanks, pipes, reservoirs, electric wires
or flammable materials in general.
Protect flammable parts with suitable guards when
welding.
Stay away from the vehicle and call a fire---fighting ex-
156NS08
pert team in the event of a large---scale fire (Fig. 2).
Stay away from the vehicle if a small fire occurs in the
brake or tire areas. The tires could explode. 2
Never stand in front of the sidewall. Keep a safe dis-
tance of at least (15 metres) (50 Ft) from the tread (Fig.
3).
Stay away from the vehicle for a few hours after putting
out the fire to allow the tires to cool down. Approach the
vehicle protected by a tracked tractor bucket, for exam-
ple.

156NS09

156NS10

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 1 SAFETY INSTRUCTIONS 17

ROLLOVER ACCIDENTS
1
Prevention
Always check height and width during the various load-
ing/unloading operations. Make sure they fall within the
specified limits (Fig. 1).
Keep the wheels perpendicular to the slope when driv-
ing up or down a gradient.
Do not make a U ---turn on a gradient to prevent rolling
over.
Respect the transverse gradient permitted for the
loaded and empty vehicle. 156NS19
Respect the maximum possible gradient for the loaded
and empty vehicle (Fig. 2).
Do not turns at high speed on flat ground. 2
Make sure you always have a hammer in the cab to
smash the windows if an accident occurs.

What to do if the vehicle rolls over

Make that users are aware of how to get out in an emer-
gency and know where the hammer for smashing the
windows is located.
The vehicle can be exited as follows (Fig. 3):
D through the door (after opening it)
D through the front right window (after smashing it).
Use the specific tool (Fig. 4) positioned under the right 156NS20
window to smash it in an emergency.

269NS073

174NS08

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
18 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS ADT 25-30 TIER3

Structure of the cab

1
The vehicle is equipped with a driver’s cab (fig. 1) that
satisfies the ROPS (RollOver Protective Structure) and
FOPS (Falling Object Protective Structure) specifica-
tions.
These features have been designed to minimize the
consequences of vehicle overturning or the fall of heavy
objects onto the cab.
The cab---chassis attachment points and the accesso-
ries inside also satisfy the ROPS---FOPS characteri-
stics.
The cab is thus a specific safety component of the vehi-
276NS002T
cle, as demonstrated by the certifications obtained by
the Manufacturer.
Any alteration of the characteristics of the cab caused
by damage, fire, corrosion or modification can reduce
the degree of protection it ensures.
In this case, the structural part of the cab and any ac-
cessories must be replaced in order to restore the origi-
nal safety conditions.
After any accident, fire, overturning or crushing it is AB-
SOLUTELY NECESSARY to that the following opera-
tions are performed by a qualified technician:
D replace the structural parts of the cab;
D inspect the couplings, seat, seat belt and all the
components that concern driver’s safety;
D replace all the components possibly damaged or no
longer satisfying the original characteristics.
. For more information on the operations to
be performed in case of damage to the cab,
contact an authorized dealer.

Do not make modifications of any type (wel-

ding, drilling, straightening or emergency
repairs) to the structure of the cab and ac-
cessory parts.
Any intervention may change the structural
characteristics of the cab and cause death
or serious injury to the driver in case of acci-
dent, fire, overturning or crushing of the ve-
hicle.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 1 SAFETY INSTRUCTIONS 19

INSTRUCTIONS FOR USE

1
Cab
Use the steps and grips to get on and off (Fig. 1).
Keep the steps and grips clean to avoid slipping.
Do not use flexible parts or controls as grips. They
could break or get damaged.
Face the vehicle while you are getting on and off. Have
three points of contact (steps and grips) at any time.
Do not jump on or off the vehicle.
Do not get on or off while the vehicle is moving.
Keep the floor clear from fragments, tools or other ob-
jects which could interfere with the pedals.
Keep the pedals clean (mud or grease).
Eliminate anything which can reduce visibility or dis-
tract the driver.
Keep windows and rearview mirrors clean.
With the vehicle stationary and the parking brake ap-
plied, before setting off, check position of the seat, the
steering wheel and the rearview mirrors to ensure maxi-
mum driving comfort and control accessibility (Fig. 2).
Make these adjustments each time the driver is
changed.
Drivers must be able to fully press the pedals and oper-
ate the controls correctly without lifting their backs from
the backrest. 269NU081
Do not adjust the seat, the steering wheel or the rear-
view mirrors while driving or in any other way than spe-
cified. 2
Always wear seat belts (Fig. 3).
The webbing must not be twisted. The belt should wrap
around your hips, not your abdomen, to prevent the
risk of slipping forwards.
In the event of an accident, replace the seat belt even
if it does not appear to be damaged.
Do not make changes which can decrease functionali-
ty of the seat belt.

156NS12

156NS13

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
20 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS ADT 25-30 TIER3

Starting and stopping

1
Before starting, check the vehicle exterior for problems,
such as flat tires, fluid leakage, broken or missing parts.
Make sure no---one is near the vehicle when starting the
engine.
Sound the horn before starting the engine (Fig. 1).
Start the engine while you are sitting in the driver’s seat.
Do not start the engine by short ---circuiting the starter
motor wires.
Two people are required to start the engine with a bat-
tery charger or auxiliary battery. One person will sit in
the driver’s seat and the other person will stand near
the battery charger or auxiliary battery.
Do not carry out this operation if the flat battery is fro-
zen. It could explode.
Respect cable connection procedure and polarity to
prevent the risk of the batteries exploding or projecting
electrolyte.
Always wear gloves and protective glasses when ap- 156NS14
proaching the batteries.
Do not smoke or use open flames near the batteries
(Fig. 2). 2
In the event of contact with electrolyte, wash the af-
fected part for at least 15 minutes and call a doctor.
Do not run the engine in closed areas without a suitable
ventilation system for evacuating the harmful gas in the
air (Fig. 3).
Never leave the vehicle with the engine running.
Do not park with the parking brake applied and the
gear engaged, also if you are sitting in the driver’s seat.
Before leaving the vehicle parked in a suitable area
where it is not a hindrance, make sure that the parking
brake is applied and that the keys have been removed 156NS15
from the control panel.
When parking truck aligh front and rear in a straight line
to avoid suspension cylinder sag. 3
Always apply the parking brake in the following cases:
D when the vehicle is parked for a long or short time;
D when loading/unloading the vehicle.

156NS16

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 1 SAFETY INSTRUCTIONS 21

Driving the vehicle

1
Make all the necessary adjustments (seat, steering
wheel, rearview mirrors) before starting engine.
Check that the engine warning lights are OK. Fwd Rev
Sound the horn before starting the machine (Fig. 1).
Check that no---one is standing near the vehicle before
starting the machine.
Be very careful when steering: the front part of the ve-
hicle can move also when the vehicle is stationary. This
can be very dangerous for persons standing near the
vehicle (Fig. 2).
Check the ground surrounding the vehicle before re- 156NS17A
versing to make sure there are no people or obstacles.
Do not transport people in the cab or in other parts of
the vehicle, with exception for the emergency seat. 2
Respect signs, especially speed limits.
Always respect speed limits. Keep a safe speed for
yourself and for others.
Do not exceed the maximum speed allowed.
Switch the lights on at night and when visibility is poor
(dust, fog, rain). Slow down.
Never travel with the transmission in neutral.
To prevent overheating do not use the service brake by
itself when going downhill for long distances. Select au-
tomatic transmission manual mode and use the low
gears (2nd and 3rd) to slow the vehicle down. 156NS18
Use all the auxiliary brakes present on the vehicle
(transmission retarder, exhaust brake).
If the brakes overheat, select automatic transmission
manual mode and use the low gears (2nd and 3rd) to
slow the vehicle down.
Do not use the parking brake for slowing down or stop-
ping the vehicle. This maneuver should only be per-
formed in an emergency after slowing the vehicle down
in other ways.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
22 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS ADT 25-30 TIER3

Working the vehicle

Do not use the vehicle for purposes other than those
1
described by the manufacturer.
Always check height and width during the various load-
ing/unloading operations. Make sure they fall within the
specified limits (Fig. 1).
Beware of overhead obstacles, such as bridges,
cables and wires. Make sure that the load and/or the
body does not knock into them.
Keep the wheels perpendicular to the slope when driv-
ing up or down a gradient.
Do not make a U ---turn on a gradient to prevent rolling
156NS19
over.
Respect the transverse gradient permitted for the
loaded and empty vehicle (see technical data section).
Do not turn at high speed on flat ground.
2
Respect the maximum possible gradient for the loaded
and empty vehicle (Fig. 2) (see technical data section).

156NS20

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 1 SAFETY INSTRUCTIONS 23

Look out for people when reversing and changing di-

rection.
1
Ideally, another person should be asked to signal when
backing up. This person will be able to observe the ap-
proach from a more favorable position with respect to
the driver.
Do not move the vehicle to loading position while the
loading machine bucket or excavator is moving over-
head.
Stay inside the cab while loading the vehicle.
Make sure that the maximum capacity of the vehicle is
not exceeded during loading operations (Fig. 1).
156NS21
Make sure that the load is well arranged and will not fall
off during transportation.
Check the area before unloading. Look out for hazard- 2
ous points: loose terrain, ditches, humps holes and
fencing.
Beware of icy ground: it may become weak and slip-
pery when the temperature rises.
Avoid loading and unloading on steep slopes: the ve-
hicle could roll over.
Be very careful of unbalancing the vehicle by the move-
ment of material out of the dump body down during un-
loading operations.
Check that the dump body down before starting off af-
ter unloading.
156NS22
No---one should ever stand in the loading and unload-
ing area of the vehicle (Fig. 2).
When unloading by means of the automatic control, the 3
operator must never leave the driving cab.
Never start off during loading or unloading operations.
Do not get on or off the vehicle during loading and un- Rev
loading operations.
When crossing another vehicle, the empty vehicle
should yelld to the loaded vehicle and the vehicle driv-
ing downhill should yelld to the vehicle running uphill.
If other vehicles and/or other machines are used in the
working area, appoint a person in charge of signalling
and use signals which can be understood by all drivers
(Fig. 3). 156NS23
In this case, all personnel will follow the instructions
provided.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
24 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS ADT 25-30 TIER3

Towing the vehicle

1
Use the specific hitches provided for this purpose to
tow the vehicle.
Do not use cables, belts or chains to have the vehicle
towed or to tow another vehicle: they could break.
Do not use cables, belts or chains to have the vehicle
towed or to tow another vehicle if the braking system
of the vehicle being towed does not work.
Always use a stiff, suitably dimensioned bar (Fig. 1).
A user must always be aboard the vehicle being towed.
Do not stand near vehicles being towed.
The parking brake will not work if the output propeller 156NS24
shaft is removed from the rear of automatic transmis-
sion and/or the transfer cases and/or the drive axles.
In this case, arrange suitable wedges under the wheels
in both directions of travel to prevent uncontrolled ve-
hicle movements.

Replacing a wheel
The wheel replacement operation requires the utmost
care. The operation must be carried out by at least two
people, using a hoist or a crane to handle the wheel.
Stop the empty vehicle on a flat area, apply the parking
brake and remove the ignition key from the panel.
Make sure that the ground is adequately firm for the
load to be supported. If in doubt, use plates and plat-
forms to prevent sinking.
ALWAYS lock the safety joint before lifting
the vehicle.

Only use the lifting points on the machine.

Make sure that the lifting device is suitable to carry out
the operations and respect safety requirements.
Keep away from tires and/or brakes that show signs of
overheating. Wait for the temperature of the compo-
nents to cool.
Deflate the tire completely, if it is not already flat.
Do not use wheels or fasteners other that those origi-
nally provided.
Excessive tightening may damage the wheel studs/
nuts.
Do not use tubes or extensions other than those pro-
vided to tighten the wheel nuts.
Check that the wheel nuts are tight after two or three
hours of vehicle operation.
Check wheel nut tightness regularly.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 1 SAFETY INSTRUCTIONS 25

MAINTENANCE

General
Personnel in charge of repairs must be aware of all the
procedures described in this handbook. The proce-
dures advise against adopting work methods which
could cause injuries and/or affect integrity of the ve-
hicle.
The procedures are not comprehensive. The Manufac-
turer cannot account for and evaluate all the possible
methods of operation or the possible consequences.
Keep the place of work clean and dry. Do not smoke
during the operations. Wear all the required personal
protection devices before starting maintenance opera-
tions.
Carry out the scheduled maintenance operations.
Carry out all the operations which are required for cor-
rect and safe use of the vehicle.
Before starting maintenance operations take the fol-
lowing precautions:
D stop the vehicle on a flat surface;
D engage the parking brake;
D shut off the engine;
D remove the ignition switch key;
D place a DO NOT OPERATE tag on the steering
wheels.
Do not allow unqualified personnel to carry out mainte-
nance or repair operations on the vehicle.
Carry out maintenance and repair operations with the
utmost care.
Only use the specific tools or wrenches expressly spe-
cified for replacement, checking and maintenance op-
erations.
Never tamper with valves, regulators or other devices,
unless specified in the handbook, to prevent damage
to vehicle components and consequent hazards for
persons.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
26 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS ADT 25-30 TIER3

Power supply disconnection

1
Battery disconnect switch
Every time the user must operate directly or indirectly
on parts of the electrical system, it is necessary to be
absolutely certain to cut off the power supply using the
battery disconnection switch.
Proceed as follows:
D go to the left side of the engine hood (Fig. 1, see ar-
row)
or
D climb into the cab (Fig. 2, see arrow); 276NS003T
D to connect the power supply to the equipment press
the button (Fig. 3, ref. 1): the upper part of the switch
lights up (green ideogram); 2
D to disconnect the power supply to the equipment
press the button (Fig. 3, ref. 2): the lower part of the
switch lights up (red ideogram).

To disconnect the power supply the user must:

D switch off the engine;
D wait about 10 seconds.

. After the engine has been switched off, the

EDC engine control unit must perform a se- 269NS0F2
ries of procedures that require keeping the
power supply on for a few seconds.
Consequently, it is not possible to discon- 3
nect the power supply using the switch for
about 10 seconds after the engine has been
turned off.

269NS0F6

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 1 SAFETY INSTRUCTIONS 27

Emergency switch
1
The emergency switch disconnects electri-
cal power to all utilities, none excluded.
This can cause considerable functional
problems to the engine control system. For
this reason, the switch must only be tripped
when absolutely necessary.

. After 5 (five) consecutive switch---offs of the

engine using the emergency switch, the en-
gine restarts but remains in idle and does
not respond to the accelerator.
269NS102
IT IS NOT POSSIBLE TO RESTORE FUNC-
TIONALITY OF THE CONTROL UNIT USING
THE DIAGNOSIS EQUIPMENT.
IN THIS CASE IT MUST BE REPLACED.

Proceed as follows:
D lift the protective cover and operate the switch be-
low (Fig. 1, green arrow).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
28 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS ADT 25-30 TIER3

Safety locks
1
Always lock the joint in secured position unless other-
wise specified.
Proceed as follows:
D align the vehicle (front and rear chassis);
D remove the pin (Fig. 1, ref. 1);
D swing the tie---rod forward to make the holes in the
tie---rod and chassis coincide (Fig. 1, ref. 2);
D insert the pin through the holes and fasten it with the
retaining pin (Fig. 1, ref. 3).

269NS111

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 1 SAFETY INSTRUCTIONS 29

Always lock the tipped body when operating in the rear

chassis area. 1
Proceed as follows:
D remove the pin (Fig. 1, ref. 1);
D tip the body completely;
D twist the tie---rod to make the holes in the tie---rod
and chassis coincide (Fig. 1, ref. 2);
D insert the pin through the holes and fasten it with the
split pin (Fig. 1, ref. 3).

269NS121

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
30 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS ADT 25-30 TIER3

Preventing injuries
1
Use the steps and grips for getting on and off the left ---
hand side of operators platform (Fig. 1, see arrow).
Use the steps and hand grips for getting on and off the
right ---hand side platform (Fig. 2, see arrow).
Keep the steps and grips clean to avoid slipping.
Do not use flexible parts or controls as grips. They
could break or get damaged.
Face the vehicle while you are getting on and off. Keep
three points of contact (steps and grips) at all times.
Do not jump on or off the vehicle.
Do not get on or off while the vehicle is moving.

269NS131

269NS132

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 1 SAFETY INSTRUCTIONS 31

All checking, bleeding, topping---up, maintenance and

replacement operations must be carried out with the
1
vehicle stationary, on level ground, in a well lit and venti-
lated area. Apply the parking brake, arrange wedges
under the wheels and remove the keys from the ignition
switch, unless otherwise specified in the handbook
(Fig. 1). Attach a DO NOT OPERATE tag on the steering
wheel.
Make sure that no---one is sitting in the driver’s seat.
Use portable lamps when the lighting is not adequate
and to illuminate working areas which cannot easily be
seen otherwise.
156NS29
Use a ladder or platform with steps compliant with safe-
ty regulations to carry out repairs and maintenance op-
erations in areas which cannot be reached from the 2
ground.
Keep hands and clothes away from moving parts when
carrying out operations with the engine running.
Never put your head or other parts of your body (feet,
hands) near turning belts or fans, when the engine is
running (Fig. 2).
Do not put your head or other parts of your body (feet,
hands) near shafts or turning parts when the engine is
running (Fig. 3).
Warn people who are near the vehicle before starting
the engine (e.g. for a test).
156NS30
Wait for at least four hours after stopping the vehicle be-
fore conducting maintenance operations to avoid con-
tacts with hot parts. Be very careful of the cooling fan 3
which could start up suddenly.
Do not work over or under the vehicle propped up on
jacks or other lifting devices which are not suitable to
ensure safety (Fig. 4).
Unload the vehicle before jacking it up. Only use the lift-
ing points identified.
Make sure that the lifting device is suitable to carry out
the operations and respect safety requirements.
After jacking up the vehicle, prop it up before carrying
out operations underneath.
Fully deflate the tire before carrying out any type of op- 156NS31
eration on tires or rims.
Never stand in front of the sidewall while you are inflat-
ing a tire. 4
Never weld on rims with tires fitted to prevent explo-
sions and fire.
Only use the expressly specified tools for inflating the
tires with nitrogen.

156NS32

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
32 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS ADT 25-30 TIER3

Preventing intoxication and contamination

1
Do not run the engine in closed areas without a suitable
ventilation system for evacuating the harmful gas in the
air (Fig. 1).
Avoid prolonged, repeated contacts of fuel, lubricant
and fluids with skin to prevent skin problems and other
syndromes (Fig. 2).
In the event of accidental contact with eyes, wash the
concerned part thoroughly with water.
Do not swallow fuel, lubricant or fluids.
Be very careful: drained oil and fluids, as well as filters
and surrounding parts, could be very hot (Fig. 3). 156NS33
Ensure adequate ventilation to prevent the accumula-
tion of toxic vapors while cleaning and replacing filters.
Do not weld in closed areas or areas which are not suit- 2
ably ventilated.
Do not weld on or near painted surfaces to prevent de-
veloping toxic vapours.
Remove the paint with suitable products, wash the sur-
faces and leave to dry.
Do not breath dust and toxic residues while grinding
and sand---blasting. Protect your eyes with masks and
goggles.
Use a suitable vacuum cleaner to remove dusty resi-
dues from the vehicle or place of work.
Do not play with compressed air. Keep compressed air
guns away from people.
Wear protective goggles with side guards and a mask
when using compressed air to clean filters, to prevent
injury caused by particles of dust. You are advised to
carry out the cleaning operations in a ventilated area.
Be very careful before removing caps or covers from
reservoirs, radiators or cylinders: turn the part slowly to 156NS34
discharge any residual pressure.
Stand at a side during bleeding operations and always
wear protective goggles. Loosen the bleeder slowly by 3
a few turns to let out condense and fluid.
Discharge pressure from the circuits before carrying
out operations.
Never use your hands to feel for leakage of pressurised
fluid.
Pressurised fluid leakage can penetrate under the skin
and in the eyes, causes very severe injuries.
Never use open flames to feel for leakage of air condi-
tioning system. It could generate phosgene, a very
dangerous gas.
156NS35

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 1 SAFETY INSTRUCTIONS 33

Preventing burns and electrocution

1
Be very careful of all parts of the vehicle which could
present high operating temperatures: engine, radia-
tors, heat exchangers, exhaust pipe, automatic trans-
mission, axles, brakes, hubs (Fig. 1).
Do not loosen the radiator cap when the engine is hot.
Let the coolant cool down before removing the cap. In
any case, remove the cap very carefully. Loosen the
cap slowly to release the pressure and remove it.
Do not place sources of heat near pressurised fluid
tubes to prevent sudden failures.
Protect tubes and electrical wires with suitable guards
for welding.
Batteries contain sulphuric acid: always wear gloves
and protective glasses when approaching the batteries
(Fig. 2).
In the event of contact with electrolyte, wash the af-
fected part for at least 15 minutes and call a doctor.
Do not charge a frozen battery. It could explode. 156NS36
Respect cable connection procedure and polarity to
prevent the risk of the batteries exploding or projecting
electrolyte. 2
Do not smoke or use open flames near the batteries
(Fig. 3).
Do not test the battery charge by short ---circuiting the
terminals with a metal object.
Ensure adequate ventilation to prevent the accumula-
tion of explosive gas while recharging the battery.
Do not charge batteries near the workshop air com-
pressor intake.
Arrange the air compressor away from the area where
paint, fuel and batteries are stored to prevent taking in
vapors. 156NS37
Do not open the camera box or the monitor. Electrical
charged parts are inside.
All operations must be carried out by skilled, suitably 3
equipped personnel.
If the vehicle comes into contact with overhead electric
leads, do not leave the vehicle and do not exit from the
cab until the power has been cut out on the electric line,
or the cables have been cleared away from the vehicle.

156NS15

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
34 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS ADT 25-30 TIER3

Left intentionally blank

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 SECTION 2

TECHNICAL DATA

ADT 25
 ADT 25-30 TIER3 SECTION 2
CONTENTS
Page
VEHICLE COMPOSITION . . . . . . . . . . . . . . . . . . . . . 3
DIMENSIONS (EMPTY VEHICLE) . . . . . . . . . . . . . . 4
DIMENSIONS WITH BODY RAISED . . . . . . . . . . . . 5
WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CENTER OF GRAVITY
(HORIZONTAL POSITION) . . . . . . . . . . . . . . . . . . . . 7
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PERFORMANCE ALIGNMENT CHART . . . . . . . . 10
Using the alignment chart . . . . . . . . . . . . . . . . . . . . . 10
Performance alignment chart . . . . . . . . . . . . . . . . . . 11
MAIN TECHNICAL SPECIFICATIONS . . . . . . . . . 12
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Case PIN plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
POSITION OF IDENTIFICATION DATA
ON MAIN GROUPS . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . 14
Drive axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Dumper cylinder (two) . . . . . . . . . . . . . . . . . . . . . . . . 15
Steering cylinder (two) . . . . . . . . . . . . . . . . . . . . . . . . 15
Suspension cylinders . . . . . . . . . . . . . . . . . . . . . . . . . 15
MAIN TECHNICAL SPECIFICATIONS . . . . . . . . . 16
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . 16
Front drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Intermediate and rear drive axles . . . . . . . . . . . . . . . 17
Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Wheels and tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
TECHNICAL DATA 1
Page
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Drive cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LIST OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TIRE PRESSURE TABLE . . . . . . . . . . . . . . . . . . . . . 21
ANTIFREEZE CONCENTRATION IN ENGINE
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
ANTIFREEZE CONCENTRATION IN
WINDSCREEN WASHER FLUID . . . . . . . . . . . . . . . 21
BATTERY ELECTROLYTE DENSITY TABLE . . . . 21
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . 22
PLATES APPLIED TO THE VEHICLE . . . . . . . . . . 23
Articulation joint left size . . . . . . . . . . . . . . . . . . . . . . 24
Cab access steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
EUROPEAN VERSION . . . . . . . . . . . . . . . . . . . . . . . 24
INSIDE ENGINE HOOD PLATE . . . . . . . . . . . . . . . 27
INSIDE CAB PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . 27
U.S.A. VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSIDE ENGINE HOOD PLATE . . . . . . . . . . . . . . . 31
INSIDE CAB PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . 31
STANDARD TIGHTENING TORQUES . . . . . . . . . . 33
Screws and nuts with metric thread . . . . . . . . . . . . 33
MEASURES (INTERNATIONAL SYSTEM) . . . . . . 34
Force in N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Power in kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Torque in Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Specific consumption in g/kWh . . . . . . . . . . . . . . . . 34
Pressure in kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Conversion values for British units . . . . . . . . . . . . . . 34
2 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

Left intentionally blank

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ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 3

VEHICLE COMPOSITION

GROUPS DESCRIPTION

ENGINE

IVECO F3A (Cursor 10)

GEARSHIFT

ZF 6 WG 260

FRONT HUB
KESSLER D81

INTERMEDIATE AXLE
KESSLER D81

REAR AXLE
KESSLER D81

TRANSMISSION
LAYOUT

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4 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

DIMENSIONS (empty vehicle) [mm (ft)]

mm ft
A Wheelbase 4212 13.85
B Front track 2360 7.76
C Rear track 2360 7.76
D Front overhang 2824 9.29
E Rear overhang 1295 4.26
F Overall length 10031 33.00
G Maximum width (excluding mirrors) 2961 9.74
H Maximum height (*) 3723 12.24
I Ground clearance (*) 478 1.57
J Distance between tandem axles 1700 5.59
L Body height (*) 2756 9.06
Internal steering circle 4090 13.45
External steering circle 8256 27.16

Dimensional tolerance: 3% (*) empty vehicle

276DT001T

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ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 5

DIMENSIONS WITH BODY RAISED

mm 6500
M Maximum height of body (*)
ft 21.13
N Maximum tipping angle --- Degrees ˚ 68
mm 965
R Ground clearance (*)
ft 3.17
m3
--- Loading capacity to the brim (SAE 1:1)
yd3
m3
--- Full loading capacity (SAE 2:1)
yd3

Dimensional tolerance: 3% (*) empty vehicle

276DT002T

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6 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

WEIGHTS
Empty vehicle kg US ton lb
Total 22.240 24.515 49.031
FW Front axle 12.155 13.398 26.797
RW1 First tandem axle 5042.5 5.558 11.117
RW2 Second tandem axle 5042.5 5.558 11.117

Loaded vehicle kg US ton Lb

GVW Total 45.440 50.089 100.178
FW Front axle 15.320 16.887 33.775
RW1 First tandem axle 15.060 16.601 33.202
RW2 Second tandem axle 15.060 16.601 33.202
Q Capacity 23.200 25.573 51.147
GVW (Gross Vehicle Weight)
Dimensional tolerance: 3%

276DT003T

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ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 7

CENTER OF GRAVITY (horizontal position)

Empty vehicle mm ft
S Front distance 2444 8.02
T Rear distance 2946 9.67

Loaded vehicle mm ft
S Front distance 3573 11.7
T Rear distance 1817 5.96

Dimensional tolerance: 3%

276DT004T

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8 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

PERFORMANCE

Tire type 29.5 R 25

Total axle ratio 1:22.24

Gear Transmission Total Speed (*) Gradient (**)

ratio ratio km/h (mph) (lock-- up) (%)

1st forward 1 : 5.350 112.35 5.4 (3.4) 37.3

2nd forward 1 : 3.446 72.366 8.4 (5.3) 22.6
3rd forward 1 : 2.206 46.326 13.2 (8.3) 13.7
4th forward 1 : 1.421 29.481 20.5 (12.9) 8.2
5th forward 1 : 0.969 20.349 30 (18.9) 5.1
6th forward 1 : 0.624 13.104 46.6 (29.3) 2.6
1st reverse 1 : 5.350 112.35 5.4 (3.4) 37.3
2nd reverse 1 : 2.206 46.326 13.2 (8.3) 13.7
3rd reverse 1 : 0.969 20.349 30 (18.9) 5.1

(*) speed that can be reached with engine running at 2100 (rpm) and tire rolling circle of 4.85 m (190.94 in).
(**) full load.

Maximum torque in 1st gear: 2.6 km/h (1.62 mph)

Maximum speed (calculated). 46.6 km/h (28.96 mph)

Maximum gradient in 1st gear (calculated, locked up): 37.3%

Maximum gradient in 1st gear (calculated, using converter): 60%

Empty transversal gradeability (D) XX%

Full load transversal gradeability (D) XX%
(D) minimum adherence ratio 0.6

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ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 9

Left intentionally blank

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10 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

PERFORMANCE ALIGNMENT CHART

The performance alignment chart can be used to check whether the load/slope conditions are compatible with
the vehicle performance and if so, what this performance is.
. The alignment chart was drawn according to the engine torque curve. It is therefore valid when the
accelerator pedal is fully pressed.

The following data must be known to use the alignment diagram:

1. total ground vehicle weight (GVW)
2. slope of ground
3. rolling resistance

1. The total ground vehicle weight (GVW) is obtained by summing tare and planned load.
. Refer to tables on previous pages for maximum admitted values.

2. The slope must be expressed as a percentage. Values expressed in degrees must be converted.
3. Rolling resistance can be evaluated according to ground conditions as shown in the following table.

Resistance for 1000 kg of GVW

Conditions of terrain %
kg lb
Asphalt --- Cement 15 33 1.5
Compact dirt 20 44 2.0
Soft dirt 30 66 3.0
Mud on solid bottom 40 88 4.0
Compacted snow 25 55 2.5
Soft snow 45 49 4.5
Sand --- Gravel 100 220 10.0

Sum the slope percentage and the rolling resistance to obtain final grade.

Using the alignment chart

Starting from the GVW (point A), draw a vertical line to meet the total resistance line grade (point B).
Draw a horizontal line starting from point B to cross one of the use curves: this shows one of the possible condi-
tions of use (point C).
Continue the horizontal line to cross the ordinate axis: this shows the total traction force (RIMPULL, point D).
Draw a vertical line from point C to meet the abscissa: this shows the speed which can be reached (SPEED, point
E).

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ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 11

Performance alignment chart (Fig. 1)

C B

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12 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

MAIN TECHNICAL SPECIFICATIONS

The chassis type and number of the articulated truck id the vehicle identification data.

174DT03

The chassis number is punched on the right ---hand side of the vehicle (arrow).

Chassis number

1. International manufacturer identification

2. Type of vehicle, (AD = articulated dumper)
3. Capacity:
25 = 25 tons
4. Version:
TP = Tipper
5. Data of manufacture
6. Data of manufacture
7. Chassis progressive number.

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ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 13

Case PIN plate

The case PIN is indicated on a plate fitted in the cab rear left external side.
D Model
D Product identification Number (PIN)

276DT100

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14 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

POSITION OF IDENTIFICATION DATA ON MAIN GROUPS

All the main vehicle groups are identified with a serial Engine
number to be found on the actual group, in the posi-
tions shown below.
The group identification number is always to
be indicated when ordering spare parts.

Cab

269NM0D3
The type of engine and the serial number are indicated
on a plate on the engine.

Automatic transmission

269DT0E4

The cab number is indicated on a plate in the cab on

the right.

Chassis

269NM0D4
The type of transmission and the serial number are indi-
cated on a plate on the transmission.

174DT06
The chassis number is stamped on the right side of the
vehicle.

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ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 15

Drive axles Steering cylinder (two)

174DT11
The type and serial number are indicated on a plate on
276DT006T the cylinder casing.
The type of axle and the serial number are indicated on
a plate on the axle housing. Suspension cylinders

Dumper cylinder (two)

276DT008T

The type and serial number are indicated on a plate on

the cylinder casing.

269DT0E2
The type and serial number are indicated on a plate on
the cylinder casing.

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16 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

MAIN TECHNICAL SPECIFICATIONS

Engine
Type: IVECO F3A (Cursor 10)
Four---stoke diesel, supercharged with variable geometry exhaust gas turbo compressor.
Electronically controlled injector---pump injection system with fuel pre---filter and filter and pump in tank.
Forced lubrication with gear pump and double oil filter.
Water cooled with centrifuge pump. Radiator fan hydraulic system with pump driven by engine.
Compressed air system driven by engine.
Discharge: EPA --- CARB --- OFF ROAD TIER 3

Main geometric specifications

Number of cylinders 6
Bore mm 125
in 4,92
Stroke mm 140
in 5,51
Total displacement
p cm3 10300
cu.in 628,3
Compression ratio 16.5
Injection order 1---4---2---6---3---5

Maximum performance
p
Maximum power kW 235
BHP 315
Power ratio RPM 2100
Maximum torque
q Nm 1450
Ft lb 1070
Torque ratio RPM 1400

Automatic transmission
Type: ZF 6WG260
Automatic transmission with 6 forwards gears and 3 reverse.
Single stage hydrodynamic torque converter.
Stall ratio: 1 :1.840
Lock ---up clutch in all gears.
Incorporated transfer case with central lockable splitter between the front axle and the intermediate and rear axles.

Transmission ratios
Gear Ratio
1st 5.350
2nd 3.446
3rd 2.206
4th 1.421
5th 0.969
6th 0.624
1st R 5.350
2nd R 2.206
3rd R 0.969
R = Reverse

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ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 17

Front drive axle

Type: semi---independent with automatic transmission integrated differential, and KESSLER D81 hubs
Limited slip differential forming single block with automatic transmission, pivoting drive axles with double CV joint,
wheel hubs with planetary reductions.
Pivoting axle hinged to chassis, transversal stabilizer bar.

Axle ratios
central bevel gear pair 3.50

planetary reduction gear set 6.00

total reduction 21.00

Intermediate and rear drive axles

Type: KESSLER D81
Rigid type axle with side pinion reduction on hubs; limited slip differential.
Fixed distribution of 50/50 between the intermediate axle and rear axle.

Transmission ratios
central bevel gear pair 3.50

planetary reduction gear set 6.00

total reduction 21.00

Suspension
Front: Two hydro---pneumatic cylinders (nitrogen---oil) for variable flexibility and damping.
Rear: rigid double rocker arm, load splitter on intermediate and rear axles with reaction bar.

Brakes
Service brake: disk braking assembly with four pistons calliper, hydraulically controlled on each wheel.
Parking brake: plate and spring operated, pneumatically released calliper acting on drive shaft between automatic
transmission and intermediate axle.
Additional parking brake: can be applied when the vehicle is stationary, acts on tandem axle brake units.

Wheels and tires

Steel rims on six wheels.

Type and dimensions

Type Rims Tires
std 19.50 --- 25” 23.5 R 25

opt 22.00 --- 25” 650/65 R 25

opt 25.00 --- 25” 750/65 R 25

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18 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

Hydraulic system
Independent reservoir. Oil---air heat exchanger.
Steering---dumping circuit: suction and delivery filter. Pump mechanically operated by the automatic transmis-
sion.
Braking circuit: suction and delivery filter. Pump mechanically operated by the engine.

Steering
Hydraulically controlled, two dual acting hydraulic cylinders acting on articulation joint between chasses.
Emergency pump, operated by the automatic transmission.

Dumper
Two dual acting multistage hydraulic cylinders fitted on ball joints inside the chassis.
Assisted return stroke.

Brake
Independent front and rear wheel braking system. Hydraulic pressure accumulators.

Electrical system
Multiplex electrical system.
Connection between ECUs on CAN line.
Nominal voltage: 24 V
Starter motor: 24 V 5.5 kW
Alternator: 28 V 90 A
Batteries: 2, connected in series: 12 V 170 Ah, 700 A

Chassis
High---resistant steel (Hardox 400) structure with welded boxing and plates.
Articulated, two independent structures, connected by means of oscillation bearing and taper roller bearings for
demanding use ensuring rotation and pivoting between the two chassis.

Drive cab
Steel structure conforming to ROPS/FOPS specifications. Flexible support pads.
Can be tipped by hydraulic system. Tippable engine hood.
Electronically controlled climate control system.

Body
Structure with flat steel bottom with boxed parts strengthening subframes and flexible support pads. Walls and
bottom in high abrasion resistance steel (Hardox 400).
Dumping via hydraulic cylinders.
Body bottom heated by passage of exhaust gas.

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ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 19

LIST OF BULBS

Continuous Power (w) Type Quantity

Front

Marker 5 BA15s 2

Dipped beam/main beam 55/70 H4 2

Tipping main beam 70 H1 2

Cab ceiling light 5 2

Cab map reading light 5 2

Front direction indicator 21 BA15s 2

Side direction indicator 21 BA15s 2

Working lights 5 BA15s 4

Rear

Marker 5 BA15s 2

Direction 21 BA15s 2

Brake lights 21 BA15s 2

Reversing light 21 BA15s 1

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20 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

CAPACITIES
CAPACITY
PART TO BE FILLED SPECIFICATIONS
I (US Gal) kg (Ib)
Engine oil sump (1)
SAE 15W40
--- URANIA TURBO ACEA E3
30.5 (8) --- ---
--- AKCELA N°1 MIL L 21 04E lev.
API GF 4
Engine coolant radiator
Protective anti---freeze mixture/water 50 (13.2) --- --- ASTM 0336
Fuel tank
Diesel 440 (116.2) --- --- ASTM D ---975
Automatic transmission
SAE 15W40
--- URANIA TURBO ACEA E3
35.5 (9.4) --- ---
--- AKCELA N˚ 1 MIL L 21 04E lev.
API GF 4
Axles/Differentials/Planetary Hubs
Front differential 14.0 (3.7)
SAE 10W30
Front hub 3.0 (0.8) x 2
--- AMBRA MULTI G --- --- ISO 32/46
Intermediate axle 35.0 (9.3)
API GL4 level
Rear axle 33.0 (8.7)
Suspension
--- TUTELA GI/A
1.5 (0.41) x 2 --- --- ATF DEXRON Il
--- AKCELA A.T.F.
30 bar
--- Nitrogen --- --- --- ---
(456.9 psi)
Hydraulic circuit (2)
--- IDRAULICAR HVI 46 ISO VG 46
210.0 (55.5) --- ---
--- AKCELA HYDRAULIC Excavator Fluid DIN 51524/51525
Engine hood/cab tipping circuit
--- TUTELA GI/A
2.0 (0.5) --- --- ATF DEXRON Il
--- AKCELA A.T.F.
Greasing
--- TUTELA MR2
--- --- 2.0 (4.4) N.L.G.I. 2
--- AKCELA PREMIUM GREASE AP2
Greasing device body heating
--- MOLYCOTE Cu7439
Q.B. --- --- --- ---
--- LOCTITE 8152
Climate control system
Refrigerant fluid R134a --- --- 1.2 (2.65) --- ---
Windshield washer
Protective anti---freeze mixture/water Q.B. --- --- --- ---

(1) for ambient temperature < ---20˚C use SAE 5W30

for ambient temperature > 45˚C use SAE 20W50
(2) for ambient temperature ---40 ˚C < T < 20 ˚C use ISO VG 100
for ambient temperature 0 ˚C < T < 60 ˚C use ISO VG 22

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ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 21

TIRE PRESSURE TABLE

Pressure
Tires Front (F) Rear (R)
Bar Psi Bar Psi
23.5 R 25 (std) 3,00 43,5 3,00 43,5
650/65 R 25 (opt) 3,50 50,5 3,25 47
750/65 R 25 (opt) 2,75 40,0 2,75 40,0

ANTIFREEZE CONCENTRATION IN ENGINE COOLANT

Ambient temperature
Antifreeze Water
˚C ˚F
---35/ ---30 ---31/ ---22 50% 50%
---25/ ---20 ---13/ ---4 40% 60%
---15/ ---8 5/18 30% 70%
---5/0 23/32 20% 80%

ANTIFREEZE CONCENTRATION IN WINDSCREEN WASHER FLUID

Ambient temperature
Antifreeze Water
˚C ˚F
---35 ---31 1 0
---20 ---4 1 1
---10 14 1 2
0 32 1 6
summer 1 10

BATTERY ELECTROLYTE DENSITY TABLE

Electrolyte
y density
y
Ambient temperature
(100% of charge)
˚C ˚F g/dm3
40 104 1.265
20 68 1.285
0 32 1.300
---20 ---4 1.365

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22 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

TIGHTENING TORQUE

Tightening torque
PART Notes
Nm Ft lb
AUTOMATIC TRANSMISSION
Oil drainage cap 140 103.26

HUBS/AXLES
Front differential oil drainage cap 150 110.63 Socket head

HYDRAULIC SYSTEM
Tank drainage cap (both) 20 14.75

STEERING AND WHEELS

Wheel fastening nuts 590 435.16
Steering column fastening bolt 45 33.19

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 23

PLATES APPLIED TO THE VEHICLE

The adhesives and plates applied on the vehicles may the adhesives and plates on a 25 model, indicating the
vary according to the market and local requirements of position where they are located.
the country. These pages contain a brief description of

1 2 3
4

10 10

6 6

9 8 7 6 5

14 5
5

12
10 10

6 6

6 78 4 13

19

13 276DT010T

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24 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

Articulation joint left size Cab access steps

15

16
17
18
276DT011T 269DT202

EUROPEAN VERSION
Pos. 1 CE plate Pos. 4 Hot surface warning plate

Pos. 2 Inside noise plate

Pos. 5 Crushing hazard warning plate

Pos. 3 Outside noise plate

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 25

Pos. 6 Vehicle tie-- down plate Pos. 9 Tipping engine hood plate

Pos. 7 Crushing hazard warning plate Pos. 10 Towing eye plate

Pos. 8 Keep clear of prop shaft plate Pressurized system hazard plate
(Located on the accumulator)

Pos. 12 Hydraulic oil filler plate

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
26 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

Pos. 13 Grease point centralized plate Pos. 17 Lubrification plate

Pos. 14 Crushing hazard warning plate

Pos. 15 Safety warning plate Pos. 18 Test point plate

Pos. 16 Maintenance plate

Pos. 19 Chassis lock warning plate

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 27

INSIDE ENGINE HOOD PLATE

Moving parts warning plate Battery throw off plate

Located near the battery isolator switch button.

INSIDE CAB PLATE

Located on the side of the radiator and on the belt side
protection. Cargo body dumping control plate

Warning plate

Located on the glass near the dump---up lever.

Tilting hazard warning plate

Located on the starting motor.

Danger of burns warning plate

Located on the front right ---hand window.

Located on the upper part of the expansion tank.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
28 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

Emergency exit Tire inflation pressure plate

Located on the left ---hand side of the steering column.

Located on the front lower right ---hand window.
Voltage rating plate
Gear selector plate

Located near the electrical socket on the right ---hand si-

de under the module support panel.

Parking brake plate

Located on the ZF selector

Warning plate

Located near the parking brake control.

Located to the left of the ashtray. Warning plate

Position on the left side next to the air conditioning /

heating controls.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 29

U.S.A. VERSION
Hot Surfaces warning plate Crushing hazard warning plate

Crushing hazard warning plate Keep clear of prop shaft plate

Vehicle tie-- down plate Tipping engine hood

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
30 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

Towing eye plate Crushing hazard warning plate

Pressurized System hazard plate Safety warning plate

Hydraulic oil filler plate Crushing hazard warning plate

Grease point centralized plate Maintenance plate

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 31

Lubrification plate Test point

INSIDE ENGINE HOOD PLATE

Moving parts warning plate Danger of burns warning plate

Located on the upper part of the expansion tank.

Battery throw off plate

Located on the side of the radiator and on the belt side

protection.

Warning plate

Located near the battery isolator switch button.

INSIDE CAB PLATE

Cargo body dumping control plate

Located on the starting motor.

Located on the glass near the dump---up lever.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
32 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

Tilting hazard warning plate Tire inflation pressure plate

Located on the left ---hand side of the steering column.

Located on the front right ---hand window.
Voltage rating plate
Emergency exit

Located near the electrical socket on the right ---hand

side under the module support panel.

Parking brake plate

Located on the front lower right ---hand window.

Gear selector plate

Located near the parking brake control.

Warning plate

Located on the ZF selector

Warning plate

Located to the left of the ashtray. Position on the left side next to the air conditioning /
heating controls.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 33

STANDARD TIGHTENING TORQUES

Screws and nuts with metric thread

Maximum tightening torque for metric threads in lb ft

Diameter SCREW --- CLASS SCREW --- CLASS SCREW --- CLASS
x 8.8 10.9 12.9
Pitch
dxp DA- DA- DA-
PHOS- PHOS- PHOS-
(mm) UN- CROMET CADMIUM PHATE UN- CROMET CADMIUM PHATE UN- CROMET CADMIUM PHATE
COATED GALVA- PLATED COATED COATED GALVA- PLATED COATED COATED GALVA- PLATED COATED
NISED NISED NISED

3 x 0.5 0.88 0.88 0.81 0.66 1.25 1.18 1.10 0.96 1.55 1.40 1.33 1.11

4 x 0.7 2.06 1.92 1.77 1.47 2.88 2.73 2.51 2.14 3.47 3.24 3.02 2.58

5 x 0.8 4.13 3.83 3.54 2.95 5.83 5.46 4.94 4.20 6.93 6.49 5.90 5.01

6x1 7.37 6.64 5.90 5.16 9.59 9.59 8.85 7.37 11.80 11.06 10.32 8.85

8 x 1.25 16.96 16.22 14.75 12.54 24.34 22.86 20.65 16.96 28.76 27.29 24.34 20.65

8x1 18.44 17.70 15.49 13.27 25.81 24.34 22.12 18.44 31.71 29.50 26.55 22.12

10 x 1.5 34.66 32.45 29.50 24.34 47.94 44.99 41.30 34.66 58.26 54.57 49.41 41.30

10 x 1.25 36.87 34.66 30.97 25.81 51.62 47.94 43.51 36.14 61.95 58.26 52.36 43.51

12 x 1.75 59.00 55.31 50.15 42.04 83.34 78.17 70.80 59.00 100.30 93.66 84.81 70.80

12 x 1.25 66.37 61.95 55.31 45.72 92.92 87.02 78.17 64.16 111.36 103.99 93.66 76.70

14 x 2 94.4 88.50 80.39 67.11 132.75 124.64 112.84 94.40 159.30 148.97 135.70 112.84

14 x 1.5 103.99 96.61 87.76 71.54 146.02 136.44 123.16 100.30 175.52 163.72 147.50 120.95

16 x 2 146.02 136.44 123.90 102.51 205.76 192.49 174.05 143.81 247.06 230.84 208.71 172.57

16 x 1.5 158.56 147.50 132.75 107.67 222.72 207.97 186.59 151.92 267.71 249.27 224.20 182.16

18 x 2.5 200.60 187.32 170.36 141.60 281.72 264.02 238.95 199.12 337.77 316.39 286.89 238.95

18 x 1.5 231.57 215.35 193.22 155.61 325.24 303.11 271.40 219.03 390.87 363.59 325.97 263.29

20 x 2.5 283.20 266.24 241.16 199.12 400.46 374.65 339.25 280.25 480.85 449.87 407.10 336.30

20 x 1.5 323.76 301.64 269.19 216.82 455.03 424.06 379.07 304.59 546.49 508.14 454.30 365.06

22 x 2.5 397.51 361.37 328.92 266.97 559.76 507.40 463.15 376.12 671.12 609.17 555.34 450.61

22 x 1.5 435.12 404.15 360.64 288.36 611.39 568.61 507.40 405.62 733.81 682.19 609.17 487.48

24 x 3 491.91 460.20 415.95 343.67 691.77 646.79 584.84 483.06 829.69 775.85 702.10 579.67

24 x 2 547.22 509.61 456.51 368.75 769.95 716.85 642.36 518.46 924.09 860.66 770.69 622.45

27 x 3 727.91 679.97 612.86 502.97 1023.65 955.80 862.14 707.26 1227.94 1146.81 1033.97 848.12

27 x 2 799.45 743.40 664.48 533.95 1123.95 1045.77 934.41 750.77 1348.89 1255.22 1121.74 901.22

30 x 3.5 986.04 921.14 831.16 684.40 1386.50 1295.05 1168.94 962.47 1663.80 1553.91 1402.72 1154.18

30 x 2 1118.05 1039.87 927.77 741.92 1572.35 1461.72 1304.64 1043.56 1887.26 1754.51 1564.97 1252.27

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
34 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

MEASURES (INTERNATIONAL SYSTEM)

Force in N (Newton) Pressure in kPa (kilopascal)
Other units in use:
Conversion: kg/cm2 (kilogram per square centimeter)
1N = 0.1019 kg Atm (Metric atmosphere)
1 kg = 9.81 N psi (Pound per square inch)

Conversion:
Power in kW (kilowatt) 1 kg/cm2 = 1 Atm
Other units in use: 1 kg/cm2 = 98.1 kPa
CV (Horse) 1 kg/cm2 = 0.981 bar
HP (Horse---Power) 1 kg/cm2 = 1 bar *
1 kg/cm2 = 14.22 psi
Conversion: 1 bar = 100 kPa
1 kW = 1.36 CV 1 bar = 1.02 kg/cm2
1 kW = 1.34 HP 1 bar = 14.51 psi
1 CV = 0.736 kW 1 psi = 6.9 kPa
1 CV = 0.986 HP 1 psi = 0.069 bar
1 HP = 0.746 kW 1 psi = 0.0703 kg/cm2
1 HP = 1.014 CV 1 kPa = 0.145 psi
1 kPa = 0.0102 kg/cm2
1 kPa = 0.01 bar
Torque in Nm

Conversion: Conversion values for British units

1 Nm = 0.1019 kg 1 mm = 0.039 inch
1 kgm = 9.81 Nm 1m = 3.281 ft.
1 kgm = 10 Nm * 1 km = 0.621 miles
1 cm3 = 0.06 I cu. in.
1l = 1.759 pts (0.88 Imp. qts)
Specific consumption in g/kWh (grams per kilowat- 1 bar = 14.5038 psi
thour) 1g = 0.035 oz. (0.564 dr.)
Other unit in use: 1 kg = 2.205 Ibs.
g/CVh (grams per Horsehour) 1t = 1.102 short ton (0.9842 long ton)
(˚F − 32)
˚C =
Conversion: 1.8
1 g/kWh = 0.736 g/CVh ˚F = (˚C x 1.8) + 32
1 g/CVh = 1.36 g/kWh
(*) Nm and bar are converted according to the ratios
10:1 and 1:1

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 SECTION 2

TECHNICAL DATA

ADT 30
 ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 1

CONTENTS

Page Page

VEHICLE COMPOSITION . . . . . . . . . . . . . . . . . . . . . 3 Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DIMENSIONS (EMPTY VEHICLE) [MM (FT)] . . . . 4
Wheels and tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DIMENSIONS WITH BODY RAISED . . . . . . . . . . . . 5
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake cooling system (only wet brakes version) . . 18
CENTER OF GRAVITY Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
(HORIZONTAL POSITION) . . . . . . . . . . . . . . . . . . . . 7
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Drive cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PERFORMANCE ALIGNMENT CHART . . . . . . . . 10 Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Using the alignment chart . . . . . . . . . . . . . . . . . . . . . 10
LIST OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Performance alignment chart . . . . . . . . . . . . . . . . . . 11
CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
MAIN TECHNICAL SPECIFICATIONS . . . . . . . . . 12
TIRE PRESSURE TABLE . . . . . . . . . . . . . . . . . . . . . 21
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ANTIFREEZE CONCENTRATION IN ENGINE
Case PIN plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
POSITION OF IDENTIFICATION DATA ON
ANTIFREEZE CONCENTRATION IN
MAIN GROUPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
WINDSCREEN WASHER FLUID . . . . . . . . . . . . . . . 21
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BATTERY ELECTROLYTE DENSITY TABLE . . . . 21
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . 22
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . 14 PLATES APPLIED TO THE VEHICLE . . . . . . . . . . 23

Drive axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Articulation joint left size . . . . . . . . . . . . . . . . . . . . . . 24

Disk brakes version . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Cab access steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Wet brakes version . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 EUROPEAN VERSION . . . . . . . . . . . . . . . . . . . . . . . 24

Dumper cylinder (two) . . . . . . . . . . . . . . . . . . . . . . . . 15 INSIDE ENGINE HOOD PLATE . . . . . . . . . . . . . . . 27
Steering cylinder (two) . . . . . . . . . . . . . . . . . . . . . . . . 15
INSIDE CAB PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Suspension cylinders . . . . . . . . . . . . . . . . . . . . . . . . . 15
U.S.A. VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
MAIN TECHNICAL SPECIFICATIONS . . . . . . . . . 16
INSIDE ENGINE HOOD PLATE . . . . . . . . . . . . . . . 31
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSIDE CAB PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . 16
Front drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 STANDARD TIGHTENING TORQUES . . . . . . . . . . 33

Intermediate and rear drive axles . . . . . . . . . . . . . . . 17 MEASURES (INTERNATIONAL SYSTEM) . . . . . . 34

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2 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

Left intentionally blank

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 3

VEHICLE COMPOSITION

GROUPS DESCRIPTION

ENGINE

IVECO F3A (Cursor 10)

GEARSHIFT

ZF 6 WG 260

FRONT HUB
KESSLER D81

INTERMEDIATE AXLE
KESSLER D81

REAR AXLE
KESSLER D81

TRANSMISSION
LAYOUT

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4 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

DIMENSIONS (empty vehicle) [mm (ft)]

mm ft
A Wheelbase 4212 13.85
B Front track 2360 7.76
C Rear track 2360 7.76
D Front overhang 2824 9.29
E Rear overhang 1295 4.26
F Overall length 10031 33.00
G Maximum width (excluding mirrors) 2961 9.74
H Maximum height (*) 3723 12.24
I Ground clearance (*) 478 1.57
J Distance between tandem axles 1700 5.59
L Body height (*) 2956 9.72
Internal steering circle 4090 13.45
External steering circle 8256 27.16
Dimensional tolerance: 3% (*) empty vehicle

276DT001T

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ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 5

DIMENSIONS WITH BODY RAISED

mm 6500
M Maximum height of body (*)
ft 21.38
N Maximum tipping angle --- Degrees ˚ 68
mm 965
R Ground clearance (*)
ft 3.17
m3
--- Loading capacity to the brim (SAE 1:1)
yd3
m3
--- Full loading capacity (SAE 2:1)
yd3

Dimensional tolerance: 3% (*) empty vehicle

276DT002T

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6 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

WEIGHTS
Empty vehicle kg US ton lb
Total 22.570 24.879 49.758
FW Front axle 12.250 13.503 27.007
RW1 First tandem axle 5160 5.688 11.376
RW2 Second tandem axle 5160 5.688 11.376

Loaded vehicle kg US ton Lb

GVW Total 50.730 55.920 111.841
FW Front axle 15.900 17.527 35.053
RW1 First tandem axle 17.415 19.197 38.394
RW2 Second tandem axle 17.415 19.197 38.394
Q Capacity 28.160 31.041 62.082
GVW (Gross Vehicle Weight)
Dimensional tolerance: 3%

276DT003T

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ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 7

CENTER OF GRAVITY (horizontal position)

Empty vehicle mm ft
S Front distance 2465 8.09
T Rear distance 2925 9.59

Loaded vehicle mm ft
S Front distance 3701 12.14
T Rear distance 1689 5.54

Dimensional tolerance: 3%

276DT004T

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8 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

PERFORMANCE

Tire type 29.5 R 30

Total axle ratio 1:22.24

Gear Transmission Total Speed (*) Gradient (**)

ratio ratio km/h (mph) (lock-- up) (%)

1st forward 1 : 5.350 112.35 5.4 (3.4) 36.5

2nd forward 1 : 3.446 72.366 8.4 (5.3) 22.1
3rd forward 1 : 2.206 46.326 13.2 (8.3) 13.4
4th forward 1 : 1.421 29.481 20.5 (12.9) 8.1
5th forward 1 : 0.969 20.349 30 (18.9) 5.0
6th forward 1 : 0.624 13.104 46.6 (29.3) 2.5
1st reverse 1 : 5.350 112.35 5.4 (3.4) 36.5
2nd reverse 1 : 2.206 46.326 13.2 (8.3) 13.4
3rd reverse 1 : 0.969 20.349 30 (18.9) 5.0

(*) speed that can be reached with engine running at 2100 (rpm) and tire rolling circle of 4.85 m (190.94 in).
(**) full load.

Maximum torque in 1st gear: 3.0 km/h (1.86 mph)

Maximum speed (calculated). 46.6 km/h (28.96 mph)

Maximum gradient in 1st gear (calculated, locked up): 36.5%

Maximum gradient in 1st gear (calculated, using converter): 54%

Empty transversal gradeability (D) XX%

Full load transversal gradeability (D) XX%
(D) minimum adherence ratio 0.6

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ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 9

Left intentionally blank

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
10 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

PERFORMANCE ALIGNMENT CHART

The performance alignment chart can be used to check whether the load/slope conditions are compatible with
the vehicle performance and if so, what this performance is.
. The alignment chart was drawn according to the engine torque curve. It is therefore valid when the
accelerator pedal is fully pressed.

The following data must be known to use the alignment diagram:

1. total ground vehicle weight (GVW)
2. slope of ground
3. rolling resistance

1. The total ground vehicle weight (GVW) is obtained by summing tare and planned load.
. Refer to tables on previous pages for maximum admitted values.

2. The slope must be expressed as a percentage. Values expressed in degrees must be converted.
3. Rolling resistance can be evaluated according to ground conditions as shown in the following table.

Resistance for 1000 kg of GVW

Conditions of terrain %
kg lb
Asphalt --- Cement 15 33 1.5
Compact dirt 20 44 2.0
Soft dirt 30 66 3.0
Mud on solid bottom 40 88 4.0
Compacted snow 25 55 2.5
Soft snow 45 49 4.5
Sand --- Gravel 100 220 10.0

Sum the slope percentage and the rolling resistance to obtain final grade.

Using the alignment chart

Starting from the GVW (point A), draw a vertical line to meet the total resistance line grade (point B).
Draw a horizontal line starting from point B to cross one of the use curves: this shows one of the possible condi-
tions of use (point C).
Continue the horizontal line to cross the ordinate axis: this shows the total traction force (RIMPULL, point D).
Draw a vertical line from point C to meet the abscissa: this shows the speed which can be reached (SPEED, point
E).

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ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 11

Performance alignment chart (Fig. 1)

C B

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12 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

MAIN TECHNICAL SPECIFICATIONS

The chassis type and number of the articulated truck id the vehicle identification data.

The chassis number is punched on the right ---hand side of the vehicle (arrow).

Chassis number

1. International manufacturer identification

2. Type of vehicle, (AD = articulated dumper)
3. Capacity:
30 = 30 tons
4. Version:
TP = Tipper
5. Data of manufacture
6. Data of manufacture
7. Chassis progressive number.

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ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 13

Case PIN plate

The case PIN is indicated on a plate fitted in the cab rear left external side.
D Model
D Product identification Number (PIN)

276DT100

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14 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

POSITION OF IDENTIFICATION DATA ON MAIN GROUPS

All the main vehicle groups are identified with a serial Engine
number to be found on the actual group, in the posi-
tions shown below.
The group identification number is always to
be indicated when ordering spare parts.

Cab

269NM0D3
The type of engine and the serial number are indicated
on a plate on the engine.

Automatic transmission

269DT0E4

The cab number is indicated on a plate in the cab on

the right.

Chassis

269NM0D4
The type of transmission and the serial number are indi-
cated on a plate on the transmission.

174DT06
The chassis number is stamped on the right side of the
vehicle.

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ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 15

Drive axles Dumper cylinder (two)

Disk brakes version

269DT0E2

The type and serial number are indicated on a plate on

276DT006T
the cylinder casing.

Wet brakes version Steering cylinder (two)

174DT11
The type and serial number are indicated on a plate on
276DT007T the cylinder casing.
The type of axle and the serial number are indicated on
Suspension cylinders
a plate on the axle housing.

276DT008T

The type and serial number are indicated on a plate on

the cylinder casing.

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16 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

MAIN TECHNICAL SPECIFICATIONS

Engine
Type: IVECO F3A (Cursor 10)
Four---stoke diesel, supercharged with variable geometry exhaust gas turbo compressor.
Electronically controlled injector---pump injection system with fuel pre---filter and filter and pump in tank.
Forced lubrication with gear pump and double oil filter.
Water cooled with centrifuge pump. Radiator fan hydraulic system with pump driven by engine.
Compressed air system driven by engine.
Discharge: EPA --- CARB --- OFF ROAD TIER 3

Main geometric specifications

Number of cylinders 6
Bore mm 125
in 4,92
Stroke mm 140
in 5,51
Total displacement
p cm3 10300
cu.in 628,3
Compression ratio 16.5
Injection order 1---4---2---6---3---5

Maximum performance
p
Maximum power kW 260
BHP 348
Power ratio RPM 1900
Maximum torque
q Nm 1650
Ft lb 1217
Torque ratio RPM 1400

Automatic transmission
Type: ZF 6WG260
Automatic transmission with 6 forwards gears and 3 reverse.
Single stage hydrodynamic torque converter.
Stall ratio: 1 :1.840
Lock ---up clutch in all gears.
Incorporated transfer case with central lockable splitter between the front axle and the intermediate and rear axles.

Transmission ratios
Gear Ratio
1st 5.350
2nd 3.446
3rd 2.206
4th 1.421
5th 0.969
6th 0.624
1st R 5.350
2nd R 2.206
3rd R 0.969
R = Reverse

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ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 17

Front drive axle

Type: semi---independent with automatic transmission integrated differential, and KESSLER D81 hubs
Limited slip differential forming single block with automatic transmission, pivoting drive axles with double CV joint,
wheel hubs with planetary reductions.
Pivoting axle hinged to chassis, transversal stabilizer bar.

Axle ratios
central bevel gear pair 3.50

planetary reduction gear set 6.00

total reduction 21.00

Intermediate and rear drive axles

Type: KESSLER D81
Rigid type axle with side pinion reduction on hubs; limited slip differential.
Fixed distribution of 50/50 between the intermediate axle and rear axle.

Transmission ratios
central bevel gear pair 3.50

planetary reduction gear set 6.00

total reduction 21.00

Suspension
Front: Two hydro---pneumatic cylinders (nitrogen---oil) for variable flexibility and damping.
Rear: rigid double rocker arm, load splitter on intermediate and rear axles with reaction bar.

Brakes

Wet brakes version

Service brakes: a disk brake group with caliper and four small hydraulically controlled pistons for each wheel.
Parking brake: plate and spring applied, pneumatically released calliper acting on drive shaft between automatic
transmission and intermediate axle.
Additional parking brake: can be applied when the vehicle is stationary, acts on tandem axle brake units.

Disk brakes version

Service brake: disk braking assembly with four pistons calliper, hydraulically controlled on each wheel.
Parking brake: plate and spring operated, pneumatically released calliper acting on drive shaft between automatic
transmission and intermediate axle.
Additional parking brake: can be applied when the vehicle is stationary, acts on tandem axle brake units.

Wheels and tires

Steel rims on six wheels.

Type and dimensions

Type Rims Tires
std 19.50 --- 25” 23.5 R 25

opt 22.00 --- 25” 650/65 R 25

opt 25.00 --- 25” 750/65 R 25

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18 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

Hydraulic system
Independent reservoir. Oil---air heat exchanger.
Steering---dumping circuit: suction and delivery filter. Pump mechanically operated by the automatic transmis-
sion.
Braking circuit: suction and delivery filter. Pump mechanically operated by the engine.

Steering
Hydraulically controlled, two dual acting hydraulic cylinders acting on articulation joint between chasses.
Emergency pump, operated by the automatic transmission.

Dumper
Two dual acting multistage hydraulic cylinders fitted on ball joints inside the chassis.
Assisted return stroke.

Brake
Independent front and rear wheel braking system. Hydraulic pressure accumulators.

Brake cooling system (only wet brakes version)

Independent reservoir. Suction and delivery filter.
Hydraulically operated pump with proportional temperature control.

Electrical system
Multiplex electrical system.
Connection between ECUs on CAN line.
Nominal voltage: 24 V
Starter motor: 24 V 5.5 kW
Alternator: 28 V 90 A
Batteries: 2, connected in series: 12 V 170 Ah, 700 A

Chassis
High---resistant steel (Hardox 400) structure with welded boxing and plates.
Articulated, two independent structures, connected by means of oscillation bearing and taper roller bearings for
demanding use ensuring rotation and pivoting between the two chassis.

Drive cab
Steel structure conforming to ROPS/FOPS specifications. Flexible support pads.
Can be tipped by hydraulic system. Tippable engine hood.
Electronically controlled climate control system.

Body
Structure with flat steel bottom with boxed parts strengthening subframes and flexible support pads. Walls and
bottom in high abrasion resistance steel (Hardox 400).
Dumping via hydraulic cylinders.
Body bottom heated by passage of exhaust gas.

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ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 19

LIST OF BULBS

Continuous Power (w) Type Quantity

Front

Marker 5 BA15s 2

Dipped beam/main beam 55/70 H4 2

Tipping main beam 70 H1 2

Cab ceiling light 5 2

Cab map reading light 5 2

Front direction indicator 21 BA15s 2

Side direction indicator 21 BA15s 2

Working lights 5 BA15s 4

Rear

Marker 5 BA15s 2

Direction 21 BA15s 2

Brake lights 21 BA15s 2

Reversing light 21 BA15s 1

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20 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

CAPACITIES
CAPACITY
PART TO BE FILLED SPECIFICATIONS
I (US Gal) kg (Ib)
Engine oil sump (1)
SAE 15W40
--- URANIA TURBO ACEA E3
30.5 (8) --- ---
--- AKCELA N°1 MIL L 21 04E lev.
API GF 4
Engine coolant radiator
Protective anti---freeze mixture/water 50 (13.2) --- --- ASTM 0336
Fuel tank
Diesel 440 (116.2) --- --- ASTM D ---975
Automatic transmission
SAE 15W40
--- URANIA TURBO ACEA E3
35.5 (9.4) --- ---
--- AKCELA N˚ 1 MIL L 21 04E lev.
API GF 4
Axles/Differentials/Planetary Hubs
Front differential 14.0 (3.7)
SAE 10W30
Front hub 3.0 (0.8) x 2
--- AMBRA MULTI G --- --- ISO 32/46
Intermediate axle 35.0 (9.3)
API GL4 level
Rear axle 33.0 (8.7)
Suspension
--- TUTELA GI/A
1.5 (0.41) x 2 --- --- ATF DEXRON Il
--- AKCELA A.T.F.
30 bar
--- Nitrogen --- --- --- ---
(456.9 psi)
Hydraulic circuit (2)
--- IDRAULICAR HVI 46 ISO VG 46
210.0 (55.5) --- ---
--- AKCELA HYDRAULIC Excavator Fluid DIN 51524/51525
Engine hood/cab tipping circuit
--- TUTELA GI/A
2.0 (0.5) --- --- ATF DEXRON Il
--- AKCELA A.T.F.
Greasing
--- TUTELA MR2
--- --- 2.0 (4.4) N.L.G.I. 2
--- AKCELA PREMIUM GREASE AP2
Greasing device body heating
--- MOLYCOTE Cu7439
Q.B. --- --- --- ---
--- LOCTITE 8152
Climate control system
Refrigerant fluid R134a --- --- 1.2 (2.65) --- ---
Windshield washer
Protective anti---freeze mixture/water Q.B. --- --- --- ---

(1) for ambient temperature < ---20˚C use SAE 5W30

for ambient temperature > 45˚C use SAE 20W50
(2) for ambient temperature ---40 ˚C < T < 20 ˚C use ISO VG 100
for ambient temperature 0 ˚C < T < 60 ˚C use ISO VG 22

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ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 21

TIRE PRESSURE TABLE

Pressure
Tires Front (F) Rear (R)
Bar Psi Bar Psi
23.5 R 25 (std) 3.25 47 3.50 50.5
650/65 R 25 (opt) 3.50 50.5 3.50 50.5
750/65 R 25 (opt) 3.00 43.5 3.25 47

ANTIFREEZE CONCENTRATION IN ENGINE COOLANT

Ambient temperature
Antifreeze Water
˚C ˚F
---35/ ---30 ---31/ ---22 50% 50%
---25/ ---20 ---13/ ---4 40% 60%
---15/ ---8 5/18 30% 70%
---5/0 23/32 20% 80%

ANTIFREEZE CONCENTRATION IN WINDSCREEN WASHER FLUID

Ambient temperature
Antifreeze Water
˚C ˚F
---35 ---31 1 0
---20 ---4 1 1
---10 14 1 2
0 32 1 6
summer 1 10

BATTERY ELECTROLYTE DENSITY TABLE

Electrolyte
y density
y
Ambient temperature
(100% of charge)
˚C ˚F g/dm3
40 104 1.265
20 68 1.285
0 32 1.300
---20 ---4 1.365

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
22 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

TIGHTENING TORQUE

Tightening torque
PART Notes
Nm Ft lb
AUTOMATIC TRANSMISSION
Oil drainage cap 140 103

HUBS/AXLES
Front differential oil drainage cap 70 51 Socket head

HYDRAULIC SYSTEM
Tank drainage cap (both) 20 15

STEERING AND WHEELS

Wheel fastening nuts 590 435
Steering column fastening bolt 45 33

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 23

PLATES APPLIED TO THE VEHICLE

The adhesives and plates applied on the vehicles may the adhesives and plates on a 30 model, indicating the
vary according to the market and local requirements of position where they are located.
the country. These pages contain a brief description of

1 2 3
4

10 10

6 6

9 8 7 6 5

14 5
5

12
10 10

6 6

6 78 4 13

19

13 276DT010T

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
24 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

Articulation joint left size Cab access steps

15

16
17
18
276DT011T 269DT202

EUROPEAN VERSION
Pos. 1 CE plate Pos. 4 Hot surface warning plate

Pos. 2 Inside noise plate

Pos. 5 Crushing hazard warning plate

Pos. 3 Outside noise plate

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 25

Pos. 6 Vehicle tie-- down plate Pos. 9 Tipping engine hood plate

Pos. 7 Crushing hazard warning plate Pos. 10 Towing eye plate

Pos. 8 Keep clear of prop shaft plate Pressurized system hazard plate
(Located on the accumulator)

Pos. 12 Hydraulic oil filler plate

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
26 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

Pos. 13 Grease point centralized plate Pos. 17 Lubrification plate

Pos. 14 Crushing hazard warning plate

Pos. 15 Safety warning plate Pos. 18 Test point plate

Pos. 16 Maintenance plate

Pos. 19 Chassis lock warning plate

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 27

INSIDE ENGINE HOOD PLATE

Moving parts warning plate Battery throw off plate

Located near the battery isolator switch button.

INSIDE CAB PLATE

Located on the side of the radiator and on the belt side
protection. Cargo body dumping control plate

Warning plate

Located on the glass near the dump---up lever.

Tilting hazard warning plate

Located on the starting motor.

Danger of burns warning plate

Located on the front right ---hand window.

Located on the upper part of the expansion tank.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
28 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

Emergency exit Tire inflation pressure plate

Located on the left ---hand side of the steering column.

Located on the front lower right ---hand window.
Voltage rating plate
Gear selector plate

Located near the electrical socket on the right ---hand si-

de under the module support panel.

Parking brake plate

Located on the ZF selector

Warning plate

Located near the parking brake control.

Located to the left of the ashtray. Warning plate

Position on the left side next to the air conditioning /

heating controls.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 29

U.S.A. VERSION
Hot Surfaces warning plate Crushing hazard warning plate

Crushing hazard warning plate Keep clear of prop shaft plate

Vehicle tie-- down plate Tipping engine hood

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
30 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

Towing eye plate Crushing hazard warning plate

Pressurized System hazard plate Safety warning plate

Hydraulic oil filler plate Crushing hazard warning plate

Grease point centralized plate Maintenance plate

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 31

Lubrification plate Test point

INSIDE ENGINE HOOD PLATE

Moving parts warning plate Danger of burns warning plate

Located on the upper part of the expansion tank.

Battery throw off plate

Located on the side of the radiator and on the belt side

protection.

Warning plate

Located near the battery isolator switch button.

INSIDE CAB PLATE

Cargo body dumping control plate

Located on the starting motor.

Located on the glass near the dump---up lever.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
32 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

Tilting hazard warning plate Tire inflation pressure plate

Located on the left ---hand side of the steering column.

Located on the front right ---hand window.
Voltage rating plate
Emergency exit

Located near the electrical socket on the right ---hand

side under the module support panel.

Parking brake plate

Located on the front lower right ---hand window.

Gear selector plate

Located near the parking brake control.

Warning plate

Located on the ZF selector

Warning plate

Located to the left of the ashtray. Position on the left side next to the air conditioning /
heating controls.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 2 TECHNICAL DATA 33

STANDARD TIGHTENING TORQUES

Screws and nuts with metric thread

Maximum tightening torque for metric threads in lb ft

Diameter SCREW --- CLASS SCREW --- CLASS SCREW --- CLASS
x 8.8 10.9 12.9
Pitch
dxp DA- DA- DA-
PHOS- PHOS- PHOS-
(mm) UN- CROMET CADMIUM PHATE UN- CROMET CADMIUM PHATE UN- CROMET CADMIUM PHATE
COATED GALVA- PLATED COATED COATED GALVA- PLATED COATED COATED GALVA- PLATED COATED
NISED NISED NISED

3 x 0.5 0.88 0.88 0.81 0.66 1.25 1.18 1.10 0.96 1.55 1.40 1.33 1.11

4 x 0.7 2.06 1.92 1.77 1.47 2.88 2.73 2.51 2.14 3.47 3.24 3.02 2.58

5 x 0.8 4.13 3.83 3.54 2.95 5.83 5.46 4.94 4.20 6.93 6.49 5.90 5.01

6x1 7.37 6.64 5.90 5.16 9.59 9.59 8.85 7.37 11.80 11.06 10.32 8.85

8 x 1.25 16.96 16.22 14.75 12.54 24.34 22.86 20.65 16.96 28.76 27.29 24.34 20.65

8x1 18.44 17.70 15.49 13.27 25.81 24.34 22.12 18.44 31.71 29.50 26.55 22.12

10 x 1.5 34.66 32.45 29.50 24.34 47.94 44.99 41.30 34.66 58.26 54.57 49.41 41.30

10 x 1.25 36.87 34.66 30.97 25.81 51.62 47.94 43.51 36.14 61.95 58.26 52.36 43.51

12 x 1.75 59.00 55.31 50.15 42.04 83.34 78.17 70.80 59.00 100.30 93.66 84.81 70.80

12 x 1.25 66.37 61.95 55.31 45.72 92.92 87.02 78.17 64.16 111.36 103.99 93.66 76.70

14 x 2 94.4 88.50 80.39 67.11 132.75 124.64 112.84 94.40 159.30 148.97 135.70 112.84

14 x 1.5 103.99 96.61 87.76 71.54 146.02 136.44 123.16 100.30 175.52 163.72 147.50 120.95

16 x 2 146.02 136.44 123.90 102.51 205.76 192.49 174.05 143.81 247.06 230.84 208.71 172.57

16 x 1.5 158.56 147.50 132.75 107.67 222.72 207.97 186.59 151.92 267.71 249.27 224.20 182.16

18 x 2.5 200.60 187.32 170.36 141.60 281.72 264.02 238.95 199.12 337.77 316.39 286.89 238.95

18 x 1.5 231.57 215.35 193.22 155.61 325.24 303.11 271.40 219.03 390.87 363.59 325.97 263.29

20 x 2.5 283.20 266.24 241.16 199.12 400.46 374.65 339.25 280.25 480.85 449.87 407.10 336.30

20 x 1.5 323.76 301.64 269.19 216.82 455.03 424.06 379.07 304.59 546.49 508.14 454.30 365.06

22 x 2.5 397.51 361.37 328.92 266.97 559.76 507.40 463.15 376.12 671.12 609.17 555.34 450.61

22 x 1.5 435.12 404.15 360.64 288.36 611.39 568.61 507.40 405.62 733.81 682.19 609.17 487.48

24 x 3 491.91 460.20 415.95 343.67 691.77 646.79 584.84 483.06 829.69 775.85 702.10 579.67

24 x 2 547.22 509.61 456.51 368.75 769.95 716.85 642.36 518.46 924.09 860.66 770.69 622.45

27 x 3 727.91 679.97 612.86 502.97 1023.65 955.80 862.14 707.26 1227.94 1146.81 1033.97 848.12

27 x 2 799.45 743.40 664.48 533.95 1123.95 1045.77 934.41 750.77 1348.89 1255.22 1121.74 901.22

30 x 3.5 986.04 921.14 831.16 684.40 1386.50 1295.05 1168.94 962.47 1663.80 1553.91 1402.72 1154.18

30 x 2 1118.05 1039.87 927.77 741.92 1572.35 1461.72 1304.64 1043.56 1887.26 1754.51 1564.97 1252.27

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
34 TECHNICAL DATA SECTION 2 ADT 25-30 TIER3

MEASURES (INTERNATIONAL SYSTEM)

Force in N (Newton) Pressure in kPa (kilopascal)
Other units in use:
Conversion: kg/cm2 (kilogram per square centimeter)
1N = 0.1019 kg Atm (Metric atmosphere)
1 kg = 9.81 N psi (Pound per square inch)

Conversion:
Power in kW (kilowatt) 1 kg/cm2 = 1 Atm
Other units in use: 1 kg/cm2 = 98.1 kPa
CV (Horse) 1 kg/cm2 = 0.981 bar
HP (Horse---Power) 1 kg/cm2 = 1 bar *
1 kg/cm2 = 14.22 psi
Conversion: 1 bar = 100 kPa
1 kW = 1.36 CV 1 bar = 1.02 kg/cm2
1 kW = 1.34 HP 1 bar = 14.51 psi
1 CV = 0.736 kW 1 psi = 6.9 kPa
1 CV = 0.986 HP 1 psi = 0.069 bar
1 HP = 0.746 kW 1 psi = 0.0703 kg/cm2
1 HP = 1.014 CV 1 kPa = 0.145 psi
1 kPa = 0.0102 kg/cm2
1 kPa = 0.01 bar
Torque in Nm

Conversion: Conversion values for British units

1 Nm = 0.1019 kg 1 mm = 0.039 inch
1 kgm = 9.81 Nm 1m = 3.281 ft.
1 kgm = 10 Nm * 1 km = 0.621 miles
1 cm3 = 0.06 I cu. in.
1l = 1.759 pts (0.88 Imp. qts)
Specific consumption in g/kWh (grams per kilowat- 1 bar = 14.5038 psi
thour) 1g = 0.035 oz. (0.564 dr.)
Other unit in use: 1 kg = 2.205 Ibs.
g/CVh (grams per Horsehour) 1t = 1.102 short ton (0.9842 long ton)
(˚F − 32)
˚C =
Conversion: 1.8
1 g/kWh = 0.736 g/CVh ˚F = (˚C x 1.8) + 32
1 g/CVh = 1.36 g/kWh
(*) Nm and bar are converted according to the ratios
10:1 and 1:1

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 SECTION 3

FAILURE CODES
ADT 25-30 TIER3 SECTION 3 FAILURE CODES 1

CONTENTS

Page Page

ENGINE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . 3 TRANSMISSION FAILURE LIST . . . . . . . . . . . . . . . 11

FAULT CHECK USING THE DISPLAY . . . . . . . . . . . 3 DIAGNOSTIC CONNECTOR PIN-- OUT . . . . . . . . 36

ENGINE FAULT CODES LIST . . . . . . . . . . . . . . . . . . 4 MULTIPLEX SYSTEM FAULT CODES . . . . . . . . . . 37

AUTOMATIC TRANSMISSION FAULT CODES . . 10 FAULT CHECK USING THE DISPLAY . . . . . . . . . . 37

FAULT CHECK USING THE DISPLAY . . . . . . . . . . 10 MULTIPLEX SYSTEM FAULT CODES LIST . . . . . 38

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
2 FAILURE CODES SECTION 3 ADT 25-30 TIER3

Left intentionally blank

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 3 FAILURE CODES 3

ENGINE FAULT CODES

FAULT CHECK USING THE DISPLAY

Figure 1

276C003001A

When a fault is detected, an error code is visualized in

the string below the display (see arrow). Figure 2

Codice EDC xx

Furthermore, the indicator (Fig. 2) and the indicator

(Fig. 3, ref. 1) or both indicators (Fig. 3, ref.1 and ref. 2)
light up as a function of the fault severity. 269NS0F4
The complete list of error codes is provided in the follo-
wing pages.
Figure 3

1 2
269NU383

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
4 FAILURE CODES SECTION 3 ADT 25-30 TIER3

ENGINE FAULT CODES LIST

Failure code Failure description

Vehicle 1 (Sensors/Plausibility checks)
10011 Fault path 1 for vehicle Speed sensing
20011 Fault path 2 for vehicle Speed sensing(CAN)
30011 Fault path 3 for veh. Speed (max.pulse width)
10012 Accelerator Pedal 1
20012 Accelerator Pedal 2
10013 Accelerator Pedal and brake not plausible
10014 Multiple State Switch
10015 Cruise control actuating device evaluation error
10016 Main clutch signal
10017 Brake signal
10018 Engine brake preselection switch status
10019 No terminal 15 signals detected
1001A Terminal 50 always pressed
1001B High resolution wheel speed CAN message
2001B Vehicle dynamics control unit CAN message
1001C Water in fuel
2001D Catalyst ageing limit exceeded
3001D DCU state monitoring
1001E NH3Slip
2001E Catalyst efficiency lower than first Nox prediction threshold level
3001E Catalyst efficiency lower than first Nox prediction threshold level
4001E Catalyst presence monitoring
1001F Plausibility check of catalyst system
2001F Boost pressure actuator current monitoring
3001F Too high efficiency of catalyst system
Vehicle 2 (Lamps/relays/actuators)
10021 Adjustable speed limit lamp
10022 Power stage fault status for MIL
10023 Power stage for system lamp
10024 Cold start lamp
20024 Coolant temperature lamp
10025 Main relay defect (for High press pump P340/for engine brake decompr.valve P342))
20025 Interrupted afterrun
10026 Battery voltage fault
10027 Eng.brake decompr.valve
10028 Main relay SCBatt (Lambda H./Grid H./Batt.switch)
20028 Main relay SCGND (Lambda H./Grid H./Batt.switch)
10029 Main relay 3 (A/C compr./fuel filter heater)
1002A Main relay 4 (Exhaust valve eng.brake flap)
2002A Particulate filter lamp

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 3 FAILURE CODES 5

Failure code Failure description

1002B Power stage air heater 1 actuator
1002C Power stage air heater 2 actuator
1002D Air heater test switch on (voltage<low thresh.)
2002D Air heater test switch off (voltage>high thresh.)
1002E Grid heater always switched on
1002F Air condition power stage CAN message
Engine 1 (Temperature and Pressure Sensors)
10031 Coolant temperature sensor
10032 Coolant temperature sensor dynamic test
20032 Coolant temperature sensor absolute test
30032 Engine temperature check
10033 Boost Temp. Signal
10034 Boost pressure sensor
10035 Fuel Temp. Signal
10037 Rail pressure relief valve
10038 Oil Pressure Sensor
20038 Oil Pressure too low
30038 Oil Pressure sensor lamp
1003A Oil Temp. Sensor
2003A Oil Temperature above normal
1003C Atmospheric Temperature Sensor(Humidtiy?)
1003D Fuel pressure sensor
Engine 2 (Speed sensing/actuators)
10041 Crankshaft sensor failure
10042 Running with camshaft sensor only
10043 Camshaft sensor failure
10044 Offset between camshaft and cranksh.
10045 Power stage Fan actuator
10046 Power stage Fan 2 actuator
10047 Fan speed sensor signal
10048 Air condition power stage
10049 Fuel filter heating output
1004A Engine Compartment Start Button is stuck
2004A Engine Compartment Stop Button is stuck
1004B Blowby recircul. Control relay actuator
1004C Blowby engine overspeed detection
1004D Engine overspeed protection
1004E TurboCompound monitoring
Fuel metering Unit Injector Systems
10051 Cyl.1 specific errors
10052 Cyl.2 specific errors
10053 Cyl.3 specific errors
10054 Cyl.4 specific errors

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6 FAILURE CODES SECTION 3 ADT 25-30 TIER3

Failure code Failure description

10055 Cyl.5 specific errors
10056 Cyl.6 specific errors
10057 Disabled Cyl. Shutoff function
1005F First collection fault path for potentially long term fault path
2005F Second collection fault path for potentially long term fault path
3005F Third collection fault path for potentially long term fault path
4005F Forth collection fault path for potentially long term fault path
5005F Fifth collection fault path for potentially long term fault path
Injectors 1
10061 Cylinder1 --- Short circuit Low/High
10062 Cylinder2 --- Short circuit Low/High
10063 Cylinder3 --- Short circuit Low/High
10064 Cylinder4 --- Short circuit Low/High
10065 Cylinder5 --- Short circuit Low/High
10066 Cylinder6 --- Short circuit Low/High
10067 Cylinder1 --- Open load
10068 Cylinder2 --- Open load
10069 Cylinder3 --- Open load
1006A Cylinder4 --- Open load
1006B Cylinder5 --- Open load
1006C Cylinder6 --- Open load
1006D Fault path to disable rail monitor. while compr.test active
1006E The minimum number of injections was not reached --- ---> stop the engine
1006F Additive valve actuator
Injectors 2
10071 Bank 1 specific errors --- Short circuit / not classifyable
10072 Bank 1 specific warnings --- Open load
10073 Bank 2 specific errors --- Short circuit / not classifyable
10074 Bank 2 specific warnings --- Open load
10075 Misfire Cylinder 1
20075 leakage or misfiring in cylinder 1
10076 Misfire Cylinder 2
20076 leakage or misfiring in cylinder 2
10077 Misfire Cylinder 3
20077 leakage or misfiring in cylinder 3
10078 Misfire Cylinder 4
20078 leakage or misfiring in cylinder 4
10079 Misfire Cylinder 5
20079 leakage or misfiring in cylinder 5
1007A Misfire Cylinder 6
2007A leakage or misfiring in cylinder 6
1007B Misfire in multiple cylinders
1007C Chip---specific errors--- --->stop engine

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ADT 25-30 TIER3 SECTION 3 FAILURE CODES 7

Failure code Failure description

2007C Chip---specific errors--- --->stop engine
1007D common fault in combustion monitoring
1007E Fault path of injection limitation
Boost system and turbine speed
70090 Monitoring of the controller
10091 Boost pressure actuator current AD ---channel
10092 Short circuit to Battery for BPA powerstage
20092 Short circuit to Ground for BPA powerstage
30092 No load/excessive temp.for BPA power stage
10093 Turbine speed
20093 actual turbo speed evaluation for interface
10094 Multi signal defects in EPCtl
10095 P2 pressure errors in EPCtl
10096 P3 pressure errors in EPCtl
10097 Turbine speed errors in EPCtl
10098 Multi signal defects in PCR
10099 P2 pressure errors in PCR
1009A Turbine speed errors in PCR
1009B High turbine speed and high air pressure
1009C P3 pressure errors in PCR
1009D indicates torque limitation due to performance limiter
2009D torque limitation due to NTC
3009D Performance limit active due to either stage
4009D indicates torque limitation due to particulate filter
5009D indicates torque limitation due to SCR
1009E indicates torque limitation due to smoke limitation
2009E indicates torque limitation due to turbo compound
3009E indicates torque limitation due to turbo charger protection
4009E indicates the torque limitation due to engine protection
5009E indicates torque limitation due to noise control
6009E indicates torque limitation due to Fuel quantity Limitation
1009F Multi signal defects in EGSys_NOxEstIv
Interfaces 1 (CAN---Bus)
100B1 Busoff in CAN A
100B2 Busoff in CAN B
100B3 Busoff in CAN C
100B4 Timeout for BC2EDC1
200B4 Timeout for BC2EDC2
100B5 Timeout for VM2EDC
100B6 Timeout of CAN message WSI
100B7 Timeout in CAN send messages
100B8 Physical unplausibility of TSC---demand
100B9 MIL visualization for BC2EDC1

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8 FAILURE CODES SECTION 3 ADT 25-30 TIER3

Failure code Failure description

100BA Message Dashboard Display timeout
100BB Message ERC1DR timeout
100BC Message RxAMCONlv timeout
100BD Timeout error of RxCCVS message
100BE Physical plausibility DCS
100BF CAN message RxEngTemp2
Interfaces 2 (CAN messages timeout)
100C1 Timeout of CAN message EBC1
100C2 Timeout of CAN message ETC1
100C3 Timeout of CAN message TCO1
200C2 Timeout of CAN message ETC2
100C4 Timeout of CAN message TSC1---AE active
200C4 Timeout of CAN message TSC1---AR active
300C4 Timeout of CAN message TSC1---AE passive
400C4 Timeout of CAN message TSC1---AR passive
100C5 Timeout of CAN message TSC1---DE active
200C5 Timeout of CAN message TSC1---DR active
300C5 Timeout of CAN message TSC1---DE passive
400C5 Timeout of CAN message TSC1---DR passive
100C6 Timeout of CAN message TSC1---PE active
200C6 Timeout of CAN message TSC1---PE passive
100C7 Timeout of CAN message TSC1---TE active
200C7 Timeout of CAN message TSC1---TR active
300C7 Timeout of CAN message TSC1---TE passive
400C7 Timeout of CAN message TSC1---TR passive
100C8 Timeout of CAN message TSC1---VE active
200C8 Timeout of CAN message TSC1---VR active
300C8 Timeout of CAN message TSC1---VE passive
400C8 Timeout of CAN message TSC1---VR passive
100C9 Timeout of CAN message TF
200C9 Timeout for message TimeDate
300C9 Timeout for message HRVD (high resol.vehicle distance)
ECU 1 (internal checks)
100D1 Communication error of CJ940
100D2 Error state of EEPROM
100D3 Recovery which is locked
200D3 Recovery which is suppressed
300D3 Recovery which is visible
100D4 Communic.supervision Watchdog/Contr. ---Flag
100D5 Redundant shutoff paths during initial.
100D6 Deviation between TPU and system time
100D7 Dataset variant coding
100D8 Supervision of SPI ---handler Flag

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ADT 25-30 TIER3 SECTION 3 FAILURE CODES 9

Failure code Failure description

100D9 Error status ADC monitoring
100DA Fault FMTC_trq2qBas_MAP containes non strictly monotonous q curves
ECU 2 (Powerst./Immobil./Overrun/Sensor supply)
100E1 Short circuit to Batt or Ground, no load, excess.temp. for high side power stage
200E1 Short circuit to Batt or Ground, no load, excess.temp. for low side power stage
100E2 Error state of Immobilizer (no fuel release)
100E3 Energising time exceeds limit of overrun monitor.
100E4 Plausibility error in engine speed check
100E5 12V sensor supply voltage
100E6 Sensor supply voltage 1
100E7 Sensor supply voltage 2
100E8 Sensor supply voltage 3
100E9 Supply voltage CJ940 upper limit
100EA Supply voltage CJ940 lower limit
100EB Atmospheric Pressure Sensor
100EC Runuptest is set to disable misfire detection during runup test
100ED Fault path for Runup test
100EF Mass of soot in oil beyond prescribed limit

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10 FAILURE CODES SECTION 3 ADT 25-30 TIER3

AUTOMATIC TRANSMISSION FAULT CODES

FAULT CHECK USING THE DISPLAY

Figure 1

276C003001A

When a fault is detected, an error code is visualized in

the string below the display (Fig.1, see arrow). Figure 2

Codice TCU xx

If there is more than one error, each code is displayed

for about 1 second. 269NU153
Furthermore, the indicator (Fig. 2) and the indicator
(Fig. 3, ref. 1) or both indicators (Fig. 3, ref. 1 and ref.
2) light up as a function of the fault severity. Figure 3
The complete list of error codes is provided in the follo-
wing pages.

1 2
269NU383

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 3 FAILURE CODES 11

TRANSMISSION FAILURE LIST

Abbreviations list
o.c. open circuit
s.c. short circuit
OP-- Mode operating mode
TCU transmission control unit
EEC electronic engine controller
PTO power take off

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
LOGICAL ERROR AT GEAR TCU shifts S check the fault is taken
RANGE SIGNAL transmission cables from back if TCU
TCU detected a wrong to neutral TCU to shift detects a
signal combination for lever valid signal
the gear range OP---Mode: S check signal for the
TCU11 S cable from shift lever transmission
to TCU is broken shutdown
combinations
of shift lever
position

S cable is defective and positions for

is contacted to gear range
battery voltage or
vehicle ground
S shift lever is defective
LOGICAL ERROR AT TCU shifts S check the fault is taken
DIRECTION SELECT SIGNAL transmission cables from back if TCU
TCU detected a wrong to neutral TCU to shift detects a
signal combination for lever valid signal
the direction OP---Mode: S check signal for the
TCU12 S cable from shift lever transmission
to TCU is broken shutdown
combinations
of shift lever
direction at
the shift lever
S cable is defective and positions
is contacted to F ---N ---R
battery voltage or
vehicle ground
S shift lever is defective
LOGICAL ERROR AT ENGINE after select- S check engine This fault is
DERATING DEVICE ing neutral,
neutral derating reset after
TCU13 TCU detected no TCU changesg device p
power up p of
reaction
ti off engine
i while
hil t OP
to OP---Mode
M d TCU
derating device activ limp home
LOGICAL ERROR AT TCU shifts S check the fault is taken
DIRECTION SELECT SIGNAL transmission cables from back if TCU
2. SHIFT LEVER to neutral if TCU to shift detects a
TCU detected a wrong g selector activ lever 2 valid neutral
signal combination forf O
OP---Mode: S check signal signal for
f the
the direction transmission combinations direction at
TCU15 S cable from shift lever shutdown if of shift lever the shift lever
2 to TCU is broken selector activ positions
S cable is defective and F ---N ---R
is contacted to
battery voltage or
vehicle ground
S shift lever is defective

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
12 FAILURE CODES SECTION 3 ADT 25-30 TIER3

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
LOGICAL ERROR AT AXLE OP---Mode: S check the
CONNECTION normal cables from
feedback axle TCU to
connection measured feedback axle
by TCU and output connection
signal axle connection switch
don’t fit S check signals
TCU16 S axle can’t be of the
connected or feedback axle
disconnected due to connection
mechanical problem switch
S one of the cables
from feedback axle
connection ---switch to
TCU is broken
S.C. TO GROUND AT GEAR customer S check the
DEPENDENT SIGNAL FOR specific cable from
NOISE REDUCTION TCU to Gear
TCU detected a wrong dependent
voltage at the output signal for noise
pin, that looks like a s.c. reduction
to vehicle ground device
S cable is defective and S check the
is contacted to connectors
vehicle ground from Gear
TCU17 S Gear dependent dependent
signal for noise signal for noise
reduction device has reduction to
an internal defect TCU
S connector pin is S check the
contacted to vehicle resistance of
ground Gear
dependent
signal for noise
reduction
device
S.C. TO BATTERY VOLTAGE customer S check the
AT GEAR DEPENDENT specific cable from
SIGNAL FOR NOISE TCU to Gear
REDUCTION dependent
TCU detected a wrong signal for noise
voltage at the output reduction
pin, that looks like a s.c. device
to battery voltage S check the
S cable is defective and connectors
is contacted to from Gear
TCU18 battery voltage dependent
S Gear dependent signal for noise
signal for noise reduction to
reduction device has TCU
an internal defect S check the
S connector pin is resistance of
contacted to battery Gear
voltage dependent
signal for noise
reduction
device

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ADT 25-30 TIER3 SECTION 3 FAILURE CODES 13

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
O.C. AT GEAR DEPENDENT customer S check the
SIGNAL FOR NOISE specific cable from
REDUCTION TCU to Gear
TCU detected a wrong dependent
voltage at the output signal for noise
pin, that looks like a reduction
o.c. for this output pin device
S cable is defective and S check the
has no connection to connectors
TCU from Gear
TCU19 S Gear dependent dependent
signal for noise signal for noise
reduction device has reduction
an internal defect device to TCU
S connector has no S check the
connection to TCU resistance of
Gear
dependent
signal for noise
reduction
device
S.C. TO BATTERY VOLTAGE no reaction, S check the
OR O.C. AT TRANSMISSION TCU uses cable from
SUMP TEMPERATURE default TCU to the
SENSOR INPUT temperature sensor
the measured voltage is S check the
too high: OP---Mode: connectors
S cable is defective and normal S check the

TCU25 is contacted to
battery voltage
temperature
sensor
S cable has no
connection to TCU
S temperature sensor
has an internal defect
S connector pin is
contacted to battery
voltage or is broken
S.C. TO GROUND AT no reaction, S check the
TRANSMISSION SUMP TCU uses cable from
TEMPERATURE SENSOR default TCU to the
INPUT temperature sensor
the measured voltage is S check the
too low: OP---Mode: connectors
TCU26 S cable is defective and normal
is contacted to
S check the
temperature
vehicle ground sensor
S temperature sensor
has an internal defect
S connector pin is
contacted to vehicle
ground

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
14 FAILURE CODES SECTION 3 ADT 25-30 TIER3

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
S.C. TO BATTERY VOLTAGE no reaction, S check the
OR O.C. AT RETARDER TCU uses cable from
TEMPERATURE SENSOR default TCU to the
INPUT temperature sensor
the measured voltage is S check the
too high: OP---Mode: connectors
S cable is defective and normal S check the

TCU27 is contacted to
battery voltage
temperature
sensor
S cable has no
connection to TCU
S temperature sensor
has an internal defect
S connector pin is
contacted to battery
voltage or is broken
S.C. TO GROUND AT no reaction, S check the
RETARDER TEMPERATURE TCU uses cable from
SENSOR INPUT default TCU to the
the measured voltage is temperature sensor
too low: S check the
S cable is defective and OP---Mode: connectors
TCU28 is contacted to normal S check the
vehicle ground temperature
S temperature sensor sensor
has an internal defect
S connector pin is
contacted to vehicle
ground
S.C. TO BATTERY VOLTAGE TCU uses S check the
OR O.C. AT PARKING BRAKE default value cable from
SENSOR INPUT TCU to the
the measured voltage is OP---Mode: sensor
too high: normal S check the
S cable is defective and connectors
is contacted to S check the
TCU29 battery voltage parking brake
S cable has no sensor
connection to TCU
S sensor has an
internal defect
S connector pin is
contacted to battery
voltage or is broken
S.C. TO GROUND PARKING TCU uses S check the
BRAKE SENSOR INPUT default value cable from
the measured voltage is TCU to the
too low: OP---Mode: sensor
S cable is defective and normal S check the
TCU2A is contacted to
vehicle ground
connectors
S check the
S sensor has an parking brake
internal defect sensor
S connector pin is
contacted to vehicle
ground

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 3 FAILURE CODES 15

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
S.C. TO BATTERY VOLTAGE OP---Mode: S check the
OR O.C. AT ENGINE SPEED recovery cable from
INPUT control clutch TCU to the
TCU measures a sensor
voltage higher than S check the
7.00 V at speed input connectors
pin S check the
S cable is defective and speed sensor
TCU31 is contacted to
battery voltage
S cable has no
connection to TCU
S speed sensor has an
internal defect
S connector pin is
contacted to battery
voltage or has no
contact
S.C. TO GROUND AT ENGINE OP---Mode: S check the
SPEED INPUT recovery cable from
TCU measures a control clutch TCU to the
voltage less than 0.45V sensor
at speed input pin S check the
TCU32 S cable / connector is connectors
defective and is S check the
contacted to vehicle speed sensor
ground
S speed sensor has an
internal defect
LOGICAL ERROR AT ENGINE OP---Mode: S check the This fault is
SPEED INPUT recovery cable from reset after
TCU measures a control clutch TCU to the power up of
engine speed over a sensor TCU
threshold and the next S check the
moment the measured connectors
TCU33 speed is zero
S cable / connector is
S check the
speed sensor
defective and has S check the
bad contact sensor gap
S speed sensor has an
internal defect
S sensor gap has the
wrong size
S.C. TO BATTERY VOLTAGE OP---Mode: S check the
OR O.C. AT TURBINE SPEED recovery cable from
INPUT control clutch TCU to the
TCU measures a if a failure is sensor
voltage higher than existing at S check the
7.00 V at speed input output connectors
pin speed, S check the
S cable is defective and TCU shifts to speed sensor
TCU34 is contacted to
battery voltage
neutral
OP---Mode:
S cable has no limp home
connection to TCU
S speed sensor has an
internal defect
S connector pin is
contacted to battery
voltage or has no
contact

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
16 FAILURE CODES SECTION 3 ADT 25-30 TIER3

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
S.C. TO GROUND AT OP---Mode: S check the
TURBINE SPEED INPUT recovery cable from
TCU measures a control clutch TCU to the
voltage less than 0.45V
0 45V if a failure is sensor
at speed input pin existing at S check the
TCU35 S cable / connector is output connectors
defective and is speed, S check the
contacted
t t d tto vehicle
hi l TCU shifts
hift tto speedd sensor
ground neutral
S speed sensor has an OP---Mode:
internal defect limp home
LOGICAL ERROR AT OP---Mode: S check the This fault is
TURBINE SPEED INPUT recovery cable from reset after
TCU measures a control clutch TCU to the power up of
turbine speed over a if a failure is sensor TCU
threshold and at the existing at S check the
next moment the output connectors
measured speed is speed, S check the
TCU36 zero
S cable / connector is
TCU shifts to
neutral
speed sensor
S check the
de ect e a
defective andd has
as O ode
OP---Mode: se so gap
sensor
bad contact limp home
S speed sensor has an
internal defect
S sensor gap has the
wrong size
S.C. TO BATTERY VOLTAGE OP---Mode: S check the
OR O.C. AT INTERNAL recovery cable from
SPEED INPUT control clutch TCU to the
TCU measures a sensor
voltage higher than S check the
7.00 V at speed input connectors
pin S check the
S cable is defective and speed sensor
TCU37 is contacted to
battery voltage
S cable has no
connection to TCU
S speed sensor has an
internal defect
S connector pin is
contacted to battery
voltage or has no
contact
S.C. TO GROUND AT OP---Mode: S check the
INTERNAL SPEED INPUT recovery cable from
TCU measures a control clutch TCU to the
voltage less than 0.45V sensor
at speed input pin S check the
TCU38 S cable / connector is connectors
defective and is S check the
contacted to vehicle speed sensor
ground
S speed sensor has an
internal defect

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 3 FAILURE CODES 17

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
LOGICAL ERROR AT OP---Mode: S check the This fault is
INTERNAL SPEED INPUT recovery cable from reset after
TCU measures a control clutch TCU to the power up of
internal speed over a sensor TCU
threshold and at the S check the
next moment the connectors
measured speed is S check the
TCU39 zero speed sensor
S cable / connector is S check the
defective and has sensor gap
bad contact
S speed sensor has an
internal defect
S sensor gap has the
wrong size
S.C. TO BATTERY VOLTAGE special mode S check the
OR O.C. AT OUTPUT SPEED for gear cable from
INPUT selection TCU to the
TCU measures a OP---Mode: sensor
voltage higher than recovery S check the
12.5 V at speed input control clutch connectors
pin if a failure is S check the
S cable is defective and existing at speed sensor
TCU3A is contacted to
battery voltage
turbine
speed,
S cable has no TCU shifts to
connection to TCU neutral
S speed sensor has an OP---Mode:
internal defect limp home
S connector pin is
contacted to battery
voltage or has no
contact
S.C. TO GROUND AT special mode S check the
OUTPUT SPEED INPUT for gear cable from
TCU measures a selection TCU to the
voltage less than 1.00V OP---Mode: sensor
at speed input pin recovery S check the
S cable / connector is control clutch connectors
TCU3B defective and is
contacted to vehicle
if a failure is
existing at
S check the
speed sensor
ground turbine
S speed sensor has an speed,
speed
internal defect TCU shifts to
neutral
OP---Mode:
limp home
LOGICAL ERROR AT OUTPUTspecial mode S check the This fault is
SPEED INPUT for gear cable from reset after
TCU measures a output selection TCU to the power up of
speed over a threshold OP---Mode: sensor TCU
and at the next moment recovery S check the
the measured speed is control clutch connectors
TCU3C zero
S cable / connector is
if a failure is
existing at
S check the
speed sensor
defective and has turbine S check the
bad contact speed
speed, sensor gap
S speed sensor has an TCU shifts to
internal defect neutral
S sensor gap has the OP---Mode:
wrong size limp home

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
18 FAILURE CODES SECTION 3 ADT 25-30 TIER3

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
OUTPUT SPEED ZERO special mode S check the This fault is
DOESN’T FIT TO OTHER for gear sensor signal reset after
SPEED SIGNALS selection of output power up of
if transmission is not OP---Mode: speed sensor TCU
neutral and the shifting recovery S check the
has finished, control clutch sensor gap of
TCU measures if a failure is output speed
TCU3E outputspeed zero and
turbine speed or
existing at
turbine
sensor
S check the
internal speed not speed, cable from
equal to zero. TCU shifts to TCU to the
S speed sensor has an neutral sensor
internal defect OP---Mode:
S sensor gap has the limp home
wrong size
DCT1 TIMEOUT OP---Mode: S check display
Timeout of normal computer
CAN ---message DCT1 S check wire of
from display
p y computer
p CAN ---Bus
S interference
f on S check cable to
CAN ---Bus display
TCU54 S CAN wire/connector computer
is broken
S CAN wire/connector
is defective and has
contact to vehicle
ground or battery
voltage
ENGINE OP---Mode: S check engine
CONFIGURATION TIMEOUT substitute controller
Timeout of clutch S check wire of
CAN ---message control CAN ---Bus
ENGINE CONF from S check cable to
engine controller engine
S interference on controller
TCU56 CAN ---Bus
S CAN wire/connector
iss broken
bo e
S CAN wire/connector
is defective and has
contact to vehicle
ground or battery
voltage
EEC1 TIMEOUT OP---Mode: S check EEC
Timeout of recovery controller
CAN ---message EEC1 control clutch S check wire of
from EEC controller CAN ---Bus
S interference
f on S check cable to
CAN ---Bus EEC controller
TCU57 S CAN wire/connector
is broken
S CAN wire/connector
is defective and has
contact to vehicle
ground or battery
voltage

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 3 FAILURE CODES 19

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
EEC3 TIMEOUT OP---Mode: S check EEC
Timeout of recovery controller
CAN ---message EEC3 control clutch S check wire of
from EEC controller CAN ---Bus
S interference
f on S check cable to
CAN ---Bus EEC controller
TCU58 S CAN wire/connector
is broken
CAN wire/connector is
defective an has
contact to vehicle
ground or battery
voltage
ENGINGE TORQUE SIGNAL OP---Mode:re S check engine
CAN signal
g for engine
g y
covery controller
t
torque iis d
defective
f ti control
t l clutch
l t h S check
h k wirei off
TCU65 S engine controller is CAN ---Bus
defective S check cable to
S interference on engine
CAN ---Bus controller
REFERENCE ENGINE OP---Mode:re S check engine
TORQUE SIGNAL covery controller
CAN signal for control clutch S check wire of
reference of engine CAN ---Bus
TCU69 torque is defective S check cable to
S engine controller is engine
defective controller
S interference on
CAN ---Bus
ACTUAL ENGINE TORQUE OP---Mode:re S check engine
SIGNAL covery controller
CAN signal for actual control clutch S check wire of
engine torque is CAN ---Bus
TCU6A defective S check cable to
S engine controller is engine
defective controller
S interference on
CAN ---Bus
NOMINAL FRICTION TORQUE OP---Mode:re S check engine
SIGNAL covery controller
CAN signal for nominal control clutch S check wire of
friction torque is CAN ---Bus
TCU6B defective S check cable to
S engine controller is engine
defective controller
S interference on
CAN ---Bus
EEC2 TIMEOUT no reaction, S check EEC
Timeout of TCU uses controller
CAN ---message EEC2 default signal S check wire of
from EEC controller accelerator CAN ---Bus
S interference on pedal in idle S check cable to
CAN ---Bus position EEC controller
TCU6E S CAN wire/connector OP Mode:
OP---Mode:
is broken normal
S CAN wire/connector
is defective and has
contact to vehicle
ground or battery
voltage

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
20 FAILURE CODES SECTION 3 ADT 25-30 TIER3

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
S.C. TO BATTERY VOLTAGE TCU shifts to S check the
AT CLUTCH K1 neutral cable from
the measured OP---Mode: TCU to the
resistance value of the limp home gearbox
valve is out of limit,
limit the if failure at S check the
voltage at K1 valve is another connectors
TCU71 too high.
S cable / connector is
clutch is
pending
from TCU to
the gearbox
defective and has TCU shifts to S check the
contact to battery neutral regulator
voltage OP---Mode: resistance
S regulator has an TCU S check internal
internal defect shutdown wire harness of
the gearbox
S.C. TO GROUND AT TCU shifts to S check the
CLUTCH K1 neutral cable from
the measured OP---Mode: TCU to the
resistance value of the limp home gearbox
valve is out of limit, the if failure at S check the
voltage at K1 valve is another connectors
too low. clutch is from gearbox
S cable / connector is pending to TCU
TCU72 defective and has
contact to vehicle
TCU shifts to
neutral
S check the
regulator
ground OP---Mode: resistance
S cable / connector is TCU S check internal
defective and has shutdown wire harness of
contact to another the gearbox
regulator output of
the TCU
S regulator has an
internal defect
O.C. AT CLUTCH K1 TCU shifts to S check the
the measured neutral cable from
resistance value of the OP---Mode: TCU to the
valve is out of limit. limp home gearbox
S cable / connector is if failure at S check the
defective and has no another connectors
TCU73 contact to TCU
S regulator has an
clutch is
pending
from gearbox
to TCU
internal defect TCU shifts to S check the
neutral regulator
OP---Mode: resistance
TCU S check internal
shutdown wire harness of
the gearbox
S.C. TO BATTERY VOLTAGE TCU shifts to S check the
AT CLUTCH K2 neutral cable from
the measured OP---Mode: TCU to the
resistance value of the limp home gearbox
valve is out of limit,
limit the if failure at S check the
voltage at K2 valve is another connectors
TCU74 too high.
S cable / connector is
clutch is
pending
from gearbox
to TCU
defective and has TCU shifts to S check the
contact to battery neutral regulator
voltage OP---Mode: resistance
S regulator has an TCU S check internal
internal defect shutdown wire harness of
the gearbox

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 3 FAILURE CODES 21

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
S.C. TO GROUND AT TCU shifts to S check the
CLUTCH K2 neutral cable from
the measured OP---Mode: TCU to the
resistance value of the limp home gearbox
valve is out of limit, the if failure at S check the
voltage at K2 valve is another connectors
too low. clutch is from gearbox
S cable / connector is pending to TCU
TCU75 defective and has
contact to vehicle
TCU shifts to
neutral
S check the
regulator
ground OP---Mode: resistance
S cable / connector is TCU S check internal
defective and has shutdown wire harness of
contact to another the gearbox
regulator output of
the TCU
S regulator has an
internal defect
O.C. AT CLUTCH K2 TCU shifts to S check the
the measured neutral cable from
resistance value of the OP---Mode: TCU to the
valve is out of limit. limp home gearbox
S cable / connector is if failure at S check the
defective and has no another connectors
TCU76 contact to TCU
S regulator has an
clutch is
pending
from gearbox
to TCU
internal defect TCU shifts to S check the
neutral regulator
OP---Mode: resistance
TCU S check internal
shutdown wire harness of
the gearbox
S.C. TO BATTERY VOLTAGE TCU shifts to S check the
AT CLUTCH K3 neutral cable from
the measured OP---Mode: TCU to the
resistance value of the limp home gearbox
valve is out of limit,
limit the if failure at S check the
voltage at K3 valve is another connectors
TCU77 too high.
S cable / connector is
clutch is
pending
from gearbox
to TCU
defective and has TCU shifts to S check the
contact to battery neutral regulator
voltage OP---Mode: resistance
S regulator has an TCU S check internal
internal defect shutdown wire harness of
the gearbox
S.C. TO GROUND AT TCU shifts to S check the
CLUTCH K3 neutral cable from
the measured OP---Mode: TCU to the
resistance value of the limp home gearbox
valve is out of limit, the if failure at S check the
voltage at K3 valve is another connectors
too low. clutch is from gearbox
S cable / connector is pending to TCU
TCU78 defective and has
contact to vehicle
TCU shifts to
neutral
S check the
regulator
ground OP---Mode: resistance
S cable / connector is TCU S check internal
defective and has shutdown wire harness of
contact to another the gearbox
regulator output of
the TCU
S regulator has an
internal defect

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
22 FAILURE CODES SECTION 3 ADT 25-30 TIER3

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
O.C. AT CLUTCH K3 TCU shifts to S check the
the measured neutral cable from
resistance value of the OP---Mode: TCU to the
valve is out of limit. limp home gearbox
S cable / connector is if failure at S check the
defective and has no another connectors
TCU79 contact to TCU
S regulator has an
clutch is
pending
from gearbox
to TCU
internal defect TCU shifts to S check the
neutral regulator
OP---Mode: resistance
TCU S check internal
shutdown wire harness of
the gearbox
S.C. TO BATTERY VOLTAGE TCU shifts to S check the
AT CLUTCH K4 neutral cable from
the measured OP---Mode: TCU to the
resistance value of the limp home gearbox
valve is out of limit,
limit the if failure at S check the
voltage at K4 valve is another connectors
TCU81 too high.
S cable / connector is
clutch is
pending
from gearbox
to TCU
defective and has TCU shifts to S check the
contact to battery neutral regulator
voltage OP---Mode: resistance
S regulator has an TCU S check internal
internal defect shutdown wire harness of
the gearbox
S.C. TO GROUND AT TCU shifts to S check the
CLUTCH K4 neutral cable from
the measured OP---Mode: TCU to the
resistance value of the limp home gearbox
valve is out of limit, the if failure at S check the
voltage at K4 valve is another connectors
too low. clutch is from gearbox
S cable / connector is pending to TCU
TCU82 defective and has
contact to vehicle
TCU shifts to
neutral
S check the
regulator
ground OP---Mode: resistance
S cable / connector is TCU S check internal
defective and has shutdown wire harness of
contact to another the gearbox
regulator output of
the TCU
S regulator has an
internal defect
O.C. AT CLUTCH K4 TCU shifts to S check the
the measured neutral cable from
resistance value of the OP---Mode: TCU to the
valve is out of limit. limp home gearbox
S cable / connector is if failure at S check the
defective and has no another connectors
TCU83 contact to TCU
S regulator has an
clutch is
pending
from gearbox
to TCU
internal defect TCU shifts to S check the
neutral regulator
OP---Mode: resistance
TCU S check internal
shutdown wire harness of
the gearbox

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 3 FAILURE CODES 23

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
S.C. TO BATTERY VOLTAGE TCU shifts to S check the
AT CLUTCH KV neutral cable from
the measured OP---Mode: TCU to the
resistance value of the limp home gearbox
valve is out of limit,
limit the if failure at S check the
voltage at KV valve is another connectors
TCU84 too high.
S cable / connector is
clutch is
pending
from gearbox
to TCU
defective and has TCU shifts to S check the
contact to battery neutral regulator
voltage OP---Mode: resistance
S regulator has an TCU S check internal
internal defect shutdown wire harness of
the gearbox
S.C. TO GROUND AT TCU shifts to S check the
CLUTCH KV neutral cable from
the measured OP---Mode: TCU to the
resistance value of the limp home gearbox
valve is out of limit, the if failure at S check the
voltage at KV valve is another connectors
too low. clutch is from gearbox
S cable / connector is pending to TCU
TCU85 defective and has
contact to vehicle
TCU shifts to
neutral
S check the
regulator
ground OP---Mode: resistance
S cable / connector is TCU S check internal
defective and has shutdown wire harness of
contact to another the gearbox
regulator output of
the TCU
S regulator has an
internal defect
O.C. AT CLUTCH KV TCU shifts to S check the
the measured neutral cable from
resistance value of the OP---Mode: TCU to the
valve is out of limit. limp home gearbox
S cable / connector is if failure at S check the
defective and has no another connectors
TCU86 contact to TCU
S regulator has an
clutch is
pending
from gearbox
to TCU
internal defect TCU shifts to S check the
neutral regulator
OP---Mode: resistance
TCU S check internal
shutdown wire harness of
the gearbox
S.C. TO BATTERY VOLTAGE TCU shifts to S check the
AT CLUTCH KR neutral cable from
the measured OP---Mode: TCU to the
resistance value of the limp home gearbox
valve is out of limit,
limit the if failure at S check the
voltage at KR valve is another connectors
TCU87 too high.
S cable / connector is
clutch is
pending
from gearbox
to TCU
defective and has TCU shifts to S check the
contact to battery neutral regulator
voltage OP---Mode: resistance
S regulator has an TCU S check internal
internal defect shutdown wire harness of
the gearbox

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
24 FAILURE CODES SECTION 3 ADT 25-30 TIER3

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
S.C. TO GROUND AT TCU shifts to S check the
CLUTCH KR neutral cable from
the measured OP---Mode: TCU to the
resistance value of the limp home gearbox
valve is out of limit, the if failure at S check the
voltage at KR valve is another connectors
too low. clutch is from gearbox
S cable / connector is pending to TCU
TCU88 defective and has
contact to vehicle
TCU shifts to
neutral
S check the
regulator
ground OP---Mode: resistance
S cable / connector is TCU S check internal
defective and has shutdown wire harness of
contact to another the gearbox
regulator output of
the TCU
S regulator has an
internal defect
O.C. AT CLUTCH KR TCU shifts to S check the
the measured neutral cable from
resistance value of the OP---Mode: TCU to the
valve is out of limit. limp home gearbox
S cable / connector is if failure at S check the
defective and has no another connectors
TCU89 contact to TCU
S regulator has an
clutch is
pending
from gearbox
to TCU
internal defect TCU shifts to S check the
neutral regulator
OP---Mode: resistance
TCU S check internal
shutdown wire harness of
the gearbox
S.C. TO GROUND AT RELAY backup S check the
REVERSE WARNING ALARM alarm will be cable from
TCU detected a wrong on until TCU TCU to the
voltage at the output power down backup alarm
pin, that looks like a s.c. even if fault device
to vehicle ground vanishes S check the
TCU91 S cable is defective and (loose
is contacted to connection)
connectors
from backup
vehicle ground OP---Mode: alarm device
S backup alarm device normal to TCU
has an internal defect S check the
S connector pin is resistance of
contacted to vehicle backup alarm
ground device
S.C. TO BATTERY VOLTAGE no reaction S check the
AT RELAY REVERSE OP---Mode: cable from
WARNING ALARM normal TCU to the
TCU detected a wrong backup alarm
voltage at the output device
pin, that looks like a s.c. S check the
to battery voltage connectors
TCU92 S cable is defective and from backup
is contacted to alarm device
battery voltage to TCU
S backup alarm device S check the
has an internal defect resistance of
S connector pin is backup alarm
contacted to battery device
voltage

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 3 FAILURE CODES 25

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
O.C. AT RELAY REVERSE no reaction S check the
WARNING ALARM OP---Mode: cable from
TCU detected a wrong normal TCU to the
voltage at the output backup alarm
pin, that looks like a device
o.c. for this output pin S check the
TCU93 S cable is defective and
has no connection to
connectors
from backup
TCU alarm device
S backup alarm device to TCU
has an internal defect S check the
S connector has no resistance of
connection to TCU backup alarm
device
S.C. TO GROUND AT no reaction S check the
CONVERTER LOCK UP OP---mode: cable from
CLUTCH SOLENOID normal TCU to the
TCU detected a wrong converter
voltage at the output clutch solenoid
pin, that looks like a s.c. S check the
to vehicle ground connectors

TCU9A S cable is defective and

is contacted to
from converter
clutch solenoid
vehicle ground to TCU
S converter clutch S check the
solenoid has an resistance of
internal defect converter
S connector pin is clutch solenoid
contacted to vehicle
ground
O.C. AT CONVERTER LOCK converter S check the
UP CLUTCH SOLENOID clutch always cable from
TCU detected a wrong open, TCU to the
voltage at the output retarder not converter
pin, that looks like a available clutch solenoid
o.c. for this output pin OP---mode: S check the
TCU9B S cable is defective and normal
has no connection to
connectors
from converter
TCU clutch solenoid
S converter clutch to TCU
solenoid has an S check the
internal defect resistance of
S connector has no converter
connection to TCU clutch solenoid
S.C. TO BATTERY VOLTAGE no reaction S check the
AT CONVERTER LOCK UP OP---mode: cable from
CLUTCH SOLENOID normal TCU to the
TCU detected a wrong converter
voltage at the output clutch solenoid
pin, that looks like a s.c. S check the
to battery voltage connectors

TCU9C S cable is defective and

is contacted to
from converter
clutch solenoid
battery voltage to TCU
S converter clutch S check the
solenoid has an resistance of
internal defect converter
S connector pin is clutch solenoid
contacted to battery
voltage

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
26 FAILURE CODES SECTION 3 ADT 25-30 TIER3

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
S.C. TO GROUND AT no reaction S check the
RETARDER SOLENOID OP---mode: cable from
TCU detected a wrong normal TCU to the
voltage at the output retarder
pin, that looks like a s.c. solenoid
to vehicle ground S check the
TCU9D S cable is defective and
is contacted to
connectors
from retarder
vehicle ground solenoid to
S retarder solenoid has TCU
an internal defect S check the
S connector pin is resistance of
contacted to vehicle retarder
ground solenoid
O.C. AT RETARDER no reaction S check the
SOLENOID OP---mode: cable from
TCU detected a wrong normal TCU to the
voltage at the output retarder
pin, that looks like a solenoid
o.c. for this output pin S check the
TCU9E S cable is defective and
has no connection to
connectors
from retarder
TCU solenoid to
S retarder solenoid has TCU
an internal defect S check the
S connector has no resistance of
connection to TCU retarder
solenoid
S.C. TO BATTERY VOLTAGE no reaction S check the
AT RETARDER SOLENOID OP---mode: cable from
TCU detected a wrong normal TCU to the
voltage at the output retarder
pin, that looks like a s.c. solenoid
to battery voltage S check the
TCU9F S cable is defective and
is contacted to
connectors
from retarder
battery voltage solenoid to
S retarder solenoid has TCU
an internal defect S check the
S connector pin is resistance of
contacted to battery retarder
voltage solenoid
S.C. TO GROUND AT no reaction S check the
DIFFLOCK OR AXLE OP---mode: cable from
CONNECTION SOLENOID normal TCU to the
TCU detected a wrong difflock
voltage at the output solenoid
pin, that looks like a s.c. S check the
to vehicle ground connectors
TCUA1 S cable is defective and from difflock
is contacted to solenoid to
vehicle ground TCU
S difflock solenoid has S check the
an internal defect resistance of
S connector pin is difflock
contacted to vehicle solenoid
ground

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 3 FAILURE CODES 27

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
S.C. TO BATTERY VOLTAGE no reaction S check the
AT DIFFLOCK OR AXLE OP---mode: cable from
CONNECTION SOLENOID normal TCU to the
TCU detected a wrong difflock
voltage at the output solenoid
pin, that looks like a s.c. S check the
to battery voltage connectors
TCUA2 S cable is defective and from difflock
is contacted to solenoid to
battery voltage TCU
S difflock solenoid has S check the
an internal defect resistance of
S connector pin is difflock
contacted to battery solenoid
voltage
O.C. AT DIFFLOCK OR AXLE no reaction S check the
CONNECTION SOLENOID OP---mode: cable from
TCU detected a wrong normal TCU to the
voltage at the output difflock
pin, that looks like a solenoid
o.c. for this output pin S check the
TCUA3 S cable is defective and
has no connection to
connectors
from difflock
TCU solenoid to
S difflock solenoid has TCU
an internal defect S check the
S connector has no resistance of
connection to TCU difflock
solenoid
S.C. TO GROUND AT no reaction S check the
WARNING SIGNAL OUTPUT OP---mode: cable from
TCU detected a wrong normal TCU to the
voltage at the output warning device
pin, that looks like a s.c. S check the
to vehicle ground connectors
TCUA4 S cable is defective and
is contacted to
from warning
device to TCU
vehicle ground S check the
S warning device has resistance of
an internal defect warning device
S connector pin is
contacted to vehicle
ground
O.C. AT WARNING SIGNAL no reaction S check the
OUTPUT OP---mode: cable from
TCU detected a wrong normal TCU to the
voltage at the output warning device
pin, that looks like a S check the
o.c. for this output pin connectors
TCUA5 S cable is defective and from warning
has no connection to device to TCU
TCU S check the
S warning device has resistance of
an internal defect warning device
connector has no
connection to TCU

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
28 FAILURE CODES SECTION 3 ADT 25-30 TIER3

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
S.C. TO BATTERY VOLTAGE no reaction S check the
AT WARNING SIGNAL OP---mode: cable from
OUTPUT normal TCU to the
TCU detected a wrong warning device
voltage at the output S check the
pin, that looks like a s.c. connectors
to battery voltage from warning
TCUA6 S cable is defective and device to TCU
is contacted to S check the
battery voltage resistance of
S warning device has warning device
an internal defect
S connector pin is
contacted to battery
voltage
S.C. TO GROUND AT customer S check the
DIFFLOCK AXLE specific cable from
TCU detected a wrong TCU to
voltage at the output function 6
pin, that looks like a s.c. device
to vehicle ground S check the
TCUAD S cable is defective and
is contacted to
connectors
from Difflock
vehicle ground axle device to
S Difflock axle device TCU
has an internal defect S check the
S connector pin is resistance of
contacted to vehicle function 6
ground device
S.C. TO BATTERY VOLTAGE customer S check the
AT DIFFLOCK AXLE specific cable from
TCU detected a wrong TCU to Difflock
voltage at the output axle device
pin, that looks like a s.c. S check the
to battery voltage connectors
TCUAE S cable is defective and
is contacted to
from Difflock
axle device to
battery voltage TCU
S Difflock axle device S check the
has an internal defect resistance of
S connector pin is Difflock axle
contacted to battery device
voltage
O.C. AT DIFFLOCK AXLE customer S check the
TCU detected a wrong specific cable from
voltage at the output TCU to Difflock
pin, that looks like a axle device
o.c. for this output pin S check the
S cable is defective and connectors
TCUAF has no connection to from Difflock
TCU axle device to
S Difflock axle device TCU
has an internal defect S check the
S connector has no resistance of
connection to TCU Difflock axle
device

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 3 FAILURE CODES 29

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
SLIPPAGE AT CLUTCH K1 TCU shifts to S check
TCU calculates a neutral pressure at
differential speed at OP---Mode: clutch K1
closed clutch K1. If this limp home S check main
calculated value is out if failure at pressure in the
g , TCU interprets
of range, p another y
system
this
hi as slipping
li i clutch.
l h clutch
l h iis S check
h k sensor
S low pressure at pending gap at internal
clutch K1 TCU shifts to speed sensor
TCUB1 S low main pressure neutral S check sensor
S wrong signal at OP---Mode: gap at output
internal speed sensor TCU speed sensor
S wrong signal at shutdown S check signal at
output speed sensor internal speed
S wrong size of the sensor
sensor gap S check signal at
S clutch is defective output speed
sensor
S replace clutch
SLIPPAGE AT CLUTCH K2 TCU shifts to S check
TCU calculates a neutral pressure at
differential speed at OP---Mode: clutch K2
closed clutch K2. If this limp home S check main
calculated value is out if failure at pressure in the
g , TCU interprets
of range, p another y
system
this
hi as slipping
li i clutch.
l h clutch
l h iis S check
h k sensor
S low pressure at pending gap at internal
clutch K2 TCU shifts to speed sensor
TCUB2 S low main pressure neutral S check sensor
S wrong signal at OP---Mode: gap at output
internal speed sensor TCU speed sensor
S wrong signal at shutdown S check signal at
output speed sensor internal speed
S wrong size of the sensor
sensor gap S check signal at
S clutch is defective output speed
sensor
S replace clutch
SLIPPAGE AT CLUTCH K3 TCU shifts to S check
TCU calculates a neutral pressure at
differential speed at OP---Mode: clutch K3
closed clutch K3. If this limp home S check main
calculated value is out if failure at pressure in the
g , TCU interprets
of range, p another y
system
this
hi as slipping
li i clutch.
l h clutch
l h iis S check
h k sensor
S low pressure at pending gap at internal
clutch K3 TCU shifts to speed sensor
TCUB3 S low main pressure neutral S check sensor
S wrong signal at OP---Mode: gap at output
internal speed sensor TCU speed sensor
S wrong signal at shutdown S check signal at
output speed sensor internal speed
S wrong size of the sensor
sensor gap S check signal at
S clutch is defective output speed
sensor
S replace clutch

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
30 FAILURE CODES SECTION 3 ADT 25-30 TIER3

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
SLIPPAGE AT CLUTCH K4 TCU shifts to S check
TCU calculated a neutral pressure at
difference speed at OP---Mode: clutch K4
TCU calculates a limp home S check main
differential speed at if failure at pressure in the
closed clutch K4. If this another y
system
calculated
l l d valuel iis out clutch
l h iis S check
h k sensor
of range, TCU interprets pending gap at internal
this as slipping clutch. TCU shifts to speed sensor
TCUB4 S low pressure at neutral S check sensor
clutch K4 OP---Mode: gap at turbine
S low main pressure TCU speed sensor
S wrong signal at shutdown S check signal at
internal speed sensor internal speed
S wrong signal at sensor
turbine speed sensor S check signal at
S wrong size of the turbine speed
sensor gap sensor
S clutch is defective S replace clutch
SLIPPAGE AT CLUTCH KV TCU shifts to S check
TCU calculates a neutral pressure at
differential speed at OP---Mode: clutch KV
closed clutch KV. If this limp home S check main
calculated value is out if failure at pressure in the
g , TCU interprets
of range, p another y
system
this
hi as slipping
li i clutch.
l h clutch
l h iis S check
h k sensor
S low pressure at pending gap at internal
clutch KV TCU shifts to speed sensor
TCUB5 S low main pressure neutral S check sensor
S wrong signal at OP---Mode: gap at turbine
internal speed sensor TCU speed sensor
S wrong signal at shutdown S check signal at
turbine speed sensor internal speed
S wrong size of the sensor
sensor gap S check signal at
S clutch is defective turbine speed
sensor
S replace clutch
SLIPPAGE AT CLUTCH KR TCU shifts to S check
TCU calculates a neutral pressure at
differential speed at OP---Mode: clutch KR
closed clutch KR. If this limp home S check main
calculated value is out if failure at pressure in the
g , TCU interprets
of range, p another y
system
this
hi as slipping
li i clutch.
l h clutch
l h iis S check
h k sensor
S low pressure at pending gap at internal
clutch KR TCU shifts to speed sensor
TCUB6 S low main pressure neutral S check sensor
S wrong signal at OP---Mode: gap at turbine
internal speed sensor TCU speed sensor
S wrong signal at shutdown S check signal at
turbine speed sensor internal speed
S wrong size of the sensor
sensor gap S check signal at
S clutch is defective turbine speed
sensor
S replace clutch
OVERTEMP SUMP no reaction S cool down
TCU measured a OP---Mode: machine
TCUB7 temperature in the oil
sump that is over the
normal S check oil level
S check
allowed threshold. temperature
sensor

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 3 FAILURE CODES 31

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
OVERTEMP RETARDER TCU disables S cool down
TCU measured a retarder machine
TCUB8 temperature in the
retarder oil that is over
OP---Mode:
normal
S check oil level
S check
the allowed threshold. temperature
sensor
OVERSPEED ENGINE retarder ---
applies if
TCUB9 configured
OP---Mode:
normal
DIFFERENTIAL PRESSURE no reaction S check oil filter
OIL FILTER OP---Mode: S check wiring
TCU measured a normal from TCU to
voltage at differential differential
pressure switch out of pressure
the allowed range switch
S oil filter is polluted S check
TCUBA S cable/connector is differential
broken or pressure
cable/connector is switch
contacted to battery (measure
voltage or vehicle resitance)
ground
S differential pressure
switch is defective
SLIPPAGE AT CONVERTER S check
LOCKUP CLUTCH pressure at
TCU calculates a converter
differential speed at lockup clutch
closed converter lockup S check main
clutch. If this calculated pressure in the
value is out of range, system
TCU interprets this as S check sensor
slipping clutch. gap at engine
TCUBB S low pressure at
converter lockup
speed sensor
S check sensor
clutch gap at turbine
S low main pressure speed sensor
S wrong signal at S check signal at
engine speed sensor engine speed
S wrong signal at sensor
turbine speed sensor S check signal at
S wrong size of the turbine speed
sensor gap sensor
S clutch is defective S replace clutch
S.C. TO GROUND AT ENGINE no reaction S check the
BRAKE SOLENOID OP---mode: cable from
TCU detected a wrong normal TCU to the
voltage at the output engine brake
pin, that looks like a s.c. solenoid
to vehicle ground S check the
S cable is defective and connectors
TCUBD is contacted to from engine
vehicle ground brake solenoid
S engine brake to TCU
solenoid has an S check the
internal defect resistance of
S connector pin is engine brake
contacted to vehicle solenoid
ground

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
32 FAILURE CODES SECTION 3 ADT 25-30 TIER3

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
S.C. TO BATTERY VOLTAGE no reaction S check the
AT ENGINE BRAKE OP---mode: cable from
TCU detected a wrong normal TCU to the
voltage at the output engine brake
pin, that looks like a s.c. solenoid
to battery voltage S check the
S cable is defective and connectors
TCUBE is contacted to from engine
battery voltage brake solenoid
S engine brake to TCU
solenoid has an S check the
internal defect resistance of
S connector pin is engine brake
contacted to battery solenoid
voltage
O.C. AT ENGINE BRAKE no reaction S check the
TCU detected a wrong OP---mode: cable from
voltage at the output normal TCU to the
pin, that looks like a engine brake
o.c. for this output pin solenoid
S cable is defective and S check the
TCUBF has no connection to
TCU
connectors
from engine
S engine brake brake solenoid
solenoid has an to TCU
internal defect S check the
S connector has no resistance of
connection to TCU engine brake
solenoid
ENGINE_RETARDER OP---Mode: S check EEC
CONFIG_TIMEOUT recovery controller
Timeout of control clutch S check wire of
CAN ---message CAN ---Bus
ENGINE_RETARDER S check cable to
CONFIG from EEC EEC controller
controller

TCUCA S interference on
CAN ---Bus
S CAN wire/connector
is broken
S CAN wire/connector
is defective an has
contact to vehicle
ground or battery
voltage
ERC1 TIMEOUT OP---Mode: S check EEC
Timeout of recovery controller
CAN ---message ERC1 control clutch S check wire of
from EEC controller CAN ---Bus
S interference on S check cable to
CAN ---Bus EEC controller
TCUCB S CAN wire/connector
is broken
S CAN wire/connector
is defective an has
contact to vehicle
ground or battery
voltage

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 3 FAILURE CODES 33

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
S.C. TO BATTERY VOLTAGE see fault S check cables fault codes
AT POWER SUPPLY FOR codes no. 21 and no. 21 to no.
SENSORS to 2C connectors to 2C may be a
TCU measures more sensors, which reaction of
than 6V at the pin AU1 are supplied this fault
TCUD1 (5V sensor supply) from AU1
S check the
power supply
at the pin AU1
(should be
appx. 5V)
S.C. TO GROUND AT POWER see fault S check cables fault codes
SUPPLY FOR SENSORS codes no. 21 and no. 21 to no.
TCU measures less to 2C connectors to 2C may be a
than 4V at the pin AU1 sensors, which reaction of
(5V sensor supply) are supplied this fault
TCUD2 from AU1
S check the
power supply
at the pin AU1
(should be
appx. 5V)
LOW VOLTAGE AT BATTERY shift to S check power
measured voltage at neutral supply battery
power supply is lower OP---Mode: S check cables
than 10 V (12V device) TCU from batteries
TCUD3 lower than 18 V (24V shutdown to TCU
device) S check
connectors
from batteries
to TCU
HIGH VOLTAGE AT BATTERY shift to S check power
measured voltage at neutral supply battery
power supply is higher OP---Mode: S check cables
than 18 V (12V device) TCU from batteries
TCUD4 higher than 32.5 V (24V shutdown to TCU
device) S check
connectors
from batteries
to TCU
ERROR AT VALVE POWER shift to S check fuse
SUPPLY VPS1 neutral S check cables
TCU switched on VPS1 OP---Mode: from gearbox
and measured VPS1 is TCU to TCU
off or TCU switched off shutdown S check
VPS1 and measured connectors
VPS1 iis still
ill on f
from gearbox
b
S cable or connectors to TCU
are defect and are S replace TCU
TCUD5 contacted to battery
voltage
S cable or connectors
are defect and are
contacted to vehicle
ground
S permanent power
supply KL30 missing
S TCU has an internal
defect

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
34 FAILURE CODES SECTION 3 ADT 25-30 TIER3

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
ERROR VALVE POWER shift to S check fuse
SUPPLY VPS2 neutral S check cables
TCU switched on VPS2 OP---Mode: from gearbox
and measured VPS2 is TCU to TCU
off or TCU switched off shutdown S check
VPS2 and measured connectors
VPS2 iis still
ill on f
from gearbox
b
S cable or connectors to TCU
are defect and are S replace TCU
TCUD6 contacted to battery
voltage
S cable or connectors
are defect and are
contacted to vehicle
ground
S permanent power
supply KL30 missing
S TCU has an internal
defect
DISPAY TCU select S check display
IDENTIFICATION 1 parameter controller
TIMEOUT set with ID0 S check wire of
Timeout of OP---Mode: CAN ---Bus
CAN ---messageg Limpp Home S check cable to
DISPID ffrom di
DISPID1 display
l di l
display
controller controller
TCUE5 S interference on
CAN ---Bus
S CAN wire/connector
is broken
S CAN wire/connector
is defective and has
contact to vehicle
ground or battery
voltage
ILLEGAL transmission
IDENTIFICATION stay neutral
TCUE6 REQUEST VIA CAN OP---Mode:
TCU
shutdown
GENERAL EEPROM FAULT no reaction replace TCU often shown

TCUF1 TCU can’t

can t read non
volantile memoy
OP Mode:
OP---Mode:
normal
together with
fault code F2
S TCU is defective
CONFIGURATION LOST transmission Reprogramm the
TCU has lost the stay neutral correct
g
correct configuration OP---Mode: g
configuration for
andd can’t’t control
t l th
the TCU th vehicle
the hi l ((e.g.
transmission. shutdown with cluster
TCUF2 S interference during controller,...)
saving data on non
volatile memory
TCU is brand new or
from another vehicle
APPLICATION ERROR transmission replace TCU !! This fault
something of this stay neutral occurs only if
application is wrong OP---Mode: an test
TCU engineer did
TCUF3 shutdown something
wrong in the
application of
the
vehicle

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 3 FAILURE CODES 35

Meaning of the
Possible
Fault fault code possible Reaction
Warning light Display steps to Remarks
code reason for fault of the TCU
repair
detection
CLUTCH FAILURE transmission check clutch TCU shows
AEB was not able to y neutral
stay also the
adjust
dj t clutch
l t h filli
filling OP M d
OP---Mode: affected
ff t d
TCUF5 parameters TCU clutch on the
S One of the shutdown Display
AEB---Values is out of
limit
CLUTCH ADJUSTMENT default execute AEB
DATA LOST OR INCHPEDAL values = 0
CALIBRATION DATA LOST for AEB
TCU was not able to offsets used
Transmission
read correct clutch OP---Mode:
not
adjustment parameters normal
calibrated
S interference during no Inchmode
saving data on non available
volatile memory
S TCU is brand new

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
36 FAILURE CODES SECTION 3 ADT 25-30 TIER3

DIAGNOSTIC CONNECTOR PIN---OUT

The complete diagnosis of the automatic transmission can be performed using ZF diagnostic equipment.
The equipment must be connected to the diagnosis power---point.

. For more information on diagnosis of the automatic transmission using the diagnostic equipment,
see the specific ZF publications.

Pin Function
1 Battery supply (+)
2 Input from TCU
3 Ground
4 Output to TCU
5 ---
6 ---

The diagnostic connector is located in the lower right side of the cab.

T225050

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 3 FAILURE CODES 37

MULTIPLEX SYSTEM FAULT CODES

FAULT CHECK USING THE DISPLAY

Figure 1

276C003001A

When a fault is detected, an error code is visualized in

the string below the display (Fig. 1, see arrow). Figure 2

Codice MUX xx

If a fault occurs regarding a refuelling and/or mainte-

nance operation, then the error message is visualized.

1 2
269NU383
Codice MUX xx

If there is more than one error, each code is displayed

for about 1 second.
Furthermore, the indicator (Fig. 2, ref. 1) or both indica-
tors (Fig. 2, ref. 1 and ref. 2) light up as a function of the
fault severity.
The complete list of error codes is provided in the follo-
wing pages.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
38 FAILURE CODES SECTION 3 ADT 25-30 TIER3

MULTIPLEX SYSTEM FAULT CODES LIST

Fault Meaning of the Reaction of the

Warning light Display
code fault code system
The system cuts off
power supply to all
utilities
MUX CODE 01 MUX 01 HEAD ERRORS
The engine functions
with reduced
performance
The system cuts off
power supply to all
HEAD E2PROM MEMORY utilities
MUX CODE 08 MUX 08 ERROR The engine functions
with reduced
performance
The system cuts off
power supply to all
HEAD E2PROM MEMORY utilities
MUX CODE 12 MUX 12 ERROR The engine functions
with
reduced performance
CAN OPEN line short---
circuited
CAN OPEN LINE NOT The system does not
MUX CODE 14 MUX 14 FUNCTIONING recognise any of the
body computer system
control units
CAN J1939 line short---
circuited The system
CAN J1939 LINE NOT
MUX CODE 15 MUX 15 FUNCTIONING
does not recognise
EDC and TCU
control units
The system cuts off
MIDAC 1 NOT
MUX CODE 16 MUX 16 FUNCTIONING
power supply to all
MIDAC 1 utilities
The system cuts off
MIDAC 2 NOT
MUX CODE 17 MUX 17 FUNCTIONING
power supply to all
MIDAC 2 utilities
The system cuts off
MIDAC 3 NOT
MUX CODE 18 MUX 18 FUNCTIONING
power supply to all
MIDAC 3 utilities
The system cuts off
MUX CODE 19 MUX 19 MIDAC 1 ERRORS power supply to all
MIDAC 1 utilities
The system cuts off
MUX CODE 21 MUX 21 MIDAC 2 ERRORS power supply to all
MIDAC 2 utilities
The system cuts off
MUX CODE 23 MUX 23 MIDAC 3 ERRORS power supply to all
MIDAC 3 utilities
Conflict between
SOFTWARE VERSION management software
MUX CODE 25 MUX 25 ERROR and memorised
parameters

ENGINE OIL PRESSURE

MUX CODE 29 MUX 29 SENSOR NOT FUNCTIONING
Not active

ENGINE OIL PRESSURE

MUX CODE 30 MUX 30 LOW
Not active

ENGINE OIL PRESSURE

MUX CODE 31 MUX 31 HIGH
Not active

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 3 FAILURE CODES 39

Fault Meaning of the Reaction of the

Warning light Display
code fault code system
ENGINE OIL LEVEL SENSOR
MUX CODE 32 MUX 32 NOT FUNCTIONING
Not active

MUX CODE 33 MUX 33 ENGINE OIL LEVEL LOW Not active

MUX CODE 34 MUX 34 ENGINE OIL LEVEL HIGH Not active

ENGINE OIL TEMPERATURE

MUX CODE 35 MUX 35 SENSOR NOT FUNCTIONING
Not active

ENGINE OIL TEMPERATURE

MUX CODE 36 MUX 36 LOW
Not active

ENGINE OIL TEMPERATURE

MUX CODE 37 MUX 37 HIGH
Not active

The radiator fan circuit

is managed by water
ENGINE WATER
temperature signals
MUX CODE 38 MUX 38 TEMPERATURE SENSOR
from EDC via CAN.
NOT FUNCTIONING
Warm ---up strategy
from ground is disabled
The radiator fan circuit
is managed by water
ENGINE WATER temperature signals
MUX CODE 39 MUX 39 TEMPERATURE LOW from EDC via CAN.
Warm ---up strategy
from ground is disabled
The radiator fan circuit
is managed by water
ENGINE WATER temperature signals
MUX CODE 40 MUX 40 TEMPERATURE HIGH from EDC via CAN.
Warm ---up strategy
from ground is disabled

MAIN AIR TANK PRESSURE

MUX CODE 41 MUX 41 SENSOR NOT FUNCTIONING

MAIN TANK AIR PRESSURE

MUX CODE 42 MUX 42 LOW

MAIN TANK AIR PRESSURE

MUX CODE 43 MUX 43 HIGH

FUEL LEVEL SENSOR NOT

MUX CODE 44 MUX 44 FUNCTIONING

Body tipping
HYDRAULIC SYSTEM FLUID
AUTOMATIC
MUX CODE 47 MUX 47 TEMPERATURE SENSOR
ACCELERATOR mode
NOT FUNCTIONING
not functioning

HYDRAULIC SYSTEM FLUID

MUX CODE 48 MUX 48 TEMPERATURE LOW

HYDRAULIC SYSTEM FLUID

MUX CODE 49 MUX 49 TEMPERATURE HIGH

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
40 FAILURE CODES SECTION 3 ADT 25-30 TIER3

Fault Meaning of the Reaction of the

Warning light Display
code fault code system
If engine is running it
holds brake oil valve
BRAKE COOLING FLUID
locked in position.
MUX CODE 50 MUX 50 TEMPERATURE SENSOR
If engine is off it uses
NOT FUNCTIONING
hydraulic oil tempera-
ture sensor

BRAKE COOLING FLUID

MUX CODE 51 MUX 51 TEMPERATURE LOW

BRAKE COOLING FLUID

MUX CODE 52 MUX 52 TEMPERATURE HIGH

Retarder not function-

RETARDER COMMAND AIR
ing.
MUX CODE 65 MUX 65 PRESSURE SENSOR NOT
Warm ---up function not
FUNCTIONING
functioning
RETARDER COMMAND AIR
PRESSURE LOW (< 0.4 BAR RETARDER braking not
MUX CODE 66 MUX 66 WHEN RETARDER functioning
COMMAND IS ON)
RETARDER COMMAND AIR
PRESSURE HIGH (>6.5 BAR RETARDER braking not
MUX CODE 67 MUX 67 WHEN RETARDER functioning
COMMAND IS ON)
Body warning light on
dashboard flashing.
Selectable gear limited
(1st and 2nd)
BODY ANGULAR POSITION AUTOMATIC ACCEL-
MUX CODE 68 MUX 68 SENSOR NOT FUNCTIONING ERATOR mode not
functioning.
Body speed reduced.
Automatic raise mode
disabled
Body warning light on
dashboard flashing.
Selectable gear limited
(1st and 2nd)
BODY ANGULAR POSITION AUTOMATIC ACCEL-
MUX CODE 69 MUX 69 LOW ERATOR mode not
functioning.
Body speed reduced.
Automatic raise mode
disabled
Body warning light on
dashboard flashing.
Selectable gear limited
(1st and 2nd)
BODY ANGULAR POSITION AUTOMATIC ACCEL-
MUX CODE 70 MUX 70 HIGH ERATOR mode not
functioning.
Body speed reduced.
Automatic raise mode
disabled

ENGINE OIL FILTER

MUX CODE 71 MUX 71 CLOGGED

BRAKE OIL FILTER

MUX CODE 72 MUX 72 CLOGGED

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 3 FAILURE CODES 41

Fault Meaning of the Reaction of the

Warning light Display
code fault code system

BRAKE COOLING FLUID

MUX CODE 73 MUX 73 FILTER CLOGGED

FUEL FILTER (ON ENGINE)

MUX CODE 76 MUX 76 CLOGGED

WATER IN FUEL PREFILTER

MUX CODE 77 MUX 77 (ON CHASSIS) CLOGGED

MUX CODE 78 MUX 78 MAIN PUMP CAVITATING

BRAKING SYSTEM
MUX CODE 79 MUX 79 ACCUMULATOR FAULT

MUX CODE 80 MUX 80 AIR FILTER CLOGGED

HYDRAULIC SYSTEM FLUID

MUX CODE 81 MUX 81 FILTER CLOGGED

LOW GREASE AUTOMATIC GREASING UNIT

MUX 82
LEVEL LUBRICANT LEVEL LOW

FRONT BRAKE COOLING Brake cooling circuit

MUX CODE 83 MUX 83 SYSTEM PRESSURE SWITCH pump rate reduced to
NOT FUNCTIONING minimum
REAR BRAKE COOLING Brake cooling circuit
MUX CODE 84 MUX 84 SYSTEM PRESSURE SWITCH pump rate reduced to
NOT FUNCTIONING (TIER2) minimum
ENGINE COOLING FAN
Radiator fan speed
MUX CODE 85 MUX 85 CIRCUIT REGULATION VALVE
always at maximum
NOT FUNCTIONING

BODY RAISE VALVE NOT

MUX CODE 86 MUX 86 FUNCTIONING

BODY LOWER VALVE NOT

MUX CODE 87 MUX 87 FUNCTIONING

BRAKE COOLING FLUID

MUX CODE 88 MUX 88 RATE REGULATION VALVE
NOT FUNCTIONING

RETARDER COMMAND
MUX CODE 89 MUX 89 VALVE NOT FUNCTIONING

INSUFFICIENT ALTERNATOR
MUX CODE 90 MUX 90 CHARGE

BODY TIPPING COMMAND

Body tipping not
MUX CODE 91 MUX 91 NOT FUNCTIONING ON
functioning
RAISE

BODY TIPPING COMMAND

Body tipping not
MUX CODE 92 MUX 92 NOT FUNCTIONING ON
functioning
RAISE

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
42 FAILURE CODES SECTION 3 ADT 25-30 TIER3

Fault Meaning of the Reaction of the

Warning light Display
code fault code system
START FROM GROUND Start from ground
MUX CODE 93 MUX 93 BUTTON NOT FUNCTIONING function not functioning

Warm ---up function

WARM---UP FROM GROUND
MUX CODE 94 MUX 94 BUTTON NOT FUNCTIONING
from ground not
functioning

TIPPING BRAKE BUTTON Tipping brake not

MUX CODE 95 MUX 95 NOT FUNCTIONING functioning

EMERGENCY STEERING
MUX CODE 96 MUX 96 VALVE NOT FUNCTIONING

MAIN CIRCUIT PRESSURE

LOWVEHICLE SPEED > 0 Emergency steering
strategy activated
MUX 97 (warning light and
buzzer)

MAIN CIRCUIT PRESSURE

MUX CODE 97 LOWVEHICLE SPEED = 0

RETARDER NOT FUNCTION-

ING CORRECTLY
PRESSURE RETARDER
MUX CODE 98 MUX 98 COMPARISON (PRESSURE
SENSOR /PRESSURE PA -
RAMETER)

PRESS BRAKE DRIVER MUST PRESS

MUX 107
PEDAL SERVICE BRAKE PEDAL

NOT PROCEED TO ADJUST

MUX 108
ADJUSTED AUTOMATIC TRANSMISSION

CAN OPEN LINE

HEAD AND
BETWEEN CLUSTER not
MUX CODE 109 MUX 109 CLUSTER NOT functioning
FUNCTIONING

DISPLAY COMMUNICATION
MUX CODE 111 MUX 111 ERROR
Display not functioning

See ENGINE
MUX CODE 112 MUX 112 CAN BUS J1939 FAULT
CONTROL Section

See AUTOMATIC
MUX CODE 113 MUX 113 CAN BUS J1939 FAULT TRANSMISSION
Section
EMERGENCY STEERING
MUX CODE 114 MUX 114 PRESSURE SWITCH NOT
FUNCTIONING

If recharge is not
SYSTEM IS RECHARGING
completed within set
MUX 115 HYDRAULIC
time, code MUX 79 is
ACCUMULATORS
activated

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 3 FAILURE CODES 43

Fault Meaning of the Reaction of the

Warning light Display
code fault code system
THE SYSTEM IS IN
WARM-UP MUX 116 WARM---UP CONDITION

GREASE LEVEL IN
Greasing system pump
GREASE AUTOMATIC GREASING
blocks
MUX 117 DEVICE IS BELOW MINIMUM
EMPTY FOR A CERTAIN LENGTH OF
Grease delivery to
points NOT assured
TIME

The system cuts---off

MUX CODE 118 MUX 118 HEAD ERRORS
power to users involved

STOP LIGHTS COMMAND If electrical power ena-

PRESSURE SWITCH NOT bled with brake pedal
MUX CODE 119 MUX 119 FUNCTIONINGORBRAKE pressed switch off and
pressed,
PEDAL NOT PRESSED on again without pres-
AFTER ENGINE START sing brake pedal

GAP BETWEEN ENGINE

COOLANT AND BRAKE
COOLING FLUID > SET
VALUE
MUX CODE 120 MUX 120 BRAKE COOLING TEMPERA -
TURE SENSOR AND ENGINE
COOLANT SENSOR BOTH
FAULT

GAP BETWEEN ENGINE

COOLANT AND RADIATOR
COOLANT TEMPERATURES
> SET VALUE
MUX CODE 121 MUX 121 HEAD WATER TEMPERA -
TURE SENSOR AND EDC
WATER TEMPERATURE
SENSOR BOTH FAULT

Brake cooling circuit

pump rate reduced to
FRONT AND REAR BRAKE
minimum
COOLING SYSTEM
MUX CODE 122 MUX 122 PRESSURE SWITCHES NOT
Selectable gear limited
(1st and 2nd)
FUNCTIONING
Engine with reduced
performance

MUX CODE 123 MUX 123 DISPLAY BIOS ERROR RD only

MUX CODE 125 MUX 125 OIL FILTER BRAKE CLOGGED RD only

OIL FILTER STEERING

MUX CODE 126 MUX 126 CLOGGED
RD only

JOYSTICK RETARDER
MUX CODE 127 MUX 127 BROKEN
RD only

MUX CODE 128 MUX 128 BODY ANGLE CONGRUENCE RD only

MUX CODE 136 MUX 136 BODY JOYSTICK FAULT RD only

The system cuts off

THERE IS NO CONFORMITY
MUX CODE 139 MUX 139 BETWEEN SISTEM’S ECUS
power supply to all
utilities

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
44 FAILURE CODES SECTION 3 ADT 25-30 TIER3

Fault Meaning of the Reaction of the

Warning light Display
code fault code system
THERE IS NO ELECTRICAL
MUX CODE 140 MUX 140 SUPPLY FOR MIDAC1

THERE IS NO ELECTRICAL
MUX CODE 141 MUX 141 SUPPLY FOR MIDAC2

THERE IS NO ELECTRICAL
MUX CODE 142 MUX 142 SUPPLY FOR MIDAC3

NO READING---WRITING
MUX CODE 143 MUX 143 VEHICLE CONFIG

NO READING---WRITING
MUX CODE 144 MUX 144 FAULT MEMORY COUNTER

NO READING---WRITING TRIP
MUX CODE 145 MUX 145 COMPUTER

NO READING---WRITING
MUX CODE 146 MUX 146 FLIGTH RECORDER

NO READING---WRITING
MUX CODE 147 MUX 147 FAULT BLACK BOX

ENGINE COOLING
MUX CODE 148 MUX 148 TEMPERATURE SENSOR
FAULT

Brake cooling circuit

pump rate reduced to
minimum
BRAKE COOLING PUMP
MUX CODE 149 MUX 149 FAULT
Selectable gear limited
(1st and 2nd)
Engine with reduced
performance
MIDAC NODE
MUX CODE 150 MUX 150 CONFIGURATION NOT
FOUND

MIDAC 1 CONFIGURATION
MUX CODE 151 MUX 151 FAILED

MIDAC 2 CONFIGURATION
MUX CODE 152 MUX 152 FAILED

MIDAC 3 CONFIGURATION
MUX CODE 153 MUX 153 FAILED

Brake cooling circuit

pump rate reduced to
minimum
REAR PRESSURE SENSOR
MUX CODE 154 MUX 154 BRAKE COOLING FAULT
Selectable gear limited
(1st and 2nd)
Engine with reduced
performance
REAR PRESSURE SENSOR
MUX CODE 155 MUX 155 BRAKE COOLING UNDER
MINIMUM

Brake cooling circuit

pump rate reduced to
REAR PRESSURE SENSOR minimum
MUX CODE 156 MUX 156 BRAKE COOLING OVER Selectable gear limited
MAXIMUM (1st and 2nd)
Engine with reduced
performance
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 3 FAILURE CODES 45

Fault Meaning of the Reaction of the

Warning light Display
code fault code system
HYDRAULIC OIL FILTER
MUX CODE 157 MUX 157 SENSOR NOT CONNECTED

BRAKES OIL FILTER

MUX CODE 158 MUX 158 SENSOR NOT CONNECTED

HEAD COMMUNICATION
MUX CODE 159 MUX 159 FAULT

MUX CODE 160 MUX 160 HEAD BIOS ERROR

MUX CODE 161 MUX 161 NOT USED

STEERING OIL FILTER

MUX CODE 162 MUX 162 SENSOR NOT CONNECTED
RD only

Brake cooling circuit

pump rate reduced to
minimum
BRAKE COOLING PUMP
MUX CODE 163 MUX 163 BROKEN
Selectable gear limited
(1st and 2nd)
Engine with reduced
performance

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
46 FAILURE CODES SECTION 3 ADT 25-30 TIER3

Left intentionally blank

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
SECTION 4

ENGINE
 ADT 25-30 TIER3 SECTION 4
CONTENTS
Page
WALK AROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ELECTRONIC SYSTEM CONTROL . . . . . . . . . . . . . 8
Electrical and electronic components . . . . . . . . . . . . 8
Component location on engine right ---hand side . . 9
Component location on engine left---hand side . . . 10
FEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FUEL SUPPLY DIAGRAM . . . . . . . . . . . . . . . . . . . . . 12
Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Injector---pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pumping element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ENGINE AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . 16
Top view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
VARIABLE GEOMETRY TURBINE (VGT) . . . . . . . 17
HOLSET HY55V (Variable Geometry Turbine) . . 19
ACTUATOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . 22
Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
VGT Electromagnetic Valve . . . . . . . . . . . . . . . . . . . . 23
ENGINE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . 24
ENGINE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
EARLY CLOSING SYSTEM FOR THE
INTAKE VALVES (“MILLER” CYCLE) . . . . . . . . . . 28
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Engine cooling system general diagram . . . . . . . . 30
Main circuit engine cooling circuit . . . . . . . . . . . . . . 31
Thermostat operation --- engine cooling system . . 32
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Lubrication system outline . . . . . . . . . . . . . . . . . . . . . 35
Lubrication system outline --- Detail A . . . . . . . . . . . 36
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Overpressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Oil pressure control valve . . . . . . . . . . . . . . . . . . . . . 38
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ENGINE 1
Page
Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
By---pass valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Thermostatic valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Engine oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
TECHNICAL SPECIFICATION . . . . . . . . . . . . . . . . 40
GENERAL CHARACTERISTICS . . . . . . . . . . . . . . . 41
ASSEMBLY CLEARANCE DATA . . . . . . . . . . . . . . . 44
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . 50
TIGHTENING ORDER OF GEARBOX TO
ENGINE BLOCK FASTENING SCREWS . . . . . . . 53
DIAGRAM OF CYLINDER HEAD FIXING
SCREWS TIGHTENING SEQUENCE . . . . . . . . . . . 54
DIAGRAM OF EXHAUST MANIFOLD FIXING
SCREWS TIGHTENING SEQUENCE . . . . . . . . . . . 54
DIAGRAM OF TURBOCHARGER FIXING
SCREWS AND NUTS TIGHTENING
SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
DIAGRAM OF TIGHTENING SEQUENCE
FOR HEAT EXCHANGER SCREWS . . . . . . . . . . . . 55
DIAGRAM OF TIGHTENING SEQUENCE
FOR ENGINE OIL SUMP SCREWS . . . . . . . . . . . . 55
DIAGRAM OF TURBOCHARGER FIXING
SCREWS AND NUTS TIGHTENING
SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Engine Support and Brackets . . . . . . . . . . . . . . . . . . 57
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
TROUBLESHOOTING BY SYMPTOMS . . . . . . . . 68
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Engine oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Engine oil filter change . . . . . . . . . . . . . . . . . . . . . . . . 76
Engine oil vapour filter change . . . . . . . . . . . . . . . . . 77
Accessory drive belts . . . . . . . . . . . . . . . . . . . . . . . . . 77
Fuel circuit bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Fuel filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Engine coolant fluid change and
circuit check/cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 81
2 ENGINE SECTION 4
Page
ENGINE REMOVAL-- REPLACEMENT . . . . . . . . . 83
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Checks and tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
DETACHMENT-- REATTACHMENT OF
THE FLEXIBLE COUPLING JOINT . . . . . . . . . . . . 92
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Reattachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
RADIATOR GROUP REMOVAL--
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
AUTOMATIC TRANSMISSION OIL-- WATER
HEAT EXCHANGER REMOVAL--
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
DISMANTLING THE ENGINE ON THE
BENCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . . . 107
Cylinder block
Checks and measurements . . . . . . . . . . . . . . . . . . 107
CYLINDER LINERS . . . . . . . . . . . . . . . . . . . . . . . . . 108
Replacing cylinder liners . . . . . . . . . . . . . . . . . . . . . 109
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Fitting and checking protrusion . . . . . . . . . . . . . . . 109
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Measuring main journals and crank pins . . . . . . . 111
DETERMINATION OF PRELIMINARY
DATA FOR SELECTION . . . . . . . . . . . . . . . . . . . . . 112
Two series of numbers are marked on the
front side of the block, in the position
specified (top). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Choice of big end and main bearing
half---shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Definition of main journal and big end
diameter class (journals with nominal
diameter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Replacing the timing control gear and
the oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Checking main journal installation clearance . . . . 120
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
Page
Checking crankshaft end float . . . . . . . . . . . . . . . . 121
Piston---connecting rod assembly . . . . . . . . . . . . . 122
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Measuring the diameter of the pistons . . . . . . . . . 123
Conditions for correct gudgeon pin---piston
coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . 125
Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Checking connecting rods . . . . . . . . . . . . . . . . . . . 126
Mounting the connecting rod – piston
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Mounting the piston rings . . . . . . . . . . . . . . . . . . . . 127
Fitting the big end bearing shells . . . . . . . . . . . . . . 127
Fitting connecting rod --- piston assemblies
in the cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . 128
Checking piston protrusion . . . . . . . . . . . . . . . . . . . 128
Checking crankpin assembly clearance . . . . . . . . 129
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Dismounting the valves . . . . . . . . . . . . . . . . . . . . . . 129
Checking head bearing surface on
cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Checking clearance between valve---stem
and associated valve guide . . . . . . . . . . . . . . . . . . . 131
Valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Replacing injector cases . . . . . . . . . . . . . . . . . . . . . 131
Checking protrusion of injectors . . . . . . . . . . . . . . 133
DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Checking cam lift and pin alignment . . . . . . . . . . . 134
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Valve springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Fitting the valves and oil seal ring . . . . . . . . . . . . . 138
ROCKER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Rocker arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
ADT 25-30 TIER3 SECTION 4
Page
Timing distribution control . . . . . . . . . . . . . . . . . . . . 140
Drive cog pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Drive cog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Pin double drive cog . . . . . . . . . . . . . . . . . . . . . . . . . 140
Double drive cog . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Bushing replacement . . . . . . . . . . . . . . . . . . . . . . . . 140
ASSEMBLING THE ENGINE ON THE
BENCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Fitting the connecting rod---piston assembly
into the cylinder liners . . . . . . . . . . . . . . . . . . . . . . . 144
Fitting the cylinder head . . . . . . . . . . . . . . . . . . . . . 145
Replacing flywheel casing . . . . . . . . . . . . . . . . . . . . 146
Replacing engine flywheel . . . . . . . . . . . . . . . . . . . . 147
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ENGINE 3
Page
Fitting pump---injectors . . . . . . . . . . . . . . . . . . . . . . 149
Replacing rocker shaft assembly . . . . . . . . . . . . . . 149
Timing of timing system shaft . . . . . . . . . . . . . . . . . 150
Phonic wheel timing . . . . . . . . . . . . . . . . . . . . . . . . . 152
Adjusting the unload/intake rockers play
and pump injector control rockers preload . . . . . 153
COMPLETING ENGINE ASSEMBLY . . . . . . . . . . 155
TURBOCHARGER REPAIR . . . . . . . . . . . . . . . . . . 156
Variable geometry movement check . . . . . . . . . . . 157
Actuator check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Check actuator excursion . . . . . . . . . . . . . . . . . . . . 158
Turbine body cleaning . . . . . . . . . . . . . . . . . . . . . . . 158
4 ENGINE SECTION 4 ADT 25-30 TIER3

Page left intentionally blank

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ADT 25-30 TIER3 SECTION 4 ENGINE 5

WALK AROUND
. The views of the engine refer to the basic version. The version used on the vehicle may differ.

Figure 15

276A004001
RIGHT SIDE

1. Engine control unit --- 2. Oil sump --- 3. Braking system pump actuation --- 4. Starting motor ---
5. Air compressor --- 6. Fuel filter --- 7. Cylinder head cover --- 8. Air return line from intercooler ---
9. Alternator

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6 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 16

276A004002
LEFT SIDE

1. Oil---water heat exchanger --- 2. Engine oil filter --- 3. Water inlet from radiator --- 4. Auxiliary drive belt ---
5. Not used --- 6. Air delivery pipe to intercooler --- 7. Turbocharger intake ---
8. Exhaust gas turbo---charger --- 9. Turbocharger exhaust --- 10. Exhaust manifold ---
11. Engine cooling fan circuit pump power take---off

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ADT 25-30 TIER3 SECTION 4 ENGINE 7

Figure 17

276A004003
TOP VIEW

1. Thermostat --- 2. Air delivery pipe to intercooler --- 3. Exhaust gas turbo---charger ---
4. Exhaust manifold --- 5. Power take---off --- 6. Fuel filter ---
7. Cylinder head cover --- 8. Air return pipe from intercooler --- 9. Alternator

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8 ENGINE SECTION 4 ADT 25-30 TIER3

ELECTRONIC SYSTEM CONTROL

Electrical and electronic components

The engine injection system is equipped with high pressure injection system with pump---injectors operated by
overhead camshaft.
This engine has a high pressure type injection system with injector --- pump operated by the overhead camshaft.
The electronic control unit is mounted on the engine and contains specific software for each different power cal-
ibration.
No operations, except for configuration data entry (e.g. after replacing the pump---injector) can be carried out on
the ECU software.

ENGINE CURSOR
ENGINE INJECTOR ECU

UIS N 31 MS 7.0
Cursor 10
10 Liters

Many engine components must not be painted and some must be partially protected. For this rea-
son, the best solution is not to paint the engine.

Electrical and electronic components (sensors, ECU, wires, etc.) do not need to be painted and in fact may even
be damaged.

Specifically, in the case of EDC ECUs:

--- painting will damage ECU heat exchanging properties.
--- painting will damage connectors.
--- painting will cover labels (which must remain intact and readable).
--- painting will compromise correct operation of the environmental pressure sensor built into the ECU.

Disrespect of this specifications will cancel the warranty and may cause severe problems and faults.

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ADT 25-30 TIER3 SECTION 4 ENGINE 9

Component location on engine right-- hand side

276A004004A

1. Timing sensor (engine stroke) --- 2. Fuel temperature sensor --- 3. Engine Control Unit (EDC) ---
4. Pre---/post ---heater resistor --- 5. Supercharger air temperature and pressure sensor ---
6. Pumps---injectors

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10 ENGINE SECTION 4 ADT 25-30 TIER3

Component location on engine left-- hand side

Figure 18

276A004005A

1. VGT actuator solenoid valve --- 2. Not used ---

3. Engine coolant temperature sensor --- 4. Engine brake solenoid valve ---
5. Flywheel sensor (engine rpm) --- 6. Turbine speed sensor

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ADT 25-30 TIER3 SECTION 4 ENGINE 11

FEEDING
Fuel is supplied via a fuel pump, filter and pre --- filter,
6 pump --- injectors governed by the camshaft via
rocker arms and by the electronic control unit.

Figure 1

Return circuit

Supply circuit

104280

1. Valve for return circuit, starts opening at 3.5 bars --- 2. Valve for return circuit, starts opening at 0.2 bars

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12 ENGINE SECTION 4 ADT 25-30 TIER3

FUEL SUPPLY DIAGRAM

Figure 2

104242

1. Temperature sensor --- 2. Bleed valve --- 3. Secondary fuel filter --- 4. By---pass valve (0.3 P 0.4 bar) ---
5. Fuel supply pump --- 6. Integrated valve (3.5 bar) --- 7. Pressure relief valve (5 bar) --- 8. Fuel tank ---
9. Priming pump --- 10. Primary fuel filter --- 11. Check valve (opening 0.1 bar) --- 12. Heater ---
13. Electronic control unit --- 14. Fuel return union with valve built in (0.2 bar) --- 15. Pump---injectors

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ADT 25-30 TIER3 SECTION 4 ENGINE 13

Fuel supply circuit diagram

276C004002

1. Fuel tank filler pipe

2. Float
3. Circuit priming pump
4. Fuel pre---filter (on chassis)
5. EDC cooling heat exchanger
6. Low pressure fuel pump
7. Fuel filter (on engine)

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14 ENGINE SECTION 4 ADT 25-30 TIER3

Fuel pump The injector---pump is composed of: pumping element,

nozzle, solenoid valve.
Figure 3
Pumping element
The pumping element is operated by a rocker arm gov-
erned directly by the cam of the camshaft.
The pumping element is able to ensure a high delivery
pressure. The return stroke is made by means of a re-
turn spring.

Nozzle
Garages are authorized to perform fault diagnosis sole-
ly on the entire injection system and may not work in-
side the injector---pump, which must only be replaced.
A specific fault ---diagnosis program, included in the
73547 control unit, is able to check the operation of each injec-
A. Fuel inlet – B. Fuel delivery – C. By---pass nut – tor (it deactivates one at a time and checks the delivery
D. Fuel return from the pump---injectors – of the other five).
E. Pressure relief valve – Fault diagnosis makes it possible to distinguish errors
Opening pressure: 5---8 bars of an electrical origin from ones of a mechanical/hy-
Figure 4 draulic origin.
It indicates broken pump---injectors.
It is therefore necessary to interpret all the control unit
error messages correctly.
Any defects in the injectors are to be resolved by re-
placing them.

Solenoid valve
The solenoid, which is energized at each active phase
of the cycle, via a signal from the control unit, controls
a slide valve that shuts off the pumping element deliv-
ery pipe.
When the solenoid is not energized, the valve is open,
the fuel is pumped but it flows back into the return pipe
with the normal transfer pressure of approximately 5
bars.
73548
When the solenoid is energized, the valve shuts and the
CROSS---SECTION OF THE FUEL PUMP
fuel, not being able to flow back into the return pipe, is
1. Oil and fuel leakage indicator
pumped into the nozzle at high pressure, causing the
needle to lift.
Injector-- pump
The amount of fuel injected depends on the length of
Figure 5 time the slide valve is closed and therefore on the time
for which the solenoid is energized.
The solenoid valve is joined to the injector body and
cannot be removed.
On the top there are two screws securing the electrical
wiring from the control unit.
To ensure signal transmission, tighten the screws with a
torque wrench to a torque of 1.36 – 1.92 Nm (0.136 –
0.192 kgm).

104243
1. Fuel/oil seal – 2. Fuel/diesel seal –
3. Fuel/exhaust gas seal

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ADT 25-30 TIER3 SECTION 4 ENGINE 15

Figure 6

104245
For each injector replaced, hook up to the diagnostic
station and, when asked by the program, enter the
code punched on the injector (→) to reprogram the
control unit.

When checking the clearance of the rocker

arms, it is important to check the injector ---
pump pre---load.

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16 ENGINE SECTION 4 ADT 25-30 TIER3

ENGINE AIR INTAKE SYSTEM

Top view

7 8

5 3
1
2

276C004003
1. Air intake
2. Air filter
3. Filter --- turbo---charger hose
4. Exhaust gas turbo---charger
5. Turbo---charger --- intercooler hose
6. Intercooler
7. Intercooler --- intake manifold hose
8. Intake manifold

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ADT 25-30 TIER3 SECTION 4 ENGINE 17

VARIABLE GEOMETRY TURBINE (VGT)

Working principle
Included in the Variable Geometry Turbine (VGT) unit of the turbo---charger, there is a mobile device which, chan-
ging the area of the exhaust gas inflow section into the turbine (inflow
section), controls its speed variation.

Thanks to this solution, it is possible to keep gas and turbine speed high even when the
engine is running at low speed. Actually, if gas is conveyed through small sections, gas flows at higher speed
therefore also the turbine disk wheel rotates faster.

The motion of the exhaust gas inflow section limiting device (sliding finned sleeve) is driven by lever system starter
by a pneumatic actuator. The sliding sleeve is not rotating on its own axle but only shifts on its axle forward and
reverse. During forward motion, its fins fit into specially provided slots worked out from the turbine’s body. The
pneumatic actuator is directly controlled by the Electronic Control Unit by means of a control valve, and uses com-
pressed air sucked by the vehicle pneumatic system.

In slow speed conditions, the device set up is in maximum closure position.

Upon engine speed and load increase, the Electronic Control Unit intervenes and increases passage section to
enable incoming gas to flow without increasing turbine speed.
Working principle is explained in the page aside.

A) Exhaust gas inflow

A1) Maximum inflow section (VGT completely open)
A2) Limited inflow section
A3) Minimum inflow section (VGT completely closed)

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18 ENGINE SECTION 4 ADT 25-30 TIER3

000586t

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ADT 25-30 TIER3 SECTION 4 ENGINE 19

HOLSET HY55V (Variable geometry turbine)

Figure 7

71759

1. Air delivery to intake manifold --- 2. Compressor --- 3. Air intake--- 4. Actuator ---
5. Exhaust gas speed regulator --- 6. Exhaust gas intake --- 7. --- Exhaust gas outlet --- 8. Turbine

MINIMUM FLOW SECTION MAXIMUM FLOW SECTION

TURBOCOMPRESSOR CROSS---SECTION

1. Air delivery to intake manifold --- 2. Compressor --- 3. Air intake--- 4. Actuator --- 5. Exhaust gas flow rate
regulator ring --- 6. Exhaust gas intake --- 7. --- Exhaust gas outlet --- 8. Turbine ---
9. Exhaust gas flow ---rate command fork

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20 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 8

60753

Figure 9

60754

1. Slide guide --- 2. Compressor --- 3. Slide rod --- 4. Compressor fan --- 5. Lubrication bushings ---
6. Exhaust gas flow ---rate adjustment ring --- 7. Exhaust gas fan --- 8. Gas exhaust body ---
9. Locking rings --- 10. Oil delivery --- 11. Oil outlet --- 12. Actuator drive shaft

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ADT 25-30 TIER3 SECTION 4 ENGINE 21

Figure 10

71762

Figure 11

71763

1. Guide rail --- 3. Slider guide --- 11. Oil outlet --- 12. Actuator control shaft --- 13. Actuator ---
14. Exhaust gas flow ---rate control fork

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22 ENGINE SECTION 4 ADT 25-30 TIER3

ACTUATOR ADJUSTMENT

Figure 12

Stroke [mm]

72421

a. Gradient characterised by effect of external

spring (4)
b. Gradient characterised by effect of external
(4) and internal (6) spring
71834

1. Air intake --- 2. Gasket --- 3. Piston --- 4. External spring --- 5. Internal spring command disk ---
6. Internal spring --- 7. O---ring --- 8. Spring holder --- 9. Stroke limit --- 10. Dust seal --- 11. Command rod

Operating principle
The actuator piston connected to the command rod is
piloted by compressed air entering through the air in-
take (1) on the upper part of the actuator.
Modulating the air pressure varies the shift of the tur-
bine command piston and rod. During its excursion the
piston progressively compresses the external spring
(4) until the base of the piston reaches the internal
spring (6) command disk (5).
Further increasing the pressure the piston interferes
with the lower limit stop (10) through the disk (5).
The use of two springs permits variation in the ratio be-
tween piston excursion and pressure. Approx. 85% of
the rod stroke is contrasted by the external spring,
whereas only 15% by the internal spring.

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ADT 25-30 TIER3 SECTION 4 ENGINE 23

VGT Electromagnetic Valve

This is a N.C. proportional electromagnetic valve located on the front side of the engine.
The electronic control unit, through a PWM signal, controls this electromagnetic valve and adjusts the supply pres-
sure of the turbine actuator which, changing its position, modifies the inflow section of the exhaust gases onto
the blades of the rotor, thus changing the speed of the same.
Figure 13

1) Service tank 4) VGT control solenoid valve

2) Shut ---off solenoid valve 5) Not used
3) Air filter 6) Turbine actuator 71765

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24 ENGINE SECTION 4 ADT 25-30 TIER3

ENGINE EXHAUST SYSTEM

1 2

3 4
276C04004

1. Exhaust manifold --- 2. Exhaust gas turbo---charger --- 3. Turbo---charger --- silencer pipe --- 4. Silencer ---
5. Silencer --- exhaust terminal pipe --- 6. Exhaust terminal

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ADT 25-30 TIER3 SECTION 4 ENGINE 25

ENGINE EXHAUST SYSTEM

A B

276C04005

(A) Exhaust gas arriving from the muffler

(B) Muffler --- exhaust terminal piping
(C) Body heating connection flanges

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26 ENGINE SECTION 4 ADT 25-30 TIER3

ENGINE BRAKE
Working principle:

By the end of compression phase (Picture C), a few grades before reaching the T.D.C., a
specially provided device slightly opens up the exhaust valves, releasing this way the pressure within the cylinder.
(Picture D).

In this case the compression phase braking pair will be used, though not having the following return thrust on
the piston.

001413t

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ADT 25-30 TIER3 SECTION 4 ENGINE 27

WORKING PRINCIPLE (ITB)

By activating the engine brake, a hydraulic drive mechanism provokes slack elimination of
exhaust valves.
This way, due to the particular profile of the exhaust cams, the relevant rocking rod will be slightly lifted at the right
time of the cycle, from the engine brake elevation ramp.
As a consequence, the exhaust valves will slightly open up approaching T.D.C. at the end of compression phase,
releasing compressed air from the combustion chamber.

A Engine brake off

B Engine brake on

C Exhaust cam

d Valve elevation for engine brake

000592t

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28 ENGINE SECTION 4 ADT 25-30 TIER3

EARLY CLOSING SYSTEM FOR THE INTAKE VALVES (“MILLER” CYCLE)

The ”Miller” system is used to reduce the maximum combustion temperature in the cylinder, which is responsible
for producing nitrogen oxides (NOx).
The concentration of oxygen in the combustion chamber is reduced by closing the intake valves slightly before
the end of the intake stroke of the cylinder, (see detail C).

Figure 14

104762

1. Exhaust cams --- 2. Intake cams --- 3. EGR lobe --- S. Exhaust pipes --- A. Intake pipes

B = End of standard intake stroke

C = End of intake stroke with “Miller cycle” device

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ADT 25-30 TIER3 SECTION 4 ENGINE 29

COOLING
Forced---circulation cooling is obtained by means of a Figure 17
centrifugal pump, controlled by the crankshaft through
a Poli---V type belt.
Water circulation is regulated by a thermostat.
The radiator is vertical.

Check that the pump body has no cracks or

water leaks. Otherwise replace the com-
plete water pump
Check thermostat function. In case of
doubt, replace the thermostat.

Water pump

Figure 15 71731

ENGINE WATER PUMP

WATER PUMP SECTION

Figure 16

45159

The water pump consists of: rotor, seal bearing and

control pulley.

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30 ENGINE SECTION 4 ADT 25-30 TIER3

Engine cooling system general diagram

Figure 18

274A04006

1. Passenger compartment heater

2. Brake coolant exchanger
3. Thermostat
4. Radiator
5. Engine
6. Automatic transmission oil exchanger
7. Expansion tank
(a) tubing from passenger compartment heater to engine
(b) tubing from engine to passenger compartment heater
(c) tubing from brake coolant exchanger to thermostat
(d) tubing from thermostat to radiator
(e) tubing from radiator to engine (coolant pump)
(f) tubing from engine to automatic transmission oil exchanger
(g) tubing from automatic transmission oil exchanger to brake coolant exchanger
(h) tubing from expansion tank to engine (coolant pump)

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ADT 25-30 TIER3 SECTION 4 ENGINE 31

Main circuit engine cooling circuit

Figure 19

(b)

(a)

(d)

(c)

276C04007
1. Radiator
2. Thermostat
3. Automatic transmission oil exchanger

(c) tubing from brake coolant exchanger to thermostat

(d) tubing from thermostat to radiator
(e) tubing from radiator to engine (coolant pump)
(f) tubing from engine to automatic transmission oil exchanger
(g) tubing from automatic transmission oil exchanger to brake coolant exchanger

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32 ENGINE SECTION 4 ADT 25-30 TIER3

Thermostat operation -- engine cooling system

Thermostat closed

Figure 20

274A04008

1. Tubing from radiator to engine (coolant pump) --- 2. Tubing from expansion tank to engine
(coolant pump) --- 3. Tubing from passenger compartment heater to engine --- 4. Tubing from engine to
passenger compartment heater --- 5. Engine input --- 6. Engine output --- 7. Tubing from engine to automatic
transmission oil exchanger --- 8. Tubing from brake coolant exchanger to thermostat --- 9. Breather ---
10. Tubing from thermostat to radiator

A. Engine --- B. Automatic transmission exchanger --- C. Thermostat

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ADT 25-30 TIER3 SECTION 4 ENGINE 33

Thermostat open

Figure 21

274A04009

1. Tubing from radiator to engine (coolant pump) --- 2. Tubing from expansion tank to engine
(coolant pump) --- 3. Tubing from passenger compartment heater to engine --- 4. Tubing from engine to
passenger compartment heater --- 5. Engine input --- 6. Engine output --- 7. Tubing from engine to automatic
transmission oil exchanger --- 8. Tubing from brake coolant exchanger to thermostat --- 9. Breather ---
10. Tubing from thermostat to radiator

A. Engine --- B. Automatic transmission exchanger --- C. Thermostat

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34 ENGINE SECTION 4 ADT 25-30 TIER3

LUBRICATION

Figure 22

71578
The forced---circulation lubrication is obtained by
means of gear pump.
The pump is driven via the cog (1) by the crankshaft (2).
A heat exchanger and the oil filter are installed on the
lubrication system.

Figure 23

60651
The heat exchanger houses the by---pass valve with
opening pressure at 3 bar and the thermostatic valve
that cuts---in when temperature exceeds 82.5˚C.

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ADT 25-30 TIER3 SECTION 4 ENGINE 35

Lubrication system outline

Figure 24

Gravity fed 60628

oil
Oil under
pressure

1. Oil sump --- 2. Crankshaft --- 3. Engine oil---water heat exchanger --- 4. Engine oil filter ---
5. Turbocompressor --- 6. Camshaft --- 7. Valve timing gears
1780320

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36 ENGINE SECTION 4 ADT 25-30 TIER3

Lubrication system outline -- Detail A

Figure 25

Gravity fed oil

Oil under pressure

B -- to cylinders 1 -- 2 -- 3
C -- to cylinder 4
D -- to cylinders 5 -- 6

DETAIL A

8. Engine brake solenoid valve with 4th cylinder command piston

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ADT 25-30 TIER3 SECTION 4 ENGINE 37

Oil pump
Figure 28
Figure 26

60560
The oil pump (1) cannot be overhauled. On finding any
damage, replace the oil pump assembly. 73540
See under the relevant heading for replacing the gear
MAIN DATA TO CHECK THE OVERPRESSURE
(2) of the crankshaft.
VALVE SPRING
Overpressure valve

Figure 27

73541
OIL PUMP CROSS---SECTION
1. Overpressure valve – Start of opening pressure 10.1 +0.7 bars.

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38 ENGINE SECTION 4 ADT 25-30 TIER3

Oil pressure control valve Figure 30

Figure 29

73543
73542
MAIN DATA TO CHECK THE OIL PRESSURE
CHECK THE OIL PRESSURE CONTROL VALVE SPRING
CONTROL VALVE SPRING
The oil pressure control valve is located on the left ---
hand side of the crankcase.
Start of opening pressure 5 bars.

Heat exchanger
Figure 31

104236
HEAT EXCHANGER
The heat exchanger is fitted with: 1. Oil pressure/temperature sensor --- 2. By---pass valve --- 3. Heat valve.

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ADT 25-30 TIER3 SECTION 4 ENGINE 39

By -- pass valve This is a new generation of filters that permit much

Figure 32 more thorough filtration as they are able to holder back
a greater amount of particles of smaller dimensions
than those held back by conventional filters with a
paper filtering element.
These high---filtration devices, to date used only in in-
dustrial processes, make it possible to:
D reduce the wear of engine components over time;
D maintain the performance/specifications of the oil
and thereby lengthen the time intervals between
changes.

External spiral winding

The filtering elements are closely wound by a spiral so
73545 that each fold is firmly anchored to the spiral with re-
The valve quickly opens at a pressure of: 3 bars. spect to the others. This produces a uniform use of the
element even in the worst conditions such as cold start-
Thermostatic valve ing with fluids with a high viscosity and peaks of flow.
In addition, it ensures uniform distribution of the flow
Figure 33
over the entire length of the filtering element, with
consequent optimization of the loss of load and of its
working life.

Mount upstream
To optimize flow distribution and the rigidity of the filtering
element, this has an exclusive mount composed of a
strong mesh made of nylon and an extremely strong syn-
thetic material.
73542
Start of opening: Filtering element
D travel 0.1 mm at a temperature of 82 ±2 ˚C. Composed of inert inorganic fibres bound with an ex-
End of opening: clusive resin to a structure with graded holes, the el-
D travel 8 mm at a temperature of 97 ˚C. ement is manufactured exclusively to precise pro-
cedures and strict quality control.
Engine oil filters
Figure 34 Mount downstream
A mount for the filtering element and a strong nylon
mesh make it even stronger, which is especially helpful
during cold starts and long periods of use. The per-
formance of the filter remains constant and reliable
throughout its working life and from one element to
another, irrespective of the changes in working
conditions.

Structural parts
The o---rings equipping the filtering element ensure a
perfect seal between it and the container, eliminating
by---pass risks and keeping filter performance con-
stant. Strong corrosion---proof bottoms and a sturdy in-
ternal metal core complete the structure of the filtering
element.
When mounting the filters, keep to the following rules:
D Oil and fit new seals;
D Screw down the filters to bring the seals into contact
with the supporting bases;
D Tighten the filter to a torque of 35---40 Nm.

47447

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
40 ENGINE SECTION 4 ADT 25-30 TIER3

TECHNICAL SPECIFICATION

Figure 35
TYPE PART NUMBER

F 3 A E 0 6 8 1 A * A 0 0 1 ---

Progressive production number

Version number within the B.o.M.

Only for exhaust gas level with the same torque and
power curves
Engine power output or torque level

Use (eg I = truck)

Fuel feed + injection (TCA, direct injection diesel engine)

Number of cylinders

Number of strokes and cylinders’ position (eg 0 = 4 strokes, vertical)

Engine (invariable)

Engine family evolution (also irrespective of the displacement)

Indicates the engine family

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 41

GENERAL CHARACTERISTICS

Type F3A

Cycle
y Diesel 4 strokes
Feeding
g g with aftercooler
Turbocharged
Injection Direct

N. of cylinders 6 on---line

j
Diameter mm 125

Stroke mm 140

+ + +.. = Total displacement cm3 10.300

ρ Compression ratio 17

ADT 25 ADT 30

Max. power kW
235 260
(HP) (315) (353)
rpm

rpm 2100 1900

Max. torque Nm 1450 1650

(kgm) (148) (170)

rpm 1400 1400

Engine idling speed,

no load
rpm 550 ± 25
Maximum engine
speed, no load
rpm 2550 ± 20

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
42 ENGINE SECTION 4 ADT 25-30 TIER3

Type F3A

A VALVE TIMING

opens before T.D.C. A 17˚

closes after B.D.C. B 4˚

C opens before B.D.C. D 36˚

closes after T.D.C. C 9˚

For timing check

mm _
X
X mm _

Running

mm 0.35 to 0.45
X
mm 0.35 to 0.45

FEED Through fuel pump --- Filters

Con iniettori iniettori---pompa comandati da
Injection albero a camme in testa N31 a regolazione
type Bosch
elettronica

Injection order 1 --- 4 --- 2 --- 6 --- 3 --- 5

ba Injection pressure bar

r 1800
Injector calibration bar

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 43

F3A
Type
VGT

Holset
SUPERCHARGING geometria
variabile
Turbocharger type Variable geometry Holset HX 40 V
By centrifugal pump, regulating thermostat,
COOLING
viscostatic fan, radiator and heat exchanger
Water pump control By belt
Thermostat: N. 1
starts to open: ~85 ˚C
fully open: ---
Forced by gear pump, pressure control valve,
LUBRICATION
oil filter
Oil pressure, engine hot
bar (100 ˚C ± 5 ˚C):
at idling speed bar 1.5
at maximum speed bar 5
OIL FILLING
Total capacity at 1st filling
liters 32
kg 28,8
Capacity:
--- engine sump min level
liters 17
kg 15.3
--- engine sump max level
liters 25
kg 22.5
--- quantity in circulation that does
not flow back to the engine
g sump
p
liters 7
kg 6,3
--- quantity contained in the
cartridge filter (which has to be
added to the cartridge filter refill)
liters 2.5
kg 2.3

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44 ENGINE SECTION 4 ADT 25-30 TIER3

ASSEMBLY CLEARANCE DATA

Type F3A

CYLINDER BLOCK AND

mm
CRANKMECHANISM COMPONENTS
∅1
Bores for cylinder liners:
upper 142.000 ÷ 142.025
∅1
lower 140.000 ÷ 140.025

Cylinder liners:
external diameter:
L upper 141.961 ÷ 141.986
∅2
lower 139.890 ÷ 139.915
∅2 length L ---
Cylinder liners ---
crankcase bores
upper 0.014 ÷ 0.064
lower 0.085 ÷ 0.135
ASTRA
External diameter ∅2 ---

∅3
Cylinder sleeve
X
inside diameter ∅3A* 125.000 ÷ 125.013
inside diameter ∅3B* 125.011 ÷ 125.024
Protrusion X 0.045 ÷ 0.075
* Selection class
Pistons:
∅1 measuring dimension X 18
X external diameter ∅1AF 124.884 ÷ 124.896
external diameter ∅1BFF 124.896 ÷ 124.907
∅2
pin bore ∅2 50.010 ÷ 50.018
Piston --- cylinder sleeve
A* 0.104 ÷ 0.129
* Selection class B* 0.104 ÷ 0.128
ASTRA
Piston diameter ∅1 ---

X
Pistons protrusion X 0.23 ÷ 0.53

∅3 Gudgeon pin ∅3 49.994 ÷ 50.000

Gudgeon pin --- pin housing 0.010 ÷ 0.024

F Class A pistons supplied as spares.
FF Class B pistons are fitted in production only and are not supplied as spares.

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ADT 25-30 TIER3 SECTION 4 ENGINE 45

F3A
Type
mm

X1
X1 3.620 ÷ 2.640
X2
X3 Piston ring grooves X2 1.550 ÷ 1.570
X3 4.020 ÷ 4.040
S1 Piston rings:
S2 trapezoidal
p seal S1 2.500
S3 lune seal S2 1.490 ÷ 1.500
milled
ill d scraper ring
i
with slits and internal
spring S3 3.970 ÷ 3.990

1 0.120 ÷ 0.140
Piston rings --- grooves 2 0.050 ÷ 0.100
3 0.030 ÷ 0.070
ASTRA Piston rings ---

X1 Piston ring end gap

in cylinder liners
X2
X1 0.35 ÷ 0.50
X3
X2 0.60 ÷ 0.75
X3 0.35 ÷ 0.65
∅1 Small end bush housing
Ø1 54.000 ÷ 54.030

Big end bearing

∅2 housing Ø2 87.000 ÷ 87.030
1 87.000 ÷ 87.010
Selection classes { 2
3
87.011 ÷ 87.020
87.021 ÷ 87.030
∅4 Small end bush diameter
outside ∅4 54.085 ÷ 54.110
∅3 50.019 ÷ 50.035
inside ∅3
Big end bearing shell S
S Red 1.970 ÷ 1.980
Green 1.981 ÷ 1.990
Yellow D 1.991 ÷ 2.000
Small end bush --- housing 0.055 ÷ 0.110
Piston pin --- bush 0.019 ÷ 0.041

ASTRA Big end bearing 0.127 --- 0.254 --- 0.508

Connecting rod weight

A g. 3973 ÷ 4003
Connecting rod weight
A g. 3973 ÷ 4003
Class B g. 4004 ÷ 4034
Class C g. 4035 ÷ 4065

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46 ENGINE SECTION 4 ADT 25-30 TIER3

F3A
Type
mm
X
Measuring dimension X 125

Max. connecting rod

axis misalignment
tolerance 0.08

Main journals ∅1
--- nominal 92.970 ÷ 93.000
--- class 1 92.970 ÷ 92.979
--- class 2 92.980 ÷ 92.989
--- class 3 92.990 ÷ 93.000
∅1 ∅2
Crankpins ∅2
--- nominal 82.970 ÷ 83.000
--- class 1 82.970 ÷ 82.979
--- class 2 82.980 ÷ 82.989
--- class 3 82.990 ÷ 83.000
S1 S 2 Main bearing shells S1
Red 2.965 ÷ 2.974
Green 2.975 ÷ 2.984
Yellow* 2.985 ÷ 2.995
Big end bearing shells S2
Red 1.970 ÷ 1.980
Green 1.981 ÷ 1.990
Yellow* 1.991 ÷ 2.000
Main bearing housings ∅3
--- nominal 99.000 ÷ 99.030
∅3 --- class 1 99.000 ÷ 99.009
--- class 2 99.010 ÷ 99.019
--- class 3 99.020 ÷ 99.030
Bearing shells ---
0.050 ÷ 0.090
main journals
Bearing shells ---
0.040 ÷ 0.080
big ends
ASTRA Main bearing shells 0.127 --- 2.254 --- 0.508
Big end bearing shells 0.127 --- 2.254 --- 0.508

Main journal,
thrust bearing X1 45.95 ÷ 46.00
X1

Main bearing housing,

thrust bearing X2 38.94 ÷ 38.99
X2
X3
Thrust washer
halves X3 3.38 ÷ 3.43

Crankshaft end float 0.10 ÷ 0.30

1 2 Alignment 1 --- 2 ≤ 0.025

---
Ovalization 1 --- 2 0.010
Taper 1 --- 2 0.010

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ADT 25-30 TIER3 SECTION 4 ENGINE 47

Type F3A

CYLINDER HEAD --- VALVE TRAIN mm

∅ 1

Valve guide housings

in cylinder head
∅1 14.980 ÷ 14.997

∅ 2

Valve guide ∅2 9.015 ÷ 9.030

∅3 15.012 ÷ 15.025
∅ 3

Valve guides --- housings

0.015 ÷ 0.045
in the cylinder heads
ASTRA
Valve guide 0.2 --- 0.4

∅ 4 Valves:

∅4
8.960 ÷ 8.975
α
60° 30′ ± 7′ 30″
∅4 8.960 ÷ 8.975
α α 45° 30’ ± 7′ 30″
Valve stem and its guide 0.040 ÷ 0.070
Valve seat in
head
44.185 ÷ 44.220
∅1
∅ 1 42.985 ÷ 43.020
∅1
Outside diameter of valve
∅ 2 seat; angle of valve seat
in cylinder head:
44.260 ÷ 44.275
∅2
α 60° --- 30’
α 43.060 ÷ 43.075
∅2
α 45° --- 30′
X 0.65 ÷ 0.95
Recessing of valve
X X 1.8 ÷ 2.1

Between valve
seat and head 0.040 ÷ 0.090

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 48 ENGINE SECTION 4 ADT 25-30 TIER3

Table 1

F3A
Type
mm
Valve spring height:
free height H 75
H under a load of:
H1
H 2 N 500 ±25 H1 61
N 972 ±48 H2 47.8

Injector protrusion X 1.14 ÷ 1.4

X

Camshaft bushing housing in

the cylinder head:
1⇒7 Ø 88.000 ÷ 88.030
∅ ∅ ∅
∅ 2

Camshaft bearing
journals:
1⇒7 Ø 82.950 ÷ 82.968
∅ 1 ∅ 3

Outer diameter of
∅ camshaft bushings: ∅
88.153 ÷ 88.183

Inner diameter of
∅ camshaft bushings: ∅ 83.018 ÷ 83.085

Bushings and housings in the

0.123 ÷ 0.183
cylinder head
Bushings and bearing
journals 0.050 ÷ 0.135
Cam lift:
9.30

H 9.45

11.21

∅ 1
Rocker shaft ∅1 41.984 ÷ 42.000

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ADT 25-30 TIER3 SECTION 4 ENGINE 49

Type F3B

mm

Bushing housing in rocker arms

45.000 ÷ 45.016

59.000 ÷ 59.019

∅
46.000 ÷ 46.016

Bushing outer diameter

for rocker arms:
45.090 ÷ 45.130

Ø 59.100 ÷ 59.140

46.066 ÷ 46.091

Bushing inner diameter

for rocker arms:
42.025 ÷ 42.041

Ø 56.030 ÷ 56.049

42.015 ÷ 42.071

Between bushings and

housings
0.074 ÷ 0.130

0.081 ÷ 0.140

0.050 ÷ 0.091

Between rocker arms and shaft

0.025 ÷ 0.057

0.025 ÷ 0.057

0.015 ÷ 0.087

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50 ENGINE SECTION 4 ADT 25-30 TIER3

TIGHTENING TORQUES

PART TORQUE
Nm kgm
Capscrews, undercrankcase to crankcase ♦
Outside screws M12x1.75 First phase: preliminary tightening 30 (3)
Inner screws M 18x2 Second phase: preliminary tightening 120 (12)
Inner screws Third phase: angle locking 60˚
Inner screws Fourth phase: angle locking 55˚
Outer screws Fifth phase: angle locking 60˚
Piston cooling nozzle union ♦ 35±2 (3.5±0.2)
Heat exchanger fixing screws to the block ♦
preliminary tightening 11.5±3.5 (1.15±0.35)
tightening 19±3 (1.9±0.3)
Spacer oil sump fixing screws to undercrankcase ♦ 24.5±2.5 (2.4±0.25)
Fixing screws to oil sump ♦
preliminary tightening 38 (3.8)
tightening 45 (4.5)
Gearbox fixing screws to the block M 12x1.75 ♦ 63±7 (6.3±0.7)
Control unit fastening screws on engine block 24±2.5 (2.4±0.25)
Cylinder head fixing screws ♦
First phase preliminary tightening 60 (6)
Second phase preliminary tightening 120 (12)
Third phase angle locking 90°
Fourth phase angle locking 65°
Rocker shaft fixing screws ♦
First phase preliminary tightening 80 (8)
Second phase angle locking 60°
Lock nut for rocker adjustment screw ♦ 39±5 (3.9±0.5)
Injector blocking brackets screws ♦ 26 (2.6)
Plastic cover fastening screws 8.5±1.5 (0.85±0.15)
Shoulder plate fixing bolts to head ♦ 19±3 (1.9±0.3)
Engine mounting bracket screws on head
First phase pre---torque 120 (12)
Second phase tightening to angle 45˚
♦ Lubricate with UTD oil before installation
• Lubricate with graphitized oil before installation

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 51

TORQUE
DETAIL
Nm kgm
Engine mounting bracket fasteners at flywheel casing
First phase pre---tightening 100 (10)
Second phase closure to angle 60°
Camshaft pinion fasteners♦
First phase pre---tightening 60 (6)
Second phase closure to angle 60°
Phonic wheel fstener on camshaft pinion 8.5±1.5 (0.85±0.15)
Exhaust manifold fasteners •
pre---tightening 40±5 (4±0.5)
tightening 70±5 (7±0.5)
Engine braking actuator cylinder fasteners♦ 19±3 (1.9±0.3)
Connecting rod bolts♦
First phase pre---tightening 60 (6)
Second phase closure to angle 60°
Flywheel fasteners♦
First phase pre---tightening 120 (12)
Second phase closure to angle 90°
Damper flywheel fasteners♦
First phase pre---tightening 70 (7)
Second phase closure to angle 50°
Intermediate gear pin fasteners♦
First phase pre---tightening 30 (3)
Second phase closure to angle 90°
Link rod fasteners for adjustment of drive gear 24.5±2.5 (2.45±0.25)
Oil pump fasteners 24.5±2.5 (2.45±0.25)
Front Crankshaft gasket cover fasteners 24.5±2.5 (2.45±0.25)
Fuel pump / filter support fasteners 19±3 (1.9±0.3)
Control unit fasteners 19±3 (1.9±0.3)
Turbocompressor nuts and bolts •
pre---tightening 35 (3.5)
tightening 46 (4.6)
Thermostat group fasteners 30±2 (3.0±0.2)
Water pump fasteners 25 (2.5)
Fasteners for fan hub to spacer 30 (3)
Automatic belt tensioner to conditioner fasteners 26±3 (2.6±0.3)
Automatic belt tensioner to alternator support fasteners 50±5 (5±0.5)
Fixed auxiliaries drive pulley to engine block fasteners 105±5 (10.5±0.5)
Starter motor fasteners 74±4 (7.4±0.4)
Air heater fasteners 50±3 (5.0±0.3)
Air compressor fasteners 74±4 (7.4±0.4)

♦ Lubricate with UTDM oil before mounting

• Lubricate with graphite oil before mounting

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
52 ENGINE SECTION 4 ADT 25-30 TIER3

TORQUE
DETAIL
Nm kgm
Compressor drive cog nut♦ 170±10 (17±1)
Alternator fasteners M 8x1.25 25±3 (2.5±0.3)
M 10x1.5 44±4 (4.4±0.4)
Power steering pump fasteners 46.5±4.5 (4.65±0.45)
Air conditioner compressor to support fasteners 24.5±2.5 (2.5±0.25)
Cover fasteners 24.5±2.5 (2.5±0.25)
Filter block sensor fastener 55±5 (5.5±0.5)
Water / fuel temperature sensor fastener 35 (3.5)
Thermometric switch / transmitter fastener 25 (2.5)
Air temperature transmitter fastener 35 (3.5)
Pulse transmitter fastener 8±2 (0.8±0.2)
Engine brake electrovalve fastener 32 (3.2)
Engine

M16X130 bolt for fastening front and rear elastic mountings to engine 278 ± 28 27,8 ± 2,8
Flanged M18X62 hex head bolt for front engine mounting:

First phase pre---tightening 120 12

Second phase closure to angle 45°
TC M14X60 recessed hex head bolt for front engine mounting:

First phase pre---tightening 60 6

Second phase closure to angle 45°
Flanged M18X62 hex head bolt for rear engine mounting:
First phase pre---tightening 100 10
Second phase closure to angle 60°

♦ Lubricate with UTDM oil before mounting

• Lubricate with graphite oil before mounting

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 53

TIGHTENING ORDER OF GEARBOX TO ENGINE BLOCK FASTENING SCREWS

Figure 36

stage 1:
FRONT SIDE pretightening,
outer screws
30 Nm

60592

stage 2:
FRONT SIDE pretightenig,
inner screws
120 Nm

60593

stage 3:
angle, inner
FRONT SIDE screws
60º

60593

stage 4:
angle, inner
FRONT SIDE screws
55º

60593

stage 5:
angle, outer
FRONT SIDE screws
60º

60594
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
54 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 37

60580
DIAGRAM OF CYLINDER HEAD FIXING SCREWS TIGHTENING SEQUENCE

Figure 38

60581
DIAGRAM OF EXHAUST MANIFOLD FIXING SCREWS TIGHTENING SEQUENCE

Figure 39

60582

DIAGRAM OF TURBOCHARGER FIXING SCREWS AND NUTS TIGHTENING SEQUENCE

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 55

Figure 40

60666

DIAGRAM OF TIGHTENING SEQUENCE FOR HEAT EXCHANGER SCREWS

Figure 41

60583

DIAGRAM OF TIGHTENING SEQUENCE FOR ENGINE OIL SUMP SCREWS

Figure 42

73554

DIAGRAM OF TURBOCHARGER FIXING SCREWS AND NUTS TIGHTENING SEQUENCE

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
56 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 43

60633

Tightening order:

no. 10 M12 x 1,75 x 100 Nm screw

no. 2 M12 x 1,75 x 70 Nm screw
no. 4 M12 x 1,75 x 35 Nm screw
no. 1 M12 x 1,75 x 120 Nm screw
: no. 2 M12 x 1,75 x 193 Nm screw

Figure 44

70567A

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ADT 25-30 TIER3 SECTION 4 ENGINE 57

Engine Support and Brackets

Figure 45

S269GN001A

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
58 ENGINE SECTION 4 ADT 25-30 TIER3

TOOLS
TOOL NO. DESCRIPTION

99305019 Full---optional tool---kit to rectify valve seat

99305047 Rotary telescopic stand

(range 2000 daN, torque 375 daNm)

99322230 Rotary telescopic stand (range 2000 daN, torque 375

daN/m)

99340053 Extractor for crankshaft front gasket

99340054 Extractor for crankshaft rear gasket

99340205 Percussion extractor

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 59

TOOL NO. DESCRIPTION

99342149 Extractor for injector---holder

99346250 Tool to install the crankshaft front gasket

99346251 Tool to install the crankshaft rear gasket

99348004 Universal extractor for 5 to 70 mm internal components

99350072 Box wrench for block junction bolts to the underblock

99360143 Box wrench for block junction bolts to the underblock

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
60 ENGINE SECTION 4 ADT 25-30 TIER3

TOOL NO. DESCRIPTION

99360144 Tools (12+6) for holding sliding blocks for rockers

adjusting screws during disassembly reassembly rockers
shaft

99360180 Injector housing protecting plugs (6)

99360184 Pliers for assembling and disassembling piston split rings

(105---106 mm)

99360261 Tool to take down-fit engine valves (to be used with special
plates)

99360263 Plate for take down-fit engine valves (to be used with
99360261)

99360296 Tool to fit back valve guide (to be used with 99360143)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 61

TOOL NO. DESCRIPTION

99360314 Tool to remove oil filter (engine)

99360321 Tool to rotate engine flywheel (to be used with 99360325)

99360325 Spacer (to be used with 99360321)

99360329 Tool to install gasket on valve guide

99360334 Compression tool for checking the protrusion of cylinder

liners
(to be used with 99370415---99395603 and special plates)

99360336 Spacer (to be used with 99360334)

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62 ENGINE SECTION 4 ADT 25-30 TIER3

TOOL NO. DESCRIPTION

99360338 Cylinder liner compression plate (to be used with

99360334---99360336)

99360351 Tool to stop engine flywheel

99360499 Tool to take down and fit back camshaft bushes

99360500 Tool to lift crankshaft

99360551 Bracket to take down and fit engine flywheel

99360553 Tool for assembling and installing rocker arm shaft

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 63

TOOL NO. DESCRIPTION

99360585 Swing hoist for engine disassembly assembly

99360605 Belt to insert piston in cylinder liner (60 --- 125 mm)

99360612 Tool for positioning engine P.M.S.

99360613 Tool for timing of phonic wheel on timing gear

99360703 Tool to stop cylinder liners

99360706 Tool to extract cylinder liners (to be used with specific

rings)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
64 ENGINE SECTION 4 ADT 25-30 TIER3

TOOL NO. DESCRIPTION

99360728 Ring (125 mm) (to be used with 99360706)

99361036 Brackets fixing the engine to rotary stand 99322230

99365056 Tool for injector holder heading

99370415 Base supporting the dial gauge for checking cylinder liner
protrusion (to be used with 99395603)

99378100 Tool for printing engine identification plates (to be used

with special punches)

99378101
99378102
99378103 Punches (A,B,C,D,E,F) for printing engine identification
99378104 plates (to be used with 99378100)
99378105
99378106

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ADT 25-30 TIER3 SECTION 4 ENGINE 65

TOOL NO. DESCRIPTION

99389834 Torque screwdriver for calibrating the injector solenoid

valve connector check nut

99390330 Valve guide sleeker

99390772 Tool for removing injector holding case deposits

99390804 Tool for threading injector holding cases to be extracted

(to be used with 99390805)

99390805 Guide bush (to be used with 99390804)

99394015 Guide bush (to be used with 99394041 or 99394043)

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66 ENGINE SECTION 4 ADT 25-30 TIER3

TOOL NO. DESCRIPTION

99394041 Cutter to rectify injector holder housing (to be used with

99394015)

99394043 Reamer to rectify injector holder lower side (to be used

with 99394015)

99395216 Measuring pair for angular tightening with 1/2” and 3/4”
square couplings

99395219 Gauge for defining the distance between the centres of

camshaft and transmission gear

99395363 Complete square to check connecting rod squaring

99395603 Dial gauge (0 --- 5 mm)

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ADT 25-30 TIER3 SECTION 4 ENGINE 67

TOOL NO. DESCRIPTION

99395687 Reaming gauge (50 --- 178 mm)

99396035 Centering ring of crankshaft front gasket cap

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68 ENGINE SECTION 4 ADT 25-30 TIER3

TROUBLESHOOTING BY SYMPTOMS
Main engine operating anomalies:

1 --- The engine does not start; 6 --- Poor engine braking efficiency;
2 --- The engine is excessively heated; 7 --- The engine stops;
3 --- The engine lacks efficiency; 8 --- Excessive fuel consumption;
4 --- The engine has grey smokes (tending to white); 9 --- Excessive or insufficient oil pressure.
5 --- The engine has blue smokes;

1 ENGINE DOES NOT START

Battery efficient Pre---heating element always on

NO Check alternator efficiency
Check battery terminal connections

YES

Starter motor efficient Carry out checks / replace

NO

YES

Air heater efficient Check power supply and earth connection

NO Check heater relay by active diagnosis

YES

Main relay efficient Check fuses

NO Check relay by active diagnosis

YES

Fuel pump efficient Check efficiency checking pressure at filter

NO

YES

Fuel prefilter --- filter efficient Check for clogging / replace

NO

(continued)

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ADT 25-30 TIER3 SECTION 4 ENGINE 69

0.8 bar valve on fuel return efficient Check efficiency, replace if blocked open
NO

YES

Fuel circuit efficient Check circuit seal and bleed

NO

2 ENGINE OVERHEATS

Coolant level correct Check for leaks and top---up

NO

YES

Water pump and fan belts efficient Check, adjust tension and if necessary replace
NO components

YES

Water pump efficient Overhaul or replace group

NO

YES

Thermostat efficient Check whether remains closed or partially

NO open. Replace

YES

Radiator efficient Thoroughly clean, check for leaks, replace if

NO necessary

YES

Air filter and circuit piping efficient Check that hoses and pipes are clear
NO Check filter clog indicator, replace filter.

(continued)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
70 ENGINE SECTION 4 ADT 25-30 TIER3

Cylinder head gasket efficient Check water pressure and replace head gasket
NO

YES

Fan efficient Replace

NO

3 ENGINE LACKS POWER

Fuel circuit efficient Check whether tank filter, prefilter and fuel filter
NO are clogged. Replace.
Check whether 0.8 bar valve on fuel return from
head is blocked open (low pressure) or closed
(high temperature). Replace
Check for circuit leaks and fuel pump efficiency
YES

Injectors efficient Injector pump may seize or fuel leak from O---ring.
NO Carry out engine test and proceed as per
instructions given

YES

Engine air intake circuit efficient Remove obstruction on circuit and replace air
NO filter if clogged.
Check clogged cartridge indicator

YES

Exhaust gas circuit efficient Eliminate leaks on exhaust manifold

NO

YES

Correct running temperature Check cooling system

NO

(continued)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 71

VGT actuator efficient Carry out Engine Test following instructions

NO displayed by diagnosis tool

YES

Turbocompressor efficient Carry out Engine Test on turbine and check

NO integrity of following turbo components
--- turbine blades
--- bearings
--- modulator valve
--- Clogged VGT filter
--- turbine actuator
YES Replace faulty components
Engine Test with Modus --- IWT --- IT2000

Mechanical injection system efficient Check injector rocker wear, check rollers,
NO rocker bushes and camshaft cams

YES

Valve play correct Adjust valve play

NO

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
72 ENGINE SECTION 4 ADT 25-30 TIER3

4 ENGINE EMITS GREY/WHITE

SMOKE

Head gasket efficient Grind head and replace gasket

NO

YES

Injector sheathes efficient Replace sheathes

NO

YES

Turbocompressor cooling circuit seal efficient Overhaul turbo

NO

YES

Good quality fuel Check for water in tank and eliminate

NO

5 ENGINE EMITS BLUE SMOKE

Piston rings efficient Overhaul pistons --- cylinder

NO

YES

Turbo lubrication circuit efficient Overhaul turbo

NO

YES

Valve oil seals efficient Replace valve guide gaskets

NO

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 73

6 POOR ENGINE BRAKING EFFICIENCY

Engine braking components efficient Check correct function of engine brake actuator
NO cylinders and command solenoid
Check cylinder command oil piping seal
Check exhaust valve play
YES

Turbocompressor efficient VGT blocked open

NO Faulty VGT actuator (seepage from tie rod)
Faulty modulator valve
Incorrect air supply to modulator valve
Replace faulty components

7 ENGINE STOPS

Fuel in tank Bleed group after filling tank

NO

YES

Tank filter, pre---filter and engine fuel filter Clean tank filter and replace filter and prefilter
efficient NO

YES

Tank fuel lines correctly connected Inverting the pipes may cause vehicle to stop
NO after 200 --- 300 km even if tank has fuel because
piping that feeds engine has less scavenge.
Invert pipes.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 74 ENGINE SECTION 4 ADT 25-30 TIER3
ENGINE

8 EXCESSIVE FUEL CONSUMPTION

Air filter efficient Replace

NO

YES

Tank and fuel lines efficient. Eliminate any leaks and replace worn parts
NO

9 OIL PRESSURE INSUFFICIENT OR

EXCESSIVE

Pressure regulator valve operates correctly Check and if necessary replace

NO

YES

Oil pump and delivery piping efficient Check and if necessary replace.
NO

YES

Main bearings and big ends efficient Replace bearings and if necessary grind
NO crankshaft

YES

Engine oil SAE viscosity correct Change engine oil with suitable viscosity oil
NO

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 75

MAINTENANCE
Figure 38
Before carrying out any operation, check
that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in SEC-
TION 1 of this manual.
If in doubt, speak to a more experienced per-
son.
Respect all general recommendations for
correct execution of maintenance works.

Engine oil change

Exhausted oil and fluids must be collected
and disposed of according to standards in 269NM122
force. D clean the filler cap zone, the fill with the specified
quantity of oil through the filler;
Proceed as follows: D replace the filler cap and dipstick;
D switch off the engine after warming up and wait for D start and warm up the engine, then switch off and
coolant temperature to reach 60°C; wait a few minutes;
D Open the hood;
Figure 39
D remove the lower covers;
D remove the dipstick;

Figure 37

156NM11

D remove the dipstick and check that the level is be-

tween the notches on the dipstick. Top---up if neces-
sary.
269NM123
Do not use the vehicle if the level is not with-
D position a container with sufficient capacity, clean in the above limits.
the drain plug area, remove the plug (arrow) and al- Too much or too little oil will result in engine
low time for the oil to drain completely; damage.
D clean the thread, replace the plug;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
76 ENGINE SECTION 4 ADT 25-30 TIER3

Engine oil filter change

Exhausted oil and fluids must be collected Figure 42
and disposed of according to standards in
force.
The oil filter must be replaced at the recom-
mended intervals. If blocked the by---pass
valve permits engine lubrication but the oil
is no longer filtered.

Proceed as follows:
D switch off the engine after warming up and wait for
coolant temperature to reach 60°C;
D Open the hood;

Figure 40 156NM42

D hand---tighten the cartridge until the washer comes

into contact with the support, then tighten it by ¾ of
a turn;
Do not overtighten the cartridge to avoid
damaging the washer. Always follow the
manufacturer’s recommendations.

D Run the engine for a few minutes to check for the ab-
sence of oil leaks;
D check and if necessary top---up the oil level.

269NM131

D unscrew the filter cartridge (arrow) with the correct

spanner, then thoroughly clean the support seat;

Figure 41

156NM25
D fill the new cartridge with oil and grease the washer
with the same oil;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 77

Engine oil vapour filter change Accessory drive belts

Proceed as follows:
Figure 45
Figure 43

228NM221

D remove the lower cover screwsand remove it;

Figure 44
238NM01

The engine has two accessory drive belts:

1. alternator/water pump drive belt;
2. air---conditioner compressor drive belt.

. The belts have automatic tensioners and do

not require adjustment.

228NM222

D remove the filter (1);

When refitting, position the filter with the
support brackets (arrow) pointing toward
the cover.

D replace the cover;

D check that the breather pipe (arrow) is not kinked or
bent.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
78 ENGINE SECTION 4 ADT 25-30 TIER3

Check Replacement
Proceed as follows: Proceed as follows:
D Open the hood; D Open the hood;

Figure 46 Figure 48

276C004008 276C004008

D remove the engine belt covers by removing the D remove the engine belt covers by removing the
screws; screws;

Figure 47 Figure 49

178NM05

D with the engine off and cold, check that the belts are
not chaffed or cracked (small transverse cracks are
admissible);
D If damage is found, replace the belt as instructed
below;
D applying manual pressure to the longest section of
belt, check that the tensioners work correctly.
238NM02
D using a hexagonal wrench turn the tensioner (ar-
row) in the direction indicated to slacken the air---
conditioner compressor drive belt (2);
D insert a metal pin to lock the tensioner and remove
the belt;
Do not turn the tensioner in the opposite di-
rection to prevent damage to its loading
spring.

D using a hexagonal wrench turn the tensioner (ar-

row) in the direction indicated to slacken the alterna-
tor/water pump drive belt (1);
Do not turn the tensioner in the opposite di-
rection to prevent damage to its loading
spring.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 79

D remove the belt; Fuel circuit bleeding

D fit the new alternator/water pump belt and release
the tensioner;
Do not twist the belt on the pulley when fit-
ting it in the groove, and do not use tools (for
example screwdrivers) as levers to prevent
premature damage.
D fit the new air---conditioner compressor drive belt;
Do not twist the belt on the pulley when fit-
ting it in the groove, and do not use tools (for
example screwdrivers) as levers to prevent
premature damage.
D hold the tensioner, remove the locking pin and re-
lease it;
D start the engine for a few minutes, switch off, wait for
it to cool then check the correct function of both belt
tensioners applying manual pressure.
Proceed as follows:
D Open the hood;
D fit suitable pipes to the bleed nipples and lead them
to a container;
D loosen the bleed nipples by a few turns.
Prefilter
D Pump the manual priming pump (1, ref. 1) until fuel
flows out from the nipple (1 arrow) without air
bubbles, then tighten the nipple.
Filter
D Repeat the operation for this nipple (2, arrow).
Cylinder head bleed nipple
D Repeat the operation for this nipple (3, arrow).
Absolutely avoid smearing fuel on the
accessory drive belts to prevent damage.

Figure 50

276NM037T

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
80 ENGINE SECTION 4 ADT 25-30 TIER3

Fuel filter change

Figure 53
Figure 51

156NM25
276NM015T
D fill the new cartridge with specified lubricant and
The vehicle is fitted with two fuel filter groups: agrease the washer with the engine lubricant;
D fuel pre---filter on chassis;
Figure 54
Figure 52

156NM42

269NM182 D hand---tighten the cartridge until the washer comes

into contact with the support, then tighten it by ¾ of
D fuel filter on engine.
a turn;
Proceed as follows: Do not overtighten the cartridge to avoid
D Open the hood; damaging the washer.
D with the engine off unscrew the filter cartridge with Always follow the manufacturer’s recom-
the correct spanner if necessary, then thoroughly mendations.
clean the support seat;
D run the engine for a few minutes to check for the ab-
sence of fuel leaks.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 81

Engine coolant fluid change and circuit check/ Cleaning

cleaning Proceed as follows:
Exhausted oil and fluids must be collected D prepare am mixture of water and specific detergent,
and disposed of according to standards in slowly pour the mixture through the filler until reach-
force. ing level, then close the filler cap;
Use the proportion of detergent recom-
Drain mended by the manufacturer
Too much detergent may damage the en-
This operation must be carried out with the gine.
engine cold. Detergents do not normally contain anti---
freeze: Do not leave the vehicle exposed to
Proceed as follows: low temperatures if the cooling circuit con-
D Open the hood; tains this mixture.
D remove the lower covers;
D start the engine and run it for circa 1 hour;
Figure 55 D stop and leave the engine to cool, then drain the
mixture as previously described;
D fill the circuit again with clean water, start the engine
and run it until the thermostat is fully open;
D stop and leave the engine to cool, then drain the wa-
ter as previously described; if the drained water is
still significantly soiled, repeat the cleaning opera-
tion with detergent;

2690312

D turn the heater valve to maximum then open the filler

cap on the expansion tank;

Figure 56

276NM046T
D position a suitable container, then disconnect the
radiator hose (arrow) and discharge the engine
coolant;
D wait for the coolant to drain completely, then recon-
nect the hose.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
82 ENGINE SECTION 4 ADT 25-30 TIER3

Filling Anti---freeze percentage check

Proceed as follows:
D prepare a mixture of water and specific anti---freeze
in the required proportions. Alternatively use cool-
ant fluid with suitable specifications;
Figure 57
The minimum percentage of anti---freeze required de-
pends on the ambient temperature of the place the ve-
hicle is used.
Check the percentage of anti---freeze in engine coolant
fluid using the refractometer.
Do not use hydrometers as these are not suf-
ficiently accurate.
If special additives are used, always follow
the Supplier’s mixture recommendations.

Radiator external cleaning

Clean the radiator using compressed air to remove ac-
cumulated debris (leaves, insects).
To remove hardened debris, brush the radiator with a
water/detergent solution then use steam to remove any
residue.

Seal check on water---transmission oil and water---hy-

draulic fluid heat exchangers
2690312
Visually inspect the seal of each heat exchanger and
corresponding piping.
D VERY slowly pour the mixture through the filler (ar-
row) without closing the cap;
D start the engine and leave it to idle while adding fluid
until the circuit is completely free of air bubbles, con-
tinuing the operation for at least 15 minutes;
D close the filler cap;
D bring the motor to medium speed until the thermo-
stat is fully open;
D check for the absence of foam or air bubbles in the
tank;
D stop and leave the engine to cool, then check and
if necessary top---up the level.
Check that the pressure regulator valve
built---in to the cap is functioning correctly,
if not, replace the cap.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 83

ENGINE REMOVAL---REPLACEMENT
Figure 59
Before carrying out any operation, check
that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in SEC-
TION 1 of this manual.
If in doubt, speak to a more experienced per-
son.
Respect all general recommendations for
correct execution of maintenance works.

Removal
Proceed as follows:
D park the vehicle on a suitable flat and solid surface,
remove the ignition key, engage the handbrake and
place maintenance warning signs;
D disengage the battery cut ---off switch or disconnect
the battery leads to eliminate any risk of short ---cir-
cuit;
D lock the articulation using the steering lock bar as
instructed in SECTION 1;
Figure 58
2690702
1. High pressure circuit valve
2. Low pressure circuit valve
D proceed to discharge the air conditioner system as
instructed in SECTION 14;
The system must be discharged by special-
ist personnel using specific equipment.
For these operations, refer to the proce-
dures provided by the equipment manufac-
turer.

Do not discharge R134a fluid into the atmos-

phere. Although its potential for damaging
the ozone layer is zero, it may nevertheless
contribute to global warming.
Always use approved refrigerant recovery
and recharging apparatus.
Never mix different refrigerants in the same
apparatus.

276C04010

D proceed to remove the hood as instructed in SEC-

TION 15;
D remove the side covers and lower covers as
instructed in SECTION 15;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
84 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 60 Figure 62

2690310
2690312
D proceed to open the hood as instructed in SECTION D turn the heater valve to maximum then open the filler
15; cap on the expansion tank;
Exhausted oil and fluids must be collected D position a suitable container then discharge the
and disposed of according to standards in coolant as instructed in relative Chapter;
force. Exhausted oil and fluids must be collected
and disposed of according to standards in
Figure 61 force.

Figure 63

2690310

D position a suitable container then discharge the

main hydraulic system fluid as instructed in SEC- 276C04012

TION 10; D remove the coolant/intercooler/condenser fan/ra-

Exhausted oil and fluids must be collected
and disposed of according to standards in
force.
diator unit by following the directions in the relative
chapter.
Removal of the fastening clamps is not de-
scribed. Check correct fastening of the
clamped components.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 85

. The operations described below refer to the D disconnect the air pipes:
--- fuel return (27);
following figures.
--- fuel delivery (28);
D unscrew the screws fastening the crossbar: D disconnect the following pipes from the air---condi-
--- the automatic transmission oil filter group (22); tioner compressor (29):
--- the brake circuit oil filter (21); --- delivery (a);
D disconnect the pump---expansion tank piping (5); --- intake (b);
D disconnect the engine---expansion breather pipe D disconnect the following pipes from brake pump
(8); (26):
D disconnect the windscreen washer pump electrical --- delivery (a);
connection (30); --- intake (b);
D disconnect the windscreen washer fluid piping (2); D disconnect the electrical connections from the start-
D disconnect the hood release command pipe (23) er motor (31):
and the hood release cable (24); a. power cable (+30)
D unscrew the fastening screws from both sides (ar- b. consent cable (+50);
row) and remove the hood support crossbar (20) D disconnect the alternator electrical connections
complete with hood release cable, expansion tank (32):
and windscreen wiper fluid tank; a. power cable (B+)
D disconnect the cab heater engine coolant delivery b. connector;
(3) and return (4) pipes; D disconnect the electrical connection:
D disconnect and remove the metal engine coolant --- from the air---conditioner compressor (36);
delivery (7) and return (6) pipes from the heat ex- --- from the cold start relay device (35);
changers situated to the lower part of the chassis; --- vehicle interface (33);
Coolant may leak during these operations. D disconnect the ground braid between engine and
chassis (34);

D disconnect the intake and air pipes:

--- engine breather (12);
--- compressor intake (13);
D disconnect and remove the intake air pipes (from
turbogroup filter) (10);
D remove the flexible compressor delivery pipe (14);
D disconnect the air pipes:
--- connecting tanks---compressor cut ---out (ener-
gy saving) (15);
--- waste---gate piloting (17);
D remove the exhaust pipes (from turbogroup to flex-
ible) (19);

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
86 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 64

276C04015

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 87

Figure 65

276C04016

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
88 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 66

276C04017

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 89

Figure 67

276C04018

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
90 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 68 Figure 69

38

37

D disconnect the transmission shaft (arrow) between

276C04019 engine and transmission.
D disconnect the lower connector (37) from the en- Figure 70
gine control unit (38);

Do not disconnect the engine wiring con-

nectors (arrow).
For more informatin on the procedure, refer
to SECTION 11 Electrical system.

D using suitable lifting gear, apply the chains to the en-

gine lifting brackets (arrow). Tension them and
check that the load is evenly distributed;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 91

Figure 71

D remove the front and rear engine mounting bolts
from both sides;
Check that all connections and pipes are
disconnected and all fastening clamps re-
moved.
D carefully lift the group, removing it from above.
Replacement
Replace the group following the instructions in reverse
order, and in particular:
D check the elastic engine mountings: if deteriorated,
replace them;
D check the integrity of exhaust and intake pipes and
joints;
D check the integrity of fuel intake and return pipes
and joints;
D check the integrity of engine cooling system and
cab heater pipes and joints;
D fill the engine oil sump as instructed in the chapter
MAINTENANCE;
D fill the engine cooling circuit as instructed in the
chapter MAINTENANCE;
D Bleed the fuel supply circuit as instructed in the
chapter MAINTENANCE.
Checks and tests
After starting and warming up the engine, check:
D the absence of coolant leaks from the engine cool-
ing and cab heater system hoses: if located, tighten
joints or replace faulty parts;
D the absence of hydraulic fluid leaks from pipes that
have been disconnected: if located, tighten joints or
replace faulty parts;
D the absence of oil leaks between rocker cover and
cylinder head, sump and engine block, filter and
seat and between the various pipes: if located, tight-
en joints or replace faulty parts;
D the absence of leaks from fuel supply system piping
and joints: if located, tighten joints or replace faulty
parts;
D the absence of air leaks from intake pipes and ex-
haust gas from the exhaust pipes: if located, tighten
joints or replace faulty parts;
D that the reconnected temperature and pressure
warning lights function correctly.
Fill the vehicle hydraulic circuit as instructed
in SECTION 16.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
92 ENGINE SECTION 4 ADT 25-30 TIER3

DETACHMENT ---REATTACHMENT OF THE FLEXIBLE COUPLING JOINT

Before carrying out any operation, check
that all precautions have been taken and all Figure 72
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in SEC-
TION 1 of this manual.
If in doubt, speak to a more experienced per-
son.
Respect all general recommendations for
correct execution of maintenance works.

Removal
Proceed as follows:
D park the vehicle on a suitable flat and solid surface,
remove the ignition key, engage the handbrake and
place maintenance warning signs;
D disengage the battery cut ---off switch or disconnect
the battery leads to eliminate any risk of short ---cir-
cuit;
D lock the articulation using the steering lock bar as
instructed in SECTION 1;
276C04030
D remove the protections positioned on the left side of
the vehicle by following the instructions in SECTION
15;
D tilt the cab as indicated in the use and maintenance
handbook;
D disconnect the engine---side cardan joint (1);
If difficult to access, remove the drive shaft.

Figure 73

276C04031

D unscrew the retaining screws and remove the pro-

tection (1);
D unscrew the retaining screws and remove the flexi-
ble coupling joint (2).

Reattachment
Reattachment the group following the instructions in
reserve order.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 93

RADIATOR GROUP REMOVAL---REPLACE-

Figure 75
MENT
Before carrying out any operation, check
that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in SEC-
TION 1 of this manual.
If in doubt, speak to a more experienced per-
son.
Respect all general recommendations for
correct execution of maintenance works

Removal

Wait until engine temperature is below 40° C 2690702

before beginning this operation.
1. High pressure circuit valve
Proceed as follows:
2. Low pressure circuit valve
D Park the vehicle on a suitable flat and solid surface,
remove the ignition key, engage the handbrake and
D proceed to discharge the air conditioner system as
place maintenance warning signs;
instructed SECTION 14;
D disengage the battery cut ---off switch or disconnect
the battery leads to eliminate any risk of short ---cir- The system must be discharged by special-
cuit; ist personnel using specific equipment.
D lock the articulation using the steering lock bar as For these operations, refer to the proce-
instructed in SECTION 1; dures provided by the equipment manufac-
turer.
Figure 74
Do not discharge R134a fluid into the atmo-
sphere. Although its potential for damaging
the ozone layer is zero, it may nevertheless
contribute to global warming.
Always use approved refrigerant recovery
and recharging apparatus.
Never mix different refrigerants in the same
apparatus.

Figure 76

276C005010
D proceed to remove the hood as instructed SEC-
TION 15;

2690312

D turn the heater valve to maximum then open the filler

cap on the expansion tank;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
94 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 77 . The operations described below refer to the

following figures.

D disconnect the air---conditioner pressure switch

electrical connector (1);
D remove the air---conditioner condenser inlet and
outlet pipes (2);
D remove the air---compressed inlet (3) and outlet (4)
pipes;
D disconnect the breather piping (5) from the radiator;
D disconnect the engine coolant delivery pipe (6) from
the radiator;
. Coolant may leak during these operations.

276NM046T D remove the intercooler---engine inlet (8) and outlet

D position a suitable container, then disconnect the (9) hoses;
radiator hose (arrow) and discharge the engine D remove the hydraulic circuit exchanger inlet (10)
coolant; and outlet (11) pipes.
Exhausted oil and fluids must be collected . Hydraulic fluid may leak during these opera-
and disposed of according to standards in tions.
force.

Figure 78

276C004008

D remove, if necessary, the engine belt guard grill and

support brackets by removing the fastening screws;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 95

Figure 79

276C04035

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
96 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 80 Figure 81

D support the radiator---intercooler---condenser---ex-

changer group with a suitable dolly, then from both
sides unscrew the buffer fastening screws and re-
move it.
D proceed to dismantle the group as necessary.

Handle the radiator with care, to prevent

damage to the delicate radiator fins.

Replacement
Replace the group following the instructions in reverse
order, and in particular:
276C04037 D check the elastic mountings: if deteriorated, replace
them;
D disconnect both fastening rods from the chassis
D check the integrity of engine cooling system pipes
(A);
and joints;
D fill the engine cooling circuit as instructed in the
chapter MAINTENANCE.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 97

AUTOMATIC TRANSMISSION OIL---WATER

Figure 82
HEAT EXCHANGER REMOVAL---REPLACE-
MENT
Before carrying out any operation, check
that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in SEC-
TION 1 of this manual.
If in doubt, speak to a more experienced per-
son.
Respect all general recommendations for
correct execution of maintenance works

Removal
2690312
Wait until engine temperature is below 40° C
D turn the heater valve to maximum then open the filler
(104 ˚F) before beginning this operation.
cap on the expansion tank;
Proceed as follows:
D Park the vehicle on a suitable flat and solid surface, Figure 83
remove the ignition key, engage the handbrake and
place maintenance warning signs;
D disengage the battery cut ---off switch or disconnect
the battery leads to eliminate any risk of short ---cir-
cuit;
D lock the articulation using the steering lock bar as
instructed in SECTION 1;

276NM046T
D position a suitable container, then disconnect the
radiator hose (arrow) and discharge the engine
coolant;
Exhausted oil and fluids must be collected
and disposed of according to standards in
force.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
98 ENGINE SECTION 4 ADT 25-30 TIER3

D disconnect the automatic transmission fluid delivery Replacement

(1) and return (2) lines.
. Oil may leak during these operations.
D disconnect the engine coolant delivery (3) and re-
turn (4) pipes.
. Coolant may leak during these operations.
For replacement, follow the removal instructions in re-
verse order.
Fill the engine cooling circuit as instructed in the chap-
ter MAINTENANCE.
Fill the vehicle automatic transmission circuit oil as
instructed in SECTION 5.

D support the exchanger with a suitable dolly, un-

screw the fastening screws (5) and remove it from
below.

Figure 84

1
3
2

276C04036

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 99

DISMANTLING THE ENGINE ON THE On the engine left ---hand side

BENCH
Figure 87
Before fixing the engine on the rotary stand 99322230
remove the following components:

On the engine right ---hand side

D diesel cartridge filter;
D electric connections;

Figure 85

60485

D engine support (1);

Figure 88

60482
D soundproofing shield (1);
D all the pipes connecting the compressor;

Figure 86

60486

D oil pressure controlling valve (1);

60483
D compressor (1) fitted with power steering pump (2);

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
100 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 89

71700

Fix the engine to the rotary stand 99322230, by means of brackets 99361036 (1), remove the fan.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 101

Remove all electrical wiring from the sensors and elec-

tric activators. Figure 92

Figure 90

209NM02
71701 Remove the auxiliary control belts noing a suitable tool
Remove the fan (1) from the flange (2). and working in he direction of he arrow.
A: Alternator belt ---water pump
B: Climate control compressor belt

Figure 93

71702
Lock the engine flywheel using tool 99360351 (1).
Disconnect all the electrical connections and remove
the wiring from the engine.
Remove the climate control compressor by loosening
Figure 91 the four securing bolts.
Remove also the the automatic belt tensioner.

71703 73585

Remove the flywheel pulley (1) by removing the six Remove the following parts: alternator (1), fan flange
Allen screws. (2), automatic tensioner (3), crankshaft pulley (4),
water pump (6), air conditioner drive belt tensioner (5),
and pulley (7).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
102 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 94 Figure 97

60492
98864
Unscrew the oil filter (1) using tool 99360314.
Disconnect the pipes (3 and 4) from the V.G.T. com-
mand solenoid valve. Figure 98
Remove the thermostat group (1) complete with V.G.T
command solenoid (2).

Figure 95

60490 72674

Apply extractor 99340053 (2) and remove the crank- Unscrew the screws (1) and remove the heat exchang-
shaft oil seal. Remove the flange (3). er (4).
Unscrew the screws (2) and remove the water line (3).
Figure 96
Figure 99

71707
70708
Remove the following parts: Water delivery pipe (5),
water return pipe (1), actuator command air piping (2), To remove the PTO (if applicable).
oil delivery pipe (3), oil return pipe (4), turbocompres- Disconnect the oil piping.
sor group (6), exhaust manifold (7). Unscrew the four screws 2 and 3.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 103

Figure 102
Figure 100

60575

60494
Unscrew the screws (2) and remove the gear (1) fitted
Remove the following components: fuel filter support with phonic wheel.
(1), fuel pump (2) and lines, starter (3), engine starting
button support (4), PWN valve air filter (5), suction Figure 103
manifold (6) fitted with resistance for engine pre---heat-
ing, control unit (7).

Figure 101

60497

Unscrew the screws (1); tighten one screw in a reaction

hole and remove the shoulder plate (2), remove the
sheet gasket.

85480 Figure 104

Remove the rocker arm cover (1), take off the screws
(2) and extract the cover (3), the filter (5) and the
gaskets (4 and 6).
Remove the screws (8) and the blow ---by case (7).

60498

Unscrew the screws (1) and disassemble the idle gear

(2).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
104 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 105 Unscrew the screws (1) and take down the gearbox (2).

Figure 108

60499
Stop the engine flywheel (3) rotation by means of tool 16219
99360351 (1), unscrew the fixing screws (2) and re- If applicable, disassemble the PTO control gear (1).
move the engine flywheel. Remove the screws (3) and disasseble the double gear
(2).
Figure 106 Remove the retaining screw and disassemble the small
connecting rod (5).
Disassemble the oil pump (4).

Figure 109

85480
60511
Apply the extractor 99340054 (2) and pull out the seal
D Remove the engine brake lever retaining springs
gasket (1).
(3).
Figure 107 D Unscrew screws (3) to remove injector electrical
connections.
D Unscrew screws (6) fastening injector wiring to the
head.
D Electrically disconnect the engine brake solenoid
valve (8).
D Remove the engine brake cylinder (4) feeder pipes
(5 and 7).
D Remove the rocker shaft fastening screws (2).
D Unscrew screws (6) to remove injector wiring from
the head. The wiring must be removed from the
front.

60501

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 105

Figure 110 Figure 113

73533 60515
Using tool 99360144 (3), constrain the blocks (4) to the D By means of metal ropes, lift the cylinder head (1).
rockers (2). Apply tool 99360553 (1) to the rocker D Remove the seal (2).
holder shaft (5) and remove the shaft (5) from the cylin-
der head. Figure 114
Figure 111

104784
102935
Loosen screws (3), then remove sump (1) complete
To extract the pump injector from the engine block,
with spacer (2) and seal gasket (4).
using the tool proceed as follows:
D attach the part (3) of the tool 99342155 to the pump Figure 115
injector;
D fit part (2) on part (3), resting the former on the cylin-
der head;
D tighten the nut (1) and extract the pump injector (4)
from the engine block;
Figure 112

86932
Unscrew the screws and remove suction rose (1).

60514

D Fit the plugs 99360180 (1) instead of injectors.

D Remove the camshaft (2).
D Unscrew the fixing screws on the cylinder head (3).
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
106 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 116 Figure 119

47574

Rotate the block (1) to the vertical position. 47570

Figure 117 Remove the crankshaft (2) by means of tool 99360500

(1).

Figure 120

60518

Untighten screws (2) fixing the connecting rod cap (3)

and remove it. Remove the connecting rod---piston
assembly from the upper side.
Repeat these operations for the other pistons. 47571

Remove the crankshaft half---bearings (1), untighten

Figure 118
the screws and remove oil spray nozzles (2).
Take down cylinder liners as specified in the relative
paragraph.

After disassembling the engine, thoroughly

clean disassembled parts and check their
integrity.
Instructions for main checks and measures
are given in the following pages, in order to
determine whether the parts can be
re---used.

60519

By means of proper and splined wrenches, untighten

the screws (1) and (2) and remove the under---block.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 107

REPAIR OPERATIONS Figure 123

Cylinder block
Checks and measurements

Figure 121

60595

A = Selection class Ø 125,000 to 125,013 mm

34994
Internal diameter of the cylinder liners is checked for
ovalization, taper and wear, using a bore dial (1)
centesimal gauge 99395687 (2) previously reset to ring
gauge (3), diameter 125 mm.
If a 125 mm ring gauge is not available use
a micrometer caliper.
Figure 122
B = Selection class Ø 125,011 to 125,024 mm
In case of maximum wear >0.150 mm or maximum
ovalization >0.100 mm compared to the values
indicated in the figure, the liners must be replaced as
they cannot be ground, lapped or trued.
Cylinder liners are equipped with spare
parts with “A“ selection class.
Figure 124

60597
60596 A = Ø 142,000 to 142,025 mm
1 = 1st measuring B = Ø 140,000 to 140,025 mm
2 = 2nd measuring C = Ø 141,961 to 141,986 mm
3 = 3rd measuring D = Ø 139,890 to 139,915 mm

Carry out measurings on each cylinder liner at three The figure shows the outer diameters of the cylinder
different levels and on two (A ---B) surfaces, to one liners and the relative seat inner diameters.
another perpendicular, as shown in Figure 122. The cylinder liners can be extracted and installed
several times in different seats, if necessary.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
108 ENGINE SECTION 4 ADT 25-30 TIER3

CYLINDER LINERS
Figure 125

60598

BLOCK WITH CYLINDER LINERS

Figure 126

Selection class A 125.000 ÷ 125.013 mm 60600

B 125.011 ÷ 125.024 mm

CYLINDER LINERS MAIN DATA

Figure 127

DETAIL “X”
“Y“ --- Selection class marking area 60601

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 109

Replacing cylinder liners Figure 130

Removal

Figure 128

60520

Check the protrusion of the cylinder liners, using tool

47577
Place details 99360706 (2) and plate 99360728 (4) as
shown in the figure, by making sure that the plate (4)
is properly placed on the cylinder liners.
Tighten the screw nut (1) and remove the cylinder liner
(3) from the block.
Fitting and checking protrusion
Figure 129
99260472 (2) and tightening screw (1) to 220 Nm
torque.
Using comparator 99395603 provided with comparator
base 99370415 (3) that the cylinder lining protrusion
from the cylinder head surface is 0.045 --- 0.075 mm
(Figure 71). If not, replace the adjuster shim (1) (Figure
70) supplied in various thickness.
Figure 131
0,045 ÷ 0,075

49017
CYLINDER LINER PROTRUSION

Figure 132

16798

Always replace water sealing rings (3, 4 and 5).

Install the adjustment ring (1) on the cylinder liner (2);
lubricate lower part of liner and install it in the cylinder
unit using the proper tool.

The adjustment ring (1) is supplied as spare

parts in the following thicknesses: 0.08 mm
--- 0.10 mm --- 0.12 mm.

60521

When the installation is completed, block the cylinder

liners (1) to the block (2) with studs 99360703 (3).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
110 ENGINE SECTION 4 ADT 25-30 TIER3

CRANKSHAFT
Figure 133
36,75
37,00

2,965
2,995

Upper main journal half bearing

92,970
93,000

82,970 45,95
83,000 46,00

36,750
37,000

45,75
46,00

2,965
2,995

2,965 3,380
2,995 3,430

Lower main journal half bearings 71712

MAIN DATA FOR THE CRANK SHAFT PINS AND THE HALF BEARINGS
Check the condition of the journals and the big end pins; there must no be signs of scoring, ovalization or ex-
cessive wear. The data given refer to the normal diameter of the pins

Figure 134 Figure 135

108

PULISHED PULISHED
108

3,7÷4
4,2÷4,5
ADJUSTED
ADJUSTED

ADJUSTED

60603 71713
X. Detail of main journals connections Y. Detail of crank pins connections

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 111

Measuring main journals and crank pins Figure 137

Before grinding the crank pins using a micrometer (1),
measure the main journals and the crank pins (2) and
decide, on the basis of the undersizing of the bearings,
the final diameter to which the pins are to be ground.

Figure 136

47536

During grinding, pay attention to journal and crank pins

values specified in Figure 134 and Figure 135.
47535
All journals and crank pins must also be
It is advisable to enter the values found in a ground to the same undersizing class, in
table. order to avoid any alteration to shaft
balance.

Figure 138

Fill in this table with the measurements of the main journals and the crank pins.

MAIN JOURNALS

∅ Min.
∅ Max.

∅ Min.
∅ Max.

CRANK PINS
36061

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112 ENGINE SECTION 4 ADT 25-30 TIER3

DETERMINATION OF PRELIMINARY DATA FOR SELECTION

For each journal and crankpin, the following operations must be carried out:

JOURNALS: CRANK PINS:

D determine the diameter class of the block housing; D determine the diameter class of the connecting rod
D determine the diameter class of the main journal; housing;
D select half-bearing class to be installed. D determine the diameter class of the big end pin;
D select half-bearing class to be installed.

Two series of numbers are marked on the front side of the block, in the position specified (top).
D a four---digit number, representing the coupling number of block to the relevant underblock;
D each of the following seven digits represents the diameter class of the housing they refer to (bottom);
D each digit can be 1, 2 or 3.
Figure 139

99,000÷99,009

99,010÷99,019

99,020÷99,030

47535

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 113

Choice of big end and main bearing half -- shells

In order to obtain the clearance required, main half-bearings and big end half-bearings must be
selected as specified below.

This operation makes it possible to identify the most suitable half-bearings for each journal (half-bearings can
belong to different classes for the individual journals).
Depending on half-bearing thickness, tolerance classes are selected by colors (red---green---red/black ---green/
black).
Figure 140 shows the characteristics of main half-bearings and big end half-bearings supplied as spare parts in
standard measures (STD) and admissible oversizing (+0.127, +0.254, +0.508).

Figure 140

STD +0.127 +0.254 +0.508

Big end half-bearings

red 1.970÷1.980 2.097÷2.107 2.224÷2.234

red/black 2.033÷2.043

green 1.981÷1.990 2.108÷2.117 2.235÷2.244

green/black 2.044÷2.053

yellow 1.991÷2.000

yellow/black 2.054÷2.063

STD +0.127 +0.254 +0.508

Main half-bearings

red 2.965÷2.974 3.092÷3.102 3.219÷3.229

red/black 3.028÷3.037

green 2.975÷2.984

green/black 3.038÷3.047

yellow 2.985÷2.995

yellow/black 3.048÷3.058

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
114 ENGINE SECTION 4 ADT 25-30 TIER3

Definition of main journal and big end diameter class (journals with nominal diameter)
Three series of numbers are specified on the driving shaft, in the position specified (Figure 141 to left);.
D a five---digit number, representing the shaft serial number;
D under this number, on the left, a six---digit number refers to big end pins and is preceded by a single digit, which
indicates pin status (I = STD =---0.127); each of the following six digits represents the diameter class of each
big end pin it refers to (Figure 141 to left);
D the seven---digit series, on the right, refers to the journals and is preceded by a single digit, which indicates
journal status (I = STD =---0.127); each of the following seven digits represents the diameter class of the jour-
nal it refers to (Figure 141 to right).

Figure 141

JOURNALS

82,970÷82,979

82,980÷82,989

82,990÷83,000

92,970÷92,979

92,980÷92,989

92,990÷93,000
CRANKPINS BASEMENT

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 115

Selection of main half-bearings

After detecting, for each journal, the necessary data on block and crankshaft, select the type of half-bearings to
be used, in compliance with the following table:

Figure 142

STD.

1 2 3

green green green

1
green green green

red green green

2
red green green

red red red

3
red red red

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
116 ENGINE SECTION 4 ADT 25-30 TIER3

Selection of main half-bearings (rectified)

If the journals have been rectified, the procedure described cannot be applied.
In this case, make sure that the new diameter of the journals is as specified on the table and install the only
half-bearing type required for this undersizing.
Figure 143

red/black =
mm 3.028 ÷ 3.037

green/black =
mm 3.038 ÷ 3.047

---0.127 1 2 3
92.843
1 green/black green/black green/black
92.852

92.853
2 red/black green/black green/black
92.862

92.863 red/black red/black green/black

3
92.873

red =
mm 3.092 ÷ 3.102

---0.254 1 2 3

red red red

92.726
92.746

red =
mm 3.219 ÷ 3.229

---0.508 1 2 3

red red red

92.472
92.492

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 117

Choice of big---end half---shells (standard diameter)

Three indications are marked on the connecting rod, in position “A”:

Figure 144

1 Letter indicating the weight class

A = 3973 to 4003 g.
B = 4004 to 4034 g. VIEW FROM “A”
C = 4035 to 4065 g.
2 Number indicating the diameter selected for
the housing of the big end bearing:
1 = 87.000 to 87.010 mm
2 = 87.011 to 87.020 mm
3 = 87.021 to 87.030 mm
3 Numbers identifying the cap---connecting
road coupling.

47557

The number specifying the diameter class of the half-bearing housing can be: 1, 2 or 3.
Determine the type of big end half-bearings to be installed on each pin by following the indications given in the
table (Figure 145).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
118 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 145

STD.

1 2 3

green green green

1
green green green

red green green

2
red green green

red red red

3
red red red

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 119

Choice of big---end half---shells (rectified)

If pins have been rectified, the procedure described must be applied.
In this case, (for each undersizing) determine the tolerance field the new big end pins belong to, and install the
half-bearings identified according to the relative table.
Figure 146

red/black =
mm 2.033 ÷ 2.043

green/black =
mm 2.044 ÷ 2.053

---0.127 1 2 3
82.843 1 green/black green/black green/black
82.852

82.853 2 red/black green/black green/black

82.862

92.863 3 red/black red/black green/black

82.873
red
mm 2.097 ÷ 2.107
green =
mm 2.108 ÷ 2.117

---0.254 1 2 3

82.726 red green green

82.735

82.736 red red green

82.746
red
mm 2.224 ÷ 2.234
green =
mm 2.235 ÷ 2.244

---0.508 1 2 3

82.472 red green green

82.481

82.482 red red green

82.492

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120 ENGINE SECTION 4 ADT 25-30 TIER3

Replacing the timing control gear and the oil pump Figure 149
Check that the teeth of the gears are not damaged or
worn, otherwise remove them using the appropriate
extractor.

Figure 147

47578

Using pulley system and hook 99360500 (1), mount the

crankshaft (2).
49020 Figure 150
When fitting the new gears (1) on the crankshaft (2),
heat them for about 15 minutes in an oven at 180°C.
Let them cool down after the installation.

Checking main journal installation clearance

Figure 148

49021
Install the half-bearings (1) on the main bearings in the
underblock (2).
Check the installation clearance between the main
journals and the relative bearings as follows.

47579

Install the oil spray nozzles (2) and have the dowel
coincide with the block hole (3).
Install the half-bearings (1) on the main bearings.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 121

Figure 151 Figure 152

60559 47578

Place a piece of calibrated wire on the journal of the D Lubricate inside screws (1) con UTDM oil, and
crankshaft (2), parallel to the longitudinal axis; install tighten them by dynamometric wrench to 140 Nm
the underblock (1), by hoist and appropriate hooks. torque, thus with 60º angle closing, following the
diagram in Figure 153.

Figure 153

FRONT
SIDE

60593

DIAGRAM SHOWING THE TIGHTENING ORDER OF THE SCREWS FIXING THE LOWER UNDER---BLOCK TO
THE BLOCK
Figure 154 Checking crankshaft end float
Figure 155

47579 47588

D Remove the under --- block End float is checked by placing a magnetic dial gauge
The clearance between the main bearings and the journals (1) on the crankshaft (2), as shown in the figure. If the
is obtained by comparing the calibrated wire length (2) at value obtained is higher than specified, replace the rear
the maximum deflection point, with the calibrated scale on thrust half-bearings and repeat this check.
the coating (1) containing the calibrated wire (1).
Numbers shown on the scale specify the clearance in
coupling millimeters. If the clearance obtained is different
from the clearance required, replace the half-bearings and
repeat this check.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
122 ENGINE SECTION 4 ADT 25-30 TIER3

Piston-- connecting rod assembly

Figure 156

60607

PISTON CONNECTING ROD ASSEMBLY

1. Connecting rod body --- 2. Half bearings --- 3. Connecting rod cap --- 4. Cap fastening screws ---
5. Split ring --- 6. Scraper ring with spiral spring --- 7. Bevel cut sealing ring --- 8. Trapezoidal sealing ring ---
9. Piston pin --- 10. Piston

Make sure the piston does show any trace of seizing, Pistons are equipped with three elastic rings: a sealing
scoring, cracking; replace as necessary. ring, a trapezoidal ring and a scraper ring.
Pistons are grouped into classes A and B for diameter.
Removal

Figure 157 Figure 158

60608 49024
Removal of the piston split rings (2) using the pliers Remove the piston pin split rings (2) using the round
99360184 (1). tipped pliers (1).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 123

Figure 159 Figure 161

32618
49025
Measuring the gudgeon pin diameter (1) with a
Remove the piston pin (1). micrometer (2).
If removal is difficult use the appropriate beater.
Conditions for correct gudgeon pin-- piston cou-
Measuring the diameter of the pistons pling

Figure 160 Figure 162

71714
Using a micrometer (2), measure the diameter of the
piston (1) to determine the assembly clearance; the
diameter should be measured at the specified value.
49026
Lubricate the pin (1) and the relevant housing on the
piston hubs with engine oil; piston must be inserted
with a slight finger pressure and it should not come out
by gravity.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
124 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 163

MAIN DATA ON PISTONS, AND PISTONS RINGS 104271

* Values are determined on ∅ of 120 mm.
Piston rings
Figure 164 Figure 166

3513
16552
The sealing ring (2) of the 1st cavity is trapezoidal.
Check the thickness of the piston ring (2) using a Clearance “X” between the sealing ring and its housing
micrometer (1). is measured by placing the piston (1) with its ring in the
cylinder barrel (3), so that the sealing ring is half---pro-
Figure 165
jected out of the cylinder barrel.
Figure 167

60610
36134
Check the clearance between the sealing rings (2) and
the relative piston housings (1) using a thikness gauge Check the opening between the ends of the sealing
(3). rings (1), using a thickness gauge (2), entered in the
cylinder barrel (3).
If the distance between ends is lower or higher than the
value required, replace split rings.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 125

CONNECTING ROD

Figure 168

Data concerning the class section of connecting rod

housing and weight are stamped on the big end.
VIEW FROM “A”
When installing connecting rods, make sure
they all belong to the same weight class.

DIAGRAM OF THE CONNECTING ROD MARKS

Letter indicating the weight class:
1 A = 3973 to 4003 g.
B = 4004 to 4034 g.
C = 4035 to 4065 g.
2 Number indicating the selection of diameter for
the big end bearing housing:
1 = 87.000 to 87.010 mm
2 = 87.011 to 87.020 mm
3 = 87.021 to 87.030 mm
Numbers identifying cap---connecting rod
3 coupling.

47957

Figure 169

54,000
54,030

54,085 50,019 49,994

54,110 50,035 50,000

1,970
2,000

87,000
87,030

71716
MAIN DATA --- BUSH, CONNECTING ROD, PIN AND HALF-BEARINGS
* Values to be obtained after installing the bush

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
126 ENGINE SECTION 4
Bushings
Figure 170
73535
Check the bushing in the small end has not come loose
and shows no sign of scoring or seizure; replace it if it
does.
The bushing (2) is removed and fitted with a suitable
drift (1).
When driving it in, make absolutely sure that the holes
for the oil to pass through in the bushing and small end
coincide. Using a boring machine, rebore the bushing
so as to obtain a diameter prescribed.
Checking connecting rods
Figure 171
61696
Checking axis alignment
Check the alignment of the axes of the connecting rods
(1) with device 99395363 (5), proceeding as follows:
D Fit the connecting rod (1) on the spindle of the tool
99395363 (5) and lock it with the screw (4).
D Set the spindle (3) on the V ---prisms, resting the con-
necting rod (1) on the stop bar (2).
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ADT 25-30 TIER3
Checking torsion
Figure 172
61694
Check the torsion of the connecting rod (5) by compar-
ing two points (A and B) of the pin (3) on the horizontal
plane of the axis of the connecting rod.
Position the mount (1) of the dial gauge (2) so that this
pre---loads by approx. 0.5 mm on the pin (3) at point A
and zero the dial gauge (2). Shift the spindle (4) with the
connecting rod (5) and compare any deviation on the
opposite side B of the pin (3): the difference between
A and B must be no greater than 0.08 mm.
Checking bending
Figure 173
61695
Check the bending of the connecting rod (5) by com-
paring two points C and D of the pin (3) on the vertical
plane of the axis of the connecting rod.
Position the vertical mount (1) of the dial gauge (2) so
that this rests on the pin (3) at point C.
ADT 25-30 TIER3 SECTION 4 ENGINE 127

Swing the connecting rod backwards and forwards Mounting the piston rings
seeking the highest position of the pin and in this condi-
tion zero the dial gauge (2). Shift the spindle (4) with the Figure 176
connecting rod (5) and repeat the check on the highest
point on the opposite side D of the pin (3). The differ-
ence between point C and point D must be no greater
than 0.08 mm.

Mounting the connecting rod – piston assembly

Figure 174

60614

To fit the piston rings (1) on the piston (2) use the pliers
99360184 (3).
The rings need to be mounted with the word ”TOP” (4)
facing upwards. Direct the ring openings so they are
staggered 120° apart.

Fitting the big end bearing shells

Figure 177
73536

The piston (1) has to be fitted on the connecting rod (2)

so that the graphic symbol (4), showing the assembly
position in the cylinder liner, and the punch marks (3)
on the connecting rod are observed as shown in the fig-
ure.

Figure 175

1
2

49030

Fit the bearing shells (1), selected as described under

the heading “Selecting the main and big end bearing
shells”, on both the connecting rod and the cap.
If reusing bearing shells that have been removed, fit
them back into their respective seats in the positions
marked during removal.
74052

Fit the pin (2) and fasten it on the piston (1) with the split
rings (3).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
128 ENGINE SECTION 4 ADT 25-30 TIER3

Fitting connecting rod -- piston assemblies in

the cylinder liners Figure 178
With the aid of the clamp 99360605 (1, Figure 178), fit
the connecting rod – piston assembly (2) in the cylinder
liners, according to the diagram of Figure 178, check-
ing that:
D The openings of the piston rings are staggered 120˚
apart.
D The pistons are all of the same class, A or B.
D The symbol punched on the top of the pistons faces
the engine flywheel, or the recess in the skirt of the
pistons tallies with the oil nozzles.

The pistons are supplied as spares in class

A and can be fitted in class B cylinder liners.
60616

Checking piston protrusion

On completing assembly, check the protrusion of the
pistons from the cylinder liners; it must be at the speci-
fied value.

Figure 179

ASSEMBLY DIAGRAM OF CONNECTING ROD – PISTON ASSEMBLY IN CYLINDER LINER

1. Connecting rod – piston assembly – 2. Area of punch marking on the top of the piston,
symbol showing assembly position and selection class – 3. Connecting rod punch mark area

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 129

Checking crankpin assembly clearance Figure 181

To measure the clearance, carry out the following
operations.
Connect the connecting rods to the relevant journals of
the crankshaft, placing a length of calibrated wire on
the journals.

Figure 180

47583

Mount and secure the tool 99360263 (2) with the

47594
Mount the connecting rod caps (1) together with the
bearing shells. Tighten the screws (2) fixing the con-
necting rod caps to a torque of 60 Nm (6 kgm). Using
tool 99395216 (3), further tighten the screws with an
angle of 60°.
bracket (4). Screw down with the device 99360261 (1)
to be able to remove the cotters (3). Take out the tool
(2) and extract the top plate (5), spring (6) and bottom
plate (7).
Repeat this process on all the valves.
Turn over the cylinder head and take out the valves (8).
Checking head bearing surface on cylinder block
Figure 182

The thread of the screws (2), before assem-

bly, has to be lubricated with engine oil.
Remove the caps and determine the clearance by com-
paring the width of the calibrated wire with the grad-
uated scale on the case containing the calibrated wire.
Upon final assembly: check the diameter of the thread
of the screws (2), it must be no less than 13.4 mm; if it
is, change the screw. Lubricate the crankpins and con-
necting rod bearings. Tighten the screws (2) as de-
scribed above.
36159

CYLINDER HEAD Check the supporting surface (1) of the head on the cyl-
inder block with a rule (2) and a feeler gauge (3). If you
Before dismounting cylinder head, check cylinder
find any deformation, level the head on a surface
head for hydraulic seal by proper tooling; in case of
grinder; maximum amount of material that can be re-
leaks not caused by cup plugs or threaded plugs, re-
moved 0.2 mm.
place cylinder head.
After this process, you need to check the
In case of plugs dismounting/replacement,
valve recessing and injector protrusion.
on mounting, apply sealant Loctite 270 on
plugs.

Dismounting the valves

Before dismounting cylinder head valves,

number them in view of their remounting in
the position observed on dismounting
should they not have to be overhauled or re-
placed.
Intake valves are different form exhaust
valves in that they have a notch placed at
valve head centre.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
130 ENGINE SECTION 4 ADT 25-30 TIER3

Valves Figure 184

Decarbonizing and checking valves
Figure 183 8,960
8,975
15,012
15,025

9,015 (*)
9,030

45˚30’±7’30”

60˚30’±7’30”

42,85÷43,15 41,85÷42,15
71718

MAIN DATA OF VALVES AND VALVE GUIDES

48625
Remove the carbon deposits on the valves with a wire
brush.
Check that the valves show no signs of seizure or
cracking and check with a micrometer that the valve
stem diameter comes within the required values (see
Figure 184), replace the valves if it does not.
* Measurement to be made after driving in the valve
guides
Check, by means of a micrometer, that valve stem
diameters are as specified; if necessary, grind the
valves seat with a grinder, removing the minimum
quantity of material.

Figure 185

1 2
4,30±0,06

39,00 39,20
1,8÷2,1
0,65÷0,86

71719

***
1. *** --- 2. ***

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 131

Figure 186 The valve guides are removed with the drift 99360143.
They are fitted with the drift 99360143 equipped with
part 99360296.
Part 99360296 determines the exact position of assem-
bly of the valve guides in the cylinder head. If they are
not available, you need to drive the valve guides into the
cylinder head so they protrude by 30.8÷31.2 mm.
After driving in the valve guides, rebore their holes with
the smoother 99390330.

Replacing injector cases

Removal
Figure 188

41032

Check the valve seats (2). If you find any slight scoring
or burns, regrind them with tool 99305019 (1)
according to the angles shown in Figure 185. If it is
necessary to replace them, using the same tool and
taking care not to affect the cylinder head, remove as
much material as possible from the valve seats so that,
with a punch, it is possible to extract them from the
cylinder head.
Heat the cylinder head to 80 ÷ 100°C and, using a drift,
fit in the new valve seats (2), chilled beforehand in liquid
nitrogen. Using tool 99305019 (1), regrind the valve
seats according to the angles shown in Figure 185.
After regrinding the valve seats, using tool 99370415
and dial gauge 99395603, check that the position of the
valves in relation to the plane of the cylinder head is:
D ---0,65 ÷ ---0,95 mm (recessing) intake valves
D ---1,8 ÷ ---2,1 mm (recessing) exhaust valves.

Checking clearance between valve-- stem and as-

sociated valve guide
Using a dial gauge with a magnetic base, check the
clearance between the valve stem and the associated
guide. If the clearance is too great, change the valve
and, if necessary, the valve guide.

Valve guides
Replacing valve guides 60619

Figure 187 To replace the injector case (2), proceed as follows:

D Thread the case (2) with tool 99390804 (1).
ø 9.015÷9.03 The steps described in Figure 188 --- Figure 191 ---
Figure 192 --- Figure 193 need to be carried out by fix-
ing the tools, with the bracket A, to the cylinder head.

71719

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
132 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 189 Figure 191

60622

D Lubricate sealing rings (3) and fit them to the case

60620 (4); fix tool 99365056 (2) to the cylinder head by
means of bracket A, install the new case, tighten the
D Fasten extractor 99342149 (2) to case (3), by
screw (1), upsetting the case lower part.
tightening the nut (1), and pull out the case from cyl-
inder head.

Figure 190

60621

D Remove any residue (1), with tool 99390772 (2),

from the cylinder head groove.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 133

Figure 192 D Using grinder 99394043 (1---2), ream the injector

seat in the case (3).

Checking protrusion of injectors

Figure 194

47585

Using dial gauge (1), check the protrusion of the

injector (2) which must be 0.52 to 1.34 mm.

Figure 195

60623

D Ream the case hole (3) with reamer 99394041 (1).

Figure 193

71720
INSTALLATION DIAGRAM FOR
INJECTOR CASE

60624

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
134 ENGINE SECTION 4 ADT 25-30 TIER3

DISTRIBUTION
Checking cam lift and pin alignment
Figure 196

47506

Place the camshaft (4) on the tailstock (1) and check cam lift (3) using a centesimal gauge (2).
Figure 197

47507
When the camshaft (4) is on the tailstock (1), check alignment of supporting pin (3) using a centesimal gauge (2);
it must not exceed 0.030 mm. If misalignment exceeds this value, replace the shaft.
Figure 198

47505

In order to check installation clearance, measure bush inner diameter and camshaft pin (1) diameter; the real
clearance is obtained by their difference.
If clearance exceeds 0.135 mm, replace bushes and, if necessary, the camshaft.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 135

Camshaft
Figure 199

60626

MAIN DATA --- CAMSHAFT AND TOLERANCES

The surfaces of shaft supporting pin and cams must be extremely smooth; if you see any sign of seizing or
scoring, replace the shaft and the relative bushes

TOLERANCES TOLERANCE CHARACTERISTIC SYMBOL

ORIENTATION Perpendicularity ⊥
POSITION Concentricity or coaxial alignment
OSCILLATION Circular oscillation ↗
IMPORTANCE CLASS ASSIGNED TO PRODUCT CHARACTERISTICS SYMBOL
CRITICAL 
IMPORTANT ⊕
SECONDARY ⊝

Bushes
Figure 200

60627

MAIN DATA OF CAMSHAFT BUSHES AND RELEVANT HOUSINGS ON CYLINDER HEAD.

* Bush inner diameter after installation

D The bush surfaces must not show any sign of D To take down and fit back the bushes, use the proper
seizing or scoring; if they do replace them. tool 99360499.
D Measure the bush inner diameters with a baremeter
and replace them, if the value measured exceeds the
tolerance value.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
136 ENGINE SECTION 4 ADT 25-30 TIER3

Replacing the bushes camshaft using beater 99360499

Beater
Figure 201

71721

A = Beater with seat for bushes for insertion/removal

B = Bush positioning pin
C = Mark for correct insertion of seventh bush
D = Mark for correct insertion of bushes 1, 2, 3, 4, 5 and 6 (yellow notches)
E = Guide bush
F = Guide line
G = Guide bush to fasten to seventh bush support
H = Cylinder head yellow bush fastening plate
I = Grip
L = Extension joint

Removal Replacement

Figure 202 Figure 203

Front Front

Rear
Rear
71725 71722

The bush removal order is 7, 6, 5, 4, 3, 2, 1. The bushes
are slipped out from the front side of their individual
seats. Removal does not require the beater extension
for bushes 5, 6 and 7 and use of the guide bush is not
necessary.
The extension is instead required for bushes 1, 2, 3 and
4, as well as the guide bush
Position the beater precisely during the removal oper-
ation.
Fit the beater complete with extension.
To insert bushes 1, 2, 3, 4 and 5, proceed as follows:
1. Place the bush for insertion on the beater (A) lining
up the pin (B) (Figure 201) with the seat on the bush.
2. Position the guide bush (E) and fasten the guide
bush (G) (Figure 201) in the seat of the 7th bush by
means of plate H).
3. When inserting the bush, line up notches F and M.
Doing so, when the bush is pushed in the lubrication
hole on it is aligned with the oil hole in the seat.
The bush is fully inserted when the 1st yellow refer-
ence notch (D) is flush with the guide bush (G).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 137

Figure 204

Front

Rear

71725

To insert bush 6, proceed as follows:

D remove the grip (I) and the extension (N);
D position the extension (N) and the guide bush (E) as
shown in the figure;
D repeat operations 1, 2 and 3.

Figure 205
Front

Rear

71725

To insert bush 7, proceed as follows:

D remove the grip (I) and the guide bush (G) fastened
to the head;
D replace the guide G from the inner side as shown in
the figure;
D position the bush on the beater (A) and bring it to-
ward its seat making sure the hole in the bush aligns
with the lubrication hole in the head. Proceed to fit.
The 7th bush is fully inserted when the reference
mark ( C ) is flush with the bush seat.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
138 ENGINE SECTION 4 ADT 25-30 TIER3

Valve springs Fitting the valves and oil seal ring

Figure 206 Figure 208

70000
Before installation, check valve spring flexibility using
tool 99305047 and compare the loading and elastic
deformation data with data referred to the new valves,
shown in the following figure.

Figure 207

Free spring height

Valve closed
49033
500±25N Lubricate the valve stem and place the valves in the
972±25N relevant valve guides; install the lower plates (3) using
75

tool 99360329, fit the oil seal ring (1) on valve guides
Valve open
47,80

(2), then install the valves as shown:

61

Figure 209

71726

MAIN DATA TO CONTROL EXHAUST AND DIS-

CHARGE VALVE SPRING

47583
D fit springs (6) and the upper plate (5);
D apply tool 99360263 (2) and block it with bracket (4);
tighten the lever (1) until cotters are installed (3), re-
move tool (2).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 139

ROCKER SHAFT
Figure 210

44925
The camshaft cams directly control rockers: 6 for injectors and 12 for valves.
Rockers slide directly on the cam profiles via rollers. The other end acts on a bar directly supported by the two
valves stems. A pad is placed between the rocker adjusting screw and the bar.
Two lubrication holes are obtained inside the rockers. The rocker shaft practically covers the whole cylinder head;
remove it to have access to all the underlying components.
The length of the rocker shaft is practically the same as that of the cylinder head. It must be removed in order to
remove all the components located beneath it.
Shaft
Figure 211

73557
MAIN DATA OF THE ROCKER ARM SHAFT
Check that the surface of the shaft shows no scoring or signs of seizure; if it does, replace it.
Rocker arms
Figure 212 Figure 213

SECTION A-A

SECTION B-B

47586
47586 Check the surfaces of the bushings, which must show
PUMP INJECTOR ROCKER ARMS no signs of scoring or excessive wear; if they do, re-
place the rocker arm assembly.
Figure 214 Figure 215

SECTION A---A
SECTION A-A
SECTION B---B
SECTION B-B

47586 47586
INTAKE VALVE ROCKER ARMS EXHAUST VALVE ROCKER ARMS

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
140 ENGINE SECTION 4 ADT 25-30 TIER3

Timing distribution control Pin double drive cog

Figure 216 Double drive cog

Figure 218

86925
TIMING DISTRIBUTION COMPONENTS
1. Camshaft --- 2. Bush --- 3. Pin --- 4. Con---rod --- 86934
5. Camshaft drive pinion --- 6. Drive cog --- 7. Double
drive cog --- 8. Camshaft drive pinion Bushing replacement
The bushes (2, Figure 217 and 2, Figure 218) can be
Drive cog pin replaced if worn. After fitting the bush, ream to obtain
the diameter indicated in Figure 217 or Figure 218.
Drive cog
The bush must be fitted into the gear in the
Figure 217 direction of the arrow, positioning it at the le-
vel indicated in Figure 217 or Figure 218.
Nominal gear pin/bush play:
Figure 217 --- 0.045 to 0.075 mm
Figure 218 --- 0.045 to 0.085 mm.

86933

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 141

ASSEMBLING THE ENGINE ON THE BENCH Figure 221

Fix the engine block to the stand 99361036 by means
of brackets 99322230.
Install the cylinder liners as described in the relevant
paragraph.

Figure 219

49021

Place the half---bearings (1) on the main bearings in the

underblock (2).

Figure 222

48586

Fit the oil spray nozzles (2), so that the dowel coincides
with the block hole (3).
Place the half bearings (1) on the main bearings.

Figure 220

47595
By means of suitable equipment (1) apply silicone
LOCTITE 5699 to the block, as shown in Figure 223.

48570

Lubricate the half bearings, then install the crankshaft

(2) by means of hoist and hook 99360500 (1).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
142 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 223 Figure 226

60632

Sealant application diagram.

Fit the underblock within 10’ of the

application of the sealant. 47579

Close the inner screws (1) to 120 Nm torque by means

Figure 224 of a dynamometric wrench (3, Figure 226), then with
two further angular phases 90° + 45°, using tool
99395216 (4). Tighten again the outer screws (1,
Figure 225) with 60° angular closing, using tool
99395216 (3, Figure 225).

60559
Fit the underblock by means of a suitable hoist and
hooks (1).

Figure 225

47581

Fit the underblock and, using a dynamometric wrench

(2), close the splined outer screws (1) to 30 Nm torque,
according to the diagram shown in Figure 226.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 143

Figure 227

stage 1:
FRONT SIDE pretightening
outer screws
30 Nm

60592

stage 2:
FRONT SIDE pretightenig
inner screws
120 Nm

60593

stage 3:
angle
FRONT SIDE inner
screws
60˚

60593

stage 4:
angle
FRONT SIDE inner
screws
55˚

60593

FRONT SIDE stage 5:

angle
outer
screws
60˚

60594

DIAGRAM SHOWING TIGHTENING ORDER OF UNDER---CRANKCASE SECURING SCREWS

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
144 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 228 Figure 229

49030 60616

Rotate the cylinder assembly placing it vertically.
Fit the half---bearings (1) on both the connecting rod
and the cap.
Fit the connecting rod---piston assemblies (2) into the
piston liners, using the band 99360605 (1). Check the
following:
D the openings of the split rings are offset by 120˚;
D all pistons belong to the same class, A or B;
D ideogram (2), stamped on the piston crown, is
placed toward the engine flywheel, or the cavity, on
the piston skirt, corresponds to the position of the
oil spray nozzles.

Fitting the connecting rod-- piston assembly into the cylinder liners

Figure 230

1 Connecting rod---piston
assembly

2 Piston ceiling area where the

assembly position and the
selection class ideogram is
printed

3 Connecting rod marking area

60615

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 145

Fitting the cylinder head Figure 234

Figure 231

47594
Connect the connecting rods to the relative journals, fit
the connection rod caps (1) with half bearings; tighten
the fixing screws (2) of the connecting rod caps to 60
Nm torque (6 kgm). Using tool 99395216 (3), further
tighten screws with 60° angle.
60515
Make sure that pistons 1---6 are exactly at the TDC
Place the sealing gasket (2) on the block.
Fit the cylinder head (1) and tighten screws as shown
in Figure 235, Figure 236 and Figure 237.
Figure 235

Figure 232

61270
Diagram showing the cylinder head fixing screws
tightening order

Figure 236

60563

By means of centering ring 99396035 (2), check the

exact cover position (1), otherwise act as necessary
and tighten the screws (3).

Figure 233

60565
--- Preliminary tightening by means of a dynamometric
wrench (1):
1st phase: 60 Nm (6 kgm)
2nd phase: 120 Nm (12 kgm);

60564

Fit the sealing gasket (1), install the fitting tool

99346250 (2) and drive the sealing gasket (1) by
screwing nut (3).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
146 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 237 Install the gear box within 10’ of the

application of the sealant.

Figure 240

60566

D Angular tightening using tool 99395216 (1);

3rd phase: 90˚ angle
4th phase: 45˚ angle for screws 4, 5, 12, 13, 20, 21
5th phase: 65˚ angle for screws 1, 2, 3, 6, 7, 8, 9, 10,
11.

Figure 238

60633
Tighten the screws shown in the figure by means of a
dynamometric wrench, in compliance with the
following order and tightening torque:
no. 10 M12 x 1,75 x 100 56 to 70 Nm
no. 2 M12 x 1,75 x 70 56 to 70 Nm
71773
no. 4 M12 x 1,75 x 35 56 to 70 Nm
Fit the oil pump (5), intermediate cogs (2) complete
with P.T.O tie---rod (1) and drive cog (3) no. 1 M12 x 1,75 x 120 56 to 70 Nm
Tighten the screws (4) to the specified torque. : no. 2 M12 x 1,75 x 193 56 to 70 Nm

Replacing flywheel casing

Figure 241
Figure 239

60568

Fit the sealing gasket (1), install the fitting tool

47592 99346251 (2) and drive the sealing gasket by screwing
Apply (as shown in the figure) sealant LOCTITE 5699 the nut (3).
to the gear box using the proper equipment (1).

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ADT 25-30 TIER3 SECTION 4 ENGINE 147

Replacing engine flywheel

Figure 242

HOLES VIEW: HOLE VIEW:

A --- B --- C D

DETAIL OF PISTON POSITION MARKS ON ENGINE FLYWHEEL

60668

A = Hole on the flywheel with 1 notch, C = Hole on the flywheel with 1 notch,
corresponding to TDC of pistons 3---4. corresponding to TDC of pistons 2---5
B = Hole on the flywheel with 1 notch, D = Hole on the flywheel with 2 notches, correspon-
corresponding to TDC of pistons 1---6. ding to 54°.

Figure 243 Figure 244

49036
49037

Stop rotation using the tool 99360351 (3); tighten the Second and third phase: tighten at a 60º + 30º angle
screws (2) in three phases. using the tool 99395216 (1).
First phase: pre---torque at a 120 Nm (12 kgm) torque
using a torque wrench (4).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
148 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 247

Figure 245

60570

D Fit the gauge 99395215 (1) and check and adjust

the transmission gear connecting rod (3), tighten
the screw (2) at the prescribed torque.

Figure 248
72436

Position the crankshaft with the pistons 1 and 6 at the

top dead centre (T.D.C.).
This situation occurs when:
1. The hole with reference mark (5) of the engine fly-
wheel (4) can be seen through the inspection win-
dow.
2. The tool 99360612 (1), through the seat (2) of the en-
gine speed sensor, enters the hole (3) in the engine
flywheel (4).
If this condition does not occur, turn the engine flywheel
(4) appropriately.
Remove the tool 99360612 (1).
60571
Figure 246 D Refit the motion transmission gear (1) and secure
the screws (2) to tightening torque.

73843
Fit the camshaft (4), positioning it observing the refer-
ence marks (→) as shown in the figure.
Lubricate the seal (3) and fit it on the shoulder plate (2).
Mount the shoulder plate (2) with the sheet metal
gasket (1) and tighten the screws (5) to the required tor-
que.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 149

Figure 249 Figure 251

60572
Fit back the gear (2), without fully tightening screws (5)
on the camshaft and place it so that the 4 oval holes
are centered with respect to the camshaft fixing holes.
Using a magnetic gauge (1), make sure that the gear
(2 and 3) clearance is 0.073 to 0.195 mm, otherwise
adjust the clearance as follows:
D untighten screws (4) fixing transmission gear (3);
D untighten screws (2, Figure 247) fixing the rod,
move the rod (3, Figure 247) to obtain the required
clearance;
D Tighten the rod fixing screw (2, Figure 247) as well
as the screws (4, Figure 249) fixing the gear to the
prescribed torque.
104260
Fit:
D The injectors (1) and, using a torque wrench, lock
the bracket fixing screws to a torque of 26 Nm.
D The crosspieces (2) on the valve stem, all with the
largest hole on the same side.
Replacing rocker shaft assembly
Before fitting back the rocker shaft
assembly, make sure that all the adjusting
screws have been completely unscrewed.
Figure 252

Fitting pump -- injectors

Figure 250

73533
Using tool 99360144 (3), fasten the blocks (4) to the
rocker arms (2).
Apply tool 99360553 (1) and remove the rocker shaft
assembly.

104243
Fit the sealing rings (1) (2) (3) on injectors.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
150 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 253 Timing of timing system shaft

Figure 256

70567A

SCHEME OF SCREW TIGHTENING SEQUENCE

SECURING ROCKER ARMS

Screw screws (1 --- 2 --- 3) until rocker arms are brought

to contact relating seats on cylinder head, tighten the
screws according to sequence indicated in figure ope-
rating in two steps as indicated in successive figure.

Figure 254

71776
Apply tool 99360321 (7) and shim 99360325 (6) to the
gearbox.

The arrow shows the direction of rotation of

the engine when running.
Using the above---mentioned tool, turn the
engine flywheel (1) in the direction of rota-
tion of the engine so as to take the piston of
cylinder no.1 to approximately the T.D.C. in
45261 the phase of combustion.
This condition occurs when the hole with
Lock the screws (2) fixing the rocker---arm shaft as fol-
one reference mark (4), after the hole with
lows:
two reference marks (5) on the engine flyw-
D 1st phase: tightening to a torque of 40 Nm (10 kgm)
heel (1), can be seen through the inspection
with the torque wrench (1).
window (2).
D 2nd phase: closing with an angle of 605 using the
tool 99395216 (3).

Figure 255

60574

D Mount the engine brake lever retaining springs (3).

D Connect the pipe (2) to the engine brake cylinders
(4) and to the cylinder with the engine brake sole-
noid valve (1).
Mount the electric wiring on the electro---injectors.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4
Figure 257
71774
The exact position of piston 1 at TDC is achieved in the
previously described position, when tool 99360612 (1)
fits into the hole (3) on the flywheel (4) through the
engine revs sensor seat (2).
Figure 258
60573
Position the magnetic dial gauge (1) with the stem on
the roller (2) of the rocker controlling the injector of
cylinder 1, and pre---load it 6 mm.
Using tool 99350321 (7) Figure 256, turn the crankshaft
clockwise until the pointer on the gauge reaches the
minimum value beyond which it cannot go.
Reset the dial gauge.
Turn the flywheel anti---clockwise until the gauge reads
a lift value of 4.44 ± 0.05 mm for the camshaft cam.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ENGINE 151
Figure 259
72436
The camshaft is timed if the following conditions are
present when the cam lift values are 4.44 ± 0.05 mm:
1) the hole marked with double notch (5) can be seen
through the inspection window;
2) tool 99360612 (1) can be inserted into hole (3) on
the engine flywheel (4) through the seat (2) of the
engine rpm sensor.
Figure 260
60575
If the conditions illustrated in Figure 259 and specified
in points 1 and 2 above do not exist, proceed as follows:
D Loosen the screws (2) securing gear (1) to the
camshaft and use the slots (1) on the gear;
D Move the engine flywheel to obtain the conditions
described in points 1 and 2, Figure 259, while
keeping the cam lift value the same;
D Lock the screws (2) and repeat the check already
described;
D Tighten the screws (2) to the specified torque
152 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 261 Fit the gear (2) Figure 261, with the 4 slotted holes
centred with respect to the threaded holes in the cam-
shaft tightening the screws to the specified torque.
Check the timing of the camshaft by first rotating the fly-
wheel clockwise to fully drop the cam and then turning
it anticlockwise until the comparator read 4.44 ± 0.05.
Check the timing conditions described in Figure 259.
Phonic wheel timing

Figure 263

71778

When adjustment in the slots (1) is not sufficient to re-

cover timing offset and the camshaft rotates tight with
the gear (2), to consequently vary the cam lift reference
value, proceed as follows:
D Check that the screws (2, Figure 260) are tight.
D Rotate the flywheel by ca. ½ a turn clockwise.
D Rotate the flywheel anticlockwise until a cam lift va-
lue of 4.44 ± 0.05 mm can be read on the compara-
tor.
D Remove the screws (2, Figure 260) and remove the
gear (2) from the camshaft.

Figure 262

77260

Turn the crankshaft by taking the piston of cylinder no.

1 into the compression phase at T.D.C.; turn the flywhe-
el in the opposite direction to the normal direction of ro-
tation by approximately 1/4 of a turn.
Again turn the flywheel in its normal direction of rotation
72436
until you see the hole marked with the double notch (4)
Rotate the flywheel again to bring it into the following through the inspection hole under the flywheel hou-
conditions: sing. Insert tool 99360612 (5) into the seat of the flywhe-
D Double notch (5) visible through lower inspection el sensor (6).
hole. Insert the tool 99360613 (2), via the seat of the phase
D Tool 99360612 (1) fitted flush into the engine revs sensor, onto the tooth obtained on the phonic wheel.
Should inserting the tool (2) prove difficult, loosen the
sensor seat (2) and (3).
screws (3) and adjust the phonic wheel (1) appropriate-
ly so that the tool (2) gets positioned on the tooth cor-
rectly. Go ahead and tighten the screws (3).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 153

Adjusting the unload/intake rockers play and pump injector control rockers preload

Figure 264

60577
ADJUSTMENT OF INTAKE, EXHAUST AND INJECTION ROCKERS

The adjustment of clearance between the rockers and FIRING ORDER 1 -- 4 -- 2 -- 6 -- 3 -- 5

rods controlling the intake and exhaust valves, as well
as the adjustment of pre---loading of the rockers Clockwise Adjusting Adjusting Adjusting
controlling pump injectors, must be carried out start---up and cylinder clearance of pre---loading
rotation valve no. cylinder of cylinder
carefully. valve no. injector no.
Take the cylinder where clearance must be adjusted to 1 and 6 at 6 1 5
the bursting phase; its valves are closed while TDC
balancing the symmetric cylinder valves. 120º 3 4 1
Symmetric cylinders are 1---6, 2---5 and 3---4.
120º 5 2 4
In order to properly operate, follow these instructions 120º 1 6 2
and data specified on the table.
120º 4 3 6

Adjustment of clearance between the rockers and rods 120º 2 5 3

controlling intake and exhaust valves:
D Using a polygonal wrench, loosen nut (1) locking
the adjustment screw; In order to properly carry out the above---
D Insert the thickness gauge blade (3); mentioned adjustments, follow the se-
D Tighten or untighten the adjustment screw with the quence specified in the table, checking the
appropriate wrench; exact position in each rotation phase by
D Make sure that the gauge blade (3) can slide with a means of pin 99360612, to be inserted in the
slight friction; 11th hole in each of the three sectors with 18
D Lock the nut (1), by blocking the adjustment screw. holes each.
Pre---loading of rockers controlling pump injectors:
D Using a polygonal wrench, loosen the nut locking
the rocker adjustment screw (5) controlling the
pump injector (6);

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
154 ENGINE SECTION 4 ADT 25-30 TIER3

Figure 265
Figure 267

85480

Fit the distribution cover (1).

Fit the blow ---by case (7) and its gasket and then tigh-
ten the screws (8) to the prescribed torque.
Install the filter (5) and the gaskets (4 and 6).

The filter (5) operation is unidirectional, the-

refore it must be assembled with the two
sight supports as illustrated in the figure.
Fit the cover (3) and tighten the fastening screws (2) to
the prescribed torque. 47573
D Ruotare il motore e montare la succhieruola olio. Si-
Apply silicone LOCTITE 5970 (IVECO No. stemare la guarnizione (4) sulla coppa olio (1) posi-
2995644) on the blow---by case (7) surface zionare il distanziale (3) e montare la coppa sul ba-
of engines fitted with P.T.O. according to the samento motore avvitando le viti (2) alla coppia
procedure described in the following figure. prescritta.

Figure 266

85481

Apply silicone LOCTITE 59709 (IVECO No. 2995644)

on the blow ---by case and form a string (2) of ∅ 1,5
0,5
+ 0,2 as shown in the figure.

Fit the blow---by case (1) within 10’ from sea-

ler application.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4 ENGINE 155

COMPLETING ENGINE ASSEMBLY Turbocharger cooling water and lube oil pi-
Complete the engine assembly by assembling or con- ping unions must be tighten at a torque of:
necting the following components: D 35 ± 5 Nm, water pipe unions;
D thermostat unit; D 55 ± 5 Nm, oil pipe female union;
D automatic belt tightener, water pump, alternator; D 20---25 Nm, oil pipe male union.
D control belt.
D Oil dipstick.
Figure 268 D Electrical connections and dipstick.
D Fill engine with specified quantity of oil.
D Remove engine from rotary bench and remove en-
gine mounting brackets (99361036).
Fit:
D Air conditioner automatic belt tensioner.
D Drive belt.

In order to mount the belts, use appropriate equipment

to act on the belt tensioners in the direction indicated
by the arrow.
a. loosen the belt tensioner
b. put on the belt
c. release the belt tensioner

Do not invert the direction of action on the

belt tensioner in order to avoid damage to
60578 the tensioning mechanism.
WATER PUMP --- ALTERNATOR CONTROL BELT
ASSEMBLY DIAGRAM The belt tensioners are automatic and thus
1. Alternator --- 2. Free wheel --- 3. Water pump ---
4. Crankshaft do not require further adjustments after as-
sembly.
D damping flywheel;
D starter;
D fuel pump; Figure 85
D power steering system tank;
D fuel filter and line;
D pre---heating resistance;
D suction manifold;
D heat exchanger
D oil filter, lubricating gaskets;
D exhaust manifold;
D turbocharger and relevant water and oil lines;
D Power take off (P.T.O) and respective piping.

209NM02
A: WATER PUMP --- ALTERNATOR BELT
B: AIR CONDITIONER COMPRESSOR BELT

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
156 ENGINE SECTION 4 ADT 25-30 TIER3

TURBOCHARGER REPAIR

On detecting an engine problem attributa-

ble to the supercharger system, it is a good
idea to check the efficiency of the connector
manifold gaskets and fasteners before
checking the turbocompressor itself, as well
as the absence of blockages in the intake
manifolds and air filter. If the damage to the
turbocompressor is due to lack of oil, check
that the oil circulation pipes are not dama-
ged, and if so replace them or eliminate the
problem.
After carrying out the above preliminary checks, check
turbo function by means of an engine test using the
IVECO diagnosis tools, following the instructions provi-
ded with them.

The test must be carried out in the following

conditions:
D engine coolant temperature >50 ˚C;
D battery charge (voltage 22V for com-
pression test;
D generator efficient.
On finding values outside tolerance, check efficiency
of:
D shut ---off valve;
D pressure sensor;
D engine bay pressure sensor connection (if oxidise,
clean with specific product);
D absence of solenoid valve electrical faults WGT
(connection continuity);
D actuator movement via active diagnosis as descri-
bed in the related chapter, in case of seizure, grease
the bush with Kernite lubricant (high temperature).
If the problem persists, replace the actuator;
D sliding coupling, when moved manually should sli-
de freely. If seized and if the above check on the
bush proves negative, or if efficiency problems are
not found at the above indicated points, after con-
tacting the technical “Help Desk”, replace the turbo-
compressor, proceeding as follows:

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 4
Variable geometry movement check
Figure 86
106229
Remove the screws (2) and detach the actuator (1)
from the turbocompressor (7).
Remove the screw (6), the disk beneath (5), the ring (4)
and disconnect the actuator (1) rod (3) from the varia-
ble geomtry control lever pin (8)
Thoroughly clean the pin (→) of the lever (8) and the
bush (→) of the rod (3) using a non---abrasive microfi-
bre cloth.
Do not use abrasive paper of any kind.
Visually inspect the condition of the bush (→) of the rod
(3) and the pin (→) of the lever (8), if worn, replace the
actuator (1) or the turbocompressor (7).
Check the movement of the variable geometry internal
mechanism, by means of the lever (8), there must be
no snagging. Otherwise proceed to clean the turbine
body, as instructed in the related chapter.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ENGINE 157
Actuator check
Figure 87
106227
Check the efficiency of the actuator (1), proceeding as
follows.
Apply the compressed air supply pipe with pressure re-
gulator (4) to the connector (2) on the actuator (1). With
the pressure regulator, introduce compressed air into
the actuator, gradually modulating pressure between 0
3.5 bar, the rod (3) of the actuator (1) should move wi-
thout snagging. If not, replace the actuator (1).
Figure 88
106228
Check for any leaks from the actuator at the indicated
(→) by applying a solution of soap and water.
Powering the actuator (1) with compressed air, no bub-
bles should appear at the indicated (→), otherwise re-
place the actuator (1).
158 ENGINE SECTION 4
Figure 89
106229
Lubricate the bush (→) of the rod (3) and the of the lever
(8) with lithium---based Castrol LM GREASE and refit
the actuator (1) to the turbocompressor (7) proceeding
as follows.
Connect the rod (3) to the lever (8).
Fit: a new ring (4), the disk (5) and tighten the screw (6).
Tighten the actuator fasteners (2) to the turbocompres-
sor (7).
Tighten the screws (2 and 6) to torque of 25 Nm.
Check actuator excursion
Figure 90
106230
Check the X excursion of the actuator (1) rod (2) pro-
ceeding as follows.
Measure the distance X1, between the actuator (1) and
the centre distance of the grommet (4).
Apply the compressed air supply pipe (3) with pressure
regulator to the actuator connector (1). Throught the
pressure regulator introduce compressed air into the
actuator (1) gradually regulating pressure from 0 to 3.5
bar, until the lever (5) reaches full excursion.
Measure the distance X2, between the actuator (1) and
the centre distance of the grommet (4).
The excursion X of the actuator (1) rod (2) is given by
the following subtraction X = X2---X1 and should result
as 11.5±0.5 mm.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
Turbine body cleaning
Figure 91
106231
Mark the fitting position of the clamps (2) on the central
body (1).
Apply anti---oxidant spray to the thread and nut (4) and
loosen the clamp (2) by means of the nut.
Slightly turn the clamp (2) using pliers (5).
Mark the fitting position of the turbine body (3) on the
central body (1).
Figure 92
106232
Using a copper hammer, knock the turbine body (2)
from two opposing sides (~ 180º) to separate it from
the central body (1).
During the operation take particular care not
to damage the turbine propeller.
After dismantling the turbine body, check the move-
ment of the variable geometry as instructed in the rela-
ted chapter. If the movement has not improved with re-
spect to the previous check, replace the
turbocompressor.
ADT 25-30 TIER3 SECTION 4 ENGINE 159

Figure 93 Remove the the clamp (1) from the central body (2) and
check that it is not damaged. Otherwise replace it.

Figure 96

106233
106236
Thoroughly clean the slotted ring (1) and the surroun-
ding area of the turbine body of all carbon deposits and Remove the external O---ring (1) from the central body
check that the ring rotates freely. Otherwise replace the (2).
turbocompressor. Thoroughly clean the O---ring (1) and check that it is not
damaged. Otherwise replace it.
Any small cracks between the slots and the
Figure 97
ring may be tolerated as they do not impair
turbocompressor function.

Figure 94

106234
With a suitable craper and abrasive paper, thoroughly
clean the surfaces (→) of the turbine body (1) of all car-
bon deposits, taking care not to damage it.
Figure 95
106237
Check the turbine propellor (1), there must be no: car-
bon deposits, deformation, breaks, scoring of the bla-
des and it must rotate freely.
Ceck the play on the propeller shaft (1). It must result
as:
--- axial play 0.025 to 0.127 mm
--- radial play 0.381 to 0.533 mm
If higher values are found or any other of the above pro-
blems, replace the turbocompressor.

Before proceeding to clean the central bo-

dy, turbine side, suitably cover the oil, water
and air (→ →) intakes and outlets to prevent
dirt or foreign matter entering the turbocom-
pressor.

106235

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
160 ENGINE SECTION 4
Figure 98
106238
With a suitable craper and abrasive paper, thoroughly
clean the surfaces of the central body (1) of all carbon
deposits, taking care not to damage it and the variable
geometry ring.
Then clean the surfaces and the variable geomtry ring
of all remaining deposits using compressed air.
Check again, as instructed in the related chapters:
--- movement of the variable geomtery;
--- the actuator;
--- actuator excursion.
Figure 99
106235
Position the clamp (1) on the central body (2).
If the clamp (1) with incorporated heat shield has to be
replaced, a new actuator with incorporated heat shield
has to be fitted in place of the existing one.
Position the thoroughly cleaned external O---ring on the
central body.
Apply a thin layer of anti---seize to the clean couping
surfaces of: central body / turbine body.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
Figure 100
106240
Mount turbine body (1) on central body (2) taking care
to avoid damaging turbine rotor and align turbine body
variable geometry slot ring. Do not force mounting
operation: in case of jamming, it might damage vari-
able geometry with consequent regulation system
faulty operation.
Once mounting has been completed, make sure that
turbine body results to be matched correctly on central
body.
Position turbine body on central body and clamp on
central body in such a way that marks, made on dis-
mounting, are matching.
Tighten nut clamping the clamp at 11.3 Nm torque.
Check again, as described in relating chapters:
--- actuator;
--- actuator travel.
 SECTION 5

AUTOMATIC TRANSMISSION
Page left intentionally blank
 ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 1

CONTENTS

Page Page

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

AUTOMATIC TRANSMISSION TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . 29

CROSS-- SECTION VIEW . . . . . . . . . . . . . . . . . . . . . . 4
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
AUTOMATIC TRANSMISSION EXTERNAL PIPE
ARRANGEMENT VIEW . . . . . . . . . . . . . . . . . . . . . . . . 5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
TRANSMISSION SPEED SENSORS . . . . . . . . . . . . 6
Cold check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Speed sensor location . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hot check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Speed sensor setting . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
FUNDAMENTAL COMPONENTS . . . . . . . . . . . . . . . 8
Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
AEB procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Lock ---up clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Display – meaning of AEB procedure messages . 41
Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TRANSMISSION HYDRAULIC CONTROL
Hydrodynamic brake (retarder) . . . . . . . . . . . . . . . . 11
DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Central differential lock . . . . . . . . . . . . . . . . . . . . . . . . 12
Position of the pressure and temperature
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 measuring points . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1st forward gear: ratio 1:5.350 . . . . . . . . . . . . . . . . . 14 Electro---hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . 42

2nd forward gear: ratio 1:3.446 . . . . . . . . . . . . . . . . 15 REMOVAL-- REPLACEMENT

AUTOMATIC TRANSMISSION GEARBOX . . . . . . 44
3rd forward gear: ratio 1:2.207 . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4th forward gear: ratio 1:1.421 . . . . . . . . . . . . . . . . . 17
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5th forward gear: ratio 1:0.970 . . . . . . . . . . . . . . . . . 18
6th forward gear: ratio 1:0.625 . . . . . . . . . . . . . . . . . 19 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

1st reverse gear: ratio 1:5.350 . . . . . . . . . . . . . . . . . 20 Preliminary operations . . . . . . . . . . . . . . . . . . . . . . . . 50

2nd reverse gear: ratio 1: 2.207 . . . . . . . . . . . . . . . . 21 HYDRAULIC CONTROL UNIT . . . . . . . . . . . . . . . . . 51

3rd reverse gear: ratio 1:0.970 . . . . . . . . . . . . . . . . . 22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

FRONT DIFFERENTIAL FITTING . . . . . . . . . . . . . . 23 Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

OIL CIRCULATION SYSTEM -- VERSION WITH LOCK -- UP CLUTCH VALVE (WK) . . . . . . . . . . . . . 53

RETARDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Removal and disassembly . . . . . . . . . . . . . . . . . . . . . 53
OIL CIRCULATION SYSTEM -- VERSION Assembly and refit . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
WITHOUT RETARDER . . . . . . . . . . . . . . . . . . . . . . . 25
GEARBOX AND GEAR DISASSEMBLY . . . . . . . . 55
TRANSMISSION CONTROL SYSTEM
Converter and converter bell . . . . . . . . . . . . . . . . . . . 55
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
AN input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Lubricating pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Connector key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Central splitter lock device . . . . . . . . . . . . . . . . . . . . 57

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 2 AUTOMATIC TRANSMISSION SECTION 5
Page
Intermediate shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Central splitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Multiple---disk clutches . . . . . . . . . . . . . . . . . . . . . . . . 59
Power takeoff shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Transmitter disassembly . . . . . . . . . . . . . . . . . . . . . . 60
CLEANING, INSPECTING AND CHECKING . . . . 60
Cleaning components . . . . . . . . . . . . . . . . . . . . . . . . 60
INSPECTING AND CHECKING . . . . . . . . . . . . . . . 61
Guards and machined surfaces . . . . . . . . . . . . . . . . 61
Bearings and axial shims . . . . . . . . . . . . . . . . . . . . . . 61
O---rings and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Gears, grooves and threaded parts . . . . . . . . . . . . . 61
Rings and springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Clutch plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
GENERAL ASSEMBLY STANDARDS . . . . . . . . . . 61
Lubricants used for assembly . . . . . . . . . . . . . . . . . . 61
Clutches and pistons . . . . . . . . . . . . . . . . . . . . . . . . . 61
Lip seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Roller bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Shrink ---fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
DISMANTLING AND REASSEMBLY OF MAIN
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Clutch shaft K4/K3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Plate 1: clutch shaft K4/K3 . . . . . . . . . . . . . . . . . . . . . 63
Reassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Plate 2A: clutch K4 --- Version A (12 surfaces) . . . . 68
Plate 2B: clutch K4 --- Version B (10 surfaces) . . . . 69
Plate 3A: clutch K3 --- Version A (18 surfaces) . . . . 70
Plate 3B: clutch K3 --- Version B (14 surfaces) . . . . 71
Clutch shaft KR/K2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
Page
Plate 4: clutch shaft KR/K2 . . . . . . . . . . . . . . . . . . . . 74
Reassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Plate 5A: clutch KR --- Version A (24 surfaces) . . . 79
Plate 5B: clutch KR --- Version B (20 surfaces) . . . 80
Plate 6A: clutch K2 --- Version A (18 surfaces) . . . . 81
Plate 6B: clutch K2 --- Version B (14 surfaces) . . . . 82
Clutch shaft KV/K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Plate 7: clutch shaft KV/K1 . . . . . . . . . . . . . . . . . . . . 87
Reassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Plate 8A: clutch KV --- Version A (24 surfaces) . . . 91
Plate 8B: clutch KV --- Version B (20 surfaces) . . . 92
Plate 9A: clutch K1 --- Version A (18 surfaces) . . . . 93
Plate 9B: clutch K1 --- Version B (14 surfaces) . . . . 94
Power takeoff shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Central splitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
AN input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
GEARBOX AND GEAR ASSEMBLY . . . . . . . . . . . 104
Power takeoff shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Intermediate shaft gear . . . . . . . . . . . . . . . . . . . . . . 104
Clutch shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Gearbox cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Intermediate shaft pin . . . . . . . . . . . . . . . . . . . . . . . . 111
Central splitter lock device . . . . . . . . . . . . . . . . . . . 111
Pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Power takeoff flange . . . . . . . . . . . . . . . . . . . . . . . . . 113
Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
AN input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Converter bell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
ADT 25-30 TIER3 SECTION 5
DESCRIPTION
The ZF ZF6W260 automatic transmission consists of
the following fundamental parts.
Transmission ECU and wiring: The ECU receives the
input signals and controls the outputs to ensure correct
operation of the transmission.
Hydraulic unit: The unit consists of a set of solenoid
valves controlled by the transmission ECU and pipes
for conveying pressurized oil to the points required.
Torque converter: The torque converter transmits the
drive torque from the engine to the transmission with---
out employing stiff components.
It consists of three parts: the impeller, the turbine and
the stator. The impeller is the suction element. It is con-
trolled by the engine. The turbine is the outlet element.
It is hydraulically controlled by the impeller. The stator
is the reaction element (torque multiplier).
Lock-- up clutch: It is fitted between the impeller and
the turbine. The lock ---up clutch is engaged when the
turbine speed approaches that of the impeller so that
the engine drive torque is directly transferred to the
transmission at a ratio of 1 : 1.
The vehicle is fitted with integrated version automatic transmission with front differential.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
AUTOMATIC TRANSMISSION 3
Hydrodynamic brake (Retarder): It is fitted upstream
to the torque converter. The purpose is to transmit the
drag torque from the vehicle wheels during deceler-
ation.
Shaft and gears: The transmission is characterized by
an input shaft, driven by the converter, by an output
shaft, to which has a transmission differential lock, and
by three main shafts, each equipped with two or three
helical, permanently engaged gears.
The forward and reverse gear ratios are obtained by en-
gaging the different clutches fitted on the three main
shafts.
A supplementary driven PTO shaft is also included for
steering emergency pump.
Clutches: Each shaft is equipped with two hydrauli-
cally controlled, multiple plate clutches.
Oil pressure pump: The pump is fitted on the input
shaft. It is a gear pump and ensures the pressure re-
quired for lubricating and operating the hydraulic trans-
mission functions.
Power take-- off (PTO): The PTO is controlled by a
shaft driven directly by the input shaft (consequently by
the engine flywheel) and is fitted on the back of the
transmission enclosure. This PTO shaft is used to drive
the main hydraulic pump of the vehicle.
4 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

AUTOMATIC TRANSMISSION CROSS---SECTION VIEW

1. drive torque input flange 11. KR (reverse) and K2 clutch shaft
2. R hydrodynamic brake (retarder) 12. K3 and K4 clutch shaft
3. WK lock ---up clutch 13. drive torque output flange, rear side
4. W torque converter 14. differential lock
5. breather 15. drive torque output flange, front side
6. hydraulic control unit 16. intermediate shaft
7. PTO drive shaft
8. transmission oil pressure pump Version without front differential.
9. drive torque input shaft AN
10. KV (forward gear) and K1 clutch shaft

Figure 1

1730702Z

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 5

AUTOMATIC TRANSMISSION EXTERNAL PIPE ARRANGEMENT VIEW

1. hydraulic control unit K1: K1 clutch control pipe
2. AN drive torque input shaft K2: K2 clutch control pipe
3. KR (reverse) and K2 clutch shaft K3: K3 clutch control pipe
4. intermediate shaft K4: K24 clutch control pipe
5. AB drive torque output shaft KV: KV clutch control pipe
6. K3 and K4 clutch shaft KR: KR clutch control pipe
7. KV (forward gear) and K1 clutch shaft
8. PTO drive shaft S1: KR---K2 shaft lubrication pipe
S2: K3---K4 shaft lubrication pipe
S4: AN output shaft lubrication pipe

Figure 2

1730703Z

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
6 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

TRANSMISSION SPEED SENSORS

Speed sensor location A) drive torque input flange
31 output shaft speed Hall---effect sensor B) front drive torque output flange
6 turbine speed inductive sensor C) rear drive torque output flange
13 central speed gear shaft inductive sensor
14 engine speed inductive sensor

Figure 3

rear view left view

T269CT03A

T225036

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 7

Speed sensor setting

Inductive sensors
For the inductive sensors, the following different gap between tooth and sensor area must to be adjusted.

6 turbine speed sensor S=0,5+0,3 mm (0,20+0,08 in)

13 central speed gear shaft sensor S=0,3+0,1 mm (0,12+0,08 in)
14 engine speed sensor S=0,5+0,3 mm (0,20+0,08 in)

1. Sensor
2. Gear
3. Housing

T225037

Hall sensor
31 output shaft speed Hall---effect sensor S=1,0/1,5 mm (0.39/0.59 in)

1. Spur gear K3
2. Clutch axle K4/K3
3. Housing
4. Sensor

T225038

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
8 AUTOMATIC TRANSMISSION SECTION 5
FUNDAMENTAL COMPONENTS
Torque converter
The torque converter hydraulically transmits the engine
drive force from the engine to the transmission, accord-
ing to a multiplying ratio in the range from a maximum
Figure 4
The torque converter W consists of three parts: the
pump P, the turbine T and the stator S. The pump is the
input element. It is controlled by the engine. The tur-
bine is the outlet element. It is hydraulically controlled
by the pump. The stator is the reaction element (torque
multiplier). It is fitted on a one---way bearing allowing
revolution in the direction of the pump only.
The assembly is enclosed in a box full of specific oil.
The unit also includes:
D a hydrodynamic brake R (retarder)
D a lock ---up clutch WK, which, when engaged, stiffly
connects the pump and the turbine.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
of approximately 2.5:1 to a minimum of 1:1 (direct en-
gagement).
1730705Z
Operation
The pump is connected to the engine and transmits en-
ergy to the oil by turning. The centrifuge force projects
the oil towards the edge of the pump from where it flows
to the turbine at high speed. Here, the kinetic energy
of the oil impresses a rotary movement to the turbine
in the same direction as the pump.
At turbine output, the oil is deviated by the stator at a
certain angle so to increase yield at pump return. Direc-
tion is consistent with the turbine vanes.
In this way, the stator, which cannot turn due to the ac-
tion of the one---way bearing, provides a reaction
torque which is summed to that turbine torque.
ADT 25-30 TIER3 SECTION 5
The resistance ratio between the torque on the turbine
and the drive torque is the converter multiplication
ratio. It is proportion to the difference in speed between
the pump and the turbine.
Figure 5
1730714
Specifically:
D When the vehicle wheels are stationary, the ratio is
approximately 1:2.5 (condition A, maximum slip-
ping).
D During converter operating driving conditions (slip-
ping ≠ 0), this ratio is reduced to intermediate values
(condition B).
D When the pump speed is comparable to the turbine
speed, the ratio approaches 1:1 (slipping ≈ 0).
. Slipping = 0 condition is only fully reached
when the lock---up clutch is engaged (condi-
tion C).
When the pump and turbine pump speeds are nearly
the same, the stator is invested by the flow of oil which
causes it to turn in the direction of the turbine.
This is because the one---way bearing only permits
turning in the direction of the turbine. In this way, the
stator reaction torque is entirely absent. The converter
becomes a simple hydraulic coupling.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
AUTOMATIC TRANSMISSION 9
Lock-- up clutch
The lock ---up clutch WK is a device which mechanically
couples the pump and the converter turbine when it is
engaged.
When the lock ---up clutch is engaged, the slipping be-
tween the pump P and the turbine T is eliminated. The
transmission is, consequently, transformed into a
mechanical transmission unit, with respective loss of
friction in the converter and fuel consumption reduc-
tion.
Figure 6
1730707Z
Clutch disengaged (converter phase)
The oil circulating in the converter impresses the same
pressure on the rear a and front b side of the clutch (2)
engagement piston (1): the turbine T is free to turn with
respect to the pump P.
Clutch engaged (lock ---up phase)
The control unit operates a solenoid valve which in-
creases the pressure in the rear area a. Consequently,
the piston (1) slides and locks the clutch (2). In this
way, the turbine T is solidly fastened to the pump P,
whereby eliminating relative sliding.
10 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Clutches
The multiple plate clutches prevent the relative rotation
between the hub and the bell when engaged.

Figure 7

1730708Z

Each clutch consists of a set of plates with grooves on

the outside (1a) arranged alternatively with a set of
plates with grooves on the inside (1b).
The plates with grooves on the outside engage the bell
(2), while the plates with grooves on the inside engage
the hub (3).
The clutch is hydraulically locked by sending pressur-
ised oil to the back of the control piston (4) by means
of solenoid valves.
In this condition, the plates cannot slide. The bell and
the hub are solidly fastened.
Release is ensured by the mechanical action of a
spring (5) on the piston in the opposite direction of the
oil pressure, when this is no longer applied to the pis-
ton.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 11

Hydrodynamic brake (retarder)

Figure 8
It is fitted upstream to the torque converter. The pur-
pose is to transmit the drag torque from the vehicle
wheels during deceleration.
If consists of a fixed stator (1), solidly fastened to the ex-
ternal transmission box, and a rotor, solidly fastened to
the drive torque input shaft, and consequently to the
crankshaft.
Both parts present vanes on the inside. They are
closed in a box containing the same oil as the trans-
mission box.

The retarder is engaged by sending pressurised oil into

the box via a set of valves, so that the stator strongly op-
poses rotor rotation.
By engaging the lock ---up clutch at the same time, the
converter pump (and, consequently, the retarder rotor)
is solidly fastened to the converter turbine (and, conse-
quently, the AN input shaft and to the vehicle wheels).

In this way, the drive torque from the vehicle is partially

dissipated by the oil in the retarder box, whereby brak-
ing the vehicle.
1730710Z

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
12 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Central differential lock

This is a double satellite sun and planet gear differential Operation
lock (Ravigneaux model). In normal conditions (position A), the drive torque from
This configuration shares the drive force while the two the K4---K3 shaft gear is taken by the external crown
elements transmitting the output drive (sun gear and gear and is shared by 2/3 via the gear set holder (4) to
gear set holder) turn in the same direction. the rear output shaft and by 1/3 via the sun gear to the
front output shaft (7).
The central differential lock share the drive force be- In differential lock conditions (position B), the sliding
tween the front and rear axle in fixed proportions. sleeve (11) fastens the gear set holder (4) --- which is
Specifically, torque is shared are follows: solidly fastened to the rear output shaft --- to the front
D 1/3 to the front axle output shaft --- which is solidly fastened to the sun gear.
D 2/3 to the rear axle The drive torque is consequently shared equally on
both sides because the unit forms a single part with the
The driver can lock the differential by means of an elec- crown gear (8).
trical hydraulic control if either axles slip.
This control works on a sliding sleeve which, when
moved, fastens the two elements transmitting the out-
put drive (sun gear and gear set holder). In this way, the
output shaft turn together and make drive transmission
stiff.
Do not steer when vehicle when the central
differential is locked to prevent severely
damaging the transmission.
Do not drive on terrain offering high grip
with the rear differential locked to prevent
severely damaging the transmission and the
tyres.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 13

1. Crown wheel external gear 10. Lubrication pipe fitting

2. External planetary satellite gear 11. Differential lock sliding sleeve
3. Internal satellite gear (not shown) 12. Hydraulic lock control fitting
4. Gear set holder (carrier) 13. Sliding sleeve control lever
5. Protective guard 14. Lever control piston
6. Sun gear
7. Output shaft front end A. disengaged position (differential released)
8. Crown gear B. engaged position (differential locked)
9. Output shaft rear end

Figure 9

T269TM01

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
14 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

OPERATION
1st forward gear: ratio 1:5.350 The driving torque passes from the input shaft AN
through the input gear and clutch KV to shaft KV ---K1,
Clutches free locked then through clutch K1 to the output gear of shaft KV ---
KV X K1 and finally through the output gears of shaft KR---K2
and shaft K4---K3 to output shaft AB, which turns the
KR X same direction as shaft AN.
K1 X
K2 X
K3 X
K4 X

Figure 10

1730711Z

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 15

2nd forward gear: ratio 1:3.446

Clutches free locked The driving torque passes from input shaft AN through
the input gear of shaft KR---K2 and the intermediate
KV X
gear and clutch K4 to shaft K4---K3, then through shaft
KR X KR---K2 and clutch K1 to shaft KV ---K1, and finally
K1 X through the output gears of shaft KR---K2 and shaft
K4---K3 to output shaft AB, which turns in the same
K2 X
direction as shaft AN.
K3 X
K4 X

Figure 11

1730712Z

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
16 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

3rd forward gear: ratio 1:2.207

Clutches free locked The driving torque passes from the input shaft AN
through the input gear and clutch KV to shaft KV ---K1,
KV X X
then through clutch K2 to the output gear of shaft KR---
KR X K2 and finally through the output gear of shaft K4---K3
K1 X to output shaft AB, which turns the same direction as
shaft AN.
K2 X
K3 X
K4 X

Figure 12

1730713Z

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 17

4th forward gear: ratio 1:1.421

Clutches free locked The driving torque passes from input shaft AN through
the input gear of shaft KR---K2 and the intermediate
KV X
gear and clutch K4 to shaft K4---K3, then through clutch
KR X K2 to the output gear of the shaft KR---K2, and finally
K1 X through the output gear of shaft K4---K3 to output shaft
AB, which turns in the same direction as shaft AN.
K2 X
K3 X
K4 X

Figure 13

1730714Z

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
18 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

5th forward gear: ratio 1:0.970

Clutches free locked The driving torque passes from the input shaft AN
through the input gear and clutch KV to shaft KV ---K1,
KV X
then to shaft KV ---K1, to shaft K4---K3, then through
KR X clutch K3 to the output gear of shaft K4---K3 and finally
K1 X to output shaft AB, which turns in the same direction as
shaft AN.
K2 X
K3 X
K4 X

Figure 14

1730715Z

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 19

6th forward gear: ratio 1:0.625

Clutches free locked The driving torque passes from input shaft AN through
the input gear of shaft KR---K2 and the intermediate
KV X
gear and clutch K4 to shaft K4---K3, then through clutch
KR X K3 to the output gear of shaft K4---K3, and finally to out-
K1 X put shaft AB, which turns in the same direction as shaft
AN.
K2 X
K3 X
K4 X

Figure 15

1730716Z

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
20 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

1st reverse gear: ratio 1:5.350

Clutches free locked The driving torque passes from the input shaft AN
through the input gear and clutch KR to shaft KR---K2,
KV X
then to shaft KV ---K1, then through clutch K1 to the out-
KR X put gear of shaft KV ---K1 and finally through the output
K1 X gears of shaft KR---K2 and shaft K4---K3 to output shaft
AB, which turns the opposite direction to shaft AN.
K2 X
K3 X
K4 X

Figure 16

1730717Z

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 21

2nd reverse gear: ratio 1: 2.207

Clutches free locked The driving torque passes from the input shaft AN
through the input gear and clutch KR to shaft KR---K2,
KV X
then through clutch K2 to the output gear of shaft KR---
KR X K2 and finally through the output gear of shaft K4---K3
K1 X to output shaft AB, which turns the opposite direction
to shaft AN.
K2 X
K3 X
K4 X

Figure 17

1730718Z

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
22 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

3rd reverse gear: ratio 1:0.970

Clutches free locked The driving torque passes from the input shaft AN
through the input gear and clutch KR to shaft KR---K2,
KV X
then to shaft K4---K3, then through clutch K3 to the out-
KR X put gear of shaft K4---K3 and finally to output shaft AB,
K1 X which turns in the opposite direction to shaft AN.
K2 X
K3 X
K4 X

Figure 18

1730719Z

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 23

FRONT DIFFERENTIAL FITTING

The vehicle is fitted with integrated version automatic transmission with front differential.
It is fitted by bolting the differential box directly to the transmission box.
Drive is transferred to the differential bevelled pinion via a short hollow shaft, which has two grooves on its internal
diameter: the first engages with the automatic transmission output shaft, the second with the bevelled pinion to
which it is solidly attached.
The seal between the two boxes is made by a small diameter cylindrical washer.
An oil seal prevents the lubricants from mixing.

1. Automatic transmission output shaft

2. Hollow shaft
3. Differential bevel pinion
4. Pinion to hollow shaft locking ring
5. Seal washer
6. Oil seal

Figure 19

T269TM05

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
24 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

OIL CIRCULATION SYSTEM --- VERSION WITH RETARDER

The automatic transmission fluid is cooled by means of an oil --- water heat exchanger (A) located on the left front
side of the vehicle.
The fluid is filtered by a filter group (B) connected by two pipes to the automatic transmission box. A second return
pipe (by---pass) allows to exclude the filters in case of obstruction.
The fluid circulation is activated by the oil pressure pump inside the automatic transmission.

Figure 20

1. Filter group by---pass

2. Oil delivery to the filter group
3. Oil return from the filter group
4. Oil delivery to the exchanger
5. Oil return from the exchanger

276C05001

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 25

OIL CIRCULATION SYSTEM --- VERSION WITHOUT RETARDER

The automatic transmission fluid is cooled by means of an oil --- water heat exchanger (A) located on the left front
side of the vehicle.
The fluid is filtered by a filter group (B) connected by two pipes to the automatic transmission box. A second return
pipe (by---pass) allows to exclude the filters in case of obstruction.
The circulation of the fluid is activated by the oil pressure pump inside the automatic transmission.

Figure 21

1. Filter group by---pass

2. Oil delivery to the filter group
3. Oil return from the filter group
4. Oil delivery to the exchanger
5. Oil return from the exchanger

276C05002

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
26 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

TRANSMISSION CONTROL SYSTEM COMPONENTS

Key
1. TCU – Transmission control unit
2. ZF diagnostic connector
3. Retarder control
4. Automatic transmission distributor lock command
5. Unused
6. F35 starting switch power---supply fuse
7. F36 direct power---supply fuse
8. Retarder diagnosis resistor
9. Neutral remote starter switch E17
10. Reverse remote switch E18
11. Unused
12. Unused
13. Body position sensor 338
14. Converter downstream oil temperature sensor
15. Electrohydraulic group
16. Output speed Hall sensor
17. Lock ---up clutch valve
18. Engine speed inductive sensor
19. Turbine speed inductive sensor
20. Intermediate cog speed inductive sensor
21. Automatic transmission distributor connection electromagnetic valve 515
22. Automatic transmission distributor connection sensor 347
23. Retarder electromagnetic valve air pressure switch 335
24. Retarder electromagnetic valve 319
25. Filter obstruction switch 512
26. Accelerator pedal
27. EDC – engine control unit
28. MIDAC 2
29. Unused
30. CLUSTER
31. HEAD
32. Gear selection lever

Connector key
(a) Cab bulkhead through connector (white)
(b) Cab feedthrough connector (brown)
(c) Cab feedthrough connector (yellow)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 27

Figure 22

276C05003A

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
28 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

TECHNICAL DATA

COMPONENT PARAMETER VALUE

Resistance 1050 Ohm a 20°C (±10%)
Inductive sensor Temperature range ---40 °C ÷ 150 °C
--- tturbine
bi sensor
Tightening torque 30 Nm
--- engine sensor
Gap: engine and turbine 0,5 + 0,3 mm
--- central gear shaft sensor
Gap: central gear 0,3 + 0,1 mm
Working range 2 Hz ÷ 5 kHz
Hall sensor Temperature range ---40 °C ÷ 150 °C
--- output
p shaft sensor Voltage supply 24 V
Gap 1,0 + 0,5 mm
Resistance 19 Ohm a 20°C (±10%)
Electrohydraulic
Current 100 ÷ 500 mA
proportional valve
Pressure range 0,8 ÷ 8,3 bar (11,6 ÷ 120 PSI)
Sump temperature sensor Resistance 1 ÷ 1,5 kOhm
Retarder temperature sensor Resistance 0,8 ÷ 1,5 kOhm
Resistance 60 ÷ 80 Ohm a 20°C
up clutch valve Current
Solenoid lock ---up 250 ÷ 350 mA
Voltage supply 24 V
Main pressure 16 ÷ 18 bar (232 ÷ 261 PSI)
Control pressure 16 ÷ 18 bar (232 ÷ 261 PSI)
Pressure before converter max 9 ÷ 11 bar (130 ÷ 160 PSI)
Pressure behind converter max 5,0 bar (73 PSI)
Temperature behind converter max 100 °C (120 °C temporary)
Hydraulic circuit
Temperature behind retarder max 145 °C (150 °C temporary)
115 l/min (27,7 USgpm) @ n=2000
Lubrication pump flow
1/min
80 l/min (21,0 USgpm) @ n=2000
Minimum lubrication pump flow
1/min
1st: 5.350
2nd: 3.446
3rd: 2.207
Forward
4th: 1.421
Gear ratio 5th: 0.970
6th: 0.625
1st: 5.350
Reverse 2nd: 2.207
3rd: 0.970

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 29

TIGHTENING TORQUE
Interface plate screw caps 6.0 Nm (4.43 lbf ft)
Screws fastening interface plate to valve assembly 9.5 Nm (7.01 lbf ft)
Screws fastening pipe plate to gearbox 23.0 Nm (16.96 lbf ft)
Screws fastening valve assembly to gearbox 11.0 Nm (8.11 lbf ft)
Screws fastening solenoid valve to WK valve 5.5 Nm (4.0 lbf ft)
Screws fastening WK valve to plate 9.5 Nm (7.01 lbf ft)
Screws fastening WK valve plate to bracket 23 Nm (16.96 lbf ft)
K4/K3 shaft ring nut --- K4 clutch side 550 Nm (405.66 lbf ft)
KR/K2 shaft ring nut --- KR clutch side 800 Nm (590.05 lbf ft)
KR/K2 shaft ring nut --- K2 clutch side 800 Nm (590.05 lbf ft)
KV/K1 shaft ring nut --- KV clutch side 550 Nm (405.66 lbf ft)
KV/K1 shaft ring nut --- K1 clutch side 550 Nm (405.66 lbf ft)
Screw fastening pressure pump drive bushing 32 Nm (23.60 lbf ft)
M8 Screws fastening pressure pump cover 23 Nm (16.96 lbf ft)
M6 Screws fastening pressure pump cover 9.5 Nm (7.01 lbf ft)
Screws fastening rear cover to gearbox 46 Nm (33.93 lbf ft)
Screws fastening K4/K3 clutch shaft cover 46 Nm (33.93 lbf ft)
Screws fastening KR/K2 clutch shaft cover 46 Nm (33.93 lbf ft)
Screws fastening KV/K1 clutch shaft cover 46 Nm (33.93 lbf ft)
Screws fastening pressure pump 79 Nm (58.27 lbf ft)
Screws fastening pressure pump flange 79 Nm (58.27 lbf ft)
Screws fastening power takeoff flange 125 Nm (92.19 lbf ft)
Screws fastening central splitter lock device 46 Nm (33.93 lbf ft)
Screws fastening oil supply flange cover 46 Nm (33.93 lbf ft)
Converter relief valve plug 130 Nm (95.88 lbf ft)
Screws fastening converter bell to gearbox (M8) 34 Nm (25.08 lbf ft)
Screws fastening converter bell to gearbox (M12) 115 Nm (84.82 lbf ft)
Screws fastening input/output flanges 46 Nm (33.93 lbf ft)
Screws fastening oil filter cover 23 Nm (16.96 lbf ft)
Inductive sensors tightening 30 Nm (22.13 lbf ft)
Screws fastening output shaft rpm sensor 23 Nm (16.96 lbf ft)
Breather tightening 12 Nm (8.85 lbf ft)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
30 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Figure 23

276C005004

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 31

EQUIPMENT
. The codes provided in the following list refer to the original ZF codification.

TOOL N. DESCRIPTION NAME

5870 350 000 Assembly carriage with tipping device

5870 350 071 Retention equipment (for use with 5870 350 000)

5870 204 022 Series of eyebolts

5870 000 089 Extractor for oil feed flange/lubrication pump

5870 650 014 Striking hammer extractor

5870 204 069 Threaded insert (for use with 5870 650 014)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
32 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

TOOL N. DESCRIPTION NAME

5870 204 005 Rear cover removal setscrews

5870 300 007 Internal extractor for outer ring of power take---off shaft bearing

5870 300 003 Bench support (for use with 5870 300 007)

5870 654 022 Support ring for overhaul of (all) clutch shafts

5870 971 002 Extractor for K4/K3 shaft cylindrical roller bearing

5873 012 012 Extraction gripper for inner ring of K3 clutch conic roller bearing

5873 002 001 Extractor

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 33

TOOL N. DESCRIPTION NAME

5870 401 115 Wrench for K4/K3 shaft ring nut

5873 011 012 Extractor for the inner ring of the K4/K3 shaft conic roller bearing

5873 001 000 Extraction gripper

5870 971 003 Compression spring preload tool

5870 345 072 Compression spring preload tool

5870 401 099 Wrench for KR/K2 shaft --- KV/K1 shaft ring nut

5873 012 018 Extraction gripper for inner ring of K2 clutch conic roller bearing

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
34 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

TOOL N. DESCRIPTION NAME

5873 001 023 K1 side extractor

5873 001 034 KR side extractor

5873 012 019 Extraction gripper for inner ring of conic roller bearing

5873 002 044 Extractor

5873 002 023 Extractor

5873 001 020 Extractor

5873 001 027 Extractor

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 35

TOOL N. DESCRIPTION NAME

5870 300 009 Extractor base

Extractor for the inner ring of the pressure pump conic roller bea-
5870 300 017
ring

5873 014 014 Extraction gripper for inner ring of conic roller bearing

5873 004 001 Extraction gripper

5870 345 033 K3 shaft lifting tool

5870 058 041 Pressure pump needle cage insertion block

5870 048 228 Front/rear output shaft sealing ring assembly block

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
36 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

TOOL N. DESCRIPTION NAME

5870 204 002 Intermediate shaft pin assembly guide stud

5870 260 002 Block handle

5870 058 051 Oil feed flange cover needle cage insertion block

5870 401 118 Wrench for K4/K3 shaft ring nut

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 37

MAINTENANCE Hot check (80-- 100 °C) (176-- 135,56 °C)

Proceed as follows:
Oil level check D Travel the distance necessary to warm up the trans-
mission;
The correct oil level is essential for the trans- D leave the engine to idle with gearbox in Neutral;
mission to function correctly. Too little oil
can cause irregular converter function and Figure 25
damage; too much oil causes foam to form
and transmission overheating.

Cold check (15-- 45 °C) (59-- 113 °F)

Proceed as follows:
D start the engine and leave it to idle with gearbox in
Neutral for circa one minute;

Figure 24

269NM202

D clean the filler cap area, unscrew the grip two or

three turns and remove the dipstick built ---in to the
filler cap and check that the oil level is within the HOT
notch;
D top---up or drain off oil to reach the required level
then replace the cap/dipstick;

Breather
269NM201 Proceed as follows:
D clean the filler cap area, unscrew the grip two or
Figure 26
three turns and remove the dipstick built ---in to the
filler cap and check that the oil level is not below the
COLD (minimum) notch;
D top---up if necessary. Do not drain any oil above the
notch. Replace the filler cap/dipswitch tightening
the grip;
D DO NOT drain excess oil: carry out a hot check as
soon as possible.

Z7307029
D check that the breather is perfectly clean and func-
tioning.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
38 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Oil change Oil filter change

Exhausted oil and fluids must be collected Replace the filter at every oil change.
and disposed of according to standards in
force.
Proceed as follows:
Proceed as follows:
D Position a suitable container, clean the filler cap Figure 28
zone. Unscrew the grip two or three turns and re-
move the dipstick;

Figure 27

269NM212

D Open the hood;

D with the engine off unscrew the filter cartridge with
the correct spanner if necessary, then thoroughly
269NM211 clean the support seat;
D Remove the drain plug (arrow) and fully drain the oil;
D clean the drain plug, check the thread is in good Figure 29
condition, spread sealant paste on the cap and re-
tighten it to the specified torque;
D Refill with the quantity of oil stated on the filler cap
and replace the dipstick, tightening the grip;
D Re---check oil level after one test cycle.
After the operations described we recom-
mend carrying out the AEB procedure to
permit electrovalve control parameter allow
self---adaptation by the Transmission Con-
trol Unit.

156NM25
D fill the new cartridge with oil and grease the washer
with gear oil;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 39

Figure 30

156NM42

D hand---tighten the cartridge until the washer comes

into contact with the support, then tighten it by ¾ of
a turn;
Do not overtighten the cartridge to avoid
damaging the washer. Always follow the
manufacturer’s recommendations.
D Start the engine and check for the absence of oil
leaks;
D Check oil level and top---up if necessary.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
40 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

AEB procedure
1
The following conditions must be respected
for correct execution of the AEB procedure:
D selector in Neutral position
D engine at idle speed
D parking brake engaged
D steady state automatic
transmission temperature
(80 --- 90˚C) (176---194 ˚F)
If one of these conditions is not respected
the system will not
execute the procedure. 269NU112
To activate the AEB procedure proceed as follows:
D pass from the Home page to the main menu page
pressing ENTER;
2
D select VEHICLE MANAGEMENT (2);
D select AEB REQUEST (3);
D Press ENTER to start the procedure (4).

The AEB procedure takes 3 --- 4 minutes.

During execution the display provides the user with in-
formation on procedure progress (4).
The meaning of the messages is given in the following
table.
The parameters thus identified are
269NU113
memorised in the control unit memory.

269NU191T

269NU192T

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 41

Display – meaning of AEB procedure messages

Line 6
Line 7

MESSAGE MEANING NOTES

Line 6
ADJUSTING K1...K4, KV, KR Calibration of clutches
Wait while the procedure is being
carried out
ADJUSTMENT COMPLETE Calibration completed The procedure has terminated
AEB REQUEST STOPPED Procedure stop Transmission in Neutral, switch off
and restart the engine
ABORTED ADJUSTING K1...K4, Procedure stop, clutch K1…K4, KV, Transmission in Neutral, switch off
KV, KR KR not calibrated and restart the engine
Line 7
FAULT PRESENT Type of fault present
SHIFT LEVER NOT NEU Shift lever not in Neutral Transmission in Neutral, switch off
and restart the engine
PARK BRAKE NOT INS Parking brake not applied Parking brake engaged, switch off
an restart the engine
OUTPUT SPEED NOT 0 Vehicle not stationary Transmission in Neutral, switch off
and restart the engine
LOW TC OIL TEMPER Oil temperature too low, warm---up
HIGH TC OIL TEMPER Oil temperature too high, let cool
LOW ENGINE RPM Engine speed too low, increase
HIGH ENGINE RPM Engine speed too high, reduce

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
42 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

TRANSMISSION HYDRAULIC CONTROL DIAGRAM

Position of the pressure and temperature measuring points

15 = to the heat exchanger
16 = from the heat exchanger
28 = to the filter
29 = from the filter
38 = from converter
39 = to lubrication
51 = in front of the converter ---opening pressure 9 ÷ 11 bar (130 ÷ 160 PSI)
52 = behind the converter ---opening pressure 5 bar (73 PSI)
53 = KV clutch forward 16 ÷ 18 bar (232 ÷ 261 PSI)
55 = KR clutch reverse 16 ÷ 18 bar (232 ÷ 261 PSI)
56 = K1clutch 16 ÷ 18 bar (232 ÷ 261 PSI)
57 = K2clutch 16 ÷ 18 bar (232 ÷ 261 PSI)
58 = K3clutch 16 ÷ 18 bar (232 ÷ 261 PSI)
60 = K4clutch 16 ÷ 18 bar (232 ÷ 261 PSI)
63 = temperature behind the converter 100˚ C, short time 120˚ C
(max. 5 minutes)
65 = system pressure 16 ÷ 18.5 bar (232 ÷ 268 PSI)
66 = temperature behind retarder 145˚ C, short time 150˚ C
(max. 5 minutes)
67 = WK---control pressure 12 ÷ 14 bar (174 ÷ 203 PSI)

Electro -- hydraulic unit

• PRESSURE REGULATION UNDER VOLTAGE ENGAGED

DRIVING DIRECTION SPEED Y1 Y2 Y3 Y4 Y5 Y6 CLUTCHES
1 • • K1 KV
2 • • K4 K1
3 • • KV K2
FORWARD
4 • • K4 K2
5 • • K3 KV
6 • • K4 K3
1 • • KR K1
REVERSE 2 • • KR K2
3 • • KR K3
NEUTRAL --- --- ---
ENGADED CLUTCH KR K4 K1 K3 KV K2
POSITIONS ON VALVE
F E D C B A
BLOCK (*)
REF. NO. MEASURING
55 60 56 58 53 57
PRESSURE (*)
(*) See following page

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 43

The figure shows the position of the pressure and temperature measuring points and others ele-
ments that occur on the hydraulic diagram.

Figure 31

T225045

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
44 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

REMOVAL---REPLACEMENT Figure 33
AUTOMATIC TRANSMISSION GEARBOX

Before carrying out any operation, check

that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in SEC-
TION 1 of this manual.
If in doubt, speak to a more experienced per-
son.
Respect all general recommendations for
correct execution of maintenance works.

Removal
2690702
Proceed as follows:
D Park the vehicle on a suitable flat and solid surface, 1. High pressure circuit valve
remove the ignition key, engage the handbrake and 2. Low pressure circuit valve
place maintenance warning signs;
D disengage the battery cut ---off switch or disconnect D proceed to discharge the air conditioner system;
the battery leads to eliminate any risk of short ---cir-
cuit; The system must be discharged by special-
D lock the articulation using the steering lock bar as ist personnel using specific equipment.
instructed in SECTION 1; For these operations, refer to the pro-
cedures provided by the equipment manu-
Figure 32 facturer.

Do not discharge R134a fluid into the atmos-

phere. Although its potential for damaging
the ozone layer is zero, it may nevertheless
contribute to global warming.
Always use approved refrigerant recovery
and recharging apparatus.
Never mix different refrigerants in the same
apparatus.

Figure 34

276C05010

D proceed to remove the hood;

D procedere alla rimozione del cofano motore operan-
do secondo quanto indicato nella SEZIONE 15;
D procedere alla rimozione dei ripari laterali operando
secondo quanto indicato nella SEZIONE 15;

2690703

D proceed to remove the cab;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
Figure 35
276NM010TA
D arrange a suitably---sized container underneath,
then drain the fluid of the main hydraulic system fol-
lowing the instructions provided in SECTION 10 ---
HYDRAULIC SYSTEM;
Figure 36
276C05012
D open the retaining clamp and recover the transmis-
sion --- cab interface cable along the chassis, win-
ding it up above the transmission control unit (ar-
row);
. The operations described below refer to the
figures that follow.
The removal of the tear/snap ---off fixing
bands is not shown. It is understood that
these bands must be cut/disengaged and
subsequently restored during reassembly
to ensure the correct fastening of the ele-
ments to be retained.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
SECTION 5 AUTOMATIC TRANSMISSION 45
D disconnect the electrical connections:
--- distributor differential lock sensor (11);
--- hydraulic system filter obstruction sensor (12);
--- emergency steering pump manostat (13);
--- emergency steering pump actuation electroma-
gnetic valve (14);
--- automatic transmission oil filters obstruction
sensor (15);
--- ground screw (16) from the chassis;
--- retarder electromagnetic valve (17) (if applica-
ble);
--- retarder air pressure switch (18) (if applicable);
D disconnect the pneumatic connections:
--- retarder control actuator (6) (if applicable);
--- central distributor lock actuator (7);
D disconnect the transmission oil pipelines:
--- oil delivery to the exchanger (1);
--- oil return from the exchanger (2);
Fluid leakage may occur during these ope-
rations.
D disconnect the following hydraulic fluid piping from
the hydraulic system filter group:
--- delivery (C1) to the tipping valve (23);
--- delivery (C) to the steering valve (24);
--- arrival (P1) from the emergency steering pump
(25);
--- return (T) to the tank (26);
Fluid leakage may occur during these ope-
rations.
D disconnect the following hydraulic fluid piping from
the emergency steering pump:
--- intake (27) from the tank;
--- delivery (22) to the steering---tipping valve;
D remove the intake piping (21) from the tank to the
main pump;
Fluid leakage may occur during these ope-
rations.
D unscrew the retaining screws and disconnect the
hydraulic fluid piping support bracket (30);
46 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

276C05013

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 47

18 14
17

12

15
13

276C05014

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
48 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

FWD

D Disconnect the transmission shafts respectively:

A. from engine to gearbox;
B. from gearbox to front half---shafts;
C. from gearbox to intermediate journal;
D using suitable lifting gear, apply the chains to the
group brackets and bring them into tension, check-
ing that the load is evenly distributed and that the
group does not tend too much toward any one side;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 49

D remove the ground cable (A) from the right ---side
front support bracket;
D remove the screws (arrow) fastening the elastic
mountings.
Check that all connections and pipes are
disconnected and all fastening clamps re-
moved.
D carefully lift the group, removing it from above.
D rest the group on a suitable support to prevent it
from falling;
D remove the filter support bracket and the emergen-
cy steering valve;
D remove the front and side transmission support
brackets.
Replacement
Replace the group following the instructions in reverse
order, and in particular:
D check the gearbox elastic mountings: if deterio-
rated, replace them;
D check the integrity of connector pipes and joints;
D check the transmission oil level and, if necessary,
top up the level or refill following the instructions pro-
vided in the relative Chapter.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
50 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

INSPECTION
Before starting any type of operation make Figure 38
sure all the necessary safety precautions
have been taken and fully explained to those
involved in the operations.
Read the instructions provided in SECTION
1 of this manual.
If in doubt, consult an expert.
Follow all the general recommendations for
correctly performing maintenance oper-
ations.

Preliminary operations
Proceed as follows:

Figure 37 Z7307031
D Remove the input flange fastening screws.
D Remove the input flange with an extractor.

. If the retarder is not to be dismantled, this

operation is unnecessary.
D Repeat the same operation for the rear output
flange.

Figure 39

Z7307030 Z7307032

D Fasten the transmission to the supporting tools: D Loosen the fastening screws, disassemble the
assembly trolley 5870 350 000 cover and remove the lubricant filter.
retainer 5870 350 071.
D Drain all lubricant oil.
D Detach all the hoses from the back of the gearbox.
D Remove the PTO engagement box.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 51

HYDRAULIC CONTROL UNIT D Loosen the fastening screws and separate the inter-
face plate, the seals and the intermediate plate from
Removal the valve assembly.
Proceed as follows:
Refit
Figure 40 Figure 43

Z7307033
D Loosen the fastening screws and remove the hy-
draulic unit.

Figure 41

Z7307036
D Install two M6 guide screws and fit the first seal on
the valve assembly.
Be careful to use the right seal.

Figure 44

Z7307034
D Detach the hoses from the pipe plate.
D Loosen the fastening screws, then separate the
pipe plate, the seals and the intermediate plate from
the gearbox.

Figure 42

Z7307037
D Fit the filters (6) in the respective seats in the inter-
mediate plate.
Z7307035 The filters must face upwards towards the
pipe plate.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
52 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

D Fit the intermediate plate with filters on the valve as- Figure 47
sembly.

Figure 45

Z7307040
D Fit new O---rings to the union joints (1 to 6), install
them on the pipe plate and tighten to the specified
torque.
D Fit a new O---ring on the screw cap (7), install it on
the pipe plate and tighten to the specified torque.

Figure 48

Z7307038
D Fit the second seal on the valve assembly.

Figure 46

Z7307039
D Fit the interface plate on the valve assembly, then re-
move the guide screws and tighten the fastening
screws to the specified torque.
D Fit new O---rings on the screw caps (8) and tighten Z7307041
them to the specified torque. D Install two M8 guide screws and fit the following
items on the gearbox in the order given below:
(1) first seal;
(2) intermediate plate;
(3) second seal.
Be careful to use the right seal.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 53

Figure 49 LOCK---UP CLUTCH VALVE (WK)

Removal and disassembly

Proceed as follows:

Figure 52

Z7307042
D Fit the pipe plate, then remove the guide screws and
tighten the fastening screws to the specified torque.

Figure 50
Z7307045
D Remove the hoses.
D Loosen the fastening screws and separate the com-
plete fastening plate from the bracket.
D Loosen the fastening screws and separate the com-
plete WK valve from the fastening plate.
D Loosen the fastening screws and separate the sole-
noid valve from the WK valve.
D Remove the components of the valve and fastening
plate.

Assembly and refit

Proceed as follows:
Z7307043
D Install 2 M6 guide screws. Figure 53
D Fit the seal.

Figure 51

Z7307046
D Fit setscrew (1) on the fastening plate and apply
LOCTITE 649.
Z7307044 D Fit new O---rings and install the union joints (2) on
D Fit the valve assembly and tighten the fastening the fastening plate.
screws (M6 x 105: 2x; M6 x 80: 21x) to the specified
torque, after removing the guide screws.
Take careful note of the position of the 2 side
fastening screws (M6 x 105).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
54 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Figure 54 Figure 55

Z7307048
D Fit the seal and the complete WK valve on the plate
and tighten the fastening screws to the specified
torque.

Figure 56

Z7307047

Install the components of the WK valve body in the

order given.
(1) Solenoid valve
(2) Fastening screw + spring washer (2)
(3) WK valve
(4) Piston
(5) Shim rings
(6) Compression springù
(7) Retainer Z7307049
(8) Union joint D Fit the plate complete with WK valve on the gearbox
bracket and tighten the screws to the specified
Fit a new O---ring on the joint (8).
torque.
The lock---up clutch control pressure (12 +
2 bar) is determined by the shim rings (5,
trial value, 6 elements 0.5 mm thick each)
and the retainer (7, trial thickness 3.0 mm)
Install the retainer (7) with the stepped sur-
face side facing the compression spring.
D Fit the solenoid valve on the WK valve and tighten
the fastening screws to the specified torque.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 55

GEARBOX AND GEAR DISASSEMBLY

Converter and converter bell D Loosen the screws fastening the oil supply flange
Proceed as follows: cover and remove it.

Figure 57 Figure 60

Z7307050
D Loosen the screws fastening the retarder to the con-
276C05016
verter bell. D Remove the oil supply flange from the converter bell
Mark the relative positions of the retarder with tool 5870 000 089.
and the bell.
Figure 61

Figure 58

Z7307054
D Remove the converter relief valve.
276C05015
D Lift the retarder, complete with converter, from the Figure 62
converter bell with a suitable lifting device and tools
5870 204 002.

Figure 59

276C05017
D Loosen the screws fastening the converter bell to
the gearbox.
Z7307052 D Separate the converter bell from the gearbox with a
suitable lifting device and tools 5870 204 002.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
56 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

AN input shaft Figure 65

Figure 63

Z7307058
D Remove the components of the converter reserve
Z7307056 pressure reduction valve.
D Remove the shim ring (1) and both rectangular (1) Screw cap
seals (2) from the bell. (2) Spring
(3) Piston
Figure 64
Figure 66

Z7307059
D Remove the complete input shaft from the gearbox,
and then from the lubricating pump.

Z7307057

D Turn the bell upside down, then push the input shaft
out of the straight ---tooth drive gear bearings, taking
care not to drop the gear and the bearing inner ring
on the gearbox side (B).
D Remove the bearing inner ring from the input shaft
on the converter side (A).
Take care not to lose the two pins (detail) in
the transversal hole in the input shaft.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 57

Lubricating pump Central splitter lock device

Figure 67 Figure 69

Z7307060 Z7307062
D Turn the gearbox upside down. D Loosen the fastening screws.
D Loosen the fastening screws and remove both D Remove the lock device using a pinch bar, tapping
flanges securing the pump to the gearbox. the device with a plastic hammer to make the de-
tachment easier.
Figure 68
Intermediate shaft

Figure 70

Z7307061
D Loosen the fastening screws, then remove the lubri-
cating pump with tool 5870 000 089.
Z7307063

. Tap the surface of the gearbox with a plastic D Remove the sealing cover and loosen the fastening
screw.
hammer to make the extraction procedure
easier. Figure 71

Z7307064
D Turn the gearbox upside down.
D Remove the intermediate shaft with tool 5870 650
014.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
58 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Rear cover Central splitter

Figure 72 Figure 74

Z7307065 Z7307067
D Position the gearbox with the rear cover facing up- D Loosen the fastening screws and remove the cen-
wards. tral splitter metal guard.
D Loosen the fastening screws, then remove the KV/
K1 shaft rear bearing cover with tools 5870 650 014 Figure 75
and 5870 204 069.
D In the same way, remove the cover covering the rear
bearings of shafts KR/K2 and K4/K3.

. Mark the assembly position for the rear

bearing covers.

Figure 73

Z7307068
D Remove the splitter from its housing in the gearbox
with a suitable lifting device.

Figure 76

Z7307066
D Apply two tools 5870 204 005 (pressure screws).
D Loosen the fastening screws then, acting on the
pressure screws, remove the rear cover from the
gearbox with a suitable lifting device.

. Tap the output shaft with a plastic hammer to

make the extraction procedure easier.

Z7307069
D Remove the plate and disassemble the bearing
outer ring.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 59

Multiple-- disk clutches Power takeoff shaft

Figure 77 Figure 79

Z7307072
D Remove the stop ring (1) and the adjustment shims
(2).

Figure 80

Z7307070
D Remove the shafts K4/K3, KR/K2 and KV/K1 with
tools 5870 204 002 and a suitable lifting device.

. Lift shaft KR/K2 slightly and move it to one

side (arrow) when disassembling shaft
K4/K3.
(1) Clutch shaft KV/K1
(2) Clutch shaft KR/K2
Z7307073
(3) Clutch shaft K4/K3
D Lift the shaft with a pinch bar until the bearing outer
Figure 78 ring is free.

Figure 81

Z7307071
D Remove the gear from the previously removed inter-
Z7307074
mediate shaft.
D Lower the shaft and extract it sideways.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
60 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Figure 82 CLEANING, INSPECTING AND CHECKING

Cleaning components

. All components must be clean to allow an ef-

fective inspection. During assembly, do not
let dust and foreign bodies inside the trans-
mission. Even the smallest particles can
damage accurately mated components.
Use petroleum based solvents for cleaning
only, with the exception of benzene and de-
rivatives. Solvents such as trichlorethylene,
benzol, acetone and all aromatic products
may damage polyacrylic rubber seals.
Z7307075 Accurately clean all removed parts. Follow the precau-
D Remove the outer ring of the bearing (converter tions below:
side) with tools 5870 300 007 and 5870 300 003. D Accurately clean the guards, inside and out, to allow
checking and to prevent dirt from penetrating in-
Transmitter disassembly side;
D use only solvent to clean the clutch plates. Clean all
Figure 83 other metal transmission components perfectly with
solvent or steam. Do not use caustic soda based
solutions for steam cleaning;
D dry all components with compressed air, except for
the bearings. Apply grease to steam cleaned com-
ponents immediately after drying;
D clean oil pipes by passing a piece of soft wire in both
direction and washing with solvent. Dry the pipes
with compressed air;
Never dry the bearings by turning them with
compressed air. A bearing, which turns very
fast, without being adequately lubricated,
may deteriorate very quickly.
D used bearings must be perfectly washed with sol-
vent; if the bearings are very dirty or full of hardened
grease, submerge in solvent before cleaning;
D clean bearings correctly during disassembly/as-
sembly for maximum duration;

Z7307076

D Remove the sensors given below.

(1) output shaft rpm sensor
(2) turbine rpm sensor
(3) central shaft rpm sensor
(4) engine rpm sensor

. The figure illustrates the position of the sen-

sors

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5
INSPECTING AND CHECKING
Guards and machined surfaces
Inspect borings and assembly surfaces for traces of
wear, scratches and grooves; eliminate scratches and
burring with sandpaper; replace deeply scratched or
grooved parts;
check all oil pipes; eliminate obstructions with either a
jet of compressed air or by passing a smooth wire in
both directions of the pipe. Rinse with cleaning solvent;
check threading, rectify damaged threads with a used
tap of the required size;
replace boxes or other castings which are cracked or
grooved due to excessive wear;
check all oil circuits in the control distributor and main
casing, looking for porosity, broken seats, cracks, de-
posits of dirt and surface defects;
check seal resting surfaces for deformation or surface
defects.
Bearings and axial shims
Check all bearings for notches, pricking, scratches or
excessive wear. Replace the parts which are faulty or
whose operation is irregular after cleaning and lubrica-
tion;
inspect the bearings, which present notches, burring,
ovalisation, sharp edges or traces of overheating; re-
place the damaged components;
inspect the end of stroke shims that may be deformed,
scratched, worn or burred. replace any faulty or worn
parts.
O-- rings and seals
Check the piston rings and the lip seals for notches,
cuts, tears, cracks or deformation. A deteriorated seal
may indicate the presence of faults in piston grooves or
corresponding surface. These faults will damage the
new seal.
Replace the seals and the O---rings.
Gears, grooves and threaded parts
Check gears for localised wear, pricking, burring or
broken teeth: replace the gear if faults are found;
check that the grooves are not deformed, chipped or
burred. Replace the gear if faults are found;
check for burring and damaged threads; replace the
damaged parts.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
AUTOMATIC TRANSMISSION 61
Rings and springs
Check for pricking, deformation or excessive wear on
rings. Replace the snap ring if any fault is found;
look for traces of overheating, permanent deformation
or wear due to friction on parts next to the springs. Re-
place the spring if any fault is found.
Clutch plates
Check the plates looking for encrusted metallic par-
ticles, very pricked, excessively worn, excessively tap-
ered, cracked, deformed or damaged grooves. Re-
place the damaged plates.
GENERAL ASSEMBLY STANDARDS
Lubricants used for assembly
Hold parts provisionally in place during assembly by
means of low fusion point oil soluble grease (Vaseline).
Never use fibrous, insoluble or vegetable
based products in any point of the trans-
mission.
Clutches and pistons
Soak each clutch plate in transmission fluid for at least
two minutes.
Before final assembly, apply plenty of transmission fluid
in the piston cavity.
Fit the clutch plates so that they are all directed the
same way.
Lip seals
Make sure that the spring lip side is actually on the side
of the oil to be contained (towards the inside of the box):
apply high temperature resistant grease inside the seal
to protect it during shaft assembly and ensure lubrica-
tion at the beginning of operation.
Roller bearings
Heat the bearing on an electrical radiating plate or in an
oil bath (maximum temperature of approximately 90°C)
to fit it on the shaft. Fit the bearing at the press.
Warm the bearings for the amount of time
necessary to obtain adequate dilatation.
Shrink-- fitting
Shrink ---fitting can be carried out by respectively heat-
ing and cooling the two parts. The female part can be
heated in an oven or oil bath (maximum temperature of
approximately 140°C, with the exception of bearings)
and the male part can be cooled in dry ice.
62 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

DISMANTLING AND REASSEMBLY OF MAIN UNITS

Clutch shaft K4/K3 Figure 86

. The references given in square brackets

refer to plate 1 (see following pages), which
illustrates all the components of the
clutches under examination.

Dismantling
Proceed as follows:

Figure 84

Z7307079
D Remove the straight spur gear [30].

Figure 87

Z7307077
D Secure the shaft in the vice using tool 5870 654 022.

Figure 85

Z7307080
D Extract the inner ring of the taper roller bearing [31]
using tools 5873 002 001 and 5873 012 012.

Figure 88
Z7307078
D Starting from clutch K3, use tool 5870 971 002 to ex-
tract the straight roller bearing [34].

Z7307081
D Remove the snap ring [10].
D Remove the end plate [11] and the set of K3 clutch
plates.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 63

Plate 1: clutch shaft K4/K3

Z7307082

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
64 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Figure 89 Figure 92

Z7307083 Z7307086
D Work from the opposite side and loosen ring nut D Remove the preload adjustment ring [26] of taper
[28] with tool 5870 401 115. bearings [25].
The ring nut is locked with thread locker. Figure 93
Heat the threading to about 120 °C before
unscrewing to avoid damage.

Figure 90

Z7307087
D Extract the inner ring of the taper roller bearing [25]
using tool 5870 971 002.

276C005019 Figure 94
D Extract the inner ring of the taper roller bearing [27]
using tools 5873 011 012 and 5873 001 000.

Figure 91

Z7307088
D Remove the snap ring [10].
D Remove the terminal plate [11] and the set of K4
clutch plates.
Z7307085 D Remove the shaft from the support tool.
D Extract the straight spur gear [24] with tool 5870 971
003.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 65

Figure 95 Reassembling
Proceed as follows:

Figure 97

Z7307091
Z7307089 D lubricate and fit the 0---rings [8] and [9] to the K3
clutch piston.
D Preload the compression spring [12] with tool 5870
345 072. Figure 98
D Use a screwdriver to remove the snap ring [15], then
release the spring load and remove the thrust ring
[14], the spring and the resting ring [13].

Figure 96

Z7307092
D Secure the shaft in the vice using tool 5870 654 022.
D Insert the piston of clutch K3 until it touches the bot-
tom, making sure it is straight.
Z7307090 Pay attention to the installation position of
D Use compressed air to remove the piston [7]. the piston.

Make sure the piston is held securely to

avoid injury.
D Remove O---rings [8] and [9] from the piston and
O---ring [2] from the shaft.
D Proceed in the same way for the clutch K3 compo-
nents.
Check and inspect all components accord-
ing to the instructions given in the relevant
chapter.
Replace the O---rings and seals.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
66 AUTOMATIC TRANSMISSION SECTION 5
Figure 99
Z7307093
D Insert resting ring [13] and compression ring [12].
D Position the thrust ring [14] on the compression ring
with the chamfer facing upwards.
D Position the snap ring [15].
D Remove the shaft from the support tool.
Figure 100
Z7307094
D Preload the compression spring with tool 5870 345
072.
D Push the snap ring in the circular groove, then re-
lease the spring load and remove the tool.
D Proceed in the same way for the K4 clutch compo-
nents.
D Secure the shaft in the vice using tool 5870 654 022.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
Figure 101
Z7307095
D Install the set of K4 clutch plates in the order given
in plate 2 (see following pages).
. To ensure that the resulting measurements
are correct, do not lubricate the plates.
D Insert the end shim [11] and secure it with snap ring
[10].
Figure 102
Z7307096
D Fit a centesimal dial gauge with its probe on the ter-
minal plate.
D Apply a force of 100 N and reset the gauge.
D Use compressed air to move the piston the length
of its stroke and check that the end play is within the
specified range.
K4 clutch end play: 2.2 – 2.4 mm
D If this is not so, correct the value by changing the
first internal plate and/or the snap ring.
D After adjusting the play between plates, remove the
plates, lubricate them with the specified lubricant
and then refit.
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 67

D Install the set of K3 clutch plates in the order given Figure 104
in plate 3 (see following pages).

. To ensure that the resulting measurements

are correct, do not lubricate the plates.
D Insert the end shim [11] and secure it with snap ring
[10].
D Check that the end play is within the specified range
as indicated for clutch K3.
K3 clutch end play version A: 2.6 --- 2.8 mm
K3 clutch end play version B: 2.2 --- 2.4 mm
D If this is not so, correct the value by changing the
first internal plate and/or the snap ring.
D After adjusting the play between plates, remove the
plates, lubricate them with the specified lubricant Z7307098
and then refit. D Fit a centesimal dial gauge with its probe on the
edge of the gear.
Figure 103 D Apply a force of 50,000 N and reset the gauge.
D Check that the end play is within the specified range
of values by levering with a bar.
bearing end play: 0.025±0.025 mm
D If this is not so, correct the value with a spacer of a
different thickness.
D Dismantle the unit.
D Check that the shaft is positioned so that the K4
clutch is facing upwards.

Wear protective gloves when handling hot

components.

Figure 105
Z7307097
D Temporarily assemble the bearings inside the
straight spur gear in the order given.
(1) bearing inner ring
(2) bearing outer ring
(3) spacer (trial value s = 5.4 mm)
(4) straight spur gear

Z7307099
D Heat the inner ring of the first internal bearing [25]
and fit it so that it touches the shoulder.
D Fit the spacer [26] with the oil groove facing up-
wards.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
68 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Plate 2A: clutch K4 -- Version A (12 surfaces)

Z73A7100

N. Description Quantity Thickness (mm) Remarks

1 Drum 1
2 Piston 1
3 Outer plate 2 1.85 coated on one side
4 Outer plate 5 2.5 coated on both sides
5 Inner plate 5 3.5
6 Inner plate 1 from 2.5 to 4.0 variable for play adjustment
7 Snap ring 1 from 2.55 to 3.10 variable for play adjustment
8 Terminal plate 1

Clutch end play: 2.2 --- 2.4 mm.

Install the outer plates (3) so that the uncoated surface is facing towards the piston and the terminal
plate respectively.
The side of the respective clutches can be recognised by the length of the drum.
K4 = X (short side of drum)
K3 = Y (long side of drum)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 69

Plate 2B: clutch K4 -- Version B (10 surfaces)

Z73B7100

N. Description Quantity Thickness (mm) Remarks

1 Drum 1
2 Piston 1
3 Outer plate 2 1.85 coated on one side
4 Outer plate 4 2.5 coated on both sides
5 Inner plate 6 3.5
6 Inner plate 1 from 2.5 to 4.0 variable for play adjustment
7 Snap ring 1 from 2.55 to 3.10 variable for play adjustment
8 Terminal plate 1

Clutch end play: 2.2 --- 2.4 mm.

Install the outer plates (3) so that the uncoated surface is facing towards the piston and the terminal
plate respectively.
The side of the respective clutches can be recognised by the length of the drum.
K4 = X (short side of drum)
K3 = Y (long side of drum)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
70 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Plate 3A: clutch K3 -- Version A (18 surfaces)

Z73A7101

N. Description Quantity Thickness (mm) Remarks

1 Drum 1
2 Piston 1
3 Outer plate 2 1.85 coated on one side
4 Outer plate 8 2.5 coated on both sides
5 Inner plate 3 2.5
6 Inner plate 5 3.0
7 Inner plate 1 from 2.5 to 4.0 variable for play adjustment
8 Snap ring 1 from 2.55 to 3.10 variable for play adjustment
9 Terminal plate 1

Clutch end play: 2.6 --- 2.8 mm.

Install the outer plates (3) so that the uncoated surface is facing towards the piston and the terminal
plate respectively.
The side of the respective clutches can be recognised by the length of the drum.
K4 = X (short side of drum)
K3 = Y (long side of drum)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 71

Plate 3B: clutch K3 -- Version B (14 surfaces)

Z73B7101

N. Description Quantity Thickness (mm) Remarks

1 Drum 1
2 Piston 1
3 Outer plate 2 1.85 coated on one side
4 Outer plate 6 2.5 coated on both sides
5 Inner plate 6 3.5
6 Inner plate 1 from 2.5 to 4.0 variable for play adjustment
7 Snap ring 1 from 2.55 to 3.10 variable for play adjustment
8 Terminal plate 1

Clutch end play: 2.2 --- 2.4 mm.

Install the outer plates (3) so that the uncoated surface is facing towards the piston and the terminal
plate respectively.
The side of the respective clutches can be recognised by the length of the drum.
K4 = X (short side of drum)
K3 = Y (long side of drum)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
72 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Figure 106 Figure 109

Z7307102 Z7307105
D Fit the straight spur gear so that the splined hub D Remove the shaft from the support tool.
mates with all the K4 clutch plates. D Settle the unit with a load of about 100,000 N.

Figure 107 Figure 110

Z7307103 Z7307106
D Heat the inner ring of the second internal bearing D Refit the shaft on the support tool.
[25] and fit it so that it touches the spacer. D Apply LOCTITE 262 thread locker, then fit the ring
D Heat the inner ring of the shaft taper roller bearing nut on the K4 clutch side.
on K4 clutch side [27], then fit it to point of contact. D Tighten the ring nut to the specified torque using
tool 5870 401 115.
Figure 108
Figure 111

Z7307104
D Turn the shaft upside down, then heat the inner ring Z7307107
of the shaft taper roller bearing on K3 clutch side D Fit the outer ring of the taper roller bearing [32] in the
[31], then fit it to point of contact. K3 straight spur gear, and make sure it is fully in.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 73

Figure 112 Clutch shaft KR/K2

. The references given in square brackets

refer to plate 4 (see following pages), which
illustrates all the components of the
clutches under examination.

Dismantling
Proceed as follows:

Figure 114

Z7307108
D Fit the straight spur gear so that the splined hub
mates with all the K3 clutch plates.

Figure 113

Z7307110
D Secure the shaft in the vice using tool 5870 654 022.
D Loosen the ring nut [42] using tool 5870 401 099.
The ring nut is locked with thread locker.
Heat the threading to about 120 °C before
unscrewing to avoid damage.
Z7307109
D Heat the roller bearing, then fit it fully in. Figure 115
D Fit the inner ring of the taper roller bearing [32] in the
K3 straight spur gear.
D Check operation of the clutches K3 and K4 with
compressed air.
D If the components are fitted correctly, you should
clearly hear the clutches opening and closing.
D Insert the rectangular seals [2] at the end of the
shaft on the K3 clutch side.

Z7307111
D Extract the inner ring of the taper roller bearing [41]
using tools 5873 002 001 and 5873 012 018.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
74 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Plate 4: clutch shaft KR/K2

Z7307112

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 75

Figure 116 Figure 118

Z7307113 Z7307115
D Remove the shaft from the support tool. D Extract the inner ring of the taper roller bearing [40]
D Remove the shaft from the straight spur gear – using tools 5873 002 001 and 5873 012 019.
clutch K2 using a press.
Figure 119
Support the shaft during dismantling as it is
heavy.
D Collect the bearing inner ring [38] from the gear.
D Refit the shaft on the support tool.

Figure 117

Z7307116
D Remove the snap ring [13].
D Remove the terminal plate [14] and the set of K2
clutch plates.

Figure 120
Z7307114
D Remove the preload adjustment ring [39] of taper
bearings [38] and [40].

Z7307117
D Turn the shaft upside down.
D Loosen the ring nut [33] using tool 5870 401 099.
The ring nut is locked with thread locker.
Heat the threading to about 120 °C before
unscrewing to avoid damage.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
76 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Figure 121 Figure 123

Z7307118
D Remove the inner ring of the taper roller bearing [32]
using tools 5873 002 001 and 5873 002 044.
D Use an extractor to remove the bevel gear [28].
D Collect the bearing inner ring [31] from the gear.
D Remove the preload adjustment rings [29] of taper
bearings [30] and [31].
Figure 122
Z7307120
D Remove the inner ring of the taper roller bearing [30]
using tools 5873 002 001 and 5873 002 023.
D Remove the shaft from the support tool.
D Follow the instructions given for the K4/K3 shaft and
preload the compression spring [15] with tool 5870
345 072.
D Use a screwdriver to remove the snap ring [18], then
release the spring load and remove the thrust ring
[17], the spring and the resting ring [16].

Figure 124

Z7307119
D Remove the snap ring [13].
D Remove the terminal plate [14] and the set of KR
clutch plates. Z7307121
D Use compressed air to remove the piston [8].

Make sure the piston is held securely to

avoid injury.
D Remove O---rings [11] and [9] from the piston and
O---ring [2] from the shaft.
D Proceed in the same way for the clutch KR compo-
nents.
Check and inspect all components accord-
ing to the instructions given in the relevant
chapter.
Replace the O---rings and seals.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 77

Reassembling Figure 127

Proceed as follows:

Figure 125

Z7307122
D Lubricate and fit the 0---rings [11] and [9] to the K2
clutch piston.
D Secure the shaft in the vice using tool 5870 654 022.
D Insert the piston of clutch K2 until it touches the bot-
tom, making sure it is straight.
Pay attention to the installation position of
the piston.
Figure 126
Z7307124
D Preload the compression spring with tool 5870 345
072.
D Push the snap ring in the circular groove, then re-
lease the spring load and remove the tool.
D Proceed in the same way for the KR clutch compo-
nents.
D Secure the shaft in the vice using tool 5870 654 022.
Figure 128

Z7307123
D Insert resting ring [13] and compression ring [12].
D Position the thrust ring [14] on the compression ring
with the chamfer facing upwards.
D Position the snap ring [15].
D Remove the shaft from the support tool.
Z7307125
D Install the set of KR clutch plates in the order given
in plate 5 (see following pages).
. To ensure that the resulting measurements
are correct, do not lubricate the plates.
D Insert the end shim [14] and secure it with snap ring
[13].

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
78 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Figure 129 Figure 130

Z7307126 Z7307127
D Fit a centesimal dial gauge with its probe on the ter- D Position the KR clutch bevel gear on the bearing
minal plate. inner ring [30] using a suitable support (arrow).
D Apply a force of 100 N and reset the gauge.
D Use compressed air to move the piston the length Figure 131
of its stroke and check that the end play is within the
specified range.
KR clutch end play: 2.8 ---3.0 mm
D If this is not so, correct the value by changing the
first internal plate and/or the snap ring.
D After adjusting the play between plates, remove the
plates, lubricate them with the specified lubricant
and then refit.
D Install the set of K2 clutch plates in the order given
in plate 6 (see following pages).

. To ensure that the resulting measurements

are correct, do not lubricate the plates.
D Insert the end shim [14] and secure it with snap ring Z7307128
[13]. D Insert the two spacers (trial value s1 = 3.0 mm and
D Check that the end play is within the specified range s2 = 3.10 mm).
as indicated for clutch KR. D Fit the bearing inner ring [31].
K2 clutch end play version A: 2.6 --- 2.8 mm
K2 clutch end play version B: 2.2 --- 2.4 mm
D If this is not so, correct the value by changing the
first internal plate and/or the snap ring.
D After adjusting the play between plates, remove the
plates, lubricate them with the specified lubricant
and then refit.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 79

Plate 5A: clutch KR -- Version A (24 surfaces)

Z73A7129

N. Description Quantity Thickness (mm) Remarks

1 Drum 1
2 Piston 1
3 Outer plate 2 1.85 coated on one side
4 Outer plate 11 2.5 coated on both sides
5 Inner plate 11 2.5
6 Inner plate 1 from 2.5 to 4.0 variable for play adjustment
7 Snap ring 1 from 2.55 to 3.10 variable for play adjustment
8 Terminal plate 1

Clutch end play: 2.8 ---3.0 mm.

Install the outer plates (3) so that the uncoated surface is facing towards the piston and the terminal
plate respectively.
The side of the respective clutches can be recognised by the length of the drum.
K2 = X (short side of drum)
KR = Y (long side of drum)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
80 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Plate 5B: clutch KR -- Version B (20 surfaces)

Z73A7129

N. Description Quantity Thickness (mm) Remarks

1 Drum 1
2 Piston 1
3 Outer plate 2 1.85 coated on one side
4 Outer plate 11 2.5 coated on both sides
5 Inner plate 11 2.5
6 Inner plate 1 from 2.5 to 4.0 variable for play adjustment
7 Snap ring 1 from 2.55 to 3.10 variable for play adjustment
8 Terminal plate 1

Clutch end play: 2.8 ---3.0 mm.

Install the outer plates (3) so that the uncoated surface is facing towards the piston and the terminal
plate respectively.
The side of the respective clutches can be recognised by the length of the drum.
K2 = X (short side of drum)
KR = Y (long side of drum)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 81

Plate 6A: clutch K2 -- Version A (18 surfaces)

Z73A7130

N. Description Quantity Thickness (mm) Remarks

1 Drum 1
2 Piston 1
3 Outer plate 2 1.85 coated on one side
4 Outer plate 8 2.5 coated on both sides
5 Inner plate 3 2.5
6 Inner plate 5 3,0
7 Inner plate 1 from 2.5 to 4.0 variable for play adjustment
8 Snap ring 1 from 2.5 to 3.10 variable for play adjustment
9 Terminal plate 1

Clutch end play: 2.6 --- 2.8 mm.

Install the outer plates (3) so that the uncoated surface is facing towards the piston and the terminal
plate respectively.
The side of the respective clutches can be recognised by the length of the drum.
K2 = X (short side of drum)
KR = Y (long side of drum)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
82 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Plate 6B: clutch K2 -- Version B (14 surfaces)

Z73A7130

N. Description Quantity Thickness (mm) Remarks

1 Drum 1
2 Piston 1
3 Outer plate 2 1.85 coated on one side
4 Outer plate 6 2.5 coated on both sides
5 Inner plate 6 3.5
6 Inner plate 1 from 2.5 to 4.0 variable for play adjustment
8 Snap ring 1 from 2.55 to 3.10 variable for play adjustment
9 Terminal plate 1

Clutch end play: 2.2 --- 2.4 mm.

Install the outer plates (3) so that the uncoated surface is facing towards the piston and the terminal
plate respectively.
The side of the respective clutches can be recognised by the length of the drum.
K2 = X (short side of drum)
KR = Y (long side of drum)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 83

Figure 132 Figure 134

Z7307131 Z7307133
D Fit a centesimal dial gauge with its probe on the D Fit the straight spur gear so that the splined hub
edge of the gear. mates with all the KR clutch plates.
D Apply a force of 50,000 N and reset the gauge.
D Check that the end play is within the specified range Figure 135
of values by levering with a bar.
bearing end play: 0 --- 0.05 mm
D If this is not so, correct the value with a spacer of a
different thickness.
D Dismantle the unit.
D Check that the shaft is positioned so that the KR
clutch is facing upwards.

Figure 133

Z7307134
D Fit the selected spacers [29].
D Heat the inner ring of the bearing [31] and fit it so
that it touches the spacers.

Figure 136

Z7307132

Wear protective gloves when handling hot

components.
D Heat the inner ring of the bearing [30] and fit it so
that it touches the shoulder.

Z7307135
D Heat the inner ring of the shaft taper roller bearing
on KR clutch side [32], then fit it so it touches the
shoulder.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
84 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Figure 137 D Calculate thickness s of the spacer [39] with the fol-
lowing equation.
s = (A --- B) + (0.10 ± 0.05) mm
where:
A = distance between bearings in gear
B = distance between shoulders on shaft
s = spacer thickness
(0.10 ± 0.05) = specified end play.

. Choose the spacer with the most appropri-

ate thickness.
D Dismantle the unit.
D Check that the shaft is positioned so that the K2
clutch is facing upwards.
Z7307136
D Position the K2 clutch dual straight gear on the inner Figure 140
ring of bearing [40].

Figure 138

Z7307139

Wear protective gloves when handling hot

Z7307137 components.
D Fit the bearing inner ring [38]. D Heat the inner ring of the bearing [38] and fit it so
that it touches the shoulder.
Figure 139
Figure 141

Z7307138
D Measure value A. Z7307140
D Measure value B. D Fit the K2 clutch dual spur gear so that the splined
hub mates with all the K2 clutch plates.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 85

Figure 142 Figure 145

Z7307141 Z7307144
D Fit the selected spacer [39]. D Refit the shaft on the support tool.
D Heat the inner ring of the bearing [40] and fit it so D Apply LOCTITE 262 thread locker, then fit the ring
that it touches the spacer. nut on the K2 clutch side.
D Tighten the ring nut to the specified torque using
Figure 143 tool 5870 401 099.

Figure 146

Z7307142
D Heat the inner ring of the shaft taper roller bearing
on K2 clutch side [41], then fit it so it touches the Z7307145
shoulder. D Apply LOCTITE 262 thread locker, then fit the ring
nut on the KR clutch side.
Figure 144 D Tighten the ring nut to the specified torque using
tool 5870 401 099.
D Check operation of the clutches KR and K2 with
compressed air.
D If the components are fitted correctly, you should
clearly hear the clutches opening and closing.
D Insert the rectangular seals [2] at the end of the
shaft on the K2 clutch side.

Z7307143
D Remove the shaft from the support tool
D Settle the unit with a load of about 100,000 N.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
86 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Clutch shaft KV/K1 Figure 149

. The references given in square brackets

refer to plate 7 (see following pages), which
illustrates all the components of the
clutches under examination.

Dismantling
Proceed as follows:

Figure 147

Z7307148
D Remove the K1 clutch straight spur gear complete
with external ball bearing using the tool 5870 971
003.
D Remove the bushing.
D Remove the internal ball bearing from the shaft.
Both ball bearings must be replaced if any
damage occurs.

Figure 150
Z7307146
D Secure the shaft in the vice using tool 5870 654 022.
D Loosen the ring nut [43] using tool 5870 401 099.
The ring nut is locked with thread locker.
Heat the threading to about 120 °C before
unscrewing to avoid damage.

Figure 148

Z7307149
D Remove the snap ring [16].
D Remove the terminal plate [18] and the set of K1
clutch plates.

Z7307147
D Extract the inner ring of the taper roller bearing [42]
using tools 5873 001 000 and 5873 001 023.
D Remove the spacer [8].

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 87

Plate 7: clutch shaft KV/K1

Z7307150

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
88 AUTOMATIC TRANSMISSION SECTION 5
Figure 151
Z7307151
D Turn the shaft upside down.
D Loosen the ring nut [38] using tool 5870 401 115.
The ring nut is locked with thread locker.
Heat the threading to about 120 °C before
unscrewing to avoid damage.
Figure 152
Z7307152
D Remove the inner ring of the taper roller bearing [37]
using tools 5873 001 000 and 5873 001 034.
D Use an extractor to remove the bevel gear [33].
D Collect the bearing inner ring [34] from the gear.
D Remove the preload adjustment ring [35] and
spacer [36] of taper bearings [34].
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
Figure 153
Z7307153
D Remove the inner ring of the taper roller bearing [34]
using tools 5873 001 000 and 5873 001 020.
D Remove the shaft from the support tool.
D Follow the instructions given for the K4/K3 shaft and
preload the compression spring [19] with tool 5870
345 072.
D Use a screwdriver to remove the snap ring [23], then
release the spring load and remove the thrust ring
[22], the spring and the resting ring [21].
Figure 154
Z7307154
D Use compressed air to remove the piston [10].
Make sure the piston is held securely to
avoid injury.
D Remove O---rings [14] and [50] from the piston.
D Proceed in the same way for the K1 clutch compo-
nents.
D Remove the O---rings [2] from the shaft.
Check and inspect all components accord-
ing to the instructions given in the relevant
chapter.
Replace the O---rings and seals.
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 89

Reassembling Figure 157

Proceed as follows:

Figure 155

Z7307155
D Lubricate and fit the 0---rings [12] and [13] to the
K1clutch piston.
D Secure the shaft in the vice using tool 5870 654 022.
D Insert the piston of clutch K1 until it touches the bot-
tom, making sure it is straight.
Pay attention to the installation position of
the piston.
Figure 156
Z7307157
D Preload the compression spring with tool 5870 345
072.
D Push the snap ring in the circular groove, then re-
lease the spring load and remove the tool.
D Proceed in the same way for the KV clutch compo-
nents.
D Secure the shaft in the vice using tool 5870 654 022.
Figure 158

Z7307156
D Insert resting ring [21] and compression ring [20].
D Position the thrust ring [22] on the compression ring
with the chamfer facing upwards.
D Position the snap ring [23].
D Remove the shaft from the support tool.
Z7307158
D Install the set of KV clutch plates in the order given
in plate 8 (see following pages).
. To ensure that the resulting measurements
are correct, do not lubricate the plates.
D Insert the end shim [17] and secure it with snap ring
[15].

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
90 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Figure 159 Figure 160

Z7307159 Z7307160
D Fit a centesimal dial gauge with its probe on the ter- D Position the KV clutch bevel gear on the bearing
minal plate. inner ring [34] using a suitable support (arrow).
D Apply a force of 100 N and reset the gauge.
D Use compressed air to move the piston the length Figure 161
of its stroke and check that the end play is within the
specified range.
KV clutch end play: 2.8 -- 3.0 mm
D If this is not so, correct the value by changing the
first internal plate and/or the snap ring.
D After adjusting the play between plates, remove the
plates, lubricate them with the specified lubricant
and then refit.
D Install the set of K1 clutch plates in the order given
in plate 9 (see following pages).

. To ensure that the resulting measurements

are correct, do not lubricate the plates.
D Insert the end shim [18] and secure it with snap ring Z7307161
[16]. D Insert the ring and the spacer (trial value s = 1.7
D Check that the end play is within the specified range mm).
as indicated for clutch KV. D Fit the bearing inner ring [34].
K1 clutch end play version A: 2.6 -- 2.8 mm
K1 clutch end play version B: 2.2 -- 2.4 mm
D If this is not so, correct the value by changing the
first internal plate and/or the snap ring.
D After adjusting the play between plates, remove the
plates, lubricate them with the specified lubricant
and then refit.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 91

Plate 8A: clutch KV -- Version A (24 surfaces)

Z73A7162

N. Description Quantity Thickness (mm) Remarks

1 Drum 1
2 Piston 1
3 Outer plate 2 1.85 coated on one side
4 Outer plate 11 2.5 coated on both sides
5 Inner plate 11 2.5
6 Inner plate 1 from 2.5 to 4.0 variable for play adjustment
7 Snap ring 1 from 2.55 to 3.10 variable for play adjustment
8 Terminal plate 1

Clutch end play: 2.8 ---3.0 mm.

Install the outer plates (3) so that the uncoated surface is facing towards the piston and the terminal
plate respectively.
The side of the respective clutches can be recognised by the length of the drum.
K1 = X (short side of drum)
KV = Y (long side of drum)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
92 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Plate 8B: clutch KV -- Version B (20 surfaces)

Z73A7162

N. Description Quantity Thickness (mm) Remarks

1 Drum 1
2 Piston 1
3 Outer plate 2 1.85 coated on one side
4 Outer plate 9 2.5 coated on both sides
5 Inner plate 7 3.5
6 Inner plate 2 4.0
7 Inner plate 1 from 2.5 to 4.0 variable for play adjustment
8 Snap ring 1 from 2.55 to 3.10 variable for play adjustment
9 Terminal plate 1

Clutch end play: 2.8 ---3.0 mm.

Install the outer plates (3) so that the uncoated surface is facing towards the piston and the terminal
plate respectively.
The side of the respective clutches can be recognised by the length of the drum.
K1 = X (short side of drum)
KV = Y (long side of drum)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 93

Plate 9A: clutch K1 -- Version A (18 surfaces)

Z73A7163

N. Description Quantity Thickness (mm) Remarks

1 Drum 1
2 Piston 1
3 Outer plate 2 1.85 coated on one side
4 Outer plate 8 2.5 coated on both sides
5 Inner plate 8 2.5
6 Inner plate 1 from 2.5 to 3.5 variable for play adjustment
7 Snap ring 1 from 2.10 to 2.50 variable for play adjustment
8 Terminal plate 1

Clutch end play: 2.6 --- 2.8 mm.

Install the outer plates (3) so that the uncoated surface is facing towards the piston and the terminal
plate respectively.
The side of the respective clutches can be recognised by the length of the drum.
K1 = X (short side of drum)
KV = Y (long side of drum)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
94 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Plate 9B: clutch K1 -- Version B (14 surfaces)

Z73B7163

N. Description Quantity Thickness (mm) Remarks

1 Drum 1
2 Piston 1
3 Outer plate 2 1.85 coated on one side
4 Outer plate 8 2.5 coated on both sides
5 Inner plate 8 3.5
6 Inner plate 1 from 2.5 to 3.5 variable for play adjustment
7 Snap ring 1 from 2.10 to 2.50 variable for play adjustment
8 Terminal plate 1

Clutch end play: 2.2 --- 2.4 mm.

Install the outer plates (3) so that the uncoated surface is facing towards the piston and the terminal
plate respectively.
The side of the respective clutches can be recognised by the length of the drum.
K1 = X (short side of drum)
KV = Y (long side of drum)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 95

Figure 162 Figure 164

Z7307164 Z7307166
D Fit a centesimal dial gauge with its probe on the D Fit the KV clutch bevel gear so that the splined hub
edge of the gear. mates with all the KV clutch plates.
D Apply a force of 50,000 N and reset the gauge.
D Check that the end play is within the specified range Figure 165
of values by levering with a bar.
bearing end play: 0 -- 0.05 mm.
D If this is not so, correct the value with a spacer of a
different thickness.
D Dismantle the unit.
D Check that the shaft is positioned so that the KV
clutch is facing upwards.

Figure 163

Z7307167
D Heat the inner ring of the bearing [34] and fit it so
that it touches the spacers.

Figure 166

Z7307165

Wear protective gloves when handling hot

components.
D Heat the inner ring of the bearing [34] and fit it so
that it touches the shoulder. Z7307168

D Fit the ring [35] and the spacer [36] selected. D Heat the inner ring of the shaft taper roller bearing
on KV clutch side [37], then fit it so it touches the
shoulder.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
96 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

. Before fitting, align and centre the set of K1 Figure 169

clutch plates with the spur gear.

Figure 167

Z7307171

Wear protective gloves when handling hot

components.
Z7307169
D Install the snap ring. D Heat the internal ball bearing and fit it in until it
D Insert the bushing with side collar on terminal sur- touches the shoulder.
face (arrow) facing the snap ring. Install the ball bearing with the lubrication
groove (arrow) facing upwards.
Figure 168
Figure 170

Z7307170
D Fit the external ball bearing until it touches the bush-
Z7307172
ing
D Insert the bushing.
Install the ball bearing with the lubrication
groove (arrow) facing downwards. Figure 171
Apply the pad only to the bearing outer ring.

Z7307173
D Heat the complete spur gear [40] and fit it so that the
splined hub mates with all the K1 clutch plates.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 97

Figure 172 Power takeoff shaft

Removal
Proceed as follows:

Figure 174

Z7307174
D Install the spacer [8].
D Heat the inner ring of the shaft taper roller bearing
on K1 clutch side [42], then fit it so it touches the
shoulder.
D Remove the shaft from the support tool. Z7307176
D Settle the unit with a load of about 100,000 N as de- D Remove the inner ring of the taper roller bearing
scribed for the KV/K2 clutch shaft. using tools 5873 001 000 and 5873 001 027.
D Remove the inner ring of the opposite bearing with
Figure 173
a press.
The shaft and the gear cannot be separated
(hot---coupling).

Assembly
Proceed as follows:

Figure 175

Z7307175
D Refit the shaft on the support tool.
D Apply LOCTITE 262 thread locker, then fit the ring
nut on the K1 clutch side.
D Tighten the ring nut to the specified torque using
tool 5870 401 099.
D Apply LOCTITE 262 thread locker, then fit the ring
nut on the KV clutch side.
D Tighten the ring nut to the specified torque using Z7307177
tool 5870 401 099. D Fit the inner ring on the converter side with a press.
D Check operation of the clutches KV and K1 with D Fit the inner ring of the opposite bearing with a
compressed air. press.
D If the components are fitted correctly, you should
clearly hear the clutches opening and closing.
D Insert the rectangular seals [2] at the end of the
shaft on the K1 clutch side.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
98 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Central splitter Figure 179

Removal
Proceed as follows:

Figure 176

Z7307181
D Separate the train carrier from the external crown
gear with a press.

Figure 180
Z7307178
D Remove the bushing.
D Remove the snap ring and extract the rear output
shaft from the train carrier.

Figure 177

Z7307182
D Remove the inner ring of the taper roller bearing on
rear side from the external crown gear using tools
5873 004 001 and 5870 014 014.
D If necessary, remove the outer ring of the taper roller
bearing on front side from the external crown gear.
Z7307179
D Remove the snap ring securing the sun gear. Figure 181

Figure 178

Z7307183
D Use a drift to push the lockpins of a pair of side pin-
Z7307180 ions inwards.
D Remove the snap ring securing the external crown
flange.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 99

Figure 182 Assembly

Proceed as follows:

Figure 184

Z7307184
D Remove the pins from the side pinions then remove
the side pinions.
D If necessary, remove the other side pinions in the Z7307186
same way. D Insert the front output shaft and fit the snap ring.
D Collect up all the internal components of each side D Position the sun gear with the stepped side facing
pinion. the snap ring. Then insert the front output shaft until
the snap ring clicks into position.
Figure 183 D Fit the sun gear snap ring from the opposite side.

Figure 185

Z7307185
D Push the front output shaft until the sun gear can be
removed.
D Remove the snap ring (1) and separate the output
shaft from the train carrier.

Z7307187

(1) thrust washer

(2) needles ( 30 )
(3) spacer
(4) pin
(5) side pinion gear

D Grease the components for easy assembly, then fit

them.
D Position the crown wheel gear, align it and secure it
with the pin.
D Check that the centre oil hole for the side pinion pin
is facing forwards.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
100 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Figure 186 Figure 189

Z7307188 Z7307191
D Fix the pin with the lockpin by inserting it to the pin’s
half---way point. Wear protective gloves when handling hot
components.
Figure 187
D Heat the inner ring of the taper roller bearing on the
rear side and fit it so that it touches the shoulder.

Figure 190

Z7307189
D Fit the train carrier in the external crown gear.
D If it has been removed, fit the outer ring of the bear-
ing in the external crown gear until it touches. Z7307192

Figure 188 D Fit the rear output shaft and secure it with the snap
ring.

Figure 191

Z7307190

Wear protective gloves when handling very

Z7307193
cold components.
D Fit both rectangular seals.
D Cool the external crown flange in dry ice, and fit it up D Fit the bushing.
to point of contact.
D Fit the snap ring.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 101

AN input shaft Figure 195

Removal
Proceed as follows:

Figure 192

Z7307197
D Use an extractor to remove the inner ring of the taper
roller bearing and the pump drive bushing from the
shaft.
Z7307194 Figure 196
D Remove the upper snap ring.
D Separate the straight spur gear from the shaft.
D Remove the lower snap ring.

Figure 193

Z7307198
D Collect up the play adjustment rings.
D Separate the inner ring of the bearing from the bush-
ing.
D Remove the bushing inner rings.
Z7307195
D Extract the inner ring of the taper roller bearing from
the spur gear using tools 5873 001 000 and 5873
001 020.

Figure 194

Z7307196
D Loosen the screw securing the drive bushing.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
102 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Assembly Figure 199

Proceed as follows:

Figure 197

Z7307201
D Fit the selected spacer.
D Fit the bearing inner ring and bushing to point of
Z7307199 contact.
D Fit the internal seals. D Fit the tightening disk on the inside and tighten the
D Fit the drive key. securing screw to the specified torque.
D Fit the ring (1.90 mm thick) and the bearing inner
ring to point of contact. Figure 200

Figure 198

Z7307202
D Fit the inner ring of the taper roller bearing on the
gear to point of contact using a press.

Figure 201

Z7307200
D Measure value A.
D Measure value B.
D Calculate thickness s of the spacer with the follow-
ing equation:
s = (A -- B) + (0.50) mm
where:
A = distance between bearing ring and drive bushing
B = distance between bushing shoulders and bear-
ing on shaft.
s = spacer thickness
(0.50) = specified end play.
Z7307203
. Choose the spacer with the most appropri- D Fit the lower snap ring on the shaft.
ate thickness. D Insert the gear and fit the upper snap ring.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 103

Pressure pump Assembly

Removal Proceed as follows:
Proceed as follows: Figure 205
Figure 202

276C05018

Z7307204
D Insert the rotor unit with the tooth edge chamfer
facing downwards, then install the housing cover.
D Remove the needle bearing retainer.
D Fit the needle bearing retainer to the point of contact
D Remove the external O---ring.
using tool 5870 058 041, making sure the reinforced
Figure 203 shell faces the tool.
D Fit the external O---ring.
Figure 206

Z7307205
D Extract the inner ring of the taper roller bearing
using tools 5870 300 017 and 5870 300 009, then re-
Z7307208
move the spacer.
D Fit the spacer.
Figure 204 D Fit the taper roller bearing outer ring.

Z7307206
D Loosen the fastening screws and dismantle the
pump.
The whole pump must be replaced if there
are signs of wear in the housing or cover.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
104 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

GEARBOX AND GEAR ASSEMBLY Intermediate shaft gear

Proceed as follows:
Power takeoff shaft
Figure 209
Proceed as follows:
Figure 207

Z7307209
D Fit the bearing outer ring (A) on converter side to
point of contact.
D Insert the power takeoff shaft in its housing. Fit the
outer ring (B) of the opposite bearing to point of con-
tact.
Figure 208

Z7307211

D Assemble the bearing rings inserting a spacer with

Z7307210
D Fit play adjustment spacers (1) and check that the
end play is within the specified range of values.
pwr takeoff shaft end play: 0.05-- 0.10 mm
D If this is not so, correct the value by removing or ad-
ding spacers.
D Once the play has been adjusted, lock the shaft with
the retainer snap ring (2).
D Turn the gearbox upside down.
D Insert a seal in the housing hole with its concave
side facing downwards.
D Apply LOCTITE 262 sealant.
thickness s = 7.95 mm, then measure distance A.
D Fit the taper bearing rings on the gear without the
spacer, position the pre---assembled gear on a flat
surface and measure value B.
D Check that the end play is within the specified va-
lues by applying the following equation:
0.00 mm < (A -- B) < 0.05 mm
D If it is not, increase or decrease the thickness s of the
spacer as necessary.
. Choose the spacer with the most appropri-
ate thickness.
D Position the gear complete with bearing inner rings
in its seat.
. The intermediate shaft pin can only be fitted
if the clutches and relative covers have been
installed (see following pages).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 105

Clutch shafts Figure 213

Proceed as follows:
Figure 210

Z7307215
D Check the position of the intermediate shaft and
Z7307212 correct if necessary.
D Fit the bearing outer rings of shafts KV/K1 (1), KR/K2 Figure 214
(2) and K3/K4 (3) in the housing holes to point of
contact.
Figure 211

Z7307216
D Fit the tool 5870 345 033 to hold the K3 clutch
straight spur gear in position and prevent the plates
Z7307213 falling out.
D Position the KV/K1 clutch with an eyebolt and a suit- D Slightly lift the KR/K2 clutch shaft, move it to one
able lifting device. side and position clutch shaft K3/K4.
D Remove the tool.
Figure 212

Z7307214
D Position the KR/K2 clutch in the same way.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
106 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Figure 215 Gearbox cover

Proceed as follows:
D Fit any covers, plugs and unions that have been re-
moved.
Apply LOCTITE 262 sealant where necess-
ary.
Install a new seal where necessary

Differential bearing preload

Figure 218

Z7307217
D Heat the inner ring of the taper roller bearing on the
front side and fit it so that it touches the gearbox
shoulder.
D Fit the metal guard.
Figure 216

Z7307220
D Measure value A.
Figure 219

Z7307218
D Insert the differential in its seat with a suitable lifting
device.
Figure 217

Z7307221
D Install the bearing outer ring.
D Measure value B.
Use rods and calibrated reference blocks.
Exert an even pressure on the bearing outer
ring.
Measure at various points and calculate the
average.
D Calculate thickness s of the spacer with the follow-
Z7307219 ing equation:
D Fit the central splitter metal guard and tighten the s = (A -- B) + (0.05 ± 0.05) mm
fastening screws. where:
A = distance between bearing seat shoulder and
gearbox cover mating surface.
B = distance between bearing ring resting surface
and the gearbox mating surface.
s = spacer thickness
(0.05 ± 0.05) = specified end play.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 107

Figure 220 D Insert both cylindrical pins (1) and (2) to point of
contact.
D Insert the roller pin (3) so it is flush to the edge.
Figure 223

Z7307222
D Fit the selected spacer.
D Fit the taper roller bearing outer ring.
Figure 221

Z7307225

D Fit the splitter output shaft ball bearing on rear side

to point of contact.
D Fit a spacer with thickness s = 4.0 mm.
D Fit another spacer so that the bearing has no play.
D Fit the snap ring.
Figure 224

Z7307223
D Apply LOCTITE 574 sealant on the assembly sur-
face making sure it is applied inside the holes (de-
tail).
D Install two guide screws.
D Position the cover on the gearbox to point of contact
using a suitable lifting device and eyebolts.
Figure 222

Z7307226
D Fit the sealing ring with tool 5870 048 228.

Z7307224
D Tighten the cover fastening screws to the specified
torque.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
108 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

K3/K4 clutch shaft bearings preload Figure 227

Figure 225

Z7307227
D Install the bearing inner ring.
D Measure value A.
Z7307229
Figure 226 D Fit the selected spacer.

Wear protective gloves when handling hot

components.
D Heat the inner ring of the bearing and fit it so that it
touches the shoulder.
D Fit the O---ring.
D Heat the internal diameter of the cover (straight
roller bearing seat).
Figure 228

Z7307228
D Measure value B.
Use rods and calibrated reference blocks.
Exert an even pressure on the bearing inner
ring.
Measure at various points and calculate the
average.
D Calculate thickness s of the spacer with the follow-
ing equation:
s = (A -- B) + (0.025 ± 0.025) mm
where:
A = distance between bearing ring resting surface
and the gearbox mating surface.
B = distance between bearing seat shoulder and
cover mating surface.
s = spacer thickness Z7307230
(0.025 ± 0.025) = specified end play.
D Lubricate and centre the rectangular seals.
. Choose the spacer with the most appropri- D Fit the cover in accordance with the installation posi-
ate thickness. tion indicated by the notches.
D Tighten the fastening screws to the specified
torque.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 109

KR/K2 clutch shaft bearing preload Figure 231

Figure 229

Z7307233

Z7307231 D Fit the selected spacer.

D Install the bearing outer ring. D Fit the O---ring.
D Measure value A. Figure 232
Figure 230

Z7307232
D Measure value B.
Exert an even pressure on the bearing outer
ring.
Measure at various points and calculate the
average. Z7307234
D Lubricate and centre the rectangular seals.
D Calculate thickness s of the spacer with the follow- D Fit the cover in accordance with the installation posi-
ing equation: tion indicated by the notches.
s = (A -- B) + (0.025 ± 0.025) mm D Tighten the fastening screws to the specified
where: torque.
A = distance between bearing ring resting surface and
the gearbox mating surface.
B = distance between bearing seat shoulder and cover
mating surface.
s = spacer thickness
(0.025 ± 0.025) = specified end preload.

. Choose the spacer with the most appropri-

ate thickness.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
110 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

KV/K1 clutch shaft bearing preload Figure 235

Figure 233

Z7307237

Z7307235 D Fit the selected spacer.

D Install the bearing outer ring. D Fit the bearing outer ring.
D Measure value A. D Fit the O---ring.

Figure 234 Figure 236

Z7307236
D Insert the ring in the cover, with the chamfer facing
downwards.
D Measure value B.
Use rods and calibrated reference blocks.
Exert an even pressure on the bearing outer Z7307238
ring. D Lubricate and centre the rectangular seals.
Measure at various points and calculate the D Fit the cover in accordance with the installation posi-
average. tion indicated by the notches.
D Calculate thickness s of the spacer with the follow- D Tighten the fastening screws to the specified
ing equation: torque.
s = (A -- B) + (0.025 ± 0.025) mm
where:
A = distance between bearing ring resting surface
and the gearbox mating surface.
B = distance between bearing seat shoulder ring and
cover mating surface.
s = spacer thickness
(0.025 ± 0.025) = specified axial preload.

. Choose the spacer with the most appropri-

ate thickness.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 111

Intermediate shaft pin Figure 239

Proceed as follows:
Figure 237

Z7307241
D Remove the tool 587 204 022.
Z7307239 Apply LOCTITE 243. Tighten the fastening screw to the
D Turn the gearbox upside down. specified torque.
D Centre the secondary shaft gear.
D Fit the tool 587 204 022. Central splitter lock device
Proceed as follows:
Figure 238
Figure 240

Z7307240
Z7307242
Wear protective gloves when handling very D Fit a flat seal.
cold components. D Heat the internal ball bearing.
D Carefully insert the lock device and position it flat
D Cool the pin in dry ice.
against the seal.
D Fit the pin to point of contact.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
112 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Figure 241 Pressure pump

Proceed as follows:
Figure 244

Z7307243
D Fit both dowels (arrows).
D Tighten the fastening screws to the specified Z7307246
torque.
Wear protective gloves when handling very
Figure 242
cold components.
D Cool the pump in dry ice.
D Fit the pump in accordance with the installation
position indicated by the notches.
Figure 245

Z7307244
D Fit the sealing ring with tool 5870 048 228.
Figure 243

Z7307247
D Fit the O---ring.
D Fit the pump flange.

Z7307245
D Insert the perforated disk (1) and the filter (2) in the
housing hole.
D Temporarily close the hole with plug (3) until the hy-
draulic pipes are fitted.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 113

Figure 246 Covers

Proceed as follows:
Figure 248

Z7307248
D Tighten the screws fastening the pump and the
pump flange to the specified torque. Z7307250
Apply LOCTITE 243 sealant to the two D Insert the sealing covers with the concave side
screws indicated by the arrow. facing downwards so that they are flush with the
housing surface.
D Apply LOCTITE 262 sealant to the edges of the
Power takeoff flange
covers.
Proceed as follows:
AN input shaft
Figure 247
Proceed as follows:
Figure 249

Z7307249
D Fit the O---ring.
D Fit the power takeoff flange.
D Tighten the flange fastening screws to the specified
torque.

Z7307251
D Fit the input shaft to point of contact.
Take care that the drive key is inserted cor-
rectly in the relevant seat in the pressure
pump.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
114 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

AN input shaft bearing end play Figure 252

Figure 250

Z7307254

Z7307252 D Fit the selected spacer.

D Fit the flat seal. D Fit the bearing outer ring.
D Install the bearing inner ring.
D Measure value A. Converter bell
Proceed as follows:
. After measuring remove the input shaft.
Figure 253
Figure 251

Z7307255
D Fit the bearing outer ring on drive gear shift side to
Z7307253
point of contact, then fit the inner ring of the same
D Measure value B.
bearing.
Use rods and calibrated reference blocks.
Figure 254
Exert an even pressure on the bearing outer
ring.
Measure at various points and calculate the
average.
D Calculate thickness s of the spacer with the follow-
ing equation:
s = (A -- B) + (0.025 ± 0.025) mm
where:
A = distance between bearing ring resting surface
and the gearbox mating surface.
B = distance between bearing seat shoulder and
converter bell mating surface.
s = spacer thickness
(0,025 ± 0.025) = specified end play. Z7307256
D Insert the straight drive gear from the side with the
. Choose the spacer with the most appropri- long collar facing upwards, then centre it.
ate thickness.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 115

Figure 255 Drive gear bearings end play

Figure 257

Z7307257
D Insert both roller pins (diameter 2.5 mm and 1.5 Z7307259
mm) in the input shaft hole (detail) and make sure D Measure value A.
they are flush with the edge.
Figure 258
Wear protective gloves when handling very
cold components.
D Cool the input shaft with dry ice and insert it to point
of contact.
Figure 256

Z7307260
D Fit the flat seal.
D Measure value B.
Use rods and calibrated reference blocks.
Exert an even pressure on the bearing inner
ring.
Z7307258
Measure at various points and calculate the
average.
Wear protective gloves when handling hot
components. D Calculate thickness s of the spacer with the follow-
ing equation:
D Heat the inner ring of the drive gear bearing on the
s = (A -- B) + (0.05 ± 0.02) mm
converter side and fit it so that it touches the con-
where:
verter bell shoulder.
A = distance between bearing ring resting surface
and the converter bell mating surface.
B = distance between bearing seat shoulder and oil
supply flange mating surface.
s = spacer thickness
(0.05 ± 0.02) = specified end play.

. Choose the spacer with the most appropri-

ate thickness.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
116 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Figure 259 Figure 262

Z7307261 Z7307264
D Fit the needle bearing retainer to the point of contact
using tools 5870 260 002 and 5870 058 051, making Wear protective gloves when handling very
sure the reinforced shell faces the tool. cold components.
Figure 260 D Fit the oil supply flange in accordance with the in-
stallation position indicated by the notches.
Figure 263

Z7307262
D Fit the seal (1).
D Fit the converter relief valve (2). Z7307265
D Fit both rectangular seals in the input shaft splines D Fit the oil supply flange cover in accordance with the
(3). installation position indicated by the notches.
Figure 261 D Tighten the cover fastening screws (common to the
flange) to the specified torque.
Figure 264

Z7307263
D Cool the oil supply flange with dry ice.
D Fit the selected spacer, making sure it sticks with Z7307266
grease. D Insert the pin to point of contact.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 117

D Fit the components of the converter relief valve and Figure 267
tighten the screw cap to the specified torque.
D Fit two guide screws.
D Heat the converter bell housing hole on the gear-
box.
The following three operations must be per-
formed in quick succession to permit cor-
rect converter bell assembly.
Prepare all the necessary elements.

Figure 265

Z7307269
D Using a suitable lifting device, fit the converter bell
in accordance with the installation position indi-
cated by the notches.
Turn the input shaft slightly to make insertion
easier.
Protect the splines.

Figure 268

Z7307267
D Fit the input shaft to point of contact.
Take care that the drive key is inserted cor-
rectly in the relevant seat in the pressure
pump.

Figure 266
Z7307270
D Tighten the converter bell fastening screws to the
specified torque.
D Insert the O---ring in the converter bell.

Z7307268
D Fit the flat seal (1).
D Fit the O---ring (2) in the circular seat.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
118 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

Figure 269 Air gap adjustment

. The following procedure is valid for all gear-

box sensors.
Proceed as follows:
Figure 271

Z7307271
D Using a suitable lifting device, fit the converter re-
tarder unit in accordance with the installation posi-
tion indicated by the notches.
D Tighten the converter retarder unit fastening screws
to the specified torque.

Transmitters
Proceed as follows:
Figure 270

Z7307273

D Measure value A.
D Measure value B.
D Calculate thickness s of the spacer with the follow-
ing equation:
s = A -- (B + X) mm
where:
A = distance between sensor resting surface on
gearbox and tip of phonic wheel tooth.
B = distance between shoulder and end of sensor.
s = spacer thickness.
X = specified air gap:
sensor (1) :1.0+0.5 mm
sensor (2) :0.5+0.3 mm
sensor (3) :0.3 ± 0.1 mm
sensor (4) :0.5+0.3 mm

. Pay attention to the different air gap value.

Choose the spacer with the most appropri-
Z7307272
ate thickness.
D Fit the sensors given below.
(1) output shaft rpm sensor D Fit each sensor and tighten it/the fastening screws
(2) turbine rpm sensor to the specified torque.
(3) central shaft rpm sensor
(4) engine rpm sensor

. The figure illustrates the position of the sen-

sors

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 5 AUTOMATIC TRANSMISSION 119

Completion Lubricant filter

Proceed as follows:
Flanges
Figure 273
. The following procedure is valid for all gear-
box flanges.
Proceed as follows:
Figure 272

Z7307275
D Insert the filter in its housing.
D Lubricate the seal.
Figure 274

Z7307274
D Fit the flange to the shaft splined tang.
D Apply LOCTITE 574 sealant to the disk contact sur-
face.
D Fit the disk and secure it with the fastening screws.
D Tighten the screws to the specified torque.
D Secure the screws with the shakeproof plate.

Z7307276
D Fit the cover and secure it with the fastening screws.
D Tighten the screws to the specified torque.
D Fit the hydraulic control unit.
D all the oil pipes.
D Install all the hoses on the back of the gearbox.
D Fit the PTO engagement box.
D Remove the transmission from the supporting tools:

. The transmission has no lubricating oil.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
120 AUTOMATIC TRANSMISSION SECTION 5 ADT 25-30 TIER3

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For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 SECTION 6.1

FRONT AXLE --- DISC BRAKES

 ADT 25-30 TIER3 SECTION 6.1
CONTENTS
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Swinging fork type II . . . . . . . . . . . . . . . . . . . . . . . . . . 4
First reduction: bevel pair . . . . . . . . . . . . . . . . . . . . . . 5
Second reduction: hub and epicyclic train . . . . . . . 10
Brake pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . 15
Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Brake disc and caliper . . . . . . . . . . . . . . . . . . . . . . . . 15
Bevel gear (first reduction) . . . . . . . . . . . . . . . . . . . . 16
Epicyclic train and hub (second reduction) . . . . . . 17
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . 18
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Replacement of the brake pads . . . . . . . . . . . . . . . . 30
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . 32
Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
FRONT HUBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
FRONT HUB REMOVAL-- REFIT . . . . . . . . . . . . . . . 34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Reattachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
FRONT AXLE -- DISC BRAKES 1
Page
BRAKE CALIPER DETACHMENT--
REATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Detachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Reattachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
EPICYCLIC REDUCER OVERHAUL . . . . . . . . . . . . 37
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Inspection of the dismantled parts . . . . . . . . . . . . . . 43
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Epicyclic reduction gear seals and thread---stops
application and bearings scheme . . . . . . . . . . . . . . 44
Epicyclic reduction gear seals and thread---stops
application and bearings scheme . . . . . . . . . . . . . . 45
Planet ---wheel holding plate assembly . . . . . . . . . . 46
Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Hub bearing preload determination . . . . . . . . . . . . . 49
Concluding operations . . . . . . . . . . . . . . . . . . . . . . . . 53
FRONT DIFFERENTIAL OVERHAUL . . . . . . . . . . . 54
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Inspection of the disassembled parts . . . . . . . . . . . 58
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Diagram of bearings and the application of
thread---locks and distributor and differential
seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Diagram of the self---locking differential
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
BRAKE CALIPER OVERHAUL . . . . . . . . . . . . . . . . 74
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Inspection of the disassembled parts . . . . . . . . . . . 75
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
BRAKE DISC OVERHAUL . . . . . . . . . . . . . . . . . . . . 77
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

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For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 3

DESCRIPTION
The axle has independent wheels with double reduc- 1. Swinging fork
tion. 2. Left hub
The differential unit is composed of a box structure 3. Left axle shaft
which contains the cylindrical wheel transmission and 4. Differential and transfer case
the crown wheel and pinion with differential (first reduc- 5. Right axle shaft
tion). The structure is solidly connected to the automat- 6. Right hub
ic transmission box with a series of screws.

Figure 1

2
1

276C061D001

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
4 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Swinging fork type II

The axle is double reduction type with independent 1. Swinging fork
wheels. 2. Left hub
The differential unit consists of a box structure contai- 3. Left axle shaft
ning inside the cylindrical wheels transmission and the 4. Transfer case and differential
bevel pair with the differential (first reduction). The 5. Right axle shaft
structure is stiffly connected to the automatic transmis- 6. Right hub
sion box by screws.

Figure 2

276C061D001B

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 5

First reduction: bevel pair

The first reduction is obtained through the pinion---ring Legend (figure on next page)
bevel gear assembly (bevel pair) inside the differential.
The pinion shaft receives motion from the central dis- 1. Input shaft
tributor inside the automatic transmission. 2. Grooved sleeve
The shaft integral with the crown gear inside the central 3. External pinion bearing
distributor transmits the torque to a sleeve, that in its 4. Internal pinion bearing
turn is integral with the bevel pinion. 5. Bevel pinion
A seal ring keeps the differential lubrication separate 6. Ring bevel gear
from that of the transmission. 7. Crown bearing with right taper rollers
The pinion is supported by two taper roller bearings as- 8. Differential box
sembled in O arrangement with a preload that can be 9. Multiple disk clutch
adjusted by a spacer. The axial position of the pinion 10. Differential gear carrier shaft
can also be adjusted by shims. 11. Planetary gear
The box of the differential with ring bevel gear is sup- 12. Planet
ported by two tapered roller bearings assembled in X 13. Crown bearing with left taper rollers
arrangement with preload and axial position that can 14. Pinion axial position adjustment shim
be adjusted by shims. 15. Pinion bearing preload adjustment spacer

A: Section
B: Functional layout

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
6 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Figure 3

26912101

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 7

The differential is limited slip type.
It has a multiple disk clutch inserted between the differ-
ential gear box (train carrier) and the crown wheels on
each side.
The multiple disk clutch includes the external disks
connected to the differential gear box and internal disks
connected to the crown wheel gears by appropriate
pressure plates.
The internal disk friction surfaces have a patented mo-
lybdenum coating that ensures a constant friction coef-
ficient and thus holds the braking torque constant for
the whole useful life of the differential.
The thrust on the disks is ensured by the sloped con-
tact between the shaft and the pressure plate: therefore
a greater radial peripheral thrust on the train carrier
shaft (from the ring bevel gear) will cause a greater axial
thrust on the disks.
The thrust on the disks generates a stall torque that
acts on the crown wheel.

Figure 4

1731214

1. Crown wheel
2. Differential gear box
3. Differential cover
4. Crown wheel gear
5. Side pinion
6. Differential gear carrier shaft
7. Bevel pinion
8. Pressure plate (quantity: 2)
9. Multiple disk clutch --- external disk
10. Multiple disk clutch --- internal disk
11. Shoulder
12. Pressure plate rings sloped surfaces

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
8 FRONT AXLE -- DISC BRAKES SECTION 6.1
Operation
The driving torque coming from the propeller shaft is
transmitted by a universal joint to the bevel pinion.
From here the torque passes to the ring bevel gear,
which is integral to the differential gear box.
The differential is a gear for which the box represents
the train carrier, that carries the differential gear carrier
shafts and receives the driving torque, whereas the two
side gears, which represent the crown wheels, both of
which rotate, receive the driving torque and transmit it
to the axle shafts.
When both wheels are subject to the same stall torque
or have the same speed (vehicle being driven on a
straight road), the ring bevel gear and the differential
gear box rotate as one, transmitting the torque in equal
parts to the two crown wheels, and from here to the two
axle shafts, that rotate at the same speed: the wheels
transmit the same driving torque.
Figure 5
1731215
Right wheel with road grip the same as the left one
IN: driving torque input
DX: RH side: torque delivered 50% of total
SX: LH side: torque delivered 50% of total
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
Under these conditions there is no relative motion be-
tween the two crown wheels and therefore the side pin-
ions do not turn around their shaft which is integral to
the differential gear box.
When the resistance of one wheel is greater than that
of the other, or when the speed of the two wheels is not
the same (vehicle on a road with bends) the crown
wheel gears have a different rotation speed: the rele-
vant motion is permitted by the side pinions, that now
turn around their shafts in directions opposite to each
other.
Obviously at a lower crown wheel rotation speed the
transmitted driving torque is greater, and vice versa.
Therefore when the differential is operating, the wheel
with a lower speed can transmit a greater torque,
whereas the wheel with a higher speed can transmit a
lower torque.
Under certain conditions it may happen that the slower
wheel loses its grip completely, since the torque is ex-
ceeded that can be transmitted to the ground, and
therefore meets practically no resistance: in this case,
the standard differential causes the wheel that slips to
freewheel, and stops the wheel that still has grip: the
axle traction is reduced to nothing.
To avoid this problem the self---locking differential is
used, which can generate a stall torque on each crown
wheel, which is no longer free to rotate in relation to the
differential gear box, but is braked in proportion to the
torque that the differential is to transmit.
This stall torque , that depends on the thrust applied to
the multiple disk clutch, always has a fixed ratio with the
input torque, that is called the “locking ratio”.
The locking ratio is the maximum difference between
the transmittable torque on the two axle shafts, in per-
centage.
For example, with a locking ratio of 45%, 72.5% of the
driving torque may be transferred to a rear axle shaft
(instead of 50% as in normal cases), whereas the other
axle shaft only receives 27.5%.
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 9

If the two wheels do not have the same grip, the stall In fact, the multiple disk clutches automatically com-
torque generated by the multiple disk clutches partially pensate the grip variations of the wheels from the left
locks the crown wheel on the side with less grip and in- and right sides of the vehicle, without the need of any
creases the torque delivered by the crown wheel on the operation on the part of the driver. It is therefore pos-
side with stronger grip. In other words, the braking sible to apply a much higher driving force during the
torque replaces the reaction torque that is lacking on use of the vehicle, and avoid slipping when one of the
the side of the wheel with less grip. wheels runs on a surface with poor grip.
In this way, looking at the example given beforehand of
a wheel that loses grip, this can no longer freewheel
and therefore the other wheel will still be able to trans-
mit part of the driving torque, ensuring at least in part
the axle traction.

Figure 6

1731216

Right ---hand wheel with less grip than the left one (ex-
ample)

IN: driving torque input

DX: RH side: torque delivered 27,5% of total
SX: LH side: torque delivered 72,5% of total

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
10 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Second reduction: hub and epicyclic train

The second reduction is obtained by an epicyclical re- Legend (figure on following page)
duction unit with cylindrical wheels contained in the
wheel hub. 1. Epicyclic train upright
The hub is supported by two taper roller bearings (planet ---wheel holding plate)
mounted in O arrangement with a pre---load that can be 2. Thrust spacer (Version A)
adjusted by a ring nut. The side pinion gears rotate on 3. Planet ---wheel
pivoting roller bearings. 4. Epicyclic train fixed gear
5. Planet ---wheel pin
Operation 6. Unused
7. Adjustment ring nut
The driving torque coming from the differential is trans-
8. Epicyclic train crown wheel
mitted through a floating axle shaft to the crown gear
9. Hub
by means of a grooved shank.
10. Wheel fastening column
The four side pinion gears rotate in the opposite direc-
11. Brake caliper
tion to the crown gear, whereas the crown wheel is inte-
12. Brake disc
gral to the hub support and therefore does not turn.
13. Hub support
This makes the train carrier turn in the opposite direc-
14. Flange
tion to the side pinions, therefore in the same direction
15. Cardan joint flange
as the axle shafts.
16. Sealing ring
Since the train carrier is integral to the wheel hub, the
17. Ball bearing
wheel turns in the same direction as the axle shaft.
18. Sealing rings
19. Central retaining screw spacer ring
20. Internal conic roller bearing
21. External conic roller bearing
22. Axle shaft

A: Cross section
B: Functional diagram

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 11

VERSION A

Figure 7

276C061D008

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12 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

VERSION B

Figure 8

276C061D008B

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 13

Brake pad

Figure 9

2
4
3

12
11
10
5
9
8
7

276C062D009

1. Brake Pads
2. Caliper
3. Pin
4. Bleeder fitting
5. Brake control fitting
6. Cover
7. Cap
8. Cap gasket
9. Piston
10. Sealant ring
11. Piston gasket
12. Dust cover

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
14 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Page left intentionally blank

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 15

SPECIFICATIONS AND DATA

Hub
KESSLER R 81 (Hub) and ZF LK
Code
(front differential)

Type Independent, with double reduction

With limited slip

Central differential
Integrated in automatic transmission box

Pinion bearings 2 taper rollers mounted in O arrangement

Differential bearings 2 taper rollers mounted in X arrangement

Hub bearings 2 taper rollers mounted in X arrangement

Hub planet bearings 3 x 4 Pivoting barrel rollers

bevel gear pair 1 : 3.50

Reduction ratio wheel reducer 1 : 6.00

total 1 : 21.00

Autom. pinion transm. output shaft axial clearance 0.30 --- 0.50 mm (0.012 --- 0.020 in)

3.5 --- 4.5 Nm

Pinion bearings preload
(2.60 --- 3.30 ft lb (without seal rings)

Differential bearings preload 3.0 --- 4.0 Nm (2.20 --- 2.90 ft lb)

Bevel gear pair clearance 0.20 --- 0.30 mm (0.008 --- 0.012 in)

Self---locking disks axial clearance 0.20 --- 0.80 mm (0.008 --- 0.032 in)

Drive axle---reduction carrier axial clearance

0.30 --- 0.70 mm (0.012 --- 0.028 in)
(Version A)

8.00 --- 14.00 Nm

Hub bearings
(5.9 --- 10.3 ft (without seal rings))

Hub bearing preload determined by the ring nut tightening torque

1st tightening: 700---900 Nm then loosen

Ring nut tightening torque
2nd tightening: 450 Nm

Brake disc and caliper

Caliper CARLISLE M -- 4
Type Fixed
N. calipers per wheel 2
N. cylinders per caliper 2x2
New 17 mm
Brake pad thickness
Wear limit 3 ± 0.5 mm
Disc Fixed
Outer diameter 476 mm
Inner diameter 250 mm
New 19 mm
Thickness Wear limit 17 mm
Max roughness 1 mm

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
16 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Bevel gear (first reduction)

Figure 10

T269PT03

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 17

Epicyclic train and hub (second reduction)

Figure 11

276C061D002

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
18 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

TIGHTENING TORQUES

Figure 12

276C061D013A

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 19

TIGHTENING TORQUES

Figure 13

276C061014

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
20 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

TIGHTENING TORQUES

Figure 14

276C061D014B

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 21

TIGHTENING TORQUES

Figure 15

276C063D015

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22 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

EQUIPMENT
. The tools indicated in the following list should be requested from the Supplier (KESSLER + CO
GmbH & Co. KG).

TOOL CODE DESCRIPTION

038.586.0---2 Spanner for wheel safety nut

031.107.0---3 Seal ring sleeve driver

038.525.0---4 Seal ring sleeve driver

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 23

. The tools indicated in the following list should be requested from the Supplier (ZF GmbH).

TOOL CODE DESCRIPTION

Pinion/crown wheel --- spacer clearance

5870.351.016
adjustment device

Pinion/crown wheel --- clamping disk

5870.351.019
clearance adjustment device

Pinion/crown wheel --- keying disk clear-

5870.500.015
ance adjustment device

Pinion/crown wheel --- measuring shaft

5870.500.001
clearance adjustment device

Bearings--- guide external track assembly

5870.058.077
device

5870.204.040 Centring screws

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
24 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

TOOL CODE DESCRIPTION

5870.204.021 Centring screws

5870.048.227 Centring guide/pad for seal rings

5870.048.228 Centring guide/pad for seal rings

5870.053.024 Centring guide/pad for seal rings

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 25

DIAGNOSTICS

Axle
1. Continuous noise
2. Cornering noise
3. Alternating noise
4. Sharp bangs during acceleration or deceleration
5. Oil leak from the axle shafts

1 CONTINUOUS NOISE

Worn bearings. Replace them.

YES

NO

Gears damaged or worn. Replace them.

YES

NO

Lack of lubrication. Restore oil level.

YES

NO

Incorrect adjustment of the clearances. Adjust again

YES

2 CORNERING NOISE

Worn planet ---wheels or crown wheels. Replace.

YES

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 26 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

3 ALTERNATING NOISE

Wheel bearings with excessive clearance. Adjust the bearings.

YES

NO

Wheels mounted incorrectly. Disassemble and remount correctly.

YES

NO

Too little clearance in the bevel gear set. Adjust again.

YES

NO

Too much clearance in the bevel gear set. Adjust again.

YES

4 SHARP BANGS DURING

ACCELERATION OR DECELERATION

Incorrect gear train adjustment. Adjust again.

YES

NO

Pivot of the anchoring structure has too much Replace the parts of the articulated joint.
play. YES

NO

Loose fastening of the anchoring structure to Tighten the screws to the prescribed tightening
the chassis. YES torque.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 27

5 OIL LEAK FROM THE AXLE SHAFTS

Worn oil seals. Replace them.

YES

NO

Loose screws. Tighten the screws to the prescribed tightening

YES torque.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 28 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Brakes
1. Weak braking action
2. Unequal action of the brakes
3. Brakes that remain blocked

1 WEAK BRAKING ACTION

Worn pads. Replace them.

YES

NO

Brake discs dirty with lubricant. Clean the discs and replace the pads.
YES

NO

Worn brake discs. Replace them.

YES

NO

Defective hydraulic system See Section 10 --- HYDRAULIC SYSTEM.

YES

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 29

2 UNEQUAL ACTION OF THE BRAKES

Pads and/or discs dirty with lubricant. Clean the discs and replace the pads.
YES

NO

Non---approved/different pads on the two sides. Replace with approved pads.

YES

NO

Worn brake discs. Replace them

YES

NO

Defective hydraulic system. See Section 10 --- HYDRAULIC SYSTEM.

YES

3 BRAKES THAT REMAIN BLOCKED

Foreign bodies between the discs. Overhaul the brakes.

YES

NO

Defective hydraulic system. See Section 10 --- HYDRAULIC SYSTEM.

YES

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
30 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

MAINTENANCE
The braking system components are funda- Figure 17
mental for the safe use of the vehicle.
All inspection and replacement operations
must be performed following the
manufacturer’s maintenance schedule and
procedures.
All the maintenance operations must be per-
formed by specialized personnel which has
been suitably trained and equipped with the 3
proper tools.
Replacements must be made with original
spare parts or parts satisfying the same spe- 1
cifications.
The pads (friction material) that have burns,
localized wear or cracks absolutely must be
replaced. Do not use different brands of
pads on the same axle. 2
If topping up is necessary, the same fluid as
that contained in the tank must be used.

Replacement of the brake pads

Proceed as follows:
D detach the caliper following the instructions in the
relative chapter;

Figure 16

276C061D060

D unscrew both the retaining screws (1) and partially

slip off both the upper centering pins (2) so as to free
the eyelets of the pads (3);
D remove both the pads by slipping them off the upper
part of the caliper (arrow);

274A061010

D connect a tube to the bleeding valve (arrow) and ar-

range a suitable container to collect the fluid that
leaks out;
D place two soft slats between the pistons, then force-
fully spread the pads apart using a lever or large
screwdriver and at the same time open the bleeding
valve until the cylinders return as far as possible into
their seats ;
D close the bleeding valve and disconnect the tube;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 31

Remove the dirt using a NON ---metallic

brush and a vacuum cleaner.
Visually examine the dust covers, and check
that there is no seeping of hydraulic fluid.
If irregularities are found, proceed to the
brake caliper overhaul.

Figure 18

276C062D016

D mount the new pads by inserting them from the

upper part of the caliper (arrow), sliding them on the
disc surface and fitting them on the lower centering
pins (arrow);

Figure 19

276C061D061

D insert the centering pins (2) into the relative seats

and block them with the relative retaining screws
(1);
D proceed to the reattachment of the caliper following
the directions in the relative chapter.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
32 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

MAINTENANCE Changing the oil

Collect and dispose of used lubricants and
FRONT DIFFERENTIAL fluids, according to the laws in force.

Checking oil level Proceed as follows to drain the system:

Proceed as follows:
Figure 21
Figure 20

1
1

2 269NM221
D clean the cap area and open the level cap (1). Lubri-
cant should drip out of the hole;
D top up the level as shown in the following para-
graph, if required;
D close the filler cap and fasten at the specified
torque.
2 269NM221
D arrange a suitably sized container, clean the cap
area and remove the level cap (1);
D remove drain cap (2) and fully drain the oil;
D clean the drain caps. Check that the threading is in
good condition. Replace the seal and apply sealant
to both caps and close them at the specified torque.
Proceed as follows to fill the system:
D fill until oil spills out of the hole on the cap (1);
D replace the seal, apply sealant onto the cap and
close it at the specified torque;
D run a road test, check the cap level (1);
D if required, top up oil of the specified type until it
spills out of the hole. Repeat the road test and check
the level again.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 33

FRONT HUBS Changing the oil

Collect and dispose of used lubricants and

Checking oil level fluids, according to the laws in force
Proceed as follows:
Proceed as follows to drain the system:
Final reductions
Final reductions

Figure 22 Figure 23

1 1

276C062022
276C062020 D take the reference on the hub to horizontal position
D take the reference on a hub to horizontal position (see arrow);
(see arrow); D arrange a suitably sized container, clean the cap
D clean the cap area and open the level cap (1). Lubri- area and remove the cap (1) and the drain cap (2);
cant should drip out of the hole; drain all the lubricant.
D top up the level as shown in the following para- D clean the cap, check that the threading is in good
graph, if required; condition, replace the sealing ring with a new one
D close the filler cap. and close the drain cap.
D repeat the procedure for the other hub.
D arrange a suitably sized container, clean the cap
area and remove the cap (1) and the drain cap (2);
drain all the lubricant.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
34 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

FRONT HUB REMOVAL---REFIT

. Before starting any operation, make sure
that all the precautions have been taken and
all aspects regarding safety of the personnel
involved on the job have been made quite
clear.
Read the relevant instructions contained in
SECTION 1 of this handbook.
If in doubt ask someone who is more expert.
Comply to all the general recommendations
for correct execution of maintenance work.
Removal
Proceed as follows:
D bring the vehicle on a suitable flat, solid surface,
switch off the engine, remove the key from the igni-
tion switch, engage the parking brake and affix the
warning notices;
D deactivate the battery isolator or disconnect the bat-
tery terminals to prevent any risk of a short circuit;
D block articulation by means of the steering lock bar,
proceeding as indicated in SECTION 1;
D raise the vehicle so that the wheels are off the
ground, then place two supporting trestles under
the front chassis, without touching the suspension;
D place a suitable hydraulic supporting device under
the suspension, then sustain the suspension so as
to keep the shock absorbers compressed;
This operation facilitates the removal of the
axle shaft from the hub.
D disconnect the braking system hydraulic connector
(20) and plug it to prevent fluid leaks;
. Hydraulic oil leakage may occur during
these operations.
D remove the axle shafts metal protection following
the description in SECTION 8 --- SUSPENSIONS;
D disconnect the transmission axle shaft (18) from the
hub following the instructions in SECTION 7;
D lower the suspension until maximum extension per-
mitted by the retaining ropes;
D release the axle shaft from the cardan joint to facili-
tate access to the locking nuts of the hub;
D sling the hub using hooks and cables appropriate
for the size of the load and a suitable lifting device;
D remove all the locking nuts (15) fastening the hub to
fork, recovering the relative washers;
D carefully slip the hub (14) off.
Reattachment
Proceed to the reattachment by following the detach-
ment steps in the reverse order.
After the refit procedure, check the brakes
drive circuit following the indications in
SECTION 10.

. The following procedures relate to the side

where the operation takes place.
D remove the wheel following the instructions in SEC-
TION 9;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 35

Figure 24

276C061D027

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
36 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

BRAKE CALIPER DETACHMENT --- Figure 26

REATTACHMENT
Before performing any intervention, ensure
that all precautions have been taken and all
aspects clarified regarding the safety of per-
sonnel involved in the intervention.
Read the relative instructions provided in
SECTION 1 of this manual.
In case of doubt, consult a more experience
person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.
Detachment
Do as follows:
D bring the vehicle onto an appropriately solid flat sur-
face, shut off the engine, remove the key from the
ignition switch, engage the parking brake and affix
the indication signs;
D disconnect the battery---disconnect switch or dis-
connect the battery terminals in order to eliminate
any risk of short ---circuit;
D block the articulation by means of the steering lock
bar, operating as indicated in SECTION 1;
D block the rear wheels appropriately;
D use a hydraulic lift to raise the chassis until the rear
wheels are off the ground;
D disassemble the wheel concerned;
Figure 25
4 1
3
2
2
3
4
1
276C061D029
D disconnect the braking system hydraulic connector
(4) and plug it to prevent fluid leaks;
. Hydraulic oil leakage may occur during
these operations.
D support the caliper (2) appropriately, unscrew the
retaining screws (3) of the support bracket and re-
move the caliper complete with the bake pads.
Reattachment
Proceed to the reattachment by following the detach-
ment steps in the reverse order.
After reassembled, perform a bleeding of
the brake hydraulic circuit following the in-
structions in SECTION 10 --- HYDRAULIC
SYSTEM.

276C061D028

D insert appropriate support trestles under the axle,

then lower the chassis, resting the axle on the indi-
cated points (arrow) and remove the lift;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 37

EPICYCLIC REDUCER OVERHAUL

Before starting any operation, make sure
that all the precautions have been taken and
all aspects regarding safety of the personnel
involved on the job have been made quite
clear.
Read the relevant instructions contained in
SECTION 1 of this handbook.
If in doubt ask someone who is more expert.
Comply to all the general recommendations
for correct execution of maintenance work.

. Before proceeding, it is necessary to:

D drain the lubricant from the wheel hub
D drain the lubricant from the central differ-
ential
following the instructions provided in the
relative chapter.

. Before proceeding, the brake caliper must

be removed following the instructions in the
relative chapter.

Disassembly
Proceed as follows:

Figure 27

3 1

2
276C061D030

D mark the mutual position of the planet ---wheel hol-

ding plate and the hub;
D loosen and remove all the retaining screws (1);
D remove the planet ---wheel holding plate assembly
(2) and O---ring (3);
D VERSION A: Recover the thrust spacer ring (4);

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
38 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Figure 28 Figure 31

276C061D031
D VERSION A: Withdraw the axle shaft (1). 2

Figure 29 276C062032
D unscrew the setscrew (1) of the ring nut;
D remove the locking ring nut (2) of the internally too-
thed crown wheel.

The ring nut is locked with thread ---stops.

2 To prevent damage to the threading, heat to
approximately 120˚C before unscrewing.
1

276C061D031B
D VERSION B: Unscrew the screw (1) and remove the
disk (2).

Figure 30

276C061D031
D VERSION B: Withdraw the axle shaft (1).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 39

D using a suitable lifting device, carefully remove the Figure 34

complete hub from the hub support;
D place the hub vertically; 1

Figure 32

2
276C062D036

D unscrew the retain screws (1) and remove the brake

disck (2);
D if necessary remove the wheel fastening screws
from the hub;

1 Figure 35
276C062D033

D use a suitable extractor to remove the internally too- 1

thed crown wheel (1); 1
Figure 33 2

1 2

4
3
276C062D035

3 D VERSION A: Remove the two oil seal rings (1);

D use a suitable extractor to remove the outer race (2)
276C062D034
of the axle---side bearing (A) and the outer race (3)
D remove the retaining screws (1) and relative stop of the wheel---side bearing (B);
plates (2);
D separate the internally toothed crown wheel (3) from
the relative flange (4);
D using a suitable extractor, remove the inner race (5)
of the wheel---side bearing (B) from the crown wheel
flange;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
40 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Figure 36 Figure 38

3
276C062035B 276C061D040
D VERSION B: Remove the oil seal ring (1); D unscrew the retaining screws (1) and remove the
D with an appropriate puller remove the outer ring complete cardan joint support (2) from the hub sup-
(2)of the bearing on rear axle side (A) and the outer port (3);
ring (3) of bearing on wheel side (B);
Figure 39
Figure 37

276C061040B

Reach the fastening screws through the

2
1 hole (arrow) provided on the flange.
276C061D037

D remove the inner race (1) of the axle---side bearing

(A) and the spacer ring (2) from the hub;
The spacer ring is locked with sealant.
To avoid damaging it, before removing, heat
it to approx 120 ˚C.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 41

Figure 40 Figure 43

2 1

276C061D041A
D remove the elastic ring (1) and spacer (2), then use
a suitable extractor to remove the cardan joint flan-
ge (3) from the ball bearing (4) and flange (5);
Figure 41
274A062029
D place the planet ---wheel holding plate on a suitable
work surface;
D use a punch to push the retaining pin (1) down in the
pivot, freeing the pivot (2);
D extract the pivot (2) by pushing it towards the inside
of the planet ---wheel holding plate (arrow);
D remove the O---ring (3);
D extract the pin from the pivot.
. Do not push the pivot towards the outside of
the planet---wheel holding plate, otherwise
its seat may be damaged due to the differ-
ence between the internal and external di-
ameter of the pivot..

276C061042A

D VERSION A: Remove the sealing rings;

Figure 42

276C061D042B
D VERSION B: Remove the seal rings;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
42 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Figure 44

276C062038
D remove the planet wheel (1) and relative shim rings
(2);

Figure 45

274A062039
D remove the needle cages (arrow) from the planet ---
wheel;
D repeat the procedure for all the planet ---wheels.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 43

Inspection of the dismantled parts Reassembly

During reassembly, consider the following

Wheel hub
general observations:
D check the seats of the bearings: they must not have D heat, to 100˚C in the oven, the bearings
any deformations and/or ovalling; and rings to be mounted by pushing;
D check the condition of the bearings: replace them D carefully center and mount the sealing
if they have bluish halos, cracks and/or signs of rings and bearings with a suitable adju-
wear. ster;
D lubricate the ring nuts and bearings.
Axle shafts
D check the condition of the axle shafts: replace them
if they have deformations on the end grooves and/or
on the entire length.

Final reductions
D check the condition of the gear toothing: replace
them if they have pitting, cracks and/or cavities;
D verify the good operation of the planet ---wheels and
the roller bushings;
D check the threading for the bearing locking ring nut:
it must not have any dents, deformations and/or
jams.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
44 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Epicyclic reduction gear seals and thread-- stops application and bearings scheme

VERSION A

276C061D044A

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 45

Epicyclic reduction gear seals and thread-- stops application and bearings scheme

VERSION B

276C061D044B

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
46 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Planet-- wheel holding plate assembly Figure 47

Proceed as follows:
D position the planet ---wheel holding plate horizontal- 2
ly;

Figure 46

1
2

276C062052

D mount the planet ---wheel (1) complete with shim

274A062032
rings in the seat on the planet ---wheel holding plate;
D mount the needle cages inside the planet gear; Figure 48

1 274A062035
D insert the O---ring (1) in the seat of the planet ---wheel
holding plate;
D insert the pivot (2) of the planet ---wheel holding gear
so that the pin holes match up;
D or according to the versions;
D insert the pivot (2) of the planet ---wheel holding gear
up to the complete expulsion of the internal reten-
tion bush so that the pin holes match up;
Mount the pivot from the internal part of the
planet---wheel holding plate, otherwise its
seat may be damaged due to the pivot dia-
meter difference.
D mount the catch pin (3);
D repeat the procedure for all the planet ---wheels.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 47

Hub Figure 51
Proceed as follows:

Figure 49

3
2

1
276C062053

D place the hub vertically;

D using a suitable introducer, mount the outer race (1)
of the wheel---side conic roller bearing (B) and the
outer race (2) of the axle---side conic roller bearing
(A);
D mount the inner race (3) of the axle---side conic roller
bearing (A);

Figure 50
276C062054B
D VERSION B: With the appropriate tool, insert the
seal ring (1) in the seat, flush with the external rim
of the hub taking care that the orientation is correct
(detail);

Figure 52

276C061D054A
D VERSION A: With the appropriate tool, insert the
seal rings (1) into the seat on the hub taking care
that the orientation is correct (detail) and fill them
completely with lubricant grease for bearings (ar-
row);
1

276C062D055

D mount the disc (1) on the hub;

D mount retaining screws (2) and tighten.

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48 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Figure 53

3 1

276C062D066

D heat the spacer ring (1) and insert it completely on

the axle axis;
D using a suitable lifting device, support the hub as-
sembly in order to ensure its correct centering;
D introduce the hub assembly (2) on the end of the
hub support (3), placing the inner race of the axle---
side conic roller bearing (A) so that it rests against
the spacer ring;
During this operation, keep the hub parallel
to the axle axis.
Work with caution to avoid damaging the
sealing rings and the brake disc teeth.
Continue to support the hub assembly until
it is completely mounted.
D if removed, mount the stud bolts fastening the wheel
to the hub.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 49

Figure 54 Hub bearing preload determination

Proceed as follows:

Figure 56
4

2
2
3
276C062W067
D heat the inner race (1) of the wheel---side conic roller
bearing (B) and insert it until it rests against the gear
wheel flange;
D insert the gear wheel flange (2) onto the gear wheel
1
with internal toothing (3);
D mount the retention plates (4) and fix them with the
setscrews; 276C062069

Figure 55 D apply MOLYKOTE lubricant on the hub support

1 forth by striking it with a plastic hammer to
276C062W068
D mount the flange and internally toothed gear wheel
assembly (1) onto the hub until the two parts meet
the wheel---side conic roller bearing (B).
The lubrication oil passage hole on the gear
wheel flange is to face downwards.
threading and on the threading and contact area of
the locking ring nut;
D hand mount the ring nut (1) without tightening;
D tighten the locking ring nut to the prescribed tighte-
ning torque:
Locking ring nut tightening torque for bearings
Phase 1: 700-- 900 Nm
During the locking, rotate the hub back and
forth by striking it with a plastic hammer to
settle the bearings.
D unscrew the locking ring nut half a turn;
D tighten the locking ring nut to the prescribed tighte-
ning torque:
Locking ring nut tightening torque for bearings
Phase 2: 450 Nm
During the locking, rotate the hub back and
settle the bearings.
D after having adjusted the bearing preload, block the
locking ring nut with the relative setscrew (2);
If this is not possible, unscrew the ring nut
as much as needed in order to mount the
clamp screw.

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50 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

VERSION A Figure 59

Figure 57 3

2
276C061055A 276C061057
D fit the seal rings; D mount the complete cardan joint support (1) onto
D it the oil seal ring taking care with the indicated as- the hub (2) and screw on the retaining screws (3);
sembly direction (detail) and fill it completely with lu-
bricating grease for bearings; Figure 60

Figure 58

276C061040B

Reach the fastening screws through the

hole (arrow) provided on the flange.

276C061056A

D mount the flange (1) complete with sealing rings on-

to the cardan joint flange (2);
D mount the ball bearing (3), spacer (4) and elastic
ring (5);

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ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 51

Figure 61 Figure 63

1
276C061D059

D insert the axle shafts (1) into the hub.

VERSION B

Figure 62

276C061D055C

D with the appropriate tool, insert the seal ring (1) in

the seat, flush with the external rim of the flange tak-
ing care to have the correct orientation (detail);

Figure 64

276C061D055B
D fit the O---ring (arrow) on the flange;

276C061D056A
D fit the flange (1) with the seal ring on the universal
joint flange (2);
D fit the ball bearing (3), spacer (4) and spring washer
(5);

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52 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Figure 65 Figure 66
3

2 276C061D059
276C061057 D insert the axle shafts (1) in the hub;
D fit the complete universal joint support (1) on the Figure 67
hub (2) and tighten the fastening screws (3).

276C061040B

Reach the fastening screws through the ho-

le (arrow) provided on the flange.

276C061D070B

D fit the disk (1) and tighten the screw (2).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 53

Planet ---wheel holding plate --- fixed gear axial clear- Concluding operations
ance determination (VERSION A)
Proceed as follows: Figure 69

Figure 68

A
3
B 1
2
276C061D073

D mount the O---ring (1) in the seat of the planet ---whe-

el holding plate;
D mount the planet ---wheel holding plate assembly (2)
in the hub.
Respect the reference marks made during
274A062043
disassembly.
D determine the dimension A;
D determine the dimension B;
D determine the thickness of the thrust spacer as fol- D mount the retaining screws (3) and tighten to the
lows: prescribed torque.
S = A -- B +(0.30 ÷ 0.70) (mm) . If no intervention on the differential is
where: planned, proceed to:
A = distance between the planet ---wheel holding D the filling of the wheel hub;
plate mounting surface and the seat of the thrust D the filling of the central differential;
spacer on the same plate following the instructions provided in the
B = distance between the hub mounting surface relative chapter.
and the thrust spacer seat on the fixed gear
S = thrust spacer thickness
0.30 ÷ 0.70 = prescribed clearance in mm
D mount the chosen thrust spacer onto the planet ---
wheel holding plate.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
54 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

FRONT DIFFERENTIAL OVERHAUL Figure 71

Before performing any intervention, ensure

that all precautions have been taken and all
aspects clarified regarding the safety of per-
sonnel involved in the intervention.
Read the relative instructions provided in
SECTION 1 of this manual.
In case of doubt, consult a more experi-
enced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.

Disassembly
. Before proceeding it is necessary to remove
the front differential box from the automatic
transmission by following the instructions in
Section 5 --- AUTOMATIC TRANSMISSION.
276A061151
D Support the differential with a suitable lift.
D Unscrew the retaining screws and remove the sup-
port flange complete with hub, hub support bearing
and differential conic roller bearing external ring.
D Repeat the operation for the other support flange.

Proceed as follows: Keep the details making up the right and left
D Position the complex on the support trestle using output flanges separate.
appropriate adaptation elements.
Figure 72
Figure 70

269A061003
276A061150
D Using a suitable lifting device, extract the differential
D Mark the radial position of the support flanges (ar- complex from the external box and put it on the
row). workbench.
D Mark the right and left support flanges as well in or-
der to prevent interchanging their position during
reassembly.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 55

Support flange disassembly Figure 75

. The operations described below are valid

for both flanges.
Proceed as follows:

Figure 73

276A061006
D Extract the elastic ring and relative spacer.

Figure 76

276A061004
D Extract the external ring (1) of the differential conic
roller bearing and the spacer ring (2).

Figure 74

276A061007
D Use a press to remove the ball bearing and sealing
ring from the hub.

276A061005
D Use a plastic hammer to remove the hub with output
flange.

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56 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Differential disassembly D Mark the positions of the cover and the differential
Proceed as follows: box.

Figure 77 Figure 80

276A061008 276A061011

D Use an extractor to remove both the internal rings of
the conic roller bearings from the differential.
Figure 78
D Remove the cover.
D Remove the shoulder rings, the driven/driving
discs, the planet ---wheel shoulder plate and the
planetary gear.
Do not invert the position of the discs.

Figure 81

276A061009
D Loosen the hexagonal head retaining screws.

Figure 79
276A061012
D Remove the planet ---wheel group.
D Remove the planetary gear, the planet ---wheel
shoulder plate, the driven and driving discs, and the
shoulder rings.
Do not invert the position of the discs

276A061010
D Loosen the two socket head cap retaining screws,
then using the two screws as an extractor, remove
the toothed crown wheel.

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ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 57

Pinion disassembly Figure 84

Proceed as follows:

Figure 82

276A061015

Provide a suitable support to prevent the

276A061013
The bush is blocked with thread ---locks.
To prevent damaging the threading, heat it to
approximately 120˚C before unscrewing.
D Remove the bush.
pinion from falling.
D Using a pad and a press, extract the pinion from the
external box.
D Recover the internal ring of the external conic roller
bearing and the relative spacer.
D Remove the oil seal ring from its seat.

Figure 83 Figure 85

276A061014 276A061016

D Remove the washer and the splined sleeve.
D Use an extractor and a press to remove the internal
ring of the internal conic roller bearing from the pin-
ion.
D Remove both the external rings of the conic roller
bearings from the external box and the relative
spacer.

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58 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Inspection of the disassembled parts Reassembly

During reassembly consider the following

Bearings
general observations:
D check the condition of the bearings: replace them D heat, to 100˚ C in the oven, the bearings
if they have bluish halos, cracks and/or signs of and rings to be mounted by pushing;
wear. D carefully center and mount the sealing
rings and bearings with a suitable adjust-
Crown wheels er;
D check the condition of the toothing: replace it if it has D lubricate the bushes, sealing rings and
pits, cracks and/or cavities. bearings.

Planet ---gears Perform all the indicated measurements

D check the condition of the toothing: replace it if it has
pits, cracks and/or cavities;
D check the coupling surfaces with the pins.
Damage to a single element entails the re-
placement of the entire gear unit.
with maximum precision.
Imprecise measurements lead to bad con-
tact of the bevel gear and thus make it nec-
essary to repeat the procedure.

Cross pins
D check the coupling surfaces with the planet ---gears.

Shoulder rings
D check the condition of the rings: replace them if they
have bluish halos, cracks and/or signs of wear.

Bevel gear
D check that the toothing of the crown wheel and the
pinion show uniform wear on the entire working
zone of the teeth: replace the bevel gear if it has pits,
cracks and/or cavities;
An anomalous wear may indicate an incor-
rect adjustment of the bearings: check their
integrity before proceeding to the reas-
sembly.
Damage to a single element entails the re-
placement of the entire gear unit.

D when installing a new bevel gear group, check that

the wheel and pinion have the same coupling num-
ber;
D check the bearing seats: they must not have de-
formations or ovalling.

Bushes
D check the threading for the bearing locking bush: it
must not have dents, deformations and/or jams.

External box
D check the bearing seats: they must not have de-
formations or ovalling;
D check that the sealing surfaces and the threadings
are integral and free of dents or damage.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 59

Diagram of bearings and the application of thread-- locks and distributor and differential seals

276A061017

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
60 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Determination of the pinion axial position spacer thickness S1

Proceed as follows:

Figure 86

276A061018
D Insert the tools 5870.500.015 + 5870.500.001 into
the differential support seats and the tools
5870.351.016 + 5870.351.019 into the pinion seats.
D Determine the distance H between the internal
bearing (A) rest surface and the differential support
center as follows.
H = a + b + c (mm)
Example:
dimension a: 224.00 mm
dimension b: 2.50 mm
The dimension b must be determined with a
thickness gauge.
dimension c: 15.00 mm
mm (1/2 measuring rod diameter)
dimension H= a+b+c: 241.50 mm

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ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 61

Figure 87 D Determine the thickness of the spacer as follows:

S1 = H -- X (mm)
where
H = distance between the internal bearing (A) rest
surface and the differential support center
X = assembly height
S1 = spacer thickness S1

Example:
spacer thickness S1= H --- X: 1.20 mm
D Remove the special tools used for the measure-
ments.

Figure 89
1731272
D Determine the thickness S of the internal conic roller
bearing (A).
Example:
Dimension d: 90.00 mm
Value measured e: 47.70 mm
Bearing thickness = d --- e: 42.30 mm.

Figure 88

1731273
D Read the value V engraved on the surface of the pin-
ion (arrow).
D Determine the value X of the assembly height as fol-
lows.
X = V + S (mm)
where
V = value engraved on the surface of the pinion
S = bearing thickness

Example:
engraved value V: 198.00 mm
bearing thickness S: 42.30 mm
height X = 240.30 mm.
276A061021
D Position the chosen spacer S1 in the box.
D Insert the external track of the bearing (A) into the
differential box.
D Rotate the box.
D With the aid of tool 5870.058.077, mount the exter-
nal track of bearing (B) in its seat.

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62 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Determination of the bearing preload spacer thickness Figure 92

S2 and assembly of the pinion
Proceed as follows:

Figure 90

276A061024
D Mount the splined sleeve.

Figure 93

276A061022

D Heat the internal ring (1) of bearing (A) and mount

it on the pinion. Ensure that it rests against the
shoulder of the pinion.
D Mount the spacer S2 (2) having thickness equal to
that of the spacer removed during disassembly.

Figure 91

276A061023
D Mount the pinion in the box.
D Heat the internal ring of the external conic roller
bearing (B) and mount it on the pinion.
276A061025
D Mount the washer, mount the bush and tighten it to
the prescribed torque.
When blocking, rotate the pinion in both di-
rections.
D Use a suitable device to check that the rolling torque
is within the prescribed values.
pinion rolling torque
3.5 -- 4.5 Nm
D Otherwise, correct the rolling resistance by using a
spacer S2 with different thickness.
D In particular:
--- increase the thickness to reduce the torque
--- reduce the thickness to increase the torque
Take note of the effective value of the rolling
torque for subsequent operations.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 63

Diagram of the self -- locking differential assembly

The total height of the crown wheel---side

disc pack (B) must be identical to that on the
opposite side (A).

276A061026

1. Flange screw (x2)

2. Differential housing closure flange
3. Steel shoulder ring
4. Brass shoulder ring
5. Driven disc
6. Driving disc
7. Planet ---wheel shoulder plate
8. Crown wheel gear
9. Planet ---wheel
10. Shaft
11. Differential housing

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64 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Complete self---locking differential assembly . The numbering of the parts corresponds to

the legend on the previous page.
Figure 94

A E

B F

C G

D H

Do as follows:
A. Position the steel shoulder ring (3) and then the
brass shoulder ring (4);
B. Alternatively mount an externally slotted disc (5A,
driven disc) and an internally slotted disc (6A, driv-
ing disc) until using up all the discs.
The last disc is a driving disc.
C. Mount the planet ---wheel shoulder plate (7) with the
flat side against the driving disc.
D. Mount the crown wheel gear (8) on the shoulder
plate.
269A061027
E. Assemble the shafts (10) and planet ---wheel gears
(9) and mount them on the crown wheel.
F. Mount the second crown wheel gear (8) on the plan-
et ---wheel gear unit.
G. Mount the second planet ---wheel shoulder plate (7)
with the flat side up.
H. Alternatively mount an internally slotted disc (6B,
driving disc) and an externally slotted disc (5B, driv-
en disc) until using up all the discs.
The first disc is a driving disc.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 65

Determination of the disc pack axial clearance

Figure 97
Do as follows:

Figure 95

276A061030
D Position the steel shoulder ring and then the brass
276A061028 shoulder ring on the cover, making them adhere
D Determine the dimension a with lubricating grease for bearings.

Figure 96 Figure 98

276A061029
276A061031
D Determine the dimension b
D Position the cover on the differential gearbox, mount
D Check that the disc pack axial clearance is within
the hexagonal socket head cap screws and tighten
the prescribed values as follows:
them to the prescribed torque.
0.20 < a – b < 0.80 (mm)
where:
a = distance between box attachment plane and the
last driven disc
b = distance between the working surface and the cov-
er attachment plane

Example:
dimension a: 104.30 mm
dimension b: 103.95 mm
Difference a – b: 0.35 mm = axial clearance

D The clearance can be corrected by installing discs

of various thickness.
The total height of the crown wheel---side
disc pack must be identical to that on the op-
posite side.

It is recommended to approach the lower

value as much as possible.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
66 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Differential assembly
Figure 101
Do as follows:

Figure 99

276A061034

276A061032 D Heat the crown wheel---side conic roller bearing in-

ner track (C) and position it against the differential
D Mount the centering screws 5870 204 040 (n. 3) (ar-
semibox until contact.
row) and position the crown wheel.
D Heat the planet ---wheel side conic roller bearing in-
ner track (D) and position it against the differential
Figure 100 semibox.
The two bearings must NOT be inter-
changed since they have different lengths.
D Position both the conic roller bearing external tracks
on the ends of the differential.

Figure 102

276A061033
D Using a press to keep the crown wheel loaded,
screw on the retaining screws and tighten them to
the prescribed torque.
D Remove the calibrated screws, screw on and tight-
en the remaining retaining screws.
Use exclusively new screws.
276A061035
D With the aid of suitable lifting equipment, mount the
crown wheel unit in the differential gearbox.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 67

Determination of the differential bearing preload

Figure 105
Proceed as follows:

Figure 103

276A061036
D Mount the spacer S3 (1) having thickness equal to
that removed during disassembly onto the crown
wheel---side support flange.
D Mount the external ring (2) of the crown wheel---side
conic roller bearing (C).
The two bearings must NOT be inter-
changed since they have different widths..
276A061038
D Mount the calibrated screws 5870 204 021 (n. 2) (ar-
row) and position the flange.
D Temporarily fix the flange by tightening the screws
to the prescribed torque.
D Working from the opposite side (planet ---gear side)
mount the external ring of the conic roller bearing
(D) onto the relative internal ring already installed on
the differential.
Figure 106

Figure 104

276A061039
D Determine the dimension a.
276A061037
D Mount the O---ring (arrow).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
68 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Figure 108
Figure 107

276A061040
D Determine the dimension b.
D Determine the thickness of the spacer as follows:
S4 = a -- b +(0.30 ÷ 0.40) (mm)
where
a = distance between the box attachment surface and
bearing external ring side
b = distance between the conic roller bearing shoulder
and the cover attachment surface
S4 = bearing spacer thickness (D)
0.30 ÷ 0.40 = differential bearing preload in mm
276A061036
D Mount the chosen spacer S4 (1) onto the planet ---
gear---side support flange.
D Mount the external ring (2) of the planet ---gear ---
side conic roller bearing (D).
The two bearings must NOT be inter-
changed since they have different widths.
Figure 109

Example:
dimension a: 141.60 mm
dimension b: 139.90 mm
Difference a --- b: 1.70 mm
Thickness S4: 1.70 + 0.30 = 2.00 mm

276A061037
D Mount the O---ring (arrow).
D Use a suitable device to check that the rolling torque
is within the prescribed values.
total rolling torque
pinion torque + (3.0 ÷ 4.0) Nm

D It is possible to correct the rolling torque by adjust-

ing both the adjustment spacers S3 and S4 by one
quantity.
D In particular:
--- reduce the thickness of the spacers to decrease
the rolling torque;
--- increase the thickness of the spacers to in-
crease the rolling torque.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 69

Pinion---crown wheel clearance check

Proceed as follows:

Figure 110

276A061043
D Mount a quadrant comparator at a right angle with
respect to the external diameter of the crown wheel
toothed side and make the crown wheel oscillate
back and forth, paying attention not to move the pin-
ion;
D Check that the clearance between the crown wheel
and pinion is within the prescribed values
pinion-- crown wheel clearance: 0.20 -- 0.30 mm

Figure 111

269A061044
D Otherwise, perform the adjustment by acting on the
adjustment spacers.
D The clearance can be regulated without modifying
the bearing preload by reducing one thickness and
increasing the other by the same quantity.
D In particular:
--- increase the thickness S3 and reduce the thick-
ness S4 to reduce the clearance
--- reduce the thickness S3 and increase the thick-
ness S4 to increase the clearance

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
70 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Verification of the pinion---crown wheel engagement

impression area
Do as follows:

Figure 112

276A061045
D Cover a dozen teeth of the crown wheel with Prus-
sian blue, lubricated with minium, or another paint
or dye that can be easily eliminated.
D Make a complete rotation by hand.
D When the teeth engage, the paint is removed by the
contact of the teeth, leaving zones exposed with the
exact dimension, shape and location of contact.

Figure 113

276A061046

Contact area position and shape
1. Correct bevel gear position.
2. Position with the pinion too far back: it is neces-
sary to reduce the distance between the pinion
and the crown wheel axis by using a spacer S1 of
greater thickness; then adjust the clearance by
moving the crown wheel further from the pinion.
3. Position with the pinion too far forward: it is neces-
sary to increase the distance between the pinion
and the crown wheel axis by using a spacer S1 of
smaller thickness; then adjust the clearance by
moving the crown wheel closer to the pinion.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 71

Pinion assembly Figure 116

Proceed as follows:
D Remove the locking bush and the splined sleeve.

Figure 114

276A061025
D Mount the washer, mount the bush and tighten it to
the prescribed torque.

276A061047

D Use the tool 5870 048 227 to insert both the sealing
rings inside the pinion box with the edges orientated
in opposition, and fill them completely with bearing
lubricant.
The tool 5870 048 227 enables the correct
axial positioning of the sealing ring.

Figure 115

276A061024
D Mount the splined sleeve.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
72 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Support flange assembly Figure 119

. The operations described below are valid

for both flanges.
Proceed as follows:

Figure 117

276A061052
D Mount the spacer (1) and then the elastic ring (2).

Figure 120

276A061050
D mount the hub onto the output flange.
D use the tool 5870 048 228 to insert the sealing ring
inside the flange with the edge orientated internally
and lubricate it with bearing lubricant.

Figure 118

276A061053

D Mount the O---ring (arrow).

276A061051
D use a press to mount the ball bearing.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 73

Conclusive operations Figure 123

Proceed as follows:

Figure 121

276A061056
D Introduce the two centering pegs (arrow).
D Screw on the retaining screws and tighten to the
276A061054 prescribed torque.
D Remove the centering screws from both sides of the . Proceed to the assembly of the front differ-
differential box; remove the retaining screws
ential box onto the automatic transmission
mounted previously as well.
by following the instructions in Section 5 ---
D Heat the ball bearing seat, then introduce the com-
AUTOMATIC TRANSMISSION.
plete flange and push it down completely.
D Screw on the retaining screws and tighten them to
the prescribed torque.
D Repeat the operation for the second flange.

Figure 122

276A061055
D Mount the centering screws 5870 204 021 (n. 2) (ar-
row) and position the cover.
Do NOT invert the position of the cover.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
74 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

BRAKE CALIPER OVERHAUL Figure 125

Before performing any intervention, ensure

that all precautions have been taken and all
aspects clarified regarding the safety of per-
sonnel involved in the intervention.
Read the relative instructions provided in
SECTION 1 of this manual.
In case of doubt, consult a more experi-
enced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.

Disassembly 1
Proceed as follows:

Figure 124 2
276C062D110

D unscrew the retaining screws (1) and remove the

plate (2);

. Hydraulic oil leakage may occur during

these operations.

3 Figure 126

2 3

276C061D060
2
D unscrew both the retaining screws (1) and partially
slip off both the upper centering pins (2) so as to free
1
the eyelets of the pads (3); 276C062D111
D remove both the pads by slipping them off the upper D pressing from the inside of the piston, remove the
part of the caliper (arrow); cover (1) and the gasket (2);
D push the piston (3) towards the inside of the caliper
until it disengages from the dust cover;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 75

Figure 127 Reassembly

Proceed as follows:

Figure 128

3
2
1
1
276C062D112
2
D remove the shoulder ring (1), gasket (2) and dust 3
cover (3);
D repeat the operations for all the pistons in the cali- 276C062D113
per. D mount the dust cover (1), gasket (2) and shoulder
ring (3) in the appropriate seat on the caliper;
Inspection of the disassembled parts
Proceed as follows: Figure 129
D carefully clean the entire caliper, especially in the in-
ternal parts and around the piston seats;
D remove the bleeding valves, then carefully clean all
the internal canalizations by blowing with com-
pressed air;
D with a cloth soaked in isopropyl alcohol or equival-
ent, carefully clean the sliding surface of the pistons;
D check the wear conditions of the pistons and rela-
tive seats: if wear or damage is found, proceed to 1
their replacement;
D manually insert the pistons into the seats and check
for correct sliding: otherwise, proceed to replace-
ment;
D check the conditions of the guide pins of the pads: 274A061034
in case of damage, proceed to their replacement. D mount the piston (1) in the appropriate seat, slip-
Always replace the gaskets, sealing rings ping the dust cover onto the groove (arrow) on the
and dust covers even if apparently intact. piston;
During reassembly, lubricate all the internal To facilitate the operation, rotate the piston
components with the prescribed hydraulic slightly during insertion.
fluid.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
76 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

Figure 130

1
2
276C062D114

D mount the sealing gasket (1) and cover (2);

D repeat the operations for all the pistons in the cali-
per;

Figure 131

1
276C062D115
D mount the plate (1) and tighten the retaining screws
(2);
D proceed to the assembly of the new brake pads by
following the disassembly steps in the reverse
order.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- DISC BRAKES 77

BRAKE DISC OVERHAUL Figure 132

Before performing any intervention, ensure

that all precautions have been taken and all
aspects clarified regarding the safety of per-
sonnel involved in the intervention.
Read the relative instructions provided in
SECTION 1 of this manual.
In case of doubt, consult a more experien-
ced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.

Disassembly
Proceed to the detachment of the brake disc following
the instructions in the relative Chapter.
Inspection of the disassembled parts
Proceed as follows:
D perform a careful cleaning of the disc;
D check the conditions of the disc, making reference
to the figure:
A. Superficial microcracks on the side of the disc: 274A061037
acceptable
B. Radial cracks: NON---acceptable
C. Cracks on the edge of the attachment to the
flange: NON---acceptable.

Reassembly
Proceed to the reattachment of the brake disc following
the instructions in the relative chapter.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
78 FRONT AXLE -- DISC BRAKES SECTION 6.1 ADT 25-30 TIER3

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For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 SECTION 6.1

FRONT AXLE --- WET OIL

 ADT 25-30 TIER3 SECTION 6.1
CONTENTS
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fork type I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fork type II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
First reduction: bevel pair . . . . . . . . . . . . . . . . . . . . . . 5
Second reduction: hub and epicyclic train . . . . . . . 10
Braking assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operating brake unit . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brake system fittings . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operating brake unit . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . 15
Bevel gear (first reduction) . . . . . . . . . . . . . . . . . . . . 16
Epicyclic train and hub (second reduction) . . . . . . 17
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . 18
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . 29
Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
FRONT HUBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
FRONT AXLE -- WET OIL 1
Page
FRONT HUB REMOVAL-- REFIT . . . . . . . . . . . . . . . 31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Reattachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
EPICYCLIC REDUCER OVERHAUL . . . . . . . . . . . . 33
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Brake disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Inspection of the dismantled parts . . . . . . . . . . . . . . 38
Epicyclic reduction gear seals and thread---stops
application and bearings scheme . . . . . . . . . . . . . . 39
Epicyclic reduction gear seals and thread---stops
application and bearings scheme . . . . . . . . . . . . . . 40
Oil---wet brake assembly . . . . . . . . . . . . . . . . . . . . . . 41
Brake actuation circuit seal inspection . . . . . . . . . . 43
Piston actuation travel inspection . . . . . . . . . . . . . . . 44
Planet ---wheel holding plate assembly . . . . . . . . . . 44
Brake unit and hub assembly . . . . . . . . . . . . . . . . . . 45
Hub bearing preload determination . . . . . . . . . . . . . 50
Brake cooling circuit seal inspection . . . . . . . . . . . . 54
Concluding operations . . . . . . . . . . . . . . . . . . . . . . . . 55
FRONT DIFFERENTIAL OVERHAUL . . . . . . . . . . . 56
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Inspection of the disassembled parts . . . . . . . . . . . 60
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Diagram of bearings and the application of
thread---locks and distributor and differential
seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Diagram of the self---locking differential
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Page left intentionally blank

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 3

DESCRIPTION
Fork type I
The axle has independent wheels with double reduc- 1. Swinging fork
tion. 2. Left hub
The differential unit is composed of a box structure 3. Left axle shaft
which contains the cylindrical wheel transmission and 4. Differential and transfer case
the crown wheel and pinion with differential (first reduc- 5. Right axle shaft
tion). The structure is solidly connected to the automat- 6. Right hub
ic transmission box with a series of screws.

Figure 1

4 3

276C062W001

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4 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Fork type II
The axle is double reduction type with independent 1. Swinging fork
wheels. 2. Left hub
The differential unit consists of a box structure contai- 3. Left axle shaft
ning inside the cylindrical wheels transmission and the 4. Transfer case and differential
bevel pair with the differential (first reduction). The 5. Right axle shaft
structure is stiffly connected to the automatic transmis- 6. Right hub
sion box by screws.

Figure 2

276C061W001B

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 5

First reduction: bevel pair

The first reduction is obtained through the pinion---ring Legend (figure on next page)
bevel gear assembly (bevel pair) inside the differential.
The pinion shaft receives motion from the central dis- 1. Input shaft
tributor inside the automatic transmission. 2. Grooved sleeve
The shaft integral with the crown gear inside the central 3. External pinion bearing
distributor transmits the torque to a sleeve, that in its 4. Internal pinion bearing
turn is integral with the bevel pinion. 5. Bevel pinion
A seal ring keeps the differential lubrication separate 6. Ring bevel gear
from that of the transmission. 7. Crown bearing with right taper rollers
The pinion is supported by two taper roller bearings as- 8. Differential box
sembled in O arrangement with a preload that can be 9. Multiple disk clutch
adjusted by a spacer. The axial position of the pinion 10. Differential gear carrier shaft
can also be adjusted by shims. 11. Planetary gear
The box of the differential with ring bevel gear is sup- 12. Planet
ported by two tapered roller bearings assembled in X 13. Crown bearing with left taper rollers
arrangement with preload and axial position that can 14. Pinion axial position adjustment shim
be adjusted by shims. 15. Pinion bearing preload adjustment spacer

A: Section
B: Functional layout

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
6 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Figure 3

26912101

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 7

The differential is limited slip type.
It has a multiple disk clutch inserted between the differ-
ential gear box (train carrier) and the crown wheels on
each side.
The multiple disk clutch includes the external disks
connected to the differential gear box and internal disks
connected to the crown wheel gears by appropriate
pressure plates.
The internal disk friction surfaces have a patented mo-
lybdenum coating that ensures a constant friction coef-
ficient and thus holds the braking torque constant for
the whole useful life of the differential.
The thrust on the disks is ensured by the sloped con-
tact between the shaft and the pressure plate: therefore
a greater radial peripheral thrust on the train carrier
shaft (from the ring bevel gear) will cause a greater axial
thrust on the disks.
The thrust on the disks generates a stall torque that
acts on the crown wheel.

Figure 4

1731214

1. Crown wheel
2. Differential gear box
3. Differential cover
4. Crown wheel gear
5. Side pinion
6. Differential gear carrier shaft
7. Bevel pinion
8. Pressure plate (quantity: 2)
9. Multiple disk clutch --- external disk
10. Multiple disk clutch --- internal disk
11. Shoulder
12. Pressure plate rings sloped surfaces

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
8 FRONT AXLE -- WET OIL SECTION 6.1
Operation
The driving torque coming from the propeller shaft is
transmitted by a universal joint to the bevel pinion.
From here the torque passes to the ring bevel gear,
which is integral to the differential gear box.
The differential is a gear for which the box represents
the train carrier, that carries the differential gear carrier
shafts and receives the driving torque, whereas the two
side gears, which represent the crown wheels, both of
which rotate, receive the driving torque and transmit it
to the axle shafts.
When both wheels are subject to the same stall torque
or have the same speed (vehicle being driven on a
straight road), the ring bevel gear and the differential
gear box rotate as one, transmitting the torque in equal
parts to the two crown wheels, and from here to the two
axle shafts, that rotate at the same speed: the wheels
transmit the same driving torque.
Figure 5
1731215
Right wheel with road grip the same as the left one
IN: driving torque input
DX: RH side: torque delivered 50% of total
SX: LH side: torque delivered 50% of total
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
Under these conditions there is no relative motion be-
tween the two crown wheels and therefore the side pin-
ions do not turn around their shaft which is integral to
the differential gear box.
When the resistance of one wheel is greater than that
of the other, or when the speed of the two wheels is not
the same (vehicle on a road with bends) the crown
wheel gears have a different rotation speed: the rele-
vant motion is permitted by the side pinions, that now
turn around their shafts in directions opposite to each
other.
Obviously at a lower crown wheel rotation speed the
transmitted driving torque is greater, and vice versa.
Therefore when the differential is operating, the wheel
with a lower speed can transmit a greater torque,
whereas the wheel with a higher speed can transmit a
lower torque.
Under certain conditions it may happen that the slower
wheel loses its grip completely, since the torque is ex-
ceeded that can be transmitted to the ground, and
therefore meets practically no resistance: in this case,
the standard differential causes the wheel that slips to
freewheel, and stops the wheel that still has grip: the
axle traction is reduced to nothing.
To avoid this problem the self---locking differential is
used, which can generate a stall torque on each crown
wheel, which is no longer free to rotate in relation to the
differential gear box, but is braked in proportion to the
torque that the differential is to transmit.
This stall torque , that depends on the thrust applied to
the multiple disk clutch, always has a fixed ratio with the
input torque, that is called the “locking ratio”.
The locking ratio is the maximum difference between
the transmittable torque on the two axle shafts, in per-
centage.
For example, with a locking ratio of 45%, 72.5% of the
driving torque may be transferred to a rear axle shaft
(instead of 50% as in normal cases), whereas the other
axle shaft only receives 27.5%.
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 9

If the two wheels do not have the same grip, the stall In fact, the multiple disk clutches automatically com-
torque generated by the multiple disk clutches partially pensate the grip variations of the wheels from the left
locks the crown wheel on the side with less grip and in- and right sides of the vehicle, without the need of any
creases the torque delivered by the crown wheel on the operation on the part of the driver. It is therefore pos-
side with stronger grip. In other words, the braking sible to apply a much higher driving force during the
torque replaces the reaction torque that is lacking on use of the vehicle, and avoid slipping when one of the
the side of the wheel with less grip. wheels runs on a surface with poor grip.
In this way, looking at the example given beforehand of
a wheel that loses grip, this can no longer freewheel
and therefore the other wheel will still be able to trans-
mit part of the driving torque, ensuring at least in part
the axle traction.

Figure 6

1731216

Right ---hand wheel with less grip than the left one (ex-
ample)

IN: driving torque input

DX: RH side: torque delivered 27,5% of total
SX: LH side: torque delivered 72,5% of total

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
10 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Second reduction: hub and epicyclic train

The second reduction is obtained by an epicyclical re- Legend (figure on following page)
duction unit with cylindrical wheels contained in the
wheel hub. 1. Epicyclic train upright
The hub is supported by two taper roller bearings (planet ---wheel holding plate)
mounted in O arrangement with a pre---load that can be 2. Thrust spacer (Version A)
adjusted by a ring nut. The side pinion gears rotate on 3. Planet ---wheel
pivoting roller bearings. 4. Epicyclic train fixed gear
5. Planet ---wheel pin
Operation 6. Unused
7. Adjustment ring nut
The driving torque coming from the differential is trans-
8. Epicyclic train crown wheel
mitted through a floating axle shaft to the crown gear
9. Hub
by means of a grooved shank.
10. Wheel fastening column
The four side pinion gears rotate in the opposite direc-
11. Sealing rings
tion to the crown gear, whereas the crown wheel is inte-
12. Brake bell
gral to the hub support and therefore does not turn.
13. Brake discs
This makes the train carrier turn in the opposite direc-
14. Actuation piston
tion to the side pinions, therefore in the same direction
15. Brake unit
as the axle shafts.
16. Brake actuation fitting
Since the train carrier is integral to the wheel hub, the
17. Sealing rings
wheel turns in the same direction as the axle shaft.
18. Hub support
19. Flange
20. Cardan joint flange
21. Sealing ring
22. Ball bearing
23. Central retaining screw spacer
24. Internal conic roller bearing
25. External conic roller bearing
26. Axle shaft

A: Cross section
B: Functional diagram

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 11

VERSION A

Figure 7

13 14
12
10 15
11
9 16
8 17
18
7
19
20
5
4
3
2
1

25 23 21
26 24 22

B 9

22

18

3
20 20

276C061W008

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12 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

VERSION B

Figure 8

276C061W008B

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ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 13

Braking assembly Operation

The driving pressure depends on the driver’s pressure
on the brake pedal. As a function to major or minor hy-
Description draulic pressure, the plates slip more easily or with
The braking assembly consists of a set of plates with more difficulty: in this way the wheel braking is more or
external toothing (1) arranged alternatively with a set of less effective.
plates with internal toothing (2). The plates with exter- When oil pressure is no longer applied to the piston,
nal toothing engage in the bell (3), integral with the disengagement is guaranteed by the mechanical ac-
fixed part of the axle, whereas the plates with internal tion of a series spring that acting on the piston in the op-
toothing engage in the hub (5), integral with the wheel. posite direction to the pressure of the oil. This leads to
The brake is hydraulically activated by sending pres- play between the disks and allows them to slip freely.
sure oil behind the control piston (6) through the fitting
(7).
The discs are immersed in oil in order to ensure their Brake system fittings
cooling: the circulation of the coolant occurs through
two input and output fittings. Figure 9
A special front sealing ring (4) prevents leakage of the
cooling oil or entry of foreign matter. A double oil seal 3 2
ring (8) prevents the cooling oil from passing to the
wheel hub bearings. 1
Operating brake unit (see figure on next page) 4
1. Brake unit
2. Screw
3. Sealing ring
4. Sealing ring
5. Fitting
6. Drain 5
7. Spacer
8. Screw 6 276C061W009
9. Spring
1 Coolant input
10. Screw
2 Brake control input
11. Bushing
3 Brake control air bleeder
12. Screw
4 Coolant output
13. O---Ring
5 Inspection cap
14. Cap
6 Coolant drain
15. Sealing ring
16. Sealing ring
17. Cap
18. Sealing ring
19. Front sealing ring
20. Control piston
21. Internally toothed discs
22. Externally toothed discs
23. Brake housing (bell)
24. O---Ring

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
14 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Operating brake unit

Figure 10

1
24
2
23
3
22
4
21
5
20

19
6

10

11

12

13

14

15

16

17

18

276C062W010

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 15

SPECIFICATIONS AND DATA

Code KESSLER R 81 (Hub) and ZF LK (front differential)

Type Independent, with double reduction

With limited slip

Central differential
Integrated in automatic transmission box

Pinion bearings 2 taper rollers mounted in O arrangement

Differential bearings 2 taper rollers mounted in X arrangement

Hub bearings 2 taper rollers mounted in X arrangement

Hub planet bearings Pivoting barrel rollers

bevel gear pair 1 : 3.50

Reduction ratio wheel reducer 1 : 6.00

total 1 : 21.00

Autom. pinion transm. output shaft axial clearance 0.30 --- 0.50 mm (0.012 --- 0.020 in)

3.5 --- 4.5 Nm

Pinion bearings preload
(2.60 --- 3.30 ft lb (without seal rings))

Differential bearings preload 3.0 --- 4.0 Nm (2.20 --- 2.90 ft lb)

Bevel gear pair clearance 0.20 --- 0.30 mm (0.008 --- 0.012 in)

Self---locking disks axial clearance 0.20 --- 0.80 mm (0.008 --- 0.032 in)

Drive axle---reduction carrier axial clearance

0.30 --- 0.70 mm (0.012 --- 0.028 in)
(Version A)

8.00 --- 14.00 Nm

Hub bearings
(5.9 --- 10.3 ft (without seal rings))

Hub bearing preload determined by the ring nut tightening torque

1st tightening: 700---900 Nm then loosen

Ring nut tightening torque
2nd tightening: 450 Nm
Type of brakes Multiple discs in oil wet
Control Hydraulic
fixed 4
Discs per unit
rotating 4
Brake discs axial clearance 2.5 + 0.7 / --- 0.1 mm

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
16 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Bevel gear (first reduction)

Figure 11

T269PT03

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 17

Epicyclic train and hub (second reduction)

Figure 12

276C061W012B

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
18 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

TIGHTENING TORQUES

Figure 13

276C061W013

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 19

TIGHTENING TORQUES

Figure 14

276C061014

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
20 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

TIGHTENING TORQUES

Figure 15

276C061W014B

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 21

EQUIPMENT
. The tools indicated in the following list should be requested from the Supplier (KESSLER + CO
GmbH & Co. KG).

TOOL CODE DESCRIPTION

038.586.0---2 Spanner for wheel safety nut

031.013.0---2 Seal ring sleeve driver

038.525.0---4 Seal ring sleeve driver

1U5933 Installation tool for face seal

056.013.0---3
+ Centering tool for discs
056.019.0---3

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
22 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

. The tools indicated in the following list should be requested from the Supplier (ZF GmbH).

TOOL CODE DESCRIPTION

Pinion/crown wheel --- spacer clearance

5870.351.016
adjustment device

Pinion/crown wheel --- clamping disk

5870.351.019
clearance adjustment device

Pinion/crown wheel --- keying disk clea-

5870.500.015
rance adjustment device

Pinion/crown wheel --- measuring shaft

5870.500.001
clearance adjustment device

Bearings--- guide external track assembly

5870.058.077
device

5870.204.040 Centring screws

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 23

TOOL CODE DESCRIPTION

5870.204.021 Centring screws

5870.048.227 Centring guide/pad for seal rings

5870.048.228 Centring guide/pad for seal rings

5870.053.024 Centring guide/pad for seal rings

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 24 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

DIAGNOSTICS

Axle
1. Continuous noise
2. Cornering noise
3. Alternating noise
4. Sharp bangs during acceleration or deceleration
5. Oil leak from the axle shafts
6. Oil leak from the hubs

1 CONTINUOUS NOISE

Worn bearings. Replace them.

YES

NO

Gears damaged or worn. Replace them.

YES

NO

Lack of lubrication. Restore oil level.

YES

NO

Incorrect adjustment of the clearances. Adjust again

YES

2 CORNERING NOISE

Worn planet ---wheels or crown wheels. Replace.

YES

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 25

3 ALTERNATING NOISE

Wheel bearings with excessive clearance. Adjust the bearings.

YES

NO

Wheels mounted incorrectly. Disassemble and remount correctly.

YES

NO

Too little clearance in the bevel gear set. Adjust again.

YES

NO

Too much clearance in the bevel gear set. Adjust again.

YES

4 SHARP BANGS DURING

ACCELERATION OR DECELERATION

Incorrect gear train adjustment. Adjust again.

YES

NO

Pivot of the anchoring structure has too much Replace the parts of the articulated joint.
play. YES

NO

Loose fastening of the anchoring structure to Tighten the screws to the prescribed tightening
the chassis. YES torque.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 26 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

5 OIL LEAK FROM THE AXLE SHAFTS

Worn oil seals. Replace them.

YES

NO

Loose screws. Tighten the screws to the prescribed tightening

YES torque.

6 OIL LEAK FROM THE HUBS

Front seals worn. The coolant leaks from the Replace the seals.
hub. YES

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 27

Brakes
1. Weak braking action
2. Unequal action of the brakes
3. Brakes that remain blocked
4. Premature depletion of the accumulator pressure when braking with the engine off

1 WEAK BRAKING ACTION

Worn brake discs. Overhaul the brakes.

YES

NO

Defective hydraulic system. See Section 10 --- HYDRAULIC SYSTEM.

YES

2 UNEQUAL ACTION OF THE BRAKES

Worn brake discs. Replace.

YES

NO

Defective hydraulic system. See Section 10 --- HYDRAULIC SYSTEM.

YES

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 28 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

3 BRAKES THAT REMAIN BLOCKED

Broken or ineffective return springs. Overhaul the brakes.

YES

NO

Defective hydraulic system. See Section 10 --- HYDRAULIC SYSTEM.

YES

PREMATURE DEPLETION OF THE

4 ACCUMULATOR PRESSURE WHEN
BRAKING WITH THE ENGINE OFF

Defective accumulators. Check the preload pressure and the seals of the
YES fittings.
Replace the accumulators.

NO

Inefficient piston gliding seals. The brake fluid Overhaul the brakes.
seeps into the cooling chamber YES

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 29

MAINTENANCE Changing the oil

Collect and dispose of used lubricants and
FRONT DIFFERENTIAL fluids, according to the laws in force.

Checking oil level Proceed as follows to drain the system:

Proceed as follows:
Figure 17
Figure 16

269NM221
D clean the cap area and open the level cap (1). Lubri-
cant should drip out of the hole;
D top up the level as shown in the following para-
graph, if required;
D close the filler cap and fasten at the specified
torque.
269NM221
D arrange a suitably sized container, clean the cap
area and remove the level cap (1);
D remove drain cap (2) and fully drain the oil;
D clean the drain caps. Check that the threading is in
good condition. Replace the seal and apply sealant
to both caps and close them at the specified torque.
Proceed as follows to fill the system:
D fill until oil spills out of the hole on the cap (1);
D replace the seal, apply sealant onto the cap and
close it at the specified torque;
D run a road test, check the cap level (1);
D if required, top up oil of the specified type until it
spills out of the hole. Repeat the road test and check
the level again.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
30 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

FRONT HUBS Changing the oil

Collect and dispose of used lubricants and

Checking oil level fluids, according to the laws in force
Proceed as follows:
Proceed as follows to drain the system:
Final reductions
Final reductions

Figure 18 Figure 19

1 1

276C062022
276C062020 D take the reference on the hub to horizontal position
D take the reference on a hub to horizontal position (see arrow);
(see arrow); D arrange a suitably sized container, clean the cap
D clean the cap area and open the level cap (1). Lubri- area and remove the cap (1) and the drain cap (2);
cant should drip out of the hole; drain all the lubricant.
D top up the level as shown in the following para- D clean the cap, check that the threading is in good
graph, if required; condition, replace the sealing ring with a new one
D close the filler cap. and close the drain cap.
D repeat the procedure for the other hub.
D arrange a suitably sized container, clean the cap
area and remove the cap (1) and the drain cap (2);
drain all the lubricant.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1
FRONT HUB REMOVAL---REFIT
. Before starting any operation, make sure
that all the precautions have been taken and
all aspects regarding safety of the personnel
involved on the job have been made quite
clear.
Read the relevant instructions contained in
SECTION 1 of this handbook.
If in doubt ask someone who is more expert.
Comply to all the general recommendations
for correct execution of maintenance work.
Removal
Proceed as follows:
D bring the vehicle on a suitable flat, solid surface,
switch off the engine, remove the key from the igni-
tion switch, engage the parking brake and affix the
warning notices;
D deactivate the battery isolator or disconnect the bat-
tery terminals to prevent any risk of a short circuit;
D block articulation by means of the steering lock bar,
proceeding as indicated in SECTION 1;
D raise the vehicle so that the wheels are off the
ground, then place two supporting trestles under
the front chassis, without touching the suspension;
D place a suitable hydraulic supporting device under
the suspension, then sustain the suspension so as
to keep the shock absorbers compressed;
This operation facilitates the removal of the
axle shaft from the hub.
. This operation facilitates separation of the
axle shaft from the hub.
D remove the wheel following the instructions in SEC-
TION 9;
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
FRONT AXLE -- WET OIL 31
Before carrying out the removal of the hy-
draulic pipes, prepare appropriate plugs to
close the free ends.
D disconnect the hydraulic pipes:
--- service braking system (20);
--- brakes cooling system inlet (21);
--- brakes cooling system outlet (22);
. During this operation some hydraulic fluid
may spill out.
D remove the axle shafts metal protection following
the description in SECTION 8 --- SUSPENSIONS;
D disconnect the transmission half---shaft (18) from
the hub following the instructions in SECTION 7;
D lower the suspension to obtain maximum extension
permitted by the retaining ropes;
D release the drive shaft from the universal joint for
easier access to the hub fastening nuts;
D sling the hub using hooks and robes adequate for
the load and appropriate lifting equipment;
D remove all the nuts (15)that fasten the hub to the
fork, keeping the related washers;
D carefully withdraw the hub (14).
Reattachment
Proceed to the reattachment by following the detach-
ment steps in the reverse order.
After the refit procedure, check the brakes
drive circuit following the indications in
SECTION 10.
32 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Figure 20

276C061W027

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 33

EPICYCLIC REDUCER OVERHAUL Figure 22

Before starting any operation, make sure

that all the precautions have been taken and
all aspects regarding safety of the personnel
involved on the job have been made quite
clear.
Read the relevant instructions contained in
SECTION 1 of this handbook.
If in doubt ask someone who is more expert.
Comply to all the general recommendations
for correct execution of maintenance work.

. Before proceeding, it is necessary to:

D drain the lubricant from the wheel hub 1
D drain the lubricant from the central differ- 276C061W031
ential D VERSION A: Withdraw the axle shaft (1);
following the instructions provided in the
relative chapter. Figure 23

. Before proceeding, the brake caliper must

be removed following the instructions in the
relative chapter.

Disassembly 2
Proceed as follows:
1
Figure 21

276C061D031B
D VERSION B: Unscrew the screw (1) and remove the
disk;

Figure 24
3 1
2
276C061W030
D mark the mutual position of the planet ---wheel hol-
ding plate and the hub;
D loosen and remove all the retaining screws (1);
D remove the planet ---wheel holding plate assembly
(2) and O---ring (3);
D VERSION A: Recover the thrust spacer ring (4);

1
276C061W031

D VERSION B: Withdraw the axle shaft (1);

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
34 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Figure 25 Figure 27

1 2

1
4

3
276C062D034

2 D remove the retaining screws (1) and relative stop

plates (2);
276C062032
D separate the internally toothed crown wheel (3) from
the relative flange (4);
D unscrew the setscrew (1) of the ring nut; D using a suitable extractor, remove the inner race (5)
D remove the locking ring nut (2) of the internally too- of the wheel---side bearing (B) from the crown wheel
thed crown wheel. flange;
D if necessary, remove the wheels fastening screws
The ring nut is locked with thread ---stops. from the hub;
To prevent damage to the threading, heat to
approximately 120˚C before unscrewing. Figure 28

D using a suitable lifting device, carefully remove the 1

complete hub from the hub support;
1
During this operation, keep the hub parallel 2
to the axle axis to avoid damaging the brake
discs.
D remove the front sealing ring;
D place the hub vertically;

Figure 26

3
276C062D035

D VERSION A: Remove the two oil seal rings (1).

D use a suitable extractor to remove the outer race (2)
of the axle---side bearing (A) and the outer race (3)
of the wheel---side bearing (B);

1
276C062D033

D use a suitable extractor to remove the internally too-

thed crown wheel (1);

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 35

Figure 29 D remove the inner race (1) of the axle---side bearing

(A) and the spacer ring (2) from the hub;
The spacer ring is locked with sealant.
To avoid damaging it, before removing, heat
it to approx120 ˚C.

Figure 32

276C062035B
D VERSION B: Remove the oil seal ring (1);
D With an appropriate puller remove the outer ring 2
(2)of the bearing on rear axle side (A) and the outer
ring (3) of bearing on wheel side (B);

Figure 30
3
276C061W040

D unscrew the retaining screws (1) and remove the

complete cardan joint support (2) from the hub sup-
1 port (3);

Figure 33

2
276C061W036
D remove the screws (1) fastening the brake unit (2)
to the hub;
D carefully remove the brake unit from the hub and
place it on the workbench with the flange facing up-
wards.

Figure 31

276C061D041A

D remove the elastic ring (1) and spacer (2), then use
a suitable extractor to remove the cardan joint flan-
ge (3) from the ball bearing (4) and flange (5);

2
1
276C061W037

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
36 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Figure 34 . Do not push the pivot towards the outside of

the planet---wheel holding plate, otherwise
its seat may be damaged due to the differ-
ence between the internal and external di-
ameter of the pivot.

Figure 37

276C061042A
D VERSION A: Remove the sealing rings;

Figure 35
2

276C062038
D remove the planet wheel (1) and relative shim rings
(2);

Figure 38

276C061042B
D VERSION B: Remove the sealing rings;

Figure 36

274A062039
D remove the needle cages (arrow) from the planet ---
wheel;
D repeat the procedure for all the planet ---wheels.
2 1

274A062029
D place the planet ---wheel holding plate on a suitable
work surface;
D use a punch to push the retaining pin (1) down in the
pivot, freeing the pivot (2);
D extract the pivot (2) by pushing it towards the inside
of the planet ---wheel holding plate (arrow);
D remove the O---ring (3);
D extract the pin from the pivot.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 37

Brake disassembly D unscrew the screw (1) and remove the spring (2)
Proceed as follows: and spacer (3) from the piston;

Figure 39 Wear protective gloves and safety goggles.

Hold the screw to avoid injuries caused by
the load of the springs.
4
3 D unscrew the screw (4) and remove the bushing (5)
from the piston;
D turn the flange over, resting it on a suitable spacer
to allow the partial exit of the piston;

Figure 42

2
276C062W040

D unscrew the retaining screws (1) and remove the

1
flange (2) complete with piston form the bell (3).
D remove the peripheral sealing ring (4);

Figure 40

2
1

276C062W043
D remove the piston (1) by blowing compressed air in
from the control fitting (2);
276C062W041
D remove the internal (1) and external discs (2) from Wear protective gloves and safety goggles.
the bell, keeping their order; Hold down the flange to avoid any hand inju-
D remove the front sealing ring (3); ries.
Figure 41 D remove the sealing rings from the flange and the pi-
ston.
5
4

2
3
1
276C062W042

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
38 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Inspection of the dismantled parts

Wheel hub
D check the seats of the bearings: they must not have
any deformations and/or ovalling;
D check the condition of the bearings: replace them
if they have bluish halos, cracks and/or signs of
wear.

Axle shafts
D check the condition of the axle shafts: replace them
if they have deformations on the end grooves and/or
on the entire length.

Final reductions
D check the condition of the gear toothing: replace
them if they have pitting, cracks and/or cavities;
D verify the good operation of the planet ---wheels and
the roller bushings;
D check the threading for the bearing locking ring nut:
it must not have any dents, deformations and/or
jams.

Oil---wet brake
D check the bell and the piston: they must not have
any deformations and/or ovalling;
D carefully clean the bell, especially the canalizations;
D use new gaskets and rings;
D check the threading for the bearing locking ring nut:
it must not have any dents, deformations and/or
jams.

Front sealing rings

D check the seat of the ring: it must not have any de-
formations and/or ovalling;
D carefully clean the seat, the metal ring and the ga-
sket;
D eliminate any residue of dust, lubricant or other fo-
reign matter.
Use isopropanol for the cleaning and subse-
quent assembly operations.
Use cloths that do not fray, or paper towels.

During reassembly, consider the following

general observations:
D heat, to 100˚C in the oven, the bearings
and rings to be mounted by pushing;
D carefully center and mount the sealing
rings and bearings with a suitable adju-
ster;
D lubricate the ring nuts and bearings;
D lubricate the driving plates and driven pla-
tes of the brake with hydraulic fluid;
D follow the front sealing ring assembly in-
structions carefully.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 39

Epicyclic reduction gear seals and thread-- stops application and bearings scheme

VERSION A
Figure 43

276C061W044A

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
40 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Epicyclic reduction gear seals and thread-- stops application and bearings scheme

VERSION B
Figure 44

276C061W044B

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 41

Oil -- wet brake assembly Figure 47

Proceed as follows:
2
Figure 45
1

276C062W047
D mount the internal (1) and external discs (2) in the
bell, maintaining their order.

276C062W045

D Mount the sealing rings in the following order:

Large O---ring
Small O---ring
Large rigid ring
Small rigid ring
The larger diameter of the rigid ring must be
on the side opposite the pressure.
D install two operating screws, then mount the piston
in the flange;
Do not tilt the piston in order to avoid con-
tact and damage to the sliding surfaces.
D remove the operating screws;

Figure 46

4
5

1
2
3
276C062W046

D mount the spring (1) and spacer (2) and screw on

the screws (3);
D mount the bushing (4) and screw the screws (5) on-
to the piston;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
42 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Figure 48

276C062W048

D determine the dimension A;

D determine the dimension B;
D q determine the piston travel (without pressure)
as follows:
C = A -- B (mm)
where
A = distance between the brake bell mounting
surface and the disc surface
B = distance between the plate mounting surface
and the piston thrust surface
C = piston travel (without pressure)
D check that the piston travel (without pressure) is wi-
thin the prescribed values:
1.9 < C < 2.7 [mm]

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 43

Figure 49 Brake actuation circuit seal inspection

Proceed as follows:
1
Figure 50
2

1 2

276C062W049

D mount the peripheral sealing ring (1); 276C061W050

D mount the bell (2) onto the flange (3) and screw on
the retaining screws (4);
D mount any previously removed hydraulic fittings.
D close the bleeding valve (1);
D connect a manual high---pressure hydraulic pump
to the brake control input fitting (2);
D pump the prescribed hydraulic fluid into the actua-
tion chamber until reaching a maximum pressure of
10 bar;
D open the pressure release valve of the pump;
D open the bleeding valve;
D carefully operate the pump up to the spillage of fluid;
D close the bleeding valve;
D repeat the procedure up to the complete absence
of air in the bleeding;
D increase the pump pressure to a max of 120 bar;
D check that the seal is within the prescribed values:
Pressure reduction in 15 min
max 2% (residual pressure of at least 117.5 bar)
D open the pressure release valve of the pump;
D remove the pump and close the fitting.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
44 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Piston actuation travel inspection Planet-- wheel holding plate assembly

Proceed as follows: Proceed as follows:
D position the planet ---wheel holding plate horizontal-
Figure 51 ly;

Figure 52

274A062032
D mount the needle cages inside the planet gear;

276C061W051

D open the cap of the inspection hole (1);

D measure the distance (d) between the flange and pi-
ston without hydraulic pressure (d1);
D connect a manual high---pressure hydraulic pump
to the brake control input fitting;
D increase the pump pressure to a max of 120 bar;
D measure the distance (d) between the flange and pi-
ston with hydraulic pressure (d2);
D determine the piston travel (with pressure) as fol-
lows:
C = d2 -- d1 (mm)
where:
d1 = distance (d) between the flange and piston with-
out pressure
d2 = distance (d) between the flange and piston with
pressure
C = piston travel (with pressure)
D check that the piston travel (with pressure) is within
the prescribed values:
2.4 < C < 3.2 [mm]

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 45

Figure 53 Brake unit and hub assembly

Proceed as follows:
2 Figure 55

1 3
2
2

276C062052

D mount the planet ---wheel (1) complete with shim 1

rings in the seat on the planet ---wheel holding plate; 276C062053

Figure 54 D place the hub vertically;

D using a suitable introducer, mount the outer race (1)
of the wheel---side conic roller bearing (B) and the
2 outer race (2) of the axle---side conic roller bearing
3
(A);
D mount the inner race (3) of the axle---side conic roller
bearing (A);

Figure 56

274A062035

D insert the O---ring (1) in the seat of the planet ---wheel

holding plate;
D insert the pivot (2) of the planet ---wheel holding gear
so that the pin holes match up;
D or according to the versions;
D insert the pivot (2) of the planet ---wheel holding gear
up to the complete expulsion of the internal reten-
tion bush so that the pin holes match up;
Mount the pivot from the internal part of the
planet---wheel holding plate, otherwise its 276C062W054
seat may be damaged due to the pivot dia- D with an appropriate tool, insert the seal rings (1) in
meter difference. the seat on the hub taking care that the orientation
D mount the catch pin (3); is correct (detail) and fill completely with lubricant
D repeat the procedure for all the planet ---wheels. grease for bearings (arrow).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
46 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Front sealing ring assembly Figure 59

. The assembly instructions below are valid

for both front sealing rings (brake---side and
wheel---side).

Use isopropanol for the cleaning and subse-

quent assembly operations.

Proceed as follows:

Figure 57

276C062W062
D using a suitable tool, completely immerse the rub-
ber part of the front sealing ring in a small basin con-
taining isopropanol;
The rubber ring must be completely immer-
sed in the isopropanol in order to obtain effi-
cient lubrication.
This lubrication is indispensable to ensure
the correct assembly of the front sealing
ring.

Figure 60
276C062W060
D mount the rubber ring (1) on the metal ring (2), set-
tling it on the groove.

Figure 58

276C062W063

D extract the sealing ring from the basin and mount it

immediately in its seat, pushing it firmly so that the
rubber ring inserts into the seat and crosses the re-
tention rim;
276C062W061 D if necessary, adjust the position of the ring in the
seat using a suitable tool;
The rubber ring must NOT be twisted.
A twisted rubber ring does not guarantee the
correct position of the metal ring, resulting
in fluid leaks.
If the ring twists during assembly, it must be
straightened by rolling it until It is complete-
ly straight.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 47

Figure 61

276C062W064
D check the correct assembly of the rubber ring: the
figure illustrates some incorrect positions.
1. The rubber ring is not positioned correctly in the
seat;
2. The rubber ring has not crossed the retention
rim;
3. The rubber ring is not positioned correctly on
the metal ring.
D use a magnifying glass to inspect the sliding surfa-
ces of the rings and remove any foreign matter;
D apply a thin layer of lubricant on the external surfa-
ces of each front ring before assembling the parts.
Wait a few minutes before coupling the two
rings in order to allow the isopropanol to
evaporate completely.
The rubber ring absolutely must not move in
its seat during assembly of the parts.
A shifted rubber ring does not guarantee the
correct position of the metal ring, resulting
in fluid leaks.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
48 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Figure 62

5
4
2

276C062W065
D position the axle horizontally;
D mount the sealing ring (1) on the hub support (2);
D mount the brake unit (3) on the hub support;
D tighten the retaining screws (4) to the prescribed
tightening torque;
D use a suitable tool to align the toothing of the brake
unit discs (5);
D block the position of the discs by blowing compres-
sed air in the brake control input fitting (6) and remo-
ve the tool.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 49

Figure 63

3 1
276C062W066

D heat the spacer ring (1) and insert it completely on

the axle axis;
D using a suitable lifting device, support the hub as-
sembly in order to ensure its correct centering;
D introduce the hub assembly (2) on the end of the
hub support (3), placing the inner race of the axle---
side conic roller bearing (A) so that it rests against
the spacer ring;
During this operation, keep the hub parallel
to the axle axis.
Work with caution to avoid damaging the
sealing rings and the brake disc teeth.
Continue to support the hub assembly until
it is completely mounted.
D release the brake discs by discharging the pressure
from the piston;
D if removed, mount the stud bolts fastening the wheel
to the hub (4).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
50 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Figure 64 Hub bearing preload determination

Proceed as follows:

Figure 66
4

2
2
3
276C062W067
D heat the inner race (1) of the wheel---side conic roller
bearing (B) and insert it until it rests against the gear
wheel flange;
D insert the gear wheel flange (2) onto the gear wheel
with internal toothing (3); 1
D mount the retention plates (4) and fix them with the
setscrews; 276C062069
D apply MOLYKOTE lubricant on the hub support
Figure 65
threading and on the threading and contact area of
the locking ring nut;
D hand mount the ring nut (1) without tightening;
D tighten the locking ring nut to the prescribed tighte-
ning torque:
Locking ring nut tightening torque for bearings
Phase 1: 700-- 900 Nm
During the locking, rotate the hub back and
forth by striking it with a plastic hammer to
settle the bearings.
D unscrew the locking ring nut half a turn;
D tighten the locking ring nut to the prescribed tighte-
ning torque:
Locking ring nut tightening torque for bearings
Phase 2: 450 Nm
During the locking, rotate the hub back and
1 forth by striking it with a plastic hammer to
settle the bearings.
276C062W068
D after having adjusted the bearing preload, block the
D mount the flange and internally toothed gear wheel
locking ring nut with the relative setscrew (2);
assembly (1) onto the hub until the two parts meet
the wheel---side conic roller bearing (B). If this is not possible, unscrew the ring nut
as much as needed in order to mount the
The lubrication oil passage hole on the gear
clamp screw.
wheel flange is to face downwards.

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ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 51

VERSION A Figure 69

Figure 67

276C061055A 276C061W057
D fit the seal rings; D mount the complete cardan joint support (1) onto
D fit the oil seal ring taking care with the indicated as- the hub (2) and screw on the retaining screws (3);
sembly direction (detail) and fill it completely with lu-
bricating grease for bearings; Figure 70

Figure 68

276C061040B

Reach the fastening screws through the ho-

le (arrow) provided on the flange.

Figure 71
276C061056A

D mount the flange (1) complete with sealing rings on-

to the cardan joint flange (2);
D mount the ball bearing (3), spacer (4) and elastic
ring (5);

1
276C061W070

D insert the axle shafts (1) into the hub.

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52 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

VERSION B Figure 74

Figure 72

276C061D055B

D fit the O---ring (arrow) on the flange;

Figure 73
276C061D056A
D fit the flange (1) with the seal ring on the universal
joint flange (2);
D fit the ball bearing (3), spacer (4) and spring washer
(5).

276C061W055C

D with the appropriate tool, insert the seal ring (1) in

the seat, flush with the external rim of the flange ta-
king care to have the correct orientation (detail);

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 53

Figure 75 Figure 77

1
276C061W070
D insert the axle shafts (1) into the hub;
276C061W057

D fit the complete universal joint support (1) on the Figure 78

hub (2) and tighten the fastening screws (3);

Figure 76

276C061040B

Reach the fastening screws through the ho-

le (arrow) provided on the flange. 276C061D070B

D fit the disk (1) and tighten the screw (2).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
54 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Planet ---wheel holding plate --- fixed gear axial clear- Brake cooling circuit seal inspection
ance determination (VERSION A) Proceed as follows:
Proceed as follows:
Figure 80
Figure 79

B 276C061W072

D close one of the two brake cooling circuit pipe fit-

tings (1);
D blow compressed air at a maximum pressure of 1.5
bar into the second fitting (2);
Do not exceed the pressure of 1.5 bar as this
may damage the sealing rings.
D turn the hub a few times;
274A062043
D check that the seal is within the prescribed values:
D determine the dimension A; Minimum pressure acceptable after 10 minutes
D determine the dimension B; 1.4 bar
D determine the thickness of the thrust spacer as fol- D close the fitting.
lows:
S = A -- B +(0.30 ÷ 0.70) (mm)
where:
A = distance between the planet ---wheel holding
plate mounting surface and the seat of the thrust
spacer on the same plate
B = distance between the hub mounting surface
and the thrust spacer seat on the fixed gear
S = thrust spacer thickness
0.30 ÷ 0.70 = prescribed clearance in mm
D mount the chosen thrust spacer onto the planet ---
wheel holding plate.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 55

Concluding operations

Figure 81

1 3
2 276C061W073

D mount the O---ring (1) in the seat of the planet ---whe-

el holding plate;
D mount the planet ---wheel holding plate assembly (2)
in the hub.
Respect the reference marks made during
disassembly.

D mount the retaining screws (3) and tighten to the

prescribed torque.

. If no intervention on the differential is

planned, proceed to:
D the filling of the wheel hub;
D the filling of the central differential;
following the instructions provided in the
relative chapter.

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56 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

FRONT DIFFERENTIAL OVERHAUL Figure 83

Before performing any intervention, ensure

that all precautions have been taken and all
aspects clarified regarding the safety of per-
sonnel involved in the intervention.
Read the relative instructions provided in
SECTION 1 of this manual.
In case of doubt, consult a more experi-
enced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.

Disassembly
. Before proceeding it is necessary to remove
the front differential box from the automatic
transmission by following the instructions in
Section 5 --- AUTOMATIC TRANSMISSION.
276A061151
D Support the differential with a suitable lift.
D Unscrew the retaining screws and remove the sup-
port flange complete with hub, hub support bearing
and differential conic roller bearing external ring.
D Repeat the operation for the other support flange.

Proceed as follows: Keep the details making up the right and left
D Position the complex on the support trestle using output flanges separate.
appropriate adaptation elements.
Figure 84
Figure 82

269A061003
276A061150
D Using a suitable lifting device, extract the differential
D Mark the radial position of the support flanges (ar- complex from the external box and put it on the
row). workbench.
D Mark the right and left support flanges as well in or-
der to prevent interchanging their position during
reassembly.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 57

Support flange disassembly Figure 87

. The operations described below are valid

for both flanges.
Proceed as follows:

Figure 85

276A061006
D Extract the elastic ring and relative spacer.

Figure 88

276A061004
D Extract the external ring (1) of the differential conic
roller bearing and the spacer ring (2).

Figure 86

276A061007
D Use a press to remove the ball bearing and sealing
ring from the hub.

276A061005
D Use a plastic hammer to remove the hub with output
flange.

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58 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Differential disassembly D Mark the positions of the cover and the differential
Proceed as follows: box.

Figure 89 Figure 92

276A061008 276A061011

D Use an extractor to remove both the internal rings of
the conic roller bearings from the differential.
Figure 90
D Remove the cover.
D Remove the shoulder rings, the driven/driving
discs, the planet ---wheel shoulder plate and the
planetary gear.
Do not invert the position of the discs.

Figure 93

276A061009
D Loosen the hexagonal head retaining screws.

Figure 91
276A061012
D Remove the planet ---wheel group.
D Remove the planetary gear, the planet ---wheel
shoulder plate, the driven and driving discs, and the
shoulder rings.
Do not invert the position of the discs

276A061010
D Loosen the two socket head cap retaining screws,
then using the two screws as an extractor, remove
the toothed crown wheel.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 59

Pinion disassembly Figure 96

Proceed as follows:

Figure 94

276A061015

Provide a suitable support to prevent the

276A061013
The bush is blocked with thread ---locks.
To prevent damaging the threading, heat it to
approximately 120˚C before unscrewing.
D Remove the bush.
pinion from falling.
D Using a pad and a press, extract the pinion from the
external box.
D Recover the internal ring of the external conic roller
bearing and the relative spacer.
D Remove the oil seal ring from its seat.

Figure 95 Figure 97

276A061014 276A061016

D Remove the washer and the splined sleeve.
D Use an extractor and a press to remove the internal
ring of the internal conic roller bearing from the pin-
ion.
D Remove both the external rings of the conic roller
bearings from the external box and the relative
spacer.

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60 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Inspection of the disassembled parts Reassembly

Bearings
During reassembly consider the following
D check the condition of the bearings: replace them
general observations:
if they have bluish halos, cracks and/or signs of
D heat, to 100˚ C in the oven, the bearings
wear.
and rings to be mounted by pushing;
Crown wheels
D carefully center and mount the sealing
D check the condition of the toothing: replace it if it has
rings and bearings with a suitable adjust-
pits, cracks and/or cavities.
er;
Planet ---gears
D lubricate the bushes, sealing rings and
D check the condition of the toothing: replace it if it has
bearings.
pits, cracks and/or cavities;
D check the coupling surfaces with the pins. Perform all the indicated measurements
Damage to a single element entails the re- with maximum precision.
placement of the entire gear unit. Imprecise measurements lead to bad con-
tact of the bevel gear and thus make it nec-
Cross pins
essary to repeat the procedure.
D check the coupling surfaces with the planet ---gears.
Shoulder rings
D check the condition of the rings: replace them if they
have bluish halos, cracks and/or signs of wear.
Bevel gear
D check that the toothing of the crown wheel and the
pinion show uniform wear on the entire working
zone of the teeth: replace the bevel gear if it has pits,
cracks and/or cavities;
An anomalous wear may indicate an incor-
rect adjustment of the bearings: check their
integrity before proceeding to the reas-
sembly.
Damage to a single element entails the re-
placement of the entire gear unit.

D when installing a new bevel gear group, check that

the wheel and pinion have the same coupling num-
ber;
D check the bearing seats: they must not have de-
formations or ovalling.
Bushes
D check the threading for the bearing locking bush: it
must not have dents, deformations and/or jams.
External box
D check the bearing seats: they must not have de-
formations or ovalling;
D check that the sealing surfaces and the threadings
are integral and free of dents or damage.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 61

Diagram of bearings and the application of thread-- locks and distributor and differential seals

276A061017

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62 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Determination of the pinion axial position spacer thickness S1

Proceed as follows:

Figure 98

276A061018
D Insert the tools 5870.500.015 + 5870.500.001 into
the differential support seats and the tools
5870.351.016 + 5870.351.019 into the pinion seats.
D Determine the distance H between the internal
bearing (A) rest surface and the differential support
center as follows.
H = a + b + c (mm)
Example:
dimension a: 224.00 mm
dimension b: 2.50 mm
The dimension b must be determined with a
thickness gauge.
dimension c: 15.00 mm
mm (1/2 measuring rod diameter)
dimension H= a+b+c: 241.50 mm

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ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 63

Figure 99 D Determine the thickness of the spacer as follows:

S1 = H -- X (mm)
where
H = distance between the internal bearing (A) rest
surface and the differential support center
X = assembly height
S1 = spacer thickness S1

Example:
spacer thickness S1= H --- X: 1.20 mm
D Remove the special tools used for the measure-
ments.

Figure 101
1731272
D Determine the thickness S of the internal conic roller
bearing (A).
Example:
Dimension d: 90.00 mm
Value measured e: 47.70 mm
Bearing thickness = d --- e: 42.30 mm.

Figure 100

1731273
D Read the value V engraved on the surface of the pin-
ion (arrow).
D Determine the value X of the assembly height as fol-
lows.
X = V + S (mm)
where
V = value engraved on the surface of the pinion
S = bearing thickness

Example:
engraved value V: 198.00 mm
bearing thickness S: 42.30 mm
height X = 240.30 mm.
276A061021
D Position the chosen spacer S1 in the box.
D Insert the external track of the bearing (A) into the
differential box.
D Rotate the box.
D With the aid of tool 5870.058.077, mount the exter-
nal track of bearing (B) in its seat.

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64 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Determination of the bearing preload spacer thickness Figure 104

S2 and assembly of the pinion
Proceed as follows:

Figure 102

276A061024
D Mount the splined sleeve.

Figure 105

276A061022

D Heat the internal ring (1) of bearing (A) and mount

it on the pinion. Ensure that it rests against the
shoulder of the pinion.
D Mount the spacer S2 (2) having thickness equal to
that of the spacer removed during disassembly.

Figure 103

276A061023
D Mount the pinion in the box.
D Heat the internal ring of the external conic roller
bearing (B) and mount it on the pinion.
276A061025
D Mount the washer, mount the bush and tighten it to
the prescribed torque.
When blocking, rotate the pinion in both di-
rections.
D Use a suitable device to check that the rolling torque
is within the prescribed values.
pinion rolling torque
3.5 -- 4.5 Nm
D Otherwise, correct the rolling resistance by using a
spacer S2 with different thickness.
D In particular:
--- increase the thickness to reduce the torque
--- reduce the thickness to increase the torque
Take note of the effective value of the rolling
torque for subsequent operations.

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ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 65

Diagram of the self -- locking differential assembly

The total height of the crown wheel---side

disc pack (B) must be identical to that on the
opposite side (A).

Figure 106

276A061026

1. Flange screw (x2)

2. Differential housing closure flange
3. Steel shoulder ring
4. Brass shoulder ring
5. Driven disc
6. Driving disc
7. Planet ---wheel shoulder plate
8. Crown wheel gear
9. Planet ---wheel
10. Shaft
11. Differential housing

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66 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Complete self---locking differential assembly . The numbering of the parts corresponds to

the legend on the previous page.
Figure 107

A E

B F

C G

D H

Do as follows:
A. Position the steel shoulder ring (3) and then the
brass shoulder ring (4);
B. Alternatively mount an externally slotted disc (5A,
driven disc) and an internally slotted disc (6A, driv-
ing disc) until using up all the discs.
The last disc is a driving disc.
C. Mount the planet ---wheel shoulder plate (7) with the
flat side against the driving disc.
D. Mount the crown wheel gear (8) on the shoulder
plate.
269A061027
E. Assemble the shafts (10) and planet ---wheel gears
(9) and mount them on the crown wheel.
F. Mount the second crown wheel gear (8) on the plan-
et ---wheel gear unit.
G. Mount the second planet ---wheel shoulder plate (7)
with the flat side up.
H. Alternatively mount an internally slotted disc (6B,
driving disc) and an externally slotted disc (5B, driv-
en disc) until using up all the discs.
The first disc is a driving disc.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 67

Determination of the disc pack axial clearance

Figure 110
Do as follows:

Figure 108

276A061030
D Position the steel shoulder ring and then the brass
276A061028 shoulder ring on the cover, making them adhere
D Determine the dimension a with lubricating grease for bearings.

Figure 109 Figure 111

276A061029
276A061031
D Determine the dimension b
D Position the cover on the differential gearbox, mount
D Check that the disc pack axial clearance is within
the hexagonal socket head cap screws and tighten
the prescribed values as follows:
them to the prescribed torque.
0.20 < a – b < 0.80 (mm)
where:
a = distance between box attachment plane and the
last driven disc
b = distance between the working surface and the cov-
er attachment plane

Example:
dimension a: 104.30 mm
dimension b: 103.95 mm
Difference a – b: 0.35 mm = axial clearance

D The clearance can be corrected by installing discs

of various thickness.
The total height of the crown wheel---side
disc pack must be identical to that on the op-
posite side.

It is recommended to approach the lower

value as much as possible.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
68 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Differential assembly
Figure 114
Do as follows:

Figure 112

276A061034

276A061032 D Heat the crown wheel---side conic roller bearing in-

ner track (C) and position it against the differential
D Mount the centering screws 5870 204 040 (n. 3) (ar-
semibox until contact.
row) and position the crown wheel.
D Heat the planet ---wheel side conic roller bearing in-
ner track (D) and position it against the differential
Figure 113 semibox.
The two bearings must NOT be inter-
changed since they have different lengths.
D Position both the conic roller bearing external tracks
on the ends of the differential.

Figure 115

276A061033
D Using a press to keep the crown wheel loaded,
screw on the retaining screws and tighten them to
the prescribed torque.
D Remove the calibrated screws, screw on and tight-
en the remaining retaining screws.
Use exclusively new screws.
276A061035
D With the aid of suitable lifting equipment, mount the
crown wheel unit in the differential gearbox.

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ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 69

Determination of the differential bearing preload

Figure 118
Proceed as follows:

Figure 116

276A061036
D Mount the spacer S3 (1) having thickness equal to
that removed during disassembly onto the crown
wheel---side support flange.
D Mount the external ring (2) of the crown wheel---side
conic roller bearing (C).
The two bearings must NOT be inter-
changed since they have different widths..
276A061038
D Mount the calibrated screws 5870 204 021 (n. 2) (ar-
row) and position the flange.
D Temporarily fix the flange by tightening the screws
to the prescribed torque.
D Working from the opposite side (planet ---gear side)
mount the external ring of the conic roller bearing
(D) onto the relative internal ring already installed on
the differential.
Figure 119

Figure 117

276A061039
D Determine the dimension a
276A061037
D Mount the O---ring (arrow).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
70 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Figure 121
Figure 120

276A061040
D Determine the dimension b
D Determine the thickness of the spacer as follows:
S4 = a -- b +(0.30 ÷ 0.40) (mm)
where
a = distance between the box attachment surface and
bearing external ring side
b = distance between the conic roller bearing shoulder
and the cover attachment surface
S4 = bearing spacer thickness (D)
0.30 ÷ 0.40 = differential bearing preload in mm
276A061036
D Mount the chosen spacer S4 (1) onto the planet ---
gear---side support flange.
D Mount the external ring (2) of the planet ---gear ---
side conic roller bearing (D).
The two bearings must NOT be inter-
changed since they have different widths.
Figure 122

Example:
dimension a: 141.60 mm
dimension b: 139.90 mm
Difference a --- b: 1.70 mm
Thickness S4: 1.70 + 0.30 = 2.00 mm

276A061037
D Mount the O---ring (arrow).
D Use a suitable device to check that the rolling torque
is within the prescribed values.
total rolling torque
pinion torque + (3.0 ÷ 4.0) Nm

D It is possible to correct the rolling torque by adjust-

ing both the adjustment spacers S3 and S4 by one
quantity.
D In particular:
--- reduce the thickness of the spacers to decrease
the rolling torque;
--- increase the thickness of the spacers to in-
crease the rolling torque.

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ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 71

Pinion---crown wheel clearance check

Proceed as follows:

Figure 123

276A061043
D Mount a quadrant comparator at a right angle with
respect to the external diameter of the crown wheel
toothed side and make the crown wheel oscillate
back and forth, paying attention not to move the pin-
ion;
D Check that the clearance between the crown wheel
and pinion is within the prescribed values
pinion-- crown wheel clearance: 0.20 -- 0.30 mm

Figure 124

269A061044
D Otherwise, perform the adjustment by acting on the
adjustment spacers.
D The clearance can be regulated without modifying
the bearing preload by reducing one thickness and
increasing the other by the same quantity.
D In particular:
--- increase the thickness S3 and reduce the thick-
ness S4 to reduce the clearance
--- reduce the thickness S3 and increase the thick-
ness S4 to increase the clearance

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
72 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Verification of the pinion---crown wheel engagement

impression area
Do as follows:

Figure 125

276A061045
D Cover a dozen teeth of the crown wheel with Prus-
sian blue, lubricated with minium, or another paint
or dye that can be easily eliminated.
D Make a complete rotation by hand.
D When the teeth engage, the paint is removed by the
contact of the teeth, leaving zones exposed with the
exact dimension, shape and location of contact.

Figure 126

276A061046

Contact area position and shape

1. Correct bevel gear position.
2. Position with the pinion too far back: it is neces-
sary to reduce the distance between the pinion
and the crown wheel axis by using a spacer S1 of
greater thickness; then adjust the clearance by
moving the crown wheel further from the pinion.
3. Position with the pinion too far forward: it is neces-
sary to increase the distance between the pinion
and the crown wheel axis by using a spacer S1 of
smaller thickness; then adjust the clearance by
moving the crown wheel closer to the pinion.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 73

Pinion assembly Figure 129

Proceed as follows:
D Remove the locking bush and the splined sleeve.

Figure 127

276A061025
D Mount the washer, mount the bush and tighten it to
the prescribed torque.

276A061047

D Use the tool 5870 048 227 to insert both the sealing
rings inside the pinion box with the edges orientated
in opposition, and fill them completely with bearing
lubricant.
The tool 5870 048 227 enables the correct
axial positioning of the sealing ring.

Figure 128

276A061024
D Mount the splined sleeve.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
74 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

Support flange assembly Figure 132

. The operations described below are valid

for both flanges.
Proceed as follows:

Figure 130

276A061052
D Mount the spacer (1) and then the elastic ring (2).

Figure 133

276A061050
D mount the hub onto the output flange.
D use the tool 5870 048 228 to insert the sealing ring
inside the flange with the edge orientated internally
and lubricate it with bearing lubricant.

Figure 131

276A061053

D Mount the O---ring (arrow).

276A061051
D use a press to mount the ball bearing.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.1 FRONT AXLE -- WET OIL 75

Conclusive operations Figure 136

Proceed as follows:

Figure 134

276A061056
D Introduce the two centering pegs (arrow).
D Screw on the retaining screws and tighten to the
276A061054 prescribed torque.
D Remove the centering screws from both sides of the . Proceed to the assembly of the front differ-
differential box; remove the retaining screws
ential box onto the automatic transmission
mounted previously as well.
by following the instructions in Section 5 ---
D Heat the ball bearing seat, then introduce the com-
AUTOMATIC TRANSMISSION.
plete flange and push it down completely.
D Screw on the retaining screws and tighten them to
the prescribed torque.
D Repeat the operation for the second flange.

Figure 135

276A061055
D Mount the centering screws 5870 204 021 (n. 2) (ar-
row) and position the cover.
Do NOT invert the position of the cover.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
76 FRONT AXLE -- WET OIL SECTION 6.1 ADT 25-30 TIER3

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 SECTION 6.2

INTERMEDIATE AXLE --- DISC BRAKES

 ADT 25-30 TIER3 SECTION 6.2
CONTENTS
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tandem transfer case . . . . . . . . . . . . . . . . . . . . . . . . . . 4
First reduction: bevel gear pair . . . . . . . . . . . . . . . . . . 5
Second reduction: hub and epicyclic train . . . . . . . 12
Brake pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . 16
Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Brake disc and caliper . . . . . . . . . . . . . . . . . . . . . . . . 16
Splitter unit and bevel gear pair (first reduction) . . 17
Hub and epicyclic gear (second reduction) . . . . . . 18
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . 19
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Replacement of the brake pads . . . . . . . . . . . . . . . . 28
Breaking---in of the pads . . . . . . . . . . . . . . . . . . . . . . 29
Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INTERMEDIATE AXLE REMOVAL-- REFIT . . . . . . 32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
BRAKE CALIPER DETACHMENT--
REATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Detachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Reattachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
EPICYCLIC REDUCER OVERHAUL . . . . . . . . . . . . 36
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Inspection of the dismantled parts . . . . . . . . . . . . . . 39
Epicyclic reduction gear seals and thread---stops
application and bearings scheme . . . . . . . . . . . . . . 40
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
INTERMEDIATE AXLE -- DISC BRAKES 1
Page
Planet ---wheel holding plate assembly . . . . . . . . . . 42
Brake unit and hub assembly . . . . . . . . . . . . . . . . . . 43
Hub bearing preload determination . . . . . . . . . . . . . 45
Planet ---wheel holding plate --- fixed gear axial
clearance determination . . . . . . . . . . . . . . . . . . . . . . 46
Concluding operations . . . . . . . . . . . . . . . . . . . . . . . . 47
TANDEM TRANSMISSION AND DIFFERENTIAL
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Inspection of the disassembled parts . . . . . . . . . . . 53
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Differential seals and thread---stops application
and bearings scheme . . . . . . . . . . . . . . . . . . . . . . . . . 54
Complete limited---skid differential assembly . . . . . 55
Crown wheel and bearings assembly . . . . . . . . . . . 57
Determination of the pinion axial position
spacer (S1) thickness . . . . . . . . . . . . . . . . . . . . . . . . . 58
Check of the pinion---crown wheel clearance . . . . 60
Verification of the pinion---crown wheel
engagement impression area . . . . . . . . . . . . . . . . . . 61
Idle gear bearing preload determination . . . . . . . . . 62
Pinion bearing preload determination . . . . . . . . . . . 64
Idle gear and pinion assembly . . . . . . . . . . . . . . . . . 65
Differential bearing preload determination . . . . . . . 66
Coutershaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . 67
BRAKE CALIPER OVERHAUL . . . . . . . . . . . . . . . . 69
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Inspection of the disassembled parts . . . . . . . . . . . 70
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
BRAKE DISC OVERHAUL . . . . . . . . . . . . . . . . . . . . 72
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

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ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 3

DESCRIPTION
The axle is a dual reduction bearing type. The structure has mountings for connection to the
It consists of a boxed structure containing the cylindri- chassis and housings for the bearings.
cal wheel transmission, the bevel gear pair with the dif-
ferential (first reduction), the drive shafts and hubs with
the epicyclic reducer (second reduction).

Figure 1

8
7

4
3 2
5

276C062D001
1. Rear suspension
2. Hub with epicyclic gears
3. Differential case
4. Motion input flange
5. Axle
6. Upper stabilizer bar
7. Service brake caliper
8. Service brake disc

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
4 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

Tandem transfer case

The transfer case is composed of a pair of spur gears The torque is always divided into equal parts between
and an output shaft. the two tandem axles.
The pair of gears (having ratio 1:1) transmit the motion
to the differential pinion while the output shaft transmits
the motion to the rear axle.

Figure 2

276C062002A
1. Input flange
2. Input countershaft
3. Output shaft to rear axle
4. Transmission conic roller bearings
5. Gear for motion transmission to pinion
6. Pinion conic roller bearings
7. Ball bearing
8. Intermediate axle differential unit

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 5

First reduction: bevel gear pair

The first reduction is obtained by the pinion---ring bevel Legend (figure on following page)
gear unit (bevel gear pair) inside the differential.
The input shaft is supported by two taper roller bear- 1. Adjustment ring nut
ings mounted in O arrangement with preload that can 2. Internal conic roller bearing
be adjusted by spacer. 3. External conic roller bearing
The pinion shaft receives motion from a cylindrical 4. Motion input flange
wheel transmission with ratio 1:1. 5. Transmission spur gear
The pinion is supported by two taper roller bearings 6. Double sealing ring
mounted in O arrangement with preload that can be ad- 7. Pinion spur gear
justed by spacer. The axial position of the pinion can 8. Pinion external conic roller bearing
also be adjusted by shims. 9. Bevel pinion
The differential box with ring bevel gear is supported by 10. Pinion internal conic roller bearing
two taper roller bearings mounted in X arrangement 11. Axle
with preload and axial position adjustable by two op- 12. Differential semicase
posing ring nuts. 13. Output flange
14. Sealing ring
15. Ball bearing
16. Shaft
17. Crown wheel---side conic roller bearing
18. Axle shaft
19. Adjustment ring nut
20. Differential case
21. Crown wheel
22. Planet ---wheel
23. Planet wheel---side conic roller bearing
24. Adjustment ring nut
25. Planet wheel holding shaft
26. Differential semicase
27. Crown wheel

A: Cross section
B: Functional diagram

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
6 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

Figure 3

276C062003A

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 7

Figure 4

276C062004

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
8 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

The differential is a limited---skid differential, characteri-
zed by the positioning of a multiple---disc clutch betwe-
en the differential case (upright) and the crown wheels
(sun gears) for each side.
The multiple---disc clutch includes external discs con-
nected to the differential case and internal discs con-
nected to the planetary gears.
The thrust on the discs is ensured by the axial compo-
nent of the force exchanged between the teeth of the
planet ---wheels and crown wheels.
The axial thrust on the discs generates a resistant tor-
que that acts on the crown wheel when the crown whe-
el tends to rotate with respect to the differential case
due to the speed difference between the two wheels.
This resistant torque depends, with equal axial thrust,
on the dimensions and the coating material of the
discs.

Figure 5

3,1 2

2,15

0,48

1. Differential semicase
2. Planetary gear
3. Multiple---disc device for skid limitation
3

52,8 --- 53,27

276C062005

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2
Operation
The torque coming from drive shaft is transmitted
through a cardan joint to the bevel pinion.
From this, the torque passes to the ring bevel gear,
which is integral with the differential case.
The differential is a gear train in which the case repre-
sents the upright, that holds the planet ---wheel holding
shafts and receives the torque, while the two crown
wheels represent the sun gears, both rotary, that recei-
ve the torque and transmit it to the axle shafts.
When both the wheels are subject to the same resistant
torque or have the same speed (vehicle traveling along
a straight path), the ring bevel gear and the differential
case rotate as a block, transmitting the torque in equal
parts to the two crown wheels, and from these to the
two axle shafts that rotate at the same speed: the whe-
els transmit the same driving torque.
Figure 6
LH RH
276C062006
The right wheel with the same adherence as the left.
RH: right side: torque supplied is 50% of the total
LH: left side: torque supplied is 50% of the total
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
INTERMEDIATE AXLE -- DISC BRAKES 9
Under these conditions, there is no relative motion bet-
ween the two crown wheels, and thus the planet ---whe-
els do not rotate around their shaft which is integral with
the differential case.
When the resistance of one wheel exceeds that of the
other or when the speed of the two wheels is no longer
equal (vehicle traveling a curved path) the planetary
gears assume a different rotation speed: their relative
motion is allowed by the presence of the planet ---whe-
els, which now rotate around their own shaft in opposi-
te directions.
Naturally, a slower rotation speed of the crown wheel
corresponds to a greater driving torque transmitted,
and vice versa.
Thus when the differential operates the wheel that has
a smaller speed, it is able to transmit a greater driving
torque, while the one with the greater speed transmits
a smaller torque.
Under certain conditions it may occur that the slower
wheel completely loses adhesion, since the torque that
can be transmitted to the ground is exceeded, and thus
it encounters practically zero resistance: in this case, a
normal differential causes the free rotation of the wheel
that skids and the stopping of the wheel that still adhe-
res to the ground: the traction capacity of the axle beco-
mes zero.
To remedy this inconvenience, a limited---skid differen-
tial is used that is characterized by the possibility to ge-
nerate a resistant torque on each crown wheel, which
is no longer free to rotate with respect to the differential
case, but is braked in proportion to the torque that the
differential must transmit.
This resistant torque, which depends on the thrust ap-
plied to the multiple---disc clutch, is always in a fixed ra-
tio with the input torque, known as the ”locking ratio”.
The locking ratio is the percentage of maximum diffe-
rence between the torque transmittable to the wheel
with greater adherence and that on the wheel with less
adherence.
For example, with a locking ratio of 45%, 72,5% of the
driving torque is transferred to one rear axle shaft (ra-
ther than the normal 50%), while the other axle shaft re-
ceives only 27.5%: the difference is precisely 45% (with
respect to a total of 100%).
10 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

If the two wheels do not have the same adherence, the In practice, the multiple---disc clutches automatically
resistant torque generated by the multiple---disc clut- compensate the adherence variations of the wheels
ches partially locks the crown wheel on the side having from the left side and right side of the vehicle, without
less adherence and increases the torque supplied by requiring any driver operation. It is thus possible to ap-
the crown wheel on the side with more adherence. In ply a much larger driving force when using the vehicle,
other words, the braking torque replaces the reaction and prevent skidding when one of the wheels encoun-
torque missing from the side of the wheel with less ad- ters a surface lacking adherence.
herence.
In this manner, considering the previous case in which
one wheel loses adherence, this wheel is not able to
turn freely and thus the other wheel will still be able to
transmit part of the driving torque, ensuring at least so-
me traction capacity of the axle.

Figure 7

LH RH

276C062007
Left wheel with less adherence than the right wheel
(example)

RH: right side: torque supplied is 72.5% of the total

LH: left side: torque supplied is 27.5% of the total

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 11

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For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
12 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

Second reduction: hub and epicyclic train

The second reduction is obtained by an epicyclic re- Legend (figure on following page)
ducer with cylindrical wheels in the wheel hub.
The hub is supported by two taper roller bearings 1. Epicyclic train upright
mounted in O arrangement with preload that can be ad- (planet ---wheel holding plate)
justed by a ring nut. The planetary gear gears turn on 2. Thrust spacer
pivoting roller bearings. 3. Planet ---wheel
4. Epicyclic train fixed gear
Operation 5. Planet ---wheel pin
6. Guide bushing
The torque from the differential is transmitted by a float-
7. Adjustment ring nut
ing axle shaft to the sun gear by the grooved shank.
8. Epicyclic train crown wheel
The four planetaries gears rotate in the opposite direc-
9. Hub
tion to the sun gear, where as the crown wheel is inte-
10. Wheel fastening column
gral to the hub support, and therefore does not rotate.
11. Brake caliper
This forces the train carrier to turn in the opposite direc-
12. Brake disc
tion to the planetaries gear, therefore in the same direc-
13. Hub support
tion as the drive shaft.
14. Spacer ring
15. Sealing ring
16. Internal conic roller bearing
17. External conic roller bearing
18. Axle shaft
19. Central retaining screw

A: Cross section
B: Functional diagram

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 13

VERSION A
Figure 8

A
11
10
9 12
8
7
6

5
13
4
3
2
1

18 16 14

19 17 15

B 9

13
4

21 20 22
3
8

276C062D008

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
14 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

VERSION B
Figure 9

276C062D008A

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 15

Brake pad

Figure 10

2
4
3

12
11
10
5
9
8
7

276C062D009

1. Brake Pads
2. Caliper
3. Pin
4. Bleeder fitting
5. Brake control fitting
6. Cover
7. Cap
8. Cap gasket
9. Piston
10. Sealant ring
11. Piston gasket
12. Dust cover

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
16 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

SPECIFICATIONS AND DATA

Hub
KESSLER R 81 (Hub) and ZF LK
Code
(front differential)

Type Independent, with double reduction

With limited slip

Central differential
Integrated in automatic transmission box

Pinion bearings 2 taper rollers mounted in O arrangement

Differential bearings 2 taper rollers mounted in X arrangement

Hub bearings 2 taper rollers mounted in X arrangement

Hub planet bearings 3 x 4 Pivoting barrel rollers

bevel gear pair 1 : 3.50

Reduction ratio wheel reducer 1 : 6.00

total 1 : 21.00

Autom. pinion transm. output shaft axial clearance 0.30 --- 0.50 mm (0.012 --- 0.020 in)

3.5 --- 4.5 Nm

Pinion bearings preload
(2.60 --- 3.30 ft lb (without seal rings)

Differential bearings preload 3.0 --- 4.0 Nm (2.20 --- 2.90 ft lb)

Bevel gear pair clearance 0.20 --- 0.30 mm (0.008 --- 0.012 in)

Self---locking disks axial clearance 0.20 --- 0.80 mm (0.008 --- 0.032 in)

Drive axle---reduction carrier axial clearance 0.30 --- 0.70 mm (0.012 --- 0.028 in)

8.00 --- 14.00 Nm

Hub bearings
(5.9 --- 10.3 ft (without seal rings))

Hub bearing preload determined by the ring nut tightening torque

1st tightening: 700---900 Nm then loosen

Ring nut tightening torque
2nd tightening: 450 Nm

Brake disc and caliper

Caliper CARLISLE M -- 4
Type Fixed
N. calipers per wheel 2
N. cylinders per caliper 2x2
New 17 mm
Brake pad thickness
Wear limit 3 ± 0.5 mm
Disc Fixed
Outer diameter 476 mm
Inner diameter 250 mm
New 19 mm
Thickness Wear limit 17 mm
Max roughness 1 mm

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 17

Splitter unit and bevel gear pair (first reduction)

Figure 11

276C062011A

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
18 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

Hub and epicyclic gear (second reduction)

Figure 12

276C062D012B

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 19

TIGHTENING TORQUES

Figure 13

276C062D013

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20 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

TIGHTENING TORQUES

Figure 14

276C062D014A

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 21

TIGHTENING TORQUES

Figure 15

276C062D014B

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
22 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

TIGHTENING TORQUES

Figure 16

276C063D015

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 23

TOOLS
. The tools indicated in the following list should be requested from the Supplier (KESSLER + CO
GmbH & Co. KG).

TOOL CODE DESCRIPTION

038.586.0---2 Spanner for wheel safety nut

031.107.0---3 Seal ring sleeve driver

031.476.0---3 Seal ring sleeve driver

Spanner for thread rings

038.005.0---3
(differential bearing)

038.007.2---4 Seal ring sleeve driver

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 24 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

DIAGNOSTICS

Axle
1. Continuous noise
2. Cornering noise
3. Alternating noise
4. Sharp bangs during acceleration or deceleration
5. Oil leak from the axle shafts
6. Oil leak from the hubs

1 CONTINUOUS NOISE

Worn bearings. Replace them.

YES

NO

Gears damaged or worn. Replace them.

YES

NO

Lack of lubrication. Restore oil level.

YES

NO

Incorrect adjustment of the clearances. Adjust again

YES

2 CORNERING NOISE

Worn planet ---wheels or crown wheels. Replace.

YES

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 ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 25

3 ALTERNATING NOISE

Wheel bearings with excessive clearance. Adjust the bearings.

YES

NO

Wheels mounted incorrectly. Disassemble and remount correctly.

YES

NO

Too little clearance in the bevel gear set. Adjust again.

YES

NO

Too much clearance in the bevel gear set. Adjust again.

YES

4 SHARP BANGS DURING

ACCELERATION OR DECELERATION

Incorrect gear train adjustment. Adjust again.

YES

NO

Pivot of the anchoring structure has too much Replace the parts of the articulated joint.
play. YES

NO

Loose fastening of the anchoring structure to Tighten the screws to the prescribed tightening
the chassis. YES torque.

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 26 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

5 OIL LEAK FROM THE AXLE SHAFTS

Worn oil seals. Replace them.

YES

NO

Loose screws. Tighten the screws to the prescribed tightening

YES torque.

Brakes
1. Weak braking action
2. Unequal action of the brakes
3. Brakes that remain blocked

1 WEAK BRAKING ACTION

Worn pads. Replace them.

YES

NO

Brake discs dirty with lubricant. Clean the discs and replace the pads.
YES

NO

Worn brake discs. Replace them.

YES

NO

Defective hydraulic system See Section 10 --- HYDRAULIC SYSTEM.

YES

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 27

2 UNEQUAL ACTION OF THE BRAKES

Pads and/or discs dirty with lubricant. Clean the discs and replace the pads.
YES

NO

Non---approved/different pads on the two sides. Replace with approved pads.

YES

NO

Worn brake discs. Replace them

YES

NO

Defective hydraulic system. See Section 10 --- HYDRAULIC SYSTEM.

YES

3 BRAKES THAT REMAIN BLOCKED

Foreign bodies between the discs. Overhaul the brakes.

YES

NO

Defective hydraulic system. See Section 10 --- HYDRAULIC SYSTEM.

YES

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
28 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

MAINTENANCE
The braking system components are funda- Figure 18
mental for the safe use of the vehicle.
All inspection and replacement operations
must be performed following the
manufacturer’s maintenance schedule and
procedures.
All the maintenance operations must be per-
formed by specialized personnel which has
been suitably trained and equipped with the 3
proper tools.
Replacements must be made with original
spare parts or parts satisfying the same spe- 1
cifications.
The pads (friction material) that have burns,
localized wear or cracks absolutely must be
replaced. Do not use different brands of
pads on the same axle. 2
If topping up is necessary, the same fluid as
that contained in the tank must be used.

Replacement of the brake pads

Proceed as follows:
D detach the caliper following the instructions in the
relative chapter;

Figure 17

276C061D060

D unscrew both the retaining screws (1) and partially

slip off both the upper centering pins (2) so as to free
the eyelets of the pads (3);
D remove both the pads by slipping them off the upper
part of the caliper (arrow);

274A061010

D connect a tube to the bleeding valve (arrow) and ar-

range a suitable container to collect the fluid that
leaks out;
D place two soft slats between the pistons, then force-
fully spread the pads apart using a lever or large
screwdriver and at the same time open the bleeding
valve until the cylinders return as far as possible into
their seats ;
D close the bleeding valve and disconnect the tube;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 29

Remove the dirt using a NON ---metallic Breaking -- in of the pads

brush and a vacuum cleaner.
Visually examine the dust covers, and check
that there is no seeping of hydraulic fluid.
If irregularities are found, proceed to the
brake caliper overhaul.
Figure 19
During this procedure there may be an
emission of unpleasant vapors and odors
originating from the friction material of the
pads.
After replacement of the brake pads, they must be
broken---in by traveling about 500 km.
During the breaking---in period the vehicle must be
used with caution, avoiding intensive use of the brakes
such as panic stopping.
During the breaking---in period it is good practice to
check the temperature of the brake discs: this tempera-
ture must not exceed 200 ˚C.
Determine the temperature of the disc by
stopping the vehicle and placing a pyrome-
ter in contact with the disc.

. The procedures described below refer to

both axles.
D inserire i perni (2) di centraggio nelle relative sedi e
bloccarli con le relative viti di arresto (1);

276C062D016

D mount the new pads by inserting them from the

upper part of the caliper (arrow), sliding them on the
disc surface and fitting them on the lower centering
pins (arrow);

Figure 20

276C061D061

D insert the centering pins (2) into the relative seats

and block them with the relative retaining screws
(1);
D proceed to the reattachment of the caliper following
the directions in the relative chapter.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
30 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

Checking oil level Changing the oil

Proceed as follows:
Collect and dispose of used lubricants and
The level check can be carried out on the fluids, according to the laws in force
hubs or on the differential .
Proceed as follows to drain the system:
If the level has to be restored, this is to be
carried out on the differential. Figure 23

Figure 21

276C062022
D take the reference on the hub to horizontal position
276C062020
(see arrow);
D arrange a suitably sized container, clean the cap
D take the reference on a hub to horizontal position area and remove the cap (1) and the drain cap (2);
(see arrow); drain all the lubricant;
D clean the cap area and open the level cap (1). Lubri- D clean the cap, check that the threading is in good
cant should drip out of the hole; condition, replace the sealing ring with a new one
D close the filler cap. and close the drain cap;
D repeat the procedure for the other hub;
Axle
D arrange a suitably sized container, clean the cap
area and remove the cap (1) and the drain cap (2);
Figure 22
drain all the lubricant.

276C062021
D clean the area of the cap, then open the cap (1): the
lubricant must leak from the hole;
D if necessary, restore the level until it overflows from
the same cap;
D close the cap;
D check that the breather is perfectly clean and ope-
rational.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 31

Figure 24 To fill the oil, proceed as follows:

Figure 26

276C062021
D arrange a suitably---sized container under the drain
cap, clean the cap areas and then remove the filling
cap (1); 276C062020

D pour in approx 3 litres of the prescribed lubricant un-

Figure 25
til it overflows from the cap hole (1);
D replace the sealing ring with a new one and close
the cap;
D repeat the procedure for the other hub.

Figure 27

1
2

276C062024
D remove the drain cap (1) and completely drain the
lubricant;
D clean the caps, check that the threading is in good
condition, replace the sealing ring with a new one
and close the drain cap.
276C062021
D refill with the prescribed lubricant until it overflows
from the hole of the filling cap (1);
Fill up slowly.
The operation is finished when the level at
the hole does not lower for a few minutes.
D replace the sealing ring with a new one and close
the cap;
D perform a test drive and then recheck the level (1);
D if necessary, top up with the prescribed lubricant un-
til it overflows from the hole, repeat the test drive and
recheck the level.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
32 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2
INTERMEDIATE AXLE REMOVAL---REFIT
. Before starting any operation, make sure
that all the precautions have been taken and
all aspects regarding safety of the personnel
involved on the job have been made quite
clear .
Read the relevant instructions contained in
SECTION 1 of this handbook.
If in doubt ask someone who is more expert.
Comply to all the general recommendations
for correct execution of maintenance work.
Removal
Proceed as follows:
D Bring the vehicle on a suitable flat, solid surface,
switch off the engine, remove the key from the igni-
tion switch, engage the parking brake and affix the
warning notices;
D deactivate the battery isolator or disconnect the bat-
tery terminals to prevent any risk of a short circuit;
D block articulation by means of the steering lock bar,
proceeding as indicated in SECTION 1;
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
D raise the vehicle until the wheels are off the ground,
then position two support trestles under the rear
chassis, without acting on the axles;
D position a suitable hydraulic support device under
the intermediate axle and under the rear axle in
order that, when lowering the axles after detach-
ment, the two axles remain in a horizontal position
during this phase;
D remove both the wheels following the directions in
SECTION 9;
D disconnect the axle breather pipe (4);
Before detaching the hydraulic pipelines,
prepare suitable plugs to close the free
ends.
D disconnect the hydraulic pipelines:
--- service braking system (20);
. Hydraulic oil leakage may occur during
these operations.
D disconnect the drive shaft on the input side (18) and
output side (19) following the instructions in SEC-
TION 7;
D working on both sides of each rocker arm, remove
the split pin and unscrew the locking nut (8) of the
rocker arm pin;
D remove the bolts (10) that fasten the tie---rod to the
bracket;
D slip the pin (9) off the rocker arm, recovering the
washers (6) and the guide bushings (7), disengag-
ing the rocker arm from the axle;
D carefully lower the axle and slip it off the vehicle.
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 33

Figure 28

276C062D027

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
34 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

BRAKE CALIPER DETACHMENT --- Figure 30

REATTACHMENT
1
Before performing any intervention, ensure
that all precautions have been taken and all
aspects clarified regarding the safety of per- 3
sonnel involved in the intervention.
Read the relative instructions provided in
4
SECTION 1 of this manual.
In case of doubt, consult a more experience 2
person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.

Detachment
Do as follows:
D bring the vehicle onto an appropriately solid flat sur-
face, shut off the engine, remove the key from the
ignition switch, engage the parking brake and affix
the indication signs;
D disconnect the battery---disconnect switch or dis-
connect the battery terminals in order to eliminate
any risk of short ---circuit;
D block the articulation by means of the steering lock
bar, operating as indicated in SECTION 1;
D block the rear wheels appropriately;
D use a hydraulic lift to raise the chassis until the rear
wheels are off the ground;
D disassemble the wheel concerned;
Figure 29
276C062D029
D disconnect the braking system hydraulic connector
(4) and plug it to prevent fluid leaks;
. Hydraulic oil leakage may occur during
these operations.
D support the caliper (2) appropriately, unscrew the
retaining screws (3) of the support bracket and re-
move the caliper complete with the bake pads.
Reattachment
Proceed to the reattachment by following the detach-
ment steps in the reverse order.
After reassembled, perform a bleeding of
the brake hydraulic circuit following the in-
structions in SECTION 10 --- HYDRAULIC
SYSTEM.

276C062D028

D insert appropriate support trestles under the axle,

then lower the chassis, resting the axle on the indi-
cated points (arrow) and remove the lift;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 35

Page left intentionally blank

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
36 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

EPICYCLIC REDUCER OVERHAUL Figure 32

Before starting any operation, make sure

that all the precautions have been taken and
all aspects regarding safety of the personnel
involved on the job have been made quite
clear.
Read the relevant instructions contained in
SECTION 1 of this handbook.
If in doubt ask someone who is more expert.
Comply to all the general recommendations
for correct execution of maintenance work.
5
. Before proceeding, it is necessary to: 4
D drain the lubricant from the wheel hub 3
D drain the lubricant from the central differ- 2
ential;
following the instructions provided in the
276C062D031
relative chapter.
D unscrew the central retaining screw (1) and remove
the fixed gear (2) and guide bushing (3) complete
. Before proceeding, the brake caliper must
with spacer ring (4);
be removed following the instructions in the D slip off the axle shaft (5) if necessary;
relative chapter.
Figure 33
Disassembly
Proceed as follows:

Figure 31

1
4

3 1
2 D unscrew the setscrew (1) of the ring nut;
276C062D030
D mark the mutual position of the planet ---wheel hol-
ding plate and the hub;
D loosen and remove all the retaining screws (1);
D remove the planet ---wheel holding plate assembly
(2) and O---ring (3) and recover the thrust spacer
ring (4);
2
276C062032
D remove the locking ring nut (2) of the internally too-
thed crown wheel.
The ring nut is locked with thread ---stops.
To prevent damage to the threading, heat to
approximately 120˚C before unscrewing.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 37

D using a suitable lifting device, carefully remove the Figure 36

complete hub from the hub support;
D place the hub vertically; 1

Figure 34

2
276C062D036

D Unscrew the retain screws (1) and remove the brake

disc (2);
D if necessary remove thewheel fastening screws
from the hub;

1 Figure 37
276C062D033

D use a suitable extractor to remove the internally too- 1

thed crown wheel (1); 1
Figure 35 2

1 2

3
3 276C062D035
276C062D034 D VERSION A: Remove the two oil seal rings (1);
D remove the retaining screws (1) and relative stop D use a suitable extractor to remove the outer race (2)
plates (2); of the axle---side bearing (A) and the outer race (3)
D separate the internally toothed crown wheel (3) from of the wheel---side bearing (B);
the relative flange (4);
D using a suitable extractor, remove the inner race (5)
of the wheel---side bearing (B) from the crown wheel
flange;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
38 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

Figure 38 Figure 40

2 1

276C062035B
D VERSION B: Remove the oil seal ring (1);
D with an appropriate puller remove the outer ring (2)
of the bearing on the axle side (A) and the outer ring
(3) of the bearing on the wheel side (B);
Figure 39
274A062029
D place the planet ---wheel holding plate on a suitable
work surface;
D use a punch to push the retaining pin (1) down in the
pivot, freeing the pivot (2);
D extract the pivot (2) by pushing it towards the inside
of the planet ---wheel holding plate (arrow);
D remove the O---ring (3);
D extract the pin from the pivot.
. Do not push the pivot towards the outside of
the planet---wheel holding plate, otherwise
its seat may be damaged due to the differ-
ence between the internal and external di-
ameter of the pivot.

Figure 41

2
1
2
276C062D037

D remove the screws (1) fastening the brake unit (2)

276C062038
to the hub;
D remove the planet wheel (1) and relative shim rings
The spacer ring is blocked with sealant.
(2);
To avoid damaging it, before removing, heat
to approx. 120 ˚C.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 39

Figure 42 Inspection of the dismantled parts

Wheel hub
D check the seats of the bearings: they must not have
any deformations and/or ovalling;
D check the condition of the bearings: replace them
if they have bluish halos, cracks and/or signs of
wear.

Axle shafts
D check the condition of the axle shafts: replace them
if they have deformations on the end grooves and/or
on the entire length.

274A062039 Final reductions

D remove the needle cages (arrow) from the planet ---
wheel;
D repeat the procedure for all the planet ---wheels.
D check the condition of the gear toothing: replace
them if they have pitting, cracks and/or cavities;
D verify the good operation of the planet ---wheels and
the roller bushings;
D check the threading for the bearing locking ring nut:
it must not have any dents, deformations and/or
jams.
During reassembly, consider the following
general observations:
D heat, to 100˚C in the oven, the bearings
and rings to be mounted by pushing;
D carefully center and mount the sealing
rings and bearings with a suitable adju-
ster;
D lubricate the ring nuts and bearings.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
40 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

Epicyclic reduction gear seals and thread-- stops application and bearings scheme

VERSION A

Figure 43

276C062D044A

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 41

Epicyclic reduction gear seals and thread-- stops application and bearings scheme

VERSION B

Figure 44

276C062D044B

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
42 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

Planet-- wheel holding plate assembly Figure 46

Proceed as follows:
D position the planet ---wheel holding plate horizontal- 2
ly;

Figure 45

1
2

276C062052

D mount the planet ---wheel (1) complete with shim

274A062032
rings in the seat on the planet ---wheel holding plate;
D mount the needle cages inside the planet gear; Figure 47

1 274A062035

D insert the O---ring (1) in the seat of the planet ---wheel

holding plate;
D insert the pivot (2) of the planet ---wheel holding gear
so that the pin holes match up;
D or according to the versions;
D insert the pivot (2) of the planet ---wheel holding gear
up to the complete expulsion of the internal reten-
tion bush so that the pin holes match up;
Mount the pivot from the internal part of the
planet---wheel holding plate, otherwise its
seat may be damaged due to the pivot dia-
meter difference.
D mount the catch pin (3);
D repeat the procedure for all the planet ---wheels.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 43

Brake unit and hub assembly Figure 50

Proceed as follows:

Figure 48

3
2

1
276C062053

D place the hub vertically;

D using a suitable introducer, mount the outer race (1)
of the wheel---side conic roller bearing (B) and the
outer race (2) of the axle---side conic roller bearing
(A);
D mount the inner race (3) of the axle---side conic roller
bearing (A);

Figure 49

276C062054B

D VERSION B: Fit the metal ring (1) in the seat on the

hub;
D with an appropriate inserter, fit the seal ring (2) into
the seat, flush with the external edge of the hub,
paying attention to the orientation (detail);

Figure 51

276C061D054A
D VERSION A: With an appropriate inserter, fit the seal
rings (1) into the seat on the hub paying attention to
the orientation (detail) and fill them completely with
lubrication grease for bearings (arrow);

276C062D055

D mount the brake disc (1) on the hub;

D mount retain screw (2) and tighten.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
44 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

Figure 52

3 1

276C062D066

D heat the spacer ring (1) and insert it completely on

the axle axis;
D using a suitable lifting device, support the hub as-
sembly in order to ensure its correct centering;
D introduce the hub assembly (2) on the end of the
hub support (3), placing the inner race of the axle---
side conic roller bearing (A) so that it rests against
the spacer ring;
During this operation, keep the hub parallel
to the axle axis.
Work with caution to avoid damaging the
sealing rings and the brake disc teeth.
Continue to support the hub assembly until
it is completely mounted.
D if removed, mount the stud bolts fastening the wheel
to the hub.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 45

Figure 53 Hub bearing preload determination

Proceed as follows:

Figure 55
4

2
2
3
276C062W067
D heat the inner race (1) of the wheel---side conic roller
bearing (B) and insert it until it rests against the gear
wheel flange;
D insert the gear wheel flange (2) onto the gear wheel
1
with internal toothing (3);
D mount the retention plates (4) and fix them with the
setscrews; 276C062069

Figure 54 D apply MOLYKOTE lubricant on the hub support

threading and on the threading and contact area of
the locking ring nut;
D hand mount the ring nut (1) without tightening;
D tighten the locking ring nut to the prescribed tighte-
ning torque:
Locking ring nut tightening torque for bearings
Phase 1: 700-- 900 Nm
During the locking, rotate the hub back and
forth by striking it with a plastic hammer to
settle the bearings.
D unscrew the locking ring nut half a turn;
D tighten the locking ring nut to the prescribed tighte-
ning torque:
Locking ring nut tightening torque for bearings
Phase 2: 450 Nm
During the locking, rotate the hub back and
1 forth by striking it with a plastic hammer to
settle the bearings.
276C062W068
D after having adjusted the bearing preload, block the
D mount the flange and internally toothed gear wheel
locking ring nut with the relative setscrew (2);
assembly (1) onto the hub until the two parts meet
the wheel---side conic roller bearing (B). If this is not possible, unscrew the ring nut
as much as needed in order to mount the
The lubrication oil passage hole on the too-
clamp screw.
thed wheel flange is to face downwards.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
46 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

Figure 56 Planet-- wheel holding plate -- fixed gear axial clear-

ance determination
Proceed as follows:

Figure 57

2
3
4 A
5
B
276C062D070
D insert the axle shafts (1) into the axle;
D mount the spacer ring (2), guide bushing (3) and fi-
xed gear (4);
D mount the central retaining screw (5) and tighten it.

274A062043

D determine the dimension A;

D determine the dimension B;
D determine the thickness of the thrust spacer as fol-
lows:
S = A -- B +(0.30 ÷ 0.70) (mm)
where:
A = distance between the planet ---wheel holding
plate mounting surface and the seat of the thrust
spacer on the same plate
B = distance between the hub mounting surface
and the thrust spacer seat on the fixed gear
S = thrust spacer thickness
0.30 ÷ 0.70 = prescribed clearance in mm
D mount the chosen thrust spacer onto the planet ---
wheel holding plate.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 47

Concluding operations

Figure 58

1 3
2
276C062D073

D mount the O---ring (1) in the seat of the planet ---whe-

el holding plate;
D mount the planet ---wheel holding plate assembly (2)
in the hub.
Respect the reference marks made during
disassembly.

D mount the retaining screws (3) and tighten to the

prescribed torque.

. If no intervention on the differential is

planned, proceed to:
D the filling of the wheel hub;
D the filling of the central differential;
following the instructions provided in the
relative chapter.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
48 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

TANDEM TRANSMISSION AND DIFFERENTIAL OVERHAUL

Before performing any intervention, ensure Disassembly

that all precautions have been taken and all
aspects clarified regarding the safety of per- . Before proceeding, the axle shafts must be
sonnel involved in the intervention. removed following the instructions in the re-
Read the relative instructions provided in lative chapter.
SECTION 1 of this manual.
In case of doubt, consult a more experien-
ced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.

Proceed as follows:

Figure 59

4
3

2
1

276C062D080

D straighten the dent and remove the motion input
flange stop nut (1);
D using a suitable extractor, remove the flange (2);
D straighten the dent and remove the motion output
flange stop nut (3);
D using a suitable extractor, remove the flange (4);
D mark the relative position between box and axle;
D loosen and remove the screws (3) fastening the ex-
ternal box to the axle;
D using a suitable lifting device, remove the external
box assembly from the axle;
D position the assembly on the support trestle, adap-
ting as necessary.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 49

Differential disassembly
Figure 60 Proceed as follows:

Figure 62
2
4
1
3 3

1 4
2

2 276C062081
D unscrew the retaining screws and remove the loc-
king plate (1) of both the bearing preload adjust- 274A062048
ment ring nuts;
D loosen both the bearing preload adjustment ring D remove the outer race (1) of the crown wheel---side
nuts (2); bearing (C) and the outer race (2) of the planet whe-
D mark each support cap and the corresponding ex- el---side bearing (D);
ternal box location; D use appropriate extractors to extract the inner race
D loosen the retaining screws (3) and remove both the (3) of the crown wheel---side bearing (C) and the in-
support caps (4); ner race of the planet wheel---side bearing (D) from
D remove both the adjustment ring nuts; the differential semicases;
D mark both the differential semicases;
Figure 61 D loosen the retaining screws and remove the diffe-
rential semicase;

Figure 63

274A062047
274A062049
D using a suitable lifting device, extract the differential
D disassemble the planet ---wheel group into the diffe-
assembly (1) from the relative case.
rent components;
D remove the discs of the skid limitation device and
the relative shoulder rings;
D if necessary, separate the ring bevel gear from the
differential semicase by unscrewing the retaining
screws.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
50 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

Idle gear and pinion disassembly

Figure 66
Proceed as follows:

Figure 64
2

2 4
1
1

276C062084
D remove the idle gear (1) from the pinion box;
276C062082 D remove the stop plate (2), adjustment ring nut (3)
D position the assembly horizontally; and the outer race (4) of bearing (E);
D remove the cover (1);
Figure 67
D straighten the dent and remove the pinion stop nut
(2).

Figure 65

5
3
4
2
1

276C062085

1 D remove the bearing preload spacer S2 (1), spacer

(2) and coaxial gear (3) from the pinion;
2 D remove the pinion (4);
D use a suitable extractor to remove the outer race of
276C062083
bearing (B) from the pinion box.
D unscrew the retaining screws and separate the pi-
nion box (1) from the external box (2);
D recover the inner races of bearing (B) and bearing
(F) from the external box.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 51

Figure 68

5
4
1
3
2

274A062086
D remove the outer race (1) of bearing (A) and the pi-
nion position spacer S1 (2) from the external box;
D remove the sealing ring (3) from the external box;
D remove the elastic ring (4) and outer race (5) of bea-
ring (F).

Figure 69

276C062087
D using a suitable extractor, remove the inner race (1)
of bearing (E) from the gear

Figure 70

274A062055

D using a suitable extractor (1), remove the inner race

(2) of bearing (A).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
52 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

Coutershaft disassembly
Proceed as follows:

Figure 71

2
5
4
1
3

276C062D088

D loosen the retaining screws and remove the coun-

tershaft cover (1) complete with countershaft;
D using a suitable extractor, remove the countershaft
(2) complete with ball bearing;
D remove the elastic ring (3) and spacer ring (4);
D use a press and pad to separate the countershaft (2)
from the bearing (5);
D remove the sealing ring (6) from the cover.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 53

Inspection of the disassembled parts Reassembly

During reassembly consider the following

Bearings
general observations:
D check the condition of the bearings: replace them D heat, to 100˚C in the oven, the bearings
if they have bluish halos, cracks and/or signs of and rings to be mounted by pushing;
wear. D carefully center and mount the sealing
rings and bearings with a suitable adju-
Crown wheels ster;
D check the condition of the toothing: replace it if it has D lubricate the bushes, sealing rings and
pits, cracks and/or cavities. bearings.

Planet ---gears Perform all the indicated measurements

D check the condition of the toothing: replace it if it has
pits, cracks and/or cavities;
D check the coupling surfaces with the pins.
Damage to a single element entails the re-
placement of the entire gear unit.
with maximum precision.
Imprecise measurements lead to bad con-
tact of the bevel gear and thus make it ne-
cessary to repeat the procedure.

Cross pins
D check the coupling surfaces with the planet ---gears.

Shoulder rings
D check the condition of the rings: replace them if they
have bluish halos, cracks and/or signs of wear.

Bevel gear
D check that the toothing of the crown wheel and the
pinion show uniform wear on the entire working zo-
ne of the teeth: replace the bevel gear if it has pits,
cracks and/or cavities;
An anomalous wear may indicate an incor-
rect adjustment of the bearings: check their
integrity before proceeding to the reassem-
bly.
Damage to a single element entails the re-
placement of the entire gear unit.
D check the bearing seats: they must not have defor-
mations or ovalling.

Bushes
D check the threading for the bearing locking bush: it
must not have dents, deformations and/or jams.

External box
D check the bearing seats: they must not have defor-
mations or ovalling;
D check that the sealing surfaces and the threadings
are integral and free of dents or damage.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
54 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

Differential seals and thread-- stops application and bearings scheme

Figure 72

276C062090A

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 55

Complete limited-- skid differential assembly

Proceed as follows:

. Refer to the following figure.

D check the following measurements:
SP1 = 3.10 mm minimum;
SP2 = 2.15 mm minimum.
D otherwise, use shoulder discs with a greater thick-
ness;
D mount the shoulder ring (2) and elastic ring (3);
D position the shoulder disc (SP1) (4);
D alternately mount an externally grooved disc (driven
plate) and an internally grooved disc (driving plate)
until all discs (5) have been mounted;
The last disc is a driving plate.

D mount the shoulder disc (SP2) (6);

D mount the elastic ring (7);
D mount the planetary gear;
D repeat the assembly for the other semicase;
D when finished, check that dimension A falls within
the prescribed values;
52.8 < A < 53.27 mm
D when finished, check that dimension B falls within
the prescribed values;
B < 0.48 mm
D otherwise, use shoulder discs with a greater thick-
ness or reduce the thickness by grinding;
D assemble the shafts and planet ---wheel gears and
mount the assembly on the crown wheel;
D join the two semicases and tighten the retaining
screws to the prescribed torque.
The two semicases are symmetric except for
the crown wheel assembly flange.
The total height of the crown wheel---side
disc pack must be identical to that on the op-
posite side.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
56 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

Figure 73

1. Differential semicase
2. Shoulder ring
3. Elastic ring
4. Semicase shoulder disc SP1
5. Driven (N.4) and driving (N.4) discs
6. Crown wheel shoulder disc SP2
7. Elastic ring
8. Crown wheel --- planet ---wheel group SP1
Dimension A: disc pack thickness
Dimension B: Shoulder ring --- crown wheel clearance

SP2

1
2

4 A
5
6
7

6
5
4

2
1

276C062091

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 57

Crown wheel and bearings assembly

Figure 74

274A062060
Proceed as follows:
D check that the area of contact between the gear (1)
and differential semicase (2) is clean and free of
grease;
D mount the crown wheel on the semicase and tighten
the fastening bolts (3) to the prescribed torque;

Figure 75

2
274A062062
D heat the inner race (1) of the planet wheel---side co-
nic roller bearing (D) and mount it against the diffe-
rential semicase;
D heat the inner race (2) of the crown wheel---side co-
nic roller bearing (C) and mount it against the diffe-
rential semicase.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
58 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

Determination of the pinion axial position spacer (S1) thickness

Figure 76

276C062092

Proceed as follows:
D determine the thickness beff of the internal conic rol-
ler bearing (A);
D calculate the difference d between the effective
thickness and the theoretical thickness bteor = 40.0
mm of the internal conic roller bearing (A);
d = beff -- bteor (mm)
D measure the dimension a;
D determine the effective thickness of the pinion posi-
tion spacer (S1) as follows:
S1eff = S1teor -- (d + a) (mm)
where:
S1teor = theoretical thickness of the pinion position
spacer (S1) = 3 mm
S1eff = effective thickness of the pinion position
spacer (S1)
d= difference between the effective and theo-
retical thickness of the internal conic roller
bearing (A) calculated previously
a= value stamped on the pinion head

Example 1:
beff = 39.95 mm
difference d = 39.95 --- 40.00 = --- 0.05 mm
a = + 0.10
thickness S1eff = 3 --- ( --- 0.05 + 0.10) = 2.95 mm

Example 2:
beff = 40.05 mm
difference d = 40.05 --- 40.00 = --- 0.05 mm
a = --- 0.10
thickness S1eff = 3 --- (0.05 --- 0.10) = 3.05 mm

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 59

Figure 77

276C062093
D heat the inner race of bearing (A) and mount it on the
pinion;

Figure 78

4 1

6 3
5

276C062094

D position the chosen pinion position spacer (S1) (1)
in its seat;
D mount the outer race (2) of bearing (A) until it rests
against spacer S1;
D insert the pinion (3) into the external box;
D mount the pinion box on the external box and
tighten the retaining screws to the prescribed
tightening torque;
D mount the outer race (4) of bearing (B) until it rests
against the box;
D mount the inner race (5) of bearing (B) on the pinion;
D apply MOLYKOTE on the pinion threading and on
the threading and contact area of the stop nut;
D mount the stop nut (6) and tighten it until there is no
play in the bearings.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
60 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

Check of the pinion-- crown wheel clearance D apply MOLYKOTE on the threading of the adjust-
Proceed as follows: ment ring nuts;
D screw on both the ring nuts by hand until there is no
Figure 79 play in the bearings;

Figure 81

17312101
D position the conic roller bearing outer races on both
ends of the differential;
D using a suitable lifting device, mount the crown whe-
el assembly in the differential case;

Figure 80 17312104

D mount a dial gauge at a right angle with respect to

the external diameter of the crown wheel’s toothed
side and turn the crown wheel back and forth, being
careful not to move the pinion;
D check that the clearance between the crown wheel
and pinion falls within the prescribed values:
pinion-- crown wheel clearance
see value engraved on the crown wheel
D otherwise, adjust the clearance using the adjust-
ment ring nuts;
D the clearance can be adjusted by unscrewing one
adjustment ring nut by a certain number of notches
and screwing on the opposite adjustment ring nut
by the same number of notches;
17312102
Figure 82
D align the reference marks and mount the bearing
support caps;
D mount the cap retaining screws and tighten to the
prescribed tightening torque;

17312105
D In particular:
--- unscrew the ring nut (D) and screw on the ring
nut (C) to reduce the clearance (white arrow);
--- unscrew the ring nut (C) and screw on the ring
nut (D) to increase the clearance (black arrow).
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 61

Verification of the pinion-- crown wheel engagement

impression area
Proceed as follows:

Figure 83

17312106

D cover a dozen teeth of the crown wheel with Prus-

sian blue, lubricated with minium, or another paint
or dye that can be easily removed;
D make a complete rotation of the crown wheel by
hand;
D when the teeth engage, the paint is removed by the
contact of the teeth, leaving zones exposed with the
exact dimension, shape and location of contact;

Figure 84

274A062063

Contact area position and shape D to replace the spacer S1, remove the retaining
1. correct bevel gear position; screws (1) and slip off the complete pinion box;
2. position with the pinion too far back: it is necessa- D position the new spacer S1, then reassemble the pi-
ry to reduce the distance between the pinion and nion box and tighten the retaining screws to the pre-
the crown wheel axis by using a spacer S1 of grea- scribed tightening torque.
ter thickness; then adjust the clearance by mo-
When finished, remove the differential, pi-
ving the crown wheel further from the pinion;
nion and pinion box.
3. position with the pinion too far forward: it is neces-
sary to increase the distance between the pinion
and the crown wheel axis by using a spacer S1 of
smaller thickness; then adjust the clearance by
moving the crown wheel closer to the pinion;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
62 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

Idle gear bearing preload determination Figure 87

Proceed as follows:

1
Figure 85

1 2

276C062097

276C062095 D mount the bearing (E) outer race (1);

D heat the inner race (1) of bearing (E) and mount it D apply MOLYKOTE on the threading of the adjust-
on the idle gear; ment ring nut;
D mount the adjustment ring nut (2) without tighte-
ning.
Figure 86

1
276C062096
D mount the bearing (F) elastic stop ring (1);
D mount the complete bearing (F) (2) until it rests
against the elastic ring;
D insert the idle gear (3) into the external box;
D mount the pinion box on the external box and tigh-
ten the retaining screws to the prescribed tightening
torque.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 63

Figure 88 Figure 89

276C062098A
D mount the flange (1), inserting it inside bearing (F);
D apply MOLYKOTE on the gear threading and on the
threading and contact area of the stop nut;
Use a new stop nut.
D mount the stop nut (2) and tighten it to the prescri-
bed torque.
276C062099
D tighten the adjustment ring nut (1) until obtaining
the prescribed value for the bearing rolling torque.
Rolling torque for gear bearings
1.0 Nm
D unscrew the ring nut by two notches;
D fix the locking plate (2) of the ring nut by screwing
on the clamp screw.
When finished, remove the external box,
then remove the idle gear by unscrewing the
stop nut.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
64 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

Pinion bearing preload determination

Proceed as follows:

Figure 90

5 2

6 1

276C062100

D insert the pinion (1), complete with inner race of the
conic roller bearing (A), into the external box;
D mount the coaxial gear (2), spacer (3) and spacer
S2 (4), which were removed during disassembly,
onto the pinion;
D mount the pinion box on the external box and tigh-
ten the retaining screws to the prescribed tightening
torque;
D mount the inner race (5) of conic roller bearing (B)
on the pinion;
D apply MOLYKOTE on the pinion threading and on
the threading and contact area of the stop nut;
Use a new stop nut.
D mount the stop nut (6) and tighten it to the prescri-
bed torque;
Block the coaxial gear during this operation.
D use a suitable tool to check that the rolling torque
falls within the prescribed values:
Rolling torque for pinion bearings
1.5-- 1.8 Nm
D otherwise correct the rolling resistance by using a
spacer S2 with a different thickness;
D In particular:
--- increase the thickness to reduce the torque;
--- reduce the thickness to increase the torque.
When finished, unscrew the stop nut and re-
move the external box.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 65

Idle gear and pinion assembly Figure 93

Proceed as follows:
D insert the idle gear into the external box;
D mount the pinion box on the external box and tigh- 1
ten the retaining screws to the prescribed tightening
torque; 2
Figure 91

276C062102
D mount the inner race (1) of bearing (B);
D mount the pinion stop nut (2) and tighten it to the
prescribed torque;

Figure 94

276C062101A

D use a suitable tool to insert the sealing ring (1) in the

seat and fill it completely with lubricating grease for
bearings;
D mount the flange (2), inserting it inside bearing (F);
D mount the idle gear stop nut (3) and tighten it to the
prescribed torque;
274A062066
Figure 92
D dent the nut as described in the figure;
If this is not possible, unscrew the nut as
much as necessary to dent it.
D mount the cover and screw on the retaining screws.

274A062066

D dent the nut as described in the figure.

If this is not possible, unscrew the nut as
much as necessary to dent it.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
66 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

Differential bearing preload determination Figure 96

Proceed as follows:

Figure 95

274A062064

D once all the adjustments and configurations are cor-

rect, fix the locking plate (1) of both the ring nuts
17312102
using screws;
D support the complete external box with suitable lif-
D align the reference marks and mount the bearing ting equipment;
support caps; D mount the complete external box assembly onto the
D mount the cap retaining screws and tighten to the axle respecting the reference marks made during
prescribed tightening torque; disassembly;
D screw on both the ring nuts by hand until there is no D screw on the retaining screws and tighten to the pre-
play in the bearings; scribed torque.
D as described previously, check that the clearance
between the crown wheel and pinion falls within the
prescribed values:
pinion-- crown wheel clearance
see value engraved on the crown wheel
D otherwise, adjust the clearance using the adjust-
ment ring nuts;
D use a suitable tool to check that the rolling torque
falls within the prescribed values:
Rolling torque for crown wheel and pinion bea-
rings
5,0÷5,5 Nm (including pinion and transmission)
D the rolling torque can be corrected by turning both
the adjustment ring nuts by the same number of not-
ches;
D in particular:
--- unscrew the ring nuts to decrease the torque;
--- screw on the ring nuts to increase the torque.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 67

Coutershaft assembly
Proceed as follows:

Figure 97

276C062103

Proceed as follows:
D determine the dimension b of the ball bearing;
D determine the dimension A on the box;
D determine the dimension B on the cover;
D check that the clearance between the bearing side
and the edge of the cover fall within the prescribed
values:
bearing -- cover clearance
A -- (B + b) = 0.05 ÷ 0.2 mm
where:
A = the distance between the bearing assembly pla-
ne and the cover support plane
B = the depth of the cover
b = effective thickness of the bearing

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
68 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

Figure 98

4
3
5
2
6

276C062D104

Mount the sealing ring (1) on the cover.

The sealing ring must be flush with the exter-
nal surface of the cover.
D mount the cover (2) complete with sealing ring onto
the shaft;
D mount the bearing (3) on the shaft (4);
D mount the spacer ring (5) and elastic ring (6);
D mount the countershaft complete with bearing and
cover onto the axle housing until the groove inserts
into the corresponding seat on the countershaft;
D screw on the retaining screws fastening the cover to
the axle.

. Proceed to:
D the reassembly of the axle shafts;
D the filling of the wheel hubs;
D the filling of the central differential;
following the instructions provided in the re-
lative chapter.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 69

BRAKE CALIPER OVERHAUL Figure 100

Before performing any intervention, ensure

that all precautions have been taken and all
aspects clarified regarding the safety of per-
sonnel involved in the intervention.
Read the relative instructions provided in
SECTION 1 of this manual.
In case of doubt, consult a more experi-
enced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.

Disassembly 1
Proceed as follows:

Figure 99 2
276C062D110

D unscrew the retaining screws (1) and remove the

plate (2);

. Hydraulic oil leakage may occur during

these operations.

3 Figure 101

2 3

276C061D060
2
D unscrew both the retaining screws (1) and partially
slip off both the upper centering pins (2) so as to free
1
the eyelets of the pads (3); 276C062D111
D remove both the pads by slipping them off the upper D pressing from the inside of the piston, remove the
part of the caliper (arrow); cover (1) and the gasket (2);
D push the piston (3) towards the inside of the caliper
until it disengages from the dust cover;

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70 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

Figure 102 Reassembly

Proceed as follows:

Figure 103

3
2
1
1
276C062D112
2
D remove the shoulder ring (1), gasket (2) and dust 3
cover (3);
D repeat the operations for all the pistons in the cali- 276C062D113
per. D mount the dust cover (1), gasket (2) and shoulder
ring (3) in the appropriate seat on the caliper;
Inspection of the disassembled parts
Proceed as follows: Figure 104
D carefully clean the entire caliper, especially in the in-
ternal parts and around the piston seats;
D remove the bleeding valves, then carefully clean all
the internal canalizations by blowing with com-
pressed air;
D with a cloth soaked in isopropyl alcohol or equival-
ent, carefully clean the sliding surface of the pistons;
D check the wear conditions of the pistons and rela-
tive seats: if wear or damage is found, proceed to 1
their replacement;
D manually insert the pistons into the seats and check
for correct sliding: otherwise, proceed to replace-
ment;
D check the conditions of the guide pins of the pads: 274A061034
in case of damage, proceed to their replacement. D mount the piston (1) in the appropriate seat, slip-
Always replace the gaskets, sealing rings ping the dust cover onto the groove (arrow) on the
and dust covers even if apparently intact. piston;
During reassembly, lubricate all the internal To facilitate the operation, rotate the piston
components with the prescribed hydraulic slightly during insertion.
fluid.

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ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- DISC BRAKES 71

Figure 105

1
2
276C062D114

D mount the sealing gasket (1) and cover (2);

D repeat the operations for all the pistons in the cali-
per;

Figure 106

1
276C062D115
D mount the plate (1) and tighten the retaining screws
(2);
D proceed to the assembly of the new brake pads by
following the disassembly steps in the reverse
order.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
72 INTERMEDIATE AXLE -- DISC BRAKES SECTION 6.2 ADT 25-30 TIER3

BRAKE DISC OVERHAUL Figure 107

Before performing any intervention, ensure

that all precautions have been taken and all
aspects clarified regarding the safety of per-
sonnel involved in the intervention.
Read the relative instructions provided in
SECTION 1 of this manual.
In case of doubt, consult a more experien-
ced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.

Disassembly
Proceed to the detachment of the brake disc following
the instructions in the relative Chapter.
Inspection of the disassembled parts
Proceed as follows:
D perform a careful cleaning of the disc;
D check the conditions of the disc, making reference
to the figure:
A. Superficial microcracks on the side of the disc: 274A061037
acceptable
B. Radial cracks: NON---acceptable
C. Cracks on the edge of the attachment to the
flange: NON---acceptable.

Reassembly
Proceed to the reattachment of the brake disc following
the instructions in the relative chapter.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 SECTION 6.2

INTERMEDIATE AXLE --- WET OIL

 ADT 25-30 TIER3 SECTION 6.2
CONTENTS
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tandem transfer case . . . . . . . . . . . . . . . . . . . . . . . . . . 4
First reduction: bevel gear pair . . . . . . . . . . . . . . . . . . 5
Second reduction: hub and epicyclic train . . . . . . . 12
Braking assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Brake system fittings . . . . . . . . . . . . . . . . . . . . . . . . . 14
Operating brake unit . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . 16
Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Splitter unit and bevel gear pair (first reduction) . . 17
Hub and epicyclic gear (second reduction) . . . . . . 18
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . 19
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INTERMEDIATE AXLE REMOVAL-- REFIT . . . . . . 30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
EPICYCLIC REDUCER OVERHAUL . . . . . . . . . . . . 32
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Brake disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Inspection of the dismantled parts . . . . . . . . . . . . . . 36
Epicyclic reduction gear seals and thread---stops
application and bearings scheme . . . . . . . . . . . . . . 37
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
INTERMEDIATE AXLE -- WET OIL 1
Page
Oil---wet brake assembly . . . . . . . . . . . . . . . . . . . . . . 38
Brake actuation circuit seal inspection . . . . . . . . . . 40
Piston actuation travel inspection . . . . . . . . . . . . . . . 41
Planet ---wheel holding plate assembly . . . . . . . . . . 41
Brake unit and hub assembly . . . . . . . . . . . . . . . . . . 42
Hub bearing preload determination . . . . . . . . . . . . . 47
Planet ---wheel holding plate --- fixed gear axial
clearance determination . . . . . . . . . . . . . . . . . . . . . . 48
Brake cooling circuit seal inspection . . . . . . . . . . . . 49
Concluding operations . . . . . . . . . . . . . . . . . . . . . . . . 49
TANDEM TRANSMISSION AND DIFFERENTIAL
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Inspection of the disassembled parts . . . . . . . . . . . 55
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Differential seals and thread---stops application
and bearings scheme . . . . . . . . . . . . . . . . . . . . . . . . . 56
Complete limited---skid differential assembly . . . . . 57
Crown wheel and bearings assembly . . . . . . . . . . . 59
Determination of the pinion axial position
spacer (S1) thickness . . . . . . . . . . . . . . . . . . . . . . . . . 60
Check of the pinion---crown wheel clearance . . . . 62
Verification of the pinion---crown wheel
engagement impression area . . . . . . . . . . . . . . . . . . 63
Idle gear bearing preload determination . . . . . . . . . 64
Pinion bearing preload determination . . . . . . . . . . . 66
Idle gear and pinion assembly . . . . . . . . . . . . . . . . . 67
Differential bearing preload determination . . . . . . . 68
Coutershaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . 69
2 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

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ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 3

DESCRIPTION
The axle is a dual reduction bearing type. The structure has mountings for connection to the
It consists of a boxed structure containing the cylindri- chassis and housings for the bearings.
cal wheel transmission, the bevel gear pair with the dif-
ferential (first reduction), the drive shafts and hubs with
the epicyclic reducer (second reduction).

Figure 1

276C062W001
1. Rear suspension
2. Hub with epicyclic gears
3. Differential case
4. Motion input flange
5. Axle
6. Oil---wet brake unit
7. Upper stabilizer bar

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4 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

Tandem transfer case

The transfer case is composed of a pair of spur gears The torque is always divided into equal parts between
and an output shaft. the two tandem axles.
The pair of gears (having ratio 1:1) transmit the motion
to the differential pinion while the output shaft transmits
the motion to the rear axle.

Figure 2

276C062002A
1. Input flange
2. Input countershaft
3. Output shaft to rear axle
4. Transmission conic roller bearings
5. Gear for motion transmission to pinion
6. Pinion conic roller bearings
7. Ball bearing
8. Intermediate axle differential unit

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ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 5

First reduction: bevel gear pair Legend (figure on following page)

The first reduction is obtained by the pinion---ring bevel
1. Adjustment ring nut
gear unit (bevel gear pair) inside the differential.
2. Internal conic roller bearing
The input shaft is supported by two taper roller bear-
3. External conic roller bearing
ings mounted in O arrangement with preload that can
4. Motion input flange
be adjusted by spacer.
5. Transmission spur gear
The pinion shaft receives motion from a cylindrical
6. Double sealing ring
wheel transmission with ratio 1:1.
7. Pinion spur gear
The pinion is supported by two taper roller bearings
8. Pinion external conic roller bearing
mounted in O arrangement with preload that can be ad-
9. Bevel pinion
justed by spacer. The axial position of the pinion can
10. Pinion internal conic roller bearing
also be adjusted by shims.
11. Axle
The differential box with ring bevel gear is supported by
12. Differential semicase
two taper roller bearings mounted in X arrangement
13. Output flange
with preload and axial position adjustable by two op-
14. Sealing ring
posing ring nuts.
15. Ball bearing
16. Shaft
17. Crown wheel---side conic roller bearing
18. Axle shaft
19. Adjustment ring nut
20. Differential case
21. Crown wheel
22. Planet ---wheel
23. Planet wheel---side conic roller bearing
24. Adjustment ring nut
25. Planet wheel holding shaft
26. Differential semicase
27. Crown wheel

A: Cross section
B: Functional diagram

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6 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

Figure 3

276C062003A

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ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 7

Figure 4

276C062004

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8 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

The differential is a limited---skid differential, characteri-
zed by the positioning of a multiple---disc clutch betwe-
en the differential case (upright) and the crown wheels
(sun gears) for each side.
The multiple---disc clutch includes external discs con-
nected to the differential case and internal discs con-
nected to the planetary gears.
The thrust on the discs is ensured by the axial compo-
nent of the force exchanged between the teeth of the
planet ---wheels and crown wheels.
The axial thrust on the discs generates a resistant tor-
que that acts on the crown wheel when the crown whe-
el tends to rotate with respect to the differential case
due to the speed difference between the two wheels.
This resistant torque depends, with equal axial thrust,
on the dimensions and the coating material of the
discs.

Figure 5

3,1 2

2,15

0,48

1. Differential semicase
2. Planetary gear
3. Multiple---disc device for skid limitation
3

52,8 --- 53,27

276C062005

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2
Operation
The torque coming from drive shaft is transmitted
through a cardan joint to the bevel pinion.
From this, the torque passes to the ring bevel gear,
which is integral with the differential case.
The differential is a gear train in which the case repre-
sents the upright, that holds the planet ---wheel holding
shafts and receives the torque, while the two crown
wheels represent the sun gears, both rotary, that recei-
ve the torque and transmit it to the axle shafts.
When both the wheels are subject to the same resistant
torque or have the same speed (vehicle traveling along
a straight path), the ring bevel gear and the differential
case rotate as a block, transmitting the torque in equal
parts to the two crown wheels, and from these to the
two axle shafts that rotate at the same speed: the whe-
els transmit the same driving torque.
Figure 6
LH RH
276C062006
The right wheel with the same adherence as the left.
RH: right side: torque supplied is 50% of the total
LH: left side: torque supplied is 50% of the total
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
INTERMEDIATE AXLE -- WET OIL 9
Under these conditions, there is no relative motion bet-
ween the two crown wheels, and thus the planet ---whe-
els do not rotate around their shaft which is integral with
the differential case.
When the resistance of one wheel exceeds that of the
other or when the speed of the two wheels is no longer
equal (vehicle traveling a curved path) the planetary
gears assume a different rotation speed: their relative
motion is allowed by the presence of the planet ---whe-
els, which now rotate around their own shaft in opposi-
te directions.
Naturally, a slower rotation speed of the crown wheel
corresponds to a greater driving torque transmitted,
and vice versa.
Thus when the differential operates the wheel that has
a smaller speed, it is able to transmit a greater driving
torque, while the one with the greater speed transmits
a smaller torque.
Under certain conditions it may occur that the slower
wheel completely loses adhesion, since the torque that
can be transmitted to the ground is exceeded, and thus
it encounters practically zero resistance: in this case, a
normal differential causes the free rotation of the wheel
that skids and the stopping of the wheel that still adhe-
res to the ground: the traction capacity of the axle beco-
mes zero.
To remedy this inconvenience, a limited---skid differen-
tial is used that is characterized by the possibility to ge-
nerate a resistant torque on each crown wheel, which
is no longer free to rotate with respect to the differential
case, but is braked in proportion to the torque that the
differential must transmit.
This resistant torque, which depends on the thrust ap-
plied to the multiple---disc clutch, is always in a fixed ra-
tio with the input torque, known as the ”locking ratio”.
The locking ratio is the percentage of maximum diffe-
rence between the torque transmittable to the wheel
with greater adherence and that on the wheel with less
adherence.
For example, with a locking ratio of 45%, 72,5% of the
driving torque is transferred to one rear axle shaft (ra-
ther than the normal 50%), while the other axle shaft re-
ceives only 27.5%: the difference is precisely 45% (with
respect to a total of 100%).
10 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

If the two wheels do not have the same adherence, the In practice, the multiple---disc clutches automatically
resistant torque generated by the multiple---disc clut- compensate the adherence variations of the wheels
ches partially locks the crown wheel on the side having from the left side and right side of the vehicle, without
less adherence and increases the torque supplied by requiring any driver operation. It is thus possible to ap-
the crown wheel on the side with more adherence. In ply a much larger driving force when using the vehicle,
other words, the braking torque replaces the reaction and prevent skidding when one of the wheels encoun-
torque missing from the side of the wheel with less ad- ters a surface lacking adherence.
herence.
In this manner, considering the previous case in which
one wheel loses adherence, this wheel is not able to
turn freely and thus the other wheel will still be able to
transmit part of the driving torque, ensuring at least so-
me traction capacity of the axle.

Figure 7

LH RH

276C062007
Left wheel with less adherence than the right wheel
(example)

RH: right side: torque supplied is 72.5% of the total

LH: left side: torque supplied is 27.5% of the total

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ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 11

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12 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

Second reduction: hub and epicyclic train

The second reduction is obtained by an epicyclic re- Legend (figure on following page)
ducer with cylindrical wheels in the wheel hub.
The hub is supported by two taper roller bearings 1. Epicyclic train upright
mounted in O arrangement with preload that can be ad- (planet ---wheel holding plate)
justed by a ring nut. The planetary gear gears turn on 2. Thrust spacer
pivoting roller bearings. 3. Planet ---wheel
4. Epicyclic train fixed gear
Operation 5. Planet ---wheel pin
6. Guide bushing
The torque from the differential is transmitted by a float-
7. Adjustment ring nut
ing axle shaft to the sun gear by the grooved shank.
8. Epicyclic train crown wheel
The four planetaries gears rotate in the opposite direc-
9. Hub
tion to the sun gear, where as the crown wheel is inte-
10. Wheel fastening column
gral to the hub support, and therefore does not rotate.
11. Sealing rings
This forces the train carrier to turn in the opposite direc-
12. Brake bell
tion to the planetaries gear, therefore in the same direc-
13. Brake discs
tion as the drive shaft.
14. Actuation piston
15. Brake unit
16. Brake actuation fitting
17. Sealing rings
18. Hub support
19. Spacer
20. Internal conic roller bearing
21. External conic roller bearing
22. Axle shaft
23. Central retaining screw

A: Cross section
B: Functional diagram

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ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 13

Figure 8

276C062W008A

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14 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

Braking assembly

Description Operation
The braking assembly consists of a set of plates with The driving pressure depends on the driver’s pressure
external toothing (1) arranged alternatively with a set of on the brake pedal. As a function to major or minor hy-
plates with internal toothing (2). The plates with exter- draulic pressure, the plates slip more easily or with mo-
nal toothing engage in the bell (3), integral with the fi- re difficulty: in this way the wheel braking is more or less
xed part of the axle, whereas the plates with internal effective.
toothing engage in the hub (5), integral with the wheel. When oil pressure is no longer applied to the piston, di-
The plates are enclosed in an oil wet and cooled by sengagement is guaranteed by the mechanical action
means of an inlet fitting (8) and an outlet fitting (9). A of a series spring that acting on the piston in the opposi-
special seal ring (4) prevents the cooling oil from flo- te direction to the pressure of the oil. This leads to play
wing out and impedes entry of foreign matter. An oil between the disks and allows them to slip freely.
seal ring (10) prevents the cooling oil passing to the
wheel hub bearings.
The brake is engaged hydraulically, sending oil under Brake system fittings
pressure to the rear of the control piston (6) through the
fitting (7). Figure 9
The discs are immersed in oil in order to ensure their
cooling: the circulation of the coolant occurs through 3 2 1
two input and output fittings.
A special front sealing ring (4) prevents leakage of the
cooling oil or entry of foreign matter. A double oil seal
ring (8) prevents the cooling oil from passing to the
wheel hub bearings.
Operating brake unit (see figure on next page)
1. Brake unit 4
2. Screw
3. Sealing ring
4. Sealing ring
5. Fitting
6. Drain
7. Spacer
8. Screw
9. Spring
10. Screw
11. Bushing
12. Screw
13. O---Ring 5
14. Cap
15. Sealing ring 6
16. Sealing ring 276C062W009
17. Cap 1 Coolant input
18. Sealing ring 2 Brake control input
19. Front sealing ring 3 Brake control air bleeder
20. Control piston 4 Coolant output
21. Internally toothed discs 5 Inspection cap
22. Externally toothed discs 6 Coolant drain
23. Brake housing (bell)
24. O---Ring

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ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 15

Operating brake unit

Figure 10

1
24
2
23
3
22
4
21
5
20

19
6

10

11

12

13

14

15

16

17

18

276C062W010

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16 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

SPECIFICATIONS AND DATA

Hub

Code KESSLER D 81
Type Rigid with double reduction
Central differential Limited skid – Gleason crown wheel and pinion
Rear axle transmission Fixed distribution 50 --- 50
Pinion bearings 2 O---mounted conic roller bearings
Differential bearings 2 X---mounted conic roller bearings
Tandem transmission bearings 2 X---mounted conic roller bearings
Hub bearings 2 O---mounted conic roller bearings for each side
Hub planet ---wheel bearings 3 x 4 needle cages for each side
Reduction ratio bevel gear set 1 : 3.50
wheel reducer 1 : 6.00
total 1 : 21.00
Pinion bearing preload 1.5 – 1.8 Nm
Differential bearing preload 5.0 – 5.5 Nm (including pinion and transmission)
Crown wheel and pinion clearance see value engraved on the crown wheel
Self---blocking discs axial clearance 0.48 mm minimum
Tandem transmission conic bearing preload 1.0 Nm
Tandem countershaft axial clearance 0.05 --- 0.2 mm
Reduction gear upright–axle shaft axial clear-
0.30 – 0.70 mm
ance
Hub bearing preload determined by the ring nut tightening torque
Ring nut tightening torque 1st tightening: 700---900 Nm then loosen
2nd tightening: 450 Nm
Brake type Multiple discs in oil wet
Control Hydraulic
Discs per group fixed 4
rotating 4
Brake control piston axial travel 2.5 + 0.7 / --- 0.1 mm under pressure

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ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 17

Splitter unit and bevel gear pair (first reduction)

Figure 11

276C062011A

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18 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

Hub and epicyclic gear (second reduction)

Figure 12

276C062W012

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ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 19

TIGHTENING TORQUES

Figure 13

276C062W013

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20 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

TIGHTENING TORQUES

Figure 14

276C062D014A

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ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 21

TIGHTENING TORQUES

Figure 15

276C062D014B

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22 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

EQUIPMENT
. The tools indicated in the following list should be requested from the Supplier (KESSLER + CO
GmbH & Co. KG).

TOOL CODE DESCRIPTION

038.586.0---2 Spanner for wheel safety nut

031.013.0---2 Seal ring sleeve driver

031.476.0---3 Seal ring sleeve driver

Spanner for thread rings

038.005.0---3
(differential bearing)

056.013.0---3
+ Installation tool for face seal
056.019.0---3

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ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 23

TOOL CODE DESCRIPTION

1U5933 Centering tool for discs

038.007.2---4 Seal ring sleeve driver

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 24 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

DIAGNOSTICS

Axle
1. Continuous noise
2. Cornering noise
3. Alternating noise
4. Sharp bangs during acceleration or deceleration
5. Oil leak from the axle shafts
6. Oil leak from the hubs

1 CONTINUOUS NOISE

Worn bearings. Replace them.

YES

NO

Gears damaged or worn. Replace them.

YES

NO

Lack of lubrication. Restore oil level.

YES

NO

Incorrect adjustment of the clearances. Adjust again

YES

2 CORNERING NOISE

Worn planet ---wheels or crown wheels. Replace.

YES

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 ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 25

3 ALTERNATING NOISE

Wheel bearings with excessive clearance. Adjust the bearings.

YES

NO

Wheels mounted incorrectly. Disassemble and remount correctly.

YES

NO

Too little clearance in the bevel gear set. Adjust again.

YES

NO

Too much clearance in the bevel gear set. Adjust again.

YES

4 SHARP BANGS DURING

ACCELERATION OR DECELERATION

Incorrect gear train adjustment. Adjust again.

YES

NO

Pivot of the anchoring structure has too much Replace the parts of the articulated joint.
play. YES

NO

Loose fastening of the anchoring structure to Tighten the screws to the prescribed tightening
the chassis. YES torque.

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 26 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

OIL LEAK FROM THE AXLE

5
BREATHER

Internal lip seals worn. The coolant passes onto Replace the seals.
the axle. SI Perform the seal test to identify the defective
hub.

6 OIL LEAK FROM THE HUBS

Front seals worn. The coolant leaks from the Replace the seals.
hub. YES

Brakes
1. Weak braking action
2. Unequal action of the brakes
3. Brakes that remain blocked
4. Premature depletion of the accumulator pressure when braking with the engine off

1 WEAK BRAKING ACTION

Worn brake discs. Overhaul the brakes.

YES

NO

Defective hydraulic system. See Section 10 --- HYDRAULIC SYSTEM.

YES

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 ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 27

2 UNEQUAL ACTION OF THE BRAKES

Worn brake discs. Replace.

YES

NO

Defective hydraulic system. See Section 10 --- HYDRAULIC SYSTEM.

YES

3 BRAKES THAT REMAIN BLOCKED

Broken or ineffective return springs. Overhaul the brakes.

YES

NO

Defective hydraulic system. See Section 10 --- HYDRAULIC SYSTEM.

YES

PREMATURE DEPLETION OF THE

4 ACCUMULATOR PRESSURE WHEN
BRAKING WITH THE ENGINE OFF

Defective accumulators. Check the preload pressure and the seals of the
YES fittings.
Replace the accumulators.

NO

Inefficient piston gliding seals. The brake fluid Overhaul the brakes.
seeps into the cooling chamber YES

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28 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

MAINTENANCE Changing the oil

Checking oil level Collect and dispose of used lubricants and

fluids, according to the laws in force
Proceed as follows:
Proceed as follows to drain the system:
The level check can be carried out on the
hubs or on the differential . Figure 18
If the level has to be restored, this is to be
carried out on the differential.

Figure 16

1 2

276C062022
D take the reference on the hub to horizontal position
(see arrow);
D arrange a suitably sized container, clean the cap
area and remove the cap (1) and the drain cap (2);
276C062020
drain all the lubricant;
D take the reference on a hub to horizontal position D clean the cap, check that the threading is in good
(see arrow); condition, replace the sealing ring with a new one
D clean the cap area and open the level cap (1). Lubri- and close the drain cap;
cant should drip out of the hole; D repeat the procedure for the other hub;
D close the filler cap. D arrange a suitably sized container, clean the cap
area and remove the cap (1) and the drain cap (2);
Axle drain all the lubricant.
Figure 17

276C062021
D clean the area of the cap, then open the cap (1): the
lubricant must leak from the hole;
D if necessary, restore the level until it overflows from
the same cap;
D close the cap;
D check that the breather is perfectly clean and ope-
rational.

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ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 29

Figure 19 Final reductions

Figure 21

276C062021
D arrange a suitably---sized container under the drain
cap, clean the cap areas and then remove the filling
cap (1); 276C062020

Figure 20 D pour in approx 3 litres of the prescribed lubricant un-

til it overflows from the cap hole (1);
D replace the sealing ring with a new one and close
the cap;
D repeat the procedure for the other hub.

Figure 22

2 1

276C062024
D remove the drain cap (1) and completely drain the
lubricant;
D clean the caps, check that the threading is in good
condition, replace the sealing ring with a new one
and close the drain cap.
276C062021
D refill with the prescribed lubricant until it overflows
from the hole of the filling cap (1);
Fill up slowly.
The operation is finished when the level at
the hole does not lower for a few minutes.
D replace the sealing ring with a new one and close
the cap;
D perform a test drive and then recheck the level (1);
D if necessary, top up with the prescribed lubricant un-
til it overflows from the hole, repeat the test drive and
recheck the level.

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30 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

INTERMEDIATE AXLE REMOVAL---REFIT

. Before starting any operation, make sure
that all the precautions have been taken and
all aspects regarding safety of the personnel
involved on the job have been made quite
clear .
Read the relevant instructions contained in
SECTION 1 of this handbook.
If in doubt ask someone who is more expert.
Comply to all the general recommendations
for correct execution of maintenance work.
Removal
Proceed as follows:
D Bring the vehicle on a suitable flat, solid surface,
switch off the engine, remove the key from the igni-
tion switch, engage the parking brake and affix the
warning notices;
D deactivate the battery isolator or disconnect the bat-
tery terminals to prevent any risk of a short circuit;
D block articulation by means of the steering lock bar,
proceeding as indicated in SECTION 1;
D raise the vehicle so that the wheels are off the
ground, then place two supporting trestles under
the front chassis, without touching the suspension;
D place a suitable hydraulic supporting device under
each of the intermediate and rear axles, that allows
the lowering at the time of removal, so that at this
stage the two axles are more or less horizontal;
D remove both wheels following the instructions in
SECTION 9;
D disconnect the electrical (2) and pneumatic (3) con-
nection to lock the inter---axles distribution;
D disconnect the axle bleed pipe (4);
Before the removal of the hydraulic pipes,
prepare appropriate plugs to close the free
ends.
D disconnect the hydraulic pipes:
--- service braking system (20);
--- brakes cooling system inlet (21);
--- brakes cooling system outlet (22);
. During this operation the hydraulic fluid
could spill out.
D remove the input (18) and the output (19) propeller
shaft following the instructions in SECTION 7;
D working on both sides of each rocker arm, remove
the split pin and unscrew the locking nut (08) of the
rocker arm pin;
D remove both the bolts (10) that fasten the tie---rod to
the bracket;
D take out the rocker arm pin (9) keeping the washers
(6) and guide bushings (7), releasing the rocker arm
from the axle;
D carefully lower the axle and remove it from the ve-
hicle.

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ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 31

Figure 23

276C062D027

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32 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

EPICYCLIC REDUCER OVERHAUL Figure 25

Before starting any operation, make sure

that all the precautions have been taken and
all aspects regarding safety of the personnel
involved on the job have been made quite
clear.
Read the relevant instructions contained in
SECTION 1 of this handbook.
If in doubt ask someone who is more expert.
Comply to all the general recommendations
for correct execution of maintenance work.
5
. Before proceeding, it is necessary to:
D drain the lubricant from the wheel hub 4
D drain the lubricant from the central differ- 3
ential; 2
following the instructions provided in the 1
relative chapter.
276C062D031
D unscrew the central retaining screw (1) and remove
. Before proceeding, the brake caliper must
the fixed gear (2) and guide bushing (3) complete
be removed following the instructions in the with spacer ring (4);
relative chapter. D slip off the axle shaft (5) if necessary;

Disassembly Figure 26
Proceed as follows:

Figure 24

1
4

3 1 276C062032

2 D unscrew the setscrew (1) of the ring nut;

276C062D030
D mark the mutual position of the planet ---wheel hold-
ing plate and the hub;
D loosen and remove all the retaining screws (1);
D remove the planet ---wheel holding plate assembly
(2) and O---ring (3) and recover the thrust spacer
ring (4);
D remove the locking ring nut (2) of the internally
toothed crown wheel.
The ring nut is locked with thread ---stops.
To prevent damage to the threading, heat to
approximately 120˚C before unscrewing.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 33

D using a suitable lifting device, carefully remove the Figure 29

complete hub from the hub support;
1
During this operation, keep the hub parallel 1
to the axle axis to avoid damaging the brake
discs.
2
D remove the front sealing ring;
D place the hub vertically;

Figure 27

3
276C062D035
D remove the two oil seal rings (1);
D use a suitable extractor to remove the outer race (2)
of the axle---side bearing (A) and the outer race (3)
of the wheel---side bearing (B);

Figure 30

1
276C062D033

D use a suitable extractor to remove the internally

toothed crown wheel (1);
1

Figure 28

1 2
2 276C06W036

D remove the screws (1) fastening the brake unit (2)

5 to the hub;
D carefully remove the brake unit from the hub and
place it on the workbench with the flange facing up-
wards;
4

3
276C062D034

D remove the retaining screws (1) and relative stop

plates (2);
D separate the internally toothed crown wheel (3) from
the relative flange (4);
D using a suitable extractor, remove the inner race (5)
of the wheel---side bearing (B) from the crown wheel
flange;
D if necessary remove the wheel fastening screws
from the hub;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
34 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

Figure 31 . Do not push the pivot towards the outside of

the planet---wheel holding plate, otherwise
its seat may be damaged due to the differ-
ence between the internal and external di-
ameter of the pivot.

Figure 33

2 2
1
276C062D037

D remove the inner race (1) of the axle---side bearing 276C062038

(A) and the spacer ring (2) from the hub;
D remove the planet wheel (1) and relative shim rings
The spacer ring is blocked with sealant. (2);
To avoid damaging it, before removing, heat
to approx. 120 ˚C. Figure 34

Figure 32

2 1

274A062039
D remove the needle cages (arrow) from the planet ---
274A062029 wheel;
D place the planet ---wheel holding plate on a suitable D repeat the procedure for all the planet ---wheels.
work surface;
D use a punch to push the retaining pin (1) down in the
pivot, freeing the pivot (2);
D extract the pivot (2) by pushing it towards the inside
of the planet ---wheel holding plate (arrow);
D remove the O---ring (3);
D extract the pin from the pivot.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 35

Brake disassembly D unscrew the screw (1) and remove the spring (2)
Proceed as follows: and spacer (3) from the piston;

Figure 35 Wear protective gloves and safety goggles.

Hold the screw to avoid injuries caused by
the load of the springs.
4
3 D unscrew the screw (4) and remove the bushing (5)
from the piston;
D turn the flange over, resting it on a suitable spacer
to allow the partial exit of the piston;

Figure 38

2
276C062W040

D unscrew the retaining screws (1) and remove the

1
flange (2) complete with piston form the bell (3).
D remove the peripheral sealing ring (4);

Figure 36

2
1

276C062W043
D remove the piston (1) by blowing compressed air in
from the control fitting (2);
276C062W041
D remove the internal (1) and external discs (2) from Wear protective gloves and safety goggles.
the bell, keeping their order; Hold down the flange to avoid any hand inju-
D remove the front sealing ring (3); ries.
Figure 37 D remove the sealing rings from the flange and the pis-
ton.
5
4

2
3
1
276C062W042

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
36 INTERMEDIATE AXLE -- WET OIL SECTION 6.2
Inspection of the dismantled parts
Wheel hub
D check the seats of the bearings: they must not have
any deformations and/or ovalling;
D check the condition of the bearings: replace them
if they have bluish halos, cracks and/or signs of
wear.
Axle shafts
D check the condition of the axle shafts: replace them
if they have deformations on the end grooves and/or
on the entire length.
Final reductions
D check the condition of the gear toothing: replace
them if they have pitting, cracks and/or cavities;
D verify the good operation of the planet ---wheels and
the roller bushings;
D check the threading for the bearing locking ring nut:
it must not have any dents, deformations and/or
jams.
Oil---wet brake
D check the bell and the piston: they must not have
any deformations and/or ovalling;
D carefully clean the bell, especially the canalizations;
D use new gaskets and rings;
D check the threading for the bearing locking ring nut:
it must not have any dents, deformations and/or
jams.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
Front sealing rings
D check the seat of the ring: it must not have any de-
formations and/or ovalling;
D carefully clean the seat, the metal ring and the gas-
ket;
D eliminate any residue of dust, lubricant or other for-
eign matter.
Use isopropanol for the cleaning and subse-
quent assembly operations.
Use cloths that do not fray, or paper towels.
During reassembly, consider the following
general observations:
D heat, to 100˚C in the oven, the bearings
and rings to be mounted by pushing;
D carefully center and mount the sealing
rings and bearings with a suitable adjust-
er;
D lubricate the ring nuts and bearings;
D lubricate the driving plates and driven
plates of the brake with hydraulic fluid;
D follow the front sealing ring assembly in-
structions carefully.
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 37

Epicyclic reduction gear seals and thread-- stops application and bearings scheme

Figure 39

276C062W044

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
38 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

Oil -- wet brake assembly Figure 42

Proceed as follows:
2
Figure 40
1

276C062W047
D mount the internal (1) and external discs (2) in the
bell, maintaining their order.

276C062W045

D Mount the sealing rings in the following order:

Large O---ring
Small O---ring
Large rigid ring
Small rigid ring
The larger diameter of the rigid ring must be
on the side opposite the pressure.
D install two operating screws, then mount the piston
in the flange;
Do not tilt the piston in order to avoid con-
tact and damage to the sliding surfaces.
D remove the operating screws;

Figure 41

4
5

1
2
3
276C062W046

D mount the spring (1) and spacer (2) and screw on

the screws (3);
D mount the bushing (4) and screw the screws (5)
onto the piston;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 39

Figure 43

276C062W048

D determine the dimension A;

D determine the dimension B;
D q determine the piston travel (without pressure)
as follows:
C = A -- B (mm)
where
A = distance between the brake bell mounting
surface and the disc surface
B = distance between the plate mounting surface
and the piston thrust surface
C = piston travel (without pressure)
D check that the piston travel (without pressure) is
within the prescribed values:
1.9 < C < 2.7 [mm]

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
40 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

Figure 44 Brake actuation circuit seal inspection

Proceed as follows:
1
Figure 45
2
1 2

276C062W049

D mount the peripheral sealing ring (1);

D mount the bell (2) onto the flange (3) and screw on
the retaining screws (4);
D mount any previously removed hydraulic fittings. 276C062W050

D close the bleeding valve (1);

D connect a manual high---pressure hydraulic pump
to the brake control input fitting (2);
D pump the prescribed hydraulic fluid into the actua-
tion chamber until reaching a maximum pressure of
10 bar;
D open the pressure release valve of the pump;
D open the bleeding valve;
D carefully operate the pump up to the spillage of fluid;
D close the bleeding valve;
D repeat the procedure up to the complete absence
of air in the bleeding;
D increase the pump pressure to a max of 120 bar;
D check that the seal is within the prescribed values:
Pressure reduction in 15 min
max 2% (residual pressure of at least 117.5 bar)
D open the pressure release valve of the pump;
D remove the pump and close the fitting.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 41

Piston actuation travel inspection Planet-- wheel holding plate assembly

Proceed as follows: Proceed as follows:
D position the planet ---wheel holding plate horizontal-
Figure 46 ly;

Figure 47

274A062032
D mount the needle cages inside the planet gear;

276C062W051

D open the cap of the inspection hole (1);

D measure the distance (d) between the flange and
piston without hydraulic pressure (d1);
D connect a manual high---pressure hydraulic pump
to the brake control input fitting;
D increase the pump pressure to a max of 120 bar;
D measure the distance (d) between the flange and
piston with hydraulic pressure (d2);
D determine the piston travel (with pressure) as fol-
lows:
C = d2 -- d1 (mm)
where:
d1 = distance (d) between the flange and piston with-
out pressure
d2 = distance (d) between the flange and piston with
pressure
C = piston travel (with pressure)
D check that the piston travel (with pressure) is within
the prescribed values:
2.4 < C < 3.2 [mm]

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
42 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

Figure 48 Brake unit and hub assembly

Proceed as follows:
2 Figure 50

1 3
2
2

276C062052

D mount the planet ---wheel (1) complete with shim 1

rings in the seat on the planet ---wheel holding plate;
Le spine devono essere montate orientando
il taglio come indicato in figura (tagli sfalsati
di 180˚ e orientati lungo la circonferenza).
Figure 49
2
3 Figure 51
276C062053
D place the hub vertically;
D using a suitable introducer, mount the outer race (1)
of the wheel---side conic roller bearing (B) and the
outer race (2) of the axle---side conic roller bearing
(A);
D mount the inner race (3) of the axle---side conic roller
bearing (A);

274A062035
D insert the O---ring (1) in the seat of the planet ---wheel
holding plate;
D insert the pivot (2) of the planet ---wheel holding gear
so that the pin holes match up;
D or according to the versions;
D insert the pivot (2) of the planet ---wheel holding gear
276C062W054
up to the complete expulsion of the internal reten-
tion bush so that the pin holes match up; D with an appropriate tool insert the seal rings (1) into
the seat on the hub paying attention to the orienta-
Mount the pivot from the internal part of the tion (detail) and fill them completely with lubrication
planet---wheel holding plate, otherwise its grease for bearings (arrow).
seat may be damaged due to the pivot diam-
eter difference.
D mount the catch pin (3);
D repeat the procedure for all the planet ---wheels.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 43

Front sealing ring assembly Figure 54

. The assembly instructions below are valid

for both front sealing rings (brake---side and
wheel---side).

Use isopropanol for the cleaning and subse-

quent assembly operations.

Proceed as follows:

Figure 52

276C062W062
D using a suitable tool, completely immerse the rub-
ber part of the front sealing ring in a small basin con-
taining isopropanol;
The rubber ring must be completely im-
mersed in the isopropanol in order to obtain
efficient lubrication.
This lubrication is indispensable to ensure
the correct assembly of the front sealing
ring.

Figure 55
276C062W060
D mount the rubber ring (1) on the metal ring (2), set-
tling it on the groove.

Figure 53

276C062W063

D extract the sealing ring from the basin and mount it

immediately in its seat, pushing it firmly so that the
rubber ring inserts into the seat and crosses the
retention rim;
276C062W061 D if necessary, adjust the position of the ring in the
seat using a suitable tool;
The rubber ring must NOT be twisted.
A twisted rubber ring does not guarantee the
correct position of the metal ring, resulting
in fluid leaks.
If the ring twists during assembly, it must be
straightened by rolling it until It is complete-
ly straight.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
44 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

Figure 56

276C062W064
D check the correct assembly of the rubber ring: the
figure illustrates some incorrect positions.
1. The rubber ring is not positioned correctly in the
seat;
2. The rubber ring has not crossed the retention
rim;
3. The rubber ring is not positioned correctly on
the metal ring.
D use a magnifying glass to inspect the sliding sur-
faces of the rings and remove any foreign matter;
D apply a thin layer of lubricant on the external sur-
faces of each front ring before assembling the parts.
Wait a few minutes before coupling the two
rings in order to allow the isopropanol to
evaporate completely.
The rubber ring absolutely must not move in
its seat during assembly of the parts.
A shifted rubber ring does not guarantee the
correct position of the metal ring, resulting
in fluid leaks.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 45

Figure 57

5
4
2

276C062W065
D position the axle horizontally;
D mount the sealing ring (1) on the hub support (2);
D mount the brake unit (3) on the hub support;
D tighten the retaining screws (4) to the prescribed
tightening torque;
D use a suitable tool to align the toothing of the brake
unit discs (5);
D block the position of the discs by blowing com-
pressed air in the brake control input fitting (6) and
remove the tool.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
46 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

Figure 58

3 1
276C062W066

D heat the spacer ring (1) and insert it completely on

the axle axis;
D using a suitable lifting device, support the hub as-
sembly in order to ensure its correct centering;
D introduce the hub assembly (2) on the end of the
hub support (3), placing the inner race of the axle---
side conic roller bearing (A) so that it rests against
the spacer ring;
During this operation, keep the hub parallel
to the axle axis.
Work with caution to avoid damaging the
sealing rings and the brake disc teeth.
Continue to support the hub assembly until
it is completely mounted.
D release the brake discs by discharging the pressure
from the piston;
D if removed, mount the stud bolts fastening the wheel
to the hub (4).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 47

Figure 59 Hub bearing preload determination

Proceed as follows:

Figure 61
4

2
2
3
276C062W067
D heat the inner race (1) of the wheel---side conic roller
bearing (B) and insert it until it rests against the gear
wheel flange;
D insert the gear wheel flange (2) onto the gear wheel
with internal toothing (3); 1
D mount the retention plates (4) and fix them with the
setscrews; 276C062069
D apply MOLYKOTE lubricant on the hub support
Figure 60
threading and on the threading and contact area of
the locking ring nut;
D hand mount the ring nut (1) without tightening;
D tighten the locking ring nut to the prescribed tight-
ening torque:
Locking ring nut tightening torque for bearings
Phase 1: 700-- 900 Nm
During the locking, rotate the hub back and
forth by striking it with a plastic hammer to
settle the bearings.
D unscrew the locking ring nut half a turn;
D tighten the locking ring nut to the prescribed tight-
ening torque:
Locking ring nut tightening torque for bearings
Phase 2: 450 Nm
During the locking, rotate the hub back and
1 forth by striking it with a plastic hammer to
settle the bearings.
276C062W068
D after having adjusted the bearing preload, block the
D mount the flange and internally toothed gear wheel
locking ring nut with the relative setscrew (2);
assembly (1) onto the hub until the two parts meet
the wheel---side conic roller bearing (B). If this is not possible, unscrew the ring nut
as much as needed in order to mount the
The lubrication oil passage hole on the too-
clamp screw.
thed wheel flange is to face downwards.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
48 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

Figure 62 Planet-- wheel holding plate -- fixed gear axial clear-

ance determination
Proceed as follows:

Figure 63

1
2
3
4 A
5
276C062D070 B
D insert the axle shafts (1) into the axle;
D mount the spacer ring (2), guide bushing (3) and
fixed gear (4);
D mount the central retaining screw (5) and tighten it.

274A062043
D determine the dimension A;
D determine the dimension B;
D determine the thickness of the thrust spacer as fol-
lows:
S = A -- B +(0.30 ÷ 0.70) (mm)
where:
A = distance between the planet ---wheel holding
plate mounting surface and the seat of the thrust
spacer on the same plate
B = distance between the hub mounting surface
and the thrust spacer seat on the fixed gear
S = thrust spacer thickness
0.30 ÷ 0.70 = prescribed clearance in mm
D mount the chosen thrust spacer onto the planet ---
wheel holding plate.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 49

Brake cooling circuit seal inspection Concluding operations

Proceed as follows:
Figure 65
Figure 64

276C062W072

D close one of the two brake cooling circuit pipe fit-

1 3
tings (1);
D blow compressed air at a maximum pressure of 1.5 2
bar into the second fitting (2); 276C062W073

Do not exceed the pressure of 1.5 bar as this D mount the O---ring (1) in the seat of the planet ---
may damage the sealing rings. wheel holding plate;
D mount the planet ---wheel holding plate assembly (2)
D turn the hub a few times; in the hub.
D check that the seal is within the prescribed values:
Respect the reference marks made during
Minimum pressure acceptable after 10 minutes
disassembly.
1.4 bar
D close the fitting.
D mount the retaining screws (3) and tighten to the
prescribed torque.

. If no intervention on the differential is

planned, proceed to:
D the filling of the wheel hub;
D the filling of the central differential;
following the instructions provided in the
relative chapter.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
50 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

TANDEM TRANSMISSION AND DIFFERENTIAL OVERHAUL

Before performing any intervention, ensure Disassembly

that all precautions have been taken and all
aspects clarified regarding the safety of per- . Before proceeding, the axle shafts must be
sonnel involved in the intervention. removed following the instructions in the re-
Read the relative instructions provided in lative chapter.
SECTION 1 of this manual.
In case of doubt, consult a more experien-
ced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.

Proceed as follows:

Figure 66

4 3

2
1

276C062W080

D straighten the dent and remove the motion input
flange stop nut (1);
D using a suitable extractor, remove the flange (2);
D straighten the dent and remove the motion output
flange stop nut (3);
D using a suitable extractor, remove the flange (4);
D mark the relative position between box and axle;
D loosen and remove the screws (3) fastening the ex-
ternal box to the axle;
D using a suitable lifting device, remove the external
box assembly from the axle;
D position the assembly on the support trestle, adap-
ting as necessary.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 51

Differential disassembly
Figure 67 Proceed as follows:

Figure 69
2
4
1
3 3

1 4
2

2 276C062081
D unscrew the retaining screws and remove the loc-
king plate (1) of both the bearing preload adjust- 274A062048
ment ring nuts;
D loosen both the bearing preload adjustment ring D remove the outer race (1) of the crown wheel---side
nuts (2); bearing (C) and the outer race (2) of the planet whe-
D mark each support cap and the corresponding ex- el---side bearing (D);
ternal box location; D use appropriate extractors to extract the inner race
D loosen the retaining screws (3) and remove both the (3) of the crown wheel---side bearing (C) and the in-
support caps (4); ner race of the planet wheel---side bearing (D) from
D remove both the adjustment ring nuts; the differential semicases;
D mark both the differential semicases;
Figure 68 D loosen the retaining screws and remove the diffe-
rential semicase;

Figure 70

274A062047
274A062049
D using a suitable lifting device, extract the differential
D disassemble the planet ---wheel group into the diffe-
assembly (1) from the relative case.
rent components;
D remove the discs of the skid limitation device and
the relative shoulder rings;
D if necessary, separate the ring bevel gear from the
differential semicase by unscrewing the retaining
screws.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
52 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

Idle gear and pinion disassembly

Figure 73
Proceed as follows:

Figure 71
2

2 4
1
1

276C062084
D remove the idle gear (1) from the pinion box;
276C062082 D remove the stop plate (2), adjustment ring nut (3)
D position the assembly horizontally; and the outer race (4) of bearing (E);
D remove the cover (1);
Figure 74
D straighten the dent and remove the pinion stop nut
(2).

Figure 72

5
3
4
2
1

276C062085

1 D remove the bearing preload spacer S2 (1), spacer

(2) and coaxial gear (3) from the pinion;
2 D remove the pinion (4);
D use a suitable extractor to remove the outer race of
276C062083
bearing (B) from the pinion box.
D unscrew the retaining screws and separate the pi-
nion box (1) from the external box (2);
D recover the inner races of bearing (B) and bearing
(F) from the external box.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 53

Figure 75

5
4
1
3
2

274A062086
D remove the outer race (1) of bearing (A) and the pi-
nion position spacer S1 (2) from the external box;
D remove the sealing ring (3) from the external box;
D remove the elastic ring (4) and outer race (5) of bea-
ring (F).

Figure 76

276C062087
D using a suitable extractor, remove the inner race (1)
of bearing (E) from the gear

Figure 77

274A062055

D using a suitable extractor (1), remove the inner race

(2) of bearing (A).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
54 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

Coutershaft disassembly
Proceed as follows:

Figure 78

276C062W088

D loosen the retaining screws and remove the coun-

tershaft cover (1) complete with countershaft;
D using a suitable extractor, remove the countershaft
(2) complete with ball bearing;
D remove the elastic ring (3) and spacer ring (4);
D use a press and pad to separate the countershaft (2)
from the bearing (5);
D remove the sealing ring (6) from the cover.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 55

Inspection of the disassembled parts Reassembly

During reassembly consider the following

Bearings
general observations:
D check the condition of the bearings: replace them D heat, to 100˚C in the oven, the bearings
if they have bluish halos, cracks and/or signs of and rings to be mounted by pushing;
wear. D carefully center and mount the sealing
rings and bearings with a suitable adju-
Crown wheels ster;
D check the condition of the toothing: replace it if it has D lubricate the bushes, sealing rings and
pits, cracks and/or cavities. bearings.

Planet ---gears Perform all the indicated measurements

D check the condition of the toothing: replace it if it has
pits, cracks and/or cavities;
D check the coupling surfaces with the pins.
Damage to a single element entails the re-
placement of the entire gear unit.
with maximum precision.
Imprecise measurements lead to bad con-
tact of the bevel gear and thus make it ne-
cessary to repeat the procedure.

Cross pins
D check the coupling surfaces with the planet ---gears.

Shoulder rings
D check the condition of the rings: replace them if they
have bluish halos, cracks and/or signs of wear.

Bevel gear
D check that the toothing of the crown wheel and the
pinion show uniform wear on the entire working zo-
ne of the teeth: replace the bevel gear if it has pits,
cracks and/or cavities;
An anomalous wear may indicate an incor-
rect adjustment of the bearings: check their
integrity before proceeding to the reassem-
bly.
Damage to a single element entails the re-
placement of the entire gear unit.
D check the bearing seats: they must not have defor-
mations or ovalling.

Bushes
D check the threading for the bearing locking bush: it
must not have dents, deformations and/or jams.

External box
D check the bearing seats: they must not have defor-
mations or ovalling;
D check that the sealing surfaces and the threadings
are integral and free of dents or damage.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
56 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

Differential seals and thread-- stops application and bearings scheme

Figure 79

276C062090A

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 57

Complete limited-- skid differential assembly

Proceed as follows:

. Refer to the following figure.

D check the following measurements:
SP1 = 3.10 mm minimum;
SP2 = 2.15 mm minimum.
D otherwise, use shoulder discs with a greater thick-
ness;
D mount the shoulder ring (2) and elastic ring (3);
D position the shoulder disc (SP1) (4);
D alternately mount an externally grooved disc (driven
plate) and an internally grooved disc (driving plate)
until all discs (5) have been mounted;
The last disc is a driving plate.

D mount the shoulder disc (SP2) (6);

D mount the elastic ring (7);
D mount the planetary gear;
D repeat the assembly for the other semicase;
D when finished, check that dimension A falls within
the prescribed values;
52.8 < A < 53.27 mm
D when finished, check that dimension B falls within
the prescribed values;
B < 0.48 mm
D otherwise, use shoulder discs with a greater thick-
ness or reduce the thickness by grinding;
D assemble the shafts and planet ---wheel gears and
mount the assembly on the crown wheel;
D join the two semicases and tighten the retaining
screws to the prescribed torque.
The two semicases are symmetric except for
the crown wheel assembly flange.
The total height of the crown wheel---side
disc pack must be identical to that on the op-
posite side.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
58 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

Figure 80

1. Differential semicase
2. Shoulder ring
3. Elastic ring
4. Semicase shoulder disc SP1
5. Driven (N.4) and driving (N.4) discs
6. Crown wheel shoulder disc SP2
7. Elastic ring
8. Crown wheel --- planet ---wheel group SP1
Dimension A: disc pack thickness
Dimension B: Shoulder ring --- crown wheel clearance

SP2

1
2

4 A
5
6
7

6
5
4

2
1

276C062091

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 59

Crown wheel and bearings assembly

Figure 81

274A062060
Proceed as follows:
D check that the area of contact between the gear (1)
and differential semicase (2) is clean and free of
grease;
D mount the crown wheel on the semicase and tighten
the fastening bolts (3) to the prescribed torque;

Figure 82

2
274A062062
D heat the inner race (1) of the planet wheel---side co-
nic roller bearing (D) and mount it against the diffe-
rential semicase;
D heat the inner race (2) of the crown wheel---side co-
nic roller bearing (C) and mount it against the diffe-
rential semicase.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
60 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

Determination of the pinion axial position spacer (S1) thickness

Figure 83

276C062092

Proceed as follows:
D determine the thickness beff of the internal conic rol-
ler bearing (A);
D calculate the difference d between the effective
thickness and the theoretical thickness bteor = 40.0
mm of the internal conic roller bearing (A);
d = beff -- bteor (mm)
D measure the dimension a;
D determine the effective thickness of the pinion posi-
tion spacer (S1) as follows:
S1eff = S1teor -- (d + a) (mm)
where:
S1teor = theoretical thickness of the pinion position
spacer (S1) = 3 mm
S1eff = effective thickness of the pinion position
spacer (S1)
d= difference between the effective and theo-
retical thickness of the internal conic roller
bearing (A) calculated previously
a= value stamped on the pinion head

Example 1:
beff = 39.95 mm
difference d = 39.95 --- 40.00 = --- 0.05 mm
a = + 0.10
thickness S1eff = 3 --- ( --- 0.05 + 0.10) = 2.95 mm

Example 2:
beff = 40.05 mm
difference d = 40.05 --- 40.00 = --- 0.05 mm
a = --- 0.10
thickness S1eff = 3 --- (0.05 --- 0.10) = 3.05 mm

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 61

Figure 84

276C062093
D heat the inner race of bearing (A) and mount it on the
pinion;

Figure 85

4 1

6 3
5

276C062094

D position the chosen pinion position spacer (S1) (1)
in its seat;
D mount the outer race (2) of bearing (A) until it rests
against spacer S1;
D insert the pinion (3) into the external box;
D mount the pinion box on the external box and
tighten the retaining screws to the prescribed
tightening torque;
D mount the outer race (4) of bearing (B) until it rests
against the box;
D mount the inner race (5) of bearing (B) on the pinion;
D apply MOLYKOTE on the pinion threading and on
the threading and contact area of the stop nut;
D mount the stop nut (6) and tighten it until there is no
play in the bearings.

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62 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

Check of the pinion-- crown wheel clearance D apply MOLYKOTE on the threading of the adjust-
Proceed as follows: ment ring nuts;
D screw on both the ring nuts by hand until there is no
Figure 86 play in the bearings;

Figure 88

17312101
D position the conic roller bearing outer races on both
ends of the differential;
D using a suitable lifting device, mount the crown whe-
el assembly in the differential case;

Figure 87 17312104

D mount a dial gauge at a right angle with respect to

the external diameter of the crown wheel’s toothed
side and turn the crown wheel back and forth, being
careful not to move the pinion;
D check that the clearance between the crown wheel
and pinion falls within the prescribed values:
pinion-- crown wheel clearance
see value engraved on the crown wheel
D otherwise, adjust the clearance using the adjust-
ment ring nuts;
D the clearance can be adjusted by unscrewing one
adjustment ring nut by a certain number of notches
and screwing on the opposite adjustment ring nut
by the same number of notches;
17312102
Figure 89
D align the reference marks and mount the bearing
support caps;
D mount the cap retaining screws and tighten to the
prescribed tightening torque;

17312105
D In particular:
--- unscrew the ring nut (D) and screw on the ring
nut (C) to reduce the clearance (white arrow);
--- unscrew the ring nut (C) and screw on the ring
nut (D) to increase the clearance (black arrow).
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 63

Verification of the pinion-- crown wheel engagement

impression area
Proceed as follows:

Figure 90

17312106

D cover a dozen teeth of the crown wheel with Prus-

sian blue, lubricated with minium, or another paint
or dye that can be easily removed;
D make a complete rotation of the crown wheel by
hand;
D when the teeth engage, the paint is removed by the
contact of the teeth, leaving zones exposed with the
exact dimension, shape and location of contact;

Figure 91

274A062063

Contact area position and shape D to replace the spacer S1, remove the retaining
1. correct bevel gear position; screws (1) and slip off the complete pinion box;
2. position with the pinion too far back: it is necessa- D position the new spacer S1, then reassemble the pi-
ry to reduce the distance between the pinion and nion box and tighten the retaining screws to the pre-
the crown wheel axis by using a spacer S1 of grea- scribed tightening torque.
ter thickness; then adjust the clearance by mo-
When finished, remove the differential, pi-
ving the crown wheel further from the pinion;
nion and pinion box.
3. position with the pinion too far forward: it is neces-
sary to increase the distance between the pinion
and the crown wheel axis by using a spacer S1 of
smaller thickness; then adjust the clearance by
moving the crown wheel closer to the pinion;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
64 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

Idle gear bearing preload determination Figure 94

Proceed as follows:

1
Figure 92

1 2

276C062097

276C062095 D mount the bearing (E) outer race (1);

D heat the inner race (1) of bearing (E) and mount it D apply MOLYKOTE on the threading of the adjust-
on the idle gear; ment ring nut;
D mount the adjustment ring nut (2) without tighte-
ning.
Figure 93

1
276C062096
D mount the bearing (F) elastic stop ring (1);
D mount the complete bearing (F) (2) until it rests
against the elastic ring;
D insert the idle gear (3) into the external box;
D mount the pinion box on the external box and tigh-
ten the retaining screws to the prescribed tightening
torque.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 65

Figure 95 Figure 96

276C062098A
D mount the flange (1), inserting it inside bearing (F);
D apply MOLYKOTE on the gear threading and on the
threading and contact area of the stop nut;
Use a new stop nut.
D mount the stop nut (2) and tighten it to the prescri-
bed torque.
276C062099
D tighten the adjustment ring nut (1) until obtaining
the prescribed value for the bearing rolling torque.
Rolling torque for gear bearings
1.0 Nm
D unscrew the ring nut by two notches;
D fix the locking plate (2) of the ring nut by screwing
on the clamp screw.
When finished, remove the external box,
then remove the idle gear by unscrewing the
stop nut.

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66 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

Pinion bearing preload determination

Proceed as follows:

Figure 97

5 2

6 1

276C062100

D insert the pinion (1), complete with inner race of the
conic roller bearing (A), into the external box;
D mount the coaxial gear (2), spacer (3) and spacer
S2 (4), which were removed during disassembly,
onto the pinion;
D mount the pinion box on the external box and tigh-
ten the retaining screws to the prescribed tightening
torque;
D mount the inner race (5) of conic roller bearing (B)
on the pinion;
D apply MOLYKOTE on the pinion threading and on
the threading and contact area of the stop nut;
Use a new stop nut.
D mount the stop nut (6) and tighten it to the prescri-
bed torque;
Block the coaxial gear during this operation.
D use a suitable tool to check that the rolling torque
falls within the prescribed values:
Rolling torque for pinion bearings
1.5-- 1.8 Nm
D otherwise correct the rolling resistance by using a
spacer S2 with a different thickness;
D In particular:
--- increase the thickness to reduce the torque;
--- reduce the thickness to increase the torque.
When finished, unscrew the stop nut and re-
move the external box.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 67

Idle gear and pinion assembly Figure 100

Proceed as follows:
D insert the idle gear into the external box;
D mount the pinion box on the external box and tigh- 1
ten the retaining screws to the prescribed tightening
torque; 2
Figure 98

276C062102
D mount the inner race (1) of bearing (B);
D mount the pinion stop nut (2) and tighten it to the
prescribed torque;

Figure 101

276C062101A

D use a suitable tool to insert the sealing ring (1) in the

seat and fill it completely with lubricating grease for
bearings;
D mount the flange (2), inserting it inside bearing (F);
D mount the idle gear stop nut (3) and tighten it to the
prescribed torque;
274A062066
Figure 99
D dent the nut as described in the figure;
If this is not possible, unscrew the nut as
much as necessary to dent it.
D mount the cover and screw on the retaining screws.

274A062066

D dent the nut as described in the figure.

If this is not possible, unscrew the nut as
much as necessary to dent it.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
68 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

Differential bearing preload determination Figure 103

Proceed as follows:

Figure 102

274A062064

D once all the adjustments and configurations are cor-

rect, fix the locking plate (1) of both the ring nuts
17312102
using screws;
D support the complete external box with suitable lif-
D align the reference marks and mount the bearing ting equipment;
support caps; D mount the complete external box assembly onto the
D mount the cap retaining screws and tighten to the axle respecting the reference marks made during
prescribed tightening torque; disassembly;
D screw on both the ring nuts by hand until there is no D screw on the retaining screws and tighten to the pre-
play in the bearings; scribed torque.
D as described previously, check that the clearance
between the crown wheel and pinion falls within the
prescribed values:
pinion-- crown wheel clearance
see value engraved on the crown wheel
D otherwise, adjust the clearance using the adjust-
ment ring nuts;
D use a suitable tool to check that the rolling torque
falls within the prescribed values:
Rolling torque for crown wheel and pinion bea-
rings
5,0÷5,5 Nm (including pinion and transmission)
D the rolling torque can be corrected by turning both
the adjustment ring nuts by the same number of not-
ches;
D in particular:
--- unscrew the ring nuts to decrease the torque;
--- screw on the ring nuts to increase the torque.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.2 INTERMEDIATE AXLE -- WET OIL 69

Coutershaft assembly
Proceed as follows:

Figure 104

276C062103

Proceed as follows:
D determine the dimension b of the ball bearing;
D determine the dimension A on the box;
D determine the dimension B on the cover;
D check that the clearance between the bearing side
and the edge of the cover fall within the prescribed
values:
bearing -- cover clearance
A -- (B + b) = 0.05 ÷ 0.2 mm
where:
A = the distance between the bearing assembly pla-
ne and the cover support plane
B= the depth of the cover
b= effective thickness of the bearing

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
70 INTERMEDIATE AXLE -- WET OIL SECTION 6.2 ADT 25-30 TIER3

Figure 105

276C062W104

Mount the sealing ring (1) on the cover.

The sealing ring must be flush with the exter-
nal surface of the cover.
D mount the cover (2) complete with sealing ring onto
the shaft;
D mount the bearing (3) on the shaft (4);
D mount the spacer ring (5) and elastic ring (6);
D mount the countershaft complete with bearing and
cover onto the axle housing until the groove inserts
into the corresponding seat on the countershaft;
D screw on the retaining screws fastening the cover to
the axle.

. Proceed to:
D the reassembly of the axle shafts;
D the filling of the wheel hubs;
D the filling of the central differential;
following the instructions provided in the re-
lative chapter.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 SECTION 6.3

REAR AXLE --- DISC BRAKES

 ADT 25-30 TIER3 SECTION 6.3
CONTENTS
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
First reduction: bevel gear pair . . . . . . . . . . . . . . . . . . 4
Drive input flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Second reduction: hub and epicyclic train . . . . . . . 10
Brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . 14
Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Brake disc and caliper . . . . . . . . . . . . . . . . . . . . . . . . 14
Bevel gear (first reduction) . . . . . . . . . . . . . . . . . . . . 15
Hub and epicyclic gear (second reduction) . . . . . . 16
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . 17
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Replacement of the brake pads . . . . . . . . . . . . . . . . 25
Breaking---in of the pads . . . . . . . . . . . . . . . . . . . . . . 26
Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INTERMEDIATE AXLE REMOVAL-- REFIT . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
BRAKE CALIPER DETACHMENT--
REATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Detachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Reattachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
EPICYCLIC REDUCER OVERHAUL . . . . . . . . . . . . 33
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Inspection of the dismantled parts . . . . . . . . . . . . . . 36
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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REAR AXLE -- DISC BRAKES 1
Page
Epicyclic reduction gear seals and thread---stops
application and bearings scheme . . . . . . . . . . . . . . 37
Planet ---wheel holding plate assembly . . . . . . . . . . 39
Brake unit and hub assembly . . . . . . . . . . . . . . . . . . 40
Hub bearing preload determination . . . . . . . . . . . . . 42
Planet ---wheel holding plate --- fixed gear axial
clearance determination . . . . . . . . . . . . . . . . . . . . . . 43
Concluding operations . . . . . . . . . . . . . . . . . . . . . . . . 44
DIFFERENTIAL OVERHAUL . . . . . . . . . . . . . . . . . . 46
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Inspection of the disassembled parts . . . . . . . . . . . 50
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Differential seals and thread---stops application
and bearings scheme . . . . . . . . . . . . . . . . . . . . . . . . . 51
Complete limited---skid differential assembly . . . . . 52
Crown wheel and bearings assembly . . . . . . . . . . . 54
Thickness determination for bearing preload
spacer S2 and bearing assembly . . . . . . . . . . . . . . 55
Differential bearing preload determination . . . . . . . 57
Pinion assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Check of the pinion---crown wheel clearance . . . . 59
Verification of the pinion---crown wheel
engagement impression area . . . . . . . . . . . . . . . . . . 60
BRAKE CALIPER OVERHAUL . . . . . . . . . . . . . . . . 62
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Inspection of the disassembled parts . . . . . . . . . . . 63
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
BRAKE DISC OVERHAUL . . . . . . . . . . . . . . . . . . . . 65
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

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ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 3

DESCRIPTION
The axle is a dual reduction bearing type. The structure has mountings for connection to the
It consists of a boxed structure containing the cylindri- chassis and housings for the bearings.
cal wheel transmission, the bevel gear pair with the dif-
ferential (first reduction), the drive shafts and hubs with
the epicyclic reducer (second reduction).

Figure 1

8
3

5
6 2
8

276C063D001

1. Rear suspension
2. Hub with epicyclic gears
3. Differential case
4. Motion input flange
5. Axle
6. Upper stabilizer bar
7. Service brake caliper
8. Service brake disc

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4 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

First reduction: bevel gear pair

The first reduction is obtained by the pinion---ring bevel
gear unit (bevel gear pair) inside the differential.
The input shaft is supported by two taper roller bear-
ings mounted in O arrangement with preload that can
be adjusted by spacer.
The pinion shaft receives motion from a cylindrical
wheel transmission with ratio 1:1.
The pinion is supported by two taper roller bearings
mounted in O arrangement with preload that can be ad-
justed by spacer. The axial position of the pinion can
also be adjusted by shims.
The differential box with ring bevel gear is supported by
two taper roller bearings mounted in X arrangement
with preload and axial position adjustable by two op-
posing ring nuts.

Drive input flange

Figure 2

ADT 30 ADT 25

276C063D001B
Legend (figure on following page)
1. Right adjustment ring nut
2. Planet wheel---side conic roller bearing (D)
3. Crown wheel
4. Planet wheel holding shaft
5. Planet ---wheel
6. Crown wheel---side conic roller bearing (C)
7. Differential box
8. Left adjustment ring nut
9. Differential box
10. Ring bevel gear
11. Bevel pinion
12. Pinion internal conic roller bearing (A)
13. Pinion external conic roller bearing (B)
14. Motion input flange
15. Sealing ring

A: Cross section
B: Functional diagram

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ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 5

Figure 3

276C063003

Leggere attentamente le NORME DI SICUREZZA contenute in questo manuale, per la protezione del personale e della macchina
6 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

The differential is a limited---skid differential, characteri-
zed by the positioning of a multiple---disc clutch betwe-
en the differential case (upright) and the crown wheels
(sun gears) for each side.
The multiple---disc clutch includes external discs con-
nected to the differential case and internal discs con-
nected to the planetary gears.
The thrust on the discs is ensured by the axial compo-
nent of the force exchanged between the teeth of the
planet ---wheels and crown wheels.
The axial thrust on the discs generates a resistant tor-
que that acts on the crown wheel when the crown whe-
el tends to rotate with respect to the differential case
due to the speed difference between the two wheels.
This resistant torque depends, with equal axial thrust,
on the dimensions and the coating material of the
discs.

Figure 4

3,1 2

2,15

0,48

1. Differential semicase
2. Planetary gear
3. Multiple---disc device for skid limitation
3

52,8 --- 53,27

276C062005

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ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 7

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8 REAR AXLE -- DISC BRAKES SECTION 6.3
Operation
The torque coming from drive shaft is transmitted
through a cardan joint to the bevel pinion.
From this, the torque passes to the ring bevel gear,
which is integral with the differential case.
The differential is a gear train in which the case repre-
sents the upright, that holds the planet ---wheel holding
shafts and receives the torque, while the two crown
wheels represent the sun gears, both rotary, that recei-
ve the torque and transmit it to the axle shafts.
When both the wheels are subject to the same resistant
torque or have the same speed (vehicle traveling along
a straight path), the ring bevel gear and the differential
case rotate as a block, transmitting the torque in equal
parts to the two crown wheels, and from these to the
two axle shafts that rotate at the same speed: the whe-
els transmit the same driving torque.
Figure 5
LH RH
276C062006
The right wheel with the same adherence as the left.
RH: right side: torque supplied is 50% of the total
LH: left side: torque supplied is 50% of the total
Leggere attentamente le NORME DI SICUREZZA contenute in questo manuale, per la protezione del personale e della macchina
ADT 25-30 TIER3
Under these conditions, there is no relative motion bet-
ween the two crown wheels, and thus the planet ---whe-
els do not rotate around their shaft which is integral with
the differential case.
When the resistance of one wheel exceeds that of the
other or when the speed of the two wheels is no longer
equal (vehicle traveling a curved path) the planetary
gears assume a different rotation speed: their relative
motion is allowed by the presence of the planet ---whe-
els, which now rotate around their own shaft in opposi-
te directions.
Naturally, a slower rotation speed of the crown wheel
corresponds to a greater driving torque transmitted,
and vice versa.
Thus when the differential operates the wheel that has
a smaller speed, it is able to transmit a greater driving
torque, while the one with the greater speed transmits
a smaller torque.
Under certain conditions it may occur that the slower
wheel completely loses adhesion, since the torque that
can be transmitted to the ground is exceeded, and thus
it encounters practically zero resistance: in this case, a
normal differential causes the free rotation of the wheel
that skids and the stopping of the wheel that still adhe-
res to the ground: the traction capacity of the axle beco-
mes zero.
To remedy this inconvenience, a limited---skid differen-
tial is used that is characterized by the possibility to ge-
nerate a resistant torque on each crown wheel, which
is no longer free to rotate with respect to the differential
case, but is braked in proportion to the torque that the
differential must transmit.
This resistant torque, which depends on the thrust ap-
plied to the multiple---disc clutch, is always in a fixed ra-
tio with the input torque, known as the ”locking ratio”.
The locking ratio is the percentage of maximum diffe-
rence between the torque transmittable to the wheel
with greater adherence and that on the wheel with less
adherence.
For example, with a locking ratio of 45%, 72,5% of the
driving torque is transferred to one rear axle shaft (ra-
ther than the normal 50%), while the other axle shaft re-
ceives only 27.5%: the difference is precisely 45% (with
respect to a total of 100%).
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 9

If the two wheels do not have the same adherence, the In practice, the multiple---disc clutches automatically
resistant torque generated by the multiple---disc clut- compensate the adherence variations of the wheels
ches partially locks the crown wheel on the side having from the left side and right side of the vehicle, without
less adherence and increases the torque supplied by requiring any driver operation. It is thus possible to ap-
the crown wheel on the side with more adherence. In ply a much larger driving force when using the vehicle,
other words, the braking torque replaces the reaction and prevent skidding when one of the wheels encoun-
torque missing from the side of the wheel with less ad- ters a surface lacking adherence.
herence.
In this manner, considering the previous case in which
one wheel loses adherence, this wheel is not able to
turn freely and thus the other wheel will still be able to
transmit part of the driving torque, ensuring at least so-
me traction capacity of the axle.

Figure 6

LH RH

276C062007
Left wheel with less adherence than the right wheel
(example)

RH: right side: torque supplied is 72.5% of the total

LH: left side: torque supplied is 27.5% of the total

Leggere attentamente le NORME DI SICUREZZA contenute in questo manuale, per la protezione del personale e della macchina
10 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

Second reduction: hub and epicyclic train

The second reduction is obtained by an epicyclic re- Legenda (figura pagina seguente)
ducer with cylindrical wheels in the wheel hub. 1. Epicyclic train upright
The hub is supported by two taper roller bearings (planet ---wheel holding plate)
mounted in O arrangement with preload that can be ad- 2. Thrust spacer
justed by a ring nut. The planetary gear gears turn on 3. Planet ---wheel
pivoting roller bearings. 4. Epicyclic train fixed gear
5. Planet ---wheel pin
Operation 6. Guide bushing
The torque from the differential is transmitted by a float- 7. Adjustment ring nut
ing axle shaft to the sun gear by the grooved shank. 8. Epicyclic train crown wheel
The four planetaries gears rotate in the opposite direc- 9. Hub
tion to the sun gear, where as the crown wheel is inte- 10. Wheel fastening column
gral to the hub support, and therefore does not rotate. 11. Brake caliper
This forces the train carrier to turn in the opposite direc- 12. Brake disc
tion to the planetaries gear, therefore in the same direc- 13. Hub support
tion as the drive shaft. 14. Spacer ring
15. Sealing ring
16. Internal conic roller bearing
17. External conic roller bearing
18. Axle shaft
19. Central retaining screw

A: Cross section
B: Functional diagram

Leggere attentamente le NORME DI SICUREZZA contenute in questo manuale, per la protezione del personale e della macchina
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 11

VERSION A

Figure 7

276C062D008

Leggere attentamente le NORME DI SICUREZZA contenute in questo manuale, per la protezione del personale e della macchina
12 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

VERSION B

Figure 8

276C062D008A

Leggere attentamente le NORME DI SICUREZZA contenute in questo manuale, per la protezione del personale e della macchina
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 13

Brake caliper

Figure 9

2
4
3

12
11
10
5
9
8
7

276C062D009

1. Brake Pads
2. Caliper
3. Pin
4. Bleeder fitting
5. Brake control fitting
6. Cover
7. Cap
8. Cap gasket
9. Piston
10. Sealant ring
11. Piston gasket
12. Dust cover

Leggere attentamente le NORME DI SICUREZZA contenute in questo manuale, per la protezione del personale e della macchina
14 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

SPECIFICATIONS AND DATA

Hub

KESSLER R 81 (Hub) and ZF LK

Code
(front differential)

Type Independent, with double reduction

With limited slip

Central differential
Integrated in automatic transmission box

Pinion bearings 2 taper rollers mounted in O arrangement

Differential bearings 2 taper rollers mounted in X arrangement

Hub bearings 2 taper rollers mounted in X arrangement

Hub planet bearings 3 x 4 Pivoting barrel rollers

bevel gear pair 1 : 3.50

Reduction ratio wheel reducer 1 : 6.00

total 1 : 21.00

Autom. pinion transm. output shaft axial clearance 0.30 --- 0.50 mm (0.012 --- 0.020 in)

3.5 --- 4.5 Nm

Pinion bearings preload
(2.60 --- 3.30 ft lb (without seal rings)

Differential bearings preload 3.0 --- 4.0 Nm (2.20 --- 2.90 ft lb)

Bevel gear pair clearance 0.20 --- 0.30 mm (0.008 --- 0.012 in)

Self---locking disks axial clearance 0.20 --- 0.80 mm (0.008 --- 0.032 in)

Drive axle---reduction carrier axial clearance 0.30 --- 0.70 mm (0.012 --- 0.028 in)

8.00 --- 14.00 Nm

Hub bearings
(5.9 --- 10.3 ft (without seal rings))

Hub bearing preload determined by the ring nut tightening torque

1st tightening: 700---900 Nm then loosen

Ring nut tightening torque
2nd tightening: 450 Nm

Brake disc and caliper

Caliper CARLISLE M -- 4
Type Fixed
N. calipers per wheel 2
N. cylinders per caliper 2x2
New 17 mm
Brake pad thickness
Wear limit 3 ± 0.5 mm
Disc Fixed
Outer diameter 476 mm
Inner diameter 250 mm

Leggere attentamente le NORME DI SICUREZZA contenute in questo manuale, per la protezione del personale e della macchina
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 15

Bevel gear (first reduction)

Figure 10

276C063009

Leggere attentamente le NORME DI SICUREZZA contenute in questo manuale, per la protezione del personale e della macchina
16 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

Hub and epicyclic gear (second reduction)

Figure 11

276C062D012B

Leggere attentamente le NORME DI SICUREZZA contenute in questo manuale, per la protezione del personale e della macchina
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 17

TIGHTENING TORQUES

Figure 12

276C063D011A

Leggere attentamente le NORME DI SICUREZZA contenute in questo manuale, per la protezione del personale e della macchina
18 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

TIGHTENING TORQUES
Figure 13

276C062D014B

Leggere attentamente le NORME DI SICUREZZA contenute in questo manuale, per la protezione del personale e della macchina
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 19

TIGHTENING TORQUES
Figure 14

276C063D015

Leggere attentamente le NORME DI SICUREZZA contenute in questo manuale, per la protezione del personale e della macchina
20 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

EQUIPMENT
. The tools indicated in the following list should be requested from the Supplier (KESSLER + CO
GmbH & Co. KG).

TOOL CODE DESCRIPTION

038.586.0---2 Spanner for wheel safety nut

031.107.0---3 Seal ring sleeve driver

031.1351.0---3 (ADT 30)

Seal ring sleeve driver
038.007.0---4 (ADT 25)

038.005.0---3 (ADT 30)

038.005.0---3 Spanner for thread rings
+ (differential bearing)
038.005.1---3 (ADT 25)

Leggere attentamente le NORME DI SICUREZZA contenute in questo manuale, per la protezione del personale e della macchina
 ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 21

DIAGNOSTICS

Axle
1. Continuous noise
2. Cornering noise
3. Alternating noise
4. Sharp bangs during acceleration or deceleration
5. Oil leak

1 CONTINUOUS NOISE

Worn bearings. Replace them.

YES

NO

Gears damaged or worn. Replace them.

YES

NO

Lack of lubrication. Restore oil level.

YES

NO

Incorrect adjustment of the clearances. Adjust again

YES

2 CORNERING NOISE

Worn planet ---wheels or crown wheels. Replace.

YES

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 22 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

3 ALTERNATING NOISE

Wheel bearings with excessive clearance. Adjust the bearings.

YES

NO

Wheels mounted incorrectly. Disassemble and remount correctly.

YES

NO

Too little clearance in the bevel gear set. Adjust again.

YES

NO

Too much clearance in the bevel gear set. Adjust again.

YES

4 SHARP BANGS DURING

ACCELERATION OR DECELERATION

Incorrect gear train adjustment. Adjust again.

YES

NO

Pivot of the anchoring structure has too much Replace the parts of the articulated joint.
play. YES

NO

Loose fastening of the anchoring structure to Tighten the screws to the prescribed tightening
the chassis. YES torque.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 23

5 OIL LEAK

Worn oil seals. Replace them.

YES

NO

Loose screws. Tighten the screws to the prescribed tightening

YES torque.

Brakes
1. Weak braking action
2. Unequal action of the brakes
3. Brakes that remain blocked

1 WEAK BRAKING ACTION

Worn pads. Replace them.

YES

NO

Brake discs dirty with lubricant. Clean the discs and replace the pads.
YES

NO

Worn brake discs. Replace them.

YES

NO

Defective hydraulic system See Section 10 --- HYDRAULIC SYSTEM.

YES

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 24 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

2 UNEQUAL ACTION OF THE BRAKES

Pads and/or discs dirty with lubricant. Clean the discs and replace the pads.
YES

NO

Non---approved/different pads on the two sides. Replace with approved pads.

YES

NO

Worn brake discs. Replace them

YES

NO

Defective hydraulic system. See Section 10 --- HYDRAULIC SYSTEM.

YES

3 BRAKES THAT REMAIN BLOCKED

Foreign bodies between the discs. Overhaul the brakes.

YES

NO

Defective hydraulic system. See Section 10 --- HYDRAULIC SYSTEM.

YES

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 25

MAINTENANCE
The braking system components are funda- Figura 16
mental for the safe use of the vehicle.
All inspection and replacement operations
must be performed following the
manufacturer’s maintenance schedule and
procedures.
All the maintenance operations must be per-
formed by specialized personnel which has
been suitably trained and equipped with the 3
proper tools.
Replacements must be made with original
spare parts or parts satisfying the same spe- 1
cifications.
The pads (friction material) that have burns,
localized wear or cracks absolutely must be
replaced. Do not use different brands of
pads on the same axle. 2
If topping up is necessary, the same fluid as
that contained in the tank must be used.

Replacement of the brake pads

Proceed as follows:
D detach the caliper following the instructions in the
relative chapter;

Figura 15

276C061D060

D unscrew both the retaining screws (1) and partially

slip off both the upper centering pins (2) so as to free
the eyelets of the pads (3);
D remove both the pads by slipping them off the upper
part of the caliper (arrow);

274A061010

D connect a tube to the bleeding valve (arrow) and ar-

range a suitable container to collect the fluid that
leaks out;
D place two soft slats between the pistons, then force-
fully spread the pads apart using a lever or large
screwdriver and at the same time open the bleeding
valve until the cylinders return as far as possible into
their seats ;
D close the bleeding valve and disconnect the tube;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
26 REAR AXLE -- DISC BRAKES SECTION 6.3
Remove the dirt using a NON ---metallic
brush and a vacuum cleaner.
Visually examine the dust covers, and check
that there is no seeping of hydraulic fluid.
If irregularities are found, proceed to the
brake caliper overhaul.
Figura 17
276C062D016
D mount the new pads by inserting them from the
upper part of the caliper (arrow), sliding them on the
disc surface and fitting them on the lower centering
pins (arrow);
Figura 18
276C061D061
D insert the centering pins (2) into the relative seats
and block them with the relative retaining screws
(1);
D proceed to the reattachment of the caliper following
the directions in the relative chapter.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
Breaking -- in of the pads
During this procedure there may be an
emission of unpleasant vapors and odors
originating from the friction material of the
pads.
After replacement of the brake pads, they must be
broken---in by traveling about 500 km.
During the breaking---in period the vehicle must be
used with caution, avoiding intensive use of the brakes
such as panic stopping.
During the breaking---in period it is good practice to
check the temperature of the brake discs: this tempera-
ture must not exceed 200 ˚C.
Determine the temperature of the disc by
stopping the vehicle and placing a pyrome-
ter in contact with the disc.
. The procedures described below refer to
both axles.
D inserire i perni (2) di centraggio nelle relative sedi e
bloccarli con le relative viti di arresto (1);
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 27

Checking oil level Changing the oil

Proceed as follows:
Collect and dispose of used lubricants and
The level check can be carried out on the fluids, according to the laws in force
hubs or on the differential .
Proceed as follows to drain the system:
If the level has to be restored, this is to be
carried out on the differential. Figura 21

Figura 19

276C062022
D take the reference on the hub to horizontal position
276C062020
(see arrow);
D arrange a suitably sized container, clean the cap
area and remove the cap (1) and the drain cap (2);
Final reductions
drain all the lubricant.
D take the reference on a hub to horizontal position D clean the cap, check that the threading is in good
(see arrow); condition, replace the sealing ring with a new one
D clean the cap area and open the level cap (1). Lubri- and close the drain cap.
cant should drip out of the hole; D repeat the procedure for the other hub.
D close the filler cap. D arrange a suitably sized container, clean the cap
area and remove the cap (1) and the drain cap (2);
or drain all the lubricant.
Figura 20

276C063021
D clean the area of the cap, then open the cap (1): the
lubricant must leak from the hole;
D if necessary, restore the level until it overflows from
the same cap;
D close the cap.
D check that the breather is perfectly clean and ope-
rational.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
28 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

Figura 22 To fill the oil, proceed as follows:

Figura 24

276C063021
D arrange a suitably---sized container under the drain
cap, clean the cap areas and then remove the filling 276C062020
cap (1); D pour in approx 3 litres of the prescribed lubricant un-
Figura 23 til it overflows from the cap hole (1);
D replace the sealing ring with a new one and close
the cap;
D repeat the procedure for the other hub.

Figura 25
1

276C063023
D remove the drain cap (1) and completely drain the
lubricant;
D clean the caps, check that the threading is in good
condition, replace the sealing ring with a new one
and close the drain cap.
1
276C063021
D refill with the prescribed lubricant until it overflows
from the hole of the filling cap (1);
Fill up slowly.
The operation is finished when the level at
the hole does not lower for a few minutes.
D replace the sealing ring with a new one and close
the cap;
D perform a test drive and then recheck the level (1);
D if necessary, top up with the prescribed lubricant un-
til it overflows from the hole, repeat the test drive and
recheck the level.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3
INTERMEDIATE AXLE REMOVAL---REFIT
. Before starting any operation, make sure
that all the precautions have been taken and
all aspects regarding safety of the personnel
involved on the job have been made quite
clear .
Read the relevant instructions contained in
SECTION 1 of this handbook.
If in doubt ask someone who is more expert.
Comply to all the general recommendations
for correct execution of maintenance work.
Removal
Proceed as follows:
D Bring the vehicle on a suitable flat, solid surface,
switch off the engine, remove the key from the igni-
tion switch, engage the parking brake and affix the
warning notices;
D deactivate the battery isolator or disconnect the bat-
tery terminals to prevent any risk of a short circuit;
D block articulation by means of the steering lock bar,
proceeding as indicated in SECTION 1;
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
REAR AXLE -- DISC BRAKES 29
D raise the vehicle until the wheels are off the ground,
then position two support trestles under the rear
chassis, without acting on the axles;
D position a suitable hydraulic support device under
the intermediate axle and under the rear axle in
order that, when lowering the axles after detach-
ment, the two axles remain in a horizontal position
during this phase;
D remove both the wheels following the directions in
SECTION 9;
D disconnect the axle breather pipe (4);
Before detaching the hydraulic pipelines,
prepare suitable plugs to close the free
ends.
D disconnect the hydraulic pipelines:
--- service braking system (20);
. Hydraulic oil leakage may occur during
these operations.
D disconnect the drive shaft on the input side (18) and
output side (19) following the instructions in SEC-
TION 7;
D working on both sides of each rocker arm, remove
the split pin and unscrew the locking nut (8) of the
rocker arm pin;
D remove both the bolts (10) that fasten the tie---rod to
the bracket;
D slip the pin (9) off the rocker arm, recovering the
washers (6) and the guide bushings (7), disengag-
ing the rocker arm from the axle;
D carefully lower the axle and slip it off the vehicle.
30 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

Figura 26

10

20
4

18

6
9
7

7
6

276C063D027

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 31

BRAKE CALIPER DETACHMENT --- Figura 28

REATTACHMENT
1
Before performing any intervention, ensure
that all precautions have been taken and all
aspects clarified regarding the safety of per- 3
sonnel involved in the intervention.
Read the relative instructions provided in
4
SECTION 1 of this manual.
In case of doubt, consult a more experience 2
person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.

Detachment
Do as follows:
D bring the vehicle onto an appropriately solid flat sur-
face, shut off the engine, remove the key from the
ignition switch, engage the parking brake and affix
the indication signs;
D disconnect the battery---disconnect switch or dis-
connect the battery terminals in order to eliminate
any risk of short ---circuit;
D block the articulation by means of the steering lock
bar, operating as indicated in SECTION 1;
D block the rear wheels appropriately;
D use a hydraulic lift to raise the chassis until the rear
wheels are off the ground;
D disassemble the wheel concerned;
Figura 27
276C062D029
D disconnect the braking system hydraulic connector
(4) and plug it to prevent fluid leaks;
. Hydraulic oil leakage may occur during
these operations.
D support the caliper (2) appropriately, unscrew the
retaining screws (3) of the support bracket and re-
move the caliper complete with the bake pads.
Reattachment
Proceed to the reattachment by following the detach-
ment steps in the reverse order.
After reassembled, perform a bleeding of
the brake hydraulic circuit following the in-
structions in SECTION 10 --- HYDRAULIC
SYSTEM.

276C062D028

D insert appropriate support trestles under the axle,

then lower the chassis, resting the axle on the indi-
cated points (arrow) and remove the lift;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
32 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

Page left intentionally blank

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 33

EPICYCLIC REDUCER OVERHAUL Figure 30

Before starting any operation, make sure

that all the precautions have been taken and
all aspects regarding safety of the personnel
involved on the job have been made quite
clear.
Read the relevant instructions contained in
SECTION 1 of this handbook.
If in doubt ask someone who is more expert.
Comply to all the general recommendations
for correct execution of maintenance work.
5
. Before proceeding, it is necessary to: 4
D drain the lubricant from the wheel hub 3
D drain the lubricant from the central differ- 2
ential;
following the instructions provided in the
276C062D031
relative chapter.
D unscrew the central retaining screw (1) and remove
the fixed gear (2) and guide bushing (3) complete
. Before proceeding, the brake caliper must
with spacer ring (4);
be removed following the instructions in the D slip off the axle shaft (5) if necessary;
relative chapter.
Figure 31
Disassembly
Proceed as follows:

Figure 29

1
4

3 1
2 D unscrew the setscrew (1) of the ring nut;
276C062D030
D mark the mutual position of the planet ---wheel hold-
ing plate and the hub;
D loosen and remove all the retaining screws (1);
D remove the planet ---wheel holding plate assembly
(2) and O---ring (3) and recover the thrust spacer
ring (4);
2
276C062032
D remove the locking ring nut (2) of the internally
toothed crown wheel.
The ring nut is locked with thread ---stops.
To prevent damage to the threading, heat to
approximately 120˚C before unscrewing.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
34 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

D using a suitable lifting device, carefully remove the Figure 34

complete hub from the hub support;
1
During this operation, keep the hub parallel
to the axle axis to avoid damaging the brake
discs.
D remove the front sealing ring;
D place the hub vertically;

Figure 32

2
276C062D036

D Unscrew the retain screws (1) and remove the brake

disc (2);
D if necessary remove the wheel fastening screws
from the hub;

Figure 35

1
1
1 2
276C062D033

D use a suitable extractor to remove the internally

toothed crown wheel (1);

Figure 33

1 2

5
3
276C062D035

4 D VERSION A: Remove the two oil seal rings (1);

D use a suitable extractor to remove the outer race (2)
of the axle---side bearing (A) and the outer race (3)
of the wheel---side bearing (B);
3
276C062D034

D remove the retaining screws (1) and relative stop

plates (2);
D separate the internally toothed crown wheel (3) from
the relative flange (4);
D using a suitable extractor, remove the inner race (5)
of the wheel---side bearing (B) from the crown wheel
flange;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 35

Figure 36 Figure 38

2 1

276C062035B
D VERSION B: Remove the oil seal ring (1);
D with an appropriate puller remove the outer ring (2)
of the bearing on the axle side (A) and the outer ring
(3) of the bearing on the wheel side (B);
Figure 37
274A062029
D place the planet ---wheel holding plate on a suitable
work surface;
D use a punch to push the retaining pin (1) down in the
pivot, freeing the pivot (2);
D extract the pivot (2) by pushing it towards the inside
of the planet ---wheel holding plate (arrow);
D remove the O---ring (3);
D extract the pin from the pivot.
. Do not push the pivot towards the outside of
the planet---wheel holding plate, otherwise
its seat may be damaged due to the differ-
ence between the internal and external di-
ameter of the pivot.

Figure 39

2
1
2
276C062D037

D remove the inner race (1) of the axle---side bearing

276C062038
(A) and the spacer ring (2) from the hub;
D remove the planet wheel (1) and relative shim rings
The spacer ring is blocked with sealant.
(2);
To avoid damaging it, before removing, heat
to approx. 120 ˚C.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
36 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

Figure 40 Inspection of the dismantled parts

Wheel hub
D check the seats of the bearings: they must not have
any deformations and/or ovalling;
D check the condition of the bearings: replace them
if they have bluish halos, cracks and/or signs of
wear.

Axle shafts
D check the condition of the axle shafts: replace them
if they have deformations on the end grooves and/or
on the entire length.

274A062039 Final reductions

D remove the needle cages (arrow) from the planet ---
wheel;
D repeat the procedure for all the planet ---wheels.
D check the condition of the gear toothing: replace
them if they have pitting, cracks and/or cavities;
D verify the good operation of the planet ---wheels and
the roller bushings;
D check the threading for the bearing locking ring nut:
it must not have any dents, deformations and/or
jams.

Reassembly

During reassembly, consider the following

general observations:
D heat, to 100˚C in the oven, the bearings
and rings to be mounted by pushing;
D carefully center and mount the sealing
rings and bearings with a suitable adjust-
er;
D lubricate the ring nuts and bearings.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 37

Epicyclic reduction gear seals and thread-- stops application and bearings scheme

VERSION A

Figure 41

276C062D044A

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
38 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

Epicyclic reduction gear seals and thread-- stops application and bearings scheme

VERSION B

Figure 42

276C062D044B

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 39

Planet-- wheel holding plate assembly Figure 44

Proceed as follows:
D position the planet ---wheel holding plate horizontal- 2
ly;

Figure 43

1
2

276C062052

D mount the planet ---wheel (1) complete with shim

274A062032
rings in the seat on the planet ---wheel holding plate;
D mount the needle cages inside the planet gear; Figure 45

1 274A062035

D insert the O---ring (1) in the seat of the planet ---wheel

holding plate;
D insert the pivot (2) of the planet ---wheel holding gear
so that the pin holes match up;
D or according to the versions;
D insert the pivot (2) of the planet ---wheel holding gear
up to the complete expulsion of the internal reten-
tion bush so that the pin holes match up;
Mount the pivot from the internal part of the
planet---wheel holding plate, otherwise its
seat may be damaged due to the pivot diam-
eter difference.
D mount the catch pin (3);
D repeat the procedure for all the planet ---wheels.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
40 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

Brake unit and hub assembly Figure 48

Proceed as follows:

Figure 46

3
2

1
276C062053

D place the hub vertically;

D using a suitable introducer, mount the outer race (1)
of the wheel---side conic roller bearing (B) and the
outer race (2) of the axle---side conic roller bearing
(A);
D mount the inner race (3) of the axle---side conic roller
bearing (A);

Figure 47 276C061054B

D VERSION B:with an appropriate tool, insert the seal

ring (2) into the seat, flush with the external edge of
the hub, paying attention to the orientation (detail);

Figure 49

276C062054
D VERSION A: With an appropriate tool, insert the seal
rings (1) into the seat, flush with the external edge 1
of the hub, paying attention to the orientation (de-
tail); 276C062D055

D mount the brake disc (1) on the hub;

D mount retain screw (2) and tighten.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 41

Figure 50

3 1

276C062D066

D heat the spacer ring (1) and insert it completely on

the axle axis;
D using a suitable lifting device, support the hub as-
sembly in order to ensure its correct centering;
D introduce the hub assembly (2) on the end of the
hub support (3), placing the inner race of the axle---
side conic roller bearing (A) so that it rests against
the spacer ring;
During this operation, keep the hub parallel
to the axle axis.
Work with caution to avoid damaging the
sealing rings and the brake disc teeth.
Continue to support the hub assembly until
it is completely mounted.
D release the brake discs by discharging the pressure
from the piston;
D if removed, mount the stud bolts fastening the wheel
to the hub (4).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
42 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

Figure 51 Hub bearing preload determination

Proceed as follows:

Figure 53
4

2
2
3
276C062W067
D heat the inner race (1) of the wheel---side conic roller
bearing (B) and insert it until it rests against the gear
wheel flange;
D insert the gear wheel flange (2) onto the gear wheel
1
with internal toothing (3);
D mount the retention plates (4) and fix them with the
setscrews; 276C062069

Figure 52 D apply MOLYKOTE lubricant on the hub support

1 forth by striking it with a plastic hammer to
276C062W068
D mount the flange and internally toothed gear wheel
assembly (1) onto the hub until the two parts meet
the wheel---side conic roller bearing (B).
The lubrication oil passage hole on the too-
thed wheel flange is to face downwards.
threading and on the threading and contact area of
the locking ring nut;
D hand mount the ring nut (1) without tightening;
D tighten the locking ring nut to the prescribed tight-
ening torque:
Locking ring nut tightening torque for bearings
Phase 1: 700-- 900 Nm
During the locking, rotate the hub back and
forth by striking it with a plastic hammer to
settle the bearings.
D unscrew the locking ring nut half a turn;
D tighten the locking ring nut to the prescribed tight-
ening torque:
Locking ring nut tightening torque for bearings
Phase 2: 450 Nm
During the locking, rotate the hub back and
settle the bearings.
D after having adjusted the bearing preload, block the
locking ring nut with the relative setscrew (2);
If this is not possible, unscrew the ring nut
as much as needed in order to mount the
clamp screw.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 43

Figure 54 Planet-- wheel holding plate -- fixed gear axial clear-

ance determination
Proceed as follows:

Figure 55

2
3
4 A
5
B
276C062D070
D insert the axle shafts (1) into the axle;
D mount the spacer ring (2), guide bushing (3) and
fixed gear (4);
D mount the central retaining screw (5) and tighten it.

274A062043

D determine the dimension A;

D determine the dimension B;
D determine the thickness of the thrust spacer as fol-
lows:
S = A -- B +(0.30 ÷ 0.70) (mm)
where:
A = distance between the planet ---wheel holding
plate mounting surface and the seat of the thrust
spacer on the same plate
B = distance between the hub mounting surface
and the thrust spacer seat on the fixed gear
S = thrust spacer thickness
0.30 ÷ 0.70 = prescribed clearance in mm
D mount the chosen thrust spacer onto the planet ---
wheel holding plate.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
44 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

Concluding operations

Figure 56

1 3
2
276C062D073

D mount the O---ring (1) in the seat of the planet ---

wheel holding plate;
D mount the planet ---wheel holding plate assembly (2)
in the hub.
Respect the reference marks made during
disassembly.

D mount the retaining screws (3) and tighten to the

prescribed torque.

. If no intervention on the differential is

planned, proceed to:
D the filling of the wheel hub;
D the filling of the central differential;
following the instructions provided in the
relative chapter.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 45

Page left intentionally blank

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
46 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

DIFFERENTIAL OVERHAUL Disassembly

. Before proceeding, the axle shafts must be

Before performing any intervention, ensure removed following the instructions in the re-
that all precautions have been taken and all lative chapter.
aspects clarified regarding the safety of per-
sonnel involved in the intervention.
Read the relative instructions provided in
SECTION 1 of this manual.
In case of doubt, consult a more experien-
ced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.

Proceed as follows:

Figure 57

2 3

276C063D080

D straighten the dent and remove the motion input
flange stop nut (1);
D using a suitable extractor, remove the flange (2);
D mark the relative position between box and axle;
D loosen and remove the screws (3) fastening the ex-
ternal box to the axle;
D using a suitable lifting device, remove the external
box assembly from the axle;
D position the assembly on the support trestle, adap-
ting as necessary.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 47

Differential disassembly
Figure 58 Proceed as follows:

Figure 60
2 4
1
3
3

1
4
2
2
276C063081
D unscrew the retaining screws and remove the loc-
king plate (1) of both the bearing preload adjust- 274A062048
ment ring nuts;
D loosen both the bearing preload adjustment ring D remove the outer race (1) of the crown wheel---side
nuts (2); bearing (C) and the outer race (2) of the planet whe-
D mark each support cap and the corresponding ex- el---side bearing (D);
ternal box location; D use appropriate extractors to extract the inner race
D loosen the retaining screws (3) and remove both the (3) of the crown wheel---side bearing (C) and the in-
support caps (4); ner race of the planet wheel---side bearing (D) from
D remove both the adjustment ring nuts; the differential semicases;
D mark both the differential semicases;
Figure 59 D loosen the retaining screws and remove the diffe-
rential semicase;

Figure 61

274A062047
274A062049
D using a suitable lifting device, extract the differential
D disassemble the planet ---wheel group into the diffe-
assembly (1) from the relative case.
rent components;
D remove the discs of the skid limitation device and
the relative shoulder rings;
D if necessary, separate the ring bevel gear from the
differential semicase by unscrewing the retaining
screws.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
48 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

Pinion disassembly
Figure 65
Proceed as follows:

Figure 62

276C063082A
D ADT 30: Remove the cover (1) the seal ring (2) and 276C063084
the O---ring (3); D use a press and pad to extract the pinion (1) from
the pinion box;
Figure 63
Figure 66

1
276C063082B
D ADT 25: Remove the seal ring (1);

Figure 64
276C063D095

D remove the inner race (1) of bearing (B) and bearing

preload spacer S2 (2) from the pinion box.

2
276C063083
D remove the complete pinion box (1);
D recover the pinion position adjustment spacer S1
(2);

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 49

Figure 67

276C063D096

D use a suitable extractor to remove the outer race (1)

of bearing (B) and the outer race (2) of bearing (A)
from the pinion box;

Figure 68

274A062055

D using a suitable extractor (1), remove the inner race

(2) of bearing (A).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
50 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

Inspection of the disassembled parts Reassembly

During reassembly consider the following

Bearings
general observations:
D check the condition of the bearings: replace them D heat, to 100˚C in the oven, the bearings
if they have bluish halos, cracks and/or signs of and rings to be mounted by pushing;
wear. D carefully center and mount the sealing
rings and bearings with a suitable adju-
Crown wheels ster;
D check the condition of the toothing: replace it if it has D lubricate the bushes, sealing rings and
pits, cracks and/or cavities. bearings.

Planet ---gears Perform all the indicated measurements

D check the condition of the toothing: replace it if it has
pits, cracks and/or cavities;
D check the coupling surfaces with the pins.
Damage to a single element entails the re-
placement of the entire gear unit.
with maximum precision.
Imprecise measurements lead to bad con-
tact of the bevel gear and thus make it ne-
cessary to repeat the procedure.

Cross pins
D check the coupling surfaces with the planet ---gears.

Shoulder rings
D check the condition of the rings: replace them if they
have bluish halos, cracks and/or signs of wear.

Bevel gear
D check that the toothing of the crown wheel and the
pinion show uniform wear on the entire working zo-
ne of the teeth: replace the bevel gear if it has pits,
cracks and/or cavities;
An anomalous wear may indicate an incor-
rect adjustment of the bearings: check their
integrity before proceeding to the reassem-
bly.
Damage to a single element entails the re-
placement of the entire gear unit.
D check the bearing seats: they must not have defor-
mations or ovalling.

Bushes
D check the threading for the bearing locking bush: it
must not have dents, deformations and/or jams.

External box
D check the bearing seats: they must not have defor-
mations or ovalling;
D check that the sealing surfaces and the threadings
are integral and free of dents or damage.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 51

Differential seals and thread-- stops application and bearings scheme

Figure 69

276C063087A

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
52 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

Complete limited-- skid differential assembly

Proceed as follows:

. Refer to the following figure.

D check the following measurements:
SP1 = 3.10 mm minimum;
SP2 = 2.15 mm minimum.
D otherwise, use shoulder discs with a greater thick-
ness;
D mount the shoulder ring (2) and elastic ring (3);
D position the shoulder disc (SP1) (4);
D alternately mount an externally grooved disc (driven
plate) and an internally grooved disc (driving plate)
until all discs (5) have been mounted;
The last disc is a driving plate.

D mount the shoulder disc (SP2) (6);

D mount the elastic ring (7);
D mount the planetary gear;
D repeat the assembly for the other semicase;
D when finished, check that dimension A falls within
the prescribed values;
52.8 < A < 53.27 mm
D when finished, check that dimension B falls within
the prescribed values;
B < 0.48 mm
D otherwise, use shoulder discs with a greater thick-
ness or reduce the thickness by grinding;
D assemble the shafts and planet ---wheel gears and
mount the assembly on the crown wheel;
D join the two semicases and tighten the retaining
screws to the prescribed torque.
The two semicases are symmetric except for
the crown wheel assembly flange.
The total height of the crown wheel---side
disc pack must be identical to that on the op-
posite side.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 53

Figure 70

1. Differential semicase
2. Shoulder ring
3. Elastic ring
4. Semicase shoulder disc SP1
5. Driven (N.4) and driving (N.4) discs
6. Crown wheel shoulder disc SP2
7. Elastic ring
8. Crown wheel --- planet ---wheel group SP1
Dimension A: disc pack thickness
Dimension B: Shoulder ring --- crown wheel clearance

SP2

1
2

4 A
5
6
7

6
5
4

2
1

276C062091

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
54 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

Crown wheel and bearings assembly

Figure 71

274A062060
Proceed as follows:
D check that the area of contact between the gear (1)
and differential semicase (2) is clean and free of
grease;
D mount the crown wheel on the semicase and tighten
the fastening bolts (3) to the prescribed torque;

Figure 72

2
274A062062
D heat the inner race (1) of the planet wheel---side co-
nic roller bearing (D) and mount it against the diffe-
rential semicase;
D heat the inner race (2) of the crown wheel---side co-
nic roller bearing (C) and mount it against the diffe-
rential semicase.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 55

Thickness determination for bearing preload spacer S2 and bearing assembly

Figure 73

Bearing B

d1
d2

Bearing A

276C063088

Proceed as follows:
D position the pinion box vertically;
D mount both the outer races of bearings (A) and (B)
in the seat;
D temporarily mount both the inner races of bearings
(A) and (B);
D determine the dimension d1;
D determine the dimension d2 on the pinion;
D determine the thickness of the bearing preload spa-
cer S2 as follows:
S2 = d1 -- d2 (mm)
where:
d1 = distance between the bearing (A) inner race
shoulder and the internal edge of the bearing
(B) inner race
d2 = distance between the internal bearing inner
race support and the bearing preload spacer
S2 support
S2 = thickness of the bearing preload spacer S2.
D remove both the inner races of bearings (A) and (B.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
56 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

Figure 74 Figure 76

276C062093
D heat the inner race of bearing (A) and mount it on the
pinion; 2
Figure 75

4 3

276C063091A

D tighten the fastening screws (1) to the specified tor-

que;
1 D couple the flange (2) onto the groove of the pinion;
D apply MOLYKOTE on the pinion threading and on
the threading and contact area of the stop nut;
D mount the stop nut (3) and tighten it to the prescri-
bed torque.
Use a new stop nut.
During the locking, rotate the pinion back
and forth by striking it with a plastic hammer
to settle the bearings.

2
3

276C063090
D insert the pinion (1) into the pinion box;
D mount the chosen bearing preload spacer S2 (2);
D heat the inner race (3) of bearing (B) and mount it
on the pinion;
D position the spacer S1 (4) and then mount the pi-
nion box in the external box.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3
Figure 77
1731281
D use a suitable tool to check that the rolling torque
falls within the prescribed values:
Rolling torque for pinion bearings
0.8 -- 1.2 Nm
D otherwise, correct the rolling resistance by using a
spacer S2 with a different thickness;
D in particular:
--- increase the thickness to reduce the torque
--- reduce the thickness to increase the torque
D remove the pinion stop nut and relative flange;
D remove the retaining screws and slip off the comple-
te pinion box.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
REAR AXLE -- DISC BRAKES 57
Differential bearing preload determination
Proceed as follows:
Figure 78
17312101
D position the bearing outer races on both ends of the
differential;
D using a suitable lifting device, mount the crown whe-
el assembly in the differential box;
D apply MOLYKOTE on the threading of the adjust-
ment ring nuts;
D screw on both the ring nuts by hand;
Figure 79
17312102
D align the reference marks and mount the bearing
support caps;
D mount the cap retaining screws and tighten them;
D use a suitable tool to check that the rolling torque
falls within the prescribed values:
Rolling torque for crown wheel and pinion
bearings
2.0-- 3.0 Nm
D the rolling torque can be corrected by turning both
the adjustment ring nuts by the same number of not-
ches;
D In particular:
--- unscrew the ring nuts to decrease the torque;
--- screw on the ring nuts to increase the torque.
58 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

Pinion assembly ADT 25

Proceed as follows:
Figure 82
ADT 30

Figure 80

1
3

276C063092A
1
D insert the sealing ring (1) into the cover (2) following
the assembly direction and fill it completely with lu- 2
bricating grease for bearings;
D fit the O---ring (3) in the cover;

Figure 81 3

276C063093B
D assemble the complete pinion box in the extrnal
box;
D tighten the fastening screws to the specified torque;
D fit the seal ring (1) following the assembly direction
and fill completely with lubricating grease for bear-
ings;
D insert the flange (2) and tighten the locking nut (3)
to the specified torque.

1
2

276C063093A

D mount the complete pinion box in the external box;

D tighten the fastening screws to the specified torque;
D mount the cover (1) complete with sealing ring;
D screw on the retaining screws and tighten to the pre-
scribed tightening torque;
D insert the flange (2) and tighten the stop nut (3) to
the prescribed torque;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 59

Check of the pinion-- crown wheel clearance

Proceed as follows:

Figure 83

17312104

D mount a dial gauge at a right angle with respect to

the external diameter of the crown wheel’s toothed
side and turn the crown wheel back and forth, being
careful not to move the pinion;
D check that the clearance between the crown wheel
and pinion falls within the prescribed values:
pinion-- crown wheel clearance
see value engraved on the crown wheel
D otherwise, adjust the clearance using the adjust-
ment ring nuts;
D the clearance can be adjusted without modifying
the bearing preload by unscrewing one adjustment
ring nut by a certain number of notches and scre-
wing on the opposite adjustment ring nut by the sa-
me number of notches.

Figure 84

17312105
D In particular:
--- unscrew the ring nut (D) and screw on the ring
nut (C) to reduce the clearance (white arrow);
--- unscrew the ring nut (C) and screw on the ring
nut (D) to increase the clearance (black arrow).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
60 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

Verification of the pinion-- crown wheel engagement

impression area
Proceed as follows:

Figure 85

17312106

D cover a dozen teeth of the crown wheel with Prus-

sian blue, lubricated with minium, or another paint
or dye that can be easily removed;
D make a complete rotation of the crown wheel by
hand;
D when the teeth engage, the paint is removed by the
contact of the teeth, leaving zones exposed with the
exact dimension, shape and location of contact;

Figure 86

274A062063

Contact area position and shape D to replace the spacer S1, remove the retaining
1. correct bevel gear position; screws (1) and slip off the complete pinion box;
2. position with the pinion too far back: it is necessa- D position the new spacer S1, then reassemble the pi-
ry to reduce the distance between the pinion and nion box and tighten the retaining screws to the pre-
the crown wheel axis by using a spacer S1 of less scribed tightening torque.
thickness; then adjust the clearance by moving
When finished, remove the differential, pi-
the crown wheel further from the pinion;
nion and pinion box.
3. position with the pinion too far forward: it is neces-
sary to increase the distance between the pinion
and the crown wheel axis by using a spacer S1 of
greater thickness; then adjust the clearance by
moving the crown wheel closer to the pinion;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3
D to replace the spacer S1, remove the stop nut, flan-
ge, and retaining screws and slip off the complete
pinion box;
D position the new spacer, then reassemble the pinion
box and tighten the retaining screws to the prescri-
bed tightening torque;
D insert the flange and tighten the stop nut to the pre-
scribed torque;
Figure 87
274A062066
D dent the nut as described in the figure;
If this is not possible, unscrew the nut as
much as necessary to dent it.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
REAR AXLE -- DISC BRAKES 61
Figure 88
274A062064
D once all the adjustments and configurations are cor-
rect, fix the locking plate (1) of both the ring nuts
using screws;
D support the complete external box with suitable lif-
ting equipment;
D mount the complete external box assembly onto the
axle respecting the reference marks made during
disassembly;
D screw on the retaining screws and tighten to the pre-
scribed torque.
. Proceed to:
D the reassembly of the axle shafts;
D the filling of the wheel hubs;
D the filling of the central differential;
following the instructions provided in the re-
lative chapter.
62 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

BRAKE CALIPER OVERHAUL Figure 90

Before performing any intervention, ensure

that all precautions have been taken and all
aspects clarified regarding the safety of per-
sonnel involved in the intervention.
Read the relative instructions provided in
SECTION 1 of this manual.
In case of doubt, consult a more experi-
enced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.

Disassembly 1
Proceed as follows:

Figure 89 2
276C062D110

D unscrew the retaining screws (1) and remove the

plate (2);

. Hydraulic oil leakage may occur during

these operations.

3 Figure 91

2 3

276C061D060
2
D unscrew both the retaining screws (1) and partially
slip off both the upper centering pins (2) so as to free
1
the eyelets of the pads (3); 276C062D111
D remove both the pads by slipping them off the upper D pressing from the inside of the piston, remove the
part of the caliper (arrow); cover (1) and the gasket (2);
D push the piston (3) towards the inside of the caliper
until it disengages from the dust cover;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 63

Figure 92 Reassembly
Proceed as follows:

Figure 93

3
2
1
1
276C062D112
2
D remove the shoulder ring (1), gasket (2) and dust 3
cover (3);
D repeat the operations for all the pistons in the cali- 276C062D113
per. D mount the dust cover (1), gasket (2) and shoulder
ring (3) in the appropriate seat on the caliper;
Inspection of the disassembled parts
Proceed as follows: Figure 94
D carefully clean the entire caliper, especially in the in-
ternal parts and around the piston seats;
D remove the bleeding valves, then carefully clean all
the internal canalizations by blowing with com-
pressed air;
D with a cloth soaked in isopropyl alcohol or equival-
ent, carefully clean the sliding surface of the pistons;
D check the wear conditions of the pistons and rela-
tive seats: if wear or damage is found, proceed to 1
their replacement;
D manually insert the pistons into the seats and check
for correct sliding: otherwise, proceed to replace-
ment;
D check the conditions of the guide pins of the pads: 274A061034
in case of damage, proceed to their replacement. D mount the piston (1) in the appropriate seat, slip-
Always replace the gaskets, sealing rings ping the dust cover onto the groove (arrow) on the
and dust covers even if apparently intact. piston;
During reassembly, lubricate all the internal To facilitate the operation, rotate the piston
components with the prescribed hydraulic slightly during insertion.
fluid.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
64 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

Figure 95

1
2
276C062D114

D mount the sealing gasket (1) and cover (2);

D repeat the operations for all the pistons in the cali-
per;

Figure 96

1
276C062D115
D mount the plate (1) and tighten the retaining screws
(2);
D proceed to the assembly of the new brake pads by
following the disassembly steps in the reverse
order.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- DISC BRAKES 65

BRAKE DISC OVERHAUL Figure 97

Before performing any intervention, ensure

that all precautions have been taken and all
aspects clarified regarding the safety of per-
sonnel involved in the intervention.
Read the relative instructions provided in
SECTION 1 of this manual.
In case of doubt, consult a more experien-
ced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.

Disassembly
Proceed to the detachment of the brake disc following
the instructions in the relative Chapter.
Inspection of the disassembled parts
Proceed as follows:
D perform a careful cleaning of the disc;
D check the conditions of the disc, making reference
to the figure:
A. Superficial microcracks on the side of the disc: 274A061037
acceptable
B. Radial cracks: NON---acceptable
C. Cracks on the edge of the attachment to the
flange: NON---acceptable.

Reassembly
Proceed to the reattachment of the brake disc following
the instructions in the relative chapter.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
66 REAR AXLE -- DISC BRAKES SECTION 6.3 ADT 25-30 TIER3

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For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 SECTION 6.3

REAR AXLE --- WET OIL

 ADT 25-30 TIER3 SECTION 6.3
CONTENTS
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
First reduction: bevel gear pair . . . . . . . . . . . . . . . . . . 4
Second reduction: hub and epicyclic train . . . . . . . . 9
SPECIFICATION AND DATA . . . . . . . . . . . . . . . . . . 12
Bevel gear (first reduction) . . . . . . . . . . . . . . . . . . . . 13
Hub and epicyclic gear (second reduction) . . . . . . 14
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . 16
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REAR AXLE REMOVAL-- REFIT . . . . . . . . . . . . . . . 24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
EPICYCLIC REDUCER OVERHAUL . . . . . . . . . . . . 26
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Inspection of the dismantled parts . . . . . . . . . . . . . . 29
Epicyclic reduction gear seals and thread---stops
application and bearings scheme . . . . . . . . . . . . . . 30
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
REAR AXLE -- WET OIL 1
Page
Planet ---wheel holding plate assembly . . . . . . . . . . 32
Brake unit and hub assembly . . . . . . . . . . . . . . . . . . 33
Hub bearing preload determination . . . . . . . . . . . . . 35
Planet ---wheel holding plate --- fixed gear axial
clearance determination . . . . . . . . . . . . . . . . . . . . . . 36
Concluding operations . . . . . . . . . . . . . . . . . . . . . . . . 37
TANDEM TRANSMISSION AND DIFFERENTIAL
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Inspection of the disassembled parts . . . . . . . . . . . 43
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Differential seals and thread---stops application
and bearings scheme . . . . . . . . . . . . . . . . . . . . . . . . . 44
Complete limited---skid differential assembly . . . . . 45
Crown wheel and bearings assembly . . . . . . . . . . . 47
Thickness determination for bearing preload
spacer S2 and bearing assembly . . . . . . . . . . . . . . 48
Differential bearing preload determination . . . . . . . 50
Pinion assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Check of the pinion---crown wheel clearance . . . . 51
Verification of the pinion---crown wheel
engagement impression area . . . . . . . . . . . . . . . . . . 52
2 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

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For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 3

DESCRIPTION
The axle is a dual reduction bearing type.
It consists of a boxed structure containing the cylindri-
cal wheel transmission, the bevel gear pair with the dif-
ferential (first reduction), the drive shafts and hubs with
the epicyclic reducer (second reduction).
The structure has mountings for connection to the
chassis and housings for the bearings.

Figure 1

276C063W001

1. Rear suspension
2. Transmission box and differential
3. Axle
4. Hub with epicyclic gears
5. Upper stabilizer bar
6. Motion input flange

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
4 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

First reduction: bevel gear pair

The first reduction is obtained by the pinion---ring bevel Legend (figure on following page)
gear unit (bevel gear pair) inside the differential.
The input shaft is supported by two taper roller bear- 1. Right adjustment ring nut
ings mounted in O arrangement with preload that can 2. Planet wheel---side conic roller bearing (D)
be adjusted by spacer. 3. Crown wheel
The pinion shaft receives the motion from a cylindrical 4. Planet wheel holding shaft
wheel transmission with ratio 1:1. 5. Planet ---wheel
The pinion is supported by two taper roller bearings 6. Crown wheel---side conic roller bearing (C)
mounted in O arrangement with preload that can be ad- 7. Differential box
justed by spacer. The pinion axial position can also be 8. Left adjustment ring nut
adjusted by shims. 9. Differential box
The differential box with ring bevel gear is supported by 10. Ring bevel gear
two taper roller bearings mounted in X arrangement 11. Bevel pinion
with preload and axial position that can be adjusted by 12. Pinion internal conic roller bearing (A)
two opposing ring nuts. 13. Pinion external conic roller bearing (B)
14. Motion input flange
15. Sealing ring

A: Cross section
B: Functional diagram

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 5

Figure 2

276C063003

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
6 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

The differential is a limited---skid differential, characteri-
zed by the positioning of a multiple---disc clutch betwe-
en the differential case (upright) and the crown wheels
(sun gears) for each side.
The multiple---disc clutch includes external discs con-
nected to the differential case and internal discs con-
nected to the planetary gears.
The thrust on the discs is ensured by the axial compo-
nent of the force exchanged between the teeth of the
planet ---wheels and crown wheels.
The axial thrust on the discs generates a resistant tor-
que that acts on the crown wheel when the crown whe-
el tends to rotate with respect to the differential case
due to the speed difference between the two wheels.
This resistant torque depends, with equal axial thrust,
on the dimensions and the coating material of the
discs.

Figure 3

3,1 2

2,15

0,48

1. Differential semicase
2. Planetary gear
3. Multiple---disc device for skid limitation
3

52,8 --- 53,27

276C062005

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3
Operation
The torque coming from drive shaft is transmitted
through a cardan joint to the bevel pinion.
From this, the torque passes to the ring bevel gear,
which is integral with the differential case.
The differential is a gear train in which the case repre-
sents the upright, that holds the planet ---wheel holding
shafts and receives the torque, while the two crown
wheels represent the sun gears, both rotary, that recei-
ve the torque and transmit it to the axle shafts.
When both the wheels are subject to the same resistant
torque or have the same speed (vehicle traveling along
a straight path), the ring bevel gear and the differential
case rotate as a block, transmitting the torque in equal
parts to the two crown wheels, and from these to the
two axle shafts that rotate at the same speed: the whe-
els transmit the same driving torque.
Figure 4
LH RH
276C062006
The right wheel with the same adherence as the left.
RH: right side: torque supplied is 50% of the total
LH: left side: torque supplied is 50% of the total
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
REAR AXLE -- WET OIL 7
Under these conditions, there is no relative motion bet-
ween the two crown wheels, and thus the planet ---whe-
els do not rotate around their shaft which is integral with
the differential case.
When the resistance of one wheel exceeds that of the
other or when the speed of the two wheels is no longer
equal (vehicle traveling a curved path) the planetary
gears assume a different rotation speed: their relative
motion is allowed by the presence of the planet ---whe-
els, which now rotate around their own shaft in opposi-
te directions.
Naturally, a slower rotation speed of the crown wheel
corresponds to a greater driving torque transmitted,
and vice versa.
Thus when the differential operates the wheel that has
a smaller speed, it is able to transmit a greater driving
torque, while the one with the greater speed transmits
a smaller torque.
Under certain conditions it may occur that the slower
wheel completely loses adhesion, since the torque that
can be transmitted to the ground is exceeded, and thus
it encounters practically zero resistance: in this case, a
normal differential causes the free rotation of the wheel
that skids and the stopping of the wheel that still adhe-
res to the ground: the traction capacity of the axle beco-
mes zero.
To remedy this inconvenience, a limited---skid differen-
tial is used that is characterized by the possibility to ge-
nerate a resistant torque on each crown wheel, which
is no longer free to rotate with respect to the differential
case, but is braked in proportion to the torque that the
differential must transmit.
This resistant torque, which depends on the thrust ap-
plied to the multiple---disc clutch, is always in a fixed ra-
tio with the input torque, known as the ”locking ratio”.
The locking ratio is the percentage of maximum diffe-
rence between the torque transmittable to the wheel
with greater adherence and that on the wheel with less
adherence.
For example, with a locking ratio of 45%, 72,5% of the
driving torque is transferred to one rear axle shaft (ra-
ther than the normal 50%), while the other axle shaft re-
ceives only 27.5%: the difference is precisely 45% (with
respect to a total of 100%).
8 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

If the two wheels do not have the same adherence, the

resistant torque generated by the multiple---disc clut-
ches partially locks the crown wheel on the side having
less adherence and increases the torque supplied by
the crown wheel on the side with more adherence. In
other words, the braking torque replaces the reaction
torque missing from the side of the wheel with less ad-
herence.
In this manner, considering the previous case in which
one wheel loses adherence, this wheel is not able to
turn freely and thus the other wheel will still be able to
transmit part of the driving torque, ensuring at least so-
me traction capacity of the axle.

Figure 5

LH RH

276C062007
Left wheel with less adherence than the right wheel
(example)

RH: right side: torque supplied is 72.5% of the total

LH: left side: torque supplied is 27.5% of the total

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 9

Second reduction: hub and epicyclic train

The second reduction is obtained by an epicyclic re- Legend (figure on following page)
ducer with cylindrical wheels in the wheel hub.
The hub is supported by two taper roller bearings 1. Epicyclic train upright
mounted in O arrangement with preload that can be ad- (planet ---wheel holding plate)
justed by a ring nut. The planetaries gear rotate on pi- 2. Thrust spacer
voting roller bearings. 3. Planet ---wheel
4. Epicyclic train fixed gear
Operation 5. Planet ---wheel pin
6. Guide bushing
The torque from the differential is transmitted by a float-
7. Adjustment ring nut
ing drive shaft to the sun gear by the grooved shank.
8. Epicyclic train crown wheel
The four planetaries gears rotate in the opposite direc-
9. Hub
tion to the sun gear, whereas the crown wheel is inte-
10. Wheel fastening column
gral with the hub support and therefore does not turn.
11. Sealing rings
This forces the train carrier to turn in the opposite direc-
12. Hub support
tion to the planetaries gear, therefore in the same direc-
13. Spacer
tion as the drive shaft.
14. Internal conic roller bearing
Since the train carrier is integral with the wheel hub, the
15. External conic roller bearing
wheel turns in the same direction as the drive shaft.
16. Axle shaft
17. Central retaining screw

A: Cross section
B: Functional diagram

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
10 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

VERSION A
Figure 6

276C063W007A
B
9

12
4

15 14 16
3
8

276C063W008

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 11

VERSION B
Figure 7

276C063W007B

276C063W008B

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
12 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

SPECIFICATION AND DATA

Code KESSLER D 81

Type Rigid, dual reduction

Central differential With limited slip

Tandem splitter Locking

Pinion bearings 2 taper rollers mounted in O arrangement

Differential bearings 2 taper rollers mounted in X arrangement

2 ball bearings
Tandem splitter bearings
2 taper rollers mounted in O arrangement

Hub bearings 2 taper rollers mounted in O arrangement

Hub planet bearings Pivoting barrel rollers

bevel gear pair 1 : 3.50

Reduction ratio wheel reducer 1 : 6.35

total 1 : 22.24

Pinion bearings preload 3.5 --- 4.0 Nm (2.60 --- 2.96 ft lb)

Differential bearings preload 3.0 --- 4.0 Nm (2.20 --- 2.90 ft lb)

Tandem distributor conic bearings preload 0.5 --- 2.0 Nm (0.37 --- 1.49 ft lb)

Distributor differential axial clearance 0.18 --- 0.23 mm (0.07 --- 0.09 in)

Bevel gear pair clearance 0.27 --- 0.33 mm (0.011 --- 0.013 in)

Self---locking disks axial clearance 0.20 --- 0.60 mm (0.008 --- 0.024 in)

8.00 --- 14.00 Nm

Hub bearings
(5.9 --- 10.3 ft lb without seal rings)

Drive axle---reduction carrier axial clearance 0.30 --- 0.60 mm (0.012 --- 0.024 in)

Type of brakes Multiple discs in oil wet

Control Hydraulic

fixed 5
Discs per unit
rotating 4

Brake discs axial clearance 0.30 --- 0.60 mm (0.012 --- 0.024 in)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 13

Bevel gear (first reduction)

Figure 8

276C063009

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
14 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

Hub and epicyclic gear (second reduction)

Figure 9

276C063W010

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 15

TIGHTENING TORQUES

Figure 10

276C063W011A

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
16 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

TIGHTENING TORQUES

Figure 11

276C063W014B

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 17

EQUIPMENT

. The tools indicated in the following list should be requested from the Supplier (KESSLER + CO
GmbH & Co. KG).

TOOL CODE DESCRIPTION

038.586.0---2 Spanner for wheel safety nut

031.107.0---3 Seal ring sleeve driver

038.1351.0---3 Seal ring sleeve driver

Spanner for thread rings

038.005.0---3
(differential bearing

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 18 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

DIAGNOSTICS

Axle
1. Continuous noise
2. Cornering noise
3. Alternating noise
4. Sharp bangs during acceleration or deceleration
5. Oil leak

1 CONTINUOUS NOISE

Worn bearings. Replace them.

YES

NO

Gears damaged or worn. Replace them.

YES

NO

Lack of lubrication. Restore oil level.

YES

NO

Incorrect adjustment of the clearances. Adjust again

YES

2 CORNERING NOISE

Worn planet ---wheels or crown wheels. Replace.

YES

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 19

3 ALTERNATING NOISE

Wheel bearings with excessive clearance. Adjust the bearings.

YES

NO

Wheels mounted incorrectly. Disassemble and remount correctly.

YES

NO

Too little clearance in the bevel gear set. Adjust again.

YES

NO

Too much clearance in the bevel gear set. Adjust again.

YES

4 SHARP BANGS DURING

ACCELERATION OR DECELERATION

Incorrect gear train adjustment. Adjust again.

YES

NO

Pivot of the anchoring structure has too much Replace the parts of the articulated joint.
play. YES

NO

Loose fastening of the anchoring structure to Tighten the screws to the prescribed tightening
the chassis. YES torque.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 20 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

5 OIL LEAK

Worn oil seals. Replace them.

YES

NO

Loose screws. Tighten the screws to the prescribed tightening

YES torque.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 21

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For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
22 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

MAINTENANCE Changing the oil

Checking oil level Collect and dispose of used lubricants and

fluids, according to the laws in force
Proceed as follows:
Per effettuare lo scarico operare come segue:
The level check can be carried out on the
hubs or on the differential. Figure 14
If the level has to be restored, this is to be
carried out on the differential.

Figure 12
1

1 2

276C062022
D take the reference on the hub to horizontal position
(see arrow);
D arrange a suitably sized container, clean the cap
area and remove the cap (1) and the drain cap (2);
276C062020
drain all the lubricant.
D take the reference on a hub to horizontal position D clean the cap, check that the threading is in good
(see arrow); condition, replace the sealing ring with a new one
D clean the cap area and open the level cap (1). Lubri- and close the drain cap.
cant should drip out of the hole; D repeat the procedure for the other hub.
D close the filler cap. D arrange a suitably sized container, clean the cap
area and remove the cap (1) and the drain cap (2);
Figure 13
drain all the lubricant.

276C063021
D clean the area of the cap, then open the cap (1): the
lubricant must leak from the hole;
D close the cap;
D check that the breather is perfectly clean and ope-
rational.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 23

Figure 15 To fill the oil, proceed as follows:

Figure 17

276C063021
D arrange a suitably---sized container under the drain
cap, clean the cap areas and then remove the filling 276C062020
cap (1); D pour in approx 3 litres of the prescribed lubricant un-
Figure 16 til it overflows from the cap hole (1);
D replace the sealing ring with a new one and close
the cap;
D repeat the procedure for the other hub.

Figure 18
1

276C063023
D remove the drain cap (1) and completely drain the
lubricant;
D clean the caps, check that the threading is in good
condition, replace the sealing ring with a new one
and close the drain cap.
1
276C063021
D refill with the prescribed lubricant until it overflows
from the hole of the filling cap (1);
Fill up slowly.
The operation is finished when the level at
the hole does not lower for a few minutes.
D replace the sealing ring with a new one and close
the cap;
D perform a test drive and then recheck the level (1);
D if necessary, top up with the prescribed lubricant un-
til it overflows from the hole, repeat the test drive and
recheck the level.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
24 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

REAR AXLE REMOVAL ---REFIT

. Before starting any operation, make sure
that all the precautions have been taken and
all aspects regarding safety of the personnel
involved on the job have been made quite
clear.
Read the relevant instructions contained in
SECTION 1 of this handbook.
If in doubt ask someone who is more expert.
Comply to all the general recommendations
for correct execution of maintenance work.

Removal
Proceed as follows:
D bring the vehicle on a suitable flat, solid surface,
switch off the engine, remove the key from the igni-
tion switch, engage the parking brake and affix the
warning notices;
D deactivate the battery isolator or disconnect the bat-
tery terminals to prevent any risk of a short circuit;
D Block articulation by means of the steering lock bar,
proceeding as indicated in SECTION 1;
D raise the vehicle so the wheels are off the ground,
then place two supporting trestles under the rear
chassis without touching the axles;
D position under each intermediate and rear axle an
appropriate hydraulic supporting device that per-
mits lowering for the removal, so that at this stage
the two axles are more or less horizontal;
D remove both wheels following the instructions in
SECTION 9;
D disconnect the electrical connection of the brake
cooling circuits pressure switch (1);
D disconnect the axle bleed pipe (4);
D remove the propeller shaft (18) following the instruc-
tions in SECTION 7;
D working on both sides of each rocker arm, remove
the split pin and unscrew the locking nut (8) of the
rocker arm pin;
remove both the bolts (10) that fasten the tie---rod to
the bracket;
D take out the rocker arm pin (9), keeping the washers
(6) and the guide bushings (7), releasing the rocker
arm from the axle;
D lower the axle with care and remove it from the ve-
hicle.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 25

Figure 19

276C063W027

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
26 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

EPICYCLIC REDUCER OVERHAUL Figure 21

Before starting any operation, make sure

that all the precautions have been taken and
all aspects regarding safety of the personnel
involved on the job have been made quite
clear.
Read the relevant instructions contained in
SECTION 1 of this handbook.
If in doubt ask someone who is more expert.
Comply to all the general recommendations
for correct execution of maintenance work.
5
4
. Before proceeding, it is necessary to:
D drain the lubricant from the wheel hub; 3
2
D drain the lubricant from the central differ-
ential; 1
following the instructions provided in the 276C063W031
relative chapter.
D unscrew the central retaining screw (1) and remove
the fixed gear (2) and guide bushing (3) complete
. Before proceeding, the brake caliper must with spacer ring (4);
be removed following the instructions in the D slip off the axle shaft (5) if necessary;
relative chapter.
Figure 22
Disassembly
Proceed as follows:

Figure 20

3 1
2
276C063W030

D mark the mutual position of the planet ---wheel hol- 276C062032

ding plate and the hub;
D loosen and remove all the retaining screws (1);
D remove the planet ---wheel holding plate assembly
(2) and O---ring (3) and recover the thrust spacer
ring (4);
D unscrew the setscrew (1) of the ring nut;
D remove the locking ring nut (2) of the internally too-
thed crown wheel.
The ring nut is locked with thread ---stops.
To prevent damage to the threading, heat to
approximately 120˚C before unscrewing.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 27

D using a suitable lifting device, carefully remove the Figure 25

complete hub from the hub support;
During this operation, keep the hub parallel 1
to the axle axis to avoid damaging the brake 1
discs. 2
D remove the front sealing ring;
D place the hub vertically;

Figure 23

3
276C062D035
D VERSION A: Remove the two oil seal rings (1);
D use a suitable extractor to remove the outer race (2)
of the axle---side bearing (A) and the outer race (3)
of the wheel---side bearing (B);

Figure 26
1
276C062D033

D use a suitable extractor to remove the internally too-

thed crown wheel (1);

Figure 24

1 2

276C062035B
D VERSION B: Remove the oil seal ring (1);
4 D with an appropriate puller remove the outer ring (2)
of the bearing on the axle side (A) and the outer ring
(3) of the bearing on the wheel side (B).
3
276C062D034

D remove the retaining screws (1) and relative stop

plates (2);
D separate the internally toothed crown wheel (3) from
the relative flange (4);
D using a suitable extractor, remove the inner race (5)
of the wheel---side bearing (B) from the crown wheel
flange;
D If necessary remove the wheel fastening screws
from the hub;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
28 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

Figure 27 Figure 29

276C062038

276C062W037 D remove the planet wheel (1) and relative shim rings
D remove the inner race (1) of the axle---side bearing (2);
(A) and the spacer ring (2) from the hub; Figure 30
The spacer ring is blocked with sealant.
To avoid damaging it, before removing, heat
to approx. 120 ˚C.

Figure 28

274A062039
2 1
D remove the needle cages (arrow) from the planet ---
wheel;
D repeat the procedure for all the planet ---wheels.

274A062029
D place the planet ---wheel holding plate on a suitable
work surface;
D use a punch to push the retaining pin (1) down in the
pivot, freeing the pivot (2);
D extract the pivot (2) by pushing it towards the inside
of the planet ---wheel holding plate (arrow);
D remove the O---ring (3);
D extract the pin from the pivot.

. Do not push the pivot towards the outside of

the planet---wheel holding plate, otherwise
its seat may be damaged due to the differ-
ence between the internal and external di-
ameter of the pivot.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 29

Inspection of the dismantled parts During reassembly, consider the following

Wheel hub
D check the seats of the bearings: they must not have
any deformations and/or ovalling;
D check the condition of the bearings: replace them
if they have bluish halos, cracks and/or signs of
wear.
general observations:
D heat, to 100˚C in the oven, the bearings
and rings to be mounted by pushing;
D carefully center and mount the sealing
rings and bearings with a suitable adju-
ster;
D lubricate the ring nuts and bearings.

Axle shafts
D check the condition of the axle shafts: replace them
if they have deformations on the end grooves and/or
on the entire length.

Final reductions
D check the condition of the gear toothing: replace
them if they have pitting, cracks and/or cavities;
D verify the good operation of the planet ---wheels and
the roller bushings;
D check the threading for the bearing locking ring nut:
it must not have any dents, deformations and/or
jams.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
30 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

Epicyclic reduction gear seals and thread-- stops application and bearings scheme

VERSION A

Figure 31

276C063W044A

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 31

Epicyclic reduction gear seals and thread-- stops application and bearings scheme

VERSION B

Figure 32

276C063W044B

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
32 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

Planet-- wheel holding plate assembly Figure 35

Proceed as follows:
D position the planet ---wheel holding plate horizontal-
ly;
3

Figure 33

1 274A062035
D insert the O---ring (1) in the seat of the planet ---wheel
holding plate;
274A062032 D insert the pivot (2) of the planet ---wheel holding gear
so that the pin holes match up;
D mount the needle cages inside the planet gear; D or according to the versions;
Figure 34 D insert the pivot (2) of the planet ---wheel holding gear
up to the complete expulsion of the internal reten-
tion bush so that the pin holes match up;
2
Mount the pivot from the internal part of the
planet---wheel holding plate, otherwise its
seat may be damaged due to the pivot dia-
meter difference.
D mount the catch pin (3);
D repeat the procedure for all the planet ---wheels.

1
2

276C062052

D mount the planet ---wheel (1) complete with shim

rings in the seat on the planet ---wheel holding plate;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 33

Brake unit and hub assembly Figure 38

Proceed as follows:

Figure 36

3
2

1
276C062053

D place the hub vertically;

D using a suitable introducer, mount the outer race (1)
of the wheel---side conic roller bearing (B) and the
outer race (2) of the axle---side conic roller bearing
(A);
D mount the inner race (3) of the axle---side conic roller
bearing (A);

Figure 37

276C062W054
D VERSION B: With an appropriate tool, insert the seal
ring (2) into the seat, flush with the external edge of
the hub, paying attention to the orientation (detail);

276C061W054
D VERSION A: With an appropriate tool, insert the seal
rings (1) into the seat, paying attention to the orien-
tation (detail) fill completely with lubricating grease
for bearings (arrow);

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
34 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

Figure 39

2 1

276C063W066

D heat the spacer ring (1) and insert it completely on

the axle axis;
D using a suitable lifting device, support the hub as-
sembly in order to ensure its correct centering;
D introduce the hub assembly (2) on the end of the
hub support (3), placing the inner race of the axle---
side conic roller bearing (A) so that it rests against
the spacer ring;
During this operation, keep the hub parallel
to the axle axis.
Work with caution to avoid damaging the
sealing rings and the brake disc teeth.
Continue to support the hub assembly until
it is completely mounted.
D release the brake discs by discharging the pressure
from the piston;
D if removed, mount the stud bolts fastening the wheel
to the hub (4);

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 35

Figure 40 Hub bearing preload determination

Proceed as follows:

Figure 42
4

2
2
3
276C062W067
D heat the inner race (1) of the wheel---side conic roller
bearing (B) and insert it until it rests against the gear
wheel flange;
D insert the gear wheel flange (2) onto the gear wheel
with internal toothing (3); 1
D mount the retention plates (4) and fix them with the
setscrews; 276C062069
D apply MOLYKOTE lubricant on the hub support
Figure 41
threading and on the threading and contact area of
the locking ring nut;
D hand mount the ring nut (1) without tightening;
D tighten the locking ring nut to the prescribed tighte-
ning torque:
Locking ring nut tightening torque for bearings
Phase 1: 700-- 900 Nm
During the locking, rotate the hub back and
forth by striking it with a plastic hammer to
settle the bearings.
D unscrew the locking ring nut half a turn;
D tighten the locking ring nut to the prescribed tighte-
ning torque:
Locking ring nut tightening torque for bearings
Phase 2: 450 Nm
During the locking, rotate the hub back and
1 forth by striking it with a plastic hammer to
settle the bearings.
276C062W068
D after having adjusted the bearing preload, block the
D mount the flange and internally toothed gear wheel
locking ring nut with the relative setscrew (2);
assembly (1) onto the hub until the two parts meet
the wheel---side conic roller bearing (B). If this is not possible, unscrew the ring nut
as much as needed in order to mount the
The lubrication oil passage hole on the too-
clamp screw.
thed wheel flange is to face downwards.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
36 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

Figure 43 Planet-- wheel holding plate -- fixed gear axial clear-

ance determination
Proceed as follows:

Figure 44

1
2
3
4 A
5
B
276C063W031
D insert the axle shafts (1) into the axle;
D mount the spacer ring (2), guide bushing (3) and fi-
xed gear (4);
D mount the central retaining screw (5) and tighten it.

274A062043

D determine the dimension A;

D determine the dimension B;
D determine the thickness of the thrust spacer as fol-
lows:
S = A -- B +(0.30 ÷ 0.70) (mm)
where:
A = distance between the planet ---wheel holding
plate mounting surface and the seat of the thrust
spacer on the same plate
B = distance between the hub mounting surface
and the thrust spacer seat on the fixed gear
S = thrust spacer thickness
0.30 ÷ 0.70 = prescribed clearance in mm
D mount the chosen thrust spacer onto the planet ---
wheel holding plate.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 37

Concluding operations

Figure 45

3
1
2
276C063W073

D mount the O---ring (1) in the seat of the planet ---whe-

el holding plate;
D mount the planet ---wheel holding plate assembly (2)
in the hub.
Respect the reference marks made during
disassembly.

D mount the retaining screws (3) and tighten to the

prescribed torque.

. If no intervention on the differential is

planned, proceed to:
D the filling of the wheel hub;
D the filling of the central differential;
following the instructions provided in the
relative chapter.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
38 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

Page left intentionally blank

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 39

TANDEM TRANSMISSION AND DIFFERENTIAL OVERHAUL

Before performing any intervention, ensure Disassembly

that all precautions have been taken and all
aspects clarified regarding the safety of per- . Before proceeding, the axle shafts must be
sonnel involved in the intervention. removed following the instructions in the re-
Read the relative instructions provided in lative chapter.
SECTION 1 of this manual.
In case of doubt, consult a more experien-
ced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.

Proceed as follows:

Figure 46

2 3

276C063W080

D straighten the dent and remove the motion input
flange stop nut (1);
D using a suitable extractor, remove the flange (2);
D mark the relative position between box and axle;
D loosen and remove the screws (3) fastening the ex-
ternal box to the axle;
D using a suitable lifting device, remove the external
box assembly from the axle;
D position the assembly on the support trestle, adap-
ting as necessary.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
40 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

Differential disassembly
Figure 47 Proceed as follows:

Figure 49
2 4
1
3
3

1
4
2
2
276C063081
D unscrew the retaining screws and remove the loc-
king plate (1) of both the bearing preload adjust- 274A062048
ment ring nuts;
D loosen both the bearing preload adjustment ring D remove the outer race (1) of the crown wheel---side
nuts (2); bearing (C) and the outer race (2) of the planet whe-
D mark each support cap and the corresponding ex- el---side bearing (D);
ternal box location; D use appropriate extractors to extract the inner race
D loosen the retaining screws (3) and remove both the (3) of the crown wheel---side bearing (C) and the in-
support caps (4); ner race of the planet wheel---side bearing (D) from
D remove both the adjustment ring nuts; the differential semicases;
D mark both the differential semicases;
Figure 48 D loosen the retaining screws and remove the diffe-
rential semicase;

Figure 50

274A062047
274A062049
D using a suitable lifting device, extract the differential
D disassemble the planet ---wheel group into the diffe-
assembly (1) from the relative case.
rent components;
D remove the discs of the skid limitation device and
the relative shoulder rings;
D if necessary, separate the ring bevel gear from the
differential semicase by unscrewing the retaining
screws.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 41

Pinion disassembly
Figure 53
Proceed as follows:

Figure 51

276C063082A
276C063084
D remove the cover (1) the seal ring (2) and the O---
ring (3); D use a press and pad to extract the pinion (1) from
the pinion box;
Figure 52
Figure 54

2
276C063083

D remove the complete pinion box (1);

D recover the pinion position adjustment spacer S1
(2); 276C063D095

D remove the inner race (1) of bearing (B) and bearing

preload spacer S2 (2) from the pinion box.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
42 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

Figure 55

276C063D096

D use a suitable extractor to remove the outer race (1)

of bearing (B) and the outer race (2) of bearing (A)
from the pinion box;

Figure 56

274A062055

D using a suitable extractor (1), remove the inner race

(2) of bearing (A).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 43

Inspection of the disassembled parts Reassembly

During reassembly consider the following

Bearings
general observations:
D check the condition of the bearings: replace them D heat, to 100˚C in the oven, the bearings
if they have bluish halos, cracks and/or signs of and rings to be mounted by pushing;
wear. D carefully center and mount the sealing
rings and bearings with a suitable adju-
Crown wheels ster;
D check the condition of the toothing: replace it if it has D lubricate the bushes, sealing rings and
pits, cracks and/or cavities. bearings.

Planet ---gears Perform all the indicated measurements

D check the condition of the toothing: replace it if it has
pits, cracks and/or cavities;
D check the coupling surfaces with the pins.
Damage to a single element entails the re-
placement of the entire gear unit.
with maximum precision.
Imprecise measurements lead to bad con-
tact of the bevel gear and thus make it ne-
cessary to repeat the procedure.

Cross pins
D check the coupling surfaces with the planet ---gears.

Shoulder rings
D check the condition of the rings: replace them if they
have bluish halos, cracks and/or signs of wear.

Bevel gear
D check that the toothing of the crown wheel and the
pinion show uniform wear on the entire working zo-
ne of the teeth: replace the bevel gear if it has pits,
cracks and/or cavities;
An anomalous wear may indicate an incor-
rect adjustment of the bearings: check their
integrity before proceeding to the reassem-
bly.
Damage to a single element entails the re-
placement of the entire gear unit.
D check the bearing seats: they must not have defor-
mations or ovalling.

Bushes
D check the threading for the bearing locking bush: it
must not have dents, deformations and/or jams.

External box
D check the bearing seats: they must not have defor-
mations or ovalling;
D check that the sealing surfaces and the threadings
are integral and free of dents or damage.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
44 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

Differential seals and thread-- stops application and bearings scheme

Figure 57

276C063087A

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 45

Complete limited-- skid differential assembly

Proceed as follows:

. Refer to the following figure.

D check the following measurements:
SP1 = 3.10 mm minimum;
SP2 = 2.15 mm minimum.
D otherwise, use shoulder discs with a greater thick-
ness;
D mount the shoulder ring (2) and elastic ring (3);
D position the shoulder disc (SP1) (4);
D alternately mount an externally grooved disc (driven
plate) and an internally grooved disc (driving plate)
until all discs (5) have been mounted;
The last disc is a driving plate.

D mount the shoulder disc (SP2) (6);

D mount the elastic ring (7);
D mount the planetary gear;
D repeat the assembly for the other semicase;
D when finished, check that dimension A falls within
the prescribed values;
52.8 < A < 53.27 mm
D when finished, check that dimension B falls within
the prescribed values;
B < 0.48 mm
D otherwise, use shoulder discs with a greater thick-
ness or reduce the thickness by grinding;
D assemble the shafts and planet ---wheel gears and
mount the assembly on the crown wheel;
D join the two semicases and tighten the retaining
screws to the prescribed torque.
The two semicases are symmetric except for
the crown wheel assembly flange.
The total height of the crown wheel---side
disc pack must be identical to that on the op-
posite side.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
46 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

Figure 58

1. Differential semicase
2. Shoulder ring
3. Elastic ring
4. Semicase shoulder disc SP1
5. Driven (N.4) and driving (N.4) discs
6. Crown wheel shoulder disc SP2
7. Elastic ring
8. Crown wheel --- planet ---wheel group SP1
Dimension A: disc pack thickness
Dimension B: Shoulder ring --- crown wheel clearance

SP2

1
2

4 A
5
6
7

6
5
4

2
1

276C062091

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 47

Crown wheel and bearings assembly

Figure 59

274A062060
Proceed as follows:
D check that the area of contact between the gear (1)
and differential semicase (2) is clean and free of
grease;
D mount the crown wheel on the semicase and tighten
the fastening bolts (3) to the prescribed torque;

Figure 60

2
274A062062
D heat the inner race (1) of the planet wheel---side co-
nic roller bearing (D) and mount it against the diffe-
rential semicase;
D heat the inner race (2) of the crown wheel---side co-
nic roller bearing (C) and mount it against the diffe-
rential semicase.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
48 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

Thickness determination for bearing preload spacer S2 and bearing assembly

Figure 61

Bearing B

d1
d2

Bearing A

276C063088

Proceed as follows:
D position the pinion box vertically;
D mount both the outer races of bearings (A) and (B)
in the seat;
D temporarily mount both the inner races of bearings
(A) and (B);
D determine the dimension d1;
D determine the dimension d2 on the pinion;
D determine the thickness of the bearing preload spa-
cer S2 as follows:
S2 = d1 -- d2 (mm)
where:
d1 = distance between the bearing (A) inner race
shoulder and the internal edge of the bearing
(B) inner race
d2 = distance between the internal bearing inner
race support and the bearing preload spacer
S2 support
S2 = thickness of the bearing preload spacer S2.
D remove both the inner races of bearings (A) and (B.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 49

Figure 62 Figure 64

276C062093
D heat the inner race of bearing (A) and mount it on the
pinion; 2
Figure 63

3
4
276C063091A

D tighten the fastening screws (1) to the specified tor-

que;
1 D couple the flange (2) onto the groove of the pinion;
D apply MOLYKOTE on the pinion threading and on
the threading and contact area of the stop nut;
D mount the stop nut (3) and tighten it to the prescri-
bed torque.
Use a new stop nut.
During the locking, rotate the pinion back
and forth by striking it with a plastic hammer
to settle the bearings.

2
3

276C063090
D insert the pinion (1) into the pinion box;
D mount the chosen bearing preload spacer S2 (2);
D heat the inner race (3) of bearing (B) and mount it
on the pinion;
D position the spacer S1 (4) and then mount the pi-
nion box in the external box.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
50 REAR AXLE -- WET OIL
Figure 65
1731281
D use a suitable tool to check that the rolling torque
falls within the prescribed values:
Rolling torque for pinion bearings
0.8 -- 1.2 Nm
D otherwise, correct the rolling resistance by using a
spacer S2 with a different thickness;
D in particular:
--- increase the thickness to reduce the torque
--- reduce the thickness to increase the torque
D remove the pinion stop nut and relative flange;
D remove the retaining screws and slip off the comple-
te pinion box.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
SECTION 6.3 ADT 25-30 TIER3
Differential bearing preload determination
Proceed as follows:
Figure 66
17312101
D position the bearing outer races on both ends of the
differential;
D using a suitable lifting device, mount the crown whe-
el assembly in the differential box;
D apply MOLYKOTE on the threading of the adjust-
ment ring nuts;
D screw on both the ring nuts by hand;
Figure 67
17312102
D align the reference marks and mount the bearing
support caps;
D mount the cap retaining screws and tighten them;
D use a suitable tool to check that the rolling torque
falls within the prescribed values:
Rolling torque for crown wheel and pinion
bearings
2.0-- 3.0 Nm
D the rolling torque can be corrected by turning both
the adjustment ring nuts by the same number of not-
ches;
D In particular:
--- unscrew the ring nuts to decrease the torque;
--- screw on the ring nuts to increase the torque.
ADT 25-30 TIER3 SECTION 6.3 REAR AXLE -- WET OIL 51

Pinion assembly Check of the pinion-- crown wheel clearance

Proceed as follows: Proceed as follows:

Figure 68 Figure 70

1
3

276C063092A
D insert the sealing ring (1) into the cover (2) following
the assembly direction and fill it completely with lu-
bricating grease for bearings;
D fit the O---ring (3) in the cover; 17312104

Figure 69 D mount a dial gauge at a right angle with respect to

the external diameter of the crown wheel’s toothed
side and turn the crown wheel back and forth, being
careful not to move the pinion;
D check that the clearance between the crown wheel
and pinion falls within the prescribed values:
pinion-- crown wheel clearance
see value engraved on the crown wheel
D otherwise, adjust the clearance using the adjust-
ment ring nuts;
D the clearance can be adjusted without modifying
the bearing preload by unscrewing one adjustment
ring nut by a certain number of notches and scre-
wing on the opposite adjustment ring nut by the sa-
me number of notches.

Figure 71

1
2

276C063093A

D mount the complete pinion box in the external box;

D tighten the fastening screws to the specified torque; 17312105
D mount the cover (1) complete with sealing ring;
D In particular:
D screw on the retaining screws and tighten to the pre-
--- unscrew the ring nut (D) and screw on the ring
scribed tightening torque;
nut (C) to reduce the clearance (white arrow);
D insert the flange (2) and tighten the stop nut (3) to
--- unscrew the ring nut (C) and screw on the ring
the prescribed torque.
nut (D) to increase the clearance (black arrow).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
52 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

Verification of the pinion-- crown wheel engagement

impression area
Proceed as follows:

Figure 72

17312106

D cover a dozen teeth of the crown wheel with Prus-

sian blue, lubricated with minium, or another paint
or dye that can be easily removed;
D make a complete rotation of the crown wheel by
hand;
D when the teeth engage, the paint is removed by the
contact of the teeth, leaving zones exposed with the
exact dimension, shape and location of contact;

Figure 73

274A062063

Contact area position and shape D to replace the spacer S1, remove the retaining
1. correct bevel gear position; screws (1) and slip off the complete pinion box;
2. position with the pinion too far back: it is necessa- D position the new spacer S1, then reassemble the pi-
ry to reduce the distance between the pinion and nion box and tighten the retaining screws to the pre-
the crown wheel axis by using a spacer S1 of less scribed tightening torque.
thickness; then adjust the clearance by moving
When finished, remove the differential, pi-
the crown wheel further from the pinion;
nion and pinion box.
3. position with the pinion too far forward: it is neces-
sary to increase the distance between the pinion
and the crown wheel axis by using a spacer S1 of
greater thickness; then adjust the clearance by
moving the crown wheel closer to the pinion;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 6.3
D to replace the spacer S1, remove the stop nut, flan-
ge, and retaining screws and slip off the complete
pinion box;
D position the new spacer, then reassemble the pinion
box and tighten the retaining screws to the prescri-
bed tightening torque;
D insert the flange and tighten the stop nut to the pre-
scribed torque;
Figure 74
274A062066
D dent the nut as described in the figure;
If this is not possible, unscrew the nut as
much as necessary to dent it.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
REAR AXLE -- WET OIL 53
Figure 75
274A062064
D once all the adjustments and configurations are cor-
rect, fix the locking plate (1) of both the ring nuts
using screws;
D support the complete external box with suitable lif-
ting equipment;
D mount the complete external box assembly onto the
axle respecting the reference marks made during
disassembly;
D screw on the retaining screws and tighten to the pre-
scribed torque.
. Proceed to:
D the reassembly of the axle shafts;
D the filling of the wheel hubs;
D the filling of the central differential;
following the instructions provided in the re-
lative chapter.
54 REAR AXLE -- WET OIL SECTION 6.3 ADT 25-30 TIER3

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For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
SECTION 7

DRIVELINE
 ADT 25-30 TIER3 SECTION 7 DRIVELINE 1

CONTESTS

Page Page

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INSPECTION PROCEDURES . . . . . . . . . . . . . . . . . 11

Central splitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Distribution between the axles . . . . . . . . . . . . . . . . . . 3
Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Intermediate and rear drive axles . . . . . . . . . . . . . . . . 3
Drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Central section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Parking brake unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Parking brake caliper release . . . . . . . . . . . . . . . . . . 11
Parking brake efficiency verification . . . . . . . . . . . . . 11
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Replacement of the parking brake pads . . . . . . . . . 12
DETACHMENT-- REATTACHMENT OF THE
PARKING BRAKE DISC AND CALIPER . . . . . . . . 14
Detachment of disc . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Detachment of the central section . . . . . . . . . . . . . . 16
Reattachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . . 8 CENTRAL BEARING OVERHAUL . . . . . . . . . . . . . 17

TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . 9 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
2 DRIVELINE SECTION 7 ADT 25-30 TIER3

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For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 7 DRIVELINE 3

DESCRIPTION Intermediate and rear drive axles

The driveline consists of the following parts:
Central splitter
The double satellite sun and planet gearbox central
splitter can be locked through a control in the cab. It is
built into the lower part of the automatic gearbox.
Splitting ratio is 2/3 to the rear axle and 1/3 to the front
axle in normal conditions.
Locking is controlled by an electro---pneumatic actua-
tor.
Distribution between the axles
The distribution between the axles is fixed since there
is no differential. Consequently the distribution ratio is
1/2 to the intermediate axle and 1/2 to the rear axle.
The intermediate and rear drive axles are rigid type.
They are fitted with limited slip central differential and
central limited slip wheel hubs with final planetary gear
reducer.
Drive shafts
The drive shafts are:
D drive---gear shaft
D front axle shafts (two)
D first rear section of the drive shaft
D central section of the drive shaft
D second rear section of the drive shaft
D shaft between the axles
Each shaft is equipped with cardan joints at the ends.

Front axle
The front axle is semi---independent. The limited slip
central differential is built into the automatic gearbox:
Motion is transmitted to the two hubs through front
floating drive shafts.
The wheel hubs, with end planetary gear reducer, are
supported by an articulated central floating axle to a
central joint and are guided by a Panhard type cross
bar, fastened on the right side of the chassis.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 4

Driveline
Figure 1
DRIVELINE
SECTION 7

1. Engine
2. Engine---to---transmission shaft
3. Automatic transmission with central splitter
4. Front differential
5. Front drive shafts
6. Front hubs
7. Rear shaft1st section
8. Propeller shaft central support
9. Rear shaft2nd section
10. IParking brake caliper

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
11. Intermediate axle
12. Shaft between axles
13. Rear axle
276C007001
ADT 25-30 TIER3
ADT 25-30 TIER3 SECTION 7 DRIVELINE 5

Drive shaft
The drive shafts are all equipped with cardan joints at 1. Axle shaft with external groove
the ends. 2. Axle shaft with internal groove
The self---adapting shaft is capable of absorbing, within 3. Sealing ring
certain limits, variations of length during operation cau- 4. Protective sleeve
sed by the relative movement of the respective end
joints.

Figure 2

276C007002

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
6 DRIVELINE SECTION 7 ADT 25-30 TIER3

Central section
The central section uncouples the two motion drive 1. Input flange
shafts from the axles and supports the parking brake 2. Rigid support
disc. 3. Parking brake disc
It is supported by two rigid spherical watertight sup- 4. Output flange
ports.

Figure 3

3
2
1
276C007003

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 7 DRIVELINE 7

Parking brake unit

Description For further information on the parking brake
The parking brake acts on the transmission at the tan- control, see Section 12 --- PNEUMATIC SY-
dem axles of the vehicle. STEM.
The brake unit is composed of a caliper with two pads
on the two sides of a disc.
The disc is mounted on the central section of the drive 1. Brake disc
shaft. 2. Brake caliper
The pads are mounted on a floating caliper operated by 3. Spring cylinder
a pneumatically controlled spring cylinder. 4. Central section of the drive shaft
The caliper is mounted on the chassis by means of an 5. Parking brake caliper support bracket
interface bracket.

Figure 4

276C007004

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
8 DRIVELINE SECTION 7 ADT 25-30 TIER3

SPECIFICATIONS AND DATA

Parking brake
Circuit Independent
Type of brake Disc on the transmission
Control Pneumatic
Type of caliper Floating
fixed
Discs per unit ---
rotary
External diameter of disc 378.0 mm 14.88 in
Internal diameter of disc --- --- --- ---
rated 25.4 mm 1.0 in
Thickness of disc
minimum 22.0 mm 0.87 in
Minimum pad thickness 5.1 mm 0.20 in

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 7 DRIVELINE 9

TIGHTENING TORQUES

276C007005

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
10 DRIVELINE SECTION 7 ADT 25-30 TIER3

TIGHTENING TORQUES

276C007006

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 7 DRIVELINE 11

INSPECTION PROCEDURES
Figure 7
Parking brake caliper release
In the event in which the compressed air does not arrive
in the parking brake circuit, the vehicle is automatically
braked by the force gradient cylinder.

Figure 5

269NU4D3

D work on the nut until achieving the release of the

brake pads.
To restore the normal functional conditions it is suffi-
cient to repeat the operations described above in the
reverse order, recovering the maneuver screw and clo-
269NU4D2
sing the protection plug and lower cover.
To allow for the towing of the vehicle, the brake must be
disengaged through the mechanical release device After the intervention on the emergency re-
operated through a maneuver screw. lease device, the vehicle must be towed ex-
clusively and absolutely must not circulate
Do as follows: in an independent manner.
D place appropriate wedges in front of wheels; Before resuming normal use of the vehicle,
D open the rubber protection plug; it is IMPERATIVE to restore the working posi-
tion of the force gradient cylinder.
Figure 6

Parking brake efficiency verification

Proceed as follows:
D Bring the vehicle onto a surface which is flat and lar-
ge enough to allow for small movements.
D Shut off the engine, move the selector to the Neutral
position and engage the parking brake; the parking
brake indicator light must light up.
D With the engine off, disengage the parking brake:
the parking brake indicator light must turn off.
D Engage and disengage the parking brake repea-
tedly until the indicator light remains on when it is di-
sengaged.
269NU4D3
D Start the engine and wait until the parking brake
light turns off.
D insert the maneuver screw and rotate it by 90˚ in or- D Select manual mode, engage first gear, let the vehi-
der to engage it in the slot; cle advance VERY SLOWLY, then operate the par-
king brake: the indicator light must light up and the
vehicle must stop immediately (the gear automati-
cally enters Neutral).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
12 DRIVELINE SECTION 7 ADT 25-30 TIER3

MAINTENANCE Figure 10

Replacement of the parking brake pads

Removal
Do as follows:

Figure 8

269NU271

D disengage the parking brake (position 0);

Figure 11

269NU271

D engage the parking brake (position 1);

Figure 9

276A007002

D remove the upper cover (arrow) from the rear chas-

sis;

276A007001

D disconnect the pneumatic piping (1) of the parking

brake control;
D release the pads by following the instructions in the
relative chapter;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 7 DRIVELINE 13

Figure 12

5
5
2

1 3
4

276A007003

D remove the plastic dust cover (1); D unscrew the automatic clearance recovery mecha-
D remove the lock ring (2) and take off the pin (3); nism completely;
D turn over (arrow) the retaining bracket (4), then slip D mount the new pads by inserting them from the
off both pads (5). upper part and sliding them on the surface of the
disc until making contact with the lower rest sup-
Installation ports;
Do as follows: D lower the retaining bracket, then mount the pin and
D thoroughly clean the caliper; secure it with the lock ring;
D mount the dust ---cover;
Remove the dirt using a NON ---metallic D screw on the automatic clearance recovery mech-
brush and a vacuum cleaner. anism completely until zeroing the clearance, then
Figure 13 unscrew it by seven clicks (2/3 of a turn) in order to
obtain the of correct operational clearance;
D mount the washer and screw cap;
D connect the pneumatic pipe fitting;
D proceed to the restoration of the rotocamera oper-
ation as indicated in the relative chapter;
D restore the functional conditions of the vehicle.

Activate the parking brake 10---12 times to

obtain the correct arrangement of pads.
During the first period of use the effective-
ness of the parking brake may be slightly re-
duced.

276A007004

D remove the screw cap (arrow) and relative washer;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
14 DRIVELINE SECTION 7 ADT 25-30 TIER3

DETACHMENT ---REATTACHMENT OF THE Figure 14

PARKING BRAKE DISC AND CALIPER
Before performing any intervention, ensure
that all precautions have been taken and all
aspects have been clarified regarding the
safety of personnel involved in the interven-
tion.
Read the relative instructions provided in
SECTION 1 of this manual.
If in doubt, consult a more experienced per-
son.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions. 269NU271

D engage the parking brake (position 1);

Detachment of disc
Do as follows: Figure 15
D bring the vehicle onto an appropriately solid flat sur-
face, shut off the engine, remove the key from the
ignition switch, engage the parking brake and affix
the indication signs;
D disconnect the battery---disconnect switch or di-
sconnect the battery terminals in order to eliminate
any risk of short ---circuit;
D block the articulation by means of the steering lock
bar, as indicated in SECTION 1;

276A007001

D disconnect the pneumatic piping (1) of the parking

brake control;
D release the pads following the instructions in the re-
lative chapter;

Figure 16

269NU271

D disengage the parking brake (position 0);

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ADT 25-30 TIER3 SECTION 7 DRIVELINE 15

Figure 17 Figure 20

276A007002

D remove the upper cover (arrow) from the rear chas-

sis;

Figure 18

276A007012
D unscrew the screws fastening the caliper (arrow) to
1 the support bracket;

Figure 21

276C07010
D disconnect all the hydraulic pipelines from the rear
chassis plate;
D unscrew the retaining screws and remove the plate
(1) from the chassis;

Figure 19

276A007013
D remove the caliper including the rotochamber, ex-
tracting it from the upper part of the chassis.

276C07011
D remove the drive shaft (1) between the central sup-
port and automatic transmission;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
16 DRIVELINE SECTION 7 ADT 25-30 TIER3

Detachment of the central section Figure 24

Proceed as follows:
D remove the parking brake caliper following the in-
structions provided previously;

Figure 22

1 276C07014
D remove the retaining screws between the rear shaft
cardan joint flange (1) and the central section flan-
ge;
Figure 23
276C07016
D remove the central section complete with supports,
extracting it from the upper part of the chassis.
Reattachment
Proceed with the reattachment by performing the de-
tachment operations in the reverse order.
Apply LOCTITE 242 thread ---stops to the re-
taining screws of the caliper and cardan
joint flange.
Tighten to the prescribed tightening torque.

After having connected the pneumatic pi-

ping of the parking brake control, restore
the rotochamber.

276C07015
D remove the retaining screws (arrow) fastening both
supports to the chassis;

Support the central section appropriately

during removal, making sure that it doesn’t
fall.

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ADT 25-30 TIER3 SECTION 7 DRIVELINE 17

CENTRAL BEARING OVERHAUL

Dismantling
Proceed as follows:

Figure 25

1
2

2
3
1
276C07020
D Remove the locking nuts (1) from both sides and re-
cover the washer (2).
D Remove the flange (3) from both sides.

Figure 26

2 4 1
1

276C07020

D Slip off the rigid support (1) from both sides.

D Remove the disc locking ring nut (2).
D Slip the disc (3) off the shaft (4).

Reassembly
Proceed with the reattachment by performing the de-
tachment operations in the reverse order.
Tighten the ring nut to the prescribed tighte-
ning torque.

Proceed with the dynamic balancing of the

group before reassembling.
Residual unbalance Grade G16 (ISO 1940).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
18 DRIVELINE SECTION 7 ADT 25-30 TIER3

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For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 SECTION 8

SUSPENSIONS
ADT 25-30 TIER3 SECTION 8
CONTENTS
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front suspension --- Type I . . . . . . . . . . . . . . . . . . . . . 3
Front suspension --- Type II . . . . . . . . . . . . . . . . . . . . . 4
Hydro---pneumatic cylinder --- description . . . . . . . . 5
Hydro---pneumatic cylinder --- section . . . . . . . . . . . . 5
Hydro---pneumatic cylinder --- view . . . . . . . . . . . . . . 6
Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . 9
Front suspension --- Type I . . . . . . . . . . . . . . . . . . . . . 9
Front suspension --- Type II . . . . . . . . . . . . . . . . . . . . 10
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . 11
Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Front suspension cylinder inflating device . . . . . . . 12
Equipment connection diagram . . . . . . . . . . . . . . . . 12
Checking suspension cylinder height . . . . . . . . . . . 13
Checking suspension element pressure . . . . . . . . 13
Inflating the suspension elements . . . . . . . . . . . . . . 14
Deflating the suspension element pressure . . . . . . 14
Changing the suspension fluid element . . . . . . . . . 14
DISASSEMBLY-- REASSEMBLY OF THE
AXLE SHAFT PROTECTIONS . . . . . . . . . . . . . . . . . 15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FRONT SUSPENSION REMOVAL--
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Type I suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Type II suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Detachment of the hubs . . . . . . . . . . . . . . . . . . . . . . 23
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
SUSPENSIONS 1
Page
FRONT SUSPENSION CYLINDER REMOVAL--
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Type I suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Type II suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REPLACEMENT OF THE FRONT SUSPENSION
BALL JOINT (Type II suspensions only) . . . . . . . 26
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REAR SUSPENSION REMOVAL--
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DISASSEMBLY-- REASSEMBLY OF THE REAR
SUSPENSION CENTRAL BUSHINGS . . . . . . . . . . 30
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DETACHMENT-- REATTACHMENT OF THE
REAR SUSPENSION STABILIZER BARS . . . . . . 32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DETACHMENT-- REATTACHMENT OF THE
REAR SUSPENSION BUSHINGS . . . . . . . . . . . . . 34
Detachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Reattachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
REPLACEMENT OF THE FLEXIBLE
COUPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SUSPENSION CYLINDER OVERHAUL . . . . . . . . . 39
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2 SUSPENSIONS SECTION 8 ADT 25-30 TIER3

Left intentionally blank

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ADT 25-30 TIER3 SECTION 8 SUSPENSIONS 3

DESCRIPTION

Front suspension -- Type I

The hubs are connected to an oscillating plate connected to the vehicle chassis by means of a central joint equip-
ped with an elastic bush. A Panhard---type transversal bar absorbs the transverse stresses. The vertical stresses
are controlled by a pair of pneumohydraulic cylinders that functions as an elastic element and shock absorber.
The cylinders are connected to the plate and the chassis with elastic bushes.
There are no elements in the entire front suspension that need lubrication.
Two steel---wire ropes (detail) connect the fork to the chassis and determine the extension limit of the suspension.

Figure 1

1. Swash plate
2. Central ball joint
3. Panhard bar
4. Right pneumo---hydraulic element
5. Left pneumo---hydraulic element
276C08001A

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4 SUSPENSIONS SECTION 8 ADT 25-30 TIER3

Front suspension -- Type II

The hubs are connected to an oscillating plate connected to the vehicle chassis by means of a central articulation
equipped with a ball joint. A Panhard---type transversal bar absorbs the transverse stresses. The vertical stresses
are controlled by a pair of pneumohydraulic cylinders functioning as an elastic element and shock ---absorber.
The cylinders are connected to the plate and the chassis with elastic bushes.
Two steel---wire ropes (detail) connect the fork to the chassis and determine the extension limit of the suspension.

Figure 2

276C08001B

1. Oscillating plate
2. Central articulation
3. Panhard transversal bar
4. Right pneumohydraulic cylinder
5. Left pneumohydraulic cylinder

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ADT 25-30 TIER3 SECTION 8 SUSPENSIONS 5

Hydro -- pneumatic cylinder -- description

The hydro---pneumatic element consists of a coaxial Hydro -- pneumatic cylinder -- section
shock absorber filled with oil and nitrogen.
The internal piston, integral with the large diameter . The cylinder is shown in the completely
hollow rod, separates the two internal and external closed position.
chambers: it has one---way valves that act as shock
absorbers.
The external casing of the cylinder is connected to the Figure 3
front suspension floating plate, whereas the rod is
fastened to the vehicle chassis: in both cases
connection is by ball joint.
A lining ensures the piston seal inside the cylinder, whe-
reas a set of gaskets prevents the liquid flowing out
between the rod and the cylinder base .
The hydro---pneumatic element uses hydraulic fluid for
hydraulic braking during the return stroke, while the ni-
trogen acts as the suspension elastic element during
the compression stroke.

1. Bottom attachment
2. Top attachment
3. Cylinder
4. Rod and piston
5. Base
6. Drain plug
7. Seals of the piston
8. Seals of the rod
9. Filling valve

276D008011

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6 SUSPENSIONS SECTION 8 ADT 25-30 TIER3

Hydro -- pneumatic cylinder -- view

Figure 4

276D00012

1. Bottom attachment
2. Top attachment
3. Cylinder
4. Rod and piston
5. Base
6. Drain plug
7. Seals of the piston
8. Seals of the rod
9. Filling valve

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ADT 25-30 TIER3 SECTION 8 SUSPENSIONS 7

Rear suspension
The rear suspension consists of two rocker arms linked to the chassis in their central point. The ends of the rocker
arm are connected respectively to the intermediate axle and the rear axle.
Two upper reaction rods, inserted between each axle and the chassis control the lengthwise sway.
The suspension has no flexible elements or shock absorbers.

Figure 5

7 2

1
8
6

276C08004

1. Left rocker arm (right not shown)

2. Central rocker arm articulation
3. Rear axle
4. Rear reaction rod
5. Rear axle---balancer trunnion
6. Intermediate axle
7. Front reaction rod
8. Rear axle---balancer trunnion

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8 SUSPENSIONS SECTION 8 ADT 25-30 TIER3

TECHNICAL DATA
Stem diameter 100 mm (3.94 in)
External diameter 150 mm (5.91 in)
Internal diameter (bore) 125 mm (4.92 in)
Center---to---center with cylinder closed 506 mm (19.92 in)
Maximum travel 120 mm (4.72 in)
Internal volume with cylinder closed 1705 cc (104.05 cuin)
Working pressure 156 bar (2262.59 psi)
Maximum working pressure 200 bar (2900.75 psi)
Inflation pressure 30 bar (435.11 psi)
Quantity of fluid 1.50 liters (0.33 imp gal)
Nominal tare height 114.5 mm (4.51 in)
100 < X < 130 mm

Tare height (measurement X)

(vehicle in running order)

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ADT 25-30 TIER3 SECTION 8 SUSPENSIONS 9

TIGHTENING TORQUES

Front suspension -- Type I

Figure 6

276C08005A

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10 SUSPENSIONS SECTION 8 ADT 25-30 TIER3

Front suspension -- Type II

Figure 7

276C08005B

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ADT 25-30 TIER3 SECTION 8 SUSPENSIONS 11

TIGHTENING TORQUES

Rear suspension

Figure 8

800 Nm
590.05 lbf ft

800 Nm 1
590.05 lbf ft

800 Nm
590.05 lbf ft

2000 Nm
1475.12 lbf ft

1 Loctite 270

276C08006

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12 SUSPENSIONS SECTION 8 ADT 25-30 TIER3

MAINTENANCE Equipment connection diagram

The following operations must be carried
Figure 10
out by experienced personnel using suitably
equipment.
Only use the specific equipment expressly
required to carry out suspension inflating
operations.

. Carry out the following operations on both

suspension cylinders at the same time.

Front suspension cylinder inflating device

Figure 9

269NM271

B: inflating device
C. copper seal
D: copper seal
E: pressure gauge (0 --- 50 bar) (0 --- 725 PSI)
F: hose
G: clear tube
H: hose
276D008016
I: nitrogen cylinder fitting
L: hose fitting a. suspension cylinder
b. nitrogen supply cylinder
B: inflating device
E: pressure gauge (0 --- 50 bar) (0 --- 725 PSI)

IN: nitrogen into suspension knob (control)

OUT: nitrogen suspension breather knob (control)

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ADT 25-30 TIER3 SECTION 8 SUSPENSIONS 13

Checking suspension cylinder height

Figure 13
Carry out the check after parking the empty
vehicle on flat ground for at least one hour.

Figure 11

276D008013

D check that position x shown in the figure is within the

specified range for both elements;
D check inflation pressure as follows if the measure-
ments are not correct.

Checking suspension element pressure

Carry out the check after parking the empty
vehicle on flat ground for at least one hour.

Proceed as follows:
D remove the fastening bolt from both sides and di-
sconnect the steel---wire stop ropes in order to allow
the maximum extension of the cylinders;
D raise the vehicle wheels off the ground with suitable
devices to fully extend the suspension;
Proceed with caution in order to avoid da- 276D008016
maging the cylinders when themaximumex-
D check that the inlet knob IN and the breather tap
tension is reached.
OUT on the inflation tool (B) are closed;
D connect the inflation tool (B) to the quick coupling;
Figure 12 D check that the pressure on the gauge (E) is in the
specified range;
D otherwise inflate or deflate as shown below;
D disconnect the inflation tool, remove all equipment
and install the protective cap.

276D008017

D loosen the protective cap on the element (1);

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
14 SUSPENSIONS SECTION 8 ADT 25-30 TIER3

Inflating the suspension elements Figure 14

D open the nitrogen supply cylinder knob (b) and the
inlet knob IN to let nitrogen into the suspension ele-
ment (a);
D let in nitrogen at a pressure of approximately 38 bar
(551 PSI), then close the inlet knob IN and the sup-
ply cylinder knob;
D adjust the suspension element pressure to the spe-
cific value by means of the breather knob OUT;
D close the OUT breather, disconnect the inflation
tool, remove all equipment and install the protective
cap;
D restore the functionality of the vehicle.

Deflating the suspension element pressure

D release gas by means of the OUT breather valve
knob to reach the required pressure;
D close the OUT breather, disconnect the inflation
tool, remove all equipment and install the protective
cap;
276D008018
D restore the functionality of the vehicle.
D arrange a container of suitable capacity, remove the
Changing the suspension fluid element filler cap (1) and drain cap (2) and drain the fluid;
D clean the drain cap. Check that the threads are in
Collect and dispose of used lubricants and
good condition. Replace the O---ring and close it;
fluids, according to the local laws and regu-
D introduce the fixed quantity of prescribed fluid into
lations in force.
the hole of the filling cap;

Proceed as follows: Figure 15

D remove the fastening bolt from both sides and di-
sconnect the steel---wire stop ropes in order to allow
the maximum extension of the cylinders;
D raise the vehiclewith suitable lifting equipment until
the wheels no longer touch the ground in order to
completely extend the suspension;
Proceed with caution in order to avoid da-
maging the cylinders when themaximumex-
tension is reached.
D release ALL pressure from the suspension cylinder
as shown above;

276D008013

D close the filler cap and inflate the suspension as

shown previously;
D restore the functionality of the vehicle;
D check that position X is within the specific check ran-
ge valve after travelling a short distance.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 8 SUSPENSIONS 15

DISASSEMBLY---REASSEMBLY OF THE Figure 17

AXLE SHAFT PROTECTIONS
Before performing any intervention, ensure
that all precautions have been taken and all
aspects have been clarified regarding the
safety of personnel involved in the interven-
tion.
Read the relative instructions provided in
SECTION 1 of this manual.
In case of doubt, consult a more experien-
ced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.
276C008031
D loosen the metal clamp (1) and disconnect the bel-
Disassembly lows (2) from the case (3);
Proceed as follows: . In order to provide greater clarity in the pro-
D bring the vehicle onto an appropriately solid flat sur- cedure described below, an unfastened fork
face, shut off the engine, remove the key from the has been used.
ignition switch, engage the parking brake and affix
Figure 18
the indication signs;
D disconnect the battery---disconnect switch or di-
sconnect the battery terminals in order to eliminate
any risk of short ---circuit;
D block the articulation by means of the steering lock
bar, as indicated in SECTION 1;
D remove both wheels following the instructions in
SECTION 9;

. This procedure refers to the right side of the

fork: the left side is symmetric.

Figure 16

276C008032
D unscrew the retaining screws (arrow) and remove
the top cylindrical guard (1);

276C008030
D unscrew the retaining screws (arrow) and remove
the plate (1);

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
16 SUSPENSIONS SECTION 8 ADT 25-30 TIER3

Figure 19 Figure 21

276C008035
D disconnect the axle shaft (1) from the hub joint (2)
following the instructions in SECTION 8;

Figure 22

276C008033
D unscrew the top and bottom retaining screws (ar-
row) fastening the front cylindrical guard (1) to the
chassis;
D proceed in a similar manner for the rear cylindrical
guard (2);
D unscrew the connection screws (arrow) between
the two guards as well; 276C008040

Figure 20 D unscrew the retaining screws (arrow) and remove

the flange (1) from the fork;

276C008034
D turn (arrow) and remove both the cylindrical guards;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 8 SUSPENSIONS 17

Figure 23

276C008041
D unscrew the two retaining screws (arrow) fastening
the tubular protection to the automatic transmission
flange;
D shorten the axle shaft as much as possible and re-
move the tubular protection complete with bellows;

Figure 24

276C008042
D if necessary, unscrew the retaining screws (arrow)
of the two half flanges (1) and remove the bellows
(2) from the tubular protection (3).
Reassembly
Proceed with the reassembly by performing the disas-
sembly operations in the reverse order.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
18 SUSPENSIONS SECTION 8
FRONT SUSPENSION
REMOVAL---REPLACEMENT
. Before carrying out any operation, check
that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in
SECTION 1 of this manual.
If in doubt, speak to a more experienced
person.
Respect all general recommendations for
correct execution of maintenance works.
Removal
Proceed as follows:
D Park the vehicle to a suitable flat and solid surface,
remove the ignition key, engage the handbrake and
place maintenance warning signs;
D disengage the battery cut ---off switch or disconnect
the battery leads to eliminate any risk of
short ---circuit;
D lock the articulation using the steering lock bar as
instructed in SECTION 1;
D lift the vehicle to raise the wheels from the floor, then
position two supports under the front chassis
without touching the axle;
D position a suitable hydraulic support under the axle
that allows the axle to be lowered once detached,
such that in this phase the axle remains in a more
or less horizontal position;
D remove both wheels as instructed in SECTION 9;
D remove the axle shaft protections from both sides
following the instructions provided in the relative
chapter;
. The operations described below refer to the
following figures.
Before detaching the hydraulic pipes
prepare plugs suitable for closing the free
ends.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
Vehicles with disk brakes only
D disconnect the hydraulic pipelines:
--- service braking system (20).
Vehicles with oil wet brakes only
D disconnect the piping of brake cooling circuit pres-
sure switch (1):
D disconnect the hydraulic pipelines:
--- service braking system (20);
--- brake cooling system input (21);
--- brake cooling system output (22).
. Hydraulic fluid leakage may occur during
these operations.
All vehicles
D remove, on both sides, the lower retaining screws
(6) fastening the suspension stop braid to the axle;
D remove both the cylinders (7) by following the in-
structions provided in the relative chapter;
D remove the bolts (10) fastening the central articula-
tion to the chassis;
D remove the screws (5) fastening the transversal bar
to the oscillating axle, disengage the bar (3) and
temporarily fasten it to the chassis;
D support the axle shafts appropriately before remo-
ving the fork;
Figure 25
276D08028
In order to prevent the disassembly of the
axle shafts, it is advisable to fix them by in-
serting an iron wire in the two slots (arrow).
D carefully lower the axle and slip it off the vehicle.
ADT 25-30 TIER3 SECTION 8 SUSPENSIONS 19

Type I suspension

Figure 26

20

276C08010

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
20 SUSPENSIONS SECTION 8 ADT 25-30 TIER3

Figure 27

276C08012A

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 8 SUSPENSIONS 21

Type II suspension

Vehicles with disc brakes

Figure 28

276C08010A

Vehicles with oil wet brakes

Figure 29

276C08011A

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
22 SUSPENSIONS SECTION 8 ADT 25-30 TIER3

All vehicles

Figure 30

276C08012B

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 8 SUSPENSIONS 23

Figure 31

2691401
D disconnect both the final drive shafts from the front
automatic transmission side (arrow) following the
instructions provided in SECTION 7;

Detachment of the hubs

. For further information on the procedure for

detachment and reattachment of the hubs,
refer to SECTION 6.1 --- FRONT AXLE.

Replacement
For replacement, follow the removal instructions in
reverse order.

Vehicles with oil wet brakes only

On completing the replacement procedure,

check the brake cooling circuit as instructed
in SECTION 10 --- HYDRAULIC SYSTEM.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
24 SUSPENSIONS
FRONT SUSPENSION CYLINDER
REMOVAL---REPLACEMENT
. Before carrying out any operation, check
that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in
SECTION 1 of this manual.
If in doubt, speak to a more experienced
person.
Respect all general recommendations for
correct execution of maintenance works.
Removal
Proceed as follows:
D park the vehicle to a suitable flat and solid surface,
remove the ignition key, engage the handbrake and
place maintenance warning signs;
D disengage the battery cut ---off switch or disconnect
the battery leads to eliminate any risk of
short ---circuit;
D lock the articulation using the steering lock bar as
instructed in SECTION 1;
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
SECTION 8 ADT 25-30 TIER3
D lift the vehicle to raise the wheels from the floor, then
position two supports under the front chassis
without touching the axle;
D position a suitable hydraulic support under the axle
that allows the axle to be lowered, such that in this
phase the axle remains in a more or less horizontal
position;
D remove the wheel concerned as instructed in
SECTION 9;
D proceed to discharge the gas from the cylinder
concerned as instructed in the MAINTENANCE
chapter;
Before proceeding make absolutely certain
that all remaining pressure has been
discharged from the cylinder.
D remove the fastening bolts (2) of the lower elastic
bush on both sides;
. The fixing plate (4) of the rope remains con-
nected to the rope itself (only for Type II su-
spensions).
D support the cylinder (1) with suitable lifting equip-
ment;
D remove the locking nuts (3) of the upper elastic
bush;
D remove the cylinder (1).
Replacement
For replacement, follow the removal instructions in
reverse order.
On completing the replacement procedure
recharge the cylinder and carry out the
check foreseen in the MAINTENANCE
Chapter.
ADT 25-30 TIER3 SECTION 8 SUSPENSIONS 25

Type I suspension
Figure 32

1
3

2
276C08014
Type II suspension
Figure 33

276D008030

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
26 SUSPENSIONS
REPLACEMENT OF THE FRONT SUSPEN-
SION BALL JOINT (Type II suspensions on-
ly)
. Before carrying out any operation, check
that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in
SECTION 1 of this manual.
If in doubt, speak to a more experienced
person.
Respect all general recommendations for
correct execution of maintenance works.
Disassembly
Proceed as follows:
D bring the vehicle onto an appropriately solid flat sur-
face, shut off the engine, remove the key from the
ignition switch, engage the parking brake and affix
the indication signs;
D disconnect the battery---disconnect switch or di-
sconnect the battery terminals in order to eliminate
any risk of short ---circuit;
Figure 34
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
SECTION 8 ADT 25-30 TIER3
D block the articulation by means of the steering lock
bar, as indicated in SECTION 1;
D raise the vehicle until the wheels are off the ground,
then position two support trestles under the front
undercarriage, without acting on the axle;
D support the axle with a suitable hydraulic support
device that allows to lower the axle so that the axle
remains in an approximately horizontal position du-
ring this phase;
D remove the bolts (6) fastening the central articula-
tion to the chassis;
D slightly lower the fork in order to take the ball joint
off its seat:
D unscrew the retaining screws and remove the stop
flange (1);
D remove the pin (3) complete with ball joint (4);
D remove an elastic ring (2) and take the ball joint off
the pin;
D if necessary, remove the second elastic ring (5).
Reassembly
Proceed with the reassembly by performing the disas-
sembly operations in the reverse order.
276C008043
ADT 25-30 TIER3 SECTION 8
REAR SUSPENSION REMOVAL---
REPLACEMENT
. Before carrying out any operation, check
that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in
SECTION 1 of this manual.
If in doubt, speak to a more experienced
person.
Respect all general recommendations for
correct execution of maintenance works.
Removal
Proceed as follows:
D park the vehicle to a suitable flat and solid surface,
remove the ignition key, engage the handbrake and
place maintenance warning signs;
D disengage the battery cut ---off switch or disconnect
the battery leads to eliminate any risk of
short ---circuit;
D lock the articulation using the steering lock bar as
instructed in SECTION 1;
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
SUSPENSIONS 27
D lift the vehicle to raise the wheels from the floor, then
position two supports under the rear chassis
without touching the axle;
D position two supports under the intermediate and
rear axles such that the two axles remain more or
less horizontal during this phase;
D position a suitable hydraulic jack under the rocker
arm to permit lowering once detached;
D remove both wheels from the side concerned as
instructed in SECTION 9;
D disconnect the drive shaft from one side of the axles
following the instructions in SECTION 7;
D remove both wheels from the side concerned;
D disconnect the central greasing system pipes
(arrow);
--- rocker arm pin B3 right and B4 left;
D working from both sides of the rocker are remove
the split pin and unscrew the rocker arm pin nut (8);
D working from both sides of the rocker arm, remove
the rocker arm pin (9), collecting the washers (6)
and guide bushes (7), removing the rocker arm from
the axles;
D unscrew the screws (10) and remove the pin (11);
D carefully lower the rocker arm and extract it from the
chassis, collecting the washers (12).
Replacement
For replacement, follow the removal instructions in
reverse order.
Removal and replacement of the central pin
bushes and terminal bearing articulations
must be carried out using appropriate tools.
28 SUSPENSIONS SECTION 8 ADT 25-30 TIER3

Figure 35

12 6
7
(B3)
7 B4

9
6 6
7
8

12

6
7 11
8 10

276C08015

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 8 SUSPENSIONS 29

Reassembly
Proceed as follows:

Figure 36

276D008032

D check that the internal sides of the rocker---arm sup-

ports are not worn or damaged;
D orientate the shims so that the milling (arrow) lines
up with the relative seat made on the chassis.

Proceed with the reassembly by performing the disas-

sembly operations in the reverse order.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
30 SUSPENSIONS
DISASSEMBLY---REASSEMBLY OF THE
REAR SUSPENSION CENTRAL BUSHINGS
. Before performing any intervention, ensure
that all precautions have been taken and all
aspects clarified regarding the safety of per-
sonnel involved in the intervention.
Read the relative instructions provided in
SECTION 1 of this manual.
In case of doubt, consult a more experien-
ced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.
Figure 37
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
SECTION 8 ADT 25-30 TIER3
Disassembly
Proceed as follows:
D bring the vehicle onto an appropriately solid flat sur-
face, shut off the engine, remove the key from the
ignition switch, engage the parking brake and affix
the indication signs;
D disconnect the battery---disconnect switch or di-
sconnect the battery terminals in order to eliminate
any risk of short ---circuit;
D block the articulation by means of the steering lock
bar, as indicated in SECTION 1;
D remove the rocker arm by following the instructions
provided in the relative chapter;
D extract both the bushings from the rocker arm using
a suitable punch;
D check that the housing of the bushing is not worn or
damaged (arrow);
D remove the dust and dirt from the area concerned;
276D008033
ADT 25-30 TIER3 SECTION 8 SUSPENSIONS 31

Figure 38

276D008034

D orientate the bushings so that the two millings (ar-

row) line up with the relative seats made on the roc-
ker arm;

Figure 39

276D008035

D insert each steel bushing (arrow) into its seat by tap-

ping lightly with a hammer;

Figure 40

276D008036

D thoroughly lubricate the internal part of the bu-

shings before reassembling the rocker arm;
D reassemble the rocker arm by following the instruc-
tions provided in the relative Chapter.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
32 SUSPENSIONS SECTION 8 ADT 25-30 TIER3

DETACHMENT ---REATTACHMENT OF THE D support the stabilizer bar concerned with appro-
REAR SUSPENSION STABILIZER BARS priate lifting equipment;

Figure 41
. Before carrying out any operation, check
that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in
SECTION 1 of this manual.
If in doubt, speak to a more experienced
person.
Respect all general recommendations for
correct execution of maintenance works.

Removal
Proceed as follows:
D lift the body following the instructions in the Use and
Maintenance Manual;
276C08016
D block the body using the appropriate rod as
indicated in SECTION 1; D Position a suitable lift under each balancer (arrow)
D park the vehicle to a suitable flat and solid surface, and raise the vehicle so that the wheels barely touch
remove the ignition key, engage the handbrake and the ground;
place maintenance warning signs;
D disengage the battery cut ---off switch or disconnect Figure 42
the battery leads to eliminate any risk of
short ---circuit;
D lock the articulation using the steering lock bar as
instructed in SECTION 1;

276C08017

Place a trestle under the front part of the

intermediate axle (arrow) to avoid possible
uncontrolled movements of the axle itself.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 8 SUSPENSIONS 33

D Remove the fastening bolts (1);

D Remove the locking nuts (2) and disengage the bar
(3) from the stud bolts;
D Remove the complete bar.

Figure 43

276C08020

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
34 SUSPENSIONS SECTION 8 ADT 25-30 TIER3

DETACHMENT ---REATTACHMENT OF THE Detachment

REAR SUSPENSION BUSHINGS
. Before performing any intervention, ensure
that all precautions have been taken and all
aspects clarified regarding the safety of per-
sonnel involved in the intervention.
Read the relative instructions provided in
SECTION 1 of this manual.
In case of doubt, consult a more experien-
ced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.
Proceed as follows:
D Remove the balancer from the suspension by follo-
wing the instructions provided in the relative Chap-
ter;
D Remove the synthetic bushing using a suitable
punch.
Remove the metal bushing as well by cutting
it with the flexible and extracting it from the
balancer seat.
It is good practice to replace both the
bushings.
D Make a tool for the bushing assembly by following
the indications in the figure.

Figure 44
13 mm 152 mm
0,51 in 5,98 in
= 143 mm
= 5,63 in 148 mm
5,83 in 100 mm
3,94 in
21 mm
0,83 in
103 mm
4,06 in
167 mm
6,57 in

2 2

1
276C08021
1 welded brackets
2 M14 bolts

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 8 SUSPENSIONS 35

Reattachment
Figure 47
Proceed as follows:

Figure 45

276C08024
D Lubricate the internal part of the balancer seat;
276C08022
D Check that the lateral parts of the seat are not dama- Figure 48
ged or show irregular wear (arrow);

Figure 46 160 mm
6,30 in

250 mm
9,84 in
1
50 mm
1,97 in
2
276C08025
D Prepare a support for the balancer, as indicated in
the figure, in order to avoid contact between the
bushing and the press surface during assembly.

276C08023
D Mount the two halves of the special tool (1) on the
bushing (2) as indicated in the figure, and tighten
the jointing bolts until the two flanges fit together;
The protruding edge inside the tool must
rest against the metal edge of the bushing
(arrow).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
36 SUSPENSIONS SECTION 8 ADT 25-30 TIER3

Figure 49

276C08026
D Position the balancer on the support;
D Position the special tool---bushing group on the
balancer;
Use a press with a load capacity of at least
200 kN.
D Push the bushing with the press until the edge of the
special tool meets the balancer;
Check that the lower protruding part of the
bushing does not interfere with the support
placed on the press surface.
D Reattach the balancer by following the instructions
provided in the relative Chapter.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 8 SUSPENSIONS 37

REPLACEMENT OF THE FLEXIBLE COUPLING

. The flexible couplings are used in the following parts of the vehicle:
A. rear and intermediate axle stabilizer bars
B. front suspension cylinders
C. front axle central joint
D. front axle central articulation (Type I suspensions only)

Figure 50

D
C

C 276C08027

The replacement of the flexible coupling must be performed using appropriate equipment only.

. The tools indicated in the following list should be requested from the Supplier (ZF).

Location Type of joint Tool a Tool b Tool c

A --- D 110 52574---126.2/I 55531---126.1/M 40176---126.1
B --- C 90 52574---126.2/H 55531---126.1/B 52575---126.1/B

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
38 SUSPENSIONS SECTION 8 ADT 25-30 TIER3

Disassembly
Figure 52
Proceed as follows:
D Remove the part concerned by following the
instructions provided in the relative Chapter;

Figure 51

3
3 2
b

1
c

2
1
276C08037
276C08036 D Insert the flexible coupling (1) into its seat;
D Remove the elastic ring (1);
Figure 53
D Remove the spacer (2);
D Remove the elastic bush (3);
D Thoroughly clean the seat and eliminate any trace
of dirt or foreign bodies.
NO ANGLE
Assembly
Proceed as follows:
Do not mix the removed elements with the
new ones.
Discard all the removed parts immediately.
Always replace all the coupling elements.
No partial replacements are allowed.

276C08038

D Check that the metal brackets of the coupling are

correctly positioned with respect to the bar axis;
D Rest the bar complete with coupling on the assem-
bly tool (c) and overlay the assembly tool (b);
D Insert the spacer (2) and the elastic ring (3) in the
assembly tool (b);
Check that:
D The holes of the elastic ring are oriented
at 45˚ with respect to the bar axis.
D The ends of the spacer are oriented at
180˚ with respect to the holes of the ela-
stic ring.
D Insert the assembly tool (a) on the elastic ring and
push axially until the elastic ring inserts completely
into its seat.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 8 SUSPENSIONS 39

SUSPENSION CYLINDER OVERHAUL

Before performing any intervention, ensure
that all precautions have been taken and all
aspects clarified regarding the safety of per-
sonnel involved in the intervention.
Read the relative instructions provided in
SECTION 1 of this manual.
In case of doubt, consult a more experien-
ced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.

Ensure that the gas has already been di-

scharged from the cylinder.
In case of doubt, empty the cylinder using
the appropriate equipment provided for this
purpose.

Disassembly
Do as follows:
D Clean the outside of the cylinder with water and a
non---inflammable detergent in order to eliminate
any excess of dust and dirt, then dry it;
D Proceed to the draining of the oil from the cylinder
as described in the relative Chapter;
D Remove the flexible couplings from the upper and
lower end by following the instructions in the relative
chapter;
D Remove the inflation valve;
D Position the lower end in a. vice with the interposi-
tion of soft material.

Figure 54

276A008004
D Using a hook wrench, thoroughly tighten the drive
head onto the body of the cylinder.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
40 SUSPENSIONS SECTION 8 ADT 25-30 TIER3

Figure 55 Figure 57

276A008005

D Slip the stem (1) complete with the drive head off the
cylinder;
D Slip the drive head (2) off the stem.

Figure 56
276A008007

D Remove the gaskets from the drive head:

a. above the brim
b. inside the drive head
c. outside the drive head

1
276A008006

D Remove the gasket (1) from the stem (1);

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 8 SUSPENSIONS 41

Assembly
Figure 60
All gaskets must be replaced during reas-
sembly.
Thoroughly lubricate all the gaskets with hy-
draulic oil.
Do as follows:

Figure 58

18916209
D Mount the O---ring outside the drive head, resting it
on the sealing ring.

Figure 61

18916208A

Each gasket inside the drive head is compo-

sed of a spring and a ring that should be
mounted separately.
Begin the assembly from the one furthest
from the output edge of the drive head.
D Mount the spring inside the seat (a) and then mount
the Teflon ring (b).

Figure 59

276A008008
D Introduce the drive head (1) onto the stem (2)
paying attention not to damage the previously
mounted gaskets.

18916208B
D Mount the sealing ring outside the drive head.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
42 SUSPENSIONS SECTION 8 ADT 25-30 TIER3

D Slowly Introduce the stem complete with drive head

Figure 62 into the cylinder, paying attention not to damage the
previously mounted gaskets.

Figure 64

276A008011
D Using a hook wrench, thoroughly tighten the drive
head onto the body of the cylinder.
D Mount the inflation valve.
D Remove the cylinder from the vice.
D Mount the upper and lower flexible coupling as de-
scribed in the relative chapter

At the end of the operations, fill with hydrau-

lic fluid as described in the relative Chapter.

276A008009

D Mount the gasket (1) on the stem.

D Position the cylinder vertically, tightening the lower
end in a vice with the interposition of soft material.

Figure 63

276A008010

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 SECTION 9

WHEELS AND TIRES

ADT 25-30 TIER3 SECTION 9 WHEELS AND TIRES 1

CONTENTS

Page Page

WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . . 4
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . 5
REPLACING A COMPLETE WHEEL . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TIRE-- RIM DISASSEMBLY-- ASSEMBLY . . . . . . . 8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cleaning of the wheel parts . . . . . . . . . . . . . . . . . . . . . 9
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
2 WHEELS AND TIRES SECTION 9 ADT 25-30 TIER3

Left intentionally blank

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 9 WHEELS AND TIRES 3

WHEELS

DESCRIPTION
The vehicle is fitted with tubeless tyres (no inner tube)
mounted on modular rims.
The tyre is the flexible part of the wheel and has the
following tasks:
D to absorb impacts caused by roughness of the
terrain;
D to transmit the engine torque to the ground;
D transmit the braking force applied to the brakes to
the ground;
D ensure side gripping round bends.

The rim is the rigid structure of the wheel and consists

of the following:
1. Side flanges
2. Rim (channel)
3. Bull ring
4. Inflation valve
5. O---ring seal

Figure 1

276C009001

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
4 WHEELS AND TIRES SECTION 9 ADT 25-30 TIER3

SPECIFICATIONS AND DATA

ADT 25

174NM39

Pressure

Tires Front (F) Rear (R)

Bar Psi Bar Psi

23.5 R 25 (std) 3.00 43.5 3.00 43.5

650/65 R 25 (opt) 3.50 50.5 3.25 47.0

750/65 R 25 (opt) 2.75 40.0 2.75 40.0

ADT 30

Pressure
Tires
Front (F) Rear (R)

Pneumatici Bar Psi Bar Psi

23.5 R 25 (std) 3.25 47.0 3.50 50.5

650/65 R 25 (opt) 3.50 50.5 3.50 50.5

750/65 R 25 (opt) 3.00 43.5 3.25 47.0

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 9 WHEELS AND TIRES 5

TIGHTENING TORQUE

Figure 2

276C009002

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
6 WHEELS AND TIRES SECTION 9 ADT 25-30 TIER3

REPLACING A COMPLETE WHEEL ALWAYS lock the articulation safety joint be-
fore lifting the vehicle.
The wheel replacement operation requires
the utmost care. The operation must be car- Figure 4
ried out by at least two people using a hoist
to lift the vehicle and a forklift to handle the
wheel.

ALWAYS MAKE SURE that the wheel being

replaced is completely flat before procee-
ding.
Proceed as follows:

Figure 3

276A009018 269NS111

D approach the wheel requiring repair with safety cau- D remove the pin (1);
tion D swing the tie---rod forward to make the holes in the
D remove the protective cap and operate the valve (1). tie---rod and chassis coincide (2);
D insert the pin through the holes and fasten it with the
Disassembly retaining pin (3).
Proceed as follows:
Figure 5
D align the vehicle;
D stop the engine and apply the parking brake;

269NU492+

D loosen the wheel nuts (arrow) on the wheel to be re-

moved without removing them

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 9 WHEELS AND TIRES 7

D raise the vehicle to lift the wheel from the ground, Figure 8
then support the vehicle with suitable supports;

The vehicle can be lifted by means of a gan-

try crane or other suitable means using sui-
table steel cables fastened to the eyebolts
provided for this purpose.

Figure 6

221nu62
D position the specific lift truck under the wheel so as
to support it;
D completely unscrew the lock nuts and remove
them; then operate the lift truck to remove the wheel
from the hub, being careful not to damage the bolt
threading.

Fitting
Proceed as follows:
269NU493
D clean the threads of the bolts and nuts and the ma-
D front jacking/hitching points (arrow) ting surfaces between rim and hub;
D position the wheel on the forklift truck;;
Figure 7 D move the wheel into place and fit it on the hub; be
careful not to damage the bolt threads;
D tighten the nuts lightly until the wheel is pressed to
the hub;
D inflate the tire at a pressure of approximately 1.5
bars (22 psi);

Figure 9

269NU494
D rear jacking/hitching points (arrow)

Otherwise, position the steel cables under

the chassis, being careful not to damage
components or piping during lifting. 2761009019
D lower the vehicle to the ground and tighten the nuts
to the specified torque in the order shown
D inflate to the specific pressure (see tire pressure
chart).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
8 WHEELS AND TIRES SECTION 9 ADT 25-30 TIER3

TIRE ---RIM DISASSEMBLY---ASSEMBLY Figure 11

Before performing any intervention, ensure

that all precautions have been taken and all
aspects have been clarified regarding the
safety of personnel involved in the interven-
tion.
Read the relative instructions provided in
SECTION 1 of this manual.
If in doubt, consult a more experienced per-
son.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.

. Before proceeding it is necessary to remove

the wheel from the vehicle following the in- 276A009002
structions provided in the relative chapter. D Use a suitable lever (1) to lower the retention ring (2)
and free the safety peg (3);
Disassembly
Figure 12
Do as follows:

Figure 10

2761009003
D Slip off the elastic ring (1);
2761009001
Figure 13
D Completely deflate the tire using the valve (1);

Before proceeding, it is ABSOLUTELY ne-

cessary to check that the tire is completely
deflated.

2761009004
D Use a suitable lever to slip the retention ring (1) off;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 9 WHEELS AND TIRES 9

Cleaning of the wheel parts

Figure 14
D Visually check that the rim parts have no cracks, de-
formations or corroded parts;
D Carefully clean and remove the grease from the rim,
lateral flanges, retention ring and elastic ring;
D Remove any rust and repaint the parts;
D Remove the O---ring seal and dispose of it accor-
ding to the current regulations;
D Carefully check the condition of the inflation valve
and replace it if necessary;
D Carefully check the condition of the elastic ring and
replace it if necessary.

Reassembly
Do as follows:

Figure 16

2761009005

D Slip off the lateral flange (1);

D Use an appropriate lifting device to separate the tire
(2) from the rim (3);

Figure 15

2761009007

D Insert the first lateral flange (1) onto the rim (2) with
the concavity turned downwards;

. The lateral flanges are interchangeable.

2761009006

D Slip the second lateral flange (1) off the rim (2);

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
10 WHEELS AND TIRES SECTION 9 ADT 25-30 TIER3

Figure 17 Figure 20

276A009011
276A009008
D Insert the second lateral flange (1) onto the rim (2)
D Lubricate the lower part of the rim (1) abundantly
with the concavity turned upwards;
with the specific lubricant for tires;
Figure 21
Figure 18

276A009009
D Lubricate abundantly the zones of the tire in contact
with the rim (1) with the specific lubricant for tires;
Figure 19

276A009012
D Lubricate the internal part (1) and the external part
(2) of the retention ring abundantly with the specific
lubricant for tires;
D Insert the retention ring between the rim and the la-
teral flange;
. In order to insert the retention ring, strike the
entire circumference uniformly with a rub-
2761009010 ber hammer.
D Use a suitable lifting device to move the tire (1) and
put it on the rim (2); . Be careful that the slot (3) coincides with the
groove (4) of the retention ring during the
assembly.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 9 WHEELS AND TIRES 11

Figure 22 Figure 24

276A009015
276A009013 D Insert the elastic ring (1) between the rim (2) and the
D Use suitable levers (1) to force the retention ring retention ring (3);
down so as to be able to insert the O---ring seal cor- Figure 25
rectly;
Figure 23

276A009016
D Use suitable levers (1) to arrange the retention ring
(2) in order to insert the safety peg (3) in the slot of
the rim (4);
Figure 26

276A009014
D Insert the O---ring seal (1) in the appropriate seat ob-
tained in the rim;

. Always use new O---ring seals during assem-

bly.
2761009001
D Introduce through the valve (1), with an appropriate
. Pay particular attention to make sure that the inflation gun, compressed air at a pressure of 3.5
sealing ring is positioned correctly. bar in order to allow the various parts of the wheel
to settle correctly.

. When the parts are settled, adjust the tire

pressure to the prescribed values.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
12 WHEELS AND TIRES SECTION 9 ADT 25-30 TIER3

Left intentionally blank

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 SECTION 10

HYDRAULIC SYSTEM
 ADT 25-30 TIER3 SECTION 10
CONTENTS
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General diagram --- Vehicles with oil bath brakes . . 7
HYDRAULIC SYSTEM PRESSURE TEST
POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Vehicles with disc brakes . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic system pressures table --- Vehicles with
disk brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
HYDRAULIC SYSTEM PRESSURE TEST
POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Vehicles with oil bath brakes . . . . . . . . . . . . . . . . . . . 10
Table of hydraulic system pressures --- Vehicles with
oil bath brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Main pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Brake pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Emergency steering pump . . . . . . . . . . . . . . . . . . . . 12
Dumping distributor . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Back ---pressure valve . . . . . . . . . . . . . . . . . . . . . . . . . 12
Accumulators (disk brakes) . . . . . . . . . . . . . . . . . . . 12
Accumulators (wet oil) . . . . . . . . . . . . . . . . . . . . . . . . 12
Cartridge filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 10.1
STEERING AND DUMPING SYSTEM . . 13
STEERING AND DUMPING SYSTEM -- DE-
SCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Main components of the steering---dumping
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . 17
Steering---dumping hydraulic system . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TOPOGRAPHICAL DIAGRAMS . . . . . . . . . . . . . . . 23
Forward chassis diagram . . . . . . . . . . . . . . . . . . . . . 23
Rear chassis diagram . . . . . . . . . . . . . . . . . . . . . . . . . 24
A. OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
HYDRAULIC SYSTEM 1
Page
B. STEERING/DUMPING DISTRIBUTOR . . . . 27
C. MAIN FILTER -- TIPPING AND
EMERGENCY STEERING GROUP . . . . . . . 28
D. COUNTERBALANCE VALVE . . . . . . . . . . . . 29
E. MAIN PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
F. EMERGENCY STEERING PUMP . . . . . . . . 31
G. POWER STEERING . . . . . . . . . . . . . . . . . . . . 32
H. HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . 33
L. DUMPING CYLINDER . . . . . . . . . . . . . . . . . . 34
M. STEERING CYLINDER . . . . . . . . . . . . . . . . . 35
N. REAR CHASSIS CONNECTOR PLATE . . . 36
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Checking fitting and pipe tightness . . . . . . . . . . . . . 37
Changing the fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
MAIN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Replacing pressurised filter . . . . . . . . . . . . . . . . . . . . 40
Cleaning the (suction) filter . . . . . . . . . . . . . . . . . . . . 40
STEERING -- DUMPING SYSTEM TEST
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Prescribed pressure values . . . . . . . . . . . . . . . . . . . . 44
Dumping and steering valves . . . . . . . . . . . . . . . . . . 45
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Prescribed pressure values . . . . . . . . . . . . . . . . . . . . 46
DETACHMENT-- REATTACHMENT OF THE
EMERGENCY STEERING VALVE -- MAIN
FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Detachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Reattachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
DUMPING VALVE REMOVAL--
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Dumping valve removal---replacement . . . . . . . . . . 54
DUMPING CYLINDER REMOVAL--
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Dumping cylinder removal---replacement . . . . . . . . 56
2 HYDRAULIC SYSTEM SECTION 10
Page
STEERING VALVE REMOVAL--
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
MAIN PUMP REMOVAL-- REPLACEMENT . . . . . 59
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
STEERING CYLINDER REMOVAL--
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
DUMPING CYLINDER OVERHAUL . . . . . . . . . . . . 61
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Checking components . . . . . . . . . . . . . . . . . . . . . . . . 62
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Functional testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
STEERING CYLINDER OVERHAUL . . . . . . . . . . . . 65
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
STEERING -- DUMPING VALVE BLOCK
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Component position identification . . . . . . . . . . . . . . 70
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Checks and inspections . . . . . . . . . . . . . . . . . . . . . . 73
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
SECTION 10.2
EMERGENCY STEERING SYSTEM . . . . 75
EMERGENCY STEERING SYSTEM . . . . . . . . . . . . 76
Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Main component emergency steering system . . . . 76
Emergency steering hydraulic diagram . . . . . . . . . 77
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
INSPECTION PROCEDURES . . . . . . . . . . . . . . . . . 79
Check the efficiency of the emergency steering p
ump control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
EMERGENCY STEERING PUMP
REMOVAL-- REPLACEMENT . . . . . . . . . . . . . . . . . . 80
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
Page
SECTION 10.3
BRAKING SYSTEM --- DISC BRAKES
VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Main components of the braking system . . . . . . . . 83
Service and parking brakes --- location . . . . . . . . . . 84
Braking system hydraulic diagram . . . . . . . . . . . . . 85
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
TOPOGRAPHICAL DIAGRAMS . . . . . . . . . . . . . . . 89
Forward chassis diagram . . . . . . . . . . . . . . . . . . . . . 89
Rear chassis diagram . . . . . . . . . . . . . . . . . . . . . . . . . 90
A. BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 91
B. OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
C. ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . 92
D. FILTER AND LIMITATION VALVE . . . . . . . . 93
E. BRAKE COMMAND VALVE . . . . . . . . . . . . . 94
H. REAR CHASSIS CONNECTOR PLATE . . . 94
BRAKING SYSTEM TEST PROCEDURES . . . . . . 96
Prescribed pressure values . . . . . . . . . . . . . . . . . . . . 99
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Checking fitting and pipe tightness . . . . . . . . . . . . 105
Changing the fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Replacing pressurised filter . . . . . . . . . . . . . . . . . . . 105
Cleaning the (suction) filter . . . . . . . . . . . . . . . . . . . 106
BRAKE PUMP REMOVAL-- REPLACEMENT . . . 107
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
HYDRAULIC ACCUMULATOR
DETACHMENT-- REATTACHMENT . . . . . . . . . . . 108
Detachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Reattachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
BRAKE PEDAL VALVE DETACHMENT--
REATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Detachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Reattachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
ADT 25-30 TIER3 SECTION 10
Page
SECTION 10.3
BRAKING SYSTEM --- WET OIL
VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . 111
BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 112
Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Main components of the braking system . . . . . . . 113
Operating brake assembly . . . . . . . . . . . . . . . . . . . 114
Service and parking brakes --- location . . . . . . . . . 116
Braking system hydraulic diagram . . . . . . . . . . . . 117
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
BRAKING SYSTEM TEST PROCEDURES . . . . . 121
Prescribed pressure values . . . . . . . . . . . . . . . . . . . 124
Prescribed pressure values . . . . . . . . . . . . . . . . . . . 126
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Checking fitting and pipe tightness . . . . . . . . . . . . 130
Changing the fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Replacing pressurised filter . . . . . . . . . . . . . . . . . . . 130
Cleaning the (suction) filter . . . . . . . . . . . . . . . . . . . 131
BRAKE PUMP REMOVAL-- REPLACEMENT . . . 132
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
HYDRAULIC ACCUMULATOR DETACHMENT--
REATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Detachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Reattachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
DISASSEMBLY-- REASSEMBLY OF THE RELAY
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
BRAKE PEDAL VALVE DETACHMENT--
REATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Detachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Reattachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
HYDRAULIC SYSTEM 3
Page
SECTION 10.4
BRAKE COOLING SYSTEM
(WET OIL VERSION) . . . . . . . . . . . . . . . . 137
BRAKE COOLING SYSTEM . . . . . . . . . . . . . . . . . 138
Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Main components of the brake cooling system . . 139
Brake cooling system hydraulic diagram . . . . . . . 141
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
General description . . . . . . . . . . . . . . . . . . . . . . . . . 144
TOPOGRAPHIC DIAGRAMS . . . . . . . . . . . . . . . . . 145
Topographic diagram of the front chassis . . . . . . 145
Topographic diagram of the rear chassis . . . . . . . 146
A. OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
B. BRAKE COOLING MOTOR/PUMP
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
C. FRONT AXLE BRAKE COOLING
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
D. REAR CHASSIS CONNECTION PLATE . 149
E. INTERMEDIATE AXLE BRAKE COOLING
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
BRAKE COOLING CIRCUIT PUMP--
MOTOR REMOVAL-- REPLACEMENT . . . . . . . . 150
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 5

DESCRIPTION
The total hydraulic system of the vehicle is made up of a series of hydraulic systems, which are:
10.1. steering---dumping system
10.2. emergency steering system
10.3. braking system
10.4. service brake cooling system (vehicles with oil wet brakes only)

The main hydraulic pump (with variable displacement) provides the rate of flow required by the steering and
dumping functions.
The system distributes the fluid flow between the two functions giving priority to the steering.
In the event of failure, an emergency pump (driven by the automatic transmission) ensures adequate steering
capacity.
The brake pump supplies the rate of flow required for the braking function. The system has energy accumulators
located between the pump and the actuators.
The discharge flow coming from the brake pump drives (through a hydraulic motor) the pumps of the service
brake cooling circuit (vehicles with oil wet brakes only).

. For more information on the individual systems see the relative chapters.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
6 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

General diagram
1. Main tank
2. Main pump
3. Emergency steering pump
4. Priority valve
5. Steering system
6. Dumping system
7. Brake pump
8. Brake actuation system

5
2
4

3 6

7 8

276C10001

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 7

General diagram -- Vehicles with oil bath brakes

1. Tank
2. Main pump
3. Emergency steering pump
4. Priority valve
5. Steering system
6. Tipping system
7. Brake pump
8. Brake actuation system
9. Brake cooling system motor
10. Brake cooling system pump
11. Brake cooling system

T276C010013

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8 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

HYDRAULIC SYSTEM PRESSURE TEST POINTS

Vehicles with disc brakes

B H
A
I
C

N
M

276C10003

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 9

Hydraulic system pressures table -- Vehicles with disk brakes

Values
Point Pressure
bar psi
A Driving pressure 18 + 2 --- 1 261 + 29 --- 15
B Reduced pressure 50 ± 3 725 ± 24
203 + 7 --- 6 2944 + 102 --- 87
C Dumping---steering pressure (main) (*)
203 + 7 --- 6 2944 + 102 --- 87
D LS pressure (load signal) 203 + 7 --- 6 2944 + 102 --- 87
E Dumping pressure (1---3 stages section outlet) 203 + 7 --- 6 2944 + 102 --- 87
Dumping back ---pressure (fourth stage section dis-
F 120 ± 5 1740 ± 73
charge)
H Rear brake actuation circuit pressure 155 + 7 --- 3 2248 + 102 --- 44

I Front brake actuation circuit pressure 155 + 7 --- 3 2248 + 102 --- 44

165 + 7 --- 3 2248 + 102 --- 44

M Front accumulator refueling pressure (**)
195 ± 5 2828 ± 73
165 + 7 --- 3 2248 + 102 --- 44
N Rear accumulator refueling pressure (pedal valve) (**)
195 ± 5 2828 ± 73

(*) The value of the main pressure depends on the test conditions. For more information, see Section 10.1 ---
STEERING AND DUMPING SYSTEM.
(**) The value of the accumulator refueling pressure depends on the operation conditions. For more informa-
tion, see Section 10.3 --- BRAKING SYSTEM.

The pressure intakes are “minimess” unions located in the positions indicated above.
The pressure specifications are given in the respective table.
Use a pressure gauge with a suitable full---scale for testing.
For more information on the inspection procedures see the respective sections.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
10 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

HYDRAULIC SYSTEM PRESSURE TEST POINTS

Vehicles with oil bath brakes

T276C010015

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 11

Table of hydraulic system pressures -- Vehicles with oil bath brakes

Values
Fitting Pressure
bar psi
A Pilot pressure 18 + 2 --- 1 261 + 29 --- 15
B Reduced pressure 50 ± 3 725 ± 44
C Steering---tipping pressure (main) (*) 203 + 7 --- 6 2944 + 102 – 87
D LS pressure (load signal) 203 + 7 --- 6 2944 + 1020 – 87
E Tipping pressure (moving struts outlet) 203 + 7 --- 6 2944 + 1020 – 87
Tipping backpressure (fourth moving strut di-
F 120 ± 5 1740 ± 73
scharge)
Rear brakes actuation circuit pressure (pedal
H1 110 + 7 --- 3 1595+ 102 – 44
valve)
Rear brakes actuation circuit pressure (relay
H2 110 + 7 --- 3 1595+ 102 – 44
valve)
I Front brakes actuation circuit pressure 110 + 7 --- 3 1595+ 102 – 44
Pedal valve discharge circuit pressure (brake coo-
K 1.6 ± 0.4 23 ± 6
ling motor intake)
M Front accumulator recharge pressure (**) 140 --- 195 ± 5 2031 – 2828 ± 73
Rear accumulator recharge pressure (pedal val- Min160 + 7 --- 6 Min 2321 +102 --- 44
N1
ve) (**) Max195 ± 5 Max 2828 ± 73
Rear accumulator recharge pressure (accumula- Min160 + 7 --- 6 Min 2321 +102 --- 44
N2
tor) (**) Max195 ± 5 Max 2828 ± 73

(*) The value of the main pressure depends on the test conditions. For more information, see Section 10.1 ---
STEERING AND TIPPING SYSTEM.
(**) The value of the accumulator recharge pressure depends on the operating conditions. For more information,
see Section 10.3 --- BRAKING SYSTEM.

The pressure fittings are composed of “minimess” fittings located in the positions indicated pre-
viously.
The prescribed pressure values are provided in the relative table.
The test must be performed using a pressure gauge with a suitable end ---of---scale value.
For more information on the test procedures, see the respective Sections.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
12 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

TECHNICAL DATA

Main pump
Engine ratio 1:1
Maximum rpm 262 rad/sec (2500 rpm)
Maximum displacement 122.86 cm3/rev (7.5 in3/rev)
Maximum pressure (2100 rpm) 245 I/min (53.9 Imp gal/min)

Brake pump
Engine ratio 1 : 1.36
Displacement 19.0 cm3/rev (1.16 in3/rev)
Rate of flow at maximum operating speed (2850 rpm) 16.0 I/min (3.52 Imp gal/min)

Emergency steering pump

Engine ratio 1:1
Displacement 32 cm3/rev (0.35 in3/rev)
Maximum pressure (2100 rpm) 64.0 I/min (14 Imp gal/min)

Dumping distributor
Maximum valve nominal calibration 250 bar (3.626 psi)
Steering --- dump pressure (main) 185 bar (2.683 psi)
Driving pressure 18 bar (261 psi)
Dumping pressure (removable strut outlet) 185 bar (2.683 psi)
Dump back ---pressure (fourth rod telescopic section outlet) 120 bar (1.740 psi)

Steering valve
Displacement 985 cm3/rev (58.46in3/rev)
Internal amplification ratio 1 : 1.6

Back-- pressure valve

Nominal calibration 120 bar (1.740 psi)

Accumulators (disk brakes)

Nominal capacity (front) 1.4 litres (0.31 Imp gal)
Nominal capacity (rear) 1.4 litres (0.31 Imp gal)
Operating pressure 65 bar (943 psi)

Accumulators (wet oil)

Nominal capacity (front) 3 litres (0.66 Imp gal)
Nominal capacity (rear) 3 litres (0.66 Imp gal)
Operating pressure 55 bar (798 psi)

Cartridge filters
Nominal filtering capacity (steering---dumping) 10 µm
Nominal filtering capacity (brake actuation) 10 µm
Nominal filtering capacity (brake cooling) 20 µm
Nominal filtering capacity (net to filter) 90 µm

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 13

SECTION 10.1

STEERING AND DUMPING SYSTEM

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14 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

STEERING AND DUMPING SYSTEM --- DESCRIPTION

Main components
(see figures on next page)
Pump: with variable displacement pistons (1), fitted to the upper power take---off of the automatic
transmission: the pump rotates at the same speed as the engine.
Actuator: steering cylinders (6), controlled by the steering valve (5);
dumping cylinders (8), controlled by the dumping distributor (7).
Exchanger: oil---air model.
Filter: net on the intake (10) with by---pass valve, fitted inside the tank;
on the delivery side (3) (pressurized) cartridge with by---pass valve and electric clogging indi-
cator, fitted on the side of the automatic transmission.
Tank: single (16).

Function
To ensure the rate of flow needed for the steering and/or dumping operations, in relation to the request, with prior-
ity given to steering.
The circuit features two main groups: steering system and dumping system. The main pump adjusts its rate of
flow according to the load signal from both systems.
An priority valve valve defines the priority in favour of the steering system if both systems make a request at the
same time.

. The references with which the components are identified are the same used in the hydraulic diagram
shown on the following pages.

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 15

Main components of the steering -- dumping system

276C010006

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16 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 17

HYDRAULIC DIAGRAM

Steering -- dumping hydraulic system (see next page)

1. Main pump with variable displacement
2. Emergency steering pump
3. Pressurised filter
4. Steering emergency operating valve
5. Steering valve
6. Steering cylinders
7. Dumping valve
8. Dumping cylinders
9. Pressure vent
10. Dumping---steering system intake filter
11. Steering emergency pressure switch
12. Brake actuation system intake filter
13. Dumping back ---pressure valve
14. Level indicator
15. Oil temperature sensor
16. Tank
17. Brake system intake
18. Head exchanger

The dumping valve 7 consists of three modules that are coupled together:
(˚) pressure control valves module
(˚˚) dumping actuation valves module
(˚˚˚) priority control priority valve valve module

(a) Pressure limit valve (270 bar (3916 PSI)) (code 1.02)
(b) Operating pressure limit valve (230 bar (3336 PSI)) (code 1.03)
(c) Dumping LS pressure limiting valve (180 bar (2611 PSI)) (code 1.04)
(d) LS pressure cumulative valve for priority (shuttle) (code 1.05)
(e) Dumping actuation pressure limiting valve (50 bar (725 PSI)) (code 1.11)
(f) Dumping body drive proportional valve (code 1.13)
(g) Dumping box
(h) Priority valve (code 1.16)
(i) Pressure limiting valve driving dumping box valve (22 bar (319 PSI)) (code 1.15)
(m) Driven dumping discharge valve (anti---shock)
(n) Dumping anti---shock driving valve
(p) Steering valve box
(q) Steering valve rotor
(s) Steering anti---shock valve
(t) Steering anti---cavitation valve
(u) Piloted sequential valve (code 1.12)

List of pressure intakes (n˚ 9 on the diagram)

A. Driving pressure
B. Reduced pressure
C. Dumping---steering pressure (main)
D. LS pressure (load signal)
E. Dumping pressure (1---3 stages section outlet)
F. Dumping back ---pressure (fourth stage section discharge)

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18 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Steering -- dumping hydraulic diagram

276C010007

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 19

276C010008

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20 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

OPERATION
. Refer to the previous figure.

. Concerning the steering, the condition of stand ---by continues until the steering wheel is rotated,
regardless of the position of the vehicle (straight or turned): thus this situation is not typical of a
straight steering wheel, but of an IMMOBILE steering wheel.

Stand---by conditions
The LS signal coming from the steering valve that arrives at the opening 2a of valve [7] and then to valve (d) is
null since the relative LS opening is not being fed by the steering valve.
The LS signal coming internally from the dumping distributor slide valve (g) to the valve (d) is null since the relative
opening is not being fed by the distributor.
Thus the LS signal outcoming from the valve (d) --- the sum of the two LS signals described above --- is substantially
null.
This signal outcoming from valve (d) arrives, through the opening 3 of valve [7], to the opening PL of pump [1]
that is regulated by the internal valves so as to supply the minimum flow.
Under these conditions the flow of pump [1] arrives through opening P and is discharged through opening T by
means of the sequential valve [u] that regulates the internal pressure on the basis of the control received from
the limitation valve [a].
When the system requires additional pressure (due to a steering and/or tipping operation) the relative LS signal
outgoing from valve (d) is summed with the calibration pressure of valve [a] driving the valve [u] to increasing
pressures.
Furthermore, the flow of the pump [1] arrives to the valve [e] that regulates the pressure at the anti---saturation
valve [h] and discharges any excess flow from opening 5. This occurs only if the pressure regulated by valve [u]
exceeds the calibration value of valve [e].
The control from HEAD via CAN OPEN visualizes on the display the value of the hydraulic fluid temperature read
by the sensor 325.
Steering without dumping
The steering valve slide valve (p) is moved by the action of the steering wheel. Such movement puts the port P
in communication with the steering cylinder chambers according to the direction of rotation. At the same time the
opposite chambers are discharged by port T.
The LS signal coming from the steering valve increases (as a function of the steering speed), the relative LS open-
ing being fed by part of the steering valve slide valve.
This signal is limited by the valve (b) that discharges any excess pressure.
The LS steering signal arrives at the opening 2a of valve [7] and then to valve (d) and is added to that of the dump-
ing, which is null since dumping is not being requested.
Furthermore, the LS steering signal outcoming from the opening 2b arrives to the opening LS1 of the same valve
[7] and determines the downward movement of the slide valve (h) of the anti---saturation valve, ensuring --- if it
becomes necessary --- the priority of the steering.

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 21

Tipping without steering

The slide (g) of the tipping valve is interlocked to two proportional reducing valves (f1) and (f2) that determine the
signal to the sides of the slide and thus its position.
From the hydraulic point of view, the supply of the proportional valves is intercepted by the anti---saturation valve
(h). The slide of this valve is subject from one side to the pressure coming from the main line and on the other
side to the load signal coming from the steering valve through the opening LS1, which is null since steering is not
being requested.
This causes the lifting of the slide of valve (h) and allows the tipping.
From the system point of view, the proportional valves (f1) and (f2) are controlled in duty---cycle by MIDAC2 as
a function of the following signals:
D position of the body control 307, detected by HEAD;
D angular position of the body, detected by MIDAC2 through the sensor 338.
Based on these signals, the control determines the command duty and, consequently, the actuation speed of the
tipping cylinders.
Steering and body tipping
The system is not sized to supply both functions beyond a certain degree.
Therefore, when there are simultaneous requests, the anti---saturation valve (h) gives priority to the steering valve.
In fact, the load signal coming from the opening 2a of the steering valve [5] increases, since steering is underway.
This causes the downward movement of the slide of the anti---saturation valve (h) and the consequent more or
less elevated discharge of the signal that, through the proportional valve (f), directs the slide (g) of the tipping valve
[7], regardless of the phase of tipping underway (rise or descent of the body).
Consequently, the slide (g) of the tipping valve [7] tends to return to center and reduce the flow to the cylinders,
in favor of that destined to the steering.

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22 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 23

TOPOGRAPHICAL DIAGRAMS

Forward chassis diagram

H

E D
276C1009X
A. Oil tank
B. Dumping distributor
C. Main filter --- emergency steering/dumping group
D. Counterbalance valve
E. Main pump
F. Emergency steering pump
G. Power steering
H. Heat exchanger

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24 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Rear chassis diagram

276C1009Y

L Dumping cylinder
M Steering cylinder
N Connector plate on rear chassis

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 25

A. OIL TANK

276C1009A

1. Drain cock / brake cooling circuit return (only for vehicles with oil bath brakes)
2. Brake cooling motor---pump intake (only for vehicles with oil bath brakes)
3. Opening (D2) for brake pump intake / opening (D1) for emergency steering pump intake
4. Opening (E) for main pump intake
5. Opening (F1) for return from brake control valve opening (B) / return from brake cooling motor---pump
(only for vehicles with oil bath brakes)
6. Opening (F4) for return from tipping distributor opening (Y)
7. Opening (F2) for return from emergency steering valve opening (T)
8. Opening (L) for return from heat exchanger
9. Opening (F3) for return from tipping distributor opening (5)
10. Opening (F5) for return from brake control valve opening (N)
11. Opening (F6) for return from relay valve opening (N) (only for vehicles with oil bath brakes)
12. Delivery to heat exchanger
13. Return from tipping distributor opening (T)

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26 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 27

B. STEERING/DUMPING DISTRIBUTOR

LS
RP

1.16 Y
LS1
XP
1.13
1.15

B1
RP1 A1 1.13

P
T 1.12 T1

1.05

6
1.11
3a 4 1.04
7 1.03
3
2b 5
1

2
2a

1.02 276C010015
A1. Connection to forward right chassis plate for box dumping (raise)
B1. Connection to forward right chassis plate for box dumping (lower)
P. Connection to emergency steering/dumping group (C1) (feed)
T1. Connection to power steering (t) for tank discharge
Y. Connection oil tank (C)
Xp. Connection to pilot pressure test point (test point pilot pressure) A
2b. Connection to (LS1)
6. Connection to (RP1)
RP. Connection to reduced pressure test point plate B
RP1. Connection to (6)
LS1. Connection to (2b)
T. Connection to oil tank (R)
2a. Connection to power steering (LS) (pilot signal)
2. Connection to load sensing test point plate (test point load sensing) D
4. Connection to main pressure test point plate C
5. Connection to oil tank (D)

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28 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

C. MAIN FILTER --- TIPPING AND EMERGENCY STEERING GROUP

P1

C1

276C1009C

P Delivery pipe from main pump

C1 Tipping distributor opening ”P” connection pipe
C Hydraulically assisted steering opening ”P” connection pipe
T Outlet pipe to tank opening (F2)
P1 Delivery pipe from emergency steering pump

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 29

D. COUNTERBALANCE VALVE

276C1009D
1 Return to the tipping distributor opening (B1)
2 Pipe from rear chassis connection plate opening (X) (return from tipping cylinders)

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30 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

E. MAIN PUMP

276C1009E

1 Intake from tank opening (E)

2 Delivery to emergency steering/tipping group through main filter opening (P)

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 31

F. EMERGENCY STEERING PUMP

276C1009F

1 Intake from tank opening (D1)

2 Delivery to emergency steering/tipping group opening (P1)

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32 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

G. POWER STEERING

L
T
R
LS

276C1009G

P. Connector pipe from emergency steering/dumping group to power steering

R. Connector pipe to plate on forward right chassis
L. Connector pipe to plate on forward left chassis plate
T. Connector pipe to steering and dumping distributor (T1)
LS. Connector pipe to steering and dumping distributor (2a) (load sensing)

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 33

H. HEAT EXCHANGER

276C1009H

1 Connection pipe from tipping distributor opening (T)

2 Connection pipe to tank opening (L)

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34 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

L. DUMPING CYLINDER

276C1009L

1. Box dumping cylinder

2. Extension delivery
3. Retraction delivery

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 35

M. STEERING CYLINDER

276C1009M

1 Left steering hose from rear chassis connection plate

2 Right steering hose from rear chassis connection plate
3 Right steering hose connection to right cylinder
4 Left steering hose connection to right cylinder
5 Left steering hose connection to left cylinder
6 Right steering hose connection to left cylinder

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36 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

N. REAR CHASSIS CONNECTOR PLATE

276C1009N

1 Body tipping cylinders delivery

2 Brake operation relay valve return (oil bath brakes version)
3 Rear brakes actuation
4 Rear accumulator recharge (oil bath brakes version)
5 Right steering pipes
6 Unused
7 Parking brake pneumatic control
8 Electrical connections
9 Lubrication
10 Camera wiring
11 Body tipping return
12 Left steering pipes
13 Rear brake cooling delivery (oil bath brakes version)
14 Rear brake cooling return (oil bath brakes version)
15 Pressure fitting

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 37

MAINTENANCE Changing the fluid

Proceed as follows:
Checking fitting and pipe tightness D wait for the fluid temperature to reach 40 ˚C;
Visually check for system leaks and tightness of line D tip the engine hood;
connections.
Figure 27
In the event of faults or leakage from any of
the circuits, repairs MUST be carried out be-
fore using the vehicle.

Check by implementing all the specific safe-

ty precautions.
Collect and dispose of used lubricants and
fluids, according to the local laws and regu-
lations in force.

276NM047T
D take a suitably sized container, clean the fill cap and
drain cap areas and remove the filler cap (1);
D remove the drain cap (see arrow) and drain the fluid;
D clean the drain cap and remove any metallic resi-
dues. Check that the threads are in good condition,
replace the seal and close at the specific torque;
D pour in the specified amount of fluid through the filler
and install the cap;
D close the engine hood.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
38 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Brake pump priming test

The operations below must be carried out after changing the hydraulic fluid in order to verify the
correct priming of the brake pump.

Proceed as follows:

Figure 28

276C010041

Values
Pressure
bar psi
Min 160 + 7 --- 3 Min 2320 + 100 --- 44
Disc brakes
Max 195 ± 5 Max 2828 ± 72
M and N
Min 160 + 7 --- 3 Min 2320 + 100 --- 44
Wet oil brakes
Max 195 ± 5 Max 2828 ± 72
Disc brakes 155 + 7 --- 3 2248 + 100 --- 44
H and I
Wet oil brakes 110 + 7 --- 3 1596 + 100 --- 44

D connect a pressure gauge with max 200 bar end---of---scale value to the pressure fitting (M) or (N);
D connect a pressure gauge with max 200 bar end---of---scale value to the pressure fitting (H) or (I);

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 39

Figure 29

276C010045
D disconnect the piping from the oil vapor separator
connecting it to the hydraulic oil tank (see arrow);
D connect the piping to a pneumatic fitting.

Maximum pressure: 0.45 ± 0.15 bar (6.5 ±

2.2 psi).

DO NOT EXCEED THE RECOMMENDED

MAXIMUM PRESSURE VALUE IN ORDER TO
AVOID RISKS TO THE PERSONNEL AND
DAMAGE TO THE VEHICLE.

D start the engine and let it idle for about ten minutes;
D disconnect the pneumatic fitting from the hydraulic
oil tank;

Unscrew the cap of the hydraulic oil tank

and discharge any residual pressure.

D reconnect the piping connecting the oil vapor sepa-

rator to the hydraulic oil tank;
D operate the brake pedal a few times and check that
the accumulator recharge pressure (fittings M and
N) and the brake actuation pressure (fittings H and
I) are within the correct values;
D turn off the engine;
D remove the pressure gauges;
D perform a bleeding following as shown in the specif-
ic paragraph.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
40 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

MAIN SYSTEM Cleaning the (suction) filter

Proceed as follows:
Replacing pressurised filter Clean the filter when you change the hidraul-
Replace the filter when you change the hy- ic fluid, when the reservoir is empty.
draulic fluid.

Figure 32
Proceed as follows:
D tip the engine hood up;

Figure 30

276NM027T
D loosen the filter cartridge housing (see arrow) using
the hexagonal wrench and carefully clean the hous-
ing;

Figure 31
2 D remove the batteries as indicated in the Use and
1 D remove the battery case;
269NM312
D check condition of the seals on the cartridge (1): re-
place as required;
D replace the filtering element by inserting it in the car-
tridge housing. Check that the seals, are correctly
positioned (2);
D fill the new cartridge housing with the specified fluid
and apply the same fluid to the seals;
D install the cartridge housing then loosen;
276C010048
D open the engine hood;
Maintenance Manual;
D remove the brake actuation circuit damping valve
from the battery case and fasten it temporarily to the
chassis;
D open the cover (1) of the tank;
D unscrew the cartridge (2) from the housing;
D clean the cartridge using a suitable detergent or re-
place it, then screw it back into the housing;
D close the cover of the tank, replacing the seal (3);
D reassemble the battery case and relative compo-
nents connected to it;
D install the batteries as indicated in the Use and
Maintenance Manual;
D fill the reservoir as shown in the specific paragraph.

Do not tighten the cartridge excessively.

This could damage the support. In any case
respect the manufacturer’s specifications.

D run the engine for a few minutes and check for oil
leakage;
D close the engine hood.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 41

STEERING ---DUMPING SYSTEM TEST PROCEDURES

Before performing any intervention, ensure that all precautions have been taken and all aspects clar-
ified regarding the safety of personnel involved in the intervention.
Read the relative instructions provided in SECTION 1 of this manual.
In case of doubt, consult a more experienced person.

1. Hydraulic system air bleeding

Steering system
Proceed as follows:
D start the engine, then steer slowly and completely to the right and then to the left;
D repeat the operation several times so as to eliminate the air bubbles present in the circuit.

Dumping system
Proceed as follows:
D start the engine, then proceed to the dumping of the body so as to completely fill the entire circuit;
D return the body to the rest position;
D repeat the operation several time so as to eliminate the air bubbles present in the cylinders.

When the operations are completed, check the fluid level in the tank and top up if necessary, following the direc-
tions in the relative paragraph.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
42 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

2. Hydraulic system pressure discharge with engine off

Proceed as follows:
D bring the vehicle onto an appropriately solid flat surface, shut off the engine, remove the key from the ignition
switch, engage the parking brake and affix the indication signs;
D block the articulation by means of the steering lock bar, operating as indicated in SECTION 1.

A. Main tank

There may be pressure in the following tubes when the engine is off:
D tubing (double) between cylinders (8) and outlet D of the supercharging pressure (13).
Maximum value: 100 bar (1450 PSI) approx
Proceed as follows:
D Carefully open the union cap (F) and wrap the union in absorbent material.
D Use a suitable tool on the valve to release the pressure.
D Close the cap.

1 Main pump
5 Steering valve
6 Steering cylinders
7 Dumping valve
8 Dumping cylinders
9 Test point
13 Control pressure dumping valve
16 Main tank

276C10010

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 43

3. Steering -- dumping hydraulic system pressures check

The procedures described below allow to check the pressures for the dumping group which has
already been calibrated.
To perform the calibration of the group, refer to the relative chapter.
The procedures described below must be performed with the body empty.

Proceed as follows:
D bring the vehicle onto an appropriately solid flat surface, shut off the engine, remove the key from the ignition
switch, engage the parking brake and affix the indication signs;
D discharge the hydraulic pressure of all the circuits;
D connect respectively and as needed:
--- a pressure gauge with max range value of 100 bar to the pressure point (A);
--- a pressure gauge with max range value of 100 bar to the pressure point (B);
--- a pressure gauge with max range value of 300 bar to the pressure point (C);
--- a pressure gauge with max range value of 200 bar to the pressure point (F).

B
A
C

276C10011

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
44 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Prescribed pressure values

Test Values
Point Pressure
procedure bar psi
3.1 C Steering pressure 185 ± 5 2683 ± 73
3.2 B Reduced pressure 50 ± 3 725 ± 44
3.3 C Dumping pressure (moving struts output) 203 + 7 --- 6 2944 + 102 --- 87
Dumping back ---pressure (fourth moving
3.4 F 120 ± 5 1740 ± 73
strut discharge)
3.5 A Piloting pressure 18 + 2 --- 1 261 + 29 --- 15

Test Procedure n. 3.1 --- Steering pressure
Clear the work area of all personnel since
the stationary steering causes movement of
the front part of the vehicle.
Proceed as follows:
D start the engine;
D take the vehicle to the following conditions:
--- engine speed: low idle
--- hydraulic fluid temperature: 35 ˚C ≤ Toil ≤ 45 ˚C
D turn the vehicle completely in both directions;
D check that in both cases the pressure falls within the
prescribed values.
Test Procedure n. 3.2 --- Reduced pressure
D take the vehicle to the following conditions:
--- engine speed: low idle;
--- hydraulic fluid temperature: 35 ˚C ≤ Toil ≤ 45 ˚C
D activate the raise body control until the full extension
of the cylinders;
D keep the lever engaged and check that at full---travel
the pressure falls within the prescribed values.
Test Procedure n. 3.4 --- Dumping back ---pressure ---
fourth moving strut discharge
Proceed as follows:
D perform Test procedure n. 3.3;
D activate the lower body control;
D check that the pressure falls within the prescribed
values.

The reading of the pressure must be per-

Clear the work area of all personnel since
the stationary steering causes movement of
the front part of the vehicle.
Proceed as follows:
D repeat procedure 3.1;
D check that in both cases the pressure falls within the
prescribed values.
Test Procedure n. 3.3 --- Dumping pressure --- moving
struts output
Proceed as follows:
D start the engine;
D use the display to select the BODY ANGLE SET-
TING page from the main menu;
In this manner the body speed management
strategies are excluded, and the lifting oc-
curs with the nominal pressure for the entire
travel.
formed only upon re---entry of the fourth
moving strut.
Test Procedure n. 3.5 --- Piloting pressure
Proceed as follows:
D take the vehicle to the following conditions:
--- engine speed: low idle;
--- hydraulic fluid temperature: 35 ˚C ≤ Toil ≤ 45 ˚C
D check that the pressure falls within the prescribed
values.
Test Procedure n. 3.6 --- Anti---saturation (priority)
Clear the work area of all personnel since
the stationary steering causes movement of
the front part of the vehicle.
Proceed as follows:
D take the vehicle to the following conditions:
--- engine speed: about: 1000 RPM
--- hydraulic fluid temperature: 35 ˚C ≤ Toil ≤ 45 ˚C
D activate the dumping control as described in Test
procedure n. 3.3 and at the same time turn the ve-
hicle very quickly;
D check that during this operation the dumping cylin-
ders tend to almost stop due to lack of piloting pres-
sure.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 45

Dumping and steering valves

1.02 Maximum pressure limitation valve
1.03 Working pressure limitation valve
1.04 Dumping LS pressure limitation valve
1.05 LS pressures summation valve for anti---saturation
1.11 Dumping actuation pressure limitation valve
1.12 Steering pressure limitation valve
1.13 Dumping piloting proportional slide valve
1.15 Dumping piloting pressure limitation slide valve
1.16 Anti---saturation valve

LS
RP

1.16 Y
LS1
XP
1.13
1.15

B1
RP1 A1 1.13

P
T 1.12 T1

1.05

6
1.11
3a 4 1.04
7 1.03
3
2b 5
1

2
2a

1.02 276C010015

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46 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

DIAGNOSTICS
. This section covers operating anomalies resulting from problems with the steering ---tipping distrib-
utor.
For a complete system diagnosis, the relative tests must be carried out on the other elements of the
same system.

Prescribed pressure values

Values
Test Fitting Pressure
bar psi
1 C Steering pressure 203 + 7 --- 6 2944 + 102 --- 87
2.1 C Tipping pressure (moving struts outlet) 203 + 7 --- 6 2944 + 102 --- 87
2.2 B Reduced pressure 50 ± 3 725 ± 44
2.3 A Pilot pressure with steering stationary 17 --- 19 247 --- 276
3 A Pilot pressure with steering at full travel 21 --- 23 305 --- 334

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 47

1. The steering valve does not work (the vehicle does not turn when operating the steering wheel)

Problem Tests Results Repairs

Safety valve --- Connect a pressure gauge The maximum pres- Operate the steering and at the same
out of adjust- with 300 bar end---of---scale sure is lower than time adjust the valve in pos. 1.03 to
ment value to the pressure fitting C; the prescribed val- the prescribed pressure value.
g
--- start the engine; ue.
--- turn
t the
th steering
t i wheel
h l com-
Remove the valve in pos. 1.03; make
pletely. sure that it is not dirty and that the
seal is not deteriorated.
Replace it if necessary.
Repeat the adjustment of the valve
as described in the previous point.

XP
LS RP

Y
1.15

1.13

B1

A1
P
T1
1.12

1.11
1.04

1.03

276C010011A

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
48 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

2. The body does not tip

Problem Tests Results Repairs

Safety valve out --- Connect a pressure gauge The pressure does Select the BODY ANGLE SETTING
of adjustment with 300 bar end---of---scale not reach the pre- menu.
value to the pressure fitting scribed value.
C; Start the engine and tip the body
--- start the engine; completely. Keeping the control in
the raised position, adjust the valve
--- raise the body completely
1.04 to the prescribed pressure va-
with arrival at low speed. lue.
Defective op- --- Start the engine; The coil is not ex- Check the wiring.
eration electro- --- raise the body and use a volt- cited.
magnetic valve meter to check that the coil is
excited.
--- Start the engine; The body raises. Replace the coil.
--- check the valve operation by
manually operating the plung-
er of the tube.
XP
LS RP

Y
1.15

1.13

B1

A1
P
T1
1.12

1.11
1.04
1.03

276C010011B

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 49

3. The body raises slowly even with the engine at maximum speed

Problem Tests Results Repairs

Insufficient --- Connect a pressure gauge
control with 100 bar end---of---scale
value to the pressure fitting A;
--- start the engine.
With steering at full Adjust the valve in pos. 1.15 to the
travel, the pressure prescribed pressure value and op-
does not reach the erate the tipping.
prescribed
ib d value.
l
If it is not possible to reach the pre-
scribed pressure with the steering
operated at full travel, remove the
steering---tipping distributor and
replace the priority control anti---
saturation valve module (arrow).

XP
LS RP

1.15

1.13

B1

A1
P
T1
1.12

1.11
1.04

1.03

276C010011C

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
50 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

4. The body does not lower

Problem Tests Results Repairs

Insufficient con- --- Connect a pressure gauge
trol with 100 bar end---of---scale
value to the pressure fitting A;
--- start the engine.
Defective op- --- Start the engine;
eration electro- --- raise the body and use a vol-
magnetic valve tmeter to check that the coil is
excited.
--- Start the engine;
--- check the valve operation by
manually operating the plun-
ger of the tube.
With steering at full trav- Adjust the valve in pos. 1.15 to
el, the pressure does the prescribed pressure value
not reach the pre- p and operate the tipping.
scribed
ib d value.
l
If it is not possible to reach the
prescribed pressure with the
steering operated at full travel,
remove the steering---tipping dis-
tributor and replace the priority
control anti---saturation valve
module (arrow).
The coil is not excited. Check the wiring.
The body raises. Replace the coil.

XP
LS RP

1.15

1.13

B1

A1
P
T1
1.12

1.11
1.04

1.03

276C010011C

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
DETACHMENT ---REATTACHMENT OF THE
EMERGENCY STEERING VALVE --- MAIN
FILTER
Before performing any intervention, ensure
that all precautions have been taken and all
aspects clarified regarding the safety of per-
sonnel involved in the intervention.
Read the relative instructions provided in
SECTION 1 of this manual.
In case of doubt, consult a more experi-
enced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.
Detachment
Proceed as follows:
D bring the vehicle onto an appropriately solid flat sur-
face, shut off the engine, remove the key from the
ignition switch, engage the parking brake and affix
the indication signs;
D disconnect the battery---disconnect switch or dis-
connect the battery terminals in order to eliminate
any risk of short ---circuit;
D block the articulation by means of the steering lock
bar, as indicated in SECTION 1;
D discharge the hydraulic pressure from all the cir-
cuits;
D remove the right side guard following the instruction
in SECTION 15;
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
SECTION 10 HYDRAULIC SYSTEM 51
D disconnect the following hydraulic fluid piping from
the filter group:
--- delivery (C1) to the tipping valve (2);
--- delivery (C) to the steering valve (3);
--- arrival (P1) from the emergency steering pump
(4);
--- return (T) to the tank (5).
Additional hydraulic fluid leakage may occur
during these operations.
. It is recommended to suitably mark the fit-
tings in order to facilitate reassembly.
D disconnect the following hydraulic fluid piping from
the automatic transmission filter group:
--- oil delivery to the filter group (6);
--- oil return from the filter group (7);
--- filter group by---pass (8).
Additional hydraulic fluid leakage may occur
during these operations.
D disconnect the electrical connections:
--- hydraulic system filter obstruction sensor (12);
--- emergency steering pump manostat (13);
--- emergency steering pump actuation electro-
magnetic valve (14);
--- automatic transmission oil filters obstruction
sensor (15);
D using a suitable lifting device, sling the entire group;
D unscrew the retaining screws fastening the group
support bracket (1) to the automatic transmission
and remove the group;
D disassemble the group on the workbench.
Reattachment
Proceed with the reattachment by following the detach-
ment instructions in the reverse order.
52 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

14

12 1

8
7

4 5

2 3

15

13

276C10017

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
DUMPING VALVE REMOVAL---
REPLACEMENT
Before carrying out any operation, check
that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in
SECTION 1 of this manual.
If in doubt, speak to a more experienced
person.
Respect all general recommendations for
correct execution of maintenance works.
Removal
Proceed as follows:
D park the vehicle on a suitable flat and solid surface,
remove the ignition key, engage the handbrake and
place maintenance warning signs.
D disengage the battery cut ---off switch or disconnect
the battery leads to eliminate any risk of
short ---circuit;
D lock the articulation using the steering lock bar as
instructed in SECTION 1;
D discharge the hydraulic pressure from all circuits;
D remove the right side cover;
D remove the right side guard following the instruction
in SECTION 15;
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
SECTION 10 HYDRAULIC SYSTEM 53
D disconnect the following pipes:
(2) dumping lower command (A1)
(3) dumping raise command (B1)
(4) delivery from pump (P)
(5) return to tank (T)
(6) return from steering valve (T1)
(7) steering LS load signal (2a)
(8) pump LS load signal (3)
(9) return to tank signal (5)
(10) return to tank signal (Y)
(11) pressure signal (point A)
(12) pressure signal (point B)
(13) pressure signal (point C)
D remove the following rigid pipes:
(14) anti---saturation valve piloting
(15) tipper box pressure limiter valve piloting;
Additional hydraulic fluid may leak during
these operations.
. We recommend marking the pipes to
facilitate reconnection.
D disconnect the following electrical connections:
(16) box raise electrovalve piloting
(17) box lower electrovalve piloting.
D with suitable lifting gear, unscrew and remove the
valve (1).
Replacement
For replacement, follow the removal instructions in
reverse order.
54 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Dumping valve removal -- replacement

276C010018

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10
DUMPING CYLINDER REMOVAL---
REPLACEMENT
Before carrying out any operation, check
that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in
SECTION 1 of this manual.
If in doubt, speak to a more experienced
person.
Respect all general recommendations for
correct execution of maintenance works.
Removal
Proceed as follows:
D park the vehicle on a suitable flat and solid surface,
remove the ignition key, engage the handbrake and
place maintenance warning signs.
D disengage the battery cut ---off switch or disconnect
the battery leads to eliminate any risk of
short ---circuit;
D lock the articulation using the steering lock bar as
instructed in SECTION 1;
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
HYDRAULIC SYSTEM 55
D discharge the hydraulic pressure from all circuits;
D using a bridge crane lift the box enough to access
the box articulation pins, then lock it in place with
suitable spacers between box and chassis;
D unscrew and disconnect the following connectors
from the cylinder:
(2) extension delivery
(3) retraction delivery
Hydraulic fluid may leak during these
operations.
D remove the screws (4) fastening the cylinder (1) to
the box, along with all bushes and washers;
D using the bridge crane fully lift the box and secure
as instructed in SECTION 1;
D support the cylinder (1) with suitable lifting gear;
D remove the screws (5) fastening the cylinder (1) to
chassis, along with all bushes and washers, and
remove the cylinder.
Replacement
For replacement, follow the removal instructions in
reverse order.
Steer in both directions a few times to free the circuit of
air bubbles.
56 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Dumping cylinder removal -- replacement

276C010046

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 57

STEERING VALVE REMOVAL---
REPLACEMENT
Before carrying out any operation, check
that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in
SECTION 1 of this manual.
If in doubt, speak to a more experienced
person.
Respect all general recommendations for
correct execution of maintenance works.
D discharge the hydraulic pressure from all circuits;
D lift the cab as instructed in the USE AND
MAINTENANCE MANUAL;
D disconnect the steering column from the steering
valve;
D disconnect all connections to the steering valve (1):
(2) LS load signal
(3) return (T)
(4) Left steering command (L)
(5) delivery (P)
(6) Right steering command (R)
Hydraulic fluid may leak during these
operations.

Removal
Proceed as follows:
. We recommend marking the pipes to
facilitate reconnection.
D park the vehicle on a suitable flat and solid surface,
remove the ignition key, engage the handbrake and
place maintenance warning signs.
D disengage the battery cut ---off switch or disconnect
the battery leads to eliminate any risk of
short ---circuit;
D lock the articulation using the steering lock bar as
instructed in SECTION 1;

2691627

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
58 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

D unscrew the retaining screws (3) and remove the

valve (4) and the top flange (2) from the
cross---piece (1).

Replacement
For replacement, follow the removal instructions in
reverse order.

276C010047

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 59

MAIN PUMP REMOVAL---REPLACEMENT
Before carrying out any operation, check
that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in
SECTION 1 of this manual.
If in doubt, speak to a more experienced
person.
Respect all general recommendations for
correct execution of maintenance works.
Removal
Proceed as follows:
D park the vehicle on a suitable flat and solid surface,
remove the ignition key, engage the handbrake and
place maintenance warning signs.
D disengage the battery cut ---off switch or disconnect
the battery leads to eliminate any risk of
short ---circuit;
D lock the articulation using the steering lock bar as
instructed in SECTION 1;
D discharge the air pressure from the main tank and
hydraulic pressure from all circuits;
D lift the cab as instructed in the USE AND
MAINTENANCE MANUAL;
D disconnect the intake pipe (2) removing the pump
side screws and removing the chassis mounting
bracket (see arrow);
D remove the delivery pipe (3) removing the screws
from both sides (see arrow);
D disconnect the following pipes from the pump:
(4) LS signal
(5) Return
Hydraulic fluid may leak during these
operations.
D disconnect the following electrical connections from
the pump:
(6) pump vacuum switch;
D supporting the pump (1) with suitable means,
unscrew the screws and remove the pump.
Replacement
For replacement, follow the removal instructions in
reverse order.

276C10016

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
60 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

STEERING CYLINDER REMOVAL--- . Use clamps to fasten the pipes in a raised

REPLACEMENT position to prevent fluid spillage.

Before carrying out any operation, check D disconnect all connections from the cylinder (1):
that all precautions have been taken and all (2) extension delivery
aspects regarding safety of the personnel (3) retraction delivery
involved have been clarified. Hydraulic fluid may leak during these
Read the related instructions given in operations.
SECTION 1 of this manual.
If in doubt, speak to a more experienced
person.
. We recommend marking the pipes to
facilitate reconnection.
Respect all general recommendations for
correct execution of maintenance works. D disconnect the central greasing system
connectors:
Removal (4) steering cylinder front joint B RH / B1 LH
(5) steering cylinder rear joint B9 RH / B10 LH.
Proceed as follows: D support the cylinder (1) with suitable lifting gear;
D park the vehicle on a suitable flat and solid surface, D Remove the bold (see arrow) and remove the
remove the ignition key, engage the handbrake and cylinder, with all bushes and washers.
place maintenance warning signs.
D disengage the battery cut ---off switch or disconnect Replacement
the battery leads to eliminate any risk of
For replacement, follow the removal instructions in
short ---circuit;
reverse order.
D lock the articulation using the steering lock bar as
Steer in both directions a few times to free the circuit of
instructed in SECTION 1;
air bubbles.
D discharge the hydraulic pressure from all circuits;

5
4

276C10019

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
DUMPING CYLINDER OVERHAUL
Dismantling
Proceed as follows:
D Wash the outside of the telescopic cylinder with
water and a non---inflammable detergent to remove
excess dust and grime, then dry it.
Figure 33
18916100
D Position the cylinder horizontally in a V vice with the
lower end (base side) towards the operator and
slightly protruding from the working plane.
Take care when tightening in the vice not to
ovalise the liner, making dismantling of the
components difficult.
D Place a recipient with adequate capacity under the
base.
Figure 34
18916101
D Loosen the base grub screw (detail), then using a
long lever loosen the base by a few turns. Proceed
with final removal manually allowing the hydraulic
fluid to drain.
. Take care not to drop the base.
Pay attention to leakage of the hydraulic
fluid left inside the cylinder itself.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
SECTION 10 HYDRAULIC SYSTEM 61
D Using a flat head screwdriver as a lever, delicately
extract the special polyurethane seal from the seat
in the base. Check integrity of the base itself:
. If still intact after removal, the seal may be
re---used.
Figure 35
18916102
D Remove the elastic stop rings one at a time starting
with the smallest diameter one. Move the element
covering the ring forward using a hammer and a
plastic spacer. Using a screwdriver and a mallet, lift
the ring itself and extract it from its seat taking care
that it does not spring out;
Figure 36
18916103
D Unscrew the plunger using a long lever and the two
holes on the bottom of the plunger to prevent it rotat-
ing.
D Two operatives are required to extract the plunger:
one to move the plunger with a hammer and a long
spacer and the other ready to catch it as soon as it
is pushed out.
It is advisable to extract the plunger from the
opposite end to the base to prevent damage
to the seal.
Figure 37
62 HYDRAULIC SYSTEM SECTION 10
18916104
D Once the terminal and plunger are removed, the
most internal slider can be removed from the base
side. Lightly tap the element with a mallet and plas-
tic spacer to move it and then slide it by hand to pre-
vent damage to the precision ground surfaces.
D Proceed in the same way with the other sliders.
Figure 38
D Proceed to unscrew the locking ring fitted to the
second slider: prevent the element from rotating by
adequately locking it and proceed to unscrew the
locking ring with a special fork spanner inserted in
the two holes provided.
D Using a flat head screwdriver as a lever, delicately
raise the seals from their seats and remove them by
hand.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
Checking components
D If the cylinders leak oil or are a few years old, it is ad-
visable to replace all the seals, guides and scrapers
with new and original parts. For cylinders less than
one year old without leaks, the removed compo-
nents may be re---used after carefully checking their
integrity.
D Thoroughly wash the elements, the liner, terminal,
locking ring and plunger. Thoroughly dry them.
D Thoroughly clean the interiors and the channels for
the guides, the seals and scrapers.
D Using an exterior micrometer, check the diameter of
the elements, which must not be greater than the
given value.
D Check the integrity of the external (precision
ground) and internal (rolled) surfaces, and for the
absence of scratches, distortion or dents. If even the
smallest defect is found, proceed by replacing the
element.
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 63

Rings and seals present on the sliders

Figure 39
A. Starting from the terminal side, fitted inside the
liner there is a polyurethane scraper (a), a Delrin
guide (b) and a polyurethane seal (c);
B. From the terminal side fitted inside the first tele-
scopic element there is a polyurethane scraper, a
Delrin guide (upper guide) and a polyurethane
seal, and externally, from the base side a Delrin
guide (a) (lower guide);
C. The second element only has the lower guide.
From the terminal side, fitted inside the locking
ring there is a polyurethane scraper (a), two Delrin
guides (b) (upper guides), and a polyurethane
seal (c), while outside there is an Ertalon pad (d)
and an O---ring (e) with stopper (f);
D. Inside the plunger there is an O---ring (a) with
stopper (b), while outside (from the terminal side)
there is a DAS type seal (c) and a Delrin guide (d)
(lower guide).

Assembly

While the guides can be fitted either way, the

seals and scrapers are asymmetric: they
both have a groove that for the seals has to
be facing downward (toward the inside of
the cylinder) and for the scrapers has to be
facing toward the outside. Attention there-
fore has to be paid to fitting the seals and
scrapers in the right direction, because in-
verting them will cause serious cylinder mal-
function.
Proceed as follows:
D Fit the seals and guide on the plunger and locking
ring. Tighten the locking ring on the second element
using the same tool used for unscrewing it.
D Position the liner horizontally and lock it in a V vice
by the lower end (base side) so that it protrudes
slightly from the bench

Take care not to distort (ovalise) the liner

when tightening it in the vice, which would
make fitting the elements difficult.
D Fit the seals and guide inside the liner and grease
them.
D Fit the first element (with the largest diameter), in-
serting it into the liner from the base side. Leaving
the element protruding from the liner from the base
side, fit the lower guide the push the element for-
ward sing a hammer an plastic spacer. Fit the seals
and guide inside the element and grease them.
D Insert the second telescopic element inside the first
from the base side and fit the lower guide the same
way as for the first element.
D Push the element forward using a hammer and
plastic spacer and grease the seals and guide fitted
inside the locking ring.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
64 HYDRAULIC SYSTEM
Figure 40
18916107
D Proceed by inserting the terminal inside the second
element from the opposite side to the base.
D Grease the seals and guide fitted to the outside of
the plunger and apply locktite to the internal thread.
Figure 41
18916108
D Insert the plunger inside the second element from
the base side with the seat of the O---ring turned to
face the base side itself, then push the plunger until
it rests against the terminal. At this point screw the
plunger to the terminal proceeding as already ex-
plained for removal.
D Move the second element and terminal forward to
reveal the seats for the stop rings. Fit the stop rings,
starting from the largest diameter one, using a
screwdriver.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
SECTION 10 ADT 25-30 TIER3
Figure 42
18916109
D Move the entire block of elements forward using a
hammer and plastic spacer until revealing the seat
for the base on the liner.
D Manually fit the seal on the base in the seat
provided. Initially tighten the base on the liner by
hand, then finish tightening using a long lever.
Tighten the grub screw in its seat.
Functional testing
D With the oil feed open, tap the top of the terminal
with a plastic mallet to fully close the assembly, mini-
mising the quantity of air present inside it.
D Before refitting the cylinder to the vehicle, perform
a brief functional test on a test bench.
D Connect the cylinder to the bench hydraulic system,
and raise and lower it a few times, checking the reg-
ularity of operation (the first cycles will be irregular
due to the air present in the cylinder itself).
D Hold the cylinder under pressure for several min-
utes to check for any oil seepage.
D If a suitable test bench is not available, test the cylin-
der directly on the vehicle, carrying out the same
operations as described above.
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 65

STEERING CYLINDER OVERHAUL Figure 45

Before carrying out any operation, check

that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in SEC-
TION 1 of this manual.
If in doubt, speak to a more experienced per-
son.
Respect all general recommendations for
correct execution of maintenance works.

Dismantling
18916201
Proceed as follows:
D Wash the cylinder exterior with water and a non---in- D Place the rod in a vice with soft material between it
flammable detergent to remove excess dirt and gri- and the jaws.
me, then dry it. D Remove both the hydraulic pipe fittings.
D Using a plumber’s wrench, unscrew the guide head
Figure 43 from the cylinder body.
D Pull out the rod complete with piston and guide
head from the cylinder.

Figure 46

276A010034
D Remove the retaining rings (1) from the front termi-
nal;
D Remove the ball joint (2);
18916202
Figure 44 D Using a drill bit, remove the caulking (a), and allow
the centring pin (b) to drop out of its housing.

276A010035
D Remove the retaining rings (1) from the rear termi-
nal;
D Remove the ball joint (2);

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
66 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Figure 47 Figure 49

18916203
D Place the rod in a vice with soft material between it
and the jaws.
D Using a pin wrench, remove the piston from the rod.

Figure 48

d
276A010036
D Remove the seals
a. external, from the piston
18916204
b. external, from the guide head
c. internal, from the guide head
D Slip the guide head off the rod.
d. from the rod

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 67

Assembly Figure 52
All seals must be replaced when assem-
bling.
Carefully lubricate all seals with hydraulic
fluid.
Proceed as follows:

Figure 50

18916208B
D Fit the sealing ring to the outside of the guide head.

Figure 53

18916207

Apply LOCKTITE 243 (arrow) to threads.

D Using a lever, fully tighten the lower joint on the rod.

Figure 51

18916209
D Fit the O---ring to the outside of the guide head, re-
sting it on the sealing ring.
D Fit the O---ring onto the rod.

Figure 54

Each seal inside the guide head is made up

of a spring and a ring, which must be fitted
separately.
Begin assembly with the seal furthest from
the trailing edge of the guide head.

D Fit the spring into the seat (a) then fit the Teflon ring
(b). 18916210
D Insert the guide head (a) onto the rod, taking great
care not to damage the previously fitted seals.
D Using a pin wrench, fully tighten the piston (b) onto
the rod.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
68 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Figure 55 Figure 58

18916211 18916215
D Insert the centring pin (a) into its seat, then apply D Using a plumber’s wrench fully tighten the guide
caulking (b) to block it. head onto the cylinder body.

Figure 56 Figure 59

276A010035
18916212
D Fit the seals onto the piston starting with the most D Mount the rear spherical joint (1) with the elastic
internal one. stop rings (2).
D Mount both the hydraulic pipe fittings. D Remove the cylinder from the vice.

Figure 57 Figure 60

18916214 276A010034
D Delicately insert the rod complete with piston and D Mount the front spherical joint (1) with the elastic
guide head into the cylinder taking great care not to stop rings (2).
damage the previously fitted seals.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 69

STEERING ---DUMPING VALVE BLOCK Figure 62

OVERHAUL
Before carrying out any operation, check
that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in SEC-
TION 1 of this manual.
If in doubt, speak to a more experienced per-
son.
Respect all general recommendations for
correct execution of maintenance works.

Disassembly 276A010039

Proceed as follows: D Use a wrench to remove the valve 1.03;

D Externally clean the block with water and a non---in- Figure 63
flammable detergent in order to eliminate excess
dust and dirt, then dry it.
For the identification of the valves and cali-
brating setscrews refer to the figure on the
following page.

Additional hydraulic fluid leakage may occur

during these operations.

Figure 61

276A010040
D Use a wrench to remove the valve 1.04;

Figure 64

276A010038
D Use a wrench to remove the valve 1.02;

276A010041
D Use a wrench to remove the valve 1.11;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
70 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Component position identification

1.02
1.02
1.03

1.04
2a
1.03
1.11
2 D
1.04
1
2b
1.11
5
3 3a
7
C 4

6 1.13 1.12
T1
P
A1
1.05

B1

RP1

BY PASS

1.15
BY PASS
Y

1.13
LS1
1.16 B RP LS

A XP

code 1.02 Maximum pressure limitation valve

code 1.03 Working pressure limitation valve
code 1.04 Dumping LS pressure limitation valve
code 1.06 Blind setscrew (protected by cap)
code 1.07 Calibrated setscrew
code 1.08 Calibrated setscrew (accessible after disassembly of the group)
code 1.10 Calibrated setscrew (protected by cap)
code 1.11 Dumping actuation pressure limitation valve
code 1.12 Hydrostatic valve
code 1.13 Dumping piloting proportional slide valve
code 1.15 Dumping piloting pressure limitation slide valve (priority)
code 1.16 Anti---saturation valve

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 71

Figure 65 Figure 68

276A010043 276A010046
D Use a wrench to remove the valve 1.12; D Remove the three hexagonal socket head cap
screws (arrows) that keep the block modules pac-
Figure 66 ked;

Figure 69
2

276A010044
D Use a wrench to remove the valve 1.15 (1) and valve
1.16 (2); 276A010047
D Remove the block 1.14 (sensor valve);
Figure 67
Figure 70

1 276A010045
D Unscrew the retaining bush (1) of the proportional 276A010048
valve 1.13; D Remove the proportional valve block (directional
D Slip off the body (2) of the proportional valve; control valve);
The two proportional valves 1.13 are identi-
cal.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
72 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Figure 71 Figure 74

276A010049 276A010052
D Unscrew the calibrated setscrew 1.08; D Remove the threaded connector (if present);
D Unscrew the calibrated setscrew 1.07;
Figure 72
Figure 75

D Remove the threaded cap; 276A010053

D Remove the threaded cap;
Figure 73
Figure 76

276A010051
D Unscrew the calibrated setscrew 1.10; 276A010054
D Unscrew the calibrated setscrew 1.06.
The caps not shown in this procedure must
be removed only if necessary (severe pollu-
tion of the hydraulic fluid).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 73

Cleaning Assembly
Thoroughly clean all the disassembled components, All gaskets must be replaced during reas-
taking the following recommendations into consider- sembly.
ation: Thoroughly lubricate all the gaskets and all
D thoroughly clean the blocks externally as well in or- the inner details with hydraulic oil.
der to allow their inspection and to prevent dirt from
penetrating inside;
Proceed with the assembly by following the disassem-
D all the components must be perfectly cleaned with
bly steps in the reverse order.
suitable detergent;
D clean the oil channels by passing a piece of soft wire
in both directions and then washing with solvent.
Dry the channels with compressed air.

Checks and inspections

The components subject to the procedure
described above can not be dismounted fur-
ther.
In case of damage or proven malfunction of
a component, it must be replaced.

D check all the oil channels: any obstructions should

be eliminated with a jet of compressed air or by pas-
sing a smooth wire in both directions of the channel
and then washing with solvent;
D check the threadings of the blocks, correct any da-
maged threads with a threading tap of the required
size;
D check for the absence of deformations and dama-
ged threads on the disassembled valves; replace
any damaged pieces.
D replace all the gaskets.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
74 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Page left intentionally blank

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 75

SECTION 10.2

EMERGENCY STEERING SYSTEM

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
76 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

EMERGENCY STEERING SYSTEM

Main components
Pump: fixed displacement with radial pistons (2), fitted to the lower power take---off of the automatic
transmission: the pump only rotates if the vehicle is moving.
Actuator: steering cylinders, controlled by the steering valve.
Filter: in induction (12) to system, common to the brakes actuation system (12).
Tank: common to the steering and dumping system (16).

Function
To ensure the rate of flow needed by the steering operations in the event of a failure in the main pump/main pump
control system.
The delivery of the pump is directed to discharge or to the steering valve by an actuation valve (4) controlled by
the electromagnetic valve 321 which is in turn controlled by the body computer.

. The references with which the components are identified are the same used in the hydraulic diagram
shown on the following pages.

. For more information on the topographic diagram, see Section 10.1 --- Steering and tipping system.

Main component emergency steering system

276C010030

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 77

Emergency steering hydraulic diagram

1. Main pump with variable displacement (fixed) 9.
2. Emergency steering pump 10.
3. Pressurized filter 11. Emergency steering pressure switch 336
4. Emergency steering actuation valve with 12. Brake actuation system intake filter
actuation electromagnetic valve 321 13.
5. Steering valve 14.
6. Steering cylinders 15.
7. Dumping valve 16. Tank
8.

276C10031

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
78 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

OPERATION
. Refer to the previous figure.
The emergency steering pump [2] is always in operation when the vehicle is moving, since the power intake is
coupled on the output of the automatic transmission.
The delivery of the emergency pump is intercepted by an ON---OFF electromagnetic valve 321 mounted on valve
[4].
The electromagnetic valve 321 is controlled by MIDAC3 as a function of the manostat signal [11] / 336 sensitive
to the output pressure of the main pump.

If the manostat is closed (pressure greater than the set value) the electromagnetic valve 321 is de---energized and
the delivery is sent to the drain.

If the manostat is open (pressure less than the set value) the contact earths pin C3 of MIDAC3. The control by
HEAD via CAN OPEN brings the pin C8 of MIDAC3 to +Vbatt and the electromagnetic valve 321 is energized.
In this manner the delivery is sent to the steering valve [5].

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 79

INSPECTION PROCEDURES

Check the efficiency of the emergency steering

pump control
Do as follows:
D Shut off the engine, move the selector lever to the
Neutral position and engage the parking brake.
D Move the starting switch to the position 1.
D Move the selector to the position Forward.
In this condition the display will show the symbol and
the relevant message.

276NU110
Both the generic and serious anomaly warning lights
will come on.
In addition, the warning buzzer (continual buzz) will
start on vehicles that are fitted with this device.

T269NU383

. The buzzer will activate even if it has been di-

sabled from the display.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
80 HYDRAULIC SYSTEM
EMERGENCY STEERING PUMP
REMOVAL---REPLACEMENT
Before carrying out any operation, check
that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in
SECTION 1 of this manual.
If in doubt, speak to a more experienced
person.
Respect all general recommendations for
correct execution of maintenance works.
Removal
Proceed as follows:
D park the vehicle on a suitable flat and solid surface,
remove the ignition key, engage the handbrake and
place maintenance warning signs.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
SECTION 10 ADT 25-30 TIER3
D disengage the battery cut ---off switch or disconnect
the battery leads to eliminate any risk of
short ---circuit;
D lock the articulation using the steering lock bar as
instructed in SECTION 1;
D discharge the hydraulic pressure from all circuits;
D to allow access to the pump, disconnect the output
shaft joint from the automatic transmission side as
described in SECTION 7;
D disconnect the following pipes from the pump:
(2) intake
(3) delivery
Hydraulic fluid may leak during these
operations.
D Unscrew and remove the pump (1) and the
O---rings.
Replacement
For replacement, follow the removal instructions in
reverse order.
2691625
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 81

SECTION 10.3

BRAKING SYSTEM --- DISC BRAKES VERSION

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
82 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

BRAKING SYSTEM

Main components
Pump: gear type (1) fitted to the engine air compressor.
Actuator: brake valve --- brake valve distributor (8) relay valve (10) (multiple disk cylinder) --- dumping brake
valve
Filter: net on the intake (11) with by---pass valve, fitted inside the tank;
on the delivery side (2) (pressurized) cartridge with by---pass valve and electric clogging indicator,
fitted on the side of the automatic transmission oil filters.
Tank: common (12) to steering and dumping.

Function
To ensure that the accumulators front (4) and rear (5) are recharged and to supply the pressure needed to operate
the brakes.

. The references with which the components are identified are the same used in the hydraulic diagram
shown on the following pages.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 83

Main components of the braking system

276C010035

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
84 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Service and parking brakes -- location

Intermediate axle brakes

Front axle brakes

Rear axle
2

1.
2.
3.
1

276C10036

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 85

Braking system hydraulic diagram

1. Brake pump
2. Pressurized filter
3. Brakes valve
4. 1.4 litre accumulator
5. 1.4 litre accumulator
6. Pressure vent
7. Not used
8. Accumulator pressure switch
9. Brake lights pressure switch
10. Not used
11. Intake filter
12. Tank
13. Front axle brake actuators
14. Intermediate axle brake actuators
15. Rear axle brake actuators

(a) Accumulators recharge distributor box

(b) Adjustment valve
(c) Accumulators isolation valve
(d) Brakes control valve (brake pedal valve)

List of pressure vents (see 6 on the diagram)

H. Rear brakes actuation circuit pressure

I. Front brakes actuation circuit pressure

M. Front accumulator refueling pressure

N. Rear accumulator refueling pressure (pedal valve)

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86 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Braking system hydraulic diagram

276C010037

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 87

Braking system hydraulic diagram

13

14

15

15

276C010038

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88 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

OPERATION
. Refer to the previous figure.

Stand---by conditions
The brake pedal valve (d) operates the actuators exclusively through the pressure coming from the accumulators.
These latter are refueled through the distributor slide valve (a).
The brake pedal valve (d) acts directly on both the front brake actuators [15] and the intermediate [14] and rear
[13] axle brake actuators.
The brake pump [1] is always in operation when the engine is running since the power take---off is coupled to
the air compressor.

Braking conditions
The distributor slide valve (d) of the brake valve [3] is controlled by the pedal.
With the pedal released, the position of the distributor slide valve (d) discharges the actuators of the front brakes
--- connected to opening T2 --- and the actuators of the rear brakes --- connected to the opening T1 --- through
the opening N.
Operating the brake pedal, the distributor slide (d) of the brake valve [3] moves to the right and repectively con-
nects:
D the accumulator [4] with the actuators of the front brakes [15] through the opening T2;
D the accumulator [5] with the actuators of the tandem brakes [14] and [13] through the opening T1.
The manostat [9] 337, if open, determines via CAN OPEN the lighting of the rear stop lights 125.
The manostat [8] 341, if open, determines via CAN OPEN the activation of an alarm on the display and the lighting
of the emergency indicator light.

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 89

TOPOGRAPHICAL DIAGRAMS

Forward chassis diagram

276C1039X

A. Brake pump
B. Oil tank
C. Accumulators
D. Filter and limitation valve
E. Brake command valve
F. Not used

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
90 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Rear chassis diagram

276C1039Y
H. Rear chassis connector plate

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 91

A. BRAKE PUMP

276C1039A
1. Intake from tank (O’)
2. Delivery to brake command valve outlet (P) through oil filter

B. OIL TANK

. See section 10.1 --- Topographical diagrams.

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92 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

C. ACCUMULATORS

276C1039C

1. Brake control valve opening (R1) connection pipe

2. Brake control valve opening (R2) connection pipe

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 93

D. FILTER AND LIMITATION VALVE

276C1039D

1. Limitation valve
2. Filter
3. Main pump connection pipe
4. Brake control valve opening (P) connection pipe

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
94 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

E. BRAKE COMMAND VALVE

276C1039E

P. Delivery from brake pump through filter

F. Accumulator recharge control pressure switch
F1. Brake control pressure switch
T1. Connector pipe to rear axle brake
T2. Connector pipe to front axle brake
R1. Connector pipe to front accumulator S1
R2. Connector pipe to front accumulator S2
B. Connector pipe to oil tank (F1)
N. Connector pipe to oil tank (F5)

H. REAR CHASSIS CONNECTOR PLATE

. See section 10.1 --- Topographical diagrams.

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 95

H. REAR CHASSIS CONNECTION PLATE

276C1009N

1 Body tipping cylinders delivery

2 Brake operation relay valve return (oil bath brakes version)
3 Rear brakes actuation
4 Rear accumulator recharge (oil bath brakes version)
5 Right steering pipes
6 Unused
7 Parking brake pneumatic control
8 Electrical connections
9 Lubrication
10 Camera wiring
11 Body tipping return
12 Left steering pipes
13 Rear brake cooling delivery (oil bath brakes version)
14 Rear brake cooling return (oil bath brakes version)
15 Pressure fitting

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96 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

BRAKING SYSTEM TEST PROCEDURES

Figure 78
Before carrying out any operation, check
that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in SEC-
TION 1 of this manual.
If in doubt, speak to a more experienced per-
son.

1. Braking hydraulic system air bleeding

Proceed as follows:
D start the engine and leave it at minimum;

Figure 77

276NM049T
D repeat the operation for all the brake groups of the
vehicle (see arrow).
At the end of the operations, check the fluid level in the
tank and top up if necessary.

2
1

276NM048T
D remove the dust cap, then fit a piece of transparent
tube onto the front brakes pressure fitting (1) and
immerge the other end in a container that already
contains a certain amount of fluid;
D press the brake pedal down completely, keeping it
in this position;
D loosen the valve, letting the fluid seep out until the
fluid coming out from the fitting is bubble---free;
D close the valve and remount the dust cap;
D repeat the operation for the rear brakes pressure fit-
ting (2);

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 97

2. Braking system pressure discharge with engine off

There may be pressure in the following tubes with the engine off:
D tubing between accumulator 4 and outlet R2 of the brake valve 3;
D tubing between accumulator 5 and outlet R1 and R2 of the relay valve 3.
Maximum value: 195 bar (2828 PSI).
Proceed as follows:
D bring the vehicle onto an appropriately solid flat surface, shut off the engine, engage the parking brake and
affix the indication signs;
D move the ignition switch to position 1;
D activate the service brake control until the brake pedal goes all the way down (the stop lights no longer light
up);
D perform at least another five actuations of the control.

276C10040

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98 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

3. Braking hydraulic system pressures check

Proceed as follows:
D bring the vehicle onto an appropriately solid flat surface, shut off the engine, remove the key from the ignition
switch, engage the parking brake and affix the indication signs;
D block the articulation by means of the steering lock bar, operating as indicated in SECTION 1;
D discharge the pneumatic pressure of the main hydraulic tank and the hydraulic pressure of all the circuits;

D connect respectively and as needed:

--- a pressure gauge with max range value of 200 bar to the pressure point (I);
--- a pressure gauge with max range value of 200 bar to the pressure point (H);
--- a pressure gauge with max range value of 100 bar to the pressure point (M);
--- a pressure gauge with max range value of 100 bar to the pressure point (N);

N I
M

276C10041

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 99

Prescribed pressure values

Values
Procedure Point Pressure
bar psi
I Front brakes actuation pressure 155 + 7 --- 3 2248 + 102 --- 44
31
3.1
H Rear brakes actuation pressure 155 + 7 --- 3 2248 + 102 --- 44
M Front brakes accumulator charge pressure 65 ± 3 943 ± 44
32
3.2
N Rear brakes accumulator charge pressure 65 ± 3 943 ± 44

Test Procedure n. 3.1 --- Braking

Proceed as follows:
D start the engine
D take the vehicle to the following conditions:
--- engine speed: low idle;
--- hydraulic fluid temperature: 35 ˚C ≤ Toil ≤ 45 ˚C;
--- press the brake pedal;
D check that the front and rear brake pressures fall within the prescribed values.

Test Procedure n. 3.2 --- Accumulator charge pressure check

Proceed as follows:
D completely discharge the hydraulic pressure of the braking circuit as described in the relative procedure;
D check that the pressure falls within the prescribed values.

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100 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

4. Braking hydraulic system pressures adjustment

Proceed as follows:
D bring the vehicle onto an appropriately solid flat surface, shut off the engine, remove the key from the ignition
switch, engage the parking brake and affix the indication signs;
D block the articulation by means of the steering lock bar, operating as indicated in SECTION 1;
D discharge the pneumatic pressure of the main hydraulic tank and the hydraulic pressure of all the circuits;
D connect respectively and as needed:
--- a pressure gauge with max range value of 200 bar to the pressure point (I);
--- a pressure gauge with max range value of 200 bar to the pressure point (H);
--- a pressure gauge with max range value of 200 bar to the pressure point (M);
--- a pressure gauge with max range value of 200 bar to the pressure point (N).

N I
M 276C10041

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 101

Prescribed pressure values

Values
Procedure Point Pressure
bar psi
Front accumulator recharge start pressure 160 + 7 --- 3 2321 + 102 --- 44
M
Front accumulator recharge end pressure 195 ± 5 2828 ± 73
41
4.1
Rear accumulator recharge start pressure 160 + 7 --- 3 2321 + 102 --- 44
N
Rear accumulator recharge end pressure 195 ± 5 2828 ± 73
I Front brakes actuation pressure 155 +7 --- 3 2248 + 102 --- 44
42
4.2
H Rear brakes actuation pressure 155 +7 --- 3 2248 + 102 --- 44

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102 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Test Procedure n. 4.1 --- Accumulator recharge pressure adjustment

Proceed as follows:
D remove the cap (3);
D loosen the lock ---nut of the screw (2) and then that of the screw (1);
D start the engine;
D take the vehicle to the following conditions:
--- engine speed: low idle
--- hydraulic fluid temperature: 35 ˚C ≤ Toil ≤ 45 ˚C
D Operate the brake pedal: with each operation the pressure read on the pressure points M (front) and N (rear)
drops by a certain quantity until reaching a minimum value. This value represents the recharge start pressure:
adjust the pressure by acting on the screws (1) until obtaining the prescribed value, then block the lock ---nut.

. D to increase the pressure SCREW ON the screw;

D to reduce the pressure UNSCREW the screw.
D Release the brake pedal: the pressure tends to a maximum value. This value represents the recharge end pres-
sure: adjust the pressure by acting on the screws (2) until obtaining the prescribed value, then block the lock ---
nut.

. D to increase the pressure SCREW ON the screw;

D to reduce the pressure UNSCREW the screw.
D replace the cap (3).

P Final recharge
press

3
2
Starting
recharge press

t 1

276A010092

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 103

Test Procedure n. 4.2 --- Braking pressure adjustment

Proceed as follows:
D loosen the lock ---nut of the screw (1);
D start the engine;
D take the vehicle to the following conditions:
--- engine speed: low idle
--- hydraulic fluid temperature: 35 ˚C ≤ Toil ≤ 45 ˚C
D operate the brake pedal and adjust the braking pressure using screw (1) until obtaining the prescribed value,
then block the lock ---nut.

. D to increase the braking pressure UNSCREW the screw: at the same time there occurs a DE-
CREASE in the travel of the pedal;
D to reduce the braking pressure SCREW ON the screw: at the same time there occurs an IN-
CREASE in the travel of the pedal.

R1

R2

F1

1
276A010085

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104 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

5. Brake pedal position adjustment

Proceed as follows:
D bring the vehicle onto an appropriately solid flat surface, shut off the engine, remove the key from the ignition
switch, engage the parking brake and affix the indication signs;
D adjust the inclination of the pedal using the screw (a): when finished, tighten the lock ---nut;
D block the position of the pedal with the screw (b): when finished, tighten the lock ---nut.

276A010086

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 105

MAINTENANCE
Figure 80
Checking fitting and pipe tightness
Visually check for system leaks and tightness of line
connections.

In the event of faults or leakage from any of

the circuits, repairs MUST be carried out be-
fore using the vehicle.

Check by implementing all the specific safe-

ty precautions.

Changing the fluid

. For more information see section 10.1. 269NM312

Do not tighten the cartridge excessively.

Replacing pressurised filter This could damage the support. In any case
respect the manufacturer’s specifications.
Replace the filter when you change the hy-
draulic fluid.
D run the engine for a few minutes and check for oil
leakage;
Proceed as follows:
D close the engine hood.
D tip the engine hood up;

Figure 79

276NM029
D loosen the filter cartridge housing (see arrow) using
the hexagonal wrench and carefully clean the hous-
ing;
D check condition of the seals on the cartridge (1): re-
place as required;
D replace the filtering element by inserting it in the car-
tridge housing. Check that the seals, are correctly
positioned (2);
D fill the new cartridge housing with the specified fluid
and apply the same fluid to the seals;
D install the cartridge housing then loosen;

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106 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Cleaning the (suction) filter

Proceed as follows:
Clean the filter when you change the hidraul-
ic fluid, when the reservoir is empty.

Figure 81

276C010048
D open the engine hood;
D remove the batteries as indicated in the Use and
Maintenance Manual;
D remove the brake actuation circuit damping valve
from the battery case and fasten it temporarily to the
chassis;
D remove the battery case;
D open the cover (1) of the tank;
D unscrew the cartridge (2) from the housing;
D clean the cartridge using a suitable detergent or re-
place it, then screw it back into the housing;
D close the cover of the tank, replacing the seal (3);
D reassemble the battery case and relative compo-
nents connected to it;
D install the batteries as indicated in the Use and
Maintenance Manual;
D fill the reservoir as shown in the specific paragraph.

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 107

BRAKE PUMP REMOVAL---REPLACEMENT
Before carrying out any operation, check
that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in
SECTION 1 of this manual.
If in doubt, speak to a more experienced
person.
Respect all general recommendations for
correct execution of maintenance works.
D lock the articulation using the steering lock bar as
instructed in SECTION 1;
D discharge the hydraulic pressure from all circuits;
D lift the hood as instructed in the USE AND
MAINTENANCE MANUAL;
D position a suitable container and drain the hydraulic
fluid tank as instructed in the Chapter;
D disconnect the following pipes from the pump:
(2) intake
(3) delivery
Hydraulic fluid may leak during these
operations.

Removal
D Unscrew and remove the pump (1).
Proceed as follows:
D park the vehicle on a suitable flat and solid surface, Replacement
remove the ignition key, engage the handbrake and For replacement, follow the removal instructions in
place maintenance warning signs. reverse order.
D disengage the battery cut ---off switch or disconnect Fill the main hydraulic tank as instructed in the Chapter.
the battery leads to eliminate any risk of
short ---circuit;

2691624

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108 HYDRAULIC SYSTEM
HYDRAULIC ACCUMULATOR DETACH-
MENT ---REATTACHMENT
Before performing any intervention, ensure
that all precautions have been taken and all
aspects clarified regarding the safety of per-
sonnel involved in the intervention.
Read the relative instructions provided in
SECTION 1 of this manual.
In case of doubt, consult a more experien-
ced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.
The procedure described below concerns
the rear accumulator but is valid for both the
accumulators.
Detachment
Do as follows:
D bring the vehicle onto an appropriately solid flat sur-
face, shut off the engine, remove the key from the
ignition switch, engage the parking brake and affix
the indication signs;
D disconnect the battery---disconnect switch or di-
sconnect the battery terminals in order to eliminate
any risk of short ---circuit;
D block the articulation by means of the steering lock
bar, as indicated in SECTION 1;
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
SECTION 10 ADT 25-30 TIER3
D discharge the pneumatic pressure of the main hy-
draulic tank and the hydraulic pressure of all the cir-
cuits;
D arrange a suitable container, then proceed to the di-
scharge of the hydraulic tank following the instruc-
tions provided in the relative chapter;
D disconnect the connection fitting (1) from the accu-
mulator;
There may be a leakage of hydraulic fluid
during these operations.
The accumulator contains hydraulic fluid. It
is advisable to apply a threaded cap to the
fitting.
D unscrew the fastening nut (2) fixing the accumulator
to the bracket;
D unscrew the tightening screws and open the sup-
port clamps (2) so as to free the accumulator;
D remove the accumulator (3).
Reattachment
Proceed with the reattachment by performing the de-
tachment steps in the reverse order.
Proceed with the filling of the hydraulic oil tank by fol-
lowing the instructions provided in the relative chapter.
Proceed to the bleeding of the braking cir-
cuit by following the instructions provided in
the relative chapter.
276C10042
ADT 25-30 TIER3
BRAKE PEDAL VALVE DETACHMENT ---
REATTACHMENT
Before performing any intervention, ensure
that all precautions have been taken and all
aspects clarified regarding the safety of per-
sonnel involved in the intervention.
Read the relative instructions provided in
SECTION 1 of this manual.
In case of doubt, consult a more experien-
ced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.
Detachment
Do as follows:
D bring the vehicle onto an appropriately solid flat sur-
face, shut off the engine, remove the key from the
ignition switch, engage the parking brake and affix
the indication signs;
D disconnect the battery---disconnect switch or di-
sconnect the battery terminals in order to eliminate
any risk of short ---circuit;
D block the articulation by means of the steering lock
bar, as indicated in SECTION 1;
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
SECTION 10 HYDRAULIC SYSTEM 109
D discharge the hydraulic pressure of all the circuits;
D disconnect the following piping from the valve:
(2) stop ignition control manostat 337 connection
(F1)
(3) accumulator failure manostat 341 connection
(F)
(4) connection (P) from the brake pump
(5) tandem axle brakes connection (T1)
(6) front axle brakes connection (T2)
(7) connection (R1) to rear accumulator
(8) connection (R2) to front accumulator
(9) connection (B) to discharge in oil tank
(10) connection (N) to discharge in oil tank
There may be a leakage of hydraulic fluid
during these operations.
D support the accumulator with a suitable jack;
D unscrew the retaining screws of the bracket and re-
move the valve (1).
Reattachment
Proceed with the reattachment by performing the de-
tachment steps in the reverse order.
Proceed to the bleeding of the braking cir-
cuit by following the instructions provided in
the relative chapter.
276C10043
110 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Page left intentionally blank

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 111

SECTION 10.3

BRAKING SYSTEM --- WET OIL VERSION

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112 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

BRAKING SYSTEM

Main components
Pump: gear type (1) fitted to the engine air compressor.
Actuator: brake valve --- brake valve distributor (8); relay valve (10); front brakes groups (15) and rear (14);
Filter: net on the intake (11) with by---pass valve, fitted inside the tank;
on the delivery side (2) (pressurized) cartridge with by---pass valve and electric clogging indicator,
fitted on the side of the automatic transmission oil filters.
Tank: common (12) to steering and dumping.

Function
To ensure that the accumulators front (4) and rear (5) are recharged and to supply the pressure needed to operate
the brakes.

. The references with which the components are identified are the same used in the hydraulic diagram
shown on the following pages.

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 113

Main components of the braking system

276C010049

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114 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Operating brake assembly

Description
The brake assembly is composed of a series of externally toothed discs (1) alternated with a series of internally
toothed discs (2). The externally toothed discs engage in the bell (3), which is integral with the fixed part of the
axle, while the internally toothed discs engage in the hub (5), which is integral with the wheel.
The discs are closed in an oil bath in order to ensure their cooling through an input (8) and output (9) fitting. A
special sealing ring (4) prevents leakage of the cooling oil or entry of foreign matter. An oil seal ring (10) prevents
the cooling oil from passing to the wheel hub bearings.
The brake is hydraulically activated by sending pressure oil behind the control piston (6) through the fitting (7).

Operation
The operation pressure depends on the load exercised by the driver on the brake pedal. As a function of the
greater or lesser hydraulic pressure, the discs can slide among one another with more or less difficulty: in this
manner the wheel is braked to a more or less effective degree.
When the oil pressure is no longer applied to the piston, the release is ensured by the mechanical action of a series
of disc springs that act on the piston in the direction opposite to the pressure of the oil. This creates a clearance
between the discs that allows them to slide freely.

. For more information on the brake assembly, see Section 6 --- AXLES.

Operating brake assembly (see figure on next page)

1. Brake assembly
2. Screw
3. Sealing ring
4. Sealing ring
5. Fitting
6. Drain
7. Spacer
8. Screw
9. Spring
10. Screw
11. Bushing
12. Screw
13. O---Ring
14. Cap
15. Sealing ring
16. Sealing ring
17. Cap
18. Sealing ring
19. Front sealing ring
20. Control piston
21. Internally toothed discs
22. Externally toothed discs
23. Brake housing (bell)
24. O---Ring

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 115

Operating brake assembly

276C062W010

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116 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Service and parking brakes -- location

1. Front axle brakes
2. Intermediate axle brakes

. The rear axle has no braking system.

276C010050

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 117

Braking system hydraulic diagram

1. Brake pump
2. Pressurized filter
3. Brakes valve
4. 1.4 litre accumulator
5. 1.4 litre accumulator
6. Pressure vent
7. Not used
8. Accumulator pressure switch
9. Brake lights pressure switch
10. Not used
11. Intake filter
12. Tank
13. Unused
14. Intermediate axle brake actuators
15. Rear axle brake actuators
16. Brake cooling system

(a) Accumulators recharge distributor box

(b) Adjustment valve
(c) Accumulators isolation valve
(d) Brakes control valve (brake pedal valve)

List of pressure vents (see 6 on the diagram)

H1 Rear brake circuit pressure

H2 Rear brake circuit pressure
I Front brake circuit pressure

M Front accumulator recharge pressure

N1 Rear accumulator recharge pressure (pedal valve)
N2 Rear accumulator recharge pressure (accumulator)

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118 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Braking system hydraulic diagram

276C010051

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 119

Braking system hydraulic diagram

H2

N2

276C010052

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120 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

OPERATION
. Refer to the previous figure.

Stand---by conditions
The brake pedal valve (d) operates the actuators exclusively through the pressure coming from the accumulators.
These latter are refueled through the distributor slide valve (a).
The brake pedal valve (d) acts directly on the front brake actuators [15] and indirectly --- through the relay valve
[10] --- on the intermediate axle brake actuators [14].
The brake pump [1] is always in operation when the engine is running since the power take---off is coupled to
the air compressor.
The return flow from the brake valve [3] is sent to the hydraulic motor of the brake cooling circuit [16] and then
discharged.

Braking conditions
The distributor slide valve (d) of the brake valve [3] is controlled by the pedal.
With the pedal released, the position of the distributor slide valve (d) discharges the actuators of the front brakes
--- connected to opening T2 --- and the control of the relay valve [10] through the opening N; furthermore, lacking
the control of the relay valve [10], the actuators of the rear brakes --- connected to the opening T2 of the same
relay valve [10] --- are also directly discharged.
Operating the brake pedal, the distributor slide (d) of the brake valve [3] moves to the right and repectively con-
nects:
D the accumulator [4] with the actuators of the front brakes through the opening T2;
D the accumulator [5] with the relay valve [10] through the opening T1.
The relay valve [10], controlled by the signal coming from opening T1, moves to the right connecting the actuators
of the intermediate axle brakes (opening T2 of the relay valve [10]) with the rear accumulator [5].
The manostat [9] 337, if open, determines via CAN OPEN the lighting of the rear stop lights 125.
The manostat [8] 341, if open, determines via CAN OPEN the activation of an alarm on the display and the lighting
of the emergency indicator light.

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 121

BRAKING SYSTEM TEST PROCEDURES

Figure 83
Before carrying out any operation, check
that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in SEC-
TION 1 of this manual.
If in doubt, speak to a more experienced per-
son.

1. Braking hydraulic system air bleeding

Proceed as follows:
D start the engine and leave it at minimum;

Figure 82

276NM026T
D repeat the operation for all the brake groups of the
vehicle (see arrow).

At the end of the operations, check the fluid level in the

tank and top up if necessary.

2
1

276NM048T
D remove the dust cap, then fit a piece of transparent
tube onto the front brakes pressure fitting (1) and
immerge the other end in a container that already
contains a certain amount of fluid;
D press the brake pedal down completely, keeping it
in this position;
D loosen the valve, letting the fluid seep out until the
fluid coming out from the fitting is bubble---free;
D close the valve and remount the dust cap;
D repeat the operation for the rear brakes pressure fit-
ting (2);

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122 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

2. Braking system pressure discharge with engine off

There may be pressure in the following tubes with the engine off:
D tubing between accumulator 4 and outlet R2 of the brake valve 3;
D tubing between accumulator 5 and outlet R1 and R2 of the relay valve 3;
D piping between opening R of the relay valve [10] and opening R1 of the brake valve [3].
Maximum value: 60 bar
Proceed as follows:
D bring the vehicle onto an appropriately solid flat surface, shut off the engine, engage the parking brake and
affix the indication signs;
D move the ignition switch to position 1;
D activate the service brake control until the brake pedal goes all the way down (the stop lights no longer light
up);
D perform at least another five actuations of the control.

N2

H1

N1
I

276C010053

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 123

3. Braking hydraulic system pressures check

Proceed as follows:
D bring the vehicle onto an appropriately solid flat surface, shut off the engine, remove the key from the ignition
switch, engage the parking brake and affix the indication signs;
D block the articulation by means of the steering lock bar, operating as indicated in SECTION 1;
D discharge the pneumatic pressure of the main hydraulic tank and the hydraulic pressure of all the circuits;

D connect respectively and as needed:

--- a pressure gauge with max 100 bar end---of---scale value to the pressure fitting (I);
--- a pressure gauge with max 100 bar end---of---scale value to the pressure fitting (H1);
--- a pressure gauge with max 200 bar end---of---scale value to the pressure fitting (M);
--- a pressure gauge with max 200 bar end---of---scale value to the pressure fitting (N1).

T276C010012

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124 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Prescribed pressure values

Values
Procedure Point Pressure
bar psi
I Front brakes actuation pressure 110 +7 --- 3 1595 + 102 --- 44
31
3.1
H1 Rear brakes actuation pressure 110 +7 --- 3 1595 + 102 --- 44
M Front brakes accumulator charge pressure 55 ± 3 798 ± 44
32
3.2
N1 Rear brakes accumulator charge pressure 55 ± 3 798 ± 44

Test Procedure n. 3.1 --- Braking

Proceed as follows:
D start the engine
D take the vehicle to the following conditions:
--- engine speed: low idle;
--- hydraulic fluid temperature: 35 ˚C ≤ Toil ≤ 45 ˚C;
--- press the brake pedal;
D check that the front and rear brake pressures fall within the prescribed values.

Test Procedure n. 3.2 --- Accumulator charge pressure check

Proceed as follows:
D completely discharge the hydraulic pressure of the braking circuit as described in the relative procedure;
D check that the pressure falls within the prescribed values.

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 125

4. Braking hydraulic system pressures adjustment

Proceed as follows:
D bring the vehicle onto an appropriately solid flat surface, shut off the engine, remove the key from the ignition
switch, engage the parking brake and affix the indication signs;
D block the articulation by means of the steering lock bar, operating as indicated in SECTION 1;
D discharge the pneumatic pressure of the main hydraulic tank and the hydraulic pressure of all the circuits;
D connect respectively and as needed:
--- a pressure gauge with max 100 bar end---of---scale value to the pressure fitting (I);
--- a pressure gauge with max 100 bar end---of---scale value to the pressure fitting (H1);
--- a pressure gauge with max 200 bar end---of---scale value to the pressure fitting (M);
--- a pressure gauge with max 200 bar end---of---scale value to the pressure fitting (N1);

T276C010012

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
126 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Prescribed pressure values

Values
Procedure Point Pressure
bar psi
Front accumulator recharge start pressure 160 + 7 --- 3 2321 + 102 --- 44
M
Front accumulator recharge end pressure 195 ± 5 2828 ± 73
41
4.1
Rear accumulator recharge start pressure 160 + 7 --- 3 2321 + 102 --- 44
N1
Rear accumulator recharge end pressure 195 ± 5 2828 ± 73
I Front brakes actuation pressure 110 +7 --- 3 1595 + 102 --- 44
42
4.2
H1 Rear brakes actuation pressure 110 +7 --- 3 1595 + 102 --- 44

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 127

Test Procedure n. 4.1 --- Accumulator recharge pressure adjustment

Proceed as follows:
D remove the cap (3);
D loosen the lock ---nut of the screw (2) and then that of the screw (1);
D start the engine;
D take the vehicle to the following conditions:
--- engine speed: low idle
--- hydraulic fluid temperature: 35 ˚C ≤ Toil ≤ 45 ˚C
D Operate the brake pedal: with each operation the pressure read on the pressure points M (front) and N (rear)
drops by a certain quantity until reaching a minimum value. This value represents the recharge start pressure:
adjust the pressure by acting on the screws (1) until obtaining the prescribed value, then block the lock ---nut.

. D to increase the pressure SCREW ON the screw;

D to reduce the pressure UNSCREW the screw.
D Release the brake pedal: the pressure tends to a maximum value. This value represents the recharge end pres-
sure: adjust the pressure by acting on the screws (2) until obtaining the prescribed value, then block the lock ---
nut.

. D to increase the pressure SCREW ON the screw;

D to reduce the pressure UNSCREW the screw.
D replace the cap (3).

P Final recharge
press

3
2
Starting
recharge press

t 1

276A010092

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
128 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Test Procedure n. 4.2 --- Braking pressure adjustment

Proceed as follows:
D loosen the lock ---nut of the screw (1);
D start the engine;
D take the vehicle to the following conditions:
--- engine speed: low idle
--- hydraulic fluid temperature: 35 ˚C ≤ Toil ≤ 45 ˚C
D operate the brake pedal and adjust the braking pressure using screw (1) until obtaining the prescribed value,
then block the lock ---nut.

. D to increase the braking pressure UNSCREW the screw: at the same time there occurs a DE-
CREASE in the travel of the pedal;
D to reduce the braking pressure SCREW ON the screw: at the same time there occurs an IN-
CREASE in the travel of the pedal.

R1

R2

F1

1
276A010085

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 129

5. Brake pedal position adjustment

Proceed as follows:
D bring the vehicle onto an appropriately solid flat surface, shut off the engine, remove the key from the ignition
switch, engage the parking brake and affix the indication signs;
D adjust the inclination of the pedal using the screw (a): when finished, tighten the lock ---nut;
D block the position of the pedal with the screw (b): when finished, tighten the lock ---nut.

276A010086

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
130 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

MAINTENANCE
Figure 85
Checking fitting and pipe tightness
Visually check for system leaks and tightness of line
connections.

In the event of faults or leakage from any of

the circuits, repairs MUST be carried out be-
fore using the vehicle.

Check by implementing all the specific safe-

ty precautions.

Changing the fluid

. For more information see section 10.1. 269NM312

Do not tighten the cartridge excessively.

Replacing pressurised filter This could damage the support. In any case
respect the manufacturer’s specifications.
Replace the filter when you change the hy-
draulic fluid.
D run the engine for a few minutes and check for oil
leakage;
Proceed as follows:
D close the engine hood.
D tip the engine hood up;

Figure 84

276NM029
D loosen the filter cartridge housing (see arrow) using
the hexagonal wrench and carefully clean the hous-
ing;
D check condition of the seals on the cartridge (1): re-
place as required;
D replace the filtering element by inserting it in the car-
tridge housing. Check that the seals, are correctly
positioned (2);
D fill the new cartridge housing with the specified fluid
and apply the same fluid to the seals;
D install the cartridge housing then loosen;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 131

Cleaning the (suction) filter

Proceed as follows:
Clean the filter when you change the hidraul-
ic fluid, when the reservoir is empty.

Figure 86

276C010048
D open the engine hood;
D remove the batteries as indicated in the Use and
Maintenance Manual;
D remove the brake actuation circuit damping valve
from the battery case and fasten it temporarily to the
chassis;
D remove the battery case;
D open the cover (1) of the tank;
D unscrew the cartridge (2) from the housing;
D clean the cartridge using a suitable detergent or re-
place it, then screw it back into the housing;
D close the cover of the tank, replacing the seal (3);
D reassemble the battery case and relative compo-
nents connected to it;
D install the batteries as indicated in the Use and
Maintenance Manual;
D fill the reservoir as shown in the specific paragraph.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
132 HYDRAULIC SYSTEM SECTION 10
BRAKE PUMP REMOVAL---REPLACEMENT
Before carrying out any operation, check
that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in
SECTION 1 of this manual.
If in doubt, speak to a more experienced
person.
Respect all general recommendations for
correct execution of maintenance works.
Removal
Proceed as follows:
D park the vehicle on a suitable flat and solid surface,
remove the ignition key, engage the handbrake and
place maintenance warning signs.
D disengage the battery cut ---off switch or disconnect
the battery leads to eliminate any risk of
short ---circuit;
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
D lock the articulation using the steering lock bar as
instructed in SECTION 1;
D discharge the hydraulic pressure from all circuits;
D lift the hood as instructed in the USE AND
MAINTENANCE MANUAL;
D position a suitable container and drain the hydraulic
fluid tank as instructed in the Chapter;
D disconnect the following pipes from the pump:
(4) intake
(5) delivery
Hydraulic fluid may leak during these
operations.
D Unscrew and remove the pump (1).
Replacement
For replacement, follow the removal instructions in
reverse order.
Fill the main hydraulic tank as instructed in the Chapter.
2691624
ADT 25-30 TIER3
HYDRAULIC ACCUMULATOR DETACH-
MENT ---REATTACHMENT
Before performing any intervention, ensure
that all precautions have been taken and all
aspects clarified regarding the safety of per-
sonnel involved in the intervention.
Read the relative instructions provided in
SECTION 1 of this manual.
In case of doubt, consult a more experien-
ced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.
The procedure described below concerns
the rear accumulator but is valid for both the
accumulators.
Detachment
Do as follows:
D bring the vehicle onto an appropriately solid flat sur-
face, shut off the engine, remove the key from the
ignition switch, engage the parking brake and affix
the indication signs;
D disconnect the battery---disconnect switch or di-
sconnect the battery terminals in order to eliminate
any risk of short ---circuit;
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
SECTION 10 HYDRAULIC SYSTEM 133
D block the articulation by means of the steering lock
bar, as indicated in SECTION 1;
D discharge the hydraulic pressure of all the circuits;
D arrange a suitably---sized container underneath,
then drain the hydraulic tank following the instruc-
tions in the relative chapter;
D disconnect the connection fitting (1) from the accu-
mulator;
Hydraulic fluid leakage may occur during
these operations.
The accumulator contains hydraulic fluid. It
is advisable to apply a threaded cap to the
fitting.
D support the accumulator with a suitable jack;
D unscrew the clamping screws and open the support
clamps (2) so as to free the accumulator;
D remove the accumulator (3).
Reattachment
Proceed with the reattachment by performing the de-
tachment steps in the reverse order.
Proceed with the filling of the hydraulic oil tank by fol-
lowing the instructions provided in the relative chapter.
Proceed to the bleeding of the braking cir-
cuit by following the instructions provided in
the relative chapter.
276C010053
134 HYDRAULIC SYSTEM SECTION 10
DISASSEMBLY---REASSEMBLY OF THE
RELAY VALVE
Before performing any intervention, ensure
that all precautions have been taken and all
aspects clarified regarding the safety of per-
sonnel involved in the intervention.
Read the relative instructions provided in
SECTION 1 of this manual.
In case of doubt, consult a more experien-
ced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.
Disassembly
Proceed as follows:
D bring the vehicle onto an appropriately solid flat sur-
face, shut off the engine, remove the key from the
ignition switch, engage the parking brake and affix
the indication signs;
D disconnect the battery---disconnect switch or di-
sconnect the battery terminals in order to eliminate
any risk of short ---circuit;
D block the articulation by means of the steering lock
bar, as indicated in SECTION 1;
D discharge the hydraulic pressure from all the cir-
cuits;
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
D arrange a suitably---sized container underneath,
then drain the hydraulic tank following the instruc-
tions in the relative chapter;
D disconnect the following piping from the valve:
(2) connection (R1) to rear accumulator
(3) unused
(4) pedal valve opening R1 connection (R)
(5) discharge connection (N) to tank
(6) intermediate axle brakes connection (T)
(7) pedal valve opening T1 connection (Y)
Hydraulic fluid leakage may occur during
these operations.
D support the valve appropriately;
D unscrew the retaining screws of the bracket and re-
move the valve (1).
Reassembly
Proceed with the reassembly by performing the disas-
sembly operations in the reverse order.
Fill the hydraulic oil tank, following the instructions in
the relative chapter.
Proceed with bleeding the braking circuit by
following the instructions provided in the re-
lative chapter.
276C010054
ADT 25-30 TIER3
BRAKE PEDAL VALVE DETACHMENT ---
REATTACHMENT
Before performing any intervention, ensure
that all precautions have been taken and all
aspects clarified regarding the safety of per-
sonnel involved in the intervention.
Read the relative instructions provided in
SECTION 1 of this manual.
In case of doubt, consult a more experien-
ced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.
Detachment
Do as follows:
D bring the vehicle onto an appropriately solid flat sur-
face, shut off the engine, remove the key from the
ignition switch, engage the parking brake and affix
the indication signs;
D disconnect the battery---disconnect switch or di-
sconnect the battery terminals in order to eliminate
any risk of short ---circuit;
D block the articulation by means of the steering lock
bar, as indicated in SECTION 1;
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
SECTION 10 HYDRAULIC SYSTEM 135
D discharge the hydraulic pressure of all the circuits;
D disconnect the following piping from the valve:
(2) stop ignition control manostat 337 connection
(F1)
(3) accumulator failure manostat 341 connection
(F)
(4) connection (P) from the brake pump
(5) connection (T1) to relay valve opening (Z)
(6) front axle brakes connection (T2)
(7) connection (R1) to relay valve opening (R)
(8) connection (R2) to front accumulator
(9) connection (B) to discharge in oil tank
(10) connection (N) to discharge in oil tank
There may be a leakage of hydraulic fluid
during these operations.
D support the accumulator with a suitable jack;
D unscrew the retaining screws of the bracket and re-
move the valve (1).
Reattachment
Proceed with the reattachment by performing the de-
tachment steps in the reverse order.
Proceed to the bleeding of the braking cir-
cuit by following the instructions provided in
the relative chapter.
276C10043
136 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 137

SECTION 10.4

BRAKE COOLING SYSTEM

(wet oil version)

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138 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

BRAKE COOLING SYSTEM

Main components
Pump: double (front and tandem), gear pump in block with the motor (1)
Engine: in block with the pumps, driven by the fluid coming form the brake valve (12) discharge
Actuator: --- ---
Filter: --- ---
Tank: common (9) for steering and tipping.

Function
Ensures circulation of the hydraulic fluid in the brakes as a function of the pressure and the temperature conditions
of the fluid itself.

. The references with which the components are identified are the same used in the hydraulic diagram
shown on the following pages.

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 139

Main components of brake cooling system

276C010055

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
140 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 141

Brake cooling system hydraulic diagram

1. Motor/pump assembly
2. Brake valve
3. Hydraulic fluid temperature sensor
4. Unused
5. Unused
6. Front axle braking assembly
7. Intermediate axle braking assembly
8. Pressure transducer
9. Tank
10. Pressure fitting
11. Brake actuation pump

List of pressure fittings (n. 10 on the diagram)

K Pedal valve discharge circuit pressure (brake cooling motor intake)

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142 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Brake cooling system hydraulic diagram

276C010056

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 143

276C010057

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144 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

OPERATION

General description

. Refer to the previous figure.

The circuit is always in operation when the Diesel engine is running since the hydraulic motor is operated by the
return of the brake actuation pump which is driven by the Diesel engine.
An integrated proportional electromagnetic valve 351 regulates the by---pass of the brake pump return flow, deter-
mining the speed of the hydraulic motor and thus the flow of the cooling fluid.

The electromagnetic valve 351 is controlled in duty---cycle through CAN OPEN by means of MIDAC1 as a function
of the working pressure (detected by MIDAC1 with pressure switch 332 on the front axle and by MIDAC2 with the
pressure transducer 333 on the intermediate axle) and the hydraulic fluid temperature, read by MIDAC1 with the
sensor 325 in the tank.

The control, through CAN OPEN, displays the value of the hydraulic fluid temperature read by the sensor 325 on
the display.

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 145

TOPOGRAPHIC DIAGRAMS

Topographic diagram of the front chassis

A. Oil tank.
B. Brake cooling motor/pump assembly.
C. Front axle brake cooling assembly.
276C1059X

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
146 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

Topographic diagram of the rear chassis

D. Rear chassis connection plate.

E. Intermediate axle brake cooling assembly.

276C1059Y

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 147

A. OIL TANK
. See SECTION 10.1 --- Topographic diagrams.

B. BRAKE COOLING MOTOR/PUMP ASSEMBLY

1. Connection pipe to oil tank opening (F1) for return from brake control valve opening (B) through brake
cooling motor---pump.
2. Brake cooling motor/pump assembly by---pass pipe.
3. Connection pipe to the oil tank (return from front and intermediate axles).
4. Connection pipe to the oil tank (front axle brake cooling).
5. Connection pipe to the oil tank (tandem rear axle brake cooling).
6. Connection pipe to the brake control valve opening (B).
7. Connection pipe to the front axle brake cooling assembly (delivery).
8. Connection pipe to the intermediate axle brake cooling assembly (delivery).
9. Connection pipe to the front axle brake cooling assembly (return).
10. Connection pipe to the intermediate axle brake cooling assembly (return).

276C1049F

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148 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

C. FRONT AXLE BRAKE COOLING ASSEMBLY

1. Connection pipe to the brake cooling motor/pump assembly (brake cooling oil inlet).
2. Connection pipe to the oil tank (brake cooling oil outlet).

276C1059C

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ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 149

D. REAR CHASSIS CONNECTION PLATE

. See SECTION 10.1 --- Topographic diagrams.

E. INTERMEDIATE AXLE BRAKE COOLING ASSEMBLY

1. Connection pipe to the oil tank (brake cooling oil outlet).

2. Connection pipe to the brake cooling motor/pump assembly (brake cooling oil inlet).

276C1059E

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
150 HYDRAULIC SYSTEM SECTION 10
BRAKE COOLING CIRCUIT
PUMP---MOTOR
REMOVAL---REPLACEMENT
Before carrying out any operation, check
that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in
SECTION 1 of this manual.
If in doubt, speak to a more experienced
person.
Respect all general recommendations for
correct execution of maintenance works.
Removal
Proceed as follows:
D park the vehicle on a suitable flat and solid surface,
remove the ignition key, engage the handbrake and
place maintenance warning signs.
D disengage the battery cut ---off switch or disconnect
the battery leads to eliminate any risk of
short ---circuit;
D lock the articulation using the steering lock bar as
instructed in SECTION 1;
D discharge the air pressure from the main tank and
hydraulic pressure from all circuits;
D position a suitable container and drain the hydraulic
fluid tank as instructed in the MAINTENANCE
Chapter;
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
D position a suitable container and drain the brake
cooling circuit tank as instructed in the
MAINTENANCE Chapter;
D disconnect all connections from the motor---pump
group (1):
(2) front brake intake
(3) tandem brakes intake
(4) front brake delivery
(5) tandem brakes delivery
(6) brake actuation return to tank
(7) brake actuation intake from accumulator re-
charge valve
(8) brake actuation return to tank (by---pass)
D disconnect the following electrical connections:
(9) piloting by---pass electrovalve
Hydraulic fluid may leak during these oper-
ations.
. We recommend marking the pipes to
facilitate reconnection.
D supporting the pump (1) with suitable means,
unscrew the screws and remove the pump.
Replacement
For replacement, follow the removal instructions in
reverse order.
Fill the main hydraulic tank as instructed in the
MAINTENANCE Chapter.
Fill the brake cooling oil tank as instructed in the
MAINTENANCE Chapter.
ADT 25-30 TIER3 SECTION 10 HYDRAULIC SYSTEM 151

276C010058

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
152 HYDRAULIC SYSTEM SECTION 10 ADT 25-30 TIER3

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 SECTION 11

ELECTRICAL SYSTEM
ADT 25-30 TIER3 SECTION 11
CONTENTS
Page
MULTIPLEX SYSTEM OVERVIEW . . . . . . . . . . . . . . 3
Conventional control . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MULTIPLEX system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CAN LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Static efficiency tests . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Measurement values . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MULTIPLEX SYSTEM GENERAL DIAGRAM . . . . . 6
TOPOGRAPHIC DIAGRAMS . . . . . . . . . . . . . . . . . . . 7
Chassis services wiring . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Automatic transmission wiring . . . . . . . . . . . . . . . . . . 9
Cab wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BULKHEAD CONNECTORS . . . . . . . . . . . . . . . . . . 11
Bulkhead location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cab/engine wiring WHITE through bulkhead
connector PIN OUT side . . . . . . . . . . . . . . . . . . . . . . 12
Cab/services wiring BROWN through bulkhead
connector PIN OUT side . . . . . . . . . . . . . . . . . . . . . . 13
Cab/automatic transmission wiring YELLOW
through bulkhead connector PIN OUT side . . . . . . 14
DIAGNOSTIC CONNECTOR PIN-- OUT . . . . . . . . 16
CAN OPEN LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CAN OPEN line block diagram . . . . . . . . . . . . . . . . . 17
CAN OPEN line circuit diagram . . . . . . . . . . . . . . . . 18
BODY COMPUTER SYSTEM COMPONENTS . . . 20
CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CLUSTER location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
MIDAC 1 control unit PIN OUT . . . . . . . . . . . . . . . . . 21
HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
HEAD and closing resistor location . . . . . . . . . . . . . 23
HEAD control unit PIN OUT . . . . . . . . . . . . . . . . . . . . 24
MIDAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
MIDAC location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
MIDAC 1 control unit PIN---OUT . . . . . . . . . . . . . . . . 27
MIDAC 2 control unit PIN---OUT . . . . . . . . . . . . . . . . 28
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ELECTRICAL SYSTEM 1
Page
LOCATION OF SENSORS AND ACTUATORS . . 29
MIDAC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
MIDAC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CAN J1939 LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
CAN J1939 line circuit diagram . . . . . . . . . . . . . . . . 36
EDC ENGINE CONTROL UNIT . . . . . . . . . . . . . . . . 37
EDC engine control unit PIN---OUT . . . . . . . . . . . . . 38
“A” Electro---injectors connector . . . . . . . . . . . . . . . . 39
Color legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
“B” chassis connector . . . . . . . . . . . . . . . . . . . . . . . . 40
“C” sensors connector . . . . . . . . . . . . . . . . . . . . . . . . 41
Color legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
TRANSMISSION CONTROL UNIT (TCU) . . . . . . . 42
TCU identification plate . . . . . . . . . . . . . . . . . . . . . . . 42
Transmission control unit pin---out . . . . . . . . . . . . . . 43
ELECTRICAL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . 44
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
GROUND POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Interior control and utility arrangement . . . . . . . . . 47
Indicators and warning lights . . . . . . . . . . . . . . . . . . 49
RELAYS AND FUSES INTERCONNECTION
CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
RELAYS AND FUSES . . . . . . . . . . . . . . . . . . . . . . . . 52
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Supplementary relays . . . . . . . . . . . . . . . . . . . . . . . . . 53
Relays, resistors and diodes supplementary . . . . . 54
Fuse overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Supplementary fuses . . . . . . . . . . . . . . . . . . . . . . . . . 56
Fusebox component wiring . . . . . . . . . . . . . . . . . . . . 57
VEHICLE DIAGNOSTIC CONTROL SYSTEM . . . 58
List of problems and interventions . . . . . . . . . . . . . . 58
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
CAN OPEN line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
CAN J1939 line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

Page Page

BATTERY USE AND MAINTENANCE . . . . . . . . . . 91 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Automatic transmission control unit . . . . . . . . . . . . . 97

Battery maintenance (unsealed batteries) . . . . . . . 92 Cluster control unit (Body Computer) . . . . . . . . . . . 98

Recharging with external devices . . . . . . . . . . . . . . 93 Head Control Unit (Body Computer) . . . . . . . . . . . . 98

Emergency electrical power . . . . . . . . . . . . . . . . . . . 93 MIDAC connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

DISASSEMBLY-- REASSEMBLY OF THE ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 101

ELECTRONIC CONTROL UNITS . . . . . . . . . . . . . . 94
General information . . . . . . . . . . . . . . . . . . . . . . . . . . 94

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 3

MULTIPLEX SYSTEM OVERVIEW

Rapid data transfer is very important in vehicle management, and reliability must be ensured for applications asso-
ciated with command safety for transmission, brakes, engine and control units and there must be no communica-
tion problems, especially in the presence of electromagnetic fields.
Many problems regarding the electrical circuits present on the vehicle concern connection technology and usually
involve corrosion or oxidation of the connector contacts themselves, cable sheathing wear or defective assembly.

Conventional control

At present the vehicle electrical system foresees that each utility is commanded directly by its switch. This necess-
arily means that the harness has many different wires with the above---mentioned risks.
The overall length of the wiring may even reach several kilometres, and the greater number of connections in-
creases the risk of possible faults.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
4 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

In MULTIPLEX systems the connection between the various control units is achieved by means of a communica-
tions network, capable of effectuating the necessary data transfer both rapidly and reliably.

MULTIPLEX system

DATA BUS

Multiplexer De ---Multiplexer

MULTPLEX systems permit improved communication between the various electronic systems present on a ve-
hicle and allow for easier diagnosis of the electronic system.
As opposed to traditional systems, in this case each switch is connected to a Multiplexed unit, to which it transmits
its state (open or closed). A coded value, different for each switch, is transmitted to the CANBUS (CAN communi-
cation line). The signal is decoded by a Demultiplexer unit that provides the voltage required by the utility involved.
The MULTIPLX structure is very flexible: control units can be added or removed without interrupting the function
of the others.
The advantages of the MULTIPLEX system can be summarised as follows:
D greater functionality thanks to sharing of sensor signals by the various systems;
D improved on---board diagnostics function.

On the other hand, its disadvantages include:

D higher design costs than conventional systems;
D greater technical training requirements.

All the control units are connected by CAN line.

CAN stands for Controller Area Network This consists of dedicated wiring that permits instantaneous exchange
of large amounts of data between the various electronic systems on the vehicle.

Information travels according to a protocol that defines the dialogue mode:

D Information synchronisation;
D Call and response modes between the various systems;
D Identification and correction of any transmission errors.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 5

CAN LINE

A. Sheath
B. Braided wires
In physical terms, the CAN line consists of a two---pole twisted cable, enclosed in a sheath. Each CAN line has
two 120 Ohm closing resistors.

Static efficiency tests

Static efficiency tests on the CAN line are carried out using a Multimeter.

CAN CAN
DRIVER DRIVER

CAN_H
120 120
Ohm Ohm
CAN_L

Measurement values

0Ω ~ 60 Ω ~ 120 Ω INFINITE

CAN LINE SHORT---CIR- CAN line OK ONE RESISTOR OFF--- CAN line INTERRUPTED
CUIT LINE

Disconnect the batteries before carrying out any check on the CAN line.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
6 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

MULTIPLEX SYSTEM GENERAL DIAGRAM

276C11001

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 7

TOPOGRAPHIC DIAGRAMS

Chassis services wiring

1. Chassis services wiring feedthrough connector (brown)
2. Unused
3. Left front services
4. Left front lights
5. Right front lights
6. Right front services
7. MIDAC 1
8. Right side services
9. MIDAC 2
10. Rear cable junction
11. Rear services cable

276C011002

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
8 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

Engine wiring
1. Engine wiring feedthrough connector (white)
2. Starter motor
3. EDC engine control unit (89---pin connector)
4. Air conditioner
5. Users
6. Alternator
7. Pre---heating
4
5

276C011003

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 9

Automatic transmission wiring

1. Speed sensor
2. Speed sensor
3. Speed sensor
4. Lock ---up control
5. Speed sensor
6. Automatic transmission wiring feedthrough connector (yellow)
7. Central distributor lock
8. Oil filter obstruction
9. TCU automatic transmission control unit (in cab)
10. Retarder temperature
11. Hydraulic control unit

6 8
7

10 9
11
5
4
3
2

276C011004

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
10 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

Cab wiring
1. Feedthrough connectors plate
A. Engine wiring connector WHITE
B. Chassis services wiring connector BROWN
C. Automatic transmission wiring connector YELLOW
D. Unused connector GREEN

2. HEAD control unit

3. CLUSTER instrument panel
4. Cab services
5. TCU automatic transmission control unit
6. Contactors and fuses control unit

2 3

A
B
1 C 4
D
5

276A011004

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 11

BULKHEAD CONNECTORS

Bulkhead location

T269IE10

1. WHITE connector: cab/engine wiring interface

2. BROWN connector: cab/services wiring interface
3. YELLOW connector: cab/automatic transmission wiring interface
4. GREEN connector: not used
To disconnect the connector, proceed as follows:
A. lift the safety catch;
B. pull away the connector.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
12 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

Cab/engine wiring WHITE through bulkhead connector PIN OUT side

PIN Wire code UTILITY
1 8876 + 15 Alternator
2 --- ---
3 --- ---
4 --- ---
5 23---H Engine diesel filter obstruction switch
6 24---H Engine oil filter obstruction switch
7 --- ---
8 --- ---
9 29---H Input D + alternator
10 0157 Load sensor on accelerator for EDC (terminal C)
11 --- ---
12 0159 Load sensor on accelerator for EDC (terminal E)
13 5157 Load sensor on accelerator for EDC (terminal A)
14 5158 Load sensor on accelerator for EDC (terminal B)
15 --- ---
16 0008 Start contactor Pin 86
17 8908 Start contactor Pin 85
18 2298 Connection with diagnostics (terminal E)
19 --- ---
20 --- ---
21 --- ---
22 8015 Key positive (15/54) for EDC connection
23 --- ---
24 0158 Load sensor on accelerator for EDC (terminal D)
25 0285 Start connector Pin 87 + 50 key
26 --- ---
27 9993 Air conditioning compressor electromagnet connection
28 --- ---
29 --- ---
30 J1939H CAN line – Diagnostics connector (H)
31 J1939L CAN line – Diagnostics connector (J)
32 J1939S Can line --- Screen
33 --- ---
34 --- ---
35 0650 Diesel---fuel heating contactor Pin 86
36 8056 Diesel---fuel heating contactor Pin 85
37 --- ---
38 --- ---
39 8888 Chassis start contactor
40 7155 Positive

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 13

Cab/services wiring BROWN through bulkhead connector PIN OUT side

PIN Wire code UTILITY
1 7136 Power supply + 24V MIDAC1 – Fuse 52
2 7136 Power supply + 24V MIDAC1 – Fuse 52
3 7138 Power supply + 24V MIDAC1 – Fuse 54
4 7139 Power supply + 24V MIDAC2 – Fuse 55
5 7140 Power supply + 24V body sensor – rear brakes cooling sensor
6 0178 Battery---disconnect / connect switch
7 0078 Battery---disconnect / connect switch
8 0176 Start request E20 contactor
9 7742 Cab / fleet link interface (setup)
10 8886 Windshield washer motor
11 8886* Side windshield washer motor
12 0550 N.O. air conditioner manostat
13 3304 Left parking lights (front, rear and side)
14 3314 Right parking lights (front, rear and side)
15 457 Not used
16 944 External actuators power supply (automatic transmission control unit)
17 2219 Left high---beam light
18 2221 Right high---beam light
19 2226 E29 relay (camera)
20 --- --- --- ---
21 --- --- --- ---
22 0220 Not used
23 0180 Battery ground
24 0181 Battery ground
25 8360 Electromagnetic valve shut ---off
26 8840 Air drier resistance
27 2226 E29 relay (camera)
28 --- --- --- ---
29 --- --- --- ---
30 --- --- --- ---
31 CAN---0---H CAN OPEN line – Diagnostics connector (terminal C)
32 CAN---0---L CAN OPEN line – Diagnostics connector (terminal D)
33 CAN---0---S CAN OPEN line --- Screen
34 --- --- --- ---
35 1116 Horn
36 1172 Stop lights
37 2231 Left low ---beam light
38 2223 Right low ---beam light
39 7753 Fuel heater
40 8281 Hood raising motor

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
14 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

Cab/automatic transmission wiring YELLOW through bulkhead connector PIN OUT side
PIN Wire code UTILITY
1 419 Engine speed sensor input
2 903 Engine/intermediate cog/turbine speed sensor ground
3 441 Turbine speed sensor input
4 903 Engine/intermediate cog/turbine speed sensor ground
5 442 Intermediate cog speed sensor input
6 903 Engine/intermediate cog/turbine speed sensor ground
7 456 Hydraulic group electrovalve Y2 input
8 410 Hydraulic group electrovalve Y1 input
9 432 Hydraulic group electrovalve Y3 input
10 455 Hydraulic group electrovalve Y4 input
11 409 Hydraulic group electrovalve Y5 input
12 451 Hydraulic group electrovalve Y6 input
13 906 Hydraulic group power supply
14 439 Converter oil temperature sensor
15 904 Ground
16 449 Retarder oil temperature sensor
17 904 Ground
18 --- --- Spare
19 417 Oil filter block input
20 404 Output shaft sensor ground
21 462 Output shaft sensor output
22 900 Electrical power under key
23 940 Hydraulic lock electrovalve output
24 944 External actuators power supply
25 434 Lock ---up clutch electrovalve output
26 944 External actuators power supply

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 15

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For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
16 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

DIAGNOSTIC CONNECTOR PIN---OUT

Pin Cable code Function
A 0000 Battery (---)
B 7797 Battery (+) fuse 33
C BROWN CAN OPEN (H)
D WHITE CAN OPEN (L)
E 2298 EDC central unit --- pin 89
F --- Not used
G --- Not used
H BROWN CAN J 1939 (H)
J WHITE CAN J 1939 (L)

276A011005

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 17

CAN OPEN LINE

The CAN OPEN line represents the BUS connecting the elements of the body computer system.
It allows communication between the main control unit (CLUSTER) and the peripheral control units (MIDAC and
HEAD).
The MIDAC and HEAD control units gather information and send it to the CLUSTER, and they also receive com-
mands and control the actuators.
The CLUSTER control unit also manages operation of the instrument panel, particularly the display.

The body computer system exchanges information through the CLUSTER control unit with the CAN J1939 line,
which connects the two control units for engine control (ECU) and automatic transmission (TCU).
Finally, the body computer system manages all diagnostics with the exclusion of the parts concerning engine con-
trol and transmission control.

CAN OPEN line block diagram

276C11005

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18 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

CAN OPEN line circuit diagram

The various sections of the CAN OPEN line and jointed inside the control units (CLUSTER, HEAD
or MIDAC), except for the diagnosis socket.
As a result, removing a control unit connector (in particular the MIDAC) causes exclusion of all the
components downstream of it.

Key to following figure

1. HEAD (body computer)

2. CLUSTER
3. Diagnostics connector
4. Batteries
5. Bulkhead through connector (brown)
6. MIDAC 1 (slave 1)
7. MIDAC 2 (slave 2)
8. Rear chassis articulation plate connector

A. 120 Ohm closing resistor

B. 120 Ohm closing resistor

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 19

CAN OPEN line circuit diagram

120O
B
8
08
13
15
19
MIDAC
2

7
6

FWD
MIDAC
1
08
13

15
19
3

CLUSTER
C D
DIA

C6
C7

B7
B6

32 31 33
4

+ _ + _

5
120O
A
48
47

H
L
HEAD
1

276C11006

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20 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

BODY COMPUTER SYSTEM COMPONENTS

CLUSTER
The CLUSTER forms the Master control unit of the CAN OPEN system.
It operates in connection with the other system peripherals able to accept the CAN OPEN protocol.
The CLUSTER receives information on the operating conditions of the vehicle and displays this information using
instruments and indicator lights.
There is also a 3.8---inch monochrome display for viewing parameters and messages, as well as setting certain
adjustments. The brightness of the display can be adjusted using the button on the display control lever.
The CLUSTER is equipped with a RAM---type non---erasable memory for the storing of data and software and the
management of the display, and EEPROM and Flash EPROM erasable memories for the storing of parameter ca-
libration values.
The IN/OUT circuits are protected against short circuits and overloads.
The power supply circuits operate at low voltage and are completely protected against adverse environmental
conditions.

Mechanical features
Preformed box in ABS
24 pin automotive standard connector
Protection rating: IP67
Fully resin filled

Electrical specifications
Power supply voltage: +8 ÷ +30 Volt DC (direct power supply on the vehicle)
Operating temperature: ---20 ˚C ÷ +70 ˚C
Storage temperature: ---30 C ÷ +80 ˚C
Power absorption on stand---by: 500 mA
Maximum power absorption: 10 A

CLUSTER location

T269IE35

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ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 21

MIDAC 1 control unit PIN OUT

PIN Wire code UTILITY SIGNAL
A1 --- --- ---- --- ---
A2 2A --- D Shunting switch (enter)
A3 3A --- D Shunting switch (esc)
A4 4A --- D Shunting switch (scroll +)
A5 5A --- D Shunting switch (scroll ---)
A6 6A --- D Shunting switch (right turn signal)
A7 7A --- D Shunting switch (left turn signal)
A8 --- --- --- ---
B1 --- --- --- ---
B2 --- --- --- ---
B3 CAN H CAN L1939 H CAN BUS 2– line H
B4 CAN L CAN J1939 L CAN BUS 2 – line L
B5 --- --- --- ---
B6 CAN H CAN OPEN H CAN BUS 1 – line H
B7 CAN L CAN OPEN L CAN BUS 1 – line L
B8 --- --- --- ---
C1 7141 Power supply +24 Volt FUSE 46 (5A)
C2 C2 --- D CLUSTER configuration
C3 --- --- --- ---
C4 8802 + 15 key
C5 --- --- --- ---
C6 CAN H CAN OPEN H CAN BUS 1 – line H
C7 CAN L CAN OPEN L CAN BUS 1 – line L
C8 0181 Battery ground Power ground

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22 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

HEAD
The HEAD is equipped with an EPROM---type non---erasable memory for storing data and software and an EE-
PROM---type erasable memory for storing parameter calibration values.
The IN/OUT circuits are protected against short circuits and overloads. The power supply circuits operate at low
voltage and are completely protected against adverse environmental conditions.

Mechanical features
UNI 5076 die---cast aluminium box
Dimensions: widthxdepthxheight = 185.5 x 139 x 36.5 (mm)
56 pin automotive standard connector
Protection rating: IP67
Fully resin filled

Electrical specifications
Voltage +10 ÷ +30 Volt DC (direct power supply on vehicle)
Separate power supply for microprocessor and outputs
Operating temperature: ---25 °C ÷ +70 °C
Storage temperature: ---35 °C ÷ +85 °C
Power absorption on stand---by: 500 mA
Maximum power absorption: 8 A

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 23

HEAD and closing resistor location

1. HEAD
2. 120 Ohm resistor (inside HEAD connector)
3. 120 Ohm resistor

276C11007

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
24 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

HEAD control unit PIN OUT

PIN Wire code UTILITY SIGNAL
1 RX2 RS232 serial line
2 TX2 RS232 serial line
3 RSG RS 232 serial line ground
4 04 – H Sensor power supply + 5V (body joystick
potentiometer)
5 05 --- H Analog sensors ground Analog sensors ground
6 06 – H Analog sensors ground Analog sensors ground
7 --- --- --- --- --- ---
8 08 – H Motor oil level sensor input (inactive) 12bit analog input
9 09 – H --- --- --- ---
10 10 – H --- --- --- ---
11 11 – H Body tipping joystick signal 12bit analog input
12 --- --- --- --- --- ---
13 --- --- --- --- --- ---
14 14 – H Engine brake input 12bit analog input
15 15 – H +15 A key output On/Off output
16 16 – H Battery---disconnect switch auto---retention On/Off output
output
17 17 – H Battery disconnection output On/Off output
18 18 – H Stop signal output On/Off output
19 19 – H Lubricating device output On/Off output
20 20 --- H Air conditioning output On/Off output
21 21 – H GSM power supply output On/Off output
22 22 – H Raise hood / cab output On/Off output
23 23 – H Engine diesel filter obstruction switch On/Off input (active at ground)
24 24 – H Engine oil filter obstruction switch On/Off input (active at ground)
25 25 – H Accumulator failure switch On/Off input (active at ground)
26 26 – H Stop switch On/Off input (active at ground)
27 27 – H Gear lever in neutral output (parking brake) On/Off output
28 28 – H Gear reduction output (body) On/Off output

T269IE26

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ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 25

HEAD control unit PIN OUT

PIN Wire code UTILITY SIGNAL
PIN Cd. cavo UTENZE SEGNALE
29 29 – H Input D+ alternator 10bit analog input
30 30 – H Start 50 input 10bit analog input
31 31 --- H +15 A key input 10bit analog input
32 --- --- --- --- --- ---
33 33 – H Emergency lights input On/Off input (active at +24 Volts)
34 34 – H --- --- --- ---
35 35 – H Body ascent input On/Off input (active at +24 Volts)
36 36 – H Body descent input On/Off input (active at +24 Volts)
37 37 – H Parking light input On/Off input (active at +24 Volts)
38 38 – H High---beam input On/Off input (active at +24 Volts)
39 39 – H Lubricating device level low input On/Off input (active at +24 Volts)
40 --- --- --- --- --- ---
41 41 --- H Vehicle config. input (retarder) On/Off input (active at +24 Volts)
42 42 --- H Air conditioning consent input On/Off input (active at +24 Volts)
43 --- --- --- --- --- ---
44 --- --- --- --- --- ---
45 --- --- --- --- --- ---
46 --- --- --- --- --- ---
47 CAN H CAN OPEN (H) CAN BUS 1 – line H
48 CAN L CAN OPEN (L) CAN BUS 1 – line L
49 7135 Power supply 24V FUSE 51
50 7135 Power supply 24V FUSE 51
51 0180 Battery ground Power ground
52 --- --- --- --- --- ---
53 7137 Power supply 24 V (Watchdog) FUSE 53
54 7137 Power supply 24 V (Watchdog) FUSE 53
55 7137 Power supply 24 V (Watchdog) FUSE 53
56 7137 Power supply 24 V (Watchdog) FUSE 53

T269IE26

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26 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

MIDAC
The MIDAC is the CAN OPEN system Slave control unit. It works in connection with the other system peripherals
able to accept CAN OPEN protocol. The system has two MIDACs.
The MIDAC has a non---erasable RAM type memory for storing data and software and an erasable EEPROM mem-
ory for storing parameter calibration values.
The IN/OUT circuits have short ---circuit and overload protection. The power circuits operate at low voltage and
are all protected against harsh environmental conditions.
The system envisages two MIDACs connected via CAN OPEN.

Mechanical features
Stainless steel box
24---pin connector
Protection rating: IP67
Fully resin filled

Electrical specifications
Power supply voltage: +9 ÷ +32 Volt DC (direct power supply on the vehicle)
Separate power supply for internal logic and outputs
Operating temperature: ---25 ˚C ÷ +70 ˚C
Storage temperature: ---35 ˚C ÷ +85 ˚C
Power absorption on stand---by: 100 mA
Maximum power absorption: 10 A

MIDAC location
1. MIDAC1
2. MIDAC2

1 2

276C11008

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 27

MIDAC 1 control unit PIN-- OUT

PIN Wire code UTILITY SIGNAL

1 0184 Battery ground Power ground
2 02M1 Sensor ground Analog ground
3 03M1 Brake oil filter obstruction switch (actuation) On/Off input (active at ground)
4 --- --- --- --- --- ---
5 05M1 Brake cooling flow electromagnetic valve(*) PWM output (duty---cycle supply)
6 7136 Power supply +24 Volt FUSE 52 (5A)
7 7138 Power supply +24 Volt FUSE 54 (15A)
8 CAN L CAN OPEN L CAN BUS 1 – line L
9 09M1 Front brake cooling flow switch(*) Analog input 0---30V
10 10M1 Fuel level sensor Analog input
11 11M1 General tank oil temperature sensor 0---5 V with current pump
12 12M1 Diesel prefilter water presence switch On/Off input (active at +24 Volts)
13 CAN H CAN OPEN H CAN BUS 1 – line H
14 --- --- --- --- --- ---
15 CAN L CAN OPEN L CAN BUS 1 – line L
16 16M1 MIDAC 1 configuration Ground 0V
17 17M1 Main tank air pressure sensor Analog input 0.5 – 5 V
18 --- --- --- --- --- ---
19 CAN H CAN OPEN H CAN BUS 1 – line H
20 --- --- --- --- --- ---
21 21M1 Start switch On/Off input (active at ground)
22 22M1 Front turn signal On/Off output
23 23M1 Engine air filter obstruction switch On/Off input (active at ground)
24 24M1 Warm---up switch On/Off input (active at ground)

(*) versions with oil wet brakes only

276C11010

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
28 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

MIDAC 2 control unit PIN-- OUT

PIN Wire code UTILITY SIGNAL

1 0185 Battery ground Power ground
2 02M2 Sensor ground
3 03M2 General oil filter obstruction switch On/Off input (active at ground)
4 04M2 Retarder electromagnetic valve PWM output (duty---cycle supply)
5 05M2 Emergency steering electromagnetic valve On/Off output
6 7136 Power supply +24 Volt FUSE 52 (5A)
7 7139 Power supply +24 Volt FUSE 55 (15A)
8 CAN L CAN OPEN L CAN BUS 1 – line L
9 09M2 Distributor lock switch On/Off input (active at ground)
10 10M2 Retarder air pressure sensor Analog input 0---30V
11 11M2 Rear brake cooling flow transducer(*) Analog input 0---30V
12 12M2 Body descent electromagnetic valve PWM output (duty---cycle supply)
13 CAN H CAN OPEN H CAN BUS 1 – line H
14 --- --- --- --- --- ---
15 CAN L CAN OPEN L CAN BUS 1 – line L
16 16M2 MIDAC 2 configuration (ground) --- ---
17 17M2 Body potentiometer On/Off input (active at +24 Volts)
18 18M2 Body ascent electromagnetic valve PWM output (duty---cycle supply)
19 CAN H CAN OPEN H CAN BUS 1 – line H
20 --- --- --- --- --- ---
21 --- --- --- --- --- ---
22 22M2 Rear turn signal On/Off output
23 23M2 Emergency steering switch On/Off input (active at ground)
24 24M2 Parking brake switch On/Off input (active at ground)

(*) versions with oil wet brakes only

276C11010

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 29

LOCATION OF SENSORS AND ACTUATORS

MIDAC1
1. Main tank air pressure sensor 334
2. Front brake cooling oil flow switch (*) 332
3. Ground start/ground warm---up switch 308
4. Air filter obstruction switch 342

(*) versions with oil wet brakes only

1 2

3 4

276C011015

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30 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

MIDAC1
1. Main hydraulic tank oil temperature sensor 325
2. Brake coolant flow electromagnetic valve (*) 351
3. Fuel level switch 326
4. Fuel prefilter water presence switch 330
5. Brake actuation oil filter obstruction switch 345

(*) versions with oil wet brakes only

5
1 2

3 4

276C11016

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 31

MIDAC2
1. Body ascent electromagnetic valve 316
2. Body descent electromagnetic valve 317
3. Central distributor lock switch 347
4. Parking brake manostat 339
5. Rear brake cooling oil flow transducer (*) 333

(*) versions with oil wet brakes only

1 2 5

3 4

276C011017

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
32 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

MIDAC2
1. Emergency steering manostat 336
2. Emergency steering electromagnetic valve 321
3. Retarder electromagnetic valve 319
4. General oil filter obstruction switch 343
5. Retarder air pressure switch 335
6. Body position potentiometer 338

(*) versions with oil wet brakes only

1 2 3

4 5 6

276C11018

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 33

HEAD
1. Engine oil level sensor 431 (inactive)
2. Stop ignition control manostat 337
3. Accumulator failure manostat 341
4. Automatic lubricating tank level low switch 315
5. Engine oil filter obstruction sensor 429
6. Fuel filter obstruction sensor 430
7. Retarder control 318
8. Body control switch 307 and potentiometer 359

1 3 2 4

5 6 7

276C11019

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
34 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

Page left intentionally blank

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 35

CAN J1939 LINE

The CAN J1939 line allows communication between the CLUSTER and the engine control unit (ECU) and auto-
matic transmission control unit (TCU).
The control units, concerning vehicle interface functions, gather information and send it to the CLUSTER; they
also receive commands and control the actuators.
The CLUSTER also exchanges information with the CAN OPEN line that connects the MIDAC and HEAD control
units.
The diagnostic part of the system that concerns control of the engine and automatic transmission is managed
directly by the respective control units.

276C11020

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
36 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

CAN J1939 line circuit diagram

1. CLUSTER (body computer)

2. Diagnostics connector
3. Automatic transmission control unit (TCU)
4. Bulkhead through connector (white)
5. Engine control unit (ECU)

A. 120 Ohm closing resistor (incorporated in TCU)

B. 120 Ohm closing resistor (incorporated in ECU)

TCU ECU
A 120 O B 120 O
DIA

2 J H 25 26 28 3 35 34 5

1 2 4

FWD

B3 B4

CLUSTER

1
4
31 30 32

L
H

276C11021

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 37

EDC ENGINE CONTROL UNIT

The EDC engine control unit is located on the right side of the engine block.

276C11025

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
38 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

EDC engine control unit PIN-- OUT

The engine control unit is equipped with three connectors:
A. Electro---injectors connector
B. Chassis connector
C. Sensors connector

276C11026

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 39

“A” Electro -- injectors connector

Color legend
B black 12 16
R red
U blue
W white
P purple
G green
N brown 6 11
Y yellow
O orange

1 5

276C11027

ECU Cable
Function
Pin Color
1 --- Free
2 --- Free
3 B Electromagnetic valve for cylinder (4---5---6) electronic injection
4 --- Free
5 --- Free
6 Y Electromagnetic valve for cylinder 2 electronic injection
7 O Engine brake control electromagnetic valve
8 N Engine brake control electromagnetic valve
9 --- Free
10 --- Free
11 R Electromagnetic valve for cylinder (1---2---3) electronic injection
12 G Electromagnetic valve for cylinder 3 electronic injection
13 W Electromagnetic valve for cylinder 1 electronic injection
14 U Electromagnetic valve for cylinder 4 electronic injection
15 E Electromagnetic valve for cylinder 6 electronic injection
16 P Electromagnetic valve for cylinder 5 electronic injection

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
40 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

“B” chassis connector

71 89 72 54 6 11

1
7
12

53 35 18 36 17

276C11028

ECU Pin Cable Function

2 7151 Positive +30
3 7151 Positive +30
5 0150 Ground
6 0150 Ground
8 7151 Positive +30
9 7151 Positive +30
10 0150 Ground
11 0150 Ground
12 0096 Preheating connection consent relay ground
13 8056 Preheating fuel connection relay
17 0008 Start relay
29 0158 Power supply +30
32 0285 Power supply + 30
34 W CAN L line
35 N CAN H line
36 0650 Preheating fuel connection relay
37 8908 Start relay
40 8015 +15
48 0159 Accelerator control
55 9966 Engine brake electromagnetic valve
58 0043 Engine brake electromagnetic valve
75 9164 Preheating contactor excitation signal for EDC
77 5158 Accelerator control
78 0157 Accelerator control
79 5157 Accelerator control
89 2298 EDC control unit diagnostics line K

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 41

“C” sensors connector

Color legend
B black 6 8 16 9 15 22
R red
U blue
W white
P purple
G green
N brown
Y yellow
O orange 4
E grey 5
K pink

1 3 23 30 36 29

276C11029

Cable
ECU Pin Function
Color
1 N Electromagnetic valve for variable---geometry turbine control
2 --- Free
3 B Electromagnetic valve for variable---geometry turbine control
4÷8 --- Free
9 W Distribution sensor
10 R Distribution sensor
11 ÷ 14 --- Free
15 K Coolant temperature sensor
16 --- Free
17 Free
18 O/B Fuel temperature sensor
19 B Flywheel sensor
20 N Turbocharger speed sensor
21 ÷ 22 --- Free
23 W Flywheel sensor
24 N Ground for engine oil pressure / temperature sensor
25 W Power supply for air pressure / temperature sensor
26 Y Coolant temperature sensor
27 O/B Oil temperature signal from engine oil pressure / temperature sensor
28 U Oil pressure signal from engine oil pressure / temperature sensor
29 --- Free
30 W Turbocharger speed sensor
31 --- Free
32 O Power supply for engine oil pressure / temperature sensor
33 R Power supply for air pressure / temperature sensor
34 G Air pressure signal from air pressure / temperature sensor
35 W/R Fuel temperature sensor
36 O Air temperature signal from air pressure / temperature sensor

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
42 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

TRANSMISSION CONTROL UNIT (TCU)

T225039

TCU identification plate

1. TCU type
2. Transmission type
3. Supply voltage
4. Progressive identification No
5. TCU part list No.
6. Software release

The automatic transmission control unit TCU (1) is located inside the cab, in a door---closed space on the right
side.
To access the control unit it is necessary to:
D remove the wall---board;
D unscrew the retaining screws and remove the door.

276A011001

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 43

Transmission control unit pin-- out

01 Ground 35 ---
02 Ground 36 ---
03 Engine/turbine/internal speed pick ---up 37 ---
ground
04 Output speed pick ---up ground 38 ---
05 --- 39 Converter oil temperature input
06 --- 40 ---
07 Relay (E18) for reversing drive output 41 Turbine speed pick ---up input
08 External actuators supply 42 Internal speed pick ---up input
09 Hydraulic control unit Y5 valve input 43 Controller lever input
10 Hydraulic control unit Y1 valve input 44 Parking brake engaged signal input from
HEAD
11 Transmission difflock valve output 45 Key supply
12 Hydraulic control unit supply 46 Ground
13 Hydraulic control unit supply 47 ---
14 --- 48 ---
15 Output to diagnostic connector 49 Retarder oil temperature input
16 --- 50 ---
17 Switch filter restriction input 51 Hydraulic control unit Y6 valve input
18 Input from diagnostic connector 52 ---
19 Engine speed pick ---up input 53 External actuators supply
20 --- 54 ---
21 --- 55 Hydraulic control unit Y4 valve input
22 Controller lever input 56 Hydraulic control unit Y2 valve input
23 Battery supply 57 ---
24 --- 58 ---
25 CAN J1939 --- H line 59 ---
26 CAN J1939 --- L line 60 ---
27 CAN J1939 --- L line (doubled) 61 ---
28 CAN J1939 line --- Shielding 62 Output speed pick ---up input
29 --- 63 Controller lever input
30 Transmission difflock preselect switch input 64 Controller lever input
31 Retarder preselect switch input 65 Controller lever input
32 Hydraulic control unit Y3 valve input 66 Body raised signal input from HEAD
33 Retarder valve output 67 Controller lever input
34 Lock ---up clutch valve output 68 Battery supply

T225087

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
44 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

ELECTRICAL SUPPLY

Batteries

Do not disconnect the batteries from the system while the engine is running.
Do not switch off the battery emergency cutout switch with thel motor
running, if not in an emergency.
To disconnect the batteries, carry out the following steps:
D disconnect the cable from the positive pole;
D disconnect the cable from the negative pole.
Make sure the system is correctly isolated before connecting the batteries.
Disconnect the batteries from the system while recharging them.
The electrical system generates, regulates, accumulates and distributes electricity needed for vehicle component
operation.
The electrical system is powered by a generator (28V --- 90A alternator) and two batteries connected in series for
this purpose. The nominal voltage of each battery is 12V; capacity is 170 Ah.
The nominal voltage of the system is consequently 24V; the total capacity of the batteries is 170 Ah.

1. Battery
2. Battery cable (bridge)
3. Positive pole
4. Negative pole

T276C011050

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 45

GROUND POINTS
The ground points of the system are shown in the diagram.

1. Front chassis --- cab ground

2. Engine --- chassis ground (on engine)
3. Right front chassis --- engine ground / battery negative
4. Multiplex system logic ground (on the battery negative terminal)

276C011041

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
46 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

5. Right chassis --- automatic transmission ground

6. Right chassis --- services ground

276C11042

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 47

Interior control and utility arrangement

1. External lights/headlight control
2. Front working lights control
3. Rotating beacon
4. Not used
5. Hazard light control
6. Instrument and warning light panel (see following pages)
7. Not used
8. Rearview mirrors heating control --- if equipped
9. Side window wiper control
10. Side window washer control
11. Battery disconnect switch
12. Integrated IRCM (engine brake + retarder) auxiliary brake control
13. Driven mirror adjustment control --- if equipped
14. Parking brake
15. 12V power socket
16. Body tipping parking brake (hold) button
17. Automatic transmission lever
18. Cigar lighter
19. Rear axle longitudinal lock control
20. Central longitudinal lock control
21. Ashtray
22. Windscreen wiper, washer and display management control
23. Accelerator pedal
24. Brake pedal
25. Ignition key switch
26. Steering wheel
27. Steering column slant adjustment lever
28. Direction indicators and horn control
29. Headlight and daytime flashing control
30. Climate control system controls

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
48 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

Interior control and utility arrangement

269NM112

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 49

Indicators and warning lights

1. Engine rpm gauge
2. Automatic transmission oil temperature gauge and hot oil temperature warning light
3. Engine coolant temperature gauge and hot engine coolant warning light
4. Fuel level gauge and reserve warning light
5. Multifunctional display

Detail warning lights

1. Central differential lock on

2. Axle differential lock on
3. Body not at rest
4. Parking brake on
5. Dump parking brake (hold) applied
6. Engine brake applied
7. Transmission Retarder on
8. TCU transmission control unit failure
9. Generic failure
10. Severe failure
11. EDC engine control unit failure
12. Direction indicators/hazard lights on
13. Low generator charge
14. Main beam headlights on

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
50 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

Indicators and warning lights

2
3

electronik
00000 00

1 5

1 3 5 7
2 4 6

8 9 10 11
12 13 14 12

269NU135

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 51

RELAYS AND FUSES INTERCONNECTION CONTROL UNIT

The main interconnection control unit contains the relays and fuses for the entire vehicle. It is situated in the cab,
to the lower right.

269DT0F1

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
52 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

RELAYS AND FUSES

Relays

269DT0F2

Code Type Description

E1 --- --- --- ---
E2 N Headlights circuit contactor
E3 F Contactor for user exclusion during starting phase
E4 N Light flash contactor
E5 --- --- --- ---
E6 N Stop lights contactor
E7 --- --- --- ---
E8 --- --- --- ---
E9 X Windshield wiper intermittence
E10 S High---beam lights contactor
E11 N Work floodlights contactor
E12 N Horn contactor
E13 --- --- --- ---
E14A --- --- --- ---
E14B --- --- --- ---
E15 --- --- --- ---

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 53

Supplementary relays

269DT0F2

Code Type Description

E17 H Gear in neutral start contactor (K1)
E18 H Reverse contactor (K2)
E19 H Battery exclusion automation contactor
E20 H Start request contactor
E21 H Camera contactor
E22 H Air conditioning contactor
E23 H Automatic lubrication contactor
E24 H Battery---disconnect auto---retention contactor
E25 H Left side windshield wiper contactor
E26 H Right side windshield wiper contactor
E27 H Side windshield washer pump contactor
E28 H Fuel heater

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
54 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

Relays, resistors and diodes supplementary

269DT0F2

Code Type Description

D1 G Panel connection – Battery disconnection diodes
GA L Key services
GC L Hood/cab tipping
GE L Start

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 55

Fuse overview

269DT0F3

Flow
Nr. Function
rate
1 7.5A Parking lights – dashboard lighting
2 7.5A Parking lights – indicator
3 3A High---beam connection – low ---beam disconnection with high---beams connected
4 5A Left low ---beam light
5 5A Right low ---beam light
6 7.5A Left high---beam light --- indicator
7 7.5A Right high---beam light
8 20A Front work floodlights
9 10A Heated electropneumatic seat
10 7.5A --- ---
11 10A Horns
12 5A High---beam circuit
13 3A Electromagnetic valve shut ---off
14 5A Lubricating device
15 7.5A Windshield wiper --- washer
16 10A Key power supply +30
17 7.5A Reverse – camera stand---by
18 7.5A Stop lights
19 7.5A Air drier
20 3A Interior light
21 10A Air conditioning compressor
22 5A Rotary lights
23 20A Fuel heater
24 15A Air conditioning fan

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
56 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

Supplementary fuses

269DT0F4

Colour code N°° Flow rate Function

31 5A Power supply +15 --- alternator
32 20A Power supply from main engine ECU relay
33 5A Power supply +30 outlet 30 poles (diagnostics)
WHITE
34 5A Power supply +15 – Engine ECU
35 15A ECU EST 37 Power supply (+15) – E17/E21 relay
36 10A ECU EST 37 Power supply (+30 memory)
41 10A Left windshield wiper
42 10A Right windshield wiper – side window washer
43 15A Power outlet 12V --- cigarette lighter 12V
BLACK
44 20A Voltage reducer 24---12 V
45 25A Hood tipping
46 10A Dashboard power supply
51 3A HEAD power supply
52 5A MIDAC (all) power supply
53 10A HEAD I/O power supply
RED
54 15A MIDAC_1 I/O power supply
55 15A MIDAC_2 I/O power supply
56 5A Body potentiometer – Rear brake flow transducer

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 57

Fusebox component wiring

Code Diagram Description

F 50 A relay

G Diode block

H 10/20 A exchange micro relay

L 40 A N.O. relay

N 20 A N.O. relay

R Resistors

S Supply contactor 10/20 A

X Windscreen wiper relay

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
58 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

VEHICLE DIAGNOSTIC CONTROL SYSTEM

List of problems and interventions

The diagnostic procedures shown below refer to the alarm messages which may appear on the dis-
play.

MUX 01

HEAD connector disconnected Connect

SI

NO

Faulty HEAD Replace

SI

MUX 08

Faulty HEAD Replace

SI

MUX 12

Faulty HEAD Replace

SI

MUX 14

CAN OPEN line not working Run diagnostic procedure (see Procedures:
SI CAN OPEN line)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 59

MUX 15

CAN J1939 line not working Run diagnostic procedure (see Procedures:
SI CAN J1939 line)

MUX 16

Fuse F52 blown Replace

SI

NO

MIDAC 1 connector disconnected Connect

SI

NO

CAN OPEN line not working Run diagnostic procedure (see Procedures:
SI CAN OPEN line)

NO

CAN J1939 line not working Run diagnostic procedure (see Procedures:
SI CAN J1939 line)

NO

Faulty MIDAC1 Replace

SI

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
60 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

MUX 17

Fuse F52 blown Replace

SI

NO

MIDAC 2 connector disconnected Connect

SI

NO

CAN OPEN line not working Run diagnostic procedure (see Procedures:
SI CAN OPEN line)

NO

CAN J1939 line not working Run diagnostic procedure (see Procedures:
SI CAN J1939 line)

NO

Faulty MIDAC2 Replace

SI

MUX 19

Faulty MIDAC1 Replace

SI

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 61

MUX 21

Faulty MIDAC2 Replace

SI

MUX 25

Software version not compatible with parame- Reprogram the ECU

ters SI

MUX 41

Connector disconnected Connect the connector

SI

NO

Pneumatic system pressure switch not working Run diagnostic procedure (see Procedures:
SI component 334)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
62 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

MUX 42

To avoid seriously damaging the parking brake, DO NOT use the vehicle.
If the vehicle has been driven under these conditions, check the parking brake pads and disk, and
restore if necessary.

Air pressure under minimum at start ---up Idle engine until light goes out
SI

NO

Wrong dryer calibration Check

SI

NO

Tank and/or system piping damaged Replace

SI

NO

Faulty air pressure sensor Replace

SI

MUX 43

Wrong dryer calibration Check

SI

NO

Faulty air pressure sensor Replace

SI

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 63

MUX 44

Connector disconnected Connect the connector

SI

NO

Fuel level sensor not working Run diagnostic procedure (see Procedures:
SI component 326)

MUX 47

Connector disconnected Connect the connector

SI

NO

Hydraulic system temperature sensor not work- Run diagnostic procedure (see Procedures:
ing SI component 325)

MUX 48

Hydraulic oil temperature under minimum level Idle engine until light goes out
when engine is cold SI

NO

Faulty hydraulic fluid temperature sensor Replace

SI

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
64 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

MUX 49

Hydraulic oil under minimum level Fill to appropriate level

SI

NO

Hydraulic oil temperature exceeding maximum Idle till light goes out
with maximum effort on steering and tipping SI
system in tropical climate (hydraulic system
overheating)

NO

Faulty hydraulic fluid temperature sensor Replace

SI

MUX 65

Connector disconnected Connect the connector

SI

NO

Retarder air pressure sensor does not work Run diagnostic procedure (see Procedures:
SI component 335)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 65

MUX 66

Insufficient air pressure Check (see MUX 42)

SI

NO

Damaged tubes Fill to appropriate level

SI

NO

Solenoid valve jammed Replace

SI

NO

Faulty air pressure sensor Replace

SI

MUX 67

Excessive air pressure Check (see MUX 43)

SI

NO

Solenoid valve jammed Replace

SI

NO

Faulty air pressure sensor Replace

SI

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
66 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

MUX 68

Connector disconnected Connect the connector

SI

NO

Body angle position sensor not working Run diagnostic procedure (see Procedures:
SI component 338)

MUX 69

Wrong body potentiometer calibration Calibrate body via display

SI

MUX 70

Wrong body potentiometer calibration Calibrate body via display

SI

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 67

MUX 71

Message can only be displayed with engine oil hot.

Obstructed engine oil filter Replace

SI

MUX 72

Obstructed brake oil filter Replace

SI

MUX 76

Filtro combustibile (su motore) intasato Replace

SI

MUX 77

Obstructed fuel filter (on chassis) Bleed

SI

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
68 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

MUX 79

Connector disconnected Connect the connector

SI

NO

Brake recharging system pressure switch not Run diagnostic procedure (see Procedures:
working SI component 341)

NO

Inefficient accumulator recharging circuit Check circuit (see 10.3 BRAKING SYSTEM)
SI

NO

Inefficient front and/or rear accumulator Check circuit (see 10.3 BRAKING SYSTEM)
SI

MUX 80

Clogged engine air cleaner Replace

SI

MUX 81

Obstructed hydraulic system oil filter Replace

SI

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 69

MUX 82

Lubricant grease under minimum level Fill to appropriate level

SI

MUX 83

Solo per veicoli con freni a bagno d’olio.

Connector disconnected Connect the connector

SI

NO

Brake cooling system front pressure switch not Run diagnostic procedure (see Procedures:
working SI component 349)

MUX 86

Connector disconnected Connect the connector

SI

NO

Body raising solenoid valve not working Run diagnostic procedure (see Procedures:
SI component 316)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
70 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

MUX 87

Connector disconnected Connect the connector

SI

NO

Body lowering solenoid valve not working Run diagnostic procedure (see Procedures:
SI component 317)

MUX 88

Solo per veicoli con freni a bagno d’olio.

To avoid seriously damaging the brake system, DO NOT start the engine.

Connector disconnected Connect the connector

SI

NO

Engine cooling system solenoid valve is not Run diagnostic procedure (see Procedures:
working SI component 322)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 71
MOTORE

MUX 89

Connector disconnected Connect the connector

SI

NO

Retarder air solenoid valve not working Run diagnostic procedure (see Procedures:
SI component 319)

MUX 90

Alternator electrical connector disconnected Connect

SI

NO

Faulty rectifier diode bridge Replace

SI

NO

Damaged winding Replace

SI

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
72 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

MUX 91

Command activated when starting engine Do not touch command until engine started
SI

NO

Faulty microswitch Run diagnostic procedure (see Procedures:

SI component 307)

MUX 92

Command activated when starting engine Do not touch command until engine started
SI

NO

Faulty microswitch Run diagnostic procedure (see Procedures:

SI component 307)

MUX 93

Command activated when starting engine Do not touch command until engine started
SI

NO

Faulty microswitch Run diagnostic procedure (see Procedures:

SI component 308)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 73

MUX 94

Command activated when starting engine Do not touch command until engine started
SI

NO

Faulty microswitch Run diagnostic procedure (see Procedures:

SI component 308)

MUX 96

DO NOT use the vehicle: if the main pressure is insufficient it may be difficult or impossible to steer
the vehicle.

Connector disconnected Connect the connector

SI

NO

Steering emergency solenoid valve not working Run diagnostic procedure (see Procedures:
SI component 321)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
74 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

(MUX 97)

Steering emergency solenoid valve not working Replace pressure switch 336
SI

NO

Main hydraulic system pressure switch not wor- Run diagnostic procedure (see Procedures:
king SI component 336)

NO

Leakage from tubes Fill to appropriate level

SI

NO

Faulty main pump Check main pump

SI

MUX 98

Retarder starts working without being Check solenoid valve (see MUX 89)
controlled SI

NO

Air pressure lower/higher than required value Check electrovalve and/or pneumatic system
SI

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 75

MUX 109

CAN OPEN line not working Run diagnostic procedure (see Procedures:
SI CAN OPEN line)

NO

CLUSTER Replace
SI

MUX 111

CAN OPEN line not working Run diagnostic procedure (see Procedures:
SI CAN OPEN line)

MUX 112

CAN J1939 line not working Run diagnostic procedure (see Procedures:
SI CAN J1939 line)

MUX 113

CAN J1939 line not working Run diagnostic procedure (see Procedures:
SI CAN J1939 line)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
76 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

MUX 114

Main hydraulic system pressure switch not Run diagnostic procedure (see Procedures:
functioning SI component 336)

MUX 117

Automatic greasing system pump clogs. Grease delivery to greasing points Not assured.

Grease level lower than minimum for some Fill to appropriate level
time SI

MUX 118

CAN OPEN line not functioning Run diagnostic procedure (see Procedures:
SI CAN OPEN line)

NO

Faulty HEAD Replace

SI

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ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 77

MUX 119

Vehicle electrical power supply activated with Deactivate, then activated without pressing
brake pedal pressed SI brake pedal

NO

Connector disconnected Connect the connector

SI

NO

Stop lights pressure switch not functioning Run diagnostic procedure (see Procedures:
SI component 337)

MUX 122

Solo per veicoli con freni a bagno d’olio.

Both connectors disconnected Connect connectors

SI

NO

Brake cooling system pressure switches not Run diagnostic procedure (see Procedures:
functioning SI component 349 (front) and component 350
(rear))

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78 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

MUX 140

Fuse F52 and/or fuse F54 blown Replace

SI

NO

MIDAC1 connector disconnected Connect the connector

SI

NO

MIDAC1 wiring electrical power fault Repair

SI

MUX 141

Fuse F52 and/or fuse F55 blown Replace

SI

NO

MIDAC2 connector disconnected Connect the connector

SI

NO

MIDAC2 wiring electrical power fault Repair

SI

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ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 79

MUX 154

Il connettore è scollegato Collegare il connettore

SI

NO

Il trasduttore di pressione posteriore del siste- Effettuare la diagnosi (vedere Procedure: com-
ma raffreddamento freni non funziona SI ponente 333)

MUX 157

Connettore filtro olio impianto idraulico scolle- Collegare

gato SI

MUX 158

Connettore filtro olio freni scollegato Collegare

SI

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80 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

PROCEDURE
Unless stated otherwise, all the procedures described below must be preceded by the following
operations:
D bring the vehicle onto an appropriately solid flat surface in a well---lighted area
D shut off the engine
D remove the key from the ignition switch
D engage the parking brake
D affix the indication signs.
Unless stated otherwise, the temperature of the components to be checked must be stabilized at
a value of 20 ± 5 ˚C (68 ± 41 ˚F).

CAN OPEN line

1. Check between diagnostics connector pins C and D : resistance must be 60 ohm ± 10%
2. Check between pin C and vehicle ground: resistance must be >=1Mohm
3. Check between pin D and vehicle ground: resistance must be >=1Mohm
4. Check between pin C and vehicle power supply (24V batteries): resistance must be >=1Mohm
5. Check between pin D and vehicle power supply (24V batteries): resistance must be >=1Mohm
If this is so, the line is OK

6. Disconnect the BROWN bulkhead connection

7. Check between BROWN bulkhead connector pins 31 and 32:
resistance must be 120 ohm ± 10%
If so, go to point 22

8. Disconnect the closure resistance connector

9. Check between pin 1 and 2 of the resistor: the resistance must be 120 ohm ± 10%
If not, replace the resistor

10. Disconnect MIDAC2

11. Check between pin 1 of the resistor connector and pin 13 of the MIDAC2 connector:
there must be continuity --- it must not be in short circuit to ground or to line L

12. Check between pin 2 of the resistor connector and pin 08 of the MIDAC2 connector:
there must be continuity --- it must not be in short circuit to ground or to line H
If not, restore the wiring

13. Check between pins 19 and 13 of MIDAC2: there must be continuity

14. Check between pins 15 and 08 of MIDAC2: there must be continuity

15. Disconnect MIDAC1

16. Check between pin 19 of the MIDAC2 connector and pin 13 of the MIDAC1 connector:
there must be continuity/must not be in short circuit to ground or to line L
17. Check between pin 15 of the MIDAC2 connector and pin 08 of the MIDAC1 connector:
there must be continuity / must not be in short circuit to ground or to line H
If not, restore the wiring

18. Check between pin 19 of the MIDAC1 connector and pin 31 of the BROWN bulkhead
connector: there must be continuity / must not be in short circuit to ground or to line H
19. Check between pin 15 of the MIDAC1 connector and pin 32 of the BROWN bulkhead
connector: there must be continuity / must not be in short circuit to ground or to line L
If not, restore the wiring

20. Check between pin 19 and 13 of MIDAC1: there must be continuity

21. Check between pin 15 and 8 of MIDAC1: there must be continuity
If not, replace MIDAC1

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 81

22. Check between BROWN bulkhead connector pins 31 and 32: resistance must be 120 ohm ± 10%
If so, check diagnostics connector wiring

23. Disconnect HEAD

24. Check between pins 48 and 47 of the HEAD connector: resistance must be 120 ohm ± 10%
If not, replace the resistor

25. Disconnect CLUSTER

26. Check between pin C6 of the CLUSTER connector and pin 47 of the HEAD connector:
there must be continuity / must not be in short circuit to ground or to line L
27. Check between pin C7 of the CLUSTER connector and pin 48 of the HEAD connector:
there must be continuity / must not be in short circuit to ground or to line H
If not, restore the wiring

28.Check between pin 31 of the BROWN bulkhead connector and pin B6 of the CLUSTER
connector: there must be continuity/must not be in short circuit to ground or to line L
29. Check between pin 32 of the BROWN bulkhead connector and pin B7 of the CLUSTER
connector: there must be continuity / must not be in short circuit to ground or to line H
If not, restore the wiring

30. Check between pin B6 and C6 of CLUSTER: there must be continuity

31. Check between pin B7 and C7 of CLUSTER: there must be continuity
If not, replace CLUSTER

CAN J1939 line

1. Check between pin H and J of the diagnostics connector: resistance must be 60 ohm ± 10%
2. Check between pin H and vehicle ground: resistance must be >=1Mohm
3. Check between pin J and vehicle ground: resistance must be >=1Mohm
4. Check between pin H and vehicle power supply (24V batteries): resistance must be >=1Mohm
5. Check between pin J and vehicle power supply (24V batteries): resistance must be >=1Mohm
If this is so, the line is OK

6. Disconnect the WHITE bulkhead connection

7. Check between WHITE bulkhead connector pins 30 and 31:
resistance must be 120 ohm ±10%
If so, go to point 12

8. Disconnect the engine ECU

9. Check between pins 11 and 12 of the ECU: resistance must be 120 ohm ± 10%
If not, replace the ECU

10. Check between pin 12 of the ECU and pin 30 of the WHITE bulkhead connector:
there must be continuity / must not be in short circuit to ground or to line H
11. Check between pin 11 of the ECU and pin 31 of the WHITE bulkhead connector:
there must be continuity / must not be in short circuit to ground or to line L
If not, restore the wiring

12. Check between pins 30 and 31 of the WHITE bulkhead connector:

resistance must be 120 ohm ±10%
If so, check diagnostics connector wiring

13. Disconnect the automatic transmission TCU connector

14. Check between pins 25 and 26 of the TCU: resistance must be 120 ohm ±10%
If not, replace the TCU

15. Check between pin 30 of the WHITE bulkhead connector and pin 25 of the TCU
connector: there must be continuity / must not be in short circuit to ground or to line L
16. Check between pin 31 of the WHITE bulkhead connector and pin 26 of the TCU
connector: there must be continuity / must not be in short circuit to ground or to line H
If not, restore the wiring

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82 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

17. Disconnect CLUSTER

18. Check between pin 30 of the WHITE bulkhead connector and pin B3 of the CLUSTER
connector: there must be continuity / must not be in short circuit to ground or to line L
19. Check between pin 31 of the WHITE bulkhead connector and pin B4 of the CLUSTER
connector: there must be continuity / must not be in short circuit to ground or to line H
If not, restore the wiring

334 TANK AIR PRESSURE TRANSDUCER SWITCH (MUX 41)

1. Check integrity of fuses F52 and F54
2. Power up the system (BATTERY ON)
3. Disconnect the component connector
4. Check between pin 1 and vehicle ground: power supply voltage must be present (24 V)
If not, check component power supply/MIDAC1 power supply wiring (see point 7)

5. Switch off power to system (BATTERY OFF)

6. Check between component pins 2 and 3: there must be a resistance of 1000 ohm ±10%
If not, replace the component

7. Disconnect MIDAC1
8. Check between pin 2 of the component connector and pin A4 of the MIDAC1 connector:
there must be continuity
9. Check between pin 3 of the component connector and pin A3 of the MIDAC1 connector:
there must be continuity / must not be in short circuit to ground
10. Check between pin 7 of the MIDAC1 connector and fuse F54:
there must be continuity / must not be in short circuit to ground
11. Check between pin 6 of the MIDAC1 connector and fuse F52:
there must be continuity / must not be in short circuit to ground
If not, restore the wiring
If so, check MIDAC 1

326 FUEL LEVEL SENSOR (MUX 44)

1. Check integrity of fuses F52 and F54
2. Power up the system (BATTERY ON)
3. Disconnect the component connector
4. Check between component connector pins 1 and 2: power supply voltage 22 V ± 5% must be present
If not, check wiring (see point 7)

5. Switch off power to system (BATTERY OFF)

6. Check between component pins 1 and 2: there must be a resistance between 20 ohm (full tank) and 300
ohm (empty tank)
If not, replace the component

7. Disconnect MIDAC1
8. Check between pin 2 of the component connector and pin 2 of the MIDAC1 connector:
there must be continuity / must not be in short circuit to ground
9. Check between pin 1 of the component connector and pin 10 of the MIDAC1 connector:
there must be continuity / must not be in short circuit to ground
10. Check between pin 7 of the MIDAC1 connector and fuse F54:
there must be continuity / must not be in short circuit to ground
11. Check between pin 6 of the MIDAC1 connector and fuse F52:
there must be continuity / must not be in short circuit to ground
If not, restore the wiring
If so, check MIDAC 1

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 83

325 HYDRAULIC FLUID TEMPERATURE SENSOR ( MUX 47)

1. Check integrity of fuses F52 and F55
2. Power up the system (BATTERY ON)
3. Disconnect the component connector
4. Check between component connector pins 1 and 2: power supply voltage 22 V ± 5% must be present
If not, check wiring (see point 7)

5. Switch off power to system (BATTERY OFF)

6. Check between component pins 1 and 2: there must be a resistance of 1800 ohm ± 5% to temperature
of 30 ˚C (68 ˚F)
If not, replace the component

7. Disconnect MIDAC1
8. Check between pin 2 of the component connector and pin 2 of the MIDAC1 connector:
there must be continuity / must not be in short circuit to ground
9. Check between pin 1 of the component connector and pin 11 of the MIDAC1 connector:
there must be continuity / must not be in short circuit to ground
10. Check between pin 7 of the MIDAC1 connector and fuse F54:
there must be continuity / must not be in short circuit to ground
11. Check between pin 1 of the MIDAC1 connector and fuse F52:
there must be continuity / must not be in short circuit to ground
If not, restore the wiring
If so, check MIDAC 1

335 RETARDER AIR PRESSURE SENSOR (MUX 65)

1. Check integrity of fuses F52 and F56
2. Power up the system (BATTERY ON)
3. Disconnect the component connector
4. Check between pin 1 and vehicle ground: power supply voltage must be present (24 V)
If not, check component power supply/MIDAC2 power supply wiring (see point 7)

5. Switch off power to system (BATTERY OFF)

6. Check between component pins 2 and 3: there must be a resistance of 1000 ohm ±10%
If not, replace the component

7. Disconnect MIDAC2
8. Check between pin 2 of the component connector and pin 2 of the MIDAC2 connector:
there must be continuity
9. Check between pin 3 of the component connector and pin B2 of the MIDAC2 connector:
there must be continuity / must not be in short circuit to ground
10. Check between pin 7 of the MIDAC2 connector and fuse F55:
there must be continuity / must not be in short circuit to ground
11. Check between pin 6 of the MIDAC2 connector and fuse F52:
there must be continuity / must not be in short circuit to ground
If not, restore the wiring
If so, check MIDAC 2

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84 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

338 BODY ANGLE SENSOR (MUX 68)

1. Check integrity of fuses F52 and F55 and F56
2. Power up the system (BATTERY ON)
3. Disconnect the component connector
4. Check between pin 2 and the vehicle ground: there must be
the supply voltage
(24 Volt)
5. Switch off power to system (BATTERY OFF)
6. Check between pin 3 and the vehicle ground: there must be
a resistance of 175 ± 10% ohm / must not be in short cir-
cuit to ground
If not, check wiring (see point 11)
7. select the BODY ANGLE SETTING page;
8. Start the engine and leave it in low idle;
9. Activate the raise body raise control;
10. Check that the current value displayed during the operation falls within the prescribed values:
12000 ± 10% microA with body lowered, 4000 ± 10% microA with body raised
If not, replace the component
11. Disconnect MIDAC2
12. Check between pin 1 of the component connector and pin 2 of the MIDAC2 connector:
there must be continuity
13. Check between pin 2 of the component connector and pin 17 of the MIDAC2 connector:
there must be continuity / must not be in short circuit to ground
14. Check between pin 7 of the MIDAC2 connector and fuse F55:
there must be continuity / must not be in short circuit to ground
15. Check between pin 6 of the MIDAC2 connector and fuse F52:
there must be continuity / must not be in short circuit to ground
If not, restore the wiring
If so, check MIDAC2

341 ACCUMULATOR SWITCH (MUX 79)

1. Check integrity of fuses F51 and F53
2. Power up the system (BATTERY ON)
3. Disconnect the component connector
4. Check between component connector pins 1 and 2: power supply voltage 18 V ±5% must be present
If not, check wiring (see point 7)
5. Switch off power to system (BATTERY OFF)
6. Check between component pins 1 and 2: must not be in short circuit
If not, replace the component
7. Disconnect HEAD
8. Check between component connector pin 2 and vehicle ground: there must be continuity
9. Check between pin 1 of the component connector and pin 25 of the HEAD connector:
there must be continuity / must not be in short circuit to ground
10. Check between pins 53/54/55/56 of the HEAD connector and fuse F53:
there must be continuity / must not be in short circuit to ground
11. Check between pins 49/50 of the HEAD connector and fuse F51:
there must be continuity / must not be in short circuit to ground
If not, restore the wiring
If so, check HEAD

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 85

349 FRONT BRAKE COOLING PRESSURE SWITCH FAULT (MUX 83)

1. Check integrity of fuses F52 and F54
2. Power up the system (BATTERY ON)
3. Disconnect the component connector
4. Check between component connector pins 1 and 2: power supply voltage 18 V ±5% must be present
If not, check wiring (see point 7)

5. Switch off power to system (BATTERY OFF)

6. Check between component pins 1 and 2: there must be continuity
If not, replace the component

7. Disconnect MIDAC1
8. Check between component connector pin 2 and vehicle ground: there must be continuity
9. Check between pin 1 of the component connector and pin 9 of the MIDAC1 connector:
there must be continuity / must not be in short circuit to ground
10. Check between pin 7 of the MIDAC1 connector and fuse F54:
there must be continuity / must not be in short circuit to ground
11. Check between pin 6 of the MIDAC1 connector and fuse F52:
there must be continuity / must not be in short circuit to ground
If not, restore the wiring

333 REAR BRAKE COOLING PRESSURE SWITCH (MUX 154)

1. Check integrity of fuses F52 and F55
2. Power up the system (BATTERY ON)
3. Disconnect the component connector
4. Check between component connector pins 1 and vehicle ground: power supply voltage 18 V ± 5% must
be present
If not, check wiring MIDAC2 (see point 7)

5. Switch off power to system (BATTERY OFF)

6. Check between component pins 2 and 3: there must be continuity
If not, replace the component

7. Disconnect MIDAC2
8. Check between pin 2 of the component connector and pin 2 of the MIDAC2 connector:
there must be continuity / must not be in short circuit to ground
9. Check between pin 7 of the MIDAC2 connector and fuse F55:
there must be continuity / must not be in short circuit to ground
10. Check between pin 6 of the MIDAC2 connector and fuse F52:
there must be continuity / must not be in short circuit to ground
If not, restore the wiring
If so, check MIDAC2

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
86 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

316 BODY RAISE SOLENOID VALVE (MUX 86)

1. Check integrity of fuses F52 and F55
2. Power up the system (BATTERY ON)
3. Disconnect the connector
4. Check between component connector pins 1 and 2: power supply voltage 0.2 V ±20%
If not, check wiring (see point 7)

5. Switch off power to system (BATTERY OFF)

6. Check between component pins A and B: there must be a resistance of 26 ohm ±10%
If not, replace the component

7. Disconnect MIDAC2
8. Check between pin A of the component connector and pin 4 of the MIDAC2 connector:
there must be continuity / must not be in short circuit to ground
9. Check between component connector pin B and vehicle ground: there must be continuity
10. Check between pin 7 of the MIDAC2 connector and fuse F55:
there must be continuity / must not be in short circuit to ground
11. Check between pin 6 of the MIDAC2 connector and fuse F52:
there must be continuity / must not be in short circuit to ground
If not, restore the wiring
If so, check MIDAC 2

317 BODY LOWER SOLENOID VALVE (MUX 87)

1. Check integrity of fuses F52 and F55
2. Power up the system (BATTERY ON)
3. Disconnect the connector
4. Check between component connector pins 1 and 2: power supply voltage 0.2 V ±20%
must be present
If not, check wiring (see point 7)

5. Switch off power to system (BATTERY OFF)

6. Check between component pins A and B: there must be a resistance of 26 ohm ±10%
If not, replace the component

7. Disconnect MIDAC2
8. Check between pin A of the component connector and pin 52 of the MIDAC2 connector:
there must be continuity / must not be in short circuit to ground
9. Check between component connector pin B and vehicle ground: there must be continuity
10. Check between pin 7 of the MIDAC2 connector and fuse F55:
there must be continuity / must not be in short circuit to ground
11. Check between pin 6 of the MIDAC2 connector and fuse F52:
there must be continuity / must not be in short circuit to ground
If not, restore the wiring
If so, check MIDAC 2

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 87

322 BRAKE COOLING FLUID RATE SOLENOID VALVE (MUX 88)

1. Check integrity of fuses F52 and F54
2. Power up the system (BATTERY ON)
3. Disconnect the connector
4. Check between component connector pins 1 and 2: power supply voltage 0.2 V ±20%
must be present
If not, check wiring (see point 7)

5. Switch off power to system (BATTERY OFF)

6. Check between component pins A and B: there must be a resistance of 22 ohm ±10%
If not, replace the component

7. Disconnect MIDAC1
8. Check between pin A of the component connector and pin 12 of the MIDAC1 connector:
there must be continuity / must not be in short circuit to ground
9. Check between component connector pin B and vehicle ground: there must be continuity
10. Check between pin 7 of the MIDAC1 connector and fuse F54:
there must be continuity / must not be in short circuit to ground
11. Check between pin 6 of the MIDAC1 connector and fuse F52:
there must be continuity / must not be in short circuit to ground
If not, restore the wiring
If so, check MIDAC 1

319 RETARDER SOLENOID VALVE (MUX 89)

1. Check integrity of fuses F52 and F54
2. Power up the system (BATTERY ON)
3. Disconnect the connector
4. Check between component connector pins 1 and 2: : power supply voltage 0.2 V ±20%
must be present
If not, check wiring (see point 7)

5. Switch off power to system (BATTERY OFF)

6. Check between component pins 1 and 4: there must be a resistance of 15 ohm ±15%
If not, replace the component

7. Disconnect MIDAC2
8. Check between pin 1 of the component connector and pin 4 of the MIDAC2 connector:
there must be continuity / must not be in short circuit to ground
9. Check between component connector pin 4 and vehicle ground: there must be continuity
10. Check between pins 7 of the MIDAC2 connector and fuse F55:
there must be continuity / must not be in short circuit to ground
11. Check between pin 6 of the MIDAC2 connector and fuse F52:
there must be continuity / must not be in short circuit to ground
If not, restore the wiring
If so, check MIDAC2

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
88 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

307 BODY RAISE / LOWER JOYSTICK (MUX 91/92)

1. Check integrity of fuses F51 and F53
2. Power up the system (BATTERY ON)
3. Disconnect both fastons connected to 7137 cable
4. Check between faston connected to 7137 cable and
vehicle ground:
power supply voltage must be present (24 V)
If not, check component power supply/HEAD power
supply wiring (see point 7)
5. Switch off power to system (BATTERY OFF)
6. Check between pins “No” and “Com” of each of the two
microswitches: must not be in short circuit
If not, replace the component
7. Disconnect HEAD
8. Check between faston connected to 35---H cable and
HEAD connector
pin 35: there must be continuity
9. Check between faston connected to 36---H cable and
HEAD connector
pin 36: there must be continuity
10. Check between pins 49/50 of the HEAD connector and
fuse F51: there must be continuity/must not be in short circuit to ground
11. Check between faston connected to 7137 cable and fuse F53: there must be continuity / must not be in
short circuit to ground
If not, restore the wiring
If so, check HEAD

308 EXTERNAL START / WARM UP SWITCH FAULT (MUX 93/94)

1. Check integrity of fuses F52 and F55
2. Power up the system (BATTERY ON)
3. Disconnect the component connector
4. Check between pins 2/8/5/10 and vehicle ground: power supply voltage 24 V must be present
If not, check component power supply/MIDAC2 power supply wiring (see point 10)
5. Switch off power to system (BATTERY OFF)
6. Check between component pins 3 and 2: must not be in short circuit
If not, replace the component
7. Check between component pins 4 and 5: must not be in short circuit
If not, replace the component
8. Check between component pins 7 and 8: must not be in short circuit / open circuit
If not, replace the component
9. Check between component pins 9 and 10: must not be in short circuit / open circuit
If not, replace the component
10. Disconnect MIDAC2
11. Check between pin 3 of the component connector and pin 24 of the MIDAC2 connector:
there must be continuity
12. Check between pin 4 of the component connector and pin 21 of the MIDAC2 connector:
there must be continuity
13. Check between pins 8/2/5/10 of the component connector and fuse F55:
there must be continuity / must not be in short circuit to ground
14. Check between pin 6 of the MIDAC2 connector and fuse F52:
there must be continuity / must not be in short circuit to ground
If not, restore the wiring
If so, check MIDAC 2

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 89

321 Emergency steering electromagnetic valve (MUX 96)

1. Check that the fuses F52 and F56 are intact
2. Power the system (BATTERY ON)
3. Disconnect the connector
4. Check between pins 1 and 2 of the component connector: there must be a voltage of 0.2 ± 20% Volt.
If these conditions are not met, check the wiring (see point 7)

5. Power down the system (BATTERY OFF)

6. Check between pins 1 and 2 of the component: there must be a resistance of 27 ± 10% ohm
If this condition is not met, replace the component

7. Disconnect the MIDAC3

8. Check between pin 1 of the component connector and pin 18 of the MIDAC3 connector: there must be conti-
nuity / it must not be in d.c. to ground
9. Check between pin 2 of the component connector and the vehicle’s ground: there must be continuity
10. Check between pin 7 of the MIDAC3 connector and fuse F56: there must be continuity / it must not be in
d.c. to ground
11. Check between pin 6 of the MIDAC3 connector and fuse F52: there must be continuity / it must not be in
d.c. to ground
If these conditions are not met, restore the wiring
If these conditions are met, check the MIDAC3

336 Emergency steering manostat (MUX 97)

1. Check that the fuses F52 and F56 are intact
2. Power the system (BATTERY ON)
3. Disconnect the connector of the component
4. Check between pins 1 and 2 of the component connector: there must be a voltage of 18 ± 5% Volt
If these conditions are not met, check the wiring (see point 7)

5. Power down the system (BATTERY OFF)

6. Check between pins 1 and 2 of the component: there must not be continuity.
If this condition is not met, replace the component

7. Disconnect the MIDAC3

8. Check between pin 2 of the component connector and the vehicle’s ground: there must be continuity
9. Check between pin 1 of the component connector and pin 22 of the MIDAC3 connector: there must be conti-
nuity / it must not be in d.c. to ground
10. Check between pin 7 of the MIDAC3 connector and fuse F56: there must be continuity / it must not be in
d.c. to ground
11. Check between pin 6 of the MIDAC3 connector and fuse F52: there must be continuity / it must not be in
d.c. to ground
If these conditions are not met, restore the wiring
If these conditions are met, check the MIDAC3

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
90 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

337 Stop lights manostat (MUX 119)

12. Check that the fuses F51 and F53 are intact
13. Power the system (BATTERY ON)
14. Disconnect the connector of the component
15. Check between pins 1 and 2 of the component connector: there must be a voltage of 18 ± 5% Volt.
If these conditions are not met, check the wiring (see point 7)

16. Power down the system (BATTERY OFF)

17. Check between pins 1 and 2 of the component: there must not be continuity.
If this condition is not met, replace the component

18. Disconnect the HEAD

19. Check between pin 2 of the component connector and the vehicle’s ground: there must be continuity
20. Check between pin 1 of the component connector and pin 25 of the HEAD connector: there must be continu-
ity / it must not be in d.c. to ground
21. Check between pin 53/54/55/56 of the HEAD connector and fuse F53: there must be continuity / it must not
be in d.c. to ground
22. Check between pin 49/50 of the HEAD connector and fuse F51: there must be continuity / it must not be in
d.c. to ground
If these conditions are not met, restore the wiring
If these conditions are met, check the HEAD

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 91

BATTERY USE AND MAINTENANCE

Precautions
In order to avoid incorrect interventions which may irre-
versibly damage the electronic control units installed
on board the vehicle the following recommendations
should be followed:
D After a service operation requiring battery discon-
nection, make sure that the terminals are well con-
nected.
D Do not disconnect or connect the connectors to the
electronic control unit when the engine is running or
control units are powered.
D Do not disconnect the batteries when the engine is
running.

The vehicle electrical system will work even

if the battery is flat.

D when electrical arc welding on the chassis is re-

quired, disconnect the positive and negative battery
wires, short ---circuit them and disconnect all ground
wires;
D remove the control unit to weld near the device;

Contact your Dealer for more information on

arc welding procedures.

D Remove the electronic control units in the event of

operations at temperatures exceeding 80˚C (176
˚F) (oven painting, etc.).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
92 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

Battery maintenance (unsealed batteries) The presence of some electronic devices

which must always be electrically powered
Figure 87 causes a slight current consumption, also
when the battery disconnect switch is off.
It may be difficult to start the engine after a
long stop (one month or longer) due to par-
tial discharging of the batteries.
To avoid this problem, start and warm the en-
gine up (possibly by travelling a short dis-
tance) once a month.

269NM451

Sealed batteries (maintenance free) do not

require topping up with water in normal
working conditions and mild climate.
The electrolyte should be checked approxi-
mately once a year in tropical climates.

Proceed as follows:
D tip the engine hood up;
D remove the battery compartment cover (see arrow);
D carefully clean the batteries, the cables and the
case, removing corrosion rust and dirt which can
cause voltage drops;
D check through the caps that the distance between
the electrolyte and the upper edge of the plate of
each element is as specified:
plate-- level distance: 10-- 15 mm (0.38-- 0.59 in)

Figure 88

269NM452

D if required, top up with distilled water when the bat-

teries are cold and rested, through the specific filler
holes;
D check with a hidrometer or battery load tester that
the battery charge is as specified.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11
Recharging with external devices
Batteries should normally be removed from the vehicle
to be recharged.
If this is not possible, the batteries can also be re-
charged using an external source (battery charger)
connected directly to the battery terminals.
The vehicle is equipped with a 24 volt electri-
cal system with negative ( ---) ground.
Figure 89
174NM44
Proceed as follows:
a. lay the cables on the ground ensuring that the ter-
minals do not touch metal parts or each other.
Connect the red cable (A) to the POSITIVE (+) ter-
minal of the flat battery;
b. connect the black cable (B) to the NEGATIVE (---)
terminal of the flat battery;
c. set the recharge time. Start recharging.
Respect the instructions provided by the
battery charger supplier.
Respect the sequence of the operation.
Do not reverse the polarity when making the
connection.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ELECTRICAL SYSTEM 93
Emergency electrical power
When the batteries are discharged, connect the vehicle
to external batteries to restart it.
The vehicle is equipped with a 24 volt electri-
cal system with negative and ground.
Only use 24 volt batteries to jump start the
engine.
Figure 90
174NM43
a. lay the cables on the ground ensuring that the ter-
minals do not touch metal parts or each other;
connect one end of the red cable (A) to the POS-
ITIVE terminal of the flat battery;
b. connect the other end of the red cable (A) to the
POSITIVE terminal of the external battery;
c. connect one end of the black cable (B) to the
NEGATIVE terminal of the external battery;
d. connect the other end of the black terminal (B) to
any point of the chassis of the vehicle to be started
which is certainly connected to ground.
Make this connection at a point as far as
possible from the vehicle batteries.
Make certain that two vehicles are not touch-
ing each other.
Observe the sequence of operations.
When connecting, never invert
polarity.
Using cables with adequate section
The vehicle electrical system should work
with the battery , even if flat.
In any case verify the causes of the batteries discharge.
94 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

DISASSEMBLY---REASSEMBLY OF THE General information

ELECTRONIC CONTROL UNITS
Before performing any intervention, ensure
that all precautions have been taken and all
aspects clarified regarding the safety of per-
sonnel involved in the intervention.
Read the relative instructions provided in
SECTION 1 of this manual.
In case of doubt, consult a more exper-
ienced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions
Proceed as follows:
D bring the vehicle onto an appropriately solid flat sur-
face, shut off the engine, remove the key from the
ignition switch, engage the parking brake and affix
the indication signs;
D disconnect the battery---disconnect switch or dis-
connect the battery terminals in order to eliminate
any risk of short ---circuit;
D block the articulation by means of the steering lock
bar, as indicated in SECTION 1.

The disassembly of an electronic control

unit must be carried out by specialized per-
sonnel.
Do so only if absolutely necessary and after
having disconnected the electric power
supply of the batteries.
Work in a dry and protected area.
Do not force the connectors during disas-
sembly and especially during reassembly, in
order to avoid damaging the connection
pins.
Figure 91

276D011020

During reassembly, apply the specific sili-

cone sealant before (see figure) coupling
the connector.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 95

Engine control unit Disassembly---reassembly of connector B

The engine control unit is equipped with three con- Proceed as follows:
nectors: D Open the engine hood.
A. Electro---injectors connector
B. Chassis connector Figure 93
C. Sensors connector

Figure 92

276C011051
D Lift the stop lever (1) by rotating it completely to-
wards the wiring input side (arrow).

Figure 94

276D011021

276C011052
D Extract the connector perpendicularly to the control
unit (arrow) without rotating it until it disengages
completely.
D For reassembly, follow the disassembly steps in the
reverse order.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
96 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

Disassembly---reassembly of connector C and con- Disassembly---reassembly of the control unit

nector A
Proceed as follows: Figure 96
D Open the engine hood.

Figure 95

276C011053
D Lift the stop lever (1) by rotating it completely to- 276D011025

wards the side opposite the wiring (arrow). Proceed as follows:

D Extract the connector perpendicularly to the control
unit without rotating it until it disengages complete-
ly.
D For reassembly, follow the disassembly steps in the
reverse order.
D Disconnect the three connectors (A), (B) and (C).
D Unscrew the retaining screws (arrow) and remove
the control unit.
D For reassembly, follow the disassembly steps in the
reverse order.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
Automatic transmission control unit
Disassembly---reassembly
Proceed as follows:
Figure 97
276D011026
D Remove the closure door in the cab.
Figure 98
276D011027
D Unscrew the top retaining screws (1).
D Loosen, without removing, the bottom retaining
screws (2) and remove the control unit.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
SECTION 11 ELECTRICAL SYSTEM 97
Figure 99
276D011028
D Pull the locking slide (1) towards the side opposite
the wiring and at the same time pull the connector
away from the control unit until it disengages com-
pletely.
D For reassembly, follow the disassembly steps in the
reverse order.
If the control unit is being replaced with a
new one, the following procedure must be
STRICTLY followed in order to restore the ve-
hicle’s functionality:
D Connect the electric power supply of the
vehicle.
D Wait at least 10 seconds.
D Move the switch to position MAR.
D Start the engine, then turn it off.
This allows the new control unit to be cor-
rectly recognized by the Body Computer
system.
98 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

Cluster Control Unit (Body Computer) Head Control Unit (Body Computer)

Disassembly---reassembly Disassembly---reassembly
Proceed as follows: Proceed as follows:
Figure 100 Figure 102

276D011029
D Remove the screws (arrow) fastening the instru- 276D011031

ment panel to the dashboard.
D Pull the instrument panel away from the dashboard
in order to access the rear part.
Figure 101
D Pull the locking slide (1) towards the side opposite
the wiring and at the same time pull the connector
away from the control unit until it disengages com-
pletely.
Figure 103

276D011030
D Pull the locking slide (1) towards the side opposite 276D011032

the wiring and at the same time pull the connector
away from the control unit until it disengages com-
pletely.
D For reassembly, follow the disassembly steps in the
reverse order.
D Remove the retaining screws (arrow) of the control
unit and remove the control unit.
D For reassembly, follow the disassembly steps in the
reverse order.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 99

MIDAC connector For reassembly, follow the detachment steps in the re-
verse order.
Disassembly---reassembly
Figure 3
Proceed as follows:
D unscrew the external screw (1) and loosen the inter-
nal retaining screw (2) of the MIDAC connector;

Figure 1

1
2
276C11011

Make sure that the protective sheathing is

engaged on the small hooks (arrow) on the
connector.
276C11009
D if necessary, unscrew the wiring clamp screw;
D remove the MIDAC connector from its seat;

Figure 2

276C11010
D take off the protective sheathing to access the rear
part of the electrical connector;
D unscrew the central screw (1) and disconnect the
connector.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
100 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

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For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 101

ELECTRICAL SYSTEM

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
102 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

ELECTRICAL SYSTEM
Some of the components listed in the following key may not be present on the vehicle.

Layout electrical system (1/5)

Component key
PGR DESCRIPTION
100 Fusebox
101 Batteries
102 Starter motor
103 Alternator
104 Ignition relay (chassis)
105 Shut ---off solenoid valve
106 Air dryer resistor
107 General current relay
108 Battery on/off switch
109 Key switch
110 --- ---
111 Light switch (3 fixed positions)
112 Main beam flasher button (stalk)
113 Main beam switch (stalk)
114a Front left side light
114b Left side marker light (set ---up)
114c Rear left taillight
115a Front right side light
115b Right side marker light (set ---up)
115c Rear right taillight
116 Left dipped beam headlight
117 Right dipped beam headlight
118 Left main beam headlight
119 Right main beam headlight
120 Diesel fuel heater
121 --- ---
122 Backup lights
123 Reversing siren
124 Fuel heater switch
125 Brake lights
126 Left ceiling light
127 Right ceiling light
128 Rotating light switch (1 steady position)
129 Rotating light
130 Battery on/off switch (external)
131 Cab/fleet link interface (set ---up)
132 Fleet link power (set ---up)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 103

Layout electrical system (Section 1/5)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
104 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

Layout electrical system (2/5)

Component key
PGR DESCRIPTION
200 12V socket
201 12V cigar lighter
202 24/12V voltage reducer
203 12V radio
204 Left speaker
205 Right speaker
206 CB radio (set ---up)
207 Climate control pressure switch (N.O.)
208 Climate control joint
209 Tipping hood switch (ADT 25---30---35---40) (opt.)
210 --- ---
211 --- ---
212 Motor tipping hood
213 Tipping hood switch ADT 30 (opt.)
214 --- ---
215 --- ---
216 Grease dispensing device
217 --- ---
218 --- ---
219 Electrical---pneumatic seat joint
220 Working light switch
221 Working lights
222 Windscreen wiper/washer (stalk)
223 Wiper motor
224 Washer motor
225 Side wiper switch (1 fixed position)
226 Left side wiper motor
227 Right side wiper motor
228 Side wiper switch (1 toggle position)
229 Side washer motor
230 Horn switch (stalk)
231 Horn
232 Reversing 12V motor

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 105

Layout electrical system (Section 2/5)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
106 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

Layout electrical system (3/5)

Component key
PGR DESCRIPTION
300 Body computer (HEAD) 330 Water in fuel filter sensor
301 Slave (MIDAC_1) 331 Steering/dumping pressure transducer
302 Slave (MIDAC_2) (set ---up)
303 Configuration retarder 332 Brake pressure front cooling transducer (ADT30t)
304 ADT 25/30 configuration 333 Weighing pressure transducer rear cooling (ADT30t)
305 Indicator light + Dashboard controls 334 Steering/dumping tank pressure transducer
(set ---up)
306 Hazard light switch (1 steady position)
335 Retarder air pressure transducer
307 Tipper control
336 (NO) emergency steering pump pressure switch
308 Start/stop/warm---up button
337 (NC) brake/stop pressure switch
309 Tipper control (emergency)
338 Body angle sensor
310a Left front direction indicator light
339 (NC) parking brake pressure switch
310b Left rear direction indicator light
340 --- ---
311a Right front direction indicator light
341 (NC) brake accumulator pressure switch
311b Right rear direction indicator light
342 (NO) air filter vacuum switch
312 120 ohm end of circuit resistor (CAN bus)
343 (NO) steering/dumping oil filter switch
313 --- ---
344 --- ---
314 Cluster
345 (NC) brake actuator oil filter switch
315 --- ---
346 --- ---
316 Body raise solenoid valve
347 Central differential lock switch
317 Body lower solenoid valve
348 Cab/chassis joint
318 Retarder engine---brake control
349 --- ---
319 Retarder solenoid valve
350 --- ---
320 --- ---
351 Brake flow solenoid valve
321 Steering emergency solenoid valve
352 --- ---
322 --- ---
353 --- ---
323 Start/stop button
354 --- ---
324 --- ---
355 RS 232 (GSM) serial joint
325 Steering/dumping tank oil temperature sensor
356 GSM module supply
326 Fuel level sensor
327 --- ---
328 Joistick potentiometer body (ADT30)
329 Pressure transducer (set ---up)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 107

Layout electrical system (Section 3/5)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
108 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

Layout electrical system (4/5)

PGR DESCRIPTION
400 EDC7 engine
401 E.C.U: EDC engine (cab interface)
402 E.C.U: EDC engine (injectors interface)
403 E.C.U: EDC engine (engine services interface)
404 ST82 junction (engine)
405 Diagnostics socket (9V Deutsch J1939)
406 Air conditioner (compressor)
407 Accelerator
408 --- ---
409 Engine brake electrovalve (SEB)
410 Engine preheat relay (engine)
411 CAN BUS/EDC line junction
412 Injectors power supply wiring pass---through
413 Cylinder 1 injector solenoid power supply
414 Cylinder 2 injector solenoid power supply
415 Cylinder 3 injector solenoid power supply
416 Cylinder 4 injector solenoid power supply
417 Cylinder 5 injector solenoid power supply
418 Cylinder 6 injector solenoid power supply
419 Engine decompression electrovalve
420 Variable---geometry turbine electrovalve
421 Engine turbine speed sensor
422 Camshaft speed increase sensor
423 Camshaft speed sensor
424 Engine water temperature sensor
425 Diesel fuel temperature sensor
426 Exhaust gas pressure sensor
427 Engine oil temperature/pressure sensor
428 Engine intake air temperature/pressure sensor
429 Oil filter switch
430 Diesel fuel filter switch
431 Engine oil level sensor
432 Engine air heaters

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 109

Layout electrical system (Section 4/5)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
110 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

Layout electrical system (5/5)

Component key
PGR DESCRIPTION
500 Transmission E.C.U. ZF EST 37
501 Diagnostic socket
502 Gear selector
503 CAN/EST 37 line joint
504 --- ---
505 Cab/chassis joint ZF
506 --- ---
507 ZF Astra Service 22 pin joint (X8)
508 Engine speed sensor (transmission)
509 Turbine speed sensor (transmission)
510 Chain speed sensor (transmission)
511 Retarder temperature sensor (transmission)
512 Gearbox oil filter clogged switch
513 VPF 16 pin connector
514 Speed sensor (transmission)
515 Splitter solenoid valve
516 --- ---
517 27 Ω 5 W retarder resistor
518 Lock ---up solenoid valve
519 Splitter lock switch (2 steady position)
520 --- ---

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 11 ELECTRICAL SYSTEM 111

Layout electrical system (Section 5/5)

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
112 ELECTRICAL SYSTEM SECTION 11 ADT 25-30 TIER3

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 SECTION 12

PNEUMATIC SYSTEM
 ADT 25-30 TIER3 SECTION 12 PNEUMATIC SYSTEM 1

CONTENTS

Page Page

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 MAIN COMPONENTS PNEUMATIC SYSTEM . . . 17

Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PNEUMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . 4 SINGLE-- CHAMBER AIR DRIER . . . . . . . . . . . . . . 17
Pneumatic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AIR INTAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 18
COMPONENTS LOCATION PNEUMATIC
PARKING BRAKE ENGAGING DISTRIBUTOR . . 18
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MANUAL CONDENSATION DISCHARGE
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Parking brake distributor . . . . . . . . . . . . . . . . . . . . . . 15
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
2 PNEUMATIC SYSTEM SECTION 12 ADT 25-30 TIER3

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For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 12 PNEUMATIC SYSTEM 3

DESCRIPTION
The vehicle is equipped with a pneumatic system that controls the following functions:
D Parking brake control;
D Variable geometry turbine control (engine);
D Central splitter lock control;
D Rear differential lock control;
D Retarder control (automatic transmission);
D Electro---pneumatic seat control;
D Electro---pneumatic horn control;
D Pressurizing function of the main hydraulic tank.

Main Components
Compressor: Single---cylinder liquid---cooled (1), fitted on the right side of the Diesel engine, equipped with “en-
ergy saving” control for exclusion when calibration pressure is reached.
Actuators: Pneumatic cylinders, controlled by relative valves/solenoid valves.
Filter: Interchangeable cartridge on drier (2), fitted in compartment in front of fuel tank.
Tank: Main 20---liter tank for supplying services (5).
Secondary 5---liter tank for washing drier (4).

Figure 1

T276C012001

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
4 PNEUMATIC SYSTEM SECTION 12 ADT 25-30 TIER3

PNEUMATIC DIAGRAM
1. One ---cylinder compressor
2. Drier with heater and cartridge filter
3. Air exhaust muffler
4. Air intake valve
5. 5 liter tank
6. 20 liter tank
7. parking brake valve
8. shut ---off solenoid valve
9. central splitter lock solenoid valve
10. retarder proportional valve
11. electro ---pneumatic seat
12. retarder pressure sensor
13. parking brake pressure switch
14. main tank air pressure sensor
15. retarder control actuator
16. central splitter lock control actuator
17. VGT turbine actuator control actuator
18. Parking brake control actuator

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 12 PNEUMATIC SYSTEM 5

Pneumatic diagram

276C012003

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
6 PNEUMATIC SYSTEM SECTION 12 ADT 25-30 TIER3

COMPONENTS LOCATION PNEUMATIC SYSTEM

1. Retarder solenoid valve 319
2. Retarder air pressare switch 335
3. Main reservoir air pressure sensor 334
4. Central splitter lock switch 347

1 2

3 4

276C012004

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 12 PNEUMATIC SYSTEM 7

1. Central splitter lock solenoid valve 515

2. Shut ---off solenoid off 422
3. Air intake valve
4. Paking brake pressur switch 339

1
2

3 4

276C012005

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
8 PNEUMATIC SYSTEM SECTION 12 ADT 25-30 TIER3

1. Retarder control actuator

2. Parking brake control actuator
3. VGT turbine actuator
4. Central splitter lock control actuator

1 2

3 4

276C012004

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 12 PNEUMATIC SYSTEM 9

DIAGNOSTIC

Compressor

1 OIL LEAKAGE FROM FLANGE

EXTERNAL SIDE

Oil leak from flange external side Tighten screws to specified torque
YES

NO

Flange body seal faces not perfectly flat Check seal faces. Replace defective parts or
YES grind faces flat

NO

Broken gasket Replace gasket

YES

NO

Shaft seal broken Replace gasket

YES

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
10 PNEUMATIC SYSTEM SECTION 12 ADT 25-30 TIER3

2 OIL SEEPAGE FROM HEAD

Oil scraper worn (indicated by shiny passage Replace complete piston

surface YES

NO

Incorrect oil scraper installation Fit with ”TOP” indication facing compressor
YES head

NO

Oil scraper and piston rings all aligned vertically Fit each ring 120˚ offset to the others
YES

NO

Cylinder scored or ovalised Reface cylinder a and fit oversize piston

YES

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 12 PNEUMATIC SYSTEM 11

3 NO COMPRESSION

Worn compression or intake valve Replace worn parts

YES

NO

Piston rings all aligned vertically Fit each ring 120˚ offset to the others
YES

NO

Hole in piston or failure of parts connected to Replace complete piston

piston YES

NO

Damaged gasket Replace gasket

YES

NO

Energy saving device open during charge phase Replace cylinder head
YES

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
12 PNEUMATIC SYSTEM SECTION 12 ADT 25-30 TIER3

4 POOR PERFORMANCE

Worn piston rings Replace piston (complete with rings)

YES

NO

Air loss between cylinder and head Replace gasket and tighten screws to specified
YES torque

NO

Worn energy saving device, intake or Replace worn parts

compression valve YES

NO

Excessive play between piston and cylinder Reface cylinder and fit oversize piston
YES

NO

Particles of burnt oil between intake and Clean valves

compression valves YES

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 12 PNEUMATIC SYSTEM 13

5 MECHANICAL NOISE

Excessive play between big end and gudgeon Check tolerance of all suspect couplings
pin, between gudgeon pin and piston, between YES
crankshaft and big end, between crankshaft and
bearings and between shaft and flange

NO

Excessive play between piston and cylinder Reface cylinder and fit oversize piston
YES

NO

Excessive build---up of burnt oil between piston Remove encrusted materials and replace valves
and cylinder head YES

6 WATER SEEPAGE

Head gasket or coupling faces scored or irregu- Replace damaged parts

lar YES

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
14 PNEUMATIC SYSTEM SECTION 12 ADT 25-30 TIER3

DRIER

EXCESSIVE AMOUNT OF
1
CONDENSATION IN CIRCUIT

Filter cartridge clogged Replace cartridge

YES

2 SET PRESSURE NOT REACHED

IN TANK

Air leak from safety valve Overhaul drier replacing worn parts
YES

NO

Worn head gasket Overhaul drier replacing worn parts

YES

3 AIR LEAK FROM EXHAUST

Filter cartridge clogged Replace cartridge

YES

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 12 PNEUMATIC SYSTEM 15

Parking brake distributor

1 AIR ESCAPE FROM EXHAUST WITH

CONTROL LEVER IN RELEASE POSITION

Defective exhaust valve, valve seat or O---ring Check and overhaul the component, replacing
YES defective parts. Carefully clean all components

AIR ESCAPE FROM EXHAUST WITH

2 CONTROL LEVER IN BRAKING
POSITION

Worn component control valve, O---ring and Check and overhaul the component, replacing
valve YES defective parts. Carefully clean all components

NO

Obstruction inside distributor Check and overhaul the component, and

YES lubricate all sliding parts

3 CONTROL LEVER STIFF

Obstruction inside distributor Check and overhaul the component, and

YES lubricate all sliding parts

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
16 PNEUMATIC SYSTEM SECTION 12 ADT 25-30 TIER3

Checks
Since the vehicle braking system is approved to European standards, it is essential that periodic checks are made
on all components of the same using tool 99305117.
These checks must be carried out with the vehicle at a standstill, using the compressed air in the tanks, recharged,
with the engine running, by the compressor.
Always secure the vehicle before any check. Periodically check pressure gauge readings with a
certified manometer.

COMPONENT CHECK
Compressor Check tightness of head, connectors and fasteners
Check absence of coolant leaks
Check absence of oil leaks
Drier Open bleed valve: condensation---free air should bleed off
Otherwise check efficiency of electric elements (power supply)
Tanks (all) Check pipe tightness
Discharge any accumulated condensation
In this case check efficiency of air drier (APU)
Parking brake distributor Pull lever until click: the control pressure gauge must indicate pressure discharge
(0 bar) within 1 second
Air intake valve Check union seal
Membrane brake cylinder Check pipe and fastener tightness
The drain hole must face downwards and be free of any obstruction
Pipes and connectors Check that metallic pipes are in perfect condition, without dents or kinks. Nylon pi-
pes must not have any cuts, incisions or chaffing
Also check that pipes run a safe distance from any sharp edges on bodywork or
chassis, which could cause damage
Check that all anchor brackets are well fastened. If loose these may vibrate, and
are therefore more liable to damage. Check that nylon pipes have not come into
contact with any grease, mineral oil or rubber solvents
Press hard on brake pedal and check that no pipe tends to swell
Check the absence of leaks from the various connectors. If leaks are present, fully
tighten the connector taking care not to twist the pipe while tightening
Replace the part in all the above cases even if there is a minimal doubt as to its effi-
ciency. Apart from the apparent physical condition, pipes should be replaced after
significant mileage or after a long period of vehicle use, to avoid sudden failure due
to ageing or fatigue
Pneumatic system seal This check is carried out on all threaded connectors, by charging the system with
with engine off under ope- air pressure no less than 5 bar, smearing dense soapy water on the connectors with
rating pressure a soft brush and watching for leaks

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 12 PNEUMATIC SYSTEM 17

MAIN COMPONENTS PNEUMATIC SYSTEM

COMPRESSOR SINGLE ---CHAMBER AIR DRIER

Figure 2 Figure 3

0 = intake
2 = delivery
4 = energy saving control
1 = SUPPLY (from compressor)
21 = OUTLET
The component generates the compressed air needed 4/23 = TO COMPRESSOR (Energy Saving)
to recharge the pneumatic system. 22 = TO REGENERATION TANK
The single---cylinder compressor has a displacement
of 250 cc and is equipped with an energy saving device The function of the component is to reduce the humid-
to reduce energy consumption when all systems are ity in the compressed air so that the system does not
adequately served. collect condensation.
When the built ---in regulator trips, the air in the washing
tank will release the water trapped by the filter into the
atmosphere, thus regenerating the filter.
The built ---in regulator will guarantee that the system is
recharged and that its maximum pressure is limited as
follows:
Intervention pressure: 8.3 ± 0.2 bar

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
18 PNEUMATIC SYSTEM SECTION 12 ADT 25-30 TIER3

AIR INTAKE VALVE PARKING BRAKE ENGAGING

DISTRIBUTOR
Figure 4
Figure 5

1 = Supply
2 = To tanks
1 = Supply (from tank)
2 = Delivery (to parking brake cylinder)
It supplies the braking system tanks when the supply
3 = Discharge
reaches a pressure value that ensures perfect effi-
ciency.
The device is fitted in the tractor parking brake circuit
It also interrupts the compressed air flow when the
and is used to apply the vehicle’s parking brakes and
pressure in the tanks drops below a fixed value (calibra-
discharge compressed air from the spring cylinders.
tion) after a failure or when too much pressure is taken.

Calibration: 6.8 – 7.5 bar

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 12 PNEUMATIC SYSTEM 19

MANUAL CONDENSATION DISCHARGE

VALVE

Figure 6

The component is used to manually eliminate any con-

densation that may have accumulated in the system
tanks.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
20 PNEUMATIC SYSTEM SECTION 12 ADT 25-30 TIER3

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For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 SECTION 13

GREASING SYSTEM
ADT 25-30 TIER3 SECTION 13 GREASING SYSTEM 1

CONTENTS

Page Page

MANUAL GREASING . . . . . . . . . . . . . . . . . . . . . . . . . 3 Lay-out system II type --- rear chassis . . . . . . . . . . . 17

Lubrication system checks . . . . . . . . . . . . . . . . . . . . . 3 Restoring grease dispenser functionality . . . . . . . . 18

Lay-out system --- I type . . . . . . . . . . . . . . . . . . . . . . . . 5 Restore operation of the automatic greasing

Lay-out system --- II type . . . . . . . . . . . . . . . . . . . . . . . 7
AUTOMATIC GREASE SYSTEM . . . . . . . . . . . . . . . . 8
GREASING SYSTEM CALIBRATION . . . . . . . . . . 10
GREASING TIME ADJUSTMENT . . . . . . . . . . . . . . 11
Lay-out system I type --- front chassis . . . . . . . . . . . 13
Lay-out system I type --- rear chassis . . . . . . . . . . . 14
Lay-out system II type --- front chassis . . . . . . . . . . 16
control unit after disassembly/draining . . . . . . . . . . 18
Checks of the lubrication control unit
components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DISTRIBUTION DIVIDER . . . . . . . . . . . . . . . . . . . . . 20
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Quantity of lubricant supplied (A) . . . . . . . . . . . . . . . 21
Indicators (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
2 GREASING SYSTEM SECTION 13 ADT 25-30 TIER3

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For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 13 GREASING SYSTEM 3

MANUAL GREASING Lubrication system checks

Figure 1 The opening pressure of a lubricator is

70---80 bar (1015---1160 psi).

Proceed as follows:
D Check the hardness of the piping between the deli-
very fitting and grease nipples. Normally the pipes
should be squeezeable when grease is not injected.
D If necessary, connect a manual pump with a pressu-
re gauge to the delivery fitting.
D Operate the manual pump and verify that the wor-
king pressure falls within the prescribed values.
D Otherwise:
A. check that the piping is not crushed and/or de-
formed;
B. check that the corresponding grease nipple is
not blocked.

276DNM0010

The vehicle is equipped with a greasing system, the fit-

tings of which are grouped in the rear plate (Fig. 1, see
arrow).
Use only a hand pump for greasing; never use a high---
pressure lubricator.
Proceed as follows:
D clean the fitting concerned;
D inject the prescribed grease into the fitting.

To guarantee an efficient lubrication, the lu-

bricant must be injected until it leaks out
from the lubricated points.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
4 GREASING SYSTEM SECTION 13 ADT 25-30 TIER3

Location of the greasing points --- I type

Circuit Greasing point Circuit Greasing point

Front articulation of left steering cylin-
B1 Top articulation of right tipping cylinder B12
der
B2 Top articulation of left tipping cylinder B13 Bottom fifth wheel hinge
B3 Rear suspension right rocker arm B14 Top fifth wheel hinge
B4 Rear suspension left rocker arm B15 Fifth wheel
Bottom articulation of right tipping cylin-
B5 B16 Fifth wheel
der
B6 Bottom articulation of left tipping cylinder B17 Fifth wheel
B7 Front fixed drive bearing B18 Fifth wheel
B8 Rear fixed drive bearing B19 Fifth wheel
B9 Rear articulation of right steering cylinder B20 Fifth wheel
B10 Rear articulation of left steering cylinder B21 Right body tipping pivot pin
B11 Front articulation of right steering cylinder B22 Left body tipping pivot pin

276C013004

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 13 GREASING SYSTEM 5

Lay-out system -- I type

276C013006

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
6 GREASING SYSTEM SECTION 13 ADT 25-30 TIER3

Location of the greasing points --- II type

Circuit Greasing point Circuit Greasing point

Front articulation of left steering cylin-
B1 Top articulation of right tipping cylinder B12
der
B2 Top articulation of left tipping cylinder B13 Bottom fifth wheel hinge
B3 Rear suspension right rocker arm B14 Top fifth wheel hinge
B4 Rear suspension left rocker arm B15 Fifth wheel
Bottom articulation of right tipping cylin-
B5 B16 Fifth wheel
der
B6 Bottom articulation of left tipping cylinder B17 Fifth wheel
B7 Front axle articulation B18 Fifth wheel
B8 Front/rear fixed drive bearing B19 Fifth wheel
B9 Rear articulation of right steering cylinder B20 Fifth wheel
B10 Rear articulation of left steering cylinder B21 Right body tipping pivot pin
B11 Front articulation of right steering cylinder B22 Left body tipping pivot pin

276C013005

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 13 GREASING SYSTEM 7

Lay-out system -- II type

276C013007

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
8 GREASING SYSTEM SECTION 13 ADT 25-30 TIER3

AUTOMATIC GREASE SYSTEM

Figure 2

269NM3F7A

The vehicle is equipped with a centralised grease dis-

pensing system.
The system does not required specific maintenance.

Filling the reservoir

Proceed as follows to fill the grease reservoir:
D clean the filler grease fitting (ref. 1);
D connect the dispenser to the fitting and fill the tank
to the MAX line;
D disconnect the dispenser and clean the fitting.

Full functionality will be restore after approx-

imately 10 minutes of operation following re-
moval or emptying procedures.
The leakage of lubricant from the maxi-
mum---pressure valve (ref. 2) indicates the
presence of a blockage or obstruction in the
system.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 13 GREASING SYSTEM 9

Automatic greasing system calibration adjustment

Greasing and pause times are adjusted via
the display.

. For more information, refer to SECTION USE

of the Use and Maintenance Handbook.

Proceed as follows:

Figure 3

276NU112A

D select MAIN MENU, then select VEHICLE MANAGE-

MENT;

Figure 4

276NU113A

D select the CALIBRATED GREASING function.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
10 GREASING SYSTEM SECTION 13 ADT 25-30 TIER3

GREASING SYSTEM CALIBRATION

Sequence of available options.

Meaning of options.

GREASING SYSTEM CALIBRATION

Figure 5

276DNU004

GREASING TIME ADJUSTMENT

This adjusts the centralised greasing system stand---by
and function time.
. For more information on the greasing sys-
tem, see the following page.

FORCED GREASING START

Starts the greasing pump unconditionally.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 13 GREASING SYSTEM 11

GREASING TIME ADJUSTMENT

Sequence of available options.

Meaning of options.

GREASING TIME ADJUSTMENT

Figure 6

276DNU005

The ON time (duration of greasing phase) is fixed (10

minutes).
The OFF time (duration of pause between two succes-
sive greasing phases) is adjustable from a minimum of
100 minutes to a maximum of 240 minutes, in 5 minute
steps.
Therefore:
D to increase the quantity of grease delivered, reduce
the OFF time;
D to reduce the quantity of grease delivered, increase
the OFF time.

After the first hours of operation, we recom-

mend checking the condition of the greas-
ing points and if necessary adjusting the
time according to environmental and ve-
hicle use conditions.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
12 GREASING SYSTEM SECTION 13 ADT 25-30 TIER3

Location of the greasing points --- I type

Circuit Greasing point Circuit Greasing point

Front articulation of left steering cylin-
B1 Top articulation of right tipping cylinder B12
der
B2 Top articulation of left tipping cylinder B13 Bottom fifth wheel hinge
B3 Rear suspension right rocker arm B14 Top fifth wheel hinge
B4 Rear suspension left rocker arm B15 Fifth wheel
Bottom articulation of right tipping cylin-
B5 B16 Fifth wheel
der
B6 Bottom articulation of left tipping cylinder B17 Fifth wheel
B7 Front fixed drive bearing B18 Fifth wheel
B8 Rear fixed drive bearing B19 Fifth wheel
B9 Rear articulation of right steering cylinder B20 Fifth wheel
B10 Rear articulation of left steering cylinder B21 Right body tipping pivot pin
B11 Front articulation of right steering cylinder B22 Left body tipping pivot pin

276C013013

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 13 GREASING SYSTEM 13

Lay-out system I type -- front chassis

276C013008

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
14 GREASING SYSTEM SECTION 13 ADT 25-30 TIER3

Lay-out system I type -- rear chassis

276C013009

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 13 GREASING SYSTEM 15

Location of the greasing points --- II type

Circuit Greasing point Circuito Greasing point

Front articulation of left steering cylin-
B1 Top articulation of right tipping cylinder B12
der
B2 Top articulation of left tipping cylinder B13 Bottom fifth wheel hinge
B3 Rear suspension right rocker arm B14 Top fifth wheel hinge
B4 Rear suspension left rocker arm B15 Fifth wheel
Bottom articulation of right tipping cylin-
B5 B16 Fifth wheel
der
B6 Bottom articulation of left tipping cylinder B17 Fifth wheel
B7 Front axle articulation B18 Fifth wheel
B8 Front/rear fixed drive bearing B19 Fifth wheel
B9 Rear articulation of right steering cylinder B20 Fifth wheel
B10 Rear articulation of left steering cylinder B21 Right body tipping pivot pin
B11 Front articulation of right steering cylinder B22 Left body tipping pivot pin

276C013010

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
16 GREASING SYSTEM SECTION 13 ADT 25-30 TIER3

Lay-out system II type -- front chassis

276C013011

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 13 GREASING SYSTEM 17

Lay-out system II type -- rear chassis

276C013012

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
18 GREASING SYSTEM SECTION 13 ADT 25-30 TIER3

Restoring grease dispenser functionality
Grease application will not work if the on of the grease
lines or greased point (joint) is obstructed.
Restore operation of the dispenser is very important in
this case.
Proceed as follows:
D locate the obstructed grease point from which no
grease is being let out;
D check that the grease point or tube are not dam-
aged; replace if required;
D disconnect pipe from grease gun in question;
D inject pressurised lubricant in the fitting until it pours
out of the grease point;
D reconnect pipe;
D start the pump from the display as previously
instructed, checking that lubricant is delivered to all
greasing points.
Restore operation of the automatic greasing control
unit after disassembly/draining
In case of:
D disassembly of the control unit;
D complete draining of the tank.
It is necessary restore operation.
Proceed as follows:
D start the pump from the display as previously in-
structed, checking that lubricant is delivered to all
greasing points;
D if these conditions occur, stop the pump;
D otherwise, check the components (pump, piping,
distributor, grease nipples) as described in the rela-
tive chapter.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 13
Checks of the lubrication control unit components
The working pressure of the system is ap-
proximately 150---200 bar (2175---2900 psi),
depending on the temperature and type of
lubricant used;
The maximum---pressure valve is set at 350
bar (5075 psi).
The opening pressure of a lubricator is
70---80 bar (1015---1160 psi).
Figure 7
276C013001
Proceed as follows:
D connect a manual pump equipped with a pressure
gauge to the maximum---pressure valve;
D operate the manual pump and verify that the wor-
king pressure falls within the prescribed values;
Figure 8
276C013002
D check that the maximum---pressure valve does not
have any leaks;
D the presence of a leak (arrow) indicates a possible
obstruction or block downstream from the pump;
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
GREASING SYSTEM 19
D check the hardness of the pipes between the pump
and distributor and the distributor and lubricating
points;
D normally the pipes should be squeezable when the
system is off;
The distributor blocks completely even with
a single element or single pipe blocked.
Figure 9
276C013003
D If necessary, connect a manual pump with a pressu-
re gauge to the lubricator;
D operate the manual pump and verify that the wor-
king pressure falls within the prescribed values;
D otherwise:
A. Check that the distributor is operating correctly;
B. Check that the distributor is fastened correctly
(the loosening of one of the retaining screws can
block an internal element);
C. Replace the distributor.
20 GREASING SYSTEM SECTION 13 ADT 25-30 TIER3

DISTRIBUTION DIVIDER
Description
The lubricant distribution divider is a multiple plunger
device that automatically distributes lubricant to the va-
rious lubrication points.
The quantity of lubricant supplied to each plunger is ap-
proximately 0.2 cc/stroke. Suitably blocking one or mo-
re outlets it is possible to obtain a multiple supply from
a single one.
The various plungers move in a predefined sequence
that is continually repeated. Each plunger has to have
completed its stroke before the next one can move.

Operation
The illustrations refer to an eight plunger di-
vider.
The descriptions that follow also apply to di-
viders with more plungers.
Stage 1
Lubricant enters the divider from above and fills the lo-
wer left chamber of plunger A.
Under the pressure, plunger A shifts to the left forcing
the lubricant in the upper left chamber to flow from ou-
tlet 2 through the lower right chamber of plunger D.
Stage 3
When plunger B has reached the left end of its stroke,
the channel connecting the arriving lubricant with the
upper right chamber of plunger C opens.
Under pressure plunger C shifts to the left forcing the
lubricant present in the upper left chamber to flow
through outlet 5 through the lower left chamber of plun-
ger B.

Stage 4
When plunger C has reached the left end of its stroke,
the channel connecting the arriving lubricant with the
upper right chamber of plunger D opens.
Under the pressure, plunger D shifts to the left forcing
Stage 2 the lubricant present in the upper left chamber to flow
through outlet 3 through the lower left chamber of plun-
When plunger A has reached the left end of its stroke,
ger C.
the channel connecting the arriving lubricant with the
upper right chamber of plunger B opens.
Under pressure plunger B shifts to the left forcing the
lubricant in the upper left chamber to flow through ou-
tlet 7 through the lower left chamber of plunger A.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 13 GREASING SYSTEM 21

Stage 5 Indicators (B)

When plunger D has reached the left end of its stroke
the channel connecting the arriving lubricant with the
upper left chamber of plunger A opens.
Under the pressure, plunger A shifts to the right forcing
the lubricant present in the upper right chamber to flow
through outlet 1 through the lower left chamber of plun-
ger D.
The sequence is completed as plungers B then C and
D shift to the right in succession. At this point a new cy-
cle then starts from stage 1.
Each block of the divider has an indicator arrow faste-
ned to the plunger rod.
Movement of the rod indicates that the plunger is func-
tioning correctly: If the system seizes, the indicator rod
no longer moves.
Figure 10

Quantity of lubricant supplied (A)

The standard quantity of lubricant supplied --- corre-
sponding to one stroke of a plunger --- is approximately
0.2 cc.
If one or more lubrication points require more oil, the
standard quantity can be doubled or tripled by suitably
blocking one or more outlets.
For example, with outlet 10 closed.
The related quantity of lubricant flows out through ou-
tlet 8.
The total quantity supplied by outlet 8 is therefore the
sum of that from outlet 10 and 8, meaning double the
standard quantity.
If three times the quantity is required, as if for outlet 1,
it suffices to close the two preceding outlets, these
being outlets 3 and 5.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
22 GREASING SYSTEM SECTION 13 ADT 25-30 TIER3

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For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
 SECTION 14

AIR---CONDITIONING SYSTEM
ADT 25-30 TIER3 SECTION 14
CONTENTS
Page
AIR-- CONDITIONING SYSTEM . . . . . . . . . . . . . . . . 3
Functional principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Functional outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Component layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Climate control system . . . . . . . . . . . . . . . . . . . . . . . . . 6
Climate control system air vents . . . . . . . . . . . . . . . . 7
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fan not working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fan works but with poor air---flow . . . . . . . . . . . . . . . 9
Normal function but poor air cooling . . . . . . . . . . . . . 9
Compressor not functioning or functioning poorly . 9
Diagnosis by pressure measurement . . . . . . . . . . . 10
Low pressure circuit --- insufficient pressure . . . . . 10
Low pressure circuit --- excessive pressure . . . . . . 10
High pressure circuit --- insufficient pressure . . . . . 10
High pressure circuit --- excessive pressure . . . . . . 10
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
System charge check . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cleaning/replacing passenger air cleaner . . . . . . . 11
Cleaning condenser . . . . . . . . . . . . . . . . . . . . . . . . . . 12
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
AIR-- CONDITIONING SYSTEM 1
Page
GENERAL SERVICING . . . . . . . . . . . . . . . . . . . . . . . 12
Usable fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Draining R134a fluid . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Works on system piping . . . . . . . . . . . . . . . . . . . . . . 13
Compressor lubricant . . . . . . . . . . . . . . . . . . . . . . . . . 13
SYSTEM DRAINING AND RECHARGING
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
R134A REFRIGERANT RECHARGING AND
RECOVERY STATION (99305146) . . . . . . . . . . . . . 14
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CHARGE CYLINDER AND OIL TANK . . . . . . . . . . 16
SAFETY STANDARDS . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATIONS FLOW DIAGRAM . . . . . . . . . . . . . . 18
RECOVERING REFRIGERANT FROM
SYSTEM ON VEHICLE . . . . . . . . . . . . . . . . . . . . . . . 19
CREATING VACUUM IN SYSTEM . . . . . . . . . . . . . 21
RESTORING SYSTEM OIL . . . . . . . . . . . . . . . . . . . 23
CHARGING THE SYSTEM WITH
REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CHECKING SYSTEM PRESSURES . . . . . . . . . . . . 26
OPERATIONS PRIOR TO REMOVING
STATION FROM SYSTEM . . . . . . . . . . . . . . . . . . . . 26
LEAK DETECTOR FOR AIR CONDITIONING
SYSTEMS WITH HFC R134A (99305147) . . . . . . 27
2 AIR-- CONDITIONING SYSTEM SECTION 14 ADT 25-30 TIER3

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For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 14
AIR---CONDITIONING SYSTEM
Functional principle
Fluid in a gaseous state and at pressure 1.3 bar is
drawn in by the compressor (driven by the motor by a
pulley with an electromagnetic coupling) and brought
to a pressure of 15---20 bar according to temperature.
The increase in pressure also determines a significant
increase in temperature (80---100˚C); to cool, the fluid
passes through the condenser, positioned in front of
the engine cooling radiator in the air flow from the fan.
On cooling the gaseous fluid reaches condensation
point 8around 60˚C) and passes to liquid state. It then
flows through the dehydrator filter where it is cleaned
and dehumidified by chemicals with moisture absorb-
ing properties.
The fluid then in a liquid state reaches the expansion
valve at the intake of the evaporator, which serves to
ensure expansion of the pressurised fluid. Expanding,
the fluid absorbs heat from the surrounding ambient
causing rapid cooling.
The evaporator, cooled by the fluid expanding inside it,
draws heat from the hot humid air from the outside
and/or vehicle interior (recirculation), which passes
between the coils of the evaporator itself and is then
delivered to the cab.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
AIR-- CONDITIONING SYSTEM 3
The air delivered to the cab is thus:
D cold, because it yields part of its heat to the evapor-
ator, assisting evaporation of the fluid;
D dehumidified, since lowering the temperature
causes condensation of the water vapour present in
the warm air.
The cooled and dehumidified air is conveyed by an
electric fan and distributed through the outlets located
in the cab.
In normal conditions the degree of cooling caused by
expansion of the fluid causes the condensation to
freeze on the fins of the evaporator: the system is there-
fore fitted with a suitable control device that limits the
heat extraction of the evaporator to prevent this effect
(anti---frost function).
The condensation water is discharged outside the
vehicle.
Lastly, from the evaporator the fluid, in gaseous state
and cooled (on average 6---12˚C) and at low pressure,
is drawn in by the compressor to start the cycle again.
4 AIR-- CONDITIONING SYSTEM SECTION 14 ADT 25-30 TIER3

Functional outline
1. Compressor
2. Condenser
3. Engine radiator fan
4. Electric fan
5. Expansion valve
6. Evaporator
7. Dehydrator filter

2692001

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 14 AIR-- CONDITIONING SYSTEM 5

Component layout
1. compressor
2. condenser
3. pressure switch
4. heater radiator
5. evaporator
6. cab air filter
7. electric fans
8. controls
9. thermostat

276C014001

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
6 AIR-- CONDITIONING SYSTEM SECTION 14 ADT 25-30 TIER3

Climate control system

Controls Operation
Knob 1: regulates heater temperature: 6. Only heater
D Turn clockwise to increase heating D start engine
D Turn counter---clockwise to decrease heating D regulate fan speed with knob 4
D regulate temperature as desired with knob 1
Button 2: controls entry of outside air into the cab:
D Pressed: flap closed, internal air recirculation 7. Only air conditioner
D Not pressed: flap open, air enters from outside D start engine
D regulate fan speed with knob 4
Knob 3: air conditioner adjustment thermostat:
D Turn clockwise to increase cooling . The air conditioner will not come on if knob
D Turn counter---clockwise to decrease cooling 4 is in the off position.
D regulate the temperature as desired with knob 3
Knob 4: regulates fan speed:
D Turn clockwise to increase speed 8. Heater and air conditioner
D Turn counter---clockwise to decrease speed (posi- D start engine
tion: off). D regulate fan speed with knob 4
Warning light illuminated when air conditioning is . The air conditioner will not come on if knob
turned on. 4 is in the off position.
Figure 1
D regulate the temperature as desired with knob 1
(warm air) and knob 3 (cold air).

Recommendations
D Do not leave knob 3 (air conditioner) at maximum
and knob 4 (fan) at minimum speed for long periods
to prevent ice forming on the evaporator.
D If the cab overheats (vehicle parked under sun) turn
knobs 3 and 4 to maximum and air the cab with the
windows open for a few minutes.
D The condensation produced by dehumidification of
the interior air is discharged through a pipe under
the vehicle.
D To ensure full system efficiency, switch on the air---
conditioner for a few minutes at least once a week,
regardless of temperature.

269NU2D2

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 14 AIR-- CONDITIONING SYSTEM 7

Climate control system air vents

A. Central vents directing air to windscreen
B. Adjustable front vent directing air to driver
C. Lower vents directing air to feet
D. Side vents directing air to driver

Cool air

Warm air

269NU2E1

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
8 AIR-- CONDITIONING SYSTEM SECTION 14 ADT 25-30 TIER3

TECHNICAL DATA
Fluid quantity (kg) 1,200
Max air flow ---rate (m3/h) 1020
Fans (n˚) 1
Open (bar) 2
Two level pressure switch (*)
Close (bar) 25
(*) in the following conditions:
D motor at circa 1500 RPM
D ambient temperature 30 --- 35 ˚C

EQUIPMENT
99305146 HFC R134a refrigerant fluid recharging and recovery station
99305147 Leak detector for air---conditioning systems with HFC R134a

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 14 AIR-- CONDITIONING SYSTEM 9

DIAGNOSTICS

Fan not working

Cause Checks Remedies

Fuse blown Check fuse Replace if damaged
Damaged electrical connection or Check electrical connection and Replace or repair damaged parts
wiring wiring
Faulty electric motor Check motor winding continuity Replace if damaged
with tester
Faulty electric motor resistor Check resistor continuity with Replace if damaged
tester
Faulty electric motor command Switch on fan and check relay Replace if damaged
relay function

Fan works but with poor air-- flow

Cause Checks Remedies

Evaporator output air duct Check duct Remove obstruction
obstructed
Air leak Faulty air duct seal Repair damaged parts
Faulty thermostat Check thermostat continuity with Replace if damaged
tester (when closed)

Normal function but poor air cooling

Cause Checks Remedies

Circuit charge insufficient
Circuit charge excessive
Measured pressure in the two Eliminate any leaks
circuits similar Vapour bubbles
present in the dehumidifier
indicator Recharge system
Excessive pressure in high Recharge circuit with specified
pressure circuit. No vapour quantity of fluid
bubbles visible in dehumidifier
indicator even after cooling
condenser with water

Compressor not functioning or functioning poorly

Cause Checks Remedies

Poly---V belt slack
Damage to compressor with
increased internal resistance
Coupling does not drive
compressor
Belts visibly yields under finger Adjust tension
pressure
Belt slips even with correct tension Replace if damaged
Check power supply voltage Recharge or replace batteries
Check electrical connection and Replace or repair damaged parts
wiring
Check winding continuity with Replace if damaged
tester
Check play between contact Adjust or replace
surfaces
Check for oil on surfaces Replace soiled parts
Find source of oil

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10 AIR-- CONDITIONING SYSTEM SECTION 14 ADT 25-30 TIER3

Diagnosis by pressure measurement

The system can be diagnosed in part by measuring the pressure in the two circuits.
The typical pressure values are as follows:
D low pressure circuit (blue connector): 2.0 --- 2.2 bar
D high pressure circuit (red connector): 19 ---25 bar
in the following conditions:
D Engine at circa 1500 rpm
D ambient temperature 30 --- 35˚C

Low pressure circuit -- insufficient pressure

Cause Checks Remedies

Faulty thermostat
Faulty compressor valve and seal
Compressor internal filter
obstructed
Thermostat cuts off Replace if damaged
electromagnetic coupling when air
temperature is not low enough
Pressure in the two circuits Replace or repair damaged parts
becomes similar when
compressor stops
Compressor connection is cold Clean filter
while low pressure pipe is not

Low pressure circuit -- excessive pressure

Cause Checks Remedies
Circuit charge insufficient Measured pressure in the two Eliminate any leaks.
circuits similar Vapour bubbles Recharge system.
present in the dehumidifier
indicator
Dehumidifier obstructed Valve input connector iced up Replace
Expansion valve obstructed Pressure in the two circuits Replace
becomes similar when
compressor stops
Piping obstructed Pressure tends toward zero or Replace
negative values
Expansion valve obstructed Pressure tends toward zero or Replace
negative values
Faulty thermostat Evaporator iced up Replace

High pressure circuit -- insufficient pressure

Cause Checks Remedies
Circuit charge insufficient Measured pressure in the two Eliminate any leaks
circuits similar Vapour bubbles Recharge system
present in the dehumidifier
indicator

High pressure circuit -- excessive pressure

Cause
Condenser cooling insufficient
Faulty compressor valve and seal
Air present in circuit
Checks Remedies
Condenser soiled or blocked Clean or replace if damaged
Faulty fan function Replace or repair damaged parts
Pressure in the two circuits Replace or repair damaged parts
becomes similar when
compressor stops
Eliminate infiltration
Recharge system

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 14 AIR-- CONDITIONING SYSTEM 11

MAINTENANCE
Before carrying out any operation, check Cleaning/replacing passenger air cleaner
that all precautions have been taken and all Proceed as follows:
aspects regarding safety of the personnel
Figure 2
involved have been clarified.
Read the related instructions given in SEC-
TION 1 of this manual.
If in doubt, speak to a more experienced per-
son.
Respect all general recommendations for
correct execution of maintenance works.

System charge check

Check the system charge once per year or in case of
reduced cooling efficiency as instructed in the relative
Chapter.
The checking and recharging operations
must be carried out by suitably equipped ex-
276NM060T
pert personnel.
R134a (tetrafluoroethane) coolant is used. D release and remove the rubber stops from the left
This coolant is classified as an environmen- side (see arrows);
tally---friendly product by law. Do not use this
Figure 3
fluid in systems working with the previous
fluid R12 (Freon 12).
For reasons of incompatibility between
compressor oil and fluid, do not use R12 in
systems designed to use R134a.

Do not discharge R134a into the atmos-

phere. Although the product has a zero
ozone depletion potential it has a global
warming potential.
Recovery and recycling procedures are
governed by law.
Always use type---approved coolant recov-
ery and recharging devices.
Do not mix different coolants in the same de- 276NM061T
vice. D remove the filter;
D replace filter or clean with compressed air, max. 5
bars (72.5 PSI). Reposition and fasten the screws;
D fasten the side with the hooks.
Fit the cleaner with the arrows facing the
cab.
Draw a reference line if missing to refit it in
the original position.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
12 AIR-- CONDITIONING SYSTEM SECTION 14 ADT 25-30 TIER3

Cleaning condenser GENERAL SERVICING

Proceed as follows:
. The following instructions must be
Figure 4 respected whenever working on circuit
components or handling refrigerant fluid.

Checking and charging must be carried out

by specialist personnel using specific
equipment.

Direct contact with refrigerant fluid is dan-

gerous. Always wear protective gloves and
goggles.

Usable fluids

Figure 5
2690313
D open the hood;
D inspect and clean the condenser with compressed
air (max 5 bar), then close the hood.

2692006
R 134a (tetrafluoroethane) coolant is used, which is
rated eco---friendly by current standards: it must abso-
lutely not be used in systems operating with the previ-
ous R 12 (Freon 12) fluid.
Due to incompatibility between compressor oil and
fluid, R 12 fluid may not be used in systems designed
to use R 134a fluid.
Before recharging, check the type of fluid used.
Never mix different refrigerants in the same apparatus.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 14 AIR-- CONDITIONING SYSTEM 13

Draining R134a fluid Compressor lubricant

Use specific PAG lubricant for R134a fluid.
Figure 6 The PAG lubricant used is extremely sensitive to mois-
ture.

Figure 8

2692007
Do not discharge R134a fluid into the atmosphere.
Although its potential for damaging the ozone layer is
zero, it may nevertheless contribute to global warming. 2692008
Always use approved fluid recovery and recharging Always plug all circuit openings and containers after
equipment. maintenance operations to prevent water infiltration.

Works on system piping Lubricant must be changed or topped---up in the fol-

lowing cases:
Figure 7 D in case of leakage;
D in case of sudden circuit discharge (burst pipe);
D if compressor is replaced.
Lubricant and fluid do not mix together
above a certain temperature: a visual
inspection in these conditions through the
indicator may mistakenly lead to changing
the fluid, which appears ”soiled”’.

2692009
Fit the O---ring (1) in the seat on the nut (2) at a con-
nector (3).
Lubricate the connector and o---ring with specific PAG
lubricant.
Hand---tighten the nut then tighten to the specified
torque.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
14 AIR-- CONDITIONING SYSTEM SECTION 14 ADT 25-30 TIER3

SYSTEM DRAINING AND RECHARGING Figure 9

PROCEDURES
The system draining and recharging procedure
requires the IVECO 99305146 station and involves the
following operations:
D recovering refrigerant from the vehicle system;
D creating vacuum in system;
D restoring system oil;
D charging system with refrigerant;
D checking system pressure;
D operations prior to removing station from system;
D checking for leaks in system with 99305147 leak
detector.

R134a REFRIGERANT RECHARGING AND

RECOVERY STATION (99305146)
The station is designed for use on all vehicle air---condi-
tioning systems that use TR134A.
By connecting the station to a cooling system the gas
contained in it can be recovered, cleaned and pre-
pared for recharging into the system, or transferred to
an external container. It is also possible to assess the
quantity of oil removed from the system, restore it and
”empty” the system.
To function the station has to absorb circa 3 kg of
refrigerant.
For rapid use it is recommended to have at least 2 kg
of refrigerant in the cylinders and to keep the station as
level as possible. 50631
The station consists of:
1. Control panel
. This procedure does not describe refriger- 2. Container for restoring any oil recovered during
ant charging/discharging from external/in- draining
ternal containers or maintenance phases. 3. Flexible pipes
Refer to the equipment use and mainten- 4. Container for accumulating oil recovered from
ance handbook. system
5. Charging cylinder with rotary graduated scale

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 14 AIR-- CONDITIONING SYSTEM 15

CONTROL PANEL

50633

CONTROL PANEL KEY

M1 Low pressure gauge L4 Maximum level indicator
M2 High pressure gauge L5 Minimum level indicator
M3 Charge cylinder pressure gauge A Tank resistance/unit process switch
LOW Low pressure valve LA1 Unit process indicator
HIGH High pressure valve LA2 Tank resistance indicator
REF Refrigerant charge/discharge valve B Refrigerant process/vacuum process switch
V1 Valve on low pressure pipe LB1 Refrigerant process indicator
V2 Valve on high pressure pipe LB2 Vacuum process indicator
V3 Oil injection valve for A/C system C Recycle/recharge recovery cycle switch
V5 Oil drain valve LC1 Recovery recycle cycle indicator
V9 Service valve for A/C system coolant cleaning LC2 Charge indicator
10 Humidity indicator D Vacuum/vacuum test switch
VS Safety and discharge valve LD1 Vacuum indicator
L3 Alarm warning light LD2 Vacuum test indicator

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
16 AIR-- CONDITIONING SYSTEM SECTION 14 ADT 25-30 TIER3

CHARGE CYLINDER AND OIL TANK

50632

CHARGE CYLINDER AND OIL TANK KEY

1. Pressure values in bar (vertical lines, upper rotatable cylinder).
2. Charge weight value in grams (oblique lines, upper rotatable cylinder), subdivision 50 g between lines.
3. Tank level display (internal cylinder).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 14 AIR-- CONDITIONING SYSTEM 17

SAFETY STANDARDS
This station is destined for use exclusively The station is fitted with special connectors to prevent
contamination with systems that use R12. Do not
by professionally trained operators who
attempt to adapt this unit for use with R12.
must be familiar with cooling systems,
refrigerant gases and the potential hazards
of pressurised equipment, therefore:
D always use protective gloves and
goggles when working with refrigerant
gases. direct contact between eyes and
refrigerant fluid may cause blindness;
D avoid contact with skin (low boiling tem-
perature ---30˚C may cause frostbite);
D avoid inhaling refrigerant gas vapours;
D before making connections between sta-
tion and system or external container
check that all valves are closed;
D before disconnecting the station check
that the cycle is finished and that all
valves are closed, to prevent refrigerant
gas escaping into the atmosphere;
D do not expose or work with the unit in
acidic or damp environment or in the
vicinity of open containers with inflam-
mable substances;
D the unit must be used in areas with good
ventilation and air change;
D do not change the settings of safety
valves and control systems;
D do not use gas bottles or other storage
containers that are not approved and that
are not fitted with safety valves;
D never fill any container to over 80% of its
maximum capacity;
D do not leave the unit powered up if it is
not to be used immediately. Switch off the
mains power supply if the unit is not
being used.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
18 AIR-- CONDITIONING SYSTEM SECTION 14 ADT 25-30 TIER3

OPERATIONS FLOW DIAGRAM

2692004

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 14 AIR-- CONDITIONING SYSTEM 19

RECOVERING REFRIGERANT FROM
SYSTEM ON VEHICLE
Figure 10
2690702
Before disconnecting any pipes from the conditioner
check whether it is possible to make repairs without
discharging the gas. If this is not possible, the following
operations are mandatory:
D connect the pipe marked HIGH under the pressure
gauge to the socket (1) on the pipe coming from the
evaporators.
D Connect the pipe marked LOW under the pressure
gauge to the output socket from the filter on pipe (2).
D Connect the station to the mains power supply
(220V 50 Hz).
D Turn switch A (Process Unit) to position 1.
D The corresponding indicator LA1 comes on.
D Turn switch B (Refrigerant Process) to position 1.
D The corresponding indicator LB1 comes on.
D Turn switch C (Recovery Recycle) to position 1.
D The recovery and recycling operation will start auto-
matically, indicator LC1 on indicates operation in
progress.
D On completing the operation the unit will stop auto-
matically and indicator LC1 will go out. Wait for a few
minutes for any remaining low pressure refrigerant
in the system to increase pressure, absorb heat and
be recovered. The station will automatically repeat
the recovery cycle, if the above conditions are pres-
ent.
D Return switches A, B and C to position 0.
D Close valves V1, V2, LOW and HIGH.
. If the refrigerant reaches maximum level
(maximum level indicator L4 on), the recov-
ery cycle must be stopped immediately by
turning switch C to position 0 and decanting
the refrigerant from the charge cylinder to a
suitable external tank.

Figure 11

74126
D Open valves V1 and V2.
D Open the LOW and HIGH valves.

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20 AIR-- CONDITIONING SYSTEM SECTION 14 ADT 25-30 TIER3

Figure 12

50636

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 14
CREATING VACUUM IN SYSTEM
. Do not carry out the vacuum cycle if there is
even minimal pressure present in the station
or the system.
This operation should be carried out once all repairs
have been completed and the system components
have been correctly reassembled. This operation pre-
cedes recharging, and is carried out as follows:
D Connect the pipes to the correct sockets on the sys-
tem and open valves V1---V2/LOW and HIGH.
D Turn switch A (Process Unit) to position 1.
D The corresponding indicator LA1 comes on.
D Turn switch B (Vacuum Process) to position 2.
D The corresponding indicator LB2 comes on.
D Turn switch D (Vacuum) to position 1. The system
evacuation process will start automatically and the
corresponding indicator LD1 will come on, indicat-
ing operation in progress.
Figure 13
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
AIR-- CONDITIONING SYSTEM 21
D After a few minutes operation (maximum 10) if the
system is free of any leaks, indicator LD2 VACUUM
TEST also comes on. From this moment on evacu-
ation must continue for at least two hours to achieve
adequate vacuum.
. If vacuum test indicator LD2 does not light,
a leak is present. Interrupt evacuation, rec-
tify the leak and repeat the evacuation
procedure.
D At the end of the programmed evacuation time turn
switch D (vacuum test) to position 2 and leave the
system for 3---5 minutes in these conditions.
D VACUUM TEST indicator LD2 on indicates that the
system seal is good. VACUUM TEST indicator LD2
off indicates a leak. Rectify the leak and repeat the
vacuum cycle.
D Return switches D and B to position 0 and proceed
to the next phase.
50637
22 AIR-- CONDITIONING SYSTEM SECTION 14 ADT 25-30 TIER3

It is possible that at the end of each recovery cycle the D Quantify and note the quantity of oil discharged.
station has also recovered lubricant from the com- D Dispose of the recovered oil correctly.
pressor, which must be discharged into the graduated
container provided (1). . This oil cannot be used again.
D Slowly open valve V5 (Oil Discharge).
The same quantity of oil as removed must be replaced
D When all the oil has been discharged into the con-
in the system.
tainer, re---close valve V5.

Figure 14

50638

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 14 AIR-- CONDITIONING SYSTEM 23

RESTORING SYSTEM OIL
If oil has been discharged from the system during the
recovery and recycling phase, this must be replaced.
D Take the meter provided filled with the correct or
previously measured amount of oil for the system in
question.
D Connect the meter (1) to the lubricant input valve V3.
D Open valve V3 and run system vacuum for a few
seconds.
D Open the valve on the meter container (1). The oil
will be sucked into the system.
D Close valve V3 and the valve on the recipient once
the required quantity of oil has been taken in to the
system.
D Disconnect the meter (1) from injection valve V3 and
replace the protective cap.
. Keep oil containers sealed to prevent conta-
mination. Remember that the oil is extremely
sensitive to moisture:
Never open oil injection valve V3 if the sys-
tem is under positive pressure.
Oil must only be injected with the system
under negative pressure. The oil level
should not drop below the suction pipe level
(to prevent air entering the system).

Figure 15

50639

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
24 AIR-- CONDITIONING SYSTEM SECTION 14
CHARGING THE SYSTEM WITH
REFRIGERANT
Before recharging it is good practise to be familiar with
a number of important rule:
D Know how much refrigerant to use, (normally
written on an adhesive label applied to the vehicle).
D The charging cylinder has a minimum level check
that prevents non---condensable gas entering the
system.
D For this reason the last 600 g of refrigerant it con-
tains cannot be used.
D Therefore, before charging, check that the cylinder
contains a sufficient quantity for the charge (maxi-
mum usable quantity 3800g).
D If the pressure in the charge cylinder displayed on
the gauge (2) is greater than the required value vis-
ible on the charge cylinder glass ---10 bar max, dis-
charge the excess pressure through valve (1) on the
pressure gauge group until bringing it to the correct
level, reading the value on the gauge.
. For transferring refrigerant from an external
tank to the charge cylinder and vice---versa,
refer to the equipment manual.
Figure 16
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
. Considering that the quantity of refrigerant
is related to its pressure, to find the effective
weight turn the outer part of the charge cyl-
inder until the line of the diagram coincides
with that of the level indicator. This gives the
exact quantity of refrigerant contained in the
cylinder (starting weight).
. When calculating the weight of refrigerant,
in addition to the 600 g not usable remember
to increase the charge by circa 100 g (this is
the weight of refrigerant contained in the
two station---system connector pipes). The
correct quantity of refrigerant to charge into
the plant is therefore given by: 600 gr. + 100
gr. + (system capacity quantity).
Before charging always check that the indica-
tor on the ’console’ indicates that the refriger-
ant is free of moisture. if this is the case, the
indicator indicates an intense green colour,
otherwise replace the station internal filters as
instructed in the equipment manual.
50640
ADT 25-30 TIER3 SECTION 14
When the cylinder contains the required quantity for
charging, (the two pipes must already be connected to
the sockets on the system, since the vacuum operation
has already been performed), proceed as follows:
D Close the LOW valve keeping the HIGH and
V1---V2valves open.
D Turn switch B (Refrigerant Process) to position 1,
indicator LB1 comes on.
D Turn switch C (Charge) to position 2, the correspon-
ding indicator LC2 will come on and refrigerant will
flow from the station to the system.
. If during charging the refrigerant level in the
cylinder drops below the foreseen quantity,
the system will stop and the minimum Level
warning light will come on (L5).
Figure 17
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
AIR-- CONDITIONING SYSTEM 25
D After charging 200 + 500 g of refrigerant, according
to system dimensions, stop charging by turning
switch C (charge) to position 0.
D Using the electronic leak detector, search for any
leaks in the system.
D Complete charging the system until the pre---calcu-
lated residual weight in the cylinder has been
reached.
D (Residual weight = Total weight --- system capacity
weight).
D Complete the charge, turn switches C --- B and A to
position 0 (A having been turned to create vacuum).
D Re---check for any leaks.
D Close the HIGH valve.
50641
26 AIR-- CONDITIONING SYSTEM SECTION 14 ADT 25-30 TIER3

CHECKING SYSTEM PRESSURES OPERATIONS PRIOR TO REMOVING

After completing the charge, leave the pipes con-
nected and perform the following check:
D Close the LOW and HIGH valves, V1 and V2 open.
D Switch on the engine, switch on the air conditioner
and check on gauges M1 and M2 that pressures
correspond, normally: low pressure no lower than
1 bar, high pressure 15 --- 18 bar, according to sys-
tem characteristics.
STATION FROM SYSTEM
Carry out the following operations, observing the previ-
ously described safety standards:
D Check that all the valves (LOW --- HIGH --- V1 --- V2)
are closed.
D Disconnect the pipes from valves V1 and V2 and
replace the caps on the system valves.
D Re---check the system with the leak detector.

. Normally, with the air ---conditioner operat-

ing, air should come out from the outlets at
a temperature below 5˚C after the time
necessary for temperature to stabilise in the
ducts.

Figure 18

50642

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 14 AIR-- CONDITIONING SYSTEM 27

LEAK DETECTOR FOR AIR CONDITIONING Figure 19

SYSTEMS WITH HFC R134A (99305147)
The L---780A apparatus permits extremely precise
detection of HFC 134A gas leaks from the system in the
order of 3.3 g per year when set to maximum sensitivity.
The instrument does not require calibration. The oper-
ator only has to set the required sensitivity.
Any gas leak is indicated by an acoustic signal and an
LED that blinks in proportion to the concentration of
gas.
The LED also serves as battery charge indicator (off =
battery flat).
Operating temperature is between 0 and 50˚C.
The instrument has a flexible probe to reach particularly
inaccessible connections and parts. 50643
The two sensitivity levels are:
D Low sensitivity = 16.5 g/year.
D High sensitivity = 3.3 g/year.

. Before making checks on the vehicle, wait

for the engine to cool. Hot engine compo-
nents may cause reading errors.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
28 AIR-- CONDITIONING SYSTEM SECTION 14 ADT 25-30 TIER3

Page left intentionally blank

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
SECTION 15

CAB
 ADT 25-30 TIER3 SECTION 15 CAB 1

CONTENTS

Page Page

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CAB TILTING CYLINDER . . . . . . . . . . . . . . . . . . . . . 19

ENGINE HOOD TIPPING HYDRAULIC SYSTEM . 4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Component layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Component layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

CAB TIPPING HYDRAULIC SYSTEM . . . . . . . . . . . 8 LOWER COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Cab tipping hydraulic system components Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cab tipping hydraulic system diagram . . . . . . . . . . . 9
SIDE COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . 10
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CAB REMOVAL-- REPLACEMENT . . . . . . . . . . . . . 11
SIDE PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CAB COMPONENTS REMOVAL--
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

ENGINE HOOD TIPPING CYLINDER . . . . . . . . . . 18

Detachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Reattachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
2 CAB SECTION 15 ADT 25-30 TIER3

Page left intentionally blank

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 15 CAB 3

DESCRIPTION Figure 3
The cab consists of a steel structure in compliance with
ROPS/FOPS specifications, lined with glass fibre
panels anchored to the frame through elastic buffers.
The cab can be tilted by means of a dedicated
hydraulic system.

Figure 1

269NS073
The following escape routes can be used to exit the
vehicle in an emergency (see arrow):
D door (to open);
D front right window (break).

Figure 4

269NU081
When getting in and out of the vehicle always use the
handles provided and the steps (see arrow) specifically
designed to permit easy accessibility.

Figure 2

174NS08
To break the glass, use the tool (see arrow) under the
window itself.

269NU082
The cab has an access door: the outer door handle
(see arrow) has a lock and key.
D to lock, turn the key clockwise;
D to unlock, turn the key anticlockwise.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
4 CAB SECTION 15 ADT 25-30 TIER3

ENGINE HOOD TIPPING HYDRAULIC SYSTEM

This system has the purpose of ensuring the raising of
the engine hood by means of a hydraulic cylinder.
A second cylinder opens the closure hook.
The system can be provided with electrical operation
as well.

Figure 5

276NM039T

D position 1 = up
D position 2 = down

In either case, the operation occurs by manually select-

ing the up/down position on the tank.
If there is a manual tipping pump, this is operated using
the lever provided.

Figure 6

276NM040T

If there is an electrical pump, the tipping occurs by

pressing the button (see arrow).

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 15 CAB 5

Component layout
1. Manual pump
2. Electric pump 212
3. Hood ylinder
4. Button 213
5. Hood latch

276C015001

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
6 CAB SECTION 15 ADT 25-30 TIER3

Component layout
1. Manual pump
2. Electric pump 212
3. Hood ylinder
4. Button 213
5. Hood latch

(a) Up/down switch

(b) Overpressure valve
(c) Controlled check valve

Operation
The operation occurs by manually selecting the posi-
tion of the up/down switch (a) on the pump unit.

In the case of the electrical pump 212, pushing the but-

ton 213 supplies the electropump, which continues to
operate as long as the button is pushed.
The power supply of the electropump is subject to con-
sent provided by HEAD, which --- if the starting switch
is in position 0 (key off) --- grounds pin 22, causing the
closure of remote control switch GC.
The overpressure valve protects the circuit, opening in
case of excessive pressure.
The by---pass between the cylinder chambers has the
purpose of discharging residual pressure in rest posi-
tion.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 15 CAB 7

Diagram

3
5

1
a
2

M GC

b b

+
213

22
HEAD

276C015002

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
8 CAB SECTION 15 ADT 25-30 TIER3

CAB TIPPING HYDRAULIC SYSTEM

The system has the purpose of ensuring the raising of
the cab by means of a hydraulic cylinder.
This occurs by manually selecting the position of the
up/down switch on the tank and operating the lever
provided.

Figure 7

276NM039T

D position 1 = up
D position 2 = down

Cab tipping hydraulic system components location

276C015003

1. Manual pump
2. Cylinder

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 15 CAB 9

Cab tipping hydraulic system diagram

1. Manual pump
2. Cylinder

(a) Up/down switch

(b) Overpressure valve
(c) Controlled check valve

1
a

276C015004

Operation
The tipping occurs by manually selecting the position
of the up/down switch (a) on the pump unit.

The overpressure valve protects the circuit, opening in

case of excessive pressure.
The by---pass between the cylinder chambers has the
purpose of discharging residual pressure in rest posi-
tion.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
10 CAB SECTION 15 ADT 25-30 TIER3

TIGHTENING TORQUES

S269GN11

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 15 CAB 11

CAB REMOVAL---REPLACEMENT Figure 9

Before carrying out any operation, check

that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in
SECTION 1 of this manual.
If in doubt, speak to a more experienced
person.
Respect all general recommendations for
correct execution of maintenance works.

Removal 276NM046T
Proceed as follows: D position a suitable container, then disconnect the
D park the vehicle to a suitable flat and solid surface, radiator hose (arrow) and discharge the engine
remove the ignition key, engage the handbrake and coolant;
place maintenance warning signs;
D disengage the battery cut ---off switch or disconnect Exhausted oil and fluids must be collected
the battery leads to eliminate any risk of and disposed of according to standards in
short ---circuit; force.
D lock the articulation using the steering lock bar as
instructed in SECTION 1; Figure 10
D open the hood;
D remove the side panels as instructed in the chapter
on SIDE COVERS;

Figure 8

2691952
1. High pressure circuit valve
2. Low pressure circuit valve

276NM009T D Proceed to discharge the air conditioner system as

instructed in the chapter on the AIR---CONDITION-
ING SYSTEM;
D turn the heater valve to maximum then open the filler
cap on the expansion tank; The system must be discharged by special-
ist personnel using specific equipment.
For these operations, refer to the proce-
dures provided by the equipment manufac-
turer.

Do not discharge R134a fluid into the

atmosphere. Although its potential for
damaging the ozone layer is zero, it may
nevertheless contribute to global warming.
Always use approved refrigerant recovery
and recharging apparatus.
Never mix different refrigerants in the same
apparatus.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
12 CAB SECTION 15 ADT 25-30 TIER3

Figure 11 Figure 13

1
2691953 276NM042T
D remove the cab electrical connections cover and D working from the inside of the cab, disconnect the
the duct interface support guard (arrow); protective cap (1) from the steering column cover;
D unscrew the retaining screws (see arrow) fastening
Figure 12 the steering column front cover;
D remove the steering column front cover;
Carefully disengage the plastic locking
pawls when disassembling the cover.

Figure 14

276NM043T
D unscrew the locking bolt of the steering shaft and di-
sconnect the joint (1) of the steering shaft from the
column;
D exit from the cab and close the door;
2691954
D open the retainer clamp and disconnect the
electrical connections:
--- white connector: cab/engine wiring interface (1);
--- brown connector: cab/services wiring interface
(2);
--- yellow connector: cab/automatic transmission
wiring interface (3);
--- green connector: cab/heated rear view mirror
wiring interface (if fitted) (4);
To disconnect the connector, proceed as
follows:
A. lift the safety catch.
B. pull away the connector.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
. The operations described below refer to the
following figures.
Removal of the fastening clamps/clips is not
described. These must be cut/removed and
subsequently replaced to ensure correct
fastening of the clamped components.
D disconnect the following electrical connections:
--- cab power supply (7);
--- video camera power line (8);
--- ground braid (9);
D disconnect the following air connections:
--- pneumatic seat (10);
--- parking brake delivery (11) and return (12);
D disconnect the following pipes:
--- windscreen washer delivery (13);
--- air---conditioner fluid delivery (14) and return
(15);
--- engine coolant delivery (16) and return (17);
Coolant may leak during these operations.
D remove the clamps from the air---conditioner
condensation discharge pipes (18);
D disconnect the automatic lubrication system
delivery (19);
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
SECTION 15 CAB 13
Before detaching the hydraulic pipes
prepare plugs suitable for closing the free
ends.
D arrange a suitable container then disconnect the
brake pedal valve hydraulic lines:
--- delivery P from pump (21);
--- return B to tank (22);
--- output T1 rear brakes (23);
--- output T2 front brakes (24);
--- output R2 to auxiliary brake valve (25);
--- output R1 to relay valve (26);
--- discharge N to tank (27).
Coolant may leak during these operations.
D disconnect the hydraulic pipelines:
--- front brakes actuation pressure (28);
--- rear brakes actuation pressure (29);
D open the left mudguard;
D remove the flexible pipe (30), the connector (31) and
the exhaust silencer (32);
D remove the left side cover;
D remove the split pin and remove the articulation pin
(25) from the cab lifting cylinder, collecting the
shims;
D unscrew the universal joint screws at the groove
(33) and disconnect the steering column from the
steering valve.
14 CAB SECTION 15 ADT 25-30 TIER3

2691955

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 15 CAB 15

276C015005

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
16 CAB SECTION 15 ADT 25-30 TIER3

Figure 15 Replacement
Figure 17

2691957
D apply the lifting ring bolts (arrow) to the cab using
the threaded holes provided;
D using suitable lifting gear apply the belts to the lifting
ring bolts; 274A15007
Figure 16 If the support bushings have been removed,
position the new bushings during assembly
with the axis shifted downward (see arrow).
Proceed as follows to replace:
Figure 18

276NM045T
D use a suitable tool to support the steering shaft so
as to introduce it into the floor passage (Fig. 3, see
2691958 arrow) while lowering the cab;
D bring the belts into tension to discharge cab weight
The operator must be positioned in order to
from the silent ---blocks, then remove the split pin
move the tool while remaining outside the
and extract all four cab silent block pins (arrow),
path of the cab.
collecting the shims.
Check that all connections and pipes are
disconnected and all fastening clamps
removed.
D carefully lift the cab depositing it on a flat surface
and propping it to ensure stability.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 15 CAB 17

Figure 19

2691959
D vertically present the cab (suitably suspended9
lowering it to a distance of circa 25 cm from the silent
block pins;
D remove the support tool from the steering column;
D lower the cab until the holes of the silent ---block pins
coincide with the relative holes in the cab brackets;
Conclude as follows:
D position the fixing pins of the cab supports and se-
cure them with the relative elastic rings;
D working from inside the cab, connect the steering
shaft to the steering column;
D tighten the locking bolt of the steering column to the
prescribed tightening torque;
steering column bolt 45 Nm (33 lb ft)
D remount the steering column front cover and repla-
ce the protective cap;
D connect the discharging terminal by tightening the
retaining band;
Bleed off the air in the hydraulic circuit as
instructed in SECTION 10.
Check engine coolant level as instructed in
SECTION 4.
Recharge the air ---conditioning system as
instructed in SECTION 14.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
18 CAB SECTION 15 ADT 25-30 TIER3

CAB COMPONENTS REMOVAL---
REPLACEMENT
Before carrying out any operation, check
that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in
SECTION 1 of this manual.
If in doubt, speak to a more experienced
person.
Respect all general recommendations for
correct execution of maintenance works.
D block the articulation by means of the steering lock
bar, as indicated in SECTION 1;
D open the hood;
D sling the hood to make sure it stays open;
D empty the circuit tank of the hood tipping system
using a suitable suction syringe;
D arrange a suitably---sized container underneath,
then disconnect the hydraulic connections (2) from
the cylinder (1);
Hydraulic fluid leakage may occur during
these operations.
D support the cylinder appropriately, remove the lock-
ing seeger (3), slip off both the pins (4) and remove
the cylinder.

ENGINE HOOD TIPPING CYLINDER Reattachment

Proceed with the reattachment by following the detach-
Detachment ment steps in the reverse order.
Proceed as follows: Fill the tank with the fixed quantity of prescribed fluid.
D bring the vehicle onto an appropriately solid flat sur- Perform some opening and closing cycles until the air
face, shut off the engine, remove the key from the is completely bled from the circuit: top up the tank if
ignition switch, engage the parking brake and affix necessary.
the indication signs;
D disconnect the battery---disconnect switch or dis-
connect the battery terminals in order to eliminate
any risk of short ---circuit;
Figure 20

2691965

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 15
CAB TILTING CYLINDER
Removal
Proceed as follows:
D park the vehicle to a suitable flat and solid surface,
remove the ignition key, engage the handbrake and
place maintenance warning signs;
D disengage the battery cut ---off switch or disconnect
the battery leads to eliminate any risk of
short ---circuit;
D lock the articulation using the steering lock bar as
instructed in SECTION 1;
Since the engine exhaust system is so near,
this operation must be carried out after the
end has been stopped for at least four
hours.
D open the left mudguard fender;
D remove the left side guard;
Figure 21
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
CAB 19
D empty the tipping circuit tank using a suitable
suction syringe;
D arrange a suitably---sized container underneath,
then disconnect the hydraulic connections (2) from
the cab lifting cylinder (1);
Hydraulic fluid leakage may occur during
these operations.
D remove the seeger (3) and slip off the upper
trunnion (4) of the cylinder, recovering the shim
washers;
D support the cylinder appropriately, remove the
seeger (5), recovering the shim washers, and slip
the cylinder off the lower trunnion (6).
Replacement
For replacement, follow the removal instructions in
reverse order.
Fill the tank with the specified quantity of fluid.
Open and close several times to fully bleed the circuit:
Top---up the level if necessary.
2691966
20 CAB SECTION 15 ADT 25-30 TIER3

HOOD D harness the hood using hooks and cables suitable

for the load and suitable lifting gear;
Removal D remove the snap ring (2), extract the pin (3) and
Proceed as follows: disconnect the tilting cylinder (4) from the hood;
D park the vehicle to a suitable flat and solid surface, D from both sides unscrew the screws (5) fastening
remove the ignition key, engage the handbrake and the hinge (6) to the chassis and remove the hood.
place maintenance warning signs;
D disengage the battery cut ---off switch or disconnect Replacement
the battery leads to eliminate any risk of For replacement, follow the removal instructions in
short ---circuit; reverse order.
D lock the articulation using the steering lock bar as Open and close several times and adjust the hinge until
instructed in SECTION 1; achieving correct closure.
D open the hood (1);
Figure 22

276C015006

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 15 CAB 21

LOWER COVERS D suitably support the cover:

1. front cover
Removal 2. central cover
Proceed as follows: 3. rear cover
D park the vehicle to a suitable flat and solid surface, D remove the bolts fastening the cover to the chassis
remove the ignition key, engage the handbrake and and remove the cover.
place maintenance warning signs;
D disengage the battery cut ---off switch or disconnect Replacement
the battery leads to eliminate any risk of For replacement, follow the removal instructions in
short ---circuit reverse order.
D lock the articulation using the steering lock bar as Check that the cover closes correctly.
instructed in SECTION 1;

Figure 23

276NM055T

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
22 CAB SECTION 15 ADT 25-30 TIER3

SIDE COVERS SIDE PANELS

Removal Removal
Proceed as follows: Proceed as follows:
D park the vehicle to a suitable flat and solid surface, D park the vehicle to a suitable flat and solid surface,
remove the ignition key, engage the handbrake and remove the ignition key, engage the handbrake and
place maintenance warning signs; place maintenance warning signs;
D disengage the battery cut ---off switch or disconnect D disengage the battery cut ---off switch or disconnect
the battery leads to eliminate any risk of the battery leads to eliminate any risk of
short ---circuit; short ---circuit;
D lock the articulation using the steering lock bar as D lock the articulation using the steering lock bar as
instructed in SECTION 1; instructed in SECTION 1;
D open the mudguard from the side of the cover to
replace; . The procedure is easier if the hood is open.
D suitably support the cover;
D unscrew the side panel securing screws (arrow);
D unscrew the screws and remove the cover.
D raise the side panel to free the lower pins.
Replacement Replacement
For replacement, follow the removal instructions in
For replacement, follow the removal instructions in
reverse order.
reverse order.
Figure 24
Figure 25

276NM057T

276NM054T

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
SECTION 16

CHASSIS
 ADT 25-30 TIER3 SECTION 16 CHASSIS 1

CONTENTS

Page Page

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 BODY DETACHMENT-- REATTACHMENT . . . . . . 19

Front chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Detachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Rear chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Articulation joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Body angular position potentiometer adjustment . 21
Interface flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 BODY ANGLE SETTING . . . . . . . . . . . . . . . . . . . . . . 22
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . 9 Body angular position potentiometer
replacement --- I type . . . . . . . . . . . . . . . . . . . . . . . . . 24
Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Potentiometer control rod replacement . . . . . . . . . . 24
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Body angular position potentiometer
ARTICULATION JOINT REMOVAL-- replacement --- II type . . . . . . . . . . . . . . . . . . . . . . . . 25
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Potentiometer control rod replacement . . . . . . . . . . 25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Articulation ball joint pre---load adjustment . . . . . . 13
Reattachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
2 CHASSIS SECTION 16 ADT 25-30 TIER3

Page left intentionally blank

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 16 CHASSIS 3

DESCRIPTION
The chassis is in two distinct parts (front chassis and Maximum relative angle :
rear chassis) joined by a central joint that consists of a A. Movement around the horizontal axis:
large size fifth wheel for movements around the 15 (˚) without body heating
horizontal axis and two rotating pins on axial ball joints 12 (˚) with body heating
for movements around the vertical axis. B. Movement around vertical axis: 45 (˚)
This central articulation allows the front part of the
vehicle to move in relation to the rear part around the
horizontal axis (A) and around the vertical axis (B).

Figure 1

276C016001

276C016002

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
4 CHASSIS SECTION 16 ADT 25-30 TIER3

Front chassis
The front chassis consists of a complex structure that
sustains the propulsion units (engine with its systems
and automatic transmission), and upon which there are
the mounting points for most of the hydraulic system
units, the front suspension (1) and the cab (2).
The central articulation joint is connected to the chassis
by a flange (3).
The fuel tank (4) and the hydraulic system tank (5) are
bolted in the front part of the structure.

Figure 2

276C016003

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 16 CHASSIS 5

Rear chassis
The rear chassis consists of two side members joined
by a cross member that has the mounting points for the
central articulation joint pins (1), the rear suspension
rocker arm (2), dumping cylinders (3), steering
cylinders (4) and the body (5).

Figure 3

276C016004

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
6 CHASSIS SECTION 16 ADT 25-30 TIER3

Articulation joint
The joint around the horizontal axis is obtained using
a large diameter bearing (articulation joint with two
rows of balls) with the outer ring flanged to the front of
the chassis.
On the inner ring of the thrust ball bearing a supporting
ring is flanged that has two hubs --- lower and upper
--- into which, by means of two axial ball joints , two pins
are inserted --- lower and upper --- integral with the
fork ---like ends of the rear part of the chassis.
The lower pin ball joints are mounted in O arrangement:
both outer rings fit against a fixed shoulder inside the
hub.
In this way the position between the support ring hub
and the fork ---like end of the rear chassis are vertically
restrained .
The ball joints of the upper pin, which is also mounted
in O arrangement, are axially free in relation to the
support ring hub, to avoid that the heat expansion
causes overload.
Both pairs of ball joints are pre---loaded to ensure the
chassis deflection stiffness required.

Legend
1. articulation joint with two rows of balls
2. support ring with hubs
3. spacer
4. upper pin
5. upper axial ball joints pair
6. reaction washer
7. upper pin fastening screw
8. rear chassis
9. lower axial ball joints pair
10. lower pin
11. front chassis

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 16 CHASSIS 7

1 2 3 4

6
7

FWD

11 10 2691905

1 8

2 2691906

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
8 CHASSIS SECTION 16 ADT 25-30 TIER3

Interface flange
The connection of the systems between the front and 1. Body tipping cylinders delivery
the rear is by means of an interface flange. 2. Brake operation relay valve return
(oil bath brakes version)
3. Rear brakes actuation
4. Rear accumulator recharge
(oil bath brakes version)
5. Right steering pipes
6. Unused
7. Parking brake pneumatic control
8. Electrical connections
9. Lubrication
10. Camera wiring
11. Body tipping return
12. Left steering pipes
13. Rear brake cooling delivery
(oil bath brakes version)
14. Rear brake cooling return (oil bath brakes version)
15. Pressure fitting

Figure 4

8
5
9
10
11

4
12

13

14

1
15
276C1009N

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 16 CHASSIS 9

TIGHTENING TORQUES
Joint

Body

276C016005

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
10 CHASSIS SECTION 16
ARTICULATION JOINT REMOVAL---REPLACEMENT
Before carrying out any operation, check
that all precautions have been taken and all
aspects regarding safety of the personnel
involved have been clarified.
Read the related instructions given in
SECTION 1 of this manual.
If in doubt, speak to a more experienced
person.
Respect all general recommendations for
correct execution of maintenance works.
Removal
Proceed as follows:
D park the vehicle to a suitable flat and solid surface,
remove the ignition key, engage the handbrake and
place maintenance warning signs;
D disengage the battery cut ---off switch or disconnect
the battery leads to eliminate any risk of
short ---circuit;
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3
During the following operations the front
part of the vehicle is disconnected from the
rear part.
Provide appropriate fixed support for the
rear part of the chassis.
Set up a forklift with suitable capacity under
the front part of the chassis that is able to
move forward at least 1 meter (30 ft).
D disconnect all the centralized lubrication system fit-
tings from the fifth wheel coupling;
For more information on the lubrication
points, see SECTION 13.
D disconnect both steering control cylinders (2) from
the articulation hinge (1) following the instructions
in SECTION 10;
D disconnect the drive shaft (3) between the automa-
tic transmission and the fixed support by following
the instructions in SECTION 7;
Figure 5
276D016006
ADT 25-30 TIER3 SECTION 16 CHASSIS 11

D suitably support the articulation hinge (1) then

working from below unscrew the fastening screw
(11) and remove the washer (12) the adjuster shim
(13) and the pin (14);
D remove the o---rings (18) and (19);
D working from above unscrew the fastening screws
(21) and remove the washer (22), the adjuster shim
(23) and the pin (24);
D remove the articulation hinge from the rear chassis
(4);
D remove the o---rings (28) and (29).

Figure 6

T2691910

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
12 CHASSIS SECTION 16 ADT 25-30 TIER3

D carefully pull the front of the vehicle away to

disengage the fifth wheel bearing;
Do not pull away by more than 0.5 m (15 ft)
to prevent damage to electrical and hydrau-
lic connections.
Keep the front part of the vehicle as
horizontal as possible during this operation.
Prepare a suitable support for moving the
fifth wheel bearing.

D unscrew the retaining screws (3) and disconnect

the fifth wheel bearing (2) complete with articulation
hinge (1) from the front chassis;
D carefully put the fifth wheel bearing complete with
articulation hinge down on a suitable work surface;
D unscrew the fastening screw (4) and remove the fifth
articulation joint (2) from articulation hinge (1);

Figure 7

276D016008

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 16 CHASSIS 13

Dismantling Articulation ball joint pre-- load adjustment

Proceed as follows: Proceed as follows:
Figure 8 D position the articulation hinge at the rear chassis
attachments;
Figure 10

2691911
D remove the O---rings (15) and the ball joints (16) and
(17) from the lower seat of the articulation joint;
Figure 9 2691913
D fit the O---rings (25) and the ball joints (26) and (27)
and the shim (20) in the upper seat of the articulation
joint;
Shim (20) is placed between the two ball
joints.

2691912
D remove the O---rings (25) and the ball joints (26) and
(27) and the shim (20) from the upper seat of the
articulation joint;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
14 CHASSIS SECTION 16 ADT 25-30 TIER3

Figure 11

15

16

17

15

2691914

D fit the O---rings (15) and the ball joints (16) and (17)
in the lower seat of the articulation joint;
D working on the LOWER pin fit the pin (14) then insert
(arrow) a piece of copper wire between the pin and
the washer, fit the washer (12) WITHOUT THE
ADJUSTER SHIMS and tighten the screw (11) to the
specified torque.

Figure 12

11

12
12

14

14
T2691915

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 16 CHASSIS 15

D remove the screw and the washer and measure the

thickness X of the copper wire;
D select, from the available replacements, the
adjuster shim (13) with thickness S suitable for
ensuring the specified bearing pre---load.
S = X -- (0.02 ± 0.02) mm (0.0008 ± 0.0008) in
where:
S = shim thickness (13)
X = copper ring thickness after fitting
(0.02 ± 0.02) mm (0.0008 ± 0.0008) in = joint
pre---load
D fit the adjuster shim (13), the O---rings (18) and (19),
the washer (12) and tighten the screw (11) to the
specified torque;

Figure 13

11

12

18
13 12
13

14 19

14 T2691916

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
16 CHASSIS SECTION 16 ADT 25-30 TIER3

D working on the UPPER pin fit the pin (24) then insert
(arrow) a piece of copper wire between the pin and
the washer, fit the washer (22) WITHOUT THE
ADJUSTER SHIMS and tighten the screw (21) to the
specified torque.

Figure 14

2691917

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 16 CHASSIS 17

D remove the screw and the washer and measure the

thickness X of the copper wire;
D select, from the available replacements, the
adjuster shim (23) with thickness S suitable for
ensuring the specified bearing pre---load:
S = X -- (0.02 ± 0.02) mm (0.0008 ± 0.0008) in
where:
S = shim thickness (23)
X = copper ring thickness after fitting
(0.02 ± 0.02) mm (0.0008 ± 0.0008) in = joint
pre---load
D fit the adjuster shim (23), the O---rings (28) and (29),
the washer (22) and tighten the screw (21) to the
specified torque;

Figure 15

2691918

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
18 CHASSIS SECTION 16 ADT 25-30 TIER3

Reattachment
Proceed to the assembly of the hinge onto the chassis
by performing the detachment steps in the reverse or-
der.
During the assembly of the articulation joint
coupling it is necessary to position the ex-
ternal ring with the holes for the balls so that
it matches the zone indicated with the letter
”S” on the internal ring, as shown in the figu-
re.

Figure 16

276A016001

Tighten the retaining screws fastening the articulation

joint coupling to the front chassis and articulation hinge
to the prescribed tightening torque.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 16
BODY DETACHMENT ---REATTACHMENT
Before performing any intervention, ensure
that all precautions have been taken and all
aspects clarified regarding the safety of per-
sonnel involved in the intervention.
Read the relative instructions provided in
SECTION 1 of this manual.
In case of doubt, consult a more experi-
enced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.
Detachment
Proceed as follows:
D bring the vehicle onto an appropriately solid flat sur-
face, shut off the engine, remove the key from the
ignition switch, engage the parking brake and affix
the indication signs;
D disconnect the battery---disconnect switch or di-
sconnect the battery terminals in order to eliminate
any risk of short ---circuit;
D block the articulation by means of the steering lock
bar, as indicated in SECTION 1;
D sling the body using hooks and cables appropriate
for the size of the load and a suitable lifting device;
D attach the cylinders to the chassis with suitable
belts to prevent them from falling forward;
D unscrew the retaining screws (1) fastening the cylin-
der to the body, recovering the bushings and wa-
shers;
D disconnect the body angular position potentiometer
lever (arrow);
D unscrew the fixing nuts (2) from both sides and re-
move the shells (3) complete with felt seals (5) and
brasses (6);
D carefully lift the body;
D recover the disks (4), felt seals (5) and lower brasses
(6) from both sides.
For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
CHASSIS 19
Reassembly
Thoroughly clean the spherical ends of the
body articulation.
Proceed as follows:
D move the tipping cylinders to a nearly vertical posi-
tion and extend them by lifting their upper part by
about 30 cm (12 in) in order to facilitate coupling to
the body;
Use suitable spacers and/or belts to per-
form this operation.
These devices must be removed after the
cylinders have been coupled to the body.
D sling the body using hooks and cables appropriate
for the size of the load and a suitable lifting device;
D lower the body to a horizontal position and connect
the tipping cylinders;
D remove the tipping cylinder stop devices;
D assemble the felt seals (5) and lower brasses (6)
from both sides;
D lower the body and move it forward until the spheri-
cal ends rest in the lower brasses;
D assemble the disks (4) and upper shells (3) com-
plete with felt seals (5) and brasses (6) from both
sides;
D screw on the fixing nuts (2);
D disconnect the body angular position potentiometer
lever (arrow);
D calibrate the potentiometer following the instruc-
tions below.
Perform the calibration of the potentiometer
by following the instructions provided in the
USE section of the Use and Maintenance
Manual.
20 CHASSIS SECTION 16 ADT 25-30 TIER3

Figure 17

276C016006

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 16 CHASSIS 21

Body angular position potentiometer adjustment

The values corresponding to the ends of tra-

vel are stored using the display.

. For more information on the use of the di-

splay, see the USE Section of the Use and
Maintenance Manual.
Proceed as follows:

276NU112A

D select the MAIN MENU, then select the VEHICLE

MANAGEMENT function;

276NU113A

D select the BODY ANGLE SETTING function;

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
22 CHASSIS SECTION 16 ADT 25-30 TIER3

BODY ANGLE SETTING

Sequence of options available.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 16 CHASSIS 23

Meaning of the options.

276NU118 276NU120

ENTER PASSWORD: enter the four---digit password MINIMUM ANGLE SETTING: determines the end of tra-
using the “+” key to increase the numbering and the vel in descent read by the sensor.
“---” key to decrease it. Confirm each digit set by pres-
sing the ”enter” key. Once the four---digit password has
been entered, access the function with the ”enter” key.

276NU121

MAXIMUM ANGLE SETTING: determines the end of

276NU119 travel in ascent read by the sensor.

BODY ANGLE SETTING: allows to perform the setting

of the sensor that detects the angular position of the bo-
dy.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
24 CHASSIS SECTION 16 ADT 25-30 TIER3

Body angular position potentiometer replacement Potentiometer control rod replacement

-- I type Proceed as follows:
Proceed as follows: D disconnect the rod from both sides;
D disconnect the lever (1) of the potentiometer; D adjust the length of the new rod as indicated in the
D disconnect the electric connector (2); figure;
D unscrew the retaining screws (3) and remove the D assembly the rod.
potentiometer.

Proceed with the reassembly by performing the disas-

sembly operations in reverse order.
During reassembly, position the potentio-
meter horizontally before tightening the re-
taining screws.

Figure 18

276D016009A

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
ADT 25-30 TIER3 SECTION 16 CHASSIS 25

Body angular position potentiometer replacement Potentiometer control rod replacement

-- II type Proceed as follows:
Proceed as follows: D disconnect the rod from both sides;
D disconnect the lever (1) of the potentiometer; D adjust the length of the new rod as indicated in the
D disconnect the electric connector (2); figure;
D unscrew the retaining screws (3) and remove the D assembly the rod.
potentiometer.

Proceed with the reassembly by performing the disas-

sembly operations in reverse order.
During reassembly, turn the potentiometer
clockwise until it rests against
the slots before tightening the retaining
screws.

Figure 19

276D016009B

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook
26 CHASSIS SECTION 16 ADT 25-30 TIER3

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For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook