t156 1 Forklift Merlo P35.9ev Oem Service Manual

5 - CYLINDER OVERHAUL
0
INDEX
CYLINDER INNER PARTS DISASSEMBLY.. ....................................................................................................... 3
CYLINDER INNER PARTS REASSEMBLY ........... ......................................... .............................................. 7

UNCONTROLLED WHEN PRINTED
0
5-l
&g 5 - CYLINDER OVERHAUL
1) BRACKET 9) SCREWS
2) PIPE 10) SEAL
3) CLAMP 11) O.RING
4) PLATE 12) CIRCLIP
5) PIPE 13) HEADER SEAL
6) VALVE 14) HEADER DISTRIBUTOR
7) INNER ELEMENT SEAL 15) SEAL
8) INNER ELEMENT 16) SEAL
5-2
0
CYLINDER INNER PARTS DISASSEMBLY
1) Remove the pipe (A) as follows (see pictures

BR05.01A, BR05.01 B, BR05.01 C, BR05.01 D):
- Unscrew the nut and remove the clamp (B).

- On the cylinder bottom disconnect the pipe

from the fitting and replace the O.Ring during
reassembly.
- On the header disconnect the pipe from the

fitting and replace the O.Ring during
reassembly.
5-3
m
2) Remove the cable protection; before carrying

out this operation; it is advisable to grip the
cylinder in two vices to avoid it rotating once the
cable protection has been removed.
- Remove the fixing screws on the guide (see

picture BR 05.02A).
- Remove the two fixing screws on the cylinder

bottom (see pictures BR 05.028 and BR
05.02C).
- Extract the cable protection lifting it and

pulling it from the side of the cylinder bottom
(see picture BR 05.02D).
5-4
5 -CYLINDER OVERHAUL
3) Unscrew the two fixing nuts and remove the

guide (C) see picture BR 05.03.
0 4) By using the special tool (Part No. 025105) unscrew the header (D), see picture BR 05.04A; replace the
gasket to its inner surface (see picture BR 05.04B).
0 5) Unscrew the two bolts (E) and remove the pilot pipe (F) see picture BR 05.05A; remove the valve from the
cylinder bottom (see picture BR 05.05B) in order to eliminate the air pocket from the chamber; this will enable
you to extract the stem.
5-5
m
6) Grasp the stem and pull it hard to withdraw it from the chamber (see picture BR 05.06A and BR 05.06B)
7) Unscrew the two fixing screws (G) placed on the inner element (see picture BR 05.07A); by means of the
special wrench (Part No 022721) unscrew the inner element from the stem (see picture BR 05.078).
8) Extract and replace the gaskets placed on the

inner element (see picture BR 05.08).
5-6
0
CYLINDER INNER PARTS REASSEMBLY
1) Reassembly is the reversal of points 1 to 8 of the sections “CYLINDER INNER PARTS DISASSEMBLY”
bearing in mind the following:
- On assembly of the inner element on the stem (tightening torque = 697 Nm), add ‘Loctite 270” on the
upper screw (see point 7).
- Test the cylinder connecting it to a hydraulic gearcase, carry out about ten extension and retracting cycles,
checking there are no leaks.
If you cannot use a hydraulic gearcase, use the machine hydraulic system moving the cylinder to the rear
of the machine, so as it is possible to connect it to the relevant hoses.
5-7
m
This page has been intentionally left blank.
5-8
6 - HOW TO REPLACE FRONT AND REAR SLIDING PADS
0
INDEX
REPLACEMENT OF FRONT SLIDING PADS . . . . . . . . . . . . . . .._..........._....._......_____..................................................... 2
REPLACEMENT OF REAR SLIDING PADS .___........_......................................

.._.._._.._.._.._..__..____.____. 5
6-l
REPLACEMENT OF FRONT SLIDING PADS
1) Extend the boom till dimension A = 60 cm.

2) Remove the lock plates by loosening the lock nuts (see picture BR 06.02A) and the upper screws (see picture
BR 06.028).
[R06) (BROB)
3) Loosen lower lateral screws (see picture BR 06.03B)
6-2
4) Loosen lower screws (see picture BR 06.04A); disconnect and remove locking screws on the pad holding
plate (see picture BR 06.048).
5) Remove upper pads (see picture BR 06.05).
Either lit3 the boom by a suitable lifting device or

lay the carriage down on a stationary obstacle;
then lower the boom (see drawing BR 06.06).
6-3
8) Replace lower pads.

9) Reposition the pad holding plate (see point 7).
10) Reposition the locking screws on the pad holding plate and screw them on about two turns (see point 4).
11) Loft the boom to give clearance (see point 6).
12) Replace upper pads (see point 5).
13) Reposition pad locking plates and tighten screws fully, on both sides; thus centering the boom (see point 2).
Loosen dowels by 112 turn which gives the required clearance. Trghten Lock nuts.
14) Repeat process as shown at point 6.
15) Adjust the boom sliding pads to the following

instructions.
To adjust horizontal clearance:
- loosen lock nuts at (A)

- center the boom by tightening the screws (A)
until you get the same gap (G) on both sides.
- loosen screws by 112 turn which gives the
required clearance and tighten lock nuts.
To adjust vertical clearance:
- loosen 2 bolts at (B)

- loosen lower lock nuts at (C)
- tighten screws at (C) fully then loosen them
by 1 turn which gives the required clearance
- tighten lower lock nuts and 2 screws.
6-4
0
REPLACEMENT OF REAR SLIDING PADS
1) Retract the boom completely.
2) Unload the spare wheel; remove the rear panel of the machine (see points 1 and 2 of the section “UPPER
HYDRAULIC HOSES - DISASSEMBLY AND REPLACEMENT” of the Chapter “REPLACEMENT OF
INTERNAL HYDRAULIC HOSES OF THE BOOM”).
3) Remove the pad locking lelate (A); (see picture

BR 06.08).
4) Loosen the grub screws (see picture BR 06.09A); remove the adjusting buffers (B), see picture BR 06.09B
Extend the boom with care to free the pads.

Replace pads (see picture BR 06.10).
6-5
6) Retract the boom fully in to bring pads back into correct position
7) Re-position pad holding plate and tighten relevant screws (see point 3 of this section).
8) Re-position the adjusting buffers (B) and screw

them in until the second section of boom comes
I [BR 06.11
into contact with upper pads; tighten grub screws

(A), (see picture BR 06.11).
9) Reassemble back panel of the machine; reload the spare wheel.
6-6
IVlerlo S.p.A. lndustria Metalmeccanica
12020 S. Defendente di Cervasca (CN) - ITALY Tel. (0171) 614111 - Fax (0171) 614100
Domino Mining Equipment Pty Ltd
A.C.N. 002 706 881 P.O. Box 69, WYONG, N.S W. (Aust.) 2259 Phone: (043) 53 1033 - Fax: (043) 51 2119
SERVICE MANUAL
ELECTRICAL ENGINEERING
INSTRUCTIONS
P 35.9 EVA
MAELEVA.003 VALID FROM SAV 542201

INDEX
.c
INTRODUCTION . . . . . .. . . . . . . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . . .. . .. . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . .. .. . .. . . . . . .. . .. . 1
GLOBES DATA SUMMARY . . .. . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. . .. . .. . .. . .. . .. . . . . . . . . 2
MERLO TROUBLE SHOOTING . . .. . .. . .. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . .. . . . . . .. . . . . . .. . . . . .. . . . . . . . . . . . .. . .. .. . . . . . . . . .. . .. 3
MIRETTI TROUBLE SHOOTING . . . . . . m. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MERLO DRAWIGS
MIRETTI DRAWIGS
1 - INTRODUCTION
This manual provides the information necessary for correct and safe execution of maintenance works not
included in the INSTRUCTION HANDBOOK FOR OPERATING AND MAINTENANCE; it is addressed to
qualified fitters, who have the required knowledge of mechanical, hydraulic and electrical systems for the
machine being serviced.
All work carried out should comply with all relevant environmental and occupational health and safety
requirements.
CAUTION!!!
The symbol shown to the right hand side will be used everytime a standard Merlo
procedure will be substituted by a specific Miretti instruction valid for flameproofed
units only. Please refer to the Miretti annex, attached at the end of this chapter, in
order to follow the correct procedure.
GENERAL NOTE:
Always ensure any work carried out on the vehicle is carried out on level ground. If this is not possible
the ground should be as level as possible and the vehicle should be chocked to prevent any possibility of
the vehicle rolling.
0
l-1
2 - GLOBES DATA SUMMARY
0
2-l
M 2 - GLOBES DATA SUMMARY
TYPO Q-ty Globes
1 3 BA 95 24V 3W
2 2 P45 T 24V 50155W

3 4 BAl5S24VZlW
4 2 BAY 15 D 24V 5/21W
5 1 SV 8,5-8 11X39 24V 5W
6 13 T5 24V 1,2W
7 10 TIO 24V 3W
8 5 H3 PK22S 24V 70W
9 1 HI 24V 70W
2-2
MERLO TROUBLESHOOTING
System Description ........................................................................................ ........................... 2
Electronic Joystick and Major Components ................................................ ........................... 3
Servocontrols Main Directional Coltrol Valve ........................................................................ -4
Checking Procedure for Joystick unction.. ............................................................................. .5
Electronic Main Board Operational Check ............................................................................... 6
Servocontrols Main Directional Coltrol Valve ......................................................................... 8
Potentiometer (Sl trimmer) Check ......................................................................................... .9
0 Trimmer Adjustment .............................................................................................................. 10

Troubleshooting ..................................................................................................................... 11
3-o
3 - TROUBLE SHOOTING
0
3-l
SYSTEM DESCRIPTION
The joystick control system is composed by the following parts:

1) Electronic joystick lever
2) Main electronic control board S3
3) Maln directional control valve pre arranged for joystick operations
4) Servocontrols and entrance section valves
3-2
Electronic joystick
The joystick, assembled on the armrest, is made of one lever moving across two axis and two enabling buttons.
Moving it across the two axis along with the pressing of one or both buttons produces the mouvement of the
correspondent hydraulic section.
Main electronic control board

The main electronic board is placed underneath the driver’s seat into a plashc box.
Such electronic board receives the signals from the joystick as well as from some main safety devices,
(safe load indicator, emergency selector) and it cotrols the servocontrols as well as the solenoid interception valve.
Main directional control valve pre arranged for joystick operations

The main directional control valve is equipped with four sevocontrols (solenoid valves) for the following hydraulic
mouvements:
- Boom lifting / lowering
- Boom extension / retracting
- Fork tilting fwd/bwd
- Frame levelling R/L
Servocontrols and entrance section valves

0 Each servocontrol is made of two proportional solenoid valves S2, controlled by a small electronic board S3 which
is driven by the main electronic control board.
A feedback signal from an included linear trimmer informs the system about the actual position of the valve cursor
Sl.
3-3
SERVOCONTROLS
3 - TROUBLE
ON MAIN DIRECTIONAL
SHOOTING
CONTROL VALVE
m0
I --
0Sl
\3s3 0
In order not to accidentally swap the two solenoids pay attention to the wires colour
(upper solenoid wires are BLUE / GREEN)
0
3-4
CHECKING PROCEDURE FOR JOYSTICK FUNCTIONS
Two checkings are possible at joystick level:

- Buttons check.
- Trimmers check.
Buttons check:
- Remove the 4 fixing srews and extract the joystick from its seat.
- Disconnect the 3 wires (red, blue, orange) from the terminal.
- By using a multimeter tester on the resistence (Ohm) position check:
- open circuit between white and blue, close circuit when pressing the “A” button.
- open circuit between white and red, close circuit when pressing the “B” button.
Trimmers check:
- By using a multimeter tester on the voltage (KC) position check:
- Verify the 8 Volt voltage betweem red and black.
- Make sure the joystick lever is in its center position, then:
check 4 Volt (+/- 0.1 Volt ) presence between black and green, as well as between green and red.
By moving the lever from its center position to both full strokes the voltage should vary +/- 2 Volt,
0
(from 4 Volt to 6Volt or 2 Volt.)
Should the above test fail then act as it follows:
- Disconnect the trimmers wires from the terminal
- Loosen the screws (itenr 21 in dwg 3-21868)
- Set tester on resistence (Ohm) position
- Set the joystick lever to the center position, then adjust trimmer position by so that the
reslstence between black and green equals the one between red and green.
3-5
WI 3 - TROUBLE SHOOTING
ELECTRONIC MAIN BOARD OPERATIONAL CHECK (dwg. 3-22799)
The main electronic board identified on dwg 3-22799 has a group of LED designed to check the correct
operations during the follwing situations:
- Green led DL7 and red led DL8 lit when the starter key is in position “R”
- Red led DL4 lit when pressing the “A” button of the joystick (input signal)
- Red led DL5 lit when pressing the “B” button of the joystick (input signal)
- Red led DL3 lit when pressing either “A” or “B” button of the joystick (output signal)
Such led switches off 1.5 seconds after the button is released.
- Green led DLl lit when pressing the lever is moved across the A-B axis
(or the lever is not correctly adjusted on its central position)
- Red led DL2 lit when pressing the lever is moved across the C-D axis
(or the lever is not correctly adjusted on its central position)
NOTE: do not modify the trimmer settings on the main electronic board.
The main electronic board features two terminals for input / output wiring:
- The *A” terminal receives power supply, safety signals from the machine and joystick commands.
- The “B” terminal sends commands to the servocontrols.
rarminal A Function
1 24 volt power supply
2 24 volt power supply
3 Ground
4 Ground
5 Ground
6 Not used
7 Not used
8 Signal from safe load indicator (microswitch MC03 on rear axle)
9 Signal from SL06 when set to the emergency position (to the right)
10 Signal from SL06 when set to the normal operations position (to the left)
11 Not used
12 Negative from joystick “A” button when pressed
13 Negative from joystick “B” button when pressed
14 Not used
15 Signal + 8 Volt to joystick trimmers
16 Signal + 4 Volt from joystick in center position (+I- 2 Volt at full stroke) C-D axis
17 Signal + 4 Volt from joystick in center position (+I- 2 Volt at full stroke) A-B axis
18 Negative to joystick trimmers
3-6
Terminal. B Function
19 Signal + 8 Volt from servocontrols
20 Not used
21 Not used
22 Not used
23 Not used
24 Not used
25 Not used
26 2.4 a 5.6 Volt to servocontrol boom lift / lower
27 2.4 a 5.6 Volt to servocontrol fork tilting fwd / bwd
28 2.4 a 5.6 Volt to servocontrol boom extend I retract
29 2.4 a 5.6 Volt to servocontrol chassis tilting R / L
30 Not used
31 Not used
32 Signal + 24 Volt to servocontrol main solenoid valve
33 Signal + 24 Volt to servocontrol boom lift / lower and boom extend / retract
34 Signal + 24 Volt to servocontrol chassis tilting R / L
0 35 Not used
36 Signal + 24 Volt to servocontrol fork tilting fwd / bwd
Set the starter key to “R” position, then check the following voltages:
1) Stability cono,&-r met and joystick in center position:

24 Volt between terminals 3 & 1, 3 & 8, 3 & 10
8 Volt between terminals 3 & 15
4 Volt between terminals 3 & 16, 3 & 17
2) Stability condition not met and joystick in center posihon
3) Stability condition not met, emergency selector SL06 set to right position,
joystick in center position:
4) Stability condition met, joystick “A” or “B” button pressed but lever in center position:
0 8 Volt between terminals 3 & 15
Terminals 12, 13 are grounded (thus check 24 Volt between 12 & 1, 13 & 1)
24 Volt between terminals 3 & 33, 3 & 34, 3 & 36. 3 & 32 (power supply to servocontrols)
8 Volt between termrnals 3 & 19 (from servocontrols)
4 Volt between terminals 3 & 26, 3 & 27, 3 & 28, 3 & 29 (signal to servocontrols)
5) Stability condition met, joystick “A” or “B” button pressed and lever moved off center:
Terminals 12, 13 are grounded (thus check 24 Volt between 12 & 1, 13 & 1)
24 Volt between terminals 3 & 33, 3 & 34, 3 & 36, 3 & 32 (power supply to servocontrols)
8 Volt between terminals 3 & 19 (from servocontrols)
4 Volt (+/- 1.6 Volt depending on lever movement) between terminals 3 & 26, 3 & 27,
3 & 28, 3 & 29 (signal to servocontrols)
3-7
Ia 3 - TROUBLE SHOOTING
SERVOCONTROLS OPERATIONAL CHECK
Each servocontrol is composed by:

- one electronic board
- one feedback trimmer
- two solenoids (not to be swapped in case of valve disassembly)
- two proportional valves
Electronic board power supply check

1) Remove the plastic cover protecting the electronic board belonging to the valve to be checked.
2) Set the starter key to “R” position
3) Press the joystick button enabling the valve to be checked
4) Verify that all voltages across terminal A and B are according to the following table
A WHITE + 24 Volt
B BLACK + 8 Volt
D RED + 4 Volt
C BROWN Ground
To calibrate the electronics, please refer to relevant paragraph.
3-8
0
Potentiometer (Sl trimmer) check.
The feedback potentiometer allows the system to provide
an action proportional to the given command, and it makes
possible the electronic calibration.
To verify the correct functions of this potentiometer act as
it follows:
1) Remove the plastic cover protecting the electronic

board belonging to the valve to be checked.
2) Disconnect the 4 wire terminal at the board bottom level
3) Verify that resistances across terminal A and B are
according to the following table, first with the joystick in
center position, then by moving the lever
RESISTENCE VALUES
T
Between Terminals lever in center position Lever at stroke end
A and C About ‘IO Kohm * About 10 Kohm
B and A About 5 Kohm ** From 0 to about 10 Kohm
B and C About 5 Kohm * From 0 to about 10 Kohm
* Note: resistence absolute value could differ from the below feagures as well as from potentiometer and
potentiometer. It is important that such value does not vary drift during the joystick action.
** Should the values differ by more than 10% from each other then change potentiometer.
1D
A
c9 1
Yellow
t
B Orange
C Red
D Brown (not used)
3 -9
wi 3 - TROUBLE SHOOTING
TRIMIWER ADJUSTMENT:
Before operating the trimmers check the
potentiometers centering which are assembled in the
electronic joystick (see the handbook P35.9 EVA
ELECTRIC SYSTEfvl). Screw a lever In the pertinent
mechanical joystick of the main directional control
valve tn such a way you can easier verify the
movements:
- TRIMMER “Tl”: adjust it only when you push the
red button on the electronic joystick, the lever of
the main directional control move itself.
- TRIMMER “T2”: adjust it only when the complete
stroke of the electronic joystick does not
correspond an equal stroke of the lever of the main
directional control valve.
- All settings must be done on the trimmer one by

one:
- “Tl” TRIMMER: push the red button of the

electnc joystick, screw the regulator screw until
there is no movement of the lever on the main
directional control valve.
- “T2” TRIMMER: push the red button and
position the electrical joystick at end of its
stroke; screw the regulator screw until the
complete stroke of the lever of the main
directional control valve is obtained, then add
about l/2 turn (if the lever was already at the
end of its stroke it is necessary to unscrew it
prior to this operation). Repeat the same
operations positioning the joystick to end of its
stroke from the opposite side; tf you cannot bring the lever to the end of its stroke on one of the two sides
adjust the regulator on TRlMfvlER 1.
3-10
L 3 - TROUBLE SHOOTING
0
-‘-1
No movements (except boom in)
Buzzer AV03 warns? Turn SL06 to the right
Machine overloaded
Movements 0.K ? Check SL06 wiring
(missing + 24 Volt to 8)
0
I
Check wiring and micros\nntch

MC03
3-11
m
Anomalies when
operating the lever
Check output 4 Volt

+I-1,6 Volt from Check power supply
Check proportional sol.
electronic board to + to servocontrol
valves coils
relevant servocontrol electronrc board
(26 to 29)
Check joystick
Replace electronic
pertinent paragraph)
Adjust or replace the

Joystick
potentiometer
Check output 4 Volt

+I-1,6 Volt from Clean or replace
electronic board to - servocontrol
relevant servocontrol proportional sol valve
(26 to 29)
Adjust trimmer of Check feedback

Movement not
servocontrol + potentiometer in
proportional
electronic board servocontrol Sl
3-14
S. r. I. Via Marconi, 29/31 - 20051 Limbiate (Ml) - ITALIA
I I
I MIRETTI TROUBLE SHOOTING
Annex for Flameproof Macchines
Joystick Buttons Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~.............................. 1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~.. 2
S. r. I. Via Marconi, 29/31 - 20051 Linlbiate (Ml) - ITALIA
TROUBLE SHOOTING
JOYSTICK BUTTONS CHECK

(Flameproof version)
(Rcfcrcnce: MlRETTl wiring diagram no 4357.00.000 sivxt 4)
S34 = BUTTON B OF JOYSTICK

S35 = BUTTON A OF JOYSTICK
REDLED
S. r. I. Via Marconi, 29/31 - 20051 Limbiate (Ml) - ITALLA 0 ’
TROUBLE SHOOTLNG
SSI MIRElTI CARD is fed ? NC

(thus check 24 Vott between wire + Check wire 6 and 950
6 and 950)
YES
1
YES
Wires 037,038 are cutteds? + Change wires
I
Leds of R39, R40 relais lit when

Change SSI MIRETTI CARD
pressing the buttons
NO
ITerminal 1 wire 101 and terminal 1 , 1

4 wire 102 of R39, R40 relais are
grounded when pressing the
Change SSI MIRETTI CARD
buttons? (thus check 24 Volt
I between wire 101 or wire 102

and wire 6)
I
Check electronic main board
-----------------------------------------------------------------------------------------------------------------------------------------------
4-3
MERLO DRAWINGS
ELECTRICAL SCHEMATIC .,............,.............................................................. 3-21969/C
POWER SUPPLY CABLE .._.__._____.__,_._...,._,.

__,..,__.___,__
____,___._.,.__.__,__
____.__ 3-21998
REMOTE START TERMINAL ..__._.__________ ________

_______________..,__,......, 4-15051
DASHBOARD ELECTRIC PREASSEMBLY __._______.__

____________
_____....._.__.__.... 3-21978/B
ENGINE CABLE . . . .._ _______________

__________________
____________
__..._____.._..______ 3-21979
SERVICES IN CAB _____. __,... ._....,..,..,....._,._..___.,.._...,...__.___.__

___.___.____________
___ 3-20812/A
BOOM CABLE.. ........................... .................................................................... 3-21987

0
OVERLOADING MICROSWITCH CABLE ......... .......................................... . 3-21768
CABLE FOR WORKING LIGHT ON CAB ............................................... 3-22262/A
MONOLEVER JOY-STICK PREASSEMBLY .......................................... 3-21868
JOY-STICK LEVER PREASSEMBLY ................................................... ........... 3-21872
ELECTRIC BOX PREASSEMBLY .......................................................... 3-2 1999/A
ELECTRONIC CARD ................................................................................... 3-22799
AIR COMPRESSOR MOTOR POWER SUPPLY ........................ .................. 3-21988
WAR LIGHTS CABLE.. .............................................................................. 3-22036
0 LEFT FRONT LIGHT. _____._______________

____________. .____....................... . . 3-22009
RIGHT FRONT LIGHT.. .................................... ...... ............ . . ....................... 3-22010
RIGHT REAR TAIL LIGHT .......................................................................... 3-22008
LEFT REAR TAIL LIGHT ...................................................................... 3-22000
MAIN CABLE ...................................................................................... 3-21980

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S. r. I. Via Marconi, 29/31 - 20051 Limbiate (Ml) - ITALIA
MIRETTI DRAWINGS
Drawing No 4357.90.000
Drawing Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-5
Componets Table ......................................................................................................... 6-11
Warlights Connection ..................................................................................................... 12
Drawing No 4357.91 .OOO
Engine Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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Drawing No 4357.93.000
Cables Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~... l-2
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FOR STARTING
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?kk! COMPONENTDESCRIPTION TECHNI. DATA cC%E

C&esto disegno e’ proprieto’ dell0 MIRElll. Ogni riproduzione e
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This drawing is property of HMlll. Any reproduction or assignment gg
1 4357.90.000 (
20051 UMBIATE (MI)-VKY Marconi, 31 to third parties is forbidden as per law enacted. FILE: 435790Fl
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table Disey,r;to Vista Rev. 1 Rev.2 Rev.3 Rev.4 Rev.5 ',o,$z Segue
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DESCRIZIONE
COMPONENTE DATI TECNICI
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/IA\\ Guesto disegno e’ proprieta’ della WEllI. Ogni riproduzione e
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p?iTGEq
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20051 LIMBlATE (MI)-Ma Marconi, 31 to third parties is forbidden as per law enacted. FILE: 435790Gl
minazione: Rev. 1 Rev. 2 Rev. 3 Rev. 4 Rev. 5 Segue
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table DisCToto
Draw
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;;n;;;;;$$'~,$' MERLOP35.9 EVA E$j' 12.11.96 2205.97
Impiego:
Duty: EEx d IIB f;om$ D.Pavan D.Pavm 7 8
--.-_ ___________- - -__- . ..__. - .-....--. -. ._.-_ - ._. _ ._-, F _.
f-j26 FAR0 DI LAVOROBRACCIO/ JIB WORKUGHT ORlGlNAL
H25 SPIA ALLARMEEMERGENZA

/ EMERGENCY
ALARMWARNINGUGHT ORIGINAL :
4 FAR0 DI LAVOROPOSTERIORE
/ REARWORKUGHT ORIGINAL
\
Hz3 FAR0 DI LAVOROANTEPIORE
/FRONT WORKUGHT - I -. - --. ' ORlaNAL
I j-Q2
I LUCI STOP/ STOPUGHTS
I H21 I SPIA LUCI POSIZIONE/ TAIL WARNINGUGHT' I
I H20 I LUCl POSIZIONE

/ TAIL LIGHT I ORlaNAL
I I HI9 SPIA FRENOA MAN0 / HAND BRAKEUGHT I ORlGlNAL
H 18 SPIA UVELLOOUO / OIL LEVELLIGHT ORlGlNAL
HI7 SPIA TEMPERATURA

ACQUA/ WATERTEMPERATURE
LIGHT :' ORIGINAL
6 SPIA FILTROARIA INTASATO/ CLOGGED

AIR FILTERUGHT ORIGINAL
I l-l15
I SPIA PRESSIONE
OUO / OIL PRESSURELIGHT I ORlGlNAL
SPIA TEMPERAlURA
OUO / OIL TEMPERATUR
WARNINGUGHT I ORlaNAL
HIS SPIA STERZO/ STEERING

UGHT ORlGlNAL
H 12 SPIA ALTERNATORE
/ ALTERNATOR
LIGHT ORlGlNPL
HII LUCI ANABBAGUANTl

/ LOWBEAM ORIGiNAL
I HI 0
I LUCI ABBAGLIANTI
/ HIGHBEAM I ORIGINAL
I
l-I9 SPIA ANTIRIBALTAMENTO

/ SAFE LOADWARNINGLIGHT ORIGINAL
SPIA EMERGENZA
/ EMERGENCY
WARNING
LIGHT ORIGINAL
H7 SPIA 4 FRECCE/ 4 WARNINGUGHTARROWS &S130040122
H6 FRECCIASINISTRA/ LEFT ARROW ORIGINAL
( H5-/ RIGHTARROW
H4 LAMPEGGIANTE
/ FLASHINGBEACON I ORlGlNAL I
DESCRlZIDNE
COMPONENTE DATI TECNICI
Ektl COMPONENT DESCRIPTION TECHNLDATA cC%E
//A\\ Quest0 diseQlo e’ proprieta’ della MElll. Ogni riproduziane e
RImam
cuxessione a tetzi ne e’ pertonto interdetta o terrnini di legge.
This drawing is property of MIRElTl. Any reproduction or assignment 5%
I 20051 LlMBlAlE (HI)-Wo Marconi, 31 1 to third parties is forbidden as per law enacted.
1
FILE: 435790Hl 1
Tabellaccmponenti/Components
toMe DisDynto Vista Rev. 1 Rev. 2 Rev. 3 Rev. 4 Rev. 5 kzz Segue
Checked Follow
&;;;b';;;;$;~,$;: MERLOP35.9 EVA #; 12.11.96 22.05.97
bm,yy AD-T IP44 ii!, D.Pavan D.Pavan 8 9
K4 RELE'AWlAMENTO/ STARTERRELAY 24U 50A G&& TO09021122
4%TO09008122
4-
3 RELE'LUCI.GUERRA
/ WARLIGHTRELAY 24U 20A
. _/'
2 RELE'CHIAM/ KEY RELAY 24U 50A '@$k~TO09021122
,:;. i 1.::: RELE'COtiPRESSORE

/ COMPdESSOR
RELAY I'-:- .-- . --' -. ' -' 24V 20A‘ TO09008122
C CANDELETTA
/ GLOWPLUG 12u 4357.26.600
FUSIBIU/ FUSES 10A P‘$& FO47077122

F17
CI...
FUSIBIU/ FUSES 20A FO47079122

F-16
Ima.
F15 FUSIBIU/ FUSES 20A FO47079122

A-.
Fll FUSIBIU/ FUSES l?
16A -5EJ FO47078122
16A
6 10 FUSIBIU/ FUSES =$$$JFO47078122

9 FUSIBIU/ FUSES 20A (&FO47079122
F8 FUSIBIU/ FUSES 16A &F047078122 ;
F7 FUSIBIU/ FUSES 20A
F5 FUSIBIU/ FUSES 'ZOA
F4 FUSIBIU/ FUSES 20A $@%JFO47077122
FUSIBIU/ FUSES cc
F3 20A Qzl F047079122
F2 FUSIBIU/ FUSES 16A P-

@El FO47078122
.a...
FUSIBIU/ FUSES 16A mF047078122
SPIA TERMOVENTILATORE
/ ELECTROFAN
WARNING
UGHT gpJ s130039122
H30 SPIA TERGICRISTALLO

/ WlPERLIGHT ~g&s130039122
HZ9 SPIA LUCI ABBAGUANTI/ HIGHBEAMWARNINGLIGHT ORIGINAL
HZ8 SPIA FAR0 DI LAVOROPOSTERIORE

/ REARWORKWARNINGUGHT is-
! $!!I s130039122
HZ7 SPIA FAR0 DI !AVOROANTERIOREtBRACCIO

/ FRONTtJIBWORKWARNINGLIGHTS @&130039122
DESCRIZIONE
COMPONENTE
i%i! I COMPONENT DESCRIPTION ccsFkE
Quest0 disegno e’ prcprieto’ della MIRElll. Ogni riprcduzione e
concessione a tti ne e’ petmto interdetta a terrnini di legge.
This drawing is property of MIRElX Any reproduction or assignment 5% I
. .- I
1
20051 UMBIATE (MI)-Wa

. Marconi, 31 1 to third parties is forbidden as per law enacted. FII
. I-. F. d-457Q1
,“I, “011
I
minazione: T-L -I,- Disey;ito Vista
--” ‘~~tmponenlstable
0 componellrl/Lc
IODf?lI~ Checked Rev. 1 Rev. 2 Rev. 3 Rev. 4 Rev. 5
Description: - -. -. - - - -
sneer H
~;n;;;;;;;$;~,$;' MERLOP35.9 EVA 8;;; 12.11.96 22.05.97
Impiego:
Duty.
AD-T IP44 i;amG D.Pavan D.Pavan 9
TTROVALVOLA
FO SOLENOID
VALVE
Quest0 disegno e’ proprieta’ della YIRElll. Ogni riproduzione e

concessione a terd ne e’ pertanto interdetta a termini di legge.
Tobellaccmpcmnti/Gnnpmentstable Disqato Vista Rev. 1 Rev. 2 Rev. 3 Rev. 4 Rev. 5 $$$ Segue
Description: Draw Checked
Follow
Costruttore/M
Monufocture/Model: ode"o: MERLOP35.9 EVA i;t; 1211.96 22X5.95
Impiego: 10 II
Duty AD-T lP44 Firma D.Pavan
Drawn D.Povan
/ ALTERNATOR
RELE'ALTERNATORE RELAY 24V 60A ORlGlNAL
POTENZlOMETiiIAUSlLlARl/ AUXJJARYPOTENllOMETEi ORIGINAL
SEM 1SCHEDAELEllRONICAMERLO/ MERLOELECTRONIQUE

CARD.
I ORIGINAL
SSI1 SCHEDASlCUREZZAINTRINSECA
/ INTRINSICALLY
SAFE CARD
I 24V I
@i+$i+SO20004122
T’I TEMPORIZZATORE
/ SEAT TIMER 24V I
$$%J T065004122
M6I MOTORECOMPRESSORE
SEDILE/ SEAT COMPRESSOR
MOTOR
M5I MOTORESPRUZZAUQUIDOPOSTERIORE
/ REARSPRAYERMOTOR 24V (& 4357.09.400
4 MOTORESPRUZZALIQUID0ANTERIORE
/ FRONTSPRAYERMOTOR 24V @p-J 4357.09.300
MOTORETERGICRISTALLO
POSTERIORE
/ REARWlPERMOTOR 24V c$pJ 4357.09.500
M2I MOTORETERGICRISTALLO
ANTERIORE
/ FRONTWlPERMOTOR 24V $g+J 4357.09.100
Ml I TERMO'fENlllATORE
/ ELECTROFAN 24V I
4357.26.500
FUEL1INDICATOREUMLLO GASOLIO/ FUELLEVELINDICATOR
Im/hl CONTA Km-CONTA GlRl / RPM-Km/h METER ORIGINAL
x2 IMORSEllOPER LUCEGUERRA(POS.3) / WARLIGHTTERMINAL(POS.3)

x1IMORSETTOPER LUCEGUERRA(POS.2) / WARLIGHTTERMINAL(POS.2)
INTERMIITENZA
LUCEEMERGENZA
/ SAFELOADUGHT INTERMITTENCE 0RlUNAL
1 INERMIllENZA/ INTERMITTENCE ORIGINAL
PRO 1SENSOREDI MLOCITA' / PROXlMlTY
GEN 1ALTERNATORE
/ ALTERNATOR 24V && 4357.30.000
MCI MOTORECOMPRESSORE
/ COMPRESSOR
MOTOR 24V &pJ 4357.09.000
MA MOTOREAVVIAMENTO
/ STARTERMOTOR 24V f& 4357.05.000
DESCRIZIONE
COMPONENTE DATI TECNlCl
COMPONENT DESCRlPTlON TECHNI.DATA cc%F
(Xlesto disegno e’ proprieta’ della MlRElll. Ogni ripraduzione e
concessiane a terd ne e’ pertcmto interdetta a krmini di legge.
“;;~
This drawing is property of MIRElll. Any reproduction ar assignment 58
- 20051 UMBlAlE (MI)-Vta Marconi, 31 to third parties is forbidden as per law enacted. FILE: 435790Ml
Iescription: Tabdo camponenti/Companenls

table vista Rev. 1 Rev. 2 Rev. 3 Rev. 4 Rev. 5 Foglio
Zostruttore/M
ode"o: MERLOP35.9 EVA ;
flanufacture/Model:
Impiego:
Duty: AD-T IP44
IMPLEMENTAZIONE IMPIANTO GDF
WARLIGHTS CONNECTOR
1 Headlight gdf 171 Braun

2 Light gdf front 17 Blue
3 @ Yellow Green
4 Stop gdf 62 Braun
5 Light gdf rear 17 Blue
6 @ Yellow Green
/IA\\ Cuesto disegno e’ proprieta’ della MIRETII. Ogni riproduzione e

r/mm1
concessione a terzi ne e’ pertanto interdetta a terrnini di legge.
This drawing is property of MIRElll. Any reproduction OT assignment
1
20051 UMBIATE (Ml)-Via Marconi, 31 to third parties is forbidden OS per law enacted. FILE: 435790Nl
Disegnoto ’
Iescription: Warlights connection Draw
EtAAIRev.
CtlFChFU
1IRev. 21Rev. 31Rev. 4IRev. 51 Foglio 1 Segue
-0ilow
~o,sn:;u,,!,o:;~~;~~;;’MERLOP35.9 EVA ;;t; 10.06.96
,mpiego:
Duty:
AD-T IP44 Fima D.Pavan
Drawn
+ Generator (6 cables)
+ Starter motor
- Generator (6 cables)
Thii dmii is prqmty of YMll. Anyreproduction

or assignment
.- - ---. -
-ElPI
-El P2
J
PR S8
S16 s7
s15 S6
s14 s5
s13 s4
War lights
cable 3x1.5
NR. DIS
DRWG. I
H23
L
----I D @H24
u Grup o luci ant. destro

RighP front lights
0 u Gru po luci ant. sinistro
LefP front lights
I I 0 Grup o luci post. destro
3.
25’ RighP rear lights
Ica+
CD Segue foglio 2 0 Gru po luci post. sinistro
LefP rear lights
v Follow sheet 2
I
/
I
R A
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GEN
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?WG. I
52
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J Merlo S.p.A. lndustria
12020 S. Defendkte di Cervasca
m
(CN) - ITALY
Metalmeccanica
Tel. (0171) 614111 - Fax (0171) 614100
Domino Mining Equipment Pty Ltd
A.C.N. 002 706 881 P.O. Box 69, WYONG, N.S.W. (Aust.) 2259 Phone: (043) 53 1033 - Fax: (043) 51 2119
SERVICE MANUAL
ENGINE REMOVAL
F-ROM P35.9 EVA
MAMOEVA.003 VALID FROM SAV 542201 1

INDEX
0
INTRODUCTION .......................................................................................................................... 1
NECESSARY TOOLS AND REPAIR TIMES ............................................................................... 2
ENGINE REMOVAL FROM THE MACHINE ................................................................................ 3
1 - INTRODUCTION
0
INDEX
SAFETY AND GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .,_........................................... 3
CONVERSION FACTORS.. .......................... ......................................................................................................... 4

l-l
M 1 - INTRODUCTION
This manual provides the information necessary for correct and safe execution of maintenance works not
included in the INSTRUCTION HANDBOOK FOR OPERATING AND MAINTENANCE; it is addressed to
qualified fitters, who have the required knowledge of mechanical, hydraulic and electrical systems for the
machine being serviced.
All work carried out should comply with all relevant environmental and occupational health and safety
requirements.
This symbol is used to identify the dimensions of the spanner required for the operations described in
this handbook. The spanner type will be mentioned only if it is non standard.
A
CA UT/ON!!!
The symbol shown to the right hand side will be used everytime a standard Met-lo
procedure for engine removal will be %bstituted by a specific Miretti instruction
valid for flameproofed units only. Please refer to the Miretti annex, attached at the
end of this chapter, in order to follow the correct procedure.
GENERAL NOTE:
Always ensure any work carried out on the vehicle is carried out on level ground. If this is not possible the ground
should be as level as possible and the vehicle should be chocked to prevent any possibility of the vehicle rolling.
1-2
! ‘i .: _
1 - INTRODUCTION
SAFETY AND GENERAL INSTRUCTIONS
A CAUTION!!!
Servicing of the machine shall only be carried out by skilled and competent personnel. For repair of parts
that are not part of the normal scheduling, refer MERLO AUSTRALIA technical service.
A WARNING!!!
Always wear suitable protective clothing and safety equipment when using lubricants. Extra care should
be taken to avoid bums when working with hot fluids or elements.
A WARNING!!!
Always dispose of oils, filters or other mediums in an environmentally friendly manner. Use official
organisations for the disposal of such fluids.
0
Before carrying out any kind of servicing,

position the machine on flat, level ground and:
- retract and lower the boom
- release loads or attachments on the vehicle
- put chock (1) at the front and back of the
wheels to avoid accidental movement
- apply the hand brake. place the
transmission lever in neutral position and
stop the engine.
Should it be necessary to carry out servicing

operations with the boom lifted, use the safety
lock following these instructions:
- lift the boom
- apply the hand brake, place the
transmission lever in neutral position and
stop the engine
- working from the left rear mudguard, rotate
lever (2) and rest the safety lock (3) on the
lifting jack rod
- re-start the engine and slowly lower the
boom till the lock is at about 10 m m from
the jack head (dimension A)
- before lowering the boom, replace the
safety lock in the the original position.
When working under the vehicle it is

preferable to use a pit or height adjustable
work platform. The vehicle weight is stated on
identification plate.
1-3
1 - INTRODUCTION
m
CONVERSION FACTORS
IKgm = 9,806 N=m

II I 7,233 lb+t
II -- 86,79 Ibin
_: Z”. --
_:
_- ::
lij:;-::lpREssU.@ ‘. .j:..- ‘: -_ ‘-,I .: ., ,:;::.- ..;.I: ,.- .j -1
: .:
lbar = 100 KPa

11 = 14,5 psi (lb/in*)
WV = 01Y N/mm*
9,806
2,204 lb
1-4
2 - NECESSARY TOOLS AND REPAIR TIMES
0
INDEX
STANDARD TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .._...... . . . . . . . . . . . . . . . . . . . . .._.... 2
SPECIAL TOOLS ................................................ ................ ................................................ .......................... 3
REPAIR TIMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................. 3

a
STANDARD TOOLS
Spanner: 6, 7, 8, 10, 13, 15, 17, 19, 22, 36, 41, 50

Ratchet
(M062.02
Sockets:
- external hexagon 6
- inner hexagon 7, 13, 17, 19,24
Extension: L = 50, 100,200

~___.
r
Pipe wrench L = 580

Torque wrench
0
2-2
0
SPECIAL TOOLS
Two filter spanners (Part.No.031748)
REPAIR TIMES
l - Engine removal from the machine about 2 hour and 30 minutes.

2-3
m
2-4
3 - ENGINE REMOVAL FROM THE MACHINE
A CAUTION!!!
Refer to “GENERAL NOTE” Chapter ‘INTRODUCTION”.
1) Lift and extend the boom, to reduce the oil level in the hydraulic tank.
2) Remove the cover beside the pump by

removing the four fixing screws. See picture
M003.01
3) Remove the cover under the engine by removing the seven fixing screws. See pic.M003,02A,B & C
Remove the two protection covers. See picture

M003.03
3-l .
5) Disconnect the battery terminals; first the negative (-),

then the positive (+). See picture MOO3.04
A WARNING !!
Before carrying out any work on the batteries, read
carefully the instructions in the ‘INSTRUCTION
HANDBOOK FOR OPERA77NG AND MAINTENANCE, in
the chapter “MAINTENANCE” paragraph “ELECTRICAL
SYSTEM” and the chapter “NERY 50 HOURS OR
WEEKLY”, paragraph “BAmERlES”.
6) Remove the hose fixing clamp (see picture M003.05A) and the air intake pipe (see picture MOO3.05B).
0
7) Remove the bonnet hinge, fixing nuts (see pictures fvlOO3 06A - M003.06B) and the fixing screws from the
gas strut (see picture M003.06C); free the hinges and remove the bonnet (this should be a two man
operation).
3-2
m
8) Drain the oil from the system in a container:

- remove the following plugs & caps: radiator breather (see picture M003.07A), oil tank filler (see picture
MOO3.07B) and hydrostatic pump drain (see picture MOO3.07C).
- remove the filter using two filter spanners PartNo.031 748 (see picture M003.08A).
- remove the two fixing screws of the oil tank support (see picture Rn003.08B), then tilt it in such a way so
as to drain the remaining oil.
9) Disconnect the feed pipe from the filter manifold (see picture MOO3.09A) and the breather from the
temperature sensor manifold (see picture M003.09B).
3-3
m
10) Disconnect the electrical connector from the oil level indicator (see picture M003.10A) and the servobrake
drain pipe from the tank (see picture MOOS.lOB).
Remove the oil tank.
11) Disconnect from the filter manifold the two pipes that connect it to the radiator. (See pictures MO03.1 IA and
M003.11 B)
12) Disconnect the two connecting pipes from the filter manifold (see picture MOO3.12A) and from the pump (see
picture M003.12B) 0
3-4
ixl 3 - ENGINE REMOVAL FROM THE MACHINE
13) Remove the fixing screws; disconnect the two high pressure pipes from the pump (See pictures M003.13A
and M003.13B). To avoid losing the 0’ Rings remove them from under the flanges of the connecting pipes.
14) Loosen the locknut under the filter manifold (see picture M003.14A).
Unscrew the filter manifold and remove it from the pump (see picture. M003.14B); if necessary disassemble
the joint ref. A (see picture M003.14A) to allow the removal of the filter manifold.
15) Disconnect from the pump the feed pipe (see picture M003.15A) and the discharge pipe (see picture
M003.15B) of the speed selection control valve.
3-5
M 3 - ENGINE REMOVAL FROM THE MACHINE
16) Remove the caps of the two fwdlrev solenoid valves (see picture fvlOO3.16A) and the two pilot system pipes
(see pictures M003.16B - MOOS.lSC).
17) To avoid oil leaks when the pump suction line is disconnected, place the suction intake above the oil tan
level. Disconnect the suction pipe (see picture M003.17A) prevent oil discharge by screwing on to the
connecting-pipe fixing ring nut, a I”-l/4 cap , then disconnect the pressure line hose (see picture MOO3.17B).
18) Disconnect the diesel feed pipe from the prefilter bowl (see pictures MOO3.18A and MOO3.18B).
0
3-6
19) Remove the prefilter bowl (see pictures M003.19A and M003,19B), in order to avoid accidental breakage
during engine removal.
0 20) Remove the hydrostatic pump pipes fixing clamps (see picture M003.20A), disconnect the pipes from the
radiator (see picture M003.20B), then remove them.
21) Disconnect the heating system pipes (see pictures M003.21A and M003.21 B).
3-7
m
22) Disconnect the hydrostatic oil temperature sensor cable (see picture M003.22A), remove the spring fixing
screw from the inching regulator lever (see picture MOO3.228) and the pin from the small fork linking the
operating cable (see picture M003.22C).
23) Unscrew the radiator hose fixing clamps (see pictures M003.23A, MOO3.238 and MOO3.23C), then remove
the hoses.
24) Remove the two lower nuts fixing the radiator to the chassis (see picture MOO3.24A) and the two fixing nut
from the upper bracket (see pictures M003.248 and M003.24C).
Tilt the radiator, as much as possible, towards the rear mudguard
3-8
3 - ENGINE REWIOVAL FROM THE MACHINE
m
25) Disconnect the exhaust pipe (see pictures M003.25A and fvlOO3.258).
26) Disconnect the accelerator pedal cable (see pictures M003.26A, MOO3.26B and M003.26C).
27) Remove the engine support fixing screws attached to the chassis (see pictures M003.27A and M003,27B),
prevent the rotation of the rubber blocks by locking it with a wrench from the opposite side of the chassis (see
picture M003.27C); this is a two person operation.
3-9

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What are the main steps involved in cylinder inner parts disassembly?

What are the main steps involved in cylinder inner parts disassembly?

What are the main steps involved in removing the cylinder inner parts?

What are the main steps involved in removing the cylinder inner parts?

5 - CYLINDER OVERHAUL

CYLINDER INNER PARTS DISASSEMBLY.. ....................................................................................................... 3

CYLINDER INNER PARTS REASSEMBLY ........... ......................................... .............................................. 7

1) Remove the pipe (A) as follows (see pictures

- Unscrew the nut and remove the clamp (B).

- On the cylinder bottom disconnect the pipe

- On the header disconnect the pipe from the

2) Remove the cable protection; before carrying

- Remove the fixing screws on the guide (see

- Remove the two fixing screws on the cylinder

- Extract the cable protection lifting it and

3) Unscrew the two fixing nuts and remove the

gasket to its inner surface (see picture BR 05.04B).

8) Extract and replace the gaskets placed on the

This page has been intentionally left blank.

REPLACEMENT OF FRONT SLIDING PADS . . . . . . . . . . . . . . .._..........._....._......_____..................................................... 2

REPLACEMENT OF REAR SLIDING PADS .___........_......................................

REPLACEMENT OF FRONT SLIDING PADS

1) Extend the boom till dimension A = 60 cm.

3) Loosen lower lateral screws (see picture BR 06.03B)

5) Remove upper pads (see picture BR 06.05).

Either lit3 the boom by a suitable lifting device or

8) Replace lower pads.

9) Reposition the pad holding plate (see point 7).

11) Loft the boom to give clearance (see point 6).

12) Replace upper pads (see point 5).

14) Repeat process as shown at point 6.

15) Adjust the boom sliding pads to the following

To adjust horizontal clearance:

- loosen lock nuts at (A)

To adjust vertical clearance:

- loosen 2 bolts at (B)

1) Retract the boom completely.

3) Remove the pad locking lelate (A); (see picture

Extend the boom with care to free the pads.

8) Re-position the adjusting buffers (B) and screw

into contact with upper pads; tighten grub screws

9) Reassemble back panel of the machine; reload the spare wheel.

MAELEVA.003 VALID FROM SAV 542201

GLOBES DATA SUMMARY . . .. . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. . .. . .. . .. . .. . .. . . . . . . . . 2

MERLO TROUBLE SHOOTING . . .. . .. . .. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . .. . . . . . .. . . . . . .. . . . . .. . . . . . . . . . . . .. . .. .. . . . . . . . . .. . .. 3

MIRETTI TROUBLE SHOOTING . . . . . . m. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

This page has been intentionally left blank.

TYPO Q-ty Globes

2 2 P45 T 24V 50155W

4 2 BAY 15 D 24V 5/21W

5 1 SV 8,5-8 11X39 24V 5W

8 5 H3 PK22S 24V 70W

System Description ........................................................................................ ........................... 2

Electronic Joystick and Major Components ................................................ ........................... 3

Servocontrols Main Directional Coltrol Valve ........................................................................ -4

Checking Procedure for Joystick unction.. ............................................................................. .5

Electronic Main Board Operational Check ............................................................................... 6

Servocontrols Main Directional Coltrol Valve ......................................................................... 8

Potentiometer (Sl trimmer) Check ......................................................................................... .9

POWER SUPPLY CABLE .._.._.,_._...,._,.

REMOTE START TERMINAL ..__._.__

DASHBOARD ELECTRIC PREASSEMBLY .___.

SERVICES IN CAB ___. ,... ._....,..,..,....._,._..___.,.._...,...._.__

0 LEFT FRONT LIGHT. _.___________