Copyright ©

SERVICE MANUAL

327B and 330B

Articulated Dump Trucks

For the personnel and vehicle safety, read carefully the SAFETY
INSTRUCTIONS contained in this manual

Copyright © 2007 Case France S.A. LEP 87573455A

All right reserved Issued March 2007
Copyright ©
 Copyright ©

327B and 330B

Articulated Dump Trucks
Service Manual

CASE 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.

Publication no.: 87573455

First edition: November 2006

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

Copyright ©
 Copyright ©
TABLE OF CONTENTS

SECTIONS PAGES

CONDITIONS OF USE AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 to 36

TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327B . . . . . 2 1 to 34

330B . . . . . 2 1 to 34

FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1 to 46

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1 to 162

AUTOMATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1 to 120

FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry Disc Brakes . . . . . 6.1 1 to 68

Wet Disc Brakes -- 330B . . . . . 6.1 1 to 68

INTERMEDIATE AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry Disc Brakes . . . . . 6.2 1 to 68

Wet Disc Brakes . . . . . 6.2 1 to 70

REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry Disc Brakes . . . . . 6.3 1 to 58

Wet Disc Brakes . . . . . 6.3 1 to 52

DRIVELINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1 to 18

SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1 to 30

WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1 to 12

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1 to 6

STEERING AND DUMPING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 1 to 50

EMERGENGY STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 1 to 6

BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 1 to 24

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1 to 102

PNEUMATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1 to 20

GREASE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1 to 10

AIR CONDITIONING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1 to 16

CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1 to 24

CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1 to 22
 Copyright ©
PARTS

Figure 1

10 9

1 2 3 4 5 6 7 8

276RM100

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
 Copyright ©
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

dumper cylinder

steering cylinders

hydraulic system pump

radiator fan system pump

radiator fan system motor

flow splitter

dumper valve

steering valve
Copyright ©
 Copyright ©

SECTION 1

CONDITIONS OF USE
AND
SAFETY INSTRUCTIONS
Copyright ©
 327B & 330B SECTION 1 Copyright
CONDITIONS OF USE© 1

CONTENTS

Page Page

CONDITIONS OF USE . . . . . . . . . . . . . . . . 3 SAFETY INSTRUCTIONS . . . . . . . . . . . . . 15

INFORMATION ON THIS HANDBOOK . . . . . . . . . . 4 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety information and symbols . . . . . . . . . . . . . . . . 16
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 PREVENTING FIRES . . . . . . . . . . . . . . . . . . . . . . . . . 18
Purpose of this handbook . . . . . . . . . . . . . . . . . . . . . . 5
ROLLOVER ACCIDENTS . . . . . . . . . . . . . . . . . . . . . 20
To whom this handbook is addressed . . . . . . . . . . . 5
Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Safekeeping of this handbook . . . . . . . . . . . . . . . . . . 5
What to do if the vehicle rolls over . . . . . . . . . . . . . . 20
Updates to this handbook . . . . . . . . . . . . . . . . . . . . . . 5
Structure of the cab . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Units of measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTRUCTIONS FOR USE . . . . . . . . . . . . . . . . . . . 22
SCHEDULED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
VEHICLE DRIVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Starting and stopping . . . . . . . . . . . . . . . . . . . . . . . . . 23
WASTE DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Driving the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

WARRANTY AND LIABILITY OF THE Working the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . 25

MANUFACTURER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Towing the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Replacing a wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
After sales service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Power supply disconnection . . . . . . . . . . . . . . . . . . . 29
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Safety locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
GENERAL OPERATION RULES . . . . . . . . . . . . . . . . 9 Preventing injuries . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Pre---disassembly preparation . . . . . . . . . . . . . . . . . . 9 Preventing intoxication and contamination . . . . . . . 35
During disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Preventing burns and electrocution . . . . . . . . . . . . . 36
After disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
During assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Interchangeable parts . . . . . . . . . . . . . . . . . . . . . . . . 12
Welding on the chassis . . . . . . . . . . . . . . . . . . . . . . . 14
2 CONDITIONS OF USE SECTION 1 327BCopyright
& 330B ©
327B & 330B SECTION 1 Copyright
CONDITIONS OF USE© 3

CONDITIONS OF USE
4 CONDITIONS OF USE SECTION 1 327BCopyright
& 330B ©

INFORMATION ON THIS HANDBOOK

Definitions Symbols
Handbook is this Use and Maintenance Handbook. You will find the following symbols highlighting parts of
Vehicle is the machinery described in this handbook. the handbook. Their meaning is:
Manufacturer is the company manufacturing the ve-
hicle. Procedures, technical information and pre-
Dealership is the company or organization officially cautions which, if not respected and/or in-
representing the Manufacturer. correctly carried out, could cause injury to
Supplier is any company supplying components and/ users (safety symbol, see also SAFETY IN-
or consumable material used by the vehicle. STRUCTIONS).
User is the person directly or indirectly involved in using Failure to heed and/or correctly carry out
the vehicle. procedures, technical information and pre-
cautions given may cause damage to the ve-
Contents hicle.
This handbook contains the use and mainte- Procedures, technical information and pre-
nance instructions for all the vehicle parts cautions which, if not respected and/or in-
envisaged by the manufacturer. correctly carried out, could pollute the envi-
Some devices described in this handbook ronment.
may not be fitted in your vehicle, according
to the outfit and the market for which the ve- . Very important procedures, technical infor-
hicle was made. mation and precautions.
This handbook is organized in several sections, which
are organized in chapters and, where required, para-
graphs to ensure rapid and easy retrieval of informa-
tion:
Conditions of use
This section contains information on this USE AND
MAINTENANCE HANDBOOK, vehicle use and applica-
tions.
Safety instructions
This section contains information on the safety precau-
tions to be adopted for vehicle use and maintenance.
Use
This section contains information on the controls and
instruments, as well as the main instructions for use,
which must be respected at all times, especially when
the vehicle is new.
Maintenance
This section contains the functional instructions for
checking and maintaining the vehicle which must be
implemented to ensure satisfying operation, cost ---ef-
fective running and long life of the vehicle.
Technical specifications
This section contains the characteristic vehicle data.
327B & 330B SECTION 1 Copyright
CONDITIONS OF USE© 5

Purpose of this handbook

Purpose of this handbook is to allow users to get to
know the vehicle and use 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 handbook is addressed

This handbook is addressed to persons who either
need to provide instructions or use the vehicle.
These persons are:
D operative units/site/department managers;
D users directly concerned in vehicle use;
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 mar-
keting 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.
British Units values are expressed in brackets.
6 CONDITIONS OF USE SECTION 1 327BCopyright
& 330B ©

SCHEDULED USE VEHICLE DRIVERS

The vehicle described in this handbook was designed The vehicle can be driven exclusively by qualified per-
and made for the following use: sonnel with the necessary skills and suitable technical
D to haul excavation material in general; knowledge.
D to haul material resulting from interventions on in- Vehicle drivers must:
dustrial or civilian artefacts in general; D have the skills required to drive the vehicle in all envi-
D to haul material required to make infrastructures ronmental and weather conditions;
and/or industrial or civilian artefacts in general. D be psychologically and physically fit;
The vehicle must be used for such purposes. D be very responsible and respect the safety instruc-
The vehicle must be in proven and checked conditions tions.
of efficiency for said use, fully respecting the envisaged Vehicle maintenance personnel must:
criteria and restrictions of use. D have the operative skills required for construction
Specific care must be paid to the following aspects: site vehicle maintenance;
D do not exceed the payloads specified by the D be sensitised to respect and adopt safety instruc-
manufacturer; tions and precautions.
D do not exceed the gradients specified by the Vehicle drivers must be in condition to work in total
manufacturer; safety, also by means of suitable training periods or
D do not drive the vehicle on loose terrain which can courses, to acquire full knowledge of instructions for
compromise stability; vehicle use.
D do not use the vehicle to remove objects or prod- The direct reporting manager must ensure respect of
ucts; general safety instructions, specifically those con-
D use the vehicle paying special attention to the safety tained in this handbook.
instructions and specifications; The manager will also ascertain suitability of operating
D carry out the ordinary maintenance requirements personnel, in terms of technical skills and psychologi-
specified by the manufacturer; cal---physical conditions.
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.
327B & 330B SECTION 1 Copyright
CONDITIONS OF USE© 7

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.
8 CONDITIONS OF USE SECTION 1 327BCopyright
& 330B ©

WARRANTY AND LIABILITY OF THE SERVICE

MANUFACTURER
After sales service
Warranty conditions Dealerships are available for all types of interventions.
The user must carefully observe the precautions illus- Equipment and expert personnel are available for over-
trated in this handbook to ensure validity of the contrac- hauling and repairing operations.
tual warranty. Specifically, the user will: Dealerships can provide information and advice to en-
D respect restrictions of use specified by the manufac- sure the best use of the vehicle.
turer;
D not implement changes or variants to the vehicle Spare parts
without the manufacturer’s written approval; Use genuine spare parts for replacements which can
D always carry out the maintenance interventions; be ordered from dealers.
D always use genuine spare parts; Please remember that the following information will be
D ascertain that the personnel called to use the ve- required to order spare parts:
hicle have the necessary requirements in terms of D vehicle type;
skills and training. D chassis number;
The contractual warranty will not be applicable if the D reference and catalogue numbers shown in the
aforesaid conditions are not respected, even in part. Spare Parts Catalogue.
If the part belongs to a main assembly (engine, trans-
Liability mission, axles, motors, etc.), you will also need to spec-
The manufacturer declines all direct or indirect liabili- ify the assembly model and serial number.
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.
327B & 330B SECTION 1 Copyright
CONDITIONS OF USE© 9

GENERAL OPERATION RULES

Pre-- disassembly preparation D All units, especially those which look alike, should
be placed in order and tagged or marked when
Cleaning before bringing the vehicle into service shop necessary.
Remove mud and dirt completely before bringing the D Standard parts such as nuts and bolts are to be
vehicle into the service shop. Carrying mud and dirt into kept, noting the assembly position and the quantity.
the service shop impedes cleaning operations when D Shims and washers used to adjust clearances are
disassembling and increases the possibility of conta- to be kept so they can be re---assembled in the
mination of parts during reassembly. same conditions.
D During disassembly, carefully inspect for any seiz-
Preliminary survey before disassembly ure, interference or contact with moving parts to find
the cause of the problem.
Before disassembly, make an accurate preliminary sur-
D When measuring, record all the values, such as end
vey and make a note of the results. This will save un-
clearances, backlash or projection which only have
necessary labour and component costs and will be
significance if measured during disassembly.
useful to give advice to the user to prevent problems in
D Keep the same adjustment values of the rods as far
the future.
as possible. If it is necessary to disassemble adjust-
In particularly:
ment devices, measure the length before disassem-
D Check the type and number of the machine and ser-
bly and make a note of the value so as to be able to
vice meter reading.
reassemble in the identical condition.
D Check the reason for disassembly.
D If tapered or fitted parts that should fit tightly come
D Check the symptom, location and cause of the
off easily, inspect the parts involved to find the cause
problem and make another visual check if necess-
so that the same problem does not occur again
ary.
when reassembling.
D Check the contamination of the air cleaner and air
leakage. Figure 1
D Check the characteristics of the fuel being used,
contamination of the fuel filter and for any water in
the fuel, loss of fuel, deformed pipes.
D Check the oil level, oil contamination (viscosity, co-
lour and impurity) presence of water in the oil, oil
leakage and clogged oil filter.
D Check the tension of the V belts;
D Check for any faulty components or loosened con-
nections.

Disassembly preparation
To save unnecessary labour, make sure that the equip-
ment, area and space on the shelves is available, ac-
cording to the specific type of disassembly to be car- 1730101
ried out, and clean the area beforehand.
D Use an appropriate jig and do not try to force them.
During disassembly

Removal of parts
D Before removing parts, check the assembly condi-
tions and front/rear, left/right and up/down relations
and the removal procedures
D Make sure there are the relevant mating marks indi-
cating the mounting positions and if necessary
mark clearly to avoid errors during reassembly.
D Use the special disassembly tools where specified.
D If it is difficult to remove a part even after the mount-
ing screws have been removed, do not force it, but
check the part to find where the problem lies.
10 CONDITIONS OF USE SECTION 1 327BCopyright
& 330B ©

Disconnecting hydraulic lines After disassembly

Operate each control lever several times to When using detergents, make sure you fully
relieve any pressure in the lines to be re- understand the use instructions and take
moved. care not to bring them into contact with the
Open the air bleeder cap of the hydraulic eyes or skin. Dispose of used detergents
tank. correctly.

Figure 2 Cleaning
D Clean the disassembled parts and arrange them in
order. Completely remove sludge and dust from the
oil ports of each part.
D To clean more efficiently, divide the detergent into
two containers; one to remove the dirt and one for
finishing. When cleaning more important parts, di-
vide the containers further to avoid using dirty deter-
gent.
D When cleaning large castings, such as the cylinder
head or block, , immerse them in a container for 5
to 10 minutes with a pH 10---12 detergent, at a tem-
perature of 50 °C and 70 °C (122 ÷ 158 ˚F), then
rinse thoroughly.
1730102

D To disconnect a rigid tube from another one, or a Rust and dust prevention
rigid tube from a hose, grasp the male end with a D Cover clean parts to avoid rusting.
wrench and loosen the female nut side. D Place caps on the ends of tubes and hoses.
D Plug the end of the removed tube or hose and the D If it will be some time before assembly, use rust inhi-
oil port on the part, to prevent foreign matter from bitor.
entering.
D Since the tube or hose to be removed contains oil, During assembly
pour this off into a suitable container. Installing the parts
D Clean up any oil spills in the working area.
D Attach a tag with an appropriate marking to each D Before starting to assemble, clean all the compo-
tube, hose and hydraulic component line connec- nents and repair any damage. Dirt and dust have
tion for easier reassembly. adverse effects on moving parts and can shorten
the machine life, so take all precautions to limit their
penetration.
D Before assembly, remove the layer of rust inhibitor
if present on new parts.
D Parts with mating marks are to be mounted so that
the marks are correctly aligned.
D Use a press and appropriate tools when installing
bearings, bushings, oil gaskets etc. When mount-
ing special parts, use the specific special tools.
D Coat the surface of press---fit parts with molyb-
denum disulphate grease or other specific lubric-
ant, where prescribed.
327B & 330B SECTION 1 Copyright
CONDITIONS OF USE ©
11

Screw and nut tightening Connecting hydraulic lines

D Clean all rigid tubes with a suitable detergent and
Figure 3 blow dry with compressed air.
D Do not use coupling liquids (three components).
D When installing high pressure hoses, do not allow
any torsion. Avoid that other parts interfere with the
hoses if they have no protective spring.
D Install correctly, checking the tags on each rigid
tube or hose and on hydraulic component connec-
tions.

Figure 5

1730103
D Tighten nuts and bolts alternately so that average
torque can be applied evenly. The numbers on the
figure indicate the order of tightening.
D Unless indicated otherwise, apply lubricant to the
threaded part of the bolts, so as to obtain even
tightening.

Figure 4
1730105

D When connecting the lines, slightly tighten the nuts

at both ends, then tighten alternately.
D After completing the line connections, run the en-
gine at low speed and from the driver’s seat move
each hydraulic component through the control
levers. Make a further inspection then top up the oil
in the hydraulic tank
D Points such as end clearances, end plates, projec-
tions, steps and backlash that cannot be checked
except during the assembly process, are to be
checked and measured before passing on to the
next step.
D Shims and washers used to adjust clearances are
to be refitted in the same condition as they were be-
fore disassembly, unless worn or damaged.
D After reassembly, check the adjustment values.
1730104
D Assemble the linkage with the rod adjustment value
a: correct assembly identical to that before disassembly.
b: incorrect assembly D If parts fitted by pressure are easily inserted, check
the insertion dimensions again and correct any
D The nuts and bolts that cannot be inspected exter- flaws before assembling.
nally, or those for more important parts are to be in-
stalled and locked with an appropriate device to
prevent loosening (lock wire, split pin, bent
washer).
D Bolts on which a thread stop has been applied (resi-
due can be seen when removed) are to be cleaned
with light oil and dried before tightening. Apply 2 or
3 drops of thread stop to the threaded part of the
bolts, then tighten.
12 CONDITIONS OF USE SECTION 1 327BCopyright
& 330B ©

Interchangeable parts
Figure 7
Gaskets
D As a rule, replace all gaskets with new ones.
D Apply sealing liquid to the sealing gaskets of certain
parts.
D Remove all flaws, dust, paint, oil or previously used
seal liquids.
D Apply an even coating of the specified sealing liquid
and allow to dry for a few minutes.
D When the liquid is dry to the touch, mate the
gaskets.

O---rings
D If the O---rings have become hardened after long
1730107
storage, discard them even if they have never been
used. D When assembling oil seal gaskets, apply some
D Use only the O---rings indicated in the spare parts grease to prevent initial dry friction.
lists. For the engine, in particular, O---rings of
special material, like silicone rubber are used for a. Single lip type oil seal gasket
their resistance to heat and deterioration. Do not Apply the grease evenly over the entire external
use substitutes. border of the side opposite to the sealing part of
D Before installation, apply a coating of oil to the O--- the lip (arrow), taking care that there is no build
ring to prevent cracking. Silicone rubber tears easily up.
and must therefore be handled with care. b. Double lip type oil seal gasket
Apply grease to 40---60% of the external border of
Oil seal gaskets (oil seal rings) the section between the lips (arrow).

Figure 6 D Make sure that the contact surface (shaft area) of

the oil seal gasket is free of dust, cracks or rust and
apply lubricant to facilitate the installation.

Figure 8

1730106

A: inner side (possible pressure)

B: outer side
a: main lip (seal)
1730108
b. dust protection lip
D To install, use a guide and an assembly jig to avoid
D Pay attention to the direction of the oil seal gasket damaging the oil seal gasket lip.
lips. D After inserting the oil seal gasket and pushing it into
D Take care that no dust settles on the oil seal gasket, its seat, the gasket should have no inclination.
and ascertain that there is no rust or cracking (es-
pecially on the lip surfaces).
327B & 330B SECTION 1 Copyright
CONDITIONS OF USE ©
13

D When an adhesive product is applied to the external D Bearings to be mated with large interference values
part of the gasket, take care that none drops onto are to be inserted by shrink fitting. To avoid damag-
the lip surfaces. Since the adhesive remaining on ing the heat treatment hardening, keep the tem-
the assembly tools could easily pass onto the lips, perature below 120 °C (248 °F).
use clean guides and assembly jigs.
Figure 10
Bearings
D Since dust adversely affects bearing wear, when
disassembling and reassembling, care must be
taken to protect them from dust.
D Handle the bearings with care when cleaning and
do not allow them to spin in compressed air.
D When installing, do not knock on the bearing inner
or outer ring, as this could cause indentations on
the rolling surfaces.

Figure 9

1730110

D Non---separating bearings that require interference

on both inner and outer rings are to be inserted
using an appropriate assembly jig.

Snap rings (seeger rings)

D To insert and remove snap rings, use snap ring
pliers taking care not to widen excessively.
D After installation, make sure the snap rings are com-
pletely fitted into their groove.
1730109

D If interference is required on the inner ring, push it

in using an appropriate assembly jig.
14 CONDITIONS OF USE SECTION 1 327BCopyright
& 330B ©

Welding on the chassis D turn over and weld as specified in the previous step;
Before starting these operations, disconnect the nega- allow the side members to cool slowly and evenly;
tive terminal of the battery and connect the welder earth do not use jets of air or other methods, immediately
directly onto the piece to be welded. remove excess material by grinding;
Disconnect controllers and computer equipement on
Figure 12
machine and engine.
Work on plastic tubes is only to be carried out by skilled
experts, using the appropriate equipment and per-
formed with perfect workmanship.

Figure 11

1730112

A = 0.3 H
B = H (≥175 mm (7 in)
S = (0.8 – 1 mm) S1
1730111

D apply internal corner reinforcements in steel having

Remove the paint and any oxidation from the parts to the same characteristics as the chassis (minimum
be welded. On the yield point, on the internal part of the indicative dimensions are shown on the figure);
side member and along the entire length of the part in- D they should be fixed only to the vertical rib of the side
volved, make a 60° chamfer. member and welding beads can be used. The sec-
tion and length of the weld bead is to be adequate
Cuts on the side member are not allowed
to transmit the section bending and cutting mo-
that correspond to the stress variation ments.
zones, furthermore the line of separation is D After welding the part involved is to be efficiently pro-
not to involve the existing holes on the side tected with a rust inhibitor.
member.
The operating instructions for correct welding follow
below:
D heat all around the zone to be welded; make the arc
welding passing several times using carefully dried
basic tips , or MIG---MAG procedures with a suitable
filling material; avoid current overloads; the welding
is to be free of border incisions and spatter;
327B & 330B SECTION 1 Copyright ©15
SAFETY INSTRUCTIONS

SAFETY INSTRUCTIONS
16 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS 327BCopyright
& 330B ©

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.
327B & 330B SECTION 1 Copyright ©17
SAFETY INSTRUCTIONS

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
18 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS 327BCopyright
& 330B ©

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
327B & 330B SECTION 1 Copyright ©19
SAFETY INSTRUCTIONS

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
20 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS 327BCopyright
& 330B ©

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
327B & 330B SECTION 1 Copyright ©21
SAFETY INSTRUCTIONS

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.
22 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS 327BCopyright
& 330B ©

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
327B & 330B SECTION 1 Copyright ©23
SAFETY INSTRUCTIONS

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
24 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS 327BCopyright
& 330B ©

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.
327B & 330B SECTION 1 Copyright ©25
SAFETY INSTRUCTIONS

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
26 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS 327BCopyright
& 330B ©

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.
327B & 330B SECTION 1 Copyright ©27
SAFETY INSTRUCTIONS

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.
28 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS 327BCopyright
& 330B ©

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.
327B & 330B SECTION 1 Copyright ©29
SAFETY INSTRUCTIONS

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
30 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS 327BCopyright
& 330B ©

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).
327B & 330B SECTION 1 Copyright ©31
SAFETY INSTRUCTIONS

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
32 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS 327BCopyright
& 330B ©

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
327B & 330B SECTION 1 Copyright ©33
SAFETY INSTRUCTIONS

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
34 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS 327BCopyright
& 330B ©

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
327B & 330B SECTION 1 Copyright ©35
SAFETY INSTRUCTIONS

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
36 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS 327BCopyright
& 330B ©

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
 Copyright ©

SECTION 2

TECHNICAL DATA

327B
Copyright ©
 327B SECTION 2 Copyright
TECHNICAL DATA © 1

CONTENTS

Page Page

VEHICLE COMPOSITION . . . . . . . . . . . . . . . . . . . . . 3 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DIMENSIONS (EMPTY VEHICLE) . . . . . . . . . . . . . . 4
Drive cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DIMENSIONS WITH BODY RAISED . . . . . . . . . . . . 5
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
LIST OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CENTER OF GRAVITY
(HORIZONTAL POSITION) . . . . . . . . . . . . . . . . . . . . 7 CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 TIRE PRESSURE TABLE . . . . . . . . . . . . . . . . . . . . . 21

PERFORMANCE ALIGNMENT CHART . . . . . . . . 10 ANTIFREEZE CONCENTRATION IN ENGINE

COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Using the alignment chart . . . . . . . . . . . . . . . . . . . . . 10
ANTIFREEZE CONCENTRATION IN
Performance alignment chart . . . . . . . . . . . . . . . . . . 11
WINDSCREEN WASHER FLUID . . . . . . . . . . . . . . . 21
MAIN TECHNICAL SPECIFICATIONS . . . . . . . . . 12
BATTERY ELECTROLYTE DENSITY TABLE . . . . 21
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . 22
Case PIN plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PLATES APPLIED TO THE VEHICLE . . . . . . . . . . 23
POSITION OF IDENTIFICATION DATA
ON MAIN GROUPS . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Articulation joint left size . . . . . . . . . . . . . . . . . . . . . . 24

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cab access steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 EUROPEAN VERSION . . . . . . . . . . . . . . . . . . . . . . . 24

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 INSIDE ENGINE HOOD PLATE . . . . . . . . . . . . . . . 27
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . 14
INSIDE CAB PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Drive axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
U.S.A. VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Dumper cylinder (two) . . . . . . . . . . . . . . . . . . . . . . . . 15
INSIDE ENGINE HOOD PLATE . . . . . . . . . . . . . . . 31
Steering cylinder (two) . . . . . . . . . . . . . . . . . . . . . . . . 15
Suspension cylinders . . . . . . . . . . . . . . . . . . . . . . . . . 15 INSIDE CAB PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . 31

MAIN TECHNICAL SPECIFICATIONS . . . . . . . . . 16 STANDARD TIGHTENING TORQUES . . . . . . . . . . 33

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Screws and nuts with metric thread . . . . . . . . . . . . 33

Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . 16 MEASURES (INTERNATIONAL SYSTEM) . . . . . . 34

Front drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Force in N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Intermediate and rear drive axles . . . . . . . . . . . . . . . 17 Power in kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Torque in Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Specific consumption in g/kWh . . . . . . . . . . . . . . . . 34
Wheels and tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Pressure in kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Conversion values for British units . . . . . . . . . . . . . . 34
2 TECHNICAL DATA SECTION 2 Copyright
327B ©

Left intentionally blank

327B SECTION 2 Copyright
TECHNICAL DATA © 3

VEHICLE COMPOSITION

GROUPS DESCRIPTION

ENGINE

F3A (Cursor 10)

GEARSHIFT

6 WG 260

FRONT HUB

D81

INTERMEDIATE AXLE
D81

REAR AXLE
D81

TRANSMISSION
LAYOUT
4 TECHNICAL DATA SECTION 2 Copyright
327B ©

DIMENSIONS (empty vehicle)

mm ft in
A Wheelbase 4212 13’ 10”
B Front track 2360 7’ 9”
C Rear track 2360 7’ 9”
D Front overhang 2824 9’ 3”
E Rear overhang 1295 4’ 3”
F Overall length 10031 32’ 11”
G Maximum width (excluding mirrors) 2961 9’ 9”
H Maximum height (*) 3723 12’ 3”
I Ground clearance (*) 478 1’ 7”
J Distance between tandem axles 1700 5’ 7”
L Body height (*) 2756 9’ 1”
Internal steering circle 4090 13’ 5”
External steering circle 8256 27’ 1”

Dimensional tolerance: 3% (*) empty vehicle

276DT001T
327B SECTION 2 Copyright
TECHNICAL DATA © 5

DIMENSIONS WITH BODY RAISED

mm 6500
M Maximum height of body (*)
ft in 21’ 24”
N Maximum tipping angle --- Degrees ˚ 68
mm 965
R Ground clearance (*)
ft in 3’ 2”
m3
--- Loading capacity to the brim (SAE 1:1)
yd3
m3
--- Full loading capacity (SAE 2:1)
yd3

Dimensional tolerance: 3% (*) empty vehicle

276DT002T
6 TECHNICAL DATA SECTION 2 Copyright
327B ©

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
327B SECTION 2 Copyright
TECHNICAL DATA © 7

CENTER OF GRAVITY (horizontal position)

Empty vehicle mm ft in
S Front distance 2444 8’ 0”
T Rear distance 2946 9’ 8’

Loaded vehicle mm ft in
S Front distance 3573 11’ 9”
T Rear distance 1817 6’ 0”

Dimensional tolerance: 3%

276DT004T
 8 TECHNICAL DATA SECTION 2 Copyright
327B ©

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) 70%

Full load transversal gradeability (D) 70%
(D) minimum adherence ratio 0.6
327B SECTION 2 Copyright
TECHNICAL DATA © 9

Left intentionally blank

 10 TECHNICAL DATA SECTION 2 Copyright
327B ©

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).
327B SECTION 2 Copyright
TECHNICAL DATA ©11

Performance alignment chart (Fig. 1)

C B

A
 12 TECHNICAL DATA SECTION 2 Copyright
327B ©

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.
327B SECTION 2 Copyright
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
 14 TECHNICAL DATA SECTION 2 Copyright
327B ©

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.
327B SECTION 2 Copyright
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.
 16 TECHNICAL DATA SECTION 2 Copyright
327B ©

MAIN TECHNICAL SPECIFICATIONS

Engine
Type: 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.

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: 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
327B SECTION 2 Copyright
TECHNICAL DATA ©17

Front drive axle

Type: semi---independent with automatic transmission integrated differential, and 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: 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

 18 TECHNICAL DATA SECTION 2 Copyright
327B ©

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.
327B SECTION 2 Copyright
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

 20 TECHNICAL DATA SECTION 2 Copyright
327B ©

CAPACITIES
CAPACITY
PART TO BE FILLED SPECIFICATIONS
I (US Gal) kg (Ib)
Engine oil sump (1)
SAE 15W40
Akcela N°1 Engine Oil 30.5 (8) --- --- MIL L 21 04E lev.
API GF 4
Engine coolant radiator
Akcela Premium Anti---freeze 50 (13.2) --- --- ASTM 0336
Fuel tank
Diesel 440 (116.2) --- --- ASTM D ---975
Automatic transmission
SAE 15W40
Akcela N°1 Engine Oil 35.5 (9.4) --- --- MIL L 21 04E lev.
API GF 4
Driveshaft support
SAE 85W140
Akcela GEAR 135H EP 1.8 (0.5) --- --- MIL L 21050
API GL 5
Axles/Differentials/Planetary Hubs
Front differential 14.0 (3.7)
Front hub 9.0 (2.4) x 2 SAE 85W140
Akcela GEAR 135H EP Intermediate axle/ --- --- MIL L 21050
34.0 (9.0) API GL 5
planetary
Rear axle/planetary 33.0 (8.7)
Suspension
Akcela A.T.F. 1.6 (0.4) x 2 --- --- ATF DEXRON Il
Hydraulic circuit (2)
ISO VG 46
Akcela Hydraulic Excavators Fluid 300.0 (79.2) --- ---
DIN 51524/51525
Engine hood/cab tipping circuit
Akcela A.T.F. 2.0 (0.5) --- --- ATF DEXRON Il
Greasing
Akcela Premium Grease EP2 --- --- 2.0 (4.4) N.L.G.I. No. 2
Climate control system
Refrigerant fluid R134a --- --- 1.2 (2.6) R134a
Windshield washer
Tutela Professional SC35 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
327B SECTION 2 Copyright
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 WINDSHIEED 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
22 TECHNICAL DATA SECTION 2 Copyright
327B ©

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
327B SECTION 2 Copyright
TECHNICAL DATA ©23

PLATES APPLIED TO THE VEHICLE

The adhesives and plates applied on the vehicles may the adhesives and plates on a 327B model, indicating
vary according to the market and local requirements of the 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
 24 TECHNICAL DATA SECTION 2 Copyright
327B ©

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

327B SECTION 2 Copyright
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

 26 TECHNICAL DATA SECTION 2 Copyright
327B ©

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

327B SECTION 2 Copyright
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.

 28 TECHNICAL DATA SECTION 2 Copyright
327B ©

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.
327B SECTION 2 Copyright
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

 30 TECHNICAL DATA SECTION 2 Copyright
327B ©

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

327B SECTION 2 Copyright
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.

 32 TECHNICAL DATA SECTION 2 Copyright
327B ©

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.
327B SECTION 2 Copyright
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
 34 TECHNICAL DATA SECTION 2 Copyright
327B ©

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
 Copyright ©

SECTION 2

TECHNICAL DATA

330B
Copyright ©
 330B SECTION 2 Copyright
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

2 TECHNICAL DATA SECTION 2 Copyright
330B ©

Left intentionally blank

330B SECTION 2 Copyright
TECHNICAL DATA © 3

VEHICLE COMPOSITION

GROUPS DESCRIPTION

ENGINE

F3A (Cursor 10)

GEARSHIFT

6 WG 260

FRONT HUB

D81

INTERMEDIATE AXLE
D81

REAR AXLE
D81

TRANSMISSION
LAYOUT
4 TECHNICAL DATA SECTION 2 Copyright
330B ©

DIMENSIONS (empty vehicle)

mm ft in
A Wheelbase 4212 13’ 10”
B Front track 2360 7’ 9”
C Rear track 2360 7’ 9”
D Front overhang 2824 9’ 3”
E Rear overhang 1295 4’ 3”
F Overall length 10031 32’ 11”
G Maximum width (excluding mirrors) 2961 9’ 9”
H Maximum height (*) 3723 12’ 3”
I Ground clearance (*) 478 1’ 7”
J Distance between tandem axles 1700 5’ 7”
L Body height (*) 2956 9’ 8”
Internal steering circle 4090 13’ 5”
External steering circle 8256 27’ 1”
Dimensional tolerance: 3% (*) empty vehicle

276DT001T
330B SECTION 2 Copyright
TECHNICAL DATA © 5

DIMENSIONS WITH BODY RAISED

mm 6500
M Maximum height of body (*)
ft in 21’ 24”
N Maximum tipping angle --- Degrees ˚ 68
mm 965
R Ground clearance (*)
ft in 3’ 2”
m3
--- Loading capacity to the brim (SAE 1:1)
yd3
m3
--- Full loading capacity (SAE 2:1)
yd3

Dimensional tolerance: 3% (*) empty vehicle

276DT002T
6 TECHNICAL DATA SECTION 2 Copyright
330B ©

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
330B SECTION 2 Copyright
TECHNICAL DATA © 7

CENTER OF GRAVITY (horizontal position)

Empty vehicle mm ft in
S Front distance 2465 8’ 1”
T Rear distance 2925 9’ 7”

Loaded vehicle mm ft in
S Front distance 3701 12’ 2”
T Rear distance 1689 5’ 6”

Dimensional tolerance: 3%

276DT004T
8 TECHNICAL DATA SECTION 2 Copyright
330B ©

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) 70%

Full load transversal gradeability (D) 70%
(D) minimum adherence ratio 0.6
330B SECTION 2 Copyright
TECHNICAL DATA © 9

Left intentionally blank

10 TECHNICAL DATA SECTION 2 Copyright
330B ©

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).
330B SECTION 2 Copyright
TECHNICAL DATA ©11

Performance alignment chart (Fig. 1)

C B

A
12 TECHNICAL DATA SECTION 2 Copyright
330B ©

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.
330B SECTION 2 Copyright
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
14 TECHNICAL DATA SECTION 2 Copyright
330B ©

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

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

the right. 269DT0E4

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.
330B SECTION 2 Copyright
TECHNICAL DATA ©15

Drive axles Dumper cylinder (two)

Disk brakes version

The type and serial number are indicated on a269DT0E2

plate on
the cylinder casing.

Wet brakes version 276DT006T Steering cylinder (two)

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

Suspension cylinders

276DT008T

The type and serial number are indicated on a plate on

the cylinder casing.
16 TECHNICAL DATA SECTION 2 Copyright
330B ©

MAIN TECHNICAL SPECIFICATIONS

Engine
Type: 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.

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: 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
330B SECTION 2 Copyright
TECHNICAL DATA ©17

Front drive axle

Type: semi---independent with automatic transmission integrated differential, and 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: 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

18 TECHNICAL DATA SECTION 2 Copyright
330B ©

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. Oil---water heat exchanger. 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.
330B SECTION 2 Copyright
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

20 TECHNICAL DATA SECTION 2 Copyright
330B ©

CAPACITIES
CAPACITY
PART TO BE FILLED SPECIFICATIONS
I (US Gal) kg (Ib)
Engine oil sump (1)
SAE 15W40
Akcela N°1 Engine Oil 30.5 (8) --- --- MIL L 21 04E lev.
API GF 4
Engine coolant radiator
Akcela Premium Anti---freeze 50 (13.2) --- --- ASTM 0336
Fuel tank
Diesel 440 (116.2) --- --- ASTM D ---975
Automatic transmission
SAE 15W40
Akcela N°1 Engine Oil 35.5 (9.4) --- --- MIL L 21 04E lev.
API GF 4
Driveshaft support
SAE 85W140
Akcela GEAR 135H EP 1.8 (0.5) --- --- MIL L 21050
API GL 5
Axles/Differentials/Planetary Hubs
Front differential 14.0 (3.7)
Front hub 9.0 (2.4) x 2 SAE 85W140
Akcela GEAR 135H EP Intermediate axle/ --- --- MIL L 21050
34.0 (9.0) API GL 5
planetary
Rear axle/planetary 33.0 (8.7)
Suspension
Akcela A.T.F. 1.6 (0.4) x 2 --- --- ATF DEXRON Il
Hydraulic circuit (2)
ISO VG 46
Akcela Hydraulic Excavators Fluid 300.0 (79.2) --- ---
DIN 51524/51525
Engine hood/cab tipping circuit
Akcela A.T.F. 2.0 (0.5) --- --- ATF DEXRON Il
Greasing
Akcela Premium Grease EP2 --- --- 2.0 (4.4) N.L.G.I. No. 2
Climate control system
Refrigerant fluid R134a --- --- 1.2 (2.6) R134a
Windshield washer
Tutela Professional SC35 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
330B SECTION 2 Copyright
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
22 TECHNICAL DATA SECTION 2 Copyright
330B ©

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
330B SECTION 2 Copyright
TECHNICAL DATA ©23

PLATES APPLIED TO THE VEHICLE

The adhesives and plates applied on the vehicles may the adhesives and plates on a 330B model, indicating
vary according to the market and local requirements of the 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
24 TECHNICAL DATA SECTION 2 Copyright
330B ©

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

330B SECTION 2 Copyright
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

26 TECHNICAL DATA SECTION 2 Copyright
330B ©

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

330B SECTION 2 Copyright
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.

28 TECHNICAL DATA SECTION 2 Copyright
330B ©

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.
330B SECTION 2 Copyright
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

30 TECHNICAL DATA SECTION 2 Copyright
330B ©

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

330B SECTION 2 Copyright
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.

32 TECHNICAL DATA SECTION 2 Copyright
330B ©

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.
330B SECTION 2 Copyright
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
34 TECHNICAL DATA SECTION 2 Copyright
330B ©

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
 Copyright ©

SECTION 3

FAILURE CODES
Copyright ©
327B & 330B SECTION 3 Copyright
FAILURE CODES © 1

CONTENTS

Page Page

ENGINE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . 3 FAULT CHECK USING THE DISPLAY . . . . . . . . . . 12

FAULT CHECK USING THE DISPLAY . . . . . . . . . . . 3 TRANSMISSION FAILURE LIST . . . . . . . . . . . . . . . 13

ENGINE FAULT CODES LIST . . . . . . . . . . . . . . . . . . 4 DIAGNOSTIC CONNECTOR PIN-- OUT . . . . . . . . 38

FAULT CHECK USING THE EDC WARNING MULTIPLEX SYSTEM FAULT CODES . . . . . . . . . . 39
LIGHT (BLINK -- CODE) . . . . . . . . . . . . . . . . . . . . . . 10
FAULT CHECK USING THE DISPLAY . . . . . . . . . . 39
ERROR CODES TABLE . . . . . . . . . . . . . . . . . . . . . . 11
MULTIPLEX SYSTEM FAULT CODES LIST . . . . . 40
AUTOMATIC TRANSMISSION FAULT CODES . . 12
2 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

Left intentionally blank

327B & 330B SECTION 3 Copyright
FAILURE CODES © 3

ENGINE FAULT CODES

FAULT CHECK USING THE DISPLAY

Figure 1

276C003001

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

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

Code 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
4 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

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
327B & 330B SECTION 3 Copyright
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
6 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

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
327B & 330B SECTION 3 Copyright
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
8 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

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
327B & 330B SECTION 3 Copyright
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
 10 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

FAULT CHECK USING THE EDC WARNING LIGHT (BLINK---CODE)

The EDC warning light (1) can provide information on engine faults.
Information on the type of fault is given by the EDC warning light (1) in the form of a sequence of long and short
flashes (blink code). The diagnosis key on the interconnection unit (2), which incorporates another EDC warning
light in parallel with the one on the dashboard, is used for the check procedure.

1
2

269NS0F1

Fault check / identification procedure

D Stop the vehicle and switch off the engine (ignition switch to STOP)
D Turn the ignition switch to MAR (warning lights on and engine off)
D press the diagnosis key and check that the EDC warning light blinks once
D after a short time in which the warning light is off, it begins to blink with a sequence of long and then short
flashes.
For example, code 14 means that the warning light has given one long and four short flashes. The procedure
should be repeated until the code of the first indicated fault appears again.
The fault code is given in the following pages.
Fault memory cancellation procedure from driver’s seat
D Turn the ignition switch to STOP
D Press the blink ---code button
D Turn the ignition switch to MAR holding the button pressed
D Wait 5 seconds
D Release the button
D Turn the ignition switch to STOP
D Check successful cancellation by taking readings with the test button
327B & 330B SECTION 3 Copyright
FAILURE CODES ©11

ERROR CODES TABLE

N. of long N. of short EDC code Blink code indicator
flashes flashes on display on interconnection control unit
VEHICLE AREA
1 4 EDC 14 STEADY LIGHT
1 7 EDC 17 OFF
ENGINE AREA 1
2 1 EDC 21 OFF
2 2 EDC 22 OFF
2 3 EDC 23 OFF
2 4 EDC 24 STEADY LIGHT
2 5 EDC 25 OFF
2 6 EDC 26 STEADY LIGHT
ENGINE AREA 2
3 5 EDC 35 OFF
TURBINE AREA
4 1 EDC 41 OFF
4 2 EDC 42 STEADY LIGHT
4 3 EDC 43 STEADY LIGHT
4 4 EDC 44 STEADY LIGHT
4 5 EDC 45 STEADY LIGHT
4 6 EDC 46 STARTS FLASHING
4 7 EDC 47 STEADY LIGHT
INJECTORS
5 1 EDC 51 STEADY LIGHT
5 2 EDC 52 STEADY LIGHT
5 3 EDC 53 STEADY LIGHT
5 4 EDC 54 STEADY LIGHT
5 5 EDC 55 STEADY LIGHT
5 6 EDC 56 STEADY LIGHT
ENGINE RPM SENSORS
6 1 EDC 61 STEADY LIGHT
6 2 EDC 62 STEADY LIGHT
INTERFACE WITH OTHER ECUS
7 2 EDC 72 STEADY LIGHT
7 7 EDC 77 STEADY LIGHT
ECU
9 1 EDC 91 STARTS FLASHING
9 2 EDC 92 STEADY LIGHT
9 4 EDC 94 STEADY LIGHT
9 5 EDC 95 STEADY LIGHT
9 6 EDC 96 STEADY LIGHT

Blink code warning light off = Minor error

Blink code warning light on and steady = Serious error
Blink code warning light blinking = Severe error
 12 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

AUTOMATIC TRANSMISSION FAULT CODES

FAULT CHECK USING THE DISPLAY

Figure 1

276C003001

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

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

Code 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
327B & 330B SECTION 3 Copyright
FAILURE CODES ©13

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
14 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

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
327B & 330B SECTION 3 Copyright
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
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
16 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

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
327B & 330B SECTION 3 Copyright
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
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
18 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

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
327B & 330B SECTION 3 Copyright
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
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
20 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

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
is broken
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
327B & 330B SECTION 3 Copyright
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
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
22 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

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
327B & 330B SECTION 3 Copyright
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 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
24 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

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
327B & 330B SECTION 3 Copyright
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
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
26 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

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
327B & 330B SECTION 3 Copyright
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
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
28 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

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
327B & 330B SECTION 3 Copyright
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
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
30 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

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
327B & 330B SECTION 3 Copyright
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
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
32 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

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
327B & 330B SECTION 3 Copyright
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
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
34 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

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
327B & 330B SECTION 3 Copyright
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
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
36 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

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
327B & 330B SECTION 3 Copyright
FAILURE CODES ©37

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 filling
filli 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
 38 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

DIAGNOSTIC CONNECTOR PIN---OUT

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

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
327B & 330B SECTION 3 Copyright
FAILURE CODES ©39

MULTIPLEX SYSTEM FAULT CODES

FAULT CHECK USING THE DISPLAY

Figure 1

276C003001

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

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

Code MUX xx

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

nance operation, then the error message is visualized.

1 2
269NU383
Code 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.
40 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

MULTIPLEX SYSTEM FAULT CODES LIST

Fault Meaning of the Reaction of the

Warning light Display
code fault code system
HEAD ERRORS The system cuts off
power supply to all
utilities
MUX CODE 01 MUX 01 The engine functions
with
reduced performance.
HEAD E2PROM MEMORY The system cuts off
ERROR power supply to all
utilities
MUX CODE 08 MUX 08 The engine functions
with
reduced performance.
HEAD E2PROM MEMORY The system cuts off
ERROR power supply to all
utilities
MUX CODE 12 MUX 12 The engine functions
with
reduced performance.
CAN OPEN LINE NOT CAN OPEN line short---
FUNCTIONING circuited
The system does not
MUX CODE 14 MUX 14 recognise any of the
body computer system
control units.
CAN J1939 LINE NOT CAN J1939 line short---
FUNCTIONING circuited The system
MUX CODE 15 MUX 15 does not recognise
EDC and TCU
control units.
MIDAC 1 NOT FUNCTION- The system cuts off
MUX CODE 16 MUX 16 ING power supply to all
MIDAC 1 utilities
MIDAC 2 NOT FUNCTION- The system cuts off
MUX CODE 17 MUX 17 ING power supply to all
MIDAC 2 utilities
MIDAC 1 ERRORS The system cuts off
MUX CODE 19 MUX 19 power supply to all
MIDAC 1 utilities
MIDAC 2 ERRORS The system cuts off
MUX CODE 21 MUX 21 power supply to all
MIDAC 2 utilities
SOFTWARE VERSION Conflict between
ERROR management software
MUX CODE 25 MUX 25 and memorised
parameters.
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
327B & 330B SECTION 3 Copyright
FAILURE CODES ©41

Fault Meaning of the Reaction of the

Warning light Display
code fault code system
HYDRAULIC SYSTEM FLUID Body tipping
TEMPERATURE SENSOR AUTOMATIC
MUX CODE 47 MUX 47 NOT FUNCTIONING ACCELERATOR mode
not functioning
HYDRAULIC SYSTEM FLUID
MUX CODE 48 MUX 48 TEMPERATURE LOW

HYDRAULIC SYSTEM FLUID

MUX CODE 49 MUX 49 TEMPERATURE HIGH

RETARDER COMMAND AIR Retarder not function-

PRESSURE SENSOR NOT ing.
MUX CODE 65 MUX 65 FUNCTIONING Warm ---up function not
functioning.
RETARDER COMMAND AIR RETARDER braking not
PRESSURE LOW (< 0.4 BAR functioning
MUX CODE 66 MUX 66 WHEN RETARDER COM-
MAND IS ON)
RETARDER COMMAND AIR RETARDER braking not
PRESSURE HIGH (>6.5 BAR functioning.
MUX CODE 67 MUX 67 WHEN RETARDER COM-
MAND IS ON)
BODY ANGULAR POSITION Body warning light on
SENSOR NOT FUNCTIONING dashboard flashing.
Selectable gear limited
(1st and 2nd)
AUTOMATIC ACCEL-
MUX CODE 68 MUX 68 ERATOR mode not
functioning.
Body speed reduced.
Automatic raise mode
disabled
BODY ANGULAR POSITION Body warning light on
LOW dashboard flashing.
Selectable gear limited
(1st and 2nd)
AUTOMATIC ACCEL-
MUX CODE 69 MUX 69 ERATOR mode not
functioning.
Body speed reduced.
Automatic raise mode
disabled
BODY ANGULAR POSITION Body warning light on
HIGH dashboard flashing.
Selectable gear limited
(1st and 2nd)
AUTOMATIC ACCEL-
MUX CODE 70 MUX 70 ERATOR mode not
functioning.
Body speed reduced.
Automatic raise mode
disabled
ENGINE OIL FILTER
CLOGGED
MUX CODE 71 MUX 71

BRAKE OIL FILTER

CLOGGED
MUX CODE 72 MUX 72
42 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

Fault Meaning of the Reaction of the

Warning light Display
code fault code system
FUEL FILTER (ON ENGINE)
CLOGGED
MUX CODE 76 MUX 76

WATER IN FUEL PREFILTER

(ON CHASSIS) CLOGGED
MUX CODE 77 MUX 77

BRAKING SYSTEM ACCUMU -

MUX CODE 79 MUX 79 LATOR FAULT

AIR FILTER CLOGGED

MUX CODE 80 MUX 80

HYDRAULIC SYSTEM FLUID

FILTER CLOGGED
MUX CODE 81 MUX 81

AUTOMATIC GREASING UNIT

LUBRICANT LEVEL LOW
MUX CODE 82 MUX 82

FRONT BRAKE COOLING Brake cooling circuit

MUX CODE 83 MUX 83 SYSTEM PRESSURE SWITCH pump rate reduced to
NOT FUNCTIONING minimum
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

START FROM GROUND BUT- Start from ground

MUX CODE 93 MUX 93 TON NOT FUNCTIONING function not
functioning.
WARM---UP FROM GROUND Warm ---up function
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
327B & 330B SECTION 3 Copyright
FAILURE CODES ©43

Fault Meaning of the Reaction of the

Warning light Display
code fault code system
MAIN CIRCUIT PRESSURE
LOWVEHICLE SPEED > 0

MUX 97
Emergency steering
strategy activated (war-
ning light and buzzer)

MAIN CIRCUIT PRESSURE

MUX CODE 97 MUX 97 LOWVEHICLE SPEED = 0

DRIVER MUST PRESS SER -

Press brake pedal MUX 107 VICE BRAKE PEDAL

PROCEED TO ADJUST AU -
not adjusted MUX 108 TOMATIC TRANSMISSION

CAN OPEN LINE BE - CLUSTER not

TWEEN HEAD AND functioning.
MUX CODE 109 MUX 109 CLUSTER NOT FUNC-
TIONING

DISPLAY COMMUNICATION Display not functioning.

MUX CODE 111 MUX 111 ERROR

CAN BUS J1939 FAULT See ENGINE

MUX CODE 112 MUX 112 CONTROL Section

CAN BUS J1939 FAULT See AUTOMATIC

MUX CODE 113 MUX 113 TRANSMISSION
Section
EMERGENCY STEERING
MUX CODE 114 MUX 114 PRESSURE SWITCH NOT
FUNCTIONING

SYSTEM IS RECHARGING If recharge is not

HYDRAULIC ACCUMULA - completed within set
TORS time, code MUX 79 is
activated
MUX 115

THE SYSTEM IS IN WARM---

Warm--up MUX 116 UP CONDITION

GREASE LEVEL IN AUTO - Greasing system pump

MATIC GREASING DEVICE IS blocks
MUX CODE 117 MUX 117 BELOW MINIMUM FOR A Grease delivery to
CERTAIN LENGTH OF TIME points NOT assured
HEAD ERRORS The system cuts---off
MUX CODE 118 MUX 118 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
44 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

Fault Meaning of the Reaction of the

Warning light Display
code fault code system
FRONT AND REAR BRAKE Brake cooling circuit
COOLING SYSTEM PRES - pump rate reduced to
SURE SWITCHES NOT minimum
MUX CODE 122 MUX 122 FUNCTIONING Selectable gear limited
(1st and 2nd)
Engine with reduced
performance
THERE IS NO CONFORMITY The system cuts off
MUX CODE 139 MUX 139 BETWEEN SISTEM’S ECUS power supply to all
utilities
THERE IS NO ELECTRICAL
MUX CODE 140 MUX 140 SUPPLY FOR MIDAC1

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

NO READING---WRITING VE -
MUX CODE 143 MUX 143 HICLE 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 TEM-

MUX CODE 148 MUX 148 PERATURE 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 CONFIGUR -

MUX CODE 150 MUX 150 ATION NOT FOUND.

MIDAC 1 CONFIGURATION
MUX CODE 151 MUX 151 FAILED

MIDAC 2 CONFIGURATION
MUX CODE 152 MUX 152 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
327B & 330B SECTION 3 Copyright
FAILURE CODES ©45

Fault Meaning of the Reaction of the

Warning light Display
code fault code system
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

HYDRAULIC OIL FILTER

MUX CODE 157 MUX 157 SENSOR NOT CONNECTED

BRAKES OIL FILTER SEN-

MUX CODE 158 MUX 158 SOR 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

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
46 FAILURE CODES SECTION 3 Copyright
327B & 330B ©

Left intentionally blank

 Copyright ©

SECTION 4

ENGINE
Copyright ©
 327B & 330B SECTION 4 Copyright
ENGINE© 1

CONTENTS

Page Page

WALK AROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
ELECTRONIC SYSTEM CONTROL . . . . . . . . . . . . . 8
Electrical and electronic components . . . . . . . . . . . . 8 TECHNICAL SPECIFICATION . . . . . . . . . . . . . . . . 39

Component location on engine right ---hand side . . 9 GENERAL CHARACTERISTICS . . . . . . . . . . . . . . . 40

Component location on engine left ---hand side . . . 10 ASSEMBLY CLEARANCE DATA . . . . . . . . . . . . . . . 43
FUEL SUPPLY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . 11 TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . 49
Pump---injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TIGHTENING ORDER OF GEARBOX TO
Pumping element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 ENGINE BLOCK FASTENING SCREWS . . . . . . . 52
Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Engine Support and Brackets . . . . . . . . . . . . . . . . . . 56
Solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Replacing pump---injectors . . . . . . . . . . . . . . . . . . . . 13
TROUBLESHOOTING BY SYMPTOMS . . . . . . . . 68
Injection phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Filling phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Injection phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine oil filter change . . . . . . . . . . . . . . . . . . . . . . . . 75
Pressure reduction phase . . . . . . . . . . . . . . . . . . . . . 15
Engine oil vapour filter change . . . . . . . . . . . . . . . . . 76
ENGINE AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . 16
Fuel circuit bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Top view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fuel filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
VARIABLE GEOMETRY TURBINE (VGT) . . . . . . . 17 Engine coolant fluid change and circuit check/
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
ACTUATOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . 22
Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ENGINE REMOVAL-- REPLACEMENT . . . . . . . . . 82
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
VGT CONTROL SOLENOID VALVE . . . . . . . . . . . . 22
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
ENGINE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . 24
Checks and tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
ENGINE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . 25
REMOVAL-- INSTALLATION OF THE
ENGINE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 FLEXIBLE COUPLING JOINT . . . . . . . . . . . . . . . . . 91
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Engine cooling system general diagram . . . . . . . . 29 RADIATOR GROUP REMOVAL--
Main circuit engine cooling circuit . . . . . . . . . . . . . . 30 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Thermostat operation --- engine cooling system . . 31 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Lubrication system outline . . . . . . . . . . . . . . . . . . . . . 34 AUTOMATIC TRANSMISSION OIL-- WATER
HEAT EXCHANGER REMOVAL--
Lubrication system outline --- Detail A . . . . . . . . . . . 35 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Lubrication pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
 2 ENGINE SECTION 4 327BCopyright
& 330B ©

Page Page
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
DISMANTLING THE ENGINE ON THE Dismounting the valves . . . . . . . . . . . . . . . . . . . . . . 128
BENCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Checking head bearing surface on cylinder
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . . . 106 block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Cylinder block Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Checks and measurements . . . . . . . . . . . . . . . . . . 106 Checking clearance between valve---stem and
Cilinder lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 associated valve guide . . . . . . . . . . . . . . . . . . . . . . . 130

Replacing cylinder liners . . . . . . . . . . . . . . . . . . . . . 108 Valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Replacing injector cases . . . . . . . . . . . . . . . . . . . . . 130

Fitting and checking protrusion . . . . . . . . . . . . . . . 108 Checking protrusion of injectors . . . . . . . . . . . . . . 132

Timing distribution control . . . . . . . . . . . . . . . . . . . . 133
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Drive cog pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Measuring main journals and crank pins . . . . . . . 110
Drive cog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
DETERMINATION OF PRELIMINARY DATA
FOR SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Pin double drive cog . . . . . . . . . . . . . . . . . . . . . . . . . 133

Two series of numbers are marked on the front Double drive cog . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
side of the block, in the position specified (top). . 111 Bushing replacement . . . . . . . . . . . . . . . . . . . . . . . . 133
Choice of big end and main bearing
DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
half---shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Checking cam lift and pin alignment . . . . . . . . . . . 134
Definition of main journal and big end diameter
class (journals with nominal diameter) . . . . . . . . . 113 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Replacing the timing control gear and the oil Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Checking main journal installation clearance . . . . 119 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Checking crankshaft end float . . . . . . . . . . . . . . . . 120 Valve springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Piston---connecting rod assembly . . . . . . . . . . . . . 121 Fitting the valves and oil seal ring . . . . . . . . . . . . . 138
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
ROCKER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Measuring the diameter of the pistons . . . . . . . . . 122
ROCKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Conditions for correct gudgeon pin---piston
coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 ASSEMBLING THE ENGINE ON THE BENCH . 140
Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Fitting the connecting rod---piston assembly
into the cylinder liners . . . . . . . . . . . . . . . . . . . . . . . 143
CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . 124
Fitting the cylinder head . . . . . . . . . . . . . . . . . . . . . 144
Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Replacing flywheel casing . . . . . . . . . . . . . . . . . . . . 145
Checking connecting rods . . . . . . . . . . . . . . . . . . . 125
Replacing engine flywheel . . . . . . . . . . . . . . . . . . . . 146
Mounting the connecting rod – piston assembly 126
Fitting pump---injectors . . . . . . . . . . . . . . . . . . . . . . 148
Mounting the piston rings . . . . . . . . . . . . . . . . . . . . 126
Replacing rocker shaft assembly . . . . . . . . . . . . . . 148
Fitting the big end bearing shells . . . . . . . . . . . . . . 126
Timing of timing system shaft . . . . . . . . . . . . . . . . . 149
Fitting connecting rod --- piston assemblies in
the cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Phonic wheel timing . . . . . . . . . . . . . . . . . . . . . . . . . 151

Checking piston protrusion . . . . . . . . . . . . . . . . . . . 127 Adjusting the unload/intake rockers play and
pump injector control rockers preload . . . . . . . . . 152
Checking crankpin assembly clearance . . . . . . . . 128
327B & 330B SECTION 4 Copyright
ENGINE© 3

Page Page

COMPLETING ENGINE ASSEMBLY . . . . . . . . . . 154 POWER TAKE OFF DISTRIBUTION -- P.T.O. . . 160

REPAIR WORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Variable geometry movement check . . . . . . . . . . . 156 Removal---reassembly of the power take---off . . . 162

Actuator check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Check actuator excursion . . . . . . . . . . . . . . . . . . . . 157 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Turbine body cleaning . . . . . . . . . . . . . . . . . . . . . . . 157

4 ENGINE SECTION 4 327BCopyright
& 330B ©

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327B & 330B SECTION 4 Copyright
ENGINE© 5

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

Figure 1

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
6 ENGINE SECTION 4 327BCopyright
& 330B ©

Figure 2

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
327B & 330B SECTION 4 Copyright
ENGINE© 7

Figure 3

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
8 ENGINE SECTION 4 327BCopyright
& 330B ©

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
ENGINE INJECTOR ECU

MS 7.0
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.
327B & 330B SECTION 4 Copyright
ENGINE© 9

Component location on engine right-- hand side

Figure 4

276A004004

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
10 ENGINE SECTION 4 327BCopyright
& 330B ©

Component location on engine left-- hand side

Figure 5

276A004005

1. VGT actuator solenoid valve --- 2. VGT actuator position sensor ---
3. Engine coolant temperature sensor --- 4. Engine brake solenoid valve ---
5. Flywheel sensor (engine rpm) --- 6. Turbine speed sensor
327B & 330B SECTION 4 Copyright
ENGINE © 11

FUEL SUPPLY CIRCUIT

Supply is achieved by supply pump, fuel filter and pre--- the supply pump, whereas a one---way valve calibrated
filter, 6 injectors --- pump driven by camshaft via rockers to 0.2 --- 0.3 bar on the tank return line prevents the cyl-
and electronic control unit. inder head draining with engine off.
Fuel pressure in the cylinder head is regulated by a
valve calibrated to 3.5 bar situated on the return line to

Figure 6

Return circuit

Delivery circuit

T269MT04

1. Intake from tank --- 2. Pre---filter (on chassis) --- 3. Low pressure pump --- 4. EDC cooling heat exchanger ---
5. Electroinjector --- 6. Filter (on engine) --- 7. Tank return line
12 ENGINE SECTION 4 327BCopyright
& 330B ©

Fuel supply circuit diagram

Figure 7

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)
327B & 330B SECTION 4 Copyright
ENGINE © 13

Pump -- injector Fuel is pumped but flows back in the return duct at the
The pump---injector consists of: normal transfer pressure of approx. 5 bars.
D pumping element; When the solenoid is energised, the valve is closed.
D nozzle; Fuel, which cannot flow back in the return duct, is
D solenoid valve; pumped in the high pressure nozzle causing the lifting
of the metering rod.
Figure 8 The quantity of injected fuel depends on the slide valve
closing time and therefore on the solenoid energising
time.
The solenoid valve is joined to the injector body and
cannot be disassembled.
Two screws fixing the cables transmitting the signal
coming from the control unit are fitted on the upper
part.
In order to ensure the signal transmission, tighten the
screws at a torque of 1.36 to 1.92 Nm (1 to 1.4 lbf ft)
using a torque wrench.

Replacing pump -- injectors

The replacement of the injectors must be carried out
very carefully (see Injector disassembly description).

If the operation is carried out with the motor

assembled on the vehicle, discharge the
44908
fuel contained in the cylinder head ducts un-
PUMP---INJECTOR screwing the delivery and return unions on
1. Diesel/oil seal ring --- 2. Diesel/diesel seal ring --- the cylinder head before disassembling the
3. Diesel/exhaust gas seal ring injectors.

Pumping element Figure 9

The pumping element is controlled by a rocker which,
in turn, is directly controlled by the cam of the camshaft.
The pumping element is able to ensure a high delivery
pressure.
A spring controls its return stroke.

Nozzle
Workshops will only be authorised to make the diagno- 0 411 700 002
sis of the whole injection system and may not make op- XXXXXX XXXX X
868 USA /
erations inside the pump---injector, which may be re-
placed only.
A fit diagnostic program, included in the unit, will be
able to control the operation of each injector (by disab-
ling one of them at a time and controlling the delivery
of the other five). 44908
The diagnosis allows to tell electric faults from mechan-
ical/hydraulic faults. When rockers clearance is checked, it is
It indicates malfunctioning pump---injectors. important to check pump --- injector pre ---
Therefore, it will be necessary to correctly interpret all load.
the error messages issued by the unit.
Possible faults of the injectors will be solved by replac-
ing them.

Solenoid valve
The solenoid, energised at each cycle active phase by
means of a signal coming from the control unit, controls
a slide valve which cuts off the pumping element deliv-
ery duct.
When the solenoid is not energised, the valve is open.
14 ENGINE SECTION 4 327BCopyright
& 330B ©

Injection phases

Figure 10 Figure 11

60669 60670
1. Fuel valve 1. Fuel valve
2. Pumping element 2. Pumping element
3. Fuel discharge 3. Fuel discharge
4. Filling and flowing back channel 4. Filling and flowing back channel

Filling phase Injection phase

During the filling phase, the pumping element (2) The injection phase starts when, during the pumping
moves to its upper position. element descending phase, the solenoid valve is ener-
The highest cam position is passed and the rocker roll- gized and the fuel valve (1) closes. Delivery start time,
er gets closer to the cam basic circle. properly processed by the electronic control unit, de-
The fuel valve (1) is open and the fuel can flow into the pends on engine operating conditions. Through the
injector from the lower channel (4) of the cylinder head. rocker, the cam continues to activate the pumping ele-
The filling phase continues until the pumping ele- ment (2) and the injection phase continues as long as
ment has reached its upper end --- of --- stroke position. the fuel valve is closed (1).
327B & 330B SECTION 4 Copyright
ENGINE © 15

Figure 12

1. Fuel valve
2. Pumping element
3. Fuel discharge
4. Filling and flowing back channel

60671

Pressure reduction phase

Injection stops when the fuel valve (1) opens, during
the pumping element descending phase, following the
solenoid valve de---energizing.
The fuel flows back, through the open valve (1), the in-
jector holes and the channel (4), into the cylinder head.
The solenoid valve energizing period, properly pro-
cessed by the electronic control unit, is the injection
duration (capacity) and depends on the engine operat-
ing conditions.
16 ENGINE SECTION 4 327BCopyright
& 330B ©

ENGINE AIR INTAKE SYSTEM

Top view
Figure 13

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
327B & 330B SECTION 4 Copyright
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)
18 ENGINE SECTION 4 327BCopyright
& 330B ©

Figure 14

000586t
327B & 330B SECTION 4 Copyright
ENGINE © 19

Figure 15

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
20 ENGINE SECTION 4 327BCopyright
& 330B ©

Figure 16

60753

Figure 17

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
327B & 330B SECTION 4 Copyright
ENGINE © 21

Figure 18

71762

Figure 19

71763

1. Guide rail --- 3. Slider guide --- 11. Oil outlet --- 12. Actuator control shaft --- 13. Actuator ---
14. Exhaust gas flow ---rate control fork
22 ENGINE SECTION 4 327BCopyright
& 330B ©

ACTUATOR ADJUSTMENT

Figure 20

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 VGT CONTROL SOLENOID VALVE

The actuator piston connected to the command rod is It is a proportional solenoid valve of the N.C. (usually
piloted by compressed air entering through the air in- closed) type, located on the left side of the engine block
take (1) on the upper part of the actuator. under the turbine.
Modulating the air pressure varies the shift of the tur- The electronic control unit controls the solenoid valve
bine command piston and rod. During its excursion the by a PWM signal and adjust the pressure of the turbine
piston progressively compresses the external spring actuator that, when changing its position modifies ex-
(4) until the base of the piston reaches the internal haust gas inflow section on rotor blades and therefore
spring (6) command disk (5). its speed.
Further increasing the pressure the piston interferes VGT solenoid valve is connected to control unit be-
with the lower limit stop (10) through the disk (5). tween pins A18/A31.
The use of two springs permits variation in the ratio be- Coil resistance is approx. 20---30 Ohm.
tween piston excursion and pressure. Approx. 85% of
the rod stroke is contrasted by the external spring,
whereas only 15% by the internal spring.
327B & 330B SECTION 4 Copyright
ENGINE © 23

Figure 21

CONTROL AIR SYSTEM DIAGRAM

1) Service tank 4) VGT control solenoid valve

2) Shut ---off solenoid valve 5) Actuator pressure sensor
3) Air filter 6) Turbine actuator
71765
24 ENGINE SECTION 4 327BCopyright
& 330B ©

ENGINE EXHAUST SYSTEM

Figure 22 6

2 1

FWD

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
327B & 330B SECTION 4 Copyright
ENGINE © 25

ENGINE EXHAUST SYSTEM

Figure 23

276C04005

(A) Exhaust gas arriving from the muffler

(B) Muffler --- exhaust terminal piping
(C) Body heating connection flanges
26 ENGINE SECTION 4 327BCopyright
& 330B ©

ENGINE BRAKE
Working principle:

By the end of compression phase (Picture C), a few degrees 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.

Figure 24

001413t
327B & 330B SECTION 4 Copyright
ENGINE © 27

WORKING PRINCIPLE
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.

Figure 25

A Engine brake off

B Engine brake on

C Exhaust cam

d Valve elevation for engine brake

000592t
28 ENGINE SECTION 4 327BCopyright
& 330B ©

COOLING
Forced---circulation cooling is obtained by means of a Figure 28
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 26 71731

ENGINE WATER PUMP

WATER PUMP SECTION

Figure 27

45159

The water pump consists of: rotor, seal bearing and

control pulley.
327B & 330B SECTION 4 Copyright
ENGINE © 29

Engine cooling system general diagram

Figure 29

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)
30 ENGINE SECTION 4 327BCopyright
& 330B ©

Main circuit engine cooling circuit

Figure 30

276C04007
1. Radiator
2. Thermostat
3. Automatic transmission oil exchanger
4. Brake coolant 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
327B & 330B SECTION 4 Copyright
ENGINE © 31

Thermostat operation -- engine cooling system

Thermostat closed

Figure 31

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 pas-
senger compartment heater --- 5. Engine input --- 6. Engine output --- 7. Tubing from engine to automatic tran-
smission 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. Brake oil cooling exchanger --- D. Thermostat
32 ENGINE SECTION 4 327BCopyright
& 330B ©

Thermostat open

Figure 32

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. Brake oil cooling exchanger --- D. Thermostat
327B & 330B SECTION 4 Copyright
ENGINE © 33

LUBRICATION

Figure 33

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 34

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.
34 ENGINE SECTION 4 327BCopyright
& 330B ©

LUBRICATION

Lubrication system outline

Figure 35

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
327B & 330B SECTION 4 Copyright
ENGINE © 35

Lubrication system outline -- Detail A

Figure 36

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

36 ENGINE SECTION 4 327BCopyright
& 330B ©

Lubrication pump
Figure 37
SECTION B---B

OIL PUMP SECTION

60628
327B & 330B SECTION 4 Copyright
ENGINE © 37

Heat exchanger

Figure 38

60629

HEAT EXCHANGER SECTION

Figure 39

SECTION A-- A SECTION B -- B

By---pass valve Thermostatic valve

Cut ---in pressure 2 bar Cut ---in temperature 82 ± 2˚C

60630
38 ENGINE SECTION 4 327BCopyright
& 330B ©

Engine oil filter

This is a new ---generation filter, ensuring much more accurate filtering, since it can block a higher quantity of par-
ticles of smaller dimensions compared to traditional filters, with paper filtering septum.

Outside spiral wrapping

Figure 40
The filtering elements are strictly wrapped by a spiral,
so that each fold is strongly fixed to the spiral. This
means a uniform use of the septum, also under the
toughest conditions, such as cold start ---ups with high
viscosity fluids and flow peaks. Moreover, a uniform dis-
tribution of flow is ensured through the whole length of
the filtering elements; thus the loading loss is opti-
mized, as well as its operating time.

Upstream support
In order to optimize flow distribution and filtering ele-
ment stiffness, the filtering element is equipped with an
exclusive support consisting of a strong nylon mesh
and high---strength synthetic material.

Filtering septum
It consists of inert inorganic fibers, connected by exclu-
sively manufactured resin to a shifting pore structure;
it is exclusively manufactured following precise proce-
dures and strict quality controls.

Downstream support
Thanks to the filtering septum and the strong nylon
mesh, the septum strength is improved, especially use-
ful during cold start ---ups and long use periods. Filter
performance is constant and reliable for the entire ser-
vice life, on each element, regardless of operating con-
47447 ditions changes.

Structural parts
The O---rings equipping the filtering element ensure
perfect sealing between the filtering element and the
container, thus eliminating any bypass risk and keep-
ing filter performance constant. Corrosion---proof bot-
tom sides, as well as a solid metal core, complete the
filtering element structure.

These highly filtering elements, adopted only in industrial process up to now, make it possible to:
D reduce engine components wear;
D preserve oil performance/characteristics, thus extending the period of time between replacements.
327B & 330B SECTION 4 Copyright
ENGINE © 39

TECHNICAL SPECIFICATION

Figure 41

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

40 ENGINE SECTION 4 327BCopyright
& 330B ©

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

327B 330B

Max. power kW 235 260

(HP) (315) (353)

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
327B & 330B SECTION 4 Copyright
ENGINE © 41

Type F3A

A VALVE TIMING

opens before T.D.C. A 16˚

closes after B.D.C. B 32˚

C opens before B.D.C. D 50˚

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

With electronically regulated injectors
Injection PDE31 pump injectors controlled
type Bosch
by overhead camshaft

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

ba Injection pressure bar (PSI)

r 1500 (21 755)
Injector calibration bar (PSI)
42 ENGINE SECTION 4 327BCopyright
& 330B ©

F3A
Type
VGT

SUPERCHARGING Variable geometry

Turbocharger type 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 (185 ˚F)
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 (PSI) 1.5 (22)
at maximum speed bar (PSI) 5 (73)
OIL FILLING
Total capacity at 1st filling
liters 32
Quarts 34
Capacity:
--- engine sump min level
liters 17
Quarts 18
--- engine sump max level
liters 25
Quarts 26
--- quantity in circulation that does
not flow back to the engine
g sump
p
liters 7
Quarts 7.3
--- quantity contained in the
cartridge filter (which has to be
added to the cartridge filter refill)
liters 2.5
Quarts 2.6
327B & 330B SECTION 4 Copyright
ENGINE © 43

ASSEMBLY CLEARANCE DATA

Type F3A

CYLINDER BLOCK AND CRANK

mm (in)
MECHANISM COMPONENTS
∅1
Cylinder sleeve bore
upper 142.000---142.025 (5.5905---5.5915)
∅1
lower 140.000---140.025 (5.5118---5.5128)

Cylinder liners:
outer diameter:
L upper 141.961---141.986 (5.5890---5.5900)
∅2
lower 139.890---139.915 (5.5075---5.5084)
∅2 length L _
Cylinder sleeve ---
crankcase bore
upper 0.014---0.064 (0.0006---0.0029)
lower 0.085---0.135 (0.0033---0.0053)
Outside diameter ∅2 _
∅3
X Cylinder sleeve
inner diameter ∅ 3A* 125.000---125.013 (4.9212---4.9218)
inner diameter ∅ 3B* 125.011---125.024 (4.9217---4.9222)
Protrusion X 0.045---0.075 (0.0018---0.0030)
* Available dia. class
** 8000 kg under laden

∅1 Pistons:
X measuringg dimension X 19 (0.7480)
outside
t id di
diameter
t ∅ 1 A* 124 881 124 890 (4
124.881---124.890 9166 4 9169)
(4.9166---4.9169)
outside diameter ∅1B B* 124.890---124.899 (4.9169---4.9173)
124.890 124.899 (4.9169 4.9173)
∅2
pin bore ∅2 50.010---50.018 (1.9689---1.9692)
* available dia. class
Piston---cylinder sleeve
A* 0.110---0.132 (0.0043---0.0052)
B* 0.112---0.134 (0.0044---0.0053)
* available dia. class
Piston diameter ∅1 _

X
Pistons protrusion X _

∅3 Dowell pin ∅3 49.994---50.000 (1.1983---1.1985)

Dowell pin---pin housing 0.010---0.024 (0.0004---0.0009)

44 ENGINE SECTION 4 327BCopyright
& 330B ©

F3A
Type
mm (in)

X1 X1* 2 94 (0.1157)
2.94 (0 1157)
X2 Piston ring grooves X2 3.05 3.07 (0.1201
3.05---3.07 (0.1201---0.1209)
0.1209)
X3 4.02---4.04 ((0.1583---0.1591))
X3
*measured on ∅ of 112 mm
S1 Piston rings:
S2 trapezoidal seal S1*
S1 2.796 2.830 (0.1101
2.796---2.830 (0.1101---0.1114)
0.1114)
S3 lune seal S2 2.970---3.000 (0.1169---0.1181)
milled scraper ring
with slits and internal
spring S3 3.970---3.990 (0.1563---0.1571)
*measured on ∅ of 112 mm

1 0.110---0.144
0 110 0 144 (0.0043---0.0057)
(0 0043 0 0057)
Piston rings - grooves 2 0.050---0.100 (0.0020---0.0039)
3 0.030---0.070 (0.0012---0.0028)
Piston rings _
X1 Piston ring end gap in
cylinder
li d liners:
li
X2
X3 X1 0.35---0.50
0 35 0 50 (0(0.0138---0.0197)
0138 0 0197)
X2 0.60---0.75 (0.0236---0.0295)
X3 0.35---0.65 (0.0138---0.0256)
Small end bushing housing
Ø1 54.000---54.030 (2.1260---2.1272)
∅1
Rod end bearing
housing Ø2

∅2 1 87.000---87.010 (3.4252---3.4256)
Selection classes Ø2 2 87.011---87.020 (3.4256---3.4260)
3 87.021---87.030 (3.4260---3.4264)
∅4 Small end bushing diameter
outside ∅4 54.085---54.110
54 085 54 110 (2(2.1293---2.1303)
1293 2 1303)
∅3 inside ∅3 50.019---50.035 (1.9693---1.9699)
Rod end bearing shell S
Red 1.970---1.980 ((0.0776---0.0780))
S
Green 1 981 1 990 (0
1.981---1.990 (0.0780---0.0783)
0 80 0 0 83)
Yellow 1.991---2.000 (0.0784---0.0787)
Small end bushing---housing 0.055---0.110 (0.0022---0.00434)
Piston pin---bush 0.019---0.041 (0.0007---0.0016)
Rod end bearing shells _

Connecting
g rod weight
g
A g g. 3973---4003
Class B g g. 4004---4034
C g g. 4035---4065
327B & 330B SECTION 4 Copyright
ENGINE © 45

F3A
Type
mm (in)

X
Measuring dimension X 125 (4.9213)
Max. connecting rod
axis misalignment
tolerance 0.08 (0.0031)

Main journals ∅1 92.970 93.000 (3.6602

92.970---93.000 (3.6602---3.6614)
3.6614)
Crankpins ∅2 82.970---83.000 (3.2665---3.2677)
∅1 ∅2
Main bearing
shells S1
Red 2.965---2.974 (0.1167---0.1171)
Green 2.975---2.984 (0.1171---0.1175)
Yellow 2.985---2.995 (0.1175---0.1179)
S1 S2
Rod end bearing
shells S2
Red 1.970---1.980 (0.0776---0.0780)
Green 1.981---1.990 (0.0780---0.0783)
Yellow 1.991---2.000 (0.0784---0.0787)

∅3 Main bearing
housings ∅3 99.000---99.030 (3.8976---3.8988)

Bearing shells---main journals 0.050---0.090 (0.0020---0.0035)

Bearing shells---Rod ends 0.050---0.090 (0.0020---0.0035)
Main bearing shells ---
Rod end bearing shells ---

Main journal,
thrust bearing X1 45.95---46.00 (1.8091---1.8110)
X1

Main bearing housing,

thrust bearing X2 38.94---38.99 (1.5331---1.5350)
X2

X3 Thrust washer
halves X3 3.38---3.43 (0.1331---0.5350)

Driving shaft shoulder 0.10---0.30 (0.0039---0.0118)

1 2
Alignment 1---2 ≤ 0.025 (0.0010)

Ovality 1---2 0.010 (0.0004)

Taper 1---2 0.010 (0.0004)

46 ENGINE SECTION 4 327BCopyright
& 330B ©

Type F3A

mm (in)
Valve outside spring
height:
free height H 75 (2.9528)
H H1 under a load of:
H2 500 ± 25 N H1 61 (2.4016)
975 ± 48 N H2 47.8 (1.8819)

1.14---1.4 (0.0449---0.0551) TYPE EURO 2

Injector protrusion X
1 (0.0394) TYPE EURO 3
X

Camshaft bush housing fitted in

the cylinder head:
1⇒7 Ø 88.000---88.030 (3.4646---3.4657)
∅ ∅ ∅
∅2

Camshaft journal diameter:

1⇒7 Ø 82.950---82.968 (3.2656---3.2665)

∅1 ∅3

Camshaft bushing outer

∅ diameter: ∅ 88.153---88.183 (3.4706---3.4718)

∅ Camshaft bushing inner

diameter: ∅ 83.018---83.085 (3.2684---3.2711)

Bushings and housings in

0.123---0.183 (0.0048---0.0072)
engine block
Bushings and journals 0.050---0.135 (0.0020---0.0053)
Cam lift:
9.231 (0.3634)

H 9.5607 (0.3764)

11.216 (0.4416)

∅1
Rocker shaft ∅1 41.984---42.000 (1.6529---1.6535)
327B & 330B SECTION 4 Copyright
ENGINE © 47

Type F3A

CYLINDER HEADS-- VALVE TRAIN mm (in)

∅1
Valve guide housings
in cylinder head
∅1 14.980---14.997 (0.5898---0.5904)

∅2

∅2 9.015---9.030 (0.3549---0.3555)
Valve guide
∅3 15.012---15.025 (0.5910---0.5915)
∅3

Valve guides---housings
0.015---0.045 (0.0006---0.0018)
in the cylinder heads
Valve guide _
∅4 Valves:

∅4 8.960---8.975 (0.3528---0.3533)
α 60° 30′ ± 7′ 30″

∅4 8.960---8.975 (0.3528---0.3533)
α 45° 30′ + 7′ 30″
α
Valve stem and its guide 0.040---0.070 (0.0016---0.0028)
Housing in head for valve
seat

∅1 44.185---44.220 (1.7396---1.7409)

∅1 ∅1 42.985---43.020 (1.6923---1.6937)
Outside diameter of valve seat;
angle of valve seat in cylinder
∅2 head:

∅2 44.260---44.275 (1.7425---1.7431)
α 60° 30’

a ∅2 42.060---43.075 (1.6559---1.6959)
α 45° 30′

Recessing of 0.65---0.95 (0.0256---0.0374)

valve X
X 1.8---2.1 (0.0709---0.0827)

Between valve
seat and head 0.040---0.090 (0.0016---0.0035)
48 ENGINE SECTION 4 327BCopyright
& 330B ©

Type F3B

mm (in)

Bushing housing in rocker arms

45.000---45.016 (1.7717---1.7723)

59.000---59.019 (2.3228---2.3236)

∅
46.000---46.016 (1.8110---1.8117)

Bushing outer diameter

for rocker arms:
45.090---45.130 (1.7752---1.7768)

Ø 59.100---59.140 (2.3268---2.3283)

46.066---46.091 (1.8136---1.8146)

Bushing inner diameter

for rocker arms:
42.025---42.041 (16545---1.6552)

Ø 56.030---56.049 (2.2059---2.2067)

42.015---42.071 (1.6541---1.6563)

Between bushings and

housings
0.074---0.130 (0.0029---0.0051)

0.081---0.140 (0.0032---0.0055)

0.050---0.091 (0.0020---0.0036)

Between rocker arms and shaft

0.025---0.057 (0.0010---0.0022)

0.025---0.057 (0.0010---0.0022)

0.015---0.087 (0.006---0.0034)
327B & 330B SECTION 4 Copyright
ENGINE © 49

TIGHTENING TORQUES

PART TORQUE
Nm (lb ft)
Capscrews, undercrankcase to crankcase ♦
Outside screws M12x1.75 First phase: preliminary tightening 30 (22)
Inner screws M 18x2 Second phase: preliminary tightening 120 (89)
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 (25.5±1.5)
Heat exchanger fixing screws to the block ♦
preliminary tightening 11.5±3.5 (8.5±2.5)
tightening 19±3 (14±2.2)
Spacer oil sump fixing screws to undercrankcase ♦ 24.5±2.5 (18±1.8)
Fixing screws to oil sump ♦
preliminary tightening 38 (28)
tightening 45 (33)
Gearbox fixing screws to the block M 12x1.75 ♦ 63±7 (47±6)
Control unit fastening screws on engine block 24±2.5 (17.5±1.5)
Cylinder head fixing screws ♦
First phase preliminary tightening 60 (44)
Second phase preliminary tightening 120 (89)
Third phase angle locking 90°
Fourth phase angle locking 65°
Rocker shaft fixing screws ♦
First phase preliminary tightening 80 (59)
Second phase angle locking 60°
Lock nut for rocker adjustment screw ♦ 39±5 (28.5±3.5)
Injector blocking brackets screws ♦ 26 (18)
Plastic cover fastening screws 8.5±1.5 (6±1)
Shoulder plate fixing bolts to head ♦ 19±3 (14±2)
Engine mounting bracket screws on head
First phase pre---torque 120 (89)
Second phase tightening to angle 45˚
♦ Lubricate with engine oil before installation
• Lubricate with graphitized oil before installation
50 ENGINE SECTION 4 327BCopyright
& 330B ©

PART TORQUE
Nm (lb ft)
Engine mounting bracket fastening screws on flywheel casing
First phase pre---torque 100 (74)
Second phase tightening to angle 60°
Camshaft cog fastening screws: ♦
First phase pre---torque 60 (44˚
Second phase tightening to angle 60°
Phonic wheel fastening screws to camshaft cog 8.5±1.5 (6.26±1.10)
Exhaust manifold fastening screws: •
pre---torque 40±5 (29.5±4)
full torque 70±5 (52±4)
Brake solenoid valve fastening screws ♦ 19 (14)
Big end cap fastening screws♦ 19 (14)
First phase pre---torque 60 (44)
Second phase tightening to angle 60°
Big end cap fastening screws: ♦
First phase First phase 120 (88)
Second phase tightening to angle 60°
Third phase tightening to angle 30°
Flywheel damper: ♦
First phase pre---torque 70 (52)
Second phase tightening to angle 50°
Intermediate gear pin fastening screws: ♦
First phase pre---torque 30 (22)
Second phase tightening to angle 90°
Link rod fastening screws for pulley wheel adjustment 24.5±2.5 (18±1.8)
Oil pump fastening screws 24.5±2.5 (18±1.8)
Crankshaft front gasket casing fastening screws 24.5±2.5 (18±1.8)
Fuel pump / filter bracket fastening screws 19 (14)
Control unit mounting screws 19±3 (14±♠3)
Turbocompressor screws and nuts •
pre---torque 35 (26)
full torque 46 (34)
Thermostat group fastening screws 30 (22)
Water pump fastening screws 25 (18)
Fan hub spacer fastening screws 100 (73)
Fan bracket engine block fastening screws 26±3 (19±2)
Air conditioner automatic belt tensioner fastening screws 50±5 (37±3.5)
Auxiliary organs fixed pulley engine block fastening screws 105±5 (77±3.5)
Starter motor fastening screws 74±4 (55±3)
Air heater fastening screws 30±3 (22±2)
Air compressor fastening screws 74±4 (55±3)
♦ Lubricate with engine oil before installation
• Lubricate with graphitized oil before installation
327B & 330B SECTION 4 Copyright
ENGINE © 51

PART TORQUE
Nm (lb ft)
Air compressor command cog fastening nut ♦ 170±10 (126±7)
Alternator fastening screws: M 10x1,5 l = 35 mm 30±3 (22±2)
M 10x1,5 l = 60 mm 44±4 (33±3)
Servosteering pump fastening screws 46,5±4,5 (34±3.5)
Air conditioning compressor support fastening screws 24,5±2,5 (18±2)
Cover fastening screws 24,5±2,5 (18±2)
Clogged filter sensor fastening 55±5 (41±4)
Fuel / water temperature sensor fastening 35 (26)
Thermometric transmitter / switch fastening 25 (18)
Air temperature transmitter fastening 35 (26)
Pulse transmitter fastening 8±2 (6±1.5)
Injector connector fastening 1,36±1,92 (1±0.15)
Engine brake solenoid valve fastening 32 (23)
♦ Lubricate with engine oil before installation
• Lubricate with graphitized oil before installation
52 ENGINE SECTION 4 327BCopyright
& 330B ©

TIGHTENING ORDER OF GEARBOX TO ENGINE BLOCK FASTENING SCREWS

Figure 42

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
327B & 330B SECTION 4 Copyright
ENGINE © 53

Figure 43

60580
DIAGRAM OF CYLINDER HEAD FIXING SCREWS TIGHTENING SEQUENCE

Figure 44

60581
DIAGRAM OF EXHAUST MANIFOLD FIXING SCREWS TIGHTENING SEQUENCE

Figure 45

60582

DIAGRAM OF TURBOCHARGER FIXING SCREWS AND NUTS TIGHTENING SEQUENCE

54 ENGINE SECTION 4 327BCopyright
& 330B ©

Figure 46

60666

DIAGRAM OF TIGHTENING SEQUENCE FOR HEAT EXCHANGER SCREWS

Figure 47

60583

DIAGRAM OF TIGHTENING SEQUENCE FOR ENGINE OIL SUMP SCREWS

Figure 48

73554

DIAGRAM OF TURBOCHARGER FIXING SCREWS AND NUTS TIGHTENING SEQUENCE

327B & 330B SECTION 4 Copyright
ENGINE © 55

Figure 49

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
56 ENGINE SECTION 4 327BCopyright
& 330B ©

Engine Support And Brackets

Figure 50

S269GN001
327B & 330B SECTION 4 Copyright
ENGINE © 57

TOOLS
TOOL NO. DESCRIPTION

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

(as reference only)

Standard tool Rotary telescopic stand (range 2000 daN, torque 375
(as reference only) daNm)

Standard tool Engine Overhaull revolving stand

(as reference only)

380000120 Extractor for crankshaft front gasket

380000121 Extractor for crankshaft rear gasket

380000671 Percussion extractor

58 ENGINE SECTION 4 327BCopyright
& 330B ©

TOOL NO. DESCRIPTION

380000123 Extractor for injector---holder

380000126 Tool to install the crankshaft front gasket

380000127 Tool to install the crankshaft rear gasket

Standard tool Universal extractor for 5 to 70 mm internal components

(as reference only)

380000824 Box wrench for block junction bolts to the underblock

380000367 Box wrench for block junction bolts to the underblock

327B & 330B SECTION 4 Copyright
ENGINE © 59

TOOL NO. DESCRIPTION

380000128 Tools (12+6) for holding sliding blocks for rockers

adjusting screws during disassembly reassembly rockers
shaft

Standard tool Injector housing protecting plugs (6)

(as reference only)

Standard tool Pliers for assembling and disassembling piston split rings
(as reference only) (105---106 mm)

Standard tool Tool for belt tensionner

(as reference only)

Standard tool Tool to take down-fit engine valves (to be used with special
(as reference only) plates)

Standard tool Plate for take down-fit engine valves

(as reference only)
60 ENGINE SECTION 4 327BCopyright
& 330B ©

TOOL NO. DESCRIPTION

380000113 Tool to fit back valve guide (to be used with 380000219)

Standard tool Tool to remove oil filter (engine)

(as reference only)

380000137 Tool to rotate engine flywheel (to be used with 380000138)

380000138 Spacer (to be used with 380000137)

Standard tool Tool to install gasket on valve guide

(as reference only)

Standard tool Compression tool for checking the protrusion of cylinder

(as reference only) liners
327B & 330B SECTION 4 Copyright
ENGINE © 61

TOOL NO. DESCRIPTION

Standard tool Spacer (to be used with 380000140)

(as reference only)

Standard tool Cylinder liner compression plate

(as reference only)

380000144 Tool to stop engine flywheel

380000146 Tool to take down and fit back camshaft bushes

Standard tool Tool to lift crankshaft

(as reference only)

Standard tool Bracket to take down and fit engine flywheel

(as reference only)
62 ENGINE SECTION 4 327BCopyright
& 330B ©

TOOL NO. DESCRIPTION

380000148 Tool for assembling and installing rocker arm shaft

Standard tool Swing hoist for engine disassembly assembly

(as reference only)

Standard tool Belt to insert piston in cylinder liner (60 --- 125 mm)
(as reference only)

380000150 Tool for positioning engine P.M.S.

380000151 Tool for timing of phonic wheel on timing gear

Standard tool Tool to stop cylinder liners

(as reference only)
327B & 330B SECTION 4 Copyright
ENGINE © 63

TOOL NO. DESCRIPTION

Standard tool Tool to extract cylinder liners (to be used with specific
(as reference only) rings)

Standard tool Ring (125 mm)

(as reference only)

Standard tool Brackets fixing the engine to rotary stand

(as reference only)

380000157 Tool for injector holder heading

Standard tool Base supporting the dial gauge for checking cylinder liner
(as reference only) protrusion
64 ENGINE SECTION 4 327BCopyright
& 330B ©

TOOL NO. DESCRIPTION

380000158 Torque screwdriver for calibrating the injector solenoid

valve connector check nut

380000369 Valve guide reamer

Standard tool Tool for removing injector holding case deposits

(as reference only)

380000159 Tool for threading injector holding cases to be extracted

(to be used with 380000160)

380000160 Guide bush (to be used with 380000159)

327B & 330B SECTION 4 Copyright
ENGINE © 65

TOOL NO. DESCRIPTION

380000162 Guide bush (to be used with 380000163 or 380000164)

380000163 Cutter to rectify injector holder housing (to be used with

380000162)

380000164 Reamer to rectify injector holder lower side (to be used

with 380000162)

Standard tool Measuring pair for angular tightening with 1/2” and 3/4”
(as reference only) square couplings

Standard tool Gauge for defining the distance between the centres of
(as reference only) camshaft and transmission gear

Standard tool Complete square to check connecting rod squaring

(as reference only)
66 ENGINE SECTION 4 327BCopyright
& 330B ©

TOOL NO. DESCRIPTION

Standard tool Dial gauge (0 --- 5 mm)

(as reference only)

Standard tool Reaming gauge (50 --- 178 mm)

(as reference only)

380000169 Centering ring of crankshaft front gasket cap

 327B & 330B SECTION 4 Copyright
ENGINE © 67

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 ground 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)
68 ENGINE SECTION 4 327BCopyright
& 330B ©

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)
327B & 330B SECTION 4 Copyright
ENGINE © 69

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)
70 ENGINE SECTION 4 327BCopyright
& 330B ©

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
327B & 330B SECTION 4 Copyright
ENGINE © 71

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 seals

NO
72 ENGINE SECTION 4 327BCopyright
& 330B ©

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.
 327B & 330B SECTION 4 Copyright
ENGINE © 73
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 rod bearings efficient Replace bearings and if necessary grind
NO crankshaft

YES

Engine oil SAE viscosity correct Change engine oil with suitable viscosity oil
NO
74 ENGINE SECTION 4 327BCopyright
& 330B ©

MAINTENANCE
Figure 52
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

Used oil and fluids must be collected and
disposed of according to standards in force. 269NM122
D clean the filler cap zone, the fill with the specified
Proceed as follows: quantity of oil through the filler;
D switch off the engine after warming up and wait for D replace the filler cap and dipstick;
coolant temperature to reach 60°C (140 ˚F); D start and warm up the engine, then switch off and
D Open the hood; wait a few minutes;
D remove the lower covers;
Figure 53
D remove the dipstick;

Figure 51

156NM11

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

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

D clean the thread, replace the plug;

327B & 330B SECTION 4 Copyright
ENGINE © 75

Engine oil filter change

Used oil and fluids must be collected and Figure 56
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 (140 ˚F);
D Open the hood;

Figure 54
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 55

156NM25
D fill the new cartridge with oil and lube the washer
with the same oil;
76 ENGINE SECTION 4 327BCopyright
& 330B ©

Engine oil vapour filter change Accessory drive belts

Proceed as follows:
Figure 59
Figure 57

228NM221

D remove the lower cover screwsand remove it;

Figure 58
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.
327B & 330B SECTION 4 Copyright
ENGINE © 77

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

Figure 60 Figure 62

276C004008 276C004008

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

Figure 61 Figure 63

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 238NM02
below;
D applying manual pressure to the longest section of D using a hexagonal wrench turn the tensioner (ar-
belt, check that the tensioners work correctly. 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.
78 ENGINE SECTION 4 327BCopyright
& 330B ©

D remove the belt; Fuel circuit bleeding

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

Figure 64

276NM037T
327B & 330B SECTION 4 Copyright
ENGINE © 79

Fuel filter change

Figure 52
Figure 65

156NM25
276NM015T
D fill the new cartridge with specified lubricant and
The vehicle is fitted with two fuel filter groups: lube the washer with the engine lubricant;
D fuel pre---filter on chassis;
Figure 53
Figure 51

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.
80 ENGINE SECTION 4 327BCopyright
& 330B ©

Engine coolant fluid change and circuit check/ Cleaning

cleaning Proceed as follows:
Used oil and fluids must be collected and D prepare am mixture of water and specific detergent,
disposed of according to standards in force. slowly pour the mixture through the filler until reach-
ing level, then close the filler cap;
Drain Use the proportion of detergent recom-
mended by the manufacturer
This operation must be carried out with the Too much detergent may damage the en-
engine cold. gine.
Detergents do not normally contain anti---
Proceed as follows: freeze: Do not leave the vehicle exposed to
D Open the hood; low temperatures if the cooling circuit con-
D remove the lower covers; tains this mixture.

Figure 66 D start the engine and run it for approximately 1 hour;

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 67

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.
327B & 330B SECTION 4 Copyright
ENGINE © 81

Filling Anti---freeze percentage check

Proceed as follows: The minimum percentage of anti---freeze required de-
D prepare a mixture of water and specific anti---freeze pends on the ambient temperature of the place the ve-
in the required proportions. Alternatively use cool- hicle is used.
ant fluid with suitable specifications; Check the percentage of anti---freeze in engine coolant
fluid using the refractometer.
Figure 68
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.
82 ENGINE SECTION 4 327BCopyright
& 330B ©

ENGINE REMOVAL---REPLACEMENT
Figure 70
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,
2690702
remove the ignition key, engage the handbrake and
place maintenance warning signs; 1. High pressure circuit valve
D disengage the battery cut ---off switch or disconnect 2. Low pressure circuit valve
the battery leads to eliminate any risk of short ---cir-
cuit; D proceed to discharge the air conditioner system as
D lock the articulation using the steering lock bar as instructed in SECTION 14;
instructed in SECTION 1;
The system must be discharged by special-
Figure 69 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.
Always use approved refrigerant recovery
and recharging apparatus.
Never mix different refrigerants in the same
apparatus.

Figure 71

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;

2690310

D proceed to open the hood;

327B & 330B SECTION 4 Copyright
ENGINE © 83

Figure 72 Figure 74

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;
Used oil and fluids must be collected and D position a suitable container then drain the coolant
disposed of according to standards in force. as instructed in relative Chapter;

Figure 73 Figure 75

2690310 276C04012

D position a suitable container then drain the main hy-

draulic system fluid as instructed in SECTION 15; Remove the fastening clamps and check
Used oil and fluids must be collected and correct fastening of the clamped compo-
disposed of according to standards in force. nents.
D remove the coolant/intercooler/condenser fan/ra-
diator unit by following the directions in the relative
chapter.
84 ENGINE SECTION 4 327BCopyright
& 330B ©

. The operations described below refer to the D remove the four fastening screws and disconnect
the hydraulic pump (25) from the engine without dis-
following figures (Figures 67 to 70) .
connecting the piping;
D remove the screws fastening the crossbar: D disconnect the air pipes:
--- the automatic transmission oil filter group (22); --- fuel return (27);
--- the brake circuit oil filter (21); --- fuel delivery (28);
D disconnect the pump---expansion tank piping (5); D disconnect the following pipes from the air---condi-
D disconnect the engine---expansion breather pipe tioner compressor (29):
(8); --- delivery (a);
D disconnect the windscreen washer pump electrical --- intake (b);
connection (30); D disconnect the following pipes from brake pump
D disconnect the windscreen washer fluid piping (2); (26):
D disconnect the hood release command pipe (23) --- delivery (a);
and the hood release cable (24); --- intake (b);
D unscrew the fastening screws from both sides (ar- D disconnect the electrical connections from the start-
row) and remove the hood support crossbar (20) er motor (31):
complete with hood release cable, expansion tank a. power cable (+30)
and windscreen wiper fluid tank; b. consent cable (+50);
D disconnect the cab heater engine coolant delivery D disconnect the alternator electrical connections
(3) and return (4) pipes; (32):
D disconnect and remove the metal engine coolant a. power cable (B+)
delivery (7) and return (6) pipes from the heat ex- b. connector;
changers situated to the lower part of the chassis; D disconnect the electrical connection:
Coolant may leak during these operations. --- from the air---conditioner compressor (36);
--- from the cold start relay device (35);
--- vehicle interface (33);
D disconnect the intake and air pipes: D disconnect the ground braid between engine and
--- engine breather (12); chassis (34);
--- 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);
327B & 330B SECTION 4 Copyright
ENGINE © 85

Figure 76

276C04015
86 ENGINE SECTION 4 327BCopyright
& 330B ©

Figure 77

FWD

276C04016
327B & 330B SECTION 4 Copyright
ENGINE © 87

Figure 78

FWD

276C04017
88 ENGINE SECTION 4 327BCopyright
& 330B ©

Figure 79

FWD

276C04018
327B & 330B SECTION 4 Copyright
ENGINE © 89

Figure 80 Figure 81

D disconnect the transmission shaft (arrow) between

276C04019 engine and transmission.
D disconnect the lower connector (38) from the en- Figure 82
gine control unit (37);

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;
90 ENGINE SECTION 4 327BCopyright
& 330B ©

Figure 83

D remove the front and rear engine mounting bolts Checks and tests
from both sides; After starting and warming up the engine, check:
Check that all connections and pipes are D the absence of coolant leaks from the engine cool-
disconnected and all fastening clamps re- ing and cab heater system hoses: if located, tighten
moved. joints or replace faulty parts;
D carefully lift the group, removing it from above. D the absence of hydraulic fluid leaks from pipes that
have been disconnected: if located, tighten joints or
Replacement replace faulty parts;
Replace the group following the instructions in reverse D the absence of oil leaks between rocker cover and
order, and in particular: cylinder head, sump and engine block, filter and
D check the elastic engine mountings: if deteriorated, seat and between the various pipes: if located, tight-
replace them; en joints or replace faulty parts;
D check the integrity of exhaust and intake pipes and D the absence of leaks from fuel supply system piping
joints; and joints: if located, tighten joints or replace faulty
D check the integrity of fuel intake and return pipes parts;
and joints; D the absence of air leaks from intake pipes and ex-
D check the integrity of engine cooling system and haust gas from the exhaust pipes: if located, tighten
cab heater pipes and joints; joints or replace faulty parts;
D fill the engine oil sump as instructed in the chapter D that the reconnected temperature and pressure
MAINTENANCE; warning lights function correctly.
D fill the engine cooling circuit as instructed in the Fill the vehicle hydraulic circuit as instructed
chapter MAINTENANCE; in SECTION 10.
D Bleed the fuel supply circuit as instructed in the
chapter MAINTENANCE.
327B & 330B SECTION 4 Copyright
ENGINE © 91

FLEXIBLE COUPLING JOINT

Before carrying out any operation, check
that all precautions have been taken and all Figure 54
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 2690701
the battery leads to eliminate any risk of short ---cir-
cuit; D remove the protections positioned below the engine
D lock the articulation using the steering lock bar as and those located on the left side of the vehicle by
instructed in SECTION 1; following the instructions in SECTION 15;
D disconnect the engine---side cardan joint (1);
If difficult to access, remove the drive shaft.

Figure 55

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).

Installation
Install the group following the instructions in reserve or-
der.
92 ENGINE SECTION 4 327BCopyright
& 330B ©

RADIATOR GROUP REMOVAL---REPLACE-

Figure 85
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

(104 ˚F) 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 84
Do not discharge R134a fluid into the atmo-
sphere.
Always use approved refrigerant recovery
and recharging apparatus.
Never mix different refrigerants in the same
apparatus.

Figure 56

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;
327B & 330B SECTION 4 Copyright
ENGINE © 93

Figure 86 . The operations described below refer to the

following figures.

D remove the intercooler – engine inlet (8) and outlet

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

276NM046T D disconnect the radiator fan circuit exchanger (10) in-

D position a suitable container, then disconnect the let pipe;
radiator hose (arrow) and discharge the engine D disconnect the radiator fan circuit exchanger (11)
coolant; outlet pipe;
Used oil and fluids must be collected and D disconnect the radiator fan circuit exchanger (12)
disposed of according to standards in force. by---pass pipe;
D remove the exchanger and related connectors (15);
Figure 87 D remove the engine hydraulic circuit radiator fan out-
let pipe (13);

. Hydraulic fluid may leak during these opera-

tions.

276C004008

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

support brackets by removing the fastening screws;
94 ENGINE SECTION 4 327BCopyright
& 330B ©

Figure 88

276C04035
327B & 330B SECTION 4 Copyright
ENGINE © 95

D proceed to dismantle the group as necessary.

Figure 89
Handle the radiator with care, to prevent
damage to the radiator fins.

Replacement
Replace the group following the instructions in reverse
order, and in particular:
D check the elastic mountings: if deteriorated, replace
them;
D check the integrity of engine cooling system pipes
and joints;
D fill the engine cooling circuit as instructed in the
chapter MAINTENANCE.

D disconnect both fastening rods from the chassis

(A);
D disconnect both brackets from the radiator (B) and
remove them with the tie rods;

Figure 90

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

changer---fan group with a suitable dolly, then from
both sides unscrew the buffer fastening screws and
remove it.
96 ENGINE SECTION 4 327BCopyright
& 330B ©

AUTOMATIC TRANSMISSION OIL---WATER

Figure 91
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.
Respect all general recommendations for
correct execution of maintenance works.

Removal

Wait until engine temperature is below 40° C

(104 ˚F) before beginning this operation. 2690312
Proceed as follows: D turn the heater valve to maximum then open the filler
D Park the vehicle on a suitable flat and solid surface, cap on the expansion tank;
remove the ignition key, engage the handbrake and
place maintenance warning signs; Figure 92
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;
Used oil and fluids must be collected and
disposed of according to standards in force.
327B & 330B SECTION 4 Copyright
ENGINE © 97

D disconnect the automatic transmission fluid delivery Replacement

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

D support the exchanger with a suitable dolly, un-

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

Figure 93

1
3
2

276C04036
98 ENGINE SECTION 4 327BCopyright
& 330B ©

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

BENCH
Figure 96
Before fixing the engine on the rotary stand remove the
following components:

On the engine right ---hand side

D diesel cartridge filter;
D electric connections;

Figure 94

60485

D engine support (1);

Figure 97

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

Figure 95

60486
D oil pressure controlling valve (1);

60483

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

327B & 330B SECTION 4 Copyright
ENGINE © 99

Figure 98

71700

Fix the engine to a suitable rotary stand and brackets (1), remove the fan.
100 ENGINE SECTION 4 327BCopyright
& 330B ©

Remove all electrical wiring from the sensors and elec-

tric activators. Figure 101

Figure 99

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

Figure 102

71702
Lock the engine flywheel using tool 380000144 (1).
Disconnect all the electrical connections and remove
the wiring from the engine.
Remove the climate control compressor by loosening
Figure 100 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).
327B & 330B SECTION 4 Copyright ©
ENGINE 101

Figure 103 Figure 106

60492
98864
Remove the oil filter (1) using a filter wrench.
Disconnect the pipes (3 and 4) from the V.G.T. com-
mand solenoid valve. Figure 107
Remove the thermostat group (1) complete with V.G.T
command solenoid (2).

Figure 104

60490 72674

Apply extractor 380000120 (2) and remove the crank- Remove the screws (1) and remove the heat exchanger
shaft oil seal. Remove the flange (3). (4).
Remove the screws (2) and remove the water line (3).
Figure 105
Figure 108

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).Disconnect the oil pi-
oil delivery pipe (3), oil return pipe (4), turbocharger ping.Unscrew the four screws 2 and 3.
group (6), exhaust manifold (7).
102 ENGINE SECTION 4 327BCopyright
& 330B ©

Figure 111
Figure 109

60575

60494
Remove 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 112
manifold (6) fitted with resistance for engine pre---heat-
ing, control unit (7).

Figure 110

60497

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

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

85480 Figure 113

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

Remove the screws (1) and the transmission gear (2).

327B & 330B SECTION 4 Copyright ©
ENGINE 103

Figure 114
Figure 117

60499 16219
Stop the engine flywheel (3) rotation by means of tool If applicable, disassemble the PTO control gear.
380000144 (1), unscrew the fixing screws (2) and re- Remove the screws and disasseble the double gear.
move the engine flywheel. Remove the retaining screw and disassemble the small
connecting rod.
Figure 115 Disassemble the oil pump

Figure 118

60511
85480
D Remove the engine brake lever retaining springs
Apply the extractor 380000121 (2) and pull out the seal
(3).
gasket (1).
D Unscrew screws (3) to remove injector electrical
Figure 116 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

Unscrew the screws (1) and take down the gearbox (2).
104 ENGINE SECTION 4 327BCopyright
& 330B ©

Figure 119 Figure 122

73533 60515
Using tool 380000128 (3), constrain the blocks (4) to D By means of metal ropes, lift the cylinder head (1).
the rockers (2). Apply tool 380000148 (1) to the rocker D Remove the seal (2).
holder shaft (5) and remove the shaft (5) from the cylin-
der head. Figure 123
Figure 120

86931
60515 Unscrew the screws (2) and remove the engine oil
D Unscrew the screws (2) fixing the brackets (3) and sump (1) fitted with spacer (3) and seal.
remove the injectors (1). The box shows the oil sump mounted on the engines
D Unscrew the screws (4) and remove the exhaust equipped with supplementary oil pump.
brake pins (5).
D Unscrew the screws and remove the slave cylinder Figure 124
(6).
Figure 121

86932

Unscrew the screws and remove suction rose (1).

60514 For engines equipped with supplementary oil pump,
D Remove the camshaft (2). remove the screws and take out strainers (2 and 3).
D Unscrew the fixing screws on the cylinder head (3).
327B & 330B SECTION 4 Copyright ©
ENGINE 105

Figure 125 Figure 128

47574

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

Figure 126 Remove the crankshaft (2) using a suitable tool (1).

Figure 129

60518

Loosen screws (2) fixing the connecting rod cap (3) and
remove it. Remove the connecting rod---piston
assembly from the upper side. 47571
Repeat these operations for the other pistons. Remove the crankshaft half---bearings (1), loosen the
screws and remove oil spray nozzles (2).
Figure 127
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 wrenches, loosen the screws (1)
and (2) and remove the under---block.
106 ENGINE SECTION 4 327BCopyright
& 330B ©

REPAIR OPERATIONS Figure 132

Cylinder block
Checks and measurements

Figure 130

60595

A = Selection class Ø 125.000 to 125.013 mm

B = Selection class Ø 125.011 to 125.024 mm
34994 In case of maximum wear >0.150 mm or maximum
Internal diameter of the cylinder liners is checked for ovalization >0.100 mm compared to the values
ovalization, taper and wear, using a bore dial (1) dial indicated in the figure, the liners must be replaced as
indicator gauge (2) previously reset to ring gauge (3), they cannot be ground, lapped or trued.
diameter 125 mm.
Cylinder liners are equipped with spare
If a 125 mm ring gauge is not available use parts with “A“ selection class.
a micrometer caliper.
Figure 133
Figure 131

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 131. The cylinder liners can be extracted and installed
several times in different seats, if necessary.
327B & 330B SECTION 4 Copyright ©
ENGINE 107

Cylinder lines

Figure 134

60598
BLOCK WITH CYLINDER LINERS
108 ENGINE SECTION 4 327BCopyright
& 330B ©

Replacing cylinder liners Figure 137

Removal

Figure 135

60520

Check the protrusion of the cylinder liners, using

suitable tool (1 & 2)
47577 Using proper gaging check (3) that the cylinder lining
protrusion from the cylinder head surface is 0.045 ---
Using suitable tooling (1, 2 & 4), remove the cylinder 0.075 mm (Figure 360). If not, replace the adjuster shim
liner (3) from the block. (1) (Figure 358) supplied in various thickness.
Fitting and checking protrusion Figure 138

Figure 136 0.045 to 0.075 mm

49017
CYLINDER LINER PROTRUSION

Figure 139
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 (3).
327B & 330B SECTION 4 Copyright ©
ENGINE 109

CRANKSHAFT
Figure 140
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

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

Figure 141 Figure 142

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
110 ENGINE SECTION 4 327BCopyright
& 330B ©

Measuring main and rod journals Figure 144

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

Figure 143

47536

During grinding, pay attention to journal and crank

bearing values specified in Figure 141 and Figure 142.
47535
All journals and connecting rod 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 145

Fill in this table with the measurements of the main journals and the connecting rod journals.

MAIN JOURNALS

∅ Min.
∅ Max.

∅ Min.
∅ Max.

CRANK PINS
36061
327B & 330B SECTION 4 Copyright ©
ENGINE 111

DETERMINATION OF PRELIMINARY DATA FOR SELECTION

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

JOURNALS: CONNECTING ROD:

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 crank end rod;
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 146

99,000÷99,009

99,010÷99,019

99,020÷99,030

47535
112 ENGINE SECTION 4 327BCopyright
& 330B ©

Choice of rod and main bearing half -- shells

In order to obtain the clearance required, main half-bearings and rod 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 147 shows the characteristics of main half-bearings and rod half-bearings supplied as spare parts in
standard measures (STD) and admissible oversizing (+0.127, +0.254, +0.508).

Figure 147

STD +0.127 +0.254 +0.508

Rod 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
327B & 330B SECTION 4 Copyright ©
ENGINE 113

Definition of main journal and rod bearing diameter class (journals with nominal diameter)
Three series of numbers are specified on the driving shaft, in the position specified (Figure 148 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 rod 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
rod pin it refers to (Figure 148 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 148 to right).

Figure 148

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
RODS LOWER END
114 ENGINE SECTION 4 327BCopyright
& 330B ©

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 149

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
327B & 330B SECTION 4 Copyright ©
ENGINE 115

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 150

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
3 red/black red/black green/black
92.873

red =
mm 3,092 ÷ 3,102

---0.254 1 2 3

red red red

93.224
93.234

red =
mm 3,219 ÷ 3,229

---0.508 1 2 3

red red red

93.468
93.508
116 ENGINE SECTION 4 327BCopyright
& 330B ©

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

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

Figure 151

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 rod 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
rod coupling.

47557

The number specifying the diameter class of the half-bearing housing can be: 1, 2 or 3.
Determine the type of rod half-bearings to be installed on each pin by following the indications given in the table
(Figure 152).
327B & 330B SECTION 4 Copyright ©
ENGINE 117

Choice of rod---end half---shells

Figure 152

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
118 ENGINE SECTION 4 327BCopyright
& 330B ©

Choice of rod---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 rod end pins belong to, and install the
half-bearings identified according to the relative table.
Figure 153

red/black =
mm 2,028 ÷ 2,038

green/black =
mm 2,039 ÷ 2,048

---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 2,092 ÷ 2,102
green =
mm 2,103 ÷ 2,112

---0.254 1 2 3

red green green

82.726
82.735

82.736 red red green

82.746
red
mm 2,219 ÷ 2,229
green =
mm 2,230 ÷ 2,239

---0.508 1 2 3

red green green

82.472 green
82.481 vert
grün
green
82.482 red red green

82.492
327B & 330B SECTION 4 Copyright ©
ENGINE 119

Replacing the timing control gear and the oil pump Figure 156
Check that the teeth of the gears are not damaged or
worn, otherwise remove them using the appropriate
extractor.

Figure 154

47578
Using pulley system and hook (1), mount the
crankshaft (2).
49020 Figure 157
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 155

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.
120 ENGINE SECTION 4 327BCopyright
& 330B ©

Figure 158 Figure 159

60559
47578
Place a piece of calibrated wire on the journal of the
crankshaft (2), parallel to the longitudinal axis; install D Lubricate inside screws (1) with engine oil, and
the underblock (1), by hoist and appropriate hooks. tighten them by torque wrench to 140 Nm torque,
then with 60º angle thigten, following the diagram in
Figure 160.

Figure 160

FRONT
SIDE

60593

DIAGRAM SHOWING THE TIGHTENING ORDER OF THE SCREWS FIXING THE LOWER UNDER---BLOCK TO
THE BLOCK
Figure 161 from the clearance required, replace the half-bearings and
repeat this check.

Checking crankshaft end float

Figure 162

47579

D Remove the under --- block

The clearance between the main bearings and the journals
47588
is obtained by comparing the calibrated wire width (2) at the
maximum deflection point, with the calibrated scale on the End float is checked by placing a magnetic dial
coating (1) containing the calibrated wire (1). indicator (1) on the crankshaft (2), as shown in the
Numbers shown on the scale specify the clearance in figure. If the value obtained is higher than specified,
coupling millimeters. If the clearance obtained is different replace the rear thrust half-bearings and repeat this
check.
327B & 330B SECTION 4 Copyright ©
ENGINE 121

Piston-- connecting rod assembly

Figure 163

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,

scoring, cracking; replace as necessary.
Figure 165
Removal

Figure 164

49024
Remove the piston pin split rings (2) using the round
tipped pliers (1).
60608
Removal of the piston split rings (2) using pliers (1).
Pistons are equipped with three elastic rings: a sealing
ring, a trapezoidal ring and a scraper ring.
Pistons are grouped into classes A and B for diameter.
122 ENGINE SECTION 4 327BCopyright
& 330B ©

Figure 166 Figure 168

32618
49025
Measuring the piston pin diameter (1) with a
Remove the piston pin (1). micrometer (2).
If removal is difficult use the appropriate press.
Conditions for correct piston pin-- piston coupling
Measuring the diameter of the pistons
Figure 169
Figure 167

49026
71714

Using a micrometer (2), measure the diameter of the Lubricate the pin (1) and the relevant housing on the
piston (1) to determine the assembly clearance; the piston hubs with engine oil; piston must be inserted
diameter should be measured at the specified value. with a slight finger pressure and it should not come out
by gravity.
327B & 330B SECTION 4 Copyright ©
ENGINE 123

Figure 170

3.050 4.020 2.796 2.970 3.970 A=124.881---124.890

2.940
3.070 4.040 2.830 3.000 3.990 B=124.890---124.899

19

50.010 49.994
50.018 50.000
71715
MAIN DATA ON PISTONS, AND PISTONS RINGS
* Values are determined on ∅ of 120 mm.
Piston rings
Figure 173
Figure 171

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
is measured by placing the piston (1) with its ring in the
micrometer (1).
cylinder barrel (3), so that the sealing ring is half---pro-
Figure 172 jected out of the cylinder barrel.

Figure 174

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.
124 ENGINE SECTION 4 327BCopyright
& 330B ©

CONNECTING ROD

Figure 175

Data concerning the class section of connecting rod

housing and weight are stamped on the rod end.
VIEW FROM “A”
When installing connecting rods, make sure
they all are the same weight.

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.
Number indicating the selection of diameter for
2
the rod 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 176

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 --- BUSHING, CONNECTING ROD, PIN AND HALF-BEARINGS
* Values to be obtained after installing the bushing
327B & 330B SECTION 4 Copyright ©
ENGINE 125

Bushings Checking torsion

Figure 177 Figure 179

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. 61694
The bushing (2) is removed and fitted with a suitable Check the torsion of the connecting rod (5) by compar-
press (1). ing two points (A and B) of the pin (3) on the horizontal
When pressing it in, make absolutely sure that the plane of the axis of the connecting rod.
holes for the oil to pass through in the bushing and Position the mount (1) of the dial indicator (2) so that
small end coincide. Using a boring machine, rebore the this pre---loads by approx. 0.5 mm on the pin (3) at point
bushing so as to obtain a diameter of 54.019 to 54.035. A and zero the dial indicator (2). Shift the spindle (4)
with the connecting rod (5) and compare any deviation
Checking connecting rods on the opposite side B of the pin (3): the difference be-
tween A and B must be no greater than 0.08 mm.
Figure 178
Checking bending

Figure 180

61696
61695

Check the bending of the connecting rod (5) by com-

Checking axis alignment
paring two points C and D of the pin (3) on the vertical
Check the alignment of the axes of the connecting rods plane of the axis of the connecting rod.
(1), proceed as follows: Position the vertical mount (1) of the dial indicator (2) so
D Fit the connecting rod (1) on the spindle of the tool that this rests on the pin (3) at point C.
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).
126 ENGINE SECTION 4 327BCopyright
& 330B ©

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 indicator (2). Shift the spindle (4) with Figure 183
the connecting rod (5) and repeat the check on the
highest point on the opposite side D of the pin (3). The
difference between point C and point D must be no
greater than 0.08 mm.

Mounting the connecting rod – piston assembly

Figure 181

60614

To fit the piston rings (1) on the piston (2) use pliers (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 rod end bearing shells

Figure 184
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 182

1
2

49030

Fit the bearing shells (1), selected as described under

the heading “Selecting the main and rod 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
snap rings (3).
327B & 330B SECTION 4 Copyright ©
ENGINE 127

Fitting connecting rod -- piston assemblies in

the cylinder liners Figure 185
With the aid of the clamp (1, Figure 185), fit the con-
necting rod – piston assembly (2) in the cylinder liners,
according to the diagram of Figure 185, checking 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 186

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
128 ENGINE SECTION 4 327BCopyright
& 330B ©

Checking crankpin assembly clearance Figure 188

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 187

47583

Mount and secure the proper tool (1, 2 & 4). Screw
down with the device (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.
47594 Turn over the cylinder head and take out the valves (8).
Mount the connecting rod caps (1) together with the
bearing shells. Tighten the screws (2) fixing the con- Checking head bearing surface on cylinder block
necting rod caps to a torque of 60 Nm (44 lb ft). Using
a proper tool (3), further tighten the screws with an Figure 189
angle of 60°.

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
(0.5276 in); if it is, change the screw. Lubricate the
crankpins and connecting rod bearings. Tighten the
36159
screws (2) as described above.
Check the supporting surface (1) of the head on the cyl-
CYLINDER HEAD inder block with a rule (2) and a feeler gauge (3). If you
find any deformation, level the head on a surface
Before removing cylinder head, check cylinder head for
grinder; maximum amount of material that can be re-
leakage with compression check; in case of leaks not
moved 0.2 mm.
caused by cup plugs or threaded plugs, replace cylin-
der head. After this process, you need to check the
In case of plugs removal/replacement, on valve recessing and injector protrusion.
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 removal should
they not have to be overhauled or replaced.
Intake valves are different form exhaust
valves in that they have a notch placed at
valve head centre.
327B & 330B SECTION 4 Copyright ©
ENGINE 129

Valves Figure 191

Decarbonizing and checking valves
Figure 190 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 * Measurement to be made after driving in the valve
Remove the carbon deposits on the valves with a wire guides
brush. Check, by means of a micrometer, that valve stem
Check that the valves show no signs of seizure or diameters are as specified; if necessary, grind the
cracking and check with a micrometer that the valve valves seat with a grinder, removing the minimum
stem diameter comes within the required values (see quantity of material.
Figure 191), replace the valves if it does not.

Figure 192

(*) 9.015-- 9.030

4,30±0,06

39.00 39.20
1,8 ---2,1
0,65 ---0,86

71719

INSTALLATION DIAGRAM FOR VALVE GUIDES AND VALVES

* Values to be obtained after installing the guide valves
130 ENGINE SECTION 4 327BCopyright
& 330B ©

Figure 193 The valve guides are removed with the drift 380000367.
They are fitted with the drift 380000367 equipped with
part 380000113.
Part 380000113 determines the exact position of as-
sembly 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 reamer 380000369

Replacing injector cases

Removal
Figure 195
41032

Check the valve seats (2). If you find any slight scoring
or burns, regrind them with proper tooling (1)
according to the angles shown in Figure 192. 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 proper tooling (1), regrind the valve
seats according to the angles shown in Figure 192.
After regrinding the valve seats, check that the position
of the valves in relation to the plane of the cylinder head
is:
D ---0.65 to ---0.95 mm (recessing) intake valves
D ---1.8 to ---2.1 mm (recessing) exhaust valves.

Checking clearance between valve-- stem and as-

sociated valve guide
Using a dial indicator 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 194
To replace the injector case (2), proceed as follows:
ø 9.015---9.03 D Thread the case (2) with tool 380000159 (1).
The steps described in Figure 195 --- Figure 198 ---
Figure 199 --- Figure 200 need to be carried out by fix-
ing the tools, with the bracket A, to the cylinder head.

71719
327B & 330B SECTION 4 Copyright ©
ENGINE 131

Figure 196 Figure 198

60622

D Lubricate sealing rings (3) and fit them to the case

60620 (4); fix tool 380000157 (2) to the cylinder head by
means of bracket A, install the new case, tighten the
D Fasten extractor 380000123 (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 197

60621

D Remove any residue (1), with a suitable tool (2),

from the cylinder head groove.
132 ENGINE SECTION 4 327BCopyright
& 330B ©

Figure 199 D Using grinder 380000164 (1---2), ream the injector

seat in the case (3).

Checking protrusion of injectors

Figure 201

47585
Using dial indicator (1), check the protrusion of the
injector (2) which must be 0.52 to 1.34 mm.

Figure 202

60623

D Ream the case hole (3) with reamer 380000163 (1).

Figure 200

71720
INSTALLATION DIAGRAM FOR
INJECTOR CASE

60624
327B & 330B SECTION 4 Copyright ©
ENGINE 133

Timing distribution control Pin double drive gear

Figure 203 Double drive gear

Figure 205

86925
TIMING DISTRIBUTION COMPONENTS
1. Camshaft --- 2. Bush --- 3. Pin --- 4. Con---rod --- 86934
5. Camshaft drive pinion --- 6. Drive gear --- 7. Double
drive gear --- 8. Camshaft drive pinion Bushing replacement
The bushings (2, Figure 204 and 2, Figure 205) can be
Drive gear pin replaced if worn. After fitting the bush, ream to obtain
the diameter indicated in Figure 204 or Figure 205.
Drive gear
The bush must be fitted into the gear in the
Figure 204 direction of the arrow, positioning it at the le-
vel indicated in Figure 204 or Figure 205.
Nominal gear pin/bush play:
Figure 204 --- 0.045 to 0.075 mm
Figure 205 --- 0.045 to 0.085 mm.

86933
134 ENGINE SECTION 4 327BCopyright
& 330B ©

DISTRIBUTION
Checking cam lift and pin alignment
Figure 206

47506

Place the camshaft (4) on the tailstock (1) and check cam lift (3) using a dial indicator gauge (2).
Figure 207

47507
When the camshaft (4) is on the tailstock (1), check alignment of supporting pin (3) using a dial indicator gauge
(2); it must not exceed 0.030 mm. If misalignment exceeds this value, replace the shaft.
Figure 208

47505

In order to check installation clearance, measure bushing inner diameter and camshaft pin (1) diameter; the real
clearance is obtained by their difference.
If clearance exceeds 0.135 mm, replace bushings and, if necessary, the camshaft.
327B & 330B SECTION 4 Copyright ©
ENGINE 135

Camshaft
Figure 209

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 bushings

TOLERANCES TOLERANCE CHARACTERISTIC SYMBOL

ORIENTATION Perpendicularity ⊥
POSITION Concentricity or coaxial alignment
OSCILLATION Circular oscillation ↗
IMPORTANCE CLASS ASSIGNED TO PRODUCT CHARACTERISTICS SYMBOL
CRITICAL ©
IMPORTANT ⊕
SECONDARY ⊝

Bushings
Figure 210

60627

MAIN DATA OF CAMSHAFT BUSHINGS AND RELEVANT HOUSINGS ON CYLINDER HEAD.

* Bushing inner diameter after installation

D The bushing surfaces must not show any sign of D To remove and replace the bushings, use the proper
seizing or scoring; if they do replace them. tool 380000146.
D Measure the bushing inner diameters with a
boremeter and replace them, if the value measured
exceeds the tolerance value.
136 ENGINE SECTION 4 327BCopyright
& 330B ©

Replacing the bushings camshaft using beater 380000146

Beater
Figure 211

71721

A = Beater with seat for bushings for insertion/removal

B = Bushing positioning pin
C = Mark for correct insertion of seventh bushing
D = Mark for correct insertion of bushings 1, 2, 3, 4, 5 and 6 (yellow notches)
E = Guide bushing
F = Guide line
G = Guide bushing to fasten to seventh bushing support
H = Cylinder head yellow bushing fastening plate
I = Grip
L = Extension joint

Removal Replacement

Figure 212 Figure 213

Front Front

Rear
Rear
71725 71722
The bushing removal order is 7, 6, 5, 4, 3, 2, 1. The Fit the beater complete with extension.
bushings are slipped out from the front side of their indi- To insert bushings 1, 2, 3, 4 and 5, proceed as follows:
vidual seats. Removal does not require the beater ex- 1. Place the bushing for insertion on the beater (A) lin-
tension for bushings 5, 6 and 7 and use of the guide ing up the pin (B) (Figure 211) with the seat on the
bushing is not necessary. bushing.
The extension is instead required for bushings 1, 2, 3 2. Position the guide bushing (E) and fasten the guide
and 4, as well as the guide bushing bushing (G) (Figure 211) in the seat of the 7th bush-
Position the beater precisely during the removal oper- ing by means of plate H).
ation. 3. When inserting the bushing, line up notches F and
M. Doing so, when the bushing is pushed in the lu-
brication hole on it is aligned with the oil hole in the
seat.
The bushing is fully inserted when the 1st yellow ref-
erence notch (D) is flush with the guide bushing (G).
327B & 330B SECTION 4 Copyright ©
ENGINE 137

Figure 214

Front

Rear

71725

To insert bushing 6, proceed as follows:

D remove the grip (I) and the extension (N);
D position the extension (N) and the guide bushing (E)
as shown in the figure;
D repeat operations 1, 2 and 3.

Figure 215
Front

Rear

71725
To insert bushing 7, proceed as follows:
D remove the grip (I) and the guide bushing (G) fas-
tened to the head;
D replace the guide G from the inner side as shown in
the figure;
D position the bushing on the beater (A) and bring it
toward its seat making sure the hole in the bushing
aligns with the lubrication hole in the head. Proceed
to fit.
The 7th bushing is fully inserted when the reference
mark ( C ) is flush with the bushing seat.
138 ENGINE SECTION 4 327BCopyright
& 330B ©

Valve springs Fitting the valves and oil seal ring

Figure 216 Figure 218

70000

Before installation, check valve spring flexibility using

a proper tool and compare the loading and elastic
deformation data with data referred to the new valves,
shown in the following figure.

Figure 217

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

a proper tool, fit the oil seal ring (1) on valve guides (2),
Valve open
47,80

then install the valves as shown:

61

Figure 219

71726

MAIN DATA TO CONTROL EXHAUST AND DIS-

CHARGE VALVE SPRING

47583

D fit springs (6) and the upper plate (5);

D apply tool (2) and block it with bracket (4); tighten
the lever (1) until keepers are installed (3), remove
tool (2).
327B & 330B SECTION 4 Copyright ©
ENGINE 139

ROCKER SHAFT

Figure 220

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.

ROCKERS

Figure 221

SECTION
A ---A
SECTION
B---B

The bushing surfaces must not show any

trace of scoring of excessive wear;
otherwise, replace bushings or the whole
42,015
42,071

rocker.
71728

PUMP INJECTOR ROCKER

Figure 222 Figure 223

SECTION
A ---A
SECTION SECTION
A ---A SECTION B---B
B---B
56,030
56,049
42,025
42,041

71729 71730

EXHAUST VALVES ROCKER DISCHARGE VALVE ROCKER

140 ENGINE SECTION 4 327BCopyright
& 330B ©

ASSEMBLING THE ENGINE ON THE BENCH Figure 226

Fix the engine block to a suitable stand.
Install the cylinder liners as described in the relevant
paragraph.

Figure 224

49021

Place the half---bearings (1) on the main bearings in the

underblock (2).

Figure 227
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 225

47595
By means of suitable equipment (1) apply silicone
LOCTITE 5699 to the block, as shown in Figure 228.

48570
Lubricate the half bearings, then install the crankshaft
(2) using hook (1).
327B & 330B SECTION 4 Copyright ©
ENGINE 141

Figure 228 Figure 231

60632

Sealant application diagram.

Fit the underblock within 10 min of the

application of the sealant. 47579

Close the inner screws (1) to 120 Nm torque by means

Figure 229 of a torque wrench (3, Figure 231), then with two further
angular phases 90° + 45°, using a proper tool (4).
Tighten again the outer screws (1, Figure 230) with 60°
angular closing, using a proper tool (3, Figure 230).

60559

Fit the underblock by means of a suitable hoist and

hooks (1).

Figure 230

47581

Fit the underblock and, using a torque wrench (2),

close the splined outer screws (1) to 30 Nm torque,
according to the diagram shown on page 83.
142 ENGINE SECTION 4 327BCopyright
& 330B ©

Figure 232

stage 1:
FRONT SIDE pretightening
outer screws

60592

stage 2:
FRONT SIDE pretightenig
inner screws

60593

stage 3:
angle
FRONT SIDE inner
screws

60593

stage 4:
angle
FRONT SIDE inner
screws

60593

FRONT SIDE stage 5:

angle
outer
screws

60594

DIAGRAM SHOWING TIGHTENING ORDER OF UNDER---CRANKCASE SECURING SCREWS

327B & 330B SECTION 4 Copyright ©
ENGINE 143

Figure 233 Figure 234

49030 60616

Rotate the cylinder assembly placing it vertically. Fit the connecting rod---piston assemblies (2) into the
Fit the half---bearings (1) on both the connecting rod piston liners, using a proper tool (1). Check the
and the cap. 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 235

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
144 ENGINE SECTION 4 327BCopyright
& 330B ©

Fitting the cylinder head Figure 239

Figure 236

60515
Make sure that pistons 1---6 are exactly at the TDC
Place the sealing gasket (2) on the block.
47594 Fit the cylinder head (1) and tighten screws as shown
Connect the connecting rods to the relative journals, fit in Figure 240, Figure 241 and Figure 242.
the connection rod caps (1) with half bearings; tighten
Figure 240
the fixing screws (2) of the connecting rod caps to 60
Nm torque (6 kgm). Using a proper tool (3), further
tighten screws with 60° angle.

Figure 237

61270
Diagram showing the cylinder head fixing screws
tightening order

Figure 241

60563
By means of centering ring 380000169 (2), check the
exact cover position (1), otherwise act as necessary
and tighten the screws (3).

Figure 238

60565
--- Preliminary tightening by means of a torque wrench
(1):
1st phase: 60 Nm (6 kgm)
2nd phase: 120 Nm (12 kgm);

60564

Fit the sealing gasket (1), install the fitting tool

380000126 (2) and drive the sealing gasket (1) by
screwing nut (3).
327B & 330B SECTION 4 Copyright ©
ENGINE 145

Figure 242 Install the gear box within 10 min of the

application of the sealant.

Figure 245

60566

D Angular tightening using a proper tool (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, 14, 15, 16, 17, 18, 19, 22, 23, 24, 25, 26.

Figure 243

60633
Tighten the screws shown in the figure by means of a
torque wrench, in compliance with the following order
and to 56---70 Nm (41---52 lb ft) torque:
no. 10 M12 x 1,75 x 100
no. 2 M12 x 1,75 x 70
71773
no. 4 M12 x 1,75 x 35
Fit the oil pump (5), intermediate gears (2) complete
with P.T.O tie---rod (1) and drive gear (3) no. 1 M12 x 1,75 x 120
Tighten the screws (4) to the specified torque. : no. 2 M12 x 1,75 x 193

Replacing flywheel casing

Figure 246
Figure 244

60568

Fit the sealing gasket (1), install the fitting tool

47592 380000127 (2) and drive the sealing gasket by
Apply (as shown in the figure) sealant LOCTITE 5699 screwing the nut (3).
to the gear box using the proper equipment (1).
146 ENGINE SECTION 4 327BCopyright
& 330B ©

Replacing engine flywheel

Figure 247

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 248 Figure 249

49036
49037

Stop rotation using the tool 380000144 (3); tighten the Second and third phase: tighten at a 60º + 30º angle
screws (2) in three phases. using a proper tool (1).
First phase: pre---torque at a 120 Nm (12 kgm) torque
using a torque wrench (4).
327B & 330B SECTION 4 Copyright ©
ENGINE 147

Figure 252

Figure 250

60570
D Fit a proper gauge (1) and check and adjust the
transmission gear connecting rod (3), tighten the
screw (2) at the prescribed torque.

Figure 253
72436

Position the crankshaft with the pistons 1 and 6 at the

top dead center (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 380000150 (1), through the seat (2) of the
engine 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 380000150 (1).
60571
Figure 251 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.
148 ENGINE SECTION 4 327BCopyright
& 330B ©

Figure 254 Figure 256

60572 71775
Fit back the gear (2), without fully tightening screws (5) Fit:
on the camshaft and place it so that the 4 oval holes D the injectors (2) and tighten the bracket screws to
are centered with respect to the camshaft fixing holes. 26 Nm using a torque wrench.
Using a dial indicator (1), make sure that the gear (2 D The engine brake cylinders (1) and (4), tightening to
and 3) clearance is 0.073 to 0.195 mm, otherwise torque of 19 Nm using a torque wrench.
adjust the clearance as follows: D The valve bridge bars (4) with the larger hole on the
D loosen screws (4) fixing transmission gear (3); same side
D loosen screws (2, Figure 252) fixing the rod, move
the rod (3, Figure 252) to obtain the required
clearance; Replacing rocker shaft assembly
D Tighten the rod fixing screw (2, Figure 252) as well
as the screws (4, Figure 254) fixing the gear to the Before re---installing the rocker shaft
prescribed torque. assembly, make sure that all the adjusting
screws have been completely unscrewed.
Fitting pump -- injectors
Figure 257
Figure 255

73533

Using tool 380000128 (3), fasten the blocks (4) to the

rocker arms (2).
Apply tool 380000148 (1) and remove the rocker shaft
assembly.

44908

Fit the sealing rings (1) (2) (3) on injectors.

327B & 330B SECTION 4 Copyright ©
ENGINE 149

Figure 258 Figure 261

70567A

SCREW TIGHTENING SEQUENCE

SECURING ROCKER ARMS

Tighten screws (1 --- 2 --- 3) until rocker arms are

brought to contact relating seats on cylinder head, tigh-
71777
ten the screws according to sequence indicated in figu-
re operating in two steps as indicated in successive fi- Mount the electric wiring (2), securing it on the electro---
gure. injectors with a torque screwdriver (1) to a torque of
1.36 --- 1.92 Nm (1.3 to 1.4 lb ft).
Figure 259
Timing of timing system shaft

Figure 262

45261
Lock the screws (2) fixing the rocker---arm shaft as fol-
lows:
D 1st phase: tightening to a torque of 40 Nm (30 lb ft)
with the torque wrench (1).
D 2nd phase: closing with an angle of 60˚ using a pro-
per tool (3).

Figure 260
71776

Apply tool 380000137 (7) and shim 380000138 (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
the phase of combustion.
This condition occurs when the hole with
one reference mark (4), after the hole with
60574
two reference marks (5) on the engine flyw-
D Mount the engine brake lever retaining springs (3). heel (1), can be seen through the inspection
D Connect the pipe (2) to the engine brake cylinders window (2).
(4) and to the cylinder with the engine brake sole-
noid valve (1).
150 ENGINE SECTION 4 327BCopyright
& 330B ©

Figure 263 Figure 265

71774

The exact position of piston 1 at TDC is achieved in the

previously described position, when tool 380000150
(1) fits into the hole (3) on the flywheel (4) through the
engine rpm sensor seat (2). 72436
The camshaft is timed if the following conditions are
Figure 264
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 380000150 (1) can be inserted into hole (3) on
the engine flywheel (4) through the seat (2) of the
engine rpm sensor.

Figure 266

60573

Position the magnetic dial indicator (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 380000137 (7) Figure 262, turn the
crankshaft clockwise until the pointer on the gauge
reaches the minimum value beyond which it cannot go. 60575
Reset the dial indicator.
If the conditions illustrated in Figure 265 and specified
Turn the flywheel anti---clockwise until the gauge reads
in points 1 and 2 above do not exist, proceed as follows:
a lift value of 4.44 ± 0.05 mm for the camshaft cam.
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 265, 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
327B & 330B SECTION 4 Copyright ©
ENGINE 151

Figure 267 Fit the gear (2) Figure 267, 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 indicator read 4.44 ± 0.05 mm.
Check the timing conditions described in Figure 265.

Figure 269

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 266) are tight.
D Rotate the flywheel by 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 266) and remove the
gear (2) from the camshaft.

Figure 268

77260

Phonic wheel timing

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 380000150 (5) into the seat of the flyw-
D Double notch (5) visible through lower inspection heel sensor (6).
hole. Insert the tool 380000151 (2), via the seat of the phase
D Tool 380000150 (1) fitted flush into the engine rpm 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).
152 ENGINE SECTION 4 327BCopyright
& 330B ©

Adjusting the unload/intake rockers play and pump injector control rockers preload

Figure 270

60577

ADJUSTMENT OF INTAKE, EXHAUST AND INJECTION ROCKERS

The adjustment of clearance between the rockers and FIRING ORDER 1 -- 4 -- 2 -- 6 -- 3 -- 5

push 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 compression 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 120º 2 5 3

push rods controlling intake and exhaust valves:
D Using a box end 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 loosen the adjustment screw with the ap- quence specified in the table, checking the
propriate wrench; exact position in each rotation phase by
D Make sure that the gauge blade (3) can slide with a means of pin 380000150, to be inserted in
slight friction; the 11th hole in each of the three sectors with
D Also lock the nut (1), while holding the adjustment 18 holes each.
screw.
Pre---loading of rockers controlling pump injectors:
D Using a box endl wrench, loosen the nut locking the
rocker adjustment screw (5) controlling the pump
injector (6);
327B & 330B SECTION 4 Copyright ©
ENGINE 153

Figure 271
Figure 273

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 Turn the engine and mount the oil suction strainer.

Apply silicone LOCTITE 5970 on the blow--- Fill the gasket (4) on the oil sump, position the
by case (7) surface of engines fitted with spacer (3) and assemble the oil sump on the engine
P.T.O. according to the procedure described block tightening the screws (2) at the prescribed
in the following figure. torque.

Figure 272

85481

Apply silicone LOCTITE 59709 on the blow ---by case

0,5
and form a string (2) of ∅ 1,5 + 0,2 as shown in the figu-
re.

Fit the blow---by case (1) within 10 minutes

from sealer application.
154 ENGINE SECTION 4 327BCopyright
& 330B ©

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 30---40 Nm (26 ± 4 lb ft), water pipe
D thermostat unit; unions;
D automatic belt tightener, water pump, alternator; D 50---60 Nm (40 ± 4 lb ft), oil pipe female
D control belt. union;
D 20---25 Nm (15---18 lb ft), oil pipe male
Figure 274 union.
D Oil dipstick.
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
60578
WATER PUMP --- ALTERNATOR CONTROL BELT Do not invert the direction of action on the
ASSEMBLY DIAGRAM belt tensioner in order to avoid damage to
1. Alternator --- 2. Free wheel --- 3. Water pump --- the tensioning mechanism.
4. Crankshaft
The belt tensioners are automatic and thus
D damping flywheel;
do not require further adjustments after as-
D starter;
sembly.
D fuel pump;
D power steering system tank;
D fuel filter and line;
D pre---heating resistance; Figure 275
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
327B & 330B SECTION 4 Copyright ©
ENGINE 155

REPAIR WORKS

On detecting an engine problem attributa-

ble to the turbocharger system, it is a good
idea to check the efficiency of the connector
manifold gaskets and fasteners before
checking the turbocharger itself, as well as
the absence of blockages in the intake mani-
folds and air filter. If the damage to the turbo-
charger is due to lack of oil, check that the
oil circulation pipes are not damaged, 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.

The test must be carried out in the following

conditions:
D engine coolant temperature >50 ºC;
D battery charge (voltage 22V for compres-
sion test;
D alternator efficient.
On finding values outside tolerance, check efficiency
of:
D shut ---off valve;
D pressure sensor;
D engine pressure sensor connection (if oxidize,
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 bushing with Kernite lubricant (high temperatu-
re). 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
bushing proves negative, or if efficiency problems
are not found at the above indicated points, after
contacting the technical ”Help Desk”, replace the
turbocharger, proceeding as follows:
156 ENGINE SECTION 4 327BCopyright
& 330B ©

Variable geometry movement check Actuator check

Figure 276 Figure 277

106227
106229 Check the efficiency of the actuator (1), proceeding as
Remove the screws (2) and detach the actuator (1) follows.
from the turbocharger (7). Apply the compressed air supply pipe with pressure re-
Remove the screw (6), the disk beneath (5), the ring (4) gulator (4) to the connector (2) on the actuator (1). With
and disconnect the actuator (1) rod (3) from the varia- the pressure regulator, introduce compressed air into
ble geomtry control lever pin (8) the actuator, gradually modulating pressure between 0
Thoroughly clean the pin (→) of the lever (8) and the 3.5 bar, the rod (3) of the actuator (1) should move wi-
bushing (→) of the rod (3) using a non---abrasive micro- thout snagging. If not, replace the actuator (1).
fibre cloth.
Figure 278
Do not use abrasive paper of any kind.

Visually inspect the condition of the bushing (→) of the

rod (3) and the pin (→) of the lever (8), if worn, replace
the actuator (1) or the turbocharger (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.

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).
327B & 330B SECTION 4 Copyright ©
ENGINE 157

Figure 279 Turbine body cleaning

Figure 281

106229

Lubricate the bushing (→) of the rod (3) and the of the 106231
lever (8) with lithium---based Castrol LM GREASE and Mark the fitting position of the clamps (2) on the central
refit the actuator (1) to the turbocharger (7) proceeding body (1).
as follows. Apply anti---oxidant spray to the thread and nut (4) and
Connect the rod (3) to the lever (8). loosen the clamp (2) by means of the nut.
Fit: a new ring (4), the disk (5) and tighten the screw (6). Slightly turn the clamp (2) using pliers (5).
Tighten the actuator fasteners (2) to the turbocharger Mark the fitting position of the turbine body (3) on the
(7). central body (1).
Tighten the screws (2 and 6) to torque of 25 Nm.

Check actuator tension Figure 282

Figure 280

106232

Using a copper hammer, knock the turbine body (2)

106230
from two opposing sides (~ 180º) to separate it from
Check the X tension of the actuator (1) rod (2) procee- the central body (1).
ding as follows.
Measure the distance X1, between the actuator (1) and During the operation take particular care not
the center distance of the grommet (4). to damage the turbine propeller.
Apply the compressed air supply pipe (3) with pressure
regulator to the actuator connector (1). Throught the After dismantling the turbine body, check the move-
pressure regulator introduce compressed air into the ment of the variable geometry as instructed in the rela-
actuator (1) gradually regulating pressure from 0 to 3.5 ted chapter. If the movement has not improved with re-
bar, until the lever (5) reaches full excursion. spect to the previous check, replace the turbocharger.
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.
158 ENGINE SECTION 4 327BCopyright
& 330B ©

Figure 283 Remove the the clamp (1) from the central body (2) and
check that it is not damaged. Otherwise replace it.

Figure 286

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).
turbocharger. 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 287
ring may be tolerated as they do not impair
turbocharger function.

Figure 284

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.
106234 Check the play on the propeller shaft (1). It must result
as:
With a suitable scraper and abrasive paper, thoroughly
--- axial play 0.025 to 0.127 mm
clean the surfaces (→) of the turbine body (1) of all car-
--- radial play 0.381 to 0.533 mm
bon deposits, taking care not to damage it.
If higher values are found or any other of the above pro-
Figure 285 blems, replace the turbocharger.

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 turbochar-
ger.

106235
327B & 330B SECTION 4 Copyright ©
ENGINE 159

Figure 288 Figure 290

106238 106240
With a suitable scraper and abrasive paper, thoroughly Mount turbine body (1) on central body (2) taking care
clean the surfaces of the central body (1) of all carbon to avoid damaging turbine rotor and align turbine body
deposits, taking care not to damage it and the variable variable geometry slot ring. Do not force mounting
geometry ring. operation: in case of jamming, it might damage vari-
Then clean the surfaces and the variable geomtry ring able geometry with consequent regulation system
of all remaining deposits using compressed air. faulty operation.
Check again, as instructed in the related chapters: Once mounting has been completed, make sure that
--- movement of the variable geomtery; turbine body results to be matched correctly on central
--- the actuator; body.
--- actuator excursion. Position turbine body on central body and clamp on
central body in such a way that marks, made on dis-
Figure 289 mounting, are matching.
Tighten nut clamping the clamp at 11.3 Nm torque.
Check again, as described in relating chapters:
--- actuator;
--- actuator travel.

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.
160 ENGINE SECTION 4 327BCopyright
& 330B ©

POWER TAKE OFF DISTRIBUTION -- P.T.O.

This is a single axis type power take off with gearing and engagement via clutch that takes the drive from the valve
train gears independent of the vehicle clutch. It can be used with the vehicle stopped of in motion and for continual
use can be engaged/disengaged with the engine running.

Figure 291

71835
327B & 330B SECTION 4 Copyright ©
ENGINE 161

Tightening torques
Figure 292

71838

TORQUE
DESCRIPTION
Nm (lb ft)
1 Flanged head screw M10 x 1.5 x 120 53 ± 2.7 (39 ± 2)
2* Flanged head screw M10 x 1.5 x 120 53 ± 2.7 (39 ± 2)
3 Screw M10 x 1.5 x 120 53 ± 2.7 (39 ± 2)
4 DIN pump flange securing screw 140 ± 5 (103 ± 3.5)

* Apply LOCTITE 275

162 ENGINE SECTION 4 327BCopyright
& 330B ©

Removal -- reassembly of the power take-- off

Figure 294
Removal
1
Figure 293

1
2

2
3
3

4
71772

Use a new gasket to reassemble the power takeoff

71840 (either if the power takeoff is replaced or if the previous
power takeoff is to be reused).
Disconnect union (1) of the oil delivery line and air union As long as the power takeoffs are not supplied with la-
(2) of the clutch engagement control. bels indicating the value necessary to calculate the cor-
Remove the eight securing screws (3) and remove the rect thickness of the gasket, gaskets of 1+0.5 mm
power take---off (4). must be placed on top of each other from the kit pro-
vided.
Reassembly This will help obtain correct engagement between the
Reverse the operation and tighten the securing screws gears.
to the specified torque. In the future the power takeoffs will bear a label specify-
ing a value which when added to that printed on the fly-
wheel cover and used with the appropriate table will
make it possible to calculate the exact type of gasket
to be fitted.
 Copyright ©

SECTION 5

AUTOMATIC TRANSMISSION
 Copyright ©

Page left intentionally blank

 327B & 330B SECTION 5 Copyright © 1
AUTOMATIC TRANSMISSION

CONTENTS

Page Page

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TRANSMISSION HYDRAULIC CONTROL

DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
AUTOMATIC TRANSMISSION
CROSS-- SECTION VIEW . . . . . . . . . . . . . . . . . . . . . . 4 Position of the pressure and temperature
measuring points . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
AUTOMATIC TRANSMISSION EXTERNAL PIPE
Electro---hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . 42
ARRANGEMENT VIEW . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL-- REPLACEMENT
TRANSMISSION SPEED SENSORS . . . . . . . . . . . . 6
AUTOMATIC TRANSMISSION GEARBOX . . . . . . 44
Speed sensor location . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Speed sensor setting . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
FUNDAMENTAL COMPONENTS . . . . . . . . . . . . . . . 8
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Preliminary operations . . . . . . . . . . . . . . . . . . . . . . . . 50
Lock ---up clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
HYDRAULIC CONTROL UNIT . . . . . . . . . . . . . . . . . 51
Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Hydrodynamic brake (retarder) . . . . . . . . . . . . . . . . 11
Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Central differential lock . . . . . . . . . . . . . . . . . . . . . . . . 12
LOCK -- UP CLUTCH VALVE (WK) . . . . . . . . . . . . . 53
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal and disassembly . . . . . . . . . . . . . . . . . . . . . 53
FRONT DIFFERENTIAL FITTING . . . . . . . . . . . . . . 23
Assembly and refit . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
OIL CIRCULATION SYSTEM -- VERSION
GEARBOX AND GEAR DISASSEMBLY . . . . . . . . 55
WITH RETARDER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Converter and converter bell . . . . . . . . . . . . . . . . . . . 55
OIL CIRCULATION SYSTEM -- VERSION
WITHOUT RETARDER . . . . . . . . . . . . . . . . . . . . . . . 25 AN input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Lubricating pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
TRANSMISSION CONTROL SYSTEM
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Central splitter lock device . . . . . . . . . . . . . . . . . . . . 57
Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Intermediate shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Connector key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Central splitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Multiple---disk clutches . . . . . . . . . . . . . . . . . . . . . . . . 59
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . 29
Power takeoff shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Transmitter disassembly . . . . . . . . . . . . . . . . . . . . . . 60
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
CLEANING, INSPECTING AND CHECKING . . . . 60
Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Cleaning components . . . . . . . . . . . . . . . . . . . . . . . . 60
Cold check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSPECTING AND CHECKING . . . . . . . . . . . . . . . 61
Hot check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Guards and machined surfaces . . . . . . . . . . . . . . . . 61
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Bearings and axial shims . . . . . . . . . . . . . . . . . . . . . . 61
Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
O---rings and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
AEB procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Gears, grooves and threaded parts . . . . . . . . . . . . . 61
Display – meaning of AEB procedure messages . 41
 2 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

Page Page
Rings and springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Roller bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Clutch plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Shrink ---fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

GENERAL ASSEMBLY STANDARDS . . . . . . . . . . 61 DISMANTLING AND REASSEMBLY OF MAIN

UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Lubricants used for assembly . . . . . . . . . . . . . . . . . . 61
Clutches and pistons . . . . . . . . . . . . . . . . . . . . . . . . . 61 GEARBOX AND GEAR ASSEMBLY . . . . . . . . . . . 104

Lip seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
327B & 330B SECTION 5 Copyright © 3
AUTOMATIC TRANSMISSION

DESCRIPTION Hydrodynamic brake (Retarder): It is fitted upstream

The 6WG310 automatic transmission consists of the to the torque converter. The purpose is to transmit the
following fundamental parts. drag torque from the vehicle wheels during deceler-
ation.
Transmission ECU and wiring: The ECU receives the
input signals and controls the outputs to ensure correct Shaft and gears: The transmission is characterized by
operation of the transmission. an input shaft, driven by the converter, by an output
shaft, to which has a transmission differential lock, and
Hydraulic unit: The unit consists of a set of solenoid by three main shafts, each equipped with two or three
valves controlled by the transmission ECU and pipes helical, permanently engaged gears.
for conveying pressurized oil to the points required. The forward and reverse gear ratios are obtained by en-
Torque converter: The torque converter transmits the gaging the different clutches fitted on the three main
drive torque from the engine to the transmission with--- shafts.
out employing stiff components. A supplementary driven PTO shaft is also included for
steering emergency pump.
It consists of three parts: the impeller, the turbine and
the stator. The impeller is the suction element. It is con- Clutches: Each shaft is equipped with two hydrauli-
trolled by the engine. The turbine is the outlet element. cally controlled, multiple plate clutches.
It is hydraulically controlled by the impeller. The stator Oil pressure pump: The pump is fitted on the input
is the reaction element (torque multiplier). shaft. It is a gear pump and ensures the pressure re-
Lock-- up clutch: It is fitted between the impeller and quired for lubricating and operating the hydraulic trans-
the turbine. The lock ---up clutch is engaged when the mission functions.
turbine speed approaches that of the impeller so that Power take-- off (PTO): The PTO is controlled by a
the engine drive torque is directly transferred to the shaft driven directly by the input shaft (consequently by
transmission at a ratio of 1 : 1. 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.

The vehicle is fitted with integrated version automatic transmission with front differential.
4 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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
327B & 330B SECTION 5 Copyright © 5
AUTOMATIC TRANSMISSION

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
6 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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
327B & 330B SECTION 5 Copyright © 7
AUTOMATIC TRANSMISSION

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 (0.020+0.012 in)

13 central speed gear shaft sensor S=0.3+0.1 mm (0.012+0.004 in)
14 engine speed sensor S=0.5+0.3 mm (0.020+0.012 in)

1. Sensor
2. Gear
3. Housing

T225037

Hall sensor
31 output shaft speed Hall---effect sensor S=1.0/1.5 mm (0.039/0.059 in)

1. Spur gear K3
2. Clutch axle K4/K3
3. Housing
4. Sensor

T225038
8 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

FUNDAMENTAL COMPONENTS

Torque converter
The torque converter hydraulically transmits the engine of approximately 2.5:1 to a minimum of 1:1 (direct en-
drive force from the engine to the transmission, accord- gagement).
ing to a multiplying ratio in the range from a maximum

Figure 4

1730705Z

The torque converter W consists of three parts: the Operation

pump P, the turbine T and the stator S. The pump is the The pump is connected to the engine and transmits en-
input element. It is controlled by the engine. The tur- ergy to the oil by turning. The centrifuge force projects
bine is the outlet element. It is hydraulically controlled the oil towards the edge of the pump from where it flows
by the pump. The stator is the reaction element (torque to the turbine at high speed. Here, the kinetic energy
multiplier). It is fitted on a one---way bearing allowing of the oil impresses a rotary movement to the turbine
revolution in the direction of the pump only. in the same direction as the pump.
The assembly is enclosed in a box full of specific oil. At turbine output, the oil is deviated by the stator at a
The unit also includes: certain angle so to increase yield at pump return. Direc-
D a hydrodynamic brake R (retarder) tion is consistent with the turbine vanes.
D a lock ---up clutch WK, which, when engaged, stiffly In this way, the stator, which cannot turn due to the ac-
connects the pump and the turbine. tion of the one---way bearing, provides a reaction
torque which is summed to that turbine torque.
327B & 330B SECTION 5 Copyright © 9
AUTOMATIC TRANSMISSION

The resistance ratio between the torque on the turbine Lock-- up clutch
and the drive torque is the converter multiplication The lock ---up clutch WK is a device which mechanically
ratio. It is proportion to the difference in speed between couples the pump and the converter turbine when it is
the pump and the turbine. engaged.
When the lock ---up clutch is engaged, the slipping be-
Figure 5
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

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 1730707Z
speed, the ratio approaches 1:1 (slipping ≈ 0).
Clutch disengaged (converter phase)
. Slipping = 0 condition is only fully reached
The oil circulating in the converter impresses the same
when the lock---up clutch is engaged (condi- pressure on the rear a and front b side of the clutch (2)
tion C). engagement piston (1): the turbine T is free to turn with
respect to the pump P.
When the pump and turbine pump speeds are nearly
the same, the stator is invested by the flow of oil which Clutch engaged (lock ---up phase)
causes it to turn in the direction of the turbine. The control unit operates a solenoid valve which in-
This is because the one---way bearing only permits creases the pressure in the rear area a. Consequently,
turning in the direction of the turbine. In this way, the the piston (1) slides and locks the clutch (2). In this
stator reaction torque is entirely absent. The converter way, the turbine T is solidly fastened to the pump P,
becomes a simple hydraulic coupling. whereby eliminating relative sliding.
10 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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.
327B & 330B SECTION 5 Copyright ©11
AUTOMATIC TRANSMISSION

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
12 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

Central differential lock

This is a double satellite sun and planet gear differential Operation
lock. 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
tires.
327B & 330B SECTION 5 Copyright ©13
AUTOMATIC TRANSMISSION

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
14 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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
327B & 330B SECTION 5 Copyright ©15
AUTOMATIC TRANSMISSION

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
16 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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
327B & 330B SECTION 5 Copyright ©17
AUTOMATIC TRANSMISSION

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
18 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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
327B & 330B SECTION 5 Copyright ©19
AUTOMATIC TRANSMISSION

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
20 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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
327B & 330B SECTION 5 Copyright ©21
AUTOMATIC TRANSMISSION

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
22 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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
327B & 330B SECTION 5 Copyright ©23
AUTOMATIC TRANSMISSION

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
24 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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
327B & 330B SECTION 5 Copyright ©25
AUTOMATIC TRANSMISSION

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
26 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

TRANSMISSION CONTROL SYSTEM COMPONENTS

Key
1. TCU – Transmission control unit
2. Selector lever
3. Retarder control
4. Automatic transmission distributor lock command
5. ZF diagnostic connector
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. HEAD (body computer)
30. CLUSTER

Connector key
(a) Cab bulkhead through connector (white)
(b) Cab bulkhead through connector (yellow)
(c) Unused
(d) CAN J1939 line connector
(e) Transmission junction connector (X8)
327B & 330B SECTION 5 Copyright ©27
AUTOMATIC TRANSMISSION

Figure 22

276C05003
28 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

TECHNICAL DATA

COMPONENT PARAMETER VALUE

Resistance 1050 Ohm @ 20°C (68 ˚F) (±10%)
Inductive sensor Temperature range ---40 °C to 150 °C (---40 ˚F to 302 ˚F)
--- tturbine
bi sensor
Tightening torque 30 Nm
--- engine sensor
Gap: engine and turbine 0.5 + 0.3 mm (0.020 + 0.012 in)
--- central gear shaft sensor
Gap: central gear 0.3 + 0.1 mm (0.012 + 0.004 in)
Working range 2 Hz to 5 kHz
Hall sensor Temperature range ---40 °C to 150 °C (---40 ˚F to 302 ˚F)
--- output
p shaft sensor Voltage supply 24 V
Gap 1.0 to 1.5 mm (0.04 to 0.06 in)
Resistance 19 Ohm @ 20°C (68 ˚F) (±10%)
Electrohydraulic
Current 100 to 500 mA
proportional valve
Pressure range 0.8 to 8.3 bar (11.6 to 120 PSI)
Sump temperature sensor Resistance 1 to 1.5 kOhm
Retarder temperature sensor Resistance 0.8 to 1.5 kOhm
Resistance 60 to 80 Ohm @ 20°C (68 ˚F)
up clutch valve Current
Solenoid lock ---up 250 to 350 mA
Voltage supply 24 V
Main pressure 16 to 18 bar (232 to 261 PSI)
Control pressure 16 to 18 bar (232 to 261 PSI)
Pressure before converter max 9 to 11 bar (130 to 160 PSI)
Pressure behind converter max 5,0 bar (73 PSI)
max 100 °C (120 °C temporary)
Temperature behind converter
max 212 °F (248 °F temporary)
Hydraulic circuit
max 145 °C (150 °C temporary)
Temperature behind retarder
max 293 °F (302 °F 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
327B & 330B SECTION 5 Copyright ©29
AUTOMATIC TRANSMISSION

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)
30 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

Figure 23

S269GN02
327B & 330B SECTION 5 Copyright ©31
AUTOMATIC TRANSMISSION

EQUIPMENT
CASE TOOL N. DESCRIPTION NAME

Standard tool
(as reference Assembly carriage with tipping device
only)

Standard tool
(as reference Retention equipment
only)

Standard tool
(as reference Series of eyebolts
only)

380 002 272 Extractor for oil feed flange/lubrication pump

Standard tool
(as reference Sliding hammer extractor
only)

Standard tool
(as reference Threaded insert (for use with Sliding hammer extractor)
only)
32 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

CASE TOOL N. DESCRIPTION NAME

Standard tool
(as reference Rear cover removal screws
only)

Standard tool
(as reference Internal extractor for outer ring of power take---off shaft bearing
only)

Standard tool
(as reference Bench support
only)

Standard tool
(as reference Support ring for overhaul of (all) clutch shafts
only)

Standard tool
(as reference Extractor for K4/K3 shaft cylindrical roller bearing
only)

Standard tool
(as reference Extraction gripper for inner ring of K3 clutch conic roller bearing
only)

Standard tool
(as reference Extractor
only)
327B & 330B SECTION 5 Copyright ©33
AUTOMATIC TRANSMISSION

CASE TOOL N. DESCRIPTION NAME

380 002 2320

(for type 1)
Wrench for K4/K3 shaft ring nut
380 002 2321
(for Type 2)

Standard tool
(as reference Extractor for the inner ring of the K4/K3 shaft conic roller bearing
only)

Standard tool
(as reference Extraction gripper
only)

Standard tool
(as reference Extractor
only)

380 002 310 Compression spring preload tool

380 002 399 Wrench for KR/K2 shaft --- KV/K1 shaft ring nut

Standard tool
(as reference Extraction gripper for inner ring of K2 clutch conic roller bearing
only)
34 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

CASE TOOL N. DESCRIPTION NAME

Standard tool
(as reference K1 side extractor
only)

Standard tool
(as reference KR side extractor
only)

Standard tool
(as reference Extraction gripper for inner ring of conic roller bearing
only)

Standard tool
(as reference Extractor
only)

Standard tool
(as reference Extractor
only)

Standard tool
(as reference Extractor
only)

Standard tool
(as reference Extractor
only)
327B & 330B SECTION 5 Copyright ©35
AUTOMATIC TRANSMISSION

CASE TOOL N. DESCRIPTION NAME

Standard tool
(as reference Extractor base
only)

Standard tool
Extractor for the inner ring of the pressure pump conic roller bea-
(as reference
ring
only)

Standard tool
(as reference Extraction gripper for inner ring of conic roller bearing
only)

Standard tool
(as reference Extraction gripper
only)

Standard tool
(as reference K3 shaft lifting tool
only)

Standard tool
(as reference Pressure pump needle cage insertion block
only)

380 002 275 Front/rear output shaft sealing ring assembly block
36 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

CASE TOOL N. DESCRIPTION NAME

Standard tool
(as reference Intermediate shaft pin assembly guide stud
only)

380 001 278 Block handle

380 002 281 Oil feed flange cover needle cage insertion block
327B & 330B SECTION 5 Copyright ©37
AUTOMATIC TRANSMISSION

MAINTENANCE Hot check (80-- 100 °C) (176-- 212 °F)

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 idle with gearbox in
Neutral for approximately 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/dipstich 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.
38 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

Oil change Oil filter change

Used oil and fluids must be collected and Replace the filter at every oil change.
disposed of according to standards in force.
Proceed as follows: Proceed as follows:
D Position a suitable container, clean the filler cap
zone. Unscrew the grip two or three turns and re- Figure 28
move the dipstick;

Figure 27

269NM212

D Open the hood;

D with the engine off unscrew the filter cartridge with
269NM211 the correct spanner if necessary, then thoroughly
D Remove the drain plug (arrow) and fully drain the oil; clean the support seat;
D clean the drain plug, check the thread is in good
condition, spread sealant paste on the cap and re- Figure 29
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 lube the seal with
gear oil;
327B & 330B SECTION 5 Copyright ©39
AUTOMATIC TRANSMISSION

Figure 30

156NM42
D hand---tighten the cartridge until the seal comes into
contact with the support, then tighten it by ¾ of a
turn;
Do not overtighten the cartridge to avoid
damaging the seal.
D Start the engine and check for the oil leaks;
D Check oil level and top---up if necessary.
40 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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
327B & 330B SECTION 5 Copyright ©41
AUTOMATIC TRANSMISSION

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
42 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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 to 11 bar (130 to 160 PSI)
52 = behind the converter ---opening pressure 5 bar (73 PSI)
53 = KV clutch forward 16 to 18 bar (232 to 261 PSI)
55 = KR clutch reverse 16 to 18 bar (232 to 261 PSI)
56 = K1clutch 16 to 18 bar (232 to 261 PSI)
57 = K2clutch 16 to 18 bar (232 to 261 PSI)
58 = K3clutch 16 to 18 bar (232 to 261 PSI)
60 = K4clutch 16 to 18 bar (232 to 261 PSI)
63 = temperature behind the converter 100˚ C, short time 120˚ C
(max. 5 minutes)
65 = system pressure 16 to 18.5 bar (232 to 268 PSI)
66 = temperature behind retarder 145˚ C, short time 150˚ C
(max. 5 minutes)
67 = WK---control pressure 12 to 14 bar (174 to 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
327B & 330B SECTION 5 Copyright ©43
AUTOMATIC TRANSMISSION

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
44 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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.
Always use approved refrigerant recovery
and recharging apparatus.
Never mix different refrigerants in the same
apparatus.

Figure 34

276C05010

D proceed to remove the engine hood as instructed in

SECTION 15;
D proceed to remove the side guards as instructed in
SECTION 15;

2690703

D proceed to remove the cab as instructed in SEC-

TION 15;
327B & 330B SECTION 5 Copyright ©45
AUTOMATIC TRANSMISSION

Figure 35 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:
276NM010TA
--- oil delivery to the exchanger (1);
D arrange a suitably---sized container underneath, --- oil return from the exchanger (2);
then drain the fluid of the main hydraulic system fol-
Fluid leakage may occur during these ope-
lowing the instructions provided in SECTION 10 ---
rations.
HYDRAULIC SYSTEM;
D disconnect the following hydraulic fluid piping from
Figure 36 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;
276C05012
D open the retaining clamp and remove the transmis- Fluid leakage may occur during these ope-
sion --- cab interface cable along the chassis, win- rations.
ding it up above the transmission control unit (ar- D unscrew the retaining screws and disconnect the
row); hydraulic fluid piping support bracket (30);

. 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 replaced during reassembly
to ensure the correct fastening of the ele-
ments to be retained.
46 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

276C05013
327B & 330B SECTION 5 Copyright ©47
AUTOMATIC TRANSMISSION

18 14
17

12

15
13

276C05014
48 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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;
327B & 330B SECTION 5 Copyright ©49
AUTOMATIC TRANSMISSION

D remove the ground cable (A) from the right ---side Replacement
front support bracket; Replace the group following the instructions in reverse
D remove the screws (arrow) fastening the elastic order, and in particular:
mountings. D check the gearbox elastic mountings: if deterio-
Check that all connections and pipes are rated, replace them;
disconnected and all fastening clamps re- D check the integrity of connector pipes and joints;
moved. D check the transmission oil level and, if necessary,
top up the level or refill following the instructions pro-
D carefully lift the group, removing it from above. vided in the relative Chapter.
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.
50 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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 supporting tools (1). D Loosen the fastening screws, disassemble the
D Drain all lubricant oil. cover and remove the lubricant filter.
D Detach all the hoses from the back of the gearbox.
D Remove the PTO engagement box.
327B & 330B SECTION 5 Copyright ©51
AUTOMATIC TRANSMISSION

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.
52 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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.
327B & 330B SECTION 5 Copyright ©53
AUTOMATIC TRANSMISSION

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).
54 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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 spring
(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.
327B & 330B SECTION 5 Copyright ©55
AUTOMATIC TRANSMISSION

GEARBOX AND GEAR DISASSEMBLY

Converter and converter bell
Figure 60
Proceed as follows:
380 002 272
Figure 57

276C05016
Z7307050
D Remove the oil supply flange from the converter bell
D Loosen the screws fastening the retarder to the con- with tool 380 002 272.
verter bell.
Figure 61
Mark the relative positions of the retarder
and the bell.

Figure 58

Z7307054
D Remove the converter relief valve.

Figure 62
276C05015
D Lift the retarder, complete with converter, from the
converter bell with a suitable lifting device.

Figure 59

276C05017
D Loosen the screws fastening the converter bell to
the gearbox.
D Separate the converter bell from the gearbox with a
Z7307052 suitable lifting device.
D Loosen the screws fastening the oil supply flange
cover and remove it.
56 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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 (Fig.
64).
327B & 330B SECTION 5 Copyright ©57
AUTOMATIC TRANSMISSION

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

380 002 272

Z7307061
D Loosen the fastening screws, then remove the lubri-
cating pump with tool 380 002 272.
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.
58 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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. Figure 75
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 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.
327B & 330B SECTION 5 Copyright ©59
AUTOMATIC TRANSMISSION

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 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.
60 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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). 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
327B & 330B SECTION 5 Copyright ©61
AUTOMATIC TRANSMISSION

INSPECTING AND CHECKING Rings and springs

Check for pitting, deformation or excessive wear on
Guards and machined surfaces rings. Replace the snap ring if any fault is found;
Inspect borings and assembly surfaces for traces of look for traces of overheating, permanent deformation
wear, scratches and grooves; eliminate scratches and or wear due to friction on parts next to the springs. Re-
burring with sandpaper; replace deeply scratched or place the spring if any fault is found.
grooved parts;
check all oil pipes; eliminate obstructions with either a Clutch plates
jet of compressed air or by passing a smooth wire in Check the plates looking for encrusted metallic par-
both directions of the pipe. Rinse with cleaning solvent; ticles, very pitted, excessively worn, excessively tap-
check threading, rectify damaged threads with a tap or ered, cracked, deformed or damaged grooves. Re-
die of the required size; place the damaged plates.
replace boxes or other castings which are cracked or
grooved due to excessive wear; GENERAL ASSEMBLY STANDARDS
check all oil circuits in the control distributor and main
casing, looking for porosity, broken seats, cracks, de- Lubricants used for assembly
posits of dirt and surface defects; Hold parts provisionally in place during assembly by
check seal resting surfaces for deformation or surface means of low fusion point oil soluble grease (Vaseline).
defects.
Never use fibrous, insoluble or vegetable
Bearings and axial shims based products in any point of the trans-
Check all bearings for notches, pitting, scratches or ex- mission.
cessive wear. Replace the parts which are faulty or
irregular after cleaning and lubrication; Clutches and pistons
inspect the bearings, which present notches, burring, Soak each clutch plate in transmission fluid for at least
ovalisation, sharp edges or traces of overheating; re- two minutes.
place the damaged components; Before final assembly, apply plenty of transmission fluid
inspect the end of stroke shims that may be deformed, in the piston cavity.
scratched, worn or burred. replace any faulty or worn Fit the clutch plates so that they are all directed the
parts. same way.

O-- rings and seals Lip seals

Check the piston rings and the lip seals for notches, Make sure that the spring lip side is actually on the side
cuts, tears, cracks or deformation. A deteriorated seal of the oil to be contained (towards the inside of the box):
may indicate the presence of faults in piston grooves or apply high temperature resistant grease inside the seal
corresponding surface. These faults will damage the to protect it during shaft assembly and ensure lubrica-
new seal. tion at the beginning of operation.
Replace the seals and the O---rings.
Roller bearings
Gears, grooves and threaded parts
Heat the bearing on an electrical radiating plate or in an
Check gears for wear, pitting, burring or broken teeth: oil bath (maximum temperature of approximately 90°C)
replace the gear if faults are found; to fit it on the shaft.
check that the grooves are not deformed, chipped or
burred. Replace the gear if faults are found; Warm the bearings for the amount of time
check for burring and damaged threads; replace the necessary to obtain adequate dilatation.
damaged parts.
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 327BCopyright
& 330B ©

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.

Figure 85

Z7307080
D Extract the inner ring of the taper roller bearing [31].

Figure 88
Extractor
Z7307078
D Starting from clutch K3, use extractor to remove 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.
327B & 330B SECTION 5 Copyright ©63
AUTOMATIC TRANSMISSION

Plate 1: clutch shaft K4/K3

Z7307082
64 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

Figure 89 Figure 92

380 002 320

Z7307083 Z7307086
D Work from the opposite side and loosen ring nut D Remove the preload adjustment ring [26] of taper
[28] with tool 380 002 320. 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].

Figure 94
276C005019
D Extract the inner ring of the taper roller bearing [27]
using tools 380 002 785 and 380 001 289.

Figure 91

Extractor

Z7307088
D Remove the snap ring [10].
D Remove the terminal plate [11] and the set of K4
clutch plates.
D Remove the shaft from the support tool.
Z7307085
D Remove the straight spur gear [24] with an extrac-
tor.
327B & 330B SECTION 5 Copyright ©65
AUTOMATIC TRANSMISSION

Figure 95 Reassembling
Proceed as follows:
380 002 310
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 380
002 310. 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.
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.
66 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

Figure 99 Figure 101

Z7307093 Z7307095
D Insert resting ring [13] and compression ring [12]. D Install the set of K4 clutch plates in the order given
D Position the thrust ring [14] on the compression ring in plate 2 (see following pages).
with the chamfer facing upwards.
D Position the snap ring [15]. . To ensure that the resulting measurements
D Remove the shaft from the support tool. are correct, do not lubricate the plates.

Figure 100 D Insert the end shim [11] and secure it with snap ring
[10].

380 002 310 Figure 102

Z7307096
D Fit a dial indicator with its probe on the terminal
Z7307094 plate.
D Preload the compression spring with tool 380 002 D Apply a force of 100 N and reset the gauge.
310. D Use compressed air to move the piston the length
D Push the snap ring in the circular groove, then re- of its stroke and check that the end play is within the
lease the spring load and remove the tool. specified range.
D Proceed in the same way for the K4 clutch compo- K4 clutch end play: 2.2 – 2.4 mm
nents. D If this is not so, correct the value by changing the
D Secure the shaft in the vice. 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.
327B & 330B SECTION 5 Copyright ©67
AUTOMATIC TRANSMISSION

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 dial indicator 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.
68 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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)
327B & 330B SECTION 5 Copyright ©69
AUTOMATIC TRANSMISSION

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)
70 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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)
327B & 330B SECTION 5 Copyright ©71
AUTOMATIC TRANSMISSION

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)
72 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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

380 002 320

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 380 002 320.
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.
327B & 330B SECTION 5 Copyright ©73
AUTOMATIC TRANSMISSION

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

380 002 399

Z7307110
D Secure the shaft in the vice.
D Loosen the ring nut [42] using tool 380 002 399.
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].
74 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

Plate 4: clutch shaft KR/K2

Z7307112
327B & 330B SECTION 5 Copyright ©75
AUTOMATIC TRANSMISSION

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 –
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].

380 002 399

Z7307117
D Turn the shaft upside down.
D Loosen the ring nut [33] using tool 380 002 399.
The ring nut is locked with thread locker.
Heat the threading to about 120 °C before
unscrewing to avoid damage.
76 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

Figure 121 Figure 123

Z7307118 Z7307120
D Remove the inner ring of the taper roller bearing D Remove the inner ring of the taper roller bearing
[32]. [30].
D Use an extractor to remove the bevel gear [28]. D Remove the shaft from the support tool.
D Collect the bearing inner ring [31] from the gear. D Follow the instructions given for the K4/K3 shaft and
D Remove the preload adjustment rings [29] of taper preload the compression spring [15] with tool 380
bearings [30] and [31]. 002 310.
D Use a screwdriver to remove the snap ring [18], then
Figure 122 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.
327B & 330B SECTION 5 Copyright ©77
AUTOMATIC TRANSMISSION

Reassembling Figure 127

Proceed as follows:

Figure 125 380 002 310

Z7307122
D Lubricate and fit the 0---rings [11] and [9] to the K2 Z7307124
clutch piston.
D Secure the shaft in the vice. D Preload the compression spring with tool 380 002
D Insert the piston of clutch K2 until it touches the bot- 310.
tom, making sure it is straight. D Push the snap ring in the circular groove, then re-
lease the spring load and remove the tool.
Pay attention to the installation position of D Proceed in the same way for the KR clutch compo-
the piston. nents.
D Secure the shaft in the vice.
Figure 126
Figure 128

Z7307123
Z7307125
D Insert resting ring [13] and compression ring [12].
D Position the thrust ring [14] on the compression ring D Install the set of KR clutch plates in the order given
with the chamfer facing upwards. in plate 5 (see following pages).
D Position the snap ring [15].
D Remove the shaft from the support tool.
. 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].
78 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

Figure 129 Figure 130

Z7307126 Z7307127
D Fit a dial indicator with its probe on the terminal D Position the KR clutch bevel gear on the bearing
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.
327B & 330B SECTION 5 Copyright ©79
AUTOMATIC TRANSMISSION

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)
80 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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)
327B & 330B SECTION 5 Copyright ©81
AUTOMATIC TRANSMISSION

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)
82 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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)
327B & 330B SECTION 5 Copyright ©83
AUTOMATIC TRANSMISSION

Figure 132 Figure 134

Z7307131 Z7307133
D Fit a dial indicator with its probe on the edge of the D Fit the straight spur gear so that the splined hub
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.
84 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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.
327B & 330B SECTION 5 Copyright ©85
AUTOMATIC TRANSMISSION

Figure 142 Figure 145

380 002 399

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 380 002 399.

Figure 146

Z7307142
380 002 399
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 380 002 399.
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.
86 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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 an extractor.
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
380 002 399
Z7307146
D Secure the shaft in the vice.
D Loosen the ring nut [43] using tool 380 002 399.
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].
D Remove the spacer [8].
327B & 330B SECTION 5 Copyright ©87
AUTOMATIC TRANSMISSION

Plate 7: clutch shaft KV/K1

88 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

Figure 151 Figure 153

380 002 320

Z7307151 Z7307153
D Turn the shaft upside down. D Remove the inner ring of the taper roller bearing
D Loosen the ring nut [38] using tool 380 002 320. [34].
D Remove the shaft from the support tool.
The ring nut is locked with thread locker.
D Follow the instructions given for the K4/K3 shaft and
Heat the threading to about 120 °C before
preload the compression spring [19] with tool 380
unscrewing to avoid damage.
002 310.
D Use a screwdriver to remove the snap ring [23], then
Figure 152 release the spring load and remove the thrust ring
[22], the spring and the resting ring [21].

Figure 154

Z7307152
D Remove the inner ring of the taper roller bearing
[37].
D Use an extractor to remove the bevel gear [33]. Z7307154
D Collect the bearing inner ring [34] from the gear. D Use compressed air to remove the piston [10].
D Remove the preload adjustment ring [35] and
spacer [36] of taper bearings [34]. 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.
327B & 330B SECTION 5 Copyright ©89
AUTOMATIC TRANSMISSION

Reassembling Figure 157

Proceed as follows:
380 002 310
Figure 155

Z7307155
D Lubricate and fit the 0---rings [12] and [13] to the Z7307157
K1clutch piston.
D Secure the shaft in the vice. D Preload the compression spring with tool 380 002
D Insert the piston of clutch K1 until it touches the bot- 310.
tom, making sure it is straight. D Push the snap ring in the circular groove, then re-
lease the spring load and remove the tool.
Pay attention to the installation position of D Proceed in the same way for the KV clutch compo-
the piston. nents.
D Secure the shaft in the vice using tool.
Figure 156
Figure 158

Z7307156
Z7307158
D Insert resting ring [21] and compression ring [20].
D Position the thrust ring [22] on the compression ring D Install the set of KV clutch plates in the order given
with the chamfer facing upwards. in plate 8 (see following pages).
D Position the snap ring [23].
D Remove the shaft from the support tool.
. 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].
90 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

Figure 159 Figure 160

Z7307159 Z7307160
D Fit a dial indicator with its probe on the terminal D Position the KV clutch bevel gear on the bearing
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 values = 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.
327B & 330B SECTION 5 Copyright ©91
AUTOMATIC TRANSMISSION

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)
92 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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)
327B & 330B SECTION 5 Copyright ©93
AUTOMATIC TRANSMISSION

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)
94 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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)
327B & 330B SECTION 5 Copyright ©95
AUTOMATIC TRANSMISSION

Figure 162 Figure 164

Z7307164 Z7307166
D Fit a dial indicator with its probe on the edge of the D Fit the KV clutch bevel gear so that the splined hub
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.
96 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

. 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.
327B & 330B SECTION 5 Copyright ©97
AUTOMATIC TRANSMISSION

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. D Remove the inner ring of the opposite bearing with
a press.
Figure 173
The shaft and the gear cannot be separated
(hot---coupling).

Assembly
Proceed as follows:

Figure 175
380 002 399

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 380 002 399.
D Apply LOCTITE 262 thread locker, then fit the ring
nut on the KV clutch side. Z7307177
D Tighten the ring nut to the specified torque using D Fit the inner ring on the converter side with a press.
tool 380 002 399. D Fit the inner ring of the opposite bearing with a
D Check operation of the clutches KV and K1 with press.
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 K1 clutch side.
98 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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.
D If necessary, remove the outer ring of the taper roller
bearing on front side from the external crown gear.

Z7307179
Figure 181
D Remove the snap ring securing the sun gear.

Figure 178

Z7307183
D Use a drift to push the lockpins of a pair of side pin-
ions inwards.
Z7307180
D Remove the snap ring securing the external crown
flange.
327B & 330B SECTION 5 Copyright ©99
AUTOMATIC TRANSMISSION

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.
100 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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.
327B & 330B SECTION 5 Copyright 101
AUTOMATIC TRANSMISSION ©

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.

Figure 194

Z7307196
D Loosen the screw securing the drive bushing.
102 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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.
327B & 330B SECTION 5 Copyright 103
AUTOMATIC TRANSMISSION ©

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 con-
D Remove the external O---ring.
tact, making sure the reinforced shell faces the tool.
Figure 203 D Fit the external O---ring.
Figure 206

Z7307205
D Extract the inner ring of the taper roller bearing, then
Z7307208
remove 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.
104 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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

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
Z7307210 spacer as necessary.
D Fit play adjustment spacers (1) and check that the
end play is within the specified range of values. . Choose the spacer with the most appropri-
pwr takeoff shaft end play: 0.05-- 0.10 mm ate thickness.
D If this is not so, correct the value by removing or ad-
D Position the gear complete with bearing inner rings
ding spacers.
in its seat.
D Once the play has been adjusted, lock the shaft with
the retainer snap ring (2). . The intermediate shaft pin can only be fitted
D Turn the gearbox upside down.
if the clutches and relative covers have been
D Insert a seal in the housing hole with its concave
installed (see following pages).
side facing downwards.
D Apply LOCTITE 262 sealant.
327B & 330B SECTION 5 Copyright 105
AUTOMATIC TRANSMISSION ©

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 Hold the K3 clutch straight spur gear in position to
prevent the plates falling out.
Z7307213 D Slightly lift the KR/K2 clutch shaft, move it to one
D Position the KV/K1 clutch with an eyebolt and a suit- side and position clutch shaft K3/K4.
able lifting device. D Remove the tool.

Figure 212

Z7307214
D Position the KR/K2 clutch in the same way.
106 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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.
327B & 330B SECTION 5 Copyright 107
AUTOMATIC TRANSMISSION ©

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 380 002 275.

Z7307224
D Tighten the cover fastening screws to the specified
torque.
108 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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.
327B & 330B SECTION 5 Copyright 109
AUTOMATIC TRANSMISSION ©

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.
110 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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.
327B & 330B SECTION 5 Copyright 111
AUTOMATIC TRANSMISSION ©

Intermediate shaft pin Figure 239

Proceed as follows:
Figure 237
380 002 293

Z7307241
D Remove the tool 380 002 293.
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 380 002 293. 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.
112 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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.
380 002 275
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 380 002 275.
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.
327B & 330B SECTION 5 Copyright 113
AUTOMATIC TRANSMISSION ©

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.
114 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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.
327B & 330B SECTION 5 Copyright 115
AUTOMATIC TRANSMISSION ©

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.
116 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

Figure 259 Figure 262

380 002 281

380 001 278

Z7307261 Z7307264
D Fit the needle bearing retainer to the point of contact
using tools 380 001 278 and 380 002 281, 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.
327B & 330B SECTION 5 Copyright 117
AUTOMATIC TRANSMISSION ©

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.
118 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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
327B & 330B SECTION 5 Copyright 119
AUTOMATIC TRANSMISSION ©

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.

120 AUTOMATIC TRANSMISSION SECTION 5 327BCopyright
& 330B ©

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 Copyright ©

SECTION 6.1

FRONT AXLE --- DRY DISC BRAKES

Copyright ©
 327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES © 1

CONTENTS

Page Page

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 BRAKE CALIPER DETACHMENT--

REATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
First reduction: bevel pair . . . . . . . . . . . . . . . . . . . . . . 4
Detachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Second reduction: hub and planitary train . . . . . . . 10
Reattachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Brake pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PLANITARY REDUCER OVERHAUL . . . . . . . . . . . 33
SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . 13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inspection of the dismantled parts . . . . . . . . . . . . . . 37
Brake disc and caliper . . . . . . . . . . . . . . . . . . . . . . . . 13
Planitary reduction gear seals and thread---stops
Bevel gear (first reduction) . . . . . . . . . . . . . . . . . . . . 14
application and bearings scheme . . . . . . . . . . . . . . 38
Planitary train and hub (second reduction) . . . . . . 15
Planet ---wheel holding plate assembly . . . . . . . . . . 39
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . 16 Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Hub bearing preload determination . . . . . . . . . . . . . 42
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Planet ---wheel holding plate --- fixed gear axial
clearance determination . . . . . . . . . . . . . . . . . . . . . . 44
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Concluding operations . . . . . . . . . . . . . . . . . . . . . . . . 44
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
FRONT DIFFERENTIAL OVERHAUL . . . . . . . . . . . 45
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Replacement of the brake pads . . . . . . . . . . . . . . . . 26
Inspection of the disassembled parts . . . . . . . . . . . 49
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . 28
Diagram of bearings and the application of
Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 thread---locks and distributor and differential
seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Diagram of the self---locking differential
FRONT HUBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
BRAKE CALIPER OVERHAUL . . . . . . . . . . . . . . . . 65
Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
FRONT HUB REMOVAL-- REFIT . . . . . . . . . . . . . . . 30 Inspection of the disassembled parts . . . . . . . . . . . 66
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

BRAKE DISC OVERHAUL . . . . . . . . . . . . . . . . . . . . 68

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

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327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES © 3

DESCRIPTION
The axle has independent wheels with double reduc- the crown wheel and pinion with differential (first reduc-
tion. tion). The structure is solidly connected to the automat-
The differential unit is composed of a box structure ic transmission box with a series of screws.
which contains the cylindrical wheel transmission and

Figure 1

2
1

276C061D001

1. Oscillating plate
2. Left hub
3. Left axle shaft
4. Differential and transfer case
5. Right axle shaft
6. Right hub
4 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

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
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES © 5

Figure 2

26912101
6 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

The differential is limited slip type. ficient and thus holds the braking torque constant for
It has a multiple disk clutch inserted between the differ- the whole useful life of the differential.
ential gear box (train carrier) and the crown wheels on The thrust on the disks is ensured by the sloped con-
each side. tact between the shaft and the pressure plate: therefore
The multiple disk clutch includes the external disks a greater radial peripheral thrust on the train carrier
connected to the differential gear box and internal disks shaft (from the ring bevel gear) will cause a greater axial
connected to the crown wheel gears by appropriate thrust on the disks.
pressure plates. The thrust on the disks generates a stall torque that
The internal disk friction surfaces have a patented mo- acts on the crown wheel.
lybdenum coating that ensures a constant friction coef-

Figure 3

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
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES © 7

Operation Under these conditions there is no relative motion be-

The driving torque coming from the propeller shaft is tween the two crown wheels and therefore the side pin-
transmitted by a universal joint to the bevel pinion. ions do not turn around their shaft which is integral to
From here the torque passes to the ring bevel gear, the differential gear box.
which is integral to the differential gear box. When the resistance of one wheel is greater than that
The differential is a gear for which the box represents of the other, or when the speed of the two wheels is not
the train carrier, that carries the differential gear carrier the same (vehicle on a road with bends) the crown
shafts and receives the driving torque, whereas the two wheel gears have a different rotation speed: the rele-
side gears, which represent the crown wheels, both of vant motion is permitted by the side pinions, that now
which rotate, receive the driving torque and transmit it turn around their shafts in directions opposite to each
to the axle shafts. other.
When both wheels are subject to the same stall torque Obviously at a lower crown wheel rotation speed the
or have the same speed (vehicle being driven on a transmitted driving torque is greater, and vice versa.
straight road), the ring bevel gear and the differential Therefore when the differential is operating, the wheel
gear box rotate as one, transmitting the torque in equal with a lower speed can transmit a greater torque,
parts to the two crown wheels, and from here to the two whereas the wheel with a higher speed can transmit a
axle shafts, that rotate at the same speed: the wheels lower torque.
transmit the same driving torque. Under certain conditions it may happen that the slower
wheel looses its grip completely, since the torque is ex-
ceeded that can be transmitted to the ground, and
Figure 4 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%.

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
8 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

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 5

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
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES © 9

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10 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

Second reduction: hub and planitary 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. Planitary 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
adjusted by a ring nut. The side pinion gears rotate on 3. Planet ---wheel
pivoting roller bearings. 4. Planitary train fixed gear
5. Planet ---wheel pin
Operation 6. Unused
7. Adjustment ring nut
The driving torque coming from the differential is trans-
8. Planitary 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. ”U” 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
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©11

Figure 6

276C061D008
12 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

Brake pad

Figure 7

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
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©13

SPECIFICATIONS AND DATA

Hub
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

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
14 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

Bevel gear (first reduction)

Figure 8

T269PT03
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©15

Planitary train and hub (second reduction)

Figure 9

Hub bearing pre ---load is

Ring nut tightening torque: determined by the ring nut
1st tightening: 700 --- 900 Nm tightening torque
(516.29 --- 663.80 lbf ft)
then loosen
2nd tightening: 450 Nm
(331.9 lbf ft)

Axial clearance
0.30 --- 0.70 mm
(0.012 --- 0.028 in)

276C061D012
16 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

TIGHTENING TORQUES

Figure 10

276C061D013
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©17

TIGHTENING TORQUES

Figure 11

276C061014
18 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

TIGHTENING TORQUES

Figure 12

276C063D015
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©19

EQUIPMENT
. Prior to ordering tools, refer to the this matrix. The type of axle is found on a plate on the axle housing.

TYPE OF AXLE
DESCRIPTION 82.0905.3 82.0689.3 82.0690.3 82.1249.3 82.1232.3 82.0832.3
(327B) (327B/330B) (330B) (327B) (330B) (330B)

Wheel nut spanner 380002787

Seal ring sleeve driver 380002788

Seal ring sleeve driver 380002790 380002791 380002792 380002793

Thread ring spanner 380002794

380002794 --
(Differential) 380002795

Seal ring sleeve driver -- 380002799 --

. The following tools are necessary when performing service repair on the differential.

Tool Number DESCRIPTION

380002274 Driver

380002275 Driver

380002282 Driver

380002283 Driver

380002316 Plug Gage

380002317 Stop Disc

380002325 Shaft

380002326 Dummy Differential Bearing Set

20 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

Page left intentionally blank

 327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©21

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
 22 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

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.
 327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©23

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.
 24 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

Brakes
1. Weak braking action
2. Unequal action of the brakes
3. Brakes that remain locked

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
 327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©25

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 LOCKED

Foreign bodies between the discs. Overhaul the brakes.

YES

NO

Defective hydraulic system. See Section 10 --- HYDRAULIC SYSTEM.

YES
26 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

MAINTENANCE
The braking system components are funda- Figure 14
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 13

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;
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©27

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 15

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 16

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.
28 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

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 18
Figure 17

269NM221
269NM221
D arrange a suitably sized container, clean the plug
D clean the plug area and open the level plug (1). Lu- area and remove the level plug (1);
bricant should drip out of the hole; D remove drain plug (2) and fully drain the oil;
D top up the level as shown in the following para- D clean the drain plugs. Check that the threading is in
graph, if required; good condition. Replace the seal and apply sealant
D close the filler plug and fasten at the specified to both plugs and close them at the specified
torque. torque.

Proceed as follows to fill the system:

D fill until oil spills out of the hole on the plug (1);
D replace the seal, apply sealant onto the plug and
close it at the specified torque;
D run a road test, check the plug 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.
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©29

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 19 Figure 20

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 plug
D clean the plug area and open the level plug (1). Lu- area and remove the plug (1) and the drain plug (2);
bricant should drip out of the hole; drain all the lubricant.
D top up the level as shown in the following para- D clean the plug, check that the threading is in good
graph, if required; condition, replace the sealing ring with a new one
D close the filler plug. and close the drain plug.
D repeat the procedure for the other hub.
D arrange a suitably sized container, clean the plug
area and remove the plug (1) and the drain plug (2);
drain all the lubricant.
30 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

FRONT HUB REMOVAL

. Before starting any operation, make sure D disconnect the braking system hydraulic connector
(20) and plug it to prevent fluid leaks;
that all the precautions have been taken and
all aspects regarding safety of the personnel . Hydraulic oil leakage may occur during
involved on the job have been made quite
these operations.
clear.
Read the relevant instructions contained in D disconnect the transmission axle shaft (18) from the
SECTION 1 of this handbook. hub following the instructions in SECTION 7;
If in doubt ask someone who is more experi- D lower the suspension until maximum extension of
enced. the shock absorbers;
Comply to all the general recommendations D release the axle shaft from the universal joint to facili-
for correct execution of maintenance work. 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;
Removal
D remove all the locking nuts (15) fastening the hub to
Proceed as follows: the axle, recovering the relative washers;
D bring the vehicle on a suitable flat, solid surface, D carefully slip the hub (14) off;
switch off the engine, remove the key from the igni-
tion switch, engage the parking brake and affix the Check that the brake caliper fastening flan-
warning notices; ge remains on the hub.
D deactivate the battery isolator or disconnect the bat-
tery terminals to prevent any risk of a short circuit; D screw two operating nuts (arrow) onto the stud bolts
D block articulation by means of the steering lock bar, in a diametrically opposite position to prevent the fall
proceeding as indicated in SECTION 1; of the brake caliper fastening flange.
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;

. The following procedures relate to the side

where the operation takes place.
D remove the wheel following the instructions in SEC-
TION 9;
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©31

Figure 21

18

20
14
15

276C061D027
32 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

BRAKE CALIPER DETACHMENT --- Figure 23

REATTACHMENT
4 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 2
SECTION 1 of this manual. 2
In case of doubt, consult a more experience 3
person.
Furthermore, respect all the general recom- 4
mendations for a correct execution of the
maintenance interventions. 1
276C061D029
Detachment D disconnect the braking system hydraulic connector
Do as follows: (4) and plug it to prevent fluid leaks;
D bring the vehicle onto an appropriately solid flat sur-
face, shut off the engine, remove the key from the . Hydraulic oil leakage may occur during
ignition switch, engage the parking brake and affix these operations.
the indication signs;
D support the caliper (2) appropriately, remove the re-
D disconnect the battery---disconnect switch or dis-
taining screws (3) of the support bracket and re-
connect the battery terminals in order to eliminate
move the caliper complete with the bake pads.
any risk of short ---circuit;
D block the articulation by means of the steering lock
Reattachment
bar, operating as indicated in SECTION 1;
D block the wheels appropriately; Proceed with reattachment by following the detach-
D use a hydraulic lift to raise the chassis until the ment steps in the reverse order.
wheels are off the ground; After reassembled, perform a bleeding of
D disassemble the wheel concerned; the brake hydraulic circuit following the in-
structions in SECTION 10 --- HYDRAULIC
Figure 22 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;
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©33

PLANETARY 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.

. Before proceeding, it is necessary to:

D drain the lubricant from the wheel hub
D drain the lubricant from the central differ-
ential 276C061D031
following the instructions provided in the D slip off the axle shaft (1);
relative chapter.
Figure 26
. Before proceeding, the brake caliper must
be removed following the instructions in the
relative chapter.

Disassembly
Proceed as follows:

Figure 24
1

276C062032

D unscrew the setscrew (1) of the ring nut;

D remove the locking ring nut (2) of the internally too-
1 thed crown wheel.
3
2 The ring nut is locked with thread ---stops.
276C061D030 To prevent damage to the threading, heat to
D mark the mutual position of the planet ---wheel hol- approximately 120˚C before unscrewing.
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);
34 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

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
to the axle axis to avoid damaging the brake
discs.
D remove the front sealing ring;
D place the hub vertically;

Figure 27

2
276C062D036

D Unscrew the retain screws (1) and remove the brake

disck (2).

Figure 30

1
1
2

1
276C062D033

D use a suitable extractor to remove the internally too-

thed crown wheel (1);

Figure 28

1 2

5 3
276C062D035
D remove the two oil seal rings (1) from the hub;
D use a suitable extractor to remove the outer race (2)
4 of the axle---side bearing (A) and the outer race (3)
of the wheel---side bearing (B);
D if necessary, remove the wheel---fastening screws
from the hub;
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;
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©35

Figure 31 Figure 33

5
4
2
2 1
1 276C061D041
276C061D037
D remove the snap ring (1) and spacer (2), then use
D remove the inner race (1) of the axle---side bearing
a suitable extractor to remove the universal joint
(A) and the spacer ring (2) from the hub;
flange (3) from the ball bearing (4) and flange (5);
Figure 32
Figure 34

2
276C061D042

D remove the sealing rings;

3
276C061D040
D unscrew the retaining screws (1) and remove the
complete universal joint support (2) from the hub
support (3);
36 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

Figure 35 Figure 36

3
1

2 1

274A062029
D place the planet ---wheel holding plate on a suitable 276C062038
work surface; D remove the planet wheel (1) and relative shim rings
D use a punch to push the retaining pin (1) down in the (2);
pivot, freeing the pivot (2);
D extract the pivot (2) by pushing it towards the inside Figure 37
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..

274A062039
D remove the needle cages (arrow) from the planet ---
wheel;
D repeat the procedure for all the planet ---wheels.
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©37

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 teeth: 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.
38 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

Planetary reduction gear seals and thread-- stops application and bearings scheme

LOCTITE 262

LOCTITE 270

LOCTITE 270 LOCTITE 270

LOCTITE 270

LOCTITE 572

MOLYKOTE LOCTITE 572 rubber

LOCTITE 270 steel

LOCTITE 270

LOCTITE 638

LOCTITE 638

LOCTITE 572 rubber

LOCTITE 270 steel

LOCTITE 638

276C061D044
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©39

Planet-- wheel holding plate assembly Figure 39

Proceed as follows:
D position the planet ---wheel holding plate horizontal- 2
ly;

Figure 38

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 40

2
3

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 bushing 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.
40 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

Hub Figure 42
Proceed as follows:

Figure 41

3
2
1
1

1 276C062054
276C062053
D insert the sealing ring (1) into the bushing (detail)
D place the hub vertically; and fill it completely with lubricating oil for bearings.
D using a suitable introducer, mount the outer race (1)
of the wheel---side conic roller bearing (B) and the Figure 43
outer race (2) of the axle---side conic roller bearing
(A); 2
D mount the inner race (3) of the axle---side conic roller
bearing (A);

276C062D055

D mount the disc (1) on the hub.

D mount retaining screws (2) and tighten.
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©41

Figure 44

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.
42 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

Figure 45 Hub bearing preload determination

Proceed as follows:

Figure 47
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 teeth (3); 1
D mount the retention plates (4) and fix them with the
set screws; 276C062069
D apply MOLYKOTE lubricant on the hub support
Figure 46
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
set 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
set 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
clamp screw.
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©43

Figure 48 Figure 50

276C061055
D mount the sealing rings according to the assembly
direction indicated;
2
Figure 49 276C061057
D mount the complete unisersal joint support (1) onto
the hub (2) and screw on the retaining screws (3);

Figure 51

1
3
4
5
276C061056

D mount the flange (1) complete with sealing rings on-

to the unisersal joint flange (2);
1
D mount the ball bearing (3), spacer (4) and snap ring
(5); 276C061D059

D insert the axle shafts (1) into the hub.

44 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

Planet-- wheel holding plate -- fixed gear axial clear- Concluding operations
ance determination
Proceed as follows: Figure 53

Figure 52

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.
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©45

FRONT DIFFERENTIAL OVERHAUL Figure 55

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.

276A061151
Disassembly
D Support the differential with a suitable lift.
. Before proceeding it is necessary to remove D Remove the retaining screws and remove the sup-
the front differential box from the automatic port flange complete with hub, hub support bearing
transmission by following the instructions in and differential conic roller bearing external ring.
Section 5 --- AUTOMATIC TRANSMISSION. D Repeat the operation for the other support flange.

Proceed as follows: Keep the details making up the right and left
D Position the housing on the support trestle using ap- output flanges separate.
propriate adaptation elements.
Figure 56
Figure 54

269A061003
276A061150
D Using a suitable lifting device, extract the differential
D Mark the radial position of the support flanges (ar- from the external box and put it on the workbench.
row).
D Mark the right and left support flanges as well in or-
der to prevent interchanging their position during
reassembly.
46 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

Support flange disassembly Figure 59

. The operations described below are valid

for both flanges.
Proceed as follows:

Figure 57

276A061006
D Extract the snap ring and relative spacer.

Figure 60

276A061004
D Extract the external ring (1) of the differential conic
roller bearing and the spacer ring (2).

Figure 58

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.
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©47

Differential disassembly D Mark the positions of the cover and the differential
Proceed as follows: box.

Figure 61 Figure 64

276A061008 276A061011

D Use an extractor to remove both the internal rings of D Remove the cover.
the conic roller bearings from the differential. D Remove the shoulder rings, the driven/driving
discs, the planet ---wheel shoulder plate and the
Figure 62 planetary gear.
Do not invert the position of the discs.

Figure 65

276A061009
D Loosen the hexagonal head retaining screws.

Figure 63
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.
48 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

Pinion disassembly Figure 68

Proceed as follows:

Figure 66

276A061015

Provide a suitable support to prevent the

276A061013 pinion from falling.
D Using a pad and a press, extract the pinion from the
The bush is blocked with thread ---locks.
external box.
To prevent damaging the threading, heat it to
D Recover the internal ring of the external conic roller
approximately 120˚C (248 ˚F) before un-
bearing and the relative spacer.
screwing.
D Remove the oil seal ring from its seat.
D Remove the bushing.
Figure 69
Figure 67

276A061016
276A061014 D Use an extractor and a press to remove the internal
D Remove the washer and the splined sleeve. 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.
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©49

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
wear. D heat, to 100˚ C (212 ˚F) in the oven, the
Crown wheels bearings and rings to be mounted by
D check the condition of the toothing: replace it if it has pushing;
pits, cracks and/or cavities. D carefully center and mount the sealing
Planet ---gears rings and bearings with a suitable ad-
D check the condition of the toothing: replace it if it has juster;
pits, cracks and/or cavities; D lubricate the bushes, sealing rings and
D check the coupling surfaces with the pins. bearings.
Damage to a single element entails the re- Perform all the indicated measurements
placement of the entire gear unit. with maximum precision.
Imprecise measurements lead to bad con-
Cross pins
tact of the bevel gear and thus make it nec-
D check the coupling surfaces with the planet ---gears.
essary to repeat the procedure.
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;
Irregular wear may indicate an incorrect ad-
justment of the bearings: check their integri-
ty before proceeding to the reassembly.
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.
50 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

Diagram of bearings and the application of thread-- locks and distributor and differential seals

276A061017
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©51

Determination of the pinion axial position spacer thickness S1

Proceed as follows:

Figure 70

380 002 325

380 002 326 380 002 326

380 002 316

380 002 317

276A061018
D Insert the tools 380 002 326 +380 002 325 into the
differential support seats and the tools 380 002 316
+380 002 317 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 (8.8189 in)
dimension b: 2.50 mm (0.09842 in)
The dimension b must be determined with a
thickness gauge.
dimension c: 15.00 mm (0.5905 in)
(1/2 measuring rod diameter)
dimension H= a+b+c: 241.50 mm (9.5078 in)
52 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

Figure 71 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 73
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 72

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) 380 002 282
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 380 002 282, mount the external
rack of bearing (B) in its seat.
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©53

Determination of the bearing preload spacer thickness Figure 76

S2 and assembly of the pinion
Proceed as follows:

Figure 74

276A061024
D Mount the splined sleeve.

Figure 77

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 75

276A061025
D Mount the washer, mount the bushing 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
276A061023 D Otherwise, correct the rolling resistance by using a
D Mount the pinion in the box. spacer S2 with different thickness.
D Heat the internal ring of the external conic roller D In particular:
bearing (B) and mount it on the pinion. --- 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.
54 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

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 78

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
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©55

Complete self---locking differential assembly . The numbering of the parts corresponds to

the legend on the previous page.
Figure 79

A E

B F

C G

D H

269A061027
Do as follows: E. Assemble the shafts (10) and planet ---wheel gears
A. Position the steel shoulder ring (3) and then the (9) and mount them on the crown wheel.
brass shoulder ring (4); F. Mount the second crown wheel gear (8) on the plan-
B. Alternatively mount an externally slotted disc (5A, et ---wheel gear unit.
driven disc) and an internally slotted disc (6A, driv- G. Mount the second planet ---wheel shoulder plate (7)
ing disc) until using up all the discs. with the flat side up.
H. Alternatively mount an internally slotted disc (6B,
The last disc is a driving disc.
driving disc) and an externally slotted disc (5B, driv-
en disc) until using up all the discs.
C. Mount the planet ---wheel shoulder plate (7) with the
The first disc is a driving disc.
flat side against the driving disc.
D. Mount the crown wheel gear (8) on the shoulder
plate.
56 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

Determination of the disc pack axial clearance

Figure 82
Do as follows:

Figure 80

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 81 Figure 83

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.
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©57

Differential assembly
Figure 86
Do as follows:

Figure 84

centering screws

276A061034

276A061032 D Heat the crown wheel---side conic roller bearing in-

ner track (C) and position it against the differential
D Mount centering screws (n. 3) (arrow) and position
semibox until contact.
the crown wheel.
D Heat the planet ---wheel side conic roller bearing in-
ner track (D) and position it against the differential
Figure 85 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 87

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.
58 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

Determination of the differential bearing preload

Figure 90
Proceed as follows:

Figure 88
Calibrated screws

276A061038
D Mount calibrated screws (n. 2) (arrow) and position
276A061036
the flange.
D Mount the spacer S3 (1) having thickness equal to D Temporarily fix the flange by tightening the screws
that removed during disassembly onto the crown to the prescribed torque.
wheel---side support flange. D Working from the opposite side (planet ---gear side)
D Mount the external ring (2) of the crown wheel---side mount the external ring of the conic roller bearing
conic roller bearing (C). (D) onto the relative internal ring already installed on
The two bearings must NOT be inter- the differential.
changed since they have different widths..
Figure 91

Figure 89

276A061039
D Determine the dimension a
276A061037
D Mount the O---ring (arrow).
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©59

Figure 93
Figure 92

276A061036
276A061040 D Mount the chosen spacer S4 (1) onto the planet ---
D Determine the dimension b gear---side support flange.
D Determine the thickness of the spacer as follows: D Mount the external ring (2) of the planet ---gear ---
S4 = a -- b +(0.30 to 0.40) (mm) side conic roller bearing (D).
where
a = distance between the box attachment surface and The two bearings must NOT be inter-
bearing external ring side changed since they have different widths.
b = distance between the conic roller bearing shoulder
and the cover attachment surface Figure 94
S4 = bearing spacer thickness (D)
0.30 to 0.40 = differential bearing preload in mm

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 to 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.
60 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

Pinion---crown wheel clearance check

Proceed as follows:

Figure 95

276A061043
D Mount a dial indicator 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 pinion;
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 96

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
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©61

Verification of the pinion---crown wheel engagement D Cover a dozen teeth of the crown wheel with Prus-
impression area sian blue, lubricated with minium, or another paint
Do as follows: 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
Figure 97 contact of the teeth, leaving zones exposed with the
exact dimension, shape and location of contact.

276A062176

Figure 98

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.
62 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

Pinion assembly Figure 101

Proceed as follows:
D Remove the locking bushing and the splined
sleeve.

Figure 99

380 002 274

276A061025
D Mount the washer, mount the bushing and tighten
it to the prescribed torque.

276A061047

D Use the tool 380 002 274 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 380 002 274 enables the correct ax-
ial positioning of the sealing ring.

Figure 100

276A061024
D Mount the splined sleeve.
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©63

Support flange assembly Figure 104

. The operations described below are valid

for both flanges.
Proceed as follows:

Figure 102

276A061052
D Mount the spacer (1) and then the snap ring (2).

Figure 105
380 002 275

276A061050
D mount the hub onto the output flange.
D use the tool 380 002 275 to insert the sealing ring in-
side the flange with the edge orientated internally
and lubricate it with bearing lubricant.

Figure 103

276A061053

D Mount the O---ring (arrow).

276A061051
D use a press to mount the ball bearing.
64 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

Conclusive operations Figure 108

Proceed as follows:

Figure 106

276A061056
D Introduce the two centering dowell (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 107

Centering
screws

276A061055
D Mount centering screws (n. 2) (arrow) and position
the cover.
Do NOT invert the position of the cover.
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©65

BRAKE CALIPER OVERHAUL Figure 110

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 109 2
276C062D110

D unscrew the retaining screws (1) and remove the

plate (2);

. Hydraulic oil leakage may occur during

these operations.

3 Figure 111

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;
66 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

Figure 112 Reassembly

Proceed as follows:

Figure 113

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 114
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.
327B & 330B SECTION 6.1 Copyright
FRONT AXLE -- DRY DISC BRAKES ©67

Figure 115

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 116

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.
68 FRONT AXLE -- DRY DISC BRAKES SECTION 6.1 327BCopyright
& 330B ©

BRAKE DISC OVERHAUL Figure 117

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.
 Copyright ©

SECTION 6.1

FRONT AXLE --- WET DISC BRAKES

330B
Copyright ©
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©1

CONTENTS

Page Page

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 PLANETARY REDUCER OVERHAUL . . . . . . . . . . 29

First reduction: bevel pair . . . . . . . . . . . . . . . . . . . . . . 4 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Second reduction: hub and planetary train . . . . . . 10 Brake disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Braking assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Inspection of the dismantled parts . . . . . . . . . . . . . . 34
Operating brake unit . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Planetary reduction gear seals and thread---stops
application and bearings scheme . . . . . . . . . . . . . . 35
Brake system fittings . . . . . . . . . . . . . . . . . . . . . . . . . 12
Oil---bath brake assembly . . . . . . . . . . . . . . . . . . . . . 36
Operating brake unit . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brake actuation circuit seal inspection . . . . . . . . . . 38
SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . 14
Piston actuation travel inspection . . . . . . . . . . . . . . . 39
Bevel gear (first reduction) . . . . . . . . . . . . . . . . . . . . 15
Planet ---wheel holding plate assembly . . . . . . . . . . 39
Planetary train and hub (second reduction) . . . . . . 16
Brake unit and hub assembly . . . . . . . . . . . . . . . . . . 40
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . 17
Hub bearing preload determination . . . . . . . . . . . . . 45
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Planet ---wheel holding plate --- fixed gear
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 axial clearance determination . . . . . . . . . . . . . . . . . . 47

Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Brake cooling circuit seal inspection . . . . . . . . . . . . 47

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Concluding operations . . . . . . . . . . . . . . . . . . . . . . . . 48

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 FRONT DIFFERENTIAL OVERHAUL . . . . . . . . . . . 49

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . 25
Inspection of the disassembled parts . . . . . . . . . . . 53
Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Diagram of bearings and the application of
FRONT HUBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 thread---locks and distributor and differential
Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Diagram of the self---locking differential

assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
FRONT HUB REMOVAL-- REFIT . . . . . . . . . . . . . . . 27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

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330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©3

DESCRIPTION
The axle has independent wheels with double reduc- the crown wheel and pinion with differential (first reduc-
tion. tion). The structure is solidly connected to the automat-
The differential unit is composed of a box structure ic transmission box with a series of screws.
which contains the cylindrical wheel transmission and

Figure 1

276C062W001
1. Oscillating plate
2. Left hub
3. Left axle shaft
4. Differential and transfer case
5. Right axle shaft
6. Right hub
4 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

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
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©5

Figure 2

26912101
6 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

The differential is limited slip type. ficient and thus holds the braking torque constant for
It has a multiple disk clutch inserted between the differ- the whole useful life of the differential.
ential gear box (train carrier) and the crown wheels on The thrust on the disks is ensured by the sloped con-
each side. tact between the shaft and the pressure plate: therefore
The multiple disk clutch includes the external disks a greater radial peripheral thrust on the train carrier
connected to the differential gear box and internal disks shaft (from the ring bevel gear) will cause a greater axial
connected to the crown wheel gears by appropriate thrust on the disks.
pressure plates. The thrust on the disks generates a stall torque that
The internal disk friction surfaces have a patented mo- acts on the crown wheel.
lybdenum coating that ensures a constant friction coef-

Figure 3

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
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©7

Operation Under these conditions there is no relative motion be-

The driving torque coming from the propeller shaft is tween the two crown wheels and therefore the side pin-
transmitted by a universal joint to the bevel pinion. ions do not turn around their shaft which is integral to
From here the torque passes to the ring bevel gear, the differential gear box.
which is integral to the differential gear box. When the resistance of one wheel is greater than that
The differential is a gear for which the box represents of the other, or when the speed of the two wheels is not
the train carrier, that carries the differential gear carrier the same (vehicle on a road with bends) the crown
shafts and receives the driving torque, whereas the two wheel gears have a different rotation speed: the rele-
side gears, which represent the crown wheels, both of vant motion is permitted by the side pinions, that now
which rotate, receive the driving torque and transmit it turn around their shafts in directions opposite to each
to the axle shafts. other.
When both wheels are subject to the same stall torque Obviously at a lower crown wheel rotation speed the
or have the same speed (vehicle being driven on a transmitted driving torque is greater, and vice versa.
straight road), the ring bevel gear and the differential Therefore when the differential is operating, the wheel
gear box rotate as one, transmitting the torque in equal with a lower speed can transmit a greater torque,
parts to the two crown wheels, and from here to the two whereas the wheel with a higher speed can transmit a
axle shafts, that rotate at the same speed: the wheels lower torque.
transmit the same driving 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
Figure 4 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%.

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
8 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

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 5

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
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©9

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10 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

Second reduction: hub and planetary train

The second reduction is obtained by and planetary re- Legend (figure on following page)
duction unit with cylindrical wheels contained in the
wheel hub. 1. Planetary train upright
The hub is supported by two taper roller bearings (planet ---wheel holding plate)
mounted in dia. arrangement with a pre---load that can 2. Thrust spacer
be adjusted by a ring nut. The side pinion gears rotate 3. Planet ---wheel
on pivoting roller bearings. 4. Planetary train fixed gear
5. Planet ---wheel pin
Operation 6. Unused
7. Adjustment ring nut
The driving torque coming from the differential is trans-
8. Planetary 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. ”U” 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
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©11

Figure 6

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
12 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

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 oil pres- play between the disks and allows them to slip freely.
sure behind the control piston (6) through the fitting (7).
The discs are immersed in oil in order to ensure their
cooling: the circulation of the coolant occurs through Brake system fittings
two input and output fittings.
A special front sealing ring (4) prevents leakage of the Figure 7
cooling oil or entry of foreign matter. A double oil seal
ring (8) prevents the cooling oil from passing to the 3 2
wheel hub bearings.
1
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 5
8. Screw
9. Spring 6 276C061W009
10. Screw
1 Oil input
11. Bushing
2 Brake control input
12. Screw
3 Brake control air bleeder
13. O---Ring
4 Coolant output
14. Plug
5 Inspection plug
15. Sealing ring
6 Oil drain
16. Sealing ring
17. Plug
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
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©13

Operating brake unit

Figure 8

1
24
2
23
3
22
4
21
5
20

19
6

10

11

12

13

14

15

16

17

18

276C062W010
14 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

SPECIFICATIONS AND DATA

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)

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
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©15

Bevel gear (first reduction)

Figure 9

T269PT03
16 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

Planetary train and hub (second reduction)

Figure 10

Hub bearing pre ---load is

determined by the ring nut
tightening torque

Ring nut tightening torque:

1st tightening: 700 --- 900 Nm
(516.29 --- 663.80 lbf ft)
then loosen
2nd tightening: 450 Nm
(331.9 lbf ft)

Axial clearance
0.30 --- 0.70 mm
(0.012 --- 0.028 in)

276C061W012
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©17

TIGHTENING TORQUES

Figure 11

276C061W013
18 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

TIGHTENING TORQUES

Figure 12

276C061014
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©19

TOOLS
. Prior to ordering tools, refer to the matrix. The type of axle is found on a plate on the axle housing.

TYPE OF AXLE
DESCRIPTION 82.0984.3
82.0802.3 82.1233.3 82.0960.3
(no brake)

Wheel nut spanner 380002787

Seal ring sleeve driver 380002789 380002788 380002789

Seal ring sleeve driver 380002791 380002792 380002793

Thread ring spanner

380002794 --
(Differential)

Face seal installation tool 380002796 -- 380002796

380002797
Disc centering tool + -- 380002797+380002798
380002798

Seal ring sleeve driver 380002799 --

. The following tools are necessary when performing service repair on the differential.

Tool Number DESCRIPTION

380002274 Driver

380002275 Driver

380002282 Driver

380002283 Driver

380002316 Plug Gage

380002317 Stop Disc

380002325 Shaft

380002326 Dummy Differential Bearing Set

 20 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

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
 330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©21

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.
 22 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

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
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©23

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
 24 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

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
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©25

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 14
Figure 13

269NM221
269NM221
D arrange a suitably sized container, clean the plug
D clean the plug area and open the level plug (1). Lu- area and remove the level plug (1);
bricant should drip out of the hole; D remove drain plug (2) and fully drain the oil;
D top up the level as shown in the following para- D clean the drain plugs. Check that the threading is in
graph, if required; good condition. Replace the seal and apply sealant
D close the filler plug and fasten at the specified to both plugs and close them at the specified
torque. torque.

Proceed as follows to fill the system:

D fill until oil spills out of the hole on the plug (1);
D replace the seal, apply sealant onto the plug and
close it at the specified torque;
D run a road test, check the plug 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.
26 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

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 15 Figure 16

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 plug
D clean the plug area and open the level plug (1). Lu- area and remove the plug (1) and the drain plug (2);
bricant should drip out of the hole; drain all the lubricant.
D top up the level as shown in the following para- D clean the plug, check that the threading is in good
graph, if required; condition, replace the sealing ring with a new one
D close the filler plug. and close the drain plug.
D repeat the procedure for the other hub.
D arrange a suitably sized container, clean the plug
area and remove the plug (1) and the drain plug (2);
drain all the lubricant.
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©27

PLANETARY HUB REMOVAL---REPLACE

. Before starting any operation, make sure Before carrying out the removal of the hy-
draulic pipes, prepare appropriate plugs to
that all the precautions have been taken and
close the free ends.
all aspects regarding safety of the personnel
involved on the job have been made quite D disconnect the hydraulic pipes:
clear. --- service braking system (20);
Read the relevant instructions contained in --- brakes cooling system inlet (21);
SECTION 1 of this handbook. --- brakes cooling system outlet (22);
If in doubt ask someone who is more expert.
Comply to all the general recommendations . During this operation some hydraulic fluid
for correct execution of maintenance work. may spill out.
D disconnect the transmission half---shaft (18) from
Removal the hub following the instructions in SECTION 7;
Proceed as follows: D lower the suspension to obtain maximum extension
D bring the vehicle on a suitable flat, solid surface, of the shock absorbers;
switch off the engine, remove the key from the igni- D release the drive shaft from the universal joint for
tion switch, engage the parking brake and affix the easier access to the hub fastening nuts;
warning notices; D sling the hub using hooks and roper adequate for
D deactivate the battery isolator or disconnect the bat- the load and appropriate lifting equipment;
tery terminals to prevent any risk of a short circuit; D remove all the nuts (15)that fasten the hub to the
D block articulation by means of the steering lock bar, axle, keeping the related washers;
proceeding as indicated in SECTION 1; D carefully withdraw the hub (14).
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 separation of the

axle shaft from the hub.
D remove the wheel following the instructions in SEC-
TION 9;
28 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

Figure 17

18

15

14 20
21

22

276C061W027
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©29

PLANETARY REDUCER OVERHAUL Figure 19

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 slip off the axle shaft (1);
following the instructions provided in the
relative chapter. Figure 20

. Before proceeding, the brake caliper must

be removed following the instructions in the
relative chapter.

Disassembly
Proceed as follows:

Figure 18 1

276C062032
D remove the setscrew (1) of the ring nut;
D remove the locking ring nut (2) of the internally too-
thed crown wheel.
3 1
2
The ring nut is locked with thread ---stops.
276C061W030
To prevent damage to the threading, heat to
D mark the mutual position of the planet ---wheel hol- approximately 120˚C before unscrewing.
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);
30 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

D using a suitable lifting device, carefully remove the Figure 23

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 21

3
276C062D035
D remove the two oil seal rings (1) from the hub;
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);
D if necessary, remove the wheel---fastening screws
from the hub;
1
276C062D033 Figure 24
D use a suitable extractor to remove the internally too-
thed crown wheel (1);

Figure 22

1
1 2

2
276C061W036
4 D remove the screws (1) fastening the brake unit (2)
to the hub;
D carefully remove the brake unit from the hub and
3 place it on the workbench with the flange facing up-
276C062D034 wards.
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;
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©31

Figure 25 Figure 27

5
2 4
1 2
276C061W037 1
276C061D041
D remove the inner race (1) of the axle---side bearing
(A) and the spacer ring (2) from the hub; D remove the elastic ring (1) and spacer (2), then use
a suitable extractor to remove the ”U” joint flange (3)
Figure 26 from the ball bearing (4) and flange (5);
1 Figure 28

276C061D042
3
D remove the sealing rings;
276C061W040

D remove the retaining screws (1) and remove the

complete ”U” joint support (2) from the hub support
(3);
32 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

Figure 29 Figure 30

3
1

2 1

274A062029
D place the planet ---wheel holding plate on a suitable 276C062038
work surface; D remove the planet wheel (1) and relative shim rings
D use a punch to push the retaining pin (1) down in the (2);
pivot, freeing the pivot (2);
D extract the pivot (2) by pushing it towards the inside Figure 31
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..

274A062039
D remove the needle cages (arrow) from the planet ---
wheel;
D repeat the procedure for all the planet ---wheels.
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©33

Brake disassembly D remove the screw (1) and remove the spring (2) and
Proceed as follows: spacer (3) from the piston;

Figure 32 Wear protective gloves and safety goggles.

Hold the screw to avoid injuries caused by
the load of the springs.
4
3 D remove 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 35

2
276C062W040
D remove 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 33

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 34 D remove the sealing rings from the flange and the pi-
ston.
5
4

2
3
1
276C062W042
34 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

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---bath brake
D check the bell and the piston: they must not have
any deformations and/or ovalling;
D carefully clean the bell, especially the oil passages
and grooves;
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.
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©35

Planetary reduction gear seals and thread-- stops application and bearings scheme

LOCTITE 270
LOCTITE 270
MOLIKOTE

LOCTITE 262

LOCTITE 572

LOCTITE 638

Bearing B Bearing A

LOCTITE 270

LOCTITE 572 rubber

LOCTITE 270 steel

LOCTITE 638

LOCTITE 572 rubber

LOCTITE 270 steel

276C061W044
36 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

Oil -- bath brake assembly Figure 38

Proceed as follows:
2
Figure 36
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 37

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;
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©37

Figure 39

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]
38 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

Figure 40 Brake actuation circuit seal inspection

Proceed as follows:
1
Figure 41
2

1 2

276C062W049
D mount the peripheral sealing ring (1); 276C061W050
D mount the bell (2) onto the flange (3) and screw on D close the bleeding valve (1);
the retaining screws (4); D connect a manual high---pressure hydraulic pump
D mount any previously removed hydraulic fittings. 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.
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©39

Piston actuation travel inspection Planet-- wheel holding plate assembly

Proceed as follows: Proceed as follows:
D position the planet ---wheel holding plate horizontal-
Figure 42 ly;

Figure 43

274A062032
D mount the needle cages inside the planet gear;

276C061W051

D open the plug 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]
40 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

Figure 44 Brake unit and hub assembly

Proceed as follows:
2 Figure 46

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 45 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 47

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-
1
tion bush so that the pin holes match up; 1
Mount the pivot from the internal part of the
planet---wheel holding plate, otherwise its 276C062054
seat may be damaged due to the pivot dia- D insert the sealing ring (1) into the bushing (detail)
meter difference. and fill it completely with lubricating oil for bearings.
D mount the catch pin (3);
D repeat the procedure for all the planet ---wheels.
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©41

Front sealing ring assembly Figure 50

. 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. Do not touch
sealing surface with fingers.

Proceed as follows:

Figure 48

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 51

276C062W060
D mount the rubber ring (1) on the metal ring (2), set-
tling it on the groove.

Figure 49

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;
D if necessary, adjust the position of the ring in the
276C062W061 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.
42 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

Figure 52

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. Make sure face sealing surfa-
ces are absolutely clean, no finger points, or
debris.
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©43

Figure 53

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.
44 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

Figure 54

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).
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©45

Figure 55 Hub bearing preload determination

Proceed as follows:

Figure 57
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 attach them with
the setscrews; 276C062069
D apply MOLYKOTE lubricant on the hub support
Figure 56
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 (516-- 664 lb ft)
During the locking, rotate the hub back and
forth while 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 (332 lb ft)
During the locking, rotate the hub back and
1 forth while 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
clamp screw.
46 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

Figure 58 Figure 60

276C061055
D mount the sealing rings according to the assembly
direction indicated;
2
Figure 59 276C061057
D mount the complete ”U” joint support (1) onto the
hub (2) and screw on the retaining screws (3);

Figure 61

1
3
4
5
276C061056

D mount the flange (1) complete with sealing rings on- 1

to the ”U” joint flange (2);
276C061W070
D mount the ball bearing (3), spacer (4) and snap ring
(5); D insert the axle shafts (1) into the hub.
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©47

Planet-- wheel holding plate -- fixed gear axial clear- Brake cooling circuit seal inspection
ance determination Proceed as follows:
Proceed as follows:
Figure 63
Figure 62

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 (22
PSI) 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 (20 PSI)
D determine the thickness of the thrust spacer as fol- D close the fitting.
lows:
S = A -- B +0.30 to 0.70 mm (0.0118 to 0.0276 in)
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 to 0.70 mm (0.0118 to 0.0276 in)
D mount the chosen thrust spacer onto the planet ---
wheel holding plate.
48 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

Concluding operations

Figure 64

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.
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©49

FRONT DIFFERENTIAL OVERHAUL Figure 66

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.

276A061151
Disassembly
D Support the differential with a suitable lift.
. Before proceeding it is necessary to remove D Remove the retaining screws and remove the sup-
the front differential box from the automatic port flange complete with hub, hub support bearing
transmission by following the instructions in and differential conic roller bearing external ring.
Section 5 --- AUTOMATIC TRANSMISSION. D Repeat the operation for the other support flange.

Proceed as follows: Keep the details making up the right and left
D Position the housing on the support trestle using ap- output flanges separate.
propriate adaptation elements.
Figure 67
Figure 65

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.
50 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

Support flange disassembly Figure 70

. The operations described below are valid

for both flanges.
Proceed as follows:

Figure 68

276A061006
D Extract the snap ring and relative spacer.

Figure 71

276A061004
D Extract the external ring (1) of the differential conic
roller bearing and the spacer ring (2).

Figure 69

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.
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©51

Differential disassembly D Mark the positions of the cover and the differential
Proceed as follows: box.

Figure 72 Figure 75

276A061008 276A061011

D Use an extractor to remove both the internal rings of D Remove the cover.
the conic roller bearings from the differential. D Remove the shoulder rings, the driven/driving
discs, the planet ---wheel shoulder plate and the
Figure 73 planetary gear.
Do not invert the position of the discs.

Figure 76

276A061009
D Loosen the hexagonal head retaining screws.

Figure 74
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.
52 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

Pinion disassembly Figure 79

Proceed as follows:

Figure 77

276A061015

Provide a suitable support to prevent the

276A061013 pinion from falling.
D Using a pad and a press, extract the pinion from the
The bushing is blocked with thread ---locks.
external box.
To prevent damaging the threading, heat it to
D Recover the internal ring of the external conic roller
approximately 120˚C (248 ˚F) before un-
bearing and the relative spacer.
screwing.
D Remove the oil seal ring from its seat.
D Remove the bushing.
Figure 80
Figure 78

276A061016
276A061014 D Use an extractor and a press to remove the internal
D Remove the washer and the splined sleeve. 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.
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©53

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 212 ˚F 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 teeth: replace it if it has
rings and bearings with a suitable adjust-
pits, cracks and/or cavities.
er;
Planet ---gears
D lubricate the bushings, sealing rings and
D check the condition of the teeth: 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 teeth of the crown wheel and the pin-
ion 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.
Bushings
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.
54 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

Diagram of bearings and the application of thread-- locks and distributor and differential seals

276A061017
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©55

Determination of the pinion axial position spacer thickness S1

Proceed as follows:

Figure 81

380 002 325

380 002 326 380 002 326

380 002 316

380 002 317

276A061018
D Insert the tools 380 002 326 +380 002 325 into the
differential support seats and the tools 380 002 316
+380 002 317 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
Example:
dimension a: 224.00 mm (8.8189 in)
dimension b: 2.50 mm (0.09843 in)
The dimension b must be determined with a
thickness gauge.
dimension c: 15.00 mm (0.5906 in)
(1/2 measuring rod diameter)
dimension H= a+b+c: 241.50 mm (9.5078 in)
56 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

Figure 82 D Determine the thickness of the spacer as follows:

S1 = H -- X
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 (0,0472 in)
D Remove the special tools used for the measure-
ments.

Figure 84
1731272
D Determine the thickness S of the internal conic roller
bearing (A).
Example:
Dimension d: 90.00 mm (3.5433 in)
Value measured e: 47.70 mm (1.8779 in)
Bearing thickness = d --- e: 42.30 mm (1.6654 in).

Figure 83

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 380 002 282
where
V = value engraved on the surface of the pinion
S = bearing thickness

Example:
engraved value V: 198.00 mm (7.7953 in)
bearing thickness S: 42.30 mm (1.6653in)
height X = 240.30 mm (9.4606in).
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 380 002 282, mount the external
race of bearing (B) in its seat.
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©57

Determination of the bearing preload spacer thickness Figure 87

S2 and assembly of the pinion
Proceed as follows:

Figure 85

276A061024
D Mount the splined sleeve.

Figure 88

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 86

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 (2.6 -- 3.3 lb ft)
276A061023 D Otherwise, correct the rolling resistance by using a
D Mount the pinion in the box. spacer S2 with different thickness.
D Heat the internal ring of the external conic roller D In particular:
bearing (B) and mount it on the pinion. --- 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.
58 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

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 89

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
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©59

Complete self---locking differential assembly . The numbering of the parts corresponds to

the legend on the previous page.
Figure 90

A E

B F

C G

D H

269A061027
Do as follows: E. Assemble the shafts (10) and planet ---wheel gears
A. Position the steel shoulder ring (3) and then the (9) and mount them on the crown wheel.
brass shoulder ring (4); F. Mount the second crown wheel gear (8) on the plan-
B. Alternatively mount an externally slotted disc (5A, et ---wheel gear unit.
driven disc) and an internally slotted disc (6A, driv- G. Mount the second planet ---wheel shoulder plate (7)
ing disc) until using up all the discs. with the flat side up.
H. Alternatively mount an internally slotted disc (6B,
The last disc is a driving disc.
driving disc) and an externally slotted disc (5B, driv-
en disc) until using up all the discs.
C. Mount the planet ---wheel shoulder plate (7) with the
The first disc is a driving disc.
flat side against the driving disc.
D. Mount the crown wheel gear (8) on the shoulder
plate.
60 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

Determination of the disc pack axial clearance

Figure 93
Do as follows:

Figure 91

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 92 Figure 94

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.
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©61

Differential assembly
Figure 97
Do as follows:

Figure 95

Centering screws

276A061034

276A061032 D Heat the crown wheel---side conic roller bearing in-

ner track (C) and position it against the differential
D Mount centering screws (n. 3) (arrow) and position
centerbox until contact.
the crown wheel.
D Heat the planet ---wheel side conic roller bearing in-
ner track (D) and position it against the differential
Figure 96 centerbox.
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 98

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.
62 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

Determination of the differential bearing preload

Figure 101
Proceed as follows:

Figure 99
aligning screws

276A061038
D Mount aligning screws (n. 2) (arrow) and position
276A061036
the flange.
D Mount the spacer S3 (1) having thickness equal to D Temporarily fix the flange by tightening the screws
that removed during disassembly onto the crown to the prescribed torque.
wheel---side support flange. D Working from the opposite side (planet ---gear side)
D Mount the external ring (2) of the crown wheel---side mount the external ring of the conic roller bearing
conic roller bearing (C). (D) onto the relative internal ring already installed on
The two bearings must NOT be inter- the differential.
changed since they have different widths..
Figure 102

Figure 100

276A061039
D Determine the dimension a
276A061037
D Mount the O---ring (arrow).
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©63

Figure 104
Figure 103

276A061036
276A061040 D Mount the chosen spacer S4 (1) onto the planet ---
D Determine the dimension b gear---side support flange.
D Determine the thickness of the spacer as follows: D Mount the external ring (2) of the planet ---gear ---
S4 = a -- b +(0.30-- 0.40 mm) (0.0118-- 0.0157 in) side conic roller bearing (D).
where
a = distance between the box attachment surface and The two bearings must NOT be inter-
bearing external ring side changed since they have different widths.
b = distance between the conic roller bearing shoulder
and the cover attachment surface Figure 105
S4 = bearing spacer thickness (D)
0.30--- 0.40 = differential bearing preload in mm

Example:
dimension a: 141.60 mm (5.5748 in)
dimension b: 139.90 mm (5.5079 in)
Difference a --- b: 1.70 mm (0.0669 in)
Thickness S4: 1.70 + 0.30 = 2.00 mm
0.0669+0.0118=0.07887in

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) (2.2-- 2.9 lb ft)

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.
64 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

Pinion---crown wheel clearance check

Proceed as follows:

Figure 106

276A061043
D Mount a dial indicator 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 pinion;
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 107

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
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©65

Verification of the pinion---crown wheel engagement D Cover a dozen teeth of the crown wheel with Prus-
impression area sian blue, lubricated with minium, or another paint
Do as follows: 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
Figure 108 contact of the teeth, leaving zones exposed with the
exact dimension, shape and location of contact.

276A062176

Figure 109

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.
66 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

Pinion assembly Figure 112

Proceed as follows:
D Remove the locking bush and the splined sleeve.

Figure 110

380 002 274

276A061025
D Mount the washer, mount the bush and tighten it to
the prescribed torque.

276A061047

D Use the tool 380 002 274 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 380 002 274 enables the correct ax-
ial positioning of the sealing ring.

Figure 111

276A061024
D Mount the splined sleeve.
330B SECTION 6.1 Copyright
FRONT AXLE -- WET DISC BRAKES ©67

Support flange assembly Figure 115

. The operations described below are valid

for both flanges.
Proceed as follows:

Figure 113

276A061052
D Mount the spacer (1) and then the elastic ring (2).

Figure 116

380 002 275

276A061050
D mount the hub onto the output flange.
D use the tool 380 002 275 to insert the sealing ring in-
side the flange with the edge orientated internally
and lubricate it with bearing lubricant.

Figure 114

276A061053

D Mount the O---ring (arrow).

276A061051
D use a press to mount the ball bearing.
68 FRONT AXLE -- WET DISC BRAKES SECTION 6.1 Copyright
330B ©

Conclusive operations Figure 119

Proceed as follows:

Figure 117

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 118

centering screws

276A061055
D Mount centering screws (n. 2) (arrow) and position
the cover.
Do NOT invert the position of the cover.
 Copyright ©

SECTION 6.2

INTERMEDIATE AXLE --- DRY DISC BRAKES

Copyright ©
 327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES © 1

CONTENTS

Page Page

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Planet ---wheel holding plate assembly . . . . . . . . . . 38

Tandem transfer case . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Brake unit and hub assembly . . . . . . . . . . . . . . . . . . 39

First reduction: bevel gear pair . . . . . . . . . . . . . . . . . . 5 Hub bearing preload determination . . . . . . . . . . . . . 41

Second reduction: hub and planetary train . . . . . . 12 Planet ---wheel holding plate --- fixed gear axial
clearance determination . . . . . . . . . . . . . . . . . . . . . . 42
Brake pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Concluding operations . . . . . . . . . . . . . . . . . . . . . . . . 43
SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . 15
TANDEM AXLE AND DIFFERENTIAL
Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Brake disc and caliper . . . . . . . . . . . . . . . . . . . . . . . . 15 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Splitter unit and bevel gear pair (first reduction) . . 16 Inspection of the disassembled parts . . . . . . . . . . . 49
Hub and planetary gear (second reduction) . . . . . 17 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . 18 Differential seals and thread---stops application
and bearings scheme . . . . . . . . . . . . . . . . . . . . . . . . . 50
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Complete limited---slip differential assembly . . . . . 51
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Crown wheel and bearings assembly . . . . . . . . . . . 53
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Determination of the pinion axial position
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 spacer (S1) thickness . . . . . . . . . . . . . . . . . . . . . . . . . 54
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Check of the pinion---crown wheel clearance . . . . 56
Replacement of the brake pads . . . . . . . . . . . . . . . . 26 Verification of the pinion---crown wheel
engagement impression area . . . . . . . . . . . . . . . . . . 57
Breaking---in of the pads . . . . . . . . . . . . . . . . . . . . . . 27
Idle gear bearing preload determination . . . . . . . . . 58
Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Pinion bearing preload determination . . . . . . . . . . . 60
Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Idle gear and pinion assembly . . . . . . . . . . . . . . . . . 61
INTERMEDIATE AXLE REMOVAL-- REFIT . . . . . 30
Differential bearing preload determination . . . . . . . 62
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Coutershaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . 63
BRAKE CALIPER DETACHMENT--
REATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 BRAKE CALIPER OVERHAUL . . . . . . . . . . . . . . . . 65

Detachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Reattachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Inspection of the disassembled parts . . . . . . . . . . . 66

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
PLANETARY REDUCER OVERHAUL . . . . . . . . . . 33
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 BRAKE DISC OVERHAUL . . . . . . . . . . . . . . . . . . . . 68

Inspection of the dismantled parts . . . . . . . . . . . . . . 36 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Planetary reduction gear seals and thread---stops Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

application and bearings scheme . . . . . . . . . . . . . . 37
2 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

Page left intentionally blank

327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY 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 planetary reducer (second reduction).

Figure 1

8
7

4
3 2
5

276C062D001
1. Rear suspension
2. Hub with planetary gears
3. Differential case
4. Motion input flange
5. Axle
6. Upper stabilizer bar
7. Service brake caliper
8. Service brake disc
4 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

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

1 3

5 7

276C062002
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
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY 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 dia. arrangement with preload that 2. Internal conic roller bearing
can 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 dia. arrangement with preload that can be 7. Pinion spur gear
adjusted 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
6 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

Figure 3

A
1 16

2 15
3
14
4

13

12
9
11
10

27

26 16

17
25

18
24

19

23 20
21
22
276C062003
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES © 7

Figure 4

276C062004
8 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

The differential is a limited---slip differential, characteri- The axial thrust on the discs generates a resistant tor-
zed by the positioning of a multiple---disc clutch betwe- que that acts on the crown wheel when the crown whe-
en the differential case (upright) and the crown wheels el tends to rotate with respect to the differential case
(sun gears) for each side. due to the speed difference between the two wheels.
The multiple---disc clutch includes external discs con- This resistant torque depends, with equal axial thrust,
nected to the differential case and internal discs con- on the dimensions and the coating material of the
nected to the planetary gears. discs.
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.

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
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES © 9

Operation
The torque coming from drive shaft is transmitted Under these conditions, there is no relative motion bet-
through a ”U” joint to the bevel pinion. ween the two crown wheels, and thus the planet ---whe-
From this, the torque passes to the ring bevel gear, els do not rotate around their shaft which is integral with
which is integral with the differential case. the differential case.
The differential is a gear train in which the case repre- When the resistance of one wheel exceeds that of the
sents the upright, that holds the planet ---wheel holding other or when the speed of the two wheels is no longer
shafts and receives the torque, while the two crown equal (vehicle traveling a curved path) the planetary
wheels represent the sun gears, both rotary, that recei- gears assume a different rotation speed: their relative
ve the torque and transmit it to the axle shafts. motion is allowed by the presence of the planet ---whe-
When both the wheels are subject to the same resistant els, which now rotate around their own shaft in opposi-
torque or have the same speed (vehicle traveling along te directions.
a straight path), the ring bevel gear and the differential Naturally, a slower rotation speed of the crown wheel
case rotate as a block, transmitting the torque in equal corresponds to a greater driving torque transmitted,
parts to the two crown wheels, and from these to the and vice versa.
two axle shafts that rotate at the same speed: the whe- Thus when the differential operates the wheel that has
els transmit the same driving torque. a slower speed, it is able to transmit a greater driving
torque, while the one with the greater speed transmits
a smaller torque.
Figure 6 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
LH RH it encounters practically zero resistance: in this case, a
normal differential causes the free rotation of the wheel
that slips 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---slip 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 traction and that on the wheel with less
traction.
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
276C062006 respect to a total of 100%).
The right wheel with the same traction as the left.

RH: right side: torque supplied is 50% of the total

LH: left side: torque supplied is 50% of the total
10 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

If the two wheels do not have the same traction, the re- In practice, the multiple---disc clutches automatically
sistant torque generated by the multiple---disc clutches compensate the traction variations of the wheels from
partially locks the crown wheel on the side having less the left side and right side of the vehicle, without requi-
traction and increases the torque supplied by the ring any driver operation. It is thus possible to apply a
crown wheel on the side with more traction. In other much larger driving force when using the vehicle, and
words, the braking torque replaces the reaction torque prevent skidding when one of the wheels encounters
missing from the side of the wheel with less traction. a surface lacking traction.
In this manner, considering the previous case in which
one wheel loses traction, this wheel is not able to turn
freely and thus the other wheel will still be able to tran-
smit part of the driving torque, ensuring at least some
traction capacity of the axle.

Figure 7

LH RH

276C062007

Left wheel with less traction than the right wheel (exam-
ple)

RH: right side: torque supplied is 72.5% of the total

LH: left side: torque supplied is 27.5% of the total
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©11

Page left intentionally blank

12 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

Second reduction: hub and planetary train

The second reduction is obtained by an planetary Legend (figure on following page)
reducer with cylindrical wheels in the wheel hub.
The hub is supported by two taper roller bearings 1. Planetary train upright
mounted in dia. arrangement with preload that can be (planet ---wheel holding plate)
adjusted by a ring nut. The planetary gears turn on pi- 2. Thrust spacer
voting roller bearings. 3. Planet ---wheel
4. Planetary 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. Planetary 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
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©13

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
14 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

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
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©15

SPECIFICATIONS AND DATA

Hub
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

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
16 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

Splitter unit and bevel gear pair (first reduction)

Figure 10

Tandem transmission
Cuscinetti conic
conici rinvio tandem: Tandem countershaft
Gioco assiale axial
albero rinvio
bearing preload
precarico 1.0 Nm (0.74 lbf ft) tandem:clearance:
(0.05 --- 0.2 mm)
1.0 Nm
(senza (0.74
anelli lbf ft)
di tenuta) (0.002
0.05---0.2 mm--- (0.002---0.008
0.008 in) in)

Pinion bearing
Cuscinetti
preload:pignoni:
precarico 1.5 --- 1.8 Nm Crown wheel and pinion
1.5---1.8 Nm
(1.11 --- 1.17 lbf ft) Giococlearance:
coppia conica:
(1.11---1.17 lbf ft)
vedere
see valuevalore incisoon
engraved
sulla corona
the crown wheel

Self ---blocking discs axial

Gioco assiale dischi
clearance:
autobloccante:
0.48 mm (0.019 0.48in)mm
(0.019 in)
minimum(minimo)

Differential
Cuscinettibearing preload:
differenziale:
5.0---5.5 Nm (3.69---4.06
precarico lbf ft)
5.0 --- 5.5 Nm
(including
(3.69pinion
--- 4.06 and
lbf ft)trans-
mission)
(compreso anello di tenuta)

276C062011
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©17

Hub and planetary gear (second reduction)

Figure 11

Hub bearing pre ---load is

determined by the ring nut
Ring nut tightening torque: tightening torque
1st tightening: 700 --- 900 Nm
(516.29 --- 663.80 lbf ft)
then loosen
2nd tightening: 450 Nm
(331.9 lbf ft)

Axial clearance
0.30 --- 0.70 mm
(0.012 --- 0.028 in)

276C062D012
18 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

TIGHTENING TORQUES

Figure 12

276C062D013
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©19

TIGHTENING TORQUES

Figure 13

276C063D015
20 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

TOOLS
. Prior to ordering tools, refer to this matrix. The type of axle is found on a plate on the axle housing.

TYPE OF AXLE
DESCRIPTION 82.0905.3 82.0689.3 82.0690.3 82.1249.3 82.1232.3 82.0832.3
(327B) (327B/330B) (330B) (327B) (330B) (330B)

Wheel nut spanner 380002787

Seal ring sleeve driver 380002788

Seal ring sleeve driver 380002790 380002791 380002792 380002793

Thread ring spanner 380002794

380002794 --
(Differential) 380002795

Seal ring sleeve driver -- 380002799 --

327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©21

Page left intentionally blank

 22 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

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
 327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©23

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.
 24 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

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
 327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©25

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
26 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

MAINTENANCE
The braking system components are funda- Figure 15
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 14

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;
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©27

Remove the dirt using a NON ---metallic Breaking -- in of the pads

brush and a vacuum cleaner.
Visually examine the dust covers, and check During this procedure there may be an
that there is no seeping of hydraulic fluid. emission of unpleasant vapors and odors
If irregularities are found, proceed to the originating from the friction material of the
brake caliper overhaul. pads.
After replacement of the brake pads, they must be
Figure 16 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.

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 17

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.
28 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

Checking oil level Changing the oil

Proceed as follows:
Collect and dispose of used lubricants and
fluids, according to the laws in force
Final reductions
Proceed as follows to drain the system:

Figure 18 Final reductions

Figure 20

1
1

276C062020

D take the reference on a hub to horizontal position 276C062022

(see arrow); D take the reference on the hub to horizontal position
D clean the plug area and open the level plug (1). Lu- (see arrow);
bricant should drip out of the hole; D arrange a suitably sized container, clean the plug
D top up the level as shown in the following para- area and remove the plug (1) and the drain plug (2);
graph, if required; drain all the lubricant.
D close the filler plug. D clean the plug, check that the threading is in good
condition, replace the sealing ring with a new one
Axle and close the drain plug.
D repeat the procedure for the other hub.
Figure 19 D arrange a suitably sized container, clean the plug
area and remove the plug (1) and the drain plug (2);
drain all the lubricant.

276C062021
D clean the area of the plug, then open the plug (Fig.
2, ref. 1): the lubricant must leak from the hole;
D if necessary, restore the level until it overflows from
the same plug;
D close the plug.
D check that the breather is perfectly clean and ope-
rational.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©29

Axle To fill the oil, proceed as follows:

Figure 21 Final reductions

Figure 23

276C062021
D arrange a suitably---sized container under the drain
plug, clean the plug areas and then remove the fil-
ling plug (1); 276C062020

Figure 22 D refill with the prescribed lubricant until it overflows

from the hole of the level plug (1);
D replace the sealing ring with a new one and close
the plug;
D repeat the procedure for the other hub.

Ponte

Figure 24

2
1

276C062021
276C062024 D refill with the prescribed lubricant until it overflows
D remove the drain plug (1) and completely drain the from the hole of the filling plug (1);
lubricant; D replace the sealing ring with a new one and close
D clean the plugs, check that the threading is in good the plug;
condition, replace the sealing ring with a new one D perform a test drive and then recheck the level (1);
and close the drain plug. D if necessary, top up with the prescribed lubricant un-
til it overflows from the hole, repeat the test drive and
recheck the level.
30 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

INTERMEDIATE AXLE REMOVAL---REFIT

. Before starting any operation, make sure D disconnect the hydraulic pipelines:
--- service braking system (20);
that all the precautions have been taken and
all aspects regarding safety of the personnel . Hydraulic oil leakage may occur during
involved on the job have been made quite
these operations.
clear .
Read the relevant instructions contained in D disconnect the drive shaft on the input side (18) and
SECTION 1 of this handbook. output side (19) following the instructions in SEC-
If in doubt ask someone who is more expert. TION 7;
Comply to all the general recommendations D remove both the locking bolts (10) fastening the
for correct execution of maintenance work. tie---rod to the bracket;
D working from both sides of each rocker arm, remove
the split pin and unscrew the locking nut (8) of the
Removal
rocker arm pin;
Proceed as follows: D slip the pin (9) off the rocker arm, recovering the
D Bring the vehicle on a suitable flat, solid surface, washers (6) and the guide bushings (7), disengag-
switch off the engine, remove the key from the igni- ing the rocker arm from the axle;
tion switch, engage the parking brake and affix the D carefully lower the axle and slip it off the vehicle.
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 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 lines, pre-
pare suitable plugs to close the free.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©31

Figure 25

276C062D027
32 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

BRAKE CALIPER DETACHMENT --- Figure 27

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.

276C062D029
Detachment
Do as follows: D disconnect the braking system hydraulic connector
D bring the vehicle onto an appropriately solid flat sur- (4) and plug it to prevent fluid leaks;
face, shut off the engine, remove the key from the
ignition switch, engage the parking brake and affix
. Hydraulic oil leakage may occur during
the indication signs; these operations.
D disconnect the battery---disconnect switch or dis- D support the caliper (2) appropriately, remove the re-
connect the battery terminals in order to eliminate taining screws (3) of the support bracket and re-
any risk of short ---circuit; move the caliper complete with the bake pads.
D block the articulation by means of the steering lock
bar, operating as indicated in SECTION 1; Reattachment
D block the rear wheels appropriately; Proceed to the reattachment by following the detach-
D use a hydraulic lift to raise the chassis until the rear ment steps in the reverse order.
wheels are off the ground;
D disassemble the wheel concerned; After reassembled, perform a bleeding of
the brake hydraulic circuit following the in-
Figure 26 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;
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©33

PLANETARY REDUCER OVERHAUL Figure 29

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 slip off the axle shaft (1);
. Before proceeding, the brake caliper must Figure 30
be removed following the instructions in the
relative chapter.

Disassembly
Proceed as follows:

Figure 28

276C062032

D unscrew the setscrew (1) of the ring nut;

3 1 D remove the locking ring nut (2) of the internally too-
thed crown wheel.
2
276C062D030
The ring nut is locked with thread ---stops.
D mark the mutual position of the planet ---wheel hol- To prevent damage to the threading, heat to
ding plate and the hub; approximately 120˚C (248 ˚F) before un-
D loosen and remove all the retaining screws (1); screwing.
D remove the planet ---wheel holding plate assembly
(2) and O---ring (3) and recover the thrust spacer
ring (4);
34 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

D using a suitable lifting device, carefully remove the Figure 33

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 31

2
276C062D036

D Unscrew the retain screws (1) and remove the brake

disc (2);

Figure 34

1
1
2

1
276C062D033

D use a suitable extractor to remove the internally too-

thed crown wheel (1);

Figure 32

1 2

5 3
276C062D035
D remove the two oil seal rings (1) from the hub;
D use a suitable extractor to remove the outer race (2)
4 of the axle---side bearing (A) and the outer race (3)
of the wheel---side bearing (B);
D if necessary, remove the wheel---fastening screws
from the hub;
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;
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©35

Figure 35 Figure 37

2
276C062038
1 D remove the planet wheel (1) and relative shim rings
276C062D037 (2);
D remove the screws (1) fastening the brake unit (2) Figure 38
to the hub;

Figure 36

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.

. 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..
36 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

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---bath 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.
During reassembly, consider the following
general observations:
D heat, to 212 ˚F 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.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©37

Planetary reduction gear seals and thread-- stops application and bearings scheme

276C062D044
38 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

Planet-- wheel holding plate assembly Figure 40

Proceed as follows:
D position the planet ---wheel holding plate horizontal- 2
ly;

Figure 39

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 41

2
3

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 bushing 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 pin (3);
D repeat the procedure for all the planet ---wheels.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©39

Brake unit and hub assembly Figure 43

Proceed as follows:

Figure 42

3
2
1
1

1 276C062054
276C062053
D insert the sealing ring (1) into the bushing (detail)
D place the hub vertically; and fill it completely with lubricating grease for bea-
D using a suitable introducer, mount the outer race (1) rings.
of the wheel---side conic roller bearing (B) and the
outer race (2) of the axle---side conic roller bearing Figure 44
(A);
D mount the inner race (3) of the axle---side conic roller 2
bearing (A);

276C062D055

D mount the brake disc (1) on the hub;

D insert retaining screw (2) and tighten.
40 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

Figure 45

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.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©41

Figure 46 Hub bearing preload determination

Proceed as follows:

Figure 48
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 attach them with
the setscrews; 276C062069
D apply MOLYKOTE lubricant on the hub support
Figure 47
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 (516-- 664 lb ft)
During the locking, rotate the hub back and
forth striking it with a plastic hammer to set-
tle 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 (332 lb ft)
During the locking, rotate the hub back and
1 forth while 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 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 insert the set
screw.
42 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

Figure 49 Planet-- wheel holding plate -- fixed gear axial clear-

ance determination
Proceed as follows:

Figure 50

2
3
4
5 A
276C062D070
B
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.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©43

Concluding operations

Figure 51

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.
44 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

TANDEM AXLE 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 52

4
3

2
1

276C062D080

D remove the “U“ joint mont input flange stop nut (1); D mark the relative position between gear box and ax-
D using a suitable puller, remove the flange (2); le;
D remove the output flange stop nut (3); D loosen and remove the screws (3) fastening the ex-
D using a suitable puller, remove the flange (4); 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.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©45

Differential disassembly
Figure 53 Proceed as follows:

Figure 55
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 54 D loosen the retaining screws and remove the diffe-
rential semicase;

Figure 56

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 removing the retaining
screws.
46 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

Idle gear and pinion disassembly

Figure 59
Proceed as follows:

Figure 57
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 60
D straighten the dent and remove the pinion stop nut
(2).

Figure 58

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 remove 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.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©47

Figure 61

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 62

276C062087
D using a suitable puller, remove the inner race (1) of
bearing (E) from the gear

Figure 63

274A062055
D using a suitable puller (1), remove the inner race (2)
of bearing (A).
48 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

Counter shaft disassembly

Proceed as follows:

Figure 64

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 snap 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.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©49

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 212˚F 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 teeth: 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 teeth: replace it if it has with maximum precision.
pits, cracks and/or cavities; Imprecise measurements lead to bad con-
D check the coupling surfaces with the pins. tact of the bevel gear and thus make it ne-
cessary to repeat the procedure.
Damage to a single element entails the re-
placement of the entire gear unit.

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 teeth of the crown wheel and the pi-
nion 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 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.

Bushings
D check the threading for the bearing locking
bushing: 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.
50 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

Differential seals and thread-- stops application and bearings scheme

Figure 65

LOCTITE 572 (rubber )

LOCTITE 270 (steel )
LOCTITE 262
LOCTITE 510
LOCTITE 262

BEARING F BEARING E

EPPLE 33

MOLYKOTE
LOCTITE 572 (rubber )
LOCTITE 270 LOCTITE 270 (steel )

BEARING B BEARING A

LOCTITE 262

LOCTITE 510

LOCTITE 510 LOCTITE 262

LOCTITE 510

LOCTITE 262 LOCTITE 270

LOCTITE 262

GH 2 GH 1

BEARING D BEARING C

LOCTITE 262

LOCTITE 262
276C062090
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©51

Complete limited-- skid differential assembly

Proceed as follows:

. Refer to the following figure.

D check the following measurements:
SP1 = 3.10 mm (0.1220 in) minimum;
SP2 = 2.15 mm (0.0846 in) minimum.
D otherwise, use shoulder discs with a greater thick-
ness;
D mount the shoulder ring (2) and snap 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 snap 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 mm (2.0787 in) < A < 53.27 mm (2.0972 in)
D when finished, check that dimension B falls within
the prescribed values;
B < 0.48 mm (0.0189 in)
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.
52 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

Figure 66

1. Differential semicase
2. Shoulder ring
3. snap ring
4. Semicase shoulder disc SP1
5. Driven (N.4) and driving (N.4) discs
6. Crown wheel shoulder disc SP2
7. Snap 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
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©53

Crown wheel and bearings assembly

Figure 67

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 68

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.
54 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

Determination of the pinion axial position spacer (S1) thickness

Figure 69

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
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©55

Figure 70

276C062093
D heat the inner race of bearing (A) and mount it on the
pinion;

Figure 71

4 1

6 3
5

276C062094

D position the chosen pinion position spacer (S1) (1) D mount the outer race (4) of bearing (B) until it rests
in its seat; against the box;
D mount the outer race (2) of bearing (A) until it rests D mount the inner race (5) of bearing (B) on the pinion;
against spacer S1; D apply MOLYKOTE on the pinion threading and on
D insert the pinion (3) into the external box; the threading and contact area of the stop nut;
D mount the pinion box on the external box and D mount the stop nut (6) and tighten it until there is no
tighten the retaining screws to the prescribed play in the bearings.
tightening torque;
56 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

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 72 play in the bearings;

Figure 74

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 73 17312104

D mount a dial indicator at a right angle with respect

to the external diameter of the crown wheel’s too-
thed 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 75
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).
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©57

Verification of the pinion-- crown wheel engagement D cover a dozen teeth of the crown wheel with Prus-
impression area sian blue, lubricated with minium, or another paint
Proceed as follows: or dye that can be easily removed;
D make a complete rotation of the crown wheel by
Figure 76 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;

17312106

Figure 77

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;
58 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

Idle gear bearing preload determination Figure 80

Proceed as follows:

1
Figure 78

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 79

1
276C062096
D mount the bearing (F) snap stop ring (1);
D mount the complete bearing (F) (2) until it rests
against the snap 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.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©59

Figure 81 Figure 82

1 2

2 1

276C062099

276C062098 D tighten the adjustment ring nut (1) until obtaining

D mount the flange (1), inserting it inside bearing (F); the prescribed value for the bearing rolling torque.
D apply MOLYKOTE on the gear threading and on the Rolling torque for gear bearings
threading and contact area of the stop nut; 1.0 Nm
D unscrew the ring nut by two notches;
Use a new stop nut. D fix the locking plate (2) of the ring nut by screwing
on the clamp screw.
D mount the stop nut (2) and tighten it to 850 Nm (630 When finished, remove the external box,
lf ft). then remove the idle gear by unscrewing the
stop nut.
60 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

Pinion bearing preload determination

Proceed as follows:

Figure 83

5 2

6 1

276C062100

D insert the pinion (1), complete with inner race of the D mount the stop nut (6) and tighten it to the prescri-
conic roller bearing (A), into the external box; bed torque;
D mount the coaxial gear (2), spacer (3) and spacer
Block the coaxial gear during this operation.
S2 (4), which were removed during disassembly,
onto the pinion;
D mount the pinion box on the external box and tigh- D use a suitable tool to check that the rolling torque
ten the retaining screws to the prescribed tightening falls within the prescribed values:
torque; Rolling torque for pinion bearings
D mount the inner race (5) of conic roller bearing (B) 1.5-- 1.8 Nm
on the pinion; D otherwise correct the rolling resistance by using a
D apply MOLYKOTE on the pinion threading and on spacer S2 with a different thickness;
the threading and contact area of the stop nut; D In particular:
Use a new stop nut. --- 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.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©61

Idle gear and pinion assembly Figure 86

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; 1
Figure 84

2
1

276C062102
D mount the inner race (1) of bearing (B);
D mount the pinion stop nut (2) and tighten it to the
prescribed torque;

3 Figure 87

276C062101
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;

Figure 85

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.
D mount the cover and tighten 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.
62 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

Differential bearing preload determination Figure 89

Proceed as follows:

Figure 88

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.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©63

Coutershaft assembly
Proceed as follows:

Figure 90

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-- 0.20 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
64 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

Figure 91

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.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©65

BRAKE CALIPER OVERHAUL Figure 93

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 92 2
276C062D110

D remove the retaining screws (1) and remove the

plate (2);

. Hydraulic oil leakage may occur during

these operations.

3 Figure 94

2 3

276C061D060
2
D remove 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;
66 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

Figure 95 Reassembly
Proceed as follows:

Figure 96

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 97
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
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.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- DRY DISC BRAKES ©67

Figure 98

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 99

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.
68 INTERMEDIATE AXLE -- DRY DISC BRAKES SECTION 6.2 Copyright
327B & 330B ©

BRAKE DISC 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 experien-
ced person.
Furthermore, respect all the general recom-
mendations for a correct execution of the
maintenance interventions.

Disassembly
Proceed to the removal 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.
 Copyright ©

SECTION 6.2

INTERMEDIATE AXLE --- WET DISC BRAKE

Copyright ©
 327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE© 1

CONTENTS

Page Page

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Oil---bath brake assembly . . . . . . . . . . . . . . . . . . . . . 38

Tandem transfer case . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Brake actuation circuit seal inspection . . . . . . . . . . 40

First reduction: bevel gear pair . . . . . . . . . . . . . . . . . . 5 Piston actuation travel inspection . . . . . . . . . . . . . . . 41

Second reduction: hub and planetary train . . . . . . 12 Planet ---wheel holding plate assembly . . . . . . . . . . 41

Braking assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Brake unit and hub assembly . . . . . . . . . . . . . . . . . . 42

Brake system fittings . . . . . . . . . . . . . . . . . . . . . . . . . 14 Hub bearing preload determination . . . . . . . . . . . . . 47

Operating brake unit . . . . . . . . . . . . . . . . . . . . . . . . . 15 Planet ---wheel holding plate --- fixed gear axial
clearance determination . . . . . . . . . . . . . . . . . . . . . . 48
SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . 16
Brake cooling circuit seal inspection . . . . . . . . . . . . 49
Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Concluding operations . . . . . . . . . . . . . . . . . . . . . . . . 49
Splitter unit and bevel gear pair (first reduction) . . 17
TANDEM TRANSMISSION AND DIFFERENTIAL
Hub and epicyclic gear (second reduction) . . . . . . 18 OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . 19 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Inspection of the disassembled parts . . . . . . . . . . . 54

DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Differential seals and thread---stops application

and bearings scheme . . . . . . . . . . . . . . . . . . . . . . . . . 55
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Complete limited---skid differential assembly . . . . . 56
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Crown wheel and bearings assembly . . . . . . . . . . . 58
Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Determination of the pinion axial position
Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 spacer (S1) thickness . . . . . . . . . . . . . . . . . . . . . . . . . 59

INTERMEDIATE AXLE REMOVAL-- REFIT . . . . . . 28 Check of the pinion---crown wheel clearance . . . . 61

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Verification of the pinion---crown wheel

engagement impression area . . . . . . . . . . . . . . . . . . 62
PLANETARY REDUCER OVERHAUL . . . . . . . . . . 32
Idle gear bearing preload determination . . . . . . . . . 63
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Pinion bearing preload determination . . . . . . . . . . . 65
Brake disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Idle gear and pinion assembly . . . . . . . . . . . . . . . . . 66
Inspection of the dismantled parts . . . . . . . . . . . . . . 36
Differential bearing preload determination . . . . . . . 67
Planetary reduction gear seals and thread---stops
Coutershaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . 68
application and bearings scheme . . . . . . . . . . . . . . 37
2 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

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327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE© 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 planetary reducer (second reduction).

Figure 1

276C062W001
1. Rear suspension
2. Hub with planatery gears
3. Differential case
4. Motion input flange
5. Axle
6. Oil---bath brake unit
7. Upper stabilizer bar
4 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

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

1 3

5 7

276C062002
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
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE© 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
6 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

Figure 3

A
1 16

2 15
3
14
4

13

12
9
11
10

27

26 16

17
25

18
24

19

23 20
21
22
276C062003
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE© 7

Figure 4

276C062004
8 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

The differential is a limited---skid differential, characteri- The axial thrust on the discs generates a resistant tor-
zed by the positioning of a multiple---disc clutch betwe- que that acts on the crown wheel when the crown whe-
en the differential case (upright) and the crown wheels el tends to rotate with respect to the differential case
(sun gears) for each side. due to the speed difference between the two wheels.
The multiple---disc clutch includes external discs con- This resistant torque depends, with equal axial thrust,
nected to the differential case and internal discs con- on the dimensions and the coating material of the
nected to the planetary gears. discs.
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.

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
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE© 9

Operation
The torque coming from drive shaft is transmitted Under these conditions, there is no relative motion bet-
through a “U” joint to the bevel pinion. ween the two crown wheels, and thus the planet ---whe-
From this, the torque passes to the ring bevel gear, els do not rotate around their shaft which is integral with
which is integral with the differential case. the differential case.
The differential is a gear train in which the case repre- When the resistance of one wheel exceeds that of the
sents the upright, that holds the planet ---wheel holding other or when the speed of the two wheels is no longer
shafts and receives the torque, while the two crown equal (vehicle traveling a curved path) the planetary
wheels represent the sun gears, both rotary, that recei- gears assume a different rotation speed: their relative
ve the torque and transmit it to the axle shafts. motion is allowed by the presence of the planet---whe-
When both the wheels are subject to the same resistant els, which now rotate around their own shaft in opposi-
torque or have the same speed (vehicle traveling along te directions.
a straight path), the ring bevel gear and the differential Naturally, a slower rotation speed of the crown wheel
case rotate as a block, transmitting the torque in equal corresponds to a greater driving torque transmitted,
parts to the two crown wheels, and from these to the and vice versa.
two axle shafts that rotate at the same speed: the whe- Thus when the differential operates the wheel that has
els transmit the same driving torque. a smaller speed, it is able to transmit a greater driving
torque, while the one with the greater speed transmits
a smaller torque.
Figure 6 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
LH RH 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
276C062006 respect to a total of 100%).
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
10 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

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
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©11

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12 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

Second reduction: hub and planetary 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. Planetary 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. Planetary 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. Planetary 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
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©13

Figure 8

276C062W008
14 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

Braking assembly

Description Operation
The braking assembly consists of a set of plates with The driving pressure depends on the driver’s pressure
external teeth (1) arranged alternatively with a set of on the brake pedal. As a function to major or minor hy-
plates with internal teeth (2). The plates with external draulic pressure, the plates slip more easily or with mo-
teeth engage in the bell (3), integral with the fixed part re difficulty: in this way the wheel braking is more or less
of the axle, whereas the plates with internal teeth enga- effective.
ge 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 bath 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
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©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
16 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

SPECIFICATIONS AND DATA

Hub

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 (0.354 in) minimum
Tandem transmission conic bearing preload 1.0 Nm (0.74 lbf ft)
Tandem countershaft axial clearance 0.05 --- 0.2 mm (0.002 --- 0.008 in)
Reduction gear upright–axle shaft axial clear-
0.30 – 0.70 mm (0.0118 --- 0.0276 in)
ance
Hub bearing preload determined by the ring nut tightening torque
Ring nut tightening torque 1st tightening: 700---900 Nm (516---664 lb ft) then loosen
2nd tightening: 450 Nm (332 lb ft)
Brake type Multiple discs in oil bath
Control Hydraulic
Discs per group fixed 4
rotating 4
Brake control piston axial travel 2.5 + 0.7 / --- 0.1 mm under pressure
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©17

Splitter unit and bevel gear pair (first reduction)

Figure 11

Tandem transmission conic Tandem countershaft

bearing preload axial clearance:
1.0 Nm (0.74 lbf ft) 0.05 ---0.2 mm
(0.002---0.008 in)

Pinion bearing
preload:
1.5 ---1.8 Nm Crown wheel and pinion
(1.11---1.17 lbf ft) clearance:
see value engraved on
the crown wheel

Self ---blocking discs axial

clearance:
0.48 mm (0.019 in)
minimum

Differential bearing preload:

5.0---5.5 Nm (3.69---4.06 lbf ft)
(including pinion and
transmission)

276C062011
18 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

Hub and planetary gear (second reduction)

Figure 12

Hub bearing pre ---load:

determined by the ring nut
tightening torque

Ring nut tightening torque:

1st tightening: 700 --- 900 Nm
(516.29 --- 663.80 lbf ft)
then loosen
2nd tightening: 450 Nm
(331.9 lbf ft)

Drive axle --- reduction

carrier axial clearance
0.30 --- 0.70 mm
(0.012 --- 0.028 in)

276C062W012
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©19

TIGHTENING TORQUES

Figure 13

276C062W013
20 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

TOOLS
. Prior to ordering tools, refer to this matrix. The type of axle is found on a plate on the axle housing.

TYPE OF AXLE
DESCRIPTION 82.0984.3
82.0802.3 82.1233.3 82.0960.3
(no brake)

Wheel nut spanner 380002787

Seal ring sleeve driver 380002789 380002788 380002789

Seal ring sleeve driver 380002791 380002792 380002793

Thread ring spanner

380002794 --
(Differential)

Face seal installation tool 380002796 -- 380002796

380002797
Disc centering tool + -- 380002797+380002798
380002798

Seal ring sleeve driver 380002799 --

327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©21

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 22 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

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
 327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©23

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.
 24 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

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 locked
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
 327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©25

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 LOCKED

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
26 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

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:
Final reductions
Final reductions

Figure 14 Figure 16

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.
Axle D arrange a suitably sized container, clean the cap
area and remove the cap (1) and the drain cap (2);
Figure 15 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.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©27

Axle To fill the oil, proceed as follows:

Figure 17 Final reductions

Figure 19

276C062021
D arrange a suitably---sized container under the drain
cap, clean the cap areas and then remove the filling
cap (1); 276C062020

Figure 18 D refill with the prescribed lubricant until it overflows

from the hole of the level cap (1);
D replace the sealing ring with a new one and close
the cap;
D repeat the procedure for the other hub.

Axle

Figure 20

2
1

276C062021
276C062024 D refill with the prescribed lubricant until it overflows
D remove the drain cap (1) and completely drain the from the hole of the filling cap (1);
lubricant; D replace the sealing ring with a new one and close
D clean the caps, check that the threading is in good the cap;
condition, replace the sealing ring with a new one D perform a test drive and then recheck the level (1);
and close the drain cap. D if necessary, top up with the prescribed lubricant un-
til it overflows from the hole, repeat the test drive and
recheck the level.
28 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

INTERMEDIATE AXLE REMOVAL---REFIT

. Before starting any operation, make sure Before the removal of the hydraulic pipes,
prepare appropriate plugs to close the free
that all the precautions have been taken and
ends.
all aspects regarding safety of the personnel
involved on the job have been made quite D disconnect the hydraulic pipes:
clear . --- service braking system (20);
Read the relevant instructions contained in --- brakes cooling system inlet (21);
SECTION 1 of this handbook. --- brakes cooling system outlet (22);
If in doubt ask someone who is more expert.
Comply to all the general recommendations . During this operation the hydraulic fluid
for correct execution of maintenance work. could spill out.
D remove the input (18) and the output (19) propeller
Removal shaft following the instructions in SECTION 7;
Proceed as follows: D remove both bolts (10) that fasten the tie---rod to the
D Bring the vehicle on a suitable flat, solid surface, bracket;
switch off the engine, remove the key from the igni- D working from both sides of each rocker arm, remove
tion switch, engage the parking brake and affix the the split pin and loosen the fastening nut (8) of the
warning notices; rocker arm pin;
D deactivate the battery isolator or disconnect the bat- D take out the rocker arm pin (9) keeping the washers
tery terminals to prevent any risk of a short circuit; (6) and guide bushings (7), releasing the rocker arm
D block articulation by means of the steering lock bar, from the axle;
proceeding as indicated in SECTION 1; D carefully lower the axle and remove it from the ve-
D raise the vehicle so that the wheels are off the hicle.
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);
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©29

Figure 21

TBD

276C062W027
30 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

PLANETARY REDUCER OVERHAUL Figure 23

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 slip off the axle shaft (1);
Disassembly
Proceed as follows: Figure 24

Figure 22

4 1

2
3 1
2 276C062032
276C062D030
D unscrew the setscrew (1) of the ring nut;
D mark the mutual position of the planet ---wheel hol- D remove the locking ring nut (2) of the internally too-
ding plate and the hub; thed crown wheel.
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 The ring nut is locked with thread ---stops.
ring (4); To prevent damage to the threading, heat to
approximately 120˚C before unscrewing.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©31

D using a suitable lifting device, carefully remove the Figure 27

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 25

3
276C062D035
D remove the two oil seal rings (1) from the hub;
D use a suitable puller to remove the outer race (2) of
the axle---side bearing (A) and the outer race (3) of
the wheel---side bearing (B);
D if necessary, remove the wheel---fastening screws
from the hub;
1
276C062D033 Figure 28
D use a suitable puller to remove the internally toothed
crown wheel (1);

Figure 26

1 2
1

4
2 276C06W036

D remove the screws (1) fastening the brake unit (2)

3 to the hub;
D carefully remove the brake unit from the hub and
276C062D034
place it on the workbench with the flange facing up-
D remove the retaining screws (1) and relative stop wards.
plates (2);
D separate the internally toothed crown wheel (3) from
the relative flange (4);
D using a suitable puller, remove the inner race (5) of
the wheel---side bearing (B) from the crown wheel
flange;
32 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

Figure 29 Figure 31

276C062038

D remove the planet wheel (1) and relative shim rings

2 (2);
1
276C062D037 Figure 32
D remove the inner race (1) of the axle---side bearing
(A) and the spacer ring (2) from the hub;

Figure 30

2 1
274A062039
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..
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©33

Brake disassembly D remove the screw (1) and remove the spring (2) and
Proceed as follows: spacer (3) from the piston;

Figure 33 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 36

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 34

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 35 D remove the sealing rings from the flange and the pi-
ston.
5
4

2
3
1
276C062W042
34 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

Inspection of the dismantled parts Front sealing rings

D check the seat of the ring: it must not have any de-
Wheel hub formations and/or ovalling;
D check the seats of the bearings: they must not have D carefully clean the seat, the metal ring and the ga-
any deformations and/or ovalling; sket;
D check the condition of the bearings: replace them D eliminate any residue of dust, lubricant or other fo-
if they have bluish halos, cracks and/or signs of reign matter.
wear. Use isopropanol for the cleaning and subse-
quent assembly operations.
Axle shafts Use cloths that do not fray, or paper towels.
D check the condition of the axle shafts: replace them
if they have deformations on the end grooves and/or During reassembly, consider the following
on the entire length. general observations:
D heat, to 212 ˚F in the oven, the bearings
Final reductions and rings to be mounted by pushing;
D check the condition of the gear toothing: replace D carefully center and mount the sealing
them if they have pitting, cracks and/or cavities; rings and bearings with a suitable adju-
D verify the good operation of the planet---wheels and ster;
the roller bushings; D lubricate the ring nuts and bearings;
D check the threading for the bearing locking ring nut: D lubricate the driving plates and driven pla-
it must not have any dents, deformations and/or tes of the brake with hydraulic fluid;
jams. D follow the front sealing ring assembly in-
structions carefully.
Oil---bath 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.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©35

Planetary reduction gear seals and thread-- stops application and bearings scheme

LOCTITE 270
LOCTITE 270
MOLIKOTE

LOCTITE 262

LOCTITE 572

LOCTITE 638

Bearing B Bearing A

LOCTITE 270

LOCTITE 572 rubber

LOCTITE 270 steel

LOCTITE 638

LOCTITE 572 rubber

LOCTITE 270 steel

276C061W044
36 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

Oil -- bath brake assembly Figure 39

Proceed as follows:
2
Figure 37
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 38

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;
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©37

Figure 40

276C062W048

D determine the dimension A;

D determine the dimension B;
D determine the piston travel (without pressure) as fol-
lows:
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 mm (0.0748 in) < C < 2.7 mm (0.1063 in)
38 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

Figure 41 Brake actuation circuit seal inspection

Proceed as follows:
1
Figure 42
2

276C062W049
D mount the peripheral sealing ring (1);
D mount the bell (2) onto the flange (3) and screw on 276C062W050
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
(1704 PSI))
D open the pressure release valve of the pump;
D remove the pump and close the fitting.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©39

Piston actuation travel inspection Planet-- wheel holding plate assembly

Proceed as follows: Proceed as follows:
D position the planet---wheel holding plate horizontal-
Figure 43 ly;

Figure 44

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 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
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 mm (0.945 in) < C < 3.2 mm (0.1260 in)
40 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

Figure 45 Brake unit and hub assembly

Proceed as follows:
2 Figure 47

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 46 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 48

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-
1
tion bush so that the pin holes match up; 1
Mount the pivot from the internal part of the
planet---wheel holding plate, otherwise its 276C062054
seat may be damaged due to the pivot dia- D insert the sealing ring (1) into the bush (detail) and
meter difference. fill it completely with lubricating grease for bearings.
D mount the catch pin (3);
D repeat the procedure for all the planet---wheels.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©41

Front sealing ring assembly Figure 51

. 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 49

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 52
276C062W060
D mount the rubber ring (1) on the metal ring (2), set-
tling it on the groove.

Figure 50

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 Do not touch mating surfaces of face seal.
in fluid leaks.
If the ring twists during assembly, it must be
straightened by rolling it until It is complete-
ly straight.
42 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

Figure 53

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;
Do not touch mating surfaces of face seal.

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.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©43

Figure 54

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.
44 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

Figure 55

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).
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©45

Figure 56 Hub bearing preload determination

Proceed as follows:

Figure 58
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 teeth (3); 1
D mount the retention plates (4) and fix them with the
setscrews; 276C062069
D apply MOLYKOTE lubricant on the hub support
Figure 57
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 (516-- 664 lb ft)
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 (332 lb ft)
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
clamp screw.
46 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

Figure 59 Planet-- wheel holding plate -- fixed gear axial clear-

ance determination
Proceed as follows:

Figure 60

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 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.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©47

Brake cooling circuit seal inspection Concluding operations

Proceed as follows:
Figure 62
Figure 61

276C062W072

D close one of the two brake cooling circuit pipe fit-

tings (1); 1 3
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 ---whe-
may damage the sealing rings. el 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:
Align the reference marks made during di-
Minimum pressure acceptable after 10 minutes
sassembly.
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.
48 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

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 63

4 3

2
1

276C062W080

D straighten the lock and remove the input flange stop D mark the relative position between box and axle;
nut (1); D loosen and remove the screws (3) fastening the ex-
D using a suitable puller, remove the flange (2); ternal box to the axle;
D straighten the lock and remove the output flange D using a suitable lifting device, remove the external
stop nut (3); box assembly from the axle;
D using a suitable puller, remove the flange (4); D position the assembly on the support trestle, adap-
ting as necessary.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©49

Differential disassembly
Figure 64 Proceed as follows:

Figure 66
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 65 D loosen the retaining screws and remove the diffe-
rential semicase;

Figure 67

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.
50 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

Idle gear and pinion disassembly

Figure 70
Proceed as follows:

Figure 68
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 71
D straighten the lock and remove the pinion stop nut
(2).

Figure 69

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 puller to remove the outer race of bea-
276C062083
ring (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.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©51

Figure 72

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 snap ring (4) and outer race (5) of bea-
ring (F).

Figure 73

276C062087
D using a suitable puller, remove the inner race (1) of
bearing (E) from the gear

Figure 74

274A062055
D using a suitable puller (1), remove the inner race (2)
of bearing (A).
52 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

Coutershaft disassembly
Proceed as follows:

Figure 75

276C062W088

D loosen the retaining screws and remove the coun-

tershaft cover (1) complete with countershaft;
D using a suitable puller, remove the countershaft (2)
complete with ball bearing;
D remove the snap 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.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©53

Page left intentionally blank

54 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

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 212 ˚F 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 teeth: replace it if it has
rings and bearings with a suitable adju-
pits, cracks and/or cavities.
ster;
Planet---gears
D lubricate the bushings, sealing rings and
D check the condition of the teeth: 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 ne-
Cross pins
cessary 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 teeth of the crown wheel and the pi-
nion 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 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.
Bushings
D check the threading for the bearing locking
bushing: 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.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©55

Differential seals and thread-- stops application and bearings scheme

Figure 76

LOCTITE 572 (rubber )

LOCTITE 270 (steel )
LOCTITE 262

LOCTITE 510
LOCTITE 262

Bearing F Bearing E

EPPLE 33

MOLYKOTE
LOCTITE 572 (rubber )
LOCTITE 270 LOCTITE 270 (steel )

Bearing B Bearing A

LOCTITE 262

LOCTITE 510

LOCTITE 510 LOCTITE 262

LOCTITE 510

LOCTITE 262 LOCTITE 270

LOCTITE 262

GH 2 GH 1

Bearing D Bearing C

LOCTITE 262

LOCTITE 262
276C062090
56 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

Complete limited-- slip 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 snap 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 snap 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.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©57

Figure 77

1. Differential semicase
2. Shoulder ring
3. Snap ring
4. Semicase shoulder disc SP1
5. Driven (N.4) and driving (N.4) discs
6. Crown wheel shoulder disc SP2
7. Snap 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
58 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

Crown wheel and bearings assembly

Figure 78

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 79

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.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©59

Determination of the pinion axial position spacer (S1) thickness

Figure 80

beff

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
60 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

Figure 81

276C062093
D heat the inner race of bearing (A) and mount it on the
pinion;

Figure 82

4 1

6 3
5

276C062094

D position the chosen pinion position spacer (S1) (1) D mount the outer race (4) of bearing (B) until it rests
in its seat; against the box;
D mount the outer race (2) of bearing (A) until it rests D mount the inner race (5) of bearing (B) on the pinion;
against spacer S1; D apply MOLYKOTE on the pinion threading and on
D insert the pinion (3) into the external box; the threading and contact area of the stop nut;
D mount the pinion box on the external box and D mount the stop nut (6) and tighten it until there is no
tighten the retaining screws to the prescribed play in the bearings.
tightening torque;
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©61

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 83 play in the bearings;

Figure 85

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 84 17312104

D mount a dial indicator at a right angle with respect

to the external diameter of the crown wheel’s too-
thed 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 86
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).
62 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

Verification of the pinion-- crown wheel engagement D cover a dozen teeth of the crown wheel with Prus-
impression area sian blue, lubricated with minium, or another paint
Proceed as follows: or dye that can be easily removed;
D make a complete rotation of the crown wheel by
Figure 87 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;

17312106

Figure 88

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;
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©63

Idle gear bearing preload determination Figure 91

Proceed as follows:

1
Figure 89

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 90

1
276C062096
D mount the bearing (F) snap stop ring (1);
D mount the complete bearing (F) (2) until it rests
against the snap 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.
64 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

Figure 92 Figure 93

1 2

2 1

276C062099

276C062098 D tighten the adjustment ring nut (1) until obtaining

the prescribed value for the bearing rolling torque.
D mount the flange (1), inserting it inside bearing (F);
D apply MOLYKOTE on the gear threading and on the Rolling torque for gear bearings
threading and contact area of the stop nut; 1.0 Nm
D unscrew the ring nut by two notches;
Use a new stop nut. D fix the locking plate (2) of the ring nut by screwing
on the clamp screw.
D mount the stop nut (2) and tighten it to the prescri- When finished, remove the external box,
bed torque. then remove the idle gear by removing the
stop nut.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©65

Pinion bearing preload determination

Proceed as follows:

Figure 94

5 2

6 1

276C062100

D insert the pinion (1), complete with inner race of the D mount the stop nut (6) and tighten it to the prescri-
conic roller bearing (A), into the external box; bed torque;
D mount the coaxial gear (2), spacer (3) and spacer
Block the coaxial gear during this operation.
S2 (4), which were removed during disassembly,
onto the pinion;
D mount the pinion box on the external box and tigh- D use a suitable tool to check that the rolling torque
ten the retaining screws to the prescribed tightening falls within the prescribed values:
torque; Rolling torque for pinion bearings
D mount the inner race (5) of conic roller bearing (B) 1.5-- 1.8 Nm
on the pinion; D otherwise correct the rolling resistance by using a
D apply MOLYKOTE on the pinion threading and on spacer S2 with a different thickness;
the threading and contact area of the stop nut; D In particular:
--- increase the thickness to reduce the torque;
Use a new stop nut.
--- reduce the thickness to increase the torque.
When finished, remove the stop nut and re-
move the external box.
66 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

Idle gear and pinion assembly Figure 97

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; 1
Figure 95

2
1

276C062102
D mount the inner race (1) of bearing (B);
D mount the pinion stop nut (2) and tighten it to the
prescribed torque;

3 Figure 98

276C062101
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;

Figure 96

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.
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.
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©67

Differential bearing preload determination Figure 100

Proceed as follows:

Figure 99

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 bearings
5-- 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.
68 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

Coutershaft assembly
Proceed as follows:

Figure 101

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
327B & 330B SECTION 6.2 Copyright
INTERMEDIATE AXLE -- WET DISC BRAKE ©69

Figure 102

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.
70 INTERMEDIATE AXLE -- WET DISC BRAKE SECTION 6.2 327BCopyright
& 330B ©

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 Copyright ©

SECTION 6.3

REAR AXLE --- DRY DISC BRAKES

Copyright ©
 327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES© 1

CONTENTS

Page Page

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 PLANETARY REDUCER OVERHAUL . . . . . . . . . . 32

First reduction: bevel gear pair . . . . . . . . . . . . . . . . . . 4 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Second reduction: hub and planetary train . . . . . . 10 Inspection of the dismantled parts . . . . . . . . . . . . . . 35
Pinza freno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Planetary reduction gear seals and thread---stops
application and bearings scheme . . . . . . . . . . . . . . 36
SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . 13
Planet ---wheel holding plate assembly . . . . . . . . . . 37
Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brake unit and hub assembly . . . . . . . . . . . . . . . . . . 38
Brake disc and caliper . . . . . . . . . . . . . . . . . . . . . . . . 13
Hub bearing preload determination . . . . . . . . . . . . . 40
Bevel gear (first reduction) . . . . . . . . . . . . . . . . . . . . 14
Planet ---wheel holding plate --- fixed gear axial
Hub and planetary gear (second reduction) . . . . . 15 clearance determination . . . . . . . . . . . . . . . . . . . . . . 41
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . 16 Concluding operations . . . . . . . . . . . . . . . . . . . . . . . . 42
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 DIFFERENTIAL OVERHAUL . . . . . . . . . . . . . . . . . . 44
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Inspection of the disassembled parts . . . . . . . . . . . 48
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Differential seals and thread---stops application

and bearings scheme . . . . . . . . . . . . . . . . . . . . . . . . . 49
Replacement of the brake pads . . . . . . . . . . . . . . . . 24
Complete limited---slip differential assembly . . . . . 50
Breaking---in of the pads . . . . . . . . . . . . . . . . . . . . . . 25
Crown wheel and bearings assembly . . . . . . . . . . . 52
Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Thickness determination for bearing preload
Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 spacer S2 and bearing assembly . . . . . . . . . . . . . . 53
INTERMEDIATE AXLE REMOVAL-- REFIT . . . . . 28 Differential bearing preload determination . . . . . . . 55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Pinion assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

BRAKE CALIPER REMOVAL-- Check of the pinion---crown wheel clearance . . . . 56

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Verification of the pinion---crown wheel
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 engagement impression area . . . . . . . . . . . . . . . . . . 57

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

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327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY 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 planetary reducer (second reduction).

Figure 1

8
3

5
6 2
8

276C063D001

1. Rear suspension
2. Hub with planetary gears
3. Differential case
4. Motion input flange
5. Axle
6. Upper stabilizer bar
7. Service brake caliper
8. Service brake disc
4 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

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.
1. Right adjustment ring nut
The input shaft is supported by two taper roller bear-
2. Planet wheel---side conic roller bearing (D)
ings mounted in dia. arrangement with preload that can
3. Crown wheel
be adjusted by spacer.
4. Planet wheel holding shaft
The pinion shaft receives motion from a cylindrical
5. Planet ---wheel
wheel transmission with ratio 1:1.
6. Crown wheel---side conic roller bearing (C)
The pinion is supported by two taper roller bearings
7. Differential box
mounted in dia. arrangement with preload that can be
8. Left adjustment ring nut
adjusted by spacer. The axial position of the pinion can
9. Differential box
also be adjusted by shims.
10. Ring bevel gear
The differential box with ring bevel gear is supported by
11. Bevel pinion
two taper roller bearings mounted in X arrangement
12. Pinion internal conic roller bearing (A)
with preload and axial position adjustable by two op-
13. Pinion external conic roller bearing (B)
posing ring nuts.
14. Motion input flange
15. Sealing ring

A: Cross section
B: Functional diagram
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES© 5

Figure 2

2
15
3

14
13
6
12
11 7

10 8

3
5

13 12 11 10 276C063003
6 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

The differential is a limited---slip differential, characteri- planet ---wheels and crown wheels.
zed by the positioning of a multiple---disc clutch betwe- The axial thrust on the discs generates a resistant tor-
en the differential case (upright) and the crown wheels que that acts on the crown wheel when the crown whe-
(sun gears) for each side. el tends to rotate with respect to the differential case
The multiple---disc clutch includes external discs con- due to the speed difference between the two wheels.
nected to the differential case and internal discs con- This resistant torque depends, with equal axial thrust,
nected to the planetary gears. on the dimensions and the coating material of the
The thrust on the discs is ensured by the axial compo- discs.
nent of the force exchanged between the teeth of the

Figure 3

3,1 2

2,15

0,48

1. Differential semicase
2. Planetary gear
3. Multiple---disc device for slip limitation
3

52,8 --- 53,27

276C062005
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES© 7

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8 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

Operation
The torque coming from drive shaft is transmitted Under these conditions, there is no relative motion bet-
through a cardan joint to the bevel pinion. ween the two crown wheels, and thus the planet ---whe-
From this, the torque passes to the ring bevel gear, els do not rotate around their shaft which is integral with
which is integral with the differential case. the differential case.
The differential is a gear train in which the case repre- When the resistance of one wheel exceeds that of the
sents the upright, that holds the planet ---wheel holding other or when the speed of the two wheels is no longer
shafts and receives the torque, while the two crown equal (vehicle traveling a curved path) the planetary
wheels represent the sun gears, both rotary, that recei- gears assume a different rotation speed: their relative
ve the torque and transmit it to the axle shafts. motion is allowed by the presence of the planet ---whe-
When both the wheels are subject to the same resistant els, which now rotate around their own shaft in opposi-
torque or have the same speed (vehicle traveling along te directions.
a straight path), the ring bevel gear and the differential Naturally, a slower rotation speed of the crown wheel
case rotate as a block, transmitting the torque in equal corresponds to a greater driving torque transmitted,
parts to the two crown wheels, and from these to the and vice versa.
two axle shafts that rotate at the same speed: the whe- Thus when the differential operates the wheel that has
els transmit the same driving torque. a smaller speed, it is able to transmit a greater driving
torque, while the one with the greater speed transmits
a smaller torque.
Figure 4 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
LH RH 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---slip 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
276C062006 respect to a total of 100%).
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
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY 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 slipping 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 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
10 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

Second reduction: hub and planetary train

The second reduction is obtained by an planetary re- Legenda (figura pagina seguente)
ducer with cylindrical wheels in the wheel hub. 1. Planetary 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. Planetary 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. Planetary 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
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©11

Figure 6

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
12 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

Pinza freno

Figure 7

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
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©13

SPECIFICATIONS AND DATA

Hub

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 (516---664 lb ft)

Ring nut tightening torque then loosen
2nd tightening: 450 Nm (332 lb ft)

Brake disc and caliper

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
14 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

Bevel gear (first reduction)

Figure 8

276C063009
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©15

Hub and planetary gear (second reduction)

Figure 9

Hub bearing pre ---load:

determined by the ring nut
Ring nut tightening torque: tightening torque
1st tightening: 700 --- 900 Nm
(516.29 --- 663.80 lbf ft)
then loosen
2nd tightening: 450 Nm
(331.9 lbf ft)

Drive axle --- reduction carrier

axial clearance
0.30 --- 0.70 mm
(0.012 --- 0.028 in)

276C062D012
16 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

TIGHTENING TORQUES

Figure 10

276C063D011
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©17

TIGHTENING TORQUES
Figure 11

276C063D015
18 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

TOOLS
. Prior to ordering tools, refer to the this matrix. The type of axle is found on a plate on the axle housing.

TYPE OF AXLE
DESCRIPTION 82.0905.3 82.0689.3 82.0690.3 82.1249.3 82.1232.3 82.0832.3
(327B) (327B/330B) (330B) (327B) (330B) (330B)

Wheel nut spanner 380002787

Seal ring sleeve driver 380002788

Seal ring sleeve driver 380002790 380002791 380002792 380002793

Thread ring spanner 380002794

380002794 --
(Differential) 380002795

Seal ring sleeve driver -- 380002799 --

. The following tools are necessary when performing service repair on the differential.

Tool Number DESCRIPTION

380002274 Driver

380002275 Driver

380002282 Driver

380002283 Driver

380002316 Plug Gage

380002317 Stop Disc

380002325 Shaft

380002326 Dummy Differential Bearing Set

327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©19

Page left intentionally blank

 20 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

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
 327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©21

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.
 22 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

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 locked

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
 327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©23

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 LOCKED

Foreign bodies between the discs. Overhaul the brakes.

YES

NO

Defective hydraulic system. See Section 10 --- HYDRAULIC SYSTEM.

YES
24 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

MAINTENANCE
The braking system components are funda- Figure 13
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 12

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;
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©25

Remove the dirt using a NON ---metallic Breaking -- in of the pads

brush and a vacuum cleaner.
Visually examine the dust covers, and check During this procedure there may be an
that there is no seeping of hydraulic fluid. emission of unpleasant vapors and odors
If irregularities are found, proceed to the originating from the friction material of the
brake caliper overhaul. pads.
After replacement of the brake pads, they must be
Figure 14 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.

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 15

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.
26 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

Checking oil level Changing the oil

Proceed as follows:
Collect and dispose of used lubricants and
fluids, according to the laws in force
Final reductions
Proceed as follows to drain the system:

Figure 16 Final reductions

Figure 18

1
1

276C062020

D take the reference on a hub to horizontal position 276C062022

(see arrow); D take the reference on the hub to horizontal position
D clean the plug area and open the level plug (1). Lu- (see arrow);
bricant should drip out of the hole; D arrange a suitably sized container, clean the plug
D top up the level as shown in the following para- area and remove the plug (1) and the drain plug (2);
graph, if required; drain all the lubricant.
D close the filler cap. D clean the cap, check that the threading is in good
condition, replace the sealing ring with a new one
Axle and close the drain cap.
D repeat the procedure for the other hub.
Figure 17 D arrange a suitably sized container, clean the plug
area and remove the plug (1) and the drain plug (2);
drain all the lubricant.

276C062021
D clean the area of the cap, then open the plug (Fig.
2, ref. 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.
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©27

Axle To fill the oil, proceed as follows:

Figure 19 Final reductions

Figure 21

276C063021
D arrange a suitably---sized container under the drain
cap, clean the plug areas and then remove the filling
276C062020
plug (1);
D refill with the prescribed lubricant until it overflows
Figure 20 from the hole of the level plug (1);
D replace the sealing ring with a new one and close
the cap;
D repeat the procedure for the other hub.

Ponte
1
Figure 22

276C063023
D remove the drain plug (1) and completely drain the
lubricant; 1
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.

276C063021
D refill with the prescribed lubricant until it overflows
from the hole of the filling plug (1);
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.
28 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

INTERMEDIATE AXLE REMOVAL---REFIT

. Before starting any operation, make sure D disconnect the hydraulic pipelines:
--- service braking system (20);
that all the precautions have been taken and
all aspects regarding safety of the personnel . Hydraulic oil leakage may occur during
involved on the job have been made quite
these operations.
clear .
Read the relevant instructions contained in D disconnect the drive shaft on the input side (18) and
SECTION 1 of this handbook. output side (19) following the instructions in SEC-
If in doubt ask someone who is more expert. TION 7;
Comply to all the general recommendations D remove both the locking bolts (10) fastening the
for correct execution of maintenance work. tie---rod to the bracket;
D working from both sides of each rocker arm, remove
the split pin and unscrew the locking nut (8) of the
Removal
rocker arm pin;
Proceed as follows: D slip the pin (9) off the rocker arm, recovering the
D Bring the vehicle on a suitable flat, solid surface, washers (6) and the guide bushings (7), disengag-
switch off the engine, remove the key from the igni- ing the rocker arm from the axle;
tion switch, engage the parking brake and affix the D carefully lower the axle and slip it off the vehicle.
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 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 open
ends.
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©29

Figure 23

10

20
4

18

6
9
7

7
6

276C063D027
30 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

BRAKE CALIPER REMOVAL --- Figure 25

INSTALLATION
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.

276C062D029
Removal
Do as follows: D disconnect the braking system hydraulic connector
D bring the vehicle onto an appropriately solid flat sur- (4) and plug it to prevent fluid leaks;
face, shut off the engine, remove the key from the
ignition switch, engage the parking brake and affix
. Hydraulic oil leakage may occur during
the indication signs; these operations.
D disconnect the battery---disconnect switch or dis- D support the caliper (2) appropriately, unscrew the
connect the battery terminals in order to eliminate retaining screws (3) of the support bracket and re-
any risk of short ---circuit; move the caliper complete with the bake pads.
D block the articulation by means of the steering lock
bar, operating as indicated in SECTION 1; Installation
D block the rear wheels appropriately; Proceed to the installation by following the detachment
D use a hydraulic lift to raise the chassis until the rear steps in the reverse order.
wheels are off the ground;
D disassemble the wheel concerned; After reassembled, perform a bleeding of
the brake hydraulic circuit following the in-
Figure 24 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;
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©31

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32 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

PLANETARY REDUCER OVERHAUL Figure 27

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 slip off the axle shaft (1);
. Before proceeding, the brake caliper must Figure 28
be removed following the instructions in the
relative chapter.

Disassembly
Proceed as follows:

Figure 26

276C062032

D unscrew the setscrew (1) of the ring nut;

3 1 D remove the locking ring nut (2) of the internally too-
thed crown wheel.
2
276C062D030
The ring nut is locked with thread ---stops.
D mark the mutual position of the planet ---wheel hol- To prevent damage to the threading, heat to
ding plate and the hub; approximately 120˚C (248 ˚F) before un-
D loosen and remove all the retaining screws (1); screwing.
D remove the planet ---wheel holding plate assembly
(2) and O---ring (3) and recover the thrust spacer
ring (4);
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©33

D using a suitable lifting device, carefully remove the Figure 31

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 29

2
276C062D036

D Unscrew the retain screws (1) and remove the brake

disc (2);

Figure 32

1
1
2

1
276C062D033

D use a suitable puller to remove the internally toothed

crown wheel (1);

Figure 30

1 2

5 3
276C062D035
D remove the two oil seal rings (1) from the hub;
D use a suitable puller to remove the outer race (2) of
4 the axle---side bearing (A) and the outer race (3) of
the wheel---side bearing (B);
D if necessary, remove the wheel---fastening screws
from the hub;
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 puller, remove the inner race (5) of
the wheel---side bearing (B) from the crown wheel
flange;
34 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

Figure 33 Figure 35

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 36
Figure 34

2 1

274A062039

274A062029 D remove the needle cages (arrow) from the planet ---
D place the planet ---wheel holding plate on a suitable wheel;
work surface; D repeat the procedure for all the planet ---wheels.
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..
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©35

Inspection of the dismantled parts During reassembly, consider the following

general observations:
Wheel hub D heat, to 212˚F in the oven, the bearings
D check the seats of the bearings: they must not have and rings to be mounted by pushing;
any deformations and/or ovalling; D carefully center and mount the sealing
D check the condition of the bearings: replace them rings and bearings with a suitable adju-
if they have bluish halos, cracks and/or signs of ster;
wear. 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 teeth: 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.
36 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

Planetary reduction gear seals and thread-- stops application and bearings scheme

Figure 37

276C062D044
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©37

Planet-- wheel holding plate assembly Figure 40

Proceed as follows:
D position the planet ---wheel holding plate horizontal-
ly;
3

Figure 38

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 39 D insert the pivot (2) of the planet ---wheel holding gear
up to the complete expulsion of the internal reten-
tion bushing 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;
38 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

Brake unit and hub assembly Figure 42

Proceed as follows:

Figure 41

3
2
1
1

1 276C062054
276C062053
D insert the sealing ring (1) into the bush (detail) and
D place the hub vertically; fill it completely with lubricating grease for bearings.
D using a suitable introducer, mount the outer race (1)
of the wheel---side conic roller bearing (B) and the Figure 43
outer race (2) of the axle---side conic roller bearing
(A); 2
D mount the inner race (3) of the axle---side conic roller
bearing (A);

276C062D055

D mount the brake disc (1) on the hub;

D mount retain screw (2) and tighten.
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©39

Figure 44

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).
40 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

Figure 45 Hub bearing preload determination

Proceed as follows:

Figure 47
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 teeth (3); 1
D mount the retention plates (4) and fix them with the
setscrews; 276C062069
D apply MOLYKOTE lubricant on the hub support
Figure 46
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 (516-- 664 lb ft)
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 (332 lb ft)
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
clamp screw.
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©41

Figure 48 Planet-- wheel holding plate -- fixed gear axial clear-

ance determination
Proceed as follows:

Figure 49

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.
42 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

Concluding operations

Figure 50

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.
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©43

Page left intentionally blank

44 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

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 51

2 3

276C063D080

D straighten the dent and remove the motion input D using a suitable lifting device, remove the external
flange stop nut (1); box assembly from the axle;
D using a suitable puller, remove the flange (2); D position the assembly on the support trestle, adap-
D mark the relative position between box and axle; ting as necessary.
D loosen and remove the screws (3) fastening the ex-
ternal box to the axle;
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©45

Differential disassembly
Figure 52 Proceed as follows:

Figure 54
2 4
1
3
3

1
4
2
2
276C063081
D remove 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 puller to extract the inner race (3)
D remove the retaining screws (3) and remove both of the crown wheel---side bearing (C) and the inner
the support caps (4); race of the planet wheel---side bearing (D) from the
D remove both the adjustment ring nuts; differential semicases;
D mark both the differential semicases;
Figure 53 D remove the retaining screws and remove the diffe-
rential semicase;

Figure 55

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 slip limitation device and the
relative shoulder rings;
D if necessary, separate the ring bevel gear from the
differential semicase by removing the retaining
screws.
46 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

Pinion disassembly
Figure 58
Proceed as follows:

Figure 56

1
276C063082

D remove the cover (1) and relative sealing ring (2). 276C063084

D use a press and pad to extract the pinion (1) from

Figure 57 the pinion box;

Figure 59

1
1

2
276C063083
D remove the complete pinion box (1); 2
D recover the pinion position adjustment spacer S1 276C063085
(1); D remove the inner race (1) of bearing (B) and bearing
preload spacer S2 (2) from the pinion box.
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©47

Figure 60

1
276C063086

D use a suitable puller to remove the outer race (1) of

bearing (B) and the outer race (2) of bearing (A)
from the pinion box;

Figure 61

274A062055

D using a suitable puller (1), remove the inner race (2)

of bearing (A).
48 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

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 212˚F 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 teeth: replace it if it has D lubricate the bushings, sealing rings and
pits, cracks and/or cavities. bearings.

Planet ---gears Perform all the indicated measurements

D check the condition of the teeth: replace it if it has with maximum precision.
pits, cracks and/or cavities; Imprecise measurements lead to bad con-
D check the coupling surfaces with the pins. tact of the bevel gear and thus make it ne-
cessary to repeat the procedure.
Damage to a single element entails the re-
placement of the entire gear unit.

Cross pins
D check the matling 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 teeth of the crown wheel and the pi-
nion 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 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
bushing: 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.
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©49

Differential seals and thread-- stops application and bearings scheme

Figure 62

276C063087
50 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

Complete limited-- slip 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 snap 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.
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©51

Figure 63

1. Differential semicase
2. Shoulder ring
3. Snap ring
4. Semicase shoulder disc SP1
5. Driven (N.4) and driving (N.4) discs
6. Crown wheel shoulder disc SP2
7. Snap 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
52 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

Crown wheel and bearings assembly

Figure 64

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 65

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.
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©53

Thickness determination for bearing preload spacer S2 and bearing assembly

Figure 66

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.
54 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

Figure 67 Figure 69

276C062093
1
D heat the inner race of bearing (A) and mount it on the
pinion; 2
Figure 68

3
4
276C063091
D mount the cover (1) and tighten the retaining screws
to the prescribed torque;
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 lock 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.
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©55

Figure 70 Differential bearing preload determination

Proceed as follows:

Figure 71

1731281
D use a suitable tool to check that the rolling torque
falls within the prescribed values:
Rolling torque for pinion bearings 17312101
0.8 -- 1.2 Nm D position the bearing outer races on both ends of the
D otherwise, correct the rolling resistance by using a differential;
spacer S2 with a different thickness; D using a suitable lifting device, mount the crown whe-
D in particular: el assembly in the differential box;
--- increase the thickness to reduce the torque D apply MOLYKOTE on the threading of the adjust-
--- reduce the thickness to increase the torque ment ring nuts;
D remove the pinion stop nut and relative flange; D screw on both the ring nuts by hand;
D remove the retaining screws and slip off the cover
and the complete pinion box. Figure 72

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.
56 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

Pinion assembly Check of the pinion-- crown wheel clearance

Proceed as follows: Proceed as follows:

Figure 73 Figure 75

276C063092
D insert the sealing ring (1) into the cover (2) and fill it
completely with lubricating grease for bearings;

Figure 74
17312104

D mount a dial indicator at a right angle with respect

to the external diameter of the crown wheel’s too-
thed 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 76
1

276C063093

D mount the complete pinion box in the external box;

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 lock nut (3) to 17312105
the prescribed torque. 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).
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- DRY DISC BRAKES ©57

Verification of the pinion-- crown wheel engagement D cover a dozen teeth of the crown wheel with Prus-
impression area sian blue, lubricated with minium, or another paint
Proceed as follows: or dye that can be easily removed;
D make a complete rotation of the crown wheel by
Figure 77 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;

17312106

Figure 78

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;
58 REAR AXLE -- DRY DISC BRAKES SECTION 6.3 Copyright
327B & 330B ©

D to replace the spacer S1, remove the lock nut, flan- Figure 80
ge, cover, and retaining screws and slip off the com-
plete pinion box;
D position the new spacer, then reassemble the pinion
box and cover and tighten the retaining screws to
the prescribed tightening torque;
D insert the flange and tighten the lock nut to the pre-
scribed torque;

Figure 79

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
274A062066 disassembly;
D screw on the retaining screws and tighten to the pre-
D dent the nut as described in the figure; scribed torque.
If this is not possible, unscrew the nut as . Proceed to:
much as necessary to dent it.
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.
 Copyright ©

SECTION 6.3

REAR AXLE --- WET DISC BRAKE

Copyright ©
 327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE© 1

CONTENTS

Page Page

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Planet ---wheel holding plate assembly . . . . . . . . . . 31

First reduction: bevel gear pair . . . . . . . . . . . . . . . . . . 4 Brake unit and hub assembly . . . . . . . . . . . . . . . . . . 32

Second reduction: hub and planetary train . . . . . . 10 Hub bearing preload determination . . . . . . . . . . . . . 34
Planet ---wheel holding plate --- fixed gear axial
SPECIFICATION AND DATA . . . . . . . . . . . . . . . . . . 12
clearance determination . . . . . . . . . . . . . . . . . . . . . . 35
Bevel gear (first reduction) . . . . . . . . . . . . . . . . . . . . 13
Concluding operations . . . . . . . . . . . . . . . . . . . . . . . . 36
Hub and planetary gear (second reduction) . . . . . 14
TANDEM TRANSMISSION AND DIFFERENTIAL
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . 15 OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Inspection of the disassembled parts . . . . . . . . . . . 42

Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Differential seals and thread---stops application
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
and bearings scheme . . . . . . . . . . . . . . . . . . . . . . . . . 43
Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Complete limited---skid differential assembly . . . . . 44
Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Crown wheel and bearings assembly . . . . . . . . . . . 46
REAR AXLE REMOVAL-- REFIT . . . . . . . . . . . . . . . 24 Thickness determination for bearing preload
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 spacer S2 and bearing assembly . . . . . . . . . . . . . . 47
Differential bearing preload determination . . . . . . . 49
EPICYCLIC REDUCER OVERHAUL . . . . . . . . . . . . 26
Pinion assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Check of the pinion---crown wheel clearance . . . . 50
Inspection of the dismantled parts . . . . . . . . . . . . . . 29
Verification of the pinion---crown wheel
Planetary reduction gear seals and thread---stops
engagement impression area . . . . . . . . . . . . . . . . . . 51
application and bearings scheme . . . . . . . . . . . . . . 30
2 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

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327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE© 3

DESCRIPTION
The axle is a dual reduction bearing type. the planetary reducer (second reduction).
It consists of a boxed structure containing the cylindri- The structure has mountings for connection to the
cal wheel transmission, the bevel gear pair with the dif- chassis and housings for the bearings.
ferential (first reduction), the drive shafts and hubs with

Figure 1

276C063W001

1. Rear suspension
2. Transmission box and differential
3. Axle
4. Hub with planetary gears
5. Upper stabilizer bar
6. Motion input flange
4 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

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 dia. arrangement with preload that can 2. Planet wheel---side conic roller bearing
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
mounted in dia. arrangement with preload that can be 7. Differential box
adjusted by spacer. The pinion axial position can also 8. Left adjustment ring nut
be 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
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE© 5

Figure 2

2
15
3

14
13
6
12
11 7

10 8

3
5

13 12 11 10 276C063003
6 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

The differential is a limited---skid differential, characteri- The axial thrust on the discs generates a resistant tor-
zed by the positioning of a multiple---disc clutch betwe- que that acts on the crown wheel when the crown whe-
en the differential case (upright) and the crown wheels el tends to rotate with respect to the differential case
(sun gears) for each side. due to the speed difference between the two wheels.
The multiple---disc clutch includes external discs con- This resistant torque depends, with equal axial thrust,
nected to the differential case and internal discs con- on the dimensions and the coating material of the
nected to the planetary gears. discs.
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.

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
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE© 7

Operation
The torque coming from drive shaft is transmitted Under these conditions, there is no relative motion bet-
through a “U” joint to the bevel pinion. ween the two crown wheels, and thus the planet ---whe-
From this, the torque passes to the ring bevel gear, els do not rotate around their shaft which is integral with
which is integral with the differential case. the differential case.
The differential is a gear train in which the case repre- When the resistance of one wheel exceeds that of the
sents the upright, that holds the planet ---wheel holding other or when the speed of the two wheels is no longer
shafts and receives the torque, while the two crown equal (vehicle traveling a curved path) the planetary
wheels represent the sun gears, both rotary, that recei- gears assume a different rotation speed: their relative
ve the torque and transmit it to the axle shafts. motion is allowed by the presence of the planet ---whe-
When both the wheels are subject to the same resistant els, which now rotate around their own shaft in opposi-
torque or have the same speed (vehicle traveling along te directions.
a straight path), the ring bevel gear and the differential Naturally, a slower rotation speed of the crown wheel
case rotate as a block, transmitting the torque in equal corresponds to a greater driving torque transmitted,
parts to the two crown wheels, and from these to the and vice versa.
two axle shafts that rotate at the same speed: the whe- Thus when the differential operates the wheel that has
els transmit the same driving torque. a smaller speed, it is able to transmit a greater driving
torque, while the one with the greater speed transmits
a smaller torque.
Figure 4 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
LH RH 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
276C062006 respect to a total of 100%).
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
8 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

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
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE© 9

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10 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

Second reduction: hub and planetary train

The second reduction is obtained by an planetary re- Legend (figure on following page)
ducer with cylindrical wheels in the wheel hub.
The hub is supported by two taper roller bearings 1. Planetary train upright
mounted in dia. arrangement with preload that can be (planet ---wheel holding plate)
adjusted by a ring nut. The planetaries gear rotate on 2. Thrust spacer
pivoting roller bearings. 3. Planet ---wheel
4. Planetary 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. Planetary 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
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE ©11

Figure 6

10
9
8
7 11

6
5
4
3
2
1

16 14 12
17 15 13

B
9

12
4

15 14 16
3
8

276C063W008
12 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

SPECIFICATION AND DATA

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 bath

Control Hydraulic

fixed 5
Discs per unit
rotating 4

Brake discs axial clearance 0.30 --- 0.60 mm (0.012 --- 0.024 in)
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE ©13

Bevel gear (first reduction)

Figure 7

276C063009
14 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

Hub and planetary gear (second reduction)

Figure 8

Ring nut tightening torque:

1st tightening: 700 --- 900 Nm
Coppia di serraggio ghiera:
(516.29 --- 663.80 lbf ft)
1 serraggio: 700 -- 900 Nm
then-- loosen
(516.29 663.80 lbf ft)
2nd tightening: 450 Nm
poi allentare; Hub bearing
Precarico pre
cuscinetti ---load:
mozzo:
(331.9
2 serraggio 450 lbf
Nm ft)
(331.90 lbf ft)
determineddalla
determinato by the ringdinut
coppia
tightening
serraggio della torque
ghiera

Drive axle --- reduction

Gioco assiale car-
rier axial clearance
semiasse--portatreno portatreno
0.30----- 0.70
0.30 0.70 mm
mm
(0.012 -- 0.028 in)
(0.012 --- 0.028 in)

276C063W010
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE ©15

TIGHTENING TORQUES

Figure 9

276C063W011
16 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

TOOLS
. Prior to ordering tools, refer to this matrix. The type of axle is found on a plate on the axle housing.

TYPE OF AXLE
DESCRIPTION 82.0984.3
82.0802.3 82.1233.3 82.0960.3
(no brake)

Wheel nut spanner 380002787

Seal ring sleeve driver 380002789 380002788 380002789

Seal ring sleeve driver 380002791 380002792 380002793

Thread ring spanner

380002794 --
(Differential)

Face seal installation tool 380002796 -- 380002796

380002797
Disc centering tool + -- 380002797+380002798
380002798

Seal ring sleeve driver 380002799 --

327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE ©17

Page left intentionally blank

 18 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

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
 327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE ©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.
 20 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

5 OIL LEAK

Worn oil seals. Replace them.

YES

NO

Loose screws. Tighten the screws to the prescribed tightening

YES torque.
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE ©21

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22 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

MAINTENANCE Changing the oil

Checking oil level Collect and dispose of used lubricants and

fluids, according to the laws in force
Proceed as follows:

Final reductions Final reductions

Figure 10 Figure 12

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 plug
D clean the plug area and open the level plug (1). Lu- area and remove the plug (1) and the drain plug (2);
bricant should drip out of the hole; drain all the lubricant.
D top up the level as shown in the following para- D clean the plug, check that the threading is in good
graph, if required; condition, replace the sealing ring with a new one
D close the filler plug. and close the drain plug.
D repeat the procedure for the other hub.
Figure 11
D arrange a suitably sized container, clean the plug
area and remove the plug (1) and the drain plug (2);
drain all the lubricant.

276C063021
D clean the area of the plug, then open the plug (1):
the lubricant must leak from the hole;
D if necessary, restore the level until it overflows from
the same plug;
D close the plug.
D check that the breather is perfectly clean and ope-
rational.
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE ©23

Axle To fill the oil, proceed as follows:

Figure 13 Final reductions

Figure 15

276C063021
D arrange a suitably---sized container under the drain
plug, clean the plug areas and then remove the fil-
276C062020
ling plug (1);
D refill with the prescribed lubricant until it overflows
Figure 14 from the hole of the level plug (1);
D replace the sealing ring with a new one and install
the plug;
D repeat the procedure for the other hub.

Axle
1
Figure 16

276C063023
D remove the drain plug (1) and completely drain the
lubricant; 1
D clean the plugs, check that the threading is in good
condition, replace the sealing ring with a new one
and close the drain plug.

276C063021
D refill with the prescribed lubricant until it overflows
from the hole of the filling plug (1);
D replace the sealing ring with a new one and close
the plug;
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.
24 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

REAR AXLE REMOVAL---REPLACE

. Before starting any operation, make sure Before the removal of the hydraulic pipes,
prepare appropriate plugs to close the open
that all the precautions have been taken and
ends.
all aspects regarding safety of the personnel
involved on the job have been made quite D disconnect the hydraulic pipes:
clear. --- service braking system (20);
Read the relevant instructions contained in --- brakes cooling system inlet (21);
SECTION 1 of this handbook. --- brakes cooling system outlet (22);
If in doubt ask someone who is more expert.
Comply to all the general recommendations . During this operation the hydraulic fluid
for correct execution of maintenance work. could spill out.
D remove the propeller shaft (18) following the instruc-
Removal tions in SECTION 7;
Proceed as follows: D remove both bolts (10) fastening the tie---rod to the
D bring the vehicle on a suitable flat, solid surface, bracket;
switch off the engine, remove the key from the igni- D working on both sides of each rocker arm, remove
tion switch, engage the parking brake and affix the the split pin and unscrew the fastening nut (8) of the
warning notices; rocker arm pin;
D deactivate the battery isolator or disconnect the bat- D take out the rocker arm pin (9), keeping the washers
tery terminals to prevent any risk of a short circuit; (6) and the guide bushings (7), releasing the rocker
D Block articulation by means of the steering lock bar, arm from the axle;
proceeding as indicated in SECTION 1; D lower the axle with care and remove it from the ve-
D raise the vehicle so the wheels are off the ground, hicle.
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);
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE ©25

Figure 17

4
10

18

6
9
7

7 276C063W027
6
26 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

PLANETARY REDUCER OVERHAUL Figure 19

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 experi-
enced.
Comply to all the general recommendations
for correct execution of maintenance work.
5
4
. Before proceeding, it is necessary to: 3
2
D drain the lubricant from the wheel hub
D drain the lubricant from the central differ- 1
ential 276C063W031
following the instructions provided in the
relative chapter. D slip off the axle shaft (1);

Figure 20
. Before proceeding, the brake caliper must
be removed following the instructions in the
relative chapter.

Disassembly
Proceed as follows:

Figure 18

3 1 276C062032
2 D unscrew the setscrew (1) of the ring nut;
276C063W030 D remove the locking ring nut (2) of the internally too-
D mark the mutual position of the planet ---wheel hol- thed crown wheel.
ding plate and the hub;
D loosen and remove all the retaining screws (1); The ring nut is locked with thread ---stops.
D remove the planet ---wheel holding plate assembly To prevent damage to the threading, heat to
(2) and O---ring (3) and recover the thrust spacer approximately 120˚C before unscrewing.
ring (4);
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE ©27

D using a suitable lifting device, carefully remove the Figure 23

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 21

3
276C062D035
D remove the two oil seal rings (1) from the hub;
D use a suitable puller to remove the outer race (2) of
the axle---side bearing (A) and the outer race (3) of
the wheel---side bearing (B);
D if necessary, remove the wheel---fastening screws
from the hub;
1
276C062D033

D use a suitable puller to remove the internally toothed

crown wheel (1);

Figure 22

1 2

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 puller, remove the inner race (5) of
the wheel---side bearing (B) from the crown wheel
flange;
28 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

Figure 24 Figure 26

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 27
Figure 25

2 1

274A062039

274A062029 D remove the needle cages (arrow) from the planet ---
D place the planet ---wheel holding plate on a suitable wheel;
work surface; D repeat the procedure for all the planet ---wheels.
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..
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE ©29

Inspection of the dismantled parts During reassembly, consider the following

general observations:
Wheel hub D heat, to 100˚C in the oven, the bearings
D check the seats of the bearings: they must not have and rings to be mounted by pushing;
any deformations and/or ovalling; D carefully center and mount the sealing
D check the condition of the bearings: replace them rings and bearings with a suitable adju-
if they have bluish halos, cracks and/or signs of ster;
wear. 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 teeth: 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.
30 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

Planetary reduction gear seals and thread-- stops application and bearings scheme

Figure 28

276C063W044
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE ©31

Planet-- wheel holding plate assembly Figure 31

Proceed as follows:
D position the planet ---wheel holding plate horizontal-
ly;
3

Figure 29

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 30 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;
32 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

Brake unit and hub assembly

Proceed as follows:

Figure 32

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 33

1
1

276C062054
D insert the sealing ring (1) into the bushing (detail)
and fill it completely with lubricating grease for bea-
rings.
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE ©33

Figure 34

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).
34 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

Figure 35 Hub bearing preload determination

Proceed as follows:

Figure 37
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 teeth (3); 1
D mount the retention plates (4) and fix them with the
setscrews; 276C062069
D apply MOLYKOTE lubricant on the hub support
Figure 36
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 (516-- 664 lb ft)
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 (332 lb ft)
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
clamp screw.
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE ©35

Figure 38 Planet-- wheel holding plate -- fixed gear axial clear-

ance determination
Proceed as follows:

Figure 39

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.
36 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

Concluding operations

Figure 40

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.
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE ©37

Page left intentionally blank

38 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

REAR 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 41

2 3

276C063W080

D straighten the dent and remove the motion input D using a suitable lifting device, remove the external
flange lock nut (1); box assembly from the axle;
D using a suitable puller, remove the flange (2); D position the assembly on the support trestle, adap-
D mark the relative position between box and axle; ting as necessary.
D loosen and remove the screws (3) fastening the ex-
ternal box to the axle;
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE ©39

Differential disassembly
Figure 42 Proceed as follows:

Figure 44
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 pullers to extract the inner race (3)
D loosen the retaining screws (3) and remove both the of the crown wheel---side bearing (C) and the inner
support caps (4); race of the planet wheel---side bearing (D) from the
D remove both the adjustment ring nuts; differential semicases;
D mark both the differential semicases;
Figure 43 D loosen the retaining screws and remove the diffe-
rential semicase;

Figure 45

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.
40 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

Pinion disassembly
Figure 48
Proceed as follows:

Figure 46

1
276C063082

D remove the cover (1) and relative sealing ring (2). 276C063084

D use a press and pad to extract the pinion (1) from

Figure 47 the pinion box;

Figure 49

1
1

2
276C063083
D remove the complete pinion box (1); 2
D recover the pinion position adjustment spacer S1 276C063085
(1); D remove the inner race (1) of bearing (B) and bearing
preload spacer S2 (2) from the pinion box.
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE ©41

Figure 50

1
276C063086

D use a suitable puller to remove the outer race (1) of

bearing (B) and the outer race (2) of bearing (A)
from the pinion box;

Figure 51

274A062055

D using a suitable puller (1), remove the inner race (2)

of bearing (A).
42 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

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 212 ˚F 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 teeth: replace it if it has
rings and bearings with a suitable adju-
pits, cracks and/or cavities.
ster;
Planet ---gears
D lubricate the bushings, sealing rings and
D check the condition of the teeth: 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 ne-
Cross pins
cessary 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 teeth of the crown wheel and the pi-
nion show uniform wear on the entire working zone
of the teeth: replace the bevel gear if it has pits,
cracks and/or cavities;
Irregular wear may indicate an incorrect ad-
justment of the bearings: check their integri-
ty before proceeding to the reassembly.
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.
Bushings
D check the threading for the bearing locking
bushing: 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.
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE ©43

Differential seals and thread-- stops application and bearings scheme

Figure 52

276C063087
44 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

Complete limited-- slip 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 snap 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 snap 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.
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE ©45

Figure 53

1. Differential semicase
2. Shoulder ring
3. Snap ring
4. Semicase shoulder disc SP1
5. Driven (N.4) and driving (N.4) discs
6. Crown wheel shoulder disc SP2
7. Snap 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
46 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

Crown wheel and bearings assembly

Figure 54

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 55

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.
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE ©47

Thickness determination for bearing preload spacer S2 and bearing assembly

Figure 56

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.
48 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

Figure 57 Figure 59

276C062093
1
D heat the inner race of bearing (A) and mount it on the
pinion; 2
Figure 58

3
4
276C063091
D mount the cover (1) and tighten the retaining screws
to the prescribed torque;
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 lock nut;
D mount the lock nut (3) and tighten it to the prescri-
bed torque.
Use a new lock 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.
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE ©49

Figure 60 Differential bearing preload determination

Proceed as follows:

Figure 61

1731281
D use a suitable tool to check that the rolling torque
falls within the prescribed values:
Rolling torque for pinion bearings 17312101
0.8 -- 1.2 Nm D position the bearing outer races on both ends of the
D otherwise, correct the rolling resistance by using a differential;
spacer S2 with a different thickness; D using a suitable lifting device, mount the crown whe-
D in particular: el assembly in the differential box;
--- increase the thickness to reduce the torque D apply MOLYKOTE on the threading of the adjust-
--- reduce the thickness to increase the torque ment ring nuts;
D remove the pinion lock nut and relative flange; D screw on both the ring nuts by hand;
D remove the retaining screws and slip off the cover
and the complete pinion box. Figure 62

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.
50 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

Pinion assembly Check of the pinion-- crown wheel clearance

Proceed as follows: Proceed as follows:

Figure 63 Figure 65

276C063092
D insert the sealing ring (1) into the cover (2) and fill it
completely with lubricating grease for bearings;

Figure 64
17312104

D mount a dial indicator at a right angle with respect

to the external diameter of the crown wheel’s too-
thed 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 66
1

276C063093

D mount the complete pinion box in the external box;

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 lock nut (3) to 17312105
the prescribed torque. 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).
327B & 330B SECTION 6.3 Copyright
REAR AXLE -- WET DISC BRAKE ©51

Verification of the pinion-- crown wheel engagement D cover a dozen teeth of the crown wheel with Prus-
impression area sian blue, lubricated with minium, or another paint
Proceed as follows: or dye that can be easily removed;
D make a complete rotation of the crown wheel by
Figure 67 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;

17312106

Figure 68

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;
52 REAR AXLE -- WET DISC BRAKE SECTION 6.3 327BCopyright
& 330B ©

D to replace the spacer S1, remove the lock nut, flan- Figure 70
ge, cover, and retaining screws and slip off the com-
plete pinion box;
D position the new spacer, then reassemble the pinion
box and cover and tighten the retaining screws to
the prescribed tightening torque;
D insert the flange and tighten the lock nut to the pre-
scribed torque;

Figure 69

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
274A062066 disassembly;
D screw on the retaining screws and tighten to the pre-
D dent the nut as described in the figure; scribed torque.
If this is not possible, unscrew the nut as . Proceed to:
much as necessary to dent it.
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.
 Copyright ©

SECTION 7

DRIVELINE
Copyright ©
 327B & 330B SECTION 7 Copyright
DRIVELINE© 1

CONTENTS

Page Page

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INSPECTION PROCEDURES . . . . . . . . . . . . . . . . . 11

Central splitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Parking brake caliper release . . . . . . . . . . . . . . . . . . 11
Distribution between the axles . . . . . . . . . . . . . . . . . . 3 Parking brake efficiency verification . . . . . . . . . . . . . 11
Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Intermediate and rear drive axles . . . . . . . . . . . . . . . . 3 Replacement of the parking brake pads . . . . . . . . . 12
Drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL -- REPLACEMENT OF THE
Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 PARKING BRAKE DISC AND CALIPER . . . . . . . . 14
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Detachment of disc . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Central section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Detachment of the central section . . . . . . . . . . . . . . 16
Parking brake unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Reattachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . . 8 CENTRAL BEARING OVERHAUL . . . . . . . . . . . . . 17

TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . 9 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2 DRIVELINE SECTION 7 Copyright
327B & 330B ©

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327B & 330B SECTION 7 Copyright
DRIVELINE© 3

DESCRIPTION Intermediate and rear drive axles

The driveline consists of the following parts: The intermediate and rear drive axles are rigid type.
They are fitted with limited slip central differential and
Central splitter central limited slip wheel hubs with final planetary gear
The double satellite sun and planet gearbox central reducer.
splitter can be locked through a control in the cab. It is
built into the lower part of the automatic gearbox. Drive shafts
Splitting ratio is 2/3 to the rear axle and 1/3 to the front The drive shafts are:
axle in normal conditions. D drive---gear shaft
Locking is controlled by an electro---pneumatic actua- D front axle shafts (two)
tor. D first rear section of the drive shaft
D central section of the drive shaft
Distribution between the axles D second rear section of the drive shaft
The distribution between the axles is fixed since there D shaft between the axles
is no differential. Consequently the distribution ratio is Each shaft is equipped with ”U” joints at the ends.
1/2 to the intermediate axle and 1/2 to the rear axle.

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.
 4
DRIVELINE
SECTION 7

Driveline
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
327B

11. Intermediate axle

12. Shaft between axles
13. Rear axle
T269TR01
© & 330B
Copyright
327B & 330B SECTION 7 Copyright
DRIVELINE© 5

Drive shaft
The drive shafts are all equipped with ”U” joints at the 1. Axle shaft with external groove
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 1

276C007002
6 DRIVELINE SECTION 7 Copyright
327B & 330B ©

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 2

3
2
1
276C007003
327B & 330B SECTION 7 Copyright
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 3

276C007004
8 DRIVELINE SECTION 7 Copyright
327B & 330B ©

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
327B & 330B SECTION 7 Copyright
DRIVELINE© 9

TIGHTENING TORQUES

276C007005
10 DRIVELINE SECTION 7 Copyright
327B & 330B ©

TIGHTENING TORQUES

200 Nm 620 Nm 1
184.39 lbf ft 457.29 lbf ft

250 Nm
800 Nm
184.39 lbf ft
590 lbf ft

250 Nm
310 Nm 184.39 lbf ft
228.64 lbf ft

1 Loctite 242

276C007006
327B & 330B SECTION 7 Copyright ©11
DRIVELINE

INSPECTION PROCEDURES
Figure 6
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 4

269NU4D3

D tighten the nut until achieving the release of the bra-

ke pads.
To restore the normal function repeat the operations
described above in the reverse order, recovering the
maneuver screw and closing the protection plug and
269NU4D2
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 5

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).
12 DRIVELINE SECTION 7 Copyright
327B & 330B ©

MAINTENANCE Figure 9

Replacement of the parking brake pads

Removal
Do as follows:

Figure 7

269NU271

D disengage the parking brake (position 0);

Figure 10

269NU271

D engage the parking brake (position 1);

Figure 8

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;
327B & 330B SECTION 7 Copyright ©13
DRIVELINE

Figure 11

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 12 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;

14 DRIVELINE SECTION 7 Copyright
327B & 330B ©

REMOVAL---REPLACEMENT OF THE PAR- Figure 13

KING 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 14
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 15

269NU271

D disengage the parking brake (position 0);

327B & 330B SECTION 7 Copyright ©15
DRIVELINE

Figure 16 Figure 19

276A007002

D remove the upper cover (arrow) from the rear chas-

sis;

Figure 17

276A007012
D unscrew the screws fastening the caliper (arrow) to
1 the support bracket;

Figure 20

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 18

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;
16 DRIVELINE SECTION 7 Copyright
327B & 330B ©

Removal of the central section Figure 23

Proceed as follows:
D remove the parking brake caliper following the in-
structions provided previously;

Figure 21

1 276C07014
D remove the retaining screws between the rear shaft 276C07016
”U” joint flange (1) and the central section flange; D remove the central section complete with supports,
extracting it from the upper part of the chassis.
Figure 22
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 ”U” 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.
327B & 330B SECTION 7 Copyright ©17
DRIVELINE

CENTRAL BEARING OVERHAUL

Dismantling
Proceed as follows:

Figure 24

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 25

276C07020
Tighten the ring nut to the prescribed tighte-
D Slip off the rigid support (1) from both sides. ning torque.
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.
18 DRIVELINE SECTION 7 Copyright
327B & 330B ©

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 Copyright ©

SECTION 8

SUSPENSIONS
Copyright ©
327B & 330B SECTION 8 Copyright ©1
SUSPENSIONS

CONTENTS

Page Page

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 FRONT SUSPENSION CYLINDER

REMOVAL-- REPLACEMENT . . . . . . . . . . . . . . . . . . 16
Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydro---pneumatic cylinder --- description . . . . . . . . 4
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydro---pneumatic cylinder --- section . . . . . . . . . . . . 4
Hydro---pneumatic cylinder --- view . . . . . . . . . . . . . . 5 REAR SUSPENSION REMOVAL--
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . 7
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL-- REPLACEMENT OF THE
Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REAR SUSPENSION STABILIZER BARS . . . . . . 18
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Front suspension element inflating device . . . . . . . . 9 REMOVAL-- REPLACEMENT OF THE
Equipment connection diagram . . . . . . . . . . . . . . . . . 9 REAR SUSPENSION BUSHINGS . . . . . . . . . . . . . 21
Checking suspension element height . . . . . . . . . . . 10 Elastic articulation bushing on the axles . . . . . . . . . 21

Checking suspension element pressure . . . . . . . . 10 Flexible coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Inflating the suspension elements . . . . . . . . . . . . . . 10 SUSPENSION CYLINDER OVERHAUL . . . . . . . . . 26

Deflating the suspension element pressure . . . . . . 11 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Changing the suspension fluid element . . . . . . . . . 11 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

FRONT SUSPENSION REMOVAL--

REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Transfer shaft removal . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal of the hubs . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 SUSPENSIONS SECTION 8 Copyright
327B & 330B ©

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327B & 330B SECTION 8 Copyright ©3
SUSPENSIONS

DESCRIPTION
Front suspension
The hubs are connected to an oscillating plate connec-
ted to the vehicle chassis by means of a central joint The cylinders are connected to the plate and the chas-
equipped with an elastic bush. A Panhard---type tran- sis with elastic bushings.
sversal bar absorbs the transverse stresses. The verti- There are no elements in the entire front suspension
cal stresses are controlled by a pair of nitrogenhydrau- that need lubrication.
lic cylinders that functions as an elastic element and
shock absorber.

Figure 1

4 1

276C08001

1. Swash plate
2. Central ball joint
3. Panhard bar
4. Right nitrogen---hydraulic element
5. Left nitrogen---hydraulic element
4 SUSPENSIONS SECTION 8 Copyright
327B & 330B ©

Hydro -- pneumatic cylinder -- description

The hydro---pneumatic element consists of shock A lining ensures the piston seal inside the cylinder,
absorber filled with oil and nitrogen. whereas a set of gaskets prevents the liquid flowing out
The internal piston, integral with the large diameter between the rod and the cylinder base .
hollow rod, separates the two internal and external The hydro---pneumatic element uses hydraulic fluid for
chambers: it has one---way valves that act as shock hydraulic braking during the return stroke, while the
absorbers. nitrogen acts as the suspension elastic element during
The external casing of the cylinder is connected to the the compression stroke.
front suspension floating plate, whereas the rod is
fastened to the vehicle chassis: in both cases Hydro -- pneumatic cylinder -- section
connection is by ball joint. 1. Low mount
2. Upper mount
3. Cylinder
4. Drain plug
5. Piston seals
6. Rod and piston
7. Rod seals
8. Filler valve
9. Base

Figure 2
3 4 5 6 7 8

UP

1 9 2
T269SP03

Hydro -- pneumatic cylinder -- 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 436 mm (17.17 in)
Maximum travel 120 mm (4.72 in)
Internal volume with cylinder closed 1911 cc (116.62 cuin)
Maximum working pressure 300 bar (4351.13 psi)
327B & 330B SECTION 8 Copyright ©5
SUSPENSIONS

Hydro -- pneumatic cylinder -- view

1. Low mount 6. Rod and piston
2. Upper mount 7. Rod seals
3. Cylinder 8. Filler valve
4. Drain plug 9. Base
5. Piston seals

Figure 3

2
7 8

9 6

7
3

4
1

276C08002
6 SUSPENSIONS SECTION 8 Copyright
327B & 330B ©

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 4

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
327B & 330B SECTION 8 Copyright ©7
SUSPENSIONS

TIGHTENING TORQUES

Front suspension

Figure 5

800 Nm
590.05 lbf ft

710 Nm 1
800 Nm 523.67 lbf ft
590.05 lbf ft
800 Nm
800 Nm
590.05 lbf ft
590.05 lbf ft

800 Nm
800 Nm
590.05 lbf ft
590.05 lbf ft

800 Nm
590.05 lbf ft
710 Nm 1
523.67 lbf ft

1 Loctite 510

276C08005
8 SUSPENSIONS SECTION 8 Copyright
327B & 330B ©

TIGHTENING TORQUES

Rear suspension

Figure 6

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
327B & 330B SECTION 8 Copyright ©9
SUSPENSIONS

MAINTENANCE
The following operations must be carried Equipment connection diagram
out by suitably equipped expert personnel.
Only use exclusively the specific equipment Figure 8
expressly required to carry out suspension
inflating operations.

. Carry out the following operations on both

suspension elements in parallel.

REQUIRED SERVICE TOOLS :

SUSPENSION TOOL KIT 380040192, includes each

of the individual tool listed below :
a. 380002263 --- Steering Cylinder Installer
b. 380002264 --- Spherical Hinge Installer
c. 380002265 --- Hinge Positioning Tool
d. 380040184 --- Suspension Kit

Suspension Kit 380040184

Figure 7

269NM272
(a) suspension element
(b) nitrogen cylinder
B: inflating device
E: pressure gauge (0 --- 50 bar) (0 --- 725 psi)
IN: nitrogen into suspension tap
OUT: nitrogen suspension breather tap

269NM271
B: checking device
C. inflating device
D: copper seal
E: pressure gauge (0 --- 50 bar) (0 --- 725 psi)
F: hose
G: clear tube
H hose
I: nitrogen cylinder fitting
L: hose fitting
10 SUSPENSIONS SECTION 8 Copyright
327B & 330B ©

Checking suspension element height Figure 11

Carry out the check after parking the empty
vehicle on flat ground for at least one hour.

Figure 9

269NM281
D Check that position X shown in the figure is within
the specified range for both elements.
check position
82 < X < 86 mm (3.23 < X < 3.39 in)
D Check inflation pressure as shown below if this is
not so.

Checking suspension element pressure 269NM272

Carry out the check after parking the empty D check that the inlet tap IN and the breather tap OUT
vehicle on flat ground for at least one hour. on the inflation tool (B) are closed;
D connect the inflation tool (B) t the quick coupling;
D check that the pressure on the gauge (E) is in the
Proceed as follows:
specified range:
D raise the vehicle wheels off the ground with suitable
suspension element pressure = 35 bar (508 psi)
devices to fully extend the suspension;
D otherwise inflate or deflate as shown below;
Figure 10 D disconnect the inflation tool, remove all equipment
and close the protective cap.

Inflating the suspension elements

D open the nitrogen cylinder tap (b) and the inlet tap
IN to let nitrogen into the suspension element (a);
D let in nitrogen at a pressure of approximately 38 bar
(550 PSI), then close the inlet tap IN and the cylinder
1 tap;
D adjust the suspension element pressure to the
specific value by means of the breather tap OUT;
D close the OUT breather, disconnect the inflation
tool, remove all equipment and close the protective
cap.
269NM282

D loosen the protective cap on the element (1);

327B & 330B SECTION 8 Copyright ©11
SUSPENSIONS

Deflating the suspension element pressure Figure 13

D release gas by means of the OUT breather valve to
reach the required pressure;
D close the OUT breather, disconnect the inflation
tool, remove all equipment and close the protective
cap.

Changing the suspension fluid element

Collect and dispose of used lubricants and

fluids, according to the laws in force.

Proceed as follows:
D lift the front end of the vehicle with suitable lifting
means to fully extend the suspension against the
mechanical stop; 269NM281
D release ALL pressure as shown above; D close the filler cap and inflate the suspension as
Figure 12 shown previously;
D check that position x is within the specific check
range valve after travelling a short distance.
check position: 82 < x < 86 mm
(3.23 < X < 3.39 in)

269NM283
D arrange a container of suitable capacity, remove the
filler cap (1) and drain plug (2) and drain the fluid
completely;
D clean the drain plug. Check that the threading is in
good condition. Replace the O---ring and close it;
D pour 1.7 litres of the specified fluid through the filler
cap;
12 SUSPENSIONS SECTION 8 Copyright
327B & 330B ©

FRONT SUSPENSION Figure 14

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; 2691401
D lift the vehicle to raise the wheels from the floor, then
position two supports under the front chassis . The operations described below refer to the
without touching the axle; following figures.
D position a suitable hydraulic support under the axle
that allows the axle to be lowered once detached, Before detaching the hydraulic pipes
such that in this phase the axle remains in a more prepare plugs suitable for closing the open
or less horizontal position; ends.
D remove both wheels as instructed in SECTION 9;
D disconnect both transfer shafts from the front
differential side (arrow) as instructed in SECTION 7; Vehicles with disk brakes only
D disconnect the hydraulic pipelines:
--- service braking system (20).
Vehicles with oil wet brakes only
D disconnect the electrical connection of brake
cooling circuit thermostat (01):
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
(06) fastening the suspension stop braid to the axle;
D remove the lower cylinder attachment retaining
screws (07) from both sides;
D remove the screws (10) fastening the central joint to
the chassis;
D remove the screws (05) fastening the transversal
bar to the oscillating axle, disengage the bar (03)
and temporarily fasten it to the chassis;
D carefully lower the axle and slip it off the vehicle.
327B & 330B SECTION 8 Copyright ©13
SUSPENSIONS

Vehicles with disk brakes only

Figure 15

20

276C08010

Vehicles with oil wet brakes only

Figure 16

20

21
22

276C08011
14 SUSPENSIONS SECTION 8 Copyright
327B & 330B ©

Figure 17

3
10
5

276C08012
327B & 330B SECTION 8 Copyright ©15
SUSPENSIONS

Transfer shaft removal

Proceed as follows:
D disconnect both transfer shafts (18) from hubs as
instructed in SECTION 7.

Figure 18

18
18

276C08013
Removal of the hubs Replacement
For replacement, follow the removal instructions in
. For further information on the procedure for reverse order.
removal and replacement of the hubs, refer
to SECTION 6.1 --- FRONT AXLE. Vehicles with oil wet brakes only

On completing the replacement procedure,

check the brake cooling circuit as instructed
in SECTION 10 --- HYDRAULIC SYSTEM.
16 SUSPENSIONS SECTION 8 Copyright
327B & 330B ©

FRONT SUSPENSION CYLINDER phase the axle remains in a more or less horizontal
REMOVAL --- REPLACEMENT position;
D remove the wheel concerned as instructed in
. Before carrying out any operation, check SECTION 9;
that all precautions have been taken and all D proceed to discharge the gas from the cylinder
aspects regarding safety of the personnel concerned as instructed in the MAINTENANCE
involved have been clarified. chapter;
Read the related instructions given in
Before proceeding make absolutely certain
SECTION 1 of this manual.
If in doubt, speak to a more experienced that all remaining pressure has been
person. discharged from the cylinder.
Respect all general recommendations for D remove the fastening bolts (02) of the lower elastic
correct execution of maintenance works. bush on both sides;
D support the cylinder (01) with suitable lifting
Removal equipment;
D remove the locking nuts (03) of the upper elastic
Proceed as follows:
bush;
D park the vehicle to a suitable flat and solid surface,
D remove the cylinder (1).
remove the ignition key, engage the handbrake and
place maintenance warning signs;
Replacement
D disengage the battery cut ---off switch or disconnect
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 On completing the replacement procedure
instructed in SECTION 1; recharge the cylinder and carry out the
D lift the vehicle to raise the wheels from the floor, then check foreseen in the MAINTENANCE
position two supports under the front chassis Chapter.
without touching the axle;
D position a suitable hydraulic support under the axle
that allows the axle to be lowered, such that in this

Figure 19

1
3

2
276C08014
327B & 330B SECTION 8 Copyright ©17
SUSPENSIONS

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;
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;
D disconnect the central greasing system pipes
(arrow);
--- rocker arm pin B1 right and B2 left;
D working from both sides of the rocker are remove
the split pin and unscrew the rocker arm pin nut
(08);
D working from both sides of the rocker arm, remove
the rocker arm pin (09), collecting the washers (06)
and guide bushes (07), 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.
18 SUSPENSIONS SECTION 8 Copyright
327B & 330B ©

Figure 20

12 6
7
(B3)
7 B4

9
6 6
7
8

12

6
7 11
8 10

276C08015
327B & 330B SECTION 8 Copyright ©19
SUSPENSIONS

REMOVAL---REPLACEMENT OF THE REAR

SUSPENSION STABILIZER BARS
. 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.

276C08017
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 support the stabilizer bar concerned with
appropriate lifting equipment;

Figure 21

276C08016
D Position a suitable lift under each balancer (arrow)
and raise the vehicle so that the wheels barely touch
the ground;

Figure 22

Place a trestle under the front part of the

intermediate axle (arrow) to avoid possible
uncontrolled movements of the axle itself.
D remove the wheels and tires;
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.
20 SUSPENSIONS SECTION 8 Copyright
327B & 330B ©

Figure 23

276C08020
327B & 330B SECTION 8 Copyright ©21
SUSPENSIONS

REMOVAL---REPLACEMENT OF THE REAR Elastic articulation bushings on the axles

SUSPENSION BUSHINGS
Removal
. Before performing any intervention, ensure Proceed as follows:
that all precautions have been taken and all D Remove the balancer from the suspension by
aspects clarified regarding the safety of per- following the instructions provided in the relative
sonnel involved in the intervention. Chapter;
Read the relative instructions provided in D Remove the synthetic bushing using a suitable
SECTION 1 of this manual. punch.
In case of doubt, consult a more experien-
ced person. Remove the metal bushing as well by cutting
Furthermore, respect all the general recom- it with the flexible and extracting it from the
mendations for a correct execution of the balancer seat.
maintenance interventions.
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 24
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
22 SUSPENSIONS SECTION 8 Copyright
327B & 330B ©

Replacement
Figure 27
Proceed as follows:

Figure 25

276C08024
D Lubricate the internal part of the balancer seat;
276C08022
D Check that the lateral parts of the seat are not Figure 28
damaged or show irregular wear (arrow);

Figure 26 160 mm
6.3 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).
327B & 330B SECTION 8 Copyright ©23
SUSPENSIONS

Figure 29

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.
24 SUSPENSIONS SECTION 8 Copyright
327B & 330B ©

Flexible coupling

. The flexible couplings are used in the follo-

wing parts of the vehicle:
A. rear and intermediate axle stabilizer
bars
B. front suspension cylinders
C. front axle central joint

Figure 30

C 276C08027

The replacement of the flexible coupling must be performed using appropriate equipment only.

Location Type of joint Tool a Tool b Tool c

A 110 TDB1A TDB1B TDB1C
B --- C 90 TDB2A TDB2B TDB2C
327B & 330B SECTION 8 Copyright ©25
SUSPENSIONS

Disassembly
Figure 32
Proceed as follows:
D Remove the part concerned by following the
instructions provided in the relative Chapter;

Figure 31

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 33
D Remove the spacer (2);
D Remove the elastic bushing (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
assembly 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.
26 SUSPENSIONS SECTION 8 Copyright
327B & 330B ©

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 lower spherical joint with elastic stop
ring.
D Remove the inflation valve;
D Position the lower end in a. vice with the
interposition of soft material.

Figure 34

276A008004
D Using a hook wrench, thoroughly tighten the drive
head onto the body of the cylinder.
327B & 330B SECTION 8 Copyright ©27
SUSPENSIONS

Figure 35 Figure 37

276A008005

D Slip the stem (1) complete with the drive head off the
cylinder;
D Slip the drive head (2) off the stem.

Figure 36
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);

28 SUSPENSIONS SECTION 8 Copyright
327B & 330B ©

Assembly
Figure 40
All gaskets must be replaced during reas-
sembly.
Thoroughly lubricate all the gaskets with hy-
draulic oil.
Do as follows:

Figure 38

18916209
D Mount the O---ring outside the drive head, resting it
on the sealing ring.

Figure 41

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 39

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.
327B & 330B SECTION 8 Copyright ©29
SUSPENSIONS

D Slowly Introduce the stem complete with drive head

Figure 42 into the cylinder, paying attention not to damage the
previously mounted gaskets.

Figure 44

276A008011
D Using a spanner 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 lower spherical joint with elastic stop ring.

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 43

276A008010
30 SUSPENSIONS SECTION 8 Copyright
327B & 330B ©

Page left intentionally blank

 Copyright ©

SECTION 9

WHEELS AND TIRES

Copyright ©
 327B & 330B SECTION 9 WHEELS Copyright
AND TIRES © 1

CONTENTS

Page Page

WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TIRE-- RIM DISASSEMBLY-- ASSEMBLY . . . . . . . 7

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning of the wheel parts . . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS AND DATA . . . . . . . . . . . . . . . . . 4
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . 4

REPLACING A COMPLETE WHEEL . . . . . . . . . . . . 5

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 WHEELS AND TIRES SECTION 9 Copyright
327B & 330B ©

Left intentionally blank

327B & 330B SECTION 9 WHEELS Copyright
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
4 WHEELS AND TIRES SECTION 9 Copyright
327B & 330B ©

SPECIFICATIONS AND DATA

174NM39
327B

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 50.5 2.75 40.0

330B

Pressure

Tires Front (F) Rear (R)

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

327B & 330B SECTION 9 WHEELS Copyright
AND TIRES © 5

TIGHTENING TORQUE

Figure 2

276C009001
6 WHEELS AND TIRES SECTION 9 Copyright
327B & 330B ©

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
327B & 330B SECTION 9 WHEELS Copyright
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 hitching
points 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).
8 WHEELS AND TIRES SECTION 9 Copyright
327B & 330B ©

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 Use a safety cage to defate 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;

327B & 330B SECTION 9 WHEELS Copyright
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);
10 WHEELS AND TIRES SECTION 9 Copyright
327B & 330B ©

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.
327B & 330B SECTION 9 Copyright
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-

2761009001
bly.
D Use a safety cage to inflate the tire.
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.
12 WHEELS AND TIRES SECTION 9 Copyright
327B & 330B ©

Left intentionally blank

 Copyright ©

SECTION 10

HYDRAULIC SYSTEM
Copyright ©
327B & 330B SECTION 10 Copyright
HYDRAULIC SYSTEM ©1

CONTENTS

Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HYDRAULIC SYSTEM PRESSURE TEST
POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Vehicles with dry disc brakes . . . . . . . . . . . . . . . . . . . 3
Hydraulic system pressures table --- Vehicles with
disc brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Main pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brake pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Emergency steering pump . . . . . . . . . . . . . . . . . . . . . 5
Dumping distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Back ---pressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cartridge filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 HYDRAULIC SYSTEM SECTION 10 327BCopyright
& 330B ©

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 bath brakes only)

The main hydraulic pump (with variable displacement) provides the rate of flow required by the steering and dum-
ping 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 bra-
ke cooling circuit (vehicles with oil bath brakes only).

. For more information on the individual systems see the relative chapters.

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
327B & 330B SECTION 10 Copyright
HYDRAULIC SYSTEM ©3

HYDRAULIC SYSTEM PRESSURE TEST POINTS

Vehicles with disc brakes

B H
A
I
C

N
M

276C10003
4 HYDRAULIC SYSTEM SECTION 10 327BCopyright
& 330B ©

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
250 ± 5 3626 ± 73
D LS pressure (load signal) 185 ± 5 2683 ± 73
E Dumping pressure (1---3 stages section outlet) 185 ± 5 2683 ± 73
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

160 + 7 --- 3 2321 + 102 --- 44

M Front accumulator refueling pressure (**)
195 ± 5 2828 ± 73
160 + 7 --- 3 2321 + 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.
327B & 330B SECTION 10 Copyright
HYDRAULIC SYSTEM ©5

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 (64.7 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 (4.23 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 (16.9 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 (0.37 gal)
Nominal capacity (rear) 1.4 litres (0.37 gal)
Operating pressure 65 bar (943 psi)

Accumulators (wet oil)

Nominal capacity (front) 3 litres (0.79 gal)
Nominal capacity (rear) 3 litres (0.79 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
6 HYDRAULIC SYSTEM SECTION 10 327BCopyright
& 330B ©

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 Copyright ©

SECTION 10.1

STEERING AND DUMPING SYSTEM

Copyright ©
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©1

CONTENTS
Page Page
STEERING AND DUMPING SYSTEM -- DUMPING VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REMOVAL-- REPLACEMENT . . . . . . . . . . . 30
Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Main components of the steering---dumping Dumping valve removal---replacement . . . . . . . . . . 31
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DUMPING CYLINDER
HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . 4 REMOVAL-- REPLACEMENT . . . . . . . . . . . 32
Steering---dumping hydraulic system . . . . . . . . . . . . 4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Steering---dumping hydraulic diagram . . . . . . . . . . . 5 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Dumping cylinder removal---replacement . . . . . . . . 33
TOPOGRAPHICAL DIAGRAMS . . . . . . . . . . . . . . . . 8 STEERING VALVE
Forward chassis diagram . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL-- REPLACEMENT . . . . . . . . . . . 34
Rear chassis diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
A. OIL TANK (ONLY DISC BRAKE VERSION) 11 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
B. STEERING/DUMPING DISTRIBUTOR . . . . 11 MAIN PUMP REMOVAL-- REPLACEMENT . . . . . 36
C. MAIN FILTER -- TIPPING AND Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
EMERGENCY STEERING GROUP . . . . . . . 12 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
D. COUNTERBALANCE VALVE . . . . . . . . . . . . 13 STEERING CYLINDER
E. MAIN PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 REMOVAL-- REPLACEMENT . . . . . . . . . . . . 37
F. EMERGENCY STEERING PUMP . . . . . . . . 15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
G. POWER STEERING . . . . . . . . . . . . . . . . . . . . 16
DUMPING CYLINDER OVERHAUL . . . . . . . . . . . . 38
H. HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . 17
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
L. DUMPING CYLINDER . . . . . . . . . . . . . . . . . . 18 Checking components . . . . . . . . . . . . . . . . . . . . . . . . 39
M. STEERING CYLINDER . . . . . . . . . . . . . . . . . 19 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
N. REAR CHASSIS CONNECTOR PLATE . . . 20 Functional testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 STEERING CYLINDER OVERHAUL . . . . . . . . . . . . 42
Checking fitting and pipe tightness . . . . . . . . . . . . . 21 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Changing the fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
MAIN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 STEERING -- DUMPING VALVE
Replacing pressurised filter . . . . . . . . . . . . . . . . . . . . 22 BLOCK OVERHAUL . . . . . . . . . . . . . . . . . . . . 46
Cleaning the (suction) filter . . . . . . . . . . . . . . . . . . . . 22 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
STEERING -- DUMPING SYSTEM TEST Component position identification . . . . . . . . . . . . . . 47
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . 23 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Prescribed pressure values . . . . . . . . . . . . . . . . . . . . 26 Checks and inspections . . . . . . . . . . . . . . . . . . . . . . 50
Dumping and steering valves . . . . . . . . . . . . . . . . . . 27 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
REMOVAL-- REPLACEMENT OF THE
EMERGENCY STEERING VALVE --
MAIN FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

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 tran-
smission: 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.

. The heat exchanger is present on the disc brake version only.

On the disc---brake version this heat exchanger is part of the brake cooling circuit..

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 priori-
ty 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.
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©3

Main components of the steering -- dumping system

276C10006
4 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

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

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) Maximum 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

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)
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©5

Steering -- dumping hydraulic diagram

276C10007
6 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

276C10008
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©7

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.
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 ope-
ning 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 dum-
ping, 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.
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.
8 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

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 (only disc brake version)
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©9

Rear chassis diagram

276C1009Y

L Dumping cylinder
M Steering cylinder
N Connector plate on rear chassis
10 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

A. OIL TANK (only disc brake version)

276C1009A

1 Main pump intake

2 Emergency steering pump intake
3 Brakes pump intake
4 Return from steering/dumping distributor outlet (T)
5 Return from the heat exchanger
6 Return from steering/dumping distributor outlet (Y)
7 Not used
8 Return from steering/dumping distributor outlet (5)
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©11

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
1.03
3a 4 1.04
7 1.11
3
2b 5
1

2
2a

1.02
276C10015
1. Plug
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
2. Connection to load sensing test point plate (test point load sensing) D
2a. Connection to power steering (LS) (pilot signal)
2b. Connection to (LS1)
3 & 3a. Plugs
4. Connection to main pressure test point plate C
5. Connection to oil tank (D)
6. Connection to (RP1)
7. Plug
A1. Connection to forward right chassis plate for box dumping (raise)
B1. Connection to forward right chassis plate for box dumping (lower)
LS1. Connection to (2b)
P. Connection to emergency steering/dumping group (C1) (feed)
RP. Connection to reduced pressure test point plate B
RP1. Connection to (6)
T. Connection to oil tank (R)
T1. Connection to power steering (t) for tank discharge
Xp. Connection to pilot pressure test point (test point pilot pressure) A
Y. Connection oil tank (C)
12 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

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
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©13

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)
14 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

E. MAIN PUMP

276C1009E

1 Intake from tank opening (E)

2 Delivery to emergency steering/tipping group through main filter opening (P)
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©15

F. EMERGENCY STEERING PUMP

276C1009F

1 Intake from tank opening (D1)

2 Delivery to emergency steering/tipping group opening (P1)
16 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

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)
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©17

H. HEAT EXCHANGER

276C1009H

1 Connection pipe from tipping distributor opening (T)

2 Connection pipe to tank opening (L)
18 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

L. DUMPING CYLINDER

276C1009L

1. Box dumping cylinder

2. Extension delivery
3. Retraction delivery
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©19

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
20 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

N. REAR CHASSIS CONNECTOR PLATE

276C1009N

1. Body dumping cylinders delivery

2. Brakes activations relay valve
(wet brakes version)
3. Rear brakes activation return
4. Accumulator recharge (wet brakes version)
5. Rear steering cylinder
6. Not used
7. Parking brake pneumatic control
8. Electrical connections
9. Greasing
10. Not used
11. Body dumping return
12. Left steering cylinder
13. Rear brakes cooling delivery (wet brakes version)
14. Rear brakes cooling return (wet brakes version)
15. Test point
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©21

MAINTENANCE Changing the fluid

Proceed as follows:
Checking fitting and pipe tightness D wait for the fluid temperature to reach 40 ˚C (104
Visually check for system leaks and tightness of line ˚F);
connections. D tip the engine hood;

Figure 1
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;
D bleed the system as described in the respective pa-
ragraph.
22 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

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 4
Proceed as follows:
D tip the engine hood up;

Figure 2

276NM027T
D loosen the filter cartridge housing (see arrow) using
the hexagonal wrench and carefully clean the hous-
ing; 276NM028T
D disconnect the hoses (1);
Figure 3 D remove the flange (2) and remove the cartridge (3)
from the flange;
D clean the cartridge with detergent and insert it onto
2 the flange;
D apply sealant paste and install the flange;
D connect the hoses;
D fill the reservoir as shown in the specific paragraph.
1

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;

Do not tighten the cartridge excessively.

This could damage the support.

D run the engine for a few minutes and check for oil
leakage;
D close the engine hood.
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©23

STEERING ---DUMPING SYSTEM TEST PROCEDURES

Before performing any intervention, ensure that all precautions have been taken and all aspects cla-
rified 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.
24 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

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
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©25

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 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 100 bar (1500 PSI) to the pressure point (A);
--- a pressure gauge with max range value of 100 bar (1500 PSI) to the pressure point (B);
--- a pressure gauge with max range value of 300 bar (4500 PSI) to the pressure point (C);
--- a pressure gauge with max range value of 200 bar (3000 PSI) to the pressure point (F).

B
A
C

276C10011
26 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

Prescribed pressure values

Test Values
Point Pressure
procedure bar psi
3.1 C Steering pressure 203 + 7 --- 6 2944 + 102 --- 87
3.2 B Reduced pressure 50 ± 3 725 ± 44
3.3 C Dumping pressure (moving struts output) 185 ± 5 2683 ± 73
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 D take the vehicle to the following conditions:
--- engine speed: low idle;
Clear the work area of all personnel since --- hydraulic fluid temperature: 35 ˚C ≤ Toil ≤ 45 ˚C
the stationary steering causes movement of D activate the raise body control until the full extension
the front part of the vehicle. of the cylinders;
D keep the lever engaged and check that at full---travel
Proceed as follows: the pressure falls within the prescribed values.
D start the engine;
D take the vehicle to the following conditions: Test Procedure n. 3.4 --- Dumping back ---pressure ---
--- engine speed: low idle fourth moving strut discharge
--- hydraulic fluid temperature: 35 ˚C ≤ Toil ≤ 45 ˚C
Proceed as follows:
D turn the vehicle completely in both directions;
D perform Test procedure n. 3.3;
D check that in both cases the pressure falls within the
D activate the lower body control;
prescribed values.
D check that the pressure falls within the prescribed
Test Procedure n. 3.2 --- Reduced pressure values.

The reading of the pressure must be perfor-

Clear the work area of all personnel since
med only upon re---entry of the fourth mo-
the stationary steering causes movement of ving strut.
the front part of the vehicle.
Proceed as follows: Test Procedure n. 3.5 --- Piloting pressure
D repeat procedure 3.1;
Proceed as follows:
D check that in both cases the pressure falls within the
D take the vehicle to the following conditions:
prescribed values.
--- engine speed: low idle;
Test Procedure n. 3.3 --- Dumping pressure --- moving --- hydraulic fluid temperature: 35 ˚C ≤ Toil ≤ 45 ˚C
struts output D check that the pressure falls within the prescribed
values.
Proceed as follows:
D start the engine; Test Procedure n. 3.6 --- Anti---saturation (priority)
D use the display to select the BODY ANGLE SET-
TING page from the main menu; Clear the work area of all personnel since
In this manner the body speed management the stationary steering causes movement of
the front part of the vehicle.
strategies are excluded, and the lifting oc-
curs with the nominal pressure for the entire Proceed as follows:
travel. 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 vehi-
cle very quickly;
D check that during this operation the dumping cylin-
ders tend to almost stop due to lack of piloting pres-
sure.
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©27

Left intentionally blank

28 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

REMOVAL---REPLACEMENT OF THE D disconnect the electrical connections:

EMERGENCY STEERING VALVE --- MAIN --- hydraulic system filter obstruction sensor (12);
--- emergency steering pump manostat (13);
FILTER
--- emergency steering pump actuation electro-
Before performing any intervention, ensure magnetic valve (14);
that all precautions have been taken and all --- automatic transmission oil filters obstruction
aspects clarified regarding the safety of per- sensor (15);
sonnel involved in the intervention. D using a suitable lifting device, sling the entire group;
Read the relative instructions provided in D unscrew the retaining screws fastening the group
SECTION 1 of this manual. support bracket (1) to the automatic transmission
In case of doubt, consult a more experien- and remove the group;
ced person. D disassemble the group on the workbench.
Furthermore, respect all the general recom- Replacement
mendations for a correct execution of the Proceed with the replacement by following the detach-
maintenance interventions. ment instructions in the reverse order.
Fill the hydraulic oil tank, following the instructions in
Removal
the relative chapter.
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;
D remove the right side guard following the instruction
in SECTION 15;
D arrange a suitably---sized container underneath, then
drain the hydraulic tank following the instructions in
the relative chapter;
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.
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©29

14

12 1

8
7

4 5

2 3

15

13

276C10017
30 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

DUMPING VALVE REMOVAL--- Additional hydraulic fluid may leak during

REPLACEMENT these operations.

Before carrying out any operation, check . We recommend marking the pipes to
that all precautions have been taken and all facilitate reconnection.
aspects regarding safety of the personnel
D disconnect the following electrical connections:
involved have been clarified.
(16) box raise electrovalve piloting
Read the related instructions given in
SECTION 1 of this manual. (17) box lower electrovalve piloting.
If in doubt, speak to a more experienced D with suitable lifting gear, unscrew and remove the
person. valve (1).
Respect all general recommendations for
Replacement
correct execution of maintenance works.
For replacement, follow the removal instructions in
reverse order.
Removal Fill the main hydraulic tank as instructed in the
Proceed as follows: MAINTENANCE Chapter.
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 remove the right side cover;
D position a suitable container and drain the hydraulic
fluid tank as instructed in the MAINTENANCE
Chapter;
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.
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©31

Dumping valve removal -- replacement

276C10018
32 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

DUMPING CYLINDER REMOVAL--- D using a bridge crane lift the box enough to access
REPLACEMENT the box articulation pins, then lock it in place with
suitable spacers between box and chassis;
Before carrying out any operation, check D unscrew and disconnect the following connectors
that all precautions have been taken and all from the cylinder:
aspects regarding safety of the personnel (2) extension delivery
involved have been clarified. (3) retraction delivery
Read the related instructions given in Hydraulic fluid may leak during these
SECTION 1 of this manual. operations.
If in doubt, speak to a more experienced
person. D harness the cylinder with belts to prevent it falling
Respect all general recommendations for forwards;
correct execution of maintenance works. 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
Removal as instructed in SECTION 1;
Proceed as follows: D remove the harness and support the cylinder (1)
D park the vehicle on a suitable flat and solid surface, with suitable lifting gear;
remove the ignition key, engage the handbrake and D remove the screws (5) fastening the cylinder (1) to
place maintenance warning signs. chassis, along with all bushes and washers, and
D disengage the battery cut ---off switch or disconnect remove the cylinder.
the battery leads to eliminate any risk of
short ---circuit; Replacement
D lock the articulation using the steering lock bar as For replacement, follow the removal instructions in
instructed in SECTION 1; reverse order.
D discharge the air pressure from the main tank and Steer in both directions a few times to free the circuit of
hydraulic pressure from all circuits; air bubbles.
D position a suitable container and drain the hydraulic
fluid tank as instructed in the MAINTENANCE
Chapter;
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©33

Dumping cylinder removal -- replacement

4
1
2

3
34 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

STEERING VALVE REMOVAL--- D discharge the air pressure from the main tank and
REPLACEMENT hydraulic pressure from all circuits;
D lift the cab as instructed in the USE AND
Before carrying out any operation, check MAINTENANCE MANUAL;
that all precautions have been taken and all D position a suitable container and drain the hydraulic
aspects regarding safety of the personnel fluid tank as instructed in the MAINTENANCE
involved have been clarified. Chapter;
Read the related instructions given in D disconnect all connections to the steering valve (1):
SECTION 1 of this manual. (2) LS load signal
If in doubt, speak to a more experienced (3) return (T)
person. (4) Left steering command (L)
Respect all general recommendations for (5) delivery (P)
correct execution of maintenance works. (6) Right steering command (R)

Hydraulic fluid may leak during these

Removal operations.
Proceed as follows:
D park the vehicle on a suitable flat and solid surface, . We recommend marking the pipes to
remove the ignition key, engage the handbrake and
facilitate reconnection.
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
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©35

D Harness the crossbar (1) with suitable belts then Replacement

remove the chassis mounting bolts (2) from both For replacement, follow the removal instructions in
sides; reverse order.
D With suitable lifting gear lift the crossbar and place Fill the main hydraulic tank as instructed in the
it horizontal on a flat surface; MAINTENANCE Chapter.
D Remove screw (3) and remove the valve (4) and
upper flange (5) from the crossbar.

1
4
2
36 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

MAIN PUMP REMOVAL---REPLACEMENT D lift the cab as instructed in the USE AND
MAINTENANCE MANUAL;
Before carrying out any operation, check D position a suitable container and drain the hydraulic
that all precautions have been taken and all fluid tank as instructed in the relative Chapter;
aspects regarding safety of the personnel D disconnect the intake pipe (2) removing the pump
involved have been clarified. side screws and removing the chassis mounting
Read the related instructions given in bracket (see arrow);
SECTION 1 of this manual. D remove the delivery pipe (3) removing the screws
If in doubt, speak to a more experienced from both sides (see arrow);
person. D disconnect the following pipes from the pump:
Respect all general recommendations for (4) LS signal
correct execution of maintenance works. (5) Return
Hydraulic fluid may leak during these
Removal operations.
Proceed as follows: D disconnect the following electrical connections from
D park the vehicle on a suitable flat and solid surface, the pump:
remove the ignition key, engage the handbrake and (6) pump vacuum switch;
place maintenance warning signs. D supporting the pump (1) with suitable means,
D disengage the battery cut ---off switch or disconnect unscrew the screws and remove the pump.
the battery leads to eliminate any risk of
short ---circuit; Replacement
D lock the articulation using the steering lock bar as For replacement, follow the removal instructions in
instructed in SECTION 1; reverse order.
D discharge the air pressure from the main tank and Fill the main hydraulic tank as instructed in the relative
hydraulic pressure from all circuits; Chapter.

276C10016
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©37

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 air pressure from the main tank and
hydraulic pressure from all circuits;

5
4

276C10019
38 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

DUMPING CYLINDER OVERHAUL D Using a flat head screwdriver as a lever, delicately

extract the special polyurethane seal from the seat
Dismantling in the base. Check integrity of the base itself:
Proceed as follows: . If still intact after removal, the seal may be
D Wash the outside of the telescopic cylinder with re---used.
water and a non---flammable detergent to remove
excess dust and grime, then dry it.
Figure 7
Figure 5

18916102
18916100
D Remove the elastic stop rings one at a time starting
D Position the cylinder horizontally in a V vice with the with the smallest diameter one. Move the element
lower end (base side) towards the operator and covering the ring forward using a hammer and a
slightly protruding from the working plane. plastic spacer. Using a screwdriver and a mallet, lift
the ring itself and extract it from its seat taking care
Take care when tightening in the vice not to that it does not spring out;
deat the liner, making dismantling of the
components difficult. Figure 8
D Place a recipient with adequate capacity under the
base.

Figure 6

18916103

D Unscrew the plunger using a long lever and the two

holes on the bottom of the plunger to prevent it rotat-
18916101 ing.
D Two operatives are required to extract the plunger:
D Loosen the base lock screw (detail), then using a one to move the plunger with a hammer and a long
long lever loosen the base by a few turns. Proceed spacer and the other ready to catch it as soon as it
with final removal manually allowing the hydraulic is pushed out.
fluid to drain. It is advisable to extract the plunger from the
opposite end to the base to prevent damage
. Take care not to drop the base.
to the seal.
Pay attention to leakage of the hydraulic
fluid left inside the cylinder itself.
Figure 9
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©39

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
18916104
the elements, which must not be greater than the
given value.
D Once the terminal and plunger are removed, the D Check the integrity of the external (precision
most internal slider can be removed from the base ground) and internal (rolled) surfaces, and for the
side. Lightly tap the element with a mallet and plas- absence of scratches, distortion or dents. If even the
tic spacer to move it and then slide it by hand to pre- smallest defect is found, proceed by replacing the
vent damage to the precision ground surfaces. element.
D Proceed in the same way with the other sliders.

Figure 10

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.
40 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

Rings and seals present on the sliders

Figure 11
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.
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©41

Figure 12 Figure 14

18916107
18916109

D Proceed by inserting the terminal inside the second D Move the entire block of elements forward using a
element from the opposite side to the base. hammer and plastic spacer until revealing the seat
D Grease the seals and guide fitted to the outside of for the base on the liner.
the plunger and apply locktite to the internal thread. D Manually fit the seal on the base in the seat
Figure 13 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).
18916108 D Hold the cylinder under pressure for several min-
utes to check for any oil seepage.
D Insert the plunger inside the second element from D If a suitable test bench is not available, test the cylin-
the base side with the seat of the O---ring turned to der directly on the vehicle, carrying out the same
face the base side itself, then push the plunger until operations as described above.
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.
42 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

STEERING CYLINDER OVERHAUL Figure 17

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 spanner wrench, unscrew the guide head
Figure 15 from the cylinder body.
D Pull out the rod complete with piston and guide
head from the cylinder.

Figure 18

276A010034
D Remove the retaining rings (1) from the front termi-
nal;
D Remove the ball joint (2);
18916202
Figure 16 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);
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©43

Figure 19 Figure 21

18916203
D Place the rod in a vice with soft material between it D Remove the seals
and the jaws. a. external, from the piston
D Using a pin wrench, remove the piston from the rod. b. external, from the guide head
c. internal, from the guide head
Figure 20 d. from the rod

18916204
D Slip the guide head off the rod.
44 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

Assembly Figure 24
All seals must be replaced when assem-
bling.
Carefully lubricate all seals with hydraulic
fluid.
Proceed as follows:

Figure 22

18916208B
D Fit the sealing ring to the outside of the guide head.

Figure 25

18916207

Apply LOCKTITE 243 (arrow) to threads.

D Using a lever, fully tighten the lower joint on the rod.

Figure 23

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 26

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.
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©45

Figure 27 Figure 30

18916211 18916215
D Insert the centring pin (a) into its seat, then apply D Using a spanner wrench fully tighten the guide head
caulking (b) to block it. onto the cylinder body.

Figure 28 Figure 31

276A010035
18916212
D Fit the seals onto the piston starting with the most D Mount the rear spherical joint (1) with the snap stop
internal one. rings (2).
D Mount both the hydraulic pipe fittings. D Remove the cylinder from the vice.

Figure 29 Figure 32

18916214 276A010034
D Delicately insert the rod complete with piston and D Mount the front spherical joint (1) with the snap stop
guide head into the cylinder taking great care not to rings (2).
damage the previously fitted seals.
46 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

STEERING ---DUMPING VALVE BLOCK Figure 34

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 35
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 33

276A010040
D Use a wrench to remove the valve 1.04;

Figure 36

276A010038
D Use a wrench to remove the valve 1.02;

276A010041
D Use a wrench to remove the valve 1.11;
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©47

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
48 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

Figure 37 Figure 40

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 38 ked;

Figure 41
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 39
Figure 42

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.
327B & 330B SECTION 10.1 Copyright
STEERING AND DUMPING SYSTEM ©49

Figure 43 Figure 46

276A010049 276A010052
D Unscrew the calibrated setscrew 1.08; D Remove the threaded connector (if present);
D Unscrew the calibrated setscrew 1.07;
Figure 44
Figure 47

D Remove the threaded plug; 276A010053

D Remove the threaded plug;
Figure 45
Figure 48

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).
50 STEERING AND DUMPING SYSTEM SECTION 10.1 327BCopyright
& 330B ©

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.
 Copyright ©

SECTION 10.2

EMERGENCY STEERING SYSTEM

Copyright ©
327B & 330B SECTION 10.2 Copyright
EMERGENCY STEERING SYSTEM ©1

INDICE
Page.
Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Main component emergency steering system . . . . . 2
Emergency steering hydraulic diagram . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSPECTION PROCEDURES . . . . . . . . . . . . . . . . . . 5
Check the efficiency of the emergency steering
pump control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
EMERGENCY STEERING PUMP
REMOVAL-- REPLACEMENT . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 EMERGENCY STEERING SYSTEM SECTION 10.2 327BCopyright
& 330B ©

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

276C10030
327B & 330B SECTION 10.2 Copyright
EMERGENCY STEERING SYSTEM ©3

Emergency steering hydraulic diagram

1. Main pump with variable displacement 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
4 EMERGENCY STEERING SYSTEM SECTION 10.2 327BCopyright
& 330B ©

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].
327B & 330B SECTION 10.2 Copyright
EMERGENCY STEERING SYSTEM ©5

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.
6 EMERGENCY STEERING SYSTEM SECTION 10.2 327BCopyright
& 330B ©

EMERGENCY STEERING PUMP D lock the articulation using the steering lock bar as
REMOVAL---REPLACEMENT instructed in SECTION 1;
D discharge the air pressure from the main tank and
Before carrying out any operation, check hydraulic pressure from all circuits;
that all precautions have been taken and all D position a suitable container and drain the hydraulic
aspects regarding safety of the personnel fluid tank as instructed in the MAINTENANCE
involved have been clarified. Chapter;
Read the related instructions given in D disconnect the following pipes from the pump:
SECTION 1 of this manual. (2) intake
If in doubt, speak to a more experienced (3) delivery
person. Hydraulic fluid may leak during these
Respect all general recommendations for operations.
correct execution of maintenance works.
D Unscrew and remove the pump (1) and the
O---rings.
Removal
Proceed as follows: Replacement
D park the vehicle on a suitable flat and solid surface, For replacement, follow the removal instructions in
remove the ignition key, engage the handbrake and reverse order.
place maintenance warning signs. Fill the main hydraulic tank as instructed in the
D disengage the battery cut ---off switch or disconnect MAINTENANCE Chapter.
the battery leads to eliminate any risk of
short ---circuit;

2691625
 Copyright ©

SECTION 10.3

BRAKING SYSTEM
Copyright ©
327B & 330B SECTION 10.3 Copyright
BRAKING SYSTEM ©1

CONTENTS
Pag.
BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . 2
Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Service and parking brakes --- location . . . . . . . . . . . 4
Braking system hydraulic diagram . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TOPOGRAPHICAL DIAGRAMS . . . . . . . . . . . . . . . . 7
Forward chassis diagram . . . . . . . . . . . . . . . . . . . . . . 7
Rear chassis diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 8
A. BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 9
C. ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . 10
D. FILTER AND LIMITATION VALVE . . . . . . . . 11
E. BRAKE COMMAND VALVE . . . . . . . . . . . . . 12
H. REAR CHASSIS CONNECTOR PLATE . . . 13
BRAKING SYSTEM TEST PROCEDURES . . . . . . 13
Pressure discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pedal position adjustment . . . . . . . . . . . . . . . . . . . . . 20
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Braking hydraulic system air bleeding . . . . . . . . . . 21
Changing the fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replacing pressurised filter . . . . . . . . . . . . . . . . . . . . 21
Cleaning the (suction) filter . . . . . . . . . . . . . . . . . . . . 21
BRAKE PUMP REMOVAL-- REPLACEMENT . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
HYDRAULIC ACCUMULATOR REMOVAL--
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
RELAY VALVE REMOVAL--
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
 2 BRAKING SYSTEM SECTION 10.3 327BCopyright
& 330B ©

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.
327B & 330B SECTION 10.3 Copyright
BRAKING SYSTEM ©3

Main components of the braking system

Figure 1

276C10035
 4 BRAKING SYSTEM SECTION 10.3 327BCopyright
& 330B ©

Service and parking brakes -- location

Figure 2

Intermediate axle brakes

Front axle brakes

Rear axle
2

1.
2.
3.
1

276C10036
327B & 330B SECTION 10.3 Copyright
BRAKING SYSTEM ©5

Braking system hydraulic schematic (Figure 3 and 4)

1. Brake pump 14. Intermediate axle brake actuators
2. Pressurized filter 15. Rear axle brake actuators
3. Brakes valve (a) Accumulators recharge distributor box
4. 1.4 litre accumulator (b) Adjustment valve
5. 1.4 litre accumulator (c) Accumulators isolation valve
6. Pressure vent (d) Brakes control valve (brake pedal valve)
7. Not used List of pressure vents (n. 6 on the diagram)
8. Accumulator pressure switch H. Rear brakes actuation circuit pressure
9. Brake lights pressure switch I. Front brakes actuation circuit pressure
10. Not used M. Front accumulator refueling pressure
11. Intake filter N. Rear accumulator refueling pressure
12. Tank (pedal valve)
13. Front axle brake actuators

Figure 3
 6 BRAKING SYSTEM SECTION 10.3 327BCopyright
& 330B ©

Figure 4

276C10038

OPERATION
. Refer to the Figures 3 and 4.

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.
* see electrical schematic
327B & 330B SECTION 10.3 Copyright
BRAKING SYSTEM ©7

TOPOGRAPHICAL DIAGRAMS

Forward chassis diagram

Figure 5

276C1039X

A. Brake pump
B. Oil tank
C. Accumulators
D. Filter and limitation valve
E. Brake command valve
 8 BRAKING SYSTEM SECTION 10.3 327BCopyright
& 330B ©

Rear chassis diagram

Figure 6

276C1039Y
F. Rear chassis connector plate
327B & 330B SECTION 10.3 Copyright
BRAKING SYSTEM ©9

A. BRAKE PUMP

Figure 7

276C1039A
1. Intake from tank
2. Delivery to brake command valve outlet (P) through oil filter
 10 BRAKING SYSTEM SECTION 10.3 327BCopyright
& 330B ©

C. ACCUMULATORS
Figure 8

276C1039C

1. Brake control valve opening (R1) connection pipe

2. Brake control valve opening (R2) connection pipe
327B & 330B SECTION 10.3 Copyright
BRAKING SYSTEM ©11

D. FILTER AND LIMITATION VALVE

Figure 9

276C1039D

1. Limitation valve
2. Filter
3. Main pump connection pipe
4. Brake control valve opening (P) connection pipe
 12 BRAKING SYSTEM SECTION 10.3 327BCopyright
& 330B ©

E. BRAKE COMMAND VALVE

Figure 10

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)

F. REAR CHASSIS CONNECTOR PLATE

. See section 10.1 --- Topographical diagrams

327B & 330B SECTION 10.3 Copyright
BRAKING SYSTEM ©13

BRAKING SYSTEM TEST PROCEDURES

Figure 12
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 11

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);
 14 BRAKING SYSTEM SECTION 10.3 327BCopyright
& 330B ©

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: 160 bar (2321 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.
Figure 13

276C10040
327B & 330B SECTION 10.3 Copyright
BRAKING SYSTEM ©15

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 (3000 PSI) to the pressure point (I);
--- a pressure gauge with max range value of 200 bar (3000 PSI) to the pressure point (H);
--- a pressure gauge with max range value of 100 bar (1500 PSI) to the pressure point (M);
--- a pressure gauge with max range value of 100 bar (1500 PSI) to the pressure point (N);

Figure 14

N I
M

276C10041
 16 BRAKING SYSTEM SECTION 10.3 327BCopyright
& 330B ©

Prescribed pressure values

Proce
Proce- Values
Point Pressure
dure 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 (95 ˚F) ≤ T˚ oil ≤ 45 ˚C (113˚ F);
--- 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.
327B & 330B SECTION 10.3 Copyright
BRAKING SYSTEM ©17

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 (3000 PSI) to the pressure point (I);
--- a pressure gauge with max range value of 200 bar (3000 PSI) to the pressure point (H);
--- a pressure gauge with max range value of 200 bar (3000 PSI) to the pressure point (M);
--- a pressure gauge with max range value of 200 bar (3000 PSI) to the pressure point (N).

Figure 15

N I
M 276C10041

Prescribed pressure values

Proce
Proce- Values
Point Pressure
dure bar PSI
Front accumulator recharge start pressure 160 + 7 --- 3 231 + 102 --- 44
M
Front accumulator recharge end pressure 195 ± 5 2378 ± 73
41
4.1
Rear accumulator recharge start pressure 160 + 7 --- 3 231 + 102 --- 44
N
Rear accumulator recharge end pressure 195 ± 5 1378 ± 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
 18 BRAKING SYSTEM SECTION 10.3 327BCopyright
& 330B ©

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 (95 ˚F) ≤ T˚ oil ≤ 45 ˚C (113˚ F)
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).

Figure 16
P Final recharge
press

3
2
Starting
recharge press

t 1

276A010092
327B & 330B SECTION 10.3 Copyright
BRAKING SYSTEM ©19

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 (95 ˚F) ≤ T˚ oil ≤ 45 ˚C (113˚ F)
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.

Figure 17
P

R1

R2

F1

1
276A010085
 20 BRAKING SYSTEM SECTION 10.3 327BCopyright
& 330B ©

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.

Figure 18

276A010086
327B & 330B SECTION 10.3 Copyright
BRAKING SYSTEM ©21

MAINTENANCE D check condition of the seals on the cartridge (1): re-

place as required;
Checking fitting and pipe tightness D replace the filtering element by inserting it in the car-
tridge housing. Check that the seals, are correctly
Visually check for system leaks and tightness of line
positioned (2);
connections.
D fill the new cartridge housing with the specified fluid
and apply the same fluid to the seals;
In the event of faults or leakage from any of D install the cartridge housing then loosen;
the circuits, repairs MUST be carried out be-
fore using the vehicle.
Do not tighten the cartridge excessively.
Check by implementing all the specific safe- This could damage the support.
ty precautions.
D run the engine for a few minutes and check for oil
leakage;
Changing the fluid
D close the engine hood.
. For more information see section 10.1.
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.

Proceed as follows: Figure 21

D tip the engine hood up;

Figure 19

276NM029
D loosen the filter cartridge housing (see arrow) using
the hexagonal wrench and carefully clean the hous-
ing; 276NM028T
D disconnect the hoses (1);
Figure 20 D remove the flange (2) and remove the cartridge (3)
from the flange;
D clean the cartridge with detergent and insert it onto
2 the flange;
D apply sealant paste and install the flange;
D connect the hoses;
D fill the reservoir as shown in the specific paragraph.
1

269NM312
 22 BRAKING SYSTEM SECTION 10.3 327BCopyright
& 330B ©

BRAKE PUMP REMOVAL---REPLACEMENT D discharge the air pressure from the main tank and
hydraulic pressure from all circuits;
Before carrying out any operation, check D lift the hood as instructed in the USE AND
that all precautions have been taken and all MAINTENANCE MANUAL;
aspects regarding safety of the personnel D position a suitable container and drain the hydraulic
involved have been clarified. fluid tank as instructed in the MAINTENANCE
Read the related instructions given in Chapter;
SECTION 1 of this manual. D disconnect the following pipes from the pump:
If in doubt, speak to a more experienced (2) intake
person. (3) delivery
Respect all general recommendations for Hydraulic fluid may leak during these
correct execution of maintenance works. 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
the battery leads to eliminate any risk of MAINTENANCE Chapter.
short ---circuit;
D lock the articulation using the steering lock bar as
instructed in SECTION 1;

Figure 22

2691624
327B & 330B SECTION 10.3 Copyright
BRAKING SYSTEM ©23

HYDRAULIC ACCUMULATOR --- D discharge the pneumatic pressure of the main hy-
REPLACEMENT draulic tank and the hydraulic pressure of all the cir-
cuits;
Before performing any intervention, ensure D arrange a suitable container, then proceed to the di-
that all precautions have been taken and all scharge of the hydraulic tank following the instruc-
aspects clarified regarding the safety of per- tions provided in the relative chapter;
sonnel involved in the intervention. D disconnect the connection fitting (1) from the accu-
Read the relative instructions provided in mulator;
SECTION 1 of this manual. There may be a leakage of hydraulic fluid
In case of doubt, consult a more experien- during these operations.
ced person.
Furthermore, respect all the general recom-
The accumulator contains hydraulic fluid. It
mendations for a correct execution of the
maintenance interventions. is advisable to apply a threaded cap to the
fitting.

The procedure described below concerns D unscrew the fastening nut (2) fixing the accumulator
the rear accumulator but is valid for both the to the bracket;
accumulators. D unscrew the tightening screws and open the sup-
port clamps (2) so as to free the accumulator;
D remove the accumulator (3).
Removal
Do as follows: Replacement
D bring the vehicle onto an appropriately solid flat sur- Proceed with the replacement by performing the
face, shut off the engine, remove the key from the removal steps in the reverse order.
ignition switch, engage the parking brake and affix Proceed with the filling of the hydraulic oil tank by fol-
the indication signs; lowing the instructions provided in the relative chapter.
D disconnect the battery---disconnect switch or di-
Proceed to the bleeding of the braking cir-
sconnect the battery terminals in order to eliminate
cuit by following the instructions provided in
any risk of short ---circuit;
the relative chapter.
D block the articulation by means of the steering lock
bar, as indicated in SECTION 1;
Figure 23

276C10042
 24 BRAKING SYSTEM SECTION 10.3 327BCopyright
& 330B ©

RELAY VALVE REMOVAL--- D arrange a suitable container, then proceed to the di-
REPLACEMENT scharge of the hydraulic tank following the instruc-
tions provided in the MAINTENANCE chapter;
Before performing any intervention, ensure D disconnect the following piping from the valve:
that all precautions have been taken and all (2) stop ignition control manostat 337 connection
aspects clarified regarding the safety of per- (F1)
sonnel involved in the intervention. (3) accumulator failure manostat 341 connection
Read the relative instructions provided in (F)
SECTION 1 of this manual. (4) connection (P) from the brake pump
In case of doubt, consult a more experien- (5) tandem axle brakes connection (T1)
ced person. (6) front axle brakes connection (T2)
Furthermore, respect all the general recom- (7) connection (R1) to rear accumulator
mendations for a correct execution of the (8) connection (R2) to front accumulator
maintenance interventions. (9) connection (B) to discharge in oil tank
(10) connection (N) to discharge in oil tank

Removal There may be a leakage of hydraulic fluid

during these operations.
Do as follows:
D bring the vehicle onto an appropriately solid flat sur-
face, shut off the engine, remove the key from the D support the accumulator with a suitable jack;
ignition switch, engage the parking brake and affix D unscrew the retaining screws of the bracket and re-
the indication signs; move the valve (1).
D disconnect the battery---disconnect switch or di-
sconnect the battery terminals in order to eliminate Replacement
any risk of short ---circuit; Proceed with the replacement by performing the
D block the articulation by means of the steering lock removal steps in the reverse order.
bar, as indicated in SECTION 1; Proceed with the filling of the hydraulic oil tank by fol-
D discharge the pneumatic pressure of the main hy- lowing the instructions provided in the relative chapter.
draulic tank and the hydraulic pressure of all the cir-
Proceed to the bleeding of the braking cir-
cuits;
cuit by following the instructions provided in
the relative chapter.
Figure 24

276C10043
 Copyright ©

SECTION 11

ELECTRICAL SYSTEM
 Copyright ©

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 327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM© 1

CONTENTS
Page Page

MULTIPLEX SYSTEM OVERVIEW . . . . . . . . . . . . . . 3 LOCATION OF SENSORS AND ACTUATORS . . 30

Conventional control . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
MULTIPLEX system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CAN J1939 LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
CAN LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CAN J1939 line circuit diagram . . . . . . . . . . . . . . . . 37
Static efficiency tests . . . . . . . . . . . . . . . . . . . . . . . . . . 5
EDC ENGINE CONTROL UNIT . . . . . . . . . . . . . . . . 38
Measurement values . . . . . . . . . . . . . . . . . . . . . . . . . . 5
EDC engine control unit PIN---OUT . . . . . . . . . . . . . 39
MULTIPLEX SYSTEM GENERAL DIAGRAM . . . . . 6 “A” Electro---injectors connector . . . . . . . . . . . . . . . . 40
TOPOGRAPHIC DIAGRAMS . . . . . . . . . . . . . . . . . . . 7 Color legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Chassis services wiring . . . . . . . . . . . . . . . . . . . . . . . . 7 “B” chassis connector . . . . . . . . . . . . . . . . . . . . . . . . 41
Engine wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 “C” sensors connector . . . . . . . . . . . . . . . . . . . . . . . . 42
Automatic transmission wiring . . . . . . . . . . . . . . . . . . 9 Color legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Cab wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 TRANSMISSION CONTROL UNIT (TCU) . . . . . . . 43
BULKHEAD CONNECTORS . . . . . . . . . . . . . . . . . . 11 TCU identification plate . . . . . . . . . . . . . . . . . . . . . . . 43
Bulkhead location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Transmission control unit pin---out . . . . . . . . . . . . . . 44
Cab/engine wiring WHITE through bulkhead ELECTRICAL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . 45
connector PIN OUT side . . . . . . . . . . . . . . . . . . . . . . 12
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Cab/services wiring BROWN through bulkhead
connector PIN OUT side . . . . . . . . . . . . . . . . . . . . . . 13 GROUND POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cab/automatic transmission wiring YELLOW Interior control and utility arrangement . . . . . . . . . 48
through bulkhead connector PIN OUT side . . . . . . 14 Interior control and utility arrangement . . . . . . . . . 49
DIAGNOSTIC CONNECTOR PIN-- OUT . . . . . . . . 16 Indicators and warning lights . . . . . . . . . . . . . . . . . . 50

CAN OPEN LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Indicators and warning lights . . . . . . . . . . . . . . . . . . 51

CAN OPEN line block diagram . . . . . . . . . . . . . . . . . 17 CLIMATE CONTROL SYSTEM . . . . . . . . . . . . . . . . 52

CAN OPEN line circuit diagram . . . . . . . . . . . . . . . . 18 Manual climate control . . . . . . . . . . . . . . . . . . . . . . . . 52

BODY COMPUTER SYSTEM COMPONENTS . . . 20 Climate control system air vents . . . . . . . . . . . . . . . 53

CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 RELAYS AND FUSES INTERCONNECTION

CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
CLUSTER location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
MIDAC 1 control unit PIN OUT . . . . . . . . . . . . . . . . . 21 RELAYS AND FUSES . . . . . . . . . . . . . . . . . . . . . . . . 55
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Supplementary relays . . . . . . . . . . . . . . . . . . . . . . . . . 56
HEAD and closing resistor location . . . . . . . . . . . . . 23
Relays, resistors and diodes supplementary . . . . . 57
HEAD control unit PIN OUT . . . . . . . . . . . . . . . . . . . . 24
Fuse overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
HEAD control unit PIN OUT . . . . . . . . . . . . . . . . . . . . 25
Supplementary fuses . . . . . . . . . . . . . . . . . . . . . . . . . 59
MIDAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Fusebox component wiring . . . . . . . . . . . . . . . . . . . . 60
MIDAC location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
VEHICLE DIAGNOSTIC CONTROL SYSTEM . . . 61
Detachment and reattachment of the MIDAC
connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 List of problems and interventions . . . . . . . . . . . . . . 61

MIDAC 1 control unit PIN---OUT . . . . . . . . . . . . . . . . 28 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

MIDAC 2 control unit PIN---OUT . . . . . . . . . . . . . . . . 29 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 92
Layout electrical system . . . . . . . . . . . . . . . . . . . . . . . 92
2 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

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327B & 330B SECTION 11 Copyright
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
4 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

In MULTIPLEX systems the connection between the various control units is achieved by means of a communica-
tions network, capable of transfering the necessary data 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 MULTIPLEX 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.
327B & 330B SECTION 11 Copyright
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.
6 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

MULTIPLEX SYSTEM GENERAL DIAGRAM

276C11001
327B & 330B SECTION 11 Copyright
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
8 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

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

276C011003
327B & 330B SECTION 11 Copyright
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

276C011004
10 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

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
327B & 330B SECTION 11 Copyright
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: cab/servo---heated mirror wiring interface
To disconnect the connector, proceed as follows:
A. lift the safety catch
B. pull away the connector.
12 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

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
327B & 330B SECTION 11 Copyright
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
14 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

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
327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©15

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16 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

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
327B & 330B SECTION 11 Copyright
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
18 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

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. MIDAC 3 (slave 3)
9. Rear chassis articulation plate connector

A. 120 Ohm closing resistor

B. 120 Ohm closing resistor
327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©19

CAN OPEN line circuit diagram

C D

276C11006
20 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

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
327B & 330B SECTION 11 Copyright
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
22 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

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 to +30 Volt DC (direct power supply on vehicle)
Separate power supply for microprocessor and outputs
Operating temperature: ---25 °C to +70 °C
Storage temperature: ---35 °C to +85 °C
Power absorption on stand---by: 500 mA
Maximum power absorption: 8 A
327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©23

HEAD and closing resistor location

1. HEAD
2. 120 Ohm resistor (inside HEAD connector)
3. 120 Ohm resistor

276C11007
24 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

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
327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©25

HEAD control unit PIN OUT

PIN Wire code UTILITY SIGNAL
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 FUSE 53
54 7137 Power supply 24 V FUSE 53
55 7137 Power supply 24 V FUSE 53
56 7137 Power supply 24 V FUSE 53

T269IE26
26 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

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 to +32 Volt DC (direct power supply on the vehicle)
Separate power supply for internal logic and outputs
Operating temperature: ---25 ˚C to +70 ˚C
Storage temperature: ---35 ˚C to +85 ˚C
Power absorption on stand---by: 100 mA
Maximum power absorption: 10 A

MIDAC location
1. MIDAC1
2. MIDAC2

1 2

276C11008
327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©27

Detachment and reattachment of the MIDAC con- For reassembly, follow the detachment steps in the re-
nector verse order.
Proceed as follows:
Figure 3
D unscrew the external screw (1) and loosen the inter-
nal retaining screw (2) of the MIDAC;

Figure 1

1
2

276C11011

Make sure that the protective sheathing is

engaged on the small hooks (arrow) on the
276C11009 connector.
D if necessary, unscrew the wiring clamp screw;
D remove the MIDAC from its support;

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.
28 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

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 bath brakes only

276C11010
327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©29

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 bath brakes only

276C11010
30 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

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 bath brakes only

1 2

3 4

276C11015
327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©31

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 bath brakes only

1 5 2

3 4

276C11016
32 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

MIDAC2
1. Body ascent electromagnetic valve 316
2. Body descent electromagnetic valve 317
3. Central distributor lock switch 347
4. Parking brake pressure switch 339
5. Rear brake cooling oil flow transducer (*) 333

(*) versions with oil bath brakes only

1 2 5

3 4

276C11017
 327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©33

MIDAC2
1. Emergency steering pressure switch 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 bath brakes only

1 2 3

4 5 6

276C11018
34 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

HEAD
1. Engine oil level sensor 431 (inactive)
2. Stop ignition control pressure switch 337
3. Accumulator failure pressure switch 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
327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©35

Page left intentionally blank

36 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

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
327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©37

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)

CLUSTER

276C11021
38 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

EDC ENGINE CONTROL UNIT

The EDC engine control unit is located on the right side of the engine block.

276C11025
327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©39

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
40 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

“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
 327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©41

“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 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 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
 42 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

“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 flywheel sensor
10 R Distribution flywheel 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
327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©43

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
44 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

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 Axle difflock preselect switch input 55 Hydraulic control unit Y4 valve input
22 Controller lever input 56 Hydraulic control unit Y2 valve input
23 Battery supply 57 Axle difflock valve output
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
327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©45

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

T269IE01
46 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

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 ground (on the battery negative terminal)

276C11041
327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©47

5. Right chassis --- automatic transmission ground

6. Right chassis --- services ground

276C11042
48 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

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. Not used
20. Longitudinal central 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
327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©49

Interior control and utility arrangement

269NM112
50 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

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. Longitudinal entral differential lock on

2. Not used
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
327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©51

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
52 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

CLIMATE CONTROL SYSTEM

1
Climate control
Controls (Fig. 1)
Knob 1: regulates heater temperature
D Turn clockwise to increase heating
D Turn counter---clockwise to decrease heating (posi-
tion D: OFF)

Button 2: controls entry of outside air into the cab:

D Pressed: flap closed, internal air recirculation
D Not pressed: flap open, air enters from outside

Knob 3: air conditioner adjustment thermostat

D Turn clockwise to increase cooling
D Turn counter---clockwise to decrease cooling (posi-
tion D: OFF)

Knob 4: regulates fan speed

D Turn clockwise to increase speed
D Turn counter---clockwise to decrease speed (posi-
tion D: OFF).
. The air conditioner will not come on if knob
4 is in the OFF position.
269NU2D2
327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©53

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
. Air from all vents is conditioned.

Cool air
Warm air

269NU2E1
54 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

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
327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©55

RELAYS AND FUSES

Relays

269DT0F2

Code Type Description

E1 --- --- --- ---
E2 N Headlights circuit relay
E3 F Contactor for user exclusion during starting phase
E4 N Light flash relay
E5 S --- ---
E6 N Stop lights relay
E7 --- --- –
E8 --- --- --- ---
E9 X Windshield wiper intermittence
E10 N High---beam lights relay
E11 N Work floodlights relay
E12 N Horn relay
E13 --- --- –
E14A --- --- --- ---
E14B --- --- --- ---
E15 --- --- --- ---
56 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

Supplementary relays

269DT0F2

Code Type Description

E17 H Gear in neutral start relay (K1)
E18 H Reverse relay (K2)
E19 H Battery exclusion automation relay
E20 H Start request relay
E21 H Camera relay
E22 H Air conditioning relay
E23 H Automatic lubrication relay
E24 H Battery---disconnect auto---retention relay
E25 H Left side windshield wiper relay
E26 H Right side windshield wiper relay
E27 H Side windshield washer pump relay
E28 H Fuel heater
327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©57

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
58 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

Fuse overview

269DT0F3

Nr. Rat- Function

ing
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
327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©59

Supplementary fuses

269DT0F4

Color code NR Rating 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 on/off power supply
RED
54 15A MIDAC_1 on/off power supply
55 15A MIDAC_2 on/off power supply
56 5A Body potentiometer – Rear brake flow transducer
60 ELECTRICAL SYSTEM SECTION 11 Copyright
327B & 330B ©

Fusebox component wiring

Code Diagram Description

F 50A relay

G Diode block

H 10/20 A exchange micro relay

L 40A relay

N 20A relay

R Resistors

X Windscreen wiper relay

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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

YES

NO

Faulty HEAD Replace

YES

MUX 08

Faulty HEAD Replace

YES

MUX 12

Faulty HEAD Replace

YES

MUX 14

CAN OPEN line not working Run diagnostic procedure (see Procedures:
YES CAN OPEN line)
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MUX 15

CAN J1939 line not working Run diagnostic procedure (see Procedures:
YES CAN J1939 line)

MUX 16

Fuse F52 blown Replace

YES

NO

MIDAC 1 connector disconnected Connect

YES

NO

CAN OPEN line not working Run diagnostic procedure (see Procedures:
YES CAN OPEN line)

NO

CAN J1939 line not working Run diagnostic procedure (see Procedures:
YES CAN J1939 line)

NO

Faulty MIDAC1 Replace

YES
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MUX 17

Fuse F52 blown Replace

YES

NO

MIDAC 2 connector disconnected Connect

YES

NO

CAN OPEN line not working Run diagnostic procedure (see Procedures:
YES CAN OPEN line)

NO

CAN J1939 line not working Run diagnostic procedure (see Procedures:
YES CAN J1939 line)

NO

Faulty MIDAC2 Replace

YES

MUX 19

Faulty MIDAC1 Replace

YES
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MUX 21

Faulty MIDAC2 Replace

YES

MUX 25

Software version not compatible with parame- Reprogram the ECU

ters YES

MUX 41

Connector disconnected Connect the connector

YES

NO

Pneumatic system pressure switch not working Run diagnostic procedure (see Procedures:
YES component 334)
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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
YES

NO

Wrong dryer calibration Check

YES

NO

Tank and/or system piping damaged Replace

YES

NO

Faulty air pressure sensor Replace

YES

MUX 43

Wrong dryer calibration Check

YES

NO

Faulty air pressure sensor Replace

YES
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MUX 44

Connector disconnected Connect the connector

YES

NO

Fuel level sensor not working Run diagnostic procedure (see Procedures:
YES component 326)

MUX 47

Connector disconnected Connect the connector

YES

NO

Hydraulic system temperature sensor not work- Run diagnostic procedure (see Procedures:
ing YES component 325)

MUX 48

Hydraulic oil temperature under minimum level Idle engine until light goes out
when engine is cold YES

NO

Faulty hydraulic fluid temperature sensor Replace

YES
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MUX 49

Hydraulic oil under minimum level Fill to appropriate level

YES

NO

Hydraulic oil temperature exceeding maximum Idle till light goes out
with maximum effort on steering and tipping YES
system in tropical climate (hydraulic system
overheating)

NO

Faulty hydraulic fluid temperature sensor Replace

YES

MUX 65

Connector disconnected Connect the connector

YES

NO

Retarder air pressure sensor does not work Run diagnostic procedure (see Procedures:
YES component 335)
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MUX 66

Insufficient air pressure Check (see MUX 42)

YES

NO

Damaged tubes Fill to appropriate level

YES

NO

Solenoid valve jammed Replace

YES

NO

Faulty air pressure sensor Replace

YES

MUX 67

Excessive air pressure Check (see MUX 43)

YES

NO

Solenoid valve jammed Replace

YES

NO

Faulty air pressure sensor Replace

YES
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MUX 68

Connector disconnected Connect the connector

YES

NO

Body angle position sensor not working Run diagnostic procedure (see Procedures:
YES component 338)

MUX 69

Wrong body potentiometer calibration Calibrate body via display

YES

MUX 70

Wrong body potentiometer calibration Calibrate body via display

YES
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MUX 71

Message can only be displayed with engine oil hot.

Obstructed engine oil filter Replace

YES

MUX 72

Obstructed brake oil filter Replace

YES

MUX 76

Filtro combustibile (su motore) intasato Replace

YES

MUX 77

Obstructed fuel filter (on chassis) Bleed

YES
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MUX 79

Connector disconnected Connect the connector

YES

NO

Brake recharging system pressure switch not Run diagnostic procedure (see Procedures:
working YES component 341)

NO

Inefficient accumulator recharging circuit Check circuit (see 10.3 BRAKING SYSTEM)
YES

NO

Inefficient front and/or rear accumulator Check circuit (see 10.3 BRAKING SYSTEM)
YES

MUX 80

Clogged engine air cleaner Replace

YES

MUX 81

Obstructed hydraulic system oil filter Replace

YES
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MUX 82

Lubricant grease under minimum level Fill to appropriate level

YES

MUX 83

Only for machines fitted with wet oil axles.

Connector disconnected Connect the connector

YES

NO

Brake cooling system front pressure switch not Run diagnostic procedure (see Procedures:
working YES component 349)

MUX 86

Connector disconnected Connect the connector

YES

NO

Body raising solenoid valve not working Run diagnostic procedure (see Procedures:
YES component 316)
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MUX 87

Connector disconnected Connect the connector

YES

NO

Body lowering solenoid valve not working Run diagnostic procedure (see Procedures:
YES component 317)

MUX 88

Only for machines fitted with wet oil axles.

To avoid seriously damaging the brake system, DO NOT start the engine.

Connector disconnected Connect the connector

YES

NO

Engine cooling system solenoid valve is not Run diagnostic procedure (see Procedures:
working YES component 322)
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MOTORE

MUX 89

Connector disconnected Connect the connector

YES

NO

Retarder air solenoid valve not working Run diagnostic procedure (see Procedures:
YES component 319)

MUX 90

Alternator electrical connector disconnected Connect

YES

NO

Faulty rectifier diode bridge Replace

YES

NO

Damaged winding Replace

YES
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MUX 91

Command activated when starting engine Do not touch command until engine started
YES

NO

Faulty microswitch Run diagnostic procedure (see Procedures:

YES component 307)

MUX 92

Command activated when starting engine Do not touch command until engine started
YES

NO

Faulty microswitch Run diagnostic procedure (see Procedures:

YES component 307)

MUX 93

Command activated when starting engine Do not touch command until engine started
YES

NO

Faulty microswitch Run diagnostic procedure (see Procedures:

YES component 308)
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MUX 94

Command activated when starting engine Do not touch command until engine started
YES

NO

Faulty microswitch Run diagnostic procedure (see Procedures:

YES 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

YES

NO

Steering emergency solenoid valve not working Run diagnostic procedure (see Procedures:
YES component 321)
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(MUX 97)

Steering emergency solenoid valve not working Replace pressure switch 336
YES

NO

Main hydraulic system pressure switch not wor- Run diagnostic procedure (see Procedures:
king YES component 336)

NO

Leakage from tubes Fill to appropriate level

YES

NO

Faulty main pump Check main pump

YES

MUX 98

Retarder starts working without being Check solenoid valve (see MUX 89)
controlled YES

NO

Air pressure lower/higher than required value Check electrovalve and/or pneumatic system
YES
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MUX 109

CAN OPEN line not working Run diagnostic procedure (see Procedures:
YES CAN OPEN line)

NO

CLUSTER Replace
YES

MUX 111

CAN OPEN line not working Run diagnostic procedure (see Procedures:
YES CAN OPEN line)

MUX 112

CAN J1939 line not working Run diagnostic procedure (see Procedures:
YES CAN J1939 line)

MUX 113

CAN J1939 line not working Run diagnostic procedure (see Procedures:
YES CAN J1939 line)
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MUX 114

Main hydraulic system pressure switch not Run diagnostic procedure (see Procedures:
functioning YES 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 YES

MUX 118

CAN OPEN line not functioning Run diagnostic procedure (see Procedures:
YES CAN OPEN line)

NO

Faulty HEAD Replace

YES
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MUX 119

Vehicle electrical power supply activated with Deactivate, then activated without pressing
brake pedal pressed YES brake pedal

NO

Connector disconnected Connect the connector

YES

NO

Stop lights pressure switch not functioning Run diagnostic procedure (see Procedures:
YES component 337)

MUX 122

Only for machines fitted with wet oil axles.

Both connectors disconnected Connect connectors

YES

NO

Brake cooling system pressure switches not Run diagnostic procedure (see Procedures:
functioning YES component 349 (front) and component 350
(rear))
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MUX 140

Fuse F52 and/or fuse F54 blown Replace

YES

NO

MIDAC1 connector disconnected Connect the connector

YES

NO

MIDAC1 wiring electrical power fault Repair

YES

MUX 141

Fuse F52 and/or fuse F55 blown Replace

YES

NO

MIDAC2 connector disconnected Connect the connector

YES

NO

MIDAC2 wiring electrical power fault Repair

YES
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MUX 154

Connector disconnected Connect the connector

YES

NO

The pressure sensor of the brake cooler system Run diagnostic procedure (see Procedures:
does not work YES component 333)

MUX 157

Hydraulic filter connector disconnected Connect the connector

YES

MUX 158

Brake oil filter connector disconnected Connect the connector

YES
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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 >=1 Mohm
3. Check between pin D and vehicle ground: resistance must be >=1 Mohm
4. Check between pin C and vehicle power supply (24V batteries): resistance must be >=1 Mohm
5. Check between pin D and vehicle power supply (24V batteries): resistance must be >=1 Mohm
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
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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 >=1 Mohm
3. Check between pin J and vehicle ground: resistance must be >=1 Mohm
4. Check between pin H and vehicle power supply (24V batteries): resistance must be >=1 Mohm
5. Check between pin J and vehicle power supply (24V batteries): resistance must be >=1 Mohm
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
327B & 330B SECTION 11 Copyright
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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

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)
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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
327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©87

338 BODY ANGLE SENSOR (MUX 68)

1. Check integrity of fuses F52 and F55
2. Disconnect the component connector
If not, check wiring (see point 9)
3. Check between pin 1 and the vehicle ground: there must
be the supply voltage (24 Volt).
4. Check between pin 2 and the vehicle ground: there must
be a resistance of 175 ± 10% ohm / must not be in short
circuit to ground
If not, check wiring (see point 9)
5. select the BODY ANGLE SETTING page;
6. Start the engine and leave it in low idle;
7. Activate the raise body raise control;
8. 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
9. Disconnect MIDAC2
10. Check between pin 1 of the component connector and pin 7 of the MIDAC2 connector:
there must be continuity / must not be in short circuit to ground
11. Check between pin 2 of the component connector and pin 16 of the MIDAC2 connector:
there must be continuity / must not be in short circuit to ground
12. Check between pin 7 of the MIDAC2 connector and fuse F55:
there must be continuity / must not be in short circuit to ground
13. 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

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

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
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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

320 FAN DRIVE SOLENOID VALVE (MUX 85)

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 C1 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 B8 of the MIDAC1 connector and fuse F54:
there must be continuity / must not be in short circuit to ground
11. Check between pin A1 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
327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©89

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
90 ELECTRICAL SYSTEM SECTION 11 327BCopyright
& 330B ©

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
327B & 330B SECTION 11 Copyright
ELECTRICAL SYSTEM ©91

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
92 ELECTRICAL SYSTEM SECTION 11 327BCopyright
& 330B ©

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)
 Copyright ©
327B & 330B SECTION 11 ELECTRICAL SYSTEM 93

Layout electrical system (Section 1/5)

 Copyright ©
94 ELECTRICAL SYSTEM SECTION 11 327B & 330B

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 (327, 330, 345 & 340) (opt.)
210 --- ---
211 --- ---
212 Motor tipping hood
213 Tipping hood switch 330 (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
 Copyright ©
327B & 330B SECTION 11 ELECTRICAL SYSTEM 95

Layout electrical system (Section 2/5)

 Copyright ©
96 ELECTRICAL SYSTEM SECTION 11 327B & 330B

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 (330Bt)
304 327B & 330B configuration 333 Weighing pressure transducer rear cooling (330Bt)
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 (330B)
329 Pressure transducer (set ---up)
 Copyright ©
327B & 330B SECTION 11 ELECTRICAL SYSTEM 97

Layout electrical system (Section 3/5)

 Copyright ©
98 ELECTRICAL SYSTEM SECTION 11 327B & 330B

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
 Copyright ©
327B & 330B SECTION 11 ELECTRICAL SYSTEM 99

Layout electrical system (Section 4/5)

 Copyright ©
100 ELECTRICAL SYSTEM SECTION 11 327B & 330B

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 --- ---
 Copyright ©
327B & 330B SECTION 11 ELECTRICAL SYSTEM 101

Layout electrical system (Section 5/5)

 Copyright ©
102 ELECTRICAL SYSTEM SECTION 11 327B & 330B

***

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 Copyright ©

SECTION 12

PNEUMATIC SYSTEM
Copyright ©
 327B & 330B SECTION 12 Copyright
PNEUMATIC SYSTEM© 1

CONTENTS

Page

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

PNEUMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . 4
Pneumatic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

COMPONENTS LOCATION PNEUMATIC

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

MAIN COMPONENTS PNEUMATIC SYSTEM . . . 17

COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

SINGLE-- CHAMBER AIR DRIER . . . . . . . . . . . . . . 17

AIR INTAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 18

PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . 18

PARKING BRAKE ENGAGING

DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

MANUAL CONDENSATION DISCHARGE

VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 PNEUMATIC SYSTEM SECTION 12 Copyright
327B & 330B ©

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327B & 330B SECTION 12 Copyright
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

T269IP03 276C012002

276C012001
 4 PNEUMATIC SYSTEM SECTION 12 Copyright
327B & 330B ©

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
327B & 330B SECTION 12 Copyright
PNEUMATIC SYSTEM© 5

Pneumatic diagram

276C012003
 6 PNEUMATIC SYSTEM SECTION 12 Copyright
327B & 330B ©

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
327B & 330B SECTION 12 Copyright
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
 8 PNEUMATIC SYSTEM SECTION 12 Copyright
327B & 330B ©

1. Retarder control actuator

2. Parking brake control actuator
3. VGT turbine actuator
4. Central splitter lock control actuator

1 2

3 4

276C012004
327B & 330B SECTION 12 Copyright
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
10 PNEUMATIC SYSTEM SECTION 12 Copyright
327B & 330B ©

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
327B & 330B SECTION 12 Copyright
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
12 PNEUMATIC SYSTEM SECTION 12 Copyright
327B & 330B ©

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
327B & 330B SECTION 12 Copyright
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
14 PNEUMATIC SYSTEM SECTION 12 Copyright
327B & 330B ©

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
327B & 330B SECTION 12 Copyright
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
16 PNEUMATIC SYSTEM SECTION 12 Copyright
327B & 330B ©

Checks
It is essential that periodic checks are made on all components of the vehicle.
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
Pressure limiting 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
pipes 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
efficiency. Apart from the apparent physical condition, pipes should be replaced
after significant mileage or after a long period of vehicle use, to avoid sudden failu-
re 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
rating pressure with a soft brush and watching for leaks
327B & 330B SECTION 12 Copyright
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 (120 ± 3 PSI)
18 PNEUMATIC SYSTEM SECTION 12 Copyright
327B & 330B ©

AIR INTAKE VALVE PRESSURE RELIEF VALVE

Figure 4 Figure 5

1 = Supply
2 = To tanks
The function of this component is to interrupt the flow
of compressed air to the main hydraulic tank and limit
It supplies the braking system tanks when the supply the operating pressure of the flow when it reaches a
reaches a pressure value that ensures perfect effi- fixed value (calibration).
ciency.
It also interrupts the compressed air flow when the Calibration: 0.3 --- 0.6 bar (4 --- 9 PSI)
pressure in the tanks drops below a fixed value (calibra-
tion) after a failure or when too much pressure is taken.

Calibration: 6.8 – 7.5 bar (100 --- 108 PSI)

327B & 330B SECTION 12 Copyright
PNEUMATIC SYSTEM ©19

PARKING BRAKE CONTROL MANUAL CONDENSATION DISCHARGE

VALVE
Figure 6
Figure 7

The component is used to manually eliminate any con-

densation that may have accumulated in the system
1 = Supply (from tank) tanks.
2 = Delivery (to parking brake cylinder)
3 = Discharge

The device is fitted in the tractor parking brake circuit

and is used to apply the vehicle’s parking brakes and
discharge compressed air from the spring cylinders.
20 PNEUMATIC SYSTEM SECTION 12 Copyright
327B & 330B ©

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 Copyright ©

SECTION 13

GREASING SYSTEM
Copyright ©
327B & 330B SECTION 13 Copyright
GREASING SYSTEM ©1

CONTENTS

Page

MANUAL GREASING SYSTEM . . . . . . . . . . . . . . . . 2

AUTOMATIC GREASING SYSTEM . . . . . . . . . . . . . 2

Location of the greasing points . . . . . . . . . . . . . . . . . 3

AUTOMATIC GREASING SYSTEM

CALIBTATION ADJUSTMENT . . . . . . . . . . . . . . . . . . 4

GREASING SYSTEM CALIBRATION . . . . . . . . . . . 5

GREASING TIME ADJUSTMENT . . . . . . . . . . . . . . . 6

Restoring grease dispenser functionality . . . . . . . . . 7

Restore operation of the automatic greasing

Control unit after disassembly/draining . . . . . . . . . . 7

CHECKS OF THE LUBRICATION CONTROL UNIT

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DISTRIBUTION DIVIDER . . . . . . . . . . . . . . . . . . . . . . 9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Quantity of lubricant supplied . . . . . . . . . . . . . . . . . . 10
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 GREASING SYSTEM SECTION 13 327BCopyright
& 330B ©

MANUAL GREASING SYSTEM AUTOMATIC GREASE SYSTEM

Figure 2
Figure 1

269NM3F7
The vehicle is equipped with a centralised grease dis-
276DNM0010
pensing system.

The vehicle is equipped with a greasing system, the fit- Filling the reservoir
tings of which are grouped in the rear plate (Fig. 1, see Proceed as follows to fill the grease reservoir:
arrow). D clean the filler grease fitting (Fig. 1, ref. 1);
Proceed as follows: D connect the dispenser to the fitting and fill the tank
D clean the fitting concerned; to the MAX line;
D inject the prescribed grease into the fitting. D disconnect the dispenser and clean the fitting.

To guarantee an efficient lubrication, the lu- Full functionality will be restore after approx-
bricant must be injected until it leaks out imately 10 minutes of operation following re-
from the lubricated points. moval or emptying procedures.
The leakage of lubricant from the maxi-
Lubrication system checks mum---pressure valve (Fig. 1, ref. 2) indica-
tes the presence of a blockage or obstruc-
The opening pressure of a lubricator is
tion in the system.
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.
327B & 330B SECTION 13 Copyright
GREASING SYSTEM ©3

Location of the greasing points

. The points that are lubricated are the same for both the manual and automatic systems.

Circuit Greasing point Circuit Greasing point

B1 Right tipping cylinder upper articulation B11 Right steering cyclinder front articulation
B2 Left tipping cyclinder upper articulation B12 Left steering cylinder front articuation
B3 Rear suspension right rocker B13 Center plate lower hinge
B4 Rear suspension left rocker B14 Center plate upper hing
B5 Right tipping cylinder lower articulation B15 Center plate
B6 Left tipping cylinder lower articulation B16 Center plate
B7 Fixed transmission front bearing B17 Center plate
B8 Fixed transmission rear bearing B18 Center plate
B9 Right steering cylinder rear articulation B19 Center plate
B10 Left steering cylinder rear articulation B20 Center plate

276NM052T
4 GREASING SYSTEM SECTION 13 327BCopyright
& 330B ©

AUTOMATIC GREASING SYSTEM CALIB-

TATION 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.

327B & 330B SECTION 13 Copyright
GREASING SYSTEM ©5

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.
6 GREASING SYSTEM SECTION 13 327BCopyright
& 330B ©

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
60 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.
327B & 330B SECTION 13 Copyright
GREASING SYSTEM ©7

Restoring grease dispenser functionality Restore operation of the automatic greasing control
Grease application will not work if the on of the grease unit after disassembly/draining
lines or greased point (joint) is obstructed. In case of:
Restore operation of the dispenser is very important in D disassembly of the control unit;
this case. D complete draining of the tank.
Proceed as follows: It is necessary restore operation.
D locate the obstructed grease point from which no
grease is being let out; Proceed as follows:
D check that the grease point or tube are not dam- D start the pump from the display as previously in-
aged; replace if required; structed, checking that lubricant is delivered to all
D disconnect pipe from grease gun in question; greasing points;
D inject pressurised lubricant in the fitting until it pours D if these conditions occur, stop the pump;
out of the grease point; D otherwise, check the components (pump, piping,
D reconnect pipe; distributor, grease nipples) as described in the rela-
D start the pump from the display as previously tive chapter.
instructed, checking that lubricant is delivered to all
greasing points.
8 GREASING SYSTEM SECTION 13 327BCopyright
& 330B ©

Checks of the lubrication control unit com- D check the hardness of the pipes between the pump
ponents and distributor and the distributor and lubricating
points;
The working pressure of the system is ap- D normally the pipes should be squeezable when the
proximately 150---200 bar (2175---2900 psi), system is off;
depending on the temperature and type of
lubricant used; The distributor blocks completely even with
The maximum---pressure valve is set at 350 a single element or single pipe blocked.
bar (5075 psi).
The opening pressure of a lubricator is Figure 8
70---80 bar (1015---1160 psi).
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 7

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
276C013002 (the loosening of one of the retaining screws can
D check that the maximum---pressure valve does not block an internal element);
have any leaks; C. Replace the distributor.
D the presence of a leak (arrow) indicates a possible
obstruction or block downstream from the pump;
327B & 330B SECTION 13 Copyright
GREASING SYSTEM ©9

DISTRIBUTION DIVIDER
Description
The lubricant distribution divider is a multiple plunger
device that automatically distributes lubricant to the va-
rious lubrication points.

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. Stage 3
The descriptions that follow also apply to di- When plunger B has reached the left end of its stroke,
viders with more plungers. the channel connecting the arriving lubricant with the
upper right chamber of plunger C opens.
Stage 1 Under pressure plunger C shifts to the left forcing the
lubricant present in the upper left chamber to flow
Lubricant enters the divider from above and fills the lo-
through outlet 5 through the lower left chamber of plun-
wer left chamber of plunger A.
ger B.
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 4
When plunger C has reached the left end of its stroke,
Stage 2 the channel connecting the arriving lubricant with the
upper right chamber of plunger D opens.
When plunger A has reached the left end of its stroke,
Under the pressure, plunger D shifts to the left forcing
the channel connecting the arriving lubricant with the
the lubricant present in the upper left chamber to flow
upper right chamber of plunger B opens.
through outlet 3 through the lower left chamber of plun-
Under pressure plunger B shifts to the left forcing the
ger C.
lubricant in the upper left chamber to flow through ou-
tlet 7 through the lower left chamber of plunger A.
10 GREASING SYSTEM SECTION 13 327BCopyright
& 330B ©

Stage 5 Indicators (B)

When plunger D has reached the left end of its stroke Each block of the divider has an indicator arrow faste-
the channel connecting the arriving lubricant with the ned to the plunger rod.
upper left chamber of plunger A opens. Movement of the rod indicates that the plunger is func-
Under the pressure, plunger A shifts to the right forcing tioning correctly: If the system seizes, the indicator rod
the lubricant present in the upper right chamber to flow no longer moves.
through outlet 1 through the lower left chamber of plun-
ger D. Figure 9
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.

Quantity of lubricant supplied (A)

The standard quantity of lubricant supplied --- corre-
sponding to one stroke of a plunger --- is approximately
0.2 cc.
 Copyright ©

SECTION 14

AIR---CONDITIONING SYSTEM
Copyright ©
327B & 330B SECTION 14 Copyright
AIR-- CONDITIONING SYSTEM © 1

CONTENTS

Page Page

AIR-- CONDITIONING SYSTEM . . . . . . . . . . . . . . . . 2 GENERAL SERVICING . . . . . . . . . . . . . . . . . . . . . . . 11

Functional principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Usable fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Functional outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Draining R134a fluid . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Component layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Works on system piping . . . . . . . . . . . . . . . . . . . . . . 12
Climate control system . . . . . . . . . . . . . . . . . . . . . . . . . 5 Compressor lubricant . . . . . . . . . . . . . . . . . . . . . . . . . 12
Climate control system air vents . . . . . . . . . . . . . . . . 6 ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . 13
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fan not working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fan works but with poor air---flow . . . . . . . . . . . . . . . 8
Normal function but poor air cooling . . . . . . . . . . . . . 8
Compressor not functioning or
functioning poorly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Diagnosis by pressure measurement . . . . . . . . . . . . 9
Low pressure circuit --- insufficient pressure . . . . . . 9
Low pressure circuit --- excessive pressure . . . . . . . 9
High pressure circuit --- insufficient pressure . . . . . . 9
High pressure circuit --- excessive pressure . . . . . . . 9

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
System charge check . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cleaning/replacing passenger air cleaner . . . . . . . 10
Cleaning condenser . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 AIR-- CONDITIONING SYSTEM SECTION 14 327BCopyright
& 330B ©
AIR---CONDITIONING SYSTEM
Functional principle
Fluid in a gaseous state and at pressure 1.3 bar (19 PSI) The air delivered to the cab is thus:
is drawn in by the compressor (driven by the motor by D cold, because it yields part of its heat to the evapor-
a pulley with an electromagnetic coupling) and brought ator, assisting evaporation of the fluid;
to a pressure of 15---20 bar (220---290 PSI) according D dehumidified, since lowering the temperature
to temperature. causes condensation of the water vapour present in
The increase in pressure also determines a significant the warm air.
increase in temperature (80---100˚C (170---212˚F)); to The cooled and dehumidified air is conveyed by an
cool, the fluid passes through the condenser, posi- electric fan and distributed through the outlets located
tioned in front of the engine cooling radiator in the air in the cab.
flow from the fan. In normal conditions the degree of cooling caused by
On cooling the gaseous fluid reaches condensation expansion of the fluid causes the condensation to
point 8 around 60˚C (140 ˚F) and passes to liquid freeze on the fins of the evaporator: the system is there-
state. It then flows through the dehydrator filter where fore fitted with a suitable control device that limits the
it is cleaned and dehumidified by chemicals with mois- heat extraction of the evaporator to prevent this effect
ture absorbing properties. (anti---frost function).
The fluid then in a liquid state reaches the expansion The condensation water is discharged outside the
valve at the intake of the evaporator, which serves to vehicle.
ensure expansion of the pressurised fluid. Expanding, Lastly, from the evaporator the fluid, in gaseous state
the fluid absorbs heat from the surrounding ambient and cooled (on average 6---12˚C (42---53 ˚F)) and at
causing rapid cooling. low pressure, is drawn in by the compressor to start the
The evaporator, cooled by the fluid expanding inside it, cycle again.
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.
327B & 330B SECTION 14 Copyright
AIR-- CONDITIONING SYSTEM © 3
Functional outline
1. Compressor
2. Condenser
3. Engine radiator fan
4. Electric fan
5. Expansion valve
6. Evaporator
7. Dehydrator filter

Vapor high
Pressure

Vapor low
Pressure

2692001
4 AIR-- CONDITIONING SYSTEM SECTION 14 327BCopyright
& 330B ©
Component layout
1. compressor
2. condenser
3. pressure switch
4. cab air filter
5. evaporator
6. heater radiator
7. electric fans
8. controls
9. thermostat

2692002
327B & 330B SECTION 14 Copyright
AIR-- CONDITIONING SYSTEM © 5
Climate control system
Controls Operation
Knob 1: regulates heater temperature: 1. 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 2. 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 3. 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
6 AIR-- CONDITIONING SYSTEM SECTION 14 327BCopyright
& 330B ©
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
327B & 330B SECTION 14 Copyright
AIR-- CONDITIONING SYSTEM © 7

TECHNICAL DATA
Fluid quantity 1.2 Kg (2.2 lb)
1020 m3/h
Max air flow ---rate
(1334 yard3/hr)
Fans (n˚) 1
Open 2 bar (29 PS1)
Two level pressure switch (*)
Close 25 bar (363 PSI)
(*) in the following conditions:
D motor at approximatly 1500 RPM
D ambient temperature 30 --- 35 ˚C (86---95 ˚F)
8 AIR-- CONDITIONING SYSTEM SECTION 14 327BCopyright
& 330B ©
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 Measured pressure in the two Eliminate any leaks
circuits similar Vapour bubbles
present in the dehumidifier
indicator Recharge system
Circuit charge excessive 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 Belts visibly yields under finger Adjust tension
pressure
Damage to compressor with Belt slips even with correct tension Replace if damaged
increased internal resistance
Coupling does not drive Check power supply voltage Recharge or replace batteries
compressor
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
327B & 330B SECTION 14 Copyright
AIR-- CONDITIONING SYSTEM © 9
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 (29---32 PSI)
D high pressure circuit (red connector): 19---25 bar (280---360 PSI)
in the following conditions:
D Engine at circa 1500 rpm
D ambient temperature 30 --- 35˚C (86 --- 95˚F)

Low pressure circuit -- insufficient pressure

Cause Checks Remedies

Faulty thermostat Thermostat cuts off Replace if damaged
electromagnetic coupling when air
temperature is not low enough
Faulty compressor valve and seal Pressure in the two circuits Replace or repair damaged parts
becomes similar when
compressor stops
Compressor internal filter Compressor connection is cold Clean filter
obstructed 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 Checks Remedies
Condenser cooling insufficient Condenser soiled or blocked Clean or replace if damaged
Faulty fan function Replace or repair damaged parts
Faulty compressor valve and seal Pressure in the two circuits Replace or repair damaged parts
becomes similar when
compressor stops
Air present in circuit Eliminate infiltration
Recharge system
10 AIR-- CONDITIONING SYSTEM SECTION 14 327BCopyright
& 330B ©
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 SYSTEM
DRAINING AND RECHARGING PROCEDURES
The checking and recharging operations
must be carried out by suitably equipped ex-
pert personnel. D remove the side board;
R134a (tetrafluoroethane) coolant is used.
This coolant is classified as an environmen- Figure 3
tally---friendly product by law. Do not use this
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.
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-
vice. D remove the filter;
D replace filter or clean with compressed air, max. 5
bars (72 PSI). Reposition and fasten the screws;
D fasten the side board.
Fit the cleaner with the arrows facing the
cab.
Draw a reference line if missing to refit it in
the original position.
327B & 330B SECTION 14 Copyright
AIR-- CONDITIONING SYSTEM ©11
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
D open the hood;
D inspect and clean the condenser with compressed
air max 5 bar (72 PSIi), 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.
12 AIR-- CONDITIONING SYSTEM SECTION 14 327BCopyright
& 330B ©
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.
Always use approved fluid recovery and recharging
equipment. 2692008
Always plug all circuit openings and containers after
Works on system piping maintenance operations to prevent water infiltration.

Figure 7 Lubricant must be changed or topped---up in the fol-

lowing cases:
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.

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).
327B & 330B SECTION 14 AIR-- CONDITIONING SYSTEM 13

Copyright ©
AIR-- CONDITIONING SYSTEM ELECTRICAL SCHEMATIC

1. Switch 2
2. Fuse 3a RØ1
3. Fuse 3a 11 4 AØ1
4. Relay
1
NØ1
5. Thermostat RØ1

6. Electric valve electronic control

7. 24/12 volt transformer -- +15 RØ1 + --
8. 3 speed switch

86

85

87

30
87 a
-- RØ1

9. 3 speed resistor compressor compressor NØ1 3 4 AØ1

10. Centrifugal fan N.O. MØ1

11. 6---way connector RØ1

12. 2---way connector NØ1 NØ1

13. 5---way connector

+15
RØ1
16
14. 3---way connector 17
15. 3---way connector

RØ1

MØ1
16. 3---way connector

V Ø 1.5

RØ1

NØ1
17. Recirculation motor IN + --

18. Potentiometer 5
19. Electric valve

Color code 6 7
3
A LIGHT BLUE
B WHITE
C ORANGE

B Ø 1.5
G YELLOW
H GREY 8 OUT -- +

RØ1
L BLUE
M BROWN

C
N BLAC
R RED

H
S PINK
V GREEN 18
12 14 15

M
Z VIOLET

L
N Ø 1.5

I
LØ1 AØ1
VØ1 BØ1

--

G Ø 1.5
RØ1.5

13 BØ1 VØ1 19
R Ø 1.5
+
10
M Ø 1.5

RØ1 NØ1

M Ø 1.5 H M L

M
9

2692003
14 AIR CONDITIONNING SYSTEM SECTION 14 327B & 330B

Copyright ©
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 Copyright ©

SECTION 15

CAB AND COVERS

Copyright ©
 327B & 330B SECTION 15 Copyright
CAB AND COVERS© 1

CONTENTS

Page Page

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ENGINE HOOD TIPPING CYLINDER . . . . . . . . . . 18

ENGINE HOOD TIPPING HYDRAULIC Detachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Reattachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Component layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CAB TILTING CYLINDER . . . . . . . . . . . . . . . . . . . . . 19
Component layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CAB TIPPING HYDRAULIC SYSTEM . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cab tipping hydraulic system components
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cab tipping hydraulic system diagram . . . . . . . . . . . 9 LOWER COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CAB REMOVAL-- REPLACEMENT . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SIDE COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CAB COMPONENTS REMOVAL--
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 SIDE PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2 CAB AND COVERS SECTION 15 Copyright
327B & 330B ©

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327B & 330B SECTION 15 Copyright
CAB AND COVERS© 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.
4 CAB AND COVERS SECTION 15 Copyright
327B & 330B ©

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.

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

The tipping occurs by pressing the button (see arrow).

327B & 330B SECTION 15 Copyright
CAB AND COVERS© 5

Component layout
1. Manual pump
2. Electric pump 212
3. Hood ylinder
4. Button 213
5. Hood latch

276C015001
6 CAB AND COVERS SECTION 15 Copyright
327B & 330B ©

Component layout
1. Manual pump
2. Electric pump 212
3. Hood cylinder
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.
327B & 330B SECTION 15 Copyright
CAB AND COVERS© 7

Diagram

3
5

1
a
2

M GC

b b

+
213

22
HEAD

276C015002
8 CAB AND COVERS SECTION 15 Copyright
327B & 330B ©

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
327B & 330B SECTION 15 Copyright
CAB AND COVERS© 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.
10 CAB AND COVERS SECTION 15 Copyright
327B & 330B ©

Left intentionally blank

327B & 330B SECTION 15 Copyright
CAB AND COVERS ©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 Used oil and fluids must be collected and
the battery leads to eliminate any risk of disposed of according to standards in force.
short ---circuit;
D lock the articulation using the steering lock bar as Figure 10
instructed in SECTION 1;
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

D Proceed to discharge the air conditioner system as

276NM009T instructed in the chapter on the AIR---CONDITION-
ING SYSTEM;

D turn the heater valve to maximum then open the filler The system must be discharged by special-
cap on the expansion tank; 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.
12 CAB AND COVERS SECTION 15 Copyright
327B & 330B ©

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.
327B & 330B SECTION 15 Copyright
CAB AND COVERS ©13

. The operations described below refer to the Before detaching the hydraulic pipes
prepare plugs suitable for closing the free
following figures.
ends.
Removal of the fastening clamps/clips is not D arrange a suitable container then disconnect the
described. These must be cut/removed and brake pedal valve hydraulic lines:
subsequently replaced to ensure correct --- delivery P from pump (21);
fastening of the clamped components. --- return B to tank (22);
D disconnect the following electrical connections: --- output T1 rear brakes (23);
--- cab power supply (7); --- output T2 front brakes (24);
--- video camera power line (8); --- output R2 to auxiliary brake valve (25);
--- ground braid (9); --- output R1 to relay valve (26);
D disconnect the following air connections: --- discharge N to tank (27).
--- pneumatic seat (10); Coolant may leak during these operations.
--- parking brake delivery (11) and return (12);
D disconnect the following pipes:
D disconnect the hydraulic pipelines:
--- windscreen washer delivery (13);
--- front brakes actuation pressure (28);
--- air---conditioner fluid delivery (14) and return
--- rear brakes actuation pressure (29);
(15);
D open the left mudguard;
--- engine coolant delivery (16) and return (17);
D remove the flexible pipe (30), the connector (31) and
Coolant may leak during these operations. the exhaust silencer (32);
D remove the left side cover;
D remove the clamps from the air---conditioner D remove the split pin and remove the articulation pin
condensation discharge pipes (18); (25) from the cab lifting cylinder, collecting the
D disconnect the automatic lubrication system front shims;
delivery (19) and rear delivery pipes (20): D unscrew the universal joint screws at the groove
(33) and disconnect the steering column from the
steering valve.
14 CAB AND COVERS SECTION 15 Copyright
327B & 330B ©

2691955
327B & 330B SECTION 15 Copyright
CAB AND COVERS ©15

276C015005
16 CAB AND COVERS SECTION 15 Copyright
327B & 330B ©

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.
327B & 330B SECTION 15 Copyright
CAB AND COVERS ©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.
18 CAB AND COVERS SECTION 15 Copyright
327B & 330B ©

CAB COMPONENTS REMOVAL--- D block the articulation by means of the steering lock
REPLACEMENT bar, as indicated in SECTION 1;
D open the hood;
Before carrying out any operation, check D sling the hood to make sure it stays open;
that all precautions have been taken and all D empty the circuit tank of the hood tipping system
aspects regarding safety of the personnel using a suitable suction syringe;
involved have been clarified. D arrange a suitably---sized container underneath,
Read the related instructions given in then disconnect the hydraulic connections (2) from
SECTION 1 of this manual. the cylinder (1);
If in doubt, speak to a more experienced Hydraulic fluid leakage may occur during
person. these operations.
Respect all general recommendations for
correct execution of maintenance works. 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
327B & 330B SECTION 15 Copyright
CAB AND COVERS ©19

CAB TILTING CYLINDER D empty the tipping circuit tank using a suitable
suction syringe;
Removal D arrange a suitably---sized container underneath,
Proceed as follows: then disconnect the hydraulic connections (2) from
D park the vehicle to a suitable flat and solid surface, the cab lifting cylinder (1);
remove the ignition key, engage the handbrake and Hydraulic fluid leakage may occur during
place maintenance warning signs; these operations.
D disengage the battery cut ---off switch or disconnect
the battery leads to eliminate any risk of D remove the seeger (3) and slip off the upper
short ---circuit; trunnion (4) of the cylinder, recovering the shim
D lock the articulation using the steering lock bar as washers;
instructed in SECTION 1; D support the cylinder appropriately, remove the
seeger (5), recovering the shim washers, and slip
Since the engine exhaust system is so near, the cylinder off the lower trunnion (6).
this operation must be carried out after the
end has been stopped for at least four Replacement
hours. For replacement, follow the removal instructions in
reverse order.
D open the left mudguard fender; Fill the tank with the specified quantity of fluid.
D remove the left side guard; Open and close several times to fully bleed the circuit:
Top---up the level if necessary.

Figure 21

2691966
20 CAB AND COVERS SECTION 15 Copyright
327B & 330B ©

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
327B & 330B SECTION 15 Copyright
CAB AND COVERS ©21

LOWER COVERS D suitably support the cover (1);

a front cover
Removal b central cover
Proceed as follows: c rear cover
D park the vehicle to a suitable flat and solid surface, D remove the bolts (arrow) fastening the cover to the
remove the ignition key, engage the handbrake and chassis 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
22 CAB AND COVERS SECTION 15 Copyright
327B & 330B ©

SIDE COVERS

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 open the mudguard from the side of the cover to
replace;
D suitably support the cover;
D unscrew the screws and remove the cover.

Replacement
For replacement, follow the removal instructions in
reverse order.
327B & 330B SECTION 15 Copyright
CAB AND COVERS ©23

SIDE PANELS

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;

. The procedure is easier if the hood is open.

D from the outside and then from the upper inside
unhook the rubber panel fasteners;
D remove the panel from the cab and lift it pulling
upwards to free the lower pins.

Replacement
For replacement, follow the removal instructions in
reverse order.
24 CAB AND COVERS SECTION 15 Copyright
327B & 330B ©

Page left intentionally blank

 Copyright ©

SECTION 16

CHASSIS
Copyright ©
 327B & 330B SECTION 16 Copyright
CHASSIS© 1

CONTENTS

Page Page

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TESTS AND CHECKS . . . . . . . . . . . . . . . . . . . . . . . . 17

Front chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Chassis lateral bending check . . . . . . . . . . . . . . . . . 17
Rear chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Chassis lateral bending admitted . . . . . . . . . . . . . . . 17
Articulation joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Finding chassis bending up and down . . . . . . . . . . 18
Interface flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Vertical bending admitted . . . . . . . . . . . . . . . . . . . . . 18

TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . 9 Finding chassis twist . . . . . . . . . . . . . . . . . . . . . . . . . 18

Bending up and down admitted on chassis . . . . . 18
ARTICULATION JOINT
REMOVAL-- REPLACEMENT . . . . . . . . . . . . . . . . . . 10 REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Straightening the chassis . . . . . . . . . . . . . . . . . . . . . 19
Articulation ball joint pre---load adjustment . . . . . . 12
BODY DETACHMENT-- REASSEMBLY . . . . . . . . . 20
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Detachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Reattachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2 CHASSIS SECTION 16 327BCopyright
& 330B ©

Page left intentionally blank

327B & 330B SECTION 16 Copyright
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
4 CHASSIS SECTION 16 327BCopyright
& 330B ©

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
327B & 330B SECTION 16 Copyright
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
6 CHASSIS SECTION 16 327BCopyright
& 330B ©

Articulation joint (Figure 4)

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 (Figure 4)
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
327B & 330B SECTION 16 Copyright
CHASSIS© 7

Figure 4 1 2 3 4

6
7

FWD

11 10 2691905

1 8

2 2691906
8 CHASSIS SECTION 16 327BCopyright
& 330B ©

Interface flange
The connection of the systems between the front and 8. Electrical connections
the rear is by means of an interface flange. 9. Greasing
1. Body dumping cylinders delivery 10. TBD
2. Brakes activations relay valve 11. Body dumping return
(wet brakes version) 12. Left steering cylinder
3. Rear brakes activation return 13. Rear brakes cooling delivery (wet brakes version)
4. Accumulator recharge (wet brakes version) 14. Rear brakes cooling return (wet brakes version)
5. Rear steering cylinder 15. Test point
6. Not used
7. Parking brake pneumatic control

Figure 5

8
5
9
10
11

4
12

13

14

1
15
276C1009N
327B & 330B SECTION 16 Copyright
CHASSIS© 9

TIGHTENING TORQUES

276C016005
10 CHASSIS SECTION 16 327BCopyright
& 330B ©

ARTICULATION JOINT REMOVAL---REPLACEMENT

Before carrying out any operation, check D position suitable supports under the rear of the
chassis, in addition to an adequate forklift under the
that all precautions have been taken and all
front of the chassis;
aspects regarding safety of the personnel
D disconnect the centralised greasing system
involved have been clarified.
connectors;
Read the related instructions given in
D from the articulation hinge (1) disconnect both
SECTION 1 of this manual.
steering command cylinders (5) as instructed in
If in doubt, speak to a more experienced
SECTION 10;
person.
D remove the transmission shaft (6) between
Respect all general recommendations for
transmission and the intermediate axle, as
correct execution of maintenance works
instructed in SECTION 7;
D unscrew the fastening screw (3) and disconnect the
fifth wheel bearing (2) from the front chassis;
Removal D carefully pull the front of the vehicle away to
Proceed as follows: disengage the fifth wheel bearing;
D park the vehicle to a suitable flat and solid surface, Do not pull away by more than 0.5 m to
remove the ignition key, engage the handbrake and prevent damage to electrical and hydraulic
place maintenance warning signs; connections.
D disengage the battery cut ---off switch or disconnect
the battery leads to eliminate any risk of D unscrew the fastening screw (4) and remove the fifth
short ---circuit; articulation joint (2) from articulation hinge (1);

Figure 6
4

3
2691909
327B & 330B SECTION 16 Copyright
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 7

T2691910
12 CHASSIS SECTION 16 327BCopyright
& 330B ©

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;
327B & 330B SECTION 16 Copyright
CHASSIS ©13

Figure 11 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.
D remove the screw and the washer and measure the
thickness X of the copper wire;

2691914
Figure 12

11

12

12

14

14 T2691915
14 CHASSIS SECTION 16 327BCopyright
& 330B ©

D select, from the available replacements, the

adjuster shim (13) with thickness S suitable for
ensuring the specified bearing pre---load.
S = X -- 0.12 mm (0.005 in)
where:
S = shim thickness (13)
X = copper ring thickness after fitting
0.12 mm (0.005 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
327B & 330B SECTION 16 Copyright
CHASSIS ©15

D working on the UPPER pin fit the pin (24) then insert D remove the screw and the washer and measure the
(arrow) a piece of copper wire between the pin and thickness X of the copper wire;
the washer, fit the washer (22) WITHOUT THE
ADJUSTER SHIMS and tighten the screw (21) to the
specified torque.

Figure 14

2691917
D select, from the available replacements, the Replacement
adjuster shim (23) with thickness S suitable for Proceed to fit the hinge to the chassis in reverse order
ensuring the specified bearing pre---load: to removal.
S = X -- 0.12 mm (0.005 in) Tighten the screws fastening the articulation joint to the
S = shim thickness (23) front chassis and to the articulation hinge to the
X = copper ring thickness after fitting specified torque.
0.12 mm (0.005 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
16 CHASSIS SECTION 16 327BCopyright
& 330B ©

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.
327B & 330B SECTION 16 Copyright
CHASSIS ©17

TESTS AND CHECKS

The chassis transmits load weight and component Chassis lateral bending check
weight to springs and axles. It absorbs the stresses
produced during running, e.g. flexure, thrust and Figure 17
torsional force, tensile stress and vibrations.
Chassis conditions are therefore essential for vehicle
operation. Inspect the chassis at regular intervals to
check that chassis and members thereof are free from
cracks or damages, that bolts and rivets are well
tightened especially in the areas submitted to stress,
i.e. on drive support, on cross members and tow hook.
Every crack or distortion of the chassis seriously
impairs chassis resistance to operating stress.
The negative consequences often result in an axial
displacement which has negative effects on the driving
performances and causes earlier tyre wear.
Any additional hole drilled inadequately in the
1731830
connection points with other components can be the
starting cause of serious damages to the chassis.
This also applies to any interference with other parts or
Chassis lateral bending admitted: a=3 mm (0.12 in)
to pits due to rust, since these can increase notch
sensitivity and favour crack formation. Chassis side bending measurement procedure.
Proceed as follows:
Proceed as follows:
Figure 18
D Visually check the chassis controlling the
alignment. If deformations can be seen, free the
relevant part of the chassis for easier measurement.

. Before checking, ascertain that all members

that could, with their imperfections,
influence the exact measurement readings
(for example, tire inflation pressure) are
efficient.
D Carefully check the entire chassis for cracks paying
special attention to highly stressed coupling points
between chassis cross members, brackets, leaf
spring supports and chassis side members.
1731931

D To find the chassis lateral bending plumb the

bearing surfaces starting from the two side
members at intervals of approx. 1 m (3 ft).
D The points obtained must be carefully marked on
the floor.
18 CHASSIS SECTION 16 327BCopyright
& 330B ©

Figure 19 D Use two shims (1) of the same thickness and of a

size that permits a cord to be stretched throught the
straight length of the lower or upper edge plate of
the side member.
D Measure the distance of the side member from the
cord at 1 metre intervals.
D Different cord distance shows position and entity of
actual side member bending.

Finding chassis twist

Figure 22

1731932

D In order to use the plumbed points, stretch a cord

through the aligned points marked.
D the points that are not aligned indicate the
beginning and the entity of the actual strain.

Finding chassis bending up and down

Figure 20

1731835

Bending up and down admitted on chassis: c=1 mm

(0.04 in)
Slight torsion may only be detected with the cab and
mechanical units removed

Proceed as follows:

Figure 23

1731833

Vertical bending admitted: b=1 mm (0.04 in)

Method for measuring chassis bending downwards or
upwards.
Proceed as follows:

Figure 21

1731836

D place the chassis on two stands;

D fasten one side of the chassis to the stand with two
clamps;
D set the other side of the chassis on the knee of an
”L” iron (1) in central position under the rear cross
member;
D place a ruler in cross position and a spirit level (2)
on the ruler and check the readings.
1731934
The same value should result at each check point,
otherwise the chassis is deformed.
327B & 330B SECTION 16 Copyright
CHASSIS ©19

REPAIR OPERATIONS
Figure 26
Precautions

Figure 24

1731839

Straighten chassis lateral bending by wedge heating

the upper and lower edge of the chassis length
1731837 concerned.
When welding, drilling, grinding or cutting near the The wedge point must in the desired bending
pipes of the braking system, especially near plastic direction.
parts or electrical wiring, take adequate precautions to If the base (a) of the two wedges is on the upper edge
protect them, and if necessary, remove them. plate of the side member, the plate must also be
All parts of the chassis that are reconditioned are to be heated, but last.
protected from oxidation and corrosion.
Figure 27
Protection and painting operations are to be carried out
accurately on all the parts involved, following any
instructions, methods, and preventive precautions
indicated by the paint manufacturers.

Straightening the chassis

Figure 25

1731840

Straighten the chassis up or down bending by wedge

heating the upper edge plate of the side member.
When bending down, the base of the wedge (a) is
down, for up bending the base is up.
The relevant lower or upper edge plate of the side
member is to be heated last in the area where the
wedge base lays.
1731838
The chassis reconditioning is obtained by wedge . For greater information on chassis welding,
heating the part concerned with a torch.
see SECTION 1.
During this operation the metal must become cherry
red coinciding with a temperature ranging between
600---680 ˚C (1112---1256 ˚F).
The points already heated must not be re---heated.
Let the heated points cool slowly without using water,
compressed air or other cooling agents.
20 CHASSIS SECTION 16 327BCopyright
& 330B ©

BODY DETACHMENT ---REASSEMBLY D attach the cylinders to the chassis with suitable
belts to prevent them from falling forward;
Before performing any intervention, ensure D unscrew the retaining screws (1) fastening the cylin-
that all precautions have been taken and all der to the body, recovering the bushings and
aspects clarified regarding the safety of per- washers;
sonnel involved in the intervention. D disconnect the body angular position potentiometer
Read the relative instructions provided in lever (arrow);
SECTION 1 of this manual. D unscrew the clamp screws (2) from both sides and
In case of doubt, consult a more experien- remove the pin (3);
ced person. D carefully lift the body;
Furthermore, respect all the general recom- D recover the washers (4), sealing rings (5) and bron-
mendations for a correct execution of the ze bush (6) from both sides.
maintenance interventions.
Reassembly
Detachment (Figure 28) Proceed with the reassembly by following the detach-
ment steps in the reverse order.
Proceed as follows:
D bring the vehicle onto an appropriately solid flat sur- Mount the sealing ring (5) on the edge of the
face, shut off the engine, remove the key from the seat, without making it rest against the bot-
ignition switch, engage the parking brake and affix tom.
the indication signs; Lubricate the lips of the ring before assem-
D disconnect the battery---disconnect switch or di- bly.
sconnect the battery terminals in order to eliminate Perform the calibration of the potentiometer by follo-
any risk of short ---circuit; wing the instructions provided in the OPERATOR’S
D block the articulation by means of the steering lock MANUAL.
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;
327B & 330B SECTION 16 Copyright
CHASSIS ©21

Figure 28

5 4
5

6
5
4 2

276C016006
22 CHASSIS SECTION 16 327BCopyright
& 330B ©

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