Fiat Kobelko Adt25 Shop Manual

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WORKSHOP MANUAL

ADT 25

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ADT 25 INTRODUCTION I

WORKSHOP MANUAL

ADT 25

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IIą INTRODUCTION ADT 25

ASTRA VEICOLI INDUSTRIALI

Product Service
Via Caorsana, 79 - 29100 PIACENZA (Italy)
Tel. 0523/5431 - Fax 0523/597068 - Telex 530148 ASTRA I

Publication no. A3000021

First edition APRIL 2001
Second edition MARCH 2002

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

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

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ADT 25 INTRODUCTION III

Figure 1

174CU01

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IVą INTRODUCTION ADT 25

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ADT 25 INTRODUCTION V

SECTIONS

TITLE SECTION PAGES

INTRODUCTION from I to VIII

CONDITIONS OF USE 1.1 from 1 to 16

SAFETY INSTRUCTIONS 1.2 from 1 to 18

GENERAL SPECIFICATIONS 2 from 1 to 28

ENGINE 3 from 1 to 52

AUTOMATIC TRANSMISSION 7 from 1 to 82

PROPELLER SHAFT 10 from 1 to 10

FRONT AXLE 12.1 from 1 to 50

INTERMEDIATE AXLE 12.2 from 1 to 58

REAR AXLE 12.3 from 1 to 48

BRAKES 13.1 from 1 to 20

WHEELS AND TYRES 13.2 from 1 to 8

SUSPENSION 14 from 1 to 10

STEERING SYSTEM 15 from 1 to 6

HYDRAULIC SYSTEM 16 from 1 to 44

ELECTRICAL SYSTEM 17 from 1 to 30

CAB AND CHASSIS 18 from 1 to 24

BODY 20 from 1 to 4

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VIą INTRODUCTION ADT 25

PARTS

Figure 2

1 3 2

4 6 9 5 7 10 8
174CU02

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

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ADT 25 INTRODUCTION VII

Main vehicle assemblies production numbers

You are advised to make a note of the model and serial The plate location is shown in Section 2-GENERAL
number (PN) and/or production code (PIN) of the main SPECIFICATIONS.
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 axle

intermediate axle

rear axle

suspension cylinder

tipper cylinder

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VIIIą INTRODUCTION ADT 25

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 SECTION 1.1

CONDITIONS OF USE
 ADT 25 SECTION 1.1 CONDITIONS OF USEą1

CONTENTS

Page Page

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 WARRANTY AND LIABILITY OF THE

MANUFACTURER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CONFORMITY MARKING . . . . . . . . . . . . . . . . . . . . . 4
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INFORMATION ON THIS HANDBOOK . . . . . . . . . 5
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warranty coupons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Purpose of this handbook . . . . . . . . . . . . . . . . . . . . . . 6
GENERAL OPERATION RULES . . . . . . . . . . . . . . . 10
To whom this handbook is addressed . . . . . . . . . . . 6
Pre-disassembly preparation . . . . . . . . . . . . . . . . . 10
Safekeeping of this handbook . . . . . . . . . . . . . . . . . . 6
During disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Updates to this handbook . . . . . . . . . . . . . . . . . . . . . . 6
After disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Units of measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
During assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SCHEDULED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Interchangeable parts . . . . . . . . . . . . . . . . . . . . . . . . 13
VEHICLE REPAIR SERVICEMEN . . . . . . . . . . . . . . . 7
Welding on the chassis . . . . . . . . . . . . . . . . . . . . . . . 15
WASTE DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SCRAPPING THE VEHICLE . . . . . . . . . . . . . . . . . . . 8

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2ąCONDITIONS OF USE SECTION 1.1 ADT 25

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ADT 25 SECTION 1.1 CONDITIONS OF USEą3

INTRODUCTION
This technical handbook contains a series of repair
procedures relating to the articulated dump trucks.
Read this handbook carefully before carrying out any
repairs on the vehicle.
Scrupulous observance of the rules and instructions
herein will ensure that repairs are carried out safely and
efficiently.

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

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4ąCONDITIONS OF USE SECTION 1.1 ADT 25

CONFORMITY MARKING
This vehicle was made in compliance with Community Figure 1
Directive 98/37/EEC and amendments (Machinery
Directive).
All parts of the vehicle comply with the aforesaid
directive, as shown by the CE marking.
The plate is located in the position shown in the figure
and must be legible at all times.

LEVEL OF NOISE
Noise outside the vehicle:
Lwa = 108 dB (A)
174CU01A
Noise at driver's seat:
Lpa = 76 dB (A)
Figure 2
measured on identical vehicle, in accordance with
Directive 86/662/EEC.

VIBRATIONS TRANSMITTED TO OPERATOR

Acceleration transmitted to the operator's arms:
weighed average quadratic level
< 2.5 m/s2 (8.2 ft/s2)

Acceleration transmitted to the operator's body:

weighed average quadratic level
< 0.5 m/s2 (1.6 ft/s2)

Measured by means of accelerometer on identical

vehicle running on medium unsurfaced terrain.

Figure 3
174CU02

174CU03

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ADT 25 SECTION 1.1 CONDITIONS OF USEą5

INFORMATION ON THIS HANDBOOK

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

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6ąCONDITIONS OF USE SECTION 1.1 ADT 25

Purpose of this handbook

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

To whom this manual is addressed

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

Safekeeping of this handbook

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

Updates to this handbook

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

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

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ADT 25 SECTION 1.1 CONDITIONS OF USEą7

SCHEDULED USE VEHICLE REPAIR SERVICEMEN

The vehicle described in this handbook was designed Any repairs to the vehicle must be carried out
and made for the following use: exclusively by qualified repair servicemen with the
D to haul excavation material in general; necessary ability and technical knowledge.
D to haul material resulting from interventions on Vehicle servicemen must:
industrial or civilian artefacts in general; D have the operative skills required for construction
D to haul material required to make infrastructures site vehicle maintenance;
and/or industrial or civilian artefacts in general. D be sensitised to respect and adopt safety
The vehicle must be used for such purposes. instructions and precautions.
The vehicle must be in proven and checked conditions The servicemen must be put in the condition to be able
of efficiency for said use, fully respecting the envisaged to work in total safety by means of suitable training
criteria and restrictions of use. periods or courses, so that they are fully aware of the
Specific care must be paid to the following aspects: rules of professional demeanor that must be followed
D do not exceed the payloads specified by the during repairs to the vehicle.
manufacturer; The direct reporting manager must ensure respect of
D do not exceed the gradients specified by the general safety instructions, specifically those
manufacturer; contained in this handbook.
D do not drive the vehicle on loose terrain which can The manager will also ascertain suitability of operating
compromise stability; personnel, in terms of technical skills and
D do not use the vehicle to remove objects or psychological-physical conditions.
products;
D use the vehicle paying special care to the safety
instructions and specifications;
D carry out the ordinary maintenance interventions
specified by the manufacturer;
D carry out the extraordinary maintenance
interventions 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.

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8ąCONDITIONS OF USE SECTION 1.1 ADT 25

WASTE DISPOSAL SCRAPPING THE VEHICLE

Collect and properly dispose of replaced material The vehicle must be scrapped according to the laws in
(brake pads, filters, etc.) and waste material, resulting force, at the end of the vehicle's working life.
from maintenance operations and repairs (material Recycle and demolish the vehicle according to the laws
soaked in fuel, oil, powder, etc.) according to the laws in force.
in force, separately from normal waste. The vehicle must be demolished by expert personnel
Collect and dispose of used lubricants and fluids, using suitable working tools to ensure the required
according to the laws in force. safety conditions.
Collect and dispose of used batteries according to the Demolish the vehicle by separating and collecting the
laws in force. various materials by type to allow recycling and
Drain and recharge the air conditioning system using disposal.
the specific devices, according to the laws in force. Please note that it is forbidden to abandon an obsolete
Furthermore, you are advised to separate ferrous vehicle at a quarry, building site, dump or in the
materials, light alloys and waste plastic materials for environment.
separate recycling. Specific attention must be devoted to certain
components and substances which can pollute the
environment and/or cause injuries, i.e.:
D presence of fuels, coolant fluids, hydraulic oil and
lubricating oils on board;
D presence of batteries and respective electrolyte;
D presence of pressurised gas (tyres, suspension
components, air conditioner);
D presence of solid polluting materials (tyres, brake
pads, plastic parts, filters) or hazardous materials
(glass, windows).
Dispose of these materials according to the laws in
force.

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Fiat Kobelko Adt25 Shop Manual
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ADT 25 SECTION 1.1 CONDITIONS OF USEą9

WARRANTY AND LIABILITY OF THE SERVICE

MANUFACTURER
Warranty coupons
Warranty conditions The manufacturer provides a warranty card to the user
The user must scrupulously observe the precautions with each vehicle.
illustrated in this handbook to ensure validity of the You are advised to use the coupon during the first hours
contractual warranty. Specifically, the user will: of operation of the vehicle.
D respect restrictions of use specified by the
manufacturer; Warranty coupon: after 250 hours of work.
D not implement changes or variants to the vehicle
without the manufacturer's written approval; . Different warranty conditions are valid only
D always carry out the maintenance interventions; if stated on the vehicle purchasing contract.
D always use genuine spare parts;
D ascertain that the personnel called to use the Service
vehicle have the necessary requirements in terms of
Dealerships are available for all types of interventions.
skills and training.
Equipment and expert personnel are available for
The contractual warranty will not be applicable if the
overhauling and repairing operations.
aforesaid conditions are not respected, even in part.
Dealerships can provide information and advice to
ensure the best use of the vehicle.
Liability
The manufacturer declines all direct or indirect Spare parts
liabilities deriving from:
Use genuine spare parts for replacements which can
D disrespect of the instructions contained in this
be ordered from dealers and authorised workshops.
handbook;
Please remember that the following information will be
D use of the vehicle by untrained or unauthorised
required to order spare parts:
personnel;
D vehicle type;
D use non complying with the regulations in force in
D chassis number;
the country where the vehicle was marketed;
D reference and catalogue numbers shown in the
D unauthorised changes and/or repairs;
Spare Parts Catalogue.
D use of other than genuine spare parts.
If the part belongs to a main assembly (engine,
transmission, axles, motors, etc.), you will also need to
specify the assembly model and serial number.

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