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TBL280 Mk4MAINTENANCE MANUAL

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Douglas EquipmentA division of Curtiss-Wright Flow Control (UK) Limited

Douglas House, Village Road, Arle, Cheltenham, Gloucestershire GL51 0AB, EnglandTelephone: 01242 527921 Fax: 01242 221198

http://douglas.cwfc.com

FOREWORD

Douglas Equipment, (the Company) reserves the right to change the specification, design,material, procedures and dimensions of the vehicle described within this manual without priornotice at any time in the future, in accordance with the company policy of continuous productimprovement.

The Company has taken every reasonable effort to supply an accurate and comprehensive guideto the safe and economic running of the vehicle.

Following the instructions for basic maintenance will help to minimise down-time and prolong thevehicle life between major overhauls.

ALL RIGHTS RESERVED

No part of this publication may be reproduced, stored in any retrieval system or transmitted in anyform without prior permission of Douglas Equipment, (the Company).

Compiled and published by Technical Publications Department at the address below.

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MODEL: TBL280

CHASSIS No: DK2892/N5331

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CHANGE OF OWNERSHIP FORM

IN THE EVENT OF THIS TUGMASTER CHANGING OWNERS, PLEASE COMPLETE THISFORM AND RETURN IT TO DOUGLAS EQUIPMENT, AT THE ADDRESS GIVEN BELOW.

COMPANY NAME...............................................................................................................................

COMPANY ADDRESS.......................................................................................................................

..................................................................................................................................................................

................................................................................................................................................................

................................................................................................................................................................

................................................................................................................................................................

POSTAL CODE...................................................................................................................................

TELEPHONE NUMBER.....................................................................................................................

FAX NUMBER.....................................................................................................................................

DATE PURCHASED..........................................................................................................................

MODEL: TBL280

CHASSIS No: DK2892/N5331

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SERVICE BULLETINS FORWARDING ADDRESS DETAILS

(To be completed BY THE CUSTOMER on first receipt of a new DOUGLAS Tugmaster) OCCASIONALLY, IT MAY BE NECESSARY FOR DOUGLAS EQUIPMENT TO SEND OUT SERVICE BULLETINS CONCERNING THIS NEW TRACTOR. TO ENSURE THESE DOCUMENTS REACH THE CORRECT AUTHORITIES, PLEASE COMPLETE THIS FORM AND RETURN IT TO THE AFTER SALES MANAGER, DOUGLAS EQUIPMENT, AT THE ADDRESS GIVEN BELOW. CUSTOMER COMPANY NAME

....................................................................................................................................... SERVICING AUTHORITY CONTACT ADDRESS ....................................................................................................................................... ....................................................................................................................................... ....................................................................................................................................... ....................................................................................................................................... POSTAL CODE............................................................................................................................. TELEPHONE NUMBER................................................................................................................... FAX NUMBER........................................................................................................................ VEHICLE TYPE.............................................................................................................................. CHASSIS NUMBER/S....................................................................................................................

Douglas Equipment

A division of Curtiss-Wright Flow Control (UK) Limited Douglas House

Village Road Cheltenham

GLOS GL51 0AB

Phone: +44 (0)1242 527921 Fax: +44 (0)1242 221198 http://douglas.cwfc.com

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CHASSIS CONFORMITY PLATE

When contacting the Service department, to assist you in looking after your vehicle, it isrecommended that you have available the data from the Chassis Conformity Plate, (exampleshown above). This plate is fitted to the chassis frame and will have the unique chassis number foryour vehicle.

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WORKSHOP MANUAL FOR DOUGLAS-KALMAR TUGMASTER

MODEL TBL280

INDEX

1. ENGINE AND TRANSMISSION

2. COOLING SYSTEM

3. INDUCTION SYSTEM

4. THROTTLE CONTROLS

5. TRANSMISSION CONTROLS

6. DRIVE/STEER AXLE

7. SUPPORT WHEELS

8. STEERING & HYDRAULICS

9. AIRCRAFT NOSEGEAR CRADLE ASSEMBLY

10. PNEUMATIC SYSTEM

11. PROPSHAFTS/TRANSFER BOX/BEVEL BOX

12. CAB HEATER/AIR CONDITIONER

13. RECOMMENDED LUBRICANTS/MAINTENANCE SCHEDULE

14. AMENDMENTS/BULLETINS

15. FILTER KIT

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Workshop\Safety Warning (English) 12-05-11

FOR YOURSAFETY

1 - 6

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Workshop\Safety Warning (English)12-05-11

SAFETY

RESPONSIBILITY - MANUFACTURERS/AGENT/USER

Issue 1 (TGC 8/91)

2 - 6

THE CONTENTS OF THIS DOCUMENT SHOULD NOT BE CONSIDERED A LEGAL OPINION.QUALIFIED LEGAL ADVICE SHOULD BE SOUGHT FOR QUERIES RELATING TO YOURPARTICULAR OPERATION.

Safety in the use of Douglas products is the responsibility of the manufacturer, agent (if applicable)and user. DOUGLAS EQUIPMENT, the manufacturers of the products, develop their range inaccordance with current industry standards ensuring safety in design and construction. Themarketing of either DOUGLAS EQUIPMENT or appointed agent act in a consultative capacity,offering the user advice and assistance in determining the most suitable product for the particularapplication, advice regarding training and equipment maintenance to improve safety in theparticular application.

It is the user’s responsibility to ensure that the tractor units are properly maintained and operated ina safe working environment by suitably trained personnel.

EQUIPMENT SELECTION

Correct matching of mechanical handling equipment to specific application requirementscontributes to a safer and more efficient operation. It is the user’s responsibility to ensure that theoperation of the products is restricted to those duties for which the manufacturer/agent hassupplied the equipment.

If, subsequently, products are to be used for tasks significantly different from those for which it wassupplied, the user should confirm with the manufacturer/agent the suitability for these additionaltasks.

ENGINEERING CAPABILITY

One potential cause of accidents and breakdowns is the use of the tractor units for purposes forwhich they were not specifically designed. Makeshift modifications must not be carried out whichmay also result in a hazardous situation.

Any product modifications and addition of parts must be approved by DOUGLAS EQUIPMENTdesign authority. Replacement parts are available in the event of a breakdown, to assist in ensuringcorrect and safe operation.

The user is responsible for ensuring these engineering actions are correctly carried out on theirequipment.

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3 - 6

STABILITY

The DOUGLAS EQUIPMENT range of products should be used with care on steep gradients.

There are absolute physical limitations on the product’s stability and that stability, during operation,depends on how the unit is operated. The tractor must be operated by a trained operator, inaccordance with the site operating instructions.

It is the user’s responsibility to ensure that all malpractices, e.g. overloading, exceeding speedlimits, operating with incorrect coupling of aircraft/trailers, should be prohibited.

OPERATING LIMITATIONS

The range of DOUGLAS EQUIPMENT products is very extensive. It is the user’s responsibility toensure that the equipment works within the laid down parameters for the particular unit and siteconditions.

HEALTH & SAFETY REQUIREMENT

The requirements will be supplemented by approved regulations, codes of practice and anyrelevant EEC machinery directives.

All users should be familiar with these requirements:

The Employers Section 2 of the Act should:

a) Make arrangements for ensuring, so far as is reasonably practical, safety in connection withthe use, handling, storage and transport of articles and substances.

b) Provide information, instructions, training and supervision as is necessary to ensure thehealth and safety of his employees.

c) Section 6 lists responsibilities of any person who designs, manufactures, imports or suppliesany article for use at work.

Statutory requirements include:

Ensuring safety in design and construction, so far as is reasonably practicable when theequipment is properly used.

Adequate testing and examination of the equipment and provision of information about theuse for which it is designed and has been tested. This should include non-standard items.

d) Section 2 places on the employer responsibility for the provision and maintenance of plantand systems of work that are, so far as is reasonably practicable, safe and without risks tohealth. Replacement parts equal to, or better than the original part, regular maintenance andinspection are implicit in the requirement.

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4 - 6

e) Noise and exhaust emissions must be in accordance with the current regulations.DOUGLAS EQUIPMENT products are supplied in accordance with current regulations.However, in the case of operating tractors with the cab windows open, it may be necessaryto supply the drivers with ear protectors.

f) Operators and occupants of cab can be subjected to vibrational forces which exceedcurrent EEC machinery directive requirements, if driven over rough surfaces and/orsleeping policemen. The driver, during normal operating conditions, will not be subjected tovibrations in excess of the following values:

Driver’s arms: 2,5m/sec2 - value will not be exceeded.Driver’s seatand posterior: 0,5m/sec2 - value will not be exceeded.

g) Ensure employees/operatives are aware of all safety notices within the manuals suppliedand those located on the equipment and ensure they are maintained in a good condition.

h) Ensure that good all-round driver visibility is retained on the equipment during drivingoperation.

OPERATOR TRAINING

DOUGLAS EQUIPMENT supply manuals and driver’s handbooks with every machine, containinginstructions and advice on how to operate and maintain the machinery.

Operator maintenance training courses are also available.

The user is responsible for ensuring that only properly trained personnel operate his/herequipment. This will also produce benefits, such as: material handling efficiency and reducedequipment abuse. It will also make a significant contribution to safe, accident free operation.

OVERHEAD GUARDS

Some DOUGLAS EQUIPMENT machines have overhead guards installed.

PERIODIC MAINTENANCE

DOUGLAS EQUIPMENT constantly update the product designs to minimise maintenance.Additionally, such maintenance as is required has been made easier, by improving serviceaccessibility. Responsibility for maintenance is that of the user, whether he contracts it out, or doesit him/herself.

a) Hydraulic and pneumatic valves controlling flow and pressure must not be tampered with andany protective devices shall be maintained. All adjustments to be undertaken by qualifiedmaintenance workshop staff or trained DOUGLAS staff only.

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5 - 6

b) All lighting equipment on the machine must remain positioned and correctly adjusted toprevent DAZZLE affecting the machine or operatives and personnel in close proximity to themachine.

REPAIRS OR REPLACEMENT PARTS

To keep DOUGLAS EQUIPMENT products operating safely and efficiently, it is recommended thatonly parts approved by DOUGLAS EQUIPMENT be used for repair or replacement.

In certain applications, particularly when operating in confined spaces, exposure to noise andexhaust emissions may constitute, or contribute to, a health hazard.

Environmental conditions existing in the workplace are a result of a combination of many factors,from a multitude of contributing sources and are usually unique to a particular operation. Therefore,the principal responsibility for ensuring compliance with existing standards lies with the user.

In-cab floor matting and anti-slip surfaces must be maintained in good condition.

REFUELLING

Fuel used to propel engine-powered tractors are volatile liquids, which can represent a potential firehazard if proper precautions are not observed during fuelling. In the case of electric tractors, theelectrolyte contained in the batteries is highly corrosive and combustible gases are given off duringcharging. Again, potential hazards if basic safety precautions are not taken.

It is the user’s responsibility to ensure that all legal requirements are complied with as regardsrefuelling on his/her premises.

HAZARD - FIRE RELATED

When there is evidence that rubber substitute components (used in the majority of motor vehicles,including DOUGLAS tractors), have been exposed to fire: DO NOT TOUCH THEM OR THEATTACHED COMPONENTS.

The problem chemical, hydrofloric acid, is a by-product of fluoro-elastomer and is used in themanufacture of oil seals, brake seals, fuel lines, brake/pneumatic lines, gaskets and wiring.

In the event of fire, the adid is released. The material melts into a black, sticky mess which canremain active for TWO YEARS.

IF THIS ACID GETS ON THE SKIN, OBTAIN MEDICAL ADVICE AND TREATMENT IMMEDIATELY.

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6 - 6

ASBESTOS SAFETY WARNING

Handle material carefully, to minimise dust emission.

Unwind rolls of cloth on smooth working surfaces, using a mandril inserted through centre of coil.Do not tear or abrade. Use sharp mechanical cutters, shears or stamping devices. Dampening thematerial will reduce dust. Low machine speeds and/or dust exhaust systems to remove dust at thepoint of emission may be necessary.

For the installation of asbestos fire rope in confined spaces, wear approved respiratory protection.Use an approved industrial vacuum cleaner to remove cutting debris. Store unused material andcut-offs in impermeable wrappings or closed containers.

Prior to the removal of heat embrittled material, dampen thoroughly. Wear approved respiratoryprotection if necessary.

Dispose of waste in heavy gauge plastic sacks, in accordance with the legislative requirements.

FOR FURTHER INFORMATION, CONSULT SUPPLIER’S DATA SHEETS AND NATIONALHEALTH & SAFETY REGULATIONS.

Douglas have eliminated the use of asbestos from all the components under the company’s directcontrol. The above notice has been retained as a reminder for pre-1996 tractor units, plus there isa possibility that certain proprietary special purpose components may include asbestos, hence theimportance of this notice.

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ENGINE AND TRANSMISSION NOTE

FOR FURTHER INFORMATION REGARDING THE ENGINE REFER TO THE MANUFACTURER’S MANUALS SUPPLIED

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12-05-11Technical data\Alternator

ALTERNATOR

IMPORTANT

The engine is fitted with an Alternator. Observe the following:

1. Never break the circuit between the alternator and the battery while the engine is running.If a master switch is fitted, this should not be switched off before the engine has finallystopped.

2. Before carrying out any repairs on the alternator equipment, first always disconnect bothbattery cables. If a rapid-charging of the battery is to be carried out, the battery cablesmust also first be disconnected.

WARNING!

Never test with a screw-driver or such-like against any connection, to see if it emits sparks.

3. The battery, battery cables and terminals should be checked regularly. The battery terminal studsshould be thoroughly cleaned and the cable terminals always tightened and well greased so as toprevent any breakdown in the circuit. All the cables should be well tightened, there must be noloose connections.

WARNING!

Never confuse the battery positive and negative poles when the batteries are being installed. Check belttension at regular intervals.

4. When starting with a spare battery, first check that the spare battery has the same voltage as thestandard battery. Connect the spare battery to the standard battery with + to + and - to -. Removethe spare battery when the engine has started.

NOTE: The cables connecting the standard battery must not be disconnected.

5. If electrical welding is to be done on the engine or on any of the installation components,disconnect and insulate the voltage regulator cables. Also disconnect the earthed battery cableterminal.

1 - 1

Page 3

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MAINTENANCE INSTRUCTIONS FOR

ZF TRANSMISSION TYPE 6 WG 211

THIS DOCUMENT OCCUPIES PAGES 5 to 138 OF THE DOUGLAS MAINTENANCE MANUAL

Page 5

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Order No.: 5871 156 002

ZF – ERGOPOWER

6 WG-211

ZF Passau GmbH Donaustr. 25 - 71 D- 94 034 Passau

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REPAIR MANUAL for

ZF - ERGOPOWER 6 WG-211

I M P O R T A N T I N F O R M A T I O N : Due to the great variety of ZF units it is necessary to limit disassembly and reassembly manuals to a current ZF production unit. Continuous technical upgrading of the ZF units and extensions concerning design options may require differing steps, which can be carried out by qualified specialists without greater difficulties by means of the perspective views included in the corresponding spare parts lists. This disassembly and reassembly manual is based on the design level of a ZF production unit at the time of issue of the manual. For information on description, operation and maintenance please refer to the Operation Manual (ZF Order No.: 5872 365 002). ZF Passau GmbH reserves the right to replace this disassembly and reassembly manual by a successive edition at any time without advance notice. Upon request, ZF Passau GmbH will advise which edition is the latest one. ---------------------------------------------------------------------------------------------------------- ATTENTION: Observe the vehicle manufacturer’s instructions and specifications for the installation and commissioning of the unit!

ZF Passau GmbH Donaustr. 25 - 71 D - 94034 Passau Abt. : ASTDM / Division : ASTDM Nachdruck auch auszugsweise ohne die Genehmigung der ZF Passau GmbH nicht gestattet! Copyright ZF Passau GmbH! Complete or partial reproduction is not permitted! Copyright ZF Passau GmbH! Toute reproduction, même partielle, est interdite! Technische Änderungen vorbehalten! Subject to technical modifications! Sous réserve de modifications techniques! Konstruktionsstand / Design Level / Niveau Technique 2006/02 1.Auflage / 1st Edition / 1ère Édition 2006/02

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T A B L E O F C O N T E N T S Chapt./Page

Preface General Denomination of standard dimensions Conversion table Tightening torques for screws Labeling of identification plate and notes on spare parts ordering Configuration of transmission Measuring points and connections Notes on oil grade and oil fill quantity

0/1

0/2 ... 3

0/4

0/5

0/6

0/7

0/8 ... 9

0/10

0/11

LIST OF TOOLS (required special tools) ILLUSTRATED TABLES

W/1 ... W/5

WB/1 ... WB/12

1. DISASSEMBLY - Electro-hydraulic control and ZF fine filter (remote-mounted filter) 1.1 Remove oil drain plug and oil filler tube 1.2 Dismounting of filter 1.3 Dismounting of electric control unit 2. DISASSEMBLY - Inductive sensor, Hall sensor, breather and temperature sensor 3. DISASSEMBLY - Engine connection and oil pressure pump 3.1 Engine connection 3.2 Oil pressure pump 4. DISASSEMBLY PTO 5. Removal of input shaft and clutches 6. DISASSEMBLY Clutches KV/KR/K1/K2/K3/K4 Input shaft 6.1 Clutch KV 6.2 Clutch KR 6.3 Clutch K1 6.4 Clutch K2 6.5 Clutch K3 6.6 Clutch K4 6.7 Input shaft

1/1 ... 6

1/1 1/2

1/2 … 6

2/1

3/1 ... 2 3/1

3/2 … 2

4/1

5/1 … 3

6.1/1 … 6.7/1

6.1/1 … 4 6.2/1 … 4 6.3/1 … 4 6.4/1 … 4 6.5/1 … 4 6.6/1 … 4

6.7/1

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T A B L E O F C O N T E N T S Chapt./Page 7. Reassembly of clutches KV/KR/K1/K2/K3/K4 Input shaft 7.1 Clutch KV 7.2 Clutch KR 7.3 Clutch K1 7.4 Clutch K2 7.5 Clutch K3 7.6 Clutch K4 7.7 Input shaft 8. Installation of input shaft and clutches 8.1 Preassembly of front and rear transmission housing 8.2 Installation of converter outlet pressure valve 8.3 Insert clutches into transmission housing front part 8.4 Install output flange 9. Reassembly engine connection and oil pressure pump 9.1 Oil pressure pump 9.2 Converter connection 10. Reassembly - PTO 11. Reassembly inductive sensor, Hall sensor, breather and temperature sensor 12. Reassembly - Electro-hydraulic control unit with proportional valves 12.1 Installation of electric control unit 13. Reassembly ZF-fine filter (pressure filter, oil filler tube and oil drain plug 13.1 Installation of ZF-fine filter (pressure filter)

7.1/1 … 7.7/2

7.1/1 … 6 7.2/1 … 6 7.3/1 … 6 7.4/1 … 6 7.5/1 … 6 7.6/1 … 6 7.7/1 … 2

8/1 … 7

8/1 … 2 8/2 … 3 8/3 … 5 8/5 … 7

9/1 … 4

9/1 … 3 9/3 … 4

10/1

11/1

12/1 … 9

12/2

13/1 … 2

13/1

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R e p a i r M a n u a l

Corporate Division Off-Road Driveline Technology

and Axle Systems

5871 156 002 0/1

PREFACE

This documentation has been developed for specialized staff trained by ZF Passau for repair and maintenance work to be made on ZF units.

This documentation describes a ZF series product with a design level valid at the date of edition. Due to the continuous technical upgrading of the product, however, the repair of the unit at your disposal may require both deviating work steps and differing setting and testing data. We would therefore recommend you to entrust masters and servicemen with the work on your ZF product whose practical and theoretical training is constantly updated in our training school. The Service Stations established by ZF Friedrichshafen all over the world offer you: 1. Permanently trained staff 2. Specified equipment, e.g. special tools 3. State-of-the-art genuine ZF spare parts

All work is done there with utmost care and reliability. In addition, repair work carried out by ZF Service Stations is covered by the ZF warranty within the terms of the currently applicable contractual conditions. Any damage resulting from work which is done in an improper and unprofessional manner by third parties and any consequential costs incurred shall be excluded from this contractual liability. This shall also be applicable if other than genuine ZF spare parts are used. ZF Passau GmbH Service Department

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and Axle Systems

5871 156 002 0/2

GENERAL

The Service Manual covers all work required for disassembly and the relating reassembly. When repairing the unit, ensure utmost cleanliness and that the work is done in a professional manner. Dismantle the unit only if any damaged parts must be replaced. After removing screws or nuts, loosen lids and housing parts, which were installed with seals, by slight hammer blows with a plastic hammer. Use suitable pulling devices for removing parts being tightly installed on the shafts, such as bearings, bearing rings and similar. Carry out disassembly and reassembly work on a clean working place. Use special tools which have been developed for this purpose. Prior to reinstallation of the parts, clean contact faces of housings and lids from residues of seals. Remove any burrs or similar irregularities with an oil stone. Clean housings and end covers, in particular corners and angles, with a suitable detergent. Damaged or heavily worn parts must be replaced, with an expert assessing whether parts subject to normal wear during operation, such as bearings, thrust washers etc. will be reinstalled. Parts such as seal rings, locking plates, split pins etc. must generally be replaced. Radial seal rings with worn or broken sealing lip must also be replaced. In particular, ensure that no chips or other foreign bodies remain in the housing. Check the lube oil holes and grooves regarding unhindered passage. Oil according to the relating List of Lubricants shall be applied to all bearings prior to their installation. NOTE: Only a heating furnace or an electric drier is permitted to be used for heating up parts

such as bearings, housings, etc! Parts fitted in heated state must be readjusted after cooling down to ensure a perfect contact.

CAUTION When assembling the unit, exactly observe the tightening torques and setting data indicated in the manual. Tighten screws and nuts according to the enclosed standard table, unless otherwise specified. The use of fluid seals or Molykote is not permitted for the control part in transmissions – due to a possible malfunction.

Never wash disks having organic friction linings (e.g. paper disks - adverse effect on lining adhesion). Only dry cleaning is permitted (leather cloth).

DANGER When using detergents, observe the manufacturer’s instructions regarding their handling.

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and Axle Systems

5871 156 002 0/3

Structure of Service Manual The structure of this manual reflects the sequence of the work steps for completely disassembling the dismantled unit. Special tools required for carrying out the repair work are listed in the current text and in chapters "W“ (List of Special Tools) and "WB" (Illustrated Tables).

Important information on industrial safety

As a basic principle, the workshop carrying out the repair or maintenance of ZF units shall be fully responsible for industrial safety. The observance of all valid safety regulations and legal requirements is a prerequisite for avoiding any damage to persons and products during maintenance and repair work. Repair workshops must familiarize themselves with these regulations prior to starting any work. A suitably trained and skilled staff is required for a proper repair of these ZF products. The repair workshop shall be responsible for the training. The following safety references are used in this manual:

CAUTION

This symbol serves as a reference to special working procedures, methods, information, use of auxiliaries etc... indicated in this repair manual.

DANGER

This symbol identifies situations in which lacking care may lead to personal injury or damage to the product.

NOTE: Thoroughly study this manual before starting any tests or repair work.

NOTE:

Figures, drawings and parts in this manual do not always represent the original; they show the working procedure. Since the figures, drawings and parts are not shown to scale, do not draw any conclusions on size and weight (not even within one and the same illustration.) Carry out work according to the legend.

NOTE: After repair work and tests, the expert staff must verify that the product is perfectly functioning again.

��

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and Axle Systems

5871 156 002 0/4

BEZEICHNUNG DER GESETZLICHEN EINHEITEN DENOMINATION OF STANDARD DIMENSIONS

DÉNOMINATION DES DIMENSIONS STANDARDISÉES

Hinweis : längenbezogene Masse in kg/m; flächenbezogene Masse in t/m2 Note : linear density in kg/m; areal density in t/m2 Nota : densité linéaire en kg/m; densité superficielle en t/m2

Begriff Unit Unité

Formelzeichen Symbol Symbole

Neu Alt New Old Nouveau Vieux

Umrechnung Conversion Conversion

Bemerkungen Note Nota

Masse Mass Masse

m kg (Kilogramm) kg

Kraft Force Force

F N (Newton) kp 1 kp = 9.81 N

Arbeit Work Travail

A J (Joule) kpm 0.102kpm = 1J = 1Nm

Leistung Power Puissance

P KW (Kilowatt) HP (DIN) 1 HP = 0.7355 KW 1 KW = 1.36 HP

Drehmoment Torque Couple

T Nm (Newtonmeter) kpm 1 kpm = 9.81 Nm T (Nm) = F (N) . r (m)

Kraftmoment Moment (Force) Moment (Force)

M Nm (Newtonmeter) kpm 1 kpm = 9.81 Nm M (Nm) = F (N) . r (m)

Druck (Über-) Pressure (Over-) Pression (Sur-)

pü bar atü 1.02 atü = 1.02 kp/cm2

= 1 bar = 750 torr

Drehzahl Speed Nombre de Tours

n min -1 rpm tr/min

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and Axle Systems

5871 156 002 0/5

VERGLEICHSTABELLE FÜR MASSEINHEITEN CONVERSION TABLE

TABLEAU DE CONVERSION

25.40 mm 1 kg ( kilogram ) 9.81 Nm ( 1 kpm ) 1.356 Nm ( 0.138 kpm ) 1 kg / cm

1 bar ( 1.02 kp/cm2 )

0.070 bar ( 0.071 kp/cm2 ) 1 Liter 4.456 Liter 1 Liter 3.785 Liter 1609.344 m 0° C ( Celsius ) 0 ° C ( Celsius )

=

=

=

=

=

=

=

=

=

=

=

=

=

=

1 in ( inch)

2.205 lb ( pounds )

7.233 lbf x ft ( pound force foot)

1 lbf x ft ( pound force foot )

5.560 lb / in ( pound per inch )

14.233 psi (pound force per square inch lbf/in2 )

1 psi ( lbf/in2 )

0.264 Gallon ( Imp. )

1 Gallon ( Imp. )

0.220 Gallon ( US )

1 Gallon ( US )

1 Mile ( land mile)

+ 32° F ( Fahrenheit )

273.15 Kelvin

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and Axle Systems

5871 156 002 0/6

TIGHTENING TORQUES FOR SCREWS (in Nm) ACC. TO ZF STANDARD 148

Friction coefficient: µ tot.= 0.12 for plugs and nuts without rework, as well as phosphated nuts. Tighten manually! Take tightening torques from the following chart, unless otherwise specified:

Metric ISO standard thread DIN 13, page 13 Dimension 8.8 10.9 12.9 M4 2.8 4.1 4.8 M5 5.5 8.1 9.5 M6 9.5 14 16.5 M7 15 23 28 M8 23 34 40 M10 46 68 79 M12 79 115 135 M14 125 185 215 M16 195 280 330 M18 280 390 460 M20 390 560 650 M22 530 750 880 M24 670 960 1100 M27 1000 1400 1650 M30 1350 1900 2250 M33 1850 2600 3000 M36 2350 3300 3900 M39 3000 4300 5100

Metric ISO fine thread DIN 13, page 13

Dimension 8.8 10.9 12.9 M 8 x 1 24 36 43 M 9 x 1 36 53 62 M 10 x 1 52 76 89 M 10 x 1.25 49 72 84 M 12 x 1.25 87 125 150 M 12 x 1.5 83 120 145 M 14 x 1.5 135 200 235 M 16 x 1.5 205 300 360 M 18 x 1.5 310 440 520 M 18 x 2 290 420 490 M 20 x 1.5 430 620 720 M 22 x 1.5 580 820 960 M 24 x 1.5 760 1100 1250 M 24 x 2 730 1050 1200 M 27 x 1.5 1100 1600 1850 M 27 x 2 1050 1500 1800 M 30 x 1.5 1550 2200 2550 M 30 x 2 1500 2100 2500 M33 x 1.5 2050 2900 3400 M 33 x 2 2000 2800 3300 M 36 x 1.5 2700 3800 4450 M 36 x 3 2500 3500 4100 M 39 x 1.5 3450 4900 5700 M 39 x 3 3200 4600 5300

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5871 156 002 0/7

LABELING OF IDENTIFICATION PLATE FOR ZF POWERSHIFT TRANSMISSION

1 = Transmission type 2 = Transmission number 3 = ZF parts list number 4 = Overall transmission ratio 5 = Oil filling (oil specification) 6 = ZF List of Lubricants 7 = Oil fill quantity 8 = Customer number

NOTES ON SPARE PARTS ORDERING:

Please indicate the following information when ordering genuine ZF spare parts:

1. = Transmission type 2. = Unit number 3. = ZF parts list number 4. = Make and type of spare part 5. = Denomination of spare part 6. = Spare part number 7. = Shipping mode Please complete the a.m. details to avoid any mistakes in the delivery of the ordered spare parts.

You will find this information on the identification plate!

1 2

7

3

6

4

5

8

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5871 156 002 0/8

LAYOUT 6 WG-211

1 = Electro-hydraulic control with intermediate sheet and duct plate 2 = Clutch shaft "KV” 3 = Clutch shaft "KR" 4 = Input shaft/ Power take-off “AN/PTO” 5 = Clutch shaft "K2" 6 = Clutch shaft "K4" 7 = Clutch shaft/ Output "K3"/AB” 8 = Clutch shaft "K1

Transmission schematics Gear schematics

K4

K1

KR

AN

KV

PTO

K2

K3/AB

AN

KR

KV

K2

K4

K3/AB

K1

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5871 156 002 0/9

1

2

3

4

5

6

7

8

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5871 156 002 0/10

MEASURING POINTS AND CONNECTIONS 6 WG-211 Carry out measurements when the transmission has reached operating temperature (approx. 80° - 90° C)!

No. DENOMINATION OF ITEM CONNECTION DESIGNATION AT

VALVE BLOCK

Measuring points for hydraulic oil and temperature: 51 = In front of the converter - opening pressure 11+2 bar M10x1 H 53 = Clutch forward 16+2 bar KV M10x1 B 55 = Clutch reverse 16+2 bar KR M10x1 E 56 = Clutch 16+2 bar K1 M10x1 D 57 = Clutch 16+2 bar K2 M10x1 A 58 = Clutch 16+2 bar K3 M10x1 C 60 = Clutch 16+2 bar K4 M10x1 F 63 = Behind the converter Temperature 100° C short-time 120° C M14x1,5 65 = System pressure 16+2,5 bar M10x1 K 67 = WK-shift pressure 15+1 bar M10x1 Measuring points for delivery rates: 15 = Connection to the heat exchanger M33x2 16 = Connection from the heat exchanger M33x2 Inductive transmitter-impulse-speed sensor and switch 21 = Inductive transmitter n Turbine M18x1,5 34 = Speed sensor n output an speedometer --------- 47 = Inductive transmitter n Central gear train M18x1,5 48 = Inductive transmitter n Engine M18x1,5 54 = Filter contamination switch M14x1,5 Connections: 10 = Breather 49 = Plug connection on the elector-hydraulic control unit 68 = WK-Valve

49 48 10 47 21

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5871 156 002 0/11

Detail-A Detail-B

60

56

55

63 (Siehe Detail-B)

15

16

57

67

53

58

34 (Siehe Detail-A)

34

15

63

68 51 48 54 65

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5871 156 002 0/12

NOTES ON THE REQUIRED OIL GRADE:

�� Approved oils for 6 WG-211 powershift transmissions see ZF List of Lubricants TE-ML 03.

�� The list of lubricants is being continuously updated and can be obtained or viewed as follows: - at all ZF plants - at all ZF service centers - Internet http://www.zf.com Informationen/Tech. Informationen

�� Information on description, operation and maintenance see relating operation manual (ZF Order No.: 5872 365 002).

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LIST OF SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

ERGOPOWER 6 WG-211

4657 066 003 / 004

Disassembly chapter/figure

Reassembly chapter/figure

Denomination and Application

Part number

5871 156 002 W/1

1/1

Assembly truck assy # with tilting device Holding fixtures# Clamping angle# For clamping and tilting the transmission assy on the assembly truck.

5870 350 000 5870 350 063 5870 350 124

1/4

Belt wrench Universal use. To loosen the filter cartridge from the filter head.

5870 105 005

1/5

13/1

Socket wrench # TX-40 / 1/2“ Universal use. To loosen and tighten the TORX – screws M8 0736 101 264 / 0736 101 335. See also: Torque wrench 5870 203 034

5873 042 004

1/7

1/13 1/17

12/10 12/13 12/16 12/24 12/31

Socket wrench # TX-27 / 1/2“ Universal use. To loosen and tighten the TORX – screws M5 = 0736 101 094 / 0736 101 257 M6 = 0736 101 259 / 260 / 261 / 407 / 408 / 409 on the control unit. See also: Torque wrench 5870 203 031

5873 042 002

1/7 1/8

12/21 12/27

Adjusting screws # M 6 Universal use. Disassembly and reassembly aid to remove and reinstall the control parts.

5870 204 063

1/20 1/21

12/7

12/12 12/13

Adjusting screws # M 5 Disassembly and reassembly aid to remove and reinstall the housings to the valve block of the control unit.

5870 204 036

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ERGOPOWER 6 WG-211

4657 066 003 / 004




Part number

5871 156 002 W/2

3/1 5/3

Eye-bolts assortment Lifting chain 3-rope Universal use. Disassembly and reassembly aid to remove and reinstall transmission parts.

5870 204 002 5870 281 047

3/4

Puller device To pull off stator hollow shaft / oil pressure pump.

5870 000 107

6.1/3

6.1/15 6.2/14 6.6/2

Grab sleeve # OR Rapid grip # To pull tapered roller bearing 0735 371 723 off the clutch shaft. To be used with: Forcing device #

5873 001 057 5873 011 011

5870 026 100

6.1/4 6.2/3 6.3/3 6.4/3 6.6/3

7/20

7.2/20 7.3/20 7.4/19

7.6/4+21

Set of external pliers A1 – A2 – A3- A4 Universal use. To snap externally clamped retaining rings in and out.

5870 900 015

6.1/5 6.2/4 6.3/6 6.4/6 6.5/5 6.6/4

Two–armed puller Universal use. To pull off and separate transmission parts.

5870 970 004

6.1/8 6.2/8 6.3/9 6.4/9 6.5/8 6.6/9

7/11 7/13

7.2/11 7.2/13

7.3/6+9 7.4/5+8 7.5/6+9

7.6/11+14

Assembly aid # To preload compression spring in the clutches.

5870 345 088

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ERGOPOWER 6 WG-211

4657 066 003 / 004




Part number

5871 156 002 W/3

6.1/12

Cut-off device Puller device To separate the idler gear 4657 375 003 from the shaft 4657 375 012 = KV

5870 300 024 5870 300 033

6.1/13 6.2/13

7/6

7.2/6

Set of internal pliers I1 –I2 – I3 – I4 Universal use. To snap internally clamped retaining rings in and out.

5870 900 013

6.2/2 6.3/2 6.4/2

6.4/14 6.5/2

6.6/14

Grab sleeve # To pull tapered roller bearing 0735 371 732 off the clutch shaft KR To be used with: Forcing device #

5873 001 059

5870 026 100

6.3/14 6.5/13

Grab sleeve # To pull tapered roller bearing 0735 371 733 off the clutch shaft K1 To be used with: Basic tool #

5873 002 038

5873 002 001

6.7/2 6.7/3

Grab sleeve # OR Rapid grip # To pull tapered roller bearing 0735 371 722 off the input shaft. To be used with: Forcing device # OR Basic tool #

5873 001 058 5873 011 014

5870 026 100 5873 001 000

7/2+7+18

7/21 7.2/2+7+18

7.2/21 7.3/2+14+21 7.4/1+13+20 7.5/2+14+21 7.6/1+19+22

7.7/4

Hot air blower # 230 V Hot air blower # 115 V Universal use. To heat up housing and transmission parts.

5870 221 500 5870 221 501

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ERGOPOWER 6 WG-211

4657 066 003 / 004




Part number

5871 156 002 W/4

7/16

7.2/16 7.3/12 7.4/11 7.5/12 7.6/17

Magnetic stand Dial indicator Universal use. To measure disc clearance.

5870 200 055 5870 200 057

7.5/1

Lever riveting pliers # To fit plug 0631 405 052.

5870 320 016

8/8

Drift # To insert converter outlet pressure valve into transmission housing front part.

5870 705 012

8/9

Press fit mandrel To insert indented ring into transmission housing front part.

5870 705 015

8/20

Driver tool # To insert shaft seal 0750 111 116 into transmission housing.

5870 048 237

8/21

Pressure sleeve To press screen sheet 4657 303 014 on the input flange 4644 303 379.

5870 506 142

8/24

Driver tool # Handle # To press on retaining ring 1269 302 164.

5870 057 009 5870 260 002

9/3

Driver tool # Handle # To insert shaft seal 0634 311 837 into pump housing.

5870 055 070 5870 260 002

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ERGOPOWER 6 WG-211

4657 066 003 / 004




Part number

5871 156 002 W/5

9/7

9/10

Adjusting screw # M10 To align and position stator shaft on transmission housing.

5870 204 007

12/10 12/13 12/16 12/24 12/31

Torque wrench # 1 – 12 Nm / ¼“ Universal use. To tighten threaded connection on control unit. To be used in connection with: Reducing adapter # ½“ to ¼“

5870 203 031

5870 656 056

13/1

Torque wrench # 10 – 90 Nm / ½“ Universal use. To tighten threaded connection M8 = 0736 101 264 0736 101 335 on filter head.

5870 203 034

# Important tools

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ZF Passau GmbH Donaustraße 25-71 94034 Passau Ausgabe:/Edition: 02/2006

SpezialS

5870 281 047

ZF - ERGOPOWER6 WG 211ANTRIEB

INPUT4657 066 003 / 004

WB

/01

5870 204 0075870 204 002

5873 011 014 5870 026 1005873 001 058

ODER / OR

5873 011 014 5873 001 000

5870 221 500 5870 221 501

230V 115V

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ZF - ERGOPOWER6 WG 211

4657 066 003 / 004

GETR. GEHAEUSE / FILTERGEARBOX HOUSING / FILTER

WB

/02

5870 350 1245870 350 0635870 350 000

5873 042 004 5870 105 005

5870 204 002 5870 281 047

5870 705 015 5870 705 012

10 - 90 Nm

5870 203 034

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SpezialS

5870 970 004


KUPPLUNG K1COUPLING K1

4657 066 003 / 004

WB

/03

5873 002 001

5873 001 059

5870 221 5015870 221 500

115V230V

5870 026 100

5873 002 038

5870 345 088

5870 900 015

5870 200 055 5870 200 057

010

20

30

4050

60

70

80

90

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5870 970 004


KUPPLUNG K2COUPLING K2

4657 066 003 / 004

WB

/04

5870 026 100

5873 001 059

5870 221 5015870 221 500

115V230V

5870 026 100

5873 001 059

5870 345 088

5870 900 015

5870 200 055 5870 200 057

010

20

30

4050

60

70

80

90

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KUPPLUNG K3

4657 066 003 / 004COUPLING K3

WB

/05

5870 221 5015870 026 100 5870 221 500

115V230V

5873 002 0015870 320 016

ODER / OR

5873 001 059 5870 970 004

5870 345 088

5870 200 055 5870 200 057

010

20

30

4050

60

70

80

90

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5870 970 004


KUPPLUNG K4

4657 066 003 / 004COUPLING K4

WB

/06

5870 026 100

5873 011 011

5870 221 5015870 221 500

115V230V

5870 026 1005870 900 015 5873 001 057

ODER / OR

5873 001 059

ODER / ORODER / OR

5870 345 0885870 200 055 5870 200 057

010

20

30

4050

60

70

80

90

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5870 900 013


KUPPLUNG KV

4657 066 003 / 004COUPLING KV

WB

/07

5873 001 057

5873 011 011

5870 221 5015873 011 011 5870 221 500

115V230V

5870 026 1005873 001 057

ODER/OR

ODER / OR

5870 970 0045870 300 024 5870 900 015

ODER / OR

5870 026 100 5870 300 033

5870 345 088

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5870 900 015ZF - ERGOPOWER6 WG 211

KUPPLUNG KR

4657 066 003 / 004COUPLING KR

WB

/08

5873 001 057 5870 221 5015873 011 011 5870 221 500

115V230V

5870 026 1005873 001 059

ODER / OR

5870 970 004

5870 900 013

ODER / OR

5870 026 100 5870 345 088 5870 200 055 5870 345 057

010

20

30

4050

60

70

80

90

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5870 260 002


ABTRIEB / OUTPUT4657 066 003/004

WB

/9

5870 048 237 5870 057 0095870 506 142

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SCHALTUNG / GEARSHIFT SYS.4657 066 003 / 004

WB

/10

5870 204 063

5873 042 002 5870 203 0315870 656 056

1 - 12 Nm1/2”-1/4”1/2”

M6

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SCHALTUNG / GEARSHIFT SYS.4657 066 003 / 004

WB

/11

5870 204 0365873 042 002 5870 204 0635870 656 056 5870 203 031

1/2” 1/2”-1/4” 1 - 12 Nm M6

5,5Nm

5,5Nm

5,5Nm

M5

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5870 260 002


DRUCKOELPUMPEPRESS. OEL PUMP4657 066 003 / 004

WB

/12

5870 055 070

5870 000 107

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5871 156 002 1/1

1. Electro-hydraulic control unit and

ZF fine filter (remote-mounted filter)

Fix transmission on assembly truck. (S) Assembly truck 5870 350 000 (S) holding fixtures (1) 5870 350 063 (S) Clamping angle (2) 5870 350 124

Figure 1

��

1.1 Remove oil drain plug and oil filler tube Drain oil before starting disassembly! Loosen screw plug (1) and remove seal ring (2).

Figure 2

Loosen hex. screw (1) from tab and hex screws (2) from oil level tube and remove oil level tube (3) with sealing (4).

Figure 3

1

2 2

1

2

1

1

2

4

3

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5871 156 002 1/2

1.2 Dismounting of filter Separate ZF-fine filter (1) from filter head by belt wrench. (S) Belt wrench 5870 105 005

Figure 4

Loosen torx screws (1), separate filter head (2) from transmission housing and remove O-rings (3). (S) Socket wrench TX 40 5873 042 004

Figure 5

1.3 Dismounting of electric control unit Loosen hollow screws, and remove both pipes (1 and 2). 1 = System pressure to lock-up clutch valve 2 = System pressure from lock-up clutch valve to lock-up

clutch

Figure 6

Dismantle control unit (1). Loosen torx screws (2). (S) Socket wrench TX-27 5873 042 002 (S) Adjusting screws M6 5870 204 063

Figure 7

1

1

2 3

2

1

2

1

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5871 156 002 1/3

Remove cpl. control unit (1), seals (2 and 4) and intermediate plate(3). (S) Adjusting screws M6 5870 204 063

Figure 8

Remove differential pressure switch for ZF fine filter from the duct plate. 1 = Switch with O-ring 2 = Piston 3 = Compression spring

Figure 9

Loosen torx screws and separate duct plate (1) and seals (2 and 3) from housing front part.

Figure 10

Pull converter safety valve out of housing hole. 1 = Piston 2 = Compression spring

Figure 11

1

S

2

3 4

1 2 3

2

1

3

1

2

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5871 156 002 1/4

Mark installation position of wiring harness (1) towards valve block (2).

Figure 12

Loosen torx screws (1). (S) Socket wrench TX-27 5873 042 002

Figure 13

Separate duct plate (1), sealings (2 and 4) and intermediate plate (3) from valve block (5).

Figure 14

Mark installation position of connecting housing (4) towards valve block (5) Loosen cyl. screws (1) and remove lock-up clutch valve. Loosen screw neck (2) and remove O-rings. Loosen torx screws (3), and remove connecting housing.

Figure 15

2 1

1

1

3

4

2

5

1

2 3

4

5

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5871 156 002 1/5

Remove retaining clamp (1).

Figure 16

Loosen torx screws (1) and remove lid (2). (S) Socket wrench TX-27 5873 042 002

Figure 17

Remove wiring harness (1). Loosen cyl. screws (3), remove fixing plates and dismount pressure controllers (2).

Figure 18

Loosen cyl. screws on opposite side, remove fixing plates and dismount pressure controllers (1).

Figure 19

1

1

2

3

1

2

1

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5871 156 002 1/6

Loosen two torx screws (1) and temporarily fix housing by means of adjusting screws (S). Then loosen remaining torx screws (Housing is spring-loaded). (S) Adjusting screws 5870 204 036

Figure 20

Separate housing from valve housing by evenly loosening the adjusting screws. (S) Adjusting screws 5870 204 036

Figure 21

Remove single components: 1 = Pressure reducing valve 2 = Vibration damper 3 = Follow-on slide

Figure 22

Remove single components of the opposite side analogously: 1 = Main pressure valve 2 = Vibration damper 3 = Follow-on slide

Figure 23

S 1

1

3

2

1

3 2

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5871 156 002 2/1

2. DISASSEMBLY: Inductive sensor, Hall sensor, breather and temperature sensor

Dismantle positioned parts. 1 = Breather 2 = Inductive sensor - n central gear chain 3 = Inductive sensor - n turbine

Figure 1

Dismantle inductive sensor - n engine (1) and temperature sensor (3) Loosen cyl. screw and remove speed sensor (2). Remove O-ring! 1 = Inductive sensor - n engine (1) 2 = Speed sensor - n output (Hall sensor) 3 = Temperature sensor measuring point „63“ after converter

Figure 2

1

2

3

1

2 3

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5871 156 002 3/1

3. DISASSEMBLY: Engine connection and oil pressure pump

3.1 Engine connection Loosen two hex. screws (2), fit eye bolts (1) and pull off converter by means of lifting device. Separate flexplate (3) from converter. (S) Eye bolts assortment 5870 204 002 (S) Lifting chain 5870 281 047

Figure 1

Loosen threaded connection converter bell-housing/ transmission housing and remove converter bell-housing (1).

Figure 2

Remove O-ring (1). Loosen threaded connection plate/transmission housing and oil pressure pump/ transmission housing, then remove plate (2).

Figure 3

1 2

3

1

2

1

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5871 156 002 3/2

3.2 Oil pressure pump: Pull off stator hollow shaft/oil pressure pump by means of puller and lifting device. (S) Puller 5870 000 107

Figure 4

��

��

Check oil pressure pump! Loosen both cyl. screws (1) and remove control disc.

In case of wear marks in the pump housing or on the control disc, replace the complete oil pressure pump.

Figure 5

Remove snap ring (1) and single components.

1 = Pump housing with rotor 2 = Snap ring 3 = Shaft seal 4 = Support shim 5 = Needle bearing 6 = Ring

Figure 6

1

6 4 2

3 5

1

1

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5871 156 002 4/1

4. DISASSEMBLY PTO Loosen hex. screws (1) and remove lid (2)

Figure 1

Take O-ring (1) out of lid, unsnap and remove retaining ring (2). Pull pump shaft (3) out of housing hole. Unsnap rectangular ring (4)

Figure 2

Snap out retaining ring (1) and press ball bearing (2) off the pump shaft.

Figure 3

1

2

1 2

3 4

2 1

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5871 156 002 5/1

5. Removal of input shaft and clutches Remove locking plate (1), loosen hex. screws, remove disc and O-ring.

Figure 1

Pull-off output flange (1) and remove shaft seal (2) Force out both cylindrical pins (3) Loosen threaded connection (4) housing front and rear part.

Figure 2

Separate housing rear part by means of lifting device. (S) Lifting chain 5870 281 047 (S) Eye-bolt assortment 5870 204 002

Figure 3

Dismantle pipes (system pressure from the electro-hydraulic control unit to the corresponding clutch). Keep the following order to dismantle the pipes: 1 = Pipe K1 2 = Pipe KV 3 = Pipe K3 4 = Pipe K2 5 = Pipe KR

Figure 4

1

1

2 3 4

3

5

4

3

2

1

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5871 156 002 5/2

��

��

Dismantle bearing outer rings from housing front part. Legend: see figure 7

If, contrary to the ZF recommendation, the tapered roller bearings of clutches and input are not replaced, it is imperative to ensure the previous pairing (bearing outer ring/bearing inner ring). Bearing outer ring and bearing inner ring must be marked!

Figure 5

Loosen cyl. screws (1), remove upper screen sheet (2) and sleeves. Remove all rectangular rings (3) from clutches KV, KR, K1; K2, K3, K4 and input shaft. Remove tubes (4) with O-rings.

Figure 6

Lift clutches out of the housing following the numeric order, as described in the legend. 1 = Clutch K3 2 = Clutch K2 3 = Clutch K1 4 = Clutch K4 5 = Clutch KR 6 = Clutch KV 7 = Input shaft

Figure 7

Loosen and remove cyl. screws of suction tube (1) in the housing front part

Figure 8

7

2

1

4

3

5

6

1

3

4 2

1

3 4 7 2

6

5

1

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5871 156 002 5/3

��

��

Dismantle bearing outer rings from housing rear part. Legend: see figure 7

If, contrary to the ZF recommendation, the tapered roller bearings of clutches and input are not replaced, it is imperative to ensure the previous pairing (bearing outer ring/bearing inner ring). Bearing outer ring and bearing inner ring must be marked!

Figure 9

6

7

2

1

3

4

5

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5871 156 002 6.1/1

Figure 1

6. DISASSEMBLY:

Clutches KV/KR/K1/ K2/K3/K4 input shaft 1 = Clutch K3 2 = Clutch K2 3 = Clutch K1 4 = Clutch K4 5 = Clutch KR 6 = Clutch KV 7 = Input shaft

6.1 Clutch KV Unsnap piston ring (1).

Figure 2

Pull tapered roller bearing (internal ring) off the shaft. (S) Forcing device 5870 026 100 (S) Grab sleeve 5873 001 057 or (S) Rapid grip 5873 011 011

Figure 3

Unsnap retaining ring (1). (S) Set of external pliers 5870 900 015

Figure 4

1

S

1

1

3 4 7 2

6

5

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5871 156 002 6.1/2

Pull clutch (1) off the shaft. (S) Two-armed puller 5870 970 004

Figure 5

Remove snap ring (1).

Figure 6

Remove end plate (1) and disc package (2) from disc carrier (3).

Figure 7

Preload compression spring and remove snap ring (1). (S) Assembly aid 5870 345 088

Figure 8

1

1

2

3

1

S

1

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5871 156 002 6.1/3

Remove guide ring (1), compression spring (2) and disc (3).

Figure 9

Lift piston (1) off the disc package by compressed air out of hole, and remove it.

Figure 10

Remove both O-rings (1 and 2).

Figure 11

Pull spur gear off the shaft. (S) Cut-off device 5870 300 024 (S) Puller 5870 300 033

Figure 12

1

3

2

1

1

2

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and Axle Systems

5871 156 002 6.1/4

Unsnap retaining ring (2) out of idler gear (1) and remove ball bearing (3). (S) Set of internal pliers 5870 900 013

Figure 13

Pull needle cage (1) off the shaft (2).

Figure 14


Figure 15

Unsnap piston ring (1).

Figure 16

2

3

1

2

S

1

1

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5871 156 002 6.2/1

6.2 Clutch KR Unsnap piston ring (1).

Figure 1

Pull tapered roller bearing (internal ring) off the shaft. (S) Forcing device 5870 026 100 (S) Grab sleeve 5873 001 059

Figure 2


Figure 3

Pull clutch (1) together with spur gear off the shaft. (S) Two-armed puller 5870 970 004

Figure 4

1

S

1

1

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5871 156 002 6.2/2

��

Pull clutch (1) off the spur gear (2).

No further disassembly of spur gear (2) is possible!

Figure 5

Remove snap ring (1)

Figure 6

Remove end plate (1) and disc package (2) from disc carrier.

Figure 7

Preload compression spring and remove snap ring (1). (S) Assembly aid 5870 345 088

Figure 8

1

2

1

1

3

2

1

S

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and Axle Systems

5871 156 002 6.2/3

Remove guide ring (1), compression spring (2) and disc (3).

Figure 9

Lift piston (1) off the disc carrier by compressed air out of hole, and remove it.

Figure 10


Figure 11

Pull off needle cage (1) off the shaft (2).

Figure 12

3

2

1

1

1

2

1

2

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and Axle Systems

5871 156 002 6.2/4

Unsnap retaining ring (2) from idler gear (1) and dismount ball bearing (3). (S) Set of internal pliers 5870 900 013

Figure 13

Pull tapered roller bearing (internal ring) off the shaft.

(S) Forcing device 5870 026 100 (S) Grab sleeve 5873 001 057 or (S) Rapid grip 5873 011 011

Figure 14


Figure 15

1

3

2

S

S

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5871 156 002 6.3/1

6.3 Clutch K1 Unsnap piston ring (1).

Figure 1


Figure 2


Figure 3

Remove cpl. axial bearing (1) and idler gear (2).

Figure 4

1

S

1

1

2

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5871 156 002 6.3/2

Remove needle cage (1) and cpl. axial bearing (2).

Figure 5


Figure 6


Figure 7


Figure 8

1

2

1

1

1

2

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and Axle Systems

5871 156 002 6.3/3

Preload cup springs and remove snap ring (1). (S) Assembly aid 5870 345 088

Figure 9

Remove guide ring (1) and cup spring package (2).

Figure 10


Figure 11


Figure 12

1

S

1

2

1

1

2

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5871 156 002 6.3/4


Figure 13

Pull tapered roller bearing (internal ring) off the shaft. (S) Basic tool 5873 002 001 (S) Grab sleeve 5873 002 038

Figure 14

1

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5871 156 002 6.4/1


Figure 1


Figure 2


Figure 3


Figure 4

1

S

1

1

2

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5871 156 002 6.4/2


Figure 5


Figure 6


Figure 7


Figure 8

1

2

1

1

1

2

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5871 156 002 6.4/3


Figure 9


Figure 10


Figure 11


Figure 12

1

S

1

2

1

1

2

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5871 156 002 6.4/4


Figure 13


Figure 14

1

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5871 156 002 6.5/1


Figure 1


Figure 2


Figure 3


Figure 4

1

S

1

2

2

1

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5871 156 002 6.5/2


Figure 5


Figure 6


Figure 7


Figure 8

1

1

1

1

S

2

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5871 156 002 6.5/3


Figure 9


Figure 10


Figure 11

Unsnap piston rings (1).

Figure 12

1

2

1

1

1

2

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5871 156 002 6.5/4

Pull tapered roller bearing (internal ring) off the shaft. (S) Basic tool 5873 002 001 (S) Grab sleeve 5873 002 038

Figure 13

1

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5871 156 002 6.6/1


Figure 1


Figure 2


Figure 3


Figure 4

1

S

1

1

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5871 156 002 6.6/2


Figure 5

��

Remove needle cage (1) and cpl. axial bearing (2). The gear (3) cannot be removed (shrink fit)!

Figure 6


Figure 7

Remove end plate (1) and disc package (2) from disc carrier .

Figure 8

1

1

1

1

2

2

2

1

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5871 156 002 6.6/3


Figure 9


Figure 10

Lift off piston (1) from disc carrier by means of compressed air from the hole, and remove it.

Figure 11


Figure 12

1

S

1

1

1

2

2

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5871 156 002 6.6/4

Unsnap piston rings (1).

Figure 13


Figure 14

1

S

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5871 156 002 6.7/1

��

6.7 Input shaft Unsnap piston rings (1 and 2). Turbine wheel shaft (3) and drive gear (4) are fixed by means of a snap ring.

When separated, the components will be destroyed!

Figure 1

Pull tapered roller bearing (internal ring) off the drive gear. (S) Basic tool 5873 001 000 (S) Rapid grip 5873 011 014 or (S) Grab sleeve 5873 001 058

Figure 2

Pull tapered roller bearing (internal ring) off the drive gear. (S) Forcing device 5870 026 100 (S) Rapid grip 5873 011 014

Figure 3

2 4

3

S

S

1

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5871 156 002 7.1/1

��

7. Reassembly of clutches: 7.1 Clutch KV Insert closing cover – orifice - (1) into hole until contact is obtained. Wet contact face with Loctite (type-no. 262)!

Figure 1

Heat up bearing inner ring (app. 120° C). (S) Hot air blower 230 V 5870 221 500 (S) Hot air blower 115 V 5870 221 501

Figure 2

��

Mount bearing inner ring (1) until contact. Mount piston ring (2).

Wear protective gloves!

Readjust bearing inner ring after cooling down!

Figure 3

Mount needle cage 60x68x20 (1) on shaft and oil it.

Figure 4

2

1

1

1

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5871 156 002 7.1/2

Mount stud bolt (1). Tightening torque (M10 /8.8 x16)............... MA = 17 Nm

Figure 5

Insert ball bearing 55x 90x18 (2) into idler gear (1) until contact is obtained and fix it by means of retaining ring (3) 90x3. (S) Set of internal pliers 5870 900 013

Figure 6

Heat up ball bearing (app. 120 ° C). (S) Hot air blower 230 V 5870 221 500 (S) Hot air blower 115 V 5870 221 501

Figure 7

Mount pre-assembled idler gear (1) until contact. Wear protective gloves!

Figure 8

3

2

1

1

1

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5871 156 002 7.1/3

��

Insert both O-rings (1 and 2) into piston grooves and oil them.

1 = 75x3 2 = 142x3 Check function of the drain valve (3) - there must be no jamming of the ball!

Figure 9

��

Insert piston into disc carrier (1).

Observe installation position, see figure!

Figure 10

Use a hand-operated press to place piston into the disc carrier by means of the assembly aid. (S) Assembly aid 5870 345 088

Figure 11

Mount disc (1), compression spring (2) and guide ring (3).

Figure 12

1

2

3

1

3

1

2

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5871 156 002 7.1/4

Preload compression spring by means of assembly aid and install snap ring 64x3.2 (1) into annular groove. (S) Assembly aid 5870 345 088

Figure 13

��

Install outer and inner clutch discs alternately into disc carrier (4) as described in figure 14. Legend: 1 = Friction disc - coated on one side - (1 pc) 2 = Inner clutch discs (10 pcs) 3 = Outer clutch discs (10 pcs) When mounting the friction disc (1), ensure that its uncoated (bare) side shows towards the piston! Number of friction surfaces: 16!

Figure 14

Mount end plate (1) and fix disc package by means of snap ring (2) (e.g. s = 2.65 mm / experience value).

Figure 15

Press on end plate with F (app. 100 N = 10 kg) and set dial indicator to „zero“. (S) Magnetic stand 5870 200 055 (S) Dial indicator 5870 200 057

Figure 16

1

1

2 3

4

1 2

F

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5871 156 002 7.1/5

��

��

Then press end plate against snap ring (upwards) and read disc clearance.

Disc clearance: 2.7 to 2.9 mm Any deviation demands a correction of the disc clearance by a suitable snap ring (optional s = 2.1 …... 4.2 mm)!

Figure 17

Heat up internal diameter of clutch (app. 120° C). (S) Hot air blower 230 V 5870 221 500 (S) Hot air blower 115 V 5870 221 501

Figure 18

Mount clutch until contact is obtained. Install inner discs on inner disc carrier by shortly rotating them cw/ccw.


Figure 19

Fix clutch (1) with retaining ring (2) 55x2. (S) Set of external pliers 5870 900 015

Figure 20

F

L R

1

2

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5871 156 002 7.1/6


Figure 21

��

Mount bearing inner ring (1) until contact.


Readjust bearing inner ring after cooling down! Check closing and opening of the clutch by means of compressed air at the hole (2). Closing and opening of the clutch must be clearly audible.

Figure 22

1 2

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5871 156 002 7.2/1

��

7.2 Clutch KR Insert closing cover – orifice - (1) into hole until contact is obtained. Wet contact face with Loctite (type no. 262)!

Figure 1


Figure 2

��




Figure 3


Figure 4

2

1

1

1

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5871 156 002 7.2/2


Figure 5

��

Insert ball bearing 55x90x18 (2) into idler gear (1) until contact is obtained and fix it by means of retaining ring (3) 90x3. (S) Set of internal pliers 5870 900 013 The idler gear (1) is only available as a complete assy in spare parts service. Consisting of: 1A = Idler gear 1B = Spur gear 1C = Retaining ring 110x4

Figure 6

Heat up ball bearing (app. 120° C). (S) Hot air blower 230 V 5870 221 500 (S) Hot air blower 115 V 5870 221 501

Figure 7

Mount pre-assembled idler gear (1) until contact. Wear protective gloves!

Figure 8

3

2

1A

1

1 1B

1C

1

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5871 156 002 7.2/3

��

Insert both O-rings (1 and 2) into piston grooves and oil them. 1 = 75x3 2 = 142x3 Check function of the drain valve (3) - there must be no jamming of the ball!

Figure 9

��

Insert piston (1) into disc carrier.


Figure 10


Figure 11

Mount disc (1), compression spring (2) and guide ring (3).

Figure 12

1

2

3

1

3

1

2

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and Axle Systems

5871 156 002 7.2/4

Preload compression spring by means of assembly aid and install snap ring 64x3.2 (1) into annular groove. (S) Assembly aid 5870 345 088

Figure 13

��

Install outer and inner clutch discs alternately into disc carrier (4) as described in figure 14. Legend: 1 = Friction disc - coated on one side - (1pc) 2 = Inner clutch discs (10 pcs) 3 = Outer clutch discs (10 pcs) When mounting the friction disc (1) ensure that its uncoated (bare) side shows towards the piston! Number of friction surfaces: 16!

Figure 14


Figure 15


Figure 16

1

1

2 3

4

1 2

F

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5871 156 002 7.2/5

��

��


Disc clearance: 2.7 to 2.9 mm Any deviation demands a correction of the disc clearance by a suitable snap ring (optional s = 2.1 …... 4.2 mm)!

Figure 17


Figure 18

Mount clutch until contact is obtained. Install inner discs on inner disc carrier by shortly rotating them cw/ccw.


Figure 19


Figure 20

F

L R

1

2

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5871 156 002 7.2/6


Figure 21

��



Readjust bearing inner ring after cooling down! Check closing and opening of the clutch by means of compressed air at the hole (2). Closing and opening of the clutch must be clearly audible.

Figure 22

1

2

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5871 156 002 7.3/1

��

7.3 Clutch K1 Insert closing cover – orifice - (1) into hole until contact is obtained. Wet contact face with Loctite (type no. 262)!

Figure 1


Figure 2

��




Figure 3

��


Figure 4

2

1

1

1

2

3

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5871 156 002 7.3/2

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Figure 5


Figure 6

��

Mount cup spring package (1) and guide ring (2). Installation position of cup springs see figure 8!

Figure 7

Install cup springs according to sketch. Legend: 1 = Disc carrier 2 = Piston 3 = Cup springs (7 pcs) 4 = Guide ring 5 = Snap ring

Figure 8

1

1

2

1

3

2

5

4

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5871 156 002 7.3/3

Preload cup spring package by means of assembly aid and install snap ring 64x3.2 (1) into annular groove. (S) Assembly aid 5870 345 088

Figure 9

��

Install outer and inner clutch discs alternately into disc carrier (4) as described in figure 10. Legend: 1 = Friction disc - coated on one side (1pc) 2 = Outer discs (9 pcs) 3 = Inner discs (9 pcs)

When mounting the friction disc (1) ensure that its uncoated (bare) side shows towards the piston! Number of friction surfaces: 18! Figure 10


Figure 11


Figure 12

F

1

1

2 3

4

1 2

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5871 156 002 7.3/4

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��


Disc clearance: 2.4 to 2.6 mm

Any deviation demands a correction of the disc clearance by a suitable snap ring (optional s = 2.1 …... 4.2 mm)!

Figure 13


Figure 14

Mount clutch (1) until contact is obtained.


Figure 15

��

Mount and oil running disc 55x78x5 (1), axial cage (2) and axial washer 55x78x1 (3). Install running disc (1) with chamfer (see arrow) showing towards the axial cage!

Figure 16

1

F

1

2

3

Chamfer

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5871 156 002 7.3/5


Figure 17

Install idler gear. Install inner discs on inner disc carrier (idler gear) by shortly rotating them cw/ccw.

Figure 18

��

Mount and oil axial washer 55x78x1 (1), axial cage (2) and running disc 55x78x5 (3).

Install running disc (3) with chamfer (see arrow) showing towards the axial cage!

Figure 19


Figure 20

L R

1

2

1

1

2

3

Chamfer

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5871 156 002 7.3/6


Figure 21

��





Figure 21

�� Check closing and opening of the clutch by means of compressed air at the hole (1). Closing and opening of the clutch must be clearly audible.

Figure 22

1 2

1

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5871 156 002 7.4/1

7.4 Clutch K2 Heat up bearing inner ring (app. 120° C). (S) Hot air blower 230 V 5870 221 500 (S) Hot air blower 115 V 5870 221 501

Figure 1

��




Figure 2

��

Insert both O-rings (1 and 2) into piston grooves and oil them.

1 = 75x3 2 = 142x3 Check function of the drain valve (3) - there must be no jamming of the ball!

Figure 3

��



Figure 4

2 1

1

2

3

1

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5871 156 002 7.4/2


Figure 5

��

Mount cup spring package (1) and guide ring (2).

Installation position of cup springs see figure 7!

Figure 6


Figure 7


Figure 8

2

1

1 3

2

5

4

1

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5871 156 002 7.4/3

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Install outer and inner clutch discs alternately into disc carrier (4) as described in figure 9. Legend: 1 = Friction disc - coated on one side - (1 pc) 2 = Outer discs (7 pcs) 3 = Inner discs (7 pcs) When mounting the friction disc (1) ensure that its uncoated (bare) side shows towards the piston! Number of friction surfaces: 14!

Figure 9


Figure 10


Figure 11

��

��


Disc clearance: 1.8 to 2.0 mm.


Figure 12

1

2 3

4

1 2

F

F

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5871 156 002 7.4/4


Figure 13

Mount clutch until contact is obtained.


Figure 14

��


Figure 15


Figure 16

1

1

2

3

Chamfer

1

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5871 156 002 7.4/5

Install idler gear. Install inner discs on inner disc carrier (idler gear) by shortly rotating them cw/ccw.

Figure 17

��

Mount axial washer 55x78x1 (1), axial cage (2) and running disc 55x78x5 (3) and oil them.


Figure 18


Figure 19


Figure 20

L R

1

2

3

Chamfer

2

1

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��





Figure 21

��

Check closing and opening of the clutch by means of compressed air at the hole (1). Closing and opening of the clutch must be clearly audible.

Figure 22

1 2

1

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5871 156 002 7.5/1

7.5 Clutch K3 Close machining aperture of the oil supply hole by means of plug (1). (S) Lever riveting pliers 5870 320 016

Figure 1


Figure 2

��

Mount bearing inner ring (1) until contact. Install rectangular rings 65x2 (2).



Figure 3

��


Figure 4

2

1

1

1

2

3

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5871 156 002 7.5/2

��



Figure 5


Figure 6

��

Mount cup spring package (1) and guide ring (2).

Installation position of cup springs see figure 8!

Figure 7

Install cup springs according to sketch.

Legend: 1 = Disc carrier 2 = Piston 3 = Cup springs (7 pcs) 4 = Guide ring 5 = Snap ring

Figure 8

1

1

2

1

3

2

5

4

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5871 156 002 7.5/3


Figure 9

��

Install outer and inner clutch discs alternately into disc carrier (4) as described in figure 10. Legend: 1 = Friction disc - coated on one side - (1pc) 2 = Outer discs (7 pcs) 3 = Inner discs (7 pcs) When mounting the friction disc (1) ensure that its uncoated (bare) side shows towards the piston! Number of friction surfaces: 14! Figure 10


Figure 11

Press on end plate with F (app. 100 N = 10 kg) and set dial indicator to „zero”. (S) Magnetic stand 5870 200 055 (S) Dial indicator 5870 200 057

Figure 12

1

F

1 2

1

2 3

4

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5871 156 002 7.5/4

��

��


Disc clearance: 1.8 to 2.0 mm


Figure 13


Figure 14

Mount clutch until contact is obtained.


Figure 15

��


Figure 16

1

F

1

2

3

Chamfer

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5871 156 002 7.5/5

Mount needle cage 55x63x50(1) on shaft and oil it.

Figure 17

Install idler gear, Install inner discs on inner disc carrier (idler gear) by shortly rotating them cw/ccw.

Figure 18

��

Mount and oil axial washer 55x78x1 (1), axial cage (2) and running disc 55x78x5 (3).


Figure 19

�� Pay attention that the running disc (1) is flush with the shaft collar to ensure that all inner discs are mounted on the idler gear teeth!

Figure 20

L R

1

1

1

2

3 Chamfer

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Figure 21

��




Figure 22


Figure 23

��

Insert closing cover – orifice - (1) into hole until contact is obtained. Wet contact face with Loctite (type no. 262)!

Figure 24

1

1

1

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5871 156 002 7.6/1

7.6 Clutch K4 Heat up bearing inner ring (app. 120° C). (S) Hot air blower 230 V 5870 221 500 (S) Hot air blower 115 V 5870 221 501

Figure 1

��




Figure 2

Undercool shaft (1) (app. -80° C), heat up gear (2) (app. +120° C) and mount until contact is obtained. Wear protective gloves!

Figure 3

Secure gear by means of retaining ring 80x2.5 (1). (S) Set of external pliers 5870 900 015

Figure 4

2 1

1

2

1

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5871 156 002 7.6/2

��

Mount and oil lower axial washer 55x78x1 (1), axial needle cage (2) and upper axial washer 55x78x1 (1)

Upper and lower axial washer are identical!

Figure 5

Mount and oil needle cage 55x63x50 (1)

Figure 6

Mount idler gear (1).

Figure 7

��

Mount axial washer 55x78x1(1), needle cage (2) and running disc 55x78x5 (3). Install running disc (3) with chamfer showing towards needle cage!

Figure 8

2 1

1

1

3

1

chamfer

2

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��


Figure 9

��



Figure 10


Figure 11

��

Mount cup spring package (1) and guide ring (2). Installation position of cup springs see figure 13!

Figure 12

1

2

3

1

2

1

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Figure 13


Figure 14

��

Install outer and inner clutch discs alternately into disc carrier (4) as described in figure 15. Legend: 1 = Friction disc - coated on one side - (1 pc) 2 = Outer discs (6 pcs) 3 = Inner discs (6 pcs) When mounting the friction disc (1) ensure that its uncoated (bare) side shows towards the piston! Number of friction surfaces: 12! Figure 15


Figure 16

1 3

2

5

4

1

1

2 3

4

1 2

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5871 156 002 7.6/5

Press on end plate with F (app. 100 N = 10 kg) and set dial indicator to „zero “. (S) Magnetic stand 5870 200 055 (S) Dial indicator 5870 200 057

Figure 17

��

��


Disc clearance: 1.4 to 1.6 mm.


Figure 18


Figure 19

Install clutch until contact is obtained. Install inner discs on inner disc carrier by shortly rotating them cw/ccw.


Figure 20

F

F

L R

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5871 156 002 7.6/6

Fix clutch (1) with retaining ring 55x2 (2). (S) Set of external pliers 5870 900 015

Figure 21


Figure 22

��

Install bearing inner ring (1) until contact. Fit stud bolt (2). Tightening torque (M10 /8.8 x16)............... MA = 17 Nm



Figure 23


Figure 24

2

1

1 2

1

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5871 156 002 7.7/1

7.7 Input shaft Insert O-ring 35x4 (1) into annular groove of input shaft (2) and grease it.

Figure 1

Install snap ring SB-38 (1) into annular groove of turbine shaft (2).

Figure 2

��

Press turbine shaft (1) into the input shaft (2) under a hand-operated press until snap ring engages into the groove.

Axial fixture of turbine shaft!

Figure 3

Heat up both bearing inner rings (app. 120° C). (S) Hot air blower 230 V 5870 221 500 (S) Hot air blower 115 V 5870 221 501

Figure 4

1

2

1

2

1

2

F

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5871 156 002 7.7/2

��

Mount bearing inner rings (1) until contact. Install rectangular ring (2) 60x3.



Figure 5

2 1

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5871 156 002 8/1

Figure 1

8. Installation of input shaft and clutches 8.1 Preassembly of front and rear transmission housing Stop for converter outlet pressure valve. Fit threaded pin M10x16 (1) with pin. Tightening torque ......................................MA = 10 Nm Fit threaded pin M10x12 (2). Tightening torque ......................................MA = 23 Nm

Fix screen sheet (1) by means of cyl. screws (2) in the transmission housing. Tightening torque M8/8.8x12 ..............................MA = 23 Nm

Figure 2

�� Figure 3

��

Figure 4

��

Insert all bearing outer rings into bearing holes of both housing parts. Housing front part: 1 = „K3“ Clutch - 3rd gear 2 = „K2“ Clutch - 2nd gear 3 = „K1“ Clutch - 1st gear 4 = „K4“ Clutch - 4th gear 5 = „KR“ Clutch - reverse 6 = „KV“ Clutch - forward 7 = „An“ Input K4/K2/K3 and „An“ have got the same outer diameter, but merely K4/K2/K3 are fitted with the same bearings. Risk of confusing! Housing rear part: Legend see figure 3! Insert bearing outer rings into bearing holes with assembly grease. If, contrary to the ZF recommendation, the tapered roller bearings of clutches and the input are not replaced, it is imperative to ensure the previous pairing (bearing inner ring/bearing outer ring) - see chapter -5 figure 5 and 9! K1/K2/KR and „An“ have got the same outer diameter, but merely K1/K2/KR are fitted with the same bearings. Risk of confusing!

1

2

2 1

7

2

1

4

3

5

6

6

7

2

1

3

4

5

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5871 156 002 8/2

Install pipes (system pressure from electro-hydraulic control unit to the corresponding clutch). Keep the following order to install the pipes with hollow screws and seal rings A14x18: 1 = Pipe KR 2 = Pipe K2 3 = Pipe K3 4 = Pipe K4 5 = Pipe K1 Figure 5

Tightening torque ......................................MA = 40 Nm

�� Figure 6

Install various screw plugs and place closing covers until contact is obtained. 1 = Screw plug M16x1.5 with O-ring 13x2 (1x) 2 = Screw plug M10x1 with O-ring 8x1.5 (14x) 3 = Closing cover 12 (3x) Tightening torque (item. 1)...............................MA = 40 Nm Tightening torque (Item. 2)...............................MA = 25 Nm Wet contact face of closing covers (3) with Loctite (type no. 262)!

��

Place closing covers (1) until contact and fasten fixing plate (2) with cyl. screws on the transmission housing rear part. 1 = Closing cover 2 = Fixing plate with cyl. screw Tightening torque (item. 2) M10/8.8x20.................MA = 46 Nm Wet contact face of closing covers (1) with Loctite (type no. 262)!

Figure 7

8.2 Installation of converter outlet pressure valve Insert valve (1) into transmission housing front part by means of drift (S) until contact is obtained (S) Drift 5870 705 012

Figure 8

1

2

3

4

5

1 1

2

1

S

1

3

2

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Figure 9

Place indented ring (1) into transmission housing front part by means of press-fit mandrel (S). (S) Press-fit mandrel 5870 705 015 Fasten fixing plate (2) on transmission housing front part by means of cyl. screws. Tightening torque M10/8.8x20.............................MA = 46 Nm Install screw plug M22x1.5 (3) with O-ring 19x2 Tightening torque M10/8.8x20.............................MA = 60 Nm

8.3 Insert clutches into transmission housing front part Install piston rings in clutches KV and KR, as well as rectangular ring 60x3 into input shaft, align and grease them. Insert clutch KR (2), clutch KV (3) and input shaft (1) jointly into bearing outer rings.

Figure 10

Install piston ring into clutch K4, align and grease it. Bring clutch K4 (1) into proper position.

Figure 11

Install piston ring in clutch K1 (1), align and grease it. Slightly raise clutch K4 (2) and bring clutch K1 (1) into proper position.

Figure 12

3 2

1

1

1

2

S 1

2

3

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5871 156 002 8/4

Mount O-ring 35x3 on suction tube (1), grease it and then fix it in the transmission housing front part with cyl. screws M8x12. Tightening torque M8/8.8x12 ..............................MA = 23 Nm

Figure 13

Mount piston ring into clutch K2, align and grease it. Bring clutch K2 (1) into proper position.

Figure 14

Mount piston ring into clutch K3, align and grease it. Place screen sheet (1) and bring clutch K3 (2) into proper position.

Figure 15

Place screen sheet (1) and fix it with cyl. screws (2) with sleeves and with cyl. screws (3). Tightening torque M6/8.8x10 ..............................MA = 9,5 Nm Tightening torque M8/8.8x65 ..............................MA = 23 Nm Insert tubes – guide tubes - (4 and 5) into connecting holes of transmission housing front part with O-rings. O-ring 24x3 (2x) O-ring 12x2.5 (7x)

Figure 16

�� Wet tubes (4 and 5) on outer diameter with Loctite (type no. 262) and insert into hole!

1

1

2 1

1 2

3 4 5

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5871 156 002 8/5

Install piston rings on clutches KV, KR, K1, K2, K4, and rectangular ring 65x3 on clutch K3 and rectangular ring 60x3 on input shaft, align and grease them. 1 = Clutch K3 2 = Clutch K1 3 = Clutch K4 4 = Input shaft 5 = Clutch KR 6 = Clutch KV 7 = Clutch K2

Figure 17

��

��

Carefully bring transmission housing rear part into contact position by means of lifting device. Ensure an exact alignment of the tubes!

Wet mounting face with Loctite (type no. 574)!

Figure 18

Fix transmission housings with 2 cyl. screws (1) crosswise by hand. Fit both cylindrical pins (2) 10x26 centrically to the mounting face. Fix transmission housing front and rear part by means of cylinder screws (1). Tightening torque M10/8.8x65 ..............................MA = 46 Nm

Figure 19

��

��

8.4 Install output flange Mount shaft seal 90x120x13 (1) by means of driver tool, with the sealing lip showing to the oil sump. (S) Driver tool 5870 048 237 Use the specified driver tool (S), to obtain the exact installation position!

Fill space between sealing lip and dust lip with grease! Wet outer diameter (rubber-coated) with spirit!

Figure 20

1

2 3 4

5

7

6

2 2 1

S 1

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5871 156 002 8/6

Install hex screws (1) M12x1.5x45 into holes of output flange (2) and press screen sheet (3) into flush position. (S) Pressure sleeve 5870 506 142

Figure 21

Mount pre-assembled output flange (1) on output shaft.

Figure 22

Insert O-ring 48x4 into space between output flange and shaft. Fix output flange with washer (1) and hex screws (2). Tightening torque (M10/8.8x30) ................ MA = 46 Nm

Figure 23

Fix locking plate by means of driver tool. (S) Driver tool 5870 057 009 (S) Handle 5870 260 002

Figure 24

1

3 2

1

1 2

1

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5871 156 002 8/7

Check clearance of gear drive train and output gears by rotating the output flange (1) and turbine shaft (2).

Figure 25

2

1

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5871 156 002 9/1

9. Reassembly engine connection and oil pressure pump

9.1 Oil pressure pump:

�� In case of wear marks in the pump housing, or on the control disc, replace the cpl. pump. Items 1 - 6 may be exchanged! 1 = Pump housing with rotor 2 = Snap ring 3 = Shaft seal (75x90x10) 4 = Support shim (95x76x84x3) 5 = Needle bearing cpl. (bearing outer ring and needle bearing) 6 = Ring (75x84x4.6)

Figure 1

Install the following parts into the pump housing (1). 6 = Ring 5A = Bearing outer ring 5B = Needle cage 4 = Support shim

Figure 2

With the sealing lip showing downwards carefully insert the shaft seal (3) into the pump housing (1) until contact is obtained and fix it by means of the snap ring (2). Wet outer diameter of shaft seal with spirit! (S) Driver tool 5870 055 070 (S) Handle 5870 260 002

Figure 3

3 5

2 4

6

1

1

6

5 B

5A

4

3

2

1

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5871 156 002 9/2

Mount outer rotor. Chamfer (arrow) to show downwards!

Figure 4

Mount inner rotor. Teeth (arrow) to show upwards!

Figure 5

��

Place control disc and fix it radially with two cylindrical screws (1).

Do not tighten the cylindrical screws - just turn them in until contact is obtained and then turn them back by approx. ½ rotation! Pay attention to correct installation position of control disc, see figure! Insert O-ring (2) 182x3 into annular groove and grease it. Figure 6

��

Install two adjusting screws (S) and mount stator shaft (1). Pay attention to hole pattern! (S) Adjusting screws (M10) 5870 204 007

Figure 7

1

2

1

S

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5871 156 002 9/3

��

Mount pre-assembled pump (1). Pay attention to hole pattern!

Figure 8

��

Provide cyl. screws with O-rings 9.5x1.6. Grease O-rings! Fix transmission pump (2) by means of cyl. screws (1). Tightening torque (M10/8.8x75)................ MA = 46 Nm Wet mounting faces – duct ribs - (3) with Loctite (type no. 574)!

Figure 9

Mount two adjusting screws (S) and place plate (1), and fix with cyl. screws (2). (S) Adjusting screws (M10) 5870 204 007 Tightening torque (M10/8.8x20)................ MA = 46 Nm

Figure 10

9.2 Converter connection:

��

Figure 11

��

Install two adjusting screws (S) and place converter bell-housing (1), and bring into contact position evenly with 3 cyl. screws (3x180 offset). Make sure that O-ring will not be damaged (sheared off)! Fix converter bell-housing with cylinder screws (2). Tightening torque (M10/8.8x30)................ MA = 46 Nm Mount, align and grease rectangular ring 36x2.5 (3) . Wet mounting face with Loctite (type no 574)!

1

1 3

S

1 2

1

2 3

2

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5871 156 002 9/4

Figure 12

��

Fix flexplates with 2 hex. screws on converter. 1 = Flexplate with welded disc 2 = Flexplate with welded hex. nut 3 = Converter 4 = Washer A10 (8x) 5 = Hex. screw (4x) Tightening torque (M12/10.9x18)................ MA = 46 Nm Wet thread with Loctite (type no. 262)!

Mount converter by means of lifting device until contact is obtained. Remove eye bolts and fix flexplates with hex. screws (see figure 12).

Figure 13

4

1

2

5

3

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5871 156 002 10/1

10. Reassembly PTO Press ball bearing (1) on pump shaft (2) until contact is obtained and fix with retaining ring (3) 45x2.2. Mount, align and grease rectangular ring (4) 60x3.

Figure 1

Mount pump shaft (1) into turbine wheel of converter until contact is obtained and fix with retaining ring (2) 85x3. Grease O-ring (3) 180x3 and insert it into hole. When mounting the pump shaft make sure that the converter will not be forced out of the converter bell-housing! Fix converter axially! Risk of injury!

Figure 2

Fix cover plate (1) with hex. screws (2). Tightening torque (M12/10.9x18)................ MA = 115 Nm

Figure 3

1

2

3

3 2

1

4

1

2

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5871 156 002 11/1

11. Reassembly inductive sensor, Hall sensor, breather and temperature sensor

Mount positioned parts. 1 = Breather Tightening torque ................ MA = 12 Nm 2 = Inductive sensor with O-ring 15.5x2.6 (n central gear chain) Tightening torque ................ MA = 30 Nm 3 = Inductive sensor with O-ring 15.5x2.6 (n turbine) Tightening torque ................ MA = 30 Nm Figure 1

Figure 2

Mount inductive sensor (1), temperature sensor (2) and speed sensor (3). 1 = Inductive sensor with O-ring 15.5x2.6 (n engine) Tightening torque ................ MA = 30 Nm 2 = temperature sensor with O-ring 11x3 (Measuring point „63“ after converter) Tightening torque ................ MA = 25 Nm 3 = Speed sensor with O-ring 15.5x2.6 (n output Hall sensor) Fix with cyl. screws Tightening torque (M8/8.8x16)............. MA = 23 Nm

1

2

3

1

3 2

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5871 156 002 12/1

12. REASSEMBLY: Electro-hydraulic control unit with proportional valves: Different versions regarding the wiring harness position are possible! Please observe the vehicle manufacturer's specifications! The following sketches show the sectional views of the electro-hydraulic control unit.

Figure 1

Section B - B

Section A - A Proportional valve P5

Figure 2 Figure 3

Pressure reducing valve 9 bar Wiring harness

Lid

Main pressure valve 16+2 bar

Housing Lid Housing Valve block

A A

B B

Follow-on slide Pressure

controller

Vibration damper

Main pressure valve 16+2

Pressure reducing valve 9bar

Wiring harness

Duct plate

Valve block

��

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5871 156 002 12/2

Figure 4

��

��

12.1 Installation of electric control unit Check all single components for damage and replace, if required! Prior to installation, ensure free travel of the moving parts in the valve block! Pistons can be exchanged individually! Prior to assembly, oil the single components according to the ZF-list of lubricants TE-ML 03! Insert orifice (1) with concave side up, until contact is obtained! For installation position see arrows!

Adjacent figure shows the following single components: 1 = Pressure reducing valve 2 = Vibration damper 3 = Follow-on slide

Figure 5

��

Install single components acc. to figure 5. Preload compression springs of the follow-on slides and fix piston temporarily by means of cyl. pins ∅∅∅∅ 5.0 mm (assembly aid), see arrows (S)!

Figure 6

Install two adjusting screws. Mount sealing (1) and housing (2). (S) Adjusting screws 5870 204 036

Figure 7

1

3

2

S

S

S

1

1 1

1

2

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5871 156 002 12/3

Evenly bring housing (1) into contact position by means of torx screws, so the pistons are preloaded and the cylindrical pins (assembly aid) can be removed.

Figure 8

��

Fix housing with torx screws (1). Tightening torque (M5/10.9x30)................. MA = 5.5 Nm (S) Torque wrench 5870 203 031 (S) Reducing adapter 5870 656 056 (S) Socket wrench TX-27 5873 042 002

Figure 9

��

Mount pressure controllers (1) and fix by means of fixing plate (2) and cylinder screw (3). Install fixing plate, with the claw showing downwards! Pay attention to radial installation position of pressure controllers, see figure! Tightening torque (M5/8.8x12)......................... MA = 5.5 Nm (S) Torque wrench 5870 203 031 (S) Reducing adapter 5870 656 056 (S) Socket wrench TX-27 5873 042 002

Figure 10

Preassemble opposite side The adjacent figure shows the following single components: 1 = Main pressure valve 2 = Vibration dampers 3 = Follow-on slide

Figure 11

1

3 1

2

1

3

2

1

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5871 156 002 12/4

��

Mount single components according to figure 11. Preload compression springs of the follow-on slides and fix piston temporarily by means of cyl. pins (S) ∅∅∅∅ 5 mm (assembly aid), see arrows (S)! Fit two adjusting screws. (S) Adjusting screws M5 5870 204 036 Mount sealing (1) and housing (2) and evenly bring into contact position.

Figure 12

Figure 13

Evenly bring housing (1) into contact position by means of torx screws, so the pistons are preloaded and the cylindrical pins (assembly aid) can be removed. Then fix housing with the torx screws. Tightening torque (M5/10.9x30).................... MA = 5.5 Nm (S) Adjusting screws 5870 204 036 (S) Torque wrench 5870 203 031 (S) Reducing adapter 5870 656 056 (S) Socket wrench TX-27 5873 042 002

��

Mount pressure controllers (1) and fix by means of fixing plates and cylinder screws. Install fixing plate, with the claw showing downwards! Pay attention to radial installation position of pressure controllers, see figure! Tightening torque (M5/8.8x12)......................... MA = 5.5 Nm

Figure 14

��

��

Mount wiring harness (1) and connect pressure controllers (6x). Installation position of pressure controllers see figure 1!

Pay attention to installation position of wiring harness, see the markings applied during disassembly!

Figure 15

S

1

1

1

1

2

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5871 156 002 12/5

Place sealing (1). With the groove showing to the cover plug nose, mount socket until contact is obtained. Fix lid by means of torx screws. Tightening torque (M5/10.9x30).................... MA = 5.5 Nm (S) Torque wrench 5870 203 031 (S) Socket wrench TX-27 5873 042 002 (S) Reducing adapter 5870 656 056

Figure 16

Fix wiring harness by means of retaining clamp (1).

Figure 17

��

Place sealing (1). Fix connecting housing (2) by means of torx screws (3). Tightening torque (M5/10.9x30).................... MA = 5.5 Nm (S) Torque wrench 5870 203 031 (S) Socket wrench TX-27 5873 042 002 (S) Reducing adapter 5870 656 056

Pay attention to installation position of connection housing, see the markings applied during disassembly!

Figure 18

Fix pressure controller (1) by means of cyl. screws (2). Tightening torque (M6/8.8x12).................... MA = 10 Nm Fit screw necks (3) with O-ring 11.3x2.4. Tightening torque ……............................... MA = 25 Nm Fit screw plug (4) with O-ring 8x1.5. Tightening torque (M10x1).......................... MA = 10 Nm Figure 19

1

1

1

2

3

3 1

2

4

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��

Flushmount screens (1) into the holes of the intermediate plate. Pay attention to installation position – screens to show upwards (towards the duct plate)!

Figure 20

��

Fit two adjusting screws. (S) Adjusting screws 5870 204 063 Place sealing (1).

Pay attention to different sealings!

Figure 21

��

Place intermediate plate (1) . Screens (2) to show upwards!

Figure 22

��

Place sealing (1) and duct plate (2). Pay attention to different sealings!

Figure 23

1 1

S 1

1

2

1 2

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and Axle Systems

5871 156 002 12/7

Place duct plate (1) and mit evenly fix by means of torx screws (2). Tightening torque (M6/10.9x25)....................... MA = 12 Nm (S) Socket wrench TX-27 5873 042 002 (S) Torque wrench 5870 203 031 (S) Reducing adapter 5870 656 056

Figure 24

Provide screw plugs (1) with O-rings 8x1.5 and fit them. Tightening torque (M10x1).............................. MA = 6 Nm

Figure 25

Insert converter outlet pressure valve (1) into housing hole.

Figure 26

Fit 4 adjusting screws. Mount sealing (1 and 2) and duct plate (3). (S) Adjusting screws 5870 204 063

Figure 27

1 2

1

1

1

2

3

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and Axle Systems

5871 156 002 12/8

Fix duct plate with torx screws (1). Tightening torque (M6/10.9x25)....................... MA = 9.50 Nm Tightening torque (M6/10.9x60)....................... MA = 9.50 Nm

Figure 28

Mount filter differential pressure valve (1). Filter differential pressure valve consists of: 2 = Switch with O-ring 13x2 3 = Piston 4 = Compression spring Tightening torque ........................................ MA = 30 Nm

Figure 29

��

��

Mount sealing (1 and 3), intermediate plate (2) and control unit (4). Pay attention to different sealings!

Use assembly grease!

Figure 30

Evenly fix electro-hydraulic control unit (1) by means of torx screws. Tightening torque (M6/10.9x80) ..................... MA = 12 Nm Tightening torque (M6/10.9x100) .................... MA = 12 Nm (S) Torque wrench 5870 203 031 (S) Reducing adapter 5870 656 056 (S) Socket wrench TX-27 5873 042 002

Figure 31

1

1

2 3

4

1

1

4 3 2

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and Axle Systems

5871 156 002 12/9

Fix pipes (1 and 2) with hollow screws (3) and O-rings and screw nut (4). Fit O-ring 13x2 on hollow screw (3), insert into eye of pipes, mount O-ring 18x2.5 and. Tightening torque........................................ MA = 45 Nm Fixing of screw nut (4). Tightening torque ........................................ MA = 35 Nm Figure 32 1 = System pressure to lock-up clutch valve 2 = System pressure from lock-up clutch valve to lock-up

clutch

1

2

4

3

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and Axle Systems

5871 156 002 13/1

13. Reassembly ZF-fine filter (pressure filter), oil filler tube and oil drain plug

13.1 Installation of ZF-fine filter (pressure filter) Fix filter head (1) with O-rings 34.2x3 (2) by means of torx screws (3) on housing rear part. Tightening torque (M8/10.9X35) ...................... MA = 23 Nm (S) Torque wrench 5870 203 034 (S) Socket wrench TX-40 5870 042 004

Figure 1

��

Figure 2

Stick to the following instructions for the installation of the ZF-filter (1): - Slightly oil sealing - Turn in the filter until contact with the sealing surface

is obtained, and then tighten it by hand with approx. 1/3 to 1/2 rotation.

Bring oil level tube (1) with seal (2) into contact position with the housing rear part and fix it by means of hexagon screws (3). Tightening torque (M8/10.9x50)................ MA = 34 Nm Fix tab of oil level tube with hexagon screw (4) on housing rear part. Tightening torque (M10/8.8x65)................ MA = 46 Nm Turn oil dipstick (5) into oil level tube. Figure 3

1

2

2

1

3

2

1

3

4

5

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and Axle Systems

5871 156 002 13/2

��

Install oil drain plug (1) with O-ring (2) 35x2

Tightening torque (M38x1.5)....................... MA = 80 Nm Fix identification plate (3) to the housing front part Use Loctite (type no. 5069) !

Figure 4

��

Fit screw plug M16x1.5 (1) with O-ring 13x2. Tightening torque ...............................MA = 23 Nm

Before putting the transmission into operation, fill it with oil according to the operation manual (order no.: 5872 365 002)!

Figure 5

3

1

2

1

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COOLING SYSTEM

RADIATOR

MAINTENANCE It is advisable to drain the radiator once a year and flush out the system with clean water. Refill the system with the correct mixture of water/anti-freeze. Check all the pipe and hose joints, to ensure there are no leaks.

RADIATOR CLEANING

MAINTENANCE It is advisable to clean the fins of the radiator once a year, by blowing through with a compressed air line.

RADIATOR REFILLING

Fill the cooling system using the filler cap on the header tank. Fill the radiator by removing the bleed elbow in the top and filling through the hole. Refit the elbow once filled. Run the engine and check all pipe and hose joints to ensure there are no leaks.

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SPARES

IF IT IS NECESSARY TO ORDER REPLACEMENT PARTS FOR THIS EQUIPMENT,

PLEASE REFER TO THE COOLING SYSTEM SECTION

OF THE SPARES MANUAL

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Spares\21556d 22 - 02 - 01

ILL No. PART No. DESCRIPTION QTY.

HYDRAULIC POWER PACK - 24V

MHS A 31666402

21556D

1 FNMF 0049 Thermal switch 12 FNKMD5 24V Electric motor - 1500W dual term 13 FNKP31 Gear pump - 3.1 cc 14 FNKN10 End head - centre section - B.S.P. 15 FNKC07 Valve kit relief & check 16 FNKH Horizontal mounting kit 17 FNKR52 Reservoir - 5 litre (plastic) 18 FNKS5 12/24 VCD start solenoid 19 MFTSDG16R0AAA F/breather & dipstick - 3/8” B.S.P.

Service kits are not available for this unit.

Failed items should be replaced.

1 - 1

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INDUCTION SYSTEM

NOTE

THERE ARE NO REPAIRABLE ITEMS IN THE INDUCTION SYSTEM.

DAMAGED OR WORN ITEMS SHOULD BE REPLACED.

THE AIR CLEANER ELEMENT SHOULD BE REPLACED IN

ACCORDANCE WITH THE MAINTENANCE SCHEDULE.

PLEASE REFER TO THE SPARE PARTS MANUAL FOR PART NUMBER

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THROTTLE CONTROLS

NOTE

THE THROTTLE CONTROL SYSTEM ON THE ENGINE IS ELECTRONIC.

THE THROTTLE PEDAL IS NOT REPAIRABLE AND SHOULD BE

REPLACED, IF FAULTY.

PLEASE REFER TO THE SPARE PARTS MANUAL FOR PART NUMBERS.

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TRANSMISSION CONTROLS

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GEARSHIFT – TWISTGRIP

Service information is not available from the manufacturer for this equipment. It is recommended that - due to the delicate nature of it’s construction - in the event of a malfunction, the unit should be returned for repair to: Douglas Equipment A division of Curtiss-Wright Flow Control (UK) Limited Douglas House Village Road Cheltenham GLOS GL51 0AB Phone: +44 (0)1242 527921 Fax: +44 (0)1242 221198 http://douglas.cwfc.com

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DRIVE/STEER AXLE

NOTE

FOR FURTHER INFORMATION REGARDING THE DRIVE AXLE REFER TO THE MANUFACTURER’S MANUALS SUPPLIED

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WARNING!

DO NOT WORK IN THE VICINITY OF THE

FRONT DRIVE WHEELS, WHILST THE IGNITION SWITCH

IS ON.

(STEERING RE-ALIGNMENT CAN OCCUR).

THIS WARNING ALSO APPLIES

TO THE REAR SUPPORT WHEELS.

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Workshop\Service Bulletin 0068-TP


Douglas HouseVillage RoadCheltenham

GLOSGL51 0AB

Phone: +44 (0)1242 527921

Fax: +44 (0)1242 221198


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12-05-11Workshop\Kessler Oil Immersed Brakes

SERVICE INFORMATION

AND

ADJUSTMENT INSTRUCTIONS

FOR

OIL-IMMERSED (WET DISK) BRAKES

FITTED TO KESSLER LT81 STEER/DRIVE AXLE

1 - 13

IF IT IS NECESSARY TO ORDER REPLACEMENT PARTS

FOR THIS EQUIPMENT,

PLEASE REFER TO

THE AXLE AND ACCESSORIES SECTION


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12-05-11 Workshop\Kessler Oil Immersed Brakes

OIL IMMERSED (WET-DISK) BRAKES

SERVICE INFORMATION

2 - 13

ASSEMBLY OF THE WET DISK BRAKE

1. Brake carrier 12. Breather

2. Brake housing 13. Sealing ring

3. Piston 14. Sealing ring

4. Inner disk 15. Spring

5. Outer disk 16. Screw

6. “O” ring 17. Seal ring

7. Screw 18. Screw plug

8. Screw plug 19. “O” ring

9. Seal ring 20. Face seal

10. Seal ring 21. Screw

11. Connection piece 22. Tube

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SERVICE INFORMATION

3 - 13

ASSEMBLY OF THE PISTON SEALS

1. Place piston with the larger diameter downwards. Note succession of the sealing parts at fitting.

2. Install “O” - rings free of torsion and loops.

ASSEMBLY OF “O”- RING AND SUPPORTING RING

1. Large supporting ring.

2. Large “O” - ring.

3. Small “O” - ring.

4. Small supporting ring.

Pressure

Install the supporting rings to the averting side of pressure!

ASSEMBLY OF THE OMEGAT SEAL KIT

1. Large “O” - ring.

2. Small “O” - ring.

3. Large supporting ring.

4. Small supporting ring.

Pressure

Install the PTFE - profile rings with small diameter to pressure side!For assembly,there can be used mounting tapes from Merkel company.

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SERVICE INFORMATION

4 - 13

ASSEMBLY OF THE PISTON

Lubricate cylinder bore. Apply the thread holes on wet disk brakes with dimension X340 with Loctite243. On wet disk brakes with dimension X460, apply Loctite 262. Place the piston onto the brakecarrier (do not cant it!).

a) Wet disk brakes with dimension X340.

Press the piston equally by hand into the brake carrier (do not cant it!).

b) Wet disk brakes with dimension X460.

Press the piston equally, with the mounting screws into the brake carrier (do not cant it!).

If necessary,adjust the piston with gentle hammer taps to the threaded holes. First install the springs,followed by the tubes, into the bore holes of the piston. Screw in the hexagon head screws withflange.

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SERVICE INFORMATION

5 - 13

PREPARE HOUSING AND CHECK THE AIR GAP

1. Lay discs into the housing.

Check the air gap:-

Air gap sL = measurement A - measurement B (measured without pressure).

Rated size sL:- see table.

2. Install “O” - ring (brake housing / brake carrier), free of torsion and loops.

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SERVICE INFORMATION

6 - 13

AIR GAP AND WEAR DIMENSIONS

BRAKE TYPE AIR GAP sL NEW WEAR DIMENSION(mm) (mm)

2340 1.7 +0.5 / -0.5 0.8

3340 * 2.0 +0.6 / -0.6 1.2

4340 1.8 +0.7 / -0.7 1.6

5340 1.7 +0.9 / -0.9 2.0

4460 1.8 +0.7 / -0.7 1.6

5460 1.8 +0.9 / -0.9 2.0

7460 2.3 +1.0 / -1.0 2.8

* The Douglas TBL 280 uses an LT81 axle fitted with type 3340 brakes.

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SERVICE INFORMATION

7 - 13

FINISH ASSEMBLY

1. Place the brake carrier onto the brake housing and bolt it. Mount breather with connection piece andseal ring and screw plugs with seal rings.

2. Check brake hydraulic system for leaks (see compactness checking instruction).

3. Install “O” - ring (brake carrier / axle spindle resp. steering knuckle), free of torsion and loops.

4. Measure (through the check hole) the distance from brake carrier to the piston end-face, whilstactuating the brake. Knock the measured value, with marking punches, into the brake carrier.

5. Install the complete brake onto the axle (coat the contact surface with Loctite 270).

6. Mount the face seal (see chapter 5).

Alignment of the discs

Wet disk brake with dimension X340:

The alignment of the discs has to be made at mounting of the wheel hub by itself.

Wet disk brake with dimension X460:

The alignment of the discs has to be made by a mounting device (056.005.0-3). Clamp the discs byactuating the brake (hydraulic or air pressure).

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SERVICE INFORMATION

8 - 13

COMPACTNESS CHECKING INSTRUCTION

FOR

BRAKE HYDRAULIC SYSTEM AND COOLING OIL ROOM.

Check the brake hydraulic system for leaks

Before conducting the test, bleed the brake hydraulic system.

The pressure drop, after applying 120 bar for a period of 15 minutes, must not exceed 2% (leaving 117.5 bar).

Test medium: Motor oil SAE 10 W corresponding to MIL-L2104.

Check cooling oil room for leaks

Brake with external cooling:

After assembly of the wheel hub with the face seal and adjusting of the wheel bearings, check thecompactness of the cooling oil room.

Install an air pressure gauge with shut-off valve.

Charge the hub assembly with 1.5 bar air pressure.

Turn the hub assembly several times.

The pressure drop after a period of 10 minutes must not exceed 0.1 bar.

Brake without external cooling:

After assembly of the planetary gear drive, check the compactness of the cooling oil room.

Install an air pressure gauge with shut-off valve.

Charge the hub assembly with 0.5 bar air pressure.

Turn the hub assembly several times.

The pressure drop after a period of 15 minutes must not exceed 0.1 bar.

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SERVICE INFORMATION

9 - 13

LUBRICATION AND ACTUATION SETTINGS

Permissible oil:-

Actuation fluid: Do not use brake fluid at any time!

Use a mineral oil based hydraulic oil type fluid only!

1) Motoroil API SE / CD.

MIL - L - 46152C / MIL - L - 2104 C or D.

2) ATF C - 3 or Dexron.

3) Hydraulic oil HLP DIN - E 51524 Teil 2.

Viscosity:

For a moderate climate: ISO VG 22 - 32.

For extremely cold climate: ISO VG 15

For extremely warm climate: ISO VG 46.

Cooling Fluid: As actuation fluid.

If the brake is making a noise, you can use oils with LS additives,(Limited Slip), according to the recommendation of the oil supplier.For example: 3 to 6% Lubrizol LZ6117.

Check Measurement: It is measured through the view hole, whilst actuating the brake.The check measurement, when new, is marked in the housing - below theview hole.

If the measured dimension is greater than the marked dimension andmaximum wear dimension, immediately consult Kessler & Co.

After working on the brake assemblies, bleed the brake hydraulic system and check for compactness!

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SERVICE INFORMATION

9 - 13

ASSEMBLY OF THE FACE SEAL

1. Seal ring.

2. Rubber toric ring.

3. Housing retaining lip.

4. Housing ramp.

5. Seal ring housing.

Seal rings, torics and housings must be clean and free of any oil film, dust, or other foreign matter.Use a solvent that evaporates quickly, leaves no residue and is compatible with the rubber toric rings.The recommended solvent is Isopropanol. Ring and housings should be wiped with a solvent-soaked,lint-free cloth or paper towel.

After all components have been wiped clean, the torics should be installed on the metal seal rings, sothat they rest in the radius on the tail of the metal ring. Ensure that the torics are not twisted, byinspecting the mould flash line on the outside diameter of the toric for true circumferential trackingaround the seal. Twisted torics will cause non-uniform face load, that can result in leakage of lubricantand pumping of debris past the toric. If a twist is apparent, it can be eliminated by gently pulling asection of the toric radially away from the metal seal ring and letting it “snap” back. Repeating this inseveral places around the ring will eliminate any twist in the toric ring.

Put the toric ring (2) on sealring (1), at the bottom of theseal ring ramp (7) andagainst the retaining lip (8).

The toric ring (2) can twist if it isnot wet all around duringinstallation or if thers are anyburrs or fins on the retaining lip(3) of the housing.

Eliminate toric twist by gentlypulling a section of the toric (2)rapidly away from the seal ring(1) and letting it “snap” back.

1

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SERVICE INFORMATION

11 - 13


Place the installation tool around the seal ring and dip the seal ring into a pan of Isopropanol solvent,to lubricate the toric ring. It is essential to lubricate the toric ring with Isopropanol, so that the toric willslip past the housing retaining lip and seal uniformly in the housing nose radius.Insufficient lubricationcan cause poor seal performance, due to non-uniform loading (twisted or cocked seals). Use ofsolvents other than Isopropanol can leave a residue on the toric or ramps and allow the toric to slide,rather than roll in seat. This can also result in poor seal performance due to non-uniform loading.

Put the installation tool (9) onto the seal ring(1) with toric ring (2). Lower the rings into acontainer with Isopropanol, until all surfacesof the toric (2) are wet.

Toric sliding on retainer ramp.

Toric caught on housing retainer lip.

Toric sliding on seal ramp.

After dipping the seal assembly in the solvent, shake the excess solvent from the seal assembly andimmediately “pop” the seal into the housing with a firm push of the installation tool. Remove theinstallation tool and check the seal standout height at several places around the circumference of thering to verify an accurate installation. If the seal does not meet the height specification, inspect thetoric for twists or obvious bulges.

With all surfaces of the toric ring (2) wet withIsopropanol, use the installation tool (9), toposition the seal ring (1) and the toric ring (2)squarely against the housing (5), as shown.Use sudden and even pressure to “pop”(push) the toric ring (2) under the retaining lip(3) of the housing (5).

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SERVICE INFORMATION

12 - 13


The seal can be adjusted by gently pushing the toric into position by hand, or by using a fabricatedadjustment hook.

If small adjustments are necessary, do notpush directly on the seal ring (1); use theinstallation tool (9) to push down, or theadjustment tool (11) to pull up.

A thin film of light oil should be applied tothe seal faces, prior to assembly. Use anapplicator, a disposable tissue or a cleanfinger to distribute the oil evenly. Be carefulnot to get any oil on the rubber toric rings.

Be sure there is no visible debris on eitherof the seal faces:- even a small piece oflint can hold the seal faces apart andcause leakage.

After successful installation, wait one minute for the Isopropanol to dray before assembling the twoseal halves in the final loaded position. This delay is to allow any excess solvent to dry, so that thetorics roll - rather than slide - in the housing as the faceload is increased. If the torics slide, this canproduce a non-uniform load that can result in poor seal performance.

Results of Incorrect assembly:

Point “A” and Point “B” remain stationary.

Points “X” and “Y” rotate 180o.

This causes high pressure at “A”/”Y” andpossible galling.

When rotated, points “B”/”X” have lowpressure and possible leakage.

11

Originalassembledposition

Rotated 180o

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SERVICE INFORMATION

13 - 13


After the unit to be sealed is assembled, a post-assembly leakage test can be performed, to ensurethe seal is properly installed. A vacuum check is recommended rather than a pressure check, asvacuum checks are more sensitive. Many users find this an easy check to combine with a vacuum filltechnique for the lubricant. It is recommended the compartment be filled to the correct level withlubricant and then rotated, slowly, several revolutions - to seat the seals. A vacuum test will catch bigseal damage, such as broken seal rings or cut torics, that may have been caused in the last phasesof assembly. The Duo-Cone seal is not designed to seal air, so some leakage can be expected usingsuch a procedure.

Following these guidelines and recommendations should ensure optimum performance from the Duo-cone seals.

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Workshop\Brake Chambers - Single Diaphragm 16-05-11

SERVICE INSTRUCTIONS

FOR

BRAKE CHAMBERS - SINGLE DIAPHRAGM


FOR THIS EQUIPMENT,

PLEASE REFER TO

THE AXLE AND ACCESSORIES OR SUPPORT WHEELS AND SUSPENSION SECTION


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Workshop\Brake Chambers - Single Diaphragm16-05-11

BRAKE CHAMBERS

SINGLE DIAPHRAGM

1 - 2

REMOVAL AND REFITTING THE DIAPHRAGM

TO REMOVE

Drain the air pressure system.

Release the brake operating rod, by removing the fork-end pin at the operating end of the rod.

Disconnect the air supply pipe from the chamber and plug the end of the pipe to prevent the ingress offoreign matter.

Remove the air chamber from it’s bracket or mounting.

TO DISMANTLE

Slacken the fork-end lock nut and unscrew the fork-end from the brake rod.

Mark both halves of the body in relation to the clamping ring, to ensure the same location onassembly. Relieve the tension of the pressure return spring on the diaphragm and clamping ring, byextending the push rod and clamping it in a vice on the plain portion of the rod, or fit a suitable sleeveover the push rod and secure by a nut - as shown.

Remove the securing bolts and - taking care not to distort the clamping ring - slightly spread the ringand push it off the halves of the body.

Release the pressure half of the body and the diaphragm. Remove the unit from the vice, or removethe sleeve. Withdraw the push rod assembly, pressure return spring, seal and seal assembly.

TO ASSEMBLE

Thoroughly clean and examine all parts for signs of wear and/or distortion, taking special note of thediaphragm and seal assembly. If there is excessive wear, the complete unit must be replaced.

RENEWING THE DIAPHRAGM

Ensure the air vent holes are free from obstruction.

Fit the seal spring, seal assembly and diaphragm return spring over the push rod assembly and insertinto the non-pressure plate.

Place the clamping ring over the body flange, align the marks on the body and clamping ring, depressthe push rod assembly against the spring pressure until the piston is below the level of the clampingring, then secure in a vice, or fit the sleeve as previously used in dismantling and secure with the pushrod nut.

Lay the diaphragm in the pressure half of the body, then fit the body into the clamping ring so that thealigning mark (made before dismantling) is in line with the mark in the clamp ring.

Draw the open ends of the clamping ring together, insert the securing bolts and do not over tighten.

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BRAKE CHAMBERS

SINGLE DIAPHRAGM

2 - 2

TO FIT

Reverse the procedure for disassembly, noting the following:

Ensure that the brake rod does not bind with the lever when the brakes are fully applied. If necessary,re-position the fork end.

TO TEST

Should the facilities be available, the unit may be tested on a suitable rig. If not, test on the chassisas follows:

Charge the system with air. With the brakes fully applied, the chamber around the pressure side of theclamping ring should be covered with a solution of soapy water. Watch for bubbles, which will indicatea leakage of air.

If a leak is detected, check the tightness of the clamping ring securing bolts; do not over tighten asthis will tend to distort the diaphragm.

Check also for leakage through the diaphragm, by applying soapy water to the air vent holes on thenon-pressure side of the chamber. If leakage is found, renew the diaphragm.

Check that the push rod operates promptly on application and release.

1. Nut - push rod.

2. Sleeve.

3. Clamping ring.

4. Diaphragm.

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Technical data\Road Wheels 12-05-11

FITTING ROAD WHEELS

1 - 1

When fitting road wheels to the axles, ensure that:

The mating faces, the cones of the wheel nuts, collets (if fitted) and the counterbores of the road wheels arefree of all foreign matter, including paint. All the threads should be clean and the wheel nut torque figurescarefully adhered to.

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SUPPORT WHEELS

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WARNING!

DO NOT WORK IN THE VICINITY OF THE FRONT DRIVE WHEELS,

WHILST THE IGNITION SWITCH IS ON.

(STEERING RE-ALIGNMENT CAN OCCUR).

THIS WARNING ALSO APPLIES TO THE

REAR SUPPORT WHEELS.

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Workshop\Support Wheel Hub Assemblies 12-05-11

MAINTENANCE INSTRUCTIONS

FOR

SUPPORT-WHEEL HUB ASSEMBLIES

(SK1998/M, SK1999/M)

TBL280

1 - 18


FOR THIS EQUIPMENT,

PLEASE REFER TO

THE SUPPORT WHEELS AND SUSPENSION SECTION


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Workshop\Support Wheel Hub Assemblies12-05-11

2 - 18

SUPPORT WHEEL HUB ASSEMBLIES

SECTION 1

MAINTENANCE AND MAINTENANCE SCHEDULES

1.1 Torque Settings.

1.2 On initial receipt and daily for first week (where applicable).

1.2.1 Torque wheel nuts, using the sequence shown.

The use of power tools for torque setting is not recommended.

M22 ISO wheel nuts should be lightly oiled on threads (engine oil S.A.E. 20/50). Keep oil away fromwheel nut chamfer and stud hole (other wheel nut types should be torqued dry).

NOTE: This initial check is also relevant after wheel changes.

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SECTION 1


3 - 18

1.2.2 Torque settings for differing wheel security types are as shown.

Metric wheels and wheels to BSF U.K. standards must not be inter-changed or mixed in anycombination.

1.2.3 For axles using the six spoke, demountable European trim.

Tighten nuts consecutively several times round.

1.2.4 Camshaft spherical bearings; see 1.1 for torque details.

1.2.5 Check oil level (oil filled axles only), see 2.4.30 for filling details.

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SECTION 1


4 - 18

1.3 After 500km.

1.3.1 Check torque on all wheel nuts (see 1.2.1 and 1.2.2 for torque details).

1.3.2 Check hub bearings for end float. Raise axle, using two jacks positioned as close as possible to thespring seats. Support by means of trestle. Release the brakes. Apply a lever between tyre and groundto check play. In the event of perceivable play, remove hub-cap and attach a magnetic dial gauge.Push and pull hub and note the indicator reading. The end float should be 0.08 - 0.2mm (3-8 thou).If adjustment is necessary, see section 2.2 for end play adjustment details.

1.4 After 5000 km.Also:- Prior to initial operation after a long idle period.

1.4.1 Check torque on all wheel nuts (see 1.2.1 and 1.2.2 for torque details).

1.4.2 Check brakes for adjustment. Check pushrod travel, by applying and releasing the brakes to ensurethat pushrod travel is satisfactory and that the camshaft returns fully to the “off” position. The clevisshould not move more than 35mm during brake applications. If adjustment is necessary, see 2.1 fordetails.

1.4.3 Lubricate camshaft bearings and slack adjusters. Use Century 20/84 grease or equivalent. Greasethrough grease nipples until grease exudes from body. However, take care not to get excess greaseinto the brake.

1.4.4 Check oil level (oil filled axles only). See 2.4.30 for filling details.

1.5 Every six months or 50,000 km.(Whichever occurs sooner).

1.5.1 Check torque on all wheel nuts. (See 1.2.1 and 1.2.2 for torque details).

1.5.2 Check brakes for adjustment. (See 1.4.2 for adjustment details).

1.5.3 Lubricate camshaft bearings and slack adjusters. (See 1.4.3 for lubrication details).

1.5.4 Check brake linings for wear. Inspection of lining thickness is possible through plugs in the dustcovers. Prise out the plug, using a screwdriver or other suitable implement. The lining should not beless than 6mm thick. A special wear indicator edge is visable and linings should be renewed whenthey have worn to this edge. See 5.10.

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SECTION 1


5 - 18

1.6 Every twelve months or 100,000 km(Whichever occurs sooner).

1.6.1 Remove brake shoes. Check linings for wear and sound attachment to shoes. Replace as necessary.Inspect anchor pins, bushes, cam rollers, camshafts and cam bearings. Clean and lubricate. Seesection 2.3 for details.

1.6.2 Renew oil in oil-filled hubs. Drain, by removing the hubcap. See 2.4.29 for refill instructions.

1.6.3 Clean and check brake drums for excessive wear or cracks. (See section 2.5 for details).

1.6.4 Check hub bearings for end-float. (See 1.3.2).

1.7 Every twenty-four months or 200,000 km(Whichever occurs sooner).

1.7.1 Remove, clean, inspect and lubricate the hub bearings. Clean hub and renew grease. (See section 2.4for details).

1.7.2 Fit new grease/oil seal. (See section 2.4 for details).

1.7.3 Renew brake return springs and retaining springs. (See section 2.3 for details).

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SECTION 2

SERVICE

6 - 18

2.1 Brake adjustment

“S” cam brakes will be fitted with either manual or automatic slack adjusters. The sequence below isfor manual slack adjusters only, as automatic slack adjusters should take up the slack when a brakecamshaft is turned by 15 degrees.

2.1.1 With brakes released, adjust the slack adjuster until shoes make contact with the drum.

2.1.2 To adjust both manual or automatic slack adjusters, ensure that the locking sleeve is disengaged.

Diagram (Fig. 16), shows the locking sleevein it’s disengaged position. Be sure this isheld in, disengaging the adjusting screw,when making adjustments.

Diagram (Fig. 17), shows the locking sleevein it’s engaged position. It is important thatthis sleeve is returned to this locked position,engaging the hexagon head of the adjustingscrew, following adjustment.

2.1.3 Adjust slack adjusters to obtain free running clearance. This is obtained when the pushrod movement(dimension A) is 10% of the lever length (dimension B), ie: a lever length of 150mm should have 15mmof movement.

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SECTION 2

SERVICE - Continued...

7 - 18

2.1.4 Check that the angle formed by the slack adjuster arm and the brake chamber pushrod is greater than90o, both with brakes released and applied.

2.1.5 When lining wear causes an increase to the stroke limit of 35mm, re-adjust.

2.2 Hub bearing adjustment

2.2.1 Raise vehicle, using jacks. Support by means of trestle. Make sure that the hub revolves freely and ifnecessary, temporarily slacken off brake adjuster to ensure complete freedom from brake binding (seesection 2.1).

2.2.2 Once brakes are slackened off and are not binding on drum, remove hub cap and hubcap gasket.

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SECTION 2


8 - 18

2.2.3 Remove the bearing locknut and lockwasher using spanner (Y500600).

2.2.4 Rotate the hub in both directions, at the same time tightening the bearing adjuster nut. Continue untila binding is felt and a torque setting of 7 kg.m (50 lb.ft) is reached.

2.2.5 Using the lockwasher as a guide, slacken the adjusting nut by 7 holes and fit the lockwasher. Takecare that the adjustment is not disturbed. Fit and tighten to 35-40 kg.m (250-300 lb.ft) torque. Checkthat hub and drum rotate freely.

2.2.6 Check end play is between 0.08-0.2mm (3-8 thou). A magnetic dial gauge should be used to make thefinal check.

2.2.7 Fit a new hub cap gasket. Re-fit hub cap.

2.3 Brakes

Please read section 5 - working with brake linings.

Whilst accepting that it is standard practice to remove the hub and drum complete with the wheel/tyreattached when working on axles with outboard hubs, it is recommended that on axles with outboarddrums, the time is taken to remove the wheel/tyre. This will allow the drum to be removed withoutdisturbing the hub.

This has three advantages:-

1. The hub bearings and end float settings are not disturbed.

2. A new grease seal will not be required.

3. An inspection of wheel studs, nuts and wheels can be made (see section 2.6 for details).

2.3.1 Outboard drum removal

2.3.2 Raise the vehicle, using jacks. Support by means of trestle.

2.3.3 Undo wheel nuts and remove wheel/tyre assembly.

2.3.4 The drum can be jacked from the hub, using two M12 bolts, by screwing them into the drum againstthe hub face. The drum will slide off the hub spigots.

2.3.5 The brakes are now accessible for work.

2.3.6 Hub and outboard drum removal.

2.3.7 Remove hub cap (2.2.2), gasket, bearing, locknut, lock washer and bearing adjuster nut (2.2.3).

2.3.8 Ensure brakes are slackened off (2.1).

2.3.9 Withdraw hub/drum/wheel/tyre assembly. Ensure that the outer bearing (early models) does not fallout of hub (later models have a bearing retainer to prevent this). If difficulty is experienced, hub pullersare available (part no. Y507527).

2.3.10 The brakes are now accessible for work.

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SECTION 2


9 - 18

2.3.11 Brake shoe removal.

2.3.12 Remove the dust covers. This will allow access to the anchor pins, which need to be pushed from theirhousing.

2.3.13 Remove the anchor pin circlip, allowing the anchor pin to be pushed out from the dust cover side.

2.3.14 Remove the anchor pin.

2.3.15 Unhook springs and remove spring bars from twin webs of shoes.

The brake shoes are now free to be inspected.

2.3.16 If on inspection, the brake linings are found to be worn or damaged, they will need to be replaced.Replacement linings are available, but it is often more economic exchange for shoes ready lined.

2.3.17 To remove linings, first remove the existing rivets. Before re-lining, clean the shoe platform and re-coatwith a rust-proof primer. Ensure linings and shoe contact faces are clean prior to fitting and that shoesare not distorted or damaged. Rivets must be the correct diameter, head size and type.

2.3.18 With the exception of 335 x 210mm (13” x 81/4”) brakes, replacement brake linings are marked “cam”and “anchor”. The anchor brake lining has a greater taper and should be fitted at the anchor end of thebrake shoe.

2.3.19 Firmly clamp lining to shoe, ensuring rivet holes are aligned. Insert rivet and drift home, taking care notto damage lining.

2.3.20 Spread the rivet shank, using a tubular rivet dolly of correct size, ensuring rivet head remains firmlyseated and shoe/lining remain firmly clamped.

2.3.21 Check lining platform and shoe contact, using a 0.203mm (8 thou) feeler gauge.

2.3.22 When fitting new brake shoes, always fit new shoe return springs.

2.3.23 Inspecting anchor pins:- See that the circlip grooves are clean and not worn. Ensure that pin rotatesfreely in it’s bush. Inspect both pin and bush for excessive wear. Replace if necessary.

2.3.24 For outboard drum models, removing the anchor pin bushes means that the hub will need to beremoved (see 2.3.6).

2.3.25 Anchor pin bushes can be drifted out, using the correct drift tool.

2.3.26 If replacement pins or bushes are required, ensure new circlips are also fitted. Lightly lubricate thebushes, pins and brake shoe ends with Century Super C anti-seize compound or equivalent.

2.3.27 Inspect cam rollers for excessive wear. Rotate cam rollers in brake shoe. Replace if necessary.

If cam rollers need replacing, ensure new retaining clips are also fitted. Lightly lubricate new rollerswith Century Super C anti-seize compound or equivalent.

2.3.28 Inspect camshaft head for excessive wear. Check the direction of camshaft rotation to ensure correctoperation and freedom of movement.

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SECTION 2


10 - 18

2.3.29 To remove camshaft, remove the circlip and washers from camshaft, adjacent to the slack adjusterand remove the slack adjuster.

2.3.30 Remove the circlip and washers from the camshaft head side. Slide the circlip and washer down thecamshaft. Remove the various components from the camshaft. Before removing the camshaft, notethat the heads are handed. Each camshaft must be refitted to the same same side from which it wastaken.

2.3.31 Remove camshaft from it’s housing. Inspect for excessive wear to the bearings, at cam face, bearingareas and splines. Excessive camshaft bush wear can cause uneven lining wear and reduce brakeefficiency.

When replacing the camshaft after inspection, grease through grease nipples until grease exudes frombody - use Century 20/84 grease or equivalent.

2.3.32 If the camshaft bearing needs replacing, drift the bearing out, using a suitable drift.

2.3.33 The spherical bearing is either removed from it’s housing for replacement, or (on later models), it is asealed unit, which simply requires four screws loosening to remove. Check for signs of wear ordamage, also the “O” rings. If damaged, it should be replaced.

2.3.34 Before replacing, lightly lubricate camshaft bearing surfaces with Century 20/84 grease or equivalent.

2.3.35 During re-assembly, rotate the camshaft to ensure correct alignment and free operation. Tighten thespherical bearing bolts to 4 kg.m (30 lb.ft). Rotate the camshaft by hand to check that it moves freely.If it binds, slacken spherical bearing bolts, re-align camshaft and re-tighten bolts. Check again for freerotation.

2.3.36 On re-assembly of brakes, take care not to allow any oil or grease onto the brake linings. Lightcontamination of the surface may be removed with a coarse file or rasp; heavy contamination, fromwhatever cause, will require replacement of linings.

2.3.37 Before re-fitting the drum (or hub), ensure the ABS sensor (if fitted) is pushed forward to it’s endstop.Fitting the drum (or hub) will then re-position the sensor correctly.

2.3.38 Ensure the sensor is clean. If the sensor is excessively worn, it must be replaced.

2.3.39 Examine the exciter ring/polewheel and renew if any damage is evident. To remove exciter rings(secured by wheel studs), see section 2.6. For ABS testing procedures, see section 2.7.

2.3.40 Inspect brake drums before re-fitting (see section 2.5).

2.3.41 If hub needs re-fitting, see section 2.4.

2.3.42 Re-torque wheel nuts, see section 1.2.1 and 1.2.2.

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SECTION 2


11 - 18

2.4 Hub bearings

2.4.1 For access to the hub bearings, the hub and drum complete with wheel/tyre will need to be removed(see section 2.3.6).

2.4.2 On later models, with the bearing retainer circlip, the circlip and retaining washer will need to beremoved for access to the outer bearing.

2.4.3 For earlier models, ensure the outer bearing cone does not fall out of the hub.

2.4.4 To recover the inner bearing cone, the seal retaining the bearing must be removed (and subsequentlyreplaced).

2.4.5 When removed, mark the de-mounted wheel hubs and bearing races, so that their identity is notmistaken when re-assembled.

2.4.6 It is advisable to wash the bearing cones thoroughly immediately after removal, using the followingprocedure. Immerse in a washing fluid such as clean white spirit or good quality paraffin (DO NOTUSE PETROL). The washing fluid must not attack the bearing components. After soaking, swirl eachseparate bearing around in the fluid, using a basket or other container if convenient. A clean fibre brushmay be used, care being taken that no bristles lodge in the bearing. Occasional slow oscillations ofthe bearing rings will help dislodge dried out grease and other matter. Never spin a dry bearing, whichcould cause the rollers to skid, thus damaging the highly finished internal surfaces of the bearing.When clean, thoroughly drain and dry in an oven or on a hot plate; a temperature of 65-80o C shouldbe adequate.

2.4.7 Ensure that the bearing cones for each hub do not become mixed.

2.4.8 To inspect the bearing, hold it against the light. Look between the rollers in order to see the racewayor outer surface. Hold the cage and slowly rotate the cone to check for wear or damage over the entiresurface.

2.4.9 Bearing defects.

Identification of wear or damage. Possible causes.

1. Dull appearance, roughness or pitting Abrasive dirt, causing premature bearing failure.of rollers and raceways.

2. Excessive wear on large end of roller. Overtightening.

3. Flaking on small end of rollers, cup Loose adjustment.and cone rolling surfaces.

4. Fracture or fine hairline cracks across Forcing a cone assembly on an oversize spindle,the cup or cone surfaces. or forcing a cone assembly on to a spindle out of

square; or by forcing a cup into a warped hub bore.

5. Series of indentations or lines on the Improper mounting or sudden excessive shockraceways. loads.

6. Corrosion. Ingress of water, or use of incorrect lubricant.Check seals.

7. Blue or blue/brown discolouration. Indicates overheating. Possibly due toovertightening, lack of lubricant, or ingress offoreign material.

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SECTION 2


12 - 18

2.4.10 Always renew any bearing which does not, without doubt or hesitation, pass inspection. The dangerand cost of bearing failure in service is many times the replacement value of any bearing. Ifreplacements are needed, it will be necessary to remove cups from hubs.

2.4.11 Check the bearing cups in the hubs. Both inner and outer bearing cups must be a tight press fit intothe hub. Any sign of looseness means replacement of the hub.

2.4.12 The bearing cups must be pressed from the hub if they are worn and replacements sought. If difficultyis encountered, special tool Y507424 is available for extracting the inner (90mm) bearing cup andY507492 for extracting the outer (65mm) cup.

2.4.13 The outer bearing cones should be a sliding fit on the spindle. They should not be loose enough tospin.

2.4.14 After checking for signs of wear or damage, lubricate the bearing immediately and re-fit. Alternatively,completely coat all parts with a rust preventative oil, working it well into the internal parts of thebearing. Then wrap in greaseproof paper and box until required for re-fitting, when the bearing willrequire re-lubricating. Oil filled hub bearings should not be greased, but dipped in Century 85W-140 oilafter inspection and prior to fitting.

2.4.15 Re-assembly.

2.4.16 Wash out all the old grease from the hub, using white spirit or good quality paraffin (DO NOT USEPETROL), and allow to dry.

2.4.17 If replacement bearings are to be fitted, the bearing cups need to be pressed firmly into the hub,against the shoulders. Take care to ensure the cups are seated squarely.

2.4.18 Thoroughly coat both cups with Century 20/84 grease prior to installation (grease filled hubs only).

2.4.19 Pressure-grease or re-pack cones thoroughly, working grease between rollers, ensuring greasereaches the inner raceway.

For oil filled hubs, a light coating of oil (Century 85E-140) should be applied to the rollers.

2.4.20 Lightly smear the hub between the two bearing cups with grease. This cavity should not be filled withgrease since, in use, pressure could build up forcing grease through the seal.

2.4.21 Place inner bearing cone onto raceway and fit a new seal. Ensure sealing lip faces the bearing. Priorto installing any seal, make certain that the seal bore is free of any nicks, gouges or other damage.This will prevent any leakage around the seal’s outer diameter.

2.4.22 It is important that the seal is fitted into the hub after the inner bearing cone.

Load the inner bearing cup and cone into the hub whilst in a vertical position. Locate the seal squarelyin the hub bore and tap into position, using a seal drift. Do not strike hard, as damage will be causedto either seal or bearing. Light taps will drive in the seal until it touches the bearing - when resistancewill be felt. Ensure seal is correct way round by noting the marking given on seal for this. Ensure thereis ample grease between inner bearing and seal.

2.4.23 Although there should be adequate grease around the outer bearing, it is not necessary to pack thehub cap with grease.

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SECTION 2


13 - 18

2.4.24 Place outer cone onto raceway and replace the thrust washer and circlip. (Earlier models withoutwasher and circlip will need the outer bearing installed once the hub is mounted on the spindle).

2.4.25 Before replacing the hub, inspect the spindle journals for excessive wear. The lower limits for journalsizes are:

Inner bearing: 89.94mm.

Outer bearing: 64.95mm.

Lightly grease spindle bearing faces (Century 20/84 grease).

2.4.26 Carefully feed hub and drum assembly onto spindle at a slight angle and with a slight rotarymovement, to seat the grease seal. Check the grease seal is in place and undamaged.

2.4.27 Fit outer bearing cone (earlier models). Fit bearing adjuster nut and adjust bearing end-float asdetailed (section 2.2).

2.4.28 Fit brake drum dust covers. Fit grease smeared hub cap and new gasket.

2.4.29 For oil filled hubs; to install hub cap, clean face of hub and apply a light coat of non-setting sealingcompound e.g. Hermetite red. Position the gasket on the hub and apply a light coat of sealant to theouter surface. Fit hub cap and secure with cheese head screws and fibre washers.

2.4.30 Remove plug from hub cap and fill with Century 85W-140 oil to level marked on cap. Allow time for oilto fill cavities, re-check level and top up as necessary.

2.5 Brake drums

Please read section 5 - working with brake linings.

2.5.1 Remove either brake drum (outboard drum models), or hub/drum complete with wheel and tyre (see2.3 for details).

2.5.2 Examine internal drum face for cracks, scoring etc. and for ovality. This is an indication that the brakehas been running excessively hot. Simply fitting new drums will not correct the problem.

2.5.3 Possible causes:-

1. Towing vehicle has a predominance valve, causing the trailer to do most of the braking.

2. Badly set or malfunctioning slack adjusters.

3. Use of trailer brakes only, to check vehicle speed during long descents.

4. The use of non-approved linings.

5. Malfunction in the air actuation system.

6. Parasitic drag of brake shoes, or “sticking” of camshaft.

2.5.4 Light crazing of the braking surface indicates that the drum has ben overheated, but does not renderthe drum inserviceable.

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SECTION 2


14 - 18

2.5.5 Brake drums with any other damage, e.g. rivet grooving, must be replaced.

2.5.6 Re-bores or skims are not recommended. It weakens the drum and the increased internal diameterpermits the cam to rotate too far. This can result in sticking cams or “cam rollover”. Both can bedangerous for obvious reasons and difficulty may be experienced in removing the brake drums.

Furthermore, if relined shoes are fitted, their contour will not conform to the shape of the skimmeddrum, resulting in poor brakes through reduced contact area.

2.6 Wheel stud removal

2.6.1 It is important to ensure that wheel nuts and collars match the wheel to be fitted, i.e. BSF conicalwheel nuts and collars should be matched with U.K. standard wheels having conical seating.Metric DIN standard wheels have spherical seating to match metric wheel nuts and collars. Whenfitting twin wheels, ensure that the inner wheel is fitted correctly on the seating and does not beardirectly on to the hub face. Single centre nave wheels do bear directly on to the hub face.Note: Twin and single ISO 4107 spigot mounted wheels do also bear directly on to the hub face.

2.6.2 Metric wheels and wheels to U.K. standard must not be interchanged or mixed in any combination.

2.6.3 It is essential, when mounting wheels on the vehicle, that they should be centred correctly - to avoidoverstrained or fractured studs, distortion of wheels, hub flanges and brake drums, loose wheels andelongated stud holes.

2.6.4 For wheel security, type identification and correct torque details, see section 1.2.2.

2.6.5 Examination of wheel fixings:- Raise the vehicle, using jacks (support by trestle) and remove roadwheels.

2.6.6 Check and replace any studs which show the slightest sign of wear. Wheel studs can be pressed out,using an hydraulic press (preferred method), or driven out using a soft metal hollow drift.

2.6.7 First remove hub and drum assembly (see section 2.3.6), then press out wheel studs. (Drive outcollars, using a steel drift: 23mm diameter). 160 or 800 series only.

2.6.8 Ensure holes in hub are clean and undamaged. Examine stud holes in wheels for wear on sphericalseat and for damage to the wheel stud threads at base of collar.

2.6.9 Wheel stud re-fitting

Wheel studs should be pressed firmly into place, taking care to ensure that the studs remain squarewith the hub face, seats flat against the inside face of the drum and that the serrations are aligned.

2.6.10 Note: BSF wheel studs are available with either left or right handed threads. Care must be taken toensure that these handed bolts do not become mixed. Metric wheel studs are right-hand thread only.

2.6.11 Press in new collars, ensuring the collar of a matching type is fitted, i.e. conical or radiused face.Ensure collars are pressed or driven in squarely and fully seated. 160 or 800 series only.

2.6.12 Collars for BSF or DIN twin wheel fixing on 2000 series axles are pushed onto studs and up to drum orhub face.

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SECTION 2


15 - 18

2.7 ABS sensors and rings

For most ABS problems, contact the manufacturer for solutions. The following tests are simple waysof eliminating or highlighting the sensor and excitor ring as a cause of the problem.

2.7.1 “A” type ABS sensors.

Equipment:

Voltage measuring device type AVO EM272. Suitable harness for easy attachment to the sensorleads.

Procedure:

1. Check that the hubs or hub and drum assemblies on each side of the vehicle freely rotate.

2. Attach the AVO harness to the sensor leads of one hub end. Select scale 0 to 3V AC on the AVOEM272. Polarity is not important.

3. Rotate the hub at a rate of approximately 30 rpm in any direction.

4. Note the reading of voltage level on the meter.

5. Remove harness and repeat the above procedure on the other side of the vehicle.

Requirements:

1. Voltage must not fall below 2.0V during any revolution of the hub at the specified speed.

2.7.2 Causes of failure.

1. Air gap too great - check run out or that sensor is pushed home against sensor ring.

2. Faulty sensor.

3. Damaged excitor ring.

2.7.3 “W” type ABS sensors.

Equipment:

RMS scaled voltmeter c/w suitable cable to connect with ABS sensor lead.

Procedure:

1. Check hub and drum assembly rotate freely.

2. Connect voltmeter to ABS sensor.

3. Rotate hub and drum at 30 rpm (1/2 rev/sec.) in any direction.

4. Note the reading of the voltage level on the meter.

5. Remove voltmeter, repeat on other hub and drum assembly.

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SECTION 2


16 - 18

Requirements:

1. Voltage reading must be above 0.2 V (RMS).

2. Variations in voltage output must not be greater than 2:1 when hub and drum assembly is rotatedat a constant speed.

Causes of failure:

1. Air gap too great - check run out or that sensor is pushed home.

2. Sensor is faulty.

3. Damaged pole wheel.

SECTION 3

FAULT DIAGNOSIS

Fault Possible Cause

3.1 Damaged wheel studs. 1. Wheel nut not tightened to recommended torque.

2. Care not taken, when fitting road wheels.

3. Stud locknut (when fitted) not tightened and locked.

4. Incorrect wheels fitted.

3.2 Brakes binding. 1. Faulty return spring.

2. Restricted hose or damaged air line.

3. Exhaust port of relay emergency, or quick release valvesobstructed.

4. Brakes incorrectly adjusted.

5. Worn camshaft bushes.

6. Tight camshaft.

7. Faulty spring brake unit (if fitted).

3.3 Hub overheating. 1. Bearings incorrectly adjusted.

2. Bearings under-greased or unsuitable grease used,causing dry running.

3. Bearings overtightened.

4. Ingress of foreign material into bearing.

5. Brakes are binding.

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SECTION 3

FAULT DIAGNOSIS - Continued...

17 - 18


Hub overheating. 6. Bearing cups loose in hubs.

7. Bearings warn.

3.4 Brakes are inefficient 1. Brakes require adjustment.

2. Grease or oil on brake linings, possibly caused by a failedhub seal.

3. Worn cams or linings.

3.5 Brakes apply slowly 1. Low air pressure caused by:a) tractor brake valve output pressure low.b) relay emergency valve output pressure low.

3.6 Brakes release slowly c) air leak in tractor and/or trailer system.

3.7 Excess tyre wear 1. Incorrect tyre pressures.

2. Wheels misaligned.

3. Bearings incorrectly adjusted. Excessive end-play.

4. Tyre sizes unmatched.

5. Bent axle beam.

6. “U” bolt nuts loose.

3.8 Premature bearing failure. 1. Bearing adjustment incorrect.

2. Condensation in bearings.

3. Dirt, foreign matter in grease.

4. Bearings loose in hub.

3.9 Loose wheels. 1. Incorrect torque.

2. Worn cones or bolts.

3. Mismatched wheels and fasteners.

4. Damaged wheels, mounting face not flat.

5. Excessive paint on hub/wheel mounting face.

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SECTION 3

FAULT DIAGNOSIS - Continued...

18 - 18


3.10 Broken or bent axle beam. 1. Welding across high stress zone.

2. Excessive shock loadings.

3. Overloading.

4. Reworked axle brackets.

3.11 Grease or oil leaks. 1. Incorrect assembly of seal.

2. Seal damaged.

3. Damaged/worn hub cap gasket.

4. Hub odometer stem leaks.

3.12 Glazed brake linings. 1. Trailer brakes are only being subjected to light dutyusage.

2. Check suitability of tractor/trailer combination.

3.13 Rapid lining wear. 1. Automatic slack-adjuster failed.

2. Trailer is braking for tractor.

3. Incorrectly set load-sensing valve.

3.14 Uneven lining wear. 1. Bent anchor bracket.

2. Worn spherical bearing or camshaft bush.

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FOR



FOR THIS EQUIPMENT,

PLEASE REFER TO



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BRAKE CHAMBERS

SINGLE DIAPHRAGM

1 - 2


TO REMOVE





TO DISMANTLE





TO ASSEMBLE








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BRAKE CHAMBERS

SINGLE DIAPHRAGM

2 - 2

TO FIT



TO TEST






1. Nut - push rod.

2. Sleeve.

3. Clamping ring.

4. Diaphragm.

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Technical data\Road Wheels 12-05-11

FITTING ROAD WHEELS

1 - 1

When fitting road wheels to the axles, ensure that:

The mating faces, the cones of the wheel nuts, collets (if fitted) and the counterbores of the road wheels arefree of all foreign matter, including paint. All the threads should be clean and the wheel nut torque figurescarefully adhered to.

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STEERING & HYDRAULICS

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1 - 15

TYPICAL HYDRAULIC SYSTEM

TEST AND CHECK LIST

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TYPICAL HYDRAULIC SYSTEM

TEST AND CHECK LIST

PLEASE NOTE

All the components listed in the following pages are not necessarily fitted to every model of DOUGLASTugmaster. Please check hydraulic equipment specification and hydraulic layout in vehicle manuals.

WARNING!

Before working on or around hydraulic systems or components, the following precautions should be observed:-

1. Stop the engine before working under a vehicle.

2. Always chock the wheels.

3. Never disconnect a hose or line containing hydraulic pressure. Never remove a component or pipeplug unless you are sure that all system pressure hes been depleted.

4. Never exceed recommended hydraulic pressure and always wear safety glasses when workingwith hydraulic oil under pressure. Never look into hydraulic pipes or direct them at anyone.

5. Never attempt to dismantle a component until you have read and understood recommendedprocedures. Some units contain powerful springs and injury can result if not properly dismantled.Use only correct tools and observe all precautions relative to the use of these tools.

NS8 TUGMASTERS ONLY.

When topping up, or refilling the main hydraulic oil tank - Ensure the lifting rams are in the fullylowered position. Failure to observe this, will result in the system being over filled and oil leakagefrom the main hydraulic tank filling cap when the rams are lowered.

VISUAL CHECKS OF HYDRAULIC SYSTEM

1. Examine all tubing for signs of kinks or dents.

2. Examine all hoses for signs of wear, drying out and overheating.

3. Check suspension of all tubing. It should be supported and not vibrate.

4. Check suspension of all hoses. Position so that hoses will not abrade or be subjected toexcessive heat.

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REASONS KEYS

1.0 PUMPS AND MOTORS

1.1 Poor oil flow

- Wrong rotation direction or - Change electric motor polesbad coupling. or check coupling key.

- Low oil level. - Clogged strainer.

- Malfunction of suction valve.

- Air bubbles in circuit. - Drain the circuit.

- Air intake through suction. - Change union or seal and checktightness of pipe.

- Cold oil (high viscosity). - Lower pump pressure or addheating system.

- No priming of pump. - Drain delivery pipe.

- Snapped pump shaft. - Determine reason why (pumpoverload or bad alignment).

- Bad quality oil.

- Too big suction height.

- Pump speed too high.

- Oil tank not air-freed. - Fit breather or air filter on tank.

1.2 Noisy pump and motor

- Cavitation. - Prime pump. Set or controlmotor valves (see 1.1 &10.2).

- Air intake throught shaft seal.

- Emulsion. - Drain circuit (see 10.2).

- Tank breather clogged ornon-existent.

- Strainer clogged or too small.

- Suction pipe too small.

- Casing oil leakage. - Tighten bolts, check presenceof possible cracks and seals

- Snapped vane spring.

- Faulty motor or pump part.

COMMON HYDRAULIC BREAKDOWNS

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REASONS KEYS

- Mis-alignment of motor and pump.

- Unconcerned particles in suctioncircuit.

- Clogged circuit. - Scour if needed.

- Flattened suction pipe or hose.

- High oil temperature too high. - See 1.3.

- Vibrations.

- Oil level too low.

- Malfunction of suction valve.

- Wrong oil quality.

- Rotation speed too high.

1.3 High temperature of pump or motor


- Oil speed in circuit too high. - Increase diameter of pipes.

- Low oil level.

- Pump rotor or motor worn out.

- Mis-alignment of motor and pump.

- Initial speed increase. - Check max. pressure. If necessary,change pump type (higher flow rate)with relevant pipes.

- Improper cooling system. - Check capacity or cleanliness.

- Differential pressure betweenset and working pressure too low.

- Pressure too high.

- Wrong pressure limiter.

- Wrong seals.

- Clogged or too small air filter.

- Rotation speed too high.

- Cavitation. - See 1.1 and 10.2.

- Emulsion. - See 10.2.


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REASONS KEYS

- Clogged circuit. - See 1.2.

- Flattened suction pipe.

- Booster pump breakdown.

1.4 No oil pressure from pump.

- Wrong pressure adjustment.

- Pressure limiter jamming.

- Faulty electric circuit.

- Pistons, valves oil leakage.

- Snapped pump shaft or tail shaft key.

- No oil flow. - See 1.1.

- Bad oil quality.

- Faulty drive device or slipping belt.

- Clogged circuit.

- Bad seals and stuffings.

1.5 Motor speed decreasing.

- Intake pressure too low.

- Delivery pressure too high. - Check circuit.

- Faulty oil tightness.

- Faulty motor parts.

- High oil temperature.

1.6 Difficult speed control.

- Important oil leakage at pump. - Check pump flow rate.

1.7 Motor not operating.

- Torque too low. - Increase initial pressure.

- Bad condition of flange pumptoric seal.


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REASONS KEYS

- Low pump flow rate.

- Motor under-sized.

1.8 Large clearance of the shaft.

- Faulty bearing.

- Abnormal load on shaft.

- Unbalanced coupling.

1.9 Oil leakage at motor or pump.

- Poor seal or union tightness.

- Casing leakage. - See 1.2.

- Bad planed flange.

- No brake valve on circuit.

2.0 ELECTRODIRECTIONAL VALVES

2.1 Defective spool.

- Jammed spool, due to distortion. - Unbolt spool and re-bolt uniformly.Check planed surfaces.

- Presence of dirt in circuit.

- Wrong quality of oil.

- Thickened oil after long stoppage - Clean spool and replace oil, if necessary.period.

- Presence of water in circuit. - Check cooling system and water circuit.

- Defective seals.

- High oil temperature. - See 10.3 and 14.1.

- High oil speed (charge loss). - Increase diameter of valve.

- Cold oil (high viscosity). - See 1.1.

- Drain pipe under pressure. - Fit a new pipe, directly connected to tank.


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REASONS KEYS

2.2 Solenoid not operating.

- Coil blown out.

- Jammed spool.

- No electric power.

- Faulty electric circuit.

2.3 No oil pressure to drive the spool.

- Jammed spool.

- No pressure. - Check the oil circuit.

- No pilot line existing.

- Clogged pilot line.

- No reverse of spool. - Adjust timing block. Check diaphragmscrew of electro-pilot.

2.4 Abnormal heating of valve.

- Oil temperature of circuit too high.

- Wrong quality of oil.

- Clogged circuit.

- Wrong electrical installation.

- Jammed spool.

2.5 Noisy valve.

- Valve under-sized.

- Vibrations in circuit. - Tighten pipes.

- No hydraulic ram device.

- Bad condition of spool.

- Jammed spool (noisy solenoid).


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REASONS KEYS

2.6 Oil leakage in valve.

- Bad oil tightness of unions.

- Defective seals/valve.

- No oil drain line.

- Oil drain line under pressure.

3.0 SERVO-VALVES

3.1 Jammed servo-valves.

- Clogged feeding line.

- Clogged filter.

- Jammed feed-back spool.

- Abnormal efforts on servo-valve. - Unbolt and re-bolt uniformly.

- Other reasons. - See 2.1.

3.2 Servo-valve not operating.

- Faulty electrical circuit.

- Faulty magnetic circuit.

- No differential electrical current.

- No oil pressure.

- Clogged feed line.

- Clogged filter.

- Jammed feed back spool.

- Abnormal efforts on servo-valve. - See 3.1.


- Oil thickened.

- High oil temperature. - Reduce initial pressure. Install orincrease cooling system.

- Under-sized valve.

- Defective valve.


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REASONS KEYS

3.3 Abnormal heating of servo-valve.

- Faulty electrical characteristics.

- Jammed feed-back spool.

- Other reasons. - See 2.4 and 2.5.

4.0 CHECK VALVES

4.1 Jammed valve.

- Abnormal efforts on valve. - See 3.3.

- Wrong assembly.

- Valve seat displaced. - Remove and replace seat.

- Jammed pilot control.

- No drain line.

- Drain line under pressure.


4.2 Oil leakages.

- Defective seat. - Replace seat and spooland check circuit cleaner.

- Bad oil tightness of unions.

- Defective seals.

- Untightened unions.

4.3 Valve resonance.

- No hydraulic circuit.

5.0 PRESSURE LIMITERS

5.1 Cavitation in pressure limiter.

- Defective seat.

- Defective intake control.

- Abnormal high oil speed.


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REASONS KEYS

- Wrong quality oil.

- Clogged circuit.

- Defective anti-shock circuit. - Repair limiter or replace spring.

5.2 Jammed pressure limiter.

- Abnormal efforts on limiter. - Unbolt and re-bolt smoothly.

- Abnormal low oil temperature.

- Abnormal efforts on pipes. - Install lee lever (if fitted).

- Drain line under pressureor not existing.


5.3 Pressure limiter not operating.

- Snapped spring.

- Jammed limiter.

5.4 Abnormal heating of limiter.

- Temperature of circuit too high.

- Speed of oil too high.

6.0 FLOW REGULATOR

6.1 Regulator not operating.

- Abnormal efforts on regulator.

- Defective seat.

- Defective choke spool.

- Jammed check valve.

- Defective compensator.

- Jammed metering device.

- Snapped spring.

- Corrosion of adjustment device.

- Wrong regulator.


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REASONS KEYS

7.0 HYDRAULIC RAM VALVES

7.1 Circuit not operating.

- Snapped spring.

- Clogged circuit.

- Jammed piston.

8.0 JACKS

8.1 Operation of jacks - too much free movement.

- Defective guide/piston seal.

- Important oil leakage.

- Abnormal pressure (high or low). - Install pressure limiter or regulator.

8.2 Jammed jack. - See 2.1

8.3 Irregular operation.

- Body not perfectly cylindrical.

- Load variations. - Install check valve.

- Pressure variations. - Check circuit.

9.0 FILTERS

9.1 Poor filtration.

- Too large mesh.

- Clogged filter, oil flows in derivation

- Wrong installation.

- Damaged magnetic device.

- Clogged elements.

- Leakages on pipes.

10.0 TANKS

10.1 Pollution of oil.

- Defective seals.

- Contamination of circuit.


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REASONS KEYS

- Wrong air filter.

- Clogged pipes.

10.2 Emulsion.

- Low oil level.

- Circuit not filled up.

- Decantation partition wall betweensuction and delivery pipes missing.

- Oil return to tank pipe locatedhigher than tank oil level.

- Cavitation. - Decompression too great at suction pipe.Check pipe section, length and strainerfiltration capacity.

- Wrong oil quality. - Weak depression through breather.

- Wrong return pipe assembly.

10.3 Temperature rise.

- No cooling system.

- Insufficient cooling system. - Check heat exchanger surface.

- Heat exchanger surface too small.

- High ambient temperature. - Install tank or change tank location.

- Source of heat nearby tank. - Install insulation screen.

- High circuit pressure.


- Defective elements of circuit(pumps etc.).

- No oil level indicator.

11. COUPLING

11.1 Temperature rise of coupling.

- Wrong axial alignment.

- Electrical defect.


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REASONS KEYS

- Wrong coupling.

- Weak elasticity.

- Defective bearing bush.

- Unbalanced coupling.

- Abnormal efforts on coupling. - Check bolts on coupling.

12.0 PIPES

12.1 Vibrations.

- Bad fixation.

- Pressure variations in circuit. - Check connections betweenpumps and valves.

- Wrong axial alignment.

- Resonance in hollow bodies.

- No hydraulic ram circuit.

- Cavitation.

- Pressure limiter unstable.

- Pulsations of pump.

12.2 Poor oil tightness.

- Wrong seal mounting.

- No seals.

- Defective seals/unions.

- Defective pipes mounting.

12.3 Contamination.

- Dirt in circuit.

- Not scoured circuit.

- Rolling skin in pipes.

- Poor welding.


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REASONS KEYS

13.0 HYDRAULIC ACCUMULATOR

13.1 Accumulator not working.

- Jammed check valve.

- Low circuit pressure.

- Low differential pressure.

- Defective stuffing/seals.

- Wrong mounting.

13.2 High temperature of circuit.

- Speed of through-flow too high. - Install a restriction valve.

- High pressure.

- Polluted circuit.

14.0 OIL COOLERS

14.1 Poor cooling.

- Initial temperature of system too high.

- Dirt in circuit.

- Weak fan power.

- Defective water inlet.

- Defective fan.

- Wrong manufacture of oil cooler.

- Under-sizing of system. - Check heat exchanger surface andtank capacity.

14.2 Emulsion.

- Defective cooling circuit. - After repair, remove and re-oil(several times if needed), untilthere is no water.

- Condensation. - Inlet water too cold.


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- Poor quality of pipes, supplied inbad condition (rolling skin).

- No provisional plug duringmounting works.

- Defective filtration.

- Introduction of dirt through - Install scraping ring sealpiston rods. and protecting devices.

15.2 Emulsion.

- Air in circuit.

- Cavitation. - See 10.2

- Wrong location of return line.

15.3 Temperature variations.

- No thermostat on cooler.

- Erratic stoppage of cooling system.

15.4 Unstable pressure gauge.


- Defective micro-contact.

- Defective electric circuit.

REASONS KEYS

15.0 MISCELLANEOUS

15.1 Contamination.


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12-05-11Workshop\02845d

1 - 6


FOR

PUMP - ELECTRIC/HYDRAULIC

0.541.200.049.000

02845D


FOR THIS EQUIPMENT,

PLEASE REFER TO

THE HYDRAULIC SYSTEM - CHASSIS SECTION


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Workshop\02845d12-05-11

2 - 6

DESCRIPTION

The hydraulic pump is a high performance gear pump of "sandwich" construction, incorporating the pressureloaded bearing principle.

Direction of the pump rotation depends upon the position of the driving gear in the pump body, relative to theinlet port - this is denoted by the arrow on the mounting flange.

DISMANTLING

IMPORTANT:- Always work at a clean workbench, under conditions of maximum cleanliness.

1. Thoroughly clean the exterior of the pump.

2. Remove the inlet and outlet port adaptors, if applicable

3. If a drive member is fitted, remove in the following manner:-

a) Release the tab of the lockwasher and unscrew shaft nut.

b) Remove the driving member with a suitable extractor.

4. Remove the key and, if fitted, the circlip from the drive shaft.

5. Clamp the pump body securely in a soft-jawed vice.

6. Fit a protective sleeve to the drive shaft, to avoid damage to the seal and cover sharp edges with tape.

7. Remove the mounting flanges and end cover securing screws or bolts.

8. Carefully remove the flange and end cover from the pump body, ensuring that the shaft seal is notdamaged, if it is intended to re-use. Should these be tight on their dowels, lightly tap with a mallet torelease. Do not use a screw driver between the faces.

9. Withdraw the gears and bearings from the body bore as an assembly and carefully note their originalpositions. It is suggested that the top bearing be lightly marked on an unmachined surface to facilitatecorrect re-assembly.

TO REMOVE THE DRIVE SHAFT OIL SEALS

1. Remove circlip, where fitted.

2. Suitably supporting the flange outer face downwards, tap out the oil seal with a soft metal drift.

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INSPECTION & SERVICING

GENERAL

Discard all seals and thoroughly clean all parts: check that all machined faces and threads are free from burrs,scores and other damage.

Replace any damaged bolts, washers and circlips, etc.

BEARINGS

Examine each bearing for wear and damage, particularly on the faces, bearing bores and across the sealbridge. The bearings' outer radii should be free from contamination and aeration.

Ensure that the lubricating scrolls in the bearing bore are free from foreign matter and excessive oil lacquer.

Finally, check that the bearings are a sliding fit in the body bore.

If the bearings are not badly damaged, they may be salvaged in the following way:

1. Place a sheet of O grade emery paper, lubricated with paraffin, on a truly flat surface. Polish thebearing face, using a light rotary motion.

2. Outer radii may be lightly polished to obtain free movement in the body. Maintain sharp corner onouter face adjacent to gears.

See also NOTE following "Body".

BODY

Inspect the pump body for external damage and cracks, etc. Examine the body bore for damage and wear. It isnormal for the gears to have cut a light track in the body on the inlet side. If the body is in good condition, withno excessive scoring or other damage of the gear track and the depth of the track does not exceed 0.10mm(0.004"), the body is re-usable.

Using a Vernier height gauge and a dial test indicator, measure the body bore track depth (see fig. 2).

The only re-working advisable is to remove burrs at the edge of the gear track and in the bearing locations. Thisshould be carefully effected with fine emery cloth.

NOTE: Under working conditions, hydraulic pressure within the pump forces the gears towards the inlet side ofthe body on the running track. Therefore, if the running track is past the limit for re-use, the fitting of newbearings may not improve efficiency, as the new bearing will tend to prevent the gears bottoming in the runningtrack.

GEARS

Inspect the gears for scored or worn side faces or journals, damaged teeth, thread or keyway and surfacecracks.

Slight wear and scoring on the journals can be erased by polishing between lathe centres, using O gradeemery paper lubricated with paraffin. Slightly scored side faces may be renovated by sandwiching emery paperbetween the gear face and a scrap bearing, as in fig. 3.

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4 - 6

IMPORTANT NOTES: Whilst servicing the drive and driven gears, particular attention should bepaid to the following points:

1. Gear widths of drive and driven gears must be within 0.005mm (0.0002") of each other, to ensuresatisfactory pump efficiency (see fig. 4).

2. Journals must be within 0.013mm (0.0005") of each other (see fig. 4).

3. Gear faces must be flat. This feature may be checked by blueing a bearing face and rotatingagainst gear - this will also reveal any sharp edges on the teeth.

4. Replacement gears are supplied only as matched pairs.

ASSEMBLY

SEALS

A) SHAFT OIL SEALS

1. Place the pump flange machined-side-downwards on a clean, flat surface.

2. Apply a little grease to the oil seal and, with garter spring facing into pump on single lip seals, use asuitable tool to press seal into it's location.

3. Replace the retaining circlip (if applicable).

B) SEALING AND PRESSURE LOADING RINGS

1. Fit the sealing and pressure loading rings to the flange cover, bearings and thrust plates asappropriate, using a little light grease to aid their retention.

PUMP

1. Ensure that any location dowels are correctly positioned.

2. Place the cover in a soft-jawed vice, with the machined face uppermost. Ensure that the sealassembly is facing the correct way, i.e: garter spring facing inwards.

3. Assemble the pump body to the cover, ensuring that the inlet side of the body is correctlypositioned. At this stage, on pumps not fitted with through securing bolts, two or more securing boltsmay be assembled to aid body retention.

4. Lightly lubricate the body bore, both faces and bore of bearings.

5. Fit the cover end bearing into the body bore, with recessed face uppermost and relieved radii towardspump outlet and slide it gently to the bottom.

6. Insert the gears into their respective bores, depending on the direction of rotation of the pump.

7. Place the flange end bearing over the gear shaft and slide into location with the gear face with therecessed face towards the gears and the relieved radii towards the pump outlet.

8. Fit a protective sleeve over the drive shaft and gently press the flange down over the seal guide andbody dowel.

9. Insert remaining securing bolts or screws and tighten with a torque wrench to the figures givenin table 1.

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TABLE 1

SECURING BOLT TORQUE

Pump Type Nm Torque lb.f/ft.

SP 1/175 19-23 14-17

SP 2/175 54-61 40-45

SP 2/250 61-68 45-50

SP 3/175 88-95 65-70

SP 3/250 88-95 65-70

SP 4/175 122-129 90-95

If the pump is not to be used, seal the ports with dust covers or adhesive tape to prevent ingress of dirt, etc.during storage.

When the unit is refitted to a system, before running the pump, drain oil, thoroughly flush the system toremove any contaminant and refill with a grade mineral-based oil with additives to resist oxidation, corrosionand foaming. This should be maintained in a truly clean condition.

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Fig. 1 TYPICAL PUMP BEARING Fig. 2

Fig. 3 POLISHING GEAR FACES

Fig. 4 GEAR MATCHING

Fig. 5 LOCATION OF SEALING AND PRESSURE LOADING RINGS

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12-05-11Workshop\Variable pump priming

VARIABLE DISPLACEMENT HYDRAULIC PUMP - PRIMING

IMPORTANT

AFTER REPLACEMENT OR REPAIR OF THE VARIABLE DISPLACEMENT PUMP OR ANYCOMPONENT(S) IN THE HYDRAULIC SYSTEM, THE VARIABLE DISPLACEMENT PUMPCASING AND HYDRAULIC SYSTEM MUST BE FULLY PRIMED WITH HYDRAULIC OILBEFORE START UP.

HYDRAULIC SYSTEM CLEANLINESS MUST BE MAINTAINED AT ALL TIMES. COVER ALLEXPOSED PORTS AND HOSE ENDS DURING REPAIR OR MAINTENANCE TO ANYCOMPONENT(S) IN THE HYDRAULIC SYSTEM.

FAILURE TO OBSERVE THESE INSTRUCTIONS WILL RESULT IN PUMP DAMAGE.

1 - 1

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Workshop\01990d 12-05-11


FOR

HYDRAULIC OIL FILTER

274A - BV50 - BL122

01990D

1 - 3


FOR THIS EQUIPMENT,

PLEASE REFER TO



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Workshop\01990d12-05-11


274A - BV50 - BL122

01990D

2 - 3

4

5

6

1

7

8

14

15

2

1011

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Workshop\01990d 12-05-11


274A - BV50 - BL122

01990D

3 - 3

WHEN TO CHANGE THE ELEMENT

Visual Clogging Indicator.

Check when the system is working at normal flow and operating temperature. As the element clogs andpressure drops to a predetermined level, RED starts to appear in the window. It is at this point, prior to theopening of the by-pass valve, that the element should be changed.

HOW TO CHANGE THE ELEMENT

1. Place a suitable receptacle beneath the filter to catch spillage.

2. Unscrew the filter bowl (2). A hexagon is provided at the base of the filter bowl. Remove filter bowl,empty it to drain. (If the filter bowl can be lowered only sufficient distance to clear the bottom of thefilter head (1), see Note 11).

3. Pull element (11) off adaptor (8).

4. Remove and replace head to bowl seal (14) and element seal (10).

5. Wet head to bowl seal (14) with system fluid.

6. Push new element (11) on to spigot of adaptor (8).

7. Thoroughly clean filter bowl (2) and fill approximately half full with clean oil.

8. Screw bowl (2) on to the head (1) and torque load to 14.4 Kg.m. (100 lbs ft.).

9. Operate system to expel all air and check filter for leaks.

10. Check reservoir level and replenish as necessary.

11. Should the filter installation be such that the filter bowl (2) cannot be fully removed while the element(11) remains attatched to the filter head (1), the following procedure should be adopted:-

a) Lower bowl (2) as far as possible.

b) Push element (11) off adaptor (8) into bowl (2), remove element and bowl together.

c) Complete 4, 5, and 7 as above.

d) Offer up bowl with element held partially inside bowl, locate new element on spigot of adaptor.

e) Continue from 8, as above.

NOTE

Scrupulous cleanliness is essential during the element change.

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12-05-11Workshop\PVG32

MAINTENANCE INFORMATION

FOR

DANFOSS PROPORTIONAL VALVE

TYPE PVG32

1 - 3


FOR THIS EQUIPMENT,

PLEASE REFER TO



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Workshop\PVG3212-05-11

DANFOSS PROPORTIONAL VALVE - PVG32

SPECIFIC SERVICE INFORMATION IS NOT AVAILABLE FOR THIS VALVE

Cost-free repairs are available at the following service shops

Authorised service shops:

Asean: Danfoss Industries Pte. Ltd., SingaporeAustralia: Danfoss (Australia) Pty. Ltd., MelbourneAustria: Hainzl Industriesysteme, Gesellschaft m.b.H, LinzBelgium: N.V. Danfoss S.A., BruxellesCanada: Danfoss Mfg. Ltd., MississaugaDenmark: H. Sondergaard A/S, MalovFinland: OY Danfoss AB, EspooFrance: Danfoss S.a.r.l., Trappes (Paris)FRG (Germany): Danfoss GmbH, Offenbach/MainGreat Britain: Danfoss Limited, GreenfordIceland: Velsmiddjan Hedinn, ReykjavikItaly: Sordella & Co. Oleodinamica s.r.l., TorinoJapan: Danfoss (Japan) Manufacturing Co. Ltd., GotembaNetherlands: ITHO B.V., SchiedamNew Zealand: Danfoss (New Zealand) Limited, AucklandNorway: Danfoss Norge A/S, SkuiSpain: Danfoss S.A., MadridSweden: Transventor Hydraulik AB, Molndal, GotenorgSwitzerland: Werner Kuster AG, FrenkendorfU.S.A.: Danfoss Inc., Rockford, Illinois

2 - 3

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12-05-11Workshop\PVG32

DANFOSS PROPORTIONAL VALVE - PVG32

SECTIONAL DRAWING

3 - 3

1. Pressure relief valve 2. Pressure reduction valve for pilot supply 3. Pressure gauge connection 4. Plug, open centre 5. Orifice, closed centre 6. Pressure adjustment spool 7. Plug, closed centre 8. LS connection 9. LS signal10. Shuttle valve11. Main spool12. LS pressure relief valve13. Shock and suction valve, PVLP14. Pressure compensator15. LS connection - port A16. LS connection - port B17. Suction valve, PVLA18. Load drop check valve19. Pilot supply for PVE

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AIRCRAFT NOSEGEAR CRADLE ASSEMBLY

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DOUGLAS EQUIPMENT LIMITED TOWBARLESS TRACTORS

CRADLE SAFETY INSPECTION MAINTENANCE SCHEDULE

IMPORTANT

The procedures detailed in this document must be followed at the specified service intervals in compliance with the requirements of the airframe manufacturers, regulatory authorities and SAE ARP 5284.

In compliance with SAE ARP 5284 paragraph 10.1:

"Records must be kept of all inspections, maintenance and calibration checks of the TLTV aircraft nose landing gear steering and tractive force protection systems or alerting devices for a minimum period of 2 years. Other relevant maintenance/inspection records should also be kept".

For further information please refer to SAE ARP 5284.

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DOUGLAS EQUIPMENT LIMITED TOWBARLESS TRACTORS SAFETY INSPECTION MAINTENANCE SCHEDULE

CHECKING OF AIRCRAFT NOSE GEAR CRADLE ASSEMBLIES

AND ASSOCIATED SAFETY-RELATED EQUIPMENT

CHECKABLE ITEMS

Area Task No. III No. OPERATION DESCRIPTION INTERVAL (whichever soonest)

A

A i)

a)

b)

A ii)

a)

CSIP001 CSIP002

CSIP003

00635

00635

00635

MECHANICAL COMPONENT CHECKS Check general condition of Cradle Assembly:- WARNING: Make sure that there are no persons or equipment in the vicinity of the cradle assembly, also that the ignition and isolation switches are OFF, to prevent accidental starting of the tractor. Check for structural damage: i) Cradle frame assembly side plates to be parallel within +/- 3mm. ii) Cradle gate to be flat, within +/- 3mm. iii) Cradle yoke to be parallel with cradle assembly within +/- 3mm, and pivot should oscillate freely. iv) Check that the cradle gate locates correctly in the locating guide when opening and closing the assembly. If not satisfactory, check for excessive pivot bush wear. Refer to appendix E, F, G & H for relevant model guide. Also ensure that the locating guides are not worn or damaged. Visual check for weld deterioration: Visual check for obvious cracking of welds on the following: i) Linkage bar mounting brackets on main chassis frame section. ii) Cradle frame assembly (complete). iii) Plough (scoop). Check condition of remainder of Cradle/Gate assembly:- Check cradle yoke etc: IMPORTANT: Lower the cradle prior to conducting the following checks:

500 hours / 3 months



ISSUE 6 Workshop\TBL Cradle Safety Document 16-12-02

1 - 29 ISSUE 7

10 - 12 - 07 Workshop\TBL Cradle Safety Document

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DOUGLAS TOWBARLESS TRACTORS SAFETY INSPECTION PROCEDURES DOCUMENT


b)

c)

d)

e)

CSIP004 CSIP005

CSIP006 CSIP007

IN ADDITION: This check to be conducted in conjunction with task no. CSIP008. i) Check for structural damage. ii) With the weight off cradle, and utilising a crowbar, check for excessive wear/flotation. Maximum allowable float is: +/-5mm, i.e. between cradle yoke and main cradle assembly at pivot position. Check suspension ride height and plough ground clearance: i) Having checked tyre pressures are correct, set height of the vehicle by adjustment of levelling valves on rear support wheels (2 off), to obtain a gap between the bump stop. Refer to Appendix E & F for the relevant model. However, the chassis should be parallel within +10mm-0, which may result in a gap variation outside the specified limits. This would be deemed acceptable. CSIP024 also refers. ii) With the cradle in the lowered position, check that ground clearance is maintained within 7mm- 10mm through the full open/closed positions of the ploughs fitted to the TBL180, TBL200/280. 10mm-15mm on TBL400 and 20-25mm on TBL600. However, ensure gate passes beneath chassis when fully open (i.e. clearance 5mm minimum). Check cradle supports & adjustments-both sides of the cradle: CSIP004 also refers. i) With the plough in the lowered position, the cradle supports must be in contact with the relevant mechanical stops. ii) The stops have their own adjusters, which should be utilised to provide the correct contact condition i.e. correct height and parallel within 3mm to cradle frame back plate. Check for loose bolted items: i) Check ALL bolts/screws on the complete cradle assembly. Check cradle parallel support rods (Link Bars): i) Check to ensure bars are not distorted or bent i.e. over length of bars. Maximum deviation +/-1mm.





ISSUE 7 2 - 29 Workshop\TBL Cradle Safety Document 10 - 12 - 07

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f)

g)

h)

i)

CSIP008 CSIP009

CSIP010 CSIP011

ii) Check for excessive flotation in spherical rod-ends. ii) Make sure pivot bar retention plates and all relevant bolts are correctly fitted. Check for fulcrum bearing wear or shaft movement: IMPORTANT: Lower the cradle prior to conducting the following checks. IN ADDITION: This check is to be conducted in conjunction with task no. CSIP003. i) Utilising a crow bar or jack, check for excessive wear/damage to spherical bush, shaft/circlips. Maximum allowable vertical movement:+/-5mm. Check front safety bar alignment: i) Make sure, with the safety bars in the fully OPEN position, that alignment is correct, i.e. within +/- 3mm. ii) Make sure, with the safety bars in the fully CLOSED position, that alignment is correct, i.e. within +/-3mm. NOTE: TBL180 has a single safety bar. TBL200/280, TBL400 & TBL600 have two safety bars. Check front safety bar for damage: i) Make sure that the safety bars have not suffered structural damage and check for weld deterioration. NOTE: TBL180 has a single safety bar. TBL200/280, TBL400 & TBL600 have two safety bars. Check wheel safety bar for damage (Left), rear bars: i) Make sure that safety bars have not suffered structural damage and check for weld deterioration.





3 - 29 ISSUE 7 10 - 12 - 07 Workshop\TBL Cradle Safety Document

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DOUGLAS TOWBARLESS TRACTORS

SAFETY INSPECTION PROCEDURES DOCUMENT Area Task No. III No. OPERATION DESCRIPTION INTERVAL

(whichever soonest)

j)

k)

l)

m)

CSIP012 CSIP013 CSIP014

CSIP015

Check wheel safety bar for damage (Right), rear bars: i) Make sure that safety bars have not suffered any structural damage and check for weld deterioration. Check safety bars for alignment (Left to Right), - rear bars: i) Make sure, with the safety bars in the fully OPEN position, that the alignment is correct. i.e. within +/-3mm ii) Make sure, with the safety bars in the fully CLOSED position, that alignment is correct. i.e. within +/-3mm. Check for safety bars closing/opening correctly: i) When opening and closing the gate, make sure that the rear safety bars do not foul the chassis frame, i.e. when the gate is fully open and beginning the gate closing operation. ii) Make sure, on TBL200/280, when in the GATE OPENED mode, that the front safety bars are not positioned above the top edge of cradle. NOTE: If this problem exists, refer to CSIP039. Check for wear and damage to spherical (ball-type) connections: i) Make sure that all connections are in good condition, via usual checks. ii) Make sure that connections do not have any excessive movement. iii) Make sure that all connections are adequately greased, including those supplied by the Autolube system (if fitted).






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n)

o)

p) q)

CSIP016 CSIP017

CSIP018 CSIP019

00708

00708

00708

Check condition and operation of gate locking mechanism and plunger, i.e. with gate open. i) Make sure that gate opening and locking system operates in the correct manner, including:

a) Ensure free movement is obtained on locking mechanism, i.e. through the full travel of the system.

b) Make sure that all moving components are free from mechanical damage and contamination, which could prevent free opening and closing of the mechanism.

b) TBL180, TBL200/280, TBL400 & TBL600: Make sure that the gate lock/plunger operates in the correct manner, when gate is opening and closing. Also check the emergency release valve.

Check all wheel size positions dimensionally: i) Make sure the gate is FULLY CLOSED & LOCKED. Select the appropriate wheel size from the control panel in the cab. Refer to Appendix D, E, F, G & H for dimensions of specific model, ensuring any adjustable stops are engaging on cradle plough/scoop, i.e. metal to metal contact. ii) Make sure that the correct dimensions are achieved between plough/scoop faces. DELETED Check gate for parallelism (lowered): i) Make sure, with the cradle in the FULLY LOWERED position, with the gate FULLY LOCKED, that the dimensions referred to in task no’s. CSIP017 are achieved. Parallelism must also be achieved i.e. within +/- 3mm.






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r)

s)

t)


Check wheel size indicator for damage: The following checks should be conducted in conjunction with CSIP023. IMPORTANT: TBL180 Mk.2 only. i) Make sure that the mechanical wheel size indicator rod is free from damage. Check over steer protection warning system: i) This system will operate mechanically in the correct manner, if all preceding checks have been conducted-with special emphasis on the function/condition of the rear safety bars. (For setting system, refer to CSIP070 and CSIP071). Check lifting operation and height: Prior to the commencement of these checks, ensure that plough/scoop is set at the correct height for ground clearance i.e. CSIP004 refers. IMPORTANT - TBL180, TBL400 & TBL600 ONLY: i) Make sure that the full stroke of the hydraulic lift cylinders is achieved, i.e. indicated by full system pressure on tractor pressure gauge and light (green), illuminating within the driver’s cab. IMPORTANT - TBL200/280 ONLY: ii) Make sure the maximum cradle lift height is achieved. Please note: maximum hydraulic cylinder stroke is not utilised on these models. For dimensional checks, refer to Appendix F for relevant model. Also ensure that the locating guides are not worn or damaged.





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u)

v)

B

CSIP023 CSIP024

Check condition of wheel size indicator: The following checks should be conducted in conjunction with CSIP020. IMPORTANT - TBL180 Mk.2 ONLY i) Make sure that the plunger/rod is not distorted or bent and that the rose end connections are secure and in good condition. Check suspension ride height for gate clearance beneath chassis: Also refers to CSIP004. WARNING! Do not work in the vicinity of any steered wheels, whilst ignition switch is ON. Steering re-alignment can occur. This warning applies to vehicles fitted with electronic steering. These checks have already been referred to in CSIP004, to allow setting of the lowered gate ground clearance. Additional check as follows: i) Make sure that the air suspension is fully operational, air bags in good condition and free from air leaks. ii) Make sure that the self-levelling valve operating rod and rod-ends (rubber or metal), are in good condition. iii) Check tyre pressures are correct. MAIN HYDRAULICS SYSTEM CHECKS WARNING! Make sure that there are no persons or equipment in the vicinity of the cradle assembly, plus ignition and isolation switches are OFF, to prevent accidental starting of the tractor. NOTE: Time settings in Appendix E, F,G and H are typical for the relevant model. However it is imperative that the opening and closing of the gate/plough and safety bars are co-ordinated to prevent fouling of the chassis frame. To achieve this condition, minor deviations to the recommended time settings is acceptable.




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a)

b)

c)

d)

e)


CSIP028 CSIP029

Hose Assemblies: Make sure that all hose assemblies are in good condition and conduct a visual check on hose end fitting connections. Lift Cylinders: i) Make sure that the cylinders are free from external damage and corrosion. ii) Look for signs of excessive oil leaks from the cylinders. Gate lock cylinders: i) Make sure that the cylinders are free from external damage and corrosion. ii) Look for signs of excessive oil leaks from the cylinders. iv) Ensure that the lock cylinder operating rod is in good condition (including the welded lock mechanism) and that it is not bent. Gate opening/closing cylinders: i) Make sure that the cylinders are free from external damage and corrosion. ii) Look for signs of excessive oil leaks from the cylinders. Hydraulic valves and fittings: i) Make sure that all hydraulic valves are operating in the correct manner, by conducting a full-cycle of cradle operations:

a) With engine running, operating the driver’s cab cradle control joystick.

b) Emergency pump, using hand control valves, i.e. short duration duty-cycle only on lifting and all safety aspects of cradle functions i.e.: emergency override switch must be operated, to energise the emergency pump.

Hand pump operation, in conjunction with hand control valve selection.




500 hours / 3months



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f)

B i)

a)

b)

c)

CSIP030


ii) Check for signs of oil leakage after having conducted the aforementioned procedures. Check operation of hydraulic pump and system pressure check: i) Make sure that the main hydraulic pump (transmission drive) is operating in the correct manner. Check system pressure in accordance with requirements of Appendix E, F, G & H of relevant model. Check for signs of oil leakage. ii) Make sure that the emergency pump is operating in the correct manner. Check for signs of oil leakage. Ensure emergency pump shutdown operates in the correct manner. Note: The emergency pump assembly incorporates a pre-set thermal shut down which shuts off after 20 minutes (10 minutes for the TBL180). This is non - adjustable. iii) Make sure that the hand pump is operating in the correct manner. Check for signs of oil leakage. Check condition of hydraulic hoses Leaks/tightness of hose ends: In conjunction with CSIP030, i.e. with the system pressurised through all cradle functions. i) Make sure that all hoses relating to the cradle assembly are free of all oil leaks. Tighten hose end fittings as required. ii) If any leaks are suspected, remove excess oil and repeat the test operation. IMPORTANT: The above check also to be applied to the hydraulic steel piping and related fittings. Check for hose deterioration: i) Check for signs of cracking on hydraulic hoses, due to possible ageing or misuse. Check for hose chaffing: i) Make sure that all hoses involved with moving components are free from chaffing and continue to be routed to prevent excessive wear, or from becoming trapped.


500 hours / 3months




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d)

B ii)

a)

b)

c)

CSIP034 CSIP035 CSIP036 CSIP037

Check main hydraulic filters: With the hydraulic pump operating: i) Make sure that the hydraulic tank filter indicator is reading correctly and that the filter is free from damage or leakage, including the filter body arrangement. IMPORTANT: The above checks also apply to the in-line hydraulic pressure filters. However, this type of filter should also be checked for cartridge and/or element tightness. Check hydraulic line pressures: Lift cylinder operation: With engine operating at normal idle speed, conduct the following checks: i) Operate the lift cylinders to maximum lift, hold position and check pressure reading on gauge (TBL180 only). All other models: lower and fully check pressure. Note: These are full pressure settings. ii) Check for oil leakage on this system. Refer to Appendix E, F, G & H for relevant model time settings. Locking cylinders: With engine operating at normal idle speed, conduct the following checks: i) Operate the gate closed procedure, ensuring that

the locking cylinder is in the fully closed position, hold position and check pressure reading on gauge.

ii) Check for oil leakage on this system. Refer to Appendix E, F, G & H for relevant model pressure settings. Gate lock cylinder operation: With engine operation at normal idle speed, conduct the following checks: i) Make sure, when closing the gate, that the locking mechanism does not start to retract until the gate is in its fully closed position.



500 hours / 3months

500 hours / 3months


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d)

e)

B iii)

a)

CSIP038 CSIP039

CSIP040

i)

ii) Check for oil leakage on this system. Gate opening/closing cylinder operation: With engine operating at normal idle speed, conduct the following checks: i) Operate the gate opening procedure, hold position and check pressure reading on gauge. ii) Check for oil leakage on this system. iii) Operate the gate closing procedure, hold position and check pressure reading on gauge. iv) Check for oil leakage on this system. Refer to Appendix E, F, G & H for relevant model pressure and time settings. Safety bar cylinder operation: With the hydraulic pump operating, conduct the following check: i) When operating safety bars fully closed, hold position and check pressure reading on gauge and check for any system leaks.

ii) Refer to Appendix E, F, G & H for relevant model. With engine running at normal idle speed and normal operating temperature (70°C-90°C), carry out the following checks: Check the speed of hydraulically controlled mechanisms, i.e. by flow gauge or timing operation. Ensure smooth proportional control is achieved. If adjustments are required, these can be carried out on the relevant facility incorporated in the hydraulic control valves. NOTE: All other speed and flow (time settings) are set on the bank of the hydraulic control valves with the exception of the safety bar controls. Cradle lifting: Make sure that the cradle gate lifting mechanism is functioning in the correct manner.





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b)

c)

d)

e)

C

C i)

a)

CSIP041 CSIP042 CSIP043 CSIP044 CSIP045

ii) Refer to Appendix E, F, G & H for relevant model pressure and time settings. Gate opening movement: i) Make sure the cradle gate opening mechanism is functioning in the correct manner. ii) Refer to Appendix E, F, G & H for relevant model pressure and time settings. Gate closing movement: i) Make sure the cradle gate closing mechanism is functioning in the correct manner. ii) Refer to Appendix E, F, G & H for relevant model pressure and time settings. Safety bars: i) Ensure that the safety bar mechanisms are functioning in the correct manner. Refer to Appendix E, F, G & H for relevant model time settings. For method of setting pressures, refer to CSIP070 and CSIP071. NOTE: The gate flow regulator is positioned on the gate lock ram if adjustment is required, (not on the hydraulic control valves used for all other adjustments in this section). Gate locking: i) Make sure that the gate locking mechanism is functioning in the correct manner. MAIN PNEUMATIC SYSTEM CHECKS IMPORTANT: Ensure, prior to the commencement of these tests, all air reservoirs are pressurised to their maximum settings. Check for pneumatic system leaks. Hose assemblies: i) Make sure that all hose assemblies are in good condition and conduct a visual check on hose end fitting connections.






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b)

c)

C ii)

a)

b)

c)

d)

CSIP046 CSIP047 CSIP048 CSIP049 CSIP050 CSIP051

Gate lock cylinder(s): i) Make sure that the cylinder has not been subjected to any external damage. ii) Make sure that the lock cylinder operates freely, when selected. i.e. locked/unlocked selection. Pneumatic valves and fittings: NOTE: Applicable to gate lock and rear air suspension only. i) Check for air leaks with leak detector/spray foam /audible detection, i.e. all valves and fittings.

ii) Check for external damage/corrosion. Check condition of pneumatic hoses: Leaks/tightness of hose ends: i) Make sure that all hoses relating to the cradle assembly are free of air leaks. Tighten hose end fittings as required. Check for hose deterioration: i) Check for signs of cracking on pneumatic hoses, due to possible ageing or misuse. ii) Make sure that hoses/pipes are well clear of any heated components. Check for hose chaffing: i) Make sure that all hoses involved with moving components are free from chaffing and continue to be routed to prevent excessive wear, or from becoming trapped. Check air reservoirs: i) Make sure that all air reservoirs are in good condition and free from external damage and corrosion. ii) Make sure “Tank Drainage” is operating in the correct manner. Confirm by opening drain taps. On completion, close drain taps.








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D)

a)

b)

c)


ELECTRICAL SYSTEM CHECKS: General check for damage/deterioration or chaffing of electrical cables.

General check of the condition of junction boxes and related internal connections: i) Check all junction and electrical connection boxes for deterioration, i.e. moisture, corrosion and debris etc, (including connections within boxes). Check cradle control switches: a) WARNING: Make sure Isolation Switch is in the ON position, the cradle assembly is free from any obstructions and ensure that all operatives are well clear of any of the moving components prior to the operation of any controls. IMPORTANT: For all cradle operations, gear change must be in NEUTRAL. b) Switch ON ignition. c) Press test switch, to ensure that all of the warning systems (lights or lights and buzzers, dependent on model type) are operating in the correct manner. d) With the gate closed, lower the cradle using the joystick i.e. by moving the joystick away from the driver to the position labelled “LOWER”. IMPORTANT: Make sure that the cradle is fully lowered, by ensuring that the “LOWERED” warning light (RED) illuminates. e) Open the cradle using the joystick, by moving the control lever to the LEFT. f) The cradle lock pin will automatically release. g) Make sure that when the cradle lock pin is removed, the gate hook releases. h) Make sure that when the gate claw or lock is fully opened, the gate opens until it meets the mechanical stop and the “GATE OPEN” warning light (RED) illuminates.


1000 hours / 6months



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j) To close cradle, reverse the procedure for opening cradle, by moving the joystick to the RIGHT. k) To raise cradle, move the joystick toward the driver (labelled “RAISE”), until the green “RAISED” warning light illuminates. IMPORTANT: Cradle will only raise and lower when fully closed. l) TBL180 Mk 2 ONLY: Wheelbase change can be implemented, as follows: 1) Select SMALL WHEEL mode, to change wheelbase to MAXIMUM extension, by operating momentary type switch marked with the label “MAXIMUM”. The support wheels will then automatically extend to their set position, when warning light (GREEN) illuminates to confirm correct position. 2) For MINIMUM wheelbase selection, press momentary type switch marked “MINIMUM”. The support wheels will then automatically retract to their set position, when warning light (GREEN) illuminates to confirm correct position. IMPORTANT: When large wheel is selected, wheelbase will automatically move to the MINIMUM position. If already in MAXIMUM wheelbase position, operation of the engine start will make the support wheels move automatically to the MINIMUM position. WHEELBASE ADJUSTMENT Small Wheelbase: Micro switch contact to be made with hydraulic cylinder fully closed. Large Wheelbase: Micro switch contact to be made with hydraulic cylinder fully extended. WARNING: This is a particular safety hazard on the TBL180 Mk 2. Employees/operatives should keep well clear of the machine.


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d)

CSIP055

NOSE WHEEL SIZE SELECTIONS. IMPORTANT: To change wheel size, cradle must be lowered and not loaded. m) TBL180: Selections for three/four aircraft nose wheel sizes: A to C/D inclusive. 1) When selecting aircraft grouped into Wheel Size ‘A’, press the switch labelled position “A”, until the wheel size indicator light illuminates (GREEN). 2) When selecting aircraft grouped into Wheel Size ‘B’, press the switch labelled position “B”, until the wheel size indicator light illuminates (GREEN). 3) When selecting aircraft grouped into Wheel Size

‘C’, press the switch labelled position “C”, until the wheel size indicator light illuminates (GREEN). 4) When selecting aircraft grouped into Wheel Size

‘D’, press the switch labelled position “D”, until the wheel size indicator light illuminates (GREEN). n) TBL200/280 ONLY: Selections for four/five

aircraft nose wheel sizes: A to D/E inclusive. o) TBL400 ONLY: Selections for three aircraft nose wheel sizes: A to C inclusive. p) TBL600 ONLY: Selections for four aircraft nose

wheel sizes: A to D inclusive. Check cradle warning lights & buzzers (excluding items already checked in section CSIP0054), for the operation of: i) “CRADLE LOWERED & OPEN” (RED warning light). ii) “WHEEL SIZE ERROR” (RED warning light). iii) “NOSE WHEEL LOADED” (RED warning light).



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e)

CSIP056

iv) “INSERT AIRCRAFT NOSE WHEEL PIN” (Operates only when in neutral and the cradle loaded). Press button to extinguish the light before the cradle can be raised. On the TBL280Mk4 & TBL600 only the prompt is shown on the driver’s display. v) “CAB ROOF ANTENNA WARNING” (If fitted). Check adjustment and operation of proximity switches. Check tightness of proximity switches and ensure target gap to be 5mm (nominal) – 8mm (maximum). Each Normally Open (N/O) switch has an LED warning light which comes on to indicate target sensed. Each Normally Closed (N/C) switch has an LED warning light which goes our to indicate target sensed. TBL280Mk1/Mk2 only: 1. Hook closed (N/O). 2. Gate closed (N/O). 3. Gate open (N/O). 4. Cradle assembly raised (N/O). 5. Cradle assembly lowered (N/O). 6. Wheel size error (N/C). 7. Wheel size A (large) (N/O). 8. Wheel size B (N/O). 9. Wheel size C (N/O). 10. Wheel size D (N/O) 11. Wheel size E (if fitted – small) (N/O). 12. Front safety bar (nearside) (N/C). 13. Front safety bar (offside) (N/C). 14. Rear safety bars inhibit (N/O). 15. Gate pin locked reed switch. LED on when in

target. TBL280Mk3/TBL200 only: 1. Hook closed (N/O). 2. Gate closed (N/O). 3. Gate open (N/O). 4. Wheel size error (N/C). 5. Front safety bar (nearside) (N/C). 6. Front safety bar (offside) (N/C). 7. Rear safety bars inhibit (N/O). 8. Gate pin locked reed switch. LED on when in

target. Cable extension transducers are used for cradle raise/lower and wheel size positions.



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TBL280Mk4: 1. Hook closed (N/O). 2. Hook open (N/O). 3. Gate closed (N/O). 4. Gate open (N/O). 5. Wheel size error (N/C). 6. Front safety bar (nearside) (N/C). 7. Front safety bar (offside) (N/C). 8. Rear safety bars inhibit (N/O). 9. Gate pin locked reed switch. LED on when in

target. 10. Gate pin opened reed switch. LED on when in

target. Cable extension transducers are used for cradle raise/lower and wheel size positions. TBL180Mk1/Mk2: 1. Hook closed (N/O). 2. Gate closed (N/O). 3. Gate open (N/O). 4. Cradle assembly raised (N/O). 5. Cradle assembly lowered (N/O). 6. Wheel size error (N/C). 7. Wheel size A (large) (N/O). 8. Wheel size B (N/O). 9. Wheel size C (N/O). 10. Wheel size D (if fitted) (N/O). 11. Front safety bar inhibit (N/O). 12. Gate pin locked reed switch. LED on when in

target or pin locked proximity switch. TBL180Mk3: 1. Hook closed (N/O). 2. Gate closed (N/O). 3. Gate open (N/O). 4. Wheel size error (N/C). 5. Front safety bar inhibit (N/O). 6. Rear safety bars open (N/C) 7. Gate pin locked reed switch. LED on when in

target or pin locked proximity switch. Cable extension transducers are used for cradle raise/lower and wheel size positions.


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Area Task No. III No. OPERATION DESCRIPTION INTERVAL

(whichever soonest)

TBL400Mk1/Mk2 only: 1. Hook closed (N/O). 2. Gate closed (N/O). 3. Gate open (N/O). 4. Cradle assembly raised (N/O). 5. Cradle assembly lowered (N/O). 6. Wheel size error (N/C). 7. Wheel size A (large) (N/O). 8. Wheel size B (N/O). 9. Wheel size C (N/O). 10. Gate pin locked reed switch. LED on when in

target. TBL400Mk3 only: 1. Hook closed (N/O). 2. Gate closed (N/O). 3. Gate open (N/O). 4. Wheel size error (N/C). 5. Gate pin locked reed switch. LED on when in


target. Cable extension transducers are used for cradle raise/lower and wheel size positions. TBL600: 1. Hook closed (N/O). 2. Hook open (N/O). 3. Wheel size error (N/C). 4. Gate pin locked reed switch. LED on when in


target. Cable extension transducers are used for cradle raise/lower and wheel size positions. Variable angle transducer is used for gate position to indicate open and closed.


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(whichever soonest)

f)

E

a)

b)


For all models, refer to the Workshop Manual (Layout Section – Electrical Diagrams) for schematics of the switches/transducers. Check wiring integrity for fail-safe operation. Refer to sections CSI0053, CSI0054, CSI0055 and CSI0056 for correct operation. If not working, check failsafe function. EMERGENCY ELECTRO/HYDRAULIC MOTOR SYSTEM CHECKS WARNING: Make sure Isolation Switch is in the ON position, the cradle assembly is free from any obstructions and ensure that all operatives are well clear of any of the moving components prior to the operation of any controls. IMPORTANT: For all cradle operations, gear change must be in NEUTRAL. Cradle lifting/lowering: i. Switch on the ignition.

ii. Switch on emergency pump. Mk3 vehicles onwards, pressing the cradle emergency override button will automatically activate the emergency pump.

iii. Lift and then lower the cradle using the manual

lever on the Danfoss proportional control valve. Gate/hook opening movement: i. Switch on the ignition.


iii. Operate the manual override to lift up the lock pin/block. Ensure the pin/block operates correctly.

iv. Open the gate using the manual lever on the Danfoss proportional control valve. Note, some vehicles are fitted with a separate manual lever for hook open.





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(whichever soonest)

c)

d)

e)


When fully open, hold this position and record the pressure indicated on the pressure gauge fitted to the vehicle. Refer to appendix E, F, G or H for the relevant model and correct pressure setting. Gate/hook closing movement: i. Switch on the ignition.


iii. Close the gate using the manual lever on the

Danfoss proportional control valve. Note, some vehicles are fitted with a separate manual lever for hook close.

iv. Reset the manual override for the lock pin/block.

Ensure the pin/block operates correctly.

When fully open, hold this position and record the pressure indicated on the pressure gauge fitted to the vehicle. Refer to appendix E, F, G or H for the relevant model and correct pressure setting.

Safety bars: i. Switch on the ignition.

ii. Switch on the emergency pump. Mk3 vehicles onwards, pressing the cradle emergency override button will automatically activate the emergency pump.

iii. Press the cradle override button and open and

close the safety bars using the manual lever on the Danfoss proportional control valve.

When fully open, hold this position and record the pressure indicated on the pressure gauge fitted to the vehicle. Refer to appendix E, F, G or H for the relevant model and correct pressure setting. Gate locking release: This task has been carried out as part of tasks CSIP059 and CSIP060.





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f)

F

a)

b)


Check operation of pump and system pressures: This task has been carried out as part of tasks CSIP058, CSIP059, CSIP060 and CSIP061. The gauge fitted to the vehicle is for reference only. For setting of pressures, a remote calibrated pressure gauge should be fitted to the Danfoss proportional valve block. HAND-OPERATED HYDRAULIC EMERGENCY PUMP SYSTEM CHECKS WARNING: Make sure the cradle assembly is free from obstructions and ensure that all operatives are well clear of any of the moving components prior to the operation of any controls. IMPORTANT: For all cradle operations, gear change must be in NEUTRAL. Cradle lifting/lowering: i. Insert the operating handle into the manual

hydraulic pump.

ii. Lift and then lower the cradle using the manual lever on the Danfoss proportional control valve and the manual hand pump.

Gate/hook opening movement: i. Insert the operating handle into the manual

hydraulic pump.

ii. Operate the manual override to lift up the lock pin/block. Ensure the pin/block operates correctly.

iii. Open the gate using the manual lever on the

Danfoss proportional control valve and the manual pump. Note, some vehicles are fitted with a separate manual lever for hook open.






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c)

d)

e)


Gate/hook closing movement: i. Insert the operating handle into the manual

hydraulic pump.

ii. Close the gate using the manual lever on the Danfoss proportional control valve and the manual pump. Note, some vehicles are fitted with a separate manual lever for hook close.

Reset the manual override for the lock pin/block. Ensure the pin/block operates correctly. Safety bars: i. Insert the operating handle into the manual

hydraulic pump.

ii. Open and close the safety bars using the manual lever on the Danfoss proportional control valve and the manual pump.

Gate locking release: This task has been carried out as part of tasks CSIP065 and CSIP066.





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(whichever soonest)

F 1)

CSIP069

PHOTO ELECTRIC CELLS Check condition of photo electric cell and signal, which indicates correct engagement of aircraft nose wheel in cradle. *NOTE: TBL180 i) Switch on ignition. ii) Simulate nose wheel landing gear in position, by breaking the infra-red beam emitted by the photo- electric cell located in the centre of the plough/scoop, simulating cradle raised and loaded conditions. iii) Make sure the “CRADLE LOADED” warning light illuminates and listen for a momentary “Bleep”. *NOTE: TBL200/280, TBL400 and TBL600. Two sets of photo-electric cells are fitted, check operation of both units.


24 - 29 ISSUE 7

10 - 12 - 07 Workshop\TBL Cradle Safety Document

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G

AIRCRAFT NOSEGEAR OVERSTEER PROTECTION SYSTEM AT TWO SETTING VALUES. Tractor Type – TBL180 and non PLC controlled TBL400 WARNING! Prior to commencement, ensure that the cradle assembly is in the fully CLOSED, LOCKED and in the raised or lowered position, the engine is NOT running and that the ignition switch is ON. IMPORTANT: Prior to the commencement of each of the Task no’s. CSIP070 & CSIP071, the following actions must be implemented: a) Using the specified ram assembly unit, (which

incorporates it’s own pressure gauge), position it as shown on illustration CTP 00703 (Appendix B) reacting against the cradle back plate and the RIGHT HAND cradle safety bar (cradle gate pivot side). Move safety bar into the vertical position in accordance with the illustration. This is achieved by operation of the electro-mechanical pump and then manually operating the relevant safety bar control valve. The integral hand pump on the ram assembly unit to be operated to increase pressure, until the pressure switch S56 opens, then decrease the pressure until S56 closes.

b) Using the specified ram assembly unit (which incorporates it’s own pressure gauge), position as shown on the illustration CTP 00703, (Appendix B) reacting against the cradle back plate and the LEFT HAND cradle safety bar (cradle gate lock side). Move the bar into the vertical position in accordance with illustration. This is achieved by operation of the electromechanical pump and then manually operating the relevant safety bar control valve. The integral hand pump on the ram assembly unit to be operated to increase pressure, until the pressure switch S54 opens, then decrease the pressure until S54 closes.




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a)

CSIP070

3. If changes to any of the settings are required, adjust the appropriate pressure switch and repeat the relevant procedure until the correct pressure values have been achieved.

NOTE: Each pressure switch has it’s own identification number. 4. At each attempt to reset the pressure switches,

the ram assembly unit should be operated to release pressure in the system prior to any attempts to conduct further adjustments to the settings.

i) Using the specified ram assembly unit, (which incorporates it’s own pressure gauge), position it as shown on illustration CTP 00703 (Appendix B) reacting against the cradle back plate and the LEFT HAND cradle safety bar (cradle gate lock side). Move the safety bar into the vertical position in accordance with the illustration. This is achieved by operation of the electro-mechanical pump and then manually operating the relevant safety bar control valve. The integral hand pump on the ram assembly unit to be operated to the required pressure. Pressure switch S53 should close. (Refer to Appendix E, F, G & H for relevant model and pressure settings). ii) Make sure that the warning light (Amber) in the cab illuminates, indicating the 80% protection warning system is correctly set. NOTE: Make sure that the warning light (Amber) in the cab illuminates, indicating the 80% protection warning system is correctly set. Some models incorporate a system allowing an audible alarm to remain on in the cab and a light on the cab roof. IF ADJUSTMENT IS REQUIRED, REFER TO MANUFACTURER.



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CSIP071

iii) Using the specified ram assembly unit, (which incorporates it’s own pressure gauge), position it as shown on illustration CTP 00703 (Appendix B) reacting against the cradle back plate and the LEFT HAND cradle safety bar (cradle gate pivot side). Move the safety bar into the vertical position in accordance with the illustration. This is achieved by operation of the electro-mechanical pump and then manually operating the relevant safety bar control valve. The integral hand pump on the ram assembly unit to be operated to the required pressure. Pressure switch S57 should close. iv) Make sure that the warning light (RED) in the cab illuminates, indicating the 100% protection warning system is correctly set. NOTE: Make sure that the warning light (RED) in the cab illuminates, indicating the 100% protection warning system is correctly set. Some models incorporate a system allowing an audible alarm to remain on in the cab and a light on the cab roof. i) Using the specified ram assembly unit, (which incorporates it’s own pressure gauge), position it as shown on illustration CTP 00703 (Appendix B) reacting against the cradle back plate and the RIGHT HAND cradle safety bar (cradle gate pivot side). Move the safety bar into the vertical position in accordance with the illustration. This is achieved by the operation of the electro- mechanical pump and then manually operating the relevant safety bar control valve. The integral hand pump on the ram assembly unit to be operated to the required pressure. Pressure switch S52 should close. (Refer to Appendix E, F and G for relevant model). ii) Make sure that the warning light (AMBER) in the cab illuminates, indicating the 80% protection warning system is correctly set. iii) Using the specified ram assembly unit, (which incorporates it’s own pressure gauge), position it as shown on illustration CTP 00703 (Appendix B) reacting against the cradle back plate and the RIGHT HAND cradle safety bar (cradle gate lock side).





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H

a)

CSIP072

Move the safety bar into the vertical position in accordance with the illustration. This is achieved by operation of the electro-mechanical pump safety bar control valve. The integral hand pump on the ram assembly unit to be operated to the required pressure. Pressure switch S55 should close. (Refer to Appendix E, F and G for relevant model). iv) Make sure that the warning light (RED) in the cab illuminates, indicating the 100% protection warning system is correctly set. Some models incorporate a system allowing an audible alarm to remain on in the cab and a light on the cab roof. Tractor Type TBL180 PLC CONTROLLED, TBL200/280, TBL400 PLC CONTROLLED AND TBL600 WARNING Prior to the commencement of this check, ensure that the cradle assembly is fully closed, locked and in the raised position, also that the photo-electric cell on the plough is covered (this simulates nose wheel in position), Select forward or reverse gear, ignition switch on and the handbrake applied. Follow the aforementioned instructions within this section G and for both the 80% and 100% over steer protection, but eliminating the references to the pressure switches S52, S53, S54, S55, S56 & S57. Adjustments are not required as they are controlled through the PLC system. Pressure settings are controlled by transducers S52 and S53, referred to in Appendix E, F, G & H of the relevant model. i.e. these are for reference purposes only. IF THE PRESSURES RECORDED ARE NOT CORRECT, REPORT TO THE MANUFACTURER. ADDITIONAL SAFETY ITEM CHECKS Check safety signs are in good condition: i) All safety related signs must be checked to ensure legibility has been maintained. ii) Replace any damaged or missing signs.



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b)

c)

l

CSIP073 CSIP074

Check safety guards are in good condition: i) Any safety guards must be free from distortion and must freely open and shut in the correct manner. Check condition of safety covers: i) Any safety covers must be free from distortion and must freely open and shut in the correct manner. ii) Any lockable safety covers must function in the correct manner. THE CHECKING ENGINEER MUST LIST BELOW ANY OTHER SIGNIFICANT OR SAFETY-CRITICAL PROBLEMS OF CONCERN I.E. ANY ITEMS THAT HAVE NOT BEEN INCLUDED IN THE ABOVE CHECKLIST:- FOR INFORMATION ONLY Further support documentation - i.e. instrument panel illustrations/proximity switch location can be found in the Technical Information Section of the Workshop Manual. The TBL range of tractor units are continually subject to change i.e. customer requirements and product development. Please ensure when conducting these checks that the latest issue of this document and supporting Technical Data Sheets are used. Prepared by Feroz Majid Douglas Equipment Limited.




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DOUGLAS TOWBARLESS TRACTORS APPENDIX “A”

TYPICAL NOSEWHEEL CRADLE ASSEMBLY

SAFETY INSPECTION CHECK “A” – TO REMAIN FLAT, WITHIN +/-3MM (Gate) “B” – TO REMAIN FLAT, WITHIN +/-3MM (Yoke) “C1 to C2” – TO REMAIN PARALLEL WITHIN +/-3MM (Cradle frame). “D” – MAXIMUM LATERAL MOVEMENT +/-5MM (Yoke). VISUALLY CHECK ALL WELDS FOR DETERIORATION.

1 - 1 ISSUE 7 10 - 12 -07 Workshop\TBL Cradle Safety Document

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DOUGLAS TOWBARLESS TRACTORS APPENDIX “B”

AIRCRAFT NOSEGEAR OVERSTEER PROTECTION SYSTEM CHECKS - CTP 00703

DIMENSION A: REFER TO APPENDIX “E”, “F” AND “G” OF THE RELEVANT MODEL DIMENSION A*: REFER TO APPENDIX “H” OF THE RELEVANT MODEL


A*

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DOUGLAS TOWBARLESS TRACTORS APPENDIX “C”

TYPICAL NOSEGEAR CRADLE ARRANGEMENT


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DOUGLAS TOWBARLESS TRACTORS APPENDIX “C”

TYPICAL NOSEGEAR CRADLE ARRANGEMENT

ILL.NO. DESCRIPTION

1 Cradle frame assembly 2 – 3 Guide – cradle – R.H. 4 Guide – cradle – L.H. 5 Pivot bracket 6 Mounting – wheel support ram 7 – 8 Spacer – pivot bracket 9 Yoke – cradle 10 Spacer – yoke pivot 11 Pivot bracket – yoke 12 Wheel support – cradle 13 – 14 – 15 Gate – cradle 16 Pivot tube – gate pin 17 Safety bar – gate – R.H. 18 Safety bar – gate – L.H. 19 Safety bar – cradle – R.H. 20 Safety bar – cradle – L.H. 21 Hinge assembly – safety bar – cradle 22 Washer – gate pin 23 Collar – gate pin 24 Keep plate – link pin 25 – 26 Mounting bracket – gate sensor 27 Mounting bracket – cradle up/down sensor 28 Assembly – gate lock 29 Shaft – yoke 30 Pin – pivot bracket 31 Pin – ram – plough 32 Pin – ram – safety bars 33 Pin – safety bar – gate – inner/R.H. 34 Pin – safety bar – gate – outer 35 Pin – ram – safety bars – cradle 36 Pin – ram 37 Ram – gate – open/close 38 Ram – gate lock 39 Ram – wheel support 40 Ram – safety bar – cradle 41 Ram – safety bar – gate 42 – 43 Modification to bush 44 Ball unit 45 Pivot bracket – safety bar ram 46 Pin – gate ram 47 Packer – gate ram pin 48 Spacer – wheel – support 49 Axle – wheel support 50 Nylon wheel – 1000 kgs 51 Pin – safety bar – gate – inner/L.H.


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DOUGLAS TOWBARLESS TRACTORS APPENDIX “D”

AIRCRAFT NOSEWHEEL SIZE SETTINGS – CTP00708


FOR SPECIFIC DIMENSIONS: REFER TO APPENDIX “E”, “F”, “G” AND “H” OF THE RELEVANT MODEL

A

B

C

D

E

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APPENDIX “E” TBL180 CRADLE SETTINGS

Refer to safety procedure document for task nos. and further instructions.

MECHANICAL

Rear support wheel levelling valve setting: Set chassis height at centre line of rear support wheel.

Ground to bottom of chassis frame: 170 - 180mm.

Lowered plough ground clearance: 7 - 10mm.

Nose wheel cradle setting dimensions-(nominal), the gap between the edge of the plough scoop and the edge of the gate when locked: Wheel size D: 220 - 225mm (set this mode first). Wheel size C: 220 - 225mm. Wheel size B: 335 - 345mm. Wheel size A: 380 - 390mm. Nose wheel cradle lift height: Full stroke of hydraulic cylinders. Pivot bush wear: 3mm (movement at pivot point, gate open 45° approx). HYDRAULIC PRESSURES-CRADLE Prior to commencement of pressure and flow speed checks-oil must be at normal operating temperature (80°C minimum). Cradle Lift Pressure: 225 Bar - Set on main pump. Locking Gate Pressure: 155 Bar - Set on control valve. Wheel Size Pressure: 100 Bar - Set on control valve. Front (Single) Safety Bar Pressure: 60 Bar - Set on control valve. Rear (Double) Safety Bar Pressure: 80 Bar - Set on control valve. (Tolerance on all pressures +/-5 bar). Wheel Base Adjustment Pressure: 150 Bar. (TBL180 Mk. 2 only) ISSUE 7 1 - 2 Workshop\TBL Cradle Safety Document 10 - 12 - 07

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APPENDIX “E” TBL180 CRADLE SETTINGS – Continued…

SPEED SETTINGS FOR HYDRAULICALLY CONTROLLED MECHANISMS Cradle up from down position: 6.5 seconds

Cradle down from up position: 13 seconds

Scoop small to large position: 9 seconds

Scoop large to small position: 9 seconds

Rear (double) safety bars out from in position: 5 seconds

Rear (double) safety bars in from out position: 4 seconds

Front (single) bar in from out position: 5 seconds

Gate closed from open position (without lock cylinder): 8 seconds*

Gate open from closed position (without lock cylinder): 8 seconds*

Items marked thus (*) must be set first.

Tolerance on the above items is +/- one second.

AIRCRAFT NOSEGEAR OVERSTEER PROTECTION SYSTEM Face of cradle back plate to centre of rear (gate) safety bar, (dimension ‘A’ Appendix B)

Vertical to plough (+/-3mm) - nominal 945mm.

AIRCRAFT NOSEGEAR OVERSTEER PRESSURE SETTINGS Pressure switch: 19 - 20 BAR falling pressure.

Wheel Size A - 100% Warning 90 - 104 BAR.

Wheel Size A - 80% Warning 70 - 82 BAR.

Wheel Size B, C & D - 100% Warning 57 - 67 BAR.

Wheel Size B, C & D - 80% Warning 46 - 56 BAR.

EMERGENCY PUMP SHUTDOWN Thermal shutdown incorporated in electro-hydraulic pump assembly the timer is set at 10 minutes.


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APPENDIX “F” TBL200/280 CRADLE SETTINGS


MECHANICAL Rear support wheel levelling valve setting: Set chassis height at centre line of rear support wheel.

30-35mm gap between bump stop and adjusting foot, i.e. access by unbolting side cover plate on

side of chassis


Pivot bush wear: 3mm (movement at pivot point, gate open 45°approx).

Nose wheel cradle setting dimensions-nominal, (the gap between the edge of the plough/scoop and the edge of the gate when locked):- Wheel Size A: 485 - 500mm. Wheel Size B: 405 - 415mm. Wheel Size C: 315 - 325mm. Wheel Size D: 225 - 235mm. Wheel Size E: 225 - 235mm. HYDRAULIC PRESSURES-CRADLE Cradle Control Valve (main Pressure): 220 BAR* Cradle Lift Pressure (Pump Pressure): 210 BAR Cradle Lower Pressure (Pump Pressure): 210 BAR Gate Open Pressure: 180 BAR Gate Close Pressure: 180 BAR Locking Gate Pressure: 140 BAR Wheel Size Pressure: 50 BAR Safety Bar (Front) Pressure: 50 BAR Safety Bar (Rear) Pressure: 70 BAR-Closed Safety Bar (Rear) Pressure: 50 BAR-Open *Set this pressure first-with the emergency pump running and remote gauge fitted into the distribution block. ISSUE 7 1 - 3 Workshop\TBL Cradle Safety Document 10 - 12 - 07

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APPENDIX “F” TBL200/280 CRADLE SETTINGS – Continued…

SPEED SETTINGS FOR HYDRAULICALLY CONTROLLED MECHANISMS Cradle up from down position: 8 seconds

Cradle down from up position (with load): 8 seconds (Approx 21 seconds no load)

Scoop size ‘E’ to size ‘A’ position: 10 seconds

Scoop size ‘A’ to size ‘E’ position: 10 seconds

Rear (gate) safety bars out from in position: 5 seconds

Rear (gate) safety bars in from out position: 5 seconds

Front (cradle) safety bar in from out position: 3 seconds

Front (cradle) safety bar out from in position: 3 seconds

Gate closed from open position: 13 - 15 seconds including hook.* (7 - 9 seconds gate only) Gate open from closed position: 13 - 15 seconds including hook* (7 - 9 seconds gate only) Items marked thus (*) must be set first.

Tolerance on the above items is +/- one second.

AIRCRAFT NOSEGEAR OVERSTEER PROTECTION SYSTEM For wheel size E – Face of cradle back plate to centre of rear (gate) safety bar - 995mm,

-dimension ‘A’ Appendix B

For wheel sizes C & D – Face of cradle back plate to centre of rear (gate) safety bar - 1030mm,


For wheel sizes A & B – Face of cradle back plate to centre of rear (gate) safety bar - 1150mm,


NOTE: Wheel Size E is only applicable to TBL280.


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SAFETY INSPECTION PROCEDURES DOCUMENT APPENDIX “F”

TBL200/280 CRADLE SETTINGS – Continued…

AIRCRAFT NOSEGEAR OVERSTEER PRESSURE SETTINGS TBL280 100% Warning: Wheel Sizes A & B: 90 - 104 BAR. Wheel Sizes C & D: 57 - 67 BAR. Wheel Size E: 29 - 34 BAR TBL280 80% Warning: Wheel Sizes A & B: 70 - 82 BAR. Wheel Sizes C & D: 46 - 56 BAR. Wheel Size E: 23 - 28 BAR.

EMERGENCY PUMP SHUTDOWN Thermal shutdown incorporated in electro-hydraulic pump assembly set at 20 minutes

- non - adjustable.


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APPENDIX “G” TBL400 CRADLE SETTINGS


MECHANICAL Rear support wheel levelling valve setting: Set chassis height at centre line of rear support wheel.

109 – 110mm gap between the under side of the top plate of the support leg to the top face of the cross-member on the support wheel fabrication.



Nose wheel cradle setting dimensions-nominal, (the gap between the edge of the plough/scoop and the edge of the gate when locked):- Wheel Size A: 550 - 560mm. Wheel Size B: 475 - 485mm. Wheel Size C: 415 - 425mm. HYDRAULIC PRESSURES-CRADLE Cradle Control Valve (main Pressure): 220 BAR* Cradle Lift Pressure (Pump Pressure): 200 BAR Cradle Lower Pressure (Pump Pressure): 200 BAR Gate Open Pressure: 180 BAR Gate Close Pressure: 180 BAR Gate Locking Pressure: 160 BAR Wheel Size Pressure: 50 BAR Safety Bar (Front) Pressure: 50 BAR Safety Bar (Rear) Pressure: 60 BAR-Closed Safety Bar (Rear) Pressure: 60 BAR-Open *Set this pressure first-with the emergency pump running and remote gauge fitted into the distribution block.


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APPENDIX “G” TBL400 CRADLE SETTINGS – Continued…



Scoop in from out position: 6 seconds

Scoop out from in position: 6 seconds





Gate closed from open position (without lock cylinder): 9 seconds*

Gate open from closed position (without lock cylinder): 8 seconds* Items marked thus (*) must be set first.

Tolerance on the above items is +/- one second, some minor deviations are allowed.

AIRCRAFT NOSEGEAR OVERSTEER PROTECTION SYSTEM Face of cradle back plate to centre of rear (gate) safety bar – 1250mm (Wheel positions A, B & C).

AIRCRAFT NOSEGEAR OVERSTEER PRESSURE SETTINGS TBL400 100% Warning:

Wheel Sizes A & B: 170 - 200 BAR.

Wheel Sizes C: 90 - 105 BAR.

TBL400 80% Warning:

Wheel Sizes A & B: 130 - 155 BAR.

Wheel Sizes C: 70 - 85 BAR.

NOTE: Vehicles with large and small wheel sizes, use the following: A – Large Wheel

i.e. Applies to non-PLC controlled units.

C – Small Wheel


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APPENDIX “G” TBL400 CRADLE SETTINGS – Continued…


- non - adjustable.


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APPENDIX “H” TBL600 CRADLE SETTINGS


MECHANICAL Rear support wheel levelling valve setting – 245 to 250mm from ground to the bottom of the chassis. Set chassis height in front of the rear wheel arch with the vehicle on flat level ground.



Nose wheel cradle setting dimensions-nominal, (the gap between the edge of the plough/scoop and the edge of the gate when locked):- Wheel Size A: 740 – 750mm. Wheel Size B: 550 - 560mm. Wheel Size C: 475 - 485mm. Wheel Size D: 415 - 425mm. HYDRAULIC PRESSURES-CRADLE Cradle Control Valve (main Pressure): 250 BAR* Cradle Lift Pressure (Pump Pressure): 240 BAR Cradle Lower Pressure (Pump Pressure): 240 BAR Gate Open Pressure: 250 BAR Gate Close Pressure: 250 BAR Gate Locking Pressure: 200 BAR Wheel Size Pressure: 60 BAR Safety Bar (Front) Pressure: 70 BAR Safety Bar (Rear) Pressure: 80 BAR-Closed Safety Bar (Rear) Pressure: 80 BAR-Open *Set this pressure first-with the emergency pump running and remote gauge fitted into the distribution block.


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APPENDIX “H” TBL600 CRADLE SETTINGS – Continued…



Scoop in from out position: 17 seconds

Scoop out from in position: 17 seconds





Gate closed from open position: 15 seconds* (9 seconds gate only) Gate open from closed position: 8 seconds* (10 seconds gate only) Items marked thus (*) must be set first.

Tolerance on the above items is +/- one second, some minor deviations are allowed.

AIRCRAFT NOSEGEAR OVERSTEER PROTECTION SYSTEM Face of cradle back plate to front face of rear (gate) safety bar – 1420mm

(Wheel positions A, B, C & D).

AIRCRAFT NOSEGEAR OVERSTEER PRESSURE SETTINGS TBL600 100% Warning:

Wheel Sizes A & B: 170-200 BAR.

Wheel Sizes C & D: 90-105 BAR.

TBL600 80% Warning:-

Wheel Sizes A & B: 130-155 BAR.

Wheel Sizes C & D: 70-85 BAR.


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APPENDIX “H” TBL600 CRADLE SETTINGS – Continued…


- non - adjustable. 3 - 3 ISSUE 7 10 - 12 - 07 Workshop\TBL Cradle Safety Document

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SAFETY INSPECTION PROCEDURES DOCUMENT

ISSUE RECORD Amdt. Details of Change Date Amdt. Details of Change Date

1. Appendix F, pages 1 & 2 revised. 04/02/97

2. Appendix E, pages 1 & 2 revised. 05/02/97

3. Appendix G added, document raised to issue 3 07/04/97

4. Appendix G revised, document raised to issue 4 02/03/98

5. Appendix G revised, document raised to issue 5 04/03/98

6. 250 hour / 6 week check removed, document raised to issue 6. 12/12/02

7. Updated to include TBL600 and 10/12/07 to reflect current production. Illustration in Appendix C updated. Document raised to issue 7

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12-05-11Workshop\TBL280 Cradle Pivot Bush Wear

TBL280 Gate Pivot Pin Bush Wear Measurement and Replacement

Wear on the gate pivot pin bush should be checked every 1000 hours or 6 months. Worn busheswill cause the end of the gate to sit lower than normal when open (approximately 12mm whenbushes are worn to the limit) and will cause the gate to ride on the guide tongue on the cradle whenit closes.

Checking bush wear

The pivot pin bushes should be checked with the cradle in the lowered position and the gate fullyopen (see figure 1). A quick visual indication of wear is possible by viewing the gate as it opens andcomes off the guide tongue on the cradle. If the gate drops approximately 12mm, it is very likelythat the bushes are worn to the recommended limit and will require replacement.

With the gate fully open, check the gap (if any) between the pivot pin and the internal bore on thelower bush as indicated in figure 1. Use a round wire 2.5mm to 3mm in diameter to check the gap.A wire is recommended due to its small contact area between the pin and the bush.

If the gap measures between 2.5mm to 3mm then the bushes are worn and will requirereplacement.

Alternatively, feeler gauges can be used to determine exact gap if the bushes are not worn to theirlimit. Note; do not use excessive force to insert the feeler gauges as this could score the internalbore of the bush.

Bush Replacement

To replace the gate pivot pin bushes, the collar retaining the gate pivot pin to the pivot tube mustfirst be removed. As the collar is installed with an interference fit, it will require heating to remove it.

1. Lower the cradle fully and open the gate to approximately 45 degrees.

2. Using the manual levers on the cradle control valve, slightly raise the cradle and supportthe cradle frame using suitable blocks. Support the gate using slightly shorter blocks sothat there is a gap between the bottom of the gate and the block.

3. Remove the pin connecting the gate open/close ram to the gate and move the ram endaway from the lugs in the gate.

4. Unbolt the gate open and 15 degree inhibit proximity switches from their respectivebrackets, move and secure them away from the collar on the top of the pivot pin and pivottube.

5. Using a jack under the pin end of the gate, raise the jack to take the weight of the gate andremove the circlip on the top of the pivot pin.

6. Once the circlip has been removed, remove the jack.

7. Place the jack near the open end of the gate and raise it to keep the gate level. This will aidthe removal of the collar.

1 - 3

16 - 01 - 03Workshop\TBL280 Cradle Pivot Bush Wear Page 295

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12-05-11 Workshop\TBL280 Cradle Pivot Bush Wear

2 - 3

8. Mark the position of the collar relative to the gate pivot tube to ensure that the collar isrefitted at the correct angle later.

9. Gently heat the collar on the top of the pin to aid removal. Note; if necessary, ensure thatany surrounding looms and hoses are adequately protected from the heat.

10. If possible, use a three-pronged extractor tool to pull the collar off the pin. Alternatively, asoft-faced mallet can be used on the top face of the pin to knock the pin out of the collarusing the weight of the gate.

11. Once the collar has been removed, unbolt the pivot tube from the cradle and remove thecomplete gate and pivot tube assembly from the cradle.

12. Disconnect the hydraulic hoses to the safety bar rams and automatic lubrication points asrequired, and cover the open ends of the hoses and ram ports to prevent dirt ingress.

13. Move the gate and pivot tube assembly to a safe working area.

14. Slide the pivot tube and washer off the gate pin and remove the worn bushes.

15. Inspect the washer for signs of wear. The washer is 3mm thick when new. If the thicknessof the washer is less than 1.5mm thick, it should be replaced.

16. Fit the new bushes to the gate pivot tube, ensuring that the greasing hole in the bush linesup with the greasing point on the pivot tube. Note; the bushes will have to be pressed in.

17. Slide the pivot tube with the new bushes back onto the pivot pin, making sure that it isadequately greased.

18. Refit the gate pin washer.

19. Heat the collar and refit onto the pin in the correct orientation relative to the pivot tube.Ensure that the top face of the collar is in line with the bottom face of the circlip groove.

20. Refit the circlip.

21. Clean and repaint as required.

22. Refit the gate and pivot tube assembly to the cradle. Torque the pivot tube mounting capscrews to 380Nm. Note; the cap screws should only be reused once. If the gate assemblyhas been removed before, it is recommended that the existing cap screws be replaced withnew ones (grade 12.9 or higher).

23. Refit the gate open/close ram to the gate.

24. Refit the gate open and 15 degree inhibit proximity switches. Fully open the gate and adjustthe proximity switches to achieve a gap of 3mm to 4mm between the face of the switchand the targets.

25. Refit the hydraulic hoses to the safety bar rams and ensure that the hoses are securelyand neatly clipped.

26. Reconnect the automatic lubrication points.

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12-05-11Workshop\TBL280 Cradle Pivot Bush Wear

3 - 3

Figure 1

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Workshop\Hydraulic rams 12-05-11

MAINTENANCE PROCEDURE

FOR

HYDRAULIC CYLINDERS

SECTION 1. MAINTENANCE

SECTION 2. SERVICE, INSPECTION AND CLEANING

SECTION 3. FAULT FINDING

1 - 4

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Workshop\Hydraulic rams12-05-11

SECTION 1

MAINTENANCE

Hydraulic cylinders require very little maintenance, but regular checks should be carried out - to reduce therisk of a breakdown.

1. Visually check for leakage from potential leakage paths.

2. Check the condition of mountings and verify the correct tighteness of associated fasteners.

3. Piston rods should be fully extended and examined for evidence of any surface damage. Any damagecould reduce the safety and reliability of the cylinder as well as the mechanism to which it is fitted.Limited on site repair is possible, and advice should be sought from the manufacturer on a suitablerepair.

4. Bearings and trunnions should be greased regularly.

2 - 4

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Workshop\Hydraulic rams 12-05-11

Prior to any disassembly, ensure that the external surfaces of the cylinder are clean and free fromcontaminants.

The work should be carried out in a clean workshop environment, having a suitable workbench, vice andcraneage where necessary.

1. Support the cylinder in a suitable vice, with a light clamping pressure or clamp to a suitable flatsurface.

2. Remove rod end eye or similar, if fitted.

3. Using an appropriate spanner (typically a Y spanner), remove the gland.

4. If it is required to remove the piston rod: Support the piston rod, holding it by the rod end flats toprevent rotation, remove the retaining pin from the nut - if necessary. Unscrew the nut and remove thepiston.

5. Examine all parts and replace bearings, rod etc. if required.

6. All parts should be thoroughly cleaned and de-greased prior to assembly.

7. Replace all seals as a matter of course, as damage is difficult to avoid during removal for cleaning.

8. Re-assemble as a reverse of dis-assembly, using a small amount of grease on each seal to assistassembly.

9. Air should be bled from the cylinder whilst in motion.

NOTE: It is advisable to replace the P.O. lock valve complete.

SECTION 2

SERVICE, INSPECTION AND CLEANING

3 - 4

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Workshop\Hydraulic rams12-05-11

FAULT CAUSE ACTION

Slow operation Pump worn Replace pumpPiston seal leaking Replace sealOil temperature too low Heat oilOil viscosity too high Change oil to lower

- viscosity

Spongy operation Air in cylinder Bleed cylinder

Jerky operation Air in cylinder or tight Bleed or return to- bearings or seals - manufacturer

Noisy operation Loose mountings or Rectify- components

Bouncy operation Air in cylinder Bleed cylinderFlexible hoses Replace with

heavier type

Cushioning ineffective Incorrectly adjusted AdjustDamaged components Investigate and

replaceCheck for valve failure Investigate and

replace

Rod scoring Foreign matter in bearing Remove, clean and- or gland seal - replaceDamaged wiper seal ReplaceDirty oil Change oil and

filtersExcessive side load Check mountings

and alignment etc.Rectify rod surface

Scored tube bore Foreign matter in piston Hone tube bore- bearings and seal Replace bearings

and sealsDirty oil Change oil and

filters

Oil leakage at gland seal Worn or damaged seals Replace rod seals,check rod fordamage, rectify

Oil leakage at gland/tube Damaged seal Replace seal- joint Loose gland ring Tighten gland after

test

Oil leakage at main port or Loose fittings Tighten fittings- cushioning valve adjuster Damaged seals Replace seals

4 - 4

SECTION 3.

FAULT FINDING

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TBL ‘Emergency’ Aircraft Undocking Procedure

In the unlikely event of a cradle operation failure while coupled to an aircraft, the aircraft can be released from the towbarless tractor using the emergency hydraulic levers situated on the left hand side of the vehicle behind a flap in the Transmission cover. The three levers that are used for the emergency undocking procedure have ‘Red’ handle’s to make them easily identifiable. There are five possibilities of removing the Towbarless vehicle from the aircraft and these are described below in five stages. The five stages should be viewed and operated in the order of Stage one to Stage Five. (Stage five being the worst case scenario and should only be conducted if all else fails). In all cases, the vehicle must not be towed for any long distance with the cradle in the lowered position. Further information can be found in the driver’s handbook and vehicle maintenance manual.

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Stage One – Cradle joystick failure In the event of an in cab cradle joystick failure, the cradle can be released as follows: This is a two man operation: One to operate the emergency hydraulic controls. One to operate the manual gate lock release and carry out visual observations. Procedure

1. Start the engine. 2. Operate the Cradle Lower Lever; this lowers the cradle to the ground. Allow the

aircraft and tractor to settle, i.e. cradle and suspension. 3. Release the Cradle Lock Pin by lifting the Release Button situated adjacent to

the cradle. 4. Manually lift the lock; this may be necessary if the air system has drained. 5. Operate the Cradle Override Button situated above the hydraulic levers (this

releases the lock valves for the rear safety bars) whilst pushing the button operate the Rear Safety Bars lever and fully open the Rear Safety Bars.

6. Ensure that aircraft park brake/wheel chocks are applied. 7. Operate the Gate Open Lever to open the gate, open gate to 40-45 degrees then

STOP. 8. Operate the Rear Safety Bar lever to fully close safety bars. (It may be necessary

to open the gate slightly more if clearance is limited between nose wheel and safety bars).

9. Fully open the Gate. 10. It is now possible to withdraw the tractor from the aircraft. 11. Once well clear of the aircraft remember to close the gate and raise the cradle and

reset the Lock Pin Button. If the vehicle has to be towed a large distance the prop shaft should be removed.

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Stage Two – Engine, Transmission or Main hydraulic pump failure In the event of engine/transmission or main hydraulic pump failure, the cradle can be released as follows: Two man operation: One to operate the emergency hydraulic controls. One to operate the manual gate lock release and carry out visual observations. Procedure

1. Switch on ignition. 2. Press the Cradle Override Button and operate the Cradle Lower Lever to

lower the cradle to the ground Allow the aircraft and tractor to settle, i.e. cradle and suspension.

3. Press the Cradle Override Button situated above the hydraulic levers (this activates the Electrical Emergency Pump, releases the Lock Valves for the Rear Safety Bars and sounds the Alarm) whilst pushing the button operate the Rear Safety Bars Lever and fully open the Rear Safety Bars.

4. Release the Cradle Lock Pin by lifting the Release Button situated adjacent to the cradle.

5. Manually lift the lock; this may be necessary if the air system has drained. 6. Operate the Cradle Override Button situated above the hydraulic levers whilst

pushing the button operate the Rear Safety Bars lever and fully open the Rear Safety Bars.

7. Ensure that aircraft park brake/wheel chocks are applied. 8. Operate the Cradle Override Button and Gate Open Lever to open the Gate,

open gate to 40-45 degrees then STOP. 9. Operate the Cradle Override Button and Rear Safety Bar Lever to fully close

Safety Bars. (It may be necessary to open the gate slightly more if clearance is limited between nose wheel and safety bars).

10. Operate the Cradle Override Button and Gate Lever to fully open the Gate. 11. It is now possible to withdraw the tractor from the aircraft, it may be necessary to

tow the vehicle remember that the cradle ground clearance is around 10mm. Once well clear of the aircraft remember to close the gate and raise the cradle and reset the Lock Pin Button. If the vehicle has to be towed a large distance the prop shaft should be removed.

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Stage Three – Ignition Failure Should the vehicle ignition fail, some of the later vehicles are equipped with a direct battery feed to the Emergency Electrical Hydraulic Pump. The switch to operate this function is situated under the cover on the right hand chassis leg, and requires a third person to operate. Three man operation: One to operate the emergency hydraulic controls. One to operate the manual gate lock release and carry out visual observations. One to operate the Direct Feed for the emergency hydraulic pump. Procedure

1. Operate the Emergency Pump Contactor on the right of the vehicle. 2. Operate the Cradle Lower Lever; this lowers the Cradle to the ground. Allow the

aircraft and tractor to settle, i.e. cradle and suspension. 3. Operate the Rear Safety Bars Lever and fully open the Rear Safety Bars. This

may not be possible as the electrical lock valves may not activate. 4. Release the Cradle Lock Pin by lifting the Release Button situated adjacent to

the cradle. 5. Manually lift the Lock; this may be necessary if the air system has drained. 6. Ensure that aircraft park brake/wheel chocks are applied. 7. Operate the Emergency Pump Contactor on the right of the vehicle and Gate

Open Lever to open the gate, open gate to 40-45 degrees then STOP. 8. Operate the Emergency Pump Contactor on the right of the vehicle and Rear

Safety Bar Lever to fully close Safety Bars. (It may be necessary to open the gate slightly more if clearance is limited between nose wheel and safety bars).

9. Operate the Emergency Pump Contactor on the right of the vehicle and Gate Lever to fully open the Gate.

It is now possible to withdraw the tractor from the aircraft, it may be necessary to tow the vehicle remember that the cradle ground clearance is around 10mm. Once well clear of the aircraft remember to close the gate and raise the cradle and reset the Lock Pin Button. If the vehicle has to be towed a large distance the prop shaft should be removed If Total Battery Power is lost try coupling with another vehicle using the Inter Vehicle Socket.

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Stage Four – Complete electrical failure. Three man operation: One to operate the emergency hydraulic controls. One to operate the manual gate lock release and carry out visual observations. One to operate the manual hydraulic pump. Procedure

1. Operate the Manual Hydraulic Pump situated at the bottom of the engine cover in the centre. The handle is located behind the passenger seat in the cab.

2. Whilst the third person operates the Manual Pump operate the Cradle Lower Lever this lowers the cradle to the ground. Allow the aircraft and tractor to settle, i.e. cradle and suspension.

3. It will not be possible to open the Rear Safety Bars as there is no power to release the Electrical Lock Valves.


5. Manually lift the Lock; this may be necessary if the air system has drained. Ensure that aircraft park brake/wheel chocks are applied. 6. Operate the Manual Hydraulic Pump and operate the Gate Open Lever,

open the gate to around 40-45 degrees then STOP. 7. Operate Manual Hydraulic Pump and Rear Safety Bars Lever to fully close

Rear Safety Bars. (It may be necessary to open the gate slightly more if clearance is limited between nose wheel and safety bars).

8. Operate Manual Hydraulic Pump and Gate Open Lever and fully open Gate. It is now possible to withdraw the tractor from the aircraft, it may be necessary to tow the vehicle remember that the cradle ground clearance is around 10mm. Once well clear of the aircraft remember to close the gate and raise the cradle and reset the Lock Pin Button. If the vehicle has to be towed a large distance the prop shaft should be removed

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Stage Five – Complete Hydraulic failure Should all three hydraulic pumps fail then the only way to release the vehicle from the aircraft is by releasing the hydraulic oils from each operation and physically operating each function. By using this method a large quantity of oil will have to be drained from the system. Two man operation: One to mechanically release the hydraulic pressure or fittings. One to carry out visual observations. Procedure

1. To lower the Cradle either operate the Cradle Lower Lever until the cradle is in the lowered position or carefully undo the union on the cradle lift cylinders, beware of the oil pressure and accessibility due to the aircraft. It may be possible to use a flat drip tray to catch the oil if you only release the union slightly.


3. Manually lift the Lock; this may be necessary if the air system has drained. Ensure that aircraft park brake/wheel chocks are applied. 4. To open the Hook cylinder you must first release a union on the hook cylinder

(Close side connection) and pull the Hook fully Out. 5. To open the Gate firstly release the union on the close side of the ram to allow

the gate to be opened. Again you must physically pull the gate open to about 40-45 degrees.

6. Close the Rear Safety Bars by releasing the unions on the safety bar rams and allow the bars to fall in the closed position.

7. It should now be possible to fully open the gate. 8. It is now possible to withdraw the tractor from the aircraft, it may be necessary to

tow the vehicle remember that the cradle ground clearance is around 10mm. Issue 1 – 10/07/2008

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PNEUMATIC SYSTEM

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Workshop\Air Brake System 12-05-11

TYPICAL AIR BRAKE SYSTEM

TEST AND CHECK LIST

1 - 8

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Workshop\Air Brake System12-05-11

PLEASE NOTE

All components listed in the following test lists are not necessarily fitted to every model of Douglas Tugmaster.Please check Air Brake Equipment Specification and Air Brake Layout in vehicle manuals.

IMPORTANT

Before working on or around Air Brake Systems and Components, the following precautions should beobserved:-

1. Stop the engine before working under a vehicle.

2. Always chock the wheels because depleting vehicle air system pressure may cause the vehicle toroll. Keep hands away from actuator push rods and slack adjusters, they may apply as systempressure drops.

3. Never connect or disconnect a hose or line containing air pressure, it may whip as air escapes.Never remove a component or pipe plug unless you are sure that all system pressure has beendepleted.

4. Never exceed recommended air pressure and always wear safety glasses when working with airpressure. Never look into air jets or direct them at anyone.

5. Never attempt to dismantle a component until you have read and understood recommendedprocedures. Some units contain powerful springs and injury can result if not properly dismantled.Use only correct tools and observe all precautions relative to the use of these tools.

Finding faults before they occur.

The six tests outlined in this programme have been designed to discover the presence of air leaks and/orsluggish performance in an Air Brake System. The entire system, from the compressor through to theactuators can easily be diagnosed in a short period of time by performing these tests. After completion, youwill know whether or not the system is building pressure rapidly enough. If there is any leakage and if theemergency components are functioning properly.

In some cases, you may find that corrections will need to be made. Each test is followed by a check list thatgives a guide to the more common causes for the vehicle failing the test. Please note that these are statictests only. They must not be interpreted as overruling the importance and necessity of functional, dynamiccontrollability tests and other tests required to assure vehicle safety and performance.

BEFORE YOU BEGIN TESTING THE AIR BRAKE SYSTEM, PERFORM THE FOLLOWING CHECKS:

1. Examine all tubing for signs of kinks or dents.

2. Examine all hoses for signs of wear, drying out and overheating.

3. Check suspension of all tubing. It should be supported and not vibrate.

4. Check suspension of all hoses. Position so that hoses will not abrade or be subjected to excessiveheat.


TEST AND CHECK LIST

2 - 8

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TEST 1

Governor/Unloader cut-out low pressure warning pressure build-up.

1. Drain all reservoir to '0' bar (0 psi).

2. Start engine (run at fast idle). Low pressure warning light should be on, buzzer should sound.

3. Low pressure warning light should go off and buzzer should stop at approx. 4 bar.

4. Governor/unloader should cut-out at 8.3 bar (120 psi).

5. Build up time. Pressure should rise from 6 bar to 7 bar (87 - 102 psi) within 40 seconds.

Make all necessary repairs before proceeding to Test 2; see Check List 1 for common corrections.

CHECKLIST 1

If the low pressure warning light or buzzer fails to operate:

a) Check the bulb.

b) Check the wiring.

c) Check the buzzer, replace if faulty.

d) Check the low pressure switch, replace if faulty.

If governor/unloader does not cut-out at 8.3 bar (120 psi):

a) Adjust governor/unloader using a gauge of known accuracy

b) Where compressor has an integral unloader, check function and repair or replace as necessary.

c) Repair or replace governor/unloader as required.

If the low pressure warning occurs above 4 bar (60 psi):

a) Check dash gauge against gauge of known accuracy.

b) Repair or replace low pressure switch.

If pressure build-up time exceeds 40 seconds or greatly exceeds previously recorded figures:

a) Examine compressor air intake filter and clean or replace.

b) Ensure that inlet line and engine intake filter are not restricted, delivery pipes that are 'carboned-up'are extremely difficult to clean.

c) Clean any excessive carbon from discharge port and delivery line.

d) If compressor is belt driven, check for drive slippage.

e) Check for compressor inlet or discharge valve leakage.

Re-test to check out all items repaired or replaced.


TEST AND CHECK LIST

3 - 8

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TEST 2

Leakage (reservoir air supply).

(Full pressure engine stopped).

1. Allow pressure to stabilise for at least 1 minute.

2. Observe dash gauge pressures for 2 minutes and note any pressure drop.

a) Single vehicle: 0.15 bar (2 psi) maximum for each reservoir.

b) Tractor and trailer: 0.40 bar (6 psi) maximum for each reservoir.

Make all necessary repairs before procreeding to Test 3. See Check List 2 for common corrections.

CHECKLIST 2

If there is excessive leakage in the supply side of the pneumatic system, one or more of the followingdevices could be causing the problem:

NOTE: A leak detector or soap solution will aid in locating the faulty component.

a) Supply lines and fittings (tighten).

b) Low pressure indicators.

c) Reservoir protection valve(s).

d) Relay valve(s).

e) Dual brake valve.

f) Trailer control relay valve.

g) Hand control valve(s).

h) Safety valve.

i) Governor/unloader.

j) Compressor delivery valve(s).

Re-test to check all items repaired or replaced.

TEST 3

Leakage (Service air delivery)

(Full pressure, engine stopped)

1. Make and hold a brake application (a block of wood can be used to hold down the foot valve treadle).

2. Allow pressure to stabilise for 1 minute; then begin timing for 2 minutes whilst watching the dashgauges for a pressure drop.


TEST AND CHECK LIST

4 - 8

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a) Single vehicle: 0.30 bar (4 psi) maximum for each reservoir.

b) Tractor and trailer: 0.40 bar (6 psi) maximum for each reservoir.

3. Check the angle formed between the brake chamber push rod and the slack adjuster arm.Minimum90o with brakes fully applied).

4. Check the brake chamber push rod travel. (Difference in push rod extension before and after releasingbrakes):

Brake Maximum StrokeChamber BeforeSize Readjustment12 35mm16 45mm20 45mm24 45mm30 51mm37 57mm

Make all necessary repairs before proceeding to Test 4; Checklist 3 for common corrections.

CHECKLIST 3

If there is excessive leakage in the service side of the system, one or more of the following devicescould be causing the problem:

NOTE: A leak detector or soap solution will aid in locating the faulty component.

a) Service lines and fittings (tighten).

b) Relay valve(s).

c) Stoplight switch(es).

d) Quick release valve(s).

e) Variable load valve(s).

f) Dual brake valve.

g) Front axle ratio valve.

h) Test point

Retest to check out all items repaired or replaced.


TEST AND CHECK LIST

5 - 8

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TEST 4

Handbrake - Secondary/Parking System.

(Full pressure, engine idling).

1. Non-towing truck.

a) Operate hand control valve. Spring brakes should apply brakes promptly.

b) Move hand control valve to PARK position. Handle should lock securely.

c) Move hand control valve to OFF position. Brakes should release promptly.

2. Towing truck/tractor with trailer.

a) Operate hand control valve. Spring actuators on truck/tractor and diaphragm actuator on trailershould apply promptly.

b) Move the control valve to the PARK position. The handle should lock securely, the spring brakeactuators should continue to apply the truck/tractor brakes. The trailer brakes should release*.

* NOTE: Some vehicles are designed to park with air pressure applied to the trailer brake actuators.In such cases, there is usually a test position on the control valve to allow the trailer brakes only to bereleased. This is to verify that the combination will not roll away in the event of air loss.

Make all necessary repairs before proceeding to Test 5; see Checklist 4 for common corrections.

CHECKLIST 4

If defective performance is noted in either test, check for:

a) Dented or kinked lines.

b) Improperly installed hose fittings.

c) A faulty relay emergency valve.

d) Faulty quick release valve(s).

e) A faulty hand control valve.

f) A faulty trailer control relay valve.


TEST 5

Secondary/Emergency System.

(Full pressure, engine stopped).

1. Drain front axle reservoir to '0' bar.

a) Remaining reservoir pressures should not fall below the closing setting of the reservoir protectionvalve(s). (See vehicle manual).


TEST AND CHECK LIST

6 - 8

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2. Without recharging front reservoir, make a brake application.

a) Rear axle brakes should apply and then release.

b) On combination vehicles, the trailer brakes should apply and release.

c) The stop light should come on.

3. Recharge the front axle reservoir and drain the rear axle reservoir to '0' bar ('0' psi).

a) Remaining reservoir pressures should not fall below the closing setting of the reservoirprotection valve(s). (See vehicle manual).

4. With no pressure in the rear axle reservoir, make a brake application.

a) The front axle brakes should apply and release.

b) On combination vehicles, the trailer brakes should apply and release.

c) The stop light should come on.

5. Recharge the rear axle reservoir, drain the reservoir feeding the spring brakes.

a) The spring brake actuators should apply.

b) On combination tractors, the trailer brakes should apply.

c) The spring brake cab warning light, if fitted, and the stop light should come on.

6. Recharge the spring brake reservoir, drain the trailer supply reservoir.

a) The trailer brakes should apply.

b) The trailer spring brakes should not apply.

7. If spring brake supply and trailer supply is combined in one reservoir, drain reservoir.

a) Tractor spring brakes should apply.

b) Trailer brakes should apply.

8. Recharge reservoir, vent trailer control (Service) line and make a full brake application. Supply dumpvalve or equivalent trailer control feature should drop. Supply (Emergency) line pressure and activatetrailer service brakes.

Make all necessary repairs before proceeding to Test 6; See checklist.


TEST AND CHECK LIST

7 - 8

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CHECKLIST 5

If the vehicle fails to pass any of the prescribed tests, check the following components for leakageand correct operation:

a) Fittings.

b) Kinked hose or tubing.

c) Reservoir protection valve(s).

d) Double check valve(s).

e) Trailer control relay valve.

f) Relay emergency valve.

g) Hand control valve(s).

h) Non-return valve(s).

i) Supply dump valve.


TEST 6

Variable load valve (Full pressure, engine stopped, vehicle unladen).

1. Make a full pressure brake application. (The foot brake valve treadle may be held down with a block ofwood). Allow 1 minute for pressure to stabilise. Using a gauge of known accuracy, measure thepressure at the test points at the inlet and discharge ports of the valve. The difference between the twopressures should be in accordance with the manufacturer's recommendation.

2. Repeat above check when vehicle is fully laden to achieve a ratio of 1:1

CHECKLIST 6

a) Distance from centre of valve control shaft to linkage to axle. (See variable load valve plate, whereapplicable).


TEST AND CHECK LIST

8 - 8

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12-05-11Workshop\40220d


FOR

AIR DRYER – LA8047

1137412

40220D

Workshop\40220d

There are no specific service instructions for this component. It is suggested that repairs arecarried out using the spare parts illustration.

DANGERIt is important to drain the system of air before attempting repairs on this component. Failure to doso could result in personal injury.


FOR THIS EQUIPMENT,

PLEASE REFER TO

THE PNEUMATICS - CHASSIS SECTION


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12-05-11Workshop\31695d - new


FOR

QUICK RELEASE VALVE

SK1294/1

31695D

1 - 2


FOR THIS EQUIPMENT,

PLEASE REFER TO

THE PNEUMATICS - CHASSIS SECTION


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Workshop\31695d - new12-05-11

QUICK RELEASE VALVE

SK1294/1

31695D

OPERATION

When air is supplied to the supply port at A, the diaphragm D is pushed away from the seat B and against theexhaust seat F, sealing the exit to port E. The air now flows around the edge of the circular flexible diaphragmand passes out of the delivery ports C and G, and thence to the brake actuators (Fig. 1).

As the applied pressure at A is reduced, the pressure present in the brake actuators and therefore under thediaphragm will be the greater. The diaphragm lifts away from seat F, allowing the air in the actuators to exhaustcompletely and quickly to atmosphere through the port E (Fig. 2).

MAINTENANCE

Every 3 months, or 10,000 miles, check Quick Release Valve as follows:

1. Apply vehicle brakes and ensure that when they are released the air pressure is quickly exhaustedthrough the valve exhaust ports.

2. With brakes applied, use soapy water to detect any air leaks from the valve body or exhaust ports.Any leakage at the exhaust port must not exceed a 25 mm diameter (1 inch) soap bubble in 1second. No other leakage is allowed.

3. If any Quick Release Valve is found to be faulty in operation, or is leaking, it is to be removed andserviced by renewing all the parts included in the Service Kit SK2614/1.

2 - 2

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Workshop\10109d 12-05-11


FOR

LOW PRESSURE SWITCH

295473

10109D

1 - 3

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12-05-11 Workshop\10109d

LOW PRESSURE SWITCH

295473

10109D

PREVENTATIVE MAINTENANCE

EVERY SIX MONTHS OR AFTER 10,000 MILES

Check electrical connections.

EVERY TWO YEARS OR AFTER 50,000 MILES

Dismantle the unit, thoroughly clean all parts and inspect for wear and damage. Repair or renew all worn ordamaged parts, or exchange the complete switch for a Factory Reconditioned Unit.

SERVICE CHECK

OPERATING TEST

Operation of the low pressure switch may be checked by reducing the reservoir pressure and being sure thatthe contacts close when the reservoir pressure is between 66 lb./sq.in. maximum and 54 lb./sq.in. minimum.The contacts will be closed when the warning light or electrical buzzer operate.

LEAKAGE TEST

A small vent hole is provided in the cover of the unit to check the condition of the diaphragm. Cover the venthole with soap suds and if a leak is indicated, it signifies a ruptured diaphragm. The diaphragm should then berenewed.

REMOVING AND REPLACING

REMOVAL

1. Drain the air from the air brake system.

2. Disconnect the electrical connections at the unit.

3. Disconnect the air line.

4. Remove the mounting bolts and detach the unit.

REPLACING

1. Bolt the unit in position.

2. Refit the air line and electrical connections.

DISMANTLING

1. Unscrew the cover retainer from the body.

2. Remove the cover and lift out the spring and diaphragm only.

2 - 3

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Workshop\10109d 12-05-11

LOW PRESSURE SWITCH

295473

10109D

CLEANING AND INSPECTION

1. Clean all metal parts in cleaning solvent.

2. Inspect the contact points for signs of pitting or wear. If pitting is not too severe, the contacts may bereconditioned by filing them with a fine file, such as used for distributor points. If they cannot bereconditioned, they should be renewed.

3. Check the spring for fracture, corrosion and permanent set. Renew if defective.

4. If the body or cover is cracked or damaged, they should be renewed.

REASSEMBLY

1. Place and position the diaphragm assembly in the body. Place shims on upper diaphragm follower.

2. Place the spring so that it will be on the upper diaphragm follower.

3. Place the cover over a new diaphragm. Attach the cover retainer to the body.

4. Carry out operating and leakage tests outlined in "SERVICE CHECK".

3 - 3

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SERVICE INFORMATION

FOR

MASTER CYLINDER

03.3131-2225.3

15499D

1 - 9


FOR THIS EQUIPMENT,

PLEASE REFER TO

THE AXLE & ACCESSORIES SECTION


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MASTER CYLINDER

03.3131-2225.3

15499D

REPAIR INSTRUCTIONS

The natural wear suffered by all units, whether they are in operation or at a standstill, requires that they beserviced, repaired and if necessary, replaced at varying intervals.

Repair sets are available for all units and it is urgently recommended to use complete units and not justparts of them. If this is not done, the undesirable consequence will be premature wear of the newly-installedparts.

Worn cups usually mean that the piston is also affected.

If the brake fluid of a vehicle undergoing repairs is found to be heavily contaminated, all components must beremoved and cleaned, including the pipes and brake hoses. Only methylated spirits or brake fluid must beused to clean the components; under no circumstances may cleaning agents containing mineral oil beused.

Unsuitable brake fluid:

If the system is topped up with unsuitable brake fluid - which causes swelling of the rubber components - oreven mineral oil, all rubber parts in the brake system are liable to be destroyed and must be replaced.In addition to the cups in the master, disc brake and wheel cylinders, these parts include the cups and rubberseals in the brake boosters of the T 50 series and braking force regulators. The brake hoses and stop lightswitch, as well as check valves or pressure valves, must also be replaced.

Checking the brake fluid for a retrofitted brake booster from the T 50 series:

Checking of the brake fluid is essential in this case. If it is contaminated, cleaning must be carried out asdescribed above, since there is otherwise a danger that the new unit will fail to operate as a result of thecontaminated brake fluid.

2 - 9

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Tools:Tools are required, depending on the type of unit, inorder to facilitate dismantling. Figs. 1 to 10 show themost important tools, which can be manufactured bythe user.

Fig. 1Pressing-in tool with handle, to insert piston incylinder without damaging the ball socket.

Fig. 2Mounting needle with rounded tip, for inserting alltypes of cups in the cylinder bore.

Fig. 3Mounting needle with flat tip, for the same purpose asthe needle in Fig. 2, to be used in confined spaces.

Fig. 4Test needle for master cylinder compensating port.Steel wire, no thicker than 0.5 mm.

Fig. 5Mounting needle for master cylinder withpretensioned push-rod and for master and tandemmaster cylinders.

Fig. 6Clamping plate for removing pretensioned push-rodsfrom master cylinders.

Fig. 7Polishing spindle, for polishing cylinder bores usinglapping cloth at approx. 1000 rpm.Diameter of spindle (hard wood) 3-4 mm less thannominal diameter D of cylinder bore.

MASTER CYLINDER

3 - 9

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Fig. 8Mounting sleeve for fitting ring-shaped cups onPiston.

Fig. 8aSecure separating cups using mounting sleeve.

Fig. 8bSecure secondary cup using mounting sleeve.

Fig. 9Mounting sleeve, for inserting complete piston incylinder bore.

Dimension table for user manufacture of mountingsleeves:

Cylinder A+0.5 B-0.2 Cdiameter dia. dia. dia.

17.46 17.46 25 27 19.05 19.05 25 27 20.64 20.64 25 27 22.20 22.20 25 27 23.81 23.81 28 30 25.40 25.40 28 30 28.57 28.57 31 33

Fig. 10Mounting fixture for tandem master cylinder of T 51and T 52 brake boosters.Use of mounting fixture:Insert all internal components including push-rod - butnot secondary cups and related components - intomaster cylinder.

4 - 9

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Push the remaining parts onto the centre column ofthe mounting fixture in the following order and securewith steel wire:

1. Retaining ring2. Stop disc3. Secondary cup (vacuum)4. Intermediate ring5. Secondary cup6. Stop disc

Fig. 11Place mounting fixture on master cylinder as shownand secure using the two claws. The componentssecured by the wire can now be mounted one afterthe other.

Repair instructions for master cylinder.

Dismantling

The exterior of all components is to be cleaned beforebeing dismantled. Use only methylated spirit; donot use cleaning agents containing mineral oil!

Fig. 12Master cylinderPush piston into bore using pressing-in tool (page 3,Fig. 1), loosen retaining ring or snap ring. The internalcomponents, piston, cups etc. can now be removed.In master cylinders with a cap valve, the rubber valveseal is at the end of the cylinder bore.

Fig. 13Master cylinder with captive push-rod.

Fig. 14Before the internal components of this mastercylinder can be removed, the pretensionedcompression spring at the push-rod must becompressed using the clamping plate as shown onpage 3, Fig.6

Fig. 15Push the piston far enough to enable the mountingneedle to be inserted behind the piston shoulder.

CAUTION!

After inserting the mounting needle, allow the pistonto retract slowly. Avoid formation of burrs at the pistonshoulder.

MASTER CYLINDER

5 - 9

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Fig. 16After removing the retaining ring, press the push-rodinwards once more. Removing the mounting needle;the internal components can then be removed fromthe cylinder.

Cleaning

After removal, all components must be thoroughlycleaned in alcohol.

Example of checking master cylinder todetermine further usability.

Fig. 17Determine by means of visual inspection, whetherscore marks or corrosion pits can be seen on theinner wall of the cylinder. If this is so, the cylindercasing must be discarded unless the score marksand corrosion pits can be removed by polishing. Afterpolishing, the diameters given in the tolerance tablemust, under no circumstances, be exceeded. Fortolerance table, see page 4.

Fig. 18Examine casing using inside calipers and dial gauge.Checking the piston diameter: Using an externalmicrometer, ascertain piston wear with the aid of thetolerance table.None of the measured values in a three-pointmeasurement may drop below the permittedtolerance. If the maximum permissable tolerance limitis reached at one of the points, proper seating of thecup is no longer guaranteed and premature wear setsin.

Installation

Always use complete repair set when replacinginternal components such as pistons or primary andsecondary cups.

MASTER CYLINDER

6 - 9

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Fig. 19Coat cylinder bore and cup surfaces with BrakeCylinder Paste or Brake Assembly Spray.Use only alcohol when fitting the secondary cup andensure that it is properly seated. Ease cup intogroove using thumb and first finger, then apply athin layer of Brake Cylinder Paste or AssemblySpray.

Fig. 20Insert check valve, compression spring and pistoninto cylinder bore. Do not forget filler disc betweenpiston and primary cup. Insert rounded end ofpressing-in tool into piston. While depressing, movethe 2mm mounting needle around the secondary cup.

Fig. 21Insert stop disc and snap ring. Press in the piston sothat the grooves for the disc and snap ring areexposed. Ensure that snap ring or retaining ring isproperly seated.

MASTER CYLINDER

7 - 9

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Cup wear

The wear on the cups shown in Figs. 23 and 25 canbe attributed to the fact that the permissableclearance between casing and piston was exceeded.The same damage can also occur as a result ofoverstressing of the brake due to excessivetemperatures. In such cases it is not only necessaryto replace the damaged cups, but also to carefullyinspect and measure the casing and piston andreplace the parts which do not meet the specifiedrequirements.

Figs. 22 and 24Cups in perfect condition.

Figs. 23 and 25Cups in damaged condition.

Fig. 26Cups with concentric grooves.

In the course of further development, cups have beendesigned which have a number of concentric grooveson the upper side of the lips. This results inimproved sliding properties and thus higherefficiency. Cups of the same type and same diameterare fully interchangeable.

During the transition period, cups both with andwithout grooves will be in use.

MASTER CYLINDER

8 - 9

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Tolerance table

Not for master and wheel cylinders.Not for master and slave cylinders.Not for cylinder bores in disc brake calipers.

Nominal Max. Min. Max.diameter permissable permissable permissable

Casing dia. Piston dia. Clearancemm inches mm mm mm12.7 1/2 12.80 12.57 0.23

14.29 9/16 14.39 14.16 0.2315.87 5/8 15.97 15.74 0.2317.46 11/16 17.56 17.33 0.2319.05 3/4 19.16 18.90 0.2620.64 13/16 20.75 20.49 0.2622.2 7/8 22.31 22.05 0.26

23.81 15/16 23.92 23.66 0.2625.4 1 25.51 25.25 0.26

26.99 11/16 27.10 26.84 0.2627.78 13/32 27.89 27.63 0.2628.57 11/8 28.68 28.42 0.2631.75 11/4 31.84 31.58 0.2633.0 1.2992 33.09 32.83 0.26

34.92 13/8 35.01 34.75 0.2638.1 11/2 38.19 37.93 0.26

41.27 15/8 41.36 41.10 0.2644.45 13/4 44.54 44.28 0.2646.83 127/32 46.92 46.66 0.2648.42 129/32 48.51 48.25 0.2650.8 2 50.90 50.60 0.354.0 2.1260 54.10 53.80 0.3

57.15 21/4 57.25 56.95 0.365.0 2.5590 65.10 64.80 0.370.0 2.7559 70.10 69.80 0.375.0 2.9528 75.10 74.80 0.3

Outlet port (See spare parts list, item 9) - Torque:100+/- 20 Nm.

Actuator plunger clearance from piston: 1mm.

MASTER CYLINDER

9 - 9

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FOR



FOR THIS EQUIPMENT,

PLEASE REFER TO



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BRAKE CHAMBERS

SINGLE DIAPHRAGM

1 - 2


TO REMOVE





TO DISMANTLE





TO ASSEMBLE








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BRAKE CHAMBERS

SINGLE DIAPHRAGM

2 - 2

TO FIT



TO TEST






1. Nut - push rod.

2. Sleeve.

3. Clamping ring.

4. Diaphragm.

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SPOOL VALVE

03060402

03315D

1 - 2


FOR THIS EQUIPMENT,

PLEASE REFER TO

THE CAB ASSEMBLY SECTION


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SPOOL VALVE

03060402

03315D

1. Secure the valve in a vice, using protective jaws.

2. Release the spring housing screws and remove the housing (5) and spring (6).

3. Undo the tappet housing screws and remove the housing (5), complete with the tappetassembly (14).

4. Remove the retainer (7) and withdraw the spool (2).

5. Carefully remove the spacers (3) and the “O” rings (4), taking care not to scratch the valvebody (1).

6. Check the valve body (1) and the spool (2) for score marks. If either is badly marked, thecomplete valve should be replaced.

7. Replace the “O” rings (4) and spacers (3).

8. Refit the retainer (7) and the tappet housing (10).

9. Replace the spool (2), ensuring that the chamfered end is to the top.

10. Replace the spring (6) and refit the spring housing (5).

2 - 2

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Workshop\10190d 12-05-11


FOR THIS EQUIPMENT,

PLEASE REFER TO

THE CAB ASSEMBLY SECTION



FOR

SPRING BRAKE CONTROL VALVE

961 723 2030

10190D

1 - 2

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12-05-11 Workshop\10190d

SPRING BRAKE CONTROL VALVE

961 723 2030

10190D

2 - 2

DESCRIPTION

The basic unit is a release mechanism with a central body consisting of a progressive air valve with the portspositioned equally around the centre line, at the base.

The lever assembly is composed of a body and a cam lever with a spring, which ensures that the lever returnsto the driving position. The parking position is locked-in automatically and is protected from the ingress ofcontaminants by a cover.

TECHNICAL DESCRIPTION OF FUNCTION OF BRAKE VALVE

When the lever is operated, chambers (B) and (C) are isolated from (A).Chamber (B) is pressurised (by Port 21connected to brake cylinders) and the pressure in (C), (by Port 22 piloting the trailer brake valve).The pressure is diminished progressively, until the lever reaches the stop. This is the emergency brake.Beyond this stop, you attain the locked-in parking position. Chamber (A) is joined to chamber (C); Chamber(B) is isolated and is connected to atmosphere by Port (3). The consequence is that the tractor and trailer isheld stationary by means of a mechanical method which is backed up by the brake cylinders.

MAINTENANCE

If a dismantling of the valve is necessary, replace all the seals and rubber valves contained in the repair kit -number: 961 723 0002. When re-assembling, lubricate all parts with grease 852 000 0304.

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PROPSHAFTS AND TRANSFER BOX

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12-05-11Workshop\24144d

1


FOR

KESSLER TRANSFER BOX TYPE W1600

24144D


FOR THIS EQUIPMENT,

PLEASE REFER TO

THE PROPSHAFTS, TRANSFER AND BEVEL BOX SECTION


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2

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12-05-11Workshop\24144d

3

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Workshop\24144d12-05-11

4

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5

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6

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7

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8

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9

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10

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11

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12

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13

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14

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15

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12-05-11Workshop\Hardy Spicer Propshaft


FOR

HARDY SPICER PROPSHAFTS

1 - 3


FOR THIS EQUIPMENT,

PLEASE REFER TO

THE TRANSMISSION AND BEVEL BOX SECTION


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Workshop\Hardy Spicer Propshaft12-05-11

DESCRIPTION

This propeller shaft incorporates a tubular shaft with a universal joint at each end. One end of the shaft issplined to carry a sliding universal joint, thus accomodating longitudinal movement of the shaft.

The universal joint cosists of two yokes (or forks); one being the sliding joint and the other forming part of aflange which is bolted to the appropriate coupling.

The ears of the yokes are drilled to take a trunnion cross. This cross is fitted to the yoke with a housing oneach spindle, containing needle roller bearings. It is upon these bearings that movement in the joint takesplace.

The housings are retained in position in the yokes by bearing caps; secured by set bolts and lock strap. Toprevent loss of lubrication, oil seals are fitted between the flanges on the trunnion cross and bearing housings.

To check for wear

1. Grasp the universal joint with the hands and test for movement between the trunnion crossassembly and yokes. If there is any apparent lift, wear has occurred to the thrust faces ofthe cages and the cork gaskets have been compressed.

2. To check for circumferential movements, hold the yoke flange with one hand and attemptto turn the propeller shaft portion with the other. If any movement is apparent, the trunnion crossassembly and needle bearings must be replaced.

To dismantle

1. Remove lubrication nipple from the trunnion.

2. Remove set bolts, lock straps and bearing caps from one yoke only. Secure yoke (fromwhich caps have been removed), in a vice and, using suitable drift, tap needle bearingscover on the outside - thus pushing the opposite bearing cover out of the yoke far enoughto be gripped and so withdrawn.

3. Tap the trunnion cross back with a drift, so that the opposite bearing assembly protrudesfar enough to be withdrawn.

4. The trunnion cross, together with the yoke flange, may then be tilted over at an angle andremoved from the propeller shaft or sliding sleeve yokes.

5. Remove the trunnion cross from the coupling yoke flanges as described in 2 and 3, above.

6. Using a screwdriver, prise the cork gaskets and retainers off the flanges of the trunnion cross.

Inspection and overhaul

1. Check the journals of the trunnion cross, needle rollers and cages for wear and signs ofrusting or pitting. The bearing cages should be a light drive fit in the yoke bores. The needlerollers, cages and trunnion cross must be removed as a complete assembly. The corkgaskets, retainers and circlips are also obtainable as separate replacements. These shouldbe renewed if the original trunnion cross and bearing assembly is refitted.

2. Check the oil passages in the trunnion cross for obstruction and blow through with compressedair.

2 - 3

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12-05-11Workshop\Hardy Spicer Propshaft

Inspection and overhaul continued...

3. Check for slackness of the sliding sleeve yoke on the splined end of the propeller shaft.Also, check the condition of the sliding sleeve cork seal and steel washer. Replace anycomponent found appreciably worn.

4. Check the yoke flanges for elongation of the securing bolt holes.

To re-assemble

1. Treat the flanges of the trunnion cross with a jointing compound, before fitting the retainerssquarely onto the flanges. Once the retainers have been fitted, wipe all traces of surplus jointingcompound from the journals. Insert the cork gaskets into the retainers.

2. Fit the trunnion cross onto the yoke flange, tilting the trunnion to engage the yoke bores.

3. Position one of the journals of the trunnion cross, so that it protrudes from a bearing cagebore in the yoke. Fit the needle bearing and cage assembly over the journal, ensuring noneof the needle roller bearings are displaced and trapped during this operation.

NOTE: Retain the needle roller bearings in position with the aid of a suitable lubricant.

4. Tap the bearing cage into the yoke, using a soft nose drift slightly smaller that the outsidediameter of the cage, until it is possible to insert the circlip, at the same time centralising thetrunnion cross in the yoke. Fit the circlip into it's specific groove.

5. Carefully move the trunnion to allow the opposite journal to protrude from the bearing cage borein the yoke. Fit the opposite needle bearing and cage assembly to the protruding journals,ensuring none of the needle roller bearings are displaced or trapped during the operation. Tap thebearing cage into the yoke, using a soft nose drift, slightly smaller than the outside diameter ofthe cage, again centralising the trunnion cross in the yoke, as it nears it's innermost position.

6. Refit the trunnion cross and yoke flange assembly to the propeller shaft or sliding sleeve,by repeating the procedure as detailed in paragraphs 3 to 5, above.

7. Make sure all circlips are seating correctly in their respective grooves and that the cages arebearing against the circlips.

To refit

To refit the propeller shaft, reverse the removal procedure, observing the following points:

1. When refitting the sliding universal joint to the propeller shaft spline end, ensure thearrows (stamped on the front end of the propeller shaft and the yoke sleeve of the sliding joint)are in line. Tighten the dust cap by hand only.

2. Lubricate all universal joints and the sliding sleeve at the lubricators provided.

3 - 3

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CAB HEATER/AIR CONDITIONER

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Workshop/D9W heater 12-05-11

TROUBLE-SHOOTING AND REPAIR INSTRUCTIONS

FOR

EBERSPACHER WATER HEATER

TYPE D9W


FOR THIS EQUIPMENT,

PLEASE REFER TO

THE OPTIONAL EXTRAS SECTION


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Workshop/D9W heater12-05-11

These troubleshooting and repair instructions are valid for the following heater versions:

D 9 W

25 1996 05 00 00 - 12V25 1815 05 00 00 - 12V

25 1997 05 00 00 - 24V25 1816 05 00 00 - 24V

Contents Page

First check the following if faults occur 2

Fuel quantity measurement 2

Function and fault test 3 - 6

Mode of operation 7

Functional sequence 7

Wiring diagram of D 9 W - 25 1815 / 25 1816 8, 9

Wiring diagram of D 9 W - TRS 003 - 25 1815 / 25 1816 10, 11

Wiring diagram of D 9 W - 25 1996 / 25 1997 12, 13

Wiring diagram of D 9 W - TRS 003 - 25 1996 / 25 1997 14, 15

Repair steps 16 - 18

1 - 18

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2 - 18

First check the following if faults occur:

Fuel in tank?

Heater lever (water valve) is on “HOT” setting?

Fuses O.K?

Electrical leads and connections O.K?

Combustion air pipe or exhaust pipe clogged?

Function and fault test

Possible faults can be displayed, by connecting the diagnostic unit (Cat. No. 22 1512 89 00 00) in place of thetimer (3.2.5 in wiring diagram). See operating instructions for diagnostic unit. A list of possible faults can befound on the next few pages.

Fuel quantity measurement

CAUTION: Only measure the fuel when the battery is sufficiently charged. At least 11/12 V and max. 13/26 V,as appropriate, must be applied to the control unit during the measurement.

1. Preparation

Detach the fuel line from the heater and place it in a measuring glass (size: 50 cm3).

Switch on the heater. When fuel is fed smoothly (about 40 seconds after switch-on), the fuel line isfilled and bled.

Switch off the heater and empty the measuring glass.

2. Measurement

Switch on the heater.

Fuel pumping starts about 40 seconds after switch-on. After another 73 seconds of pumping it isswitched off automatically.

Wait for restart. If fuel pumping is switched off automatically after another 113 seconds, switch off theheater. Measure the fuel quantity in the measuring glass.

Nominal value: 18 ml =/- 10%

If the quantity of fuel is outside the tolerance, replace the metering pump.

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3 - 18

FUN

CTI

ON

AN

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AU

LT T

EST

Faul

tco

deFa

ult d

escr

iptio

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emed

y

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No

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001

Adv

ance

war

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- o

verv

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ge.

Che

ck to

see

if v

olta

ge b

etw

een

13 a

nd 1

4 of

con

trol u

nit

(ext

erna

l plu

g) is

gre

ater

than

15

V o

r 30

V.

002

Adv

ance

war

ning

- un

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Che

ck to

see

if v

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etw

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13 a

nd 1

4 of

con

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nit

(ext

erna

l plu

g) is

less

than

10

V o

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V.

009

TRS

003

cut

out.

Sw

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heat

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in.

(TR

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due

to D

+ or

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010

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cut

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see

if v

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con

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(ext

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cut

out.

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see

if v

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13 a

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con

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(ext

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less

than

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0 oh

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Ven

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ater

(hea

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). O

pen

the

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wat

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. Che

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at th

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the

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and

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sen

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150

kohm

s at

-25o

C.

10

kohm

s at

+25

o C.

013

Exc

ess

tem

pera

ture

at f

lam

e se

nsor

.Fl

ame

sens

or s

igna

ls te

mpe

ratu

re o

f gre

ater

than

700

o C.

Impe

danc

e at

flam

e se

nsor

> 3

400

ohm

s. C

heck

the

impe

danc

e at

the

cont

rol

unit

(inte

rnal

plu

g). F

or th

is p

urpo

se, d

ism

antle

the

cont

rol u

nit,

disc

onne

ct th

ein

tern

al p

lug

from

the

cont

rol u

nit a

nd m

easu

re th

e im

peda

nce

betw

een

10an

d 12

.Fl

ame

sens

or v

alue

s:90

0 oh

ms

at -2

5o C.

1100

ohm

s at

+25

o C.

014

Diff

eren

ce b

etw

een

over

heat

and

Tem

pera

ture

diff

eren

ce b

etw

een

mea

sure

men

ts o

f ove

r-w

ater

tem

pera

ture

too

larg

e.te

mpe

ratu

re s

enso

rs is

gre

ater

than

70o

C. V

entil

ate

heat

er (w

ater

leve

l too

low

). O

pen

the

heat

er s

lide

valv

e an

d ch

eck

wat

er th

roug

hflo

w. C

heck

the

over

tem

pera

ture

sen

sor.

Che

ck th

e im

peda

nce

betw

een

5 an

d 8

at th

e co

ntro

l uni

t(in

tern

al p

lug)

.O

ver

tem

pera

ture

sen

sor

valu

es:

150

kohm

s at

-25o

C.

10

kohm

s at

+25

o C.

015

Too

man

y ov

erhe

ats.

The

cont

rol u

nit i

s in

terlo

cked

afte

r th

ree

succ

essi

ve o

verh

eats

(er

ror

code

s01

2, 0

13 a

nd 0

14).

Elim

inat

e th

e ca

use

of th

e ov

erhe

at. U

nloc

k by

del

etin

g th

eer

ror m

emor

y w

ith d

iagn

osis

uni

t/PC

or p

lus

sign

al fo

r 0.5

to 5

sec

. on

conn

ectio

n 7

(0.5

v) o

n th

e co

ntro

l uni

t (ex

tern

al p

lug)

with

hea

ter s

witc

hed

on.

FAU

LT S

IGN

AL

/ FLA

SHIN

G C

OD

E

Page 372

Prope

rty o

f Am

erica

n Airli

nes


FUN

CTI

ON

AN

D F

AU

LT T

EST

Faul

tco

deFa

ult d

escr

iptio

nR

emed

y

020

Glo

w p

lug

inte

rrup

tion.

Che

ck g

low

-plu

g (n

omin

al v

alue

: app

rox.

2 o

hms)

, rep

lace

it if

nec

essa

ry.

Che

ck te

rmin

al 4

(1.5

whi

te) o

n th

e co

ntro

l uni

t (in

tern

al p

lug)

lead

ing

to g

low

plug

to te

rmin

al 3

(1.

5 br

own)

for

cont

inui

ty/s

hort-

circ

uit.

If O

.K, r

epla

ce c

ontro

l02

1S

hort-

circ

uit a

t glo

w p

lug.

unit.

033

Bur

ner m

otor

or s

peed

con

trolle

rS

peed

dev

iatio

n fo

r lon

ger t

han

60 s

econ

ds.

defe

ctiv

e, s

peed

dev

iatio

n.N

omin

al v

alue

s:56

00 rp

m (f

ull-l

oad)

.18

50 rp

m (p

art-l

oad)

.C

heck

bur

ner

mot

or: a

pply

sup

ply

volta

ge to

mot

or.

Con

nect

+ to

1.5

bla

ck a

nd -

to 1

.5 o

rang

e. M

otor

doe

s no

t tur

n - r

epla

ce b

urne

rm

otor

with

inte

grat

ed s

enso

r.C

heck

sen

sor s

uppl

y. S

witc

h on

hea

ter a

nd m

easu

re v

olta

ge b

etw

een

outp

ut 1

3(0

.25

red)

and

14

(0.2

5 gr

een)

at t

he c

ontro

l uni

t (in

tern

al p

lug)

.N

omin

al v

alue

:8

V.If

devi

atio

n: r

epla

ce c

ontro

l uni

t.C

heck

sen

sor:

Mea

sure

vol

tage

bet

wee

n te

rmin

al 1

5 (0

.25

viol

et) a

nd 1

4 (0

.25

gree

n) w

ith a

n an

alog

ue v

oltm

eter

whe

n th

e bl

ower

is ru

nnin

g.N

omin

al v

alue

:4

V (+

/- 0.

3 V

).A

vera

ge v

alue

:8

V s

quar

e-w

ave

sign

al).

If de

viat

ion

- re

plac

e m

otor

with

inte

grat

ed s

enso

r. If

sens

or s

igna

l is

O.K

, the

nth

e sp

eed

cont

rolle

r is

def

ectiv

e -

Cha

nge

the

cont

rol u

nit.

037

Wat

er p

ump

is n

ot w

orki

ng.

Che

ck w

ater

pum

p (d

riven

ext

erna

lly).

042

Sho

rt-ci

rcui

t at w

ater

pum

p ou

tput

.Te

st c

onne

ctio

n (0

.5 b

lack

) on

the

cont

rol u

nit (

inte

rnal

plu

g) fo

r sho

rt ci

rcui

t.Te

st w

ater

pum

ps a

nd c

able

s.

043

Sho

rt-ci

rcui

t at e

xter

nal c

ompo

nent

s.C

heck

term

inal

2 (

1 gr

een)

of c

ontro

l uni

t (ex

tern

al p

lug)

for

shor

t-circ

uit.

Che

ckco

nnec

ted

com

pone

nts

(max

. cur

rent

6 A

), re

plac

e if

nece

ssar

y.

047

Sho

rt-ci

rcui

t of m

eter

ing

pum

p.C

heck

term

inal

1 (1

blu

e) o

f con

trol u

nit (

exte

rnal

plu

g) a

nd le

ads

up to

met

erin

gpu

mp

for

shor

t-circ

uit/i

nter

rupt

ion.

048

Met

erin

g pu

mp

inte

rrup

tion.

Che

ck th

e m

eter

ing

pum

p. N

omin

al v

alue

app

rox.

20

ohm

s.R

epla

ce if

nec

essa

ry.

050

Too

man

y fa

iled

star

ts.

The

cont

rol u

nit i

s in

terlo

cked

afte

r it h

as b

een

switc

hed

on 1

0 tim

es in

succ

essi

on (

= 20

faile

d st

arts

) w

ithou

t fla

me

dete

ctio

n (c

ode

052)

. Che

ck th

efu

el s

uppl

y, g

low

plu

g, e

xhau

st p

ipin

g, c

ombu

stio

n ai

r pip

ing

and

flam

e se

nsor

.U

nloc

k by

del

etin

g th

e er

ror m

emor

y w

ith d

iagn

osis

uni

t/PC

or p

lus

sign

al fo

r0.

5 to

5 s

ec. o

n co

nnec

tion

7 (0

.5 V

) on

the

cont

rol u

nit (

exte

rnal

plu

g) w

ithhe

ater

sw

itche

d on

.

051

Flam

e m

essa

ge is

dis

play

ed w

hen

heat

erFl

ame

sens

or s

igna

ls a

tem

pera

ture

of g

reat

er th

an 8

0o C d

espi

te 4

min

utes

of

is s

witc

hed

on.

cool

ing

with

col

d ai

r. Im

peda

nce

at fl

ame

sens

or >

1300

ohm

. If n

o co

mbu

stio

nta

kes

plac

e -

chec

k th

e fla

me

sens

or, r

epla

ce it

if n

eces

sary

.Fl

ame

sens

or v

alue

s:90

0 oh

ms

-25O

C.

1100

ohm

s +

25o C

.

4 - 18

FAU

LT S

IGN

AL

/ FLA

SHIN

G C

OD

E

Page 373

Prope

rty o

f Am

erica

n Airli

nes


FUN

CTI

ON

AN

D F

AU

LT T

EST

Faul

tco

deFa

ult d

escr

iptio

nR

emed

y

052

Saf

ety

time

exce

eded

- h

eate

r do

es n

ot s

tart.

No

flam

e w

as d

etec

ted

durin

g th

e st

art-u

p ph

ase.

Fla

me

sens

or v

alue

of l

ess

than

90o C

(135

0 oh

ms)

. Che

ck th

e fu

el s

uppl

y, g

low

plu

g, e

xhau

st p

ipin

g,co

mbu

stio

n ai

r pip

ing

and

flam

e se

nsor

.Fl

ame

sens

or v

alue

s:90

0 oh

ms

at -2

5o C.

1100

ohm

s at

+ 2

5o C.

053

Flam

e lo

ss in

“Pow

er” s

ettin

g.H

eate

r ha

s st

arte

d (fl

ame

dete

cted

) an

d in

dica

tes

flam

e lo

ss in

a p

ower

set

ting.

Che

ck fu

el fl

ow ra

te, b

low

er s

peed

, exh

aust

pip

e an

d co

mbu

stio

n ai

r pip

ing.

054

Flam

e lo

ss in

“H

igh”

set

ting.

If co

mbu

stio

n is

O.K

., ch

eck

flam

e se

nsor

, re

plac

e if

nece

ssar

y.Fl

ame

sens

or v

alue

s:90

0 oh

ms

at -2

5o C.

055

Flam

e lo

ss in

“Med

ium

” set

ting.

1100

ohm

s at

+ 2

5o C.

056

Flam

e lo

ss in

“Low

” set

ting.

059

Wat

er te

mpe

ratu

re r

ises

too

quic

kly.

Che

ck w

ater

circ

ulat

ion

(012

) and

tem

pera

ture

con

trol s

enso

r (06

0/06

1).

060

Tem

pera

ture

con

trol s

enso

r int

erru

ptio

n.C

ontro

l sen

sor s

igna

ls te

mpe

ratu

re v

alue

out

side

mea

sure

men

t ran

ge. C

heck

the

conn

ectin

g le

ads

(0.3

5 ye

llow

). Fo

r thi

s pu

rpos

e, d

ism

antle

the

cont

rol u

nit,

061

Sho

rt ci

rcui

t in

tem

pera

ture

con

trol s

enso

r.di

scon

nect

the

inte

rnal

plu

g fro

m th

e co

ntro

l uni

t and

mea

sure

the

impe

danc

ebe

twee

n 9

and

11. I

mpe

danc

e be

twee

n te

rmin

als

9 an

d 11

of t

he c

ontro

l uni

t(in

tern

al p

lug)

- gr

eate

r tha

n 10

koh

ms

(in th

e ev

ent o

f int

erru

ptio

n) le

ss th

an10

0 oh

ms

(in th

e ev

ent o

f a s

hort

circ

uit).

Tem

pera

ture

sen

sor v

alue

s:65

0 oh

ms

at -2

5o C.

1000

ohm

s at

+ 2

5o C.

064

Flam

e se

nsor

inte

rrup

tion.

Flam

e se

nsor

sig

nals

tem

pera

ture

val

ue o

utsi

de m

easu

rem

ent r

ange

. Che

ck th

eco

nnec

ting

lead

s (0

.35

gree

n). I

mpe

danc

e be

twee

n te

rmin

als

10 a

nd 1

2 of

the

065

Sho

rt ci

rcui

t in

flam

e se

nsor

.co

ntro

l uni

t (in

tern

al p

lug)

- gr

eate

r tha

n 50

koh

ms

(in th

e ev

ent o

f int

erru

ptio

n),

less

than

100

ohm

s (in

the

even

t of s

hort

circ

uit).

Flam

e se

nsor

val

ues:

900

ohm

s at

-25o C

.11

00 o

hms

at +

25o C

.

071

Ove

rhea

t sen

sor i

nter

rupt

ion.

Ove

rhea

t sen

sor s

igna

ls te

mpe

ratu

re v

alue

out

side

mea

sure

men

t ran

ge. C

heck

the

conn

ectin

g le

ads

(0.3

5 bl

ue).

Impe

danc

e be

twee

n te

rmin

als

5 an

d 8

of th

eco

ntro

l uni

t (in

tern

al p

lug)

- gr

eate

r tha

n 70

0 ko

hms

(in th

e ev

ent o

f int

erru

ptio

n)le

ss th

an 1

00 o

hms

(in th

e ev

ent o

f a s

hort

circ

uit).

Ove

rhea

t se

nsor

val

ues:

150

ohm

s at

-25o C

.10

koh

ms

at +

25o

C.

090

Con

trol u

nit d

efec

tive

(inte

rnal

res

et).

Inte

rnal

con

trol u

nit e

rror

in m

icro

proc

esso

r/mem

ory

dete

cted

.09

3C

ontro

l uni

t de

fect

ive

(RA

M f

ault)

.R

epla

ce c

ontro

l uni

t.09

4C

ontro

l uni

t de

fect

ive

(EP

RO

M f

ault)

.09

7C

ontro

l uni

t de

fect

ive

(gen

eral

fau

lt).

5 - 18

FAU

LT S

IGN

AL

/ FLA

SHIN

G C

OD

E

Page 374

Prope

rty o

f Am

erica

n Airli

nes


6 - 18

FAULTS WHICH ARE NOT DISPLAYED

Faults Cause Remedy

Combustion generates soot. Combustion air pipe/ Clear obstruction.exhaust pipe clogged.

Metering pump conveying too much. Measure fuel quantity.

Combustion air blower speed too low. Measure CO2 content. If >13%in “High” setting, replace blower.

Deposits inside heat exchanger. Remove heat exchanger andclean.

No hot air in interior. Heater lever closed. Open heater lever.

Vehicle blower not switched on. Switch on vehicle blower.

Vehicle blower relay defective. Replace relay.

Vehicle blower fuse blown. Renew fuse.

Page 375

Prope

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f Am

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n Airli

nes


MODE OF OPERATION

Switch-on

The pilot light in the switch or heating timer comes on when the heater is switched on. The combustion airblower and water pump start and the preheating phase of the glow plug begins.After the preheating phase, which takes approx. 40 seconds, the metering pump starts and fuel into thecombustion chamber. The fuel/air mixture ignites. Combustion air blower speed and metering pump pulsefrequency are then increased continuously up to the “Power” setting 9500 W in order to heat the combustionchamber up to operating temperature. Glow plug cutout is time-controlled. If no flame is detected by theflamesensor, the heater is re-started.If no flame is detected when the heater is started for a second time, the heater cuts out and a fault isdisplayed. The blower continues to run, to cool down the heater.

Heating operation

When the heater is first started up after switch-on, it works in the “Power” setting 9500 W until:

a) either the water temperature exceeds the changeover limit “POWER/HIGH” ( e.g. 72o C).b) or the max. operating time in this setting (2 hours) is exceeded.

The heater then switches to the “HIGH-MEDIUM-LOW-OFF” settings depending on heat demand. If the coolingwater reaches 55o C (for example), the temperature sensor switches on the vehicle blower. The max. coolingwater temperature in the individual control steps is 85o C.

a) If heat demand is 7500 Watts or higher, the heater operates in the “HIGH” setting. If the watertemperature drops to 60o C in the process, the heater switches back to the “POWER” setting.

b) If heat demand is between 7500 Watts and 3200 Watts, the heater switches between “HIGH,MEDIUM and LOW”.

c) If heat demand is 1500 Watts or less, the heater operates in the “LOW” setting.If heat demand in the “LOW” setting is so low that the cooling water temperature reaches 85o C,the heater switches from “LOW” to “OFF”. The blower continues to run for 210 seconds.The water pump continues to run until the heater is restarted.Once the temperature of the cooling water drops to 70o C (for example), the heater restarts in the“MEDIUM” setting.

Control temperatures Speed of blower motor

VEHICLE BLOWER ON 55o C. POWER 7300 rpmPOWER > HIGH 72o C. HIGH 5600 rpmHIGH > MEDIUM 78o C. MEDIUM 3000 rpmMEDIUM > LOW 79o C. LOW 1850 rpmLOW > OFF 85o C.OFF > MEDIUM 68o C.MEDIUM > HIGH 68o C.LOW > MEDIUM 73o C.HIGH > POWER 60o C

Startup sequence

7 - 18

Page 376

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8 - 18

WIRING DIAGRAM: HEATER, STANDARD VERSION - 25 1815 / 25 1816

Page 377

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f Am

erica

n Airli

nes


9 - 18

WIRING HARNESS & OPERATING ELEMENTS, STANDARD VERSION - 25 1815 / 25 1816

Page 378

Prope

rty o

f Am

erica

n Airli

nes


10 - 18

WIRING HARNESS: HEATER, TRS 003 VERSION - 25 1815 / 25 1816

Page 379

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11 - 18

WIRING HARNESS & OPERATING ELEMENTS, TRS 003 VERSION - 25 1815 / 25 1816

Page 380

Prope

rty o

f Am

erica

n Airli

nes


12 - 18

WIRING DIAGRAM: HEATER, STANDARD VERSION - 25 1996 / 25 1997

Page 381

Prope

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f Am

erica

n Airli

nes


13 - 18

WIRING HARNESS & OPERATING ELEMENTS, STANDARD VERSION - 25 1996 / 25 1997

Page 382

Prope

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f Am

erica

n Airli

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14 - 18

WIRING DIAGRAM: HEATER, TRS 003 VERSION - 25 1996 / 25 1997

Page 383

Prope

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f Am

erica

n Airli

nes


15 - 18

WIRING HARNESS & OPERATING ELEMENTS, TRS 003 VERSION - 25 1996 / 25 1997

Page 384

Prope

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f Am

erica

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nes


16 - 18

REPAIR STEPS

Remove / install

1. Control unit. 7. Housing, including heat exchanger , dismantled.

2. Glow plug cable. 8. Burner.

3. Glow plug. 9. Burner, dismantled.

4. Safety thermal cut-out switch / 10. Heat exchanger.temperature sensor/water pump.

11. Heat exchanger, dismantled.5. Cover / blower.

6. Flame sensor / heat exchangerfastening screws.

Overall view of heater

Page 385

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f Am

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nes


17 - 18

REMOVE / INSTALL

1. Control unit (on installation of the control unit, grease the gasket with sealing paste).

4. Safety thermal cut-out switch / temperature sensor / water pump.

2. Glow plug cable.5. Cover / blower (on installation of the cover, clean the sealing surface and apply liquid seal.

3. Glow plug. 6. Flame sensor / heat exchanger fastening screws.

Page 386

Prope

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f Am

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n Airli

nes


18 - 18

7. Housing, including heat exchanger, dismantled.

8. Burner.

9. Burner, dismantled.

10. Heat exchanger.

11. Heat exchanger, dismantled.

REMOVE / INSTALL continued...

Page 387

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f Am

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12-05-11Workshop\29815D

OPERATION & MAINTENANCE INSTRUCTIONS

FOR

AIR CONDITIONING & HEATING KIT

PVHK1177

29815D

1 - 6

Page 389

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f Am

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n Airli

nes

12-05-11 Workshop\29815D



CONTENTS

1. DESCRIPTION

2. OPERATION:

- AIR COOLING

- HEATING

3. MAINTENANCE

4. FAULT DIAGNOSIS

2 - 6

Page 390

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12-05-11Workshop\29815D



1. DESCRIPTION

1.1 The Air Cooling/Heating System consists of the following items:-

i) COMPRESSOR - Engine mounted and belt driven via an electro-magnetic clutch.

ii) CONDENSOR & ELECTRIC FAN - Located under decking behind the cab.

iii) RECEIVER & PRESSURE SWITCHES - Mounted behind the cab under the engine cover.The pressure switch assembly is wired in the compressor circuit and will operate thus:

Low Pressure - Switch will be open circuit in the event of total refrigerant loss.

High Pressure - Switch will be open circuit in the event of excessively high system pressures,i.e; condenser/air flow impeded or system overcharge. No. 1 condenser fan operates permanently.No. 2 conenser fan operates subject to system pressures controlled by pressure switch.

NOTE: Pressure switches reset automatically.

iv) EVAPORATOR/HEATER ENCLOSURE - Located in the cab.The enclosure also contains a relay and thermostat.Evaporator/heater air flow is either recirculatory or fresh air, introduced through filters.

v) CONTROLS - All dash mounted, consisting of:-

ON/OFF air control switch.

Rotary flap control - from fresh to recirculated air.

Rotary water valve control - from hot to cold.

3 speed fan switch.

vi) Condensed water from the A.C. heat exchanger is drained through the floor.

3 - 6

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12-05-11 Workshop\29815D



4 - 6

2. OPERATION

2.1 AIR COOLING

2.1.1 Ensure outlet louvres are open.

2.1.2 With engine running, switch ON/OFF air conditioner switch to ON.

Select fan speed: Low, Medium or High.

Ensure water valve control is at COLD.

Select “recirculated air” for best results.

2.2 HEATING

2.2.1 Open water valve, select fan speed: Low, Medium or High.

Switch off air conditioner.

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12-05-11Workshop\29815D



5 - 6

3. MAINTENANCE

3.1 MECHANICAL

Check the following:

3.1.1 Belt tension.

3.1.2 Belt condition.

3.1.3 Evaporator and condenser airways are free from obstruction.

3.1.4 Fresh air filter is not blocked.

3.2 FUNCTIONAL

3.2.1 Functional maintenance is limited to checking refrigerant status at the sight glass. Thisshould be carried out at the onset of warm weather, at the hottest time of the day; or, if poorcooling is suspected on an otherwise normally operating system.

Refrigerant Charge (R134a) : 1.1 Kg

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12-05-11 Workshop\29815D



4. FAULT DIAGNOSIS

FAULT CHECK THE FOLLOWING

1. System does not operate: i) Circuit fuses / Circuit breakers.(Fan and clutch inoperative). ii) Loom connections.

iii) Supply at evaporator interface.

2. No supply at evaporator interface: i) Refer to vehicle auxiliary circuit diagram- locate fault.

3. No cooling: i) Check evaporator thermostat + relay.(Fan and clutch inoperative). ii) Supply to and from pressure switch.

iii) Supply at pressure clutch.iv) Resistance of clutch oil: 13-14 Ohms.

4. No supply from pressure switch: * i) Refrigerant in system, (total loss ofrefrigerant will result in Low PressureSwitch open circuit).

ii) Damage to hose or fittings.

5. Poor or no cooling: i) Compressor drive belt - loose or broken.(Fan and clutch operative). ii) Clutch plate rotates when A.C. is on.Temperature difference between iii) Refrigerant status in sight glass atoutside ambient and air off. switch-on. (Should be frothy initially,Evaporator should be 10 deg. C min. then clear liquid). Some froth is

acceptable.

6. Poor or no cooling: * i) Temperature difference, outside to air-off(Fan, clutch and sight glass appear evaporator - 10 deg. C min. (Possiblenormal). malfunction of internal refrigeration

component).

* Consult A.C. Engineer.

6 - 6

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RECOMMENDED LUBRICANTS

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Lubrication charts - TBL\TBL280 Mk 4 12-05-11

CAPACITIESUNIT LUBRICANT TYPE GALLONS LITRES

ENGINE RIMULA X 15W40 4.50 20.50

TRANSMISSION RIMULA X 15W40 3.95 18.00

TRANSFER BOX SPIRAX HD85-140 2.00 9.09

STEER/DRIVE AXLEDIFFERENTIAL SPIRAX HD85-140 5.50 25.00

STEER/DRIVE AXLE HUB(EACH) SPIRAX HD85-140 0.56 2.50

SUPPORT WHEEL HUB(EACH) RETINAX LX As Required

BRAKE COOLING FLUID DONAX TD As Required

BRAKE FLUID TELLUS R10 As Required

COOLING SYSTEM (50% Water/50% Antifreeze) 4.40 20.00

HYDRAULIC SYSTEM TELLUS T46 19.80 90.00

GENERAL LUBRICATION RETINAX LX As Required

AUTOMATIC LUBRICATION(IF FITTED) SEMI-FLUID GREASE EP 4.40 lbs 2.00 kgs

TYRE PRESSURES DRIVE WHEEL (Single) 145 psi 10.00 Bar

SUPPORT WHEEL (Twin) 145 psi 10.00 Bar

TBL280 WORKSHOP MANUAL

RECOMMENDED LUBRICANTS

1 - 1

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OPERATING & MAINTENANCE INSTRUCTIONS

AC3 SYSTEM

for

DOUGLAS EQUIPMENT LTD

Introduction Interlube AC3 system has been specifically designed to provide reliable and virtually maintenance free service. The AC3 lubricator and its accessories are ruggedly constructed for faultless operation in the most demanding applications. A major benefit of the AC3 system, is that it is designed to dispense all grades of grease, from N.L.G.I. grade OOO [fluid grease] through to and including N.L.G.I. grade 2, reducing the need to stock extra lubricants. In common with other electro mechanical devices proper installation and operational procedures must be carefully observed. The lubricator will have been installed in accordance with the instructions contained in Interlube`s installation manual.

Form no. ISF132 Issue 1

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2

2

Operation. The AC3 lubricating system comprises an electrically operated lubricator and a loom of tubing connecting each chassis bearing to its own respective pumping unit. The lubricator consists of a 3 litre reservoir housing the electronic control, electric motor and drive. Housed in the reservoir is a twin bladed impeller designed to draw grease evenly into the pumping chamber and give a visual indication of cam rotation. Attached to the reservoir is a carcass ring, which houses the cams, and colour coded pumping units (red 0.010cc/shot, green 0.015cc/shot, yellow 0.025cc/shot, blue 0.04cc/shot, silver 0.06cc/shot, black 0.10cc/shot). A quick release filling adaptor is fitted to the pump, together with an alternative hydraulic grease nipple [standard fitment to Johnston Sweeper fitments only] and are the only fill points, thereby reducing most contamination risks. The AC3 system is conventionally wired to the vehicle ignition circuit and in operation the cam rotates operating each pumping unit in turn injecting a measured amount of lubricant into each supply line. An LED located in a recess underneath the motor housing indicates the following functions: -

Continuously ON – supply to circuit and during delay time Slow Flash – Motor operating Fast Flash – motor failure

The pump is available with 10 settings with the delay timing control via a rotary switch located behind a screw cap at the front of the motor housing. The motor runs for 1 minute and 8 seconds. Switch positions: -

0 - continuous priming at double speed (1.8 RPM) 1 - continuous at normal speed (0.9 RPM) – normal trailer applications. 2 - 3 minute delay (4 minute total cycle time) 3 - 7 minute delay (8 minute total cycle time) 4 - 11 minute delay (12 minute total cycle time) 5 - 15 minute delay (16 minute total cycle time) 6 - 19 minute delay (20 minute total cycle time) 7 - 24 minute delay (25 minute total cycle time) 8 - 30 minute delay (31 minute total cycle time) 9 - 36 minute delay (37 minute total cycle time)

Maintenance As an owner of an Interlube AC3 system the only maintenance you should find necessary is to periodically check the reservoir lubricant level, topping up with the preferred lubricant as necessary, and occasionally checking the condition of the loom connections.

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3

3

At all times observe the following for fault free operation. • Before filling, thoroughly clean quick fill nozzle/grease nipple before

connecting replenishing source. • Ensure stored lubricant is kept clean at all times. • Do not use grease containing graphite

If the system should fail to operate satisfactorily the following diagnostic and remedial advice will help to identify and correct any fault. Fault Finding A All lubrication points are dry. 1. Cause: The lubricant reservoir is empty. Action: Refill the reservoir and ensure that all supply pipes are free from air. 2 Cause: The reservoir has been filled with an unsuitable lubricant. Action: Drain the reservoir and thoroughly flush the system using a light mineral oil. DO NOT USE SOLVENT CLEANERS. Refill with the correct grade lubricant. 3 Cause: The power supply has failed and the indictor light will not illuminate. Action: Check main supply. Check 1A fuse which must be fitted to protect the installation. If the fuse has blown there may be a fault with the supply to the unit. Check the cable for damage/short circuits before fitting another fuse. Check continuity of wiring to unit. 4 Cause: The printed circuit has failed Action: Check main supply (A3 above). 5 Cause: The motor/gearbox assembly has failed. Action: Check for correct AC supply to motor (see A4 above). If power from PCB is correct but motor not rotating replace motor/gearbox assembly.

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4

4

B One or more points (but not all) lubricant points are dry. 1 Cause: Pipes supplying the dry lubrication points have worked loose from their connection. Action: Check pipe connections and re-connect where necessary. Ensure sufficient tubing allowance, particularly on King pins and other moving lubrication points 2 Cause: Pipes supplying the dry lubrication points are damaged or crushed. Action: Install new pipes, re-routing if necessary to avoid repeat damage. 3 Cause: No output from pumping units due to blockage. Action: Empty the reservoir and replenish with new clean lubricant of a suitable grade. Fit new pumping units. Do not attempt to clean and re-use blocked units as this could result in further problems resulting in damage to bearings. Spares parts list

Part no. Description 78033 Pumping unit 0.010cc (Red) 78034 Pumping unit 0.015cc (Green) 78035 Pumping unit 0.025cc (Yellow) 78036 Pumping unit 0.040cc (Blue) 78037 Pumping unit 0.060cc (Silver) 78038 Pumping unit 0.100cc (Black)

34237-402 Blanking plug 152823/50 Grease filled tubing AC3/SP2/24V PCB assembly AC3/SP5/2 Camshaft assembly 24 unit AC3/SP5/3 Camshaft assembly 36 unit AC3/SP5/4 Camshaft assembly 48 unit AC3/SP8/24V 24 volt motor AC3/SP9 Reservoir assembly AC3/SP10/24V Motor cover & PCB assembly LE 80588 Straight connector 1/4 BSPT PM80487 Straight connector 1/8 BSPT PM90485 Elbow connector 5/16 UNF PM90487 Elbow connector 1/8 BSPT PM90489 Elbow connector M6x1

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12-05-11Maintenance Schemes - TBL\TBL280 Mk 4 Maintenance Scheme

DOUGLAS TUGMASTER

TOWBARLESS AIRCRAFT HANDLING TRACTOR (TBL280)

GENERAL PLANNED MAINTENANCE SCHEME

PLEASE NOTE!

The following check lists are generally applicable to all Douglas Tugmaster Towbarless TBL280 AircraftHandling Tractors.For more detailed information, reference MUST be made to the relevant manuals and Data Sheets suppliedwith each tractor.

Please adhere to the Safety related documents, these can be found within the Douglas Servicemanuals.

The information given within this document was correct at the time of printing and is subject to changewithout notice. 1 - 7

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Maintenance Schemes - TBL\TBL280Mk 4 Maintenance Scheme12-05-11

2 - 7

DOUGLAS TUGMASTER (TBL280 Mk 4)

10 HOUR / DAILY CHECK SHEET

SIGNATURE: . . . . . . . . . . . . . . . . . . . . . . . .

TUG Number: DATE:

HOURMETERREADING:

1. CHECK COOLANT LEVELS

2. CHECK FUEL LEVEL

3. CHECK ENGINE OIL LEVEL

4. CHECK TYRE CONDITION - (VISUAL)

5. GENERAL CONDITION OF VEHICLE - (VISUAL)

CHECK FOR THE CORRECT FUNCTION OF:

a) INSTRUMENTATION / WARNING LIGHTS / WARNING HORNS

b) WINDSCREEN WIPERS / WINDSCREEN WASHERS

c) LIGHTING SYSTEM

d) BRAKES

e) STEERING OPERATIONS

f) ALTERNATOR CHARGING AND NO CHARGE WARNING LIGHT

g) NOSEWHEEL CRADLE

NOTE: FOR FURTHER MAINTENANCE INSTRUCTIONS, CONSULT WORKSHOP MANUALS.

NOTE ANY DEFECTS BELOW:

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3 - 7


50 HOUR / WEEKLY CHECK SHEET

SIGNATURE: . . . . . . . . . . . . . . . . . . . . . . . .

TUG Number: DATE:

HOURMETERREADING:

10 HOUR CHECK, PLUS:

1. CHECK ALL TYRE PRESSURES

2. CHECK BATTERIES AND CONDITION

3. CHECK HYDRAULIC OIL TANK LEVEL

4. CHECK DRIVE BELTS (FAN ETC.) - VISUAL

5. CHECK WHEEL NUTS TORQUE FIGURES(AFTER FIRST 50 HOURS, THEREAFTER EVERY 250 HOURS)

6. CHECK AIR INDUCTION SYSTEM FOR LEAKS OR DAMAGE

7. CHANGE FUEL FILTER CARTRIDGE(AFTER FIRST 50 HOURS, THEN EVERY 1000 HOURS)

8. CHECK/DRAIN FUEL PRE-FILTER(AFTER FIRST 50 HOURS, THEREAFTER EVERY 1000 HOURS)

9. CHECK NUTS & BOLTS INCLUDING DRIVE LINE(AFTER FIRST 50 HOURS, THEREAFTER EVERY 1000 HOURS)

10. CHECK BRAKE COOLING PUMP RESERVOIR OIL LEVEL

11. CHECK HYDRAULIC BRAKE RESERVOIR LEVEL

12. CHECK TRANSMISSION OIL LEVEL - (DIPSTICK)


NOTE ANY DEFERRED DEFECTS BELOW:

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4 - 7

20 - 02 - 07 Maintenance Schemes - TBL\TBL 280 Mk 4 Maintenance Scheme

SIGNATURE: . . . . . . . . . . . . . . . . . . . . . . . .


100 HOUR ONLY - (THEN REFER)

TUG Number: DATE:

HOURMETERREADING:

1. CHANGE AXLE HUB AND DIFFERENTIAL OIL - THEREAFTER 1000 HOURS

2. CHANGE TRANSFER BOX OIL - THEREAFTER 1000 HOURS

3. CHANGE TRANSMISSION OIL - THEREAFTER 1000 HOURS


NOTE ANY DEFECTS BELOW:

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TUG Number: DATE:

HOURMETERREADING:


1. CHECK AND CLEAN AIR FILTER ELEMENT IF REQUIRED(EXTREME CONDITIONS MAY REQUIRE MORE FREQUENT CHECKS)

2. CHECK DRIVE AXLE OIL LEVEL (DIFFERENTIAL AND HUBS)

3. CHECK TRANSFER BOX OIL LEVEL

4. GREASE SUPPORT WHEEL HUBS

5. CHECK ALL WHEEL NUT TORQUES

6. DRAIN AIR SYSTEM RESERVOIRS

7. CHECK OPERATION OF AUTOLUBE SYSTEM (IF FITTED)- REFILL IF NECESSARY

8. CHECK & ADJUST REAR SUPPORT WHEEL BRAKES

9. CHECK BRAKING EFFICIENCY

10. CHECK STEERING JOINTS - (REMOVE WHEELS)

11. CHECK MECHANICAL OPERATION OF STEERING ANGLE TRANSDUCERS- WHEELS MUST BE REMOVED

12. CHECK INJECTION LINE PIPE CONNECTIONS - VISUAL

13. LUBRICATE ALL “C” GREASE POINTS (SEE RELEVANT CHART)

14. CHECK COOLANT ADDITIVE CONCENTRATION

15. CHECK/ADJUST REAR SUSPENSION RIDE HEIGHT

16. CHECK/ADJUST CAB SUSPENSION RIDE HEIGHT

17. CHECK STEERING COMPUTER FAULT TABLE (RECORD FAULTS)

18. DRAIN ENGINE OIL, CHANGE ENGINE OIL FILTER AND REFILL

19. NOSEWHEEL CRADLE - REFER TO SEPARATE CRADLE DOCUMENT



5 - 7

20 - 02 - 07Maintenance Schemes - TBL\TBL 280 Mk 4 Maintenance Scheme

SIGNATURE: . . . . . . . . . . . . . . . . . . . . . . . .


500 HOUR / MONTHLY CHECK SHEET

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Maintenance Schemes - TBL\TBL280Mk 4 Maintenance Scheme12-05-11

6 - 7

SIGNATURE: . . . . . . . . . . . . . . . . . . . . . . . .


1000 HOUR / SIX MONTHLY CHECK SHEET

TUG Number: DATE:

HOURMETERREADING:


1. CHECK NUTS AND BOLTS, INCLUDING DRIVE LINE COMPONENTS

2. CHECK DRIVE AXLE MOUNTING BOLTS TIGHTENING TORQUE

3. CLEAN AXLE BREATHERS

4. DRAIN TRANSFER BOX - REFILL

5. DRAIN TRANSMISSION OIL, CHANGE TRANSMISSION OIL FILTER - REFILL

6. DRAIN HYDRAULIC SYSTEM OIL, CHANGE HYDRAULIC SYSTEM- FILTER - REFILL

7. DRAIN DRIVE AXLE DIFFERENTIAL AND HUBS OIL - REFILL

8. DRAIN BRAKE COOLING SYSTEM OIL, CHANGE BRAKE COOLING- SYSTEM FILTER - REFILL

9. CHECK /DRAIN FUEL PRE-FILTER

10. CHANGE FUEL FILTER

11. CHECK ENGINE IDLE SPEED




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7 - 7

SIGNATURE: . . . . . . . . . . . . . . . . . . . . . . . .


2000 HOURS / 12 MONTH CHECK SHEET

TUG Number: DATE:

HOURMETERREADING:


1. CHECK CLEARANCES OF ENGINE VALVES

2. COOLING SYSTEMS - DRAIN, FLUSH AND REFILL

3. CHECK ALL HYDRAULIC AND PNEUMATIC PIPEWORK - VISUAL

4. CHECK CHASSIS AND CAB STRUCTURE FOR DAMAGE - VISUAL

5. CHECK ALL ELECTRICAL WIRING FOR DAMAGE AND CHAFING - VISUAL

6. RECHARGE HYDRAULIC ACCUMULATORS

7. CHECK GEARCHANGE AND GEARCHANGE INHIBITS

8. CHANGE AIR DRYER DESSICANT CARTRIDGE

9. CHANGE AIR CLEANER FILTER ELEMENT

10. CHECK CONDITION OF WARNING AND SAFETY LABELS

11. CHECK FOR CORRECT FUNCTION AND SECURITY OF SEAT BELTS




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AMENDMENTS/BULLETINS

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Amdt Incorporated by Date

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

Amdt Incorporated by Date

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

21 - 09 - 04Technical Data\Manual amendment record

MANUAL AMENDMENT RECORD

1 - 1

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FILTER KIT

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ILL No. PART No. DESCRIPTION QTY.

Filter Kits\TBL280 Mk 4 12-05-11

1 12378D Engine oil filter 12 34658D Engine fuel filter 23 55219D Engine fuel water filter 14 34657D Transmission oil filter 15 34656D Hydraulic oil filter 16 26150D Brake oil cooler filter 17 03050D Fuel tank filter 18 11649D Air dryer cartridge 19 01819D Air cleaner element (main) 1

10 43958D Air cleaner element (safety) 1

* When ordering this part, you will need to supply Tugmaster chassis number to DOUGLAS.

STANDARD FILTER KIT

TBL280 Mk. 4

1 - 1

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