Terex TS14G Maintenance Manual Download Page 1

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SM 2283 Rev 1 12-05

T S1 4 G

Ove rhung Sc ra pe r

M a int e na nc e M a nua l

TECHNICAL PUBLICATIONS DEPARTMENT

TEREX EQUIPMENT LIMITED,

MOTHERWELL, SCOTLAND, ML1 5RY

REF. NO. 853

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TABLE OF

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PART No. 15501198

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Summary of Contents for TS14G

Page 1: ...per Maintenance Manual TECHNICAL PUBLICATIONS DEPARTMENT TEREX EQUIPMENT LIMITED MOTHERWELL SCOTLAND ML1 5RY REF NO 853 CLICK HERE FOR TABLE OF CONTENTS CLICK HERE TO RETURN TO MAIN LIBRARY INDEX PART...

Page 2: ...Courtesy of Machine Market...

Page 3: ...nsidered dangerous but natural rubber and nitrile are non hazardous d If Fluoro elastomer seals have been used then the affected area MUST be decontaminated before undertaking further work e Disposabl...

Page 4: ...THIS PAGE IS INTENTIONALLY LEFT BLANK Courtesy of Machine Market...

Page 5: ...ut or of the possible hazardous consequences of each way Consequently no such broad evaluation has been undertaken Accordingly anyone who uses a service procedure or tool which is not recommended must...

Page 6: ...THIS PAGE IS INTENTIONALLY LEFT BLANK Courtesy of Machine Market...

Page 7: ...40 Wheel Rim and Tyre RefertoSection160 0050 0060 Differential 1778 160 REARAXLEGROUP 0020 Differential 1780 0040 PlanetaryGearing 1779Rev1 0050 Wheel Rim and Tyre 1721 Rev 1 0080 NoSpinElement 1781 1...

Page 8: ...k Release Valve 1793 0190 Park Emergency Brake Control Valve 1795 0200 AirDrier 2284 0260 BrakeChamber 1782 0280 Relay Emergency Valve 1800 Rev 1 0280 Relay Valve 1794 0290 Pressure Protection Valve 1...

Page 9: ...mm 1 ft 11 in Overall length with optional Twin Hitch Bail Raised 13 900 mm 45 ft 7 in Bail Lowered 14 340 mm 47 ft 8 in Note All vertical measurements are with bowl at 300 mm 12 in carry position Uni...

Page 10: ...200 rev min 270 litre min 71 2 US gal min System Pressure at 1 500 rev min 127 5 bar 1 850 lbf in SPEEDS WITH STANDARD DIFFERENTIAL Forward Gear 1 2 3 4 5 6 7 Ratio 5 72 4 05 2 90 2 03 1 45 1 03 0 74...

Page 11: ...d strength and life Low wide design aids loading ability Bowl employs two single stage double acting cylinders to exert positive down pressure on the cutting edge to help penetrate hard material and l...

Page 12: ...Courtesy of Machine Market...

Page 13: ...lding and flame cutting cadmium plated metals produce odourless fumes which are toxic Recommended industrial hygiene practice for protection of the welding operator from the cadmium fumes and metallic...

Page 14: ...C AIR gouge or grind out the crack until sound metal is reached If ARC AIR method is employed pre heat area to 200 C 392 F measure 3 4 either side of repair prior to gouging On completion of gouging g...

Page 15: ...el chocks blocking materials and lifting equipment are properly secured and of adequate capacity to do the job safely To remove any of the components shown in Figs 1 2 3 or 4 or similar components the...

Page 16: ...sure wheel chocks blocking materials and lifting equipment are properly secured and of adequate capacity to do the job safely 1 Position the vehicle in a level work area apply the parking brake and sw...

Page 17: ...Locknut 6 Retainer 7 Screw 8 Lockwasher 9 Nut 10 RH Fender Assembly SM 2372 1 Radiator Guard 2 Seal 3 Grille 4 Bolt 5 Lockwasher 6 Bolt 7 Washer Fig 4 Radiator Guard and Mounting 8 Nut 9 Handle 11 Bol...

Page 18: ...6 through the spindles and banjo Align the spindle to the dimensions shown in Fig 5 and tighten alignment tool 9 Pre heat the weld joint to 149 205 C 360 400 F and maintain the heat during the welding...

Page 19: ...e 2 Banjo Outer Plate 3 Banjo 4 Nut 5 Washer 6 Pilot 7 Shaft 8 Sleeve 9 Fixture Fig 5 Tractor Spindle Installation INCHES mm 0 50 12 7 0 62 15 8 1 00 25 4 3 25 82 6 3 34 84 8 4 21 107 0 6 50 165 0 7 4...

Page 20: ...75 19 05 1 50 3 81 1 625 41 28 1 81 46 0 1 88 47 8 1 994 50 65 2 0 50 8 2 001 50 83 2 003 50 88 2 249 57 12 2 251 57 18 2 252 57 20 2 256 57 30 2 75 69 9 3 00 7 60 3 182 80 82 3 192 81 08 3 50 88 9 4...

Page 21: ...the welding process A respiratory protective device such as the M S A Gasfoe respirator with G M A cartridge will provide protection against cadmium fumes and metallic oxides The Gasfoe respirator has...

Page 22: ...aces must be prepared using paint stripper prior to area being reworked Recommended Industrial Hygiene and Safety Rules should be followed for protection of the welding operator from fumes If painting...

Page 23: ...0 STEERING LINES AND FITTINGS REMOVAL AND DISASSEMBLY Numbers in parentheses refer to Fig 1 WARNING To prevent personal injury and property damage be sure wheel chocks blocking materials and lifting e...

Page 24: ...er 3 on steering trunnion 1 and weld as shown in Fig 2 3 Attach suitable lifting equipment to steering trunnion 1 and position it on tractor frame 4 While installing steering trunnion 1 guide hydrauli...

Page 25: ...on 100 0130 3 SM 1695 2 99 SM 2201 Chassis Steering Trunnion Fig 2 Washer and Bushing Installation WASHER REF 3 FIG 1 STEERING TRUNNION REF 1 FIG 1 BUSHING REF 2 FIG 1 25 1 30 60 Courtesy of Machine M...

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Page 27: ...right hand side of the frame in a downward position 1 REFER to section 200 0040 for remote fuel filter details There is also an in line fuel filter mounted on the left hand side of the frame see fig 2...

Page 28: ...The Quantum Electronic Fuel System also takes action to prevent damage to the engine and provides the serviceman with diagnostic capabilities so that problems can be corrected quickly and easily 1 El...

Page 29: ...nic foot pedal Do not place engine under FULL LOAD at FULL SPEED IMMEDIATELY after starting ALWAYS allow the engine to fully circulate lubricant and warm up gradually before operating at full speed an...

Page 30: ...curred the maintenance monitor data can be inaccurate Operation When the Stop light on the dash panel illuminates the computer has detected a major malfunction in the engine that requires immediate at...

Page 31: ...quence until the system is advanced to the next active fault code or the diagnostic switch is switched to the OFF position To go to the next fault code press top of diagnostic engine request switch To...

Page 32: ...te Throttle Data error Red 296 Engine Auxiliary Pressure Sensor Critical range Red 297 Auxiliary Pressure Sensor Input 2 Circuit shorted high Amber 298 Auxiliary Pressure Sensor Input 2 Circuit shoret...

Page 33: ...ow Warning Amber 497 Multiple Unit Synchronization Switch Circuit Data incorrect Amber 515 Accelerator Pedal Frequency Position Sensor Supply Circuit Shorted high Amber 516 Accelerator Pedal Frequency...

Page 34: ...complete with rubber hose away from intake pipe Disconnect air cleaner intake pipe and remove from the engine Cover open ends to prevent entry of dirt WARNING Before disconnecting any air conditioner...

Page 35: ...e or flywheel cover from scraper engine whichever applies Refer to Section 110 0130 POWER TAKEOFF TRACTOR or Section 110 0130 FLYWHEEL COVER GROUP SCRAPER 5 Remove mounting hardware securing dipstick...

Page 36: ...ng brackets and carefully position engine 1 assembly in the tractor frame 2 Secure engine 1 assembly to frame mounting brackets with bolts 10 14 snubbing washers 11 washers 12 and locknuts 13 as shown...

Page 37: ...e 1 Inspect the sealing surface of the filter to ensure that the seal ring stayed with the filter If not remove it from the filter adaptor 2 Clean the filter adaptor with a clean lint free cloth 3 Lig...

Page 38: ...engine has been stopped long enough approximately 20 minutes for the oil from various parts of engine 1 to drain back to the crankcase check oil level and add oil to bring it to the proper level on t...

Page 39: ...1 6 Bolt 149 110 1 23 Bolt 176 130 1 22 Bolt 57 42 Fan Hub Mounting Bolts 34 25 SPECIAL TOOLS Refer to Section 300 0070 SERVICE TOOLS for part numbers of service tools which should be used in conjunct...

Page 40: ...Courtesy of Machine Market...

Page 41: ...is stopped vacuator valve 6 opens and expels any accumulated grit dust or water 1 Air Cleaner Body 2 Primary Element 3 Safety Element 4 Cover Assembly 5 Latch 6 Vacuator Valve Fig 1 Exploded View of A...

Page 42: ...ully and clean replace as required Refer to Primary Element Never attempt to clean safety element 3 Change safety element 3 after every third primary element 2 service Make sure vacuator valve 6 is no...

Page 43: ...of the element The air jet should be directed in the opposite direction of normal operating air flow Move the air jet up and down the pleats holding the air nozzle 25 mm 1 0 in away from the pleats to...

Page 44: ...r air cleaner outlet increases This vacuum is generally measured as restriction in mm inches of water The recommended maximum allowable intake restrictions at rated speed and load are as follows a 380...

Page 45: ...onalinjuryandpropertydamage be sure wheel blocks blocking materials and lifting equipment are properly secured and of adequate capacity to do the job safely 1 Position the vehicle in a level work area...

Page 46: ...2 6 Pull driveshaft 6 from flywheel cover case 2 Pry oil seal 1 from flywheel cover case 2 7 Pull bearings 4 29 from flywheel cover case 2 with a suitable bearing puller 8 If necessary note locations...

Page 47: ...OOLS for part numbers of general service tools required These tools are available from your dealer 2 Install new oil seal 1 in centre bore of flywheel cover case 2 so that it is flush with flywheel co...

Page 48: ...110 0130 Engine Power Takeoff Tractor SM 1693 Rev1 03 04 SPECIAL TORQUE SPECIFICATIONS TORQUE FIG NO ITEM NO ITEM NAME Nm lbf ft 1 3 Bolt 54 60 40 44 1 16 Locknut 950 1 085 700 800 Courtesy of Machin...

Page 49: ...he flywheel cover case 2 can be installed in the same position at Installation 5 Attach a suitable lifting device to the flywheel cover case 2 assembly and remove bolts 18 and lockwashers 19 securing...

Page 50: ...lly check oil seal lip contact surfaces on driveshaft 3 and yoke 4 for nicks dents scratches wear or corrosion Replace as necessary ASSEMBLY Numbers in parentheses refer to Fig 1 Note Prior to assembl...

Page 51: ...dealer INSTALLATION Numbers in parentheses refer to Fig 1 Note When reassembling flywheel cover assembly to engine flywheel housing be sure to align match marks inscribed during disassembly Note Tigh...

Page 52: ...Courtesy of Machine Market...

Page 53: ...vibration and torsional loads The transmission assembly used in both the tractor and scraper is a countershaft type gearbox with integral torque converter Signalled by electric shift control the tran...

Page 54: ...container in position under the hydraulic tank drain port remove drain plug and drain oil After draining reinstall plug and tighten securely 7 Remove air tanks and mounting bracket from the machine R...

Page 55: ...ed 2 Remove bolts 9 washers 10 spacers 7 snubbing washers 8 locknuts 11 and RH bracket assembly 2 from the frame mounts Remove isolation mounts 6 from frame mount and replace if required 3 If required...

Page 56: ...RFS connections as described in Section 220 0000 STEERING SYSTEM SCHEMATIC Renew all O rings whereused WARNING To prevent personal injury and property damage be sure wheel blocks blocking materials an...

Page 57: ...and subsequent oil deterioration Oil Level Check WARNING When checking the oil level be sure that the parking brake is applied and all road wheels are securelyblocked Check the transmission oil level...

Page 58: ...lters indicate damage has occurred in the transmission When these particles are found in the filters the cause must be established and rectified immediately to prevent damage to the transmission At ea...

Page 59: ...ow the actual gear selected The transmission uses electrohydraulic valves to control the operation of the transmission The solenoids controlling the transmission clutches solenoids A through D and 1 t...

Page 60: ...itions the display shows the actual forward or reverse transmission gear and the state of the disconnect When an error has occurred the display will flash an error code indicating that a problem has b...

Page 61: ...or Replace seal and install correctly installed incorrectly Faulty main regulator valve Replace main regulator valve Control valve body cracked Replace control valve body Low pressure in one gear but...

Page 62: ...ive noise Charge pump defective Replace pump Excessive backlash in gear train Replace bearings and inspect for defective gears Auxiliary driven pump bad Remove pump and check for noise Blows oil out o...

Page 63: ...components linked together to form a functioning system Gear shift control Wiring harnesses Electronic control units Transmission control valve Transmission hydraulic system pump relief valves lines e...

Page 64: ...1 B1 J1 C2 J1 A3 J1 B2 J1 C3 J1 D1 J3 A3 J3 B1 J3 B2 J3 B3 J3 C1 J3 C2 J3 D2 J3 D3 J3 E1 J3 E2 J3 E3 J3 F1 J3 F2 J3 F3 J3 G3 J3 H1 J1 B1 J1 C2 J1 A3 J1 B2 J1 C3 J1 D1 J2 C1 J1 K1 J2 B3 J2 E3 J2 E2 J1...

Page 65: ...r 7 cannot get up to requested current Error Open or short ground in Solenoid C circuit from output pin J3 E3 to return pin J3 F1 Diagnostic code 27 Error type Driver 8 cannot get up to requested curr...

Page 66: ...ror Request for an undefined shift being made Diagnostic code 41 Error ECU has not seen a legal Neutral input pin J2 A1 since initial power up of system Diagnostic code 42 Error type Bottom of Clutch...

Page 67: ...requency is too low Diagnostic code 82 Error Output MPU input pin J1 A3 signal missing or frequency is too low Diagnostic code 84 Error Illegal or undefined vehicle mode code Diagnostic code 85 Error...

Page 68: ...me exceeds 300 ms Diagnostic code 110 Error Clutch 2 fast fill time exceeds 300 ms Diagnostic code 111 Error Clutch 3 fast fill time exceeds 300 ms Diagnostic code 112 Error Clutch 4 fast fill time ex...

Page 69: ...stic code 198 Error CCD communications link failure between master ECU and slave ECU on CCD BUS J2 E3 and CCD BUS J2 B2 Diagnostic code 199 Error This is a non functional base ECU No application speci...

Page 70: ...erceived performance change or in a loss of function which may result in performance loss or system damage lntershift Pause Time The minimum time delay between shifts A value preprogrammed into the EC...

Page 71: ...c Pickup Sensor GND Ground RPM Revolutions Per Minute REV Reverse FOR Forward NEU Neutral P Park Transmission Transmission Electronic Controls DC Direct Current TOC Top of Clutch BOC Bottom of Clutch...

Page 72: ...Courtesy of Machine Market...

Page 73: ...in any direction and a light rigid hollow slip yoke and splined shaft assembly forming a slip joint The slip joint accommodates length variations generatedduringoperation preventingtensionor compressi...

Page 74: ...property damage be sure wheel blocks blocking materials and lifting equipment are properly secured and of adequate capacity to do the job safely 2 2 3 3 4 4 7 9 5 8 6 LH RH 1 Fig 3 Orientation of Scr...

Page 75: ...s 2 and their mating surfaces to ensure correct mating alignment when installing the Driveline assembly 1 6 Support the Front driveline assembly 1 with suitable lifting equipment and remove bolts 4 se...

Page 76: ...therwisespecified Note Tighten all fasteners without special torques specified to standard torques listed in Section 300 0080 STANDARDBOLTANDNUTTORQUE SPECIFICATIONS Note Extra care should be taken wh...

Page 77: ...153 Nm 113 lbf ft 3 Position Front driveline assembly 1 on the Transmission end as shown and align match marks on universal joint 2 with those on its mating surface 4 Apply Loctite 648 to the threads...

Page 78: ...nd If crosses are loose replace cross and bearings as an assembly Also see below Excessive wear of Lack of lubrication Replace cross and bearings as an assembly universal joints Lubricate cross assemb...

Page 79: ...ed by the driveline it transmits this torque to the axle shafts and it allows the drive wheels to rotate at different speeds When the vehicle is making a turn one drive wheel must travel a greater dis...

Page 80: ...e axle housing to ensure proper clearance between the differential carrier housing and the frame crossmember When the differential is removed from the front axle housing it will be necessary to remove...

Page 81: ...the vice so that the flange is resting on top of the jaws with seal 34 facing downward Tap out outer bearing cup 36 outer bearing cone 35 and seal 34 with a soft faced Front Axle Differential Fig 3 Re...

Page 82: ...ar 13 to show their relationship for assembly purposes 3 Place the differential assembly on a bench so that plain case 4 is facing upwards Cut lockwire 41 and remove bolts 42 from plain case 4 Lift pl...

Page 83: ...n older worn gear tends to carry an uneven portion of the load This creates an excessive amount of stress on the new gear 7 Check for pitted scored or worn thrust surfaces of differential case halves...

Page 84: ...14 plain case 4 and all component parts with gear lubricant Refer to Section 300 0020 LUBRICATION SYSTEM for proper lubricant 5 Position thrust washer 11 in bore of flanged case 14 6 Install side gea...

Page 85: ...0 03 N 9 lbf then 0 103 18 x 40 03 4 13 Nm 4 0625 x 9 36 5625 lbf in torque This is 0 18 Nm 1 56 lbf in over the high limit The bearing preload would be too great Fig 10 Checking Bearing Preload SM 21...

Page 86: ...as ring gear 13 teeth 5 Tighten bearing adjuster 23 until there is a zero backlash on the dial indicator 6 Rotate ring gear 13 checking backlash clearances at various tooth sections This will determin...

Page 87: ...ribed The following suggestions are offered to make gear tooth pattern analysis and identification easier 1 Paint twelve ring gear teeth with Prussian Blue oiled red lead or some other easily removed...

Page 88: ...dirt oil grease or other foreign matter Wipe cleaned surfaces dry Apply a pliable non hardening seal material to the mounting surface of the banjo for a leakproof seal The seal is installed by pressin...

Page 89: ...TOOLS Refer to Section 300 0070 SERVICE TOOLS for part numbers of special tools outlined in this section and general service tools required These tools are available from your dealer 7 Install the axl...

Page 90: ...of pinion or Disassemble correct or replace faulty part flanged case Continual noise Bearing worn Replace worn parts Gears damaged or worn Replace gears Noise on drive Ring and pinion gear adjustment...

Page 91: ...driveline it transmits this torque to the axle shafts and it allows the drive wheels to rotate at different speeds When the vehicle is making a turn one drive wheel must travel a greater distance than...

Page 92: ...e axle housing to ensure proper clearance between the differential carrier housing and the frame crossmember When the differential is removed from the front axle housing it will be necessary to remove...

Page 93: ...the vice so that the flange is resting on top of the jaws with seal 34 facing downward Tap out outer bearing cup 36 outer bearing cone 35 and seal 34 with a soft faced Rear Axle Differential Fig 3 Rem...

Page 94: ...eir relationship for assembly purposes Note If the differential is equipped with the NoSPIN element 44 disregard Steps 3 thru 6 and remove the NoSPIN element 44 as described in Section 160 0080 NOSPIN...

Page 95: ...ly as a matched set This set is identified by a serial number on the OD of the ring gear and outer face of the pinion gear It is also advisable to replace side gears 6 10 or spider pinion gears 8 in m...

Page 96: ...assembly on ring gear 13 and flanged case 14 2 Install bolts 1 through ring gear 13 and flanged case 14 and secure with nuts 15 Torque tighten to 260 270 Nm 190 200 lbf ft lubricated 3 Press cone 3 on...

Page 97: ...g rotated The starting torque may be higher and therefore misleading depending upon the tightness of the bearings Fig 10 Checking Bearing Preload SM 2180 The pull in Newtons lbf as indicated by the sc...

Page 98: ...refore they must be returned to their original positions by aligning the identification marks made during Disassembly 2 Install bearing adjusters 1 23 in their respective bearing caps 19 3 Install a d...

Page 99: ...ges in adjustment will frequently concentrate the bearing area on a small portion of the teeth which often results in failure Therefore it is advisable to know exactly what the end result will be befo...

Page 100: ...ation of a differential assembly Note Tighten all fasteners without special torques specified to standard torques listed in Section 300 0080 STANDARD BOLT AND NUT TORQUE SPECIFICATIONS 1 Clean mating...

Page 101: ...ngs When the differential is definitely at fault pull the drive axles before moving the machine Refer to Section 160 0040 PLANETARY GEARING Note If the differential is equipped with the NoSPIN element...

Page 102: ...n Replace worn parts Gears damaged or worn Replace gears Noise on drive Ring and pinion gear adjustment tight Adjust Noise on coast Bearing damaged Replace bearings Loose ring and pinion gear adjustme...

Page 103: ...meshed wish the ring gear to move around ling gear 4 in the direction of arrow A Driving flange 5 assembly contains the planet pinions and is bolted to the wheel Movement of the planet pinions 3 in th...

Page 104: ...16 from planetary assembly Discard gasket 16 6 Pull out sun gear 8 and axle shaft 18 Remove sun gear from axle shaft by removing snap ring 19 and sliding off gear Remove thrust washer 2 from axle sha...

Page 105: ...t all parts for damage or excessive wear In addition check pinion bearings 10 for free fit in gears 9 and on planet pins 11 Replace any parts which are in questionable condition The planet pinion wear...

Page 106: ...to the differential side gear If the end play is greater then the allowable maximum either the axle shaft end or the driving flange thrust cover or both are excessively worn To correct this replace th...

Page 107: ...res for removing tyre and rim assembly from machine and dismounting tyre from rim the use of hand hydraulic and special tools are described in this section When dismounting a tyre and rim assembly fro...

Page 108: ...on For Servicing Tape valve threads for protection 5 Break outer tyre bead loose with pry bar shown in Fig 2 6 Insert flat hooked end of pry bar into breaking slots between bead seat band 17 and outer...

Page 109: ...ced WARNING Never mix components of one manufacturer s rims with those of another Using the rim base of one manufacturer with the lock ring of another or vice versa is dangerous The lock ring of one m...

Page 110: ...l the valve core 13 in the valve assembly 12 Refer to heading Tyre Inflation in this section for the proper procedure for inflating the tyre WHEEL Removal and Disassembly Numbers in parentheses refer...

Page 111: ...replace with new parts as necessary 4 Inspect all threaded components and repair or replace as necessary 5 Discard seal 2 and replace with a new one 6 Oil seal 2 rides on a special bushing which is sh...

Page 112: ...embly 8 Rotate wheel 6 assembly and tighten spindle nut 10 to a seating torque of 1 360 Nm 1 000 lbf ft or until wheel starts to bind while rotating and bumping wheel 6 assembly to ensure adequate sea...

Page 113: ...s flammable vapours in tyres is the tyre bead lubricant Always use bead lubricants that do not introduce flammable vapours into the tyre Inflation Note Always use tyre inflation equipment with an air...

Page 114: ...Part No 9359489 for tyre inflation because this assembly does not include a pressure regulator safety relief valve and adequate pressure gauging which is mandatory for tyre inflation purposes Tyre vo...

Page 115: ...ar 60 lbf in remove the clip on chuck and adjust the pressure with the tyre gauge in the usual manner b If the required service inflation pressure is greater than 4 1 bar 60 lbf in further inflate wit...

Page 116: ...ine reaches the tyre and wheel area Under such conditions all personnel must avoid approaching the machine in a manner that could result in injury should an explosion actually occur Move the machine t...

Page 117: ...nd under inflation are detrimental to tyre life Tyre pressure should be checked daily preferably before the machine is placed in operation Refer to Tyre Inflation Pressures table Rear Axle Group Wheel...

Page 118: ...se they must mate properly to form part of the basic air chamber Since the rim base and bead seat band are mating surfaces distortion may prevent easy assembly as well as possibly resulting in no seal...

Page 119: ...ld Replace defective part WARNING Do not attempt repair of wheel components Twisted or damaged O ring Replace O ring lubricate Tyre cuts and snags Repair tyre damage Bead area awl holes Repair inner l...

Page 120: ...Courtesy of Machine Market...

Page 121: ...SPIN units using a holdout ring with cams see Fig 5 this action sets DESCRIPTION The NoSPIN element is an automatic locking device which provides positive drive to both wheels It eliminates individual...

Page 122: ...he left holdout ring rotates back away from the spider key When this happens the cams or lugs of the holdout ring whichever type is used become realigned with the centre cam permitting the left driven...

Page 123: ...tion will be required of the NoSPIN differential In other words the NoSPIN differential will go through its complete unlocking and locking SM 2184 Fig 3 Straight Forward Driving Fig 4 Right Hand Turn...

Page 124: ...osition 3 Remove the differential carrier from the drive axle If an axle shaft has failed be sure all fragments of the shaft are removed to avoid serious damage of the pinion and ring gear or NoSPIN e...

Page 125: ...personal injury and property damage be careful when disassembling the NoSPIN element because spring 3 tension can cause parts to fly apart 1 Release the retaining wing nut bolt and washer assembly ho...

Page 126: ...emove any burrs or small chipped edges with an abrasive stone or electric burr grinder If the spline is broken or twisted replace the part Check side gear 5 hubs for fractures 2 Be sure the holdout ri...

Page 127: ...g nut on retaining bolt and tighten to keep the NoSPIN assembly intact If an internal spring 3 is used position spring over hub of side gear 5 and assemble spring and side gear as an assembly in drive...

Page 128: ...hing of the NoSPIN during wheel rotation The left wheel must be firmly against the stop or the right wheel will not rotate freely 6 Repeat Steps 2 thru 5 while holding the right wheel and testing the...

Page 129: ...artment is depressed air pressure is applied to the brake chamber which forces the slack adjuster to rotate camshaft 2 The camshaft cam then forces brake shoes 5 19 outward against brake drum 15 throu...

Page 130: ...chamber push rod Refer to Section 165 0060 SLACK ADJUSTER 5 Drain differential and planetary gear lubricant and remove planetary gear assembly from the wheel Refer to Section 160 0040 PLANETARY GEARI...

Page 131: ...clean and oil if they still bind the rollers and pins 6 should be checked for excessive wear If necessary break the weld on pins 6 and replace with new pins and rollers 8 Clean all rust off face of b...

Page 132: ...STEM Refer to Section 160 0040 PLANETARY GEARING BRAKE BALANCING The brakes should be balanced prior to final reassembly of the relined brake shoes Brake balancing is checking to see that all brake sh...

Page 133: ...sh rod and adjust clevis by turning If adjustment of slack adjuster is also necessary depress locking sleeve 5 and turn adjusting screw 4 and worm gear 3 until proper angle is established After proper...

Page 134: ...Courtesy of Machine Market...

Page 135: ...ement changes the clearance between the brake lining and brake drum A locking sleeve 6 and spring 5 is used to lock adjusting shaft 7 in place ADJUSTMENT Brake Shoe Clearance Numbers in parentheses re...

Page 136: ...ICATION The slack adjuster is permanently lubricated eliminating the need periodic lubrication wheels to obtain even braking on all wheels If adjustment is necessary refer to Section 165 0031 BRAKE PA...

Page 137: ...3 Radio Cassette Relay K44 Trans Start Relay K45 Engine Alarm Relay K46 Rear Starter Inhibit K47 Intermittent Wipe Relay K53 Grid Heater Power Relay L3 Reverse Alarm L4 Buzzer L5 HornSolenoid M1 Start...

Page 138: ...TO OTHER VEHICLE SYSTEMS 3 CABLES R B 916B U 417 B 952B Y 542 TWISTED 32 TURNS METRE 4 CABLES R B 916B A U 417 A B 952B A Y 542 A TWISTED 32 TURNS METRE CALIBRATION PLUGS FOR FRONT AND REAR TRANSMISS...

Page 139: ...on Sensed Relay Contacts Air Cond TVP Opt 30A 26 Air Conditioning System 15A 27 Transmission Ignition Supply 15A 28 Ignition Auxilary Supply Option 10A 29 Work Lights 15A 30 RotatingBeacon 5A 31 CabFa...

Page 140: ...Rear Engine Ignition Supply 5A L H rail Power Box 61 Vehicle System supply 100A 62 Alternator Charge System Supply 100A Front Engine Bay 63 Front Grid Heater Supply 125A Rear Engine Bay 64 Rear Grid H...

Page 141: ...Section 190 0000 SM 2282 Rev1 04 04 5 Electrical System Circuit Diagrams SM 3178 Courtesy of Machine Market...

Page 142: ...Section 190 0000 Electrical System Circuit Diagrams 6 SM 2282 04 04 SM 3178A Courtesy of Machine Market...

Page 143: ...Section 190 0000 SM 2282 Rev1 04 04 7 Electrical System Circuit Diagrams SM 3178B Courtesy of Machine Market...

Page 144: ...Section 190 0000 Electrical System Circuit Diagrams 8 SM 2282 04 04 SM 3178C Courtesy of Machine Market...

Page 145: ...Section 190 0000 SM 2282 Rev1 04 04 9 Electrical System Circuit Diagrams SM 3178D Courtesy of Machine Market...

Page 146: ...Section 190 0000 Electrical System Circuit Diagrams 10 SM 2282 04 04 SM 3178E Courtesy of Machine Market...

Page 147: ...Section 190 0000 SM 2282 Rev1 04 04 11 Electrical System Circuit Diagrams SM 3178F Courtesy of Machine Market...

Page 148: ...Section 190 0000 Electrical System Circuit Diagrams 12 SM 2282 04 04 SM 3178G Courtesy of Machine Market...

Page 149: ...Section 190 0000 SM 2282 Rev1 04 04 13 Electrical System Circuit Diagrams SM 3178H Courtesy of Machine Market...

Page 150: ...Section 190 0000 Electrical System Circuit Diagrams 14 SM 2282 04 04 SM 3178I Courtesy of Machine Market...

Page 151: ...Section 190 0000 SM 2282 Rev1 04 04 15 Electrical System Circuit Diagrams SM 3178J Courtesy of Machine Market...

Page 152: ...Section 190 0000 Electrical System Circuit Diagrams 16 SM 2282 04 04 SM 3178K Courtesy of Machine Market...

Page 153: ...Section 190 0000 SM 2282 Rev1 04 04 17 Electrical System Circuit Diagrams SM 3178L Courtesy of Machine Market...

Page 154: ...Section 190 0000 Electrical System Circuit Diagrams 18 SM 2282 04 04 SM 3178M Courtesy of Machine Market...

Page 155: ...Section 190 0000 SM 2282 Rev1 04 04 19 Electrical System Circuit Diagrams SM 3178N Courtesy of Machine Market...

Page 156: ...Courtesy of Machine Market...

Page 157: ...ocated in the dash panel relay this information to the operator Note Always make sure all gauges warning lights and controls are working properly before operating the vehicle Engine The Quantum Electr...

Page 158: ...ches and Sensors Scraper Engine Coolant Level Senders 9 Located in the radiator top tank the sender sends a signal to engine stop light 6 or 20 Fig 3 indicating that the engine coolant level is low Ta...

Page 159: ...osest to the normal temperature range green zone If upshifting must be consistently limited to ranges lower than normal for the loads and the grades encountered to prevent overheating the transmission...

Page 160: ...ate low brake air pressure warning light 15 Fig 3 if there is a loss of air pressure in the following circuits Switch 10 Park emergency brake circuit air pressure falls below 5 5 bar 80 lbf in Switch...

Page 161: ...capacity and fuel specifications OPERATION Numbers in parentheses refer to Fig 3 4 unless otherwise specified Fuel is drawn from fuel tank through fuel line 4 21 inline filters and fuel filters 35 36...

Page 162: ...ll road wheels and place the battery master to fuel tank through fuel line 5 30 A fuel tank breather filter assembly 4 Fig 1 is incorporated into the fuel filler cap 2 Fig 1 allowing fuel tank 1 Fig 1...

Page 163: ...16 and washers 15 19 securing fuel tank 1 assembly to the frame Using a suitable lifting device remove fuel tank 1 assembly from the vehicle Fuel System Fuel Tanks Lines and Mounting Fig 3 Fuel Lines...

Page 164: ...n from contaminating the fuel Ensure vent hole in filler cap 2 is clear to prevent a vacuum from building up in fuel tank 1 When filling fuel tank 1 check that there is no buildup of dirt and sludge a...

Page 165: ...ed by depressing the left hand accelerator pedal which by means of linking bar 10 also depresses the right hand pedal Note The electronic controlled engine will override the electronic foot pedal posi...

Page 166: ...ring pedal assemblies 1 to cab floor plate Remove pedal assemblies 1 INSTALLATION Numbers in parentheses refer to Fig 1 Note Tighten all fasteners to standard torques listed in Section 300 0080 STANDA...

Page 167: ...racket 11 Bolt 12 Lockwasher 13 Stop door 14 Washer 1 Fan Guard 2 Drain Plug 3 Bolt 4 Washer 5 Plate 6 Gasket 7 Clip 22 Stud 23 Spring 24 Washer 25 Nut 26 Bolt 27 Washer 28 Radiator Assembly 1 Positio...

Page 168: ...bolts 11 lockwashers 12 washers 15 and bracket 10 from radiator assembly 28 12 Attach suitable lifting equipment to radiator assembly 28 and remove nuts 25 washers 24 springs 23 securing radiator asse...

Page 169: ...de columns 3 4 to top tank 1 and bottom tank 2 Remove side columns 3 4 4 Remove nuts 7 washers 12 and bolts 11 securing top tank 1 to core assembly 5 5 Remove top tank 1 from core assembly 5 and disca...

Page 170: ...tank 2 to core assembly 5 from the centre out to ensure an evenly spreadload 6 Install overflow tube 16 Fig 1 to filler neck 17 Fig 1 on radiator top tank 1 Secure tube with clips 7 Fig 1 and mountin...

Page 171: ...bes of the radiator it is necessary to use a suitable scale remover such as Powdered Scale Solvent or equivalent This material is a free flowing powder inhibited to prevent attack on the cooling syste...

Page 172: ...ng the fouling material out from the radiator core 8 For surfaces with stubborn deposits it may be necessary to repeat steps 5 through 7 brushing the surfaces between stages using a stiff bristle brus...

Page 173: ...ransmission oil within its required operating temperature range Refer to Section 120 0010 TRANSMISSION AND MOUNTING and Section 210 0000 COOLING SYSTEM Coolant is drawn from port D through coolant out...

Page 174: ...heat exchanger 1 Remove cooler flanges 2 from heat exchanger 1 and discard viton seals 3 1 Position the vehicle in a level work area apply the parking brake and switch off the engine Operate the stee...

Page 175: ...injury and property damage be sure wheel blocks and lifting equipment are properly secured and of adequate capacity to do the job safely 1 Using suitable lifting equipment position transmission oil c...

Page 176: ...Courtesy of Machine Market...

Page 177: ...lic oil for operating the steering and bowl hydraulic systems The triple pump is a multiple gear type pump consisting of three separate sections connected together as one assembly One section of the p...

Page 178: ...le Pump 3 Steering Valve 4 Double Relief Valve 5 Flow Reversing Valve 6 Steering Cylinders Fig 1 Steering System Schematic Diagram 1 2 P 3 4 2100 5 6 6 B A T PSI 2100 PSI 1950 PSI 25 PSI RETURN FROM S...

Page 179: ...unnion and the piston rod end is connected to the pull yoke Single stage double acting means that the piston rod can have oil applied to either side extending or retracting the piston rod Cylinder mou...

Page 180: ...warnings in the individual steering and body hydraulic component sections of this manual should be adhered to at all times Relieving Pressure In Steering System WARNING Dangerous pressure Turn steeri...

Page 181: ...lief valve 4 Its primary purpose is to bypass oil from one steering cylinder to the other cylinder when a shock load is placed on the piston rod The cored passages of both valves form a direct connect...

Page 182: ...steering valve and is directed back to tank 7 through return line L With the steering valve spool in this position any oil in the cylinders is retained there by the closing of the ports in the steerin...

Page 183: ...ed Fig 3 Reversing Mechanism in Left Turn 1 Tractor Steering Trunnion 2 Scraper Pull Yoke 3 Left Steering Cylinder 4 Left Cam 5 Flow Reversing Valve 6 Double Relief Valve Right Turn In a right turn th...

Page 184: ...half of the piston stroke into the valve passages which reverse the flow of oil The reversed flow of oil to the left cylinder is as follows Oil flows into the base of the cylinder 8 Fig 2 through lin...

Page 185: ...strokes of the steering cylinders should be adjusted as follows 1 Turn the tractor until one cylinder is extended to within 3 2 mm 0 125 in of the maximum eye to eye dimension of 1 274 1 mm 50 16 in w...

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Page 187: ...ve NEUTRAL POSITION Numbers in parentheses refer to Fig 2 Oil enters the steering valve at the inlet port flows through spool 47 bore and back out of the valve through return to tank passages and the...

Page 188: ...3 O Ring 4 Cross over Relief Valve 5 Spring 6 Valve Body 7 O Ring 8 Plug 9 Cover 10 Cap 11 O Ring 12 Retaining Ring 13 O Ring 14 Plug 43 Plate 44 Shims 45 Washer 46 Seal 47 Spool 48 Wiper 49 Plate 50...

Page 189: ...huck hole will cause one piston rod in a steering cylinder to move outward and the piston rod in the other steering cylinder to move inward The piston rod moving outward creates a void in the steering...

Page 190: ...re from steering valve and transfer steering valve to a clean area for disassembly DISASSEMBLY Numbers in parentheses refer to Fig 1 2 1 If required remove fittings from steering valve and identify to...

Page 191: ...determine the extent of wear and to see if they fit without binding If the fit is too loose or if there is damage valve body and plungers MUST be replaced as an assembly ASSEMBLY Numbers in parenthese...

Page 192: ...groove in valve body 6 Secure wiper with plate 49 and two bolts 51 and lockwashers 50 15 Place new O ring 7 on plug 8 and thread plug into valve body 6 until it bottoms 16 Install new O rings 2 3 on s...

Page 193: ...plenish if required 8 Remove wheel blocks ADJUSTING RELIEF VALVE Numbers in parentheses refer to Figures 2 and 8 Remove plug from gauge port of steering valve and fit a 0 207 bar 0 3 000 lbf in2 press...

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Page 195: ...that piston rod 20 can have oil applied to either side extending or retracting the piston rod Cylinder mounting is by pins secured with bolts lockwashers and nuts Bushings 5 permit a limited amount of...

Page 196: ...ng trunnion 7 Remove cylinder assembly from the machine 8 Remove cylinder assembly to a clean area for disassembly Drain oil from cylinder assembly into a suitable container 9 Repeat steps 3 through 8...

Page 197: ...ystem Steering Cylinder 5 Guide end cap 2 assembly onto piston rod 20 6 Install piston seal 13 and wear ring 12 into piston 3 external grooves Install O ring 19 into internal groove of piston 3 7 Inst...

Page 198: ...Remove wheel blocks 8 Place the battery master switch in the On position start the engine and operate the steering from lock to lock several times to purge air out of the hydraulic lines Check hydrau...

Page 199: ...used to relieve shock loads transmitted to the steering cylinders by the machine striking a boulder hole or other similar object When this occurs the oil that is displaced flows through the cored pas...

Page 200: ...o their normal closed positions The surplus oil flows out of the Return Port and returns to the hydraulic tank REMOVAL Numbers in parentheses refer to Fig 2 WARNINGS Hydraulic fluid pressure will rema...

Page 201: ...breaks lack of tension or other damage Replace if required 5 Check condition of valve cartridges 2 Insert a blunt nose drift or punch in cartridge end and depress piston Note If piston does not move f...

Page 202: ...Place the battery master switch in the On position start the engine and bring hydraulic oil to operating temperature 5 Check double relief valve and hydraulic line connections for leaks and tighten a...

Page 203: ...illustration They act as vent passages for high pressure oil to protect the seals OIL FLOW Right Turn Letters in parentheses refer to Fig 1 Oil flows into the valve housing through the top left port n...

Page 204: ...ected to the upper part of channel C This allows oil to flow into the base end of the right steering cylinder REMOVAL Numbers in parentheses refer to Fig 3 WARNINGS Hydraulic fluid pressure will remai...

Page 205: ...6 from valve body 1 Remove and discard O rings 5 3 Match mark plungers 2 to their respective bores in valve body 1 Pull both plungers 2 out from valve body 1 4 Pry seals 3 out of plunger stop plugs 4...

Page 206: ...bolts and lockwashers 4 2 Remove blanking caps from hydraulic lines and install lines to flow reversing valve as identified during removal 3 Connect the reversing linkage to the eye of the plungers 4...

Page 207: ...o the bell crank A grease fitting 15 is installed in each bell crank 1 to lubricate the roller shaft The function of the steering linkage is to push the flow reversing valve spool into the valve housi...

Page 208: ...bell crank 1 INSPECTION Numbers in parentheses refer to Fig 1 1 Clean all parts with a suitable solvent and dry with compressed air 2 Inspect roller assembly 16 springs 9 14 bushing 2 and clevis pins...

Page 209: ...Valve 7 Refer to Section 235 0120 RELIEF VALVE The direct acting relief valve is mounted at the right hand side of the cab below the bowl drop valve 10 The valve is installed in the lines between the...

Page 210: ...nder Fig 1 Bowl Hydraulic System Schematic 15 Apron Cylinder 16 Ejector Cylinder 17 Pressure Reducing Valve 1 2 7 8 T W1 W2 W3 B3 A1 A2 P3A B2 P2A B1 P1A P2B P3B P1B X1 X2 X3 9 A T B P P A 16 17 15 13...

Page 211: ...cumulator 12 Refer to Section 235 0070 ACCUMULATOR The accumulator 12 is mounted off the hood mounting bracket inboard of the right hand fender The accumulator is of the piston type and is precharged...

Page 212: ...auge is basically four pressure gauges in one Continuous system pressure readings are indicated on one of three simultaneously reading gauges through a pressure range of 30 in of vacuum to 5 000 lbf i...

Page 213: ...L position and the bowl cutting edge is touching the ground When the servo control bowl lever is pushed into the LOWER position a passage in the control valve is opened and oil flows from the pump int...

Page 214: ...the servo valve holds the ejector control spool in the LOWER position allowing the ejector to FLOAT down to the loading position after the material is dumped from the bowl without further attention f...

Page 215: ...eously reading gauges through a pressure range of 30 in of vacuum to 5 000 lbf in Bowl Hydraulic System Hydraulic Lines and Fittings watching the pressure gauge The maximum reading on the gauge will i...

Page 216: ...essure is low check for restrictions in lines and check pressure at control valve Bowl Apron or Bent piston tube or jammed cylinder Replace faulty parts Obstruction or bind on ejector Remove obstructi...

Page 217: ...amount of cylinder misalignment when travelling over rough terrain Main components of the cylinder include the piston rod 3 and piston 4 which slides within Cylinder assembly 1 Pressure oil in the tu...

Page 218: ...into the tank REMOVAL Numbers in parentheses refer to Figs 1 2 WARNING To prevent personal injury and property damage be sure wheel blocks blocking materials and lifting equipment are properly secured...

Page 219: ...able surface and remove the constituent parts as follows 4 Remove O ring 11 Seal 15 and Wear ring 7 from the Piston 4 Bowl Hydraulic System Bowl Cylinder Remove piston 4 from piston rod 3 by unscrewin...

Page 220: ...N Numbers in parentheses refer to Figs 1 2 Note Tighten all fasteners to standard torques listed in Section 300 0080 STANDARD BOLT AND NUT TORQUESPECIFICATIONS Note Tighten all hydraulic lines fitted...

Page 221: ...eering system Block all road wheels and place the battery master switch in the Off position 3 With a suitable container available to catch spillage disconnect hydraulic line from base end of cylinder...

Page 222: ...signs of damage Remove ridges nicks and scratches with a fine stone and re clean Replace any components which cannot be repaired 3 Inspect piston tube 2 for distortion cracks or other defects Replace...

Page 223: ...with bolts lockwashers and nuts Bowl Hydraulic System Ejector Cylinder 3 Remove caps from cylinder port and hose end and install new O ring on hose Install hose to cylinder inlet port 4 Lubricate mou...

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Page 225: ...several times to relieve pressure in the steering system Block all road wheels and place the battery master switch in the Off position 3 Identify and tag all hydraulic lines on one apron cylinder With...

Page 226: ...e any foreign material 2 Check cylinder body 1 bore outer diameter of piston 2 and end cap 18 for scratches cracks or other signs of damage Remove ridges nicks and scratches with a fine stone and re c...

Page 227: ...base end to bowl assembly with mounting pin Secure mounting pin with bolt and lockwasher as removed at Removal 3 Attach piston rod 3 end to apron arm with mounting pin Secure mounting pin with bolt an...

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Page 229: ...assembly 1 MAINTENANCE Numbers in parentheses refer to Fig 1 Note Tighten all fasteners to standard torques listed in Section 300 0080 STANDARD BOLT AND NUT TORQUE SPECIFICATIONS WARNING To prevent pe...

Page 230: ...and discard gasket 7 from tank 1 5 Remove wing nuts 16 from rods 15 Slide Filter element 14 assembly and gasket 18 over rods 15 and remove from tank assembly 1 Discard filter element 14 and gaskets 18...

Page 231: ...tank assembly 1 3 Install sight gauges 20 on tank assembly 1 4 With a suitable container in position remove drain plug 23 and drain hydraulic oil to below the level of suction screens 17 Reinstall dra...

Page 232: ...r Installation Note Tighten all fasteners to standard torques listed in Section 300 0080 STANDARD BOLT AND NUT TORQUE SPECIFICATIONS Note Tighten all hydraulic lines fitted with ORFS connections as de...

Page 233: ...ar 22 Gear Housing 23 Connecting Shaft 24 BearingCarrier 9 Bearings 10 Pocket Seals 11 Thrust Plates 12 Driveshaft Gear 13 Driven Gear 14 Seals 15 Gear Housing 16 Seals 1 Snap Ring 2 Spacer 3 Seal Ret...

Page 234: ...tank and drain the oil Reinstall the drain plug in the hydraulic tank and tighten securely 4 Clean pump housing and tag and disconnect inlet and outlet lines from pump Make sure pump is supported when...

Page 235: ...g 8 Ring Seals 9 Bearings 10 Pocket Seals 11 Thrust Plates 12 Driveshaft Gear 13 Driven Gear 14 Seals 15 Gear Housing 16 Seals 17 Connecting Shaft 18 BearingCarrier 19 Plug 20 Drive Gear 21 Driven Gea...

Page 236: ...ate 11 carefully if it remained with gear housing 27 5 Mark three meshed gear teeth with a dab of Prussian blue or similar dye and lift out matched gears 25 26 See Fig 9 Keep these gears together Do n...

Page 237: ...meshed gear teeth with a dab of Prussian blue or similar dye and remove matched driveshaft and gear 12 and driven gear 13 set See Fig 13 11 Pry thrust plate 11 from shaft end cover 6 carefully to avoi...

Page 238: ...fit A tight hand fit is allowable If the bearings can fall out of their bores the bores might be distorted or oversize When gears are replaced their bearings must also be replaced 9 Check driveshaft...

Page 239: ...press new bearings 9 into the bearing bores of shaft end cover 6 bearing carriers 18 24 and end cover 28 with an arbor press See Fig 22 4 For each thrust plate 11 using pocket seals 10 cut two pocket...

Page 240: ...th match marks aligned position bearing carrier 18 on gear housing 15 so that bearings 9 will receive the journals of the drive and driven gears 12 13 Tap bearing carrier 18 down tight with a soft ham...

Page 241: ...ead into shaft end cover 6 Install washers 29 and nuts 31 Tighten opposite nuts alternately until snug See Fig 33 Rotate driveshaft 12 with a 150 mm 6 in wrench and check carefully for pump binding If...

Page 242: ...be fabricated as shown in Fig 37 Refer to Section 300 0070 SERVICE TOOLS for part numbers of general service tools and adhesives required These tools and adhesives are available from your dealer SM 37...

Page 243: ...ION Numbers in parentheses refer to Fig 1 The control valve is used to direct hydraulic oil to the cylinders for raising or lowering the apron ejector or bowl depending on the position of the control...

Page 244: ...nd flows into the bowl cylinder rod ends This retracts the bowl cylinders which lowers the bowl and cutting edge into the ground Oil from the cylinder base ends returns to the valve housing return por...

Page 245: ...assembly Bowl Hydraulic System Bowl Control Valve Control Spool 1 Clean the entire control valve assembly with a suitable solvent and dry thoroughly Remove caps from valve housing 3 ports 2 If require...

Page 246: ...letters in parentheses refer to Fig 1 Note Lightly lubricate all components with hydraulic oil Refer to Section 300 0020 LUBRICATION SYSTEM for recommended oil specifications Note Tighten all fastene...

Page 247: ...g 1 Relief Valve Adjustment The relief valve incorporated in the control valve is set at the factory for a maximum oil pressure of 127 5 bar 1 850 lbf in2 Do not adjust the valve setting unless it has...

Page 248: ...ting is correct remove the pressure gauge and replace plug 67 8 Check control valve assembly and hydraulic lines for leaks Tighten as required 9 Remove all blocking from road wheels MAINTENANCE Relief...

Page 249: ...solenoid valve Fig 1 Exploded View of Accumulator 1 Charging Valve 1A Cap 1B Core 1C O Ring 1D Locknut 1E Body 1F O Ring 2 Screw 3 Lockwasher 4 Protector 5 Piston 6 Backup Rings 7 V Section Ring 8 We...

Page 250: ...rging valve locknut 1D Fig 1 by turning anticlockwise one to two turns 5 Turn T handle clockwise until charging valve core is depressed Be sure bleeder valve 10 is tight and does not leak and valves 4...

Page 251: ...Oxygen or any gas other than Nitrogen to charge an accumulator Oxygen under pressure coming into contact with oil or grease will cause a violent explosion Always double check to make sure you are usi...

Page 252: ...rd wear rings 8 backup rings 6 and V section ring 7 INSPECTION Numbers in parentheses refer to Fig 1 1 Wash metal components with a suitable solvent and thoroughly air dry 2 Inspect piston 5 for crack...

Page 253: ...operty damage 1 Position accumulator on mounting bracket with the oil inlet port downward 2 Attach clamps 2 securely with lockwashers 6 and nuts 7 3 Remove caps installed at Removal to prevent dirt en...

Page 254: ...392 21 70 27 5 400 27 80 28 1 408 32 90 28 6 415 38 100 29 2 423 43 110 29 7 431 49 120 30 435 54 130 30 5 442 WARNING This vehicle is equipped with a precharged nitrogen gas cylinder of more than 2...

Page 255: ...tween the triple pump and servo control valve Relief valve pressure setting is 17 bar 250 lbf in REMOVAL Numbers in parentheses refer to Fig 1 WARNING To prevent personal injury and property damage be...

Page 256: ...ll end foremost into seat 10 Install spring 8 and spring guide 7 2 Place the battery master switch in the Off position and block all road wheels 3 With suitable containers available to catch spillage...

Page 257: ...System Relief Valve ADJUSTMENTS Numbers in parentheses refer to Fig 1 Relief Valve Adjustment This type of relief valve is very sensitive to adjustment Relief valve setting and adjustment can be carri...

Page 258: ...sures are being maintained Limited repair of the control valve is with replacement of parts only SERVICE TOOLS There are no special tools required for the procedures outlined in this section Refer to...

Page 259: ...ring 36 Spacer 13 Lever Plate 14 MountingFlange 15 Screw 16 Wiper Seal 17 Retainer 18 Seal 19 Valve Housing 20 Seal 21 Retainer 22 Spool 23 SpringRetainer 24 Spring Fig 1 Cutaway View of Servo Control...

Page 260: ...ctuated spool type valve controlling and directing signal oil pressure supplied by the main control valve The valve spools are operated by levers connected to the spool ends Operation of control lever...

Page 261: ...om lever plate 13 Remove lever plate 13 from valve housing 19 SM 2166 1 Knob 2 Flexible Cover 3 Lever 4 Spool Actuator 5 Strap 6 Bolt 7 Washer 8 Pivot Block 9 Pin 10 Pin 11 Screw 12 Dowel Pin 25 Sprin...

Page 262: ...e Lightly lubricate all components with hydraulic oil Refer to Section 300 0020 LUBRICATION SYSTEM for recommended oil specifications Note Tighten all fasteners to standard torques listed in Section 3...

Page 263: ...ll nylon control lines to servo control valve as tagged at Removal 3 Fill hydraulic oil tank with hydraulic oil as specified in Section 300 0020 LUBRICATION SYSTEM Refer to Section 235 0040 HYDRAULIC...

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Page 265: ...NTING for detailed operating and servicing procedures Relay Emergency Valves 7 20 Speeds the application and release of air pressure to and from tractor and scraper brake chambers Refer to Section 250...

Page 266: ...r Kit 3 Front Primary Tank 4 Front Secondary Tank 5 Drain Cock 11 Quick Release Valve 12 Air Horn Solenoid 13 Air Horn 14 Manifold 15 Test Point 16 Tilt Drain valve TO GOOSENECK TO GOOSENECK TO GOOSEN...

Page 267: ...Fig 1 Air Braking System Schematic 17 Rear Primary Tank 18 Rear Secondary Tank 19 Relay Valve 20 Relay Emergency Valve 21 Brake Chamber 22 Quick Release Valve 23 Drain Cock 24 Test Point TO GOOSENECK...

Page 268: ...raking force The brakes are released when the treadle pedal is released Air pressure is exhausted through treadle valve 9 exhaust port Park Emergency Control Valve 8 Controls air pressure delivery to...

Page 269: ...plug unless you are certain all system pressure has been released 5 Never exceed recommended pressure and always wear safety glasses when working 6 Never attempt to disassemble a component until you h...

Page 270: ...ly Raised position move park emergency control lever to PARK position and move transmission gear shift selector to 1st gear 2 Depress front engine accelerator control and accelerate engine to 1 350 re...

Page 271: ...ponent as outlined in air brake control component sections Repair or replace as recommended Check brake air lines for leaks Restriction in tubing or hose line Replace tubing or hose lines Brakes do no...

Page 272: ...TENANCE MANUAL Brakes release too Defective brake chamber Repair or replace faulty component as slowly recommended in Section 250 0260 BRAKE CHAMBER Treadle valve not returning to fully Repair or repl...

Page 273: ...00 AIR DRIER Excessive oil or Air tanks not being drained often Drain all air tanks every 10 hours water in the system enough Compressor passing excessive oil Service compressor as recommended in ENGI...

Page 274: ...Courtesy of Machine Market...

Page 275: ...ery to the rear brake chamber There are 9 ports on the treadle valve as follows Port A Supply line from rear primary tank service circuit Port B Delivery to rear service brakes Port C Low pressure swi...

Page 276: ...tem which in turn moves its exhaust seat 4 closing the exhaust passage through exhaust valve 5 Continued movement of piston 3 contacts valve 5 and moves valve 5 off inlet valve seat 6 Air pressure fro...

Page 277: ...ION Numbers in parentheses refer to Fig 1 Note Tighten all fasteners to standard torques listed in Section 300 0080 STANDARD BOLT AND NUT TORQUESPECIFICATIONS 1 If removed install treadle 1 assembly o...

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Page 279: ...in a level work area apply the parking brake and shutdown the engine Operate the steering in both directions several times to relieve any pressure in the steering system 2 Block all road wheels and pl...

Page 280: ...22 and nuts 21 securing air tank tot clamp assembly 2 Using suitable lifting aid remove air tank 1 from assembly 11 Remove bolts 5 washers 6 and nuts 7 securing clamp assemblies 2 to bracket assembly...

Page 281: ...sition using bolts 13 and lockwashers 14 7 Using suitable lifting equipment position bracket assembly 3 on frame assembly and secure in place using bolts 8 and lockwashers 9 8 Using suitable lifting e...

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Page 283: ...ry ports B and D to the brake chambers Refer to Fig 3 Refer to Fig 4 As the applied pressure at A is reduced the pressure present in the brake chambers and therefore under the diaphragm 2 will be grea...

Page 284: ...the tanks to build up to correct operating pressure Check for leaks at air lines and tighten as required 10 Remove wheel blocks MAINTENANCE Inspect the quick release valve regularly for any signs of...

Page 285: ...8 Chamber 19 Cam Follower 20 Bracket Spacer 21 Nylon Cam 8 Exhaust Valve 9 Exhaust Passage 10 Valve Spring 11 Lower Half Piston 12 Annular Chamber 13 Air Transfer Hole 14 Chamber 1 Valve Body 2 Adjust...

Page 286: ...16 until exhaust passage 9 is closed and inlet exhaust valve 8 is unseated from valve seat 15 An increasing air pressure is then admitted to chamber 18 and the spring brake chambers to release the veh...

Page 287: ...ified maximum setting When testing for air leaks apply a soap solution to the exhaust port and valve housing and check for leakage No leakage is permitted from the valve housing or exhaust port when t...

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Page 289: ...4 controls the supply of air to the system by stopping and starting delivery of air by the compressor 2 when maximum and minimum system pressures are reached Orificed check valve 6 7 meters compresse...

Page 290: ...rt and water collected around unloader valve 4 flows out of exhaust port C to atmosphere Dry air from purge tank 1 flows through the purge choke 6 and desiccant 2 carrying the water molecules out of e...

Page 291: ...valves pressure setting The safety valve is set to open at a pressure of 13 bar 191 lbf in Operation Numbers in parentheses refer to Fig 1 When primary tank air pressure under valve 3 exceeds the max...

Page 292: ...alve is the problem Repairorreplaceunloader valve Leakage occurs while air compressor is unloaded A Continuous leakage Faulty check valve at air drier Replaceairdrier B Pulsating leakage Faulty unload...

Page 293: ...arking and secondary braking is effected by the park emergency brake valve which releases compressed air from the power spring chamber 11 portion of the actuator This allows the power spring 18 to exp...

Page 294: ...ure on the service brake push rod At PARK the air pressure has been fully exhausted and the vehicle brake is held on by the force of the power spring alone Refer to Fig 4 Fig 2 Normal Driving SM 2193...

Page 295: ...e that push rod remains extended Close air reservoir drain and fully charge air system Make a full service brake application by depressing treadle valve and hold about 5 seconds Push rod should retrac...

Page 296: ...push rod opening or tube end Only slight frothing is permitted at the clamp ring With spring chamber air applied any leakage at the open elbow 22 must not exceed a 25 mm 1 inch diameter soap bubble in...

Page 297: ...left hand side of the bowl and tail frame adjacent to the fuel tank The relay emergency valves speed the application and release of air pressure to and from tractor and scraper brake chambers The rela...

Page 298: ...C is sufficient to close the exhaust seat 7 When the vehicle is running the power spring in the spring brake chamber is held compressed by air pressure from the relay emergency valve and when the veh...

Page 299: ...Note location of adaptor 4 elbow 5 reducer 6 and tee piece 7 and remove from relay emergency valve 1 for use on the new valve 6 Replace all O rings and install adaptor 4 elbow 5 reducer 6 and tee pie...

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Page 301: ...K and opens the inlet at L Air now flows from the reservoir port F past the open valve chamber M and from there it passes out of one of the delivery ports This flow continues until the combined forces...

Page 302: ...5 Note location of adaptor 4 elbow 5 reducer 6 and tee piece 7 and remove from relay valve 1 for use on the new valve 6 Replace all O rings and install adaptor 4 elbow 5 reducer 6 and tee piece 7 in n...

Page 303: ...ve upward valves are unseated and air flows through delivery ports 21 22 23 and 24 Valve remains open until air pressure at port 1 drops below the predetermined setting At this point piston return spr...

Page 304: ...8 to pressure protection valve 1 ports 7 Secure pressure protection valve 1 to mounting bracket 2 using locknuts 4 and lockwashers 3 8 Install air lines and electrical connection to pressure protecti...

Page 305: ...er to Section 250 0000 AIR BRAKING SYSTEM SCHEMATIC for air lines Refer to Section 190 0000 CIRCUIT DIAGRAMS for electrical operation of the horn solenoid The air horn consists of a long projector 1 s...

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Page 307: ...n offered by the ROPS FOPS protective structure may be impaired if it has been subjected to any modification or damage Unauthorized modification will void certification Cab assembly 13 is spacious and...

Page 308: ...ny pressure in the steering system 2 Block all road wheels and place the battery master switch in the Off position 3 Disconnect the electrical cables in the following order to prevent damage to the el...

Page 309: ...nd locknuts 8 Tighten bolts 5 9 to a torque of 271 Nm 200 lbf ft 5 Remove blanking caps from all bowl hydraulic lines and connect lines as identified at removal Tighten all lines securely 6 Remove bla...

Page 310: ...ols referenced in this section and general service tools required These tools are available from your dealer 14 Ensure parking brake is applied and remove wheel blocks from all road wheels REPLACING G...

Page 311: ...p Bumpstop 15 Air Spring 16 Suspension Cover 17 Manual Valve 18 Bearing 19 Lever 20 Slide Adjuster 21 Lap Belt 22 Tether 23 Arm Rests 24 Bolt The driver seat is secured to the cab floor with bolts 24...

Page 312: ...at base 27 to seat assembly and secure using bolts 28 washers 29 lockwashers 30 and nuts 31 position to allow easier access The incorporated block out maintains the seat in position for driving A retr...

Page 313: ...tter Accumulation of dirt on the surface eventually turns into a hard gritty substance which cuts into the surface of the upholstery To clean seat cover 8 and back cover 6 use warm water and a mild so...

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Page 315: ...utch to engage and disengage drive to the compressor The V belt pulley is mounted on a bearing and is free to rotate without turning the compressor crankshaftanytimeelectricalpowerisdisconnected The c...

Page 316: ...in the sight glass on top of the receiverdrierduringthechargingprocedure A filter screen is located in the receiver drier to stop solid contaminates from leaving the unit Blockage of the filter will...

Page 317: ...nd reversealarm Removemountinghardwareandradiator guard from machine Refer to Section 100 0010 CHASSIS HOOD AND FENDERS 5 Discharge the air conditioning system as described under Discharging The Syste...

Page 318: ...kwasher 16 Nut 17 Bolt 18 Bolt 19 P Clip 20 P Clip 21 Refrigerant Hose 22 Refrigerant Hose 23 Refrigerant Hose 24 Refrigerant Hose 25 Spacer 26 Washer 27 Lockwasher 28 Screw 29 Water Valve 30 Lock 31...

Page 319: ...M 3158 1 Air Conditioning Unit 36 Blower Unit 37 Evaporator Matrix 38 Expansion Valve 39 Heater Matrix 40 Clamp 41 Hose Drain 42 Clamp 43 Duct Flexible 44 Filter Element Fig 3 Air Conditioner Lines an...

Page 320: ...t are properly secured and of adequate capacity to do the job safely 1 If removed slide air conditioner cover into position inside the cab and secure cover with mounting hardware as removed at Removal...

Page 321: ...rmostat fully open for a minimum of five minutes If the clutch is engaged in this situation there should be very few bubbles visible in the receiver drier sight glass Note Unit can operate with some b...

Page 322: ...ration Do not discharge refrigerant near an open flame 4 Ensure all hoses and hose clamps are free from contact with sharp metal moving parts or near to manifolds 5 Inspect condensation drain lines fo...

Page 323: ...efer to all WARNINGS listed under Maintenance prior to charging the system RecommendedEquipmentRequired Portable High Vacuum Charging Station HalogenLeakDetector For New Or Completely Empty System Not...

Page 324: ...een resulting from the increased engine speed open the low pressure side valve Allow the system to continue the charging procedure until the sight glass is clear If the sight glass remains clear with...

Page 325: ...t belt 2 Vibration Noise in Compressor area Vibration noise Stuck compressor or clutch Replace Vibration Overcharge Correctthecharge Air in system Evacuatesystemandre charge Compressor mounting or bel...

Page 326: ...at Correctthecharge Clutch Check pull in of clutch or replace Coolingintermittent Moisture in system Replacedrier 5 Electrical Trouble Blower motor or condenser fan Defective circuit breaker or bad Re...

Page 327: ...ivecondenserfanmotor Check electrical connections before replacingfanmotors Lowheadpressure Underchargeofrefrigerant Completecharge Badcompressorvalveplateor Repairorreplace gasket Restriction in drie...

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Page 329: ...27 Top Extension 28 Platform DESCRIPTION AND OPERATION Numbers in parentheses refer to Fig 1 The bowl 1 assembly is the portion of the scraper in which the load is carried The front of the bowl is sup...

Page 330: ...onent from the vehicle Refer to Section 160 0050 WHEEL RIM AND TYRE for tyre and wheel removal Section 160 0040 PLANETARY GEARING for axle and planetary removal and Section 165 0031 BRAKE PARTS for br...

Page 331: ...ust in the differential cavity of the banjo housing 7 With a suitable lifting device position the spindle on the banjo end plate 8 Install spindle alignment tool which can be fabricated as shown in Fi...

Page 332: ...Section 280 0010 Body Scraper Bowl andTail SM 1799 Rev 2 04 04 4 Fig 4 Spindle Alignment and Installation SM 2249 Courtesy of Machine Market...

Page 333: ...41 0 50 12 7 0 656 16 66 0 75 19 05 1 50 3 81 1 625 41 28 1 81 46 0 1 88 47 8 1 994 50 65 2 0 50 8 2 001 50 83 2 003 50 88 2 249 57 12 2 251 57 18 2 252 57 20 2 256 57 30 2 75 69 9 3 00 7 60 3 182 80...

Page 334: ...against cadmium fumes and metallic oxides The Gasfoe respirator has been approved by the U S Bureau of Mines Approval number 23B 10 and is designed to protect against gases vapours and or metal fumes...

Page 335: ...ed area The reinforcement stock thickness should not exceed that of the frame stock and the material should be of the same tensile strength Painting A check of the condition of the paint should be mad...

Page 336: ...Courtesy of Machine Market...

Page 337: ...jury and property damage be sure wheel blocks blocking materials and lifting equipment are properly secured and of adequate capacity to do the job safely 1 Position the vehicle in a level work area lo...

Page 338: ...h any spillage tag and disconnect apron hose assembly from scraper apron cylinder line Cap lines and ports to prevent entry of dirt 4 With a suitable container in position to catch any spillage tag an...

Page 339: ...pin from pull yoke Inspection Numbers in parentheses refer to Fig 1 Check lower and upper king pins 5 14 for excessive wear and replace as necessary Check king pin bores and bushing 6 and replace worn...

Page 340: ...tractor wheels Attach an overhead crane to the scraper pull yoke 2 If removed install lower king pin 8 in pull yoke Make sure the lube passage in the side of the king pin faces forward 3 Align the pu...

Page 341: ...the battery 5 Close all air reservoir drain cocks 6 Install the anti syphon plug in the hydraulic oil tank 7 Check hydraulic oil level and replenish if necessary 8 Place the battery master switch in t...

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Page 343: ...wheels and place battery master switch in the Off position 4 Disconnect apron cylinders Refer to Section 235 0035 APRON CYLINDER 5 Remove locking bolts 7 from apron mounting pin 6 and remove pin 6 fr...

Page 344: ...f the apron and bowl 5 Ensure parking brake is applied and remove wheel blocks from all road wheels REMOVAL Ejector Numbers in parentheses refer to Fig 1 WARNING To prevent personal injury and propert...

Page 345: ...ooling Any parts buckled sufficiently to show cracks or signs of strain afer cold straightening should be reinforced or replaced Welding WARNINGS Before any welding is done on a machine equipped with...

Page 346: ...nd contour as the panel placed in the hole Before welding the patch tack weld a piece of strap steel across it to provide a grip and to keep the patch in the proper position Next weld around the patch...

Page 347: ...nd of adequate capacity to do the job safely 1 Position the vehicle in a level work area lower ejector completely until it rests on ejector stops apply the parking brake and switch off the engine Oper...

Page 348: ...f it shows signs of wear INSTALLATION Numbers in parentheses refer to Fig 1 Note Tighten all fasteners to standard torques listed in Section 300 0080 STANDARD BOLT AND NUT TORQUE SPECIFICATIONS 1 If r...

Page 349: ...3 Disconnect lift rods 14 and roller 12 if used from bowl by removing bolts 5 nuts 10 and lockwashers 9 and driving out pins 13 Remove grease fitting 6 before removing pins 4 Remove bolts 5 nuts 11 an...

Page 350: ...le battery supply cable alternator earth cables alternator supply cables front rear transmission ECU connectors located behind access door below cab door and front rear engine ECU connectors located o...

Page 351: ...perly secured and of adequate capacity to do the job safely 1 Position the vehicle in a level work area apply the parking brake and switch off the engine Operate the steering in both directions severa...

Page 352: ...ents In addition the edges are reversible which prolongs the useful life of the edges The use of the proper edge arrangement for certain types of cut or soil conditions can save a great deal of money...

Page 353: ...Section 280 0050 3 SM 1726 2 99 Bowl Cutting Edges and Side Blades SM 2216 Fig 2 Various Cutting Edge Arrangements Courtesy of Machine Market...

Page 354: ...Courtesy of Machine Market...

Page 355: ...and side of the lubrication and service chart The numbered circles on the illustration contain reference numbers which correspond to the reference numbers in the Ref Points column of the lubrication a...

Page 356: ...1 Air Water Separator Drain water 1 Tyres Check condition Check pressures 2 Refer to Section 160 0050 when tyres are cold Controls and Instruments Check for proper operation General Inspection Check...

Page 357: ...r Replace 1 6 Engine Power Takeoff Drain oil and refill 1 EPL See Page 5 Engine Air Cleaner Clean inlet hood and tubes 1 200 Engine Crankcase Breather Replace element 1 7 Planetary Assemblies Drain oi...

Page 358: ...em Should a pressure stall condition occur this indicates that one or more of the connected bearing points cannot receive its measured quantity of grease The following procedure should be followed in...

Page 359: ...EVERY 150 HOURS OF OPERATION General Inspection Check entire scraper for leaks loose bolts and nuts or damaged parts Examine the scraper particularly the chassis for cracks or broken welds Repair wher...

Page 360: ...cations MIL L 2104E Continuous use of low viscosity oils can SAE Grade 15W 40 decrease engine life due to wear Transmission Hydraulic Transmission Oil Type C 4 Ambient Recommendation See Note 3 30 to...

Page 361: ...ndition Check pressures 2 Refer to Section 160 0050 when tyres are cold General Inspection Check for leaks and damaged parts Repair Replace as required 3 Ejector Lever Roller Pin Lube 1 EP NLGI See No...

Page 362: ...Engine Manual Drive Belts Check tension Adjust if required Ref Engine Manual 900 Engine Coolant Filter Replace filter conditioner element 1 1 000 2 Transmission Drain oil and refill 1 HTF 49 litres 1...

Page 363: ...the individually measured quantity of lubricant from the system for any reason the distribution will progressively cease to function until a pressure stall situation occurs This situation will be cle...

Page 364: ...machine Maintenance procedures should be carried out in conjunction with any additional procedures contained in the relevant manufacturers Operation and Maintenance Manual at the intervals specified M...

Page 365: ...um sulphur 0 5 DIN EN590 Drivelines Multipurpose Extreme Pressure Lithium Grease No 2 Consistency without Molybdenum with a typical melting point of 190 C Note For temperature conversions to degrees F...

Page 366: ...Courtesy of Machine Market...

Page 367: ...1 Ratio 3 000 Nm 2 200 lbf ft range The following items should be added to the multi gauge to enable the gauge to be used on diagnostic test points 15018226 Diagnostic Coupling 00118748 Connector 2 of...

Page 368: ...nditioning 15269814 DCA4 Test Kit Metric Version 15269815 DCA4 Test Kit US gallon Version 15269816 Refractometer C Scale 15269817 Refractometer F Scale 15269844 Portable High Vacuum Charging Station R...

Page 369: ...ENGINE AND MOUNTING SM 2169 Fig 2 Typical Fabricated Wheel Tool Section 160 0050 WHEEL RIM AND TYRE SM 372 Fig 3 Seal Retainer Removal Tool Section 235 0050 TRIPLE PUMP Machined Length 1 00 in 0 75 in...

Page 370: ...0 153 3 89 0 213 5 41 0 50 12 7 0 656 16 66 0 75 19 05 1 50 3 81 1 625 41 28 1 81 46 0 1 88 47 8 1 994 50 65 2 0 50 8 2 001 50 83 2 003 50 88 2 249 57 12 2 251 57 18 2 252 57 20 2 256 57 30 2 75 69 9...

Page 371: ...sembler and variance in fractional conditions All torque values are for lubricated threads The term lubricated includes the application of thread lubricants cadmium plating or the use of hardened wash...

Page 372: ...185 2 320 3 240 3 755 4 430 4 650 4 885 5 415 5 670 7 155 7 840 8 150 11 270 1 302 1 451 1 830 2 034 2 400 2 739 3 186 3 390 3 593 5 016 5 830 6 874 7 213 7 565 8 406 8 786 11 090 12 148 12 636 17 463...

Page 373: ...0 3 00 169 181 234 263 330 367 451 495 571 623 837 903 1 135 1 258 1 300 1 985 2 102 122 130 169 190 239 265 325 357 412 450 605 652 820 908 939 1 433 1 517 0 20 0 25 0 25 0 45 0 25 1 1 1 2 3 3 5 6 9...

Page 374: ...en achieved Any self locking fastener that can be removed with less than the prevailing torque value shown in the table should be discarded even if the fastener has not yet been reused five times MINI...

Page 375: ...ne surfaces with a good rust preventive 6 SUPPLY TANKS Fill fuel and hydraulic tanks to prevent moisture condensation within the tanks 7 TYRES Inflate all tyres to correct pressure During storage chec...

Page 376: ...ructions in Section 300 0020 LUBRICATION SYSTEM of this manual 2 BATTERIES Install batteries and check for a full charge Charge batteries as required 3 TYRES Inflate tyres to the proper pressures Refe...

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