Carrier

Original instructions
en-US 20 2022-10-20
Drill carrier TC8-TC12, NC7 series

Tier3
GUID-58A76D58-93B2-4505-A78A-D747ADB08928
Drill carrier TC8-TC12, NC7 series Tier3
WARNING
IGNORING INSTRUCTIONS HAZARD!
To avoid death or injury you MUST read, understand and follow
operator's and maintenance manuals before installing, inspecting,
operating, servicing, testing, cleaning, transporting, storing,
dismantling or disposing of the product or a part or accessory of the
product. Keep this publication for future reference.
Copyright © Sandvik Group

ID:GUID-58A76D58-93B2-4505-A78A-D747ADB08928 en-US 20 2022-10-20
This page is intentionally left blank

Table of Contents
1 Introduction.......................................................................9
1.1 The purpose of these instructions............................................................ 9
1.1.1 Validity of the manuals...................................................................... 9
2 Safety and Environmental Instructions........................ 11

2.1 Safety precautions.................................................................................... 11
2.2 Servicing safety precautions................................................................... 11
2.3 Hydraulic system safety precautions......................................................12
2.4 Lubrication safety and other precautions.............................................. 14
3 Main Components.......................................................... 15
3.1 Main components......................................................................................15
3.2 Diesel engine (MB 904 LA)....................................................................... 19
3.3 Diesel engine (MB 906 LA)....................................................................... 20
3.4 Transmission (T20000)............................................................................. 21
3.5 Transmission (HR32000).......................................................................... 21
3.6 Frame......................................................................................................... 22
3.7 Front axles................................................................................................. 22
3.8 Rear axles.................................................................................................. 23
3.9 Oscillation (rear)........................................................................................24
4 Drill carrier operation..................................................... 25

4.1 Wiggins service system for automatic refueling and lubrication
(option for TC8/NC7 carriers)...................................................................25
5 Operator's Maintenance Procedures............................ 31

5.1 Carrier........................................................................................................ 31
5.1.1 Checking the tire condition, pressure and nut tightness................. 31
5.1.2 Checking the transmission oil level................................................. 36
5.1.3 Checking the hydraulic oil level....................................................... 37
5.2 Diesel engine MB...................................................................................... 39
5.2.1 Cleaning the coarse filter.................................................................39
5.2.2 Checking the fuel level and filling the tank...................................... 39
5.2.3 Emptying the fuel water separator...................................................42
5.2.4 Checking the engine oil level...........................................................43
5.2.5 Checking the coolant level.............................................................. 44
6 Periodic Maintenance Procedures................................47

6.1 Carrier........................................................................................................ 47
6.1.1 Machine greasing points................................................................. 47
6.1.2 Checking the planetary gear oil level.............................................. 47
6.1.3 Checking the differential oil level.....................................................48
6.1.4 Checking the battery electrolyte level..............................................48
6.1.5 Checking the pressure of the brake accumulators.......................... 49
6.1.6 Releasing the pressure from the brake accumulators.....................49
6.1.7 Filling the brake accumulators.........................................................50

6.1.8 Bleeding the brakes.........................................................................51
6.1.9 Checking the steering wheel and control arm................................. 55
6.1.10 Checking the tightness of boom support bolts................................ 57
6.1.11 Replacing the transmission oil filter.................................................60
6.1.12 Changing the differential oil.............................................................61
6.1.13 Spicer axle types 37R, 43R.............................................................61
6.1.14 Spicer axle types 113, 114, 123, 213.............................................. 62
6.1.15 Checking the middle-joint bearings................................................. 63
6.1.16 Checking the oscillation axle bearings............................................ 63
6.1.17 Changing the transmission oil......................................................... 64
6.1.18 Changing the planetary gear oil...................................................... 65
6.1.19 Checking the specific gravity of the electrolyte and cleaning the
battery terminals..............................................................................66
6.1.20 Servicing the Ansul fire suppression system (optional)...................66
6.1.21 Maintenance procedures done as required.....................................67
6.1.22 Filling the gas pre-charge pressure for the brake accumulators..... 69
6.2 Diesel engine MB...................................................................................... 70
6.2.1 Replacing the engine oil and filter................................................... 70
6.2.2 Replacing the fuel filter....................................................................73
6.2.3 Replacing the fuel water separator filter..........................................74
6.2.4 Checking the condition of poly V-belt.............................................. 75
6.2.5 Checking the engine for leaks and general condition..................... 78
6.2.6 Checking the lines and hoses of the engine................................... 78
6.2.7 Checking the intake pipe between air cleaner and engine..............79
6.2.8 Checking the engine cooling system...............................................79
6.2.9 Replacing the intake air cleaner filter.............................................. 80
6.2.10 Replacing the safety cartridge of the air filter.................................. 81
6.2.11 Adjusting the valve clearances........................................................81
6.2.12 Cleaning the fuel pre-filter............................................................... 84
6.2.13 Checking the general condition of cooling and heating system...... 85
6.2.14 Renewing the coolant......................................................................86
6.2.15 Replacing the poly V-belt.................................................................87
7 Lubrication Specifications and Filling Capacities.......89

7.1 Lubrication specifications........................................................................89
7.1.1 Diesel engine...................................................................................89
7.1.2 Axles and planetary reduction oils...................................................93
7.1.3 Power shifted transmission and torque converter........................... 93
7.1.4 Hydraulic system............................................................................. 93
7.1.5 Greasing..........................................................................................94
7.2 Filling capacities....................................................................................... 94
7.3 Biodegradable hydraulic oils - change instructions............................104
7.3.1 General..........................................................................................104
7.3.2 General attention in oil maintenance.............................................104
7.3.3 Change instructions.......................................................................104
7.3.4 Stickers on the oil receiver............................................................ 104
7.3.5 Storage..........................................................................................105
8 Drill carrier troubleshooting........................................ 107

8.1 Troubleshooting guide for hydraulics...................................................107

8.2 Troubleshooting guide for the power shift transmission....................108
8.3 Troubleshooting guide for the axle........................................................111
9 Appendix....................................................................... 113
9.1 Tire weights............................................................................................. 113


1 INTRODUCTION
1.1 The purpose of these instructions
This manual contains supplementary information for operation,
maintenance and repair of a component.
These instructions must be followed along with other manuals of the rig,
any instructions given in local laws and regulations, any orders given by
local authorities, and all protective measures specific for the site.
Before operating, or performing maintenance or repair procedures for the
component or system described in this manual, read and understand the
information in operator´s and maintenance manuals supplied with the
machine. Pay special attention to the safety information in chapter Safety
and environmental instructions of those manuals.
1.1.1 Validity of the manuals
This manual, and especially the safety information, is valid only if no
unauthorized changes to the product are made.
Continuing improvement and advancement of product design might have
caused changes to your product which are not included in this publication.
Note also that if a third party has made changes to the product after
delivery from the manufacturer, this publication does not include information
on these changes or their influences on the product.
Whenever a question arises regarding your product, or this manual, please
consult your local Sandvik representative for the latest available
information.
Copyright © Sandvik Group 9 (116)

10 (116) Copyright © Sandvik Group

2 SAFETY AND ENVIRONMENTAL INSTRUCTIONS

2.1 Safety precautions
WARNING
SPECIAL SKILLS REQUIRED!
Incorrect operating, service, and adjustment procedures could cause
death or severe injuries.
Operating, service, and adjustment procedures must be carried out
only by personnel with specialized operation and service training.
Read and ensure that you understand the operating, maintenance,
and safety instructions before using or servicing the drill rig. Use
appropriate personal protective equipment, depending on the task.
WARNING! HIGH PRESSURE INJECTION HAZARD!

Compressed oil or air jets can cause severe injury.
Allow the pressure to be released from the hydraulic and pneumatic
circuits before opening any plugs or connectors.
WARNING! PERSONAL INJURY HAZARD!

Hazardous moving parts and dangerous rig movements (boom, feed,
rock drill, hatches, and gratings) could result in death or severe
injury.
Make sure there are no unauthorized persons inside the hazard zone
during drilling, tramming, setting up or servicing the rig.
Note! Take all safety factors into consideration and perform your work with
care. Follow all the safety regulations of the drilling site.
2.2 Servicing safety precautions
WARNING
CRUSHING AND ENTANGLEMENT HAZARD!
Unexpected machine movements could cause death or severe injury.
Shut down the engine and power pack(s) unless they are required to
be running for adjustment purposes.
Keep your head, hands, feet and loose clothing away from power-
driven parts.
Do not grab the steering wheel/stick or other controls when
mounting the vehicle.
WARNING! FALLING LOAD HAZARD!

Falling load could cause severe injury.
Do not work under devices that are supported by hydraulics only.
Use separate supports during maintenance and repair.

WARNING
FALLING LOAD HAZARD!
Lifting of parts with imported hoist or lifting accessories could cause
death or severe injury.
Always check the weights of the lifted parts from unit manuals.
Use proper hoist and lifting accesssories and follow the instructions.
WARNING
FIRE HAZARD!
Ignition sources like smoking, open flames, welding work and sparks
together with combustible materials, can cause fire and if not
avoided, could lead to death or severe injury.
Remove any accumulated oil, grease, and dirt from the machine
before starting any maintenance or service work.
• Inspect equipment daily for signs of failure or beginning of failure.

• Perform all recommended checks.
• Report all defects.
• Use the proper tools for service.
• Never attempt to clean, lubricate or adjust the machine while it is in
motion.
• Always comply with your company’s regulations and practices for the
safe servicing of this vehicle.
• See the manuals provided with the machine for recommended service
and maintenance procedures.
2.3 Hydraulic system safety precautions
DANGER
CRUSHING HAZARD!
Unexpected machine movement will cause death or severe injury.
Before removing the cylinders or their overcenter or non-return
valves, support the boom, feed and rock drill/top drive carefully so
that they do not move during maintenance. Do not work under
components that are supported only by hydraulics.

WARNING
HIGH-PRESSURE FLUID HAZARD!
High-pressure fluid remaining in hydraulic lines can cause death or
severe injury.
Never carry out maintenance or repair work on a pressurized system.
Relieve pressure before opening fittings, plugs or hydraulic valve
cartridges. Use a bleeder screw to relieve the pressure behind the
valves or cartridges, or wait until the unit is depressurized, before
removing the components.
WARNING
HYDRAULIC FLUID INJECTION HAZARD!
High-pressure hydraulic fluid spray can penetrate skin and could
cause death or severe injury.
Search for leaks with a piece of cardboard or wood. Never try to
locate a leak by feeling with your hand. Seek immediate medical
attention if you are hit by a hydraulic fluid spray.
WARNING
BURN HAZARD!
The oil circulating in the hydraulic systems is hot and can cause
severe burns to the skin.
Let the oil cool down before starting any maintenance work.
PROPERTY DAMAGE RISK!

Absolute cleanness must be observed when hydraulic devices are
NOTICE dismantled and assembled. Use pressurized air to blow the parts
clean, and wipe them with a clean, non-flully cloth before
reassembling.
• Do not change the pressure setting of any hydraulic valves unless

authorized instruction has been obtained.
• Clean the area around the component to be repaired before starting the
work. If possible, change the complete component.
• Ensure that all the connections will be made according to the hydraulic
diagram.
• Check the movements of the rig before use.

• Hydraulic components and hoses should be stored with all connections

well plugged. Do not remove the plugs until the components are
mounted on the rig.
• Hydraulic pumps and motors are heavy. Make sure you have suitable
lifting equipment at hand before starting the work.
2.4 Lubrication safety and other precautions
WARNING
BURN HAZARD!
Hot fluids can cause severe burns.
Let the fluids cool down before starting any maintenance work.
Let the fluids cool down before draining them.
Use appropriate personal protective equipment.
• Avoid mixing lubricants. Please use recommended oils or oils with

corresponding characteristics!
• Ensure the vehicle is level before filling tanks and sumps.
• When the oil is being changed, the engine must be warm.
• Clean carefully all lubricating fittings, breathers and oil check windows.
• When the engine is drained, clearly mark it so that it is not operated
before it is refilled. In the event of prolonged shutdown with engine or
circuits drained, provide a device preventing accidental startup without
refill.
• Analyze drained lubricant if appropriate.
• Ensure regularity of lubrication.
• The intervals given are those for normal usage. In tougher working
conditions, shorter intervals must be used.
• Read the hour meter daily and make sure that the proper lubrication
intervals are followed.

3 MAIN COMPONENTS
3.1 Main components
Carrier NC 7 -series
4 2
4
5
5 3 3
1 Diesel engine 2 Transmission

3 Axles 4 Tires and rims
5 Frame (rear and front) 6 Cardan shafts

Carrier TC 8
1
2
4
4
5 3 3


Carrier TC 9
4 1
2 5
5
3 3
2


Carrier TC 10-12
4
1
2 4
5 3 3


3.2 Diesel engine (MB 904 LA)
3
16
7
11
15
9 13
12
4
1
11
17
10
5
2
14
1 Fuel filters 2 Oil drain plug

3 Engine oil filter 4 Engine oil filling cap
5 Dipstick of engine oil level 6 Contamination indicator for
air filter
7 Pumps for steering and 8 Radiator (air, oil, water)
brakes
9 Expansion vessel (cooler) 10 Air filter (dry)
11 Poly V-belts 12 Level sensor
13 Exhaust catalyzer (option) 14 Muffler
15 Charger guard 16 Warning sign, finger cover
17 MR2 Engine control unit

3.3 Diesel engine (MB 906 LA)

8
7
10
9
3
6
1
11
5
4
1 Fuel filters 2 Oil drain plug

3 Engine oil filter 4 Engine oil filling cap
5 Dipstick of engine oil level 6 Radiator (air, oil, water)
7 Expansion vessel (cooler) 8 Poly V-belts
9 Charger guard 10 Warning sign, finger cover
11 MR2 Engine control unit

3.4 Transmission (T20000)

2 1
1 Gear pump for steering 2 Gear pump for brakes

3 Transmission oil filter 4 Dipstick of transmission oil
level / transmission oil filling
cap
5 Transmission oil drain plug
3.5 Transmission (HR32000)

3 1
5
2

1 Transmission oil filling cap 2 Transmission oil drain plug

3 Transmission oil filter 4 Checking mark of transmis-
sion oil level (FULL)
5 Checking mark of transmis-
sion oil level (LOW)
3.6 Frame
Carrier TC 8 / NC 7 -series
1 Hinge pins
3.7 Front axles
Carrier TC 8-9 / NC 7 -series (axles 113, 123)
2
1
1 Planetary gear units

2 Brakes

Carrier TC 10-12 (axle 37R / 43R)
1
2
1

2 Brakes
3.8 Rear axles
Carrier TC 8 / NC 7 -series (axles 113,123)
1
2
1

2 Brakes

Carrier TC 9-12 (axle 213)
1
2
1

2 Brakes
3.9 Oscillation (rear)
1 The rear axle oscillation allows the carrier to be turned ±10° (NC 7
- NC 7S) or ±8° (TC 8-12 / NC 7W) along the longitudinal axis.
2 The front axle is mounted rigidly to the frame.

4 DRILL CARRIER OPERATION

4.1 Wiggins service system for automatic refueling and lubrication
(option for TC8/NC7 carriers)
Filling engine fuel tank

The fast fuel system is based on the simple concept of using a sealed
vehicle tank to allow a small amount of back pressure to build and
automatically shut off the nozzle. A receiver is located near the bottom of
the tank for bottom filling which helps to eliminate foaming that occurs
during the traditional ”splash fill” method at the top of the tank.
2
1
Fast filling system
1 Nozzle
2 Fuel
The nozzle is attached to the receiver, the handle is turned to the ”ON”
position and the diesel pumping module automatically starts filling the
vehicle fuel tank at a rate of 100 G.P.M. As fuel enters the tank, it forces the
air inside the tank through the hollow stem in the vent. When the fuel level
in the tank nears the top, two hollow floating balls force the third ground ball
against an O-Ring seal and stops the flow of air from the tank. Fuel
continues to flow into the tank and pressure begins to build. At
approximately 5.5 PSI, a diaphragm operated piston inside the nozzle
starts to shut off the flow of fuel and system line pressure picks up and
brings the nozzle to the OFF-position and the diesel pumping module is

automatically shut off. The nozzle is disconnected and the next vehicle is
ready to refuel.
Filling motor, transmission and drilling oil (TC 8 carrier)
1 Crankcase oil evacuation 2 Transmission oil evacuation

and fill and fill
3 Hydraulic oil evacuation and 4 Collector piece
fill
5 Connection to Wiggins
evacuation and filling sys-
tem
Adding and changing of engine, transmission and hydraulic oils is

described in separate instructions: Wiggins Service Systems, automatic
refueling and lubrication service for construction and mining equipment.

Filling motor, transmission and drilling oil (NC 7 -series carriers)
1 Crankcase oil evacuation 2 Transmission oil evacuation

and fill and fill
3 Hydraulic oil evacuation and 4 Left distributor in front frame
fill
5 Connection to Wiggins
evacuation and filling sys-
tem
Adding and changing of engine, transmission and hydraulic oils is

described in separate instructions: Wiggins Service Systems, automatic
refueling and lubrication service for construction and mining equipment.

Hydraulic diagram, Wiggins evacuation (NC 7 -series)
EVACUATION
ENGINE OIL
ENGINE
DIESEL
8
SERIE
32000
SPICER
SERIE/
20000
CLARK
CRANCASE OIL
EVACUATION AND FILL
12
TRANSMISSION OIL
EVACUATION AND FILL
HYDRAULIC OIL
EVACUATION AND FILL
12
12
L5
LEFT
FROM PUMP OF ROTATION

PORT L1
12
F
OUT
L5
L4
L3
IN
24
L1
L2
T1 S5
PIPE 38X3
L7
L6
L8
PIPE 38X3
T2
X31
K425
M1
2.5bar

Crankcase oil evacuation
1 Connection to Wiggins evacuation and filling system


5 OPERATOR'S MAINTENANCE PROCEDURES

5.1 Carrier
5.1.1 Checking the tire condition, pressure and nut tightness
WARNING
FLYING MATERIAL HAZARD!
Failure to follow proper safety precautions could cause death or
severe injury.
Do not attempt to repair disc wheel assembly parts. Replace them
with new parts of the same size, type, and make. Ensure that all tire
and rim parts are undamaged and correctly assembled before
inflating the tires.
DANGER
TIRE EXPLOSION HAZARD!
In the event of tire explosion, the resulting power shock and ejected
tire/tool debris will cause death or severe injury.
Always use restraining devices (safety cage or similar protective
enclosure) when inflating tires.
Never stand in front of the assembly while inflating the tire. Use an
extended hose that allows you to stand to the side.
Do not exceed the tire manufacturer's recommended maximum
pressure.
Unauthorized people are not allowed in the vicinity of the wheel
during the tire is being inflated.
Always check after pressurization that the tire sits on the rim
correctly before removing the wheel from the cage.
See separate instructions in manual "Tire change and rim inspection".

Checking the tire condition

Check that the tires are undamaged and properly mounted.
When the tire damage is detected early enough, it may be possible to
repair the tire, which increases its service life, or remove the need to
replace the tire in difficult conditions.
Checking the tire pressure
RISK OF TIRE DAMAGE!

Use of lower tire pressure than presented below may lead to
NOTICE premature tire wear and possible tire damage.
Check the pressure of all air filled tires regularly. Use the correct tire
pressure specified for the machine.
Note! Checking the tire pressure does not apply to foam filled tires.
Check the pressure of the tires using a pressure gauge. Ensure that the
protective caps are reinstalled on the valve stems after pressure checks
and filling procedures have been performed.
The correct tire filling pressures are:
Carrier Front wheels Rear wheels Wheel size

DC302R
2,5 bar 2,5 bar 11.5/80 - 15.3
• DB120
NC5
10 bar 10 bar 12.00 - 20
• DL311 / DL321
NC5-17
10 bar 10 bar 12.00 - 20
• DD311 Streamline Package
NC7
• DD320S
• DD321 / DD411 / DT621 10 bar 10 bar 12.00 - 20
• DL411 / DL431
• DS421
NC7 12.00 - 20
10 bar 10 bar 14.00 - 20 (with RSH
• DS411
boom)
NC7W 8 bar 8 bar
• DD421 / DT721 10 bar (optional 10 bar (optional 14.00 - 24
with Bridgestone with Bridgestone
• DL421 tires) tires)


TC8
• DD511 / DD531
10 bar 10 bar 14.00 - 24
• DS511
• DT820 / DT821
TC10-12
• DT112x - DT123x
10 bar 10 bar 14.00 - 24
• DT112xi - DT123xi
• DT1131-JP / DT1131-SC
C300
10.5 bar 10.5 bar 12.00 - 20
• DD322i
C400 8 bar 8 bar

• DD422i 10 bar (DD422i, op- 10 bar (DD422i, op- 14.00 - 24
tional with Bridge- tional with Bridge-
• DU412i stone tires) stone tires)
C400
• DD422iE
• DL422i
• DL422iE
• DL432i 10 bar 10 bar 14.00 - 24
• DS412i
• DS412iE
• DS412i-R
• DS422i
C900
• DS512i 14.00 - 24
10 bar 10 bar 17.50 - 25 (with
• DT922i
TRH/SRH option)
• DT923i
C900 14.00 - 24 (rear)

10 bar 10 bar
• DU422i-W 17.50 - 25 (front)
C900DH
8 bar 8 bar 14.00 - 24
• DT912D


C1000
• DT1132i 10 bar 10 bar 14.00 - 24
• DT1232i
Checking the tire nut tightness
WARNING! CRUSHING HAZARD!

Loose tire nuts will cause a tire to fall off, which will result in
uncontrolled machine movements. Uncontrolled machine
movements could cause death or severe injury.
Do not use the machine unless all the nuts are in place and correctly
fastened.
Check the tightening torque of the nuts (lubricated). The tightening torques
are:

DC302R
300 Nm 300 Nm 11.5/80 - 15.3
• DB120
NC5
630 Nm 630 Nm 12.00 - 20
• DL311 / DL321
NC5-17
740 Nm 740 Nm 12.00 - 20
• DD311 Streamline Package
NC7
• DD320S
• DD321 / DD411 / DT621 740 Nm 740 Nm 12.00 - 20
• DL411 / DL431
• DS421
NC7 12.00 - 20
630 Nm 630 Nm
• DS411 14.00 - 20 (with RSH boom)
NC7W
• DD421 / DT721 740 Nm 740 Nm 14.00 - 24
• DL421
TC8
• DD511 / DD531
740 Nm 740 Nm 14.00 - 24
• DS511
• DT820 / DT821


TC10-12
• DT112x - DT123x
550 Nm 740 Nm 14.00 - 24
• DT112xi - DT123xi
• DT1131-JP / DT1131-SC
C300
630 Nm 630 Nm 12.00 - 20
• DD322i
C400
• DD422i
• DD422iE
• DL422i
• DL422iE
• DL432i 740 Nm 740 Nm 14.00 - 24
• DS412i
• DS412iE
• DS412i-R
• DS422i
• DU412i
C900
• DS512i 14.00 - 24
740 Nm 740 Nm
• DT922i 17.50 - 25 (with TRH/SRH option)
• DT923i
C900 14.00 - 24 (rear)

740 Nm 740 Nm
• DU422i-W 17.50 - 25 (front)
C900DH
740 Nm 740 Nm 14.00 - 24
• DT912D
C1000
• DT1132i 550 Nm 740 Nm 14.00 - 24
• DT1232i

5.1.2 Checking the transmission oil level
T20000
2 1
1. Let the engine idle. The oil temperature should be 80–90 °C.
2. Move the drive selector to the middle position.
3. Check the oil level from the dipstick (4). The oil level should be between
the min. and max. levels (preferably closer to the max. level).
HR32000
3 1
5
2
1. Start the engine and let it idle (at 500–600 rpm).

2. Keep the drive selector in the middle position.

3. Check the transmission oil level when the oil temperature is 82–93 °C
by loosening the minimum limit plug (5) carefully.
a. If oil flows out, close the plug (5); the oil level is sufficient.
b. If not, open the filler plug (1) and maximum limit plug (4). Add oil
until it flows out from the maximum limit opening. Close the plugs (1
and 4).
4. Turn off the engine.
5.1.3 Checking the hydraulic oil level
Note! Check the hydraulic oil level according to the periodic maintenance
instructions in the maintenance manual.
Note! Observe strict cleanliness replenishing oil. Contaminated oil is a
major cause of premature component failure.
Note! The oil level of the hydraulic oil tank should be checked when all of
the cylinders are retracted and the boom is in transportation position.
If replenishing is required, use only the same type of oil as already
contained in the system.
MAX
MIN
An indicator (H602B) on the tramming panel lights up if the hydraulic oil

level is too low.
Fill up the correct level by looking through the level glass on the side of the
tank. Do not overfill the tank. Avoid mixing oils of different make.

Auxiliary hydraulic oil receiver

Note! If the rig is equipped with the auxiliary hydraulic oil receiver (Aus-
optional), make sure that the rig is on even surface when filling the
receiver.
Auxiliary hydraulic oil receiver can be filled from outside of the system by
holding the on/off switch SH331 in position A on the rear mask. The switch
must be held in this position for the entire duration of pumping. The
indicator light comes on and the pump stops automatically when the
auxiliary hydraulic receiver is full.
Main hydraulic oil receiver can be filled by holding the switch SH330 in
position B. The pump stops automatically when the hydraulic receiver is
full.
SH330 SH331
A B A

5.2 Diesel engine MB

5.2.1 Cleaning the coarse filter
The service life of the disposable paper cartridge used in the filter depends
on the coarse filter being emptied regularly. If the coarse filter is not
emptied often enough, the cartridge becomes clogged very quickly. For this
reason, the coarse filter must never be more than half full and so must be
emptied daily. An indicator light (H5) on the gauge panel comes on if the air
filter has become clogged.
1. Empty the coarse filter by pressing the drain valve at the locations
indicated by arrows.
2. Remove any caked dirt by pressing the upper section of the drain valve
together.
5.2.2 Checking the fuel level and filling the tank

1. Read the fuel level from the fuel gauge (P2). An indicator on the gauge
(P2) lights up if the fuel level is too low.
2. Fill the tank with suitable diesel fuel each day at the end of the shift.
This prevents condensation in the tank when the drill rig is not in use.
Vehicle refueling NC7
Vehicle refueling TC8

Vehicle refueling TC11-TC12

Filling the fuel tank
Handle fuel with care: it is highly flammable.
WARNING
FIRE HAZARD!
Smoking, open flames, and sparks during refueling or handling of
the fuel tank could cause death or severe injury.
Do not refuel the machine while smoking or when near open flame or
sparks.

WARNING! FUEL SPLASHING HAZARD!

The fuel splashing into the eyes could cause severe injury.
Wear eye protectors when refueling the machine.
When filling the fuel tank, follow these instructions:

• Always stop the engine before refueling the machine.
• In addition, switch the cabin heater / air conditioning off.
• Keep the fuel gun in contact with the filling tube.
If this is not possible, arrange for the gun to be earthed in some other
way.
This eliminates possible sparks caused by static electricity.
• Ensure that no fuel is spilled onto hot surfaces.
• Never lock the nozzle lever in pumping position without looking after it.
• Wipe spilled fuel off before starting the engine.
• Prevent fires by keeping the machine clean of accumulated trash,
grease, and debris.
Note! See separate instructions if the drill rig is equipped with the
Wiggins fast fuel system.
5.2.3 Emptying the fuel water separator
An indicator light (H67) on the gauge panel comes on if too much water has
been collected in the water separator.
2
1 5
6
1. Place a receptacle under the separator.

2. Open the drain valve (1).

3. Pump the water out with the hand pump (2).

4. Close the drain valve (1).
5.2.4 Checking the engine oil level
PROPERTY DAMAGE RISK!

If the oil level is too low or too high it could damage the engine.
NOTICE Never operate the engine with oil level below the MIN mark or above
the MAX mark.
The engine must be level when checking the oil level to make sure the
measurement is correct.
MB904
MB906

1. Engage the parking brake and shut down the engine.

2. Check the oil level from the dipstick. The oil level must be between the
MIN and MAX marks.
3. If the oil level is too low, add oil through the filler opening up to the MAX
mark on the dipstick.
5.2.5 Checking the coolant level
WARNING
SPLASHING HAZARD!
Explosive release of fluids from pressurized cooling system can
cause serious burns.
Shut off engine. Only remove filler cap when cool enough to touch
with bare hands. Slowly loosen cap to first stop to relieve pressure
before removing completely. Always wear safety gloves and safety
glasses when adding coolant.
WARNING
FALLING HAZARD!
Falling could cause death or severe injury.
Be careful when climbing on the machine.
RISK OF PROPERTY DAMAGE!

Coolant added to the engine must be mixed with the correct
NOTICE proportions of antifreeze, supplemental coolant additive, and water
to avoid engine damage.
Use a mixture of 50-percent water and 50-percent ethylene glycol or

propylene glycol-base antifreeze to protect the engine to -32°C [-25°F]
year-around. Antifreeze is essential in every climate. It broadens the
operating temperature by lowering the coolant freezing point and by raising
its boiling point. The corrosion inhibitors also protect the cooling system
components from corrosion and provides longer component life.

1. Switch the engine off and allow the system to cool.
2. Check the coolant level on the expansion tank sight glasses.

The coolant level must be between the "MIN" and "MAX" marks. If the
level is below the "MIN" mark, coolant must be added.


6 PERIODIC MAINTENANCE PROCEDURES

6.1 Carrier
6.1.1 Machine greasing points
Use a grease gun with recommended grease.
WARNING! FIRE HAZARD!

Accumulated grease or oil on the carrier is a fire hazard. A fire could
Remove debris any time a significant quantity oil or grease is spilled
on the carrier.
Lubricate the propeller shaft fittings. All drive line sections are furnished
with grease nipples on universal joints and telescopic sections. Lubrication
must be done carefully to avoid damage of the seals.
Greasing points:
• Propeller shaft fittings
• Seat hinge pins
• Transmission
• Center hinge
• Support bearings
• Rear oscillation
• Cable reel hinges
• Switchgear hinges
• Steering cylinder pins
6.1.2 Checking the planetary gear oil level
1. Rotate the wheel hub so that the center point of the oil filler opening is
at the same horizontal level than the center point of the axle.
2. Remove the oil plug.
3. Check the oil level. The oil level must be at the lower level of the filler
opening.

4. Add oil if necessary. Allow the oil to settle for a few minutes. There is
enough oil when a drop of oil comes out of the opening during filling.
5. Reinstall the oil plug.
6.1.3 Checking the differential oil level
1. Set the axle and its components in a horizontal position.

2. Clean the breathers.
3. Remove the inspection/filler plugs (A) from the cover of the axle
housing.
4. Check the oil level The oil level must be at the bottom of the inspection/
filler plug (A).
5. Add oil if necessary. Allow the oil to settle for a few minutes.
6. Reinstall the inspection/filler plugs (A).
6.1.4 Checking the battery electrolyte level
1. Check the battery electrolyte level.

6.1.5 Checking the pressure of the brake accumulators
B
A
The pressure should be about 65 bar in TC 8 / NC 7 -series carriers.

The pressure should be about 80 bar in TC 9-12 carriers.
The pressure should be about 100 bar in NC 4 carrier.
Check the pressure as follows:
1. Remove the cap (A).
2. Screw the pressure gauge to the filling valve.
3. Undo the lock nut (B).
4. Wait until the needle of the gauge stops and then read the gauge
indication.
5. Close the lock nut (B).
6. Unscrew the gauge from the filling valve and fit the cap (A) in place.
6.1.6 Releasing the pressure from the brake accumulators
To release pressure from the brake accumulators, proceed as follows:
1. Shut down the engine.
2. Turn the ignition switch to the middle position.
3. Press the brake pedal several times.
4. Verify depressurized brake system from the brake pressure gauges in
the tramming panel.
Gauges should show 0 bar.
Note! The system may still be pressurized even when the brake
pressure gauges indicate 0 bar.

6.1.7 Filling the brake accumulators

The only allowable filling gas is nitrogen (N2 ).
Repair of a pressure accumulator by welding or by other means is

strictly forbidden.
Do not fill an unchecked or a too worn accumulator.
9 7 6 5 4 2 1
10 3
N2 8
If the pressure accumulators need to be filled, do as follows:

1. Release the pressure from the brake accumulators, according to the
chapter "Releasing the pressure from the brake accumulators".
2. Remove the cap (3).
3. Screw the elbow adapter (10) to the filling valve (1).
4. Push the quick coupling sleeve (5) onto the stem (4).
5. Undo the locking nut (2).
6. Turn the pressure regulating valve (8) open.
7. Open the nitrogen bottle valve (9). The gauge (7) indicates the pressure
in the bottle.
8. Adjust the pressure slowly in to 65 bar (TC 8 / NC 7) or to 80 bar (TC
9-12) by turning the regulating valve (8). Gauge (6) indicates the
pressure in the accumulator.
9. Close the filling valve (1) by turning the locking nut (2).
10. Close the nitrogen bottle valve (9).
11. Turn the pressure regulating valve (8) open.
12. Disconnect the quick couplings (4) and (5).

13. Release the elbow adapter (10) from the filling valve (1).
14. Tighten the locking nut (2) to 20 Nm.
15. Refit the cap (3).
16. After filling the pressure accumulators, check the brakes as follows:
a) Put the parking brake on.
b) Check that the drive selector is in the middle position
(neutral).
c) Start the diesel engine and let it run for at least three
minutes and that you can see the warning lights are turned
off.
d) Turn off the diesel engine.
e) Switch the power on by turning the ignition switch to the
middle position.
f) Pump the brake pedal all the way down at least five times
and make sure the brake pressure stays over 80 bars
(gauges P3 and P4).
1 2
1 Pressure gauge and indicator light of front brake circuit (P3)

2 Pressure gauge and indicator light of rear brake circuit (P4)
Note! Next time when you start the engine make sure that all the
pressure warning lights turn off.
6.1.8 Bleeding the brakes
WARNING
PERSONAL INJURY HAZARD!
Uncontrolled movement of the brakeless drill rig could cause death,
severe injury or property damage.
Park the drill rig on a level surface if possible. Lock the wheels
before bleeding the brakes.
For the trouble-free operation of the parking brakes it is important that the
hydraulic system is entirely free from air. Air may enter the system for
example in connection with component replacements or repairs and as a
result of possible oil leaks. The brake is released through hydraulic
pressure. If the system contains air, this causes the pressure to decrease
and the brake is not released properly, or it will engage after a while. For

this reason the brake circuit must be bled after every repair operation and
also at other times if malfunctions occur.
Bleeding the parking brakes

1. With the engine running and parking brake engaged off.
2. Open the hose connector (B1, inner) slightly and let oil flow out until the
air comes out.
3. Close the connector.
When necessary the above measures must be carried out several times.
After bleeding check the operation of the brakes and adjust them.
B1 B1
Bleeding the parking brakes (TC8-TC9, NC 7 -Series)

B1
Bleeding the parking brakes (TC10-TC12 front axle)
Bleeding the service brakes

If full braking effect is to be achieved, the oil in the centre gears, where the
brakes are located, must not contain any air. The brakes must be bled if air
has for some reason entered the system and the effect of the brakes has
diminished. Make sure the carrier is levelled, and that the wheels are
blocked against movement, before bleeding the brakes.
1. Install plastic tubes on the nipples.
2. Start the engine.
3. Open the nipples (B2, outer) about half a turn.
4. Press the brake pedal fully down (do not pump it).
5. Close the nipples when the oil is free of air.
Bleed the axle at the other end in the same way.

B2
B2
Bleeding the service brakes (TC8-9 / NC7-series axles, TC10-12 rear axle)

B2 B2
Bleeding the service brakes (TC10-TC12 front axle)
6.1.9 Checking the steering wheel and control arm

Check steering wheel and control arm:

• Swing the steering wheel to check there is no vertical or horizontal play

in steering wheel or control arm
• If any play is noticed;
- Check the fastening of the steering wheel
- Check the fastening of the control arm by dismounting the cover
plate (1).
• If necessary, replace worn/damaged components

6.1.10 Checking the tightness of boom support bolts

Boom support fixing bolts may break down and boom support with
booms may fall down if the bolts tightness is not regularly inspected.
Units with canopy
• Disconnect all necessary covers to get access to the bolts.

• Correct tightness of the bolt is 1100 Nm.
• If any of the bolts are missing, slackened or stretched, replace them
immediately with new ones.
• When using new bolts, lubricate the bolts and tighten them to specified
torque.
Units with cabin
Checking the front side bolts

Front side bolts can be checked with the following procedure:

• Disconnect all necessary covers to get access to the bolts.

torque.
Checking the rear side bolts (TC8-TC12)

To gain access to tighten the rear bolts properly, the cabin must lift up for
200-350 mm according to following instructions:
• Support the unit to the ground with the jacks.
• With help of crane, support the cabin from the lifting points
• Untighten the rear (2) and front (2) cabin mounting bolts M16x110.
• Disconnect all necessary cables and hoses in order to lift the cabin for
250-350 mm.
- Especially in electrically controlled jumbos disconnect the cable for
the diesel engine.
- Especially in hydraulically controlled jumbos disconnect the cable for
the diesel engine and the boom and drilling hoses from the THC.
• Lift the cabin for 250-350 mm up in order to get access to rear side bolts
torque.
• After replacing and tightening the bolts, reconnect all the cables and
hoses.
• Lower the cabin and refit the bolts and tighten them with correct
tightness.

Checking the rear side bolts (NC7)

To gain access to tighten the rear bolts properly, there is no need to lift the
cabin
• Tighten the bolts via the service hatch.

torque.

6.1.11 Replacing the transmission oil filter

Extreme high temperature conditions, extended periods of high
temperature, or difficult climatic conditions will accelerate deterioration and
contamination of the oil.
The normal filter replacement frequency is intended for average
environmental and operational conditions. In extreme conditions, assess
and alter the maintenance frequency according to the conditions.
2 1
T20000
3 1
5
2
HR32000
Replace the filter as follows:

1. Turn off the engine.

2. Open the filter (3) by turning it.
3. Clean the filter housing.
4. Lubricate the rubber seal and install a new filter.
5. Tighten the filter to 2.8–3.4 kpm.
6.1.12 Changing the differential oil
Change the oil while it is warm.

1. Clean the area around the inspection/filler plugs (A) and remove the
plugs.
2. Place a receptacle under the drain plugs (B).
3. Remove the drain plugs (B) of the front and rear axle differentials.
4. Let the oil flow into the receptacles.
5. Reinstall the drain plugs (B).
6. Fill the differentials with the recommended oil through the inspection/
filler plugs (A) until the oil level is at the bottom of the inspection/filler
plug (A).
7. Reinstall the inspection/filler plugs (A).
6.1.13 Spicer axle types 37R, 43R
WARNING
RUN OVER HAZARD!
Uncontrolled machine movement during brake disc wear check
could cause death, severe injury or property damage.
Always exercise extreme caution when going under the drill rig.
Apply parking brake and use wheel wedges to prevent the drill rig
movement. Make sure the drill rig can not be started unexpectedly.

Make sure the drill rig is on a steady and level surface. Apply the parking
brake and wheel wedges on place.
This check is recommended to be carried out when the oil in the centre
gear is to be changed and must be carried out for both sides of the axle.
1. Remove the plug from side of the trumpet arm, next to the center
section. The brake discs can be seen through the hole.
2. While parking brake applied, check the clearance between the reaction
plates.
3. If the clearance between the reaction plate ears is less than 4,5mm
(0.177 in), replace the friction plates and reaction plates on the both
sides of the axle.
Checking the brake discs for wear (Spicer axle types 37R, 43R)
Brake test is always performed before tramming. If the brakes do not hold
during the test and the brake pressures are correct, it is likely that the brake
discs have been worn. Replace the brake discs and intermediate discs on
the both sides of the axle.
6.1.14 Spicer axle types 113, 114, 123, 213
WARNING
RUN OVER HAZARD!
Uncontrolled machine movement during brake disc wear check
could cause death, severe injury or property damage.
Always exercise extreme caution when going under the drill rig.
Apply parking brake and use wheel wedges to prevent the machine
movement. Make sure the machine can not be started unexpectedly.
Make sure the drill rig is on a steady and level surface. Apply the parking
brake and wheel wedges on place.
This check is recommended to be carried out when the oil in the center
gear is to be changed and must be carried out for both sides of the axle.

1. Remove the inspection plug from side of the trumpet arm, next to the
center section. The brake discs can be seen through the hole.
2. While parking brake applied, check the clearance between the reaction
plates with feeler gauge.
3. If the clearance between the reaction plate is less than 5.2 mm (0.205
in), replace the friction plates and reaction plates on the both sides of
the axle.
4. Install the inspection plug and tighten to correct tightening torque.
Brake test shall always be performed before tramming. If the brakes do not
hold during the test and the brake pressures are correct, it is likely that the
brake discs have been worn. Replace the brake discs and intermediate
discs on the both sides of the axle.
6.1.15 Checking the middle-joint bearings
Turn the steering back and forth with small movements to check the middle-
joint bearings. Check the play that may have developed in the middle-joint
bearings. If there is any play, replace the bearings.
6.1.16 Checking the oscillation axle bearings
Rear-axle oscillation allows the carrier to turn in the longitudinal direction of
the axle.
Lift the rear axle off the ground and, using small movements, check the play
that may have developed in the oscillation bearings. If there is any play,
replace the bearings.

6.1.17 Changing the transmission oil

Extreme high temperature conditions, extended periods of high
temperature or difficult climatic conditions will accelerate deterioration and
contamination of the oil.
Normal oil replacement frequency is intended for average environmental
and operational conditions. In extreme conditions, assess and alter the
maintenance frequency with consideration of the conditions.
T20000
2 1
1. Drain the oil from the transmission through the drain plug (5) when the
oil is warm.
2. Fill the transmission with fresh oil up to the upper mark on the dipstick
(4).
3. Start the engine and let it idle (at 500–600 rpm).
4. Check the oil level when the engine is running and add oil up to the
lower mark on the dipstick.
5. When the oil temperature is 82.2–93.3 °C, check the oil level and add
oil up to the upper mark on the dipstick.

HR32000
3 1
5
2
1. Open the drain plug (2) and drain the oil from the transmission when the
oil is warm.
2. When oil has been drained, close the drain plug (2).
3. Open the filler plug (1).
4. Refill transmission to LOW mark (5). Pour fresh oil into the torque
converter through filling hole (1). Refer to table of oil recommendation
for appropriate oil type and quantity.
5. Run engine at 500...600 rpm to prime converter and lines.
6. Recheck level with engine running at 500...600 rpm and add oil to bring
level to LOW mark (5). When oil temperature is hot (82.2 ... 93.3 °C)
make final oil level check. Bring oil level to FULL mark (4).
6.1.18 Changing the planetary gear oil
Change the oil while it is warm.

1. Rotate the wheel hubs so that the oil plug points down.
2. Place a receptacle under the oil plug.
3. Remove the oil plug.
4. Let the oil flow into the receptacle.
5. Rotate the wheel hub so that the center point of the oil filler opening is
in the same horizontal level than the center point of the axle.

6. Fill the planetary gear with recommended oil. Allow the oil to settle for a
few minutes. There is enough oil when a drop of oil comes out of the
opening during filling.
7. Reinstall the oil plug
6.1.19 Checking the specific gravity of the electrolyte and cleaning the battery terminals
1. Check the specific gravity of the electrolyte and clean the battery
terminals.
6.1.20 Servicing the Ansul fire suppression system (optional)

Service shall be performed every 1000 hours or every 6 months (whichever
comes first).
Refer to manufacturer's instructions.

6.1.21 Maintenance procedures done as required
A B C D E F
SERVICE SERVICE PARKING PARKING CHARGING OF CLUTCH
BRAKE BRAKE BRAKE BRAKE ACCUMULATORS

FRONT REAR FRONT REAR
70 bar 70 bar 100 bar 30 bar 135-160 bar 17-19 bar

NC7, TC8

Measuring point assembly (284)
Checking the service brake pressure

Follow these steps:
1. Attach a pressure gauge to the front brake circuit's pressure inspection
point (A).
3. Press the service brake pedal to the end of its movement path.
4. The pressure should be 70 bar (TC9-12) / 80 bar (TC8, NC7).
5. Repeat the same measurement for the rear brake circuit by attaching a
pressure gauge to the rear brake circuit 's pressure inspection point (B).
Checking the front axle's parking brake pressure

Follow these steps:
1. Attach a pressure gauge to the front axle's parking brake pressure
inspection point (C).

3. Release the parking brake.

4. The release pressure should be 100 bar (TC10-12) / 30 bar (TC8–9,
NC7).
Checking the rear axle's parking brake pressure

Follow these steps:
1. Attach a pressure gauge to the rear axle's parking brake pressure
inspection point (D).
3. Release the parking brake.
4. The release pressure should be 30 bar.
Checking the charging oil pressure of the service brake accumulators

Follow these steps:
1. Attach a pressure gauge to the pressure accumulator's pressure
inspection point (E).
3. The pressure should rise quickly to 135-160 bar.
Checking the steering pressure

The pressure must be checked when the oil is at operating temperature
and the engine is running at full speed.
1. Connect the manometer to the checking point (A).

2. Turn the machine to the full turning angle against the end stops.
3. The maximum allowed pressure is 140 bar.
4. If the desired pressure differs from the given value, adjust it by turning
the adjustment screw (B, 263.01) to the desired direction.

6.1.22 Filling the gas pre-charge pressure for the brake accumulators
WARNING
EXPLOSION HAZARD!
An accumulator filled with wrong type of gas could explode and
Use only nitrogen (N2) to fill a pressure accumulator.
WARNING
RISK OF EXPLOSION!
A pressure accumulator repaired in a faulty manner can explode and
could cause death or severe injury.
Repairing a pressure accumulator by welding or in any other faulty
manner is strictly prohibited. Replace a faulty pressure accumulator
with a new one.
WARNING
HIGH PRESSURE HAZARD!
Breakage of the accumulator when filling a damaged or worn
accumulator could cause death or severe injury.
Do not fill an unchecked or too worn accumulator.
9 7 6 5 4 2 1
10 3
N2 8
1 Filling valve 2 Locking nut

3 Cap 4 Quick coupling stem
5 Quick coupling sleeve 6 Accumulator pressure
gauge
7 Gas bottle pressure gauge 8 Pressure regulating valve
9 Shut-off valve 10 Elbow adapter

If the pressure accumulators need to be filled with gas pre-charge

pressure, do the following:
1. Release the oil pressure from the brake accumulators, according to
instructions in section Releasing the oil pressure from the brake
accumulators.
2. Remove the cap (3).
3. Install the elbow adapter (10) to the filling valve (1).
4. Push the quick coupling sleeve (5) onto the stem (4).
5. Open the locking nut (2).
6. Turn the knob (8) to open the pressure regulating valve.
7. Turn the knob (9) to open the nitrogen bottle shut-off valve. The gauge
(7) indicates the pressure in the bottle.
8. Turn the knob (8) to adjust the regulating valve pressure slowly to 65
bar. Gauge (6) indicates the pressure in the accumulator.
9. Close the locking nut (2).
10. Turn the knob (9) to close the nitrogen bottle shut-off valve.
11. Turn the knob (8) to open the pressure regulating valve.
12. Disconnect the quick coupling stem (4) and sleeve (5).
13. Remove the elbow adapter (10) from the filling valve (1).
14. Tighten the locking nut (2) to torque 20 Nm.
15. Reinstall the cap (3).
16. After filling the pressure accumulators, check the brakes:
a) Engage the parking brake.
b) Select neutral gear.
c) Start the diesel engine and let it run for at least three
minutes.
d) Shut down engine.
e) Press the brake pedal all the way down at least five times
and make sure the brake pressure stays over 65 bar (check
front/rear charge pressure values from tramming display).
6.2 Diesel engine MB

6.2.1 Replacing the engine oil and filter
Note! Change the engine oil while the engine is warm.
WARNING! BURN HAZARD!

Hot oil could cause burns.
Let the engine cool down before starting any maintenance work.
Always use approved safety gloves when changing the engine oil.

Special tool: oil filter opener

Open the oil filter cover with the
oil filter opener. Empty the filter
housing of oil.
Remove the cover (1) and the oil

filter element and click the filter
element (3) off by pressing the
bottom edge to the side.
Ensure that no foreign objects
can enter the filter housing. Nev-
er wipe the filter housing clean.

Siphoning/draining engine oil
Suction the engine oil off

through the dipstick tube.
Remove the dipstick (ar-
row) and push the suction
device (cup) with the O-
ring seal to the dipstick
tube.
Alternative method:
Place a suitable recepta-
cle under the oil drain
plug in the oil pan. Open
the drain plug carefully,
and let the oil flow out.
Dispose of the engine oil and filter in accordance with the applicable regu-
lations.
Replace the cover seal

(2).
Place a new filter element
to the cover and press
the filter until it clicks into
place.
Screw the cover to the oil
filter housing and tighten
the cover to the correct
tightness. The tightening
torque is 25 Nm.
If the engine oil is drained through the oil pan, replace the drain plug with
a new seal and tighten the plug to the correct tightness. The tightening tor-
que is 80 Nm.

Add new engine oil

through the filler opening
neck (arrow) until the oil
level is in the level of the
max mark in the dipstick.
Start the engine so that the throttle pedal is in the idling position and pay
attention to the oil pressure gauge
Let the engine idle until the engine oil pressure rises to the correct level. If
the engine oil pressure does not rise to the correct level in about 10 sec-
onds, switch the engine off and determine the cause of the fault.
Check the filter and oil drain plug for leaks.
Shut down the engine. Check the oil level again in about 5 minutes. Add
oil to the max mark in the dipstick as necessary.
6.2.2 Replacing the fuel filter
1. Unscrew the cap (1) together with the filter element (3) and pull a short
distance out of the filter casing (5). Allow the fuel to drain off.
2. Remove the cap with the filter element. Unclip the filter element (3) by
pressing the lower edge of the filter element to the side.
3. Pull the dirt collector (4) from the filter casing by the tags.
Dirt and water must not be allowed to get into the filter casing. Do not
empty the dirt collector into the filter casing.
4. Clean the cap (1).
5. Clean any dirt from the collector (4).
6. Renew the sealing ring (2).
7. Clip the new filter element into place in the cap.

8. Oil the sealing ring and filter element seals lightly.

9. Insert the dirt collector into the filter casing, ensuring the correct
installation position.
10. Screw the cap with the filter element and tighten. Tightening torque 25
Nm.
6.2.3 Replacing the fuel water separator filter
5
1
1. Place a receptacle under the separator.

2. Open the drain valve (1) and bleeder screw (3) and drain the filter
cartridge (4).
3. Remove the filter cartridge (4) and separation container (5) from the
filter head.
4. Remove the separation container (5) from the filter cartridge (4).
5. Clean the seal ring groove on the separation container (5).
Note! The separation container is reusable, so do not damage it.
Note! Dispose of the old filter cartridge in accordance with
environmental regulations. Do not dispose of it as household
waste.
6. Lubricate a new seal ring with clean diesel or engine oil and install it on
the groove on the separation container (5).
7. Install the separation container (5) firmly on the new filter cartridge (4)
by twisting it into place.
Note! Do not use tools.
8. Lubricate a new seal ring with clean diesel or engine oil and install it on
the groove on the filter cartridge (4).
9. Install the filter cartridge (4) firmly on the new filter head by twisting it
into place.
Note! Do not use tools.

10. Close the drain valve (1).

11. Fill the filter with the hand pump (2).
12. Continue pumping until the fuel coming out of the bleeder screw (3) is
free of air bubbles.
13. Tighten the bleeder screw (3).
14. Check for leaks.
Note! Make sure that the drain hose (6) is not close to the hot exhaust pipe.
6.2.4 Checking the condition of poly V-belt
Special tool (turning tool) required.
Inspection hole, flywheel housing
1. Fit the turning tool to the inspection hole in the flywheel housing.
2. Make a mark on the poly V-belt with chalk.
3. Check the poly V-belt section for signs of damage. To do this, turn the
engine or poly V-belt gradually on until the chalk mark is reached again.
The poly V-belt must be renewed if any of the damage patterns listed
appear.
4. Remove the turning tool again.

Damage patterns
1 Condition as new (trapezoi- 2 Wear on one side (wedge-

dal ribs) shaped ribs)
3 Cord visible in base of ribs 4 Ribs split
5 Transverse cracks in sever- 6 Nodules of rubber in base of
al ribs belt
7 Deposits of dirt/stones 8 Rips separated from base of
belt
9 Cord torn out to the side 10 Outer cords frayed
11 Transverse cracks on the 12 Transverse cracks in sever-
reverse of belt al ribs
Removing/installing poly V-belt
ENTANGLEMENT HAZARD!
The tensioning mechanism is springloaded and could cause severe
injury.
Use proper service tools and be careful.

Removing/installing poly-V-belt
1. Plug the spanner (2) with a 17 mm socket insert onto the hexagonal bolt
on the tensioner pulley (1).
2. Turn the tensioner pulley upwards and remove the poly-V-belt.
3. Turn the tensioning mechanism back.
4. Check the tensioning mechanism and pulleys for damage (e.g. worn
bearing on tensioning mechanism, tensioner and deflector pulleys, or
pattern wear on poly-V-belt pulleys). If necessary, renew parts.
5. Lay the poly-V-belt (new) on all the pulleys except for the tensioner
pulley (see illustrations for correct routing of the poly-V-belt).
6. Turn the idler pulley upward with the handle, place the poly-V-belt onto
the idler pulley and turn the idler pulley downward.
7. Remove the handle and check that the poly-V-belt is seated correctly on
the pulleys.
Routing of poly-V-belt (engine without refrigerant compressor)
1 Crankshaft
2 Generator
3 Coolant pump
4 Tensioner pulley

Routing of poly-V-belt (engine with refrigerant compressor)
1 Crankshaft
2 Generator
3 Coolant pump
4 Tensioner pulley
5 Refrigerant compressor
6 Deflector and guide pulley
guard for alternator
When installing the body V-belt, make sure that the guard for alternator is
installed back on its place.
6.2.5 Checking the engine for leaks and general condition
Check the engine visually for signs of leakage. Slight dampness at sealing
points is acceptable.
Cause for more severe leaks must be identified and repaired without delay.
6.2.6 Checking the lines and hoses of the engine
1. Check for leaks and general condition.

2. Visually inspect lines and hoses. At the same time, check that all pipes
and hoses are undamaged, correctly positioned to avoid abrasion, and
properly secured.

6.2.7 Checking the intake pipe between air cleaner and engine
1. Check that rubber boots, intake pipes and connecting hoses are
undamaged and free from leaks.
2. Check tightness of hose clips, flange connections and the intake
manifold.
6.2.8 Checking the engine cooling system

Check fluid level and corrosion inhibitor/antifreeze concentration, and
correct if necessary.
Only use service products approved by engine manufacturer.
WARNING
BURN HAZARD!
Hot and pressurized coolant can cause serious burns.
Never open the cap of the engine cooling system if the coolant is at
normal operating temperature. Only check and correct coolant level
when the coolant temperature is below 50 °C. Remove cap slowly.
Use safety gloves.
Before correcting the coolant level, check the corrosion inhibitor/antifreeze

concentration. When topping up, use only a pre-prepared coolant mixture
containing 50% corrosion inhibitor/antifreeze by volume.
1. Open the cap of the engine cooling system slowly to allow excess
pressure to escape.
2. Check the concentration of corrosion inhibitor/antifreeze with a suitable
tester. The correct concentration of corrosion inhibitor/antifreeze, that is
50% by volume, protects the system down to a temperature of -37 °C. If
a lower level of antifreeze protection is shown, correct the
concentration. If the concentration is too low, there is a risk of corrosion/
cavitation in the cooling system. Concentrations of more than 55% by
volume should not be used, as this is the level which affords maximum
antifreeze protection (down to -45 °C), when higher concentrations
adversely affect heat dissipation.
3. Check the coolant level. The cooling system is correctly filled when the
coolant has reached the mark in the filler neck.

6.2.9 Replacing the intake air cleaner filter
3 4 1
1. Undo clip fasteners (1).

2. Take off hood (2) and remove cartridge (3).
3. Clean cartridge (replace at least once a year).
4. Clean cartridge (3).
a) Using dry compressed air (max. 5 bar), blow out from inside
outwards, or
b) Tap out (in emergencies only). Do not damage the cartridge,
or
c) Wash out according to manufacturer’s specifications
5. Check paper filter (light showing through) and gaskets for damage.
Replace if necessary.
6. After five filter services or after two year at the latest, replace safety
cartridge (4) (never clean!).
7. Install cartridge (3), replace hood (2) and do up clip fasteners (1).

6.2.10 Replacing the safety cartridge of the air filter
3 4 1
1. Undo clip fasteners (1).

2. Take off hood (2) and remove cartridge (3).
3. Replace safety cartridge (4).
4. Install cartridge (3), replace hood (2) and do up clip fasteners (1).
6.2.11 Adjusting the valve clearances
Layout of cylinders and valves
Valve clearance adjustment
WHITE ARROW = Inlet valve

BLACK ARROW = Exhaust valve
X = Flywheel end
Special tool (turning tool) required.

Valve clearance
Inlet valves = 0,40 mm
Exhaust valves = 0,60 mm
Note! Adjust the valve clearance when the engine is cold (at least 30
minutes after it was switched off, even if it was only run for a short
time). Clean a heavily soiled cylinder head cover before removing it.
Removing/installing cylinder head cover
Removing/installing cylinder head cover
1. Remove the cover.

2. Remove the crankcase breather hose (6) from the cylinder head cover.
3. Unscrew the hexagon socket-headed bolt (2) from the cylinder head
cover, together with its sealing washer (3). To install: Insert the hexagon
socket-headed bolt with a new sealing washer and tighten with a
tightening torque of 30 Nm.
4. Remove cylinder head cover.
To install: Clean the sealing surfaces of the cylinder head and the cylinder
head cover as necessary. Check the gasket between the cylinder head
cover and the charge air manifold (1). Renew as necessary. The gasket (5)
between the cover and the cylinder head must always be renewed.
The cylinder head cover is installed in reverse order.
Fit the turning tool into the inspection hole on the flywheel housing.
Valve clearance adjustment - method 1

Adjust each cylinder in the order in which fuel is injected.

• Use the turning tool to turn the crankshaft until the piston of the cylinder
at which the valve clearancea are to be set is exactly at the top dead
centre of the compression stroke. The valves must be closed and it
must be possible to turn the pushrods without effort. This position has
been reached when the valves of the cylinder in which the piston has
reached the same position overlap (see table).
Engine
OM 904 LA Injection sequence 1 3 4 2
OM 904 LA Overlap 4 2 1 3
OM 906 LA Injection sequence 1 5 3 6 2 4
OM 906 LA Overlap 6 2 4 1 5 3
Inspection hole, flywheel housing
Valve clearance adjustment - method 2

All valves can be adjusted in two crankshaft positions.
• Use the turning tool to turn the crankshaft until No. 1 cylinder is at the
ignition TDC position or at the overlap TDC position (at ignition TDC, all
valves are closed and the valves of No. 4 cylinder overlap).
• Check and adjust valves in accordance with the following table.
Crankshaft position Cylinders/valves to be adjust-

Engine
No. 1 cylinder ed
1 2 3 4 5 6
OM 904 LA Ignition TDC I/E I E -
OM 904 LA Overlap TDC - E I I/E
OM 906 LA Ignition TDC I/E I E I E -
OM 906 LA Overlap TDC - E I E I I/E
I - Inlet valve
E - Exhaust valve

Checking/adjusting valve clearance
Peephole, flywheel housing
1. Measure the valve clearance with a feeler gauge between the rocker
arm and valve stem (exhaust valve) or valve bridge (inlet valve)
(arrows). It should be possible to pull the feeler gauge through with no
more than light resistance.
2. To adjust the valve clearance, unscrew the locknut (2). Set the correct
valve clearance by turning the adjusting screw (1).
3. Retighten the locknut to a tightening torque of 25 Nm.
4. Check the valve clearance again and readjust if necessary.
Concluding operations
1. Reinstall cylinder head cover.
2. Remove the turning tool from the inspection hole in the flywheel
housing.
6.2.12 Cleaning the fuel pre-filter
1. Clean the outside of the fuel pre-filter and cover over any hoses or
pipes located beneath it.
2. Unscrew the filter bowl (1).

3. Clean the filter bowl (1) and filter element (2). Note! If the filter element
is heavily soiled or damaged, it should be renewed. Dispose of the used
filter and of residual fuel in accordance with applicable rules and
regulations.
4. Check the seal (3) for the filter casing and renew if necessary.
5. Insert the filter element (2) into the filter bowl (1) and screw the filter
bowl onto the filter casing with a tightening torque of 10 Nm.
6.2.13 Checking the general condition of cooling and heating system

Check the general condition and look for possible leaks.
Special tool (pressure tester) required.
Note! The fluid level and corrosion inhibitor/antifreeze concentration
(correcting if necessary) must be checked first.
Note! A safety valve is incorporated into the tester to prevent the pressure
from exceeding 1,2 bar.
Compressed air valve
1. On heating systems, open the regulating and cut-off valves.

2. Remove the cap from the coolant expansion tank.
3. Connect up the tester.
4. Connect the compressed air hose with the tyre inflation union to the
valve and allow pressure to build up to a level corresponding to the
opening pressure of the cooling system. The opening pressure of the
cooling system can be identified from the code on the cap or on the
pressure relief valve. Example: Code 70 = 0.7 bar gauge pressure.
5. Check all radiators, the coolant pump, the engine oil cooler, the engine
covers (corehole covers) and the heat exchanger for leaks.
6. Check all pipes and hoses for the cooling and heating system for
freedom from leaks and damage, correct positioning to avoid abrasion
and secure fastening in the specified manner.
7. Check the radiator for external contamination. The fins must not be
clogged with dirt.

8. Relieve pressure in the cooling and heating system at the valve on the
tester. Remove and re-attach the cap.
9. Close the heating system regulating valves.
6.2.14 Renewing the coolant
Only use a corrosion inhibitor/antifreeze approved by Mercedes-Benz.
WARNING
BURN HAZARD!
Hot and pressurized coolant could cause serious burns.
Never open the cap of the engine cooling system if the coolant is at
normal operating temperature. Only check and correct coolant level
when the coolant temperature is below 50 °C. Remove cap slowly.
Use safety gloves.
Note! Before renewing the coolant, check that the cooling and heating
system is in good condition and free from leaks. Confirm the coolant
renewal with an entry in the Maintenance Booklet.
Note! There are other drain plugs, for example on the radiator. Pipes etc.
below the drain plugs should first be covered over and a receptacle
suitable for the quantity of coolant should be placed underneath.
Coolant drain plug
1. Open the cap of the engine’s cooling system slowly to allow excess
pressure to escape and remove the cap.
2. On heating systems: Open the heating system regulating valves.
3. To drain the coolant from the engine, attach the hose (interior diameter
approx. 12,5 mm) to the drain plug on the engine. The coolant will drain
off after the plug has been turned through 1 to 2 turns.
Dispose of the used coolant in accordance with applicable legal
stipulations.
4. Free drain apertures if blocked by deposits.

5. Screw in the coolant drain plug on the engine tight again and remove
the drain hose.
6. Screw in other drain plugs (without hose connection) with new seals.
7. Add coolant in the specified concentration until the mark in the filler
neck is reached. Seal the cooling system again.
8. Start the engine and run it for about 1 minute at varying speeds.
9. Stop the engine and check the coolant level. Top up if necessary.
6.2.15 Replacing the poly V-belt
Replace the poly V-belt. Refer to section Checking the condition of poly V-
belt.


7 LUBRICATION SPECIFICATIONS AND FILLING

CAPACITIES
7.1 Lubrication specifications
WARNING! HEALTH AND ENVIRONMENTAL HAZARD!
Skin contact and inhalation of vapors when handling fluids could
cause damage to human health.
Incorrect disposal of fluids and greases could cause damage to the
environment.
Use personal protective equipment when handling fluids and
greases, and dispose of all fluids and greases in accordance with
local regulations.
Precautions
• Avoid mixing lubricants. Please use oils recommended or oils with
corresponding characteristics!
• Ensure the vehicle is level before filling tanks and sumps.
• Oil should only be changed with the engine hot.
• Clean carefully all lubricating fittings, breathers and oil check windows.
• When the engine is drained, clearly mark it so that it is not operated
before it is refilled. In the event of prolonged shutdown with engine or
circuits drained, provide a device preventing accidental start-up without
refill.
• Analyse drained lubricant if appropriate.
• Ensure regularity of lubrication.
• The intervals given are those for normal usage. For tougher working
conditions, the person responsible must set down other intervals.
• Ensure daily reading of hour meter. This operation determines when
lubrication is due.
7.1.1 Diesel engine
WARNING! POISONING HAZARD!

Risk of severe injury or death.
Consult a doctor immediately if any service product is swallowed.
Keep service products out of the reach of children.
Components of the engine and the lubricants must be carefully matched

together. For this reason, only brands which have been tested and
approved by Mercedes-Benz should be used. These are stated in the
Mercedes-Benz Specifications for Service Products.
No special lubricant additives are needed. The use of additives could affect
warranty rights.
Information is available from any Mercedes-Benz Service Station.

Dispose of service products and parts which have been in contact with
lubricants (e.g. filters) in an environmentally responsible manner. Comply
with legal requirements.
Diesel fuels
Only use commercially available vehicle diesel fuel (DIN EN590). Grades
such as marine diesel fuel, heating oil etc are not permissible.
No fuel additives are needed. The use of fuel additives could affect
warranty rights.
If diesel fuel with a sulphur content exceeding 0.3% by weight is used,
change the engine oil at shorter intervals. Comply with the instructions in
the Maintenance Booklet.
Note! If the Telligent maintenance system is used, the sulphur content of the
diesel must be entered in the system or adapted to the current value.
Fuel added from drums or cans could be contaminated. This could lead to
malfunctions in the fuel system. Always filter the fuel before adding it to the
tank.
Diesel fuel in extreme cold

At low ambient temperatures, paraffin may separate from the diesel and
affect its ability to flow freely.
To avoid breakdowns caused by this problem (e.g. blocked filters), diesel
fuel with improved low-temperature flow characteristics is sold during the
winter months. Differences are possible in different countries and in the
transitional periods before and after the cold season. In Germany,
particularly cold-resistant winter diesel fuels keep the engine operational
down to a temperature of approximately -20 °C. In most cases, winter-
grade diesel can be used without problems at the ambient temperatures
encountered locally.
If summer-grade diesel, or a less cold-resistant winter-grade diesel is in
use, a flow improver or kerosene can be added to it, the actual quantity
being dependent on the ambient temperature.
Do not add petrol (gasoline) to the diesel.
Mix the flow improver or kerosene with the diesel in good time, before the
fuel’s flow characteristics have been adversely affected by paraffin
separation. If faults have already been caused by paraffin separation, they
can only be rectified by heating the entire fuel system. Do not add anything
to cold-resistant winter-grade diesel fuels. The fuel’s low-temperature flow
characteristics could actually deteriorate with such an additive.
Flow improver
The effectiveness of flow improver is not guaranteed with all fuels. Comply
with the product manufacturer’s recommendations. Any Mercedes-Benz
Service Station can provide information on approved flow improver.

Kerosene
Keep the quantity added as low as possible, bearing in mind the ambient
temperature. The addition of 5 % by volume of kerosene will improve the
fuel’s resistance to cold by about 1°C. Never add more than 50 % kerosene
to the fuel.
For reasons of safety, add the kerosene to the diesel only in the fuel tank.
Add the kerosene first, then the diesel. Run the engine for a short time to
allow the mixture to reach all parts of the fuel system.
FIRE AND EXPLOSION HAZARD!

Diesel fuel is combustible and could cause severe personal injury or
death.
The addition of kerosene lowers the flash point of the diesel. This
increases the risk involved when handling the fuel mixture.
Comply with appropriate safety regulations.
The use of fuel that is approved by Daimler Chrysler AG and published in

the applicable fuel specifications is an integral part of Daimler Chrysler
warranty conditions.
Note! If Daimler Chrysler fuel specifications are not observed or if products
are used that have not been approved in writing by Daimler Chrysler
AG, serious engine damage is to be expected.
Customers, Customer Care and Manufacturing are to be informed (e.g. by
means of the Equipment Operating Instructions or a separate memo) of
Daimler Chrysler fuel specifications, in order that they can be adhered to.
Engine oils
Engine oils are specially tested to ensure their suitability for Mercedes-
Benz engines. For this reason, use only engine oil brands which Mercedes-
Benz has approved. These are stated in the Mercedes-Benz Specifications
for Service Products. Comply with the instructions in the Maintenance
Booklet.
The use of non-approved engine oils could affect warranty rights.
Select the SAE classification of the engine oil in accordance with ambient
temperatures.
When maintenance work is performed, engine oil changes will be recorded
in the Maintenance Booklet, together with details of the brand, quality
category and SAE classification of the oil.
When topping up, only use engine oils of the same quality and SAE
classification.
Note! If an oil of a lower quality grade is added, the characteristics of the oil
will be adversely affected. Oil change and filter replacement should
then be performed earlier.
Note! For detailed information on oil recommendations, refer to the
Maintenance manual, chapter "Lubricants and capacities".

Coolant
The coolant is a mixture of water and a combined corrosion inhibitor/
antifreeze. For reasons of anti-corrosion protection and to raise the boiling
point the coolant must remain in the cooling system all year round.
Renew the coolant every three years as the degree of corrosion protection
gradually drops with time.
Water
Water containing no additives is not suitable as a coolant, even if no
antifreeze protection is needed.
The water used in the coolant must comply with certain requirements,
which are not always satisfied by drinking water.
If water quality is inadequate, the water must undergo suitable treatment.
Corrosion inhibitor / antifreeze

To avoid damage to the cooling system:
• Only use an approved corrosion inhibitor/antifreeze. Information is
available from any Mercedes-Benz Service Station.
• When topping up the cooling system (after a drop in the coolant level),
the concentration of corrosion inhibitor/antifreeze in the coolant must be
50 % by volume (affords protection down to a temperature of -37 °C).
If the concentration is too low, there is a risk of corrosion/cavitation in the
cooling system.
• Do not increase the proportion of corrosion inhibitor/antifreeze beyond
55 % by volume (= maximum antifreeze protection). This would reduce
the level of antifreeze protection and adversely affect the coolant’s
ability to dissipate heat.
Coolant mixing ratio
Refer to the Maintenance manual, chapter "Lubricants and capacities".
If necessary, see detailed information from the engine manufacturer’s
manual.
In exceptional circumstances, if corrosion inhibitor/antifreeze is unavailable
and/or no antifreeze protection is needed (for instance in the tropics), an
approved coolant additive without antifreeze properties as stated on sheet
of the Mercedes-Benz Specifications for Service Products should be used
(e.g. MB corrosion inhibitor manufactured by Daimler-Benz AG or 10 % by
volume = 100 cm3/liter of VP 1749, manufactured by Hoechst of
Burghausen). In this case, renew the coolant every 12 months.

Disposal
Coolants are biodegradable substances.
When disposing of used coolant, comply with local legal regulations and/or
waste water regulations.
You are advised to consult the local water authorities to determine the best
method of disposal.
Since a modern engine coolant has complex tasks to perform, any form of
inexpert ’’reprocessing’’ which consists only of mechanical purification is to
be rejected.
7.1.2 Axles and planetary reduction oils
Note! Refer to Maintenance manual, chapter "Lubricants and capacities".
7.1.3 Power shifted transmission and torque converter
Oil specification
Recommended lubricants:
1. Caterpillar TO-4
2. John Deere J20 C, D
3. Military MIL-PRF-2140G
4. Allison C-4
5. Dexron II Equivalent - see note below
Note! Dexron II equivalent is acceptable; however it is not compatible with

torque converters or transmissions equipped with graphitic friction
material clutch plates.
Note! Dexron III, engine oil or GL-5 oils are not recommended
Preferred oil viscosity

It is recommended that the highest viscosity monograde lubricant available
be used for the anticipated ambient temperature. Typically this will be a
CAT TO-4 qualified lubricant. When large swings in ambient temperature
are probable, J20 C, D multigrades are recommended. Multigrades
lubricants should be applied at the lower viscosity rating for the prevailing
ambient temperature, i.e. a 10W20 should be used where a 10W
monograde is used. If a C-4 multigrades is used in stead of J20 lubricant it
is recommended that the viscosity span no more than 10 points, i.e.
10W20.
Note! Synthetic lubricants are approved if qualified by one of the above
specifications. Oil viscosity quidelines apply, but synthetic
multigrades may span more than 10 points.
7.1.4 Hydraulic system

7.1.5 Greasing
7.2 Filling capacities

CLASSIFICA-
FIRST FILLING
ITEM CAPACITY TION RECOM- NOTE!
OIL/FLUID
MENDATION
Diesel engine CF, CF-4, CG-4, Sandvik First filling with oil
15 L
(MB 904 LA) ACEA E3 OE10W40-LA filter
Diesel engine CF, CF-4, CG-4, Sandvik First filling with oil
28 L
(MB 906 LA) ACEA E3 OE10W40-LA filter
Diesel engine
Sandvik First filling with oil
(Deutz 14 L CF, CF-4, CG-4
OE10W40-LA filter
D914L04)
Sandvik
Diesel engine OE10W40-LA First filling with oil
9L CF, CF-4, CG-4
(Deutz TCD 3.6) Sandvik OE5W30- filter
LA
Diesel engine
CES 20081 API Sandvik First filling with oil
(Cummins 11 L
CJ-4/SL OE10W40-LA filter
QSB 4.5/B4.5)
Diesel engine
CES 20081 API Sandvik First filling with oil
(Cummins 18 L
CJ-4/SL OE10W40-LA filter
QSB 6.7/B6.7)
Driveline gear-
box
22 L GM Allison C-4 Sandvik OT3000
(T20000)
(MB 904 LA)
Driveline gear-
box
25 L GM Allison C-4 Sandvik OT3000
(HR32000)
(MB 906 LA)
Driveline gear-
box
(T20000) (Cum- 26 L GM Allison C-4 Sandvik OT3000
mins QSB 4.5/
B4.5)
Driveline gear-
box
(HR32000) 34 L GM Allison C-4 Sandvik OT3000
(Cummins
QSB 6.7/B6.7)

CLASSIFICA-
FIRST FILLING
OIL/FLUID
MENDATION
Cat T0-4
Driveline gear- John Deere J20
box C/D
32 L Sandvik OT3000
(T14) (Cummins MIL-PRF-2104G
QSB 6.7/B6.7) Dexron II(D) /
Dexron III
Transfer gearbox
(Stiebel 4382) SAE90 Renolin Unisyn XT
5.2 L
(Cummins API GL-4 150
QSB 6.7)
1.7 L / planetary
Front/rear axle
gear Sandvik
(Axle 123, wet API GL-4
8 L / differential OH10W30-KS
brake)
gear
1.6 L / planetary
Front/rear axle
gear Sandvik
brake)
gear
2.3 L / planetary
Front/rear axle
gear Sandvik
brake)
gear
4.7 L / planetary
Front axle
gear Sandvik
21 L/ differential OH10W30-KS
brake)
gear
Front/rear axle
Titan Gear LS SAE
(Axle 37R/43R, 45 L API GL-5
90
wet brake)
Front/rear axle
2-5% from axles
(Axle 37R/43R,
oil capacity Lubrizol 6178LZ
wet brake)
(45 L)
admixture

CLASSIFICA-
FIRST FILLING
OIL/FLUID
MENDATION
Sandvik OH46 for
cold ambient tem-
peratures
Sandvik OH46 Sandvik OH68 for
Sandvik OH68 normal ambient
Hydraulic oil DIN 51524 part 2 Sandvik OH100 temperatures
tank, drilling 200 L (HLP), ISO Plantohyd SE 46 Sandvik OH100 for
(NC5) 6743-4 (HM) (Biodegradable) high ambient tem-
Plantohyd SE 68 peratures
(Biodegradable) Viscosity class is
chosen according
to operating condi-
tions
Sandvik OH46 for
cold ambient tem-
peratures
TC8 (DS rigs) 6743-4 (HM) (Biodegradable) high ambient tem-
chosen according
to operating condi-
tions
Sandvik OH46 for
cold ambient tem-
peratures
Hydraulic oil
DIN 51524 part 2 Sandvik OH100 temperatures
tank, drilling
290 L (HLP), ISO Plantohyd SE 46 Sandvik OH100 for
(TC8 and NC7- 6743-4 (HM) (Biodegradable) high ambient tem-
series)
chosen according
to operating condi-
tions

CLASSIFICA-
FIRST FILLING
OIL/FLUID
MENDATION
Sandvik OH46 for
cold ambient tem-
peratures
(TC9) 6743-4 (HM) (Biodegradable) high ambient tem-
chosen according
to operating condi-
tions
Sandvik OH46 for
cold ambient tem-
peratures
(TC11–TC12) 6743-4 (HM) (Biodegradable) high ambient tem-
chosen according
to operating condi-
tions
Sandvik OH46 for
cold ambient tem-
peratures
(C1000) 6743-4 (HM) (Biodegradable) high ambient tem-
chosen according
to operating condi-
tions

CLASSIFICA-
FIRST FILLING
OIL/FLUID
MENDATION
Sandvik OH46 for
cold ambient tem-
peratures
tank, tramming 55 L (HLP), ISO Plantohyd SE 46 Sandvik OH100 for
(NC5) 6743-4 (HM) (Biodegradable) high ambient tem-
chosen according
to operating condi-
tions
Sandvik OH46 for
Sandvik OH46 cold ambient tem-
Sandvik OH68 peratures
Sandvik OH46 - normal ambient
Hydraulic oil DIN 51524 part 2 ECO (Biodegrada- temperatures
tank 145 L (HLP), ISO ble) Sandvik OH100 for
(C300) 6743-4 (HM) Sandvik OH68 - high ambient tem-
ECO (Biodegrada- peratures
ble) Viscosity class is
Plantoflux 68-AT-S chosen according
(Less flammable) to operating condi-
tions
Sandvik OH46 for
cold ambient tem-
peratures
tank 270 L (HLP), ISO Plantohyd SE 46 Sandvik OH100 for
(C400, C900) 6743-4 (HM) (Biodegradable) high ambient tem-
chosen according
to operating condi-
tions
Drop box
SAE 90 Renolin Unisyn XT
(C400, C900) 2.4 L
API GL-4 150
(NC5) (DD320S)

CLASSIFICA-
FIRST FILLING
OIL/FLUID
MENDATION
Drop box SAE 90 Renolin Unisyn
1.2 L
(C300) API GL-4 CLP 150
Transfer gearbox SAE 30
11 L Sandvik OT30
(C400E) API GL-4
Titan Supergear
HYP 75W-90 cold
ambient tempera-
SAE 75 W / 90 Titan Supergear
tures
Cable reel gear- API GL-5 HYP 75W-90
2.7 L Titan Gear HYP LD
box SAE 80 W / 90 Titan Gear HYP LD
SAE 80W-90 for
API GL-5 SAE 80W-90
normal and high
ambient tempera-
tures
Titan Supergear
HYP 75W-90 cold
ambient tempera-
SAE 75 W / 90 Titan Supergear
tures
Gear box of rota- API GL-5 HYP 75W-90
1.8 L Titan Gear HYP LD
tion mechanism SAE 80 W / 90 Titan Gear HYP LD
SAE 80W-90 for
API GL-5 SAE 80W-90
normal and high
ambient tempera-
tures
Gear box of rota-
tion mechanism ISO 12925-1 type Shell OMALA HD
6L
CKD 460
(CTU3300)
Gear box of rota-
SAE 85W-90 Titan Supergear
tion mechanism 4.5 L
API GL-5/GL-4 80W-90
(710CK)
Refer to the unit
Compressor Sandvik OC10-H / compressor decal
3L API CE/CF
(CTN9) AEON S for the exact first
filling fluid type.
Refer to the unit
5L API CE/CF
(CT10/16) AEON S for the exact first
filling fluid type.
Refer to the unit
10 L API CE/CF
(CTN10/16) AEON S for the exact first
filling fluid type.

CLASSIFICA-
FIRST FILLING
OIL/FLUID
MENDATION
Refer to the unit
8L API CE/CF
(CT28) AEON S for the exact first
filling fluid type.
Refer to the unit
11 L API CE/CF
filling fluid type.
Compressor 20 L Refer to the unit

OW cooler 3.6 L API CE/CF
OA cooler 10.8 L filling fluid type.
Compressor
17 L API CE/CF Sandvik OC10-H
(Enduro 12)
Compressor
7.7 L API CE/CF Sandvik OC10-H
(CTN27D-H)
Booster com-
132 L API CE/CF Sandvik OC10-H
pressor
Water pump
Sandvik
(Hydra-Cell D/ 0.95 L API CF
OE10W40-LA
G-03 Series)
Water pump
Sandvik
(Hydra-Cell D/ 1.05 L API CF
OE10W40-LA
G-10)
High pressure
water pump Renolin Unisyn XT
12 L
320
(HDP 142)
Sandvik OS32 for
Shank lubrica- cold ambient tem-
tion Sandvik OS32 peratures
14 L Sandvik
(Rig with 1 or 2 Sandvik OS100 Sandvik OS100 for
booms) high ambient tem-
peratures
Sandvik OS32 for
Shank lubrica- cold ambient tem-
tion Sandvik OS32 peratures
22 L Sandvik
(Rig with 3 Sandvik OS100 Sandvik OS100 for
booms) high ambient tem-
peratures

CLASSIFICA-
FIRST FILLING
OIL/FLUID
MENDATION
Oil: Sandvik
Hammer lubrica- OS100
45 L
tion Grease: Arox NM
000
Sandvik OG100-H
for cold ambient
temperatures
Sandvik OG100-H
Boom grease Sandvik OG220-H
Sandvik OG220-H
for normal and
high ambient tem-
peratures
Air conditioner
refrigerant 1500 g Sandvik R-134a
(NC4 carrier)
Air conditioner
refrigerant DS511 / DS520 ->
1950 g Sandvik R-134a
(TC8 and NC7- 2000g
series carriers)
Air conditioner
refrigerant
(TC9–12 carrier)
(C1000 carrier)
Air conditioner
refrigerant
(C400-C900 car-
rier)
Refer to separate
ISO-100 (high vis-
Air conditioner air conditioner Reniso PAG 46 /
cosity) or ISO-46
oil manual for the Reniso PAG 100
(low viscosity)
capacities.
Mobil SHC GEAR
220
Top drive 3.8 L or
Fuchs Renolin Uni-
syn XT 220
Shell Omala S4
GXV
Rotation head 5L ISO VG 220 or
Shell Omala S2
GX

CLASSIFICA-
FIRST FILLING
OIL/FLUID
MENDATION
Fuel, diesel en-
gine Thermoshell Win-
55 L EN 590
(Deutz ter 1202
D914L04)
Fuel, diesel en-
gine Thermoshell Win-
150 L EN 590
ter 1202
(Deutz TCD 3.6)
Fuel, diesel en-
gine
(MB 904/906 LA, Thermoshell Win-
Cummins 150 L EN 590
ter 1202
QSB 4.5/6.7,
Cummins B4.5/
B6.7)
Fuel, diesel en-
gine
Thermoshell Win-
(Cummins 100 / 155 L EN 590
ter 1202
QSB 4.5, Tier3/
Tier4F)
Fuel, diesel en-
gine
(Cummins Thermoshell Win-
410 L EN 590
QSB 6.7, Tier4F) ter 1202
(C900DH carri-
er)
Maintain Fricofin
Diesel engine
BS 6580, AFNOR, V(old)
coolant 22 L
ASTM D 3306 Sandvik OF-cool-
(MB 904 LA)
ant (new)
Maintain Fricofin
Diesel engine
BS 6580, AFNOR, V(old)
coolant 27 L
ASTM D 3306 Sandvik OF-cool-
(MB 906 LA)
ant (new)
Diesel engine Maintain Fricofin
coolant BS 6580, AFNOR, V(old)
32 L
(Cummins ASTM D 3306 Sandvik OF-cool-
QSB 4.5, Tier4i) ant (new)

CLASSIFICA-
FIRST FILLING
OIL/FLUID
MENDATION
Diesel engine
Maintain Fricofin
coolant
25 L (Tier3) BS 6580, AFNOR, V(old)
(Cummins ASTM D 3306
27 L (Tier4F) Sandvik OF-cool-
QSB 4.5, Tier3,
ant (new)
Tier4F)
Diesel engine
Maintain Fricofin
coolant
35 L (Tier4F) BS 6580, AFNOR, V(old)
(Cummins ASTM D 3306
45 L (Tier4i) Sandvik OF-cool-
QSB 6.7, Tier4F,
ant (new)
Tier4i)
27 L
(Cummins B4.5, ASTM D 3306 Sandvik OF-cool-
StageV) ant (new)
35 L
(Cummins B6.7, ASTM D 3306 Sandvik OF-cool-
StageV) ant (new)
Diesel engine
coolant BS 6580, AFNOR, Sandvik OF-cool-
27 L
ASTM D 3306 ant
(Deutz TCD 3.6)
Diesel exhaust
fluid
19 L ISO 22241 DEF/AdBlueR
(Cummins
QSB 4.5, Tier4F)
Diesel exhaust
fluid
17 L ISO 22241 DEF/AdBlueR
(Cummins B4.5,
StageV)
Diesel exhaust
fluid
(Cummins
QSB 6.7, Tier4F)
(C900DH carri- 38 L ISO 22241 DEF/AdBlueR
er)
(Cummins B6.7,
StageV) (C1000
carrier)

7.3 Biodegradable hydraulic oils - change instructions

Follow these instructions if the biodegradable hydraulic oils are changed to
the machine.
7.3.1 General
The demand for environment-friendly alternatives to conventional hydraulic
oil has increased, especially where rig owners work in sensitive
environments (e.g. in a water conservation area).
Sandvik sets the same high quality requirements for biodegradable oil that
it sets for conventional mineral oil when it comes to lubricating properties,
corrosion prevention, stability at different temperatures, etc. It is also
required that biodegradable oil has a low level of toxicity, does not have any
harmful effects on gaskets, decomposes without producing any
environmentally harmful by-products, and has a water content of < 0,1%
(Ref. ISO 15380).
Note! Mixing with other biodegradable hydraulic oils must be avoided.
7.3.2 General attention in oil maintenance
We emphasize, that the biodegradable oils require specific and strict
discipline in maintenance. The instructions must be followed with distinct
care!
7.3.3 Change instructions
Note! Make sure you empty the hydraulic system from the old oil as
thoroughly as possible before filling it with a new type biodegradable
oil. That is because the additives of one oil type may have negative
effects on the properties of the old oil type. The max. permissible old
oil content after oil change is 2%.
When the hydraulic system is empty, it is advisable to first flush it by filling it
with biodegradable oil. Drive and operate the rig a few hours. Then empty
the hydraulic system and fill it with fresh biodegradable oil.
Change the return oil filter after the first 50 operating hours because
biodegradable oil has the property of dissolving deposits. The second time
the filter shall be changed after 500 operating hours, to make sure all
deposits are removed from the system. After that, change the filter every
2000 operating hours or at least once a year.
Note! Changing to biodegradable oil in the hydraulic system, after using
hydraulic oil or especially motor oil must be done with extremely high
care, because these oil types do not mix.
Old biodegradable oil shall be regarded as environmentally hazardous
waste. Do not therefore empty it on the ground, but dispose of it according
to the same regulations that apply to normal waste oil.
7.3.4 Stickers on the oil receiver
Replace old stickers with the new ones after oil change. Attach new
stickers to the original places on the oil receiver.

When changing over from conventional to biodegradable oil, or vice versa,

it is advisable to provide the machine with new stickers.
7.3.5 Storage
Biodegradable oil shall be stored in a closed container to avoid absorption
of water. Avoid exposing biodegradable oil to sunlight or great variations in
temperature. The max. permissible water content is 0,1%.


8 DRILL CARRIER TROUBLESHOOTING

8.1 Troubleshooting guide for hydraulics
Trouble Location Probable cause(s) Remedy
The relief valve is dam- Check and adjust the pressure.
Steering hy-
aged or the adjustment Change a new relief valve
draulics
has altered. when necessary.
Hydraulic pump has dam-
Change a new pump.
aged.
The cylinder leakage can be
Steering is very stiff ascertained by operating the
The steering cylinder steering several times to see
Engine side
seals are leaking. whether the cylinder heats up
in abnormal way. Change the
cylinder seals.
Steering valve is dam- Change a new steering unit.
aged. Maintain strict cleanness.
Carry out bleeding by driving
the steering to extreme posi-
Air in the steering system.
tions a few times. Check the in-
Steering is sticking let side of the pump.
Steering
and unsteady
Steering valve worn. Change the steering valve.
Steering column bearing
Change the bearing.
worn.
Internal leak in the brake
Change the cylinder seals.
cylinders.
Check the brake valve spring,
and change if necessary.
Service brake Too low brake pressure.
Check and adjust the pressure
system in the hydraulic system.
Air in the brake system. Bleed the system.
Service brake does Brake plates are worn Check the brake plates, and
not hold out. change if necessary.
Brake plates are worn
Renew the brake plates.
out.
Lack of power of parking
Parking brake Renew the springs.
brake cylinder springs.
system
Oil leak in the parking
brake valve, thus pres- Change the brake valve.
sure in the spring brake.

Trouble Location Probable cause(s) Remedy

Air in the system. Bleed the system.
Check the pressure, adjust ac-
Releasing pressure too
Parking brake does Parking brake cording to the carrier technical
low.
not release (open) system manual.
Oil leak in the brake cylin-
Change the seals.
der.
8.2 Troubleshooting guide for the power shift transmission

The following information is presented as an aid ti isolating and determining
the specific problem area in a transmission that is not functioning correctly.
When troubleshooting a “transmission” problem, it should be kept in mind
that the transmission is only the central unit of a group of related power
train components. Proper operation of the transmission depends on the
condition and correct functioning of the other components of the group.
Therefore, to properly diagnose a suspected problem in the transmission, it
is necessary to consider the transmission fluid, charging pump, torque
converter, transmission assembly, oil cooler, filter, connecting lines, and
controls, including the engine, as a complete system.
By analyzing the principles of operation together with the information in this
section, it should be possible to identify and correct any malfunction which
may occur in the system.
Transmission (power shift with torque converter transmission) troubles fall
into three general categories:
• Mechanical problems
• Hydraulic problems
• Electrical problems
In addition to the mechanical and electrical components, all of which must
be in the proper condition and functioning correctly, the correct functioning
of the hydraulic circuit is most important. Transmission fluid is the “life
blood” of the transmission. It must be supplied in an adequate quantity and
delivered to the system at the correct pressures to ensure converter
operation, to engage and hold the clutches from slipping, and to cool and
lubricate the working components.
Stall test
A stall test to identifies transmission, converter, or engine problems. Use
following procedure:

1. Put the vehicle against a solid barrier, such as a wall, and/or apply the
parking brake and block the wheels.
2. Put the directional control lever in FORWARD (or REVERSE, as
applicable).
3. Select the highest speed. With the engine running, slowly increase
engine speed to approximately one-half throttle and hold until
transmission (converter outlet) oil temperature reaches the operating
range.
Note! Do not operate the converter at stall condition longer than 30 seconds
at one time, shift to neutral for 15 seconds and repeat the procedure
until desired temperature is reached. Excessive temperature 120 °C
(250 °F) maximum will cause damage to transmission clutches, fluid,
converter, and seals.
Pressure checks
Transmission problems can be isolated by the use of pressure tests. When
the stall test indicates slipping clutches, then measure clutch park pressure
to determine if the slippage is due to low pressure or clutch plate friction
material failure.
In addition, converter charging pressure and transmission lubrication
pressure can also be measured.
Mechanical and electrical checks

Prior to checking any part of the system for hydraulic function (pressure
testing), the following mechanical and electrical checks should be made:
• Check the parking brake and inching pedal for correct adjustment.
• Be sure all lever linkage is properly connected and adjusted in each
segment and at all connecting points.
• The controls are actuated electrically. Check the wiring and electrical
components.
• Be sure that all components of the cooling system are in good condition
and operating correctly. The radiator must be clean to maintain the
proper cooling and operating temperatures for the engine and
transmission. Air clean the radiator, if necessary.
• The engine must be operating correctly. Be sure that it is correctly tuned
and adjusted to the correct idle and maximum no-load governed speed
specifications.

Hydraulic checks
Also, before checking the transmission clutches, torque converter, charging
pump, and hydraulic circuit for pressure and rate of oil flow, it is important to
make the following transmission fluid check:
Check oil level in the transmission. The transmission fluid must be at the
correct (full level). All clutches and the converter and its fluid circuit lines
must be fully charged (filled) at all times.
The transmission fluid must be at operating temperature of 82...93 °C
(180...200 °F) to obtain correct fluid level and pressure readings. Do
not attempt to make these checks with cold oil.
To raise the oil temperature to this specification it is necessary to either

operate (work) the vehicle or run the engine with converter at “stall” (Refer
to “Stall test”).
Be careful that the vehicle does not move unexpectedly when
operating the engine and converter at stall rpm.
Troubleshooting guide
Refer to the following troubleshooting guide for the diagnosis of typical
transmission troubles.
Trouble Probable cause Remedy

Low oil level Fill to proper level.
Clutch pressure regulating valve
Clean valve spool and housing.
stuck open
Faulty charging pump Replace pump.
Low clutch pressure
Broken or worn clutch shaft or
Replace sealing rings.
piston sealing rings
Clutch piston bleed valve stuck
Clean bleed valves thoroughly.
open
Low charging pump out-
Suction screen plugged Clean suction pump.
put
Defective charging pump Replace pump.
Remove, disassemble, and rebuild
Worn oil sealing rings
converter assembly.
Worn charging pump Replace charging pump.
Overheating
Dirty oil cooler Clean cooler.
Restriction in cooler lines Change cooler lines.

Trouble Probable cause Remedy

Worn charging pump Replace charging pump.
Noisy converter A complete disassembly will be nec-

Worn or damaged bearings essary to determine which bearings
is faulty.
Low engine RPM at converter
Tune engine check governor.
stall
Lack of power
See “Overheating” and make Make corrections as explained in
same checks. “Overheating”.
8.3 Troubleshooting guide for the axle

Most operating problems are due to improper operation or maintenance of
the axle.
In the event of trouble, always check whether the operating instructions
have been strictly followed.
Problem Possible cause Repair

Check the thickness of the brake
The brakes are incorrectly
discs. If discs are fit for use, readjust
adjusted.
The brakes are inefficient. the brakes.
Check the thickness of the brake discs
The brake discs are worn.
and replace them if necessary.
There is air in the brake cir-
Brake pedal feels spongy. Bleed the brakes.
cuit.
The parking brake is incor-
Readjust the parking brake.
The parking brake is ineffi- rectly adjusted.
cient. Check the thickness of the brake discs
The brake discs are worn.
and replace them if necessary.
The brake disc gap is too
Readjust the brakes.
small.
The brakes are overheat- Release the brake and adjust the cor-
The parking brake drags.
ing. rect gap.
Check the lines and replace faulty
Brake lines are clogged.
ones.


9 APPENDIX
9.1 Tire weights
Tire Weight Rigs
DD421
DL421
Nokian 14.00-24 294kg
DS511
DT711, DT721, DT820, DT821, DT11-12
DL421
Nokian 14.00-24 foam fill 539kg DS511
DT711, DT721, DT820, DT821
DD421
Bridgestone 14.00-24 358kg
DL421
DD411, DD321
DL411, DL431
Nokian 12.00-20 159kg
DS421
DT611, DT621
DD411, DD321
DL411, DL431
Nokian 12.00-20 foam fill 323kg
DS421
DT611, DT621
DD321
Bridgestone 12.00-20 215kg DL411, DL431
DS421
Nokian 14.00-20 248kg DS411
Nokian 14.00-20 foam fill 437kg DS411
DD321, DD411
Solideal 12.00-20 173kg
DT611, DT621


www.sandvik.com
en-US 3 2022-01-25
Steering and braking system TC7-

TC12, NC7
GUID-89C3B251-1941-42B9-A3CB-7AEAD785A40F
Steering and braking system TC7-TC12, NC7
WARNING
Copyright © Sandvik
ID:GUID-89C3B251-1941-42B9-A3CB-7AEAD785A40F en-US 3 2022-01-25
Table of Contents
1 Introduction.......................................................................7
2 Main Components............................................................ 9
2.1 Components................................................................................................ 9
2.1.1 Double pressure relief valve (261).................................................... 9
2.1.2 Priority valve (262)............................................................................ 9
2.1.3 Steering valve (263).......................................................................... 9
2.1.4 Integrated brake valve (267)........................................................... 10
2.1.5 Parking brake control valves (270, 344).......................................... 11
2.1.6 Middle-joint locking valves (288, 289), TC7-TC8, NC7 rigs with
frame steering................................................................................. 12
2.1.7 Steering reversing valve (290), TC9-TC12 (optional)......................14
2.1.8 Emergency steering control valve (295)..........................................15
2.1.9 Pressure accumulator (296)............................................................ 15
2.1.10 Charging valve (297)....................................................................... 16
2.1.11 Release valve of the pressure accumulator (299)...........................16
2.1.12 Service brake testing valves (281, 282).......................................... 17
2.2 Parking and service brakes......................................................................17
2.2.1 Parking and service brake cylinders TC7-TC9/NC7 axles, TC10-
TC12 rear axle.................................................................................18
2.2.2 Parking brake cylinder, TC10-TC12 front axle................................ 19
3 Steering and brake circuit diagrams............................ 21

3.1 Steering circuit diagram, NC7..................................................................21
3.1.1 Components for NC7.......................................................................22
3.2 Steering circuit diagram, TC7-TC8.......................................................... 23
3.2.1 Components for TC7-TC8............................................................... 24
3.3 Steering circuit diagram, TC9-TC12........................................................ 25
3.3.1 Components for TC9-TC12............................................................. 26
3.4 Brake circuit diagram, NC7...................................................................... 27
3.4.1 Components for NC7.......................................................................28
3.5 Brake circuit diagram, TC7-TC8...............................................................31
3.5.1 Components for TC7-TC8............................................................... 32
3.6 Brake circuit diagram, TC9.......................................................................35
3.6.1 Components for TC9....................................................................... 36
3.7 Brake circuit diagram, TC10-TC12...........................................................39
3.7.1 Components for TC10-TC12........................................................... 40
4 Parking and service brakes operation..........................43

4.1 Parking brake circuit, TC7-TC12, NC7.....................................................43
4.1.1 Engaging and releasing the parking brakes.................................... 43
4.1.2 Parking brake circuit functional diagram (engaging), NC7.............. 46
4.1.3 Parking brake circuit functional diagram (engaging), TC7/TC8...... 48
4.1.4 Parking brake circuit functional diagram (engaging), TC9.............. 50
4.1.5 Parking brake circuit functional diagram (engaging), TC10-TC12.. 52
4.1.6 Parking brake circuit functional diagram (releasing), NC7.............. 54
4.1.7 Parking brake circuit functional diagram (releasing), TC7/TC8.......56
4.1.8 Parking brake circuit functional diagram (releasing), TC9...............58
4.1.9 Parking brake circuit functional diagram (releasing), TC10-TC12...60
4.2 Service brake circuit, TC7-TC12, NC7..................................................... 61
4.2.1 Service brake circuit functional diagram, NC7................................ 62
4.2.2 Service brake circuit functional diagram, TC7-TC8.........................66
4.2.3 Service brake circuit functional diagram, TC9.................................70
4.2.4 Service brake circuit functional diagram, TC10-TC12.....................74
4.2.5 Operation of the ABA-system..........................................................76
4.3 Testing the brakes.....................................................................................77
4.3.1 Service brake testing system, TC7-TC12, NC7 (optional).............. 79
5 Steering and brake system troubleshooting............... 89

5.1 Steering......................................................................................................89
5.2 Brakes........................................................................................................ 90
1 INTRODUCTION
information.
Copyright © Sandvik 7 (92)

8 (92) Copyright © Sandvik

2 MAIN COMPONENTS
2.1 Components
2.1.1 Double pressure relief valve (261)
The double pressure relief valve limits the maximum pressure of gear
pumps (251) and (252).
.01 .02
.01 Pressure relief valve

.03 Anti-cavitation valve
.04 Anti-cavitation valve
2.1.2 Priority valve (262)

The priority valve distributes the oil delivered from the gear pump (251)
primarily to the steering or secondarily to the carrier auxiliary functions.
.01 Orifice
.02 Orifice
.03 Orifice
2.1.3 Steering valve (263)

The steering valve distributes oil to the steering as necessary.

The steering unit consists of a rotary valve and a rotary meter. When the
steering wheel is turned, oil is directed via the rotary valve and rotary meter
to cylinder port L or R. The rotary meter measures the oil flow to the
steering cylinder in proportion to the angular rotation of the steering wheel.
.01
.02
.03 .05
.06 .04
.01 Pressure relief valve .02 Non-return valve

.03 Intake valve .04 Intake valve
.05 Pressure relief valve .06 Pressure relief valve
.07 Orifice
2.1.4 Integrated brake valve (267)

The brake pedal adjusts the hydraulic pressure to the service brake
cylinder proportionally in accordance with the brake pedal angle.

.01 .04 .07
.05 .02
.06
.03
.01 Priority valve .02 Control valve

.03 Pressure relief valve .04 Pressure relief valve
.05 Non-return valve .06 Pressure reducing/relieving
valve
.07 Pressure reducing/relieving
valve
2.1.5 Parking brake control valves (270, 344)

The parking brake control valves control the operation of the rear and front
axle parking brake cylinder. The pressure reducing/relieving valve (.01)
adjusts the rear axle control pressure to 30 bar (TC7- TC12, NC7) and front
axle control pressure to 30 bar (TC7–TC9, NC7) / 100 bar (TC10-TC12).
Directional valve (.02) directs the oil flow to the parking brake or receiver.

.01 .02
270
344
100 bar
(TC10-12)
30 bar
(TC7-9, NC7)
.01 Pressure reducing/relieving valve

.02 3/2 directional valve
2.1.6 Middle-joint locking valves (288, 289), TC7-TC8, NC7 rigs with frame steering
During drilling middle-joint movements are prevented with locking valves
(288).

40 Nm

2.1.7 Steering reversing valve (290), TC9-TC12 (optional)

2.1.8 Emergency steering control valve (295)
295
.02
.01
2.1.9 Pressure accumulator (296)

2.1.10 Charging valve (297)
N S1
T
.03
P .02
.01
.04
297 T
Charging the pressure accumulator

The charging valve (297) allows the oil to flow to the pressure accumulator
(296) through the port (S1). When the pressure accumulator is full, the
charging valve changes position, and the oil flows through the brake circuit
port (N).
2.1.11 Release valve of the pressure accumulator (299)

2.1.12 Service brake testing valves (281, 282)
2.2 Parking and service brakes

The TC10-12 brakes only differ from the TC7-9 / NC7 brakes in regards to
the front axle parking brake.
The integrated brake valve (267) is used for three different purposes:
priority function, charging and control.
The priority function takes care of the priority of the oil flow. Valves (267.01)
and (267.05) control the priority function. Priority is always given to the
service and parking brake circuits.
Control takes place when the service brake pedal is used.

2.2.1 Parking and service brake cylinders TC7-TC9/NC7 axles, TC10-TC12 rear axle
2 1 3
5
6
9
8 P1
B1 B2
P2
1 Parking brake control pres- 2 Parking brake operating pis-

sure chamber ton
3 Service brake operating pis- 4 Service brake control pres-
ton sure chamber
5 Adjustment spring 6 Parking brake control pres-
sure connection
7 Service brake control pres- 8 Parking brake bleeder
sure connection screw
9 Service brake bleeder
screw

2.2.2 Parking brake cylinder, TC10-TC12 front axle
2 3 4
1 Parking brake washer

2 Parking brake saddle
3 Sleeve position during towing
4 Sleeve position during tramming


3 STEERING AND BRAKE CIRCUIT DIAGRAMS

3.1 Steering circuit diagram, NC7
283 283
288 289
.06 .05
.04 .03
263
.07
.01
.02
.03
262
.01
.02
.03 .04
261
.01 .02
257 252
251
312

3.1.1 Components for NC7

251 Gear pump Feeds oil to the steering circuit and carrier circuit
252 Gear pump Feeds oil to the service and parking brake circuits
257 Diesel engine
Limits the maximum pressure of gear pumps (251) and
261 Double pressure relief valve
(252)
.01 Pressure relief valve Limits the pressure of gear pump (251) (220 bar)
.03 Anti-cavitation valve Prevents cavitation in steering and carrier circuits
.04 Anti-cavitation valve Prevents cavitation in service and parking brake circuits
Distributes the oil delivered from the gear pump (251) pri-
262 Priority valve marily to the steering or secondarily to the carrier auxiliary
functions
.01 Orifice Stabilizes the priority valve (262) spool
Distributes oil from the priority valve (262) to the steering
263 Steering valve (orbitrol)
cylinders (283)
.01 Pressure relief valve Adjusts the maximum pressure of the steering valve (263)
Prevents the pilot pressure from being released from the
.02 Non-return valve
steering circuit
.03 Non-return valve Anti-cavitation valve for the steering valve (263)
.05 Pressure relief valve Shock valve
.07 Orifice Stabilizes the pressure relief valve (263.01)
283 Steering cylinders
Middle-joint lock valve (option-
288
al)
Middle-joint lock valve (option-
289
al)
312 The hydraulic oil tank

3.2 Steering circuit diagram, TC7-TC8

LEF T RI GHT LEF T RI GHT
283 283
Y3 7 9 . 1 Y3 7 9 . 2
288 289
R L R L
190ba r 190ba r
.06 .05
ARTI CULATI ON LOCKI NG
OP TI ON
.04 .03
263
.07 LS
.01
.02
140ba r
P T
Ca r r i e r h o s i n g a n d
X9 r e t u r n f i l t e r s
X8 Ca r r i e r h o s i n g a n d
CF
EF
X7 r e t u r n f i l t e r s
.03 X2 3 Ca r r i e r h o s i n g a n d
262 r e t ur n f i l t e r s
LS
.01
.02
P
X1
B2 T A2
.03 .04
220 ba r 200 ba r
261
.01 .02
B1 T A1
X1 3 Ca r r i e r h o s i n g a n d
r e t ur n f i l t e r s
P P
16c c 16c c
257 M 252
251 S S
From port B1 when
TC8 2-boom jumbo
( B1 )
S1 S2
312

3.2.1 Components for TC7-TC8

257 Diesel engine
Limits the maximum pressure of gear pumps (251) and
261 Double pressure relief valve
(252)
Distributes the oil delivered from the gear pump (251) pri-
262 Priority valve marily to the steering or secondarily to the carrier auxiliary
functions
Distributes oil from the priority valve (262) to the steering
cylinders (283)
steering circuit
Middle-joint lock valve (frame-
288
steered rigs, optional)
Middle-joint lock valve (frame-
289
steered rigs, optional)

3.3 Steering circuit diagram, TC9-TC12

ATTENTI ON! ! !
DRI LLI NG DI RECTI ON
Note! Hosing is different comparing to the basic version.

LEF T RI GHT RI GHT LEF T
283 ( S h a f t R) 283 ( S h a f t L)
Y3 7 8 2 4
290
3 1
R L R L
190ba r 190ba r
.06 .05
OP TI ON
.04 .03
263
LS
.01
.02
140ba r
P T
Ca r r i e r p i p i n g a n d
X9 r e t u r n h o s e s
X8 Ca r r i e r p i p i n g a n d
r e t ur n hos e s
CF EF
.03 Ca r r i e r p i p i n g a n d
262 .01 X1 3 r e t u r n h o s e s
LS
.02
P
X1
2/ 11
B2 T A2
.03 .04
220 ba r 200 ba r
261
.01 .02
B1 T A1
16c c P P 16c c
257 M 252
251 S S
S1 S2
312


257 Diesel engine
261 Double pressure relief valve Limits the maximum pressure of gear pumps (251) and (252)
Distributes the oil delivered from the gear pump (251) primar-
262 Priority valve ily to the steering or secondarily to the carrier auxiliary func-
tions
Distributes oil from the priority valve (262) to the steering cyl-
inders (283)
steering circuit
Steering reversing valve (op-
290
tional)

Brake circuit diagram, NC7
.01
.07
.06
.02
.05
.04
.03
275
267
.01
276
281
.02
293
272
271
344
.01
.02
.01
.01
270
282
277
.02
.02
285
.01
274
.02
345
280
279
.05
.06
.03
SERVICE BRAKE PRESSURE FRONT (80 bar)
SERVICE BRAKE PRESSURE REAR (80 bar)
PARKING BRAKE PRESSURE FRONT (30 bar)
.04
PARKING BRAKE PRESSURE REAR (30 bar)
CHARGING PRESSURE OF ACCUMULATORS (135-160 bar)
CLARK CLUTCH PRESSURE (17-19 bar)
291
284
.02
.01
.07
.08
294
.01
286
347
278
.02
Brake circuit diagram, NC7 3.4
3.4.1 Components for NC7

Directs the oil to parking/service brake circuit or secondary con-
267 Integrated brake valve
trol circuit (port S).
.01 Priority valve
Controls the operation of the priority valve (267.01) in the brake
circuit When the pressure in the brake circuit rises to 160 bar,
the valve changes position and directs the pilot control oil of the
priority valve (267.01) to the receiver. The priority valve (267.01)
changes position and directs the oil to the secondary control cir-
.02 Control valve
cuit (port S). When the pressure in the brake circuit descends to
135 bar, the valve changes position and directs the pilot control
oil to the priority valve (267.01). The priority valve (267.01)
changes position and directs the oil to the parking/service brake
circuit.
Ensures the functioning of the rear service brake circuit in case
of a hose rupture in the front service brake circuit. Adjusts the
operating pressure of the rear service brake circuit to approxi-
mately 120 bar.
Ensures the functioning of the front service brake circuit in case
of a hose rupture in the rear service brake circuit. Adjusts the op-
erating pressure of the front service brake circuit to approximate-
ly 120 bar.
Prevents the pilot pressure from being released from the park-
ing/service brake circuit.
Pressure reducing/reliev- Adjusts the service brake pressure to the rear axle according to
.06
ing valve the pedal
Pressure reducing/reliev- Adjusts the service brake pressure to the front axle according to
.07
ing valve the pedal
Parking brake control Directs the oil flow to the rear axle parking brake. Adjusts pres-
270
valve sure to the parking brake circuit.
Pressure reducing/reliev-
.01 Adjusts the maximum pressure of the parking brake.
ing valve
.02 3/2 directional valve Directs the oil flow into the receiver, parking brake.
271 Pressure accumulator Acts as an oil storage for the rear service brake circuit.
272 Pressure accumulator Acts as an oil storage for the front service brake circuit.
Monitors the minimum charging pressure of the front service
brake circuit. Causes an indicator light to light up in gauge (P3)
(on the driving panel) when the pressure of the front service
brake drops below 100 bar. When using the ABA system (option-
274 Pressure transducer
al), the transducer monitors the minimum charging pressure of
the front service brake circuit and causes the indicator light
(H20) to light up on the driving panel when the pressure drops
below 110 bar.

Monitors the minimum charging pressure of the rear service

(on the driving panel) if the pressure drops below 100 bar. When
275 Pressure transducer using the ABA system (optional), the transducer monitors the
minimum charging pressure of the rear service brake circuit and
causes the indicator light (H20) to light up on the driving panel
when the pressure drops below 110 bar.
Pressure switch (ABA Monitors the brake pressure. If the pressure drops below 75 bar,
276
system, optional) the parking brake engages.
277
Monitors the pressure of the rear axle parking brake. If the pres-
278 Pressure switch
sure drops below 5 bar, the indicator light (H15) switches on.
Directs the pressure from the rear or front service brake circuit to
279 Shuttle valve
pressure switch (280).
280 Pressure switch Brake light switch (5 bar)
Front axle service brake
testing valve (service
281
brake testing system, op-
tional)
.02 Restricts the hydraulic oil pressure to 80 bar.
ing valve
Rear axle service brake
testing valve (service Directs the oil flow from the testing circuit to the rear axle brake.
282
brake testing system, op- Adjusts the testing circuit pressure.
tional)
ing valve
284 Measuring point assembly
Front axle service and
285
parking brake cylinders
Front service brake cylin-
.01 Controls the braking power of the front service brakes.
ders
Front parking brake cylin-
.02 Front parking brakes engaged/released.
ders
Rear axle service and
286
Rear service brake cylin-
.01 Controls the braking power of the rear service brakes.
ders

Rear parking brake cylin-

.02 Rear parking brakes engaged/released.
ders
291 Transmission
Transmission oil cooler
.01
(optional)
.02 Gearbox
Monitors the pressure of the gear box of the feed pump. When
Pressure switch (ABA
.03 the pressure drops below 4 bar, the parking brake engages and
system, optional)
the indicator light (SH2) of the parking brake button lights up.
Consists of two separate components: collector and pressure
.04 Manifold
distributor.
.05 Pressure transducer Monitors the minimum clutch thrust of the gear box (14.3 bar).
.06 The breather Takes care of the ventilation of the brakes.
.07 Temperature transducer Monitors the maximum oil temperature of the gear box (110 °C).
.08 Manifold
Shuttle valve (service
293 brake testing system, op-
tional)
tional)
Parking brake control Directs the oil flow to the front axle parking brake. Adjusts pres-
344
ing valve
345 Pressure switch (optional)
Monitors the pressure of the front axle parking brake. If the pres-
347 Pressure switch

3.5
285 286
FRONT AXLE REAR AXLE
SERVICE PARKING SERVICE PARKING
LEFT RIGHT LEFT RIGHT LEFT RIGHT LEFT RIGHT
.01 .02 .01 .02
267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293
H H
(REAR SERVICE
.07 F2 S15.1 BRAKE LIGHTS) 5 bar
F1 280 S19
.06 347 5 bar
MF1
344
X12 Y295.1 .02
T
TO CARRIER CIRCUIT T X 294

.03 A1
P .01 279
.02 30 bar
284
TO CARRIER CIRCUIT
X11
Brake circuit diagram, TC7-TC8
135-
A2

LS 160 bar Y295 .02
.04
.05 T X
B3
X1 .01
P
P .01
30 bar
S15.2
270
S MS MA X14 278
TO CARRIER CIRCUIT 5 bar
TO CARRIER CIRCUIT
X10
PRESSURE CONTROL OF PRESSURE CONTROL OF
BRAKE CIRCUIT BRAKE CIRCUIT
TO DRILLING CIRCUIT S13B S14B T2
276 277 .07

BR T3 .04 T1
.06
110° C
75 bar 75 bar C1
.05 291
P3 P1 C4 C3
275 274 B2 P / I 31 11 .08
P4 OUT IN
B1 3 P / I P/I B1 4 14,3 bar
P2 C2
100 bar 100 bar .01
(ABA 110 bar) (ABA 110 bar)
S16 OUT
GEARBOX
FRONT 65 bar 65 bar REAR 12

272 271 .03 IN
281 282 OPTION OPTION
.01 Y296 Y297 .01 Test valve of 4 bar ENGINE
80bar 80bar rear brake OPTION FAN
.02 P P .02
A A ABA
B B
Carrier hosing
OPTION and return
T T filters
Test valve of front brake X25
31 (92)

.01 Priority valve
circuit When the pressure in the brake circuit rises to 160 bar,
the valve changes position and directs the pilot control oil of the
priority valve (267.01) to the receiver. The priority valve (267.01)
.02 Control valve
circuit.
mately 120 bar.
ly 120 bar.
Prevents the pilot pressure from being released from the park-
ing/service brake circuit.
.06
ing valve the pedal
.07
ing valve the pedal
270
ing valve
(on the driving panel) when the pressure of the front service
the front service brake circuit and causes the indicator light
(H20) to light up on the driving panel when the pressure drops
below 110 bar.


276
277
278 Pressure switch (S15.2)
279 Shuttle valve
280 Pressure switch (S19) Brake light switch (5 bar)
281
tional)
ing valve
282
tional)
ing valve
284 Measuring point assembly
285
ders
ders
286
ders


ders
291 Transmission
.01
(optional)
.02 Gearbox
Pressure switch (S16,
ABA system, optional)
.04 Manifold
distributor.
.08 Manifold
tional)
tional)
344
ing valve
347 Pressure switch (S15.1)

3.6
285 FRONT AXLE 286 REAR AXLE

.01 .02 .01 .02
267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293 H H
(REAR SERVICE
F2 BRAKE LIGHTS) 5 bar
.07
280 B968P
F1
.06 294
MF1
344 0.2
TO CARRIER CIRCUIT Y960
CLARK CLUTCH
PRESSURE (17-19 bar)
X12 T T
Brake circuit diagram, TC9
X
.03 A1 278
P B961P
Brake circuit diagram, TC9

0.1 279 284
.02 30 bar
X11
135- 347
LS A2 Y961 0.2 B960P
160 bar
.04
T X 5 bar
.05 B3
X1 .01
P
.01
P
30 bar
270
X19
TO CARRIER CIRCUIT
S MS MA
X10
TO AIR CONDITION CIRCUIT PRESSURE CONTROL OF PRESSURE CONTROL OF

BRAKE CIRCUIT BRAKE CIRCUIT T2 B970T

BR T1 .07 110° C
T3
.06
B966P B967P .04
291 C1
276 277 .05
P3 P1 C4 C3
P/I 31 11 .08
75 bar 75 bar B970P P4 OUT IN
14,3 bar
P2 C2
.01
OPTION
275 274 Test valve of B975P
281 OUT
GEARBOX
B964P P/I P/I B965P rear brake .03

12
OPTION 100 bar 100 bar Y297 .01 4 bar IN ENGINE
Test valve of front brake (ABA 110 bar) (ABA 110 bar) 70bar FAN
OPTION
P .02
Y296 A ABA
80 bar 80 bar
70bar 272 271
.02 FRONT REAR B
P
A
B Carrier hosing T
and return 282
.01 T X25
filters
35 (92)
3.6.1 Components for TC9

.01 Priority valve
circuit When the pressure in the brake circuit rises to 160 bar, the
valve changes position and directs the pilot control oil of the pri-
ority valve (267.01) to the receiver. The priority valve (267.01)
.02 Control valve
circuit.
mately 120 bar.
ly 120 bar.
Prevents the pilot pressure from being released from the parking/
service brake circuit.
.06
ing valve the pedal
.07
ing valve the pedal
270
ing valve
brake circuit. Causes an indicator light to light up on the gauge
(P3) (on the driving panel) when the pressure of the front service
the front service brake circuit and causes the indicator light (H20)
to light up on the driving panel when the pressure drops below
110 bar.


276
277
278 Pressure switch
279 Shuttle valve
281
tional)
ing valve
282
tional)
ing valve
Measuring point assem-
284
bly
285
ders
ders
286
ders


ders
291 Transmission
.01
(optional)
.02 Gearbox
system, optional)
.04 Manifold
distributor.
.08 Manifold
tional)
tional)
344
ing valve
347 Pressure switch

3.7
.01 .02 .01 .02

OPTION
ONLY WITH BRAKE P2 P2 P1 P1 P2 P2 P1 P1
TEST VALVES
MF2 285
293 286
(REAR SERVICE 5 bar

BRAKE LIGHTS) OPTION
.07 F2 280 S19 ONLY WITH BRAKE
TEST VALVES
F1
.06
MF1
TO CARRIER CIRCUIT Y295.1
CLARK CLUTCH
.02 294
X12 T T 344
267
X
P
.03 A1
.01 279 284
.02 100 bar S15.1
TO CARRIER CIRCUIT
347
X11 50 bar
LS 135- A2 Y295.2
160bar .02 S15.2
.04
T 278
.05 X 5 bar
X1 B3
1/21 P .01
P .01

30 bar
270
S MS MA
X10 PRESSURE CONTROL OF
S13 B S14B BRAKE CIRCUIT
TO AIR CONDITION/
CARRIER CIRCUIT T2
276 277 B1
PRESSURE CONTROL OF BR
BRAKE CIRCUIT 75 ba r 75 bar .06
T3 T1 .07
.04 110° C
.08 C1
B2 291
275 274 P3 P1 C4 C3

.05 P / I 31 11 OUT
B13 P/I P/I B14 IN
14,3 bar
100 bar 100 bar
S16 20000/ .01
(ABA 110 bar) (ABA 110 bar) 32000
FRONT REAR .03 SERIE
272 271 .02 OUT
4 bar 12
80 bar 80 bar IN
OPTION
ABA ENGINE
Y296 Y297 FAN
.02 .01
70bar 70bar
A .01 P P .02 A
B 281 282 B
T T Carrier hosing and

OPTION return filters
X14
BRAKE TEST
VALVES
39 (92)

.01 Priority valve
circuit When the pressure in the brake circuit rises to 160 bar, the
valve changes position and directs the pilot control oil of the pri-
ority valve (267.01) to the receiver. The priority valve (267.01)
.02 Control valve
circuit.
mately 120 bar.
ly 120 bar.
Prevents the pilot pressure from being released from the parking/
service brake circuit.
.06
ing valve the pedal
.07
ing valve the pedal
270
ing valve
brake circuit. Causes an indicator light to light up on the gauge
(P3) (on the driving panel) when the pressure of the front service
the front service brake circuit and causes the indicator light (H20)
to light up on the driving panel when the pressure drops below
110 bar.


276
277
278 Pressure switch
279 Shuttle valve
281
tional)
ing valve
282
tional)
ing valve
Measuring point assem-
284
bly
285
ders
ders
286
ders


ders
291 Transmission
.01
(optional)
.02 Gearbox
system, optional)
.04 Manifold
distributor.
.08 Manifold
tional)
tional)
344
ing valve
Parking brake control
.02 Directs the oil flow into the receiver, parking brake.
valve
347 Pressure switch

4 PARKING AND SERVICE BRAKES OPERATION

4.1 Parking brake circuit, TC7-TC12, NC7
1 2 3
With Mercedes Benz engine
1 2
With Cummins engine
1 Parking brake engagement button (S21)

2 Parking brake releasing button and indicator light (SH2)
3 Parking brake engaged indicator light (H15)
4.1.1 Engaging and releasing the parking brakes

The parking brakes are engaged by pushing the parking brake engage
button (S21). This releases the pressure in the parking brake circuits. The
indicator light (H15) is lit when the control pressure of both parking brake
circuits has fallen below the set limits:
• front brake circuit 5 bar (NC7, TC7-TC9) / 50 bar (TC10-TC12)
• rear brake circuit 5 bar (NC7, TC7-TC12)

The parking brakes are released by first lifting the parking brake engage
button (S21) up. This lights up the indicator light (SH2) on the parking brake
release button. Next, push the parking brake release button (SH2) to direct
the pressure to the parking brake cylinders. The indicator lights (SH2) and
(H15) go off, and the parking brakes are released.
The indicator light (H15) blinks if the brakes of one axle are left in a different
state than the other’s when the break is engaged or released, i.e. the
pressure difference between the brake circuits becomes too high.


4.1.2 Parking brake circuit functional diagram (engaging), NC7
.02
278
347
286
.01
294
.08
.07
.01
.02
284
291
.04
.03
.06
.05
279
280
345
.02
274
.01
285
.02
.02
277
282
270
.01
.01
.02
.01
344
271
272
293
.02
281
276
.01
267
275
.03
.04
.05
.02
.06
.07
.01
Parking brake circuit functional diagram (engaging), NC7

Parking brake circuit operation (engaging)

The oil flows from the parking brake circuit gear pump (252). From the
pump (252) the oil flows through the double pressure relief valve assembly
(261) to the integrated service brake valve (267) connection (P). From the
port (P) the oil flows through the control valve (267.01) and non-return
valve (267.05) to the integrated service brake valve (267) connection (B3).
From there the oil flows to the parking brake valves (270) and (344)
connection (P) and then to the pressure reducing/relieving valves (270.01)
and (344.01). The pressure reducing/relieving valves (270.01) and (344.01)
adjust the operating pressure of the parking brake circuits. When the
operator engages the parking brake (with the parking brake button or an
emergency stop button), the directional valves (270.02) and (344.02) direct
the oil flow from the front and rear parking brake cylinders (chambers
285.02 and 286.02) to the receiver and the parking brake cylinder springs
engage the parking brakes. The indicator light (H15) on the tramming panel
lights up when the control pressure of both parking brake circuits has fallen
below the 5bar (pressure switches 278 and 347).

4.1.3
48 (92)
285 286
.01 .02 .01 .02
267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293
H H
(REAR SERVICE
F1 280 S19
.06 347 5 bar
MF1
344
X12 Y295.1 0.2
T

.03 A1
P 0.1 279
.02 30 bar
284
TO CARRIER CIRCUIT
X11
135-
LS 160 bar
A2 Y295 .02
.04
.05 T X
B3
X1 P .01
P .01
30 bar
S15.2
270
S MS MA X14 278
TO CARRIER CIRCUIT

X10
276 277 BR .07
T3 .04 T1 110° C
.06
75 bar 75 bar C1
Parking brake circuit functional diagram (engaging), TC7/TC8
.05 291
P3 P1 C4 C3
275 274 B2 P / I 31 11 .08
P4 OUT IN
B1 3 P / I P/I B1 4 14,3 bar 20000/
P2 32000 C2
100 bar 100 bar SERIE .01
Parking brake circuit functional diagram (engaging), TC7/TC8

S16 OUT
272 271 .03 IN
.02 P P .02
A A ABA
B B
Carrier hosing
OPTION T and return
T filters
Test valve of front brake


4.1.4
50 (92)
.01 .02 .01 .02
267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293 H H
(REAR SERVICE
.07
280 B968P
F1
.06 294
MF1
344 0.2
TO CARRIER CIRCUIT Y960 SERVICE BRAKE PRESSURE FRONT (70 bar)
CLARK CLUTCH
X12 T T X
.03 A1 278
P B961P
0.1 279 284
.02 30 bar
X11
135- 347
LS A2 Y961 0.2 B960P
160 bar
.04
T X 5 bar
.05 B3
X1 P .01
.01
P
30 bar
270
X19
TO CARRIER CIRCUIT
S MS MA

X10

Parking brake circuit functional diagram (engaging), TC9
T2 B970T
BR T1 .07 110° C
T3
.06
B966P B967P .04
291 C1
276 277 .05
P3 P1 C4 C3
P/I 31 11 .08
Parking brake circuit functional diagram (engaging), TC9

14,3 bar
P2 C2
.01
OPTION
281 OUT
GEARBOX

12
OPTION
P .02
Y296 A ABA
80 bar 80 bar
70bar 272 271
.02 FRONT REAR B
P
A
B Carrier hosing T
and return 282
.01 T X25
filters


4.1.5
52 (92)
.01 .02 .01 .02
OPTION
TEST VALVES
MF2 285
293 286
(REAR SERVICE 5 bar

TEST VALVES
F1
.06
MF1

CLARK CLUTCH
.02 294
X12 T T 344
267
X
P
.03 A1
.01 279 284
.02 100 bar S15.1
TO CARRIER CIRCUIT
347
X11 50 bar
LS 135- A2 Y295.2
160bar .02 S15.2
.04
278
T X
X1 .05 5 bar
B3
1/21 P .01
P .01
30 bar
270
S MS MA
TO AIR CONDITION/
CARRIER CIRCUIT T2

276 277 B1
PRESSURE CONTROL OF BR T3 T1
BRAKE CIRCUIT 75 ba r 75 bar .06 .04 .07 110° C
.08 C1
B2 291
275 274 P3 P1 C4 C3
.05 P / I 31 11 OUT
B13 P/I P/I B14 IN
14,3 bar
100 bar
100 bar S16 20000/ .01
(ABA 110 bar) 32000
(ABA 110 bar)
Parking brake circuit functional diagram (engaging), TC10-TC12
REAR .03 SERIE

FRONT 272 .02 OUT
271 4 bar
80 bar 80 bar 12
IN
OPTION
ABA ENGINE
Y296 Y297 FAN
.02 .01
70bar 70bar
Parking brake circuit functional diagram (engaging), TC10-TC12

A .01 P P .02 A
B 281 282 B

BRAKE TEST X14
VALVES

engage the parking brakes. The indicator light (H15) on the driving panel
below the set limits (front brake circuit 50 bar / rear brake circuit 5 bar)
(pressure switches 278 and 347).

4.1.6 Parking brake circuit functional diagram (releasing), NC7
.02
278
347
286
.01
294
.08
.07
.01
.02
284
291
.04
.03
.06
.05
279
280
345
.02
274
.01
285
.02
.02
277
282
270
.01
.01
.02
.01
344
271
272
293
.02
281
276
.01
267
275
.03
.04
.05
.02
.06
.07
.01
Parking brake circuit functional diagram (releasing), NC7

Parking brake circuit operation (releasing)

When the parking brake is released, the 3/2 directional valves (270.02) and
(344.02) of the parking brake control valves (270) and (344) are activated
and the oil flows to the front parking brake cylinders (285), the rear parking
brake cylinders (286), the pressure switches (278) and the measuring point
assembly (284). When the control pressure of both parking brake circuits
has risen over the 5 bar, the parking brake indicator lamp (H15) on the
tramming panel turns off. The springs in cylinders (285) and (286) are
compressed and the parking brakes are released.

4.1.7
56 (92)
285 286
.01 .02 .01 .02
267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293
H H
(REAR SERVICE
F1 280 S19
.06 347 5 bar
MF1
344
X12 Y295.1 .02
T

.03 A1
P .01 279
.02 30 bar
284
TO CARRIER CIRCUIT
X11
135-
LS 160 bar
A2 Y295 .02
.04
.05 T X
B3
X1 P .01
P .01
30 bar
S15.2
270
S MS MA X14 278
TO CARRIER CIRCUIT

X10
276 277 BR .07
T3 .04 T1 110° C
.06
75 bar 75 bar C1
.05
Parking brake circuit functional diagram (releasing), TC7/TC8
P1
291 C4 C3
275 274 P3
B2 P / I 31 11 .08
P4 OUT IN
B1 3 P / I P/I B1 4 14,3 bar
P2 C2
100 bar 100 bar .01
Parking brake circuit functional diagram (releasing), TC7/TC8

S16 OUT
GEARBOX

272 271 .03 IN
.02 P P .02
A A ABA
B B
Carrier hosing
OPTION T and return
T filters


4.1.8
58 (92)
.01 .02 .01 .02
267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293 H H
(REAR SERVICE
.07
280 B968P
F1
.06 294
MF1
344 0.2
CLARK CLUTCH
X12 T T X
.03 A1 278
P B961P
0.1 279 284
.02 30 bar
X11
135- 347
LS A2 Y961 0.2 B960P
160 bar
.04
T X 5 bar
.05 B3
X1 P .01
.01
P
30 bar
270
X19
TO CARRIER CIRCUIT
S MS MA

X10

Parking brake circuit functional diagram (releasing), TC9
T2 B970T
BR T1 .07 110° C
T3
.06
B966P B967P .04
291 C1
276 277 .05
P3 P1 C4 C3
P/I 31 11 .08
Parking brake circuit functional diagram (releasing), TC9

14,3 bar
P2 C2
.01
OPTION
281 OUT
GEARBOX

12
OPTION
P .02
Y296 A ABA
80 bar 80 bar
70bar 272 271
.02 FRONT REAR B
P
A
B Carrier hosing T
and return 282
.01 T X25
filters


4.1.9
60 (92)
.01 .02 .01 .02
OPTION
TEST VALVES
MF2 285
293 286
(REAR SERVICE 5 bar

TEST VALVES
F1
.06
MF1

CLARK CLUTCH
.02 294
X12 T T 344
267
X
P
.03 A1
.01 279 284
.02 100 bar S15.1
TO CARRIER CIRCUIT 347
X11 50 bar
LS 135- A2 Y295.2
160bar .02 S15.2
.04
278
T X
X1 .05 5 bar
B3
1/21 P .01
P .01
30 bar
270
S MS MA
TO AIR CONDITION/
CARRIER CIRCUIT T2

276 277 B1
PRESSURE CONTROL OF BR T3 T1
.08 C1
B2 291
275 274 P3 P1 C4 C3
.05 P / I 31 11 OUT
B13 P/I P/I B14 IN
14,3 bar
100 bar
100 bar S16 20000/ .01
(ABA 110 bar) 32000
(ABA 110 bar)
Parking brake circuit functional diagram (releasing), TC10-TC12
REAR .03 SERIE

FRONT 272 271 .02 OUT
80 bar 4 bar 12
80 bar IN
OPTION
ABA ENGINE
Y296 Y297 FAN
.02 .01
70bar 70bar
Parking brake circuit functional diagram (releasing), TC10-TC12

A .01 P P .02 A
B 281 282 B

BRAKE TEST X14
VALVES

has risen over the set limits (front brake circuit 50 bar / rear brake circuit 5
bar), the parking brake indicator lamp (H15) on the driving panel turns off.
The springs in cylinders (285) and (286) are compressed and the parking
brakes are released.
4.2 Service brake circuit, TC7-TC12, NC7
1 2
1 Front brake circuit pressure gauge and indicator light (P3)

2 Rear brake circuit pressure gauge and indicator light (P4)
Accumulator pressure is released by pumping the brake pedal all the way
down until the brake pressures are 0 bar (gauges P3 and P4). Note! Diesel
engine has to be switched off and the power has to be ON. For more
information, see the Maintenance and lubrication manual for drill carrier.

Service brake circuit functional diagram, NC7
.01
.07
.06
.02
.05
.04
.03
275
267
.01
276
281
.02
293
272
271
344
.01
.02
.01
.01
270
282
277
.02
.02
285
.01
274
.02
345
280
279
.05
.06
.03
.04
291
284
.02
.01
.07
.08
294
.01
286
347
278
.02
Service brake circuit functional diagram, NC7 4.2.1
Operation of the service brake circuit

The oil flows to the service brake circuit from the gear pump (252). From
the pump (252) the oil flows through the double pressure relief valve
assembly (261) to the integrated service brake valve (267) connection P.
If the brake pedal is not used and the service brake circuit pressure
accumulators (271) and (272) do not need extra oil, the oil pressure in the
service brake circuit starts to rise to 160 bar. When the control pressure
rises to 160 bar, the control valve (267.02) changes its position. The pilot
control oil from the control valve (267.01) is directed to the receiver. At the
same time, the control valve (267.01) changes position and directs the oil
from port P to port S of the integrated brake valve (267), and from there the
oil flows to the secondary circuits.
If the control pressure falls below 135 bar in the “charging circuit”, the
control valve (267.02) changes position and directs the oil flow from the
brake circuit main line to the spring side of the control valve's (267.01)
control spool. The control valve (267.01) spool changes position and directs
the main flow through the non-return valve (267.05) and pressure relief
valves (267.03) and (267.04) to ports A2 and A1 of the integrated brake
valve (267).
From port A2 the oil flows to the front brake cylinder pressure transducer
(275) and front brake cylinder pressure accumulator (272). From port A1
the oil flows to the rear brake cylinder pressure transducer (274) and rear
brake cylinder pressure accumulator (271). When the brake pedal is used,
the oil flows through the pressure reducing/relieving valves (267.06) and
(267.07) to port F1 and F2. From there the oil flows to the front service
brake cylinders (285.01), rear service brake cylinders (286.02), and
measuring point collector (284).
The control pressure value of pressure reducing/relieving valves (267.06)
and (267.07) is directly proportional to the change of the brake pedal angle.
The greater the change of angle, the greater control pressure and braking
force.
The function of the pressure accumulators (271) and (272) is to ensure a
sufficient amount of oil for brake pedal operation. Pressure transducers
(274) and (275) control the level of the service brake circuit charging
pressure. If the pressure drops below 100 bar, the warning light (P3) and/or
(P4) of the pressure gauge on the tramming panel lights up.
Normal brake circuit pressure is 135-160 bar. If the brake circuit pressure in
one or both brake circuits is below 75 bar, the brakes cannot be released.
The parking brake holding circuit will not be activated unless the pressures
at front brake circuit pressure switch (276) and rear brake circuit pressure
switch (277) are not within the permissible range. When the brake circuit
pressure in both circuits increases to above the 75 bar limit, the brakes can
be released and the rig can be taken into use by releasing the brakes with
parking brake button S21 on the tramming panel and acknowledging the
brake circuit as released with button SH2 (refer to section 3.3.1).
The pressures in the brake circuits are also monitored with front and rear
pressure transducers: (275) and B14 (274), respectively. The pressures in

the brake circuits are displayed on brake pressure gauges P3 and P4 on

the tramming panel.
If the brake circuit pressure drops below 100 bar on brake pressure gauges
P3 (front) and P4 (rear) on the tramming panel, the red low brake pressure
warning lights go on.
If the brake pressure in one or both brake circuits (front brake circuit, (276),
and/or rear brake circuit, (277)) drops below 75 bar, the pressure switch
deactivates the parking brake holding circuit and the brakes engage.


4.2.2
66 (92)
285 286
.01 .02 .01 .02
267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293
H H
(REAR SERVICE
F1 280 S19
.06 347 5 bar
MF1
344
X12 Y295.1 .02
T

.03 A1
P .01 279
.02 30 bar
284
TO CARRIER CIRCUIT
X11
135-
LS 160 bar
A2 Y295 .02
.04
.05 T X
B3
X1 P .01
P .01
30 bar
S15.2
270
X14 278
Service brake circuit functional diagram, TC7-TC8
S MS MA
TO CARRIER CIRCUIT

X10
276 277 .07

BR T3 .04 T1
.06
110° C
75 bar 75 bar C1
.05 291
P3 P1 C4 C3
275 274 B2 P / I 31 11 .08
P4 OUT IN
B1 3 P / I P/I B1 4 14,3 bar
P2 C2
100 bar 100 bar .01
S16 OUT
GEARBOX

272 271 .03 IN
.02 P P .02
A A ABA
B B
Carrier hosing
OPTION and return
T T filters

valve (267).
force.


the tramming panel.


4.2.3
70 (92)
.01 .02 .01 .02
267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293 H H
(REAR SERVICE
.07
280 B968P
F1
.06 294
MF1
344 0.2
CLARK CLUTCH
X12 T T X
.03 A1 278
P B961P
0.1 279 284
.02 30 bar
X11
135- 347
LS A2 Y961 0.2 B960P
160 bar
.04
T X 5 bar
.05 B3
X1
Service brake circuit functional diagram, TC9
P .01
.01
P
30 bar
270
X19
TO CARRIER CIRCUIT
S MS MA

X10
Service brake circuit functional diagram, TC9

BR T1 .07 110° C
T3
.06
B966P B967P .04
291 C1
276 277 .05
P3 P1 C4 C3
P/I 31 11 .08
14,3 bar
P2 C2
.01
OPTION
281 OUT
GEARBOX

12
OPTION
P .02
Y296 A ABA
80 bar 80 bar
70bar 272 271
.02 FRONT REAR B
P
A
B Carrier hosing T
and return 282
.01 T X25
filters

valve (267).
force.


the tramming panel.


4.2.4
74 (92)
.01 .02 .01 .02
OPTION
ONLY WITH BRAKE P2 P2 P1 P2 P2 P1 P1
TEST VALVES
MF2 285
293 286
(REAR SERVICE 5 bar

TEST VALVES
F1
.06
MF1

CLARK CLUTCH
.02 294
X12 T T 344
267
X
P
.03 A1
.01 279 284
.02 100 bar S15.1
TO CARRIER CIRCUIT
347
X11 50 bar
LS 135- A2 Y295.2
160bar .02 S15.2
.04
T 278
.05 X 5 bar
X1 B3
1/21 P .01
P .01
30 bar
270
S MS MA
TO AIR CONDITION/
CARRIER CIRCUIT

276 T2
277 B1
PRESSURE CONTROL OF
BR T3 T1
.08 C1
B2 291
275 274 P3 P1 C4 C3
.05 P / I 31 11 OUT
B13 P/I P/I B14 IN

14,3 bar
100 bar
S16 20000/ .01
100 bar (ABA 110 bar) 32000
(ABA 110 bar) .03 SERIE
REAR .02 OUT
FRONT 272 271 4 bar
80 bar 80 bar 12
IN
OPTION
ABA ENGINE
Y296 Y297 FAN
.02 .01
70bar 70bar
A .01 P P .02 A
B 281 282 B

BRAKE TEST X14
VALVES

valve (267).
force.


the tramming panel.
4.2.5 Operation of the ABA-system
On rigs with ABA brakes, the transmission clutch pressure is monitored
with pressure switch S16 in addition to brake pressure monitoring. The
brakes cannot be released unless the transmission clutch pressure rises to
above 4 bar. When the clutch pressure drops below 4 bar, the pressure
switch deactivates the parking brake holding circuit and the brakes engage.
Indicator light H20 (impending brake pressure) on the tramming panel
warns of falling brake pressure on rigs with ABA brakes. This indicator light
goes on when the pressure in one or both brake circuits drops below 110
bar.
Moreover, rigs with ABA brakes feature an additional indicator light, H15B,
located above the tramming panel on the right-hand side. This light
indicates that the parking brake is engaged (same function as with indicator
light H15 on the tramming panel).

4.3 Testing the brakes
Instruction plate for brake testing

Instruction plate for brake testing (USA / Canada option)

4.3.1 Service brake testing system, TC7-TC12, NC7 (optional)

rpm
0
rpm
1
SH56
With Mercedes Benz engine

rpm
0
rpm
1
SH56
With Cummins engine
1 Service brake test switch (S29)

2 Parking brake test switch (S25)

Functional diagram of the service brake testing system, NC7
.02
278
347
286
.01
294
.08
.07
.01
.02
284
291
.04
.03
.06
.05
279
280
345
.02
274
.01
285
.02
.02
277
282
270
.01
.01
.02
.01
344
271
272
293
.02
281
276
.01
267
275
.03
.04
.05
.02
.06
.07
.01
Functional diagram of the service brake testing system, NC7

Operation of the service brake testing system, TC7-TC8, NC7
Testing of the front axle service brake

When the service brake testing valve's (281) spool Y296 is activated, the
valve allows oil to flow from port P to port B. The oil flows to the front axle
service brake through the shuttle valve (293). The pressure reduction valve
decreases the oil pressure to the brakes to 80 bar.
Testing of the rear axle service brake

valve allows oil to flow from port P to port B. The oil flows to the rear axle

82 (92)
285 286
.01 .02 .01 .02
267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293
H H
(REAR SERVICE
F1 280 S19
.06 347 5 bar
MF1
344
X12 Y295.1 .02
T

.03 A1
P .01 279
.02 30 bar
284
TO CARRIER CIRCUIT
X11
135-
LS 160 bar
A2 Y295 .02
.04
.05 T X
B3
X1 P .01
P .01
30 bar
S15.2
270
S MS MA X14 278
TO CARRIER CIRCUIT

X10
276 277 BR .07
T3 .04 T1 110° C
.06
75 bar 75 bar C1
.05 291
P3 P1 C4 C3
275 274 B2 P / I 31 11 .08
P4 OUT IN
B1 3 P / I P/I B1 4 14,3 bar
Functional diagram of the service brake testing system, TC7-TC8
P2 C2
100 bar 100 bar .01
S16 OUT
GEARBOX

272 271 .03 IN

.02 P P .02
A A ABA
B B
Carrier hosing
OPTION T T and return
filters
Operation of the service brake testing system, TC7-TC8, NC7

valve allows oil to flow from port P to port B. The oil flows to the front axle

valve allows oil to flow from port P to port B. The oil flows to the rear axle

84 (92)
.01 .02 .01 .02
267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293 H H
(REAR SERVICE
.07
280 B968P
F1
.06 294
MF1
344 0.2
CLARK CLUTCH
X12 T T X
.03 A1 278
P B961P
0.1 279 284
.02 30 bar
X11
135- 347
A2
LS 160 bar Y961 0.2 B960P
.04
T X 5 bar
.05 B3
X1 P .01
P .01
30 bar
270
X19
TO CARRIER CIRCUIT
S MS MA
X10

BR T1 .07 110° C
T3
.06
B966P B967P .04
291 C1
Functional diagram of the service brake testing system, TC9
276 277 .05

P3 P1 C4 C3
P/I 31 11 .08
14,3 bar
P2 C2
.01
OPTION
Functional diagram of the service brake testing system, TC9

281 OUT
GEARBOX

12
OPTION
P .02
Y296 A ABA
80 bar 80 bar
.01 70bar
.02 FRONT 272 271 REAR
P B
A
B Carrier hosing T
T and return 282
filters X25
Operation of the service brake testing system, TC9-TC12

valve allows oil to flow from port (P) to port (B). The oil flows to the front
axle service brake through the shuttle valve (293). The pressure reduction
valve decreases the oil pressure to the brakes to 70 bar.

valve allows oil to flow from port (P) to port (B). The oil flows to the rear

86 (92)
.01 .02 .01 .02
OPTION
ONLY WITH BRAKE P2 P2 P1 P2 P2 P1 P1
TEST VALVES
MF2 285
293 286
(REAR SERVICE 5 bar

TEST VALVES
F1
.06
MF1

CLARK CLUTCH
.02 294
X12 T T 344
267
X
P
.03 A1
.01 279 284
.02 100 bar S15.1
TO CARRIER CIRCUIT
347
X11 50 bar
LS 135- A2 Y295.2
160bar .02 S15.2
.04
T 278
.05 X 5 bar
X1 B3
1/21 P .01
P .01
30 bar
270
S MS MA
TO AIR CONDITION/
CARRIER CIRCUIT T2
276

277 B1
PRESSURE CONTROL OF BR
BRAKE CIRCUIT 75 ba r 75 bar .06
T3 T1 .07
.04 110° C
.08 C1
B2 291
275 274 P3 P1 C4 C3
.05 P / I 31 11 OUT
B13 P/I P/I B14 IN
14,3 bar
100 bar
100 bar S16 20000/ .01
(ABA 110 bar) 32000
(ABA 110 bar) SERIE
REAR .03
FRONT 272 271 .02 OUT
80 bar 80 bar 4 bar 12
IN
OPTION
ABA ENGINE
Y297 FAN
Y296
.02
70bar 70bar
.01 .01
A P P .02 A
B 281 282 B

T T
OPTION X14
BRAKE TEST Carrier hosing and
return filters
VALVES
Operation of the service brake testing system, TC9-TC12

valve allows oil to flow from port (P) to port (B). The oil flows to the front

valve allows oil to flow from port (P) to port (B). The oil flows to the rear


5 STEERING AND BRAKE SYSTEM TROUBLESHOOTING

5.1 Steering
Fault Cause Action
The wheels do not stay turned in the de-
sired direction but move forward and
Air in the steering cylinder or in
backward when the steering wheel is not Bleed the steering
the piping between the cylinder
turned. The steering wheel must be system.
and the steering valve.
turned quite a distance (e.g., 1/4 of a
turn) before the wheels start turning.
sired direction but move forward and
backward when the steering wheel is not Worn connections in the steering Change the worn
turned. The steering wheel must be system controls. connections.
turned quite a distance (e.g., 1/4 of a
sired direction but move forward and Air in the steering system – e.g., if
Check the oil level
backward when the steering wheel is not the oil level in the tank is too low
and check for oil
turned. The steering wheel must be or the suction hose of the hydraul-
leaks.
turned quite a distance (e.g., 1/4 of a ic pump leaks.
Oil leaks in the hydraulic circuit
between the steering valve and
The wheels turn during tramming, usually cylinder because of:
slowly, even though the steering wheel is
not turned. When the steering wheel is • a faulty steering cylinder Replace the parts.
turned, the wheels do not turn or they turn • a worn ORBITROL steering
slowly. valve
• a faulty surge damping valve
Clean the steering

Steering is unstable and the steering
valve, and check
wheel is stiff when turned. The turning Dirt in the ORBITROL steering
the cleanliness of
movement of the steering wheel contin- valve causes the adjusting valve
the oil using an oil
ues – e.g., when the steering wheel is re- spools to stick.
analyzer. Change
leased.
the oil.

Fault Cause Action

There is no oil in the steering sys-
tem due to, for example: Check the pump
The steering wheel turns lightly approxi- output pressure
mately 8 degrees in either direction from • a faulty hydraulic pump from the pressure
the middle position, but after this turning • a faulty safety relief valve or gauge in the
feels heavy. Power steering is not work- flow regulator valve measuring point.
ing. Replace faulty/
• a faulty non-return valve in the
worn components.
ORBITROL control valve
A jammed steering wheel arm

The steering wheel is heavy when turned Replace faulty/
bearing or faulty ORBITROL con-
or does not turn at all. worn components.
trol valve.
5.2 Brakes
Fault Cause Action
Low service brake power Worn braking surfaces. Change the worn braking surfaces.
Check the adjusting pressure. Re-
place faulty components. Check the
pressure accumulators' charging
Low service brake power Low braking pressure. pressure (65 bar / TC7-8 / NC7, 80
bar / TC9-12), adjust if necessary.
Check the brake hoses, replace faul-
ty ones.
Low service brake power Air in brake circuit. Bleed the brake cylinders.
Low parking brake power Worn braking surfaces. Change the worn braking surfaces.
Brake clearance (in the
Low parking brake power Adjust the brakes.
brake cylinder) too large.
Brake cylinder springs fa-
Low parking brake power Replace the springs.
tigued.
Parking brake not properly
Air in brake circuit. Bleed the system.
released
Parking brake not properly The brake cylinder seals
Replace the seals.
released are leaking.
Parking brake not properly
Leaking connections. Tighten the connections.
released
The brake circuit cannot be
The discharge valve or one of
pressurized and the rig's
the valves is de-energized or Change / repair the valve.
parking brake cannot be re-
stuck in the open position
leased.
When servicing the brake circuit, al-
The discharge valve is stuck The pressure remains in the
ways ensure that there is no pres-
in the closed position brake valve.
sure in the system.

www.sandvik.com
en-US 5 2021-02-17
Tire change and rim inspection
GUID-9776D7EE-544C-453F-8186-A2322E29401A
WARNING
ID:GUID-9776D7EE-544C-453F-8186-A2322E29401A en-US 5 2021-02-17
Table of Contents
1 Introduction.......................................................................7
2 Safety and environmental instructions.......................... 9

2.1 Safe removal of a wheel from a machine..................................................9
2.2 Safety when fitting tires............................................................................10
3 Main components........................................................... 11
3.1 Tire markings.............................................................................................11
3.2 Rims............................................................................................................11
3.2.1 Rim markings.................................................................................. 13
4 Maintenance and repair instructions............................15

4.1 Typical defects that require parts replacements....................................15
4.2 Inspections on wheel components......................................................... 16
4.2.1 Inspections before mounting a tire on a rim.................................... 16
4.2.2 Magnetic inspection on the rim........................................................17
4.3 Mounting a tire on a rim........................................................................... 17
4.3.1 Tire pressurization...........................................................................17
4.3.2 Safety cage..................................................................................... 18
4.4 Foam fillings.............................................................................................. 20
4.4.1 General............................................................................................20
4.4.2 Accepted foam fillings..................................................................... 20
4.4.3 Applying the foam fillings.................................................................20
4.4.4 Handling the foam filled tire.............................................................21
1 INTRODUCTION
information.


2 SAFETY AND ENVIRONMENTAL INSTRUCTIONS

2.1 Safe removal of a wheel from a machine
Always follow both local and mine-specific safety regulations in
handling the wheels or the tires of the drill rigs.
Never go under the rig, when it has been lifted onto the jacks.
Always support the drill rig properly when detaching the wheels.
Also make sure that the support structure is strong enough as the
rigs weigh 3 000 – 60 000 kilos depending on the rig type. Pay special
attention to the load-carrying capacity of the ground on which the
support is placed.
Pay attention to differences of the wheel assembly weights when

handling the wheels. The weight of the wheel variates depending on
the wheel size, manufacturer and filling method. Check the weights
of the wheel assemblies from a technical manual (e.g. Weights and
dimensions).
CRUSHING HAZARD!
When removing the wheel of the oscillating axle, pay attention to the
changing weight of the axle and to the fact that the axle end of the
wheel to be detached can rise up. We recommend using wooden
wedges to prevent the swinging of the oscillating axle.
Note! It is recommended to let qualified personnel to inspect and assemble

the tires and rims.
The removal of a wheel is a specialist operation requiring special
equipment and knowledge.
Before removing a wheel always make sure that it is possible to work safely
and in accordance with the local and mine-specific safety regulations.
There shall be adequate tools and equipment available for the safe removal
of wheels.
Always before loosening any wheel nuts, check the following:
1. Has the tire been driven under inflated (80% or more under its
recommended operating pressure)? If in doubt check the pressure.
2. Is there an obvious or suspected damage on the tire or wheel
components?
If these conditions apply, prior to loosening any wheel nuts, the tire shall be
completely deflated by removing the valve core.

If the rim and tire are in good condition, deflate the tire to a pressure of 35
kPa (0.35 bar, 5 psi), prior to loosening any wheel nuts.
If it is not possible to use any devices for removing the wheel, you must do
it by hand. This is done from behind, as seen from the direction of tire
tread. The wheel may tip over, which is why you must make sure there is
enough room for escaping the falling wheel. The wheel of a drill rig can
weigh several hundreds of kilos. Be cautious when servicing the wheel on
slanting surfaces.
Most drill rigs can be lifted onto their jacks so that the tire is visibly off the
ground. Always place a support under the axle, if you take the wheel off.
Unscrew the bolts and detach the wheel.
2.2 Safety when fitting tires

Always observe the following safety precautions when pressurizing a tire:
• Never use damaged rim or rim-parts.
• Use proper lubricant.
• If lock ring is displaced, deflate the tire by removing the valve core,
before adjusting.
• Do not use force and never hammer on inflated assemblies.
• Always use safety-cage when inflating.
• If no safety-cage is available, stand well away in the direction of the tire
tread. Always pressurize from a distance (at least 1.5 m).
• Use hearing protection.
• Never sit on or lean against a tire while inflating.
• Always supervise the tire during inflation.

3 MAIN COMPONENTS
3.1 Tire markings
2
1
3
5
6
1 Tire width 2 Rim diameter

3 Ply rating (PR) 4 Operating environment
5 Year of manufacture 6 Manufacturer
(50=week n:o 50, 08=year
2008)
Sandvik uses tubeless tires with tube on drill rigs. When replacing the tire,
ensure the load capacity, size and type of the new tire are corresponding
the unit and rim specifications.
3.2 Rims
Rims are manufactured according to European Tyre and Rim Technical
Organisation (ETRTO) standards.
Sandvik uses 3- or 4-piece tube type (TT) rims.
NOTE! It is prohibited to use any other than Sandvik rims on Sandvik drill
rigs!

2 1 1 4
2 5
4
3-piece rim
1 1 4
2
3 5
3
7 6
4-piece rim
1 Side ring 2 Lock ring

3 Bead seat ring 4 Rim
5 Disc 6 Tube
7 Flap
Tires on tube type rims shall be fitted with appropriate tube and flap.
Ensure the fitted tire, tube and flap are correct for the rim size.

3.2.1 Rim markings

Disc wheels are marked with the following information:
• Rim size designation
• Identification of the rim manufacturer
• Date of manufacture
Rings are marked with the following information:
• Identification of rim size to which the part may be fitted
• Identification of manufacturer
• Date of manufacture – at least the month and year
Rim size designation
8.5 – 20
• 8.5 width code (inch)
• 20 nominal diameter code (inch)


4 MAINTENANCE AND REPAIR INSTRUCTIONS

4.1 Typical defects that require parts replacements
• Cracks in the wheel disc face, in particular the bolt holes area and the
ventilation holes can be concerned
• Deformations or abnormal imprints in the bolt/stud fixings
• Leaks in tubeless tires derived by micro-cracks in the rim or by wear and
tear marks on the rim- tire matching surface
• Bent rim flanges (generally due to impacts against obstacles)
• Circumferential cracks on the rear flange or at the gutter in the base of
multipiece rims
• Broken, buckled side/kombi ring or excessive corrosion on rings of
multipiece rims
• Twisted rings, in particular lock and buckled rings
1 2 3 4 5
1 Cracks in rim shoulder and gutter

2 Cracks involving disc ventilation holes
3 Cracks in the bolt holes area
4 Broken (continuous) side ring
5 Buckled ("kombi" - side) ring
It is not allowed to perform any technical modification on the wheel.
The repair of a damaged rim or disc by heating, by welding, by

addition or removal of material is absolutely forbidden.
When disc wheel is damaged, change the whole disc wheel at once.
Do not change a single part of the disc wheel.
Note! Wear on rim flanges (top of the flanges) can be tolerated up to a

maximum of 10 % of the initial thickness of the rim material.

4.2 Inspections on wheel components

4.2.1 Inspections before mounting a tire on a rim
The disassembling of wheels and inspection of wheel components is a
specialist operation requiring special skills and knowledge.
All multi-piece wheel components shall be inspected before assembly.
Inspect and ensure that the tire and rim components match.
Do not reuse any rim or rim component that is:
• Bent out of shape
• Corroded
• Broken
• Cracked
1. Stretched
Note! Never use a stretched lock ring (closing ring).
Do not use rims if:

• Bolt holes are worn or elliptic.
• The rim has been repaired by welding.
• The rim has extreme wear on the bead seating area.
Rim flanges, rings and rim tire bead seating surfaces shall be free of dirt
and surface rust.

Do not reuse tires if:

• The machine has been driven with empty or with notably low pressure.
• There are signs of aging in the tire or the tire is over 10 years old.
• The general condition of the tire is poor, e.g.: there are fractures or too
little tread left.
• The tire is irreparably damaged.
• The tire has been running repaired.
Check that the tire is clean and dry and that there is no foreign material
inside.
Multi-piece wheel components shall not be interchanged. Use only spare
parts provided in the spare parts package provided by Sandvik for the
applicable rim.
4.2.2 Magnetic inspection on the rim
A magnetic particle inspection should usually be performed when service
hours on the rim have reached 12 000 to 15 000 hours. If the inspection is
not carried out, the rim and its parts shall be removed from service.
Consult the rim manufacturer on the recommended hours for magnetic
inspections on rims.
The inspection shall always be repeated at the every following 12 000 to 15
000 hour intervals.
If damage is found during visual inspection the magnetic particle inspection
shall be done immediately before continuing the rim use. If the inspection is
not carried out, the rim shall immediately be removed from service.
To perform a magnetic particle inspection on a rim assembly, the tire must
be removed first.
Note! This instruction is a guideline. Always follow the regulatory agency,
statutory authority or mine-specific rules concerning the magnetic
inspections on rims.
4.3 Mounting a tire on a rim

4.3.1 Tire pressurization
The fitting of tires is a specialist operation requiring special equipment and
knowledge.
The tire should not be inflated above a pressure of 50 kPa (7 psi , 0.5 bar),
before the components are checked for correct installation.
Once the tire is mounted on a rim and all components are correctly
positioned, continue inflating, stopping at 150 kPa (22 psi, 1.5 bar).
Never exceed inflating over 150 kPa (22 psi, 1.5 bar) without safety
arrangements!
Ensure that the beads are correctly located against the rim flange. Inspect
the tire and ensure that the tire has no deformations. Any deformation
requires examination by a specialist.

Only after these precautions shall the inflating be continued, in a safety

cage or other restraining device, to the recommended operating pressure.
Never exceed the maximum permitted air pressure.
If there exists no ”maximum permitted pressure” marking on the tire, check
the rig's operator manual, consult the tire manufacturer or importer for the
maximum pressure or recommended operating pressure for the given tire
and rim.
It is recommended to mark the pressure recommendation in the rig manual
for future purposes.
Note! Check the rig's operator manual, chapter "carrier maintenance" for
correct tire filling pressures.
4.3.2 Safety cage
Always use a safety cage whenever possible.
Safety cage is a safety device for the pressurization of tires and designed
to minimize the consequences of an exploding tire. The safety net around
the safety cage will stop any propelling rim components or pieces of Tire in
the case of an exploding tire.
Safety cage with an automatic tire inflator.
After the inflation, the tire and wheel components shall be inspected while
still in the restraining device (safety cage) to make sure that they are
properly seated and locked.

If further adjustment to the tire or wheel components is necessary, the tire

shall be deflated by removal of the valve core before the adjustment is
made.
Always observe the following precautions when pressurizing a tire:
Work with care and caution.
Always inspect that tire and the rim components match before
inflating the tire. Make sure the tire fits the rim. Pay special attention
to the compatibility of the closed rim parts to each other, and make
sure all the parts are in correct place.
Always use a safety cage or some other safety device when inflating
the tires. Never pressurize the tires of heavy machines over 150 kPa
(22 psi, 1.5 bar) without a safety cage or taking other sufficient safety
precautions. After pressurization, always check that the tire sits on
the rim correctly before removing the wheel from the safety cage.
Leave the wheel attached to the mounting machine or to the vehicle.

The wheel will stay put even if the tire explodes while it is being
inflated.
Always wear hearing protectors. Even when removing the valve, 90

dB noise limit is exceeded. In case of tire explosion, if hearing
protectors are not used, hearing will be permanently damaged.
Never stand beside the wheel, sit on the tire or lean over the tire
while inflating the tire. Inflate the tire from an appropriate distance.
Stand far enough (at least 1.5 m) and on the side of the tread. Use the
kind of mouth piece for the air hose that can be locked to the valve.
Observe the tire as it is being inflated. Monitor the pressurization and

make sure the tire beads rise properly onto the rim. Make sure that
the parts of the multi-piece rim have been positioned correctly. Take
the tire with the multi-piece rim to the safety cage after pressurization
to 150 kPa (22 psi, 1.5 bar).
Unauthorized people are not allowed in the vicinity of the wheel

during the tire is being inflated.

If you notice anything abnormal, empty and check the tire, the rim
and the mounting. If the tire will not rise normally onto the rim, or if
you hear a creaky noise during the pressurization, empty the tire and
remove it from the rim and find out the reason for the problem. Never
use a damaged tire.
4.4 Foam fillings

4.4.1 General
Sandvik provides foam filled tires as an option. Foam filled tires could be
the solution for challenging road conditions. Tire won't get flat causing
downtime. Foam filling also improves the safety; hazard of losing stability
unexpectedly during tramming is avoided and dangerous tire inflating and
tire pressure check procedures are not needed.
Issues to remember when using tire fillings:
• Rolling resistance of foam filled tire is higher due the weight increase.
• Tramming speed should be reduced with foam filled tires.
• Foam filled tires changes machine's tramming comfort and
characteristics due to more rigid structure.
4.4.2 Accepted foam fillings
Before using the foam filled tires or filling the tire with the foam, make sure
that the fillings are applicable to the machine.
Increased tire mass with foam filled tires stresses the axles and
transmission more than air filled tires. Sandvik (axle manufacturer) has
approved the use of following fillings:
TyrFil XL (hardness of 15 shore A)
Zeus Polyfill SOFT (hardness of 12-15 shore)
Note! Filling above can only be used on those product models where the
use of filling is approved/provided by Sandvik. Filling shall be used
only with the tire brands and tire types used by Sandvik. Contact
Sandvik for filling availability for your product.
Use of any other brand/type filling should be approved by Sandvik case by
case. Use of any other brand/type filling without Sandvik approval will void
the warranty in case of:
• Wheel and wheel assembly failures
• Rim failures
• Axle failures
• Any other failures caused directly or indirectly by the use of disapproved
foam fillings
4.4.3 Applying the foam fillings
Sandvik recommends filling the tires only by dealers authorized by the tire
manufacturer. Foam filling procedure requires special equipment and
knowledge.

Before filling the foam, rim assembly and rim components shall be
inspected for cracks, wear and other possible failures. See chapter
"Inspections on wheel components".
4.4.4 Handling the foam filled tire
Sandvik installed foam filled tires can be separated from Sandvik air filled
ones by checking the color of the inflating valve cap. It is yellow when foam
filled tires are used.
Note! Increased tire weight must be considered when handling the tire. A
foam filled tire assembly weights up to twice as much as an air filled tire
assembly.
The foam fillings cannot be reused and are harmful to environment.
Disposal of foam filled tires shall be done according to local regulations
together with the instructions given by the manufacturer of the foam fillings
and foam dealer.
Check the weights of the wheel assemblies from a technical manual (e.g.
Weights and dimensions).


www.sandvik.com
GUID-D5BFEB18-7219-4D18-A268-74D89D303AC6 en-US 3 2020-03-10
Mercedes Benz engine fault codes

WARNING
ID:GUID-D5BFEB18-7219-4D18-A268-74D89D303AC6 en-US 3 2020-03-10
Table of Contents
1 Engine control fault codes.............................................. 7
1.1 Fault codes of engine control (PLD-MR) via SAE J1939......................... 7
2 Vehicle control fault codes............................................ 33

2.1 Fault codes of vehicle control (+CPC4-eCAN) via SAE J1939.............. 33
1 ENGINE CONTROL FAULT CODES

1.1 Fault codes of engine control (PLD-MR) via SAE J1939
Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
The heating flange becomes after Kl.
15 uniquely briefly switched on. Here if
open circuit
no break-down of the battery voltage is
fault (heater
45/12 16409D) heater flange recognized, the heating flange is clas-
flange defec-
sified as defective. Error threshold and
tive)
cyclic duration are deposited in the da-
ta record.
measuring
fuel pressure If a fuel pressure sensor or a combina-
range exceed-
sensor or fuel tion sensor fuel pressure & tempera-
94/0 11715 ed or short cir-
pressure & tem- ture is fitted to the engine depends on
cuit to terminal
perature sensor the engine make
30 / terminal 15
remains under
combination in-
measuring
94/1 11716 put (FPS, P-
range or short
DK)
circuit to ground
combination in-
signal not plau-
94/2 11717 put (FPS, P-
sible
DK)
combination in-
94/3 13015 put (FPS, P- open circuit
DK)
combination in-
short circuit to
94/4 13016 put (FPS, P-
ground
DK)
Fuel line signal measured value
94/14 11917
not plausible * not plausible
• message via CAN: warning oil level

engine oil circu- fluid level too too high (=98/0) or advance warning
98/2 02026
lation* high / too low (=98/1) or warning oil level too low
(=98/1)

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****
• check oil level, correct if necessary.

• check wire for short circuit to bat-
oil level sensor tery, repair or replace if necessary.
measured value
02517 (up to diagnosis • check oil level sensor, replace if
not plausible
version 4) necessary. nominal value: 20...25
Ohm
• perform functional check.

• check wire for short circuit to
ground, repair or replace if necessa-
measuring ry.
oil level sensor
98/4 02515 range exceed-
** • check oil level sensor, replace if
ed
necessary. nominal value: 20...25
Ohm

• check wire for short circuit to
oil level sensor measured value ry.
98/3 02516
** not plausible • check oil level sensor, replace if
necessary. nominal value: 20...25
Ohm
• check oil level sensor , replace if

necessary.
oil level sensor open circuit
98/5 02509 • check wire for open circuit fault, re-
** fault
pair or replace if necessary.

• check wire for open circuit fault, re-
oil pressure signal not plau- pair or replace if necessary.
100/2 11617
sensor sible • check oil pressure sensor, replace if
necessary.

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****
• check oil pressure sensor, replace if

necessary.
measuring
oil pressure • check wire for open circuit fault or if
sensor shortened to batteryvoltage, repair if
ed
necessary.
• check oil pressure sensor, replace if

remains under necessary.
oil pressure
100/4 11616 measuring • check wire for short circuit to
sensor
range ground, repair if necessary.
engine oil circu- pressure too • message via CAN: oil pressure ad-
100/14 02020
lation ** low vance warning or warning
• if fault codes 11415 or11417 are al-

so present, process them first.
boost pressure • boost pressure system (boost air
102/0 11820 booster path *
too high tubes, boost air cooler) visual
check.
• check tubes and connections be-

tween turbocharger, boost air cooler
booster path and the boost air tubes for leakage.
102/1 11818 booster path *
defective
• check boost air cooler.

pair if necessary.
• check boost pressure sensor, re-
boost pressure measured value place if necessary.
102/2 11417
sensor not plausible • perform functional check.
• if fault code 01315 or 01316 also
actual: replace and calibrate ECU
engine control (e.g. MR-PLD).

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****
• check boost pressure, replace if

necessary.
measuring
boost pressure • check wire for open circuit fault and
sensor if shorted to battery voltage, repair if
ed
necessary.
• unplug the connector from combina-

tion sensor. fault codes 01215 and
remains under 11415 actual: replace combination
boost pressure sensor.
102/4 11416 measuring
sensor
range • check wire for short circuit to
ground, repair if necessary.
max. output of
booster path /
booster speed
102/13 11873 boost pressure
balancing gov-
control **
ernor
booster path / (with power reduction)

11874or- set value devia-
102/13 boost pressure • check booster path fault codes
der 01874 tion too high
control 11874* , 01874**
booster path / boost pressure

102/13 11875 boost pressure deviation too
control * high
booster path /
braking power
102/13 11876 boost pressure
too low
control *
(boost pres-
scavenging gra- • check sensor, replace if necessary.
sure ) measur-
102/13 12415 dient sensor
ing range ex- • check wire for open circuit
(P2S-P3) **
ceeded
(boost pres-
scavenging gra- • check sensor, replace if necessary.
sure ) remains
102/13 12416 dient sensor
under measur- • check wire for open circuit
(P2S-P3) **
ing range
no speed boos- no engine
103/7 12612
ter 1 ** speed

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****
no speed boos- no engine
103/14 12712
ter 2 ** speed
temperature to • temperature of boost pressure too

105/0 01822 booster path **
high high
• check temperature sensor, replace if

necessary.
• nominal value: 2.4 k Ohm (corre-
measuring sponds to 215C)
boost tempera-
ture sensor • check wire if connected to battery
ed
voltage and if open circuit fault, re-
pair if necessary.
• check temperature sensor, replace if

necessary.
remains under • nominal value: 2.4 kOhm (corre-
boost tempera- sponds to 215C)
ture sensor
coolant temper- temperature too

110/0 02122
ature sensor * high
• check sensor, repair or replace if

necessary.
• nominal value: 2.4 kOhm (corre-
measuring sponds to 215C)
coolant temper-
ature sensor • check wire for open circuit fault or if
ed
shortened to battery voltage, repair
if necessary.

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****

necessary.
coolant temper- sponds to 215C)
ature sensor
range • check wire for open circuit fault, re-
• check fuse, replace if necessary.

inconsistency • check wires and plug connectors for
terminal 15 de-
158/2 12219 MR<->FR ter- open circuit fault, repair or replace if
tection *
minal 15 necessary.
• check wires and plug connectors for

open circuit fault, repair if necessa-
inconsistency ry.
terminal 50 de-
158/2 12319 MR<->FR ter-
tection * • check wires and plug connectors for
minal 50
open circuit fault, repair if necessa-
ry.
terminal 30, nominal range • 24 V-Mode: 30 V, 12 V-Mode: 16 V

168/3 07542
battery voltage exceeded • alternator or governer defect
• 24 V-Mode: 22 V, 12 V-Mode: 10 V
terminal 30, remains below
168/4 07543 • battery defect
battery voltage nominal range
• alternator, governor or fuse defect
• check wire, repair or replace if nec-

essary.
• nominal value: 2.4 kOhm (corre-
measuring sponds to 215C).
fuel tempera-
ture sensor • check wire if shortened to battery
ed
voltage and if open circuit fault, re-
pair if necessary.

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****

necessary.
fuel tempera- sponds to 215C).
ture sensor
• check oil temperature sensor and

replace if necessary.
measuring • nominal value: 2.4 kOhm (corre-
oil temperature sponds to 215C).
sensor
ed • check wire for ground short, repair if
necessary.
• check oil temperature sensor B11

and replace if necessary.
oil temperature sponds to 215C).
sensor
range • check wire for ground short, repair if
necessary.
• inform about authorized engine

engine speed speed
190/0 10530 engine speed
too high
• delete fault memory
• check all affected connectors, plug

connections and electrical compo-
nents for damage, loose contact,
backup control corrosion etc. and repair if necessa-
609/11 04056 internal fault * ry.
defective*
• if fault code is still present, renew
and program control unit.

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****
• if fault codes 11415 or 11416 are

present, remove them first.
• fault code 01315 remains present:
measuring
ambient pres- read out actual values 014 and 015
sure sensor and compare with each other.
ed
• actual value should be inside toler-
ance band (+/- 10%) while engine
stops.
• if fault codes 11415 or 11416 are

present, remove them first.
• fault code 01316 remains present:
remains under read out actual values 014 and 015
ambient pres-
609/12 01316 measuring and compare with each other.
sure sensor
range • actual value inside tolerance band
(+/- 10%) while engine stops: re-
place and program ECU engine
control (e.g. MR-PLD).

auxiliary con- corrosion etc. and repair if necessa-
609/12 04024 internal fault ry.
troller defective
• if fault code is still present, renew
HS-transistor
PVB1 high-re-
609/12 14034D) internal fault ** • Change control unit
sistance High-
side-Transistor
HS-transistor
609/12 14035D) internal fault ** PVB2 high-re- • Change control unit **
sistance
HS-transistor
609/12 14036D) internal fault PV5 high-resist- • Change control unit **
ance

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****
present, remove this fault code first.
high resistance connections and electrical compo-
starter driver nents for damage, loose contact,
609/12 04038 internal fault *
(redundant-/ corrosion etc. and repair if necessa-
auxiliary path) ry.
• check all affected plugs, plug con-

starter driver nectors and electrical components
609/12 14038 internal fault ** high-resistance for damage, loose contact, corro-
(main path) sion etc. and repair if necessary.
14039 starter • check all affected plugs, plug con-

driver low-re- nectors and electrical components
609/12 14039 internal fault * sistance (main for damage, loose contact, corro-
path or auxiliary sion etc. and repair if necessary.
path) • perform functional check.

level detection nectors and electrical components
609/12 04040 internal fault starter defec- for damage, loose contact, corro-
tive sion etc. and repair if necessary.
• perform functional.

internal fault (till PV- Highside- nectors and electrical components
609/12 14041 diagnosis ver- transistor de- for damage, loose contact, corro-
sion 4) fective sion etc. and repair if necessary.

nectors and electrical components
for damage, loose contact, corro-
CAN-data area sion etc. and repair if necessary.
609/12 14054 internal fault
defective
• if fault code is still present, replace

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****
Main branch: During the controller initi-
Starter output alization the two transistors of the main
stage with low branch are alternating switched on
impedance briefly. The level at the starter output
(main branch or changes thereby on "High", the main
branch of emer- branch is classified as low impedance.
609/12 18039 internal fault **
gency) or load Backup branch: If that changes for
(relay) also to clamp 50 signal on "High" and follows
high resistance this level change a change of the level
and/or to high at the starter output before the starter
inductance. output stage was activated, the backup
branch is classified as low impedance.

cylinder number nents for damage, loose contact,
609/14 04037 internal fault corrosion etc. and repair if necessa-
implausible
ry.

characteristic nents for damage, loose contact,
609/14 04047 internal fault data map de- corrosion etc. and repair if necessa-
fective ry.

cylinder number nents for damage, loose contact,
implausible
ry.

parametrization for damage, loose contact, corro-
609/14 14049 internal fault **
fault sion etc. and repair if necessary.

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****

incorrect hard- nents for damage, loose contact,
ware detection
ry.

EEPROM:
corrosion etc. and repair if necessa-
Checksum fail-
609/14 04051 internal fault ry.
ure1 (memory
fault) • if fault code is still present, renew

EEPROM: for damage, loose contact, corro-
CKS- fault 2 sion etc. and repair if necessary.
609/14 14052 internal fault
(groups vehicle
• if fault code is still present, replace
parameters)

connections and electric compo-
EEPROM: nents for damage, loose contact,
Checksum- corrosion etc., and repair if neces-
609/14 24053 internal fault ** fault 3 (block sary.
production or
• if fault code still present, renew and
immobilizer).
calibrate control unit.
short circuit to
611/4 06506 oil separator * ground diag-
nostic line.
oil separator
611/12 06564 oil separator *
defective

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****
• work off actual faults of SG FRE

CAN connec- CAN data not apart from CAN data bus fault co-
625/2 10102 des 10201, 00202 and 10203.
tion plausible
• check CAN connection to SG FRE.

• check cables, connectors, plug con-
for damage, correct connection,
loose contact and corrosion, repair if
necessary.
CAN connec- no connection • remove engine CAN bus fault in the
625/2 10104
tion to CAN SG FRE.
• perform functional check
• communication with the ECU engine
control (e.g. MR-PLD) restored:
check calibration of ECU engine
control (e.g. MR-PLD) for one wire
capability.
• check for open circuit fault, repair or

replace if necessary.
• switch on ignition.
CAN connec- CAN-High de-
625/14 10100 • delete fault memory in ECU engine
tion fective
• delete fault memory in SG FRE.

pair of replace if necessary.
• switch on ignition.
CAN connec- CAN-Low de-
625/14 10101 • delete fault memory in ECU engine
tion fective
• delete fault memory in SG FRE.
• perform functional.
CAN connec- parameter fault • check parameters and

625/14 10149
tion CAN • perform functional check.

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****
• pull out position sensor while engine

is stopped and perform visual
check.
• remove metal pieces/shavings if
necessary.
• replace position sensor in the case
crankshaft posi- crankshaft level of mechanical damage (clear stress
636/1 10310 marks).
tion sensor too low
• replace clamping sleeve of the posi-
tion sensor if necessary.
• press-in speed (position) sensor
during engine standstill until me-
chanical limit stop.
• check wire and position sensor for

crankshaft sen- open circuit fault, replace if neces-
crankshaft posi-
636/3 10309 sor open circuit sary.
tion
fault
• nominal value 1.2 kOhm.
• check wire and position sensor for

crankshaft posi- crankshaft sen- ground short, replace if necessary.
636/4 10308
tion sor ground
• nominal value 1.2 kOhm.
• pull out position sensor during en-

gine standstill and perform visual
check.
• replace position sensor in the case
of mechanical damage (clear stress
marks).
crankshaft/
• check crankshaft- and camshaft po-
crankshaft posi- camshaft signal
636/7 10311 sition sensor for tight fitting, replace
tion sensor assignment not
clamping sleeve if necessary.
plausible
• check wires at plug connection for
damage, correct connection and
corrosion, repair if necessary.
• check crankshaft- and camshaft po-
sition sensor at plug for interchang-
ing.

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****
• press in speed (position) sensor

crankshaft time- • fault code 10309 actual: work off
crankshaft posi- out - nocrank- this fault code.
636/8 10312
tion shaft signal
Timeout • fault code 10312 actual: check
crankshaft position sensor, replace
if necessary.
• nominal value 1.2 kOhm
crankshaft sen- • connect the position sensor correct-

crankshaft posi- ly.
636/14 10313 sor wrong po-
tion
larity • perform functional check.
shortened to
control solenoid battery voltage- • shortened to battery voltageHigh-
651/3 24805
valve ** Highside bank side bank 1
1
shortened to
control solenoid battery voltage-
651/3 24905 • switch off solenoid valves bank 2
valve ** Highside bank
2
ground short
control solenoid
651/4 24806 Low side bank • switch off solenoid valves bank 1
valve **
1
control solenoid ground short
651/4 24906 • switch off solenoid valves bank 2
valve ** Lowside bank 2
important note:
control failure • upon removing mechanical or elec-
control cylinder
651/5 15027 injector-/sole- trical faults at the injector valves, the
1 disturbed
noid valve engine-smoothness control has to
be set to zero.
important note:
short circuit in- • upon removing mechanical or elec-
solenoid valve
651/6 25028 jector solenoid trical faults at the injector valves, the
cylinder 1 **
valve cylinder 1 engine smoothness control has to
be set to zero.

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****
important note:
contact recogni- • upon removing mechanical or elec-
no contact cyl-
651/7 15026 tion injector-/ trical faults at the injector valves, the
inder 1
solenoid valve engine smoothness control has to
be set to zero.
important note:
engine-smooth- LRR-limitation • upon removing mechanical or elec-

651/12 09044 trical faults at the injector valves, the
ness cylinder 1 cylinder 1
engine smoothness control has to
be set to zero.
important note:
individual cylin- EZA-limitation • upon removing mechanical or elec-

651/14 09045 trical faults at the injector valves, the
der adaption cylinder 1
engine smoothness control has to
be set to zero
• upon removing mechanical or elec-

trical faults at the injector valves, the
engine-smoothness control has to
injector-/sole- control cylinder be set to zero.
652/5 15127 noid valve cylin- 2 disturbed /
der 2 failure • the engine-smoothness control can
be set to zero in the menu "controls"
at the menu level "check engine-
smoothness control".
• check electrical screw connections

short circuit in- of the affected injector valve for
solenoid valve short circuit.
652/6 25128 jector-/ solenoid
cylinder 2 **
valve cylinder 2 • disconnect electrical screw connec-
tions of the affected injector valve.
• upon removing mechanical or elec-

trical faults at the injector valves, the
contact recogni- engine-smoothness control has to
tion injector-/ no contact cyl- be set to zero.
652/7 15126
solenoid valve inder 2 • the engine-smoothness control can
cylinder 2 be set to zero in the menu "controls"
at the menu level "check engine-
smoothness control".

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****
important note:
engine-smooth-
injector-/sole- • upon removing mechanical or elec-
ness control:
652/12 09144 noid valve cylin- trical faults at the injector valves, the
LRR-limitation
der 2 engine smoothness control has to
cylinder
be set to zero.
important note:
individual cylin-
injector-/sole-
der adaptation: • upon removing mechanical or elec-
EZA-limitation
der engine smoothness control has to
cylinder
be set to zero.
important note:
injector-/sole- control cylinder • upon removing mechanical or elec-
653/5 15227 noid valve cylin- 3 disturbed / trical faults at the injector valves, the
der 3 failure engine-smoothness control has to
be set to zero.

injector-/sole- short circuit in- of the affected injector valve for
653/6 25228 noid valve cylin- jector-/ solenoid short circuit.
der 3 ** valve cylinder 3 • disconnect electrical screw connec-
contact recogni- important note:

injector-/sole- tion injector-/ • upon removing mechanical or elec-
653/7 15226 noid valve cylin- solenoid valve: trical faults at the injector valves, the
der 3 no contact cyl- engine smoothness control has to
inder 3 be set to zero.
important note:
engine-smooth-
ness control:
653/12 09244 noid valve: cyl- trical faults at the injector valves, the
LRR-limitation
inder 3 engine smoothness control has to
cylinder
be set to zero.
important note:
individual cylin-
injector-/sole-
653/14 09245 noid valve: cyl- trical faults at the injector valves, the
EZA-limitation
inder 3 engine smoothness control has to
cylinder 3
be set to zero.

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****

control failure tion injector-/ • upon removing mechanical or elec-
654/5 15327 injector-/sole- solenoid valve: trical faults at the injector valves, the
noid valve no contact cyl- engine smoothness control has to


important note:
engine-smooth-
ness control:
LRR-limitation
cylinder 4
be set to zero.
important note:
individual cylin-
der adaption:
EZA-limitation
cylinder 4
be set to zero.



Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****

important note:
engine-smooth-
ness control:
LRR-limitation
cylinder 5
be set to zero.
important note:
individual cylin-
injector-/sole-
EZA-limitation
cylinder 5
be set to zero.
control failure important note:

injector-/sole- injector-/sole- • upon removing mechanical or elec-
656/5 15527 noid valve cylin- noid valve: con- trical faults at the injector valves, the
der 6 trol cylinder 6 engine smoothness control has to
disturbed be set to zero.


important note:
engine-smooth-
ness control:
LRR-limitation
cylinder 6
be set to zero.

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****
important note:
individual cylin-
der adaption:
EZA-limitation
cylinder 6
be set to zero.
important note:
injector-/sole- control failure • upon removing mechanical or elec-
657/5 15627 noid valve cylin- injector-/sole- trical faults at the injector valves, the
der 7 noid valve engine smoothness control has to
be set to zero.


important note:
engine-smooth-
ness control:
LRR-limitation
cylinder 7
be set to zero.
important note:
individual cylin-
injector-/sole-
EZA-limitation
cylinder 7
be set to zero.
control failure important note:

injector-/sole- injector-/sole- • upon removing mechanical or elec-
658/5 15727 noid valve cylin- noid valve: con- trical faults at the injector valves, the
der 8 trol cylinder 8 engine smoothness control has to
disturbed be set to zero.

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****


important note:
engine-smooth-
ness control:
LRR-limitation
cylinder 8
be set to zero.
important note:
individual cylin-
injector-/sole-
EZA-limitation
cylinder 8
be set to zero.
• check wire - terminal 50 input of

starter relay if shortened to battery
starter relay ex- voltage, repair or replace if neces-
starter control sary.
677/3 18005 ternal current
(PLD-MR) **
supply • check starter relay, replace if neces-
sary.
• restore electrical connection(s)
• check of starter relay if shortened to

battery voltage, repair or replace if
starter relay ex- necessary.
starter control
677/5 18009 ternal current
(PLD-MR) ** • check starter relay, replace if neces-
supply
sary.
• restore electrical connection(s)

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****
• check wire - terminal 50 input of the

starter relay for short circuit to
starter control short circuit to ground, repair or replace if necessa-
677/6 18008 ry.
(PLD-MR) ** ground
• check starter relay, replace if neces-
sary.
• check starter electrically and me-

starter control starter does not chanically.
677/7 18086
(PLD-MR) ** engage
starter control starter relay • check starter relay, replace if neces-

677/14 18033 Starter relay is fixed in closed sary.
(PLD-MR) ** position • perform functional
proportional shortened to
697/3 17007D) valve (MBR- battery voltage • set output off
BK) (-lead)
17705 valve bank battery voltage • set output off 1 2 3 4
1PVB (+lead)*
proportional short circuit to
697/4 17708 valve bank 1 ground • set output off 1 2 3 4
(PVB 1) (+lead)**
• check parametrization.
• parameter 06 has to be set to NOT
open circuit
ACTIVE
fault** ECU en-
proportional
gine control • if not, then the data set of ECU en-
697/5 17009 valve 1 (MBR-
(e.g. MR-PLD) gine control (e.g. MR-PLD) is wrong
BK)
wrong calibra- • replace and program ECU engine
tion. control (e.g. MR-PLD).

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****
• check parametrization.
short circuit to • parameter 06 has to be set to NOT
ground (-lead) ACTIVE
proportional ECU engine
• if not, then the data set of ECU en-
697/6 17006 valve 1 (MBR- control (e.g.
gine control (e.g. MR-PLD) is wrong
BK) MR-PLD)
wrong calibra- • replace and program ECU engine
tion. control (e.g. MR-PLD).
shortened to
17305C) proportional
battery voltage
698/3 valve 2 (MBR- • set output off
17307D) (-lead) High
KD)
Side
17317C) proportional
open circuit
698/5 valve 2 (MBR- • set output off
17309D) fault Low Side
KD)
• check calibration, correct if neces-

sary. Parameter 007 has to be set to
proportional NOT ACTIVE.
short circuit to
valve 2 Activa-
ground (-lead) • if not, then the data set of the con-
tion: engine
698/6 17306 High Side trol unit MR is wrong.
brake reecom-
wrong calibra-
pression valve • replace and program ECU engine
tion
(MBR-KD) control (e.g. MR-PLD).
shortened to
proportional
699/3 17107D) battery voltage • set output off
valve 3
(-lead)*

NOT ACTIVE.
note:
open circuit
proportional • if a Linig-fan is installed, the follow-
699/5 17109 fault wrong cali-
valve 3 ing calibration applies:
bration
a) parameters 8 and 9 have to be
set to ACTIVE.
b) parameter 14 has to be set to
"Type 0".

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****

short circuit to NOT ACTIVE.
ground (-lead)
ECU engine • if the calibration is OK, check wire
proportional control (e.g. for short circuit to ground, repair or
699/6 17106 replace if necessary.
valve 3 MR-PLD)
wrong calibra- • if still no fault can be detected, re-
tion / short cir- place and program ECU engine
cuit to ground control (e.g. MR-PLD).
shortened to
proportional
700/3 17207** battery voltage • set output off
valve 4
(-lead)*
note: ECU engine control (e.g. MR-
PLD) wrong calibration / open circuit
fault
NOT ACTIVE.
note:
• if a Linnig-fan is installed, the follow-
ing calibration applies:
a) parameters 8 and 9 have to be
proportional open circuit set to ACTIVE
700/5 17209
valve 4 fault
b) parameter 14 has to be set to
"Type 0".
• fault code17209 remains actual:
check wires for open circuit fault, re-
• if no fault can be detected, replace
and program ECU engine control
(e.g. MR-PLD)
• set output off

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****
note: ECU engine control (e.g. MR-
PLD) wrong calibration / short circuit to
ground
NOT ACTIVE.
proportional short circuit to sary. Parameter 009 has to be set to
700/6 17206 NOT ACTIVE. if the calibration is
valve 4 ground (-lead)
OK, check wire for short circuit to
ry.
• if still no fault can be detected, re-
place and program ECU engine
shortened to
proportional
705/3 17405 battery voltage • set output off
valve 5
(+lead)*
proportional short circuit to
705/4 17408 • set output off for valve 6 and 5.
valve 5 ground (+lead)*
705/11 17805 valve bank 2 battery voltage • set output off for valve 6 and 5.
PVB 2 (+lead)*
proportional
short circuit to
705/11 17808 valve bank 2 • set output off for valve 6 and 5.
ground (+lead)*
PVB 2
proportional open circuit
706/3 17609 • set output off for valve 6
valve 6 fault *
camshaft sen- • check wire for open circuit, replace

camshaft posi- if necessary.
723/3 10409 sor open circuit
tion
fault • nominal value: 1.2 kOhm
camshaft sen- • check wire and position sensor for

camshaft posi- ground short, replace if necessary.
723/4 10408 sor ground
tion sensor
short • nominal value: 1.2 kOhm necessary.

Fault
codes Fault
SAE codes
J1939 PLD-MR
SPN/FMI ***
****
• if fault codes 10408 and 10409 are

current, remove them first
• pull out position sensor during en-
gine standstill and perform visual
check
camshaft time- • remove metal pieces/shavings if
camshaft posi- out (no cam necessary.
723/8 10412
tion sensor shaft signal) • replace position sensor in the case
Timeout of mechanical damage (clear stress
marks).
• press in speed (position) sensor
camshaft sen- • position sensor correctly with pin of

camshaft posi- sor wrong po- the ECU engine control (e.g. MR-
723/14 10413 PLD)
tion larity Sensor
verpolt • perform functional check.
currently not fan speed detection in-

stalled.
no signal (time-
986/8 17112 fan speed • check calibration, correct if neces-
out) Timeout
"Type 0".
* diagnosis version 5 D)=only for the D-Model of PLD-MR control units

(diagnosis version 6)
** diagnosis version 6 and newer
*** Minidiag 2 Diagnostic unit
**** Driving panel master gauge (P1)

2 VEHICLE CONTROL FAULT CODES

2.1 Fault codes of vehicle control (+CPC4-eCAN) via SAE J1939
+CPC4-
eCAN +CPC4-
fault eCAN
codes fault Description Remedial action Pin
(J1939) codes (k-
SPN/FMI line) ***
****
• restart accelerator pedal

adjustment routine
accelerator • check wiring
analog acceler-
91/0 10200 pedal not ad- • Limit value idle opera- ST1/7
ator pedal
justed tion position: 5,0 V
• Limit value kick down
position: 4,9 V
• Pedal unit exchange, if

defective
• check wiring
analog acceler- voltage not
91/2 10202 • Limit value idle opera-
ator pedal plausible
tion position: 5,0 V
• Limit value kickdown po-
sition: 4,9 V

defective
voltage too high • check wiring
analog acceler-
91/3 10203 or shorted to • Limit value idle opera- ST1/7
ator pedal
battery voltage tion position: 5,0 V
sition: 4,9 V

defective
analog acceler- voltage too low • check wiring
91/4 10204 ator pedal or shorted to • Limit value idle opera- ST1/7
AFPS ground tion position: 5,0 V
sition: 4,9 V

+CPC4-
eCAN +CPC4-
fault eCAN
(J1939) codes (k-
SPN/FMI line) ***
****
• Oil discharge with to

strong overstocking.
98/0 10400 oil level oil level to high • remark: This problem PLD-MR
can occur also if in PLD-
MR the false type of oil
pan were programmed.
98/1 10401 oil level low oil level • refill oil PLD-MR
• refill oil
• remark: This problem
98/14 10414 oil level oil level too low can occur also if in PLD- PLD-MR
MR the false type of oil
pan were programmed.
oil pressure • check oil pump and oil

100/1 10501 low oil pressure PLD-MR
sensor circuit
oil pressure oil pressure too • check oil pump and oil
100/14 10514 PLD-MR
sensor low circuit.
coolant temper- high coolant • cooling-water level and

110/0 10900 PLD-MR
ature temperature cooling circuit check.
coolant temper- coolant temper- • cooling-water level and

110/14 10914 PLD-MR
ature ature too high cooling circuit check.
low coolant lev- • refill coolant

111/1 11001 coolant level ST3/11
el • check wiring
• check wiring
111/3 11003 coolant level open circuit • Voltage must be larger ST3/11
than 2,0 V.
shorted to
111/4 11004 coolant level • check wiring. ST3/11
ground
• check battery voltage

terminal 15 (ig-
158/0 11100 over voltage • check parameter 2/08 ST2/3
nition)
(24V/12V selection)

+CPC4-
eCAN +CPC4-
fault eCAN
(J1939) codes (k-
SPN/FMI line) ***
****
• check battery voltage

terminal 15 (ig-
158/1 11101 under voltage • check parameter 2/08 ST2/3
nition)
(24V/12V selection)
Wiring idle vali-

dation switch
• check wiring ST1/3
GAS1 and
idle switch (an- and
558/1 11701 GAS2 twisted • Pedal unit exchange, if
alog pedal) ST1/6 or
or open circuit defective ST1/4
at potentiome-
ter ground FP-
both switches • check wiring ST1/3
idle switch (an- open circuit
558/5 11705 and
alog pedal) (GAS2 + GAS1 • Pedal unit exchange, if
defective ST1/6
open)
both switches • check wiring ST1/3

idle switch (an-
558/12 11712 closed (GAS2 + • Pedal unit exchange, if and
alog pedal)
GAS1 closed) defective ST1/6
power supply
620/3 12103 analog pedal voltage too high • supply voltage > 5,2 V. ST1/8
(AFP+)
power supply
620/4 12104 analog pedal voltage too low • supply voltage < 4,8 V. ST1/8
(AFP+)
• check wiring (engine

CAN)
• check configuration:
CAN link
no communica-
625/2 12202 +CPC4-eCAN2 MR parameter (../..) and
tion with MR
- MR +CPC4-eCAN2 parameter
1/01
to be set to equal function-
ality (0ne wire capability)

+CPC4-
eCAN +CPC4-
fault eCAN
(J1939) codes (k-
SPN/FMI line) ***
****
• check wiring (engine

CAN)
• check configuration:
CAN link
625/14 12214 +CPC4-eCAN2 one wire mode MR parameter (../..) and
- MR +CPC4-eCAN2 parameter
1/01
to be set to equal function-
ality (0ne wire capability)
629/12 12312 +CPC4-eCAN2 internal error
• check wiring
1004/3 14403 output relay 4 open circuit ST4/7
• check relay 4
shorted to • check wiring

1004/4 14404 output relay 4 ST4/7
ground • check relay 4
CAN identifiers • PGN ETC1 was re-

J1939 CAN- in-
639/2 14902 ETC#1 or ceived only once and
terface
ACC#1 missing did not disappear.
both signals • check wiring

PWM accelera-
1015/2 15002 missing (GAS1 • Pins ST1/6, ST1/3,
tor pedal
and GAS2) ST1/4.
PWM accelera- signal GAS2, • check wiring

1015/3 15003
tor pedal not available • Pins ST1/6, ST1/4.
PWM accelera- signal GAS1, • check wiring

1015/4 15004
tor pedal not available • Pins ST1/3, ST1/4.
accelerator
PWM accelera- • restart accelerator pedal
1015/5 15005 pedal not ad-
tor pedal adjustment routine
justed
idle position out
1015/6 15006 of adjusted
range
accelerator
1015/7 15007 pedal out of ad-
justed range

* diagnosis version 5 D)=only for the D-Model of PLD-MR control units

(diagnosis version 6)
** diagnosis version 6 and newer
*** Minidiag 2 Diagnostic unit
**** Driving panel master gauge (P1)

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Original instructions

Drill carrier TC8-TC12, NC7 series

Copyright © Sandvik Group

This page is intentionally left blank

Copyright © Sandvik Group

2 Safety and Environmental Instructions........................ 11

4 Drill carrier operation..................................................... 25

5 Operator's Maintenance Procedures............................ 31

6 Periodic Maintenance Procedures................................47

Copyright © Sandvik Group

7 Lubrication Specifications and Filling Capacities.......89

8 Drill carrier troubleshooting........................................ 107

Copyright © Sandvik Group

Copyright © Sandvik Group

This page is intentionally left blank

Copyright © Sandvik Group

Copyright © Sandvik Group 9 (116)

This page is intentionally left blank

10 (116) Copyright © Sandvik Group

2 SAFETY AND ENVIRONMENTAL INSTRUCTIONS

WARNING! HIGH PRESSURE INJECTION HAZARD!

WARNING! PERSONAL INJURY HAZARD!

2.2 Servicing safety precautions

WARNING! FALLING LOAD HAZARD!

Copyright © Sandvik Group 11 (116)

• Inspect equipment daily for signs of failure or beginning of failure.

2.3 Hydraulic system safety precautions

12 (116) Copyright © Sandvik Group

PROPERTY DAMAGE RISK!

• Do not change the pressure setting of any hydraulic valves unless

Copyright © Sandvik Group 13 (116)

• Hydraulic components and hoses should be stored with all connections

2.4 Lubrication safety and other precautions

• Avoid mixing lubricants. Please use recommended oils or oils with

14 (116) Copyright © Sandvik Group

1 Diesel engine 2 Transmission

Copyright © Sandvik Group 15 (116)

1 Diesel engine 2 Transmission

16 (116) Copyright © Sandvik Group

1 Diesel engine 2 Transmission

Copyright © Sandvik Group 17 (116)

1 Diesel engine 2 Transmission

18 (116) Copyright © Sandvik Group

3.2 Diesel engine (MB 904 LA)

1 Fuel filters 2 Oil drain plug

Copyright © Sandvik Group 19 (116)

3.3 Diesel engine (MB 906 LA)

1 Fuel filters 2 Oil drain plug

20 (116) Copyright © Sandvik Group

3.4 Transmission (T20000)

1 Gear pump for steering 2 Gear pump for brakes

3.5 Transmission (HR32000)

Copyright © Sandvik Group 21 (116)

1 Transmission oil filling cap 2 Transmission oil drain plug

3.7 Front axles

Carrier TC 8-9 / NC 7 -series (axles 113, 123)

1 Planetary gear units

22 (116) Copyright © Sandvik Group