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15/07/2015 1066187_F 1 / 53 TMX-150 2 CHAPTER 2 MAINTENANCE Property of American Airlines
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CHAPTER 2
MAINTENANCE
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1. TABLE OF CONTENTS
1. Table of contents ...................................................................................................... 2
2. Maintenance ............................................................................................................. 3
2.1. General ......................................................................................................................................... 3 2.2. Maintenance table ........................................................................................................................ 5 2.3. Maintenance operations ............................................................................................................... 9
3. Emergency procedures ........................................................................................... 35
3.1. Releasing the parking brake ....................................................................................................... 36 3.2. Using the emergency pump ........................................................................................................ 37 3.3. Towing the tractor ....................................................................................................................... 37
4. Fault diagnostic ....................................................................................................... 38
4.1. Diagnostics assistance table ...................................................................................................... 38 4.2. Engine fault ................................................................................................................................. 42 4.3. troubleshooting with the diagnostic center (Depending version) ................................................ 42
5. Repairs .................................................................................................................... 50
5.1. Risks related to repairs ............................................................................................................... 50 5.2. Tightening torque ........................................................................................................................ 50 5.3. Adjusting engine speed (ONLY Tier 3) ....................................................................................... 51 5.4. Centralized lubrication option ..................................................................................................... 52
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2. MAINTENANCE
2.1. GENERAL
CAUTION: THE FREQUENCIES GIVEN IN THE FOLLOWING TABLES ARE BASED ON NORMAL USAGE CONDITIONS. It may be necessary to reduce these maintenance intervals if the equipment is used in so-called "extreme" environmental conditions (cold or hot temperatures, salty air, dusty environment, etc.)
2.1.1 MAKING THE VEHICLE SAFE
WORKING ON A VEHICLE IN ELEVATED POSITION.
LIFTING POINT FOR JACK:
Refer to chapter 1 – Operator Manual – LIFTING POINT FOR JACK. LOCATION OF SUPPORT POINTS:
CAUTION: NEVER WORK UNDER A VEHICLE THAT IS NOT CORRECTLY CHOCKED.
CAUTION: LIFTING JACKS ARE NOT PROPER SUPPORTS.
CAUTION: BEFORE ALL WORK, CHECK THAT THE SUPPORTS ARE CORRECTLY SIZED. Refer to chapter 1 – Operator Manual – LOCATION OF SUPPORT POINTS
2.1.2 WORKING AREAS FOR MAINTENANCE
GENERAL
CAUTION: WHEN CARRYING OUT ANY MAINTENANCE WORK, USE THE AREA DEFINED BELOW
CAUTION: FOR ALL OTHER WORKING AREAS, SEE THE FOLLOWING CHAPTER. Access the area using the running board built in to the chassis. Only work in the area shown in blue in the diagram below.
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WORKING AT HEIGHT
CAUTION: USE SCAFFOLDING AND SAFETY GUARD RAILS FOR WORKING IN AREAS OTHER THAN THOSE ABOVE.
CAUTION: USE SAFE ACCESS MEANS IN COMPLIANCE WITH CURRENT REGULATIONS. NOTE: a list of tools is available from TLD EUROPE's spares department.
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2.2. MAINTENANCE TABLE
Inspection point Proce-dures Tool
100 hours after entering service
Daily Weekly
Every 500 hours or six months
Every 1000 hours or one year
Every 2000 hours or two years
Every 10000 hours or five years
Every 14000 hours or seven years
Carry out 500-hour service
Carry out 500-hour and 1000-hour services
Carry out 500-hour, 1000-hour and 2000-hour services
Carry out 1000-hour and 2000-hour services
General
Absence of leaks under the vehicle. - Inspect
General state of the tractor
See 2.3.1
Inspect and repaint, repair if necessary
Welds. See 2.3.1 Check state Check state
Lights, emergency stop(s), windows, windscreen wipers, rear-view mirrors and operation of windscreen washers.
- Check and replace if necessary
Operational checks at end of inspection
See 2.3.1 au-dessous
Apply Apply
Cab
Door hinges, closures and locks
See 2.3.3 Check and
grease Replace the locks
Cab fixings and suspensions.
See 2.3.4
Check condition and replace if necessary.
Engine
Apply the manufacturer‟s inspection plan.
Chap 5 Apply Apply Apply Apply Apply Apply
Compensator Exhaust line (TIER IV only)
- Check, and replace if necessary
Replace
Gearbox
Oil. See 2.3.2 Replace the
filter Check the level and fill if necessary
Drain and replace the filter
Axle
Connections and articulations
See 2.3.3 Grease
Grease. Check for the absence of play and replace if necessary
Differential oil. See 2.3.3 Check and fill
if necessary
Drain only 500 h after commissioning
Drain
Reduction gear oil. See 2.3.3 Check and fill
if necessary
Drain only 500 h after commissioning
Drain
Structure and mechanical elements.
- Check state.
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Inspection point Proce-dures Tool
100 hours after entering service
Daily Weekly
Every 500 hours or six months
Every 1000 hours or one year
Every 2000 hours or two years
Every 10000 hours or five years
Every 14000 hours or seven years
Carry out 500-hour service
Carry out 500-hour and 1000-hour services
Carry out 500-hour, 1000-hour and 2000-hour services
Carry out 1000-hour and 2000-hour services
Driveshaft See 2.3.3 Grease Check the
tightening
Steering cylinder See 2.3.3
Check, grease and replace if necessary
Check, grease and replace if necessary
Wheels
Tyres. See 2.3.8
Check condition and inflation pressure.
Check state. Check pressure. Change
Wheel rims. See 2.3.8 Check state
Wheel nuts. See 2.3.8 Check
presence. Check tightness.
Cooling system
Coolant. See 2.3.9
Check the level and fill if necessary
Check additive concentration Draining
Exchangers - Clean.
Fans - Check integrity and operation.
Fuel system
Fuel tank See 2.3.10
Drain oil and remove sediments
Check and clean the tank air vent. Check the condition of the tank and seals.
Braking system
Absence of leaks - Check
Brake Liquid See 2.3.11
Check the level and fill if necessary
Change liquid and bleed circuit
Brake hoses and connections -
Check condition and retighten or replace if necessary.
Braking circuit pressures
See 2.3.11 Check
Mechanical parking brake
See 2.3.11 Adjust Adjust
Hydraulic parking brake (option)
See 2.3.11
Check and replace if necessary
Immerged servicing brake Chap 5
Check the wearing of brake and replace if necessary
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Inspection point Proce-dures Tool
100 hours after entering service
Daily Weekly
Every 500 hours or six months
Every 1000 hours or one year
Every 2000 hours or two years
Every 10000 hours or five years
Every 14000 hours or seven years
Carry out 500-hour service
Carry out 500-hour and 1000-hour services
Carry out 500-hour, 1000-hour and 2000-hour services
Carry out 1000-hour and 2000-hour services
Electrical system
Fuses
See electrical diagram
Check and replace if necessary
Check and replace if necessary
Battery See 2.3.13
Check and replace if necessary
Operator interface (operational test of indicator lights, buttons, etc.)
- Inspect Check
Electrical connections and loom
- Check and replace if necessary
Hydraulic system
Tank return filter See 2.3.14 Replace
Check and replace according to clogging indicator.
Replace
Suction strainer See 2.3.14 Replace
Hydraulic oil. See 2.3.14
Check the level and fill if necessary
Check the oil's physical and chemical properties and replace the oil if TAN=1
Drain
Pressure of the system Inspect
Check the pressures according to the hydraulic diagrams.
Hydraulic hoses See 2.3.14
Check and replace if necessary
Replace
Cylinders -
Check for the absence of leaks and replace if necessary.
Check the condition of the rods and replace the ram if necessary.
Hitch
Pin See 2.3.16 Check Grease
Hitching security mechanism
See 2.3.16
Check and replace if necessary
Centralized lubrication (option)
Check the operation of the centralized lubrication system
See 2.3.16
4-hour cycle Inspect
Grease See 2.3.16
Check that there is grease in the bottle; fill if necessary.
Replace
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Inspection point Proce-dures Tool
100 hours after entering service
Daily Weekly
Every 500 hours or six months
Every 1000 hours or one year
Every 2000 hours or two years
Every 10000 hours or five years
Every 14000 hours or seven years
Carry out 500-hour service
Carry out 500-hour and 1000-hour services
Carry out 500-hour, 1000-hour and 2000-hour services
Carry out 1000-hour and 2000-hour services
Emergency unit (option)
Check operation See 2.3.16 Inspect
Carbon See 2.3.16
Check and replace if necessary
Air conditioning (option)
No leaks See 2.3.16 Inspect
Condenser. See 2.3.16 Clean
Air conditioning system charge.
See 2.3.16
Have checked by a professional.
Desiccant filter. See 2.3.16 Replace
Belt. See 2.3.16
Check and replace if necessary
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2.3. MAINTENANCE OPERATIONS
2.3.1 GENERAL
CLEANING INSTRUCTIONS
CAUTION: DO NOT USE A HIGH PRESSURE JET.
CAUTION: REFER TO THE MANUFACTURER'S SPECIFICATIONS WHEN USING CLEANING PRODUCTS.
CAUTION: RINSE OFF THE SPRAYED LIQUID DURING SALTING PERIODS. FIX ANY DAMAGE TO COATS. Clean the equipment protecting electrical components, manufacturer's plates, safety
plates and stickers. Protect the air filter and hydraulic and fuel tank air vents against water ingress. To clean electrical parts, use a suitable vacuum cleaner. To clean mechanical parts, use suitable cleansers. Clean and wash the tops of the batteries without removing the caps in order to avoid
the formation of salts and short circuits that could lead to serious damage, and to avoid the introduction of water or contamination into the elements.
Carefully clean and tidy the cabin to avoid potential accidents.
CHECKING GENERAL CONDITION
Check the absence of shocks and scratches. Check the condition of the paintwork. Check for the absence of corrosion. Check that all labels, pictograms and safety instructions are readable. If damaged, repair, repaint or replace the coat damage if necessary.
CHECKING THE CONDITION OF WELDS
Check the condition of the following critical welds: axles, couplings, cab guidance, platform under the cab, front bumper and engine-gearbox unit mounts.
Reweld if necessary.
OPERATIONAL CHECK AT END OF INSPECTION
Drive the tractor Test the braking by pressing the brake pedal. Test the steering by alternately turning the wheels to the left and to the right. Stop the vehicle on lightly sloping ground and engage the parking brake.
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2.3.2 GREASING, LUBRICATION AND LIQUIDS
IMPORTANT: OILS MUST BE CHOSEN DEPENDING ON THE AMBIENT TEMPERATURE IN THE LOCATION THE MACHINE IS USED.
CAUTION: DO NOT USE ANY OTHER LIQUIDS THAN THOSE RECOMMENDED.
IF IT IS NOT POSSIBLE TO OBTAIN THESE LIQUIDS/LUBRICANTS/GREASES PLEASE CONTACT TLD TO FIND AN EQUIVALENT FROM ANOTHER SUPPLIER OR TO ORDER THE CORRECT OIL.
CAUTION: IT IS FORBIDDEN TO MIX TWO OILS.
CAUTION: WHEN REPLACING PARTS AND/OR HYDRAULIC COMPONENTS, IT IS ESSENTIAL, IN ORDER TO AVOID COMPONENT DAMAGE, TO FILTER AND ANALYSE THE HYDRAULIC OIL BEFORE PUTTING BACK INTO SERVICE.
CAUTION: DISPOSE OF AND RECYCLE OILS AND FILTERS IN ACCORDANCE WITH CURRENT REGULATIONS.
CAUTION: OIL QUANTITIES INDICATED IN THE TABLE BELOW ARE INDICATIVE ONLY. OIL LEVEL MUST BE DONE AND CHECKED ACCORDING TO THE FILLING PROCEDURE INDICATED IN THE MANUFACTURER MANUAL (AVAILABLE ON CHAP5).
COMPONENT Marking Capacities Standards Extra information
Engine oil - Refer to internal combustion engine manual (Chapter 5)
Engine coolant (according to version) - Refer to internal combustion engine manual (Chapter 5)
Fuel tank
Tier 3: 80 litres Refer to internal combustion engine manual (Chapter 5)
Tier 4 F: 80 litres EN-590 Refer to internal combustion engine
manual (Chapter 5) Gearbox - 12 litres Chapter 5 -
Front and rear axle - 13 litres SAE90 API GL-5 MIL-L-2105B
- Wheel reduction gear -
0.75 litres per reducer
Hydraulic tank and circuit
80 litres
ISO 11158 category HV DIN 51 524 Part 2
Ambient temperature ISO Grade (see oil used in chap.5)
-40°C à +5°C
- 40°F à 41°F 22
-25°C à +20°C
- 13°F à 68°F 32
-10°C à +40°C
14 °F à 104°F 46
-5°C à +55°C
23 °F à 131°F 68
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COMPONENT Marking Capacities Standards Extra information
Grease - - -
Lithium grease Very high pressure Temperature: -30°C to +130°C NLGI 2
Braking circuit - 2,5 litres PSA B71 2710 - CDC 24 338
ATF DEXRON II acceptable
Air conditioning (oil) - 170 ml Oil polyalkylèneglycol (PAG) Quality ISO100 (SP20)
OIL QUALITY
The cleanliness class necessary for the proper operation of your tractor is defined by the following standards.
STANDARD CLASS
ISO/DIS 4406 17/14 NAS 1638 8 SAE 5
Abide by the maintenance recommendations and timetables. Test the oil quality if it seems to have deteriorated, for example after detection of
significant deposits in the oil tank return filter. NOTE: the oil's colour is not an indicator of its cleanliness. Call on a specialist laboratory to tell the oil's quality and contamination level.
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2.3.3 GREASE POINTS
Steering bar ball joint
Steering bar ball joint
Front hitch
Leaf spring
Lower Pivot
Upper Pivot
Lower Pivot
Upper Pivot
Leaf spring
Lower Pivot
Upper Pivot
Steering bar ball joint
Steering bar ball joint
Lower Pivot
Upper Pivot
Rear hitch
Driveshaft
Driveshaft
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2.3.4 CAB
CHECKING CAB FIXINGS
Check the condition and replace if necessary. To access to the fastening remove the straight plate. Access to the front fastening under the platform.
2.3.5 THE ENGINE Refer to supplier engine manual (Chapter 5)
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2.3.6 GEARBOX
CHECKING THE LEVEL
CAUTION: CARRY OUT THIS OPERATION WITH THE ENGINE RUNNING. Position the tractor on a flat area of ground. Place the gear selector in neutral. If the engine is cold, let it idle for three minutes. If the engine is hot, the temperature of the gearbox oil must be between 80 and 90 °C
(176 and 194°F) as shown on the control panel. Unscrew the dipstick by turning anticlockwise. Remove the dipstick and clean. Insert the dipstick into the filing tube as far as it will go then bring it out again. If the engine was cold, the oil level must be within zone (1) "COLD MIN". If the engine was hot, the oil level must be within zone (2) "HOT".
If necessary, add progressively oil through the filling tube using a funnel. Check the
level again using the dipstick. Replace the dipstick and tighten by turning clockwise. Close the hood of the engine compartment.
1 2
Filler plug Filter Gauge Drain plug
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DRAINING THE GEARBOX
CAUTION: PROTECT THE VARIOUS COMPONENTS FROM OIL.
CAUTION: BEFORE DRAINING, LET THE TEMPERATURE OF OIL DECREASE TO PREVENT ANY RISK OF BURN. 1. Stop the tractor on a level ground. 2. Put the gear selector in neutral position. 3. Put a container under the gearbox to collect oil. 4. Remove the drain plug. 5. Drain fully the gearbox. 6. Clean the drain plug and around the drain opening. 7. Replace the plug with a new seal. 8. Fill progressively the gearbox with oil. 9. Do a level check of oil.
REPLACING FILTER
CAUTION: PROTECT THE VARIOUS COMPONENTS FROM OIL. 1. Put a container under the filter to collect oil. 2. Remove the used filter. 3. Apply a small layer of oil on the seal of the new filter. 4. Put the new filter in contact with the seal. 5. Manually tighten a third or half a turn.
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2.3.7 AXLES
PRINCIPLE
1. Filler cap/Air vent – Yellow cap. 2. Drain plug – Red cap.
DOING A LEVEL CHECK
1. Put the tractor on pit or a vehicle lift, on a level ground. 2. Turn the wheels until the drain plugs are in median position.
3. Remove the plug of each reducer and the plug of the differential. 4. Make sure that the oil level is correct. If necessary, fill.
2 1 1
Correct level
Correct level
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DRAINING
CAUTION: PROTECT THE VARIOUS COMPONENTS FROM OIL.
CAUTION: BEFORE DRAINING, LET THE TEMPERATURE OF OIL DECREASE TO PREVENT ANY RISK OF BURN. 1. Park the tractor on a level ground. 2. Turn the wheels until the drain plugs point down.
3. Put the gear selector in neutral position. 4. Put a container under each drain plug to collect oil. 5. Remove the three drain plugs. 6. Drain fully. 7. Clean the drain plug and around the drain opening. 8. Replace the plug of the Differential with a new seal. 9. Turn the wheels until the drain plugs point median position.
10. Fill the Differential and the two reducers with oil. 11. Do a level check. 12. Replace the plug of the two Reducers with a new seal.
GREASE
GREASING PIVOTS
For each pivot, inject grease in grease fitting.
Grease fitting
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GREASING DRIVESHAFTS
CAUTION: THE TRACTOR MUST BE STOPPED, WITH THE ENGINE OFF.
Check that the driveshafts are as tight as they should be; see TUIT99051. Grease points by injecting grease into the grease fittings until the old grease comes
out. Clean excess grease.
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2.3.8 WHEELS
CAUTION: EVERY TIME THE WHEELS ARE REMOVED, RETIGHTEN TO THE RECOMMENDED TORQUE. NOTE: The tightening torque and tyre inflation pressures are written on a label affixed nearby or on an engraved plate. Each tyre must be inspected by a professional once a year in order to detect any
fatigue of the carcass or damage that may reduce tyre life. Any tyre that is damaged or showing signs of carcass wear must be replaced. Replace all tyres that are five years old. NOTE: the tyre's age may be determined using the DOT number. This number can be found on the side of the tyre.
FITTING A TYRE
CAUTION: USE AN APPROPRIATE WORKSHOP TOOL WHEN HANDLING NOTE: each tyre weighs about 100 kg. Use the fasteners recommended by the manufacturer. Tighten in the order shown below.
Tighten the nuts using a torque wrench to the correct torque. Only use an impact wrench for loosening, never for tightening. Check the nut torque according to the recommendations given in the maintenance
table.
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TLD APPROVED TIRES
WARNING: ONLY USE TIRES APPROVED BY TLD.
WARNING: DO NOT PUT TWO DIFFERENT TYPE OF TIRE ON AN AXLE.
WARNING: DO NOT REPAIR A TIRE.
REGROOVE ONLY TIRE WITH A “REGROOVABLE” LABEL ON THE SIDE OF THE TIRE.
WARNING: AN EXPERT OF THE TIRE MANUFACTURER MUST EXAMINE THE CONDITION OF TIRES AFTER 10 YEARS OF USE.
WARNING: AFTER AN EMERGENCY STOP WITH AN AIRCRAFT, AN EXPERT OF THE TIRE MANUFACTURER MUST EXAMINE THE CONDITION OF TIRES. Tires CONTINENTAL CONTI RV 20 8.25 R15 ONLY for versions 9 and 12 t.
TLD Part number : 5633421 Tires CONTINENTAL CONTI RV 20 315/70 R15
TLD Part number :5633419 Tires MICHELIN XZM 315/70 R15 (option)
TLD Part number :5633363
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2.3.9 COOLING SYSTEM
COOLANT
CAUTION: THE COOLANT IS PRESSURISED. LEAVE TO COOL DOWN BEFORE OPENING THE COVER.
CHECKING THE COOLANT LEVEL
Open the expansion vessel cover carefully. Check that the level of liquid is in the vessel filling limit. Otherwise fill.
CHECKING THE CONCENTRATION OF COOLANT ADDITIVES
Open the expansion vessel cover carefully. Check the concentration of coolant additives with a conventional antifreeze protection
measurement device. For more information, refer to the engine documentation in chapter 5.
DRAINING THE COOLING SYSTEM
Open the expansion vessel cover carefully. Place a tray to collect the coolant under the radiator hose.
Loosen the radiator hose shown above. Allow the coolant to flow out. Re-tighten the hose. Fill the expansion vessel with liquid up to the filling limit. Purge the system.
PURGING THE SYSTEM
The expansion vessel cover is open. Turn the heating on and set it to maximum to purge the heating system. Close the expansion vessel cover. Warm the engine up to operating temperature. Stop the engine. Check the coolant level, when the engine has cooled down and top up if necessary.
Hose to be loosened
Liquid level
Fill cap
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CLEAN THE COOLERS
Clean the exchangers, engine radiator, intercooler, and hydraulic oil cooler. Check for the absence of objects.
2.3.10 THE FUEL SYSTEM
REPLACING THE FUEL FILTER
Refer to supplier engine manual (Chapter 5)
REPLACING THE FUEL PRE-FILTER (OPTION)
Refer to supplier engine manual (Chapter 5)
CHECKING THE CONDITION OF THE TANK AND SEALS
Put the tractor onto the drainage pit. Open the filler cap. Take the drain plug out through the opening built into the ballast. Let the tank drain, and collect the fuel in a container. Clean the drain plug and around the drain opening. Replace the plug with a new seal. Check that there is no corrosion or grime. If traces of corrosion are present, replace the
tank. Check the condition of the seals and replace them if necessary.
Fill cap
Drain plug and seal
Dip tubes and seals
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2.3.11 BRAKING SYSTEM
SERVICE BRAKES
The TMX 150 is fitted with a hydraulically-controlled service brake (requiring specific oil) which operates the multi-disk brakes immersed in each drive axle. The braking system is controlled by operating the brake pedal. Braking assistance is limited by an adjustable pressure regulator. CHECKING FLUID LEVELS
CAUTION: THE VEHICLE MUST BE AT A STANDSTILL, UNLADEN, AND ON A FLAT SURFACE.
Open the hood to access the reservoir. Check that the level is at maximum. Top up if necessary up to the required level. CHECKING OPERATION
With the tractor at a standstill and the engine idling, press the brake pedal lightly and put the gear selector into the "D" position: the tractor should not move.
Release the pedal gently: the tractor should move gently forward. Test the brakes by pressing the brake pedal while driving the vehicle. If an anomaly is detected, have the braking system checked and repaired. PURGING THE SYSTEM
The tractor's hydraulic braking system requires purging if the hydraulic oil or a hydraulic component is replaced, or if work is carried out on the system.
CAUTION: THIS PROCEDURE REQUIRES TWO PERSONS, ONE PERSON TO OPERATE THE BRAKE PEDAL AND ANOTHER TO PURGE THE SYSTEMS. NOTE: when purging the system, the person who is holding the brake pedal pressed down must not release the pressure until the system has been closed to avoid air being sucked into the system. Immobilise the machine on a flat surface. Start up the tractor in neutral, with the parking brake on. Immobilise the machine on a flat surface. Start up the tractor in neutral with the parking brake on. One operator presses on the brake pedal and maintains pressure. The other operator
unscrews the brake cylinder purging screw on the top of the axle (see diagram below) to release the air.
Maximum
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Tighten the purging screw back into place in before releasing the pedal. Repeat the procedure for each of the four cylinders. Check the level of brake oil and fill up if necessary. ADJUSTING THE DISKS
Refer to the axle documentation in chapter 5. ADJUSTING BRAKING ASSISTANCE PRESSURE
Fit a pressure gauge to pressure outlet P5.
Start up the tractor in neutral, with the parking brake on. Chock the tractor into place. Release the parking brake. Press down the brake pedal and take a pressure reading. NOTE: the braking pressure depends on the travel of the pedal. To determine the right pressure, refer to the hydraulic diagram. If necessary, adjust the pressure with the adjustment screw located on the master
cylinder.
Purging screw
Adjustment screw
P5
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ADJUSTING THE BRAKE PEDAL CLEARANCE
The adjustment is performed on the pedal under the cab, with the pedal not pressed.
Adjust the locknut so that there is a clearance of 3 to 5 mm between the stop and the
floor.
CAUTION: THE STOP MUST NOT BE IN CONTACT WITH THE FLOOR
PARKING BRAKE
ADJUSTING THE PARKING BRAKE SENSOR
The parking brake sensor located on the righthand side of the front drive axle. Chock the vehicle. Release the parking brake. The indicator should be off in the cab. Adjust the air gap of the sensor to 4 mm using the two locknuts.
3 mm<X<5 mm
Locknut
4 mm
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ADJUSTING THE MECHANICAL BRAKE
Apply the parking brake. Chock the vehicle.
Adjust the tension of the cable on the drive axle using the two locknuts.
Check that the parking brake alone is preventing the tractor from moving with a
minimum braking coefficient of 18%. HYDRAULICS (OPTIONAL)
Check the pressure at pressure outlet P3. If necessary, adjust the pressure on the pressure limiter and pressure switch B using
the hydraulic diagram.
Brake cable
Locknuts
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2.3.12 STEERING SYSTEM
PURGING THE STEERING SYSTEM
The hydraulic steering system requires purging at periodic intervals, when hydraulic oil changes are performed or work is carried out on components of the system. Set the engine to run at idle. Turn the wheels to maximum lock in one direction. Turn the wheels to maximum lock in the other direction. Repeat the operation three times. Check the level of hydraulic oil and fill up if necessary.
REALIGNING THE WHEELS
It is sometimes necessary to realign the wheels. Position the tractor on a flat surface, with the engine at idle. Align the rear wheels with the side of the chassis by turning the steering wheel. Apply the parking brake. Open the battery compartment cover. Open the realignment valve.
Release the parking brake. Align the front wheels with the side of the chassis by turning the steering wheel. Close the realignment valve. Close the battery compartment cover.
Realignment valve
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2.3.13 THE ELECTRICAL SYSTEM See chapter "Electrical schematic"
CHECKING THE ELECTROLYTE LEVEL
CAUTION: BATTERIES PRODUCE EXPLOSIVE GASES DURING OPERATION.
CAUTION: DO NOT SMOKE OR CAUSE SPARKS NEAR A BATTERY
WORK IN A VENTILATED AREA.
CAUTION: WEAR PROTECTIVE CLOTHING AND GLOVES.
CAUTION: BATTERIES CONTAIN SULPHURIC ACID. AVOID ANY CONTACT WITH THE SKIN, EYES OR CLOTHING. Open the battery-access housing. Wipe up any spilt acid from the top of the battery and the connectors. Protect the connections with Vaseline. Dry the top of the battery, Look into each cell to verify that the electrolyte is covering the internal plates
(perforated). If the electrolyte level is too low, add distilled water but do not exceed the max. limit. Check the battery voltage and refer to the manufacturer‟s instructions (see chapter 5)
to determine if it needs replacing. POWER FUSE BOX LOCATION:
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2.3.14 HYDRAULIC SYSTEM The tractor's hydraulic system generates hydraulic power for: - steering, - braking, - the tow couplings (optional). A hydraulic gear pump is fitted to the power take-off of the transmission. It supplies flow/pressure to a priority flow valve. The priority flow is for braking assistance. The other system connected to this valve supplies power to the steering and auxiliary systems. An electrical backup generator is available on the tractor (as an option) and allows the steering and brakes to continue to be used in the event of an engine failure.
THE HYDRAULIC TANK
PRESENTATION
DOING AN OIL LEVEL CHECK OF THE HYDRAULIC TANK
1. Stop the tractor with the Wheels aligned on a level ground. 2. Make sure that the level of the oil is between the minimum level and the maximum
level. 3. If not, fill until the "MAXI" level.
Minimum level
Magnetic drain plug
Filling plug
Return filter
Oil gauge and level
Suction strainer
Clogging indicator
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DRAINING THE HYDRAULIC TANK
1. Put a container under the drain plug to collect the used oil. 2. Remove the magnetic drain plug located below the tank. 3. Drain fully. 4. Remove the inspection flap.
5. If necessary, remove the suction strainer (refer to page 30). 6. Clean the tank if necessary. 7. Attach again the inspection flap with screws. 8. Clean the drain plug and the area of the drainage orifices. 9. Install the plugs with a new seal and tight fully. 10. Fill the tank with new oil (refer to page 10). 11. Put serviceable the circuit. Putting serviceable the circuit 1. Start the engine and let it run at idle for around fifteen minutes. 2. Measure and do a check of the residual pressure of the pump for auxiliary systems. 3. Bleed the steering system (refer to bleeding procedure). 4. Bleed the braking system (refer to bleeding procedure). 5. Do an oil level check. If necessary, fill again (refer to hydraulic levels check procedure). 6. Clean away excess oil. REPLACING THE RETURN FILTER
1. Unscrew the return filter cover. 2. Remove the used filter component.
3. Clean the vessel of the return filter. 4. Install a new filter component. 5. Attach again the cover with screws. REPLACING THE SUCTION STRAINER
1. When you drain the hydraulic tank, remove the inspection flap to access the suction strainer.
2. Unscrew the suction strainer. 3. Replace by a new.
Inspection flap
Filter component
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HYDRAULIC DUCTS AND HOSE LINES
Check the condition of and for leaks on hose lines, connections and piping of the hydraulic system
Re-tighten the connections and/or replace the ducts if necessary.
CHECKING PRESSURES
CHECKING MAIN PRESSURE
Start the tractor. Turn the steering wheel until it reaches the righthand or lefthand stop. Fit a pressure gauge at P1.
Hold the steering against the stop and check the pressure using the hydraulic diagram. STEERING PRESSURE
Bleeding the LS (Load Sensing) line of the steering system Bleed the LS line of the front steering before checking the steering pressure in order to evacuate any air present in the system. Start the tractor. Turn the steering wheel until it reaches the righthand or lefthand stop. Open the filling plug of the hydraulic tank. Put a pressure gauge capillary tube into the hydraulic tank and connect the other end to
pressure outlet P4. Hold the steering against the stop and let the oil in the tank flow out until the jet of oil is
constant, not containing any air. Disconnect the capillary from pressure outlet P4, with the steering still up against the
stop. Close the filling plug of the hydraulic tank. Release the steering. Checking the steering pressure Start the tractor. Turn the steering wheel until it reaches the righthand or lefthand stop. Fit a pressure gauge at P2 and P4.
P1
P4
P2
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Hold the steering against the stop and check the pressure using the hydraulic diagram. If necessary, adjust the pressure using the Orbitrol adjustment screw.
2.3.15 HITCH
Check the condition of the pin and lock; the lock must latch by itself. Check, grease and replace if necessary
2.3.16 OPTIONS
CENTRALIZED GREASING (OPTION)
Progressively fill with a grease gun or a grease pump to not damage distributors.
AUTOMATIC OR CENTRALIZED LUBRICATION (OPTION)
CHECKING OPERATION
Press the pushbutton on the pump motor casing to trigger a greasing cycle. NOTE: A cycle lasts 4 hours. Check no overpressure alarm occurs. REPLACING THE GREASE
Open the pump bottle. Add about 4 kg / 8.8 lbs of grease.
Adjustment screw
Coupling pin
Safety lock
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AIR CONDITIONING
CAUTION: ONLY A SPECIALIST OF AIR CONDITIONING COULD WORK ON THE CIRCUIT.
CAUTION : ONLY USE APPROVED OIL : OIL PAG SP20 / PAG ISO 100.
CAUTION : WHEN YOU WORK ON THE CIRCUIT, REPLACE THE DESICCANT FILTER.
CAUTION: WHEN YOU REPLACE A COMPONENT OF THE AIR CONDITIONING CIRCUIT, BEFORE CONNECTION, LUBRICATE THE SEALS AND FACES WITH PAG20 OIL AND BEFORE LOAD, REMOVE THE AIR FROM THE CIRCUIT OF AIR CONDITIONING.
LOCATION OF COMPONENTS
Desiccant filter
Condenser Compressor Belt
Evaporator Air vents
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MEASURING THE LOAD
1. Remove the air from the hoses of the loading machine. 2. Connect the loading machine to the air conditioning circuit. 3. Measure the load of the circuit. 4. If necessary, load again. NOTE : quantity Gas: 480 g Oil: 170 cm3 /170 ml.
CAUTION: The oil quantity indicated above is the quantity for the whole circuit. When replacing the air conditioning compressor, the new compressor can be supplied filled with oil. In this case, just add the additional oil needed. REPLACING THE DESICCANT FILTER
1. Make sure that the new desiccant filter is closed with caps to prevent contamination with ambient air.
2. Connect the loading machine to the air conditioning circuit. 3. Drain the air conditioning. 4. Removed the used desiccant filter. 5. Remove the caps, lubricate the seals and faces with oil SP20 and connect the new filter
at the last moment. 6. Immediately after the connection, remove the air from the air conditioning circuit. 7. Immediately after, load the circuit. CLEANING THE CIRCUIT
If the circuit is dirty, you could clean it. 1. Connect the loading machine to the air conditioning circuit. 2. Drain the air conditioning. 3. Clean the circuit with a special product (for example : “Facilisolv”, brand DEHON). DOING A CHECK OF THE BELT
Measure the tension of the belt with tensiometer. Do a condition check of the belt. If necessary, replace.
EMERGENCY UNIT (OPTION)
Remove the spring. Remove the carbon brush. Check for wear. Replace if necessary.
HYDRAULIC COUPLING (OPTION)
Check that the pin can move up and down correctly. Check that the motion stops when the pin retracts.
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3. EMERGENCY PROCEDURES
CAUTION: THE PARKING BRAKE OF THE AIRCRAFT MUST BE ON AND THE AIRCRAFT MUST BE CHOCKED.
CAUTION: THE FIRST LEVEL OF EMERGENCY MANOEUVRES CAN BE PERFORMED BY OPERATORS. The next two levels must be performed by maintenance technicians.
Engine running
Level C troubleshooting
Emergency pump
present (optional)
Level B troubleshooting
Level A troubleshooting
1 - Release the parking brake see 3.1 2 - Tow the tractor see 3.3
1 - Use the emergency pump see 3.2 2 - Release the parking brake see 3.1 3 -Tow the tractor see 3.3.
1 - Release the parking brake see 3.1. 2 - Tow the tractor see 3.3. NOTE: as power is no longer being supplied to the hydraulic steering, it is difficult to operate.
Yes
Yes
No
No
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3.1. RELEASING THE PARKING BRAKE
3.1.1 MECHANICAL PARKING BRAKE Lower the lever to let off the parking brake. The "Parking brake" indicator switches off.
3.1.2 HYDRAULIC PARKING BRAKE (OPTIONAL)
WITH EMERGENCY PUMP
Shut off the valve on the hydraulic system (21)
WITHOUT EMERGENCY PUMP
Loosen the nut on the yoke of the cylinder to remove the cable and release the brake.
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3.2. USING THE EMERGENCY PUMP If the combustion engine stops running, the emergency pump makes it possible to operate the hydraulic components (steering, tow coupling and options). Turn on the ignition. Use the control button which is located in the cab on the control console. NOTE: The emergency pump will provide backup power for 20 to 30 min.
3.3. TOWING THE TRACTOR
CAUTION: THE TOWING SPEED MUST BE LOWER THAN 8 KM/H TO PREVENT DAMAGE ON THE GEARBOX.
CAUTION: THE PARKING BRAKE MUST BE OFF.
Put a tow bar at the front of the tractor and couple it to a tractor with a towing capacity
of 24 t. Tow the tractor with another tractor at a maximum speed of 8 km/h. If you tow the tractor on a distance greater than 8 km, disconnect the universal joints
from the gearbox.
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4. FAULT DIAGNOSTIC
4.1. DIAGNOSTICS ASSISTANCE TABLE Problem Cause Action Engine The engine does not start, the starter is not responding
Check that the parking brake is on.
Apply the parking brake to allow the engine to start.
Faulty key ignition. Check the connections and wiring. Replace if necessary.
Faulty starter relay. Replace the starter relay. Faulty starter. Check the voltage drop on the
starter. Replace or repair. Faulty wiring. Check the connections
(corrosion, loose connections, etc.)
Fault internal to engine If all the components necessary for the engine to start are working but the starter is not able to start the engine, it is probably the engine itself that is the cause of the problem. Contact the manufacturer of the engine to have it repaired.
Anti-restart timer relay is faulty. Replace the relay and adjust if necessary. (see electrical diagram).
The engine does not start or is having difficulties starting
Fuel level low or out of fuel. Check the fuel level and fill the fuel tank.
Low or faulty batteries. Recharge or replace the batteries.
Clogged fuel filter. Replace the fuel filter. Reduced fuel supply (bottleneck)
or leaks in the supply system. Look for and repair the bottlenecks or leaks.
Fuel pump out of order If no fuel is flowing from the pump, repair or replace the pump.
Air in the supply system. Purge the air. Insufficient air intake. Check and replace the air filter. Faulty connections/wiring
between the batteries, the starter and the earth.
Check the connections.
Faulty starter relay. Replace the starter relay. Incorrect setting of the time
delays of the fuel supply valve or pump.
Check the time delays on the valve and the pump.
Low compression, injection system faulty, faulty engine or stalled/seized engine.
See engine documentation or contact a representative of the engine manufacturer.
The engine does not start or is not behaving stably
Fuel level low or out of fuel. Check the fuel level and fill the fuel tank.
Low engine oil pressure Check and add oil to the engine. Coolant temperature too high. Check coolant level. Inspect the
radiator.
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Problem Cause Action Clogged fuel filter. Replace the fuel filter. Reduced fuel supply (bottleneck)
or leaks in the supply system. Look for and repair the bottlenecks or leaks.
Fuel pump not operating correctly.
If the flow of fuel is too weak, repair or replace the pump.
Air in the supply system. Purge the air. Insufficient air intake. Check and replace the air filter. Obstruction of the exhaust line. Examine the exhaust line. Incorrect time delays on the fuel
supply pump or valve. Check the supply pump or valve as per supplier recommendations.
Low compression, injection system fault, engine fault
Contact the engine supplier.
Fuel level low or out of fuel. Check the fuel level and fill the fuel tank.
The engine does not start or is having difficulties starting at low temperatures
Discharged batteries. Recharge or replace the batteries.
Preheating "Wait before starting" Wait. Preheating fault Contact the engine supplier. Incorrect oil viscosity Check engine oil. Loss of power Turbocharger failure See supplier manual or contact a
representative of the engine manufacturer.
Problem with transmission between the gearbox and the engine.
Contact a representative of the engine manufacturer.
The temperature of the engine is unstable
Low coolant level. Check level and top us as necessary.
Recycling of hot air in front of the radiator.
Locate and block off the intake of hot air
Clogged radiator Inspect the radiator. Deterioration of cooling hoses. Replace the hoses. Clogged oil cooler. Replace the cooler. The thermostat is no longer
working. Contact the engine supplier.
Ventilation problem Contact the engine supplier. Water pump belt or water pump
is not working Contact the engine supplier.
Gearbox Gearbox oil temperature alarm indicator
Lack of oil or too much oil. Re-check level and top up or drain if necessary. See chapter 5.
Gearbox fault indicator. It lights up for less than 15 seconds.
Normal operation. Check oil level.
It lights up for more than 15 seconds.
Engine at idle: top up to required level.
Faults on the display Faulty sensor. Refer to error codes. Axles Noise from the axles Incorrect wheel alignment. Check wheel alignment. Oil leak in transmission. Contact the axle supplier. Noise from brakes. Contact the axle supplier. Problem internal to axles Contact the axle supplier. Steering
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Problem Cause Action The steering of the vehicle is not working or is hard to operate
Insufficient tyre pressure. Damaged tyres/wheel.
Check the pressure and the condition of the tyres and wheels, change if necessary.
Low hydraulic oil pressure. Check for leaks in the hydraulic system and fill up with oil.
Pump fault. Repair or replace the pump. Steering valve fault. Check and replace the valve. Priority valve fault. Check and replace the valve. Damaged steering column. Check and replace the steering
column. Damaged steering cylinder or
seal. Contact the axle/drive axle supplier.
Damaged drive axle ball joint and joint.
Contact the axle/drive axle supplier.
The tractor pulls to one side Insufficient tyre pressure. Damaged tyres/wheel.
Check the pressure and the condition of the tyres and wheels, change if necessary.
Incorrect wheel alignment. Check wheel alignment. Steering valve fault. Check and replace the valve. Steering bar ball joint faulty. Contact the axle supplier. Braking Excessive braking distance Low brake fluid level. Top up to required level. Excessive brake disk wear Refer to drive axle manual
Chapter 5. Incorrect adjustment of braking
assistance pressure regulator. Check and adjust.
Air in the brake system. Locate the leak and repair, purge the system.
Master cylinder out of order Repair or replace the master cylinder.
Hydraulic leak from braking assistance system
Locate the leak and repair, top up hydraulic oil to required level.
Loose cable or excessive pedal travel
Insufficient fluid in the system. Check for leaks and refill.
Air in the system. Check, repair and purge. Excessive wear to the braking
system on the drive axle. Contact the axle supplier.
Stiff pedal Stiff pedal Check the pedal and repair. Incorrect adjustment of braking
assistance. Check and adjust.
Insufficient brake oil pressure Inspect the hydraulic system. Replace the components if necessary.
Fault in the braking system on the drive axle.
Contact the axle supplier.
Electrical system Problem when powering up The battery charge is low or the
battery has lost its mass Check battery voltage
The battery isolator switch is in the OFF position.
Move the battery isolator switch to the ON position. Check the main relays.
Main fuse blown. Determine the reason why the fuse has blown, repair and replace the fuse.
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Problem Cause Action The emergency stop is engaged Disengage the emergency stop. The key-operated ignition is not
activated. Move the ignition key to position 1.
Faulty wiring. Check the connections (corrosion, loose connections, etc.)
The batteries do not stay charged.
Battery out of order. Replace the battery.
Alternator fault. Check the wiring, the alternator and belts. Replace the damaged components.
Cab Cab heating not performing adequately
Loss of liquid Locate the leak, repair and top up to required level.
Fan out of order. Replace the fan. The cab defrosting is not working Damaged or disconnected ducts Check and repair the ducts. Cab ventilation no longer works Faulty fan. Check, and replace. Air conditioning (optional) Air conditioning not performing correctly
Lack of refrigerant Locate the leak, repair and contact a specialist to have the system to recharge the system.
Damaged compressor belt Inspect and replace the belt. Clogged condenser Clean or replace the condenser. Clogged air filter. Replace the air filter. Additional heating (option)
The heating unit shuts off automatically
No combustion after starting and restarting
Shut off the heating unit for at least two seconds, then turn it back on once
The flame turns off during operation.
Shut off the heating unit for at least two seconds, then turn it back on once
The heating unit overheats and the anomaly display light is blinking
Verify that the hot air line is not blocked, let the unit cool. Shut off the heating unit for at least two seconds, then turn it back on once
Electrical system voltage too low. Charge the battery. Shut off the heating unit for at least two seconds, then turn it back on once
The heating unit is releasing black smoke
Combustion air line and/or gas exhaust line blocked
Verify that the combustion air line and the gas exhaust line are not blocked
Centralized lubrication (option) Grease discharge Pressure in the system too high. Check the installation. Gradual distributor blocked. Change the distributor. Installation blocked. Repair fixed or blocked bearings Defective valve spring Change the relief valve Too much grease at various grease points
Incorrect metering at the control valves.
Correct.
Too much grease at all grease points
Too many revolutions or rest periods too short.
Reduce the number of revolutions or increase the rest periods.
The pump does not work Motor defective Replace the pump. Piston of pumping component
unhooked. Remove the pump component. Install it correctly.
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Problem Cause Action Defect in motor power cable Replace the pump. No grease pad at all grease points.
The pump does not work. See "The pump does not work".
Pump operating for too short a period.
Increase the pump revolutions.
Rest period too long. Reduce the rest period. Main pipes to the control valve
burst. Replace the pipes.
No grease pads at grease points. Supply pipe burst or disconnected.
Replace the pipe.
4.2. ENGINE FAULT
To tell the meaning of the error codes, refer to Chapter 5
4.3. TROUBLESHOOTING WITH THE DIAGNOSTIC CENTER (DEPENDING VERSION)
MAINTENANCE POPUP
This page will be displayed at startup for 5 seconds when time remaining is lower than 50h and permanently if time is elapsed. 1: Time remaining before next maintenance operation
1
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FAULT POPUP
If a minor fault appears this popup is displayed. Press ok to see active faults code list 1: Type of fault (minor, complementary fault, major fault) 2: Device or component in fault 3: Engine hourmeter 4: TLD ID fault
1
4 2
3
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If a major fault appears this popup is displayed. Press ok to see active faults code list 1: Type of fault (minor, complementary fault, major fault) 2: Device or component in fault 3: Engine running hours 4: TLD ID fault
Engine must be stopped as soon as possible
1
4
2
3
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FAULT LIST
If you pressed OK when popup is displayed you can see the fault code list. 1: Star indicates that fault is active 2: Fault number 3: TLD ID fault number 4: SPN number (Suspect parameter Number) 5: FMI number (Failure Mode Identifier) 6 : Engine hours meter
1 2 3 4 5 6
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It is possible to access to maintenance mode of the display by using the following code from the main page.
→ ↓ → ← → ↑ Ok Following page appears:
F1: Back to main page
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F2 - DIAGNOSTIC : Access to PLC inputs and outputs states, Engine values, Gearbox values, CAN network state and bargraph with main parameters to troubleshoot tractor.
F3 - CONFIGURATION: This menu configuration is only reserved for TLD. A special code must be entered to acess it. F4 - FAULT: Fault menu: Active faults, fault history and possibility to erase inactive faults from engine, gearbox and PLCs.
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F5 - INFORMATION:
- Information about software version (PLCs and display).
- Counters with following values:
Supply hours
Total engine hours
Engine idle hours
Travelled distance
Average speed
Average Fuel consumption
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- Maintenance: use this menu to validate the maintenance operation. It is possible to change
maintenance interval by using Maint. Config. and maintenance reminder by using Reminder
Config and Alarm Config.
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5. REPAIRS
5.1. RISKS RELATED TO REPAIRS
FOR THE WELDS: Disconnect the batteries. Unplug the electrical cabinets and components (controllers, EMR, Smart Drive, etc.). Physically remove the electronic modules of the machine during welding operations. Attach the ground as close as possible to the welding area, ensuring electrical
continuity.
5.2. TIGHTENING TORQUE
5.2.1 GENERAL
CAUTION: THE LISTED TORQUE VALUES ARE FOR GENERAL USE ONLY.
NEVER USE THESE VALUES IF A DIFFERENT TORQUE OR TIGHTENING PROCEDURE ARE GIVEN FOR A SPECIFIC APPLICATION. Replace the fasteners with fasteners of the same or higher grade, and re-tighten them
to the same torque as the original fasteners. Ensure that fixing threads are clean and properly engaged to avoid possible failure
during tightening. NOTE: „'Lubricated” means coated in engine oil or another lubricant. “Dry” means plain or zinc plated without lubrication.
5.2.2 TORQUE VALUES Refer to the instruction TUIT99051.
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5.3. ADJUSTING ENGINE SPEED (ONLY TIER 3) NOTE: the engine must be warmed up before performing the adjustment.
ADJUSTING ENGINE IDLE
Set the engine running. Measure speed with the tachometer.
Check the following: Engine idle speed without any options: 970 ± 10 rpm. If necessary, adjust the engine speed using the idle speed adjustment screw. Check that the cable is not taut so that the injection lever is up against the stop on the
idle speed adjustment screw when the pedal is released. If necessary, adjust the tension of the cable using the adjustment screw.
ADJUSTING MAXIMUM ENGINE SPEED
CAUTION: THE MAXIMUM ENGINE SPEED IS FACTORY SET. DO NOT TAMPER WITH THE MAXIMUM ENGINE SPEED STOP ON THE ENGINE.
Press the pedal right down to bring the engine up to maximum speed. Check that the accelerated speed is 2500 rpm ± 50 rpm Check that the injection lever on the engine is not in contact with the mechanical stop
on the maximum engine speed screw.
If necessary, adjust the stop screw under the accelerator pedal to adjust the maximum
engine speed.
Idle speed adj. screw
Tension adjustment nuts
Maximum engine speed stop
Stop screw
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5.4. CENTRALIZED LUBRICATION OPTION
5.4.1 CAUSES A blockage in the system may be due to: - a fouled or blocked pipe, - a bearing which has become blocked or contains too much lubricant, - inappropriate lubricant in the system, - the outlet from the distributor being closed, - the distributor being blocked.
5.4.2 VISUAL SIGNS The increase in the operating pressure is indicated by: - grease flowing from the pressure relief valve, - the overpressure indicator or the pressure relief valve with micro-coupler on the pump (option), - the pressure gauge (option).
5.4.3 FINDING A BLOCKAGE POINT Unscrew the main pipe from the main distributor. Actuate and test the pump to check that grease flows. Retighten the main pipe onto the main distributor. Unscrew each of the connections to the distributor in turn and actuate the pump each
time. Check the secondary distributors in the same way. NOTE: the blockage is in the pipe where little or no grease flows. NOTE: you can connect a hand pump directly to the main pipe.
5.4.4 REPAIRING A BLOCKED DISTRIBUTOR Remove the distributor. Note the order of the various pipes. Unscrew the end screws from the piston holes. Slide the pistons back and forth without allowing them to come out completely. Screw the end screws back in. Check the secondary distributors until the blocked piston is found. Remove the blocking piston. Check that the surface of the piston and the distributor are not scratched or damaged. Replace them if they are damaged. If the pistons and distributor holes have deposits of hardened grease, wash and blow
them to remove the residues. Check using a fine wire. Check the operation of the distributor with grease. Refit the distributor to the installation. Start the installation. Check the operating pressure.
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