STRUCTURE & FUNCTION 8.1.

REAR CHASSIS - STRUCTURE AND FUNCTION

8.1. 2 FRAME (old type)

8.1. 3 FRAME (new type)
8.1. 4 ARTICULATION HINGE
8.1. 6 BODY
8.1. 7 TAILGATE

SHOP MANUAL MT 30 -02.98

8.1.2 STRUCTURE & FUNCTION

FRAME - ( OLD TYPE)

SHOP MANUAL MT 30 - 02.98

STRUCTURE & FUNCTION 8.1.3

FRAME - ( NEW TYPE)

SHOP MANUAL MT 30 -02.98

8.1.4 STRUCTURE & FUNCTION

ARTICULATION HINGE
The articulation hinge structure is very important and has a significant function for the performance
and stability of the truck.
The turning ring is mounted in front of the articulation pin which ensures that the transferred weight
from the rear frame of the truck to the front frame is always distributed equally to the front wheels.

Ball type turning ring:

Slide type turning ring (type 1):

SHOP MANUAL MT 30 - 02.98

STRUCTURE & FUNCTION 8.1.5

Slide type turning ring (type 2):

SHOP MANUAL MT 30 -02.98

8.1.6 STRUCTURE & FUNCTION

BODY

Old type:

New type:

SHOP MANUAL MT 30 - 02.98

STRUCTURE & FUNCTION 8.1.7

TAILGATE
The tailgate, which is preloaded by the gas spring when the body is completely down, prevents
material from falling out of the body when driving. The tailgate is mechanically operated and opens
automatically when the body is lifted. The gas spring is flexible and able to prevent shock damages.

When the safety-catch has been released there has been an overload of the tailgate. The safety plate is
there to protect linkages, joints, gas cylinder and tailgate

SHOP MANUAL MT 30 -02.98

Note
TESTING &ADJUSTING 8.2.1

REAR CHASSIS - TESTING & ADJUSTING

8.2. 2 TURNING RING

8.2. 3 BODY HINGE

SHOP MANUAL MT 30 -02.98

8.2.2
TURNING RING
Machine s/no.:.......................
Operated hours.:....................
B - clearance.:.......................
C - clearance.:.......................
Total clearance.:...................
SHOP MANUAL MT 30 - 02.98
TESTING & ADJUSTING
MEASURING TURNING RING CLEARANCE:
Place the machine in a workshop on a level floor and
with front and rear chassis in line.
1. Place an indicator clock (A) on the articulation
hinge bracket as shown above with the feeler at the
outer ring of the turning ring. Adjust indicator clock
to zero.
2. Open the bonnet and lift the front chassis with
800 kg as shown (B). Read indicator clock
3. Lower the machine.
4. Place a hydraulic jack (C) underneath centre of
articulation hinge bolt and lift with 2000 kg.
Read indicator clock.
5. Dismantle articulation hinge bolt, end cover and
check/adjust for correct bearing preload:
÷ 0,05 mm. Check one bearing at the time!
Add the two readings and check according to the
standard value.
TESTING &ADJUSTING 8.2.3

BODY HINGE
Place the machine in a workshop on a level
floor and fit the articulation hinge lock and
chock the wheels.

! BODY UP Raise the body until the body floor is

UNTIL horizontal.
LEVEL
Position a measuring tool on the rear frame
with the indicator clock at the bottom of the
body hinge eye.

Adjust the indicator clock to zero.

Position an hydraulic jack under the body

bumper and lift until the indicator stops.

Slowly lower the jack and read the indicator

clock.

Check the measured clearance two times.

Standard clearance: Repair limits

0,5 mm 3,5 mm

SHOP MANUAL MT 30 -02.98

Note
DISASSEMBLY & ASSEMBLY 8.3.1

REAR CHASSIS - DISASSEMBLY & ASSEMBLY

8.3. 2 GAS CYLINDER

8.3. 3 FILLING OF GAS CYLINDER
8.3. 4 BODY HOUSING
8.3. 5 ARTICULATION HINGE (old slide type)
8.3. 8 REPAIR / MODIFICATION PROCEDURE (new type)
8.3. 5 ARTICULATION HINGE (ball type)

SHOP MANUAL MT 30 -02.98

8.3.2 DISASSEMBLY & ASSEMBLY

GAS CYLINDER
1 Remove plug and washer, pos. 5. unload needle valve to relieve gas pressure. Remove the valve.
2. Pull out the piston rod and heat eye at threads to approx. 80° C to overcome locking compound
fastening. Unscrew rod eye.
3. Push the stuffing box, pos. 16 inwards until o-ring, pos. 21 and snap ring, pos. 20 can be
removed.
4. Pull out piston rod ass’y.
5. Push piston rod, pos. l5 out of inner tube, pos. 14.
6. Replace seals, pos. 7 and 10, and bearing ring, pos. 11.
7. Unscrew stuffing box to replace o-ring, pos. 17.
8. Replace o-ring, pos. 18 and support ring, pos. 19.
9. Assemble piston rod and inner tube. Then install it into outer tube.
10. Fit snap ring, pos. 20 and replace o-ring, pos 21.
11. Fit piston rod eye with Loctite 270.
12. Remove circlip, pos. 1 and replace spherical bearings, pos. 2. Refit lock ring.

SHOP MANUAL MT 30 - 02.98

DISASSEMBLY & ASSEMBLY 8.3.3

FILLING OF GAS CYLINDER

1. Fix the cylinder carefully in the vice. Unscrew the safety screw, item V. Leave the bottom
gasket.

Note!
Keep away from the valve position!

2. Fit the filling hose to the nitrogen bottle.

3. Before fitting the armature to the cylinder using wheel A, check that needle C does not project
from the valve
If the cylinder is empty: Start filling carefully with the valve closed up to approx. 20 bar. Open
the valve carefully with wheel B. Turn clockwise until the gauge starts to read. Turn maximum
0.5 revolution further. Read the gauge.

Note!
Further turning can damage the the valve! Do not fill too fast as this can
disturb the valve.

4. Open the nitrogen bottle carefully and fill to correct pressure. Close the nitrogen bottle.

5. When correct pressure is reached, close the cylinder valve by turning the wheel B anticlockwise.
The pressure can be adjusted exactly by using wheel B and D if it should happen to be too high.

Filling pressure: 119 bar.

6. Release the gas in the armature by opening wheel D for a moment.

7. Unscrew the armature by turning wheel A. Check that the gasket U is in place. Check that the
valve is tight. Fit safety screw V, torque: 14 Nm.

Special tool:
Armature, part no. 8187

SHOP MANUAL MT 30 -02.98

 8.3.4 DISASSEMBLY & ASSEMBLY

BODY HINGE
1. Remove body hinge bolt locking and knock both bolts out.
2. Lift carefully rear end of body and replace both bushings with a suitable puller I drifter.
3. Lower the body into position and fit the bolts and lock plates.

SHOP MANUAL MT 30 - 02.98

DISASSEMBLY & ASSEMBLY 8.3.5

ARTICULATION HINGE - OLD SLIDE TYPE

DISASSEMBLY

1. Apply wheel blocks to front wheels.

2. Support front frame with two ramps, one at each side of front end.
3. Disconnect front end of articulation propeller shaft.
4. Unscrew outer turning ring bolts, pos. 9 and pull rear frame carefully backwards. Support rear
frame with ramps.

Note!
Be aware of the propeller shaft.

5. Remove seals, pos. 11 and 12.

6. Unscrew bolts, pos. 8 and carefully remove inner ring, pos. 2 and outer ring, pos. 3.
7. Remove outer seal, pos. 10.
8. Unscrew both thrust rings, pos. 5-6.
9. Remove bearing ring, pos. 4.
10. Disconnect both steering cylinder front mountings.
11. Unscrew upper and lower bolts, pos. 27 and remove thrust washer, pos. 26 and shims, pos. 23-25
(alt. 19-22).
12. Press out both bolts, pos. 18. Pull off the articulation hinge.

Note!
Be aware that the lower bearing drop down when removing the hinge.

13. Remove bearings, distance ring, pos. 15 and seals, pos. 17.

Clean, inspect and replace worn and/or damaged parts. Replace all seals.

Note!
Clean breather plug, pos. 13 before assembly

SHOP MANUAL MT 30 -02.98

8.3.6 DISASSEMBLY & ASSEMBLY

ASSEMBLY

1. Press all four bearing cups, pos. 29/31 and distance ring, pos. 15 in position.

2. Fit and grease seals, pos. 17.

18
3. Press bearing, pos. 16 onto bolts, pos. 18 and (if possible) put them in a
deep freezer. See illustration to the right. 16

4. Place bearing, pos. 29 and 30 and slide the hinge into position.

5. Press or knock the upper bolt, pos. 18 (with bearing, pos. 16 mounted) in position, then do the
same with the lower bolt, pos. 18 Use a plastic club to knock the bolts in position.

Note!
Check seals for correct installation. Incorrectly fitted seals allow dust to enter bearings.

6. Fit lower thrust washer, pos. 26 and screws, pos. 27. Swing the hinge from side
to side and tighten until you start preloading the bearings.
Tightening torque: Approx. 150 Nm.

Note!
If preloading is not attainable, the bolt is maybe too long. It's therefore necessary to put on
shims, pos. 19-22. See fig. 2

Fig. 1 Fig. 2

7. Fit upper thrust washer in the same way as in point 6. above.

Note!
It can be necessary to loosen lower bolt to "feel" the preload at the upper bearings.

8. Remove the upper thrust washer again and adjust upper and lower bearing to a preload
of 0.1 mm with shims, pos. 23-25 (alt. use shims, pos.19-22 if the bolt is to long).

A: If the bolt, pos.18 is too short (fig.1) please do following:

Measure the distance from the machined surface on the hinge to the end of the bolt (measure x,
fig.1 above)
and subtract 0.1mm = shims thickness.

E.g X = 0.7mm ÷ 0.1mm = 0.6mm shim thickness

Use shims: 0.5mm + 0.1mm = 0.6mm and the bearings has a preload of 0.1 mm.
Tightening torque: 333 Nm.

B: If the bolt, pos.18 is too long (fig.2) please do following:

Measure the distance from the machined surface on the hinge to the end of the bolt (measure x,
fig.2 above) and add 0.1mm = shims thickness.

E.g X = 0.6mm + 0.1mm = 0.7mm shim thickness

SHOP MANUAL MT 30 - 02.98
DISASSEMBLY & ASSEMBLY 8.3.7

Use shims: 0.35mm +0.35mm = 0.7mm and the bearings has a preload of 0.1 mm.
Tightening torque: 333 Nm.

9. Fit lower thrust washer in the same way as in point 8.

Note!
To check that the preload is correctly adjusted, swing the hinge from side to side and "feel" that
the hinge either run to easy or to tight. Loosen and use locktite 242 on screws when the preload
is correctly adjusted. Tighten again with the same torque as described in point 8.

10. Connect both steering cylinders and protections at front, both sides. Loctite 242 on bolts.
Tightening torque: 197 Nm

11. Install bearing ring, pos. 4 onto the outer ring, pos. 3. If a new pressure ring are necessary, drill
new holes for lubrication channels.

Note!
Grind off possible edges.

8 Fit rear thrust ring, pos. 6 into outer ring and use Loctite 242 on screws, pos. 7.
Tightening torque: 17 Nm.

9. Measure dimension A and B, see drawing next page. Determine C = A - B.

Note!
Measure at least 4 different places.

10. Select a front thrust ring, pos. 5 which is 0.15 mm less than the actual dimension c. Fit the
selected thrust ring onto front frame with bolts covered with Loctite 242.
Tightening torque: 17 Nm.

Note!
The total bearing clearance shall be within 0.10-0.20 mm.

11. Preassemble inner and outer ring.

12. Fit seal, pos. b onto inner ring.

13. Assemble preassembled turning ring onto articulation hinge.

14. Fit inner ring bolts, pos. 8 with Loctite 242 and tighten.
Tightening torque: 333 Nm.

15. Fit seals, pos. 11 and 12.

16. Insert bolts, pos. 9 into outer ring and apply Loctite 242 on threads.

17. Connect front and rear frame and tighten bolts.

Tightening torque: 333 Nm.

Note!
Centre lubricator shall face upwards.

18. Connect articulation propeller shaft.

Tightening torque: 65 Nm.

19. Remove ramps and wheel blocks, lubricate bearings. Test drive and check for faults.

SHOP MANUAL MT 30 -02.98

8.3.8 DISASSEMBLY & ASSEMBLY

TURNING RING - NEW TYPE

(Not sold as spare parts anymore!)

DISASSEMBLY:
1. Split the dump truck at the articulation turning ring as described in page 8.3.5 and remove the
original turning ring.

2. For easy lifting of the turning ring, a lifting eye bolt is included in the modification kit (part no.
057939). Unscrew the blank plug on the top of the turning ring and install the lifting eye bolt.

Note!
Check that the welding surface is machined and planed (pos 7). If the surface not is planed, grind
off the weld. This is necessary if the new turning ring shall fit correctly.

ASSEMBLY:
3 Insert the screws (pos 2) into the outer ring and install the turning ring to the articulation hinge
with screws (pos 3), using Loctite 245. Tightening torque 333 Nm

Note!
Please make sure that the marked "up" position is pointed upwards as shown in figure 1 facing
page.

4. Apply Loctite 245 into front frame holes, connect front and rear frame and tighten the screws
pos. 2. Tightening torque 277 Nm

Note!
Center lubricator shall be in upwards position!

5. Reconnect the propeller shaft with the distance ring (pos 4) between the propeller shaft and the
gear flange with screws (pos 5) and nuts (pos 6), using Loctite 262 Tightening torque: 75 Nm

6. Install the new lubrication pipes as shown in figure 2, below,

Note!
For older machines without lubrication block and lubrication pipes, new lubrication nipples are
included in the mod. kit. for installation in the lubrication holes on the turning ring.

Lubricate the turning ring and test drive the dump truck, checking for faults. Lubricate the
turning ring twice the first few days.
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FIGURE 2
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Lubrication block

Turning ring

SHOP MANUAL MT 30 - 02.98

DISASSEMBLY & ASSEMBLY 8.3.9
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FIGURE 1
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1234567890123456789012345678 Please note the
marked "up" position!

A Rear frame

1
6

Gear Propeller
flange shaft

A
5 4

SECTION A - A
2
1

Front frame
Articulation hinge
3

SHOP MANUAL MT 30 -02.98

8.3.10 DISASSEMBLY & ASSEMBLY

ARTICULATION HINGE - BALL TYPE

DISASSEMBLY

1. Apply wheel blocks to front wheels.

2. Support front frame with two ramps, one at each side of front end.

3. Disconnect rear end of articulation propeller shaft.

4. Unscrew outer turning ring bolts and pull rear frame carefully backwards. Support rear frame
with ramps.

Note!
Be aware of the propeller shaft.

5. Unscrew the turning ring by losening inner ring bolts.

6. Clean, inspect and replace worn and/or damaged parts. Replace all seals.

ASSEMBLY

1. Fit turning ring onto articulation hinge. Use Loctite 242 on bolts. Tightening torque: 333 Nm.

2. Fit outer (half moon) seals and tighten screws to pressurise lip seal.

3. Connect front and rear frame and position the turning ring in front frame.

Note!
Turn bearing until ball filling hole faces horizontally to the right of the truck.

4. Fit outer ring bolts, apply Loctite 242 and tighten. Tightening torque: 333 Nm.

5. Connect articulation propeller shaft. Tightening torque: 65 Nm.

SHOP MANUAL MT 30 - 02.98