Bonserorersrins ee SERIES: LSS5SL-LS77SL DATE:DEC7S _ISSUENo:01 PAGE: LS55SL - LS77SL OPERATING Al INSTRUCTIONS Publication No. 047951 Edition 1Boner orcranns nstaucrio SERIES: LSS5SL-LS77SL DATE:DEC79 ISSUENo.01__ PAGE: Ae INTRODUCTION Bonser Fork Lift Trucks have been designed for the economical lifting, transporting and stacking of @ variety of loads, ranging from shapes suitable for simple forks to those requiring special attachments. Load handling, driving, transporting and final pracise positioning are achieved by easily operated controls. Each type of truck has been subjected to, and conforms to the stability tests specified by the British Standards Institution BS3726, ISO Standards R1074, F.E.M. Section 4 and directives published by BLT.A, After Sales Service is available through a network of home and overseas dealers and distributors. Each truck is inspected and tested before leaving the factory. To maintain performance and reliability, periodic inspection and attention must be given at the appropriate times stated in the maintenance and servicing sections of this handbook. The objective of this book is to provide the operator and the owner, with sufficient information to safoly y use and maintain the Bonser Fork Lift Truck through a useful working life. IMPORTANT DIRECTIVE ON TOWING TORQUE CONVERTOR TRANSMISSION The foot pedal must be in neutral and the engaged gear is left engaged. 2. Do not tow the vehicle at more than 8 kmh (5 mph} 3. Do not tow the vehicle further than 0.8 to 1.61 km (% to 1 mile) NOTE: Under no circumstances attempt to tow start @ vehicle fitted with Torque Convertor Transmission, FOREWORD Itis recommended that operators/owners read this book thoroughly before the truck is put into use, Reference to right hand and left hand in the text apply from the driving position. SPECIALINSTRUCTIONS DO NOT attempt to use the truck unti all instructions regarding the preparation for use have been carried DO NOT attempt to operate the truck until you, as the driver, are fully conversant with the controls, (see Location Diagrams) and have read fully and understood the operating instructions. tion and DO NOT forget to have the vehicle serviced according to the schedule. Proper tut maintenance are essential. It is important for operators to understand that experience gained on machines using @ conventional ‘gearbox cannot directly be carried over to machines fitted with Torque Convertor Transmissions. Driving techniques, servicing, maintenance and the whole approach must be changed for the sake of safety and ‘the working life of the truck. Oper xp rs are strongly urged to strictly adhere to all instructions and to resist the temptation for personal ;nts which can prove to be costly failures.BOnser oresarincistaucrions SERIES: LSS5SL-LS77SL DATE:DEC7S _ISSUENo:0! _PAGE:a WARNING Itis extremely important to bear in mind at all times, that this class of machine, when carelessly or badly handled, can be a danger to the operator and others. Only properly trained and tested drivers should be permitted to drive. The manoeuvrability and high acceleration can produce large crushing forces at low ‘speeds. A high degree of importance is attached to safety and proper use of Fork Lift Trucks. The safety ‘codes of the British Industrial Truck Association and F.£.M. have been included in the section concerning safety. ‘SERVICE AND MAINTENANCE ‘The terms of warranty are qualified on, and are included within, the original truck delivery documents, and should be read thoroughly. Your truck carefully maintained, will give long trouble free service but inevitably, when overhauls become necessary, the question of service or replacement parts arises. Repair Kits are available, but we strongly recommend that adventage be taken of the Bonser Exchange Unit Service, wherever applicable. Correct lubrication, using the specified grades of oil and greases is of the utmost importance and cannot be too highly stressed. Guessing can be expensive in time and replacements, therefore consult the Parts Catalogue. If in difficulties refer the trouble to your authorised dealer.¢ Bonnserorerarine msstrucrio SERIES: LSSBSL-LS77SL DATE DEC TS _ ISSUE Bs PAGE: INDEX Safety Code and Regulations To Prepare the Truck for use Running in : General Vehicle Information Operating Instructions Vehicle Maintenance Servicing — Safety Precautions to be Observed. Daily inspection and Service Service Task ‘A’ Service Task ‘B" Service Task‘C’. Service Task ‘D’ ; 5 Special Service 1000 Hour — Torque Convertor Service Task ‘E’ Special Service 2000/3000 Hour Service Task — Record Chart Lift Chains . Roller Adjustment — Mast and Carriage. Trouble Tracing ‘ é Clutch Fault Diagnosis. : Engine Fault Diagnosis, : Fault Finding — Power Steering General Servicing Information . Vehicle Specification — LSB5SL Vehicle Specification — LS77SL Service Points . Hydraulic Circuit Electric Diagram Lubrication Chart—— SAFETY CODE AND REGULATIONS ‘0 BE OBSERVED BY THE OPERATOR DEFINITION For the purpose of this ditective the operator is defined as the criver of « powered industiial ruck The necessary qualifications of operators of Industril tucks ar (2). Enjoy good health, vision and hearing, (b) Understand traffic regulations (6) Be especially trained. IDENTIFICATION OF OPERATOR 1. Having beon selocted ond trained, the operator should be designated ‘authorised’ and should have the right to prevent unauthorised persons from using the machine for which he is responsible 2. The operator should wear a badge oF other fe authorisation throughout his. working hours, The safe operation of industtial wucks i dependent 10 a large extent on the mar which petscnnel operate the trick Th for the operator are provided in the folowing tegories (a) General nutes. (b) Handling the toe! (lifting anu! stock (6) Teavolting driving) {d) Operator care of the truck GENERAL 1. Only authorised personne! she industeial trucks. 2. Passengers) m except where provided ist not ride on industrial truc specific. means have boon 3. Operetors should pay pernicular attention to the operating environment, and safeguard pedestiians at al ines pould be allowed to stand or pase 4, No person Under the elevied part of any truck, wheth loaded 01 unloaded Any accidents involving pers boulietings, structures ot equipment should be reported st 6. Operatars must not atid 10 Bons? crcasinsmsteucrions SERIES: L595: DATE: DEC TS 78 ISSUE No: 01 PAGES make mechanical alterations without author: sation, 7. Operators shoul use wucks only for the purpose for which they are equipped. HANDLING THE LOAD LIFTING & STACKING 1. Only those loads which are within the rated Capacity of the Wuck and attachments (if Used) must be handled, For dotails of the rated load capacity, reference should be made to the Safe Working Load Plate on the Wuck The loads indicated are with the mast vertical. THE MAXIMUM. CAPACITY STATED MUST NOT BE EX: CEEDED 2. No means (for example — increased counter- weights or additional personnel) are to be sddled 10 the truck 10 inetease capacity. 2. Only stable oi sately arranged loads are to be handled Peviculat care should be taken when handing extre long ot high loads, 4. When hendling loads which cannot be centred, the truck should be operated with special ution operation or faulty maintenance vilicn of instability. Conditions ground and_floot cients, excessive speed, over: ‘amic and static forces and errors of ihe operator toad icy NG UP THe LOAD LIFT THE LOAD WIR THE MAST F ULTED BACKWARDS, NEVER WHEN TI.VED FORWARDS. Ake LING MOVEMENTS AS OSSIBLE ALWAYS owas 1. tnsert the forks under the toad as far as aosalbte, rise to fully support the load, ca uity vii the mast backward to increase the tabiity oF the toad. " fal caution when tiling the load ‘ang up seqmented loads jing high or segmented loads, 3 6) exienision should be used. 4. Never tit elevated loads forward, except when the jossi is directly over the setting downDATE: DEC 78 Bonnser orcaarivenstaucrions SERIES: LS5SSL-LS77SL ISSUENo:01 _PAGES6 position and then only when the load is as low as possible. STACKING 1. Approach the stack slowly with only enough backward tit of the mast to stabilise the load 2. After completing the travelling manoeuvre, ‘and only when the load is close to the facing of the stack, adjust the mast to vertical. Raise the load slightly above the stacking height and move the truck slowly forward. 3. When the load is over the stack, re-check the mast for vertical, only then lower the load 10 the stack, 4, Ensure that load is securely stacked. 5, Withdraw the forks and lower them to the travelling position, move the truck eway after ascertaining that the way is clear. REMOVING FROM THE STACK Fork spread should be suitably adjusted for the width of load to be handled. The weight of the load should be checked to ensure it is within the capacity of the truck 2. Approach the stack and stop the truck with the fork tips approximately 0.3m (13in.) from the stack, adjust the mast to the vertical position. 3, Raise the forks to @ position for inserting under the load, 4, Insert the forks under the load as far as possible, care being taken thet items beyond the load are not disturbed by the fork tips ‘Then raise the forks sufficiently to engage the load. 5, Raise the forks further until the load is just clear of the stack. Tilt backwards only enough to stabilise the load. Always make tiking move. ments as slow as possible. 6. After ensuring that the way is clear, withdraw the load from the stack 7. Lower the load to the travelling position, tilt fully backwards end move the truck away after ensuring thet the way is clear and the remaining stack is secure. ‘TRAVELLING (DRIVING) GENERAL 1. Asa general rule, keep to the side of the aisle, conforming to the road regulations. Keep @ clear view of the path ahead and keep a lookout for other traffic and personnel, and maintain safe clearances. 2. Steering knobs must not be attached to the steering wheel of industrial trucks unless originally provided 3. Observe all traffic regulations carefully, including any special regulations within the operating ar 4, Maintain @ safe distance from any other vehicle. 5. Keep the truck under control at all times and operate it in @ responsible manner. Avoid sudden starts and stops and high speed turing. When the tuck starts to move, cortect the steering to overcome wheel drag land shudder. 6. The load engaging equipment should be lowered for travelling and preferably tilted backwards. Only elevate the load during stacking operations. 7. When the truck is unladen, the operator must only trevel with the forks in their lowered position, and with the appropriate degree of backward tlt consistent with safe operation. 8, If the load obscures vision, drive the truck in reverse, making the necessary allowances for turing at the beginning end end of the journey, 9. When conditions necessitate travell ward with load which obscures visibility, exercise extreme care and make use of ancillary aids and/or assistance from other personnel. 10. When menoeuvring with the load, operate all controls in @ moderate and smooth manner. 11. Do not overtake another truck travelling in the same direction at aisle intersections, points of limited visibility or at dangerous locations. 12. Avoid running over loose objects. 13. Never place arms, legs or head within the Uprights of the mast or other working parts of the truck. 14, Do not lean outside the plan outline of the truck when travelling. 18. Give signals before turning when other vehicles or pedestrians are in the vicinity. 16. Comply with all signs and other instructions concerning floor loadings.SPEED 1. Adapt the speed of the truck to the presence ‘of personnel in the area, visibility, ground surface and load stability. Take particular care ‘on wet, loose or slippery surfaces and on gradients. 2. Under all conditions operate the truck ato speed which will permit it to be stopped safely without loss of control or oad. 3. Restrict the speed within the confines of on establishment to a maximum of 17kmh (10.5 mph) or such lower speed as may be indicated in particular circumstances or area. DRIVING ON GRADIENTS 1, When ascending or descending gradients in excess of 1:10, drive loaded trucks with the load uphill, 2. When unladen, drive forward both up or down bil. 3, On all gradients, backward tilt the mast, end tise forks to clear the road surfaces and other local obstructions. 4, Tums should not be made on a gradient and ‘tucks should not be driven across @ gradient 5. Exercise special care to maintain a safe distance from the edges of gradients, elevated docks or platforms. CLEARANCE 1. Ensure thet there is sufficient clearance und ‘overhead installations e.g. light fixtures, pipes ‘and fire protection systems. 2. When traversing passages or doorways, ensure thet there is sufficient clesrence for the truck, operator and load. USE OF TRUCK IN ROAD VEHICLES & RAILWAY CARS: 1. Before entering @ roed vehicle or railway car ensure that necessary precautions have been taken to prevent its movement 2. When driving on or off @ semi-trailer, not coupled to a tractor, ensure that supports to provent up-ending, if necessary, are in position. 2. Before entering @ road vehicle ot railway car fensure thet the floor will support the total weight of the truck, load and the operator Check the floor for breaks, holes ot other dofects, 4. When operating on elevated docks and/or DATE. DEC 7S Boinser orenarivc instructions SERIES: LSSSSL-LS77SL TSSUENe: OF PAGET, platforms, truckis) should not be used for pushing goods wagons. Trucks) should not be used for opening end closing goods wagon doors, unless the truck(s) utilises a device specially designed for that purpose, and the ‘operator is tained in its use. Whenever possible, railway tracks should be slowly crossed diagonally and with care. DRIVING ON BRIDGE PLATES OR DOCKBOARDS, 1. The rated capacity of the bridge plate or dockboard must not be exceeded. 2. Before driving over a bridge plate or dock- board, ensure that itis properly secured. 3. Before driving over a bridge plate or dock- board, ensure that it has @ slip resistant surface 4, Bolore crossing 2 bridge plate or dockboard censure that the sides are provided with means to minimise the possibility of the truck running over the edge 5. When crossing the bridge plate or dock- board, drive the truck slowly and carefully, LIGHTING 1, Never operate the truck, unless lighting of roads, sisles and stacks is adequate to operate sately Use the tuck lights to assist operating (if provided. SLINGING OF TRUCKS: 1. Slings must be ettached only at the points indicated USE OF TRUCKS IN LIFTS 1. Before trucks are driven on to a lift, ensure that it is 8 designated lift which will support the weight of the truck, load, operator and any accompanying personnel. 2. Accompanying personnel should enter a lift after the truck is in position and leave the lift before the tuck 3. Approach lifts slowly and enter only after the lit car is level with the floor Onee on the lift, the controls of the vehicle should be neutralised, the power shut off and the parking brake applied. PARKING 1, When trucks are left unattended or parked the fork carriage should be lowered to theBoner orensnuc instructions ‘SERIES: LSSSSL.LS7ISL DATE: DEC TS ISSUE No 01 PAGES ground and the mast positioned vertical Controls should be neutralised, power shut off, handbrake applied and the trucks secured against unintentional or unsuthorised move- ment. Remove ignition key. 2. Trucks should not be left unattended on gradients, 3. Perk clear of fire exits, fire equipment and access to stairways. 4, Always park at @ safe distance from railway tracks. NOTE: The handbrake is intended for parking and emergency braking only and MUST NOT BE USED FOR PROLONGED PERIODS OF NORMAL BRAKING. OPERATOR CARE OF THE TRUCK GENERAL 1, Before operating the truck, check its condition. Give special attention to the fuel system, tyres, warning devices, lights, battery, controler, lift system (including load engaging means, cchains, cables and limit switches), brakes and steering mechanism. All hydraulic hoses should be checked for leaks etc. 2. If the truck is found to be in need of repair, for develops @ defect during use report the matter immediately to the designated superior 3. Operators should not make repairs or adjust- ments unless specifically authorised to do so. REFUELLING 1. The engine must be stopped and the operator off the truck during refuelling, 2. Open flames and smoking are prohibited while refuelling 3. Only refuel at locations designated for that purpose. 4. Do not re-start the engine until the filer cap hhas been replaced on the tank and the fuel filing equipment removed from the vehicle Disperse any spilled fuel.Boner orcnaninc wstructions SERIES: LS85SLLS77SL DATE: DEC73__ ISSUENo: 01 PAG TO PREPARE THE TRUCK FOR USE Position the vehicle on level ground and replace truck components removed for transportation purposes. DO NOT start the engine until each of the following have been carried out:— NOTE To Release Bonnet {a) Operate lover situated on bulkhead at left hand side of drivers seat. (b) From the rear of the vehicle, pull the bonnet, fully rearwards. (c) From the front end, lift bonnet until restrained by the limit chain. To Close Bonnet (a) Lower the bonnet from the side until it locates conto the guide (b) From the rear of the vehicle, push the bonnet, fully forward to engage the retaining latch, 1. Chock the fue! level and fill as necessary. 2. Check the main hydraulic services system — top up if necessary with the correct grade of hydrautic oi CAUTION: Lack of hydraulic oll could result in serious damage to the hydraulic pumps. 3. Check that the engine oil level is correct as indicated on the dipstick and top up if necessary. 4, Check the final drive oil levels by means of the filer/level plugs which are located as indicated on the lubrication points diagram on page NOTE: ‘The Diff. Housing and the L.H. & R.H. final reductions are separate units each with their ‘own drain and filler/level plugs. Top up as required with the correct grade of oil 5. Check the transmission drive oll level as indicated by the oi filler/level dipstick. 6. Check that the radiator is topped up to the appropriate level with clean water or anti freeze as is applicable. NOTE: The correct grade of anti freeze specially prepared for diesel engines must be used. 7. Check that the battery electrolyte level is 6mm %") above the top of the plates. page 10. 8 Check the tyre inflation pressures as shown on a RUNNING IN ‘New or replacement engines should not be operated at full power output for the first 25 hours. Nei should an engine be run at idling speed or high r.p.m. with the vehicle unladen. ‘To assist in the initial bedding in of the moving parts, such as piston rings, bearings, seals, etc., the engine should be used at about 80% of its maximum power output for the first 25 hours, after which it may be ‘operated at full power.Boner orenarivs nsraucrio SERIES: LSOSSL-LS77SL. DATE:DEC79 __ISSUENo:01 BS 70 GENERAL VEHICLE INFORMATION UNIT CAPACITIES ENGINE: Engine Oil with Fier 7.aitves 13 pints Coolant (anti-freeze/water 1:3) 13.6 litres 2Apints Fuel Tenk 72.73 litres 128 pints NOTE: Use only a corrosion inhibited Ethanedial anti-freeze (Sodium Benzoate and Sodium Nitrate inhibitor) BS3181 Type B. TRANSMISSION: Gearbox Case 18.9 litres 2B pints Differential Case 11.4 litres 20 pints Red. Gear Case (each) 2.27 litres, 4 pints Hydraulic Tank 72.73iitres 128 pints Torque Convertor 79iitres 14 pints HYDRAULIC PUMP CHARACTERISTICS AT ENGINE SPEED OF 2000 RPM. Total Flow Rate 60 litres per min. 13.5 Imp. GPM. 7.9)itres per min. 1.75 Imp. GPM 136.05 Atmos. 2000 PSI Pressure 149.66 Atmos. 2200 PS! HYDRAULIC CONTROL VALVE Relief Valve Setting 183.06 Atmos. 250 PS! ‘TYRE PRESSURES Front (Drive) Rear (Steer) LSS5SL 2.38 Atmos.35PS! 1.9 Atmos. 29 PSIBoner orcnarneinsraucrions RS DATE: DEC79 _ISSUENo:01__ PAGE!17 CONTROL LAYOUT TORQUE CONVERTOR MODELSBonset orcranucinsrauctions lm senies: snss.s7s. DATE:DEC79__ ISSUENo:01 PAGE: 12 CONTROL LAYOUT G/BOX MODELS | Warning Light (Green) 10 Brake Peas ‘Woter Temperature Gauge M1 Throte Contot 2 38 Rata Chonge LeverBonnset orenaninc wsrrucrions SERIES: LSS5SLLS77SL DATE: DEC79 _ ISSUENo.01 PAGES OPERATING INSTRUCTIONS TO DRIVE THE TRUCK 1. Check that the vehicle handbrake is in the "ON" position and that the transmission controls are in the neutral position. 2. Check that the engine stop control is In the ‘normal run position. NOTE: On Hydrostatic Transmission vehicles ensure that the by-pass valve is closed for drive. 3. Turn the ignition key to the “ON” position. ‘The “No oil pressure” and the alternator "No Charge” warning lights will be illuminated. Increase turn of key and hold, adjusting throttle position until engine starts and continues to run. If the engine fails to start, allow @ few seconds rest before making another attempt, 4, Under cold start conditions it may be necessary to use the cold start aid on the injection pump, screw in the wing nut “Before” attempting to start the engine, and return immediately engine starts, NOTE: If a start attempt has already been made, wait 30 seconds before screwing in wingnut otherwise pump will be locked in full advance and engine will not stat. Black exhaust smoke will show that the wingnut has not been returned to its original position, INJECTOR PUMP A. Throttle adjustment screw B. Cold start screw 5. Controls are arranged conventionally with the clutch, footbrake and accelerator pedals layed out as normal commercial vehicle practice, and ‘are controlled in the same manner. Refer to pages 11 and 12 for layout of controls TORQUE CONVERTOR It is important for operstors to understand thet experience gained on vehicles using ‘conventional Transmissions cannot be directly carried over to machines fitted with torque convertor. Driving techniques servicing and maintenance ‘must be changed to maintain safety standards. Operators are strongly urged to strictly adhere to all instructions and to resist the temptation for personal experiments which can prove to be costly failures. In terms of the torque convertor gears there is no such thing as “NEUTRAL and with the foot pedal in this position the last used gear remains engaged with “NEUTRAL” selected 2 valve opens and the convertor is drained of oil, thus virtually no torque is developed, but, in’ addition, the multiplate clutch is’ also disengaged ‘and the engine power is cut off. ‘These actions take % to 1 second, if the engine has been idling, 2 to 3 seconds if the engine has been “Revved” just prior to gear change je. “Forward or Reverse”. Hence the import ance of the pause in Neutral” before attempt- ing to engage the next selected gear. A forced ‘gear change can produce the condition where the dog geat becomes trapped between ‘mating gears and unable to mesh with either due to a complete loss of revs synchronism causing “"Clashing” in this case shut off engine, apply handbrake and start again. om Always change gear with vehicle stationary and engine idling The previously selected gear under normal conditions does not move out of engagement until the pedal is moved off “Neutral” towards. the opposite gear. Power from the engine must be shared in balance between the torque convertor and hydraulic system, therefore a sudden simultaneous demand for power can cause excessive loads on the engine and possibly result in a dangerous power loss to either or both systems. During load moving operations the handbrake should be "ON" and gear pedal “Neutral”. The controls are as indicated earlier and are basically of the two pedal =|Bonserrorenarinc instauctions SERIES: LSS5SL-LS//SL DATE: DEC 78 PAGE: 14 ISSUE No: 01 Accelerator and brake. The latter has @ com- bined clutch section for dividing power supply and permits precise inching. After selecting forward or reverse gear use only accelerator and brake as in an automatic vehicle, until the load is to be picked up or put down. At this stage power can be divided to supply the hydraulics at high engine speeds if required, whilst at the same time by virtue of the slipping clutch facility of the power divider, small amounts can be kept at the wheels for slow forward or reverse movement. Practice will ‘soon permit accurate judgement in this respect ‘and by combined left foot pressure upon the brake and power divider if required. Engine when warm may be started with forward or reverse gear selected provided handbrake is applied. Select forward or reverse gear, transfer braking from handbrake to footbrake, increase engine speed as transmission takes up the drive release footbrake end increase speed as required. NOTE: The vehicle must be stationary before changing from forward to reverse. It must also be in neutral and with the handbrake applied, in order to change from high to low ratio by the hand selector. It is therefore better to select before hand ratio required. It is extremely dangerous to be out of gear CAUTION: Care must be exercised in applying the brakes when transporting a load. The handbrake is intended for parking and emergency braking only and “MUST NOT BE USED FOR PROLONGED PERIODS OR NORMAL BRAKING” VEHICLE MAINTENANCE ‘An important factor in the satisfactory operation of industrial trucks is careful maintenance. When maintenance is neglected, trucks can become a source of danger to personnel and property. Preventative maintenance and inspection should be carried out to the recommended service schedule by {Qualified and authorised personnel. Only lubricants recommended in this publication must be used. Refer to pages 33-34-35-36. ‘When the tasks are completed the completion date should be marked in the appropriate space indicated on page 20 of this book in order to keep a complete service record. 8. LIFTING MECHANISM. 9. TO STOP ENGINE b. NOTE: If, because of the working environment items reauit transferred to an earlier service task. L_ more frequent servicing then these should be To raise or lower the load, operate lever with descriptive symbol (or coloured yellow) in the direction the load is required to move. To tilt the load operate lever with descriptive symbol (or coloured red) into the position the load is required to move. To sideshift the load operate lever with descriptive symbol (or coloured biue) in the direction the load is required to move. Reduce engine speed to tick-over. Pull out engine stop control — engine stops. Turn ignition key to the off position If the vehicle is to be left for ny period Unattended the handbrake should be applied. If parked on an incline the wheels should be chocked on the lower side. Remove ignition key for complete im- mobilisation of vehicle against use by unauthorised personnel,Bonet orenarive instavctions SERIES: LSS5SLLS77SL. DATE:DEC7S ISSUENo.01 PAGE:15 SERVICING — SAFETY PRECAUTIONS TO BE OBSERVED Betore commencing any maintenance or repair work, ensure that the following precautions have been taken, 1. Never work beneath @ vehicle which is on soft ground, always take the vehicle to an area which has @ hard working surface ie. concrete. 2. The fork carriage must be lowered to the ground and the mast positioned vertically. ie. Forks resting on firm ground, 3, The handbrake should be in the “ON” position, if the handbrake is defective, then the driving wheels must be chocked. Controls should be neutralised and the vehicle immobilised against unauthorised movement and the “Ignition key removed" 4, Always ensure that personnel are clear of the vehicle when carrying out any test, servicing or repairs. 5. Ensure that the vehicle is clear of any stacked material DAILY INSPECTION AND SERVICE Check the following with the vehicle standing on level ground, 8. Engine olltevel — top up if necessary. b. Coolant ievel — top up if necessary . Transmission ol evel — top up tf necessary 4. Hydreulic ol. Top up if necessary. e. Tyre pressures — adjust if necessary — Refer to page 10 for tyre pressures. Also examine tyres for damage and remove any flints etc. from the tyre threads. {, Tightness of all wheel nuts. g. Battery — top up if necessary to correct level, h. In extreme dust conditions — empty the dust bow! of the engine air cleaner. i. For any fluid leaks and take action to eliminate SERVICE TASK ‘A’ Every 50 hours running time or every week whichever is the sooner. All items listed on the Daily Service should also be carried out. GREASING AND OILING GREASE POINTS (Refer to location diagrams peges 30) using the Location Total No. off pressure grease gun provided in the tool kit, Wheel Hubs — Steer 2 Grease the following areas using only the recom. Kingpins 4 mended lubricants listed on pages 33-34-35-36. Steering Joints 4 Steering Centre Pivot 1 ‘Steering Cylinder Pivot 2 Axle Pivot i OILING Mast Tilt Cylinder Pivot 4 Oil all other points of movement with clean engine Mast Rollers 4 oil. ie. linkages, lever and control rods, also Carriage Rollers, 4 2 locking pins on carriage forks. Reduction Unit (underside)Boner orcnarive nstaucrions SERIES: LSSSSL-LS77SL_ DATE: DEC 7S ISSUE Noro} PAGES DRIVE AXLE Remove drive wheel and check the following using only lubricants as recommended on pages 33-34.35-36. 2. Differential housing — top up if necessary. b. Final drive reduction units — top up if necessary, . Check that the breather bolt is clear. ie. the ‘uppermost bolt on the cover plate. ENGINE After the first 80 hours running only. @. Drain the sump, clean the strainer and refill with new clean engine oil to the level indicated ‘on the dipstick. Use only lubricants as recom- ‘mended on pages 33-34-35-36. bb. Check and re-set valve clearances. Refer to page 27 for valve clearances. cc. Check cylinder head bolt — tighten in the correct sequence and to the correct torque. Refer to page 27. d. Renew engine oil filter element. 2. Check coolant level and check for leaks. f. Check external nuts, setscrews, mountings ete. for tightness. ‘9. Check fan belt tightness. h. Check for lubricating oil leaks. HYDRAULIC FILTERS After first 60 hours running only. a. Change hydraulic services filter. ‘TORQUE CONVERTOR (IF FITTED) Check cil level — top up if necessary, after first 50 hours, drain ol from case and clean magnetic filter plug. Refer to page 18 SERVICE TASK ‘B’ Every 100 hours running time or every month whichever is the sooner. All items listed on the daily and 50 hours services should be carried out as well as the following: FOOTBRAKE 1. Check the fottbrake free play which should be ¥7 (3.2mm) to #4" (4.8mm) at the pedal 2. If the brakes are “Spongey” the hydraulic braking system will require bleeding or venting as follows a, Use a clear plastic tube which is a push fit ‘onto the bleed screw. b. Immerse the free end of the tube into a container containing a quantity of clean brake fluid of 1” (25mm) minimum depth, c. Loosen the bleed screw, press the foot- brake pedal to eject @ quantity of brake fluid, retighten the bleed screw and release the brake pedal. 4. Top up the brake fiuid reservoir to the correct level using only Lockheed Heavy Duty Brake Fluid, c. Repeat until all air is expelled. NOTE: To avoid contaminating the brake fluid itis essential that the reservoir cap and surrounding areas cleaned before removal HANDBRAKE 2. Adjust the handbrake by turning the PVC hand {grip until an over centre position is reached. . Release the handbrake and check that the brakes are not binding. HOSE CONNECTIONS Check tightness of all hydraulic hose connections and examine all hoses for chafing, leaks etc. WIRING Chack all electrical connections for tightness and Cleanliness, examine wiring for faults and check functioning of instruments. Particular attention should be made to the condition of electrical insulation. ENGINE BREATHER Ensure that the engine breather is clean and that, the ‘O' ring seal is in a good condition. A suspect “O' ring must be replaced MAST AND CARRIAGE ROLLERS To maintain correct alignment of mast and carriage, ensure that all mast and carriage rollers are correctly adjusted. Refer to page 22. TORQUE CONVERTOR (IF FITTED) Check oll level — top up if necessary with correct lubricant as recommended in this publication.SERVICE TASK C Every 200 hours running time or every 3 months whichever is the sooner. All items listed on the daily, 50 hour and 100 services should be carried out as well as the following: ENGINE OIL AND FILTER CHANGE a. Drain the engine sump, replace the engine oil filter element and refill to the correct level indicated on dipstick with clean engine oil Only recommended lubricants to be used. Refer to pages 33-34-35-36. 'b. Check engine for leakage of oil and coolant AIR CLEANER Remove the air cleaner filter element and clean by either tapping the element to dislodge the dust ot by reverse blowing with low pressure compressed air. FAN BELT Check the fan belt tension by deflecting midway between the alternator and crankshaft pulley. The correct tension should give 13mm (%") free ‘movernent at this point. Adjust if necessary by slackening the alternator bolts to give the correct tension. Re-tighten alternator fixing bolts. SERVICE TASK ‘D’ Boner orenarinc insrauctions SERIES: LSS6SLLS77SL DATE:DEC79 _ ISSUENo:01 PAGE: NOTE: Do not overtighten the fan belt, as this will place excessive load on the bearings and increase fan belt wear. STEERING Lift the rear of the vehicle with a jack, having first chocked the driving wheels. With the engine running slowly, check that all steering movements are free and smooth. Adjust rll where necessary. Check the steering cylinders for leakage, and service if required. MAST PIVOTS Examine mast and tilt cylinder pivot pins and bearings for weer, replace if necessary. HYDRAULIC CYLINDERS AND VALVES Check the lft and tit cylinders, also control valve for leaks, service if necessary. Every 400 hours running time or every six months whichever is the sooner. All items listed on daily, 50 hour, 100 hour and 200 hour services should be carried out as well as the following, ENGINE 1. Renew the fuel filter element. NOTE: It is always recommended to bleed or vent the system. Whenever the filters or connections are opened. This to be at the inlet to the frst filter. RENEWING THE FIRST FUEL FILTER. {A Securing bolt 2. Clean out the fuel water trap and sediment bowl, FUEL FEED PUMPBEDIMENT BOWL, A Bow! securing nut Sealing rng 8 Sediment bow 1D. Fier gure Priming lever 3. Check all hoses, pipes and clips. Renew all ‘suspect hoses and pipes.Bonser oresarivs wstaucrions py sanice:Lesso,ua7ret DATE: DEC 79 ISSUENo:01 PAGE: 18 4, VALVE CLEARANCE 6. BRAKE CYLINDERS Check and reset the valve clearances. Refer Examine brake cylinders for correct operation to page 27. and leaks, fit new seals of cylinders if required, 5. INJECTORS Remove injectors, for cleaning by 8 David 7. REAR AXLE Brown/Cav. Agent. Cleaning et this period of Chock the drive wheels and lift the rear of the time is essential otherwise reconditioning Vehicle with a jack. Remove the rear wheels will be necessary before the normal period of and hubs, examine oil seals and bearings. 1500/2000 hours. Replace any worn or damaged parts. Check the steering linkages for adjustment slackness etc, and replace any worn part or damaged part Adjust, refit hubs and wheels, check steering cylinders for leaks and damage. 8. HYDRAULIC FILTERS 9. LIFT CHAINS Inspection of lift chains must be carried out at regular intervals of not less than six months. Refer to page 21 10, GENERAL INJECTOR REMOVAL Check all bolts and nuts for tightness. 1000 HOUR SPECIAL SERVICE (TORQUE CONVERTOR) TORQUE CONVERTOR Ensure that the handbrake is in the "ON" position. Run engine forward or reverse gear engaged, until the convertor is warm. ‘Switch off engine, select “NEUTRAL” and remove drain plugs. Remove and clean oi filter by washing in petrol and using @ compressed air jet. CLEAN MAGNET FILTER Replace drain plugs and filter, sation Chart pages 36-38. For weather conditions where temperatures persist at freezing point or below, automatic transmission fluid may be Used. In this case drain the covertor and flush out with a gallon (4.5 litres) of transmission fluid. Change to 10W20 in good time as ambient temperatures rise above freezing point. On no account use oil grades that contain graphite or other lubricant adcitives. Total capacity for 833KE is 14 pints (7.9 litres) First fill with 8 pints (4.54 litres). Apply handbrake, select forward or reverse gear, run engine for about two minutes to fill convertor, then complete filing operation with reference to dipstick marks, with engine idling. NOTE: Never start engine unless there is at least 8 pints (4.54 litres) of oilin convertor. Check the oil level once every week or every 100 hours whichever is the sooner. Engine idling, select forward or reverse, check final cil level PRECAUTIONS TO BE TAKEN IN FREEZING CONDITIONS The convertor cooling system, is common to the engine cooling system anc when there is a danger of jeazing, both systems must be drained, unless antifreeze has been added to the cooling system,Bonnser operative nstaucrions SERIES: LSSBSLLS77SL DATE: DEC79 _ ISSUENo:01 PAGE:19 SERVICE TASK ‘E’ Every 1200 hours running time or every twelve months whichever is the sooner. Al items on the daily, 50 hour, 100 hour, 200 hour and 400 hour services should be carried out as well as the following 1. ENGINE OIL PUMP Drain the engine sump and clean the oil pump gauze. Refil to the correct level indicated on dipstick lubricants to be used. Refer to pages 33-34.35- REMOVING THE ENGINE OIL PUMP FILTER 2. FUELFILTER Renew socond fuel fier element. 3, GEARBOX Drain gearbox and refill with clean oil ~ only correct grade of oil as specified on lubrication ‘chart should be used. Refer to pages 3-34.35. 36. 4, AIR CLEANER Renew air cleaner filter element. 5, TORQUE CONVERTOR (IF FITTED) Drain oil from convertor and clean magnetic filter plug. Refill with clean oil as recommended ‘on lubrication chart. Refer to pages 35-36. 6. DRIVE AXLE Drain drive axle and refil with clean oil. Only correct grade of oil as specified on lubrication chart should be used. Refer to pages 33-34-35- 36. 7. FINAL DRIVE UNIT Drain final drive units and refill with clean oll Only correct grade of oil as specified on lubrication chart should be used. Refer to pages 33-34-36-36, FINAL REDUCTION UNITS. A Fiting Bug 8. HYDRAULICS Drain hydraulic tank. Remove tank top assembly in order to clean inside of tank. 8. Drain pug C. Vent plug Replace hydraulic filter and refit tank top assembly. Refill with clean hydraulic oll as specified on Lubrication Chart. Refer to pages 33-34.35.36, 2000/3000 HOUR SPECIAL SERVICE ENGINE Remove the injectors for servicing by @ David Brown/C.A.V. Agent. This to be carried out at ‘not more than 2000 hour intervals. BRAKES a. Examine the brake shoes for wear — renew ifworn, . Check all brake cylinders for leakage — renew brake cylinder seals or brake cylinders. ©. Drain the brake fluid completely from the system and refill with Lockheed heavy Duty Brake Fluid. This operation must be carried out under strictly controlled conditions. ie. Great care must be taken to see that any containers and dispensers used for filling the brake system are free from water. Brake fluid absorbs water from the atmosphere and it is therefore essential that fluid is only exposed to the atmosphere during the time it takes to fill the system It is also important that extreme care is taken to see that all dirt or dust of any kind Is prevented . a from entering the system during the filling ‘operation.Bonser orcranne structions jm SERIES: LS8SSLLSTISL DATE: DEG78 __ISSUENo:01 PAGE:20 SERVICE TASKS Enter the date in the appropriate space as the tasks are completed roa ae as ara TEs 2 100 k es obs ire so eeeLIFT CHAINS. INSPECTION: LIFT CHAINS 1. The inspection and servicing of the lift chains must be repeated at regular intervals not exceeding 6 months. 2. Clean the chains thoroughly using pat white spirit, or petrol. The use of other degreasing fluids is not recommended. Note: Every effort should be made to ensure that chains are not painted in any way. A coating of paint (or paint overspray) will inhibit thorough inspection of all chain com: ponents and may be impossible to remove with the recommended cleaning fluids. Thus the danger is incurred that unsuitable clesning fluids may be used in an endeavour to remove paint prior to inspection which could have 6 harmful effect upon the chain components. 3. Check the chains for wear on the link edges. ‘The maximum reduction in plate depth should not be more than 5% of the total plete depth, Hes MAXIMUM ALLOWABLE WEAR 5% OF ORIGINAL WIOTH Litt Chain Wear H' for 1” chain Maximum Wear 0.950" 5% of 0.950" 0.047" Minimum Plate Depth 0.950" - 0,047" 0.903" Chains having a plate width less than this figure must be replaced. 4. Examine the chains for: ‘A. Cracked or missing link plates. B. Elongated holes in outer link plates (rivet head in danger of pulling through). C. Loose or worn pins with damaged heads. D. Evidence of rust or corrosion, particularly ‘on inner faces of link plates, If any of the above defects are found the chains must be replaced. 5. Check the extension of the chain to detect wear. This extension should be measured over portions of the chain at a minimum of three locations and particularly where the chain passes over a pulley. Whilst carrying out the Boner orcnariveinstauctions SERIES: LSS5SLLS77SL DATE: DEC79 _ ISSUENo: 01 PAGE:21 check, the length of chain being measured must be held taut, @.9. under a load of approximately 1% of the manufacturers mini- ‘mum breaking load 6. The maximum extension of the chain must not exceed 2%. An elongation of 2% over a number of pitches on typical chains gives the dimensions in the following table. Nominal Number Maximum Che of Pitches Moosuremont (inches) tnd % 26 19.1 485 iz 19 193 490 Chains exceeding these dimensions must be replaced. Note: It is suggested that the number of pitches in the above table, while being recom: mended measuring lengths in order to provide 2 clearly measurable elongation, may be varied at the discretion of the examiner but prefer- ably should not be less than the quoted figure, 7. Chains that are within the specification and are to be returned to service should receive the lubrication treatment quoted in step 9. 8. The condition of the pulleys, anchors and anchor pins should be checked prior to refitting to the vehicle. 9. Lubrication prior to refitting the chains to the vehicle: ‘A. Soak the chains for one hour in resin bonded molybdenum disulphide B. Allow the chains to remain static for a minimum of three hours prior to fitting, to allow for good lubricant penetration and the draining off of excess lubricant. C. Before fitting chains, the chain anchors and cchain anchor pins should be immersed in, Or sprayed with resin bonded molybdenum disulphide, D. After fitting, the anchors should again be sprayed with resin bonded molybdenum disulphide. CHAIN LIFE A. It is recommended that all chains used in cold stores should be replaced after a period not exceeding 4000 hours or two years truck operation, whichever is the— SERIES: LSS5SL.LS77SL DATE: DEC 79 ISSUENO:01 PAGE: 22 general use should be replaced after a Period not exceeding 6000 hours truck operation or three years, whichever is the ‘sooner. REPLACEMENT & SHORTENING OF CHAINS: The practice of joining chain lengths is not recom: mended and chains from different manufacturers should not be placed together within the same application. I a chain requires shortening, itis imperative that, ‘the pin to be removed is completely “Beheaded” and free of burrs which may score the link plate bores when passing through. ‘TREATMENT OF CHAINS. Because fork truck chains are manufactured from hest treated steel THEY MUST NOT BE ‘ANNEALED. MAST AND CARRIAGE — ROLLER ADJUSTMENT ‘The following procedure to be adopted for maintaining correct mast and carriage roller adjustment. MasT 1. Establish total side movement between inner and outer mast sections. 2. The mast rollers are adjusted by means of adjusting screws, these ere also used for roller lubrication, having a grease nipple fitted in the ‘end of the adjusting screw. 3. Raise the carriage approximately 24” clear of the ground, support the carriage on suitable timber blocks to prevent accidental lowering of the carriage, while adjusting the inner mast rollers. 4, To adjust mast rollers, turn adjusting screws (4) in a clockwise direction equal amounts. This will take up side movement between inner and outer mast. NOTE: Do not over adjust mast rollers, should rollers fail to rotate, this will cause premature wear and roller failure. Raise and lower inner mast section in incre: ‘ments checking for any tight spots, until ful extent of travel has been checked. Re-adjust if necessary. NOTE: After adjusting mast rollers grease with Castro! Spheerol EPL2 or direct equivalent. CARRIAGE 1. Establish total side movement carriage and inner mast section between 2. The carriage rollers are adjusted by means of adjusting screws, these are also used for roller lubrication, having a grease nipple fitted in the fend of the adjusting screw, 15 2 2-218 2 & 3. Toadjust carriage rollers, turn adjusting screws, (22) in a clockwise direction, equal amounts this will take up side movement between inner ‘mast anc carriage. NOTE: Do not over adjust carriage rollers, should rollers fail to rotate, this will cause premature and roller failure. 4. Raise and lower carriage in increments ‘checking for any tight spots, until full travel has been checked. Re-adjust if necessary. NOTE: After adjusting carriage rollers grease with Castrol Spheerol EPL2 or direct equivalent. IMPORTANT NOTE: If during normal operation of the mast and carriage, it is found that the adjusting screws are working loose and not maintaining correct roller adjustment Replace adjusting screws by 2 new type fitted with a “Tufloc Patch.””TROUBLE TRACING Faulty Operation of the Hydraulic System. Air entering the hydraulic system through a faulty, of the system has been disturbed may produce jerky lifting or tilting action, and noisy pump running. Having corrected the connection or when pé leak, run the engine at half speed and op each of the services several times in an unladen condition until movement becomes smooth and the pump is quiet in action, If there is no positive response after 30 seconds running, switch off engine. ‘Assuming the tank is full, check for leaks at the Boner orenarincinsrructions SERIES: LS55SLLS77SL. DATE:DEC7S _ ISSUENO:01 PAGE:23, Slacken off pump connections and establish that oll has reached and filled the pump. {thas been known for pinch clamps to be fitted to tank hoses to avoid oil loss (a method we do NOT ste recommend), and these have been forgotten and, remained in position with the engine running, ‘The main relief valve has been set at the factory and should not require adjustment, Electrical Faults Major faults in the starter-motor or alternator should be corrected only by @ Lucas/C.A.V. agent hydraulic fitter flange. or representative, a ‘STARTER MOTOR FAULTS ‘Symptom Probable Fault Speed High resistance in brush gear, e.g., faulty connections, Torque — Low dirty or burned commutator causing poor brush Current contact Speed Tight or worn bearings, bent shaft, insufficient end play, Torque — Low armature fouling a pole shoe, or cracked spigot on drive Current — High end bracket. Short circuited armature, earther armatur or field coils. Speed — High Torque — Low ‘Short circuited winding in field coils. Current — High Speed Open circuited armature, field coils, or solenoid. if the as Torque ~Zero— Armature does not rotate | commutator is badly burned there may be poor contact Current — Zero between brushes and commutator. Speed Earthed field windings or short circuited solenoid Torque—Zero— Armature does not rotate | unit. Armature physically prevented from rotating, Current — High Excessive brush movement causing Low brush spring tension, worn out or out of round arcing at commutator ‘commutator. "Thrown" or high segment on commutator. Excessive arcing at the commutator Defective armature winding sticking bushes or dirty ‘commutator. ‘Transmission and Drive If the transmission and drive appear sluggish, 1, e.g., truck requires power to move downhill, check that brakes are not binding. 2. that handbrake is correctly adjusted. 3. Reconsider standard of maintenance.Bonsefrorcrarins israuctions SERIES: LSS5SL-LS77SL DATE: DEC 79 _ ISSUE Nor 01 PAGE:24 Clutch Fault Diagnosis — Gearbox Models SYMPTOM. Difficulty in engaging gears due to @) driven plate revolving after clutch pedal is depressed io te) (d) te Clutch slipping when under load (a) ib) te (a) Clutch falls to take up the drive (a smoothly o to Clutch fails to drive when pedal is (a) released (o) CAUSE | Clutch not fully disengaged due to incorrect pedal adjustment. Driven plate bonded to flywheel due to facings becoming contaminated with oil or grease. Driven plate distorted. Driven plate hub binding on clutch shaft, splines. Excessive wear in release mechanism. Lack of clutch pedal “free-play’”. Driven plate facings contaminated with oil or grease. Driven plate facings worn. ‘Thrust springs weak, due to over-he: caused by excessive slipping, Drive plate facings contaminated with grease, Wear in release mechanism or incorrect adjustment of release levers, Excessive wear in cover bearing, Incorrect adjustment of release mechanism. Fractured driven plate. ENGINE OVERHEATING ‘The usual overheating symptoms come within the province of the experienced mechani¢ and the list of faults need not be listed. However, overheating with over-pressurisation of the cooling system may indicate a cracked cylinder sleeve or @ leaking cylinder head gasket. over-pressurisation is often accompanied by heavy losses of coolant and consequently frequent “topping up", as much as every hour.FAULT FINDING CHART Bonet orenarincinstauctions SERIES: LSSSSL-LS77SL DATE: DEC7S ISSUENo:01 _ PAGE:25 ENGINE FAULT DIAGNOSIS Fault Possible Cai Low cranking speed 1.2.3.4 Will not start 5, 6, 7,8, 9, 10, 12, 19, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32,33 Diffcutt staring 5,7, 8,9, 10, 11, 12, 13, 14, 16, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32, Tack of power 8,9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25,26, 27, 31, 32, 39 Misfiring 8. 9, 10, 12, 13, 14, 16, 18, 19, 20, 25, 26, 28, 29, 30, 32 Excessive fuel consumption 11, 13, 14, 16, 18, 18, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33 Block exhaust 11, 73, 14, 16,18, 19, 20, 22, 24,25, 27, 28, 29 31,32, 33 Blue/white exhaust 4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 35, 45, 66 Tow of pressure 4, 36, 37, 38, 39, 40,42, 43, 44, 5B Knocking 314, 16, 18, 19, 22, 26, 28, 29, 3,33, 3, 3, ww, Erratle running 7,8, 5,10, 11, 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 90, 33, 5, a OO Vibration, 13, 14, 20, 23, 25, 26, 28, 30, 33, #5, #8, High of pressure 4, ‘Overheating 11, 13, 14, 16, 18, 19, 24, 25, 45, 47, 80, 81, 82, 88, 54, 67 Excessive crankcase pressure 25,31, 33, 94, 45, 55 Poor compression Ti, 19, 25, 28, 29, 31, 32, 33, 34, W, 6B ‘Starts and stops 70,11, 12 1. Battery capacity low 31. Worn cylinder bores 2. Bad electrical connections 32. Pitted valves and seats 3. Faulty starter motor 33. Broken, worn or sticking piston ring/s 4. Incorrect grade of lubricating oll 34. Wom valva stems and guide 5. Low cranking speed 35. Overful air cleaner or use of incorrect grade of oil 6. Fuel tank empty 36. Worn or damaged bearings 7. Faulty stop control operation 37. Insufficient oil in sump 8. Blocked fuel feed pipe 38. Inaccurate gauge 9. Faulty fuel ift pump. 38. Oil pump worn 10. Choked fuel filter 40. 11. Restriction in air cleaner 41 12. Airin fuel system 42. Broken relief valve spring 13. Faulty fuel injection pump 43, Faulty suction pipe 14, Faulty atomisers or incorrect type 44. Choked oil fiter 16. Incorrect use of cold start equipment 45. Piston seizure/ pick up 16. Faulty cold starting equipment 46. Incorrect piston height 17. Broken fuel injection pump drive 47, Damaged fan 18. Incorrect fuel pump timing 49. Incorrectly aligned flywheel housing, or flywheel 19. Incorrect vaive timing 80. Faulty thermostat 20. Poor compression 51. Restriction in water jacket 21. Blocked fuel tank vent 52. Loose fan belt 22. Incorrect type or grade of fuel 53. Choked radiator 23. Sticking throttle or restricted movement ‘54. Faulty water pump 24. Exhaust pipe restriction 25. Cylinder head gasket leaking 26. Overheating 27. Cold running 28. Incorrect tappet adjustment 29. Sticking valves 30. Incorrect high pressure pipes 55. Choked breather pipe 56. Damaged valve stem oil deflectors (if fitted) 57. Coolant level too low 58. Blocked sump strainer 59. Broken valve springBonserorenarive nstructions SERIES: LSS5SL-LS77SL ISSUE No: 01 DATE: DEC 79 PAGE:26. POWER STEERING FAULT FINDING CHART LOSS OF POWER STEERING Check hose connections Check hydraulic filter Renew element as required L_ sack rear of truck Hoses 0, Examine mechanical system for | tree and smooth action | =) Connection loose of damaged K, Check puoi | | Check power steer cylinder —— Recondition with Exchange cylinder for fone known to be good coal kit | i Fault cleared | is Drive O.K. steering column H Check pump relief and Orbitrol unit on flow contol valves (eat l Check hose r connections Reliet valve sticking Relief valve 0. ‘Check unit | Joints for leaks Clean, remove burrs t for renew assembly. valve Tighten bolts | | Change Fault cleared (See Note) = | i Renew parts as required | Fault cleared NOTE: Tighten or renew a5. required : Fault cleared 1 Drive geer splines Renew pump and drive gear as required Fault cleared k Check flow contro! ‘Check flow and Re-examine hoses for kinks and other restrictions 11 the orbitrol steering unit is faulty the unit complete with steering column must be changed.Bonnser orenarinc insraucrions SERIES: LSS5SLLS77SL DATE: DEC79 __ ISSUENo:01 _ PAGE:27 GENERAL SERVICING INFORMATION SETTING THE VALVE CLEARANCE ‘A Adiusting screw. LocknutC. Feler gauge The valve clearance should be set cold to 0.010 in. (0.25mm) inlet, 0.007 in. (0.18mm) exhaust and is ‘measured between the top of the rocker arm and, top of the valve stem with a feeler gauge, as shown. Open the bonnet and remove rocker cover. Adjust by slackening the locknut 8 and adjusting the screw A in or out until the correct clearance is obtained. When tightening the locknut, hold the adjustment screw to avoid it turning CYLINDER HEAD TIGHTENING SEQUENCE (90 ENGINE) Tighten the ols in the order shown andin dro stages, ‘The adjustment is best carried out when the ‘of 30, 60 and 90 tb ft (4, B end 12.6 kg metres) ‘ injectors have been removed for servicing. The engine may then be turned by the fan belt. If itis desired to turn the engine with the injectors in situ itwill be necessary to use a special box spanner on the crankshaft pulley unit. This may be purchased from your Dealer. To facilitate positioning the cam correctly, proceed in the following order: Lightly oil threads and tighten progressively in the ‘order shown above. Adjust No. 1 valve with No. 8 valve fully open Adjust No. 6 valve with No. 3 valve fully open ‘Adjust No. 4 valve with No. 5 valve fully open Adjust No. 2 valve with No. 7 valve fully open Adjust No. 8 valve with No. 1 valve fully open ‘Adjust No. 3 valve with No. 6 valve fully open Adjust No. 5 valve with No. 4 valve fully open ‘Adjust No. 7 valve with No. 2 valve fully open ‘An easy way to remember the above table is to Notice that in every case the sum of the two valve numbers concerned is always 9.Bonnser oreearine mstrucrions SERIES: LSS5SL-LS778L DATE:DEG7) _16SUENo:01 PAGE — Mest Truck Dete sess Bowe Wommisain' — Somnttaire! Comare | teavearte 0g ts Sabet 230013 Hotes Mechentam Fale ara as ee oe eyes cinta Berets” TeRama a oe Maximum Road Speed = ERD £2 Handbrake Oiidden ake year we fe Arachments a Footbrake Facets designed 10 7 eee ane a masta ae Uniadon Weight half shafts, construction industries. ‘Working Order SO1GKQ — 17IBIbs. ‘Tyre Equipment \ liftand Lower Speeds rene ure eee Lovee ae = Aisle Wisihe and Turing — {oitmm a0 Tne) Square Pallet $ Sieee aBonet orcnanncinstaucrions fh SERIES USe661 L876. DATE:DEC 79 ISSUENo:01 PAGE: 29DATE: DEC 7S Bonnser oresarine nstrucrio SERIES: LSS5SLLS77SL_ TSSUE No 07 B PAGE:30 LOCATION OF LUBRICATION AND SERVICE POINTS ON: LS55SL-LS77SL € 24 23 22 21 20 19 Litt Chain Mast Riles, Carriage Rolers Tit cyinger Pivots Di Fler Otterenta! (Torque Converter DipetickDiferntat (Toraue Converter) Brbaot Steering Unt Dipatick Gearbox Ot Filer Georoon Brake Master Cylinder — Gearbox Engine Ot Fie Fuel Fiers Engine Dipsick Injection Pome Hydraule 01 Filer (LS Series ony) Engine Oi Filer Hydrauke Od Fiter (LS Series only) Whee Hub 2 2 Fy 2 B a Fa % 2 2 B » x 2 Trackiod Steering Cylinder Prop. Shatt Pump (LS Seses only) fis Cleaner ‘iterator Engine Breather Fuel uit Pump Starter Motor Brake Master Cylinder (Torque Convertor! (Fier Dipak Torque Converts Filer Level Pg — Reduction Unite Grease Nipple — Reduction UntBonner orenarivs wsrmucrions SERIES: LSS6SLLS77SL DATE: DEC79 ISSUE No: 01 PAGE 3T HYDRAULIC DIAGRAM LSS5SL-LS77SL HYDRAULIC. ANCILLARY SERVICE ACCUMULATOR ~ CYLINDERS STEERING CONTROL VALVE (ORBITROL UNIT) [LIFT CYLINDER t WS Vi SS St TILT CYLINDER o Lo | TIT CYLINOER I CONTROL VALVE — FILTER FLOW DIVIDER PUMP ~ HYDRAULIC TANK — STEERING CYLINDER E CYLINOER STEERINGSomeone scrues. Loss .5776. 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Below 20°C P AUTRAN DX coed a -9°C to 38°C] orev re ux.| atove 206 | spsuren viscosraric 20-80 a SHEL ( Below 20°C AT.F. DEXRON Mew pveveore | ROTELLA Tx 100/30 fvowe 20% | SUPER MOTOR OIL 550 £550 AUTOMATIC TRANSMISSION All Temps FLUID — DEXRON Below —7°C Avove 10°¢ ] ESSOLUBE HDX 10W/30 or ect aC ESS0 EXTRAMOTOR OIL 100/30 | Above 26 rawoco AM0CO DEXRON A. FLUID 100 ENGINE O1L SAE 10/30 SICKOLENE pvove20°¢ | peRMavisco 1oW30 ( below 20°¢ | ZEBRA ATE. TYPE A SUFFIX Aor TeKACO Below 0°C 6673 TEXAMATIC FLUID. aaa CALTEX wae Below 0°C TEXAMATIC FLUID (DEXRON) woBTe a . Above 0°C MOBIL DELVAC SPECIAL 10W-30 Below —7°C Below 0°C MOBIL ATF 220 ~7°C t0 32°C AGIP ‘Above 0° AGIP F| WOOM SUPERMOTOROIL Up to 29°C. MULTIGRADE SAE T0W0 — seowore | AGIP FATE DEXRON oer aeBonnser orenarive insravctio SERIES: LSS5SLLS77SL_ DATE: DEC79 ISSUE No.0T PAGE 36 Bs APPROVED FLUIDS FOR TORQUE CONVERTOR TRANSMISSION ag ee en TOTAL Below 20°C TOTALOIL FLUID A vc | SERIE | FEAST Ao soaraee| | [recateruina overseas | S00 2me | TOVAL REY owen toes | esawa0e | STANDARD sowa0Dy o Tea paar peer arel | taeenalee ears ree SUPERGRADE MOTOR OIL rere | ow rc | SBR EIN or eee ite canbe one ot an ROU OF Pet AoE SESE poner peed ens oucwiaNs | eaow2re | rocetwaneD os Above 20°C FLEETOL MULTILITE ‘Borc GULF Below O°C AUTOMATIC TRANSMISSION poe re | GULeLWEEMoTaR OIL avant er eee nS aera past ioll|Nanencodarerecon = ped locates