Carrier

Original instructions
277 8 en 2011-12-20
DRILL CARRIER TC7-TC12, NC7 SERIES

Maintenance and lubrication manual
Table of Contents
1. SAFETY PRECAUTIONS .............................................................................................................. 7
2. MAIN COMPONENTS .................................................................................................................... 8

2.1. Diesel engine (MB 904 LA) ............................................................................................................................. 13
2.2. Diesel engine (MB 906 LA) ............................................................................................................................. 14
2.3. Transmission (T20000) .................................................................................................................................... 15
2.4. Transmission (HR32000) ................................................................................................................................ 15
2.5. Frame ................................................................................................................................................................... 16
2.6. Front axles .......................................................................................................................................................... 16
2.7. Rear axles ........................................................................................................................................................... 17
2.8. Oscillation (rear) ............................................................................................................................................... 18
3. DIESEL ENGINE ............................................................................................................................ 19

3.1. Periodic maintenance ...................................................................................................................................... 19
3.1.1. Cleaning the coarse filter .............................................................................................................................. 19
3.1.2. Checking the fuel level .................................................................................................................................. 20
3.1.3. Emptying the fuel water separator .............................................................................................................. 21
3.1.4. Checking the engine oil level (MB904) ....................................................................................................... 21
3.1.5. Checking the engine oil level (MB906) ....................................................................................................... 22
3.1.6. Checking the coolant level ........................................................................................................................... 23
3.1.7. Replacing the engine oil and filter ............................................................................................................... 24
3.1.8. Adjusting the valve clearance ...................................................................................................................... 27
3.1.9. Replacing the fuel filter ................................................................................................................................. 30
3.1.10. Replacing the fuel water separator filter .................................................................................................... 31
3.1.11. Checking the condition of poly-V-belt ......................................................................................................... 32
3.1.12. Engine checking for leaks and general condition ..................................................................................... 35
3.1.13. Checking the lines and hoses of the engine ............................................................................................. 35
3.1.14. Checking the intake pipe between air cleaner and engine ..................................................................... 35
3.1.15. Checking engine cooling system ................................................................................................................. 36
3.1.16. Replacing the intake air cleaner filter ......................................................................................................... 36
3.1.17. Cleaning the fuel pre-filter ............................................................................................................................ 37
3.1.18. Checking the general condition of cooling and heating system ............................................................. 38
3.1.19. Renewing the coolant ................................................................................................................................... 39
4. HYDRODYNAMIC AND MECHANICAL TRANSMISSION ........................................................... 40

4.1.1. Checking the tyre condition, pressure and nut tightness ........................................................................ 40
4.1.2. Checking the pressure of the brake accumulators ................................................................................... 42
4.1.3. Releasing the pressure from the brake accumulators ............................................................................. 42
4.1.4. Filling the brake accumulators ..................................................................................................................... 43
4.1.5. Bleeding the brakes ....................................................................................................................................... 45
4.2. As required ......................................................................................................................................................... 49
4.2.1. Checking the brake pressures ..................................................................................................................... 49
4.2.2. Checking the steering pressures ................................................................................................................. 50
Copyright © Sandvik Mining and Construction 3 (84)

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5. FRAME ........................................................................................................................................... 51
5.1.1. Checking the tightness of boom support bolts .......................................................................................... 51
5.1.2. Checking the middle-joint bearings ............................................................................................................. 53
5.1.3. Checking the oscillation axle bearings ....................................................................................................... 53
6. SAFETY DURING MAINTENANCE OPERATIONS ...................................................................... 54

6.1. Servicing safety precautions ......................................................................................................................... 54
6.2. Hydraulic system safety precautions ......................................................................................................... 55
7. WEAR LIMIT .................................................................................................................................. 57

7.1. Checking the brake discs for wear .............................................................................................................. 57
7.1.1. Spicer axle types 37R, 43R ......................................................................................................................... 57
7.1.2. Spicer axle types 113, 123, 213 .................................................................................................................. 57
8. FIELD REPAIRS ............................................................................................................................ 58

8.1. Troubleshooting guide for hydraulics ........................................................................................................ 58
8.2. Troubleshooting guide for the power shift transmission ...................................................................... 60
8.3. Troubleshooting guide for the axle ............................................................................................................. 62
9. LUBRICANT RECOMMENDATIONS ............................................................................................ 63

9.1. Diesel engine ..................................................................................................................................................... 63
9.1.1. Service products ............................................................................................................................................ 63
9.1.2. Diesel fuels ..................................................................................................................................................... 64
9.1.3. Engine oils ...................................................................................................................................................... 65
9.1.4. Coolant ............................................................................................................................................................ 66
9.1.5. Coolant mixing ratio ....................................................................................................................................... 66
9.2. Axles and planetary reduction oils .............................................................................................................. 67
9.3. Power shifted transmission and torque converter .................................................................................. 67
9.4. Hydraulic system .............................................................................................................................................. 67
9.5. Greasing .............................................................................................................................................................. 67
10. LUBRICATION ............................................................................................................................... 68

10.1. Checking the transmission oil level (T20000) ........................................................................................... 68
10.2. Checking the transmission oil level (HR32000) ....................................................................................... 68
10.3. Checking the hydraulic oil level ................................................................................................................... 69
10.4. Wiggins service system for automatic refuelling and lubrication (option for TC7/TC8/NC7
carriers) ............................................................................................................................................................... 70
10.5. Vehicle greasing points .................................................................................................................................. 75
10.6. Replacing the transmission oil filter (T20000) .......................................................................................... 75
10.7. Replacing the transmission oil filter (HR32000) ....................................................................................... 76
10.8. Changing the transmission oil (T20000) .................................................................................................... 76
10.9. Changing the transmission oil (HR32000) ................................................................................................. 77
10.10. Changing the hydraulic oil ............................................................................................................................. 78
10.11. Checking the differential oil level ................................................................................................................. 79
10.12. Checking the planetary gear oil level .......................................................................................................... 79
10.13. Changing the differential oil .......................................................................................................................... 79
4 (84) Copyright © Sandvik Mining and Construction

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10.14. Changing the planetary gear oil ................................................................................................................... 80
11. FILLING CAPACITIES ................................................................................................................... 81
12. LUBRICATION SAFETY AND OTHER PRECAUTIONS .............................................................. 83

12.1. Other precautions ............................................................................................................................................. 83

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1. SAFETY PRECAUTIONS
Take all safety factors into consideration and perform your work
with care. Follow all drilling site safety regulations.
Operating, service and adjustment procedures must be carried

out only by personnel with specialized operation and service
training. Read and ensure that you understand the operating,
maintenance, and safety instructions before using or servicing
the rig.
HIGH PRESSURE INJECTION HAZARD!

Compressed air jets can cause serious injury.
Allow the pressure to be released from the hydraulic circuit
before opening the plugs or connectors.
WARNING! PERSONAL INJURY HAZARD!

Hazardous moving parts and dangerous rig movements (boom,
feed, rock drill, hatches, and gratings) could result in death or
severe injury.
Make sure there are no unauthorized persons in the danger
areas during drilling, tramming, setting up or servicing the rig.

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2. MAIN COMPONENTS
Carrier TC 7
4 2
4
5
5 3 3
1 Diesel engine 2 Transmission

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

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Carrier NC 7 -series
4 2
4
5
5 3 3


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Carrier TC 8
1
2
4
4
5 3 3


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Carrier TC 9
4 1
2 5
5
3 3
2


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


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2.1. Diesel engine (MB 904 LA)
1 Fuel filters
2 Oil drain plug 3
3 Engine oil filter 16
4 Motor oil filling cap
5 Dipstick of engine oil level 7
6 Contamination indicator for air filter 11
7 Pumps for steering and brakes
8 Radiator (air, oil, water) 15
9 Expansion vessel (cooler)
10 Air filter (dry)
11 Poly V-belts 9 13
12 Level sensor
13 Exhaust catalysator (option)
14 Muffler
15 Charger guard
16 Warning sign, finger cover 6
17 MR2 Engine control unit 12
4
1
11
17
10
5
2
14

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2.2. Diesel engine (MB 906 LA)
1 Fuel filters 8
2 Oil drain plug 7
3 Engine oil filter
4 Motor oil filling cap
5 Dipstick of engine oil level
6 Radiator (air, oil, water)
7 Expansion vessel (cooler)
8 Poly V-belts 10
9
9 Charger guard
3
10 Warning sign, finger cover
11 MR2 Engine control unit 6
1
11
5
4

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2.3. Transmission (T20000)
1 Gear pump for steering

2 1
2 Gear pump for brakes
3 Transmission oil filter
4 Dipstick of transmission oil level / trans-
mission oil filling cap
5 Transmission oil drain plug 3
2.4. Transmission (HR32000)
1 Transmission oil filling cap

3 1
2 Transmission oil drain plug
3 Transmission oil filter
4 Checking mark of transmission oil level
(FULL)
5 Checking mark of transmission oil level
(LOW)
5
2

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2.5. Frame
Carrier TC 7-8 / NC 7 -series
1 Hinge pins
1
2.6. Front axles
Carrier TC 7-9 / NC 7 -series (axles 113, 123)
1 Planetary gear units

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

1
2 Brakes 2
1

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2.7. Rear axles
Carrier TC 7-8 / NC 7 -series (axles 113,123)

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

1
2 Brakes
2
1

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2.8. Oscillation (rear)
1 The rear axle oscillation allows the carrier

to be turned ±10° (TC 7, NC 7 - NC 7S) or
±8° (TC 8-12 / NC 7W) along the longitu-
dinal axis.
2 The front axle is mounted rigidly to the
frame.

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3. DIESEL ENGINE
3.1. Periodic maintenance
3.1.1. Cleaning the coarse filter
The service life of the disposable paper cartridge

used in the filter depends on the coarse filter be-
ing emptied regularly. If the coarse filter is not
emptied often enough, the cartridge becomes
clogged very quickly. For this reason, the coarse
filter must never be more than half full and so
must be emptied daily.
An indicator (H5) on the gauge panel lights up if
the air filter has become clogged.
1. Empty the coarse filter by pressing the drain
valve at the locations indicated by arrows.
2. Remove any caked dirt by pressing the upper
section of the drain valve together.

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3.1.2. Checking the fuel level
Read the fuel level from the fuel gauge (P2). An

indicator on the gauge (P2) lights up if the fuel
level is too low.
Fill the tank with suitable diesel fuel each day at
the end of the shift. This prevents condensation
in the tank when the rig is not in use.
Figure: Vehicle refuelling

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3.1.3. Emptying the fuel water separator
An indicator (H67) on the gauge panel lights up if

too much water has been collected in the water 2
separator.
1. Place a receptacle under the separator.
3
2. Open the drain valve (1).
3. Pump the water out with the hand pump (2).
4. Close the drain valve (1). 4
1 5
6
3.1.4. Checking the engine oil level (MB904)
PROPERTY DAMAGE RISK!

If the oil level is too low or too high it could damage the engine.
Never operate the engine with oil level below the MIN mark or
above the MAX mark.
Check the oil level as follows:

1. The engine must be level when checking the
oil level to make sure the measurement is cor-
rect.
2. Engage the parking brake and shut down the
engine.
3. Check the oil level from the dipstick.
The oil level must be between the MIN and
MAX marks. An indicator light (H65) on the
gauge panel goes on if the oil level is too low.
4. If the oil level is too low, add oil through the
filler opening up to the MAX mark on the dip-
stick.

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3.1.5. Checking the engine oil level (MB906)
PROPERTY DAMAGE RISK!

If the oil level is too low or too high it could damage the engine.
Never operate the engine with oil level below the MIN mark or
above the MAX mark.
Check the oil level as follows:

1. The engine must be level when checking the
oil level to make sure the measurement is cor-
rect.
2. Engage the parking brake and shut down the
engine.
3. Check the oil level from the dipstick.
The oil level must be between the MIN and
MAX marks. An indicator light (H65) on the
gauge panel goes on if the oil level is too low.
4. If the oil level is too low, add oil through the
filler opening up to the MAX mark on the dip-
stick.

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3.1.6. Checking the coolant level
WARNING
SPLASHING HAZARD!
Explosive release of fluids from pressurized cooling system can
cause serious burns.
Shut off engine. Only remove filler cap when cool enough to
touch with bare hands. Slowly loosen cap to first stop to relieve
pressure before removing completely. Always wear safety
gloves and safety glasses when adding coolant.
WARNING
FALLING HAZARD!
Falling could cause death or severe injury.
Be careful when climbing on the machine.
1. Switch the engine off and allow the system to

cool.
2. Check the coolant level on the expansion tank
sight glasses.
The coolant level must be between the "MIN"
and "MAX" marks. If the level is below the
"MIN" mark, coolant must be added.

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3.1.7. Replacing the engine oil and filter
NOTE! Change the engine oil while the engine is warm.
WARNING! BURN HAZARD!

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

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

and click the filter element (3) off by pressing the
bottom edge to the side.
Ensure that no foreign objects can enter the filter
housing. Never wipe the filter housing clean.

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Siphoning/draining engine oil
Suction the engine oil off through the dipstick

tube. Remove the dipstick (arrow) and push the
suction device (cup) with the O-ring seal to the
dipstick tube.
Alternative method:
Place a suitable receptacle under the oil drain
plug in the oil pan. Open the drain plug carefully,
and let the oil flow out.
Dispose of the engine oil and filter in accordance with the applicable regulations.
Replace the cover seal (2).
Place a new filter element to the cover and press
the filter until it clicks into place.
Screw the cover to the oil filter housing and tight-
en the cover to the correct tightness. The tight-
ening torque is 25 Nm.
If the engine oil is drained through the oil pan, replace the drain plug with a new seal and tighten the
plug to the correct tightness. The tightening torque is 80 Nm.

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Add new engine oil through the filler opening neck

(arrow) until the oil level is in the level of the max
mark in the dipstick.
Start the engine so that the throttle pedal is in the idling position and pay attention to the oil pressure
gauge
Let the engine idle until the engine oil pressure rises to the correct level. If the engine oil pressure
does not rise to the correct level in about 10 seconds, switch the engine off and determine the cause
of the fault.
Check the filter and oil drain plug for leaks.
Shut down the engine. Check the oil level again in about 5 minutes. Add oil to the max mark in the
dipstick as necessary.

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3.1.8. Adjusting the valve clearance
Layout of cylinders and valves
WHITE ARROW = Inlet valve

BLACK ARROW = Exhaust valve
X = Flywheel end
Figure: Valve clearance adjustment
Special tool (turning tool) required.
Valve clearance
Inlet valves = 0,40 mm

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

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Removing/installing cylinder head cover
1. Remove the cover.

2. Remove the crankcase breather hose (6) from
the cylinder head cover.
3. Unscrew the hexagon socket-headed bolt (2)
from the cylinder head cover, together with its
sealing washer (3). To install: Insert the hex-
agon socket-headed bolt with a new sealing
washer and tighten with a tightening torque of
30 Nm.
4. Remove cylinder head cover.
To install: Clean the sealing surfaces of the cyl-

inder head and the cylinder head cover as nec-
essary. Check the gasket between the cylinder
head cover and the charge air manifold (1). Re-
new as necessary. The gasket (5) between the
cover and the cylinder head must always be re- Figure: Removing/installing cylinder head cover
newed.
The cylinder head cover is installed in reverse or-
der.
Fit the turning tool into the inspection hole on the
flywheel housing.
Valve clearance adjustment - method 1
Adjust each cylinder in the order in which fuel is injected.

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

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Engine
OM 906 LA Injection sequence 1 5 3 6 2 4
OM 906 LA Overlap 6 2 4 1 5 3
Figure: Inspection hole, flywheel housing
Valve clearance adjustment - method 2
All valves can be adjusted in two crankshaft positions.

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

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

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Checking/adjusting valve clearance
1. Measure the valve clearance with a feeler

gauge between the rocker arm and valve
stem (exhaust valve) or valve bridge (inlet
valve) (arrows). It should be possible to pull
the feeler gauge through with no more than
light resistance.
2. To adjust the valve clearance, unscrew the
locknut (2). Set the correct valve clearance by
turning the adjusting screw (1).
3. Retighten the locknut to a tightening torque of
25 Nm.
4. Check the valve clearance again and readjust
if necessary.
Figure: Peephole, flywheel housing
Concluding operations
1. Reinstall cylinder head cover.

2. Remove the turning tool from the inspection hole in the flywheel housing.
3.1.9. Replacing the fuel filter
1. Unscrew the cap (1) together with the filter element (3) and pull a short distance out of the filter
casing (5). Allow the fuel to drain off.
2. Remove the cap with the filter element. Unclip the filter element (3) by pressing the lower edge
of the filter element to the side.
3. Pull the dirt collector (4) from the filter casing by the tags.
Dirt and water must not be allowed to get into the filter casing. Do not empty the dirt collector into
the filter casing.
4. Clean the cap (1).
5. Clean any dirt from the collector (4).
6. Renew the sealing ring (2).
7. Clip the new filter element into place in the cap.
8. Oil the sealing ring and filter element seals lightly.
9. Insert the dirt collector into the filter casing, ensuring the correct installation position.
10. Screw the cap with the filter element and tighten. Tightening torque 25 Nm.

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3.1.10. Replacing the fuel water separator filter
1. Place a receptacle under the separator.

2. Open the drain valve (1) and bleeder screw
(3) and drain the filter cartridge (4).
3. Remove the filter cartridge (4) and separation
container (5) from the filter head.
4. Remove the separation container (5) from the
filter cartridge (4).
5. Clean the seal ring groove on the separation
container (5).
Note! The separation container is reusa-
2
ble, so do not damage it.
Note! Dispose of the old filter cartridge in
accordance with environmental regula- 3
tions. Do not dispose of it as household
waste.
6. Lubricate a new seal ring with clean diesel or 4
engine oil and install it on the groove on the
separation container (5).
7. Install the separation container (5) firmly on
the new filter cartridge (4) by twisting it into 1 5
place. 6
Note! Do not use tools.
8. Lubricate a new seal ring with clean diesel or
engine oil and install it on the groove on the
filter cartridge (4).
9. Install the filter cartridge (4) firmly on the new
filter head by twisting it into place.
Note! Do not use tools.
10. Close the drain valve (1).
11. Fill the filter with the hand pump (2).
12. Continue pumping until the fuel coming out of
the bleeder screw (3) is free of air bubbles.
13. Tighten the bleeder screw (3).
14. Check for leaks.
Make sure that the drain hose (6) is not close to the hot exhaust
pipe.

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3.1.11. Checking the condition of poly-V-belt
Special tool (turning tool) required.
Proceed as follows:
1. Fit the turning tool to the inspection hole in the
flywheel housing.
2. Make a mark on the poly-V-belt with chalk.
3. Check the poly-V-belt section for signs of
damage. To do this, turn the engine or poly-
V-belt gradually on until the chalk mark is
reached again.
The poly-V-belt must be renewed if any of the
damage patterns listed appear.
4. Remove the turning tool again.
Figure: Inspection hole, flywheel housing

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Figure: Damage patterns
1 Condition as new (trapezoidal ribs) 2 Wear on one side (wedge-shaped ribs)

3 Cord visible in base of ribs 4 Ribs split
5 Transverse cracks in several ribs 6 Nodules of rubber in base of belt
7 Deposits of dirt/stones 8 Rips separated from base of belt
9 Cord torn out to the side 10 Outer cords frayed
11 Transverse cracks on the reverse of belt 12 Transverse cracks in several ribs

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Removing/installing poly-V-belt
ENTANGLEMENT HAZARD!
The tensioning mechanism is springloaded and could cause
severe injury.
Use proper service tools and be careful.
1. Plug the spanner (2) with a 17 mm socket in-

sert onto the hexagonal bolt on the tensioner
pulley (1).
2. Turn the tensioner pulley upwards and re-
move the poly-V-belt.
3. Turn the tensioning mechanism back.
4. Check the tensioning mechanism and pulleys
for damage (e.g. worn bearing on tensioning
mechanism, tensioner and deflector pulleys,
or pattern wear on poly-V-belt pulleys). If nec-
essary, renew parts.
5. Lay the poly-V-belt (new) on all the pulleys
except for the tensioner pulley (see illustra-
tions for correct routing of the poly-V-belt).
Figure: Removing/installing poly-V-belt
6. Turn the idler pulley upward with the handle,
place the poly-V-belt onto the idler pulley and
turn the idler pulley downward.
7. Remove the handle and check that the poly-
V-belt is seated correctly on the pulleys.
1 Crankshaft
2 Generator
3 Coolant pump
4 Tensioner pulley
Figure: Routing of poly-V-belt (engine without re-

frigerant compressor)

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1 Crankshaft
2 Generator
3 Coolant pump
4 Tensioner pulley
5 Refrigerant compressor
6 Deflector and guide pulley
Figure: Routing of poly-V-belt (engine with refrig-

erant compressor)
When installing the body V-belt, make sure that

the guard for alternator is installed back on its
place.
Figure: guard for alternator
3.1.12. Engine checking for leaks and general condition
- Visual check of engine for signs of leakage. Slight dampness at sealing points need cause no alarm.
More severe leaks with a continual loss of oil must be rectified without delay.
3.1.13. Checking the lines and hoses of the engine
Check for leaks and general condition.

- Visually inspect lines and hoses. At the same time, check that all pipes and hoses are undamaged,
correctly positioned to avoid abrasion and properly secured.
3.1.14. Checking the intake pipe between air cleaner and engine
- Check that rubber boots, intake pipes and connecting hoses are undamaged and free from leaks.
- Check tightness of hose clips, flange connections and the intake manifold.

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3.1.15. Checking engine cooling system
Check fluid level and corrosion inhibitor/antifreeze concentration, and correct if necessary.
Only use service products approved by engine manufacturer.
Before correcting the coolant level, check the corrosion inhibitor/antifreeze concentration. When
topping up, use only a pre-prepared coolant mixture containing 50% corrosion inhibitor/antifreeze by
volume.
1. Open the cap of the engine’s cooling system slowly to allow excess pressure to escape.
2. Check the concentration of corrosion inhibitor/antifreeze with a suitable tester. The correct
concentration of corrosion inhibitor/antifreeze, that is 50% by volume, protects the system down
to a temperature of -37 °C. If a lower level of antifreeze protection is shown, correct the
concentration.
If the concentration is too low, there is a risk of corrosion/cavitation in the cooling system.
Concentrations of more than 55% by volume should not be used, as this is the level which affords
maximum antifreeze protection (down to -45 °C), when higher concentrations adversely affect
heat dissipation.
3. Check the coolant level. The cooling system is correctly filled when the coolant has reached the
mark in the filler neck.
3.1.16. Replacing the intake air cleaner filter
Proceed as follows:
1. Undo clip fasteners (1).
2. Take off hood (2) and remove cartridge (3). 2
3. Clean cartridge (replace at least once a year).
4. Clean cartridge (3).
- Using dry compressed air (max. 5 bar), blow
out from inside outwards, or
- Tap out (in emergencies only). Do not dam-
age the cartridge, or
- Wash out according to manufacturer’s spec-
ifications 3 4 1
5. Check paper filter (light showing through) and
gaskets for damage. Replace if necessary.
6. After five filter services or after two year at the
latest, replace safety cartridge (4) (never
clean!).
7. Install cartridge (3), replace hood (2) and do
up clip fasteners (1).

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3.1.17. Cleaning the fuel pre-filter
1. Clean the outside of the fuel pre-filter and cov-

er over any hoses or pipes located beneath it.
2. Unscrew the filter bowl (1).
3. Clean the filter bowl (1) and filter element (2).
Huom! If the filter element is heavily soiled or
damaged, it should be renewed.
Dispose of the used filter and of residual fuel
in accordance with applicable legal stipula-
tions.
4. Check the seal (3) for the filter casing and re-
new if necessary.
5. Insert the filter element (2) into the filter bowl
(1) and screw the filter bowl onto the filter cas-
ing with a tightening torque of 10 Nm.

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3.1.18. Checking the general condition of cooling and heating system
Check the general condition and look for possible leaks.

Special tool (pressure tester) required.
The fluid level and corrosion inhibitor/antifreeze concentration
NOTE!
(correcting if necessary) must be checked first.
A safety valve is incorporated into the tester to prevent the

NOTE!
pressure from exceeding 1,2 bar.
1. On heating systems, open the regulating and

cut-off valves.
2. Remove the cap from the coolant expansion
tank.
3. Connect up the tester.
4. Connect the compressed air hose with the
tyre inflation union to the valve and allow pres-
sure to build up to a level corresponding to the
opening pressure of the cooling system. The
opening pressure of the cooling system can
be identified from the code on the cap or on
the pressure relief valve. Example: Code 70 =
0,7 bar gauge pressure.
5. Check all radiators, the coolant pump, the en-
Figure: Compressed air valve
gine oil cooler, the engine covers (corehole
covers) and the heat exchanger for leaks.
6. Check all pipes and hoses for the cooling and
heating system for freedom from leaks and
damage, correct positioning to avoid abrasion
and secure fastening in the specified manner,
7. Check the radiator for external contamination.
The fins must not be clogged with dirt.
8. Relieve pressure in the cooling and heating
system at the valve on the tester. Remove and
re-attach the cap.
9. Close the heating system regulating valves.

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3.1.19. Renewing the coolant
Only use a corrosion inhibitor/antifreeze approved by Mercedes-Benz.
WARNING
BURN HAZARD!
Hot and pressurised coolant could cause serious burns.
Never open the cap of the engine cooling system if the coolant
is at normal operating temperature. Only check and correct
coolant level when the coolant temperature is below 50 °C.
Remove cap slowly. Use safety gloves.
Before renewing the coolant, check that the cooling and heating
NOTE! system is in good condition and free from leaks. Confirm the
coolant renewal with an entry in the Maintenance Booklet.
There are other drain plugs, for example on the radiator. Pipes
etc. below the drain plugs should first be covered over and a
NOTE!
receptacle suitable for the quantity of coolant should be placed
underneath.
1. Open the cap of the engine’s cooling system

slowly to allow excess pressure to escape and
remove the cap.
2. On heating systems: Open the heating sys-
tem regulating valves.
3. To drain the coolant from the engine, attach
the hose (interior diameter approx. 12,5 mm)
to the drain plug on the engine. The coolant
will drain off after the plug has been turned
through 1 to 2 turns.
Dispose of the used coolant in accordance
with applicable legal stipulations.
4. Free drain apertures if blocked by deposits.
5. Screw in the coolant drain plug on the engine
Figure: Coolant drain plug
tight again and remove the drain hose.
6. Screw in other drain plugs (without hose con-
nection) with new seals.
7. Add coolant in the specified concentration un-
til the mark in the filler neck is reached. Seal
the cooling system again.
8. Start the engine and run it for about 1 minute
at varying speeds.
9. Stop the engine and check the coolant level.
Top up if necessary.

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4. HYDRODYNAMIC AND MECHANICAL TRANSMISSION
4.1.1. Checking the tyre condition, pressure and nut tightness
See separate instructions in manual 498 (Tyre change and rim

inspection).
Condition of the tyres
Check that the tyres are undamaged and properly mounted.

When tyre damage is detected early enough, it may be possible to repair the tyre, which increases
its service life, or remove the need to replace the tyre in difficult conditions.
DANGER
FLYING MATERIAL HAZARD!
In the event of an accident damaged rim parts will be ejected
under pressure and can cause death or serious injury.
Before loosening the wheel assembly nuts/bolts, release air
from the tyre until the pressure is just enough to keep the rim
parts firmly in place.
WARNING
CRUSHING HAZARD!
A falling wheel assembly can cause serious crush injury or
death.
Never leave a wheel assembly unsecured in a vertical position.
The wheel assembly may overturn during maintenance. Make
sure that there are no unauthorized persons in the danger area.
Do NOT attempt to repair disc wheel assembly parts by

soldering, welding, or modifying them in any way. Replace them
with new parts of the same size, type, and make.

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Tyre pressure
Check the pressure of the tyres using a pressure gauge. The maximum allowable tyre pressure is 10
bar.
Ensure that the protective caps are reinstalled on the valve stems after all inspection and filling
procedures have been performed.
DANGER
TYRE EXPLOSION HAZARD!
In the event of tyre explosion, the resulting power shock and
ejected tyre/tool debris cause serious injury or death.
Always use restraining devices (safety cage or similar
protective enclosure) when inflating tyres.
Never stand in front of the assembly while inflating the tyre. Use
an extended hose that allows you to stand to the side.
Do not exceed the tyre manufacturer's recommended maximum
pressure. Always check after pressurisation that the tyre sits on
the rim correctly before removing the wheel from the cage.
Unauthorized people are not allowed in the vicinity of the wheel
during the tyre is being inflated.
Never keep a spare tyre that is installed on detachable rims fully

inflated. With such tyres the pressure should be just enough to
keep the rim parts firmly in place. The tyre must be inflated to
the correct operating pressure only after the tyre-and-rim
assembly has been installed and all nuts/bolts tightened to the
correct torque.
Tyre nut tightness
Check the tightening torque of the nuts (lubricated).

ID: 277 8 en 2011-12-20
4.1.2. Checking the pressure of the brake accumulators
The pressure should be about 65 bar in TC 7-8 /

NC 7 -series carriers.
The pressure should be about 80 bar in TC 9-12
carriers.
Check the pressure as follows:
1. Remove the cap (A).
2. Screw the pressure gauge to the filling valve. B
3. Undo the lock nut (B).
4. Wait until the needle of the gauge stops and A
then read the gauge indication.
5. Close the lock nut (B).
6. Unscrew the gauge from the filling valve and B
fit the cap (A) in place. A
4.1.3. Releasing the pressure from the brake accumulators
To release pressure from the brake accumulators, proceed as follows:

1. Shut down the engine.
2. Turn the ignition switch to the middle position.
3. Press the brake pedal several times.
4. Verify depressurized brake system from the brake pressure gauges in the tramming panel.
Gauges should show 0 bar.
Note! The system may still be pressurized even when the brake pressure gauges indicate
0 bar.

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

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

1. Release the pressure from the brake accumulators, according to the chapter "Releasing the
pressure from the brake accumulators".
2. Remove the cap (3).
3. Screw the elbow adapter (10) to the filling valve (1).
4. Push the quick coupling sleeve (5) onto the stem (4).
5. Undo the locking nut (2).
6. Turn the pressure regulating valve (8) open.
7. Open the nitrogen bottle valve (9). The gauge (7) indicates the pressure in the bottle.
8. Adjust the pressure slowly in to 65 bar (TC 7-8 / NC 7) or to 80 bar (TC 9-12) by turning the
regulating valve (8). Gauge (6) indicates the pressure in the accumulator.
9. Close the filling valve (1) by turning the locking nut (2).
10. Close the nitrogen bottle valve (9).
11. Turn the pressure regulating valve (8) open.
12. Disconnect the quick couplings (4) and (5).
13. Release the elbow adapter (10) from the filling valve (1).
14. Tighten the locking nut (2) to 20 Nm.
15. Refit the cap (3).

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

brake circuit (P3)
2 Pressure gauge and indicator light of rear
brake circuit (P4)
1 2
Note! Next time when you start the engine make sure that all the pressure warning lights turn
off.

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4.1.5. Bleeding the brakes
WARNING
PERSONAL INJURY HAZARD!
Uncontrolled movement of the brakeless rig could cause death,
severe injury or property damage.
Park the rig on a level surface if possible. Lock the wheels
before bleeding the brakes.
For the trouble-free operation of the parking brakes it is important that the hydraulic system is entirely
free from air. Air may enter the system for example in connection with component replacements or
repairs and as a result of possible oil leaks. The brake is released through hydraulic pressure. If the
system contains air, this causes the pressure to decrease and the brake is not released properly, or
it will engage after a while. For this reason the brake circuit must be bled after every repair operation
and also at other times if malfunctions occur.

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Bleeding the parking brakes
1. With the engine running and parking brake engaged off.

2. Open the hose connector (B1, inner) slightly and let oil flow out until the air comes out.
3. Close the connector.
When necessary the above measures must be carried out several times. After bleeding check the
operation of the brakes and adjust them.
B1 B1
Figure: Bleeding the parking brakes (TC7-TC9, NC 7 -Series)
B1
Figure: Bleeding the parking brakes (TC10-TC12 front axle)

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Bleeding the service brakes
If full braking effect is to be achieved, the oil in the centre gears, where the brakes are located, must
not contain any air. The brakes must be bled if air has for some reason entered the system and the
effect of the brakes has diminished. Make sure the carrier is levelled, and that the wheels are blocked
against movement, before bleeding the brakes.
1. Install plastic tubes on the nipples.
2. Start the engine.
3. Open the nipples (B2, outer) about half a turn.
4. Press the brake pedal fully down (do not pump it).
5. Close the nipples when the oil is free of air.
Bleed the axle at the other end in the same way.
B2
B2
Figure: Bleeding the service brakes (TC7-9 / NC7-series axles, TC10-12 rear axle)

ID: 277 8 en 2011-12-20
B2 B2
Figure: Bleeding the service brakes (TC10-TC12 front axle)

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4.2. As required
4.2.1. Checking the brake pressures
A B C D E F
SERVICE SERVICE PARKING PARKING CHARGING OF CLUTCH
BRAKE BRAKE BRAKE BRAKE ACCUMULATORS

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

NC7, TC7-8

Figure: Measuring point assembly (284)
Checking the service brake pressure
Follow these steps:

1. Attach a pressure gauge to the front brake circuit's pressure inspection point (A).
3. Press the service brake pedal to the end of its movement path.
4. The pressure should be 70 bar (TC9-12) / 80 bar (TC7–8, NC7).
5. Repeat the same measurement for the rear brake circuit by attaching a pressure gauge to the
rear brake circuit 's pressure inspection point (B).
Checking the front axle's parking brake pressure
Follow these steps:

1. Attach a pressure gauge to the front axle's parking brake pressure inspection point (C).
3. Release the parking brake.
4. The release pressure should be 100 bar (TC10-12) / 30 bar (TC7–9, NC7).

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Checking the rear axle's parking brake pressure
Follow these steps:

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

1. Attach a pressure gauge to the pressure accumulator's pressure inspection point (E).
3. The pressure should rise quickly to a maximum of 135 bar.
4.2.2. Checking the steering pressures
Checking the steering pressure
A
The pressure must be checked when the oil is at
operating temperature and the engine is running
at full speed.
Follow these steps:
1. Connect the manometer to the checking point
(A).
2. Turn the machine to the full turning angle
against the end stops.
3. The maximum allowed pressure is 140 bar.
4. If the desired pressure differs from the given
value, adjust it by turning the adjustment
B
screw (B, 263.01) to the desired direction.

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

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

ID: 277 8 en 2011-12-20
Units with cabin
Checking the front side bolts
Front side bolts can be checked with the following procedure:

• Disconnect all necessary covers to get acces to the bolts.
Checking the rear side bolts (TC7-TC12)
To gain access to tighten the rear bolts properly, the cabin must lift up for 200-350 mm according to
following instructions:
• Support the unit to the ground with the jacks.
• With help of crane, support the cabin from the lifting points
• Untighten the rear (2) and front (2) cabin mount-

ing bolts M16x110.
• Disconnect all necessary cables and hoses in order to lift the cabin for 250-350 mm.
- Especially in electrically controlled jumbos disconnect the cable for the diesel engine.
- Especially in hydraulically controlled jumbos disconnect the cable for the diesel engine and the
boom and drilling hoses from the THC.
• Lift the cabin for 250-350 mm up in order to get acces to rear side bolts
• After replacing and tightening the bolts, reconnect all the cables and hoses.
• Lower the cabin and refit the bolts and tighten them with correct tightness.

ID: 277 8 en 2011-12-20
Checking the rear side bolts (NC7)
To gain access to tighten the rear bolts properly, there is no need to lift the cabin
• Tighten the bolts via the service hatch.

5.1.2. Checking the middle-joint bearings
Check the middle-joint bearings by turning the steering back and forth with small movements. Check
the play that may have developed in the middle-joint bearings. If there is any play, replace the
bearings.
5.1.3. Checking the oscillation axle bearings
Rear-axle oscillation allows the carrier to turn in the longitudinal direction of the axle.
Lift the rear axle off the ground and, using small movements, check the play that may have developed
in the oscillation bearings. If there is any play, replace the bearings.

ID: 277 8 en 2011-12-20
6. SAFETY DURING MAINTENANCE OPERATIONS
6.1. Servicing safety precautions
When servicing or repairing the vehicle, shut down the engine

unless it is required to be running for adjustment purposes.
Keep your head, hands, feet and loose clothing away from
power-driven parts.
Do not grab the steering wheel when mounting the vehicle.
Accumulated grease or oil on the vehicle is a fire hazard.

Remove debris any time a significant quantity oil is spilled on
the vehicle.
Do not arc weld on this vehicle without first disconnecting the

alternator.
Before performing maintenance or repair work on any

equipment, consult the manufacturer’s instruction manual and
follow the recommended procedures.
• Inspect equipment daily for signs of failure or beginning of failure.

• Perform all recommended checks.
• Report all defects.
• Use the proper tools for service.
• Never attempt to clean, lubricate all or adjust the vehicle while it is inmotion.
• Always comply with your company’s regulations and practices for the safe servicing of this vehicle.

ID: 277 8 en 2011-12-20
6.2. Hydraulic system safety precautions
WARNING
HIGH-PRESSURE FLUID HAZARD!
High-pressure fluid remaining in hydraulic lines can cause
serious injury.
Never carry out maintenance or repair work on a pressurized
system. Relieve pressure before opening fittings, plugs or
hydraulic valve cartridges. Always make sure the parts are not
pressurized. Use a bleeder screw to relieve the pressure behind
the valves or cartridges, or wait until the unit is depressurized,
before removing the components.
WARNING
HYDRAULIC FLUID INJECTION HAZARD!
High-pressure hydraulic fluid spray can penetrate under the
skin, causing serious injury.
Search for leaks with a piece of cardboard or wood. Never try
to locate a leak by feeling with your hand. Immediate medical
attention is required after injection.
Before performing service or maintenance work under the

raised boom (equipments) perform the following operations:
• Empty the boom.
• Place adequate support under the boom.
• Shut down the engine.
WARNING
BURN HAZARD!
The oil circulating in the hydraulic systems is hot. It can cause
severe burns to the skin.
Let the oil cool down before starting any maintenance work.
When washing parts do not use corrodents.
• Do not change the pressure setting of any hydraulic valves unless authorized instruction has been
obtained.
• Clean the area around the component to be repaired before starting work. If possible, change the
complete component.
• Ensure that all the connections will be made according to the hydraulic diagram.

ID: 277 8 en 2011-12-20
• Check the movements of the rig before use.

• Hydraulic components and hoses should be stored with all connections well plugged. Do not remove
the plugs until the components are mounted on the rig.
• Hydraulic pumps and motors are heavy. Before detachment you must have equipments to lift them
up safely.

ID: 277 8 en 2011-12-20
7. WEAR LIMIT
7.1. Checking the brake discs for wear
7.1.1. Spicer axle types 37R, 43R
This check is recommended to be carried out when the oil in the centre gear is to be changed.
The operation must be carried out for both sides of the axle.
1. Remove the plug from side of the trumpet arm, next to the center section. The brake discs can
be seen through the hole.
2. Have assistant to start the engine and fully apply the brakes.
3. While keeping the pressure up, check the clearance between the reaction plates.
4. If the clearance between the reaction plate ears is less than 4,5mm (0.177 in), replace the friction
plates and reaction plates on the both sides of the axle.
Figure: Checking the brake discs for wear (Spicer axle types 37R, 43R)
7.1.2. Spicer axle types 113, 123, 213
There is no need to check the brake discs.

Brake test is always performed before tramming. If the brakes do not hold during the test and the
brake pressures are correct, it is likely that the brake discs have been weared. Replace the brake
discs and intermediate discs on the both sides of the axle.

ID: 277 8 en 2011-12-20
8. FIELD REPAIRS
8.1. Troubleshooting guide for hydraulics
Trouble Location Probable cause(s) Remedy

Steering is very stiff Steering hydraulics The relief valve is dam- Check and adjust the
aged or the adjustment pressure. Change a
has altered. new relief valve when
necessary.
Steering is very stiff Engine side Hydraulic pump has Change a new pump.
damaged.
Steering is very stiff Engine side The steering cylinder The cylinder leakage
seals are leaking. can be ascertained by
operating the steering
several times to see
whether the cylinder
heats up in abnormal
way. Change the cylin-
der seals.
Steering is very stiff Engine side Steering valve is dam- Change a new steering
aged. unit. Maintain strict
cleanness.
Steering is sticking and Steering Air in the steering sys- Carry out bleeding by
unsteady tem. driving the steering to
extreme positions a few
times. Check the inlet
side of the pump.
Steering is sticking and Steering Steering valve worn. Change the steering
unsteady valve.
Steering is sticking and Steering Steering column bear- Change the bearing.
unsteady ing worn.
Service brake does not Service brake system Internal leak in the Change the cylinder
hold brake cylinders. seals.
Service brake does not Service brake system Too low brake pres- Check the brake valve
hold sure. spring, and change if
necessary. Check and
adjust the pressure in
the hydraulic system.
Service brake does not Service brake system Air in the brake system. Bleed the system.
hold
Service brake does not Service brake system Brake plates are worn Check the brake plates,
hold out. and change if necessa-
ry.
Parking brake does not Parking brake system Brake plates are worn Renew the brake
hold out. plates.
Parking brake does not Parking brake system Lack of power of park- Renew the springs.
hold ing brake cylinder
springs.

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Trouble Location Probable cause(s) Remedy

Parking brake does not Parking brake system Oil leak in the parking Change the brake
hold brake valve, thus pres- valve.
sure in the spring brake.
Parking brake does not Parking brake system Air in the system. Bleed the system.
release (open)
Parking brake does not Parking brake system Releasing pressure too Check the pressure, ad-
release (open) low. just according to the
workshop manual.
Parking brake does not Parking brake system Oil leak in the brake cyl- Change the seals.
release (open) inder.

ID: 277 8 en 2011-12-20
8.2. Troubleshooting guide for the power shift transmission
The following information is presented as an aid ti isolating and determining the specific problem area
in a transmission that is not functioning correctly.
When troubleshooting a “transmission” proble, it should be kept in mind that the transmission is only
the central unit of a group of related powertrain components. Proper operation of the transmission
depends on the condition and correct functioning of the other components of the group. Therefore,
to properly diagnose a suspected problem in the transmission, it is necessary to consider the
transmission fluid, charging pump, torque converter, transmission assembly, oil cooler, filter,
connecting lines, and controls, including the engine, as a complete system.
By analysing the principles of operation together with the information in this section, it should be
possible to identify and correct any malfunction which may occur in the system.
Transmission (power shift with torque converter transmission) troubles fall into three general
categories:
• Mechanical problems
• Hydraulic problems
• Electrical problems
In addition to the mechanical and electrical components, all of which must be in the proper condition
and functioning correctly, the correct functioning of the hydraulic circuit is most important.
Transmission fluid is the “life blood” of the transmission. It must be supplied in an adequate quantity
and delivered to the system at the correct pressures to ensure converter operation, to engage and
hold the clutches from slipping, and to cool and lubricate the working components.
Stall test
A stall test to identifies transmission, converter, or engine problems. Use following procedure:
1. Put the vehicle against a solid barrier, such as a wall, and/or apply the parking brake and block
the wheels.
2. Put the directional control lever in FORWARD (or REVERSE, as applicable).
3. Select the highest speed. With the engine running, slowly increase engine speed to approximately
one-half throttle and hold until transmission (converter outlet) oil temperature reaches the
operating range.
Do not operate the converter at stall condition longer than 30

seconds at one time, shift to neutral for 15 seconds and repeat
the procedure until desired temperature is reached. Excessive
temperature 120 °C (250 °F) maximum will cause damage to
transmission clutches, fluid, converter, and seals.
Pressure checks
Transmission problems can be isolated by the use of pressure tests. When the stall test indicates
slipping clutches, then measure clutch park pressure to determine if the slippage is due to low
pressure or clutch plate friction material failure.
In addition, converter charging pressure and transmission lubrication pressure can also be measured.

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Mechanical and electrical checks
Prior to checking any part of the system for hydraulic function (pressure testing), the following
mechanical and electrical checks should be made:
• Check the parking brake and inching pedal for correct adjustment.
• Be sure all lever linkage is properly connected and adjusted in each segment and at all connecting
points.
• The controls are actuated electrically. Check the wiring and electrical components.
• Be sure that all components of the cooling system are in good condition and operating correctly.
The radiator must be clean to maintain the proper cooling and operating temperatures for the engine
and transmission. Air clean the radiator, if necessary.
• The engine must be operating correctly. Be sure that it is correctly tuned and adjusted to the correct
idle and maximum no-load governed speed specifications.
Hydraulic checks
Also, before checking the transmission clutches, torque converter, charging pump, and hydraulic
circuit for pressure and rate of oil flow, it is important to make the following transmission fluid check:
Check oil level in the transmission. The transmission fluid must be at the correct (full level). All clutches
and the converter and its fluid circuit lines must be fully charged (filled) at all times.
The transmission fluid must be at operating temperature of

NOTE! 82...93 °C (180...200 °F) to obtain correct fluid level and pressure
readings. Do not attempt to make these checks with cold oil.
To raise the oil temperature to this specification it is necessary to either operate (work) the vehicle
or run the engine with converter at “stall” (Refer to “Stall test”).
Be careful that the vehicle does not move unexpectedly when

operating the engine and converter at stall rpm.
Troubleshooting guide
Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles.
Trouble Probable cause Remedy

Low clutch pressure Low oil level Fill to proper level.
Low clutch pressure Clutch pressure regulating valve Clean valve spool and housing.
stuck open
Low clutch pressure Faulty charging pump Replace pump.
Low clutch pressure Broken or worn clutch shaft or- Replace sealing rings.
piston sealing rings
Low clutch pressure Clutch piston bleed valve stuck Clean bleed valves thoroughly.
open
Low charging pump output Low oil level Fill to proper level.
Low charging pump output Suction screen plugged Clean suction pump.
Low charging pump output Defective charging pump Replace pump.
Overheating Worn oil sealing rings Remove, disassemble, and re-
build converter assembly.

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Trouble Probable cause Remedy

Overheating Worn charging pump Replace charging pump.
Overheating Low oil level Fill to proper level.
Overheating Dirty oil cooler Clean cooler.
Overheating Restriction in cooler lines Change cooler lines.
Noisy converter Worn charging pump Replace charging pump.
Noisy converter Worn or damaged bearings A complete disassembly will be
necessary to determine which
bearings is faulty.
Lack of power Low engine RPM at converter Tune engine check governor.
stall
Lack of power See “Overheating” and make Make corrections as explained
same checks. in “Overheating”.
8.3. Troubleshooting guide for the axle
Most operating problems are due to improper operation or maintenance of the axle.
In the event of trouble, always check whether the operating instructions have been strictly followed.
Problem Possible cause Repair

The brakes are inefficient. The brakes are incorrectly ad- Check the thickness of the brake
justed. discs. If discs are fit for use, re-
adjust the brakes.
The brakes are inefficient. The brake discs are worn. Check the thickness of the brake
discs and replace them if neces-
sary.
Brake pedal feels spongy. There is air in the brake circuit. Bleed the brakes.
The parking brake is inefficient. The parking brake is incorrectly Readjust the parking brake.
adjusted.
The parking brake is inefficient. The brake discs are worn. Check the thickness of the brake
discs and replace them if neces-
sary.
The brakes are overheating. The brake disc gap is too small. Readjust the brakes.
The brakes are overheating. The parking brake drags. Release the brake and adjust
the correct gap.
The brakes are overheating. Brake lines are clogged. Check the lines and replace
faulty ones.

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9. LUBRICANT RECOMMENDATIONS
9.1. Diesel engine
9.1.1. Service products
WARNING! POISONING HAZARD!

Risk of severe injury or death.
Consult a doctor immediately if any service product is
swallowed.
Keep service products out of the reach of children.
Components of the engine and the lubricants they need have to be carefully matched together. For
this reason, only brands which have been tested and approved by Mercedes-Benz should be used.
These are stated in the Mercedes-Benz Specifications for Service Products.
No special lubricant additives are needed. The use of additives could affect warranty rights.
Information is available from any Mercedes-Benz Service Station.
Dispose of service products and parts which have been in contact with them (e.g. filters) in an
environmentally responsible manner. Comply with legal requirements.

ID: 277 8 en 2011-12-20
9.1.2. Diesel fuels
Only use commercially available vehicle diesel fuel (DIN EN590). Grades such as marine diesel fuel,
heating oil etc. are not permissible.
No fuel additives are needed. The use of fuel additives could affect warranty rights.
If diesel fuel with a sulphur content exceeding 0.3% by weight is used, change the engine oil at shorter
intervals. Comply with the instructions in the Maintenance Booklet.
If the Telligent maintenance system is used, the sulphur content
of the diesel must be entered in the system or adapted to the
current value.
Fuel added from drums or cans could be contaminated. This could lead to malfunctions in the fuel
system. Always filter the fuel before adding it to the tank.
Diesel fuel in extreme cold
At low ambient temperatures, paraffin may separate from the diesel and affect its ability to flow freely.
To avoid breakdowns caused by this problem (e.g. blocked filters), diesel fuel with improved low-
temperature flow characteristics is sold during the winter months. Differences are possible in different
countries and in the transitional periods before and after the cold season. In Germany, particularly
cold-resistant winter diesel fuels keep the engine operational down to a temperature of approximately
-20 °C. In most cases, winter-grade diesel can be used without problems at the ambient temperatures
encountered locally.
If summer-grade diesel, or a less cold-resistant winter-grade diesel is in use, a flow improver or
kerosene can be added to it, the actual quantity being dependent on the ambient temperature.
Do not add petrol (gasoline) to the diesel.
Mix the flow improver or kerosene with the diesel in good time, before the fuel’s flow characteristics
have been adversely affected by paraffin separation. If faults have already been caused by paraffin
separation, they can only be rectified by heating the entire fuel system. Do not add anything to cold-
resistant winter-grade diesel fuels. The fuel’s low-temperature flow characteristics could actually
deteriorate with such an additive.
Flow improvers
The effectiveness of flow improvers is not guaranteed with all fuels. Comply with the product
manufacturer’s recommendations. Any Mercedes-Benz Service Station can provide information on
approved flow improvers.

ID: 277 8 en 2011-12-20
Kerosene
Keep the quantity added as low as possible, bearing in mind the ambient temperature. The addition
of 5 % by volume of kerosene will improve the fuel’s resistance to cold by about 1°C. Never add more
than 50 % kerosene to the fuel.
For reasons of safety, add the kerosene to the diesel only in the fuel tank. Add the kerosene first,
then the diesel. Run the engine for a short time to allow the mixture to reach all parts of the fuel
system.
FIRE AND EXPLOSION HAZARD!
Diesel fuel is combustible and could cause severe personal
injury or death.
The addition of kerosene lowers the flash point of the diesel.
This increases the risk involved when handling the fuel mixture.
Comply with appropriate safety regulations.
The use of fuel that is approved by DaimlerChrysler AG and published in the applicable fuel
specifications is an integral part of DaimlerChrysler warranty conditions.
If DaimlerChrysler fuel specifications are not observed or if
products are used that have not been approved in writing by
DaimlerChrysler AG, serious engine damage is to be expected.
Customers, Customer Care and Manufacturing are to be informed (e.g. by means of the Equipment
Operating Instructions or a separate memo) of DaimlerChrysler fuel specifications, in order that they
can be adhered to.
9.1.3. Engine oils
Engine oils are specially tested to ensure their suitability for Mercedes-Benz engines. For this reason,
use only engine oil brands which Mercedes-Benz has approved. These are stated in the Mercedes-
Benz Specifications for Service Products. Comply with the instructions in the Maintenance Booklet.
The use of non-approved engine oils could affect warranty rights.
Select the SAE classification of the engine oil in accordance with ambient temperatures.
When maintenance work is performed, engine oil changes will be recorded in the Maintenance
Booklet, together with details of the brand, quality category and SAE classification of the oil.
When topping up, only use engine oils of the same quality and SAE classification.
If an oil of a lower quality grade is added, the characteristics of
the oil will be adversely affected. Oil change and filter
replacement should then be brought forward.
For detailed information on oil recommendations, refer to the

"Lubricant and coolant recommendation" instructions.

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

• Only use an approved corrosion inhibitor/antifreeze. Information is available from any Mercedes-
Benz Service Station.
• When topping up the cooling system (after a drop in the coolant level), the concentration of corrosion
inhibitor/antifreeze in the coolant must be 50 % by volume (affords protection down to a temperature
of -37 °C).
If the concentration is too low, there is a risk of corrosion/cavitation in the cooling system.
• Do not increase the proportion of corrosion inhibitor/antifreeze beyond 55 % by volume (= maximum
antifreeze protection). This would reduce the level of antifreeze protection and adversely affect the
coolant’s ability to dissipate heat.
9.1.5. Coolant mixing ratio
Refer to the "Lubricant and coolant recommendation" instructions.

If necessary, see detailed information from the engine manufacturer’s manual.
In exceptional circumstances, if corrosion inhibitor/antifreeze is unavailable and/or no antifreeze
protection is needed (for instance in the tropics), an approved coolant additive without antifreeze
properties as stated on sheet of the Mercedes-Benz Specifications for Service Products should be
used (e.g. MB corrosion inhibitor manufactured by Daimler-Benz AG or 10 % by volume = 100 cm3/
liter of VP 1749, manufactured by Hoechst of Burghausen). In this case, renew the coolant every 12
months.
Disposal
Coolants are biologically degradable substances.

When disposing of used coolant, comply with local legal stipulations and/or waste water regulations.
You are advised to consult the local water authorities to determine the best method of disposal.
Since a modern engine coolant has complex tasks to perform, any form of inexpert ’’reprocessing’’
which consists only of mechanical purification is to be emphatically rejected.

ID: 277 8 en 2011-12-20
9.2. Axles and planetary reduction oils
Refer to the "Lubricant and coolant recommendation"

NOTE!
instructions.
9.3. Power shifted transmission and torque converter
Oil specification
Recommended lubricants:
1. Caterpillar TO-4
2. John Deere J20 C, D
3. Military MIL-PRF-2140G
4. Allison C-4
5. Dexron II Equivalent - see note below
Dexron II equivalent is acceptable; however it is not compatible

with torque converters or transmissions equipped with
graphitic friction material clutch plates.
Dexron III, engine oil or GL-5 oils are not recommended
Preferred oil viscosity
It is recommended that the highest viscosity monograde lubricant available be used for the anticipated
ambient temperature. Typically this will be a CAT TO-4 qualified lubricant. When large swings in
ambient temperature are probable, J20 C, D multigrades are recommended. Multigrades lubricants
should be applied at the lower viscosity rating for the prevailing ambient temperature, i.e. a 10W20
should be used where a 10W monograde is used. If a C-4 multigrades is used in stead of J20 lubricant
it is recommended that the viscosity span no more than 10 points, i.e. 10W20.
Synthetic lubricants are approved if qualified by one of the
above specifications. Oil viscosity quidelines apply, but
synthetic multigrades may span more than 10 points.
9.4. Hydraulic system

NOTE!
instructions.
9.5. Greasing

NOTE!
instructions.

ID: 277 8 en 2011-12-20
10. LUBRICATION
10.1. Checking the transmission oil level (T20000)
1. Let the engine idle.

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

Keep the drive selector in the middle position.
2. Check the transmission oil level when the oil
temperature is 82–93 °C by loosening the 3 1
minimum limit plug (5) carefully.
If oil flows out, close the plug (5); the oil level
is sufficient. If not, open the filler plug (1) and
maximum limit plug (4). Add oil until it flows out
from the maximum limit opening. Close the
plugs (1 and 4).
5
2
3. Turn off the engine.

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10.3. Checking the hydraulic oil level
Check the hydraulic oil level according to the periodic

maintenance instructions for the drilling equipments.
Observe strict cleanliness replenishing oil. Contaminated oil is

a moajor cause of premature component failure.
The oil level of the hydraulic oil tank should be checked when
all of the cylinders are retracted and the boom is in
transportation position.
If replenishing is required, use only the same type of oil as already contained in the system.
An indicator (H602B) on the driving panel lights

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

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10.4. Wiggins service system for automatic refuelling and lubrication (option
for TC7/TC8/NC7 carriers)
Filling engine fuel tank
The fast fuel system is based on the simple concept of using a sealed vehicle tank to allow a small
amount of back pressure to build and automatically shut off the nozzle. A receiver is located near the
bottom of the tank for bottom filling which helps to eliminate foaming that occurs during the
traditional ”splash fill” method at the top of the tank.
2
1
Figure: Fast filling system
1 Nozzle
2 Fuel
The nozzle is attached to the receiver, the handle is turned to the ”ON” position and the diesel pumping
module automatically starts filling the vehicle fuel tank at a rate of 100 G.P.M. As fuel enters the tank,
it forces the air inside the tank through the hollow stem in the vent. When the fuel level in the tank
nears the top, two hollow floating balls force the third ground ball against an O-Ring seal and stops
the flow of air from the tank. Fuel continues to flow into the tank and pressure begins to build. At
approximately 5.5 PSI, a diaphragm operated piston inside the nozzle starts to shut off the flow of
fuel and system line pressure picks up and brings the nozzle to the OFF-position and the diesel
pumping module is automatically shut off. The nozzle is disconnected and the next vehicle is ready
to refuel.

ID: 277 8 en 2011-12-20
Filling motor, transmission and drilling oil (TC 7-8 carrier)
1 Cranckcase oil evacuation and fill 2 Transmission oil evacuation and fill
3 Hydraulic oil evacuation and fill 4 Collector piece
5 Connection to Wiggins evacuation and
filling system
Adding and changing of engine, transmission and hydraulic oils is described in separate instructions:
Wiggins Service Systems, automatic refueling and lubrication service for construction and mining
equipment.

ID: 277 8 en 2011-12-20
Filling motor, transmission and drilling oil (NC 7 -series carriers)
1 Cranckcase oil evacuation and fill 2 Transmission oil evacuation and fill
3 Hydraulic oil evacuation and fill 4 Left distributor in front frame
5
Connection to Wiggins evacuation and
filling system
Adding and changing of engine, transmission and hydraulic oils is described in separate instructions:
Wiggins Service Systems, automatic refueling and lubrication service for construction and mining
equipment.

ID: 277 8 en 2011-12-20
Hydraulic diagram, wiggins evacuation (NC 7 -series)
DIESEL
ENGINE
CLARK
20000
SERIE/ 12
SPICER
32000
SERIE 12
L2
L3 L6
LEFT L4
L8
L5 L7
8 L1
FROM PUMP OF ROTATION

24
8
ENGINE OIL IN
EVACUATION X31
PORT L1
OUT
K425
PIPE 38X3
PIPE 38X3
2.5bar
12
12
L5 F T1 S5 T2 M1
EVACUATION AND FILL

EVACUATION AND FILL
EVACUATION AND FILL

TRANSMISSION OIL
HYDRAULIC OIL
CRANCASE OIL

ID: 277 8 en 2011-12-20
Figure: Crankcase oil evacuation
1 Connection to Wiggins evacuation and filling system

ID: 277 8 en 2011-12-20
10.5. Vehicle greasing points
Use a grease gun with recommendated grease.

FIRE HAZARD!
Accumulated grease or oil on the carrier is a fire hazard.
the carrier.
Lubricate the propeller shaft fittings. All drive line sections are furnished with grease nipples on
universal joints and telescopic sections. Lubrication must be done carefully to avoid damage of the
seals.
Greasing points:
• Propeller shaft fittings
• Seat hinge pins
• Transmission
• Centre hinge
• Support bearings
• Rear oscillation
• Cable reel hinges
• Switchgear hinges
• Steering cylinder pins
10.6. Replacing the transmission oil filter (T20000)
Extreme high temperature conditions, extended

periods of high temperature or difficult climatic 2 1
conditions will accelerate deterioration and con-
tamination of the oil.
The normal filter replacement frequency is inten-
ded for average environmental and operational
conditions. In extreme conditions, the mainte-
nance frequency should be judged with consid- 3
eration of the conditions.
1. Shut down the engine.
2. Screw the filter (3) off and remove it
3. Clean the filter housing.
4. Lubricate the rubber seal and install a new fil-
ter.
4
5. Tighten the filter to 2.8–3.4 kpm.

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10.7. Replacing the transmission oil filter (HR32000)
Extreme high temperature conditions, extended periods of high temperature or difficult climatic con-
ditions will accelerate deterioration and contamination of the oil.
The normal filter replacement frequency is intended for average environmental and operational
conditions. In extreme conditions, the maintenance frequency should be assessed and altered ac-
cordingly.
Replace the filter as follows:
1. Turn off the engine. 3 1
2. Open the filter (3) by turning it.
3. Clean the filter housing.
4. Lubricate the rubber seal and install a new fil-
ter.
5. Tighten the filter to 2.8–3.4 kpm.
5
2
10.8. Changing the transmission oil (T20000)
Extreme high temperature conditions, extended

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

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10.9. Changing the transmission oil (HR32000)
Change the oil while it is warm.

1. Open the drain plug (2).
3 1
2. When oil has been drained, close the drain
plug (2).
3. Open the filler plug (1).
4. Refill transmission to LOW mark (5). Pour
fresh oil into the torque converter through filling
hole (1). Refer to table of oil recommendation
for appropriate oil type and quantity.
5. Run engine at 500...600 rpm to prime 4
converter and lines.
6. Recheck level with engine running at 500...600 5
rpm and add oil to bring level to LOW mark (5). 2
When oil temperature is hot (82,2...93,3 °C)
make final oil level check. Bring oil level to
FULL mark (4).

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10.10. Changing the hydraulic oil
Change the oil according to the periodic maintenance

instructions for the drilling equipments.
To avoid contamination, clean the top of the reservoir before servicing. Change the oil while it is warm.
Remove the reservoir fill cap and empty the hy-

draulic reservoir by removing the drain plug (1).
Remove the tank cover and clean the tank. Fill the MAX
tank with fresh oil. Use oil as specified in oil rec-
ommendation. Check hydraulic reservoir sight
gauges and add fluid as needed.
MIN
Cleanliness is of extreme importance. Before changing oil, the

exterior or the tank must be thoroughly cleaned to prevent the
possibility of dirt and foreign matter entering the system.
Observe strict cleanliness replenishing oil. Contaminated oil is

a major cause of premature component failure.
The oil level of the hydraulic oil tank should be checked when
all of the cylinders are retracted and the boom is in
transportation position.

ID: 277 8 en 2011-12-20
10.11. Checking the differential oil level
1. Set the axle and its components in a horizon-

tal position. A
2. Clean the breathers.
3. Remove the inspection/filler plugs (A) from
the cover of the axle housing.
4. Check the oil level The oil level must be at the
bottom of the inspection/filler plug (A).
5. Add oil if necessary. Allow the oil to settle for
a few minutes.
6. Reinstall the inspection/filler plugs (A).
10.12. Checking the planetary gear oil level
1. Rotate the wheel hub so that the center point

of the oil filler opening is at the same horizon-
tal level than the center point of the axle.
2. Remove the oil plug.
3. Check the oil level. The oil level must be at the
lower level of the filler opening.
4. Add oil if necessary. Allow the oil to settle for
a few minutes. There is enough oil when a
drop of oil comes out of the opening during
filling.
5. Reinstall the oil plug.
10.13. Changing the differential oil
Change the oil while it is still warm and fluid.

1. Clean the area around the inspection/filler A
plugs (A) and remove the plugs.
2. Place a receptacle under the drain plugs (B).
3. Remove the drain plugs (B) of the front and
rear axle differentials.
4. Let the oil flow into the receptacles.
5. Reinstall the drain plugs (B).
6. Fill the differentials with the recommended oil
through the inspection/filler plugs (A) until the
oil level is at the bottom of the inspection/filler
plug (A).
B
7. Reinstall the inspection/filler plugs (A).

ID: 277 8 en 2011-12-20
10.14. Changing the planetary gear oil
Change the oil while it is still warm and fluid.

1. Rotate the wheel hubs so that the oil plug
points down.
2. Place a receptacle under the oil plug.
3. Remove the oil plug.
4. Let the oil flow into the receptacle.
5. Rotate the wheel hub so that the center point
of the oil filler opening is in the same horizon-
tal level than the center point of the axle.
6. Fill the planetary gear with recommended oil.
Allow the oil to settle for a few minutes. There
is enough oil when a drop of oil comes out of
the opening during filling.
7. Reinstall the oil plug.

ID: 277 8 en 2011-12-20
11. FILLING CAPACITIES
CLASSIFICATION
FIRST FILLING
ITEM CAPACITY RECOMMENDA- NOTE!
OIL/FLUID
TION
CF, CF-4, CG-4,
Diesel engine ACEA E3, Shell Rimula R3
15 l First filling with oil filter
(MB 904 LA) MB228.4, Caterpil- X 15W-40
lar ECF-1
CF, CF-4, CG-4,
Diesel engine ACEA E3, Shell Rimula R3
28 l First filling with oil filter
(MB 906 LA) MB228.4, Caterpil- X 15W-40
lar ECF-1
Driveline gear-
box 22 l GM Allison C-4 Shell Donax TM
(T20000)
Driveline gear-
box 25 l GM Allison C-4 Shell Donax TM
(HR32000)
1.7 l / planetary
Front/rear axle
gear Shell Donax TD
(Axle 123, wet API GL-4
8 l / differential 10W-30
brake)
gear
2.3 l / planetary
Front/rear axle
gear Shell Donax TD
brake)
gear
1.6 l / planetary
Front/rear axle
gear Shell Donax TD
brake)
gear
Front/rear axle
Shell Donax TD
(Axle 37R/43R, 45 l API GL-4
10W-30
wet brake)
Hydraulic oil Viscosity class is
DIN 51524 part 2
tank, drilling Shell Tellus Oil S chosen according to
210 l (HLP), ISO 6743-4
TC7/TC8 (DS 68 or 100 the operating condi-
(HM)
rigs) tions
Hydraulic oil Viscosity class is
DIN 51524 part 2
tank, drilling Shell Tellus Oil S chosen according to
290 l (HLP), ISO 6743-4
(TC8 and NC7- 68 or 100 the operating condi-
(HM)
series) tions
Viscosity class is
Hydraulic oil DIN 51524 part 2
Shell Tellus Oil S chosen according to
tank, drilling 380 l (HLP), ISO 6743-4
68 or 100 the operating condi-
(TC9) (HM)
tions
Viscosity class is
Hydraulic oil DIN 51524 part 2
Shell Tellus Oil S chosen according to
tank, drilling 470 l (HLP), ISO 6743-4
68 or 100 the operating condi-
(TC10–TC12) (HM)
tions

ID: 277 8 en 2011-12-20
CLASSIFICATION
FIRST FILLING
ITEM CAPACITY RECOMMENDA- NOTE!
OIL/FLUID
TION
SAE 75 W / 90 API
Cable reel gear- GL5 Esso GX 85
2.7 l
box SAE 80 W / 90 API W-140
GL5
Compressor Shell AEON
5l API CE/CF
(CT10/16) 3000
8l API CE/CF
(CT28) 3000
11 l API CE/CF
(CT40) 3000
Shank lubrication
Shell Torcula Oil
(Rig with 1 or 2 14 l Sandvik
100
booms)
Shank lubrication
Shell Torcula Oil
(Rig with 3 22 l Sandvik
100
booms)
Air conditioner
refrigerant 1900 g Sandvik R-134a
(TC7 carrier)
Air conditioner
refrigerant
2000 g Sandvik R-134a
(TC8 and NC7-
series carriers)
Air conditioner
refrigerant 1900 to 2000 g Sandvik R-134a
(TC9–12 carrier)
Refer to the sep-
arate air condi- ISO-100 (high vis-
Air conditioner oil Sanden PAG
tioner manual, ID cosity) or ISO-46
level SP-20 / SP-10
463, for the ca- (low viscosity)
pacities.
Fuel, diesel en- Thermoshell
150 l EN 590
gine Winter 1202
Diesel engine
BS 6580, AFNOR, GlycoShell con-
coolant 22 l
ASTM D 3306 sentrate
(MB 904 LA)
Diesel engine
BS 6580, AFNOR, GlycoShell con-
coolant 27 l
ASTM D 3306 sentrate
(MB 906 LA)

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12. LUBRICATION SAFETY AND OTHER PRECAUTIONS
When lubricating the vehicle, shut down the engine unless it is

required, see the lubrication instructions.
Keep your head, hands, feet and loose clothing away from
power-driven parts.
Do not grab the steering wheel when lubricating the vehicle.
Use caution when draining hot fluids from the vehicle,

splashing hot fluid can cause serious burns.
Accumulated grease or oil on the vehicle is a fire hazard.

the vehicle.
Before performing lubrication work on any equipment, consult

the manufacturer’s instruction manual and follow the
recommended procedures.
Never attempt to clean or lubricate the vehicle while it is in

motion.
Always comply with your company’s regulations and practices

for the safe lubrication of this vehicle.
12.1. Other precautions
• Avoid mixing lubricants. Please use oils recommended or oils with corresponding characteristics!
• Ensure the vehicle is level before filling tanks and sumps.
• Oil should only be changed with the engine hot.
• Clean carefully all lubricating fittings, breathers and oil check windows.
• When the engine is drained, clearly mark it so that it is not operated before it is refilled. In the event
of prolonged shutdown with engine or circuits drained, provide a device preventing accidental start-
up without refill.
• Analyse drained lubricant if appropriate.
• Ensure regularity of lubrication.
• The intervals given are those for normal usage. For tougher working conditions, the person
responsible must set down other intervals.
• Ensure daily reading of hour meter. This operation determines when lubrication is due.

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www.sandvik.com
310 9 en 2011-12-20
STEERING AND BRAKING SYSTEM

TC7-TC12, NC7
Table of Contents
1. CIRCUIT DIAGRAMS FOR STEERING AND BRAKES ............................................................... 6

1.1. Steering circuit diagram, NC7 ....................................................................................................................... 6
1.1.1. Components for NC7 .................................................................................................................................... 7
1.2. Steering circuit diagram, TC7-TC8 ............................................................................................................... 8
1.2.1. Components for TC7-TC8 ............................................................................................................................ 9
1.3. Steering circuit diagram, TC9-TC12 ............................................................................................................ 10
1.3.1. Components for TC9-TC12 .......................................................................................................................... 11
1.4. Brake circuit diagram, NC7 ............................................................................................................................ 12
1.4.1. Components for NC7 .................................................................................................................................... 13
1.5. Brake circuit diagram, TC7-TC8 ................................................................................................................... 16
1.5.1. Components for TC7-TC8 ............................................................................................................................ 17
1.6. Brake circuit diagram, TC9 ............................................................................................................................ 20
1.6.1. Components for TC9 ..................................................................................................................................... 21
1.7. Brake circuit diagram, TC10-TC12 ............................................................................................................... 24
1.7.1. Components for TC10-TC12 ....................................................................................................................... 25
2. COMPONENTS .............................................................................................................................. 28
2.1. Double pressure relief valve (261) ............................................................................................................... 28
2.2. Priority valve (262) ........................................................................................................................................... 28
2.3. Steering valve (263) ......................................................................................................................................... 29
2.4. Integrated brake valve (267) .......................................................................................................................... 30
2.5. Parking brake valve (270) ............................................................................................................................... 31
2.6. Parking brake valve (344) ............................................................................................................................... 32
2.7. Middle-joint locking valves (288, 289), TC7-TC8, NC7 rigs with frame steering (optional) .......... 33
2.8. Steering reversing valve (290), TC9-TC12 (optional) .............................................................................. 34
3. SERVICE AND PARKING BRAKES ............................................................................................. 35

3.1. Service and parking brake cylinders TC7-TC9/NC7 axles, TC10-TC12 rear axle ............................ 35
3.2. Parking brake cylinder, TC10-TC12 front axle .......................................................................................... 36
3.3. Parking brake circuit, TC7-TC12, NC7 ........................................................................................................ 37
3.3.1. Engaging and releasing the parking brakes .............................................................................................. 38
3.3.2. Parking brake circuit functional diagram (engaging), NC7 ..................................................................... 40
3.3.3. Parking brake circuit functional diagram (engaging), TC7/TC8 ............................................................. 42
3.3.4. Parking brake circuit functional diagram (engaging), TC9 ...................................................................... 44
3.3.5. Parking brake circuit functional diagram (engaging), TC10-TC12 ......................................................... 46
3.3.6. Parking brake circuit functional diagram (releasing), NC7 ...................................................................... 48
3.3.7. Parking brake circuit functional diagram (releasing), TC7/TC8 ............................................................. 50
3.3.8. Parking brake circuit functional diagram (releasing), TC9 ...................................................................... 52
3.3.9. Parking brake circuit functional diagram (releasing), TC10-TC12 ......................................................... 54
3.4. Service brake circuit, TC7-TC12, NC7 ......................................................................................................... 55
3.4.1. Service brake circuit functional diagram, NC7 .......................................................................................... 56
3.4.2. Service brake circuit functional diagram, TC7-TC8 ................................................................................. 58
3.4.3. Service brake circuit functional diagram , TC9 ......................................................................................... 60
3.4.4. Service brake circuit functional diagram, TC10-TC12 ............................................................................. 62
3.4.5. Operation of the ABA-system ...................................................................................................................... 64

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3.5. Testing the brakes ............................................................................................................................................ 65
3.5.1. Service brake testing system, TC7-TC12, NC7 (optional) ...................................................................... 67
4. EMERGENCY STEERING, TC7-TC8, NC7 (SPECIAL OPTION) ................................................. 76

4.1. Functional diagram of emergency steering, TC7-TC8, NC7 ................................................................. 76
4.1.1. Components ................................................................................................................................................... 77
4.1.2. Operation of the emergency steering ......................................................................................................... 77
4.2. Emergency steering control valve (295) ..................................................................................................... 78
4.3. Pressure accumulator (296) ........................................................................................................................... 78
4.4. Charging valve (297) ........................................................................................................................................ 79
4.5. Release valve of the pressure accumulator (299) ................................................................................... 79
5. TROUBLESHOOTING ................................................................................................................... 80
5.1. Steering ............................................................................................................................................................... 80
5.2. Brakes .................................................................................................................................................................. 81

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TC7-TC12, NC7

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
1. CIRCUIT DIAGRAMS FOR STEERING AND BRAKES
1.1. Steering circuit diagram, NC7
283 283
288 289
.06 .05
.04 .03
263
.07
.01
.02
.03
262
.01
.02
.03 .04
261
.01 .02
257 252
251
312

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
1.1.1. Components for NC7
251 Gear pump Feeds oil to the steering circuit and carrier circuit.
252 Gear pump Feeds oil to the service and parking brake circuits.
257 Diesel engine
261 Double pressure relief valve Limits the maximum pressure of gear pumps (251) and
(252).
.01 Pressure relief valve Limits the pressure of gear pump (251) (220 bar).
.03 Anti-cavitation valve Prevents cavitation in steering and carrier circuits
.04 Anti-cavitation valve Prevents cavitation in service and parking brake circuits
262 Priority valve Distributes the oil delivered from the gear pump (251)
primarily to the steering or secondarily to the carrier
auxiliary functions.
.01 Orifice Stabilises the priority valve (262) spool.
263 Steering valve (orbitrol) Distributes oil from the priority valve (262) to the steering
cylinders (283).
.01 Pressure relief valve Adjusts the maximum pressure of the steering valve (263).
.02 Non-return valve Prevents the pilot pressure from being released from the
steering circuit.
.03 Non-return valve Anti-cavitation valve for the steering valve (263)
.05 Pressure relief valve Shock valve
.07 Orifice Stabilises the pressure relief valve (263.01)
283 Steering cylinders
288 Middle-joint lock valve (optional)
289 Middle-joint lock valve (optional)
312 The hydraulic oil tank

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
1.2. Steering circuit diagram, TC7-TC8
L EF T RI GHT L EF T RI GHT
283 283
Y3 7 9 . 1 Y3 7 9 . 2
288 289
R L R L
190bar 190bar
.06 .05
ART I CUL AT I ON L OCKI NG
OPT I ON
.04 .03
263
.07 LS
.01
.02
140bar
P T
Ca r r i e r h o s i n g a n d
X9 r e t u r n f i l t e r s
X8 Ca r r i e r h o s i n g a n d
CF
EF
.03 X2 3 Ca r r i e r h o s i n g a n d
262 r et ur n f i l t er s
LS
.01
.02
P
X1
B2 T A2
.03 .04
220 bar 200 bar

261
.01 .02
B1 T A1
X1 3 Ca r r i e r h o s i n g a n d
r et ur n f i l t er s
P P
16c c 16c c
257 M 252
251 S S
From port B1 when
TC8 2-boom jumbo
( B1 )
S1 S2
312

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
1.2.1. Components for TC7-TC8
257 Diesel engine
(252).
cylinders (283).
steering circuit.
288 Middle-joint lock valve (frame-
steered rigs, optional)
289 Middle-joint lock valve (frame-
steered rigs, optional)

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
1.3. Steering circuit diagram, TC9-TC12
AT T ENT I ON! ! !
DRI L L I NG DI RECT I ON
Note! Hosing is different comparing to the basic version.

L EF T RI GHT RI GHT L EF T
283 ( Sh a f t R) 283 ( Sh a f t L )
2 4
Y3 7 8
290
3 1
R L R L
190bar 190bar
.06 .05
OPT I ON
.04 .03
263
LS
.01
.02
140bar
P T
Ca r r i e r p i p i n g a n d
X9 r e t u r n h o s e s
X8 Ca r r i e r p i p i n g a n d
r et ur n hos es
CF EF
.03 Ca r r i e r p i p i n g a n d
262 .01 X1 3 r e t u r n h o s e s
LS
.02
P
X1
2/ 11
B2 T A2
.03 .04
220 bar 200 bar

261
.01 .02
B1 T A1
16c c P P 16c c
257 M 252
251 S S
S1 S2
312

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
257 Diesel engine
(252).
cylinders (283).
steering circuit.
290 Steering reversing valve
(optional)

ID: 310 9 en 2011-12-20
ID: 310 9 en 2011-12-20
.01
.07
.06
.02
.05
.04
.03
275
267
.01
276
281
.02
293
272
271
344
.01
.02
.01
.01
270
282
277
.02
.02
285
.01
274
.02
345
280
279
.05
.06
.03
SERVICE BRAKE PRESSURE FRONT (80 bar)
SERVICE BRAKE PRESSURE REAR (80 bar)
PARKING BRAKE PRESSURE FRONT (30 bar)
.04
PARKING BRAKE PRESSURE REAR (30 bar)
CHARGING PRESSURE OF ACCUMULATORS (135-160 bar)
CLARK CLUTCH PRESSURE (17-19 bar)
291
284
.02
.01
.07
.08
294
.01
286
347
278
.02
Brake circuit diagram, NC7 1.4.
TC7-TC12, NC7
TC7-TC12, NC7
1.4.1. Components for NC7
267 Integrated brake valve Directs the oil to parking/service brake circuit or secondary
control circuit (port S).
.01 Priority valve Directs the oil to parking/service brake circuit or secondary
.02 Control valve Controls the operation of the priority valve (267.01) in the
brake circuit When the pressure in the brake circuit rises
to 160 bar, the valve changes position and directs the pilot
control oil of the priority valve (267.01) to the receiver. The
priority valve (267.01) changes position and directs the oil
to the secondary control circuit (port S). When the
pressure in the brake circuit descends to 135 bar, the
valve changes position and directs the pilot control oil to
the priority valve (267.01). The priority valve (267.01)
changes position and directs the oil to the parking/service
brake circuit.
.03 Pressure relief valve Ensures the functioning of the rear service brake circuit in
case of a hose rupture in the front service brake circuit.
Adjusts the operating pressure of the rear service brake
circuit to approximately 120 bar.
.04 Pressure relief valve Ensures the functioning of the front service brake circuit in
case of a hose rupture in the rear service brake circuit.
Adjusts the operating pressure of the front service brake
parking/service brake circuit.
.06 Pressure reducing/relieving valve Adjusts the service brake pressure to the rear axle
according to the pedal
.07 Pressure reducing/relieving valve Adjusts the service brake pressure to the front axle
270 Parking brake control valve Directs the oil flow to the rear axle parking brake. Adjusts
pressure to the parking brake circuit.
.01 Pressure reducing/relieving valve Adjusts the maximum pressure of the parking brake.
.02 3/2 directional valve Directs the oil flow into the receiver, parking brake.
271 Pressure accumulator Acts as an oil storage for the rear service brake circuit.
272 Pressure accumulator Acts as an oil storage for the front service brake circuit.
274 Pressure transducer Monitors the minimum charging pressure of the front
service brake circuit. Causes an indicator light to light up
in gauge (P3) (on the driving panel) when the pressure of
the front service brake drops below 100 bar. When using
the ABA system (optional), the transducer monitors the
minimum charging pressure of the front service brake
circuit and causes the indicator light (H20) to light up on
the driving panel when the pressure drops below 110 bar.

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
275 Pressure transducer Monitors the minimum charging pressure of the rear
in gauge (P4) (on the driving panel) if the pressure drops
below 100 bar. When using the ABA system (optional), the
transducer monitors the minimum charging pressure of
the rear service brake circuit and causes the indicator light
(H20) to light up on the driving panel when the pressure
drops below 110 bar.
276 Pressure switch (ABA system, Monitors the brake pressure. If the pressure drops below
optional) 75 bar, the parking brake engages.
278 Pressure switch Monitors the pressure of the rear axle parking brake. If the
pressure drops below 5 bar, the indicator light (H15)
switches on.
279 Shuttle valve Directs the pressure from the rear or front service brake
circuit to pressure switch (280).
280 Pressure switch Brake light switch (5 bar)
281 Front axle service brake testing
valve (service brake testing
system, optional)
.01 4/2 directional valve
.02 Pressure reducing/relieving valve Restricts the hydraulic oil pressure to 80 bar.
282 Rear axle service brake testing Directs the oil flow from the testing circuit to the rear axle
valve (service brake testing brake. Adjusts the testing circuit pressure.
system, optional)
284 Measuring point assembly
285 Front axle service and parking
brake cylinders
.01 Front service brake cylinders Controls the braking power of the front service brakes.
.02 Front parking brake cylinders Front parking brakes engaged/released.
286 Rear axle service and parking
brake cylinders
.01 Rear service brake cylinders Controls the braking power of the rear service brakes.
.02 Rear parking brake cylinders Rear parking brakes engaged/released.
291 Transmission
.01 Transmission oil cooler (optional)
.02 Gearbox
.03 Pressure switch (ABA system, Monitors the pressure of the gear box of the feed pump.
optional) When the pressure drops below 4 bar, the parking brake
engages and the indicator light (SH2) of the parking brake
button lights up.
.04 Manifold Consists of two separate components: collector and
pressure distributor.

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
.05 Pressure transducer Monitors the minimum clutch thrust of the gear box (14.3
bar).
.06 The breather Takes care of the ventilation of the brakes.
.07 Temperature transducer Monitors the maximum oil temperature of the gear box
(110 °C).
.08 Manifold
293 Shuttle valve (service brake
testing system, optional)
344 Parking brake control valve Directs the oil flow to the front axle parking brake. Adjusts
345 Pressure switch (optional)
347 Pressure switch Monitors the pressure of the front axle parking brake. If the
switches on.

ID: 310 9 en 2011-12-20
16 (82)
1.5.
285 286
FRONT AXLE REAR AXLE
SERVICE PARKING SERVICE PARKING
LEFT RIGHT LEFT RIGHT LEFT RIGHT LEFT RIGHT
.01 .02 .01 .02
267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293
H H
TC7-TC12, NC7
(REAR SERVICE
.07 F2 S15.1 BRAKE LIGHTS) 5 bar
F1 280 S19
.06 347 5 bar
MF1
344
X12 Y295.1 .02
T

TO CARRIER CIRCUIT T X 294
.03 A1
P .01 279
.02 30 bar
284
TO CARRIER CIRCUIT
X11
135-
LS 160 bar
A2 Y295 .02
.04
.05 T X
B3
X1 P .01
P .01
30 bar
S15.2
270
S MS MA X14 278
Brake circuit diagram, TC7-TC8
TO CARRIER CIRCUIT 5 bar

TO CARRIER CIRCUIT
X10
PRESSURE CONTROL OF PRESSURE CONTROL OF
BRAKE CIRCUIT BRAKE CIRCUIT
TO DRILLING CIRCUIT S13B S14B T2
276 277 BR .07
T3 .04 T1 110° C
.06
75 bar 75 bar
ID: 310 9 en 2011-12-20

C1
.05 291
P3 P1 C4 C3
275 274 B2 P / I 31 11 .08
P4 OUT IN
B1 3 P / I P/I B1 4 14,3 bar
P2 C2
100 bar 100 bar .01
(ABA 110 bar) (ABA 110 bar)
S16 OUT
GEARBOX
Copyright © Sandvik Mining and Construction

FRONT 65 bar 65 bar REAR 12
272 271 .03 IN
281 282 OPTION OPTION
.01 Y296 Y297 .01 Test valve of 4 bar ENGINE
80bar 80bar rear brake OPTION FAN
.02 P P .02
A A ABA
B B
Carrier hosing
OPTION and return
T T filters
Test valve of front brake X25
TC7-TC12, NC7
brake circuit.
in gauge (P3) (on the driving panel) when the pressure of
the front service brake drops below 100 bar. When using
the ABA system (optional), the transducer monitors the
minimum charging pressure of the front service brake
circuit and causes the indicator light (H20) to light up on
the driving panel when the pressure drops below 110 bar.

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
278 Pressure switch (S15.2) Monitors the pressure of the rear axle parking brake. If the
switches on.
280 Pressure switch (S19) Brake light switch (5 bar)
system, optional)
system, optional)
brake cylinders
brake cylinders
291 Transmission
.02 Gearbox
.03 Pressure switch (S16, ABA Monitors the pressure of the gear box of the feed pump.
system, optional) When the pressure drops below 4 bar, the parking brake
button lights up.

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
bar).
(110 °C).
.08 Manifold
347 Pressure switch (S15.1) Monitors the pressure of the front axle parking brake. If the
switches on.

ID: 310 9 en 2011-12-20
20 (82)
1.6.
285 FRONT AXLE 286 REAR AXLE
.01 .02 .01 .02
267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293 H H
TC7-TC12, NC7
(REAR SERVICE
F2 BRAKE LIGHTS) 5 bar
.07
280 B968P
F1
.06 294
MF1
344 0.2
TO CARRIER CIRCUIT Y960

CLARK CLUTCH
PRESSURE (17-19 bar)
X12 T T X
.03 A1 278
P B961P
0.1 279 284
.02 30 bar
X11
135- 347
LS A2 Y961 0.2 B960P
160 bar
.04
T X 5 bar
Brake circuit diagram, TC9
.05 B3
X1 P .01
P .01
30 bar
270
X19
TO CARRIER CIRCUIT
S MS MA
X10
TO AIR CONDITION CIRCUIT PRESSURE CONTROL OF PRESSURE CONTROL OF

BRAKE CIRCUIT BRAKE CIRCUIT T2 B970T
BR T1 .07 110° C
T3
.06
.04
ID: 310 9 en 2011-12-20

B966P B967P C1
276 277 .05 291
P3 P1 C4 C3
P/I 31 11 .08
75 bar 75 bar B970P P4 OUT IN
14,3 bar
P2 C2
.01
OPTION
275 274 Test valve of B975P
281 OUT

GEARBOX
B964P P/I P/I B965P rear brake .03

12
OPTION 100 bar 100 bar Y297 .01 4 bar IN ENGINE
Test valve of front brake (ABA 110 bar) (ABA 110 bar) 70bar FAN
OPTION
P .02
Y296 A ABA
80 bar 80 bar
70bar 272 271
.02 FRONT REAR B
P
A
B Carrier hosing T
and return 282
.01 T X25
filters
TC7-TC12, NC7
1.6.1. Components for TC9
brake circuit.
circuit to approximately 120 bar
on the gauge (P3) (on the driving panel) when the
pressure of the front service brake drops below 100 bar.
When using the ABA system (optional), the transducer
monitors the minimum charging pressure of the front
service brake circuit and causes the indicator light (H20)
to light up on the driving panel when the pressure drops
below 110 bar.

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
switches on.
system, optional)
system, optional)
brake cylinders
brake cylinders
291 Transmission
.02 Gearbox
optional) When the pressure drops below 4 bar the parking brake
button lights up.

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
bar).
(110 °C).
.08 Manifold
347 Pressure switch Monitors the pressure of the front axle parking brake. If the
switches on.

ID: 310 9 en 2011-12-20
24 (82)
1.7.
.01 .02 .01 .02
OPTION
ONLY WITH BRAKE P2 P2 P1 P1 P2 P2 P1 P1
TEST VALVES
MF2 285
286
TC7-TC12, NC7
293
(REAR SERVICE 5 bar

BRAKE LIGHTS) OPTION
.07 F2 280 S19 ONLY WITH BRAKE
TEST VALVES
F1
.06
MF1
TO CARRIER CIRCUIT Y295.1

CLARK CLUTCH
.02 294
X12 T T 344
267
X
P
.03 A1
.01 279 284
.02 100 bar S15.1
TO CARRIER CIRCUIT
347
X11 50 bar
LS 135- A2 Y295.2
160bar .02 S15.2
.04
T 278
.05 X 5 bar
X1 B3
1/21 P .01
P .01
30 bar
270
Brake circuit diagram, TC10-TC12
S MS MA
X10 PRESSURE CONTROL OF
S13B S14B BRAKE CIRCUIT
TO AIR CONDITION/
CARRIER CIRCUIT T2
276 277 B1
PRESSURE CONTROL OF BR
BRAKE CIRCUIT 75 ba r 75 bar .06
T3 T1 .07
.04 110° C
ID: 310 9 en 2011-12-20

.08 C1
B2 291
275 274 P3 P1 C4 C3
.05 P / I 31 11 OUT
B13 P/I P/I B14 IN
14,3 bar
100 bar 100 bar
S16 20000/ .01
(ABA 110 bar) (ABA 110 bar) 32000
FRONT REAR .03 SERIE

272 271 .02 OUT
4 bar 12
80 bar 80 bar IN
OPTION
ABA ENGINE
Y296 Y297 FAN
.02 .01
70bar 70bar
A .01 P P .02 A
B 281 282 B
T T Carrier hosing and

OPTION return filters
X14
BRAKE TEST
VALVES
TC7-TC12, NC7
brake circuit.
circuit to approximately 120 bar
on the gauge (P3) (on the driving panel) when the
pressure of the front service brake drops below 100 bar.
When using the ABA system (optional), the transducer
monitors the minimum charging pressure of the front
service brake circuit and causes the indicator light (H20)
to light up on the driving panel when the pressure drops
below 110 bar.

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
switches on.
system, optional)
system, optional)
brake cylinders
brake cylinders
291 Transmission
.02 Gearbox
optional) When the pressure drops below 4 bar, the parking brake
button lights up.

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
bar).
(110 °C).
.08 Manifold
.02 Parking brake control valve Directs the oil flow into the receiver, parking brake.
347 Pressure switch Monitors the front axle parking brake pressure. If the
switches on.

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
2. COMPONENTS
2.1. Double pressure relief valve (261)
The double pressure relief valve limits the maximum pressure of gear pumps (251) and (252).
.01 .02
.01 Pressure relief valve

.02 Pressure relief valve
.03 Anti-cavitation valve
.04 Anti-cavitation valve
2.2. Priority valve (262)
The priority valve distributes the oil delivered from the gear pump (251) primarily to the steering or
secondarily to the carrier auxiliary functions.
.01 Orifice
.02 Orifice
.03 Orifice

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
2.3. Steering valve (263)
The steering valve distributes oil to the steering as necessary.

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

.03 Intake valve .04 Intake valve
.05 Pressure relief valve .06 Pressure relief valve
.07 Orifice

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
2.4. Integrated brake valve (267)
The brake pedal adjusts the hydraulic pressure to the service brake cylinder proportionally in
accordance with the brake pedal angle.
.01 .04 .07
.05 .02
.06
.03
.01 Priority valve .02 Control valve

.03 Pressure relief valve .04 Pressure relief valve
.05 Non-return valve .06 Pressure reducing/relieving valve
.07 Pressure reducing/relieving valve

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
2.5. Parking brake valve (270)
The parking brake valve controls the operation of the rear axle parking brake cylinder.
Pressure reducing/relieving valve (.01) adjusts the control pressure to 30 bar.
Directional valve (.02) directs the oil flow to the parking brake or receiver.
.01 .02


ID: 310 9 en 2011-12-20
TC7-TC12, NC7
2.6. Parking brake valve (344)
The parking brake valve controls the operation of the front axle parking brake cylinder.
The pressure reducing/relieving valve (.01) adjusts the control pressure to 30 bar (TC7–9, NC7) / 100
bar (TC10-TC12).
Directional valve (.02) directs the oil flow to the parking brake or receiver.
.01 .02
100 bar
(TC10-12)
30 bar
(TC7-9, NC7)


ID: 310 9 en 2011-12-20
TC7-TC12, NC7
2.7. Middle-joint locking valves (288, 289), TC7-TC8, NC7 rigs with frame
steering (optional)
During drilling middle-joint movements are prevented with locking valves (288).
40 Nm

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
2.8. Steering reversing valve (290), TC9-TC12 (optional)

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
3. SERVICE AND PARKING BRAKES
The TC10-12 brakes only differ from the TC7-9 / NC7 brakes in regards to the front axle parking
brake.
The integrated brake valve (267) is used for three different purposes: priority function, charging and
control.
The priority function takes care of the priority of the oil flow. Valves (267.01) and (267.05) control the
priority function. Priority is always given to the service and parking brake circuits.
Control takes place when the service brake pedal is used.
3.1. Service and parking brake cylinders TC7-TC9/NC7 axles, TC10-TC12 rear
axle
2 1 3
5
6
9
8 P1
B1 B2
P2
1 Parking brake control pressure chamber 2 Parking brake operating piston

3 Service brake operating piston 4 Service brake control pressure chamber
5 Adjustment spring 6 Parking brake control pressure
connection
7 Service brake control pressure 8 Parking brake bleeder screw
connection
9 Service brake bleeder screw

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
3.2. Parking brake cylinder, TC10-TC12 front axle
2 3 4
1 Parking brake washer

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

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
3.3. Parking brake circuit, TC7-TC12, NC7
1 2 3
Figure: With Mercedes Benz engine
1 2
Figure: With Cummins engine
1 Parking brake engagement button (S21)

2 Parking brake releasing button and indicator light (SH2)
3 Parking brake engaged indicator light (H15)

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
3.3.1. Engaging and releasing the parking brakes
The parking brakes are engaged by pushing the parking brake engage button (S21). This releases
the pressure in the parking brake circuits. The indicator light (H15) is lit when the control pressure of
both parking brake circuits has fallen below the set limits:
• front brake circuit 5 bar (NC7, TC7-TC9) / 50 bar (TC10-TC12)
• rear brake circuit 5 bar (NC7, TC7-TC12)
The parking brakes are released by first lifting the parking brake engage button (S21) up. This lights
up the indicator light (SH2) on the parking brake release button. Next, push the parking brake release
button (SH2) to direct the pressure to the parking brake cylinders. The indicator lights (SH2) and
(H15) go off, and the parking brakes are released.
The indicator light (H15) blinks if the brakes of one axle are left in a different state than the other’s
when the break is engaged or released, i.e. the pressure difference between the brake circuits
becomes too high.

ID: 310 9 en 2011-12-20
TC7-TC12, NC7

ID: 310 9 en 2011-12-20
ID: 310 9 en 2011-12-20
.01
.07
.06
.02
.05
.04
.03
275
267
.01
276
281
.02
293
272
271
344
.01
.02
.01
.01
270
282
277
.02
.02
285
.01
274
.02
345
280
279
.05
.06
.03
.04
291
284
.02
.01
.07
.08
294
.01
286
347
278
Parking brake circuit functional diagram (engaging), NC7 .02 3.3.2.
TC7-TC12, NC7
TC7-TC12, NC7
Parking brake circuit operation (engaging)
The oil flows from the parking brake circuit gear pump (252). From the pump (252) the oil flows through
the double pressure relief valve assembly (261) to the integrated service brake valve (267) connection
(P). From the port (P) the oil flows through the control valve (267.01) and non-return valve (267.05)
to the integrated service brake valve (267) connection (B3). From there the oil flows to the parking
brake valves (270) and (344) connection (P) and then to the pressure reducing/relieving valves
(270.01) and (344.01). The pressure reducing/relieving valves (270.01) and (344.01) adjust the
operating pressure of the parking brake circuits. When the operator engages the parking brake (with
the parking brake button or an emergency stop button), the directional valves (270.02) and (344.02)
direct the oil flow from the front and rear parking brake cylinders (chambers 285.02 and 286.02) to
the receiver and the parking brake cylinder springs engage the parking brakes. The indicator light
(H15) on the driving panel lights up when the control pressure of both parking brake circuits has fallen
below the 5bar (pressure switches 278 and 347).

ID: 310 9 en 2011-12-20
42 (82)
3.3.3.
285 286
.01 .02 .01 .02
267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293
H H
TC7-TC12, NC7
(REAR SERVICE
F1 280 S19
.06 347 5 bar
MF1
344
X12 Y295.1 0.2
T

.03 A1
P 0.1 279
.02 30 bar
284
TO CARRIER CIRCUIT
X11
135-
LS 160 bar
A2 Y295 .02
.04
.05 T X
B3
X1 P .01
P .01
30 bar
S15.2
270
S MS MA X14 278
TO CARRIER CIRCUIT
X10
276 277 BR .07
T3 .04 T1 110° C
.06
75 bar 75 bar
ID: 310 9 en 2011-12-20

C1
.05 291
P3 P1 C4 C3
275 274 B2 P / I 31 11 .08
P4 OUT IN
B1 3 P / I P/I B1 4 14,3 bar 20000/
P2 32000 C2
100 bar 100 bar SERIE .01
S16 OUT

272 271 .03 IN
Parking brake circuit functional diagram (engaging), TC7/TC8
.02 P P .02
A A ABA
B B
Carrier hosing
OPTION T and return
T filters
Test valve of front brake
TC7-TC12, NC7

ID: 310 9 en 2011-12-20
44 (82)
3.3.4.
.01 .02 .01 .02
267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293 H H
TC7-TC12, NC7
(REAR SERVICE
.07
280 B968P
F1
.06 294
MF1
344 0.2

CLARK CLUTCH
X12 T T X
.03 A1 278
P B961P
0.1 279 284
.02 30 bar
X11
135- 347
LS A2 Y961 0.2 B960P
160 bar
.04
T X 5 bar
.05 B3
X1 P .01
P .01
30 bar
270
X19
TO CARRIER CIRCUIT
S MS MA
X10

BR T1 .07 110° C
T3
.06
.04
ID: 310 9 en 2011-12-20

B966P B967P C1
276 277 .05 291
P3 P1 C4 C3
P/I 31 11 .08
14,3 bar
P2 C2
.01
OPTION
281 OUT

GEARBOX

Parking brake circuit functional diagram (engaging), TC9
12
OPTION
P .02
Y296 A ABA
80 bar 80 bar
70bar 272 271
.02 FRONT REAR B
P
A
B Carrier hosing T
and return 282
.01 T X25
filters
TC7-TC12, NC7

ID: 310 9 en 2011-12-20
46 (82)
OPTION
.01 .02 .01 .02 3.3.5.
TEST VALVES
MF2 285
293 286
(REAR SERVICE 5 bar

TC7-TC12, NC7

TEST VALVES
F1
.06
MF1

CLARK CLUTCH
.02 294
X12 T T 344
267
X
P
.03 A1
.01 279 284
.02 100 bar S15.1
TO CARRIER CIRCUIT
347
X11 50 bar
LS 135- A2 Y295.2
160bar .02 S15.2
.04
T 278
.05 X 5 bar
X1 B3
1/21 P .01
P .01
30 bar
270
S MS MA
TO AIR CONDITION/
CARRIER CIRCUIT T2
276 277 B1
PRESSURE CONTROL OF BR T3 T1
BRAKE CIRCUIT 75 ba r 75 bar .06 .04 .07 110° C
.08 C1
B2 291
275 274 P3 P1 C4 C3
.05 P / I 31 11 OUT
ID: 310 9 en 2011-12-20

B13 P/I P/I B14 IN
14,3 bar
100 bar
100 bar S16 20000/ .01
(ABA 110 bar) 32000
(ABA 110 bar)
REAR .03 SERIE
FRONT 272 .02 OUT
271 4 bar
80 bar 80 bar 12
IN
OPTION
ENGINE

Y296 Y297 ABA
.02 .01 FAN
70bar 70bar
A .01 P P .02 A
B 281 282 B
Parking brake circuit functional diagram (engaging), TC10-TC12

BRAKE TEST X14
VALVES
TC7-TC12, NC7
below the set limits (front brake circuit 50 bar / rear brake circuit 5 bar)(pressure switches 278 and
347).

ID: 310 9 en 2011-12-20
ID: 310 9 en 2011-12-20
.01
.07
.06
.02
.05
.04
.03
275
267
.01
276
281
.02
293
272
271
344
.01
.02
.01
.01
270
282
277
.02
.02
285
.01
274
.02
345
280
279
.05
.06
.03
.04
291
284
.02
.01
.07
.08
294
.01
286
347
278
.02
Parking brake circuit functional diagram (releasing), NC7 3.3.6.
TC7-TC12, NC7
TC7-TC12, NC7
Parking brake circuit operation (releasing)
When the parking brake is released, the 3/2 directional valves (270.02) and (344.02) of the parking
brake control valves (270) and (344) are activated and the oil flows to the front parking brake cylinders
(285), the rear parking brake cylinders (286), the pressure switches (278) and the measuring point
assembly (284). When the control pressure of both parking brake circuits has risen over the 5 bar,
the parking brake indicator lamp (H15) on the driving panel turns off. The springs in cylinders (285)
and (286) are compressed and the parking brakes are released.

ID: 310 9 en 2011-12-20
50 (82)
3.3.7.
285 286
.01 .02 .01 .02
267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293
H H
TC7-TC12, NC7
(REAR SERVICE
F1 280 S19
.06 347 5 bar
MF1
344
X12 Y295.1 .02
T

.03 A1
P .01 279
.02 30 bar
284
TO CARRIER CIRCUIT
X11
135-
LS 160 bar
A2 Y295 .02
.04
.05 T X
B3
X1 P .01
P .01
30 bar
S15.2
270
S MS MA X14 278
TO CARRIER CIRCUIT
X10
276 277 BR .07
T3 .04 T1 110° C
.06
75 bar 75 bar
ID: 310 9 en 2011-12-20

C1
.05 291
P3 P1 C4 C3
275 274 B2 P / I 31 11 .08
P4 OUT IN
B1 3 P / I P/I B1 4 14,3 bar
P2 C2
100 bar 100 bar .01
S16 OUT
GEARBOX

272 271 .03 IN
Parking brake circuit functional diagram (releasing), TC7/TC8
.02 P P .02
A A ABA
B B
Carrier hosing
OPTION T and return
T filters
TC7-TC12, NC7

ID: 310 9 en 2011-12-20
52 (82)
3.3.8.
.01 .02 .01 .02
267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293 H H
TC7-TC12, NC7
(REAR SERVICE
.07
280 B968P
F1
.06 294
MF1
344 0.2

CLARK CLUTCH
X12 T T X
.03 A1 278
P B961P
0.1 279 284
.02 30 bar
X11
135- 347
LS A2 Y961 0.2 B960P
160 bar
.04
T X 5 bar
.05 B3
X1 P .01
P .01
30 bar
270
X19
TO CARRIER CIRCUIT
S MS MA
X10

BR T1 .07 110° C
T3
.06
.04
ID: 310 9 en 2011-12-20

B966P B967P C1
276 277 .05 291
P3 P1 C4 C3
P/I 31 11 .08
14,3 bar
P2 C2
.01
OPTION
281 OUT

GEARBOX
P/I .03
Parking brake circuit functional diagram (releasing), TC9
B964P P/I B965P rear brake

12
OPTION
P .02
Y296 A ABA
80 bar 80 bar
70bar 272 271
.02 FRONT REAR B
P
A
B Carrier hosing T
and return 282
.01 T X25
filters
TC7-TC12, NC7

ID: 310 9 en 2011-12-20
54 (82)
OPTION
.01 .02 .01 .02 3.3.9.
TEST VALVES
MF2 285
293 286
(REAR SERVICE 5 bar

TC7-TC12, NC7

TEST VALVES
F1
.06
MF1

CLARK CLUTCH
.02 294
X12 T T 344
267
X
P
.03 A1
.01 279 284
.02 100 bar S15.1
TO CARRIER CIRCUIT 347
X11 50 bar
LS 135- A2 Y295.2
160bar .02 S15.2
.04
T 278
.05 X 5 bar
X1 B3
1/21 P .01
P .01
30 bar
270
S MS MA
TO AIR CONDITION/
CARRIER CIRCUIT T2
276 277 B1
PRESSURE CONTROL OF BR T3 T1
.08 C1
B2 291
275 274 P3 P1 C4 C3
.05 P / I 31 11 OUT
ID: 310 9 en 2011-12-20

B13 P/I P/I B14 IN
14,3 bar
100 bar
100 bar S16 20000/ .01
(ABA 110 bar) 32000
(ABA 110 bar)
REAR .03 SERIE
FRONT 272 271 .02 OUT
80 bar 4 bar 12
80 bar IN
OPTION
ENGINE

Y296 Y297 ABA
.02 .01 FAN
70bar 70bar
A .01 P P .02 A
B 281 282 B
Parking brake circuit functional diagram (releasing), TC10-TC12

BRAKE TEST X14
VALVES
TC7-TC12, NC7
assembly (284). When the control pressure of both parking brake circuits has risen over the set limits
(front brake circuit 50 bar / rear brake circuit 5 bar), the parking brake indicator lamp (H15) on the
driving panel turns off. The springs in cylinders (285) and (286) are compressed and the parking
brakes are released.
3.4. Service brake circuit, TC7-TC12, NC7
1 Front brake circuit pressure gauge and in-

dicator light (P3)
2 Rear brake circuit pressure gauge and in-
dicator light (P4)
1 2
Accumulator pressure is released by pumping the brake pedal all the way down until the brake
pressures are 0 bar (gauges P3 and P4). Note! Diesel engine has to be switched off and the power
has to be ON. For more information, see the Maintenance and lubrication manual for drill carrier.

ID: 310 9 en 2011-12-20
ID: 310 9 en 2011-12-20
.01
.07
.06
.02
.05
.04
.03
275
267
.01
276
281
.02
293
272
271
344
.01
.02
.01
.01
270
282
277
.02
.02
285
.01
274
.02
345
280
279
.05
.06
.03
.04
291
284
.02
.01
.07
.08
294
.01
286
347
278
Service brake circuit functional diagram, NC7 .02 3.4.1.
TC7-TC12, NC7
TC7-TC12, NC7
Operation of the service brake circuit
The oil flows to the service brake circuit from the gear pump (252). From the pump (252) the oil flows
through the double pressure relief valve assembly (261) to the integrated service brake valve (267)
connection P.
If the brake pedal is not used and the service brake circuit pressure accumulators (271) and (272)
do not need extra oil, the oil pressure in the service brake circuit starts to rise to 160 bar. When the
control pressure rises to 160 bar, the control valve (267.02) changes its position. The pilot control oil
from the control valve (267.01) is directed to the receiver. At the same time, the control valve (267.01)
changes position and directs the oil from port P to port S of the integrated brake valve (267), and from
there the oil flows to the secondary circuits.
If the control pressure falls below 135 bar in the “charging circuit”, the control valve (267.02) changes
position and directs the oil flow from the brake circuit main line to the spring side of the control valve's
(267.01) control spool. The control valve (267.01) spool changes position and directs the main flow
through the non-return valve (267.05) and pressure relief valves (267.03) and (267.04) to ports A2
and A1 of the integrated brake valve (267).
From port A2 the oil flows to the front brake cylinder pressure transducer (275) and front brake cylinder
pressure accumulator (272). From port A1 the oil flows to the rear brake cylinder pressure transducer
(274) and rear brake cylinder pressure accumulator (271). When the brake pedal is used, the oil flows
through the pressure reducing/relieving valves (267.06) and (267.07) to port F1 and F2. From there
the oil flows to the front service brake cylinders (285.01), rear service brake cylinders (286.02), and
measuring point collector (284).
The control pressure value of pressure reducing/relieving valves (267.06) and (267.07) is directly
proportional to the change of the brake pedal angle. The greater the change of angle, the greater
control pressure and braking force.
The function of the pressure accumulators (271) and (272) is to ensure a sufficient amount of oil for
brake pedal operation. Pressure transducers (274) and (275) control the level of the service brake
circuit charging pressure. If the pressure drops below 100 bar, the warning light (P3) and/or (P4) of
the pressure gauge on the driving panel lights up.
Normal brake circuit pressure is 135-160 bar. If the brake circuit pressure in one or both brake circuits
is below 75 bar, the brakes cannot be released. The parking brake holding circuit will not be activated
unless the pressures at front brake circuit pressure switch (276) and rear brake circuit pressure switch
(277) are not within the permissible range. When the brake circuit pressure in both circuits increases
to above the 75 bar limit, the brakes can be released and the rig can be taken into use by releasing
the brakes with parking brake button S21 on the tramming panel and acknowledging the brake circuit
as released with button SH2 (refer to section 3.3.1).
The pressures in the brake circuits are also monitored with front and rear pressure transducers: (275)
and B14 (274), respectively. The pressures in the brake circuits are displayed on brake pressure
gauges P3 and P4 on the tramming panel.
If the brake circuit pressure drops below 100 bar on brake pressure gauges P3 (front) and P4 (rear)
on the tramming panel, the red low brake pressure warning lights go on.
If the brake pressure in one or both brake circuits (front brake circuit, (276), and/or rear brake circuit,
(277)) drops below 75 bar, the pressure switch deactivates the parking brake holding circuit and the
brakes engage.

ID: 310 9 en 2011-12-20
58 (82)
3.4.2.
285 286
.01 .02 .01 .02
267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293
H H
TC7-TC12, NC7
(REAR SERVICE
F1 280 S19
.06 347 5 bar
MF1
344
X12 Y295.1 .02
T

.03 A1
P .01 279
.02 30 bar
284
TO CARRIER CIRCUIT
X11
135-
LS 160 bar
A2 Y295 .02
.04
.05 T X
B3
X1 P .01
P .01
30 bar
S15.2
270
S MS MA X14 278
TO CARRIER CIRCUIT
X10
276 277 BR .07
T3 .04 T1 110° C
.06
75 bar 75 bar
ID: 310 9 en 2011-12-20

C1
.05 291
P3 P1 C4 C3
275 274 B2 P / I 31 11 .08
Service brake circuit functional diagram, TC7-TC8
P4 OUT IN
B1 3 P / I P/I B1 4 14,3 bar
P2 C2
100 bar 100 bar .01
S16 OUT
GEARBOX

272 271 .03 IN
.02 P P .02
A A ABA
B B
Carrier hosing
OPTION and return
T T filters
TC7-TC12, NC7
connection P.
brakes engage.

ID: 310 9 en 2011-12-20
60 (82)
3.4.3.
.01 .02 .01 .02
267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293 H H
TC7-TC12, NC7
(REAR SERVICE
.07
280 B968P
F1
.06 294
MF1
344 0.2

CLARK CLUTCH
X12 T T X
.03 A1 278
P B961P
0.1 279 284
.02 30 bar
X11
135- 347
LS A2 Y961 0.2 B960P
160 bar
.04
T X 5 bar
.05 B3
X1 P .01
P .01
30 bar
270
X19
TO CARRIER CIRCUIT
S MS MA
X10

BR T1 .07 110° C
T3
Service brake circuit functional diagram , TC9
.06
.04
ID: 310 9 en 2011-12-20

B966P B967P C1
276 277 .05 291
P3 P1 C4 C3
P/I 31 11 .08
14,3 bar
P2 C2
.01
OPTION
281 OUT

GEARBOX

12
OPTION
P .02
Y296 A ABA
80 bar 80 bar
70bar 272 271
.02 FRONT REAR B
P
A
B Carrier hosing T
and return 282
.01 T X25
filters
TC7-TC12, NC7
connection P.
brakes engage.

ID: 310 9 en 2011-12-20
62 (82)
OPTION
.01 .02 .01 .02 3.4.4.
ONLY WITH BRAKE P2 P2 P1 P2 P2 P1 P1
TEST VALVES
MF2 285
293 286
(REAR SERVICE 5 bar

TC7-TC12, NC7

TEST VALVES
F1
.06
MF1

CLARK CLUTCH
.02 294
X12 T T 344
267
X
P
.03 A1
.01 279 284
.02 100 bar S15.1
TO CARRIER CIRCUIT
347
X11 50 bar
LS 135- A2 Y295.2
160bar .02 S15.2
.04
T 278
.05 X 5 bar
X1 B3
1/21 P .01
P .01
30 bar
270
S MS MA
TO AIR CONDITION/
CARRIER CIRCUIT T2
276 277 B1
PRESSURE CONTROL OF
BR T3 T1
.08 C1
B2 291
275 274 P3 P1 C4 C3
.05 P / I 31 11 OUT
ID: 310 9 en 2011-12-20

B13 P/I P/I B14 IN
14,3 bar
100 bar
S16 20000/ .01
100 bar (ABA 110 bar) 32000
(ABA 110 bar) .03 SERIE
REAR
Service brake circuit functional diagram, TC10-TC12
FRONT 272 271 .02 OUT

4 bar 12
80 bar 80 bar IN
OPTION
ABA ENGINE

Y296 Y297 FAN
.02 .01
70bar 70bar
A .01 P P .02 A
B 281 282 B

BRAKE TEST X14
VALVES
TC7-TC12, NC7
connection P.
brakes engage.

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
3.4.5. Operation of the ABA-system
On rigs with ABA brakes, the transmission clutch pressure is monitored with pressure switch S16 in
addition to brake pressure monitoring. The brakes cannot be released unless the transmission clutch
pressure rises to above 4 bar. When the clutch pressure drops below 4 bar, the pressure switch
deactivates the parking brake holding circuit and the brakes engage. Indicator light H20 (impending
brake pressure) on the tramming panel warns of falling brake pressure on rigs with ABA brakes. This
indicator light goes on when the pressure in one or both brake circuits drops below 110 bar.
Moreover, rigs with ABA brakes feature an additional indicator light, H15B, located above the
tramming panel on the right-hand side. This light indicates that the parking brake is engaged (same
function as with indicator light H15 on the tramming panel).

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
3.5. Testing the brakes
Figure: Instruction plate for brake testing

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
Figure: Instruction plate for brake testing (USA / Canada option)

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
3.5.1. Service brake testing system, TC7-TC12, NC7 (optional)
rpm
0
rpm
SH56
1
Figure: With Mercedes Benz engine

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

2 Parking brake test switch (S25)

ID: 310 9 en 2011-12-20
ID: 310 9 en 2011-12-20
.01
.07
.06
.02
.05
.04
.03
275
267
.01
276
281
.02
293
272
271
344
.01
.02
.01
.01
270
282
277
.02
.02
285
.01
274
.02
345
280
279
.05
.06
.03
.04
291
284
.02
.01
.07
.08
294
.01
286
347
278
Functional diagram of the service brake testing system, NC7 .02
TC7-TC12, NC7
TC7-TC12, NC7
Operation of the service brake testing system, TC7-TC8, NC7
Testing of the front axle service brake
When the service brake testing valve's (281) spool Y296 is activated, the valve allows oil to flow from
port P to port B. The oil flows to the front axle service brake through the shuttle valve (293). The
pressure reduction valve decreases the oil pressure to the brakes to 80 bar.
Testing of the rear axle service brake
port P to port B. The oil flows to the rear axle service brake through the shuttle valve (294). The

ID: 310 9 en 2011-12-20
70 (82)
285 286
.01 .02 .01 .02
267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293
H H
TC7-TC12, NC7
(REAR SERVICE
F1 280 S19
.06 347 5 bar
MF1
344
X12 Y295.1 .02
T

.03 A1
P .01 279
.02 30 bar
284
TO CARRIER CIRCUIT
X11
135-
LS 160 bar
A2 Y295 .02
.04
.05 T X
B3
X1 P .01
P .01
30 bar
S15.2
270
S MS MA X14 278
TO CARRIER CIRCUIT
X10
276 277 BR .07
T3 .04 T1 110° C
.06
75 bar 75 bar
ID: 310 9 en 2011-12-20

C1
.05 291
P3 P1 C4 C3
275 274 B2 P / I 31 11 .08
P4 OUT IN
B1 3 P / I P/I B1 4 14,3 bar
P2 C2
100 bar 100 bar .01
S16 OUT
GEARBOX

Functional diagram of the service brake testing system, TC7-TC8
272 271 .03 IN

.02 P P .02
A A ABA
B B
Carrier hosing
OPTION T T and return
filters
TC7-TC12, NC7
Operation of the service brake testing system, TC7-TC8, NC7
port P to port B. The oil flows to the front axle service brake through the shuttle valve (293). The
port P to port B. The oil flows to the rear axle service brake through the shuttle valve (294). The

ID: 310 9 en 2011-12-20
72 (82)
.01 .02 .01 .02
267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293 H H
TC7-TC12, NC7
(REAR SERVICE
.07
280 B968P
F1
.06 294
MF1
344 0.2

CLARK CLUTCH
X12 T T X
.03 A1 278
P B961P
0.1 279 284
.02 30 bar
X11
135- 347
LS A2 Y961 0.2 B960P
160 bar
.04
T X 5 bar
.05 B3
X1 P .01
P .01
30 bar
270
X19
TO CARRIER CIRCUIT
S MS MA
X10

Functional diagram of the service brake system, TC9
BR T1 .07 110° C
T3
.06
.04
ID: 310 9 en 2011-12-20

B966P B967P C1
276 277 .05 291
P3 P1 C4 C3
P/I 31 11 .08
14,3 bar
P2 C2
.01
OPTION
281 OUT

GEARBOX

12
OPTION
P .02
Y296 A ABA
80 bar 80 bar
.01 70bar
.02 FRONT 272 271 REAR
P B
A
B Carrier hosing T
T and return 282
filters X25
TC7-TC12, NC7
Operation of the service brake testing system, TC9-TC12
port (P) to port (B). The oil flows to the front axle service brake through the shuttle valve (293). The
port (P) to port (B). The oil flows to the rear axle service brake through the shuttle valve (294). The

ID: 310 9 en 2011-12-20
74 (82)
.01 .02 .01 .02
OPTION
ONLY WITH BRAKE P2 P2 P1 P2 P2 P1 P1
TEST VALVES
MF2 285
293 286
(REAR SERVICE 5 bar

BRAKE LIGHTS)
TC7-TC12, NC7
OPTION
TEST VALVES
F1
.06
MF1

CLARK CLUTCH
.02 294
X12 T T 344
267
X
P
.03 A1
.01 279 284
.02 100 bar S15.1
TO CARRIER CIRCUIT
347
X11 50 bar
LS 135- A2 Y295.2
160bar .02 S15.2
.04
T 278
.05 X 5 bar
X1 B3
1/21 P .01
P .01
30 bar
270
S MS MA
TO AIR CONDITION/
CARRIER CIRCUIT T2
276 277 B1
PRESSURE CONTROL OF BR
BRAKE CIRCUIT 75 ba r 75 bar .06
T3 T1 .07
.04 110° C
.08 C1
B2 291
275 274 P3 P1 C4 C3
.05 P / I 31 11 OUT
ID: 310 9 en 2011-12-20

B13 P/I P/I B14 IN
14,3 bar
100 bar
100 bar S16 20000/ .01
(ABA 110 bar) 32000
(ABA 110 bar) SERIE
REAR .03
FRONT 272 271 .02 OUT
80 bar 80 bar 4 bar 12
IN
OPTION
ENGINE

ABA
Y297 FAN
Y296
.02
70bar 70bar
.01
Functional diagram of the service brake testing system, TC10-TC12
A .01 P P .02 A
B 281 282 B
T T
OPTION X14
BRAKE TEST Carrier hosing and
return filters
VALVES
TC7-TC12, NC7
Operation of the service brake testing system, TC9-TC12
port (P) to port (B). The oil flows to the front axle service brake through the shuttle valve (293). The
port (P) to port (B). The oil flows to the rear axle service brake through the shuttle valve (294). The
Service brake testing valves (281, 282)

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
4. EMERGENCY STEERING, TC7-TC8, NC7 (SPECIAL OPTION)
4.1. Functional diagram of emergency steering, TC7-TC8, NC7
L EF T RI GHT
283
R L
190bar 190bar
.06 .05 295
.01
.04 .03 1
263
.02
Y398 EMERGENCY STEERING

.07 LS OPTION
2
.01 299
80bar
.02 10L
140bar
P T 296 2 1
Ca r r i e r h o s i n g a n d X1
Y399
ONLY WITH EMERGENCY 298
STEERING X8 Ca r r i e r h o s i n g a n d
CF
EF
X7 r e t u r n f i l t e r s N S1
.03 T
262 r et ur n f i l t er s S2
LS
.01 .03
.02 P
P
297
X1 .01
.02
.04 T
B2 T A2
.03 .04
220 bar 200 bar

261 X15
Carrier hosing and
.01 .02 return filters
B1 T A1
r et ur n f i l t er s
P P
16c c 16c c
257 M 252
251 S S
From port B1 when
TC8 2-boom jumbo
( B1 )
S1 S2
312

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
4.1.1. Components
295 Emergency steering control valve Directs oil from the pressure accumulator (296) to the
(emergency steering, optional) steering valve (263).
.01 Directional valve Directs oil from the pressure accumulator (296) to the
steering valve (263).
.02 Flow control valve
296 Pressure accumulator Functions as the oil reserve for the emergency steering.
(emergency steering)
297 Charging valve (emergency Charges the pressure accumulator (296).
steering)
.01 Priority valve
.02 Charging valve
.03 Check valve
.04 Restrictor
298 Non-return valve (emergency
steering)
299 Release valve for emergency Releases the pressure from the accumulator of the
steering emergency steering.
4.1.2. Operation of the emergency steering
If the rig voltage drops below 26.5 V, the 2/2 directional valve (295.01) opens and releases the oil
from the pressure accumulator (296) to the steering circuit.
When the carrier main switch is on, the coil of valve Y399 (299) is activated and the valve close the
connection from the pressure accumulators to the tank. When the engine is started, charging of the
pressure accumulators begins.
When the carrier main switch is on, the coils of valves Y398 and
NOTE! Y399 remain continuously activated and keep discharging the
rig batteries if the rig is not connected to an external network.
WARNING
HIGH-PRESSURE FLUID HAZARD!
High-pressure fluid remaining in hydraulic lines could cause
serious injury.
Never carry out maintenance or repair work on a pressurized
system. Relieve pressure before opening fittings, plugs or
hydraulic valve cartridges. Always make sure the parts are not
pressurized. Use a bleeder screw to relieve the pressure behind
the valves or cartridges, or wait until the unit is depressurized,
before removing the components.

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
4.2. Emergency steering control valve (295)
295
.02
.01
4.3. Pressure accumulator (296)

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
4.4. Charging valve (297)
N S1
T
.03
P .02
.01
.04
297 T
Charging the pressure accumulator
The charging valve (297) allows the oil to flow to the pressure accumulator (296) through the port
(S1). When the pressure accumulator is full, the charging valve changes position, and the oil flows
through the brake circuit port (N).
4.5. Release valve of the pressure accumulator (299)

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
5. TROUBLESHOOTING
5.1. Steering
Fault Cause Action

The wheels do not stay turned in Air in the steering cylinder or in Bleed the steering system.
the desired direction but move the piping between the cylinder
forward and backward when the and the steering valve.
steering wheel is not turned. The
steering wheel must be turned
quite a distance (e.g., 1/4 of a
turn) before the wheels start
turning.
The wheels do not stay turned in Worn connections in the steer- Change the worn connections.
the desired direction but move ing system controls.
forward and backward when the
steering wheel is not turned. The
turning.
The wheels do not stay turned in Air in the steering system – e.g., Check the oil level and check for
the desired direction but move if the oil level in the tank is too oil leaks.
forward and backward when the low or the suction hose of the
steering wheel is not turned. The hydraulic pump leaks.
turning.
The wheels turn during tram- Oil leaks in the hydraulic circuit Replace the parts.
ming, usually slowly, even between the steering valve and
though the steering wheel is not cylinder because of:
turned. When the steering wheel • a faulty steering cylinder
is turned, the wheels do not turn • a worn ORBITROL steering
or they turn slowly. valve
• a faulty surge damping valve
Steering is unstable and the Dirt in the ORBITROL steering Clean the steering valve, and
steering wheel is stiff when valve causes the adjusting valve check the cleanliness of the oil
turned. The turning movement spools to stick. using an oil analyzer. Change
of the steering wheel continues the oil.
– e.g., when the steering wheel
is released.

ID: 310 9 en 2011-12-20
TC7-TC12, NC7
Fault Cause Action

The steering wheel turns lightly There is no oil in the steering Check the pump output pres-
approximately 8 degrees in ei- system due to, for example: sure from the pressure gauge in
ther direction from the middle • a faulty hydraulic pump the measuring point. Replace
position, but after this turning • a faulty safety relief valve or faulty/worn components.
feels heavy. Power steering is flow regulator valve
not working.
• a faulty non-return valve in the
ORBITROL control valve
The steering wheel is heavy A jammed steering wheel arm Replace faulty/worn compo-
when turned or does not turn at bearing or faulty ORBITROL nents.
all. control valve.
5.2. Brakes
Fault Cause Action

Low service brake power Worn braking surfaces. Change the worn braking surfa-
ces.
Low service brake power Low braking pressure. Check the adjusting pressure.
Replace faulty components.
Check the pressure accumula-
tors' charging pressure (65 bar /
TC7-8 / NC7, 80 bar / TC9-12),
adjust if necessary. Check the
brake hoses, replace faulty
ones.
Low service brake power Air in brake circuit. Bleed the brake cylinders.
Low parking brake power Worn braking surfaces. Change the worn braking surfa-
ces.
Low parking brake power Brake clearance (in the brake Adjust the brakes.
cylinder) too large.
Low parking brake power Brake cylinder springs fatigued. Replace the springs.
Parking brake not properly re- Air in brake circuit. Bleed the system.
leased
Parking brake not properly re- The brake cylinder seals are Replace the seals.
leased leaking.
Parking brake not properly re- Leaking connections. Tighten the connections.
leased
The discharge valve or one of The brake circuit cannot be Change / repair the valve.
the valves is de-energized or pressurized and the rig's parking
stuck in the open position brake cannot be released.
The discharge valve is stuck in The pressure remains in the When servicing the brake circuit,
the closed position brake valve. always ensure that there is no
pressure in the system.

ID: 310 9 en 2011-12-20
TC7-TC12, NC7

ID: 310 9 en 2011-12-20
www.sandvik.com
Instrucciones originales
498 2 es 2009-12-14
CAMBIO DEL NEUMÁTICO E INSPECCIÓN DE

LLANTA
Índice de contenidos
1. EXTRACCIÓN SEGURA DE UNA RUEDA DE LA MÁQUINA ..................................................... 3
2. MARCAS EN EL NEUMÁTICO ..................................................................................................... 5
3. LLANTAS ....................................................................................................................................... 6
3.1. Marcas en la llanta ........................................................................................................................................... 7
4. INSPECCIONES EN LOS COMPONENTES DE LA RUEDA ....................................................... 8

4.1. Inspecciones previas al montaje de un neumático en una llanta ....................................................... 8
4.2. Inspección magnética de la llanta ............................................................................................................... 9
5. MONTAJE DE UN NEUMÁTICO EN UNA LLANTA ..................................................................... 10

5.1. Seguridad en la colocación de neumáticos .............................................................................................. 10
5.2. Presurización del neumático ......................................................................................................................... 10
5.3. Jaula de seguridad ........................................................................................................................................... 11

ID: 498 2 es 2009-12-14
ID: 498 2 es 2009-12-14
CAMBIO DEL NEUMÁTICO E INSPECCIÓN DE LLANTA
1. EXTRACCIÓN SEGURA DE UNA RUEDA DE LA MÁQUINA ID: 11151
Siga siempre las normativas de seguridad locales y específicas

para minas cuando manipule las ruedas o los neumáticos de los
equipos de perforación de roca.
Nunca se posicione bajo un equipo que esté elevado sobre los

gatos.
Apoye siempre de forma adecuada el equipo de perforación de

roca cuando extraiga las ruedas. Asegúrese también de que la
estructura de apoyo sea suficientemente resistente, porque los
equipos pueden pesar de 3000 a 60000 kilos, dependiendo de
su tipo. Preste especial atención a la capacidad de transporte
de carga del suelo sobre el que está colocado el soporte.
Cuando manipule las ruedas, tenga en cuenta las cargas extra

provocadas por el inflado de los neumáticos.
Cuando extraiga la rueda del eje de oscilación, preste atención

a los cambios de peso del eje y al hecho deque el extremo del
eje de la rueda que se va a extraer puede elevarse. Peligro de
aplastamiento. Recomendamos utilizar cuñas de madera para
evitar el balanceo del eje de oscilación.
Se recomienda encargar a personal cualificado la inspección y

el montaje de los neumáticos y las llantas.
La extracción de una rueda es una operación especializada, que requiere conocimientos y equipos
especializados.
Antes de extraer una rueda, asegúrese siempre de que puede trabajar de forma segura y según lo
indicado por las normativas de seguridad locales y específicas para minas.
Deberá disponerse de herramientas adecuadas para una extracción segura de las ruedas.
Antes de aflojar ninguna de las tuercas de la rueda, compruebe siempre lo siguiente:
1. ¿Se ha estado conduciendo con el neumático desinflado (80% o más por debajo de la presión
de funcionamiento recomendada)? En caso de duda, compruebe la presión.
2. ¿Existen sospechas de deterioro o daños evidentes en el neumático o los componentes de la
rueda?
Si se cumplen estas condiciones, antes de aflojar las tuercas de la rueda, el neumático deberá
desinflarse completamente extrayendo el núcleo de la válvula.
Si la llanta y el neumático están en buenas condiciones, desinfle el neumático a una presión de 35
kPa (0,35 bares, 5 psi), antes de aflojar las tuercas de la rueda.

ID: 498 2 es 2009-12-14
Si no puede utilizar ningún dispositivo para extraer la rueda, puede hacerlo manualmente. Esta
operación se realiza desde atrás, vista desde la dirección de la superficie de rodamiento del
neumático. La rueda puede volcarse, por lo que previamente usted deberá asegurarse de que hay
suficiente espacio para que la rueda pueda rodar sin provocar lesiones ni daños materiales si se
cayera. La rueda de un equipo de perforación puede llegar a pesar varios cientos de kilos. Extreme
las medidas de precaución en las tareas de mantenimiento de la rueda sobre terrenos inclinados.
La mayoría de los equipos de perforación pueden elevarse sobre sus gatos, de forma que el
neumático quede visiblemente elevado sobre el suelo. Si saca la rueda, coloque siempre un soporte
debajo del eje. Desatornille los pernos y extraiga la rueda.

ID: 498 2 es 2009-12-14
2. MARCAS EN EL NEUMÁTICO ID: 11146
2
1
3
5
6
ID: 30003
1 Ancho del neumático 2 Diámetro de la llanta

3 Ply rating (PR) (resistencia) 4 Condiciones ambientales
5 Año de fabricación (50 = semana Nº 50, 6 Fabricante
08 = año 2008)

ID: 498 2 es 2009-12-14
3. LLANTAS ID: 11149
Existen tres tipos principales de llanta: llantas de una pieza, llantas segmentadas y llantas multipieza.
Los equipos de perforación Sandvik suelen usar llantas multipieza.
1 1 4
2
3 5
3
ID: 30015
1 Anillo lateral 2 Anillo de bloqueo

3 Anillo del asiento del talón 4 Llanta
5 Disco
Asegúrese de que la llanta es correcta para el tamaño del neumático usado.
Todos los neumáticos sin cámara deben colocarse en llantas sin cámara. Coloque siempre un anillo
tórico nuevo.
Si no aparecen marcas en las paredes laterales del neumático que indiquen que se trata de un
neumático sin cámara, los neumáticos deben colocarse con una cámara adecuada en llantas con
cámara. Debe usarse una aleta. Las aletas y cámaras nuevas son una parte necesaria para el
ensamblaje de una llanta con cámara.
En ambos casos también se recomenda colocar válvulas y anillos de sellado nuevos.

ID: 498 2 es 2009-12-14
3.1. Marcas en la llanta ID: 11150
Las ruedas de disco están marcadas con la siguiente información:

• Designación del tamaño de la llanta
• Identificación del fabricante de la llanta
• Fecha de fabricación
Los anillos están marcados con la siguiente información:

• Identificación de la llanta en la que debe colocarse la pieza
• Identificación del fabricante
• Fecha de fabricación (al menos el mes y el año)
• Designación de altura de la brida (en anillos lateriales para llantas EM)
Designación del tamaño de la llanta

8.5 – 20
• 8.5 código de ancho (pulgadas)
• 20 código de diámetro nominal (pulgadas)

ID: 498 2 es 2009-12-14
4. INSPECCIONES EN LOS COMPONENTES DE LA RUEDA ID: 29718
4.1. Inspecciones previas al montaje de un neumático en una llanta ID: 29720
El desmontaje de las ruedas y la inspección de los componentes de las ruedas son operaciones
especializadas, que requieren conocimientos y equipos especializados.
Todos los componentes de las ruedas multipieza deben inspeccionarse antes de su ensamblaje.
Realice una inspección y asegúrese de que los componentes de la llanta y el neumático coinciden.
No reutilice una llanta o un componente de una llanta que esté:
• doblado o encorvado
• corroído
• roto
• partido
ID: 29739
1. dado de sí
Nunca use un anillo de bloqueo (anillo de cierre) que haya dado

de sí.
No utilice las llantas si:
• Los orificios de los tornillos están desgastados o presentan una forma elíptica.
• La llanta se ha reparado mediante soldadura.
• La llanta presenta un desgaste avanzado en el área del asiento del talón.

ID: 498 2 es 2009-12-14
Las bridas de la llanta, los anillos y las superficies del asiento del talón del neumático de la llanta
deben estar limpias y libres de óxido.
No reutilice los neumáticos si:
• La máquina se ha conducido con neumáticos vacíos o despresurizados casi por completo.

• Existen signos de desgaste en el neumático o el neumático tiene más de 10 años.
• El estado general del neumático no es adecuado, por ejemplo: existen fracturas o queda muy poca
superficie de rodamiento.
• El neumático presenta daños irreparables.
• El neumático ha estado en funcionamiento reparado.
Compruebe que el neumático está limpio y seco y que no contiene materiales extraños.
Los componentes de ruedas multipieza no deben intercambiarse. Use exclusivamente las piezas de
recambio incluidas en el paquete de piezas de recambio suministrado por Sandvik para la llanta en
cuestión.
4.2. Inspección magnética de la llanta ID: 30027
Cuando la llanta alcance de 12000 a 15000 horas de servicio, debe realizarse una inspección de
partículas magnéticas. Si la inspección no se lleva a cabo, la llanta y sus piezas deben retirarse del
servicio.
Consulte al fabricante de la llanta los intervalos de horas recomendados para la realización de
inspecciones magnéticas en las llantas.
La inspección siempre debe repetirse en intervalos de 12000 a 15000 horas de servicio.
Si se detectan deterioros durante las inspecciones visuales, la inspección de partículas magnéticas
debe realizarse inmediatamente, antes de seguir usando la llanta. Si la inspección no se lleva a cabo,
la llanta debe retirarse del servicio.
Para realizar una inspección de partículas magnéticas en un ensamblaje de llanta, el neumático debe
extraerse primero.
Esta instrucción es una directriz. Respete siempre las normas
de agencia, obligatorias, indicadas por las autoridades, o
específicas de la mina, relativas a las inspecciones magnéticas
en llantas.

ID: 498 2 es 2009-12-14
5. MONTAJE DE UN NEUMÁTICO EN UNA LLANTA ID: 30030
5.1. Seguridad en la colocación de neumáticos ID: 30032
Cuando presurice un neumático, tome siempre las siguientes precauciones de seguridad:

• Nunca use llantas / piezas de llantas dañadas.
• Use lubricantes adecuados.
• Si se desplaza un anillo de bloqueo, desinfle el neumático extrayendo el núcleo de la válvula, antes
de realizar el ajuste.
• No aplique una fuerza excesiva y nunca golpee ensamblajes inflados.
• Use siempre la jaula de seguridad para el inflado.
• Si no dispone de ninguna jaula de seguridad, colóquese a una distancia prudencial y en el lado de
la superficie de rodamiento del neumático. Presurice siempre a distancia (al menos 1,5 m).
• Use protectores auditivos.
• Nunca se siente encima ni se apoye en un neumático mientras se está inflando.
• Supervise siempre el neumático mientras se está inflando.
5.2. Presurización del neumático ID: 30036
La colocación de neumáticos es una operación especializada, que requiere conocimientos y equipos

especializados.
El neumático no debe inflarse a más de 50 kPa (7 psi , 0,5 bares), antes de haber comprobado la
ubicación correcta de los componentes.
Cuando el neumático esté colocado en una llanta y todos los componentes estén correctamente
posicionados, continuar inflando hasta 150 kPa (22 psi, 1,5 bares).
No exceda nunca un nivel de inflado de 150 kPa (22 psi, 1,5 bares) sin equipos de seguridad
adecuados.
Asegúrese de que los talones están correctamente situados contra la brida de la llanta. Inspeccione
el neumático y asegúrese de que no presenta deformaciones. Cualquier deformación requiere una
inspección por parte de un especialista.
La aplicación de estas precauciones es indispensable para continuar con el inflado, en una jaula de
seguridad o similar, a la presión de funcionamiento recomendada.
Nunca exceda el valor máximo de presión permitido.
Si no existe una indicación de "presión máxima permitida" en el neumático, consulte el manual del
equipo o póngase en contacto con el importador o el fabricante del neumático para averiguar la
presión máxima o la presión de funcionamiento recomendada para la llanta y el neumático
correspondientes.
Se recomienda anotar la recomendación de presión en el manual del equipo para futuras referencias.

ID: 498 2 es 2009-12-14
5.3. Jaula de seguridad ID: 26731
Siempre que sea posible, use la jaula de seguridad.

La jaula de seguridad es un dispositivo de seguridad para la presurización de neumáticos, diseñado
para minimizar las consecuencias derivadas de una posible explosión de un neumático. La red de
seguridad alrededor de la jaula de seguridad detendrá los componentes de la llanta o las partes del
neumático que salgan disparados en caso de explosión del neumático.
ID: 26763
Figura: Jaula de seguridad con un inflador de neumáticos automático.
Tras el inflado, los componentes de la rueda y el neumático deben inspeccionarse aún dentro de la
jaula de seguridad para garantizar que están correctamente posicionados y sujetos.
Si es necesario realizar ajustes adicionales en los componentes de la rueda o el neumático, el
neumático debe desinflarse extrayendo el núcleo de la válvula, antes de realizar el ajuste.
Cuando presurice un neumático, tome siempre las siguientes precauciones:
Trabaje con cuidado y precaución.
Antes de inflar el neumático, asegúrese de que los

componentes de la llanta y el neumático coinciden. Asegúrese
de que el neumático encaja correctamente en la llanta. Preste
especial atención a la compatibilidad entre las partes de la llanta
cerrada, y compruebe que todas las partes están en su posición
adecuada.

ID: 498 2 es 2009-12-14
Use siempre una jaula de seguridad o dispositivos similares

cuando infle los neumáticos. Nunca presurice los neumáticos
de máquinas pesadas a más de 150 kPa (22 psi, 1,5 bares) sin
jaula de seguridad o sin tomar otras precauciones de seguridad
similares. Tras la presurización, siempre compruebe que el
neumático encaja correctamente en la llanta antes de sacar la
rueda de la jaula de seguridad.
Levante la rueda acoplada a la máquina de montaje o al

vehículo. La rueda seguirá puesta aunque el neumático explote
mientras se está inflando.
Use siempre protectores auditivos. Incluso al retirar la válvula,

se excede el límite de ruido de 90 dB. Si no se usan protectores
auditivos, en caso de explosión de un neumático, se sufrirán
lesiones auditivas permanentes.
Nunca se coloque junto a la rueda, se siente en el neumático ni

se apoye en el neumático mientras se está inflando. Infle el
neumático desde una distancia adecuada.
Colóquese a una distancia prudencial (al menos 1.5 m) y en lado

de la superficie de rodamiento. Use el tipo de pieza de entrada
para la manguera de aire que pueda acoplarse a la válvula.
Observe el neumático mientras se está inflando. Supervise la

presurización y compruebe que los talones del neumático se
elevan correctamente en la llanta. Asegúrese de que las piezas
de la llanta de tipo multipieza se han colocado correctamente.
Lleve el neumático con la llanta multipieza a la jaula de
seguridad tras la presurización a 150 kPa (22 psi, 1,5 bares).
Está prohibida la presencia de personal no autorizado cerca de

la rueda mientras se esté inflando el neumático.
Si detecta algún tipo de anomalía, vacíe y compruebe el

neumático, la llanta y el montaje. Si el neumático no se eleva
normalmente en la llanta, o si escucha un ruido chirriante
durante la presurización, vacíe el neumático, extráigalo y
averigüe la causa del problema. Nunca use un neumático
dañado.

ID: 498 2 es 2009-12-14
www.sandvik.com
506 0 en 2009-01-15
MERCEDES BENZ
Engine fault codes
Table of Contents
1. FAULT CODES OF ENGINE CONTROL (PLD-MR) VIA SAE J1939 ........................................... 3
2. FAULT CODES OF VEHICLE CONTROL (ADM2) VIA SAE J1939 ............................................. 24

ID: 506 0 en 2009-01-15
ID: 506 0 en 2009-01-15
MERCEDES BENZ
Engine fault codes
1. FAULT CODES OF ENGINE CONTROL (PLD-MR) VIA SAE J1939 ID: 28133
Fault Fault Description Repair instructions

codes codes
SAE PLD-MR
J1939 ***
SPN/FMI
****
45/12 16409D) heater flange open circuit fault The heating flange becomes after Kl. 15
(heater flange uniquely briefly switched on. Here if no
defective) break-down of the battery voltage is
recognized, the heating flange is
classified as defective. Error threshold
and cyclic duration are deposited in the
data record.
94/0 11715 fuel pressure measuring If a fuel pressure sensor or a
sensor or fuel range exceeded combination sensor fuel pressure &
pressure & or short circuit to temperature is fitted to the engine
temperature terminal 30 / depends on the engine make
sensor terminal 15
94/1 11716 combination remains under
input (FPS, P- measuring
DK) range or short
circuit to ground
94/2 11717 combination signal not
input (FPS, P- plausible
DK)
94/3 13015 combination open circuit
input (FPS, P-
DK)
94/4 13016 combination short circuit to
input (FPS, P- ground
DK)
94/14 11917 Fuel line signal measured value
not plausible * not plausible
98/2 02026 engine oil fluid level too - message via CAN: warning oil level
circulation* high / too low too high (=98/0) or advance warning
(=98/1) or warning oil level too low
(=98/1)
02517 oil level sensor measured value - check oil level, correct if necessary.
(up to diagnosis not plausible - check wire for short circuit to battery,
version 4) repair or replace if necessary.
- check oil level sensor, replace if
necessary. nominal value: 20...25
Ohm
- perform functional check.

ID: 506 0 en 2009-01-15
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Engine fault codes

codes codes
SAE PLD-MR
J1939 ***
SPN/FMI
****
98/4 02515 oil level sensor measuring - check oil level, correct if necessary.
** range exceeded - check wire for short circuit to ground,
repair or replace if necessary.
Ohm
98/3 02516 oil level sensor measured value - check oil level, correct if necessary.
** not plausible - check wire for short circuit to ground,
Ohm
98/5 02509 oil level sensor open circuit fault - check oil level sensor , replace if
** necessary.
- check wire for open circuit fault, repair
or replace if necessary.
100/2 11617 oil pressure signal not - check oil level, correct if necessary.
sensor plausible - check wire for open circuit fault, repair
- check oil pressure sensor, replace if
necessary.
100/3 11615 oil pressure measuring - check oil pressure sensor, replace if
sensor range exceeded necessary.
- check wire for open circuit fault or if
shortened to batteryvoltage, repair if
necessary.
100/4 11616 oil pressure remains under - check oil pressure sensor, replace if
sensor measuring necessary.
range - check wire for short circuit to ground,
repair if necessary.
100/14 02020 engine oil pressure too low - message via CAN: oil pressure
circulation ** advance warning or warning

ID: 506 0 en 2009-01-15
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Engine fault codes

codes codes
SAE PLD-MR
J1939 ***
SPN/FMI
****
102/0 11820 booster path * boost pressure - if fault codes 11415 or11417 are also
too high present, process them first.
- boost pressure system (boost air
tubes, boost air cooler) visual check.
102/1 11818 booster path * booster path - check tubes and connections between
defective turbocharger, boost air cooler and the
boost air tubes for leakage.
- check boost air cooler.
102/2 11417 boost pressure measured value - check wire for open circuit fault, repair
sensor not plausible if necessary.
- check boost pressure sensor, replace
if necessary.
- if fault code 01315 or 01316 also
actual: replace and calibrate ECU
engine control (e.g. MR-PLD).
102/3 11415 boost pressure measuring - check boost pressure, replace if
- check wire for open circuit fault and if
shorted to battery voltage, repair if
necessary.
102/4 11416 boost pressure remains under - unplug the connector from
sensor measuring combination sensor. fault codes
range 01215 and 11415 actual: replace
combination sensor.
- check wire for short circuit to ground,
102/13 11873 booster path / max. output of
boost pressure booster speed
control ** balancing
governor
102/13 11874ord booster path / set value (with power reduction)
er 01874 boost pressure deviation too - check booster path fault codes
control high 11874* , 01874**
102/13 11875 booster path / boost pressure
boost pressure deviation too
control * high

ID: 506 0 en 2009-01-15
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Engine fault codes

codes codes
SAE PLD-MR
J1939 ***
SPN/FMI
****
102/13 11876 booster path / braking power
boost pressure too low
control *
102/13 12415 scavenging (boost - check sensor, replace if necessary.
gradient sensor pressure ) - check wire for open circuit
(P2S-P3) ** measuring
range exceeded
102/13 12416 scavenging (boost - check sensor, replace if necessary.
gradient sensor pressure ) - check wire for open circuit
(P2S-P3) ** remains under
measuring
range
103/7 12612 no speed no engine
booster 1 ** speed
103/14 12712 no speed no engine
booster 2 ** speed
105/0 01822 booster path ** temperature to - temperature of boost pressure too
high high
105/3 11215 boost measuring - check temperature sensor, replace if
temperature range exceeded necessary.
sensor - nominal value: 2.4 k Ohm
(corresponds to 215C)
- check wire if connected to battery
voltage and if open circuit fault, repair
if necessary.
105/4 11216 boost remains under - check temperature sensor, replace if
temperature measuring necessary.
sensor range - nominal value: 2.4 kOhm
110/0 02122 coolant temperature too
temperature high
sensor *

ID: 506 0 en 2009-01-15
MERCEDES BENZ
Engine fault codes

codes codes
SAE PLD-MR
J1939 ***
SPN/FMI
****
110/3 11515 coolant measuring - check sensor, repair or replace if
temperature range exceeded necessary.
sensor - nominal value: 2.4 kOhm
- check wire for open circuit fault or if
shortened to battery voltage, repair if
necessary.
110/4 11516 coolant remains under - check sensor, repair or replace if
temperature measuring necessary.
sensor range - nominal value: 2.4 kOhm
- check wire for open circuit fault, repair
158/2 12219 terminal 15 inconsistency - check fuse, replace if necessary.
detection * MR<->FR - check wires and plug connectors for
terminal 15 open circuit fault, repair or replace if
necessary.
158/2 12319 terminal 50 inconsistency - check wires and plug connectors for
detection * MR<->FR open circuit fault, repair if necessary.
terminal 50 - check wires and plug connectors for
open circuit fault, repair if necessary.
168/3 07542 terminal 30, nominal range - 24 V-Mode: 30 V, 12 V-Mode: 16 V
battery voltage exceeded - alternator or governer defect
168/4 07543 terminal 30, remains below - 24 V-Mode: 22 V, 12 V-Mode: 10 V
battery voltage nominal range - battery defect
- alternator, governor or fuse defect
174/3 11115 fuel temperature measuring - check wire, repair or replace if
- nominal value: 2.4 kOhm
(corresponds to 215C).
- check wire if shortened to battery
voltage and if open circuit fault, repair
if necessary.

ID: 506 0 en 2009-01-15
MERCEDES BENZ
Engine fault codes

codes codes
SAE PLD-MR
J1939 ***
SPN/FMI
****
174/4 11116 fuel temperature remains under - check sensor, repair or replace if
sensor measuring necessary.
range - nominal value: 2.4 kOhm
175/3 01015 oil temperature measuring - check oil temperature sensor and
sensor range exceeded replace if necessary.
- nominal value: 2.4 kOhm
- check wire for ground short, repair if
necessary.
175/4 01016 oil temperature remains under - check oil temperature sensor B11 and
sensor measuring replace if necessary.
range - nominal value: 2.4 kOhm
- check wire for ground short, repair if
necessary.
190/0 10530 engine speed engine speed - inform about authorized engine speed
too high - delete fault memory
609/11 04056 internal fault * backup control - check all affected connectors, plug
defective* connections and electrical
components for damage, loose
contact, corrosion etc. and repair if
necessary.
- if fault code is still present, renew and
program control unit.
609/12 01315 ambient measuring - if fault codes 11415 or 11416 are
pressure sensor range exceeded present, remove them first.
- fault code 01315 remains present:
read out actual values 014 and 015
and compare with each other.
- actual value should be inside
tolerance band (+/- 10%) while engine
stops.

ID: 506 0 en 2009-01-15
MERCEDES BENZ
Engine fault codes

codes codes
SAE PLD-MR
J1939 ***
SPN/FMI
****
609/12 01316 ambient remains under - if fault codes 11415 or 11416 are
pressure sensor measuring present, remove them first.
range - fault code 01316 remains present:
read out actual values 014 and 015
and compare with each other.
- actual value inside tolerance band (+/-
10%) while engine stops: replace and
program ECU engine control (e.g. MR-
PLD).
609/12 04024 internal fault auxiliary - check all affected connectors, plug
controller connections and electrical
defective components for damage, loose
necessary.
609/12 14034D) internal fault ** HS-transistor - Change control unit
PVB1 high-
resistance
Highside-
Transistor
609/12 14035D) internal fault ** HS-transistor - Change control unit **
PVB2 high-
resistance
609/12 14036D) internal fault HS-transistor - Change control unit **
PV5 high-
resistance
609/12 04038 internal fault * high resistance present, remove this fault code first.
starter driver - check all affected connectors, plug
(redundant-/ connections and electrical
auxiliary path) components for damage, loose
necessary.
609/12 14038 internal fault ** starter driver - check all affected plugs, plug
high-resistance connectors and electrical components
(main path) for damage, loose contact, corrosion
etc. and repair if necessary.

ID: 506 0 en 2009-01-15
MERCEDES BENZ
Engine fault codes

codes codes
SAE PLD-MR
J1939 ***
SPN/FMI
****
609/12 14039 internal fault * 14039 starter - check all affected plugs, plug
driver low- connectors and electrical components
resistance for damage, loose contact, corrosion
(main path or etc. and repair if necessary.
auxiliary path) - perform functional check.
609/12 04040 internal fault level detection - check all affected plugs, plug
starter defec- connectors and electrical components
tive for damage, loose contact, corrosion
- perform functional.
609/12 14041 internal fault (till PV- Highside- - check all affected plugs, plug
diagnosis transistor connectors and electrical components
version 4) defective for damage, loose contact, corrosion
609/12 14054 internal fault CAN-data area - check all affected plugs, plug
defective connectors and electrical components
for damage, loose contact, corrosion
- if fault code is still present, replace and
609/12 18039 internal fault ** Starter output Main branch: During the controller
stage with low initialization the two transistors of the
impedance main branch are alternating switched on
(main branch or briefly. The level at the starter output
branch of changes thereby on "High", the main
emergency) or branch is classified as low impedance.
load (relay) also Backup branch: If that changes for
to high clamp 50 signal on "High" and follows
resistance and/ this level change a change of the level
or to high at the starter output before the starter
inductance. output stage was activated, the backup
branch is classified as low impedance.
609/14 04037 internal fault cylinder number - check all affected connectors, plug
implausible connections and electrical
necessary.

ID: 506 0 en 2009-01-15
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Engine fault codes

codes codes
SAE PLD-MR
J1939 ***
SPN/FMI
****
609/14 04047 internal fault characteristic - check all affected connectors, plug
data map de- connections and electrical
fective components for damage, loose
necessary.
609/14 04048 internal fault cylinder number - check all affected connectors, plug
implausible connections and electrical
necessary.
609/14 14049 internal fault ** parametrization - check all affected plugs, plug
fault connectors and electrical components
for damage, loose contact, corrosion
609/14 04050 internal fault incorrect - check all affected connectors, plug
hardware connections and electrical
detection components for damage, loose
necessary.
609/14 04051 internal fault EEPROM: - check all affected connectors, plug
Checksum connections and electrical
failure1 components for damage, loose
(memory fault) contact, corrosion etc. and repair if
necessary.
609/14 14052 internal fault EEPROM: CKS- - check all affected plugs, plug
fault 2 (groups connectors and electrical components
vehicle for damage, loose contact, corrosion
parameters) etc. and repair if necessary.
- if fault code is still present, replace and

ID: 506 0 en 2009-01-15
MERCEDES BENZ
Engine fault codes

codes codes
SAE PLD-MR
J1939 ***
SPN/FMI
****
609/14 24053 internal fault ** EEPROM: - check all affected connectors, plug
Checksum- fault connections and electric components
3 (block for damage, loose contact, corrosion
production or etc., and repair if necessary.
immobilizer). - if fault code still present, renew and
calibrate control unit.
611/4 06506 oil separator * short circuit to
ground
diagnostic line.
611/12 06564 oil separator * oil separator
defective
625/2 10102 CAN connection CAN data not - work off actual faults of SG FRE apart
plausible from CAN data bus fault codes 10201,
00202 and 10203.
625/2 10104 CAN connection no connection to - check CAN connection to SG FRE.
CAN - check cables, connectors, plug
connectors and electrical components
for damage, correct connection, loose
contact and corrosion, repair if
necessary.
- remove engine CAN bus fault in the
SG FRE.
- perform functional check
- communication with the ECU engine
control (e.g. MR-PLD) restored: check
calibration of ECU engine control (e.g.
MR-PLD) for one wire capability.
625/14 10100 CAN connection CAN-High - check for open circuit fault, repair or
defective replace if necessary.
- switch on ignition.
- delete fault memory in ECU engine
control (e.g. MR-PLD).
- delete fault memory in SG FRE.
625/14 10101 CAN connection CAN-Low - check wire for open circuit fault, repair
defective of replace if necessary.
- switch on ignition.
- delete fault memory in ECU engine
- delete fault memory in SG FRE.
- perform functional.

ID: 506 0 en 2009-01-15
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Engine fault codes

codes codes
SAE PLD-MR
J1939 ***
SPN/FMI
****
625/14 10149 CAN connection parameter fault - check parameters and
CAN - perform functional check.
636/1 10310 crankshaft crankshaft level - pull out position sensor while engine is
position sensor too low stopped and perform visual check.
- remove metal pieces/shavings if
necessary.
- replace position sensor in the case of
mechanical damage (clear stress
marks).
- replace clamping sleeve of the
position sensor if necessary.
- press-in speed (position) sensor
during engine standstill until
mechanical limit stop.
636/3 10309 crankshaft crankshaft - check wire and position sensor for
position sensor open open circuit fault, replace if necessary.
circuit fault - nominal value 1.2 kOhm.
636/4 10308 crankshaft crankshaft - check wire and position sensor for
position sensor ground ground short, replace if necessary.
- nominal value 1.2 kOhm.
636/7 10311 crankshaft crankshaft/ - pull out position sensor during engine
position sensor camshaft signal standstill and perform visual check.
assignment not - replace position sensor in the case of
plausible mechanical damage (clear stress
marks).
- check crankshaft- and camshaft
position sensor for tight fitting, replace
clamping sleeve if necessary.
- check wires at plug connection for
damage, correct connection and
corrosion, repair if necessary.
- check crankshaft- and camshaft
position sensor at plug for
interchanging.

ID: 506 0 en 2009-01-15
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Engine fault codes

codes codes
SAE PLD-MR
J1939 ***
SPN/FMI
****
636/8 10312 crankshaft crankshaft - press in speed (position) sensor
position timeout - during engine standstill until
nocrankshaft mechanical limit stop.
signal Timeout - fault code 10309 actual: work off this
fault code.
- fault code 10312 actual: check
crankshaft position sensor, replace if
necessary.
- nominal value 1.2 kOhm
636/14 10313 crankshaft crankshaft - connect the position sensor correctly.
position sensor wrong - perform functional check.
polarity
651/3 24805 control solenoid shortened to - shortened to battery voltageHighside
valve ** battery bank 1
voltageHighside
bank 1
651/3 24905 control solenoid shortened to - switch off solenoid valves bank 2
valve ** battery
voltageHighside
bank 2
651/4 24806 control solenoid ground short - switch off solenoid valves bank 1
valve ** Low side bank 1
651/4 24906 control solenoid ground short - switch off solenoid valves bank 2
valve ** Lowside bank 2
651/5 15027 control failure control cylinder important note:
injector-/ 1 disturbed - upon removing mechanical or
solenoid valve electrical faults at the injector valves,
the engine-smoothness control has to
be set to zero.
651/6 25028 solenoid valve short circuit important note:
cylinder 1 ** injector solenoid - upon removing mechanical or
valve cylinder 1 electrical faults at the injector valves,
the engine smoothness control has to
be set to zero.
651/7 15026 contact no contact important note:
recognition cylinder 1 - upon removing mechanical or
injector-/ electrical faults at the injector valves,
solenoid valve the engine smoothness control has to
be set to zero.
651/12 09044 engine- LRR-limitation important note:
smoothness cylinder 1 - upon removing mechanical or
cylinder 1 electrical faults at the injector valves,
be set to zero.

ID: 506 0 en 2009-01-15
MERCEDES BENZ
Engine fault codes

codes codes
SAE PLD-MR
J1939 ***
SPN/FMI
****
651/14 09045 individual EZA-limitation important note:
cylinder cylinder 1 - upon removing mechanical or
adaption electrical faults at the injector valves,
be set to zero
652/5 15127 injector-/ control cylinder - upon removing mechanical or
solenoid valve 2 disturbed / electrical faults at the injector valves,
cylinder 2 failure the engine-smoothness control has to
be set to zero.
- the engine-smoothness control can be
set to zero in the menu "controls" at the
menu level "check engine-
smoothness control".
652/6 25128 solenoid valve short circuit - check electrical screw connections of
cylinder 2 ** injector-/ the affected injector valve for short
solenoid valve circuit.
cylinder 2 - disconnect electrical screw
connections of the affected injector
valve.
652/7 15126 contact no contact - upon removing mechanical or
recognition cylinder 2 electrical faults at the injector valves,
injector-/ the engine-smoothness control has to
solenoid valve be set to zero.
cylinder 2 - the engine-smoothness control can be
set to zero in the menu "controls" at the
menu level "check engine-
smoothness control".
652/12 09144 injector-/ engine- important note:
solenoid valve smoothness - upon removing mechanical or
cylinder 2 control: LRR- electrical faults at the injector valves,
limitation the engine smoothness control has to
cylinder be set to zero.
652/14 09145 injector-/ individual important note:
solenoid valve cylinder - upon removing mechanical or
cylinder adaptation: electrical faults at the injector valves,
EZA-limitation the engine smoothness control has to
653/5 15227 injector-/ control cylinder important note:
solenoid valve 3 disturbed / - upon removing mechanical or
cylinder 3 failure electrical faults at the injector valves,
the engine-smoothness control has to
be set to zero.

ID: 506 0 en 2009-01-15
MERCEDES BENZ
Engine fault codes

codes codes
SAE PLD-MR
J1939 ***
SPN/FMI
****
653/6 25228 injector-/ short circuit - check electrical screw connections of
solenoid valve injector-/ the affected injector valve for short
cylinder 3 ** solenoid valve circuit.
valve.
653/7 15226 injector-/ contact important note:
solenoid valve recognition - upon removing mechanical or
cylinder 3 injector-/ electrical faults at the injector valves,
solenoid valve: the engine smoothness control has to
no contact be set to zero.
cylinder 3
solenoid valve: smoothness - upon removing mechanical or
solenoid valve: cylinder - upon removing mechanical or
cylinder 3 adaptation: electrical faults at the injector valves,
cylinder 3 be set to zero.
654/5 15327 control failure contact important note:
injector-/ recognition - upon removing mechanical or
solenoid valve injector-/ electrical faults at the injector valves,
cylinder 4
valve.
cylinder 4

ID: 506 0 en 2009-01-15
MERCEDES BENZ
Engine fault codes

codes codes
SAE PLD-MR
J1939 ***
SPN/FMI
****
cylinder 4 adaption: EZA- electrical faults at the injector valves,
cylinder 5
valve.
cylinder 5
656/5 15527 injector-/ control failure important note:
solenoid valve injector-/ - upon removing mechanical or
cylinder 6 solenoid valve: electrical faults at the injector valves,
control cylinder the engine smoothness control has to
6 disturbed be set to zero.
valve.

ID: 506 0 en 2009-01-15
MERCEDES BENZ
Engine fault codes

codes codes
SAE PLD-MR
J1939 ***
SPN/FMI
****
cylinder 6
cylinder 6 adaption: EZA- electrical faults at the injector valves,
cylinder 7 solenoid valve electrical faults at the injector valves,
be set to zero.
valve.
cylinder 7

ID: 506 0 en 2009-01-15
MERCEDES BENZ
Engine fault codes

codes codes
SAE PLD-MR
J1939 ***
SPN/FMI
****
cylinder 8 solenoid valve: electrical faults at the injector valves,
control cylinder the engine smoothness control has to
8 disturbed be set to zero.
valve.
cylinder 8
677/3 18005 starter control starter relay - check wire - terminal 50 input of starter
(PLD-MR) ** external current relay if shortened to battery voltage,
supply repair or replace if necessary.
- check starter relay, replace if
necessary.
- restore electrical connection(s)
677/5 18009 starter control starter relay - check of starter relay if shortened to
(PLD-MR) ** external current battery voltage, repair or replace if
supply necessary.
necessary.
- restore electrical connection(s)
677/6 18008 starter control short circuit to - check wire - terminal 50 input of the
(PLD-MR) ** ground starter relay for short circuit to ground,
necessary.

ID: 506 0 en 2009-01-15
MERCEDES BENZ
Engine fault codes

codes codes
SAE PLD-MR
J1939 ***
SPN/FMI
****
677/7 18086 starter control starter does not - check starter electrically and
(PLD-MR) ** engage mechanically.
677/14 18033 starter control starter relay - check starter relay, replace if
Starter relay is fixed in closed necessary.
(PLD-MR) ** position - perform functional
697/3 17007D) proportional shortened to - set output off
valve (MBR-BK) battery voltage
(-lead)
17705 proportional shortened to - set output off 1 2 3 4
valve bank battery voltage
1PVB (+lead)*
697/4 17708 proportional short circuit to - set output off 1 2 3 4
valve bank 1 ground
(PVB 1) (+lead)**
697/5 17009 proportional open circuit - check parametrization.
valve 1 (MBR- fault** ECU - parameter 06 has to be set to NOT
BK) engine control ACTIVE
(e.g. MR-PLD)
- if not, then the data set of ECU engine
wrong
control (e.g. MR-PLD) is wrong
calibration.
- replace and program ECU engine
697/6 17006 proportional short circuit to - check parametrization.
valve 1 (MBR- ground (-lead) - parameter 06 has to be set to NOT
BK) ECU engine ACTIVE
control (e.g.
- if not, then the data set of ECU engine
MR-PLD) wrong
control (e.g. MR-PLD) is wrong
calibration.
698/3 17305C) proportional shortened to - set output off
17307D) valve 2 (MBR- battery voltage
KD) (-lead) High
Side
698/5 17317C) proportional open circuit fault - set output off
17309D) valve 2 (MBR- Low Side
KD)

ID: 506 0 en 2009-01-15
MERCEDES BENZ
Engine fault codes

codes codes
SAE PLD-MR
J1939 ***
SPN/FMI
****
698/6 17306 proportional short circuit to - check calibration, correct if necessary.
valve 2 ground (-lead) Parameter 007 has to be set to NOT
Activation: High Side wrong ACTIVE.
engine brake calibration - if not, then the data set of the control
reecompression unit MR is wrong.
valve (MBR-KD)
699/3 17107D) proportional shortened to - set output off
valve 3 battery voltage
(-lead)*
699/5 17109 proportional open circuit fault - check calibration, correct if necessary.
valve 3 wrong Parameter 008 has to be set to NOT
calibration ACTIVE.
note:
- if a Linig-fan is installed, the following
calibration applies:
a) parameters 8 and 9 have to be set
to ACTIVE.
b) parameter 14 has to be set to "Type
0".
699/6 17106 proportional short circuit to - check calibration, correct if necessary.
valve 3 ground (-lead) Parameter 008 has to be set to NOT
ECU engine ACTIVE.
control (e.g. - if the calibration is OK, check wire for
MR-PLD) wrong short circuit to ground, repair or
calibration / replace if necessary.
short circuit to
- if still no fault can be detected, replace
ground
and program ECU engine control (e.g.
MR-PLD).
700/3 17207** proportional shortened to - set output off
(-lead)*

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Engine fault codes

codes codes
SAE PLD-MR
J1939 ***
SPN/FMI
****
700/5 17209 proportional open circuit fault note: ECU engine control (e.g. MR-PLD)
valve 4 wrong calibration / open circuit fault
- check calibration, correct if necessary.
Parameter 009 has to be set to NOT
ACTIVE.
note:
- if a Linnig-fan is installed, the following
calibration applies:
a) parameters 8 and 9 have to be set
to ACTIVE
b) parameter 14 has to be set to "Type
0".
- fault code17209 remains actual: check
wires for open circuit fault, repair or
replace if necessary.
- if no fault can be detected, replace and
program ECU engine control (e.g. MR-
PLD)
- set output off
700/6 17206 proportional short circuit to note: ECU engine control (e.g. MR-PLD)
valve 4 ground (-lead) wrong calibration / short circuit to ground
ACTIVE.
ACTIVE. if the calibration is OK, check
wire for short circuit to ground, repair
- if still no fault can be detected, replace
and program ECU engine control (e.g.
MR-PLD).
705/3 17405 proportional shortened to - set output off
(+lead)*
705/4 17408 proportional short circuit to - set output off for valve 6 and 5.
valve 5 ground (+lead)*
705/11 17805 proportional shortened to - set output off for valve 6 and 5.
valve bank 2 battery voltage
PVB 2 (+lead)*

ID: 506 0 en 2009-01-15
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Engine fault codes

codes codes
SAE PLD-MR
J1939 ***
SPN/FMI
****
705/11 17808 proportional short circuit to - set output off for valve 6 and 5.
valve bank 2 ground (+lead)*
PVB 2
706/3 17609 proportional open circuit fault - set output off for valve 6
valve 6 *
723/3 10409 camshaft camshaft - check wire for open circuit, replace if
position sensor open necessary.
circuit fault - nominal value: 1.2 kOhm
723/4 10408 camshaft camshaft - check wire and position sensor for
position sensor sensor ground ground short, replace if necessary.
short - nominal value: 1.2 kOhm necessary.
723/8 10412 camshaft camshaft time- - if fault codes 10408 and 10409 are
position sensor out (no cam current, remove them first
shaft signal) - pull out position sensor during engine
Timeout standstill and perform visual check
- remove metal pieces/shavings if
necessary.
- replace position sensor in the case of
mechanical damage (clear stress
marks).
- press in speed (position) sensor
during engine standstill until
mechanical limit stop.
723/14 10413 camshaft camshaft - position sensor correctly with pin of the
position sensor wrong ECU engine control (e.g. MR-PLD)
polarity Sensor - perform functional check.
verpolt
986/8 17112 fan speed no signal currently not fan speed detection
(timeout) installed.
Timeout - check calibration, correct if necessary.
Parameter 14 has to be set to "Type
0".
* diagnosis version 5 D)=only for the D-Model of PLD-MR control units (diagnosis version 6)
** diagnosis version 6 and newer
*** Minidiag 2 Diagnostic unit
**** Driving panel master gauge (P1)

ID: 506 0 en 2009-01-15
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Engine fault codes
2. FAULT CODES OF VEHICLE CONTROL (ADM2) VIA SAE J1939 ID: 28134
ADM2 ADM2 Description Remedial action Pin

fault fault
codes codes (k-
(J1939) line) ***
SPN/FMI
****
45/3 10003 decom- open circuit - check wiring 15/10
pression valve - check solenoid valve
MBR_KD
45/4 10004 decom- shorted to - check wiring 15/10
pression valve ground - check solenoid valve
MBR_KD
84/3 10103 vehicle speed open circuit - check wiring 15/03
signal C3 - check parameter 08/01
84/4 10104 vehicle speed shorted to - check wiring 15/03
signal C3 ground
84/14 10114 vehicle speed value not - check parameter 08/01 15/03
signal C3 plausible
91/0 10200 analog accelerator - restart accelerator pedal 21/11
accelerator pedal not adjustment routine
pedal adjusted - check wiring
- Limit value idle operation
position: 5,0 V
- Limit value kick down
position: 4,9 V
91/2 10202 analog voltage not - Pedal unit exchange, if
accelerator plausible defective
pedal - check wiring
position: 5,0 V
- Limit value kickdown
position: 4,9 V
91/3 10203 analog voltage too high - Pedal unit exchange, if 21/11
accelerator or shorted to defective
pedal battery voltage - check wiring
position: 5,0 V
position: 4,9 V
91/4 10204 analog voltage too low - Pedal unit exchange, if 21/11
accelerator or shorted to defective
pedal AFPS ground - check wiring
position: 5,0 V
position: 4,9 V

ID: 506 0 en 2009-01-15
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Engine fault codes

fault fault
codes codes (k-
(J1939) line) ***
SPN/FMI
****
98/0 10400 oil level oil level to high - Oil discharge with to PLD-MR
strong overstocking.
- remark: This problem can
occur also if in PLD-MR
the false type of oil pan
were programmed.
98/1 10401 oil level low oil level - refill oil PLD-MR
98/14 10414 oil level oil level too low - refill oil PLD-MR
- remark: This problem can
occur also if in PLD-MR
the false type of oil pan
were programmed.
100/1 10501 oil pressure low oil pressure - check oil pump and oil PLD-MR
sensor circuit
100/14 10514 oil pressure oil pressure too - check oil pump and oil PLD-MR
sensor low circuit.
107/0 10800 air filter sensor air pressure too - check wiring. 15/08
high
107/3 10803 air filter sensor open circuit - check wiring. 15/08
107/4 10804 air filter sensor shorted to - check wiring. 15/08
ground
110/0 10900 coolant high coolant - cooling-water level and PLD-MR
temperature temperature cooling circuit check.
110/14 10914 coolant coolant - cooling-water level and PLD-MR
temperature temperature too cooling circuit check.
high
111/1 11001 coolant level low coolant level - refill coolant 15/07
- check wiring
111/3 11003 coolant level open circuit - check wiring 15/07
- Voltage must be larger
than 2,0 V.
111/4 11004 coolant level shorted to - check wiring. 15/07
ground
158/0 11100 terminal 15 over voltage - check battery voltage 21/02
(ignition) - check parameter 2/08
(24V/12V selection)
158/1 11101 terminal 15 under voltage - check battery voltage 21/02
(ignition) - check parameter 2/08
(24V/12V selection)

ID: 506 0 en 2009-01-15
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Engine fault codes

fault fault
codes codes (k-
(J1939) line) ***
SPN/FMI
****
558/1 11701 idle switch Wiring idle - check wiring 21/12 and
(analog pedal) validation switch - Pedal unit exchange, if 21/13 or
GAS1 and defective 21/14
GAS2 twisted or
open circuit at
potentiometer
ground FP-
558/5 11705 idle switch both switches - check wiring 21/12 and
(analog pedal) open circuit - Pedal unit exchange, if 21/13
(GAS2 + GAS1 defective
open)
558/12 11712 idle switch both switches - check wiring 21/12 and
(analog pedal) closed (GAS2 + - Pedal unit exchange, if 21/13
GAS1 closed) defective
599/12 11812 cruise control both switches - check wiring 18/04 and
switch CC+ and closed - check cruise control 18/05
CC- switch
601/12 11912 cruise control both switches - check wiring 18/04 and
switch CC+ and closed - check cruise control 18/05
CC- switch
620/3 12103 power supply voltage too high - supply voltage > 5,2 V. 21/09
analog pedal
(AFP+)
620/4 12104 power supply voltage too low - supply voltage < 4,8 V. 21/09
analog pedal
(AFP+)
625/2 12202 CAN link ADM2 no - check wiring (engine CAN)
- MR communication - check configuration:
with MR
MR parameter (../..) and
ADM2 parameter 1/01
to be set to equal
functionality (0ne wire
capability)
625/14 12214 CAN link ADM2 one wire mode - check wiring (engine CAN)
- MR - check configuration:
MR parameter (../..) and

ADM2 parameter 1/01
to be set to equal
functionality (0ne wire
capability)
629/12 12312 ADM2 internal error

ID: 506 0 en 2009-01-15
MERCEDES BENZ
Engine fault codes

fault fault
codes codes (k-
(J1939) line) ***
SPN/FMI
****
677/5 13305 output relay 1 open circuit - check wiring 15/12
- check relay 1
677/6 13306 output relay 1 shorted to - check wiring 15/12
ground - check relay 1
730/0 13900 output relay 2 grid heater: no - check wiring 15/09
increasing boost - check relay 2
temperature
- check grid heater
after activation
730/1 13901 output relay 2 grid heater: - check wiring 15/09
relay - check relay 2
permanently
closed
730/2 13902 output relay 2 grid heater: - check wiring 15/09
relay - check relay 2
permanently
closed
730/3 13903 output relay 2 voltage too high - check wiring 15/09
or shorted to
battery voltage
730/4 13904 output relay 2 voltage too low - check wiring 15/09
or shorted to - check relay 2
ground
974/2 14202 remote pedal supply voltage - limit values for the supply 18/17
HFG out of range voltage of the HFG:
Minimum value: 4,8 V and

maximum value: 5,2 V.
974/3 14203 remote pedal voltage too high - check wiring 18/18
HFG or shorted to - check remote pedal
battery voltage
974/4 14204 remote pedal voltage too low - check wiring 18/18
HFG or shorted to - check remote pedal
ground
1004/3 14403 output relay 4 open circuit - check wiring 18/01
- check relay 4
1004/4 14404 output relay 4 shorted to - check wiring 18/01
ground - check relay 4
1005/3 14503 output PWM open circuit - check wiring. 15/05
pedalsupply or
transmission
1005/4 14504 output PWM shorted to - check wiring. 15/05
pedalsupply or ground
transmission

ID: 506 0 en 2009-01-15
MERCEDES BENZ
Engine fault codes

fault fault
codes codes (k-
(J1939) line) ***
SPN/FMI
****
1006/3 14603 exhaust brake open circuit - check wiring 15/06
valve MBR_BK - check exhaust brake valve
1006/4 14604 exhaust brake shorted to - check wiring 15/06
valve MBR_BK ground - check exhaust brake valve
639/2 14902 J1939 CAN- CAN identifiers - PGN ETC1 was received
interface ETC#1 or only once and did not
ACC#1 missing disappear.
1015/1 15001 PWM no supply - check wiring 15/05
accelerator voltage
pedal
1015/2 15002 PWM both signals - check wiring
accelerator missing (GAS1 - Pins 21/13, 21/12, 15/05 ,
pedal and GAS2) 21/14.
1015/3 15003 PWM signal GAS2, - check wiring
accelerator not available - Pins 21/13, 15/05 , 21/14.
pedal
1015/4 15004 PWM signal GAS1, - check wiring
accelerator not available - Pins 21/12, 15/05 , 21/14.
pedal
1015/5 15005 PWM accelerator - restart accelerator pedal
accelerator pedal not adjustment routine
pedal adjusted
1015/6 15006 PWM idle position out - restart accelerator pedal
accelerator of adjusted adjustment routine
pedal range
1015/7 15007 PWM accelerator - restart accelerator pedal
accelerator pedal out of adjustment routine
pedal adjusted range
* diagnosis version 5 D)=only for the D-Model of PLD-MR control units (diagnosis version 6)
** diagnosis version 6 and newer
*** Minidiag 2 Diagnostic unit
**** Driving panel master gauge (P1)

ID: 506 0 en 2009-01-15
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Original instructions

DRILL CARRIER TC7-TC12, NC7 SERIES

1. SAFETY PRECAUTIONS .............................................................................................................. 7

2. MAIN COMPONENTS .................................................................................................................... 8

3. DIESEL ENGINE ............................................................................................................................ 19

4. HYDRODYNAMIC AND MECHANICAL TRANSMISSION ........................................................... 40

Copyright © Sandvik Mining and Construction 3 (84)

6. SAFETY DURING MAINTENANCE OPERATIONS ...................................................................... 54

7. WEAR LIMIT .................................................................................................................................. 57

8. FIELD REPAIRS ............................................................................................................................ 58

9. LUBRICANT RECOMMENDATIONS ............................................................................................ 63

10. LUBRICATION ............................................................................................................................... 68

4 (84) Copyright © Sandvik Mining and Construction

11. FILLING CAPACITIES ................................................................................................................... 81

12. LUBRICATION SAFETY AND OTHER PRECAUTIONS .............................................................. 83

Copyright © Sandvik Mining and Construction 5 (84)

Operating, service and adjustment procedures must be carried

HIGH PRESSURE INJECTION HAZARD!

WARNING! PERSONAL INJURY HAZARD!

Copyright © Sandvik Mining and Construction 7 (84)

1 Diesel engine 2 Transmission

8 (84) Copyright © Sandvik Mining and Construction

1 Diesel engine 2 Transmission

Copyright © Sandvik Mining and Construction 9 (84)

1 Diesel engine 2 Transmission

10 (84) Copyright © Sandvik Mining and Construction

1 Diesel engine 2 Transmission

Copyright © Sandvik Mining and Construction 11 (84)

1 Diesel engine 2 Transmission

12 (84) Copyright © Sandvik Mining and Construction

2.1. Diesel engine (MB 904 LA)

Copyright © Sandvik Mining and Construction 13 (84)

2.2. Diesel engine (MB 906 LA)

14 (84) Copyright © Sandvik Mining and Construction

2.3. Transmission (T20000)

1 Gear pump for steering

2.4. Transmission (HR32000)

1 Transmission oil filling cap

Copyright © Sandvik Mining and Construction 15 (84)

Carrier TC 7-8 / NC 7 -series

2.6. Front axles

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

1 Planetary gear units

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

1 Planetary gear units

16 (84) Copyright © Sandvik Mining and Construction

2.7. Rear axles

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

1 Planetary gear units

Carrier TC 9-12 (axle 213)

1 Planetary gear units

Copyright © Sandvik Mining and Construction 17 (84)

2.8. Oscillation (rear)

1 The rear axle oscillation allows the carrier

18 (84) Copyright © Sandvik Mining and Construction

3.1. Periodic maintenance

3.1.1. Cleaning the coarse filter

The service life of the disposable paper cartridge

Copyright © Sandvik Mining and Construction 19 (84)

3.1.2. Checking the fuel level

Read the fuel level from the fuel gauge (P2). An

Figure: Vehicle refuelling

20 (84) Copyright © Sandvik Mining and Construction

3.1.3. Emptying the fuel water separator