CHAPTER 2

MAINTENANCE

JET-16

Original manual
 BLANK PAGE

2-0-02 Updated : 01.28 – 2015

 0-TABLE OF CONTENTS

0- TABLE OF CONTENTS .........................................................................................................................3

1- MAINTENANCE......................................................................................................................................1
1-1- INSTRUCTIONS FOR CLEANING ..................................................................................................1
1-2- MAINTENANCE TABLES ................................................................................................................2
1-2-1- COMMISSIONING – 1ST WEEK ..............................................................................................3
1-2-2- COMMISSIONING - 50H ..........................................................................................................4
1-2-3- COMMISSIONING - 100H ........................................................................................................4
1-2-4- DAILY CHECKS ON VEHICLE CONDITION ...........................................................................5
1-2-5- 500 H CHECK ...........................................................................................................................6
VEHICLE MAINTENANCE ..................................................................................................................6
1-2-6- 1000 HRS OR 1 YEAR CHECK (whichever occurs first) - VEHICLE MAINTENANCE ...........7
1-2-7- 2000 HRS OR 2 YEAR CHECK (whichever occurs first) - VEHICLE MAINTENANCE ...........8
1-2-8- 3000 HRS OR 4 YEAR CHECK (whichever occurs first) - VEHICLE MAINTENANCE ...........8
1-2-9- 14,000 HRS OR 7 YEAR CHECK (whichever occurs first) - VEHICLE MAINTENANCE ........9
1-2-10- INSPECTION EVERY 10 YEARS - VEHICLE MAINTENANCE ............................................9
1-2-11- WHEELS ...............................................................................................................................10
1-3- MAINTENANCE OPERATIONS ....................................................................................................11
1-3-1- MAINTENANCE WORK WITH VEHICLE IN RAISED POSITION (WORKING BENEATH
VEHICLE) ..........................................................................................................................................11
1-3-2- BRAKING SYSTEM ................................................................................................................12
1-3-3- GREASES, LUBRICATION AND OTHER LIQUIDS ..............................................................13
1-3-4- OIL QUALITY ..........................................................................................................................13
1-3-5- LUBRICATION ........................................................................................................................14
1-3-6- LEVELS...................................................................................................................................15
1-3-7- REAR AXLE ............................................................................................................................16
1-4- ELECTRICAL / HYDRAULIC DIAGRAMS ....................................................................................18
1-4-1- ELECTRICAL DIAGRAM ........................................................................................................18
1-4-2- HYDRAULIC DIAGRAM .........................................................................................................18
2- TROUBLESHOOTING ...........................................................................................................................1
2-1- REMOVAL OF THE VEHICLE - TOWING ......................................................................................1
2-1-1- EVACUATING THE VEHICLE ..................................................................................................1
2-2- DIAGNOSTIC...................................................................................................................................2
2-2-1- DIAGNOSTIC TABLES .............................................................................................................2
3- REPAIRS ................................................................................................................................................1
3-1- TIGHTENING TORQUE ..................................................................................................................1
3-1-1- GENERAL .................................................................................................................................1
3-2- REMOUNTING THE ELECTRIC MOTOR .......................................................................................2
3-3- SETTINGS .......................................................................................................................................5
3-3-1- HYDROPNEUMATIC ACCUMULATORS (DEPENDING ON VERSIONS) .............................5
3-3-2- INSTRUCTION FOR THE PRE-LOAD MECHANISM ..............................................................7

Updated : 01.28 – 2015 2-0-03

 BLANK PAGE

2-0-04 Updated : 01.28 – 2015

 1-MAINTENANCE

1-1-INSTRUCTIONS FOR CLEANING

To clean the equipment, clean normally (HIGH PRESSURE JET WASHERS NOT RECOMMENDED)
taking care to protect the electrical components, the manufacturer’s identification plate, back-up
equipment and adhesive labels.
Take care to prevent water entering the air filter and the air vents from the hydraulic reservoir and fuel
tanks.
To clean electrical parts: use an appropriate suction device.
Use appropriate products to clean mechanical parts.
Clean batteries to prevent salt formation and stray currents which could lead to serious damage. Wash the
tops of the batteries without removing the plugs in order to prevent water and contaminants entering the
cells.
Keep the cab clean and tidy in order to prevent potential accidents.

WARNING:
ALWAYS REFER TO THE MANUFACTURER’S INSTRUCTIONS FOR USE WHEN
USING CLEANING PRODUCTS AND WEAR SUITABLE PROTECTIVE CLOTHING.

Updated : 01.28 – 2015 2-1-01

 1-2-MAINTENANCE TABLES
The TLD spare parts department can supply, on request, a list of spare parts recommended for periodic
maintenance. See the information manual for contact details.

If required:

- Change the hydraulic oil and filters after replacing a hydraulic component.
- Change the axle oil after repairing/maintaining them.

REMARK :
WE WOULD ACCEPT A +/- 10% DEVIATION ON MAINTENANCE INTERVAL SCHEDULE
FOR OUR EQUIPMENT.
ANYHOW, FOR EQUIPMENT USED IN HARSH ENVIRONMENT WITH DUST, LOW FUEL
QUALITY, WITH DEMANDING APPLICATIONS AND TOUGH DUTY CYCLES, OR IN
CASES OF USAGE WITH EXTREME WEATHER CONDITIONS, THE MAINTENANCE
INTERVAL MAY HAVE TO BE REDUCED AND ADAPTED.

WARNING:

ANY DAMAGE MUST BE INDICATED TO THE RELEVANT AUTHORITIES.

WARNING:
USERS ARE RESPONSIBLE FOR THEIR OWN MACHINE.
FAILURE TO RETURN IT IN GOOD CONDITION MAY ENDANGER THE NEXT USER.
IT IS THEREFORE IMPORTANT TO RESPECT THE ELEMENTARY RULES.

IMPORTANT:
DURING CHECKS OR INSPECTIONS: IF A LEVEL IF TOO LOW, A PART, A SETTING
OR A MECHANISM IS DEFECTIVE, CARRY OUT THE UPGRADE, REPLACEMENT OR
REPAIR OPERATIONS NECESSARY.

2-1-02 Updated : 01.28 – 2015

 1-2-1-COMMISSIONING – 1ST WEEK
Vehicle number: Hour meter Date: //

Start time End time: INITIALS:

 Checked as OK  Final adjustment  Requires repair

TOOLING /
PROCEDURE
CHECKED? TASKS TO BE CARRIED OUT PARTS REMARKS
REFERENCE
REQUIRED

 Check the visual condition of the vehicle on

delivery (impacts, scratches).
 Check the routing of hydraulic hoses, electrical
cables under the cab and re-secure them if
necessary.

WHEELS
 Check the tightness of the wheels. Chap 2

HYDRAULICS
 Check that there are no leaks present.
 Re-tighten connections if necessary.

MOTOR
 Check the attachments, duct connectors/collars.

TRACTION BATTERY AND ONBOARD

CHARGER (if TLD supply)
 Apply the manufacturer’s inspection plan Chap 5

Updated : 01.28 – 2015 2-1-03

 1-2-2-COMMISSIONING - 50H
Vehicle number: Hour meter Date: //

Start time End time: INITIALS:

 Checked as OK  Final adjustment  Requires repair

PROCEDURE TOOLING / PARTS
CHECKED? TASKS TO BE CARRIED OUT REMARKS
REFERENCE REQUIRED

WHEELS
 Check the tightness of the wheels. Chap 2

REAR AXLE
 Check the oil level. Chap 2

1-2-3-COMMISSIONING - 100H
Vehicle number: Hour meter Date: //

Start time End time: INITIALS:

 Checked as OK  Final adjustment  Requires repair

PROCEDURE TOOLING / PARTS
CHECKED? TASKS TO BE CARRIED OUT REMARKS
REFERENCE REQUIRED

REAR AXLE
 Change the oil after the first time the vehicle is
Chap 2
commissioned.

2-1-04 Updated : 01.28 – 2015

 1-2-4-DAILY CHECKS
ON VEHICLE CONDITION
Vehicle number: Hour meter Date: //

Start time End time: INITIALS:

 Checked as OK  Final adjustment  Requires repair

PROCEDURE TOOLING / PARTS

CHECKED? TASKS TO BE CARRIED OUT REMARKS
REFERENCE REQUIRED

 Extinguisher check, validity date and presence of

clip (depending on versions).
 Drive and test all functions (brakes, hydrostatics,
steering, warning device, buzzer, seat belt, etc.)
 Check that there are no leaks under the equipment.
 Check the front and rear lighting and the working,
indicator and stop lights.
 Check the condition of the windows, rear view
mirrors, wiper fluid, wipers and demister.
 Clean the cab.

REMARK:
REPORT ANY DAMAGE TO THE HEAD OF WORKSHOP

1-2-5- WEEKLY CHECKS

VEHICLE MAINTENANCE
Vehicle number: Hour meter Date: //

Start time End time: INITIALS:

 Checked as OK  Final adjustment  Requires repair

PROCEDURE TOOLING / PARTS

CHECKED? TASKS TO BE CARRIED OUT REMARKS
REFERENCE REQUIRED

ONBOARD CHARGER
(DEPENDING ON VERSIONS)
 Check following weather conditions, the filter For
cleanliness. Clean it or change it if necessary. location
see Chap
4

Updated : 01.28 – 2015 2-1-05

 1-2-6-500 H CHECK
VEHICLE MAINTENANCE
Vehicle number: Date: //

Start time End time: INITIALS:

 Checked as OK  Final adjustment  Requires repair

PROCEDURE TOOLING / PARTS
CHECKED? TASKS TO BE CARRIED OUT REMARKS
REFERENCE REQUIRED

ACCELERATION / BRAKING
 Check the brake pedal clearance.
 Check the brake hoses and pipes
 Check the wear on the brake pads and Minimum
thickness : 3mm
change them if necessary.
 Check the wear on the front brake discs and Minimum
thickness : 8mm
change them if necessary.
 Check the wear on the rear brake discs and Minimum
thickness : 13mm
change them if necessary.
 Check the service brake efficiency
 Check the efficiency of the parking brake and
the cable condition.
 Check dynamic operation

LUBRICATION
 Lubricate according to plan Chap 2

GENERAL
 Clean the vehicle (take care with electrical
equipment).
 Condition of paintwork, markings.
 Check the door openings and that there are
no cracks on the door(s).

CAB
 Check the windscreen wipers and replace
them if worn.

WHEELS
 Checking the wear / Tightening the wheel
nuts. Check that there are no cuts and cracks.
 Check the tyre pressure.

HYDRAULIC EQUIPMENT
 Check the hydraulic tank level

AUTOMATIC TRAILER COUPLING

(DEPENDING ON VERSIONS)
 Apply the manufacturer’s inspection plan Chap 5

2-1-06 Updated : 01.28 – 2015

 1-2-7-1000 HRS OR 1 YEAR CHECK (WHICHEVER
OCCURS FIRST) - VEHICLE MAINTENANCE
Vehicle number: Date: //

Start time End time: INITIALS:

 Checked as OK  Final adjustment  Requires repair

PROCEDURE TOOLING / PARTS

CHECKED? TASKS TO BE CARRIED OUT REMARKS
REFERENCE REQUIRED
 Carry out the 500 hours recommended
operations
BRAKING
 Check the condition of the brake disks
 Check that there are no leaks on the master
cylinder.
 Check that the pedal is hard and the braking is
ok. Drain if necessary.

FRONT AND REAR AXLE

 Drain rear axle Chap 2
 Tightening the axle screws

ELECTRICAL EQUIPMENT
 Checks on condition of the electrical cables
(fastenings, friction, corrosion).
 Check the operation of the power contacts and
the contact condition
 Check that the power cable terminals are
tightened to the torques indicated on the
electrical diagram

HYDRAULIC EQUIPMENT
 Draining the tank, cleaning and replacing the
Chap 5
oil.
 Checking the calibration of the central hydraulic
unit's pressure limiter
 Check for wear on hoses and replace if
necessary.

CHASSIS
 Check the condition of welds.
 Touch up paint-work.
CAB
 Check the seat movement, lubricate if
necessary.
 Check the condition of the contacts, the
operator interface.
 Check the play in the pedals, steering column,
tringles.
ACCUMULATORS
 Checking the pre-load Chap 2

Updated : 01.28 – 2015 2-1-07

 1-2-8-2000 HRS OR 2 YEAR CHECK (WHICHEVER
OCCURS FIRST) - VEHICLE MAINTENANCE
Vehicle number: Hour meter Date: //

Start time End time: INITIALS:

 Checked as OK  Final adjustment  Requires repair

PROCEDURE TOOLING / PARTS

CHECKED? TASKS TO BE CARRIED OUT REMARKS
REFERENCE REQUIRED
 Carry out the 500 and 1000 hours
operations

HYDRAULIC EQUIPMENT
 Check the wear on the coupling nut Chap 5

STEERING
 Check that there are no leaks and check the
attachment of the unit and hoses.
 Check the play in the ball joints.

BRAKING
 Replace the brake fluid and purge the circuit.

1-2-9-3000 HRS OR 4 YEAR CHECK (WHICHEVER

OCCURS FIRST) - VEHICLE MAINTENANCE
Vehicle number: Hour meter Date: //

Start time End time: INITIALS:

 Checked as OK  Final adjustment  Requires repair

PROCEDURE TOOLING / PARTS

CHECKED? TASKS TO BE CARRIED OUT REMARKS
REFERENCE REQUIRED
 Carry out the 500 and 1000 hours
operations

HYDRAULIC EQUIPMENT
 Replace the central hydraulic unit's sniffer Chap 5
cap.

2-1-08 Updated : 01.28 – 2015

 1-2-10-14,000 HRS OR 7 YEAR CHECK (WHICHEVER
OCCURS FIRST) - VEHICLE MAINTENANCE
Vehicle number: Hour meter Date: //

Start time End time: INITIALS:

 Checked as OK  Final adjustment  Requires repair

PROCEDURE TOOLING / PARTS

CHECKED? TASKS TO BE CARRIED OUT REMARKS
REFERENCE REQUIRED
 Carry out the recommended 500, 1000,
2000 and 10000 hours operations
On request TLD can advise the user on a
list of operations with the aim of
extending the life of the equipment.

HYDRAULIC EQUIPMENT
 Change the hydraulic hoses, ensuring Use only
that the hoses and connectors are of components
appropriate quality: risk of injury and approved by
accidents in the event of them splitting. TLD
Check that the pressure limiters are
operating correctly (orbitrol and motor
pump group)

STRUCTURES
 Check for wear, fatigue and corrosion of
structural components.

FULL TEST
 Running
 Braking
 Lighting
 Safeties
 Step by step approach

1-2-11-INSPECTION EVERY 10 YEARS - VEHICLE

MAINTENANCE
Vehicle number: Hour meter Date: //

Start time End time: INITIALS:

 Checked as OK  Final adjustment  Requires repair

PROCEDURE TOOLING / PARTS

CHECKED? TASKS TO BE CARRIED OUT REMARKS
REFERENCE REQUIRED

HYDRAULIC EQUIPMENT
 Replace the central hydraulic unit seals Chap 5

Updated : 01.28 – 2015 2-1-09

 1-2-12-WHEELS

It is IMPERATIVE that you tighten to the recommended torque.

The tightening torque and the tyre inflation pressure are marked on a label pasted near them (or on an
engraved plate).

1 – ANNUAL TYRE MONITORING ACTION: Each tyre must be monitored by a TYRE PROFESSIONAL
at least once a year to detect any fatigue to the body or damage that may hinder the tyre's grip.

2 – RESPECT FOR THE DIAGNOSTIC & EXPIRY DATE: Any damaged tyre or tyre that presents signs of
fatigue on the body must be replaced.

Recommended tightening torque for the front and rear wheels : 25 mdaN / 180 lbft

Recommended inflation for the Front wheels (SOLIDEAL) : 8 bars / 116 psi

Recommended inflation for the Rear wheels (SOLIDEAL) : 9 bars / 130 psi

1-2.12.1.MOUNTING THE WHEEL

· Use the attachment elements recommended by the manufacturer (flat, spherical, conical, thread) and
respect the tightening order below.
· Tighten the nuts using a torque wrench, respecting the tightening torque.
· Use the impact wrench for loosening only, never for tightening.
· Check the tightening torque for the nuts at the frequency recommended in the maintenance table.

2-1-010 Updated : 01.28 – 2015

 1-3-MAINTENANCE OPERATIONS

1-3-1-MAINTENANCE WORK WITH VEHICLE IN RAISED POSITION (WORKING

BENEATH VEHICLE)

1 – LIFTING POINT FOR JACKS:

Please refer Chapter 1 – Operator Manual – LIFTING POINT FOR JACKS

2 – LOCATION OF SUPPORT POINTS:

Please refer Chapter 2 – Operator Manual – LOCATION OF SUPPORT POINTS

DANGER: CRUSHING
NEVER WORK BENEATH A VEHICLE IF IT IS NOT CORRECTLY
SUPPORTED.
LIFTING JACKS ARE NOT APPROPRIATE SUPPORTS.
CHECK THAT THE SUPPORTS ARE OF APPROPRIATE CAPACITY AND
DIMENSIONS BEFORE CARRYING OUT ANY INTERVENTION.

1-3.1.1. MAINTENANCE WORK ON SCAFFOLDING AND SAFETY BARRIERS (AT A

HEIGHT)

Fig 1 : Scaffolding

During interventions on the top of vehicles (maintenance, etc.) access and fall prevention resources
(scaffolding, barriers, etc.) that comply with current regulations must be used.
A list of tools is available from TLD EUROPE SPARE PARTS DEPARTMENT.

Updated : 01.28 – 2015 2-1-011

 1-3-2-BRAKING SYSTEM

1-3.2.1.VERIFICATION

1 - Vehicle stopped, check the brake pedal's resistance.

2 - Then at low speed, test the braking; if the test is conclusive, start again at a higher speed.
3 - If an anomaly is detected, have the braking system checked and repaired.

1-3.2.2.DRAINING THE BRAKING SYSTEM

The vehicle's hydraulic braking system required draining if the braking oil is replaced, if a hydraulic
component is replaced or if there is any intervention on the circuit.
This procedure requires 2 people: one person to activate the brake pedal and another to drain the circuits.
When a circuit is drained, the person who holds down the brake pedal must not release the pressure until
the circuit is closed again to avoid any air being sucked into the circuit. There is a drain point on the brake
cylinders.

1-3.2.3.BRAKING CIRCUIT DRAIN PROCEDURE

1 - Immobilise the machine on a flat surface.

2 - Locate the service brake drain point on the four cylinders.
3 - Start the vehicle in neutral with the parking brake off.
4 - One operator presses the brake pedal and holds down the pressure. The other operator loosens the
drain point to let the air escape. Tighten the drain point again before releasing the pedal; repeat the
procedure for the four cylinders.
5 – Check the oil level and top up if necessary.

1-3.2.4.CHECKING AND ADJUSTING THE DISKS

The brake disks have an automatic play recovery system. If, outside checking their thickness, it does not
correspond to the minimum required, they must be replaced.

2-1-012 Updated : 01.28 – 2015

 1-3-3-GREASES, LUBRICATION AND OTHER LIQUIDS

IMPORTANT:
Oils must be selected depending on the ambient temperature that exists in the equipment’s
operating LOCATION
COMPONENT Marking Capacities Standards Additional information

SAE90
REAR AXLE 2,25 litres API GL-5 -
MIL-L-2105B
ISO
Ambient temperatures
Grade
ISO 11158
HYDRAULIC -40°C to +5°C. - 40°F à 41°F 22
11 litres category HV
RESERVOIR -25°C to +20°C. - 13°F à 68°F 32
-10°C to +40°C. 14 °F à 104°F 46
-5°C to +55°C. 23 °F à 131°F 68
BRAKING CIRCUIT SAE J 1703 f
(depending on 0.75 litres FMVSS 116- DOT4 synthetic oil
versions) DOT 4
Lithium soap grease
Extreme pressure
GREASE - -
Temperature: -30°C to +130°C.
NLGI 2
Table 1 : Lubrication and liquids

WARNING: DO NOT USE LIQUIDS OTHER THAN THOSE THAT ARE RECOMMENDED.
IF THESE LIQUIDS/LUBRICANTS/GREASES CANNOT BE OBTAINED, THEN PLEASE
CONTACT TLD IN ORDER TO OBTAIN DETAILS OF EQUIVALENTS FROM ANOTHER
SUPPLIER OR TO PLACE AN ORDER FOR THE CORRECT OIL.

NOTE:
1 - DURING THE REPLACEMENT OF PARTS AND/OR MAJOR HYDRAULIC
COMPONENTS IN ORDER TO PREVENT DAMAGE TO COMPONENTS IT IS
ESSENTIAL THAT HYDRAULIC OIL IS FILTERED AND ANALYSED BEFORE BEING
RETURNED TO SERVICE.
2- THE MIXING OF TWO OILS IS PROHIBITED.

1-3-4-OIL QUALITY
The degree of cleanliness required for the vehicle to operate correctly is defined by the following
standards.
STANDARD CLASS
ISO/DIS 4406 20/18/15
NAS 1638 9
SAE 5
Table 18: Oil quality
If the recommendations for the maintenance of the filtration system as well as for oil changes are followed,
then the oil should be of the required quality level. It may prove necessary, however, to test the oil quality
when the latter appears to have deteriorated, for example when significant deposits are observed in the oil
tank return filter.

REMARK: THE COLOUR OF THE OIL IS NOT A GOOD INDICATOR OF ITS LEVEL OF
CLEANLINESS

A specialist oil laboratory should be used for a full assessment of the quality and degree of contamination
of the oil.

Updated : 01.28 – 2015 2-1-013

 1-3-5-LUBRICATION
Door runners
Seat runners

1 - Locate the lubricators:

2 - Lubricate;
3 – Clean off excess oil. Towing

FR

TOP VIEW

RE

Wheel bearings
(Only for removal or
repair)

2-1-014 Updated : 01.28 – 2015

 1-3-6-LEVELS

1-3.6.1.BRAKE FLUID

Access to the brake fluid tank: remove the plate located behind the steering wheel using a screwdriver
The level must be between the min and max indicated on the tank.

MAX
MIN

1-3.6.2.HYDRAULIC OIL

After removing the rear right cover the hydraulic oil level may be topped up by unscrewing the cap at the
back of the motor pump group. The level must be between the min and max indicated on the tank.

Updated : 01.28 – 2015 2-1-015

 1-3-7-REAR AXLE

1-3.7.1.DRAINING THE REAR AXLE BODY

Drain point

- Set the vehicle over the pit.

- Remove the caps under the rear axle body.

- Put the cap back on when all of the oil has flowed out.

WARNING:

EVACUATE AND RECYCLE THE OILS AND FILTERS WITHIN THE RULES OF THE ART

2-1-016 Updated : 01.28 – 2015

 1-3.7.2.FILLING POINT

Filling point (1)

- Remove the plugs (item 1 and 2).

- Filling up the hole item 2 (see § "GREASES, LUBRICATION AND OTHER LIQUIDS").

- Replace plugs.

Filling level (2)

Updated : 01.28 – 2015 2-1-017

 1-4- ELECTRICAL / HYDRAULIC DIAGRAMS

1-4-1-ELECTRICAL DIAGRAM

Electrical diagrams and the symbols shown in the electrical diagram are in accordance with the
standardisation rules:

CEI 60617 and CEI 1082

1-4-2-HYDRAULIC DIAGRAM

The hydraulics diagrams and the symbols shown in the hydraulic diagram are in accordance with the
standardisation rules:

- ISO 1219. ISO 1219 sets the principles for the use of symbols, specific basic symbols and the rules for
the use of these.

- ISO 3511, Processes for the inspection, measurement and instrumentation — symbolic representation

- ISO128, Technical drawings — General principles of representation.

- ISO 5598, Fluid systems and components - Vocabulary.

2-1-018 Updated : 01.28 – 2015

 2- TROUBLESHOOTING

2-1- REMOVAL OF THE VEHICLE - TOWING

IN THE EVENT OF COMPLETE BREAKDOWN:
In the event of complete breakdown, when in situ repairs are not possible or where the vehicle is
blocking traffic areas used by other vehicles, it may be necessary to move the vehicle.

WARNING:
TOWING AT AN UNSUITABLE SPEED MAY DAMAGE THE VEHICLE.

WARNING:
THE PARKING BRAKE MUST BE UNLOCKED TO TOW THE VEHICLE.

2-1-1- EVACUATING THE VEHICLE

WARNING:
DO NOT USE STRAPS OR OTHER FLEXIBLE ELEMENTS FOR TRACTION, ONLY A
TOW BAR.

WARNING:
CHOOSE A TRACTION RESOURCE THAT IS SUITED TO THE VEHICLE'S WEIGHT
AND MAKE SURE THAT IT IS IN GOOD CONDITION.

Towing is only possible under the following conditions:

- If a trolley train is coupled to the tractor, release it;

- Fit a tow bar to the rear tow ring then the towing vehicle ;

- Set the selector (5 fig.5) to neutral;

- The tractor is then ready to be towed.

MAX TOWING SPEED: 5 km/h

WARNING:
LEAVE AN OPERATOR AT THE WHEEL (THE STEERING MAY BE CONTROLLED BUT
NOT POWERED).

Updated : 01.28 – 2015 2-2-01

 2-2-DIAGNOSTIC

DIAGNOSTIC TABLES
All of the tables below must be used with the electrical and hydraulic diagrams to find the problem and
fully understand the solutions.

2-2-1-DIAGNOSTIC TABLES

2-2.1.1. – POWER UP PROBLEM

PROBLEM CAUSE ACTION

Powering up problem The key contactor is not active. Set the contact.
(nothing switches on)

The emergency stop button Release the emergency stop.

has been pushed.

The power plug is Connect the power socket.

disconnected.

Power and/or command Look for the reason why the fuses
fuses OOS are OOS, repair and replace the
fuses.

Defective cabling Check the connections (corrosion,

loosening, disconnections, etc.)

2-2-02 Updated : 01.28 – 2015

 2-2.1.2. – NO SIDEWAYS MOVEMENT
PROBLEM CAUSE
No sideways movement Alarm on the display.
Power up with acceleration
pedal activated or movement
direction triggered.
Movement direction not
selected.
Parking brake on.
Acceleration pedal not
activated.
"Dead man" pedal not
activated.
Slow speed selected (inching)
- selector mark 3 on
dashboard.
Defective cabling.
2-2.1.3. – LOSS OF POWER
PROBLEM CAUSE
Loss of power Batteries low.
Depending on versions:
Door(s) open.
2-2.1.4. – NO "STEP BY STEP" (INCHING) FUNCTION
PROBLEM CAUSE
No "step by step" (inching) Emergency stop selected.
function
Selector mark 3 on the
dashboard in driving position.
Parking brake released.
Updated : 01.28 – 2015
ACTION
Consult the display manual and the
list of fault codes in chap 5.
Remove the action from the
accelerator pedal and set the
selector to neutral.
Select a gear using the movement
direction selector.
Release the parking brake
Activate the pedal.
Activate the pedal.
Place the selector to the left (driving
position).
Check the connections (corrosion,
loosening, disconnections, etc.)
ACTION
Recharge the batteries
Close the door(s).
ACTION
Release the emergency stop.
Switch the selector to "step by step
approach" (inching) position.
Apply the parking brake.
2-2-03
 2-2.1.5.– THE VEHICLE HAS NO STEERING OR STEERING IS HARD

PROBLEM CAUSE ACTION

The vehicle has no steering Lack of pressure in the tyres Check the pressure and condition of
or steering is hard Damaged tyres/rim the tyres and rims, change if
necessary.

Steering valve fault. Check and replace the valve

Steering column damaged. Check and replace the steering column.

Steering cylinder or seal Replace

damaged.

Axle ball joints or articulations Replace

damaged.

Pump fuse OOS Replace

Pump relay OOS Replace

Motor pump group OOS Replace

Variator output OOS Replace

2-2.1.6.- STEERING: THE VEHICLE PULLS TO ONE SIDE

PROBLEM CAUSE ACTION

Steering: the vehicle pulls to Lack of pressure in the tyres Check the pressure and condition of
one side Damaged tyres/rim the tyres and rims, change if
necessary.

Steering valve fault. Check and replace the valve

Steering bar ball joints Replace

defective.

2-2-04 Updated : 01.28 – 2015

 2-2.1.7. - BRAKING SYSTEM: EXCESSIVE BRAKING DISTANCE
PROBLEM CAUSE ACTION

Braking system: excessive Brake fluid level low. Top up.

braking distance
Excessive wear on brake pads, Contact TLD.
lining or disks.

Incorrect adjustment of the Check and adjust.

assistance pressure limiter.

Air in the brake circuit. Find the leak and repair it, bleed the
circuit.

Master cylinder out of service. Repair or replace the master cylinder.

Assistance hydraulic leak. Find the leak, repair it and top up the
hydraulic oil.

Brake fluid leak Find the leak, repair it and top up

2-2.1.8. - BRAKING SYSTEM: PEDAL SPONGY OR PEDAL RUN TOO HIGH

PROBLEM CAUSE ACTION

Braking system: Pedal Insufficient fluid in the circuit. Check the leaks and fill
spongy or pedal run too high
Air in the circuit Check, repair and bleed.

Excessive wear in the braking Contact TLD.

system.

2-2.1.9. - BRAKING SYSTEM: PEDAL HARD

PROBLEM CAUSE ACTION

Braking system: Pedal hard Pedal hard Check the pedal and repair

Incorrect adjustment to the Check and adjust.

braking assistance.

Braking oil pressure low Inspect the hydraulic system.

Replace the components if necessary

Updated : 01.28 – 2015 2-2-05

 2-2.1.10. – THE BATTERIES DO NOT REMAIN CHARGED
PROBLEM CAUSE ACTION

The batteries do not remain Battery out of service Replace the battery
charged.

2-2.1.11.- NOISE IN THE AXLES

PROBLEM CAUSE ACTION

Noise in the axle Oil leak in the transmission Contact TLD.

Internal axle problem Contact TLD.

2-2-06 Updated : 01.28 – 2015

 2-2.1.12.- LACK OF CAB HEATING PERFORMANCES (DEPENDING ON VERSIONS)

PROBLEM CAUSE ACTION

Lack of cab heating Fan out of service Replace the fan

performances

2-2.1.13. – THE CAB DEICING DOES NOT WORK (DEPENDING ON VERSIONS)

PROBLEM CAUSE ACTION

The cab de-icing does not Contacts damaged or Check and repair the conduits.
work. disconnected.

Circuit breaker activated. Seek the reason why the circuit

breaker was activated, repair and
push back in.

Defective cabling. Check the connections (corrosion,

loosening, disconnections, etc.)

2-2.1.14. – NO MORE CAB VENTILATION (DEPENDING ON VERSIONS)

PROBLEM CAUSE ACTION

No more ventilation in the Fan defective. Check and replace.

cab
Circuit breaker activated. Seek the reason why the circuit
breaker was activated, repair and
push back in.

Defective cabling. Check the connections (corrosion,

loosening, etc.)

2-2.1.15. – NO MORE WIPER OR WIPER FLUID (DEPENDING ON VERSIONS)

PROBLEM CAUSE ACTION

No more wiper or wiper fluid. "Dead man" pedal not Activate the "dead man" pedal.
activated.

Wiper motor defective. Replace the motor

Circuit breaker activated. Seek the reason why the circuit

breaker was activated, repair and
push back in.

Defective cabling. Check the connections (corrosion,

loosening, disconnections, etc.)

Updated : 01.28 – 2015 2-2-07

 BLANK PAGE

2-2-08 Updated : 01.28 – 2015

 3-REPAIRS

3-1-TIGHTENING TORQUE
3-1-1-GENERAL

PRECAUTION:
DO NOT USE THESE VALUES IF A DIFFERENT TORQUE VALUES OR TIGHTENING
PROCEDURES ARE GIVEN FOR A GIVEN APPLICATION.
THE LISTED TORQUE VALUES ARE DESIGNED FOR GENERAL USE ONLY
FASTENINGS MUST BE REPLACED USING FASTENINGS OF THE SAME OR
SUPERIOR GRADE AND THEY MUST BE TIGHTENED USING THE SAME FORCE AS
USED FOR THE ORIGINAL FASTENINGS.
CHECK THAT THE THREADS ON FASTENINGS ARE CLEAN AND PROPERLY
ENGAGED IN ORDER TO AVOID FAILURES DURING TIGHTENING.

NOTE:
« LUBRICATED » MEANS COATED WITH ENGINE OIL OR ANOTHER LUBRICANT
« DRY » SIGNIFIES PLAIN OR ZINC-PLATED WITHOUT LUBRICATION.

Updated : 01.28 – 2015 2-3-01

 3-2-REMOUNTING THE ELECTRIC MOTOR

1- Tightening torque for electrical power cable connection is 16 Nm. Bottom nuts must be immobilized
while tightening. Delivered nickel-plated steel nuts and washers to be use exclusively;

2- Grease the splined-shaft using Anti-Fretting GREASE (TLD p/n 1048269). Added grease in the female
part of the rear axle.
Check of highly-rated ventilator that the splined-shaft was not forced during the assembly;

3- Check that the motor washer is mounted on the motor shaft;

4- Check that the EME O-ring is mounted on the rear axle;

2-3-02 Updated : 01.28 – 2015

5- After assembly, make sure that the 2 drain holes located in the lower part of the motor are free to
evacuate water and avoid accumulation;

6- Axle oil filling: 2.25 liters oil 80W9085;

7- Level check. Open plug. Oil must come to the plug level. The axle must be horizontal. Suspension
fixation parallel to the floor;

8- Oil change;

9- Mounting the motor support, adjusting the abutment so as to support the motor without generating
stress.

Updated : 01.28 – 2015 2-3-03

 BLANK PAGE

2-3-04 Updated : 01.28 – 2015

 3-3-SETTINGS

3-3-1-HYDROPNEUMATIC ACCUMULATORS (DEPENDING ON VERSIONS)

3-3.1.1.ACCUMULATOR REGULATIONS.

General:

The decree of 15th March 2000, relating to the use of pressurised equipment, seeks to cover in a single
document all the regulatory requirements relating to the use of Pressurised Equipment. It therefore
complements European Directive 97/23 CE (Regulations for the construction of Pressurised Equipment).
The specific nature of this Pressurised Equipment, which may present high potential for danger given the
fluids used, requires adapted regulations to maintain a high level of safety.

If Accumulator Volume ≤ 1 L and Max pressure struck on the Accu ≤ 1000b or P x V ≤ 200
- No regulations.
- Mounting according to hydraulic rules.
- No follow-up.

If Accumulator Volume ≤ 1 L and Max pressure struck on Accu >1000b.

Or
If Accumulator Volume > 1 L et P x V > 200

Accumulator subject to the decree of 15th march 2000, accepted under CE and DRIRE standards:
DRIRE stamp (horse head) or CE stamp + Accumulator user manual constructed according to European
regulations -Directive 97/23 CE.

For use with mineral oil.

- External periodic inspection every 40 months by any person competent and able to recognised faults in
the pressurised equipment concerned.
- Requalification every 10 years by a specialist body (Drire, Apave, Véritas, etc.).

Accepted with other stamps → REPLACEMENT IMPERATIVE.

Updated : 01.28 – 2015 2-3-05

 3-3.1.2.ACCUMULATOR MAINTENANCE

Basic maintenance advice

Membrane accumulators do not require maintenance.
However, for long term, fault-free use, the following maintenance operations must be carried out regularly.
- Check the nitrogen filling pressure.
- Check that the connections are sealed and leak free.
- Test the correct operation of the valves and the protection mechanisms.
- Check the support mechanisms.

Pre-filling pressure test frequency

It is recommended that the following test frequencies be adopted:
- After installation;
- One week after installation;
- Eight weeks after installation;
If no significant gas loss occurs, the test frequency must be:
- Once per year.

IMPORTANT:
PERMANENT USE AT EXTREME OPERATING TEMPERATURES REQUIRES MORE
FREQUENT INSPECTION.

Filling gas pressure test:

The filling gas pressure may be checked with or without the adapted test and filling mechanism.
For small accumulators, every time possible the filling gas pressure must be tested without the test and
filling mechanisms as this method avoids gas loss during the test.

Without test equipment

Add a pressure gauge to the circuit pressure intake where the accumulator is mounted.
Start the vehicle to apply pressure to the accumulator circuit.
Read the pressure in the circuit; see the value entered in the hydraulic diagram.
Stop the vehicle's motor (thermal or electric).
Gradually lower the circuit pressure using an activator provided for the purpose (Brake pedal, valve, flap
backup command, etc.).
To begin with the pressure falls slowly. It only falls quickly after the accumulator has been completely
emptied.
The pressure read at this point is the same as the accumulator filling pressure.
If the filling pressure is not the pressure required, the membrane must be refilled as described below with
an appropriate device.

With test equipment

See chapter PRE-LOAD MECHANISM FOR ACCUMULATORS

NOTE:
IF THE GAS PRESSURE IN THE MEMBRANE IS ZERO, EVEN AFTER THE FILLING
OPERATION, THE ACCUMULATOR MUST BE REPLACED.

2-3-06 Updated : 01.28 – 2015

 3-3.1.3.PRE-LOAD MECHANISM FOR ACCUMULATORS

1 - Tightening collar.
2 - Exhaust valve.
3 - Pressure gauge.
4 - Valve opening flap.
5 - Pre-load connector with cover.
6 – Flexible.
7 - Bottle connector.

3-3-2-INSTRUCTION FOR THE PRE-LOAD MECHANISM

3-3.2.1.PRESSURE CONTROL OR REDUCTION

A flexible does not need to be used for this operation.

Discharge the pressure in the pump circuit, remove or isolate the accumulator, remove the pre-load valve
protection cover on the accumulator and fit the pre-load mechanism by screwing the collar (1) on the
accumulator valve.
Screw without tightening the small wheel (4) and read the load pressure on the gauge (3).
If this pressure is too high, slightly open the escape screw (2).
Unscrew the wheel (4), remove the pre-load mechanism and put the protective cover back in place on the
accumulator valve.

3-3.2.2.INCREASING THE PRE-LOAD PRESSURE

To pre-load or increase the pre-load pressure, remove the accumulator valve protective cover, fit the pre-
load mechanism by screwing the collar (1), leaving the wheel unscrewed (4) and by screwing the escape
screw fully (2).
Remove the cover (5) and connect the flexible (6) to a bottle of nitrogen.
Screw the wheel (4) without forcing and open the nitrogen bottle's tap slowly, while checking the pressure
gauge (3); increase the pre-load pressure to reach a value slightly higher than the desired value.
Unscrew the wheel (4), close the bottle's tap, empty the flexible (6) by opening and closing the valve (2)
and wait a few minutes.
Screw the wheel (4) and check the pressure; if this pressure is correct, unscrew the wheel (4) and remove
the mechanism with the flexible (6) by unscrewing the collar (1). If the pressure is not at the value
requested, increase or reduce the pressure according to the instructions above.

REMARK:

ONLY USE NITROGEN FOR THE PRE-LOAD OPERATION.

Updated : 01.28 – 2015 2-3-07

 BLANK PAGE

2-3-08 Updated : 01.28 – 2015