Eng 2TH9-3900

ROYAL DUTCH ARMY
2 TH 9-3900
TECHNICAL MANUAL
Truck 40 kN 4x4
YW 4440 DAF
YAL 4440 DAF
Projectnumber: 3900
YAK 4440 DAF

Projectnumber: 0285
Modification YA 4440 DAF

Sweeping attachment
Projectnumber: 1952
2nd Maintenance level
TRANSPORT MATERIAL
DIRECTORATE
DEPARTMENT OF WHEELED VEHICLES AND ENGINEERING EQUIPMENT Publication date: 8 march 1988
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2
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REVISION HISTORY
SER.NO. CHANGED BY (in capitals): DATE INITIALS
I
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SUGGESTION FORM
MISTAKES? Copy this form as often as needed and record your proposal.
Send the completed form to the address below.
SUGGESTIONS? TRANSPORT MATERIAL DIRECTORATE

System group, weapons and transport systems
Transport Material Directorate
MPC 58AP.O.
SEND THEM RIGHT AWAY !! Box 90822
2509 LV 'S-GRAVENHAGE
Publication date: Number of last change: W
Page/Fig. My proposal is:
Location/unit Date:
Name
Rank Signature:
Telephone number
II
2 TH 9-3900
WARNING
CARBON MONOXIDE IS DEADLY
CARBON MONOXIDE IS A COLOURLESS AND ODOURLESS GAS.

CARBON MONOXIDE IS PRESENT IN ALL EXHAUST GAS.
DO NOT START ENGINES IN A POORLY-VENTILATED AREA.

DO NOT DRIVE A VEHICLE IF THE EXHAUST SYSTEM IS DAMAGED OR HAS BEEN REMOVED.
INHALATION OF CARBON MONOXIDE CAN CAUSE DEATH.

SYMPTOMS OF CARBON MONOXIDE POISONING:
– HEADACHE
– DIZZINESS
– DROWSINESS
– UNCONSCIOUSNESS
– LOSS OF MUSCLE CONTROL
– BRAIN DAMAGE
IF ANYONE EXHIBITS THESE SYMPTOMS, PROCEED AS FOLLOWS:

– 1. VENTILATE THE AREA
– 2. BRING THEM INTO AN AREA WITH FRESH AIR
– 3. If necessary, APPLY ARTIFICIAL RESPIRATION
– 4. PREVENT HYPOTHERMIA
– 5. DO NOT ALLOW PHYSICAL ACTIVITY
– 6. WARN A DOCTOR
III
2 TH 9-3900
PREFACE
THIS TECHNICAL MANUAL IS INTENDED FOR THE PERSONNEL TASKED WITH 2ND LEVEL
MAINTENANCE ON THE VEHICLE AND IT CONTAINS DETAILS OF THIS MAINTENANCE.
IV
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NUMBERING
(a) The numbering of the chapters, sections and items

(1) Chapters are sequentially numbered as follows: Chapter 1, Chapter 2, etc.
(2) Sections are sequentially numbered per chapter. The numbering is preceded by the chapter number,
as follows:
Chapter 1, section 1: Section 1.1.
(3) Items are sequentially numbered per section. The numbering is preceded by the section number, as
follows:
Section 1.1. item 3.1.1.3.
(b) The numbering of the figures and tables
Figures and tables are numbered sequentially per section.
The numbering is preceded by the section number, as follows:
Figure 3 in Chapter 1 Section 2: Fig. 1.2.3.
Table 3 in Chapter 1 Section 2: Table 1.2.3
(c) The numbering of the pages
The pages are sequentially numbered per section.
The numbering is preceded by the section number, as follows:
Section 1.1. page 21-1-2
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CONTENTS
CHAPTER 1 INTRODUCTION
Section 1.1. General
1.1.1. Purpose
1.1.2. Authority
1.1.3. Regulations and publications
CHAPTER 2 IDENTIFICATION, DESCRIPTION AND DATA
Section 2.1. Identification 2-1-1
2.1.1. Views 2-1-1
2.1.2. Component overview 2-1-1
Section 2.2. Description and data 2-2-1
2.2.1. Description 2-2-1
2.2.2. General details 2-2-1
2.2.3. Detailed data 2-2-1
2.2.4. Tightening torques 2-2-5
CHAPTER 3 MAINTENANCE
Section 3.1. General 3-1-1
3.1.1. 2nd Level Maintenance 3-1-1
3.1.2. Preventive maintenance; 3-1-1
3.1.3. Corrective maintenance 3-1-1
3.1.4. Modifications 3-1-1
3.1.5. Responsibility 3-1-1
3.1.6. Authority 3-1-1
3.1.7. General instructions 3-1-2
3.1.8. Spare parts 3-1-2
3.1.9. Tools 3-1-2
Section 3.2. Actions to be taken on receipt of the equipment 3-2-1
3.2.1. General 3-2-1
3.2.2. Test drive 3-2-1
3.2.3. Inspection and maintenance during the break-in period 3-2-1
3.2.4. Service prior to transfer 3-2-1
Section 3.3. Preventive maintenance; 3-3-1
3.3.1. Intervals 3-3-1
3.3.2. Inspection and test drive 3-3-1
3.3.3. Maintenance in accordance with the Inspection Work Card 3-3-1
3.3.4. Location of lubrication points 3-3-1
Section 3.4. Engine 3-4-1
3.4.1. Engine oil replacement 3-4-1
3.4.2. Replace oil filter 3-4-1
3.4.3. Oil sump ventilation 3-4-2
3.4.4. Valve cover 3-4-2
3.4.5. Setting valve clearance 3-4-2
3.4.6. Valve adjustment bolts 3-4-3
3.4.7. Oil sump 3-4-4
3.4.8. Inspection cover of the flywheel housing 3-4-4
3.4.9. Side covers 3-4-5
3.4.10. Engine brake 3-4-6
3.4.11 Operating mechanism engine brake 3-4-6
3.4.12. Engine mounts and rubber hangers 3-4-7
Section 3.5. Clutch assembly 3-5-1

3.5.1. Inspection cover clutch housing 3-5-1
3.5.2. Declutching lever 3-5-1
3.5.3. Clutch pedal suspension 3-5-1
3.5.4. Operating cylinder 3-5-2
3.5.5. Operating cylinder 3-5-2
3.5.6. Lines and support 3-5-2
3.5.7. Fluid reservoir 3-5-3
3.5.8. Filling and bleeding the hydraulic system 3-5-3
3.5.9. Adjustment of the pedal travel and free travel 3-5-4
VI
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Section 3.6. Fuel system 3-6-1

3.6.1. Fuel injection pipe 3-6-1
3.6.2. Fuel leak-off pipe of the injector 3-6-1
3.6.3. Air pipes and hoses 3-6-1
3.6.4. Air filter and air filter element 3-6-2
3.6.5. Fuel reservoir 3-6-3
3.6.6. Bleeding the fuel system 3-6-3
3.6.7. Fuel lines 3-6-4
3.6.8. Fuel reservoir filler cap, pipe and filter 3-6-4
3.6.9. Fine fuel filter 3-6-5
3.6.10. Coarse fuel filter 3-6-5
3.6.11. Cold start control cable 3-6-6
3.6.12. Glow plugs 3-6-7
3.6.13. Throttle mechanism 3-6-8
3.6.14. Stop control 3-6-10
Section 3.7. Exhaust system 3-7-1
3.7.1. Exhaust pipes 3-7-1
3.7.2. Exhaust silencer 3-7-1
3.7.3. Attachment of the exhaust system 3-7-1
Section 3.8. Cooling system 3-8-1
3.8.1. Fan 3-8-1
3.8.2. Wind tunnel 3-8-2
3.8.3. Radiator 3-8-2
3.8.4. Replacing the coolant 3-8-3
3.8.5. Expansion reservoir 3-8-3
3.8.6. Thermostats 3-8-3
3.8.7. Coolant pump 3-8-4
3.8.8. V-belts 3-8-4
Section 3.9. Electrical system 3-9-1
3.9.1. Alternator 3-9-1
3.9.2. Pulley 3-9-1
3.9.3. Voltage regulator 3-9-1
3.9.4. Starter motor 3-9-2
3.9.5. Switches on instrument panel 3-9-2
3.9.6. Warning lamps on the instrument panel 3-9-5
3.9.7. Instruments on the instrument panel 3-9-7
3.9.7.a. Instruments not on the instrument panel 3-9-7
3.9.8. Switches not on instrument panel 3-9-7
3.9.9. Fuse holders 3-9-9
3.9.10. Main battery switch 3-9-9
3.9.11. Relay 3-9-9
3.9.12. Headlights 3-9-10
3.9.13. Direction indicators, front 3-9-10
3.9.14. Parking lights 3-9-10
3.9.15. Darkened searchlight, front 3-9-11
3.9.16. Clearance lamps 3-9-11
3.9.17. Various lamps, rear 3-9-11
3.9.18. Horn 3-9-12
3.9.19. Batteries 3-9-12
3.9.20. Coupler socket 3-9-13
3.9.21. General purpose socket 3-9-14
3.9.22. Givers 3-9-15
3.9.23. Cable tree, main battery switch (YA 4440 - project 1952) 3-9-16
3.9.24. Main switch (YA 4440 - project 1952) 3-9-17
3.9.25. Cable tree, main socket switch (YA 4440 - project 1952) 3-9-18
3.9.26. Socket and dust cap (YA 4440 - project 1952) 3-9-18
Section 3.10. Gearbox 3-10-1
3.10.1. Replace lubricating oil 3-10-1
3.10.2. Gear shift mechanism 3-10-1
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Section 3.11. Transfer box 3-11-1

3.11.1. Rubber hangers 3-11-1
Section 3.12. Intermediate shafts 3-12-2
3.12.1. Intermediate shaft gearbox / transfer box 3-12-1
3.12.2. Intermediate shaft transfer box / front axle 3-12-1
3.12.3. Intermediate shaft transfer box / rear axle 3-12-1
3.12.4. Intermediate shaft power take off / hydraulic pump 3-12-2
Section 3.13. Front axle 3-13-1
3.13.2. Bleeding 3-13-1
Section 3.14. Rear axle 3-14-1
3.14.2. Axle housing, bleeding 3-14-1
3.14.3. Hub oil seal bearing race 3-14-2
3.14.4. Axle shaft gasket 3-14-2
Section 3.15. Brake system 3-15-1
3.15.1. Description 3-15-1
3.15.2. Brake shoes 3-15-4
3.15.3. Brake pipes, hoses and couplings 3-15-5
3.15.4. Anti-frost device 3-15-6
3.15.5. Trailer vehicle air connections 3-15-7
3.15.6. Brake camshaft lever 3-15-8
3.15.7. Brake pedal rubber 3-15-9
Section 3.16. Brake drums, wheel hubs and wheels 3-16-1
3.16.1. Brake drums 3-16-1
3.16.2. Wheel hub, front axle 3-16-1
3.16.3. Bearings and oil sealing rings, front axle 3-16-2
3.16.4. Wheel hub, rear axle 3-16-2
3.16.5. Bearings and oil sealing rings, rear axle 3-16-3
3.16.6. Rims and rim rings 3-16-3
3.16.7. Tyres 3-16-4
Section 3.17. Steering gear 3-17-1
3.17.1. Steering rod complete with ball ends 3-17-1
3.17.2. Steering rod ball ends 3-17-1
3.17.3. Track rod complete with ball ends 3-17-2
3.17.4. Track rod ball ends 3-17-3
3.17.5. Hoses and pipes 3-17-4
3.17.6. Oil reservoir 3-17-5
3.17.7. Oil reservoir filter element 3-17-5
3.17.8. Checking the oil 3-17-6
Section 3.18 Chassis 3-18-1
3.18.1. Towing hook 3-18-1
3.18.2. Spare wheel carrier 3-18-1
Section 3.19. Shock absorbers spring 3-19-1
3.19.1. Front springs 3-19-1
3.19.2. Rear springs 3-19-2
3.19.3. Spring shackles 3-19-3
3.19.4. Fenders 3-19-3
3.19.5. Shock absorbers, front 3-19-4
3.19.6 Shock absorbers, rear 3-19-5
3.19.7. Spring seats 3-19-5
Section 3.20. Cab 3-20-1
3.20.1. Window mechanism 3-20-1
3.20.2. Drop glass 3-20-1
3.20.3. Ventilation window rotation mechanism 3-20-2
3.20.4. Ventilation window 3-20-3
3.20.5. Door hinges 3-20-3
3.20.6. Door limiter 3-20-4
3.20.7. Door closing 3-20-4
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3.20.8. Door seals 3-20-4

3.20.9. Cab windows (except windscreen) 3-20-5
3.20.10.Radiator grill 3-20-6
3.20.11.Section screen 3-20-6
3.20.12.Cab seats 3-20-6
3.20.13.Corrosion inhibitor 3-20-6
3.20.14.Dobli mirror/mirror bracket 3-20-10
Section 3.21.Ammunition rack 3-21-1
3.21.1. Ammunition rack 3-21-1
Section 3.22. Bumpers, towing eyes and buffer beam 3-22-1
3.22.1. Front bumpers 3-22-1
3.22.2. Rear bumpers, towing eyes and buffer beam 3-22-1
3.22.3. DIN plate front bumper (YA 4440 - project 1952) 3-22-1
3.22.4. Socket attachment bracket (YA - 4440 - project 1952) 3-22-2
3.22.5. Fast coupling attachment bracket (YA - 4440 - project 1952) 3-22-2
Section 3.23. Tilted loading platform and secondary equipment 3-23-1
3.23.1. Tilting loading platform 3-23-1
3.23.2. Windscreen wiper motor 3-23-1
3.23.3 Wipers and rod system 3-23-2
3.23.4. Heating system 3-23-4
3.23.5. Mounting bracket 3-23-6
Section 3.24. Instruments (not electric) 3-24-1
3.24.1. Tachograph / Speedomoeter 3-24-1
3.24.2. `Rev counter 3-24-1
3.24.3. Tachograph cable and rev counter cable 3-24-1
3.24.4. Rev counter drive right-angled transmission 3-24-2
3.24.5. Air pressure meter 3-24-2
Section 3.25.Hydraulic system 3-25-1
(YA 4440 - project 1952) 3-25-1
3.25.1. Current control valve (YA 4440 - project 1952) 3-25-1
3.25.2. Current control valve attachment plate(YA 4440 - project 1952) 3-25-1
3.25.3. Hydraulic hoses (YA 4440 - project 1952) 3-25-2
3.25.4. Hydraulic quick-release couplings and dust cap (YA 4440 - project 1952) 3-25-3
3.25.5. Quick-release couplings attachment plate behind cab (YA 4440 - project 1952)3-25-1
Section 3.26.Water supply installation 3-26-1
(YA 4440 - project 1952) 3-26-1
3.26.1. Pipes (YA 4440 - project 1952) 3-26-1
3.26.2. Quick-release couplings and dust cap (YA 4440 - project 1952) 3-26-1
CHAPTER 4 IDENTIFICATION OF FAULTS

Section 4.1.Identification of faults 4-1-1
4.1.1. General 4-1-1
4.1.2. Fault table 4-1-1
CHAPTER 5 MAINTENANCE SCHEDULE (Project number 3900)

Section 5.1.Introduction 5-1-1
5.1.1. Explanation 5-1-1
5.1.2. Standard group classification 5-1-1
5.1.3. Maintenance schedule 5-1-2
CHAPTER 6 MAINTENANCE SCHEDULE (Project number 1952)

Section 6.1.Introduction 6-1-1
6.1.1. Explanation 6-1-1
6.1.2. Standard group classification 6-1-1
6.1.3. Maintenance schedule 6-1-2
APPENDIX 1. HYDRAULIC DRIVE SWEEPING ATTACHMENT DIAGRAM

APPENDIX 2. WATER SUPPLY INSTALLATION SWEEPING ATTACHMENT DIAGRAM
APPENDIX 3. MOUNTING INSTRUCTION
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ATTACHMENT 1 Consumables of vehicles in storage

ATTACHMENT 2 Brake system of vehicles in storage
ATTACHMENT 3 Clutch plate of vehicles in storage
ATTACHMENT 4 Batteries of vehicles in storage
ATTACHMENT 5 Instruction card for taken in operation
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1 INTRODUCTION
1.1 GENERAL
1.1.1 Qualifications
This Technical Manual is intended for use by TRAINING CENTRES and MAINTENANCE UNITS of the
equipment and contains information for 3rd level maintenance. The word echelon should be read as level in
these instructions. The described procedures can be performed by those authorised at the 3rd maintenance
level.
1.1.2 Regulations and publications
The documentation that applies to the equipment is shown in the VS2-100 and VS2-200 and can be
requested from the administrator.
1.1.3 Designations
The designations "left", "right", "front" and "rear" are all in reference to the driving direction unless otherwise
indicated.
1.1.4 Modifications
Modifications to this Technical Manual are made by sending replacement pages and, if necessary, a revised
table of contents. When a page is replaced, the modification number is shown at the bottom of the page.
1.1.5 Corrections and shortcomings
Suggestions that can lead to the improvement of this Technical Manual can be made by sending a copy of
the provided SUGGESTION FORM to the address shown. The SUGGESTION FORM can also be used to
provide feedback concerning the described maintenance as well as any shortcomings.
1-1-1
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1-1-2
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2 IDENTIFICATION, DESCRIPTION AND DATA

2.1. IDENTIFICATION
2.1.1 General
To provide a general impression of the vehicles truck YA-4440, TRAINING VEHICLE YAL-4440, truck with
LOADING CRANE YAK-4440 and modified truck YA-4440 for SWEEPING ATTACHMENT, figures 2.1.2.,
2.1.4. and 2.1.6., 2.1.8. show the vehicles from the front left. Fig. 2.1.3., 2.1.5., 2.1.7., 2.1.9. show the vehicles
from the rear right.
2.1.2 Component overview
Illustration 2.1.1. provides an overview of the locations of the most important components of the vehicle.
Fig. 2.1.1
Position of the components (vehicle section)
1. Engine (01)
2. Gearbox (07)
3. Transfer box (08)
4. Rear axle (11)
5. Chassis (15)
6. Fuel tank (03)
7. Air reservoirs (12)
8. Air filter (03)
9. Front axle (10)
10. Radiator (05)
11. Cab (18)
2-1-1
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Fig. 2.1.2
DAF-YA 4440, front view left
Fig. 2.1.3
DAF-YA 4440, rear view right
2-1-2
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Fig. 2.1.4
DAF-YAL 4440, front view left
Fig. 2.1.5
DAF-YAL 4440, rear view right
2-1-3
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Fig. 2.1.6
DAF-YAK 4440, front view left
Fig. 2.1.7
DAF-YAK 4440, rear view right
2-1-4
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Fig. 2.1.8
Front left view of the sweeping attachment in front of the vehicle.
Fig. 2.1.9
Rear right view of the sweeping attachment in front of the vehicle.
2-1-5
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Fig. 2.1.10
Front left view of the sweeping attachment on the vehicle.
Fig. 2.1.11
Rear right view of the sweeping attachment on the vehicle
2-1-6
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2.2 DESCRIPTION AND DATA
2.2.1 See 1 TH
2.2.2 General data
For the general data, see the related 1 TH
2.2.3 Detailed data
a. Engine
Make : DAF
Type : DT 615
Max. output : 180,5 kW (40 hZ)
(147,5 AT 2400 RPM)
Max. torque : 465 Nm (30 hZ)
(47,4 mkg at 1800 rpm)
Type : 4-stroke diesel engine with direct injection and
turbocharging
Number of cylinders :6
Bore : 104.2 mm
Stroke : 120.7 mm
Total cubic capacity : 6.17 Ltrl
Compression ratio : 16:1
Compression pressure (with warm engine, 270 rpm) : 2440-2640 kPa (24.4-26.4 bar)
Compression pressure, acceptable difference
between cylinders : 1.5 bar
Injection sequence : 1-5-3-6-2-4
Injection timing : 26° before TDC
Idle engine speed : 650 -700 rpm
Max. full-load engine speed : 2400 rpm
Max. no-load engine speed : 2620 rpm
Oil pressure at 2000 rpm (warm engine) : 2.75 - 3.75 bar
Oil pressure at idling speed : > 0.8 bar
Coolant temperature during operation : 75-80 °C
Valve clearance, : 0.5 mm (warm and cold)
Valve timing diagram with valve clearance of 1 mm
Inlet valve opens : 3° after TDC
Inlet valve closes : 34° after BDC
Exhaust valve opens : 33° before BDC
Exhaust valve closes : 2° before TDC
b. Coupling
Make : Fichtel and Sachs

Type : 350 with diaphragm spring
Diameter of clutch plater : 350 mm
Operation hydraulic : hydraulic
Min thickness clutch plate : 7.8 mm
2-2-1
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c. Fuel system
(1) Fuel injection

Make : R. Bosch
Type : PE 6 A 90 D 320 RS 2384 (2547)
(2) Regulator : R. Bosch

Make : EP/RSV 250-1200 A 5 B 779 R
Type (all speed) : 2400 rpm
Max. engine speed (loaded) : 1200 rpm
Pump speed
(3)Air filter
Make: : mann & Hummel
Type : 241505 with disposable element4
(4 Injectors
Make : R. Bosch
Nozzle type : DLL 150 S 450
Opening pressure : 216 - 224 bar
(5)Turbocharger
Make : Holset
Nozzle type : 3 L D 9/2.40
Full load. : 0.64 - 0.71 bar
d. Electrical system
(1) Dynamo
Make : Bosch
Bosch no.0.120.600.574
Type : alternating current
85A -28V
(2) Starter motor

Make : R. Bosch
Type : J.D: 24V
Bosch no : 0.001.360.058
Rated output : 4 kW
Number of brushes :4
Brush pressure : 3600 - 3800 grams
Axial play of the armature : 0.1 - 0.3 mm
Minimum collector diameter : 39.5 mm
Minimum acceptable brush length : 15.5 mm
(3) Glow plugs

Number :4
Make : Beru 0.102.124.402
Type : two-pole
Voltage : 12 Volt
Capacity : 700W
2-2-2
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e. Gearbox
Make : ZF
Type : S5 - 35/2
Transmission ratios
1st gear : 6.79:1
2nd gear : 3.97:1
3rd gear : 2.42:1
4th gear : 1.49:1
5th gear : 1.00:1
reverse gear : 6.10:1
Power take off : N 352/1 b (YAK)
f. Transfer box
Make : ZF
Type : VG 250/2
Transmission ratios : Willi Elbe
High : 1:1
Low : 1:2,027
g. Intermediate shafts
Make : Gelenkwellenbau
Type : 387.20
Intermediate shaft, PTO : Willi Elbe

Make : D75-131
h. Front axle
Make : DAF
Type : 2235 V
Gear ratio : 5.72 : 1
Caster : 2°
Camber angle : 1°
King pin angle : 9°30’
Toe-in : 0-1 mm
i. Rear axle
Make : DAF
Type : 1635
Gear ratio : 5.721 :1
j. Air compressor
Make : Clayton Dewandre

Type : PGG A 900
2-2-3
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k. Steering gear
(1)Steering box
Make : ZF
Type : 8042 (Hydraulic assisted)
Max. pressure : 130 bar
(2)Steering pump
Make : ZF
Type : 7674
Max. flow rate : 16 l/min
l. Springs and shock absorbers
(1)Front springs
Make : DAF
Length : 1540 mm
Number of leaves x thickness : 8x14 mm
(2)Rear springs Make

Length : DAF
Number of leaves x thickness : 1540 mm
: 8 x 14 mm
(3)Shock absorbers : KONI

Make : 88
Type : dubble action and adjustable
m. Cabin.
Make : DAF
Type : 218
2-2-4
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2.2.4 Tightening torque
Tightening must be performed with a force on the spanner that results in the technically-correct attachment
of the component. Use a torque wrench when the tightening torque is specified.
Description Tightening torque [Nm]
Oil sump, drain plug 78-88 Nm

Oil sump, attachment bolts 25-27 Nm
Engine side covers, attachment bolts 25-27 Nm
Engine mounting front, bolts and nuts 93 Nm
Engine mounting rear, bolts and nuts 86 Nm
Inspection cover flywheel housing, bolts 25-27 Nm
Fuel injector pipes, union nuts MAX. 25 Nm
Exhaust pipe, bolts and nuts 48-51 Nm
Fan, attachment bolts 25-27 Nm
Wind tunnel, attachment bolts 25-27 Nm
Radiator supports, bolts and nuts 48-51 Nm
Attachment bolts, thermostat-housing cover 20-25 Nm
Coolant pump pulley, bolts 87-93 Nm
Coolant pump, attachment bolts 25-27 Nm
Alternator pulley, nut 120-150 Nm
Starter motor, attachment bolts 48-51 Nm
Gearbox, filler and drain plugs 50 Nm
Transfer box filler and draining plugs 50 Nm
Transfer box supports, bolts and nuts 100 Nm
Intermediate shaft flange, bolts and nuts
transfer box / gearbox 86 Nm
transfer box / front axle 130 Nm
transfer box / rear axle 130 Nm
power take off / hydraulic pump 9,9 Nm
Axle shaft nuts 95 Nm
Wheel nuts 390-470 Nm
Wheel hub nut 147-162 Nm
Wheel hub lock nut 441-490 Nm
Steering rod ball ends, castle nut 230-280 Nm
Track rod ball ends, castle nut 201-225 Nm
Bolts, steering bracket - chassis 150-175 Nm
Ball ends clamp bolts 40-50 Nm
Towing hook, central nut 300-900 Nm
U-bolt nuts 600-650 Nm
Spring seat clamp bolts 87-93 Nm
Spring shackle clamp bolts 87-93 Nm
2-2-5
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2-2-6
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3 MAINTENANCE
3.1 GENERAL.
3.1.1 2nd Level Maintenance
2nd level maintenance is part of the parts maintenance and is carried out by 2nd level technicians
possibly aided by the crew. This maintenance includes both preventive and corrective maintenance
activities and, exceptionally, implementing changes.
3.1.2 Preventive maintenance
The purpose of preventive maintenance is to lessen the chance of non-deployability of the equipment or
to make it deployable.
It consists of:
– carrying out the prescribed actions
– inspection
– the replacement of components of the equipment in question.
3.1.3 Corrective maintenance
The purpose of corrective maintenance is to make equipment which cannot be deployed capable of being
deployed again in accordance with the prescribed norms.
It consists of:
– fault detection and fault location
– carrying out the prescribed actions (such as adjustment)
– Repairing (parts of) the equipment.
3.1.4 Modifications
The purpose of modifications to the equipment is:

– to change the functional characteristics of the equipment
– to extend its operational life
– to lower maintenance costs.
3.1.5 Responsibility
The 2nd level technician is responsible for the correct execution of the tasks assigned to him.
Commanders of maintenance groups are responsible for 2nd level maintenance of the equipment.
All faults which the 2nd level can not or may not repair must be reported to the 3rd level.
If the vehicle is offered to the 3rd level then the 2nd level should ensure that the vehicle is reasonably
clean;
this means dry and not caked with mud which would hinder inspection. Washing of the vehicle
immediately before the inspection should be avoided as various defects such as loose parts and oil leaks
are not observable immediately after washing.
1st and 2nd line maintenance should be carried out in full.
3.1.6 Authority
The 2nd line technician is authorised to replace spare parts which are included in 2DL and these should
be requested if necessary.
3-1-1
3.1.7 General instructions 2 TH 9-3900
a. Adjustment
Carry out all necessary adjustments as indicated in this manual or in the applicable technical bulletins (TBs) or
care instructions (VIs).
b. Cleaning
Clean the parts of old grease, dirt and other contamination.
If special cleaning methods are required then these will be specified in the relevant section of the manual.
NOTE: No use may be made when cleaning of a steam cleaner or high-pressure spray because this also
removes the corrosion protection.
c. Tightening.
Tightening must be performed with a force on the spanner that results in the correct tightening torque or, if the
torque is not specified, in accordance with proper technical insight.
Use a torque wrench if the tightening torque is specified.
Do not tighten too much in order to avoid damage to the thread or distortion of the part. Tightening also includes
the correct installation of circlips, lock nuts, locking wire or split pins.
3.1.8 Spare parts
Spare parts are included in the 2DL and are supplied for the replacement of parts that are broken, worn or
otherwise non-functional.
3.1.9 Tools
Tools, intended for 2nd level maintenance and the repair of the vehicle are issued according to the AS and are
classified as:
a. Organic standard tools
b. Special Tools
These tools are specified in Table 3.1.1. and are illustrated in Fig. 3.1.1.
The table shows which tools are required for the activities described in this technical manual.
TABLE 3.1.1. SPECIAL TOOLS
Fig. no. Description Intended for

- nsn 5180-17-102-2329 bleed tank Tool kit for filling and bleeding brake and clutch system.
a. 1 Hub nut wrench Hub nut
DAF no. 8-535648
b. 1 Filler strip insertion tool Windows installation
DAF no. 1-535687
C. 1 Jig Adjustment of windshield wiper
DAF no. 5-535833
d. 1 Puller Disassembly of coolant pump pulley
DAF no. 535956
e. 1 Ancillary torque wrench Allen screws between axles
DAF no. 535989
535991
3-1-2
2 TH 9-3900
Fig. 3.1.1 a.Hub nut wrench Fig. 3.1.2 b. Filler strip insertion tool
Fig. 3.1.3 c.Jig Fig. 3.1.4 d .Puller
Fig. 3.1.5 e. Ancillary torque wrench
3-1-3
2 TH 9-3900
3-1-4
2 TH 9-3900
3.2 ACTIONS TO BE TAKEN ON RECEIPT OF THE EQUIPMENT
3.2.1 General
Upon receipt of a new or overhauled vehicle by the operating unit, the 2nd level technicians must
determine whether the vehicle has been delivered by the issuing unit in a proper state of repair and
whether it satisfies all the requirements set.
Check all of the main components, assemblies and accessories for proper installation, attachment,
cleanliness, adjustment and lubrication.
Check whether the accessories indicated in the 1DL of the vehicle in question are present, in good state
of repair, clean and properly stored.
Furthermore, the 2nd level technicians must take a new or overhauled vehicle on a test drive of suitable
number of kilometres that the entire vehicle and its operation are checked. The driver must also be
present during this test drive. Next, the vehicle must be subjected to a special maintenance schedule for
the first 5000 km and/or 125 running hours.
Thereafter, the vehicle may be serviced according to the normal maintenance schedule.
3.2.2 Test drive
Carry out maintenance in accordance with 0K9.3900
3.2.3 Inspection and maintenance during the break-in period
a. At 500 km and/or 12.5 running hours.

(1) During the warranty period. Present the vehicle to the directly supporting unit.
(2) After the warranty period.
a. check cylinder head nuts and bolts
Present the vehicle to the directly supporting unit.
b. replace lubricating oil filter
c. replace engine oil.
b. At 2500 km and/or 62.5 running hours.

a. check cylinder head nuts and bolts
Present the vehicle to the directly supporting unit.
b. change the oil of the hydraulically-assisted steering system and replace the filter element in the
reserve tank
c. replace fuel fine filter
d. change oil in the gearbox and the transfer box
e. change the oil in the front and rear axles.
f. check the wheel bearing play and adjust if necessary.
g. check the stroke length of the brake cylinders and adjust the brakes if necessary.
Carry out maintenance as described in the IWK, 2nd level, 5000 km and/or 125 running time or 6 monthly
interval.
3.2.4 Service prior to transfer
If a vehicle is to be transferred to another unit then the 2-weekly service should first be carried out in
accordance with the IWK, 2nd level, LF 15729.
3-2-1
2 TH 9-3900
3-2-2
2 TH 9-3900
3.3 PREVENTIVE MAINTENANCE
3.3.1 Intervals
The periods between maintenance servicing are specified in the Inspection Work Card, 2nd level, LF 15729.
If the equipment is however used under abnormal conditions such as extremely high or low temperatures,
fording, etc., then more frequent maintenance is necessary.
Commanders are then authorised to shorten the period between two maintenance services if circumstances
make this necessary.
3.3.2 Inspection and test drive
The crew is not always aware of a defect that may develop gradually. It is therefore necessary that a 2nd line
technician test the vehicle. Before and/or after this test drive, the necessary repairs and adjustments are
performed (depending on the equipment in question).
Defects that can not or may not be repaired must be reported to the next higher level.
Before the test drive is carried out, maintenance must be performed according to the OK9-3900.
3.3.3 Maintenance in accordance with the Inspection Work Card.
The periodic 2nd line maintenance on the vehicle is specified in the Inspection Work Card, 2nd level, 2 IWK 9-
3900 LF 15729.
3.3.4 Location of lubrication points
For the lubrication of the vehicle consult the Inspection Work Card, 2nd level, and the relevant sections of this
technical manual.
For the location of the lubrication points see figures 3.3.1. to 3.3.15.
Fig. 3.3.1 Cab hinge points and steering axle Fig. 3.3.2 Door hinge lubrication points
1. Lubrication point, steering-shaft universal joint
2. Lubrication point, cab hinge
3. Lubrication point, brake pedal shaft
3-3-1
2 TH 9-3900
Fig. 3.3.3 Lubrication point, cab lift-cylinder pivot Fig. 3.3.4 Lubrication point, shackle pin (front
point
Fig. 3.3.5 Lubrication points, spring shackle Fig. 3.3.6 Lubrication point, stub-axle bearing (top
(front) and bottom)
Fig. 3.3.7 Lubrication point, drive-shaft needle Fig. 3.3.8 Lubrication points, brake camshaft (front)
bearing
3-3-2
2 TH 9-3900
Fig. 3.3.9 Lubrication point, clutch shaft Fig. 3.3.10 Lubrication point, shackle pin (rear)
Fig. 3.3.11 Lubrication points, spring shackle Fig. 3.3.12 Lubrication point universal joints for
(rear) intermediate shafts
Fig. 3.3.13 Lubrication points, brake camshaft Fig. 3.3.14 Lubrication points, towing hook
(rear)
3-3-3
2 TH 9-3900
Fig. 3.3.15 Lubrication points (oil can), clutch Fig. 3.3.16 lubrication points, intermediate shaft
pedal power take off (YAK)
3-3-4
2 TH 9-3900
3.4 ENGINE
3.4.1 CHANGING THE ENGINE OIL (FIG. 3.4.1. AND 3.4.2)
NOTE: Drain oil, preferably with a warm

engine.
a. Position the vehicle on a level surface.

b. Place a c. 15 litre bin under the oil sump.
c. Loosen the drain plug; use an open-end
spanner to prevent the adapter from turning.
d. Change the oil filter, see item 3.4.2.
e. If necessary replace the gasket and tighten the
drain plug again to the prescribed torque in the
oil sump.
f. Top up the engine with the specified type and Fig. 3.4.1 Draining the engine oi
quantity of engine oil. 1. Oil sump
g. Check the oil level and fill as necessary to reach 2. Adapter plug
3. Drain plug
the correct level.
Fig. 3.4.2 Filling up with engine oil (YA(L))

Fig. 3.4.2a Filling up with engine oil (YA(K)
3.4.2 REPLACING THE OIL FILTER (FIG. 3.4.3).
NOTE: The oil filter must be replaced

whenever the oil is changed.
a. Remove the filter by turning it anti-clockwise.

b. Lubricate the seal of the new filter with oil
fuel.
c. Fit the new filter and tighten it by hand.
d. Check the filter for leaks after running the
engine briefly. Fig. 3.4.3 Changing the oil filter
1. Lubricating oil filter
2. Air inlet pipe
3. Fuel injection pum
3-4-1
2 TH 9-3900
3.4.3 CRANKCASE VENTILATION (FIG. 3.4.4.)
a. Removal
(1) Tip the cab (see 1 TH9-3900)
(2) Remove the drain hose (2).
(3) Loosen the connecting hose (3) between
the oil separator (1) and the oil sump.
b. Cleaning
(1) Flush both hoses and the oil separator
properly in clean diesel fuel.
(2) Blow the oil separator through with
compressed air.
c. Installation
(1) Install in the reverse order.
3.4.4 VALVE COVER (FIG. 3.4.5.)

Fig. 3.4.4 Cleaning of the crankcase breather
a. Removal
1. Oil separator
(1) Tip the cab (see 1 TH9-3900) 2. Drain hose
(2) Release the three attachment bolts of the 3. Connecting hose
valve cover.
(3) Remove the valve cover.
b. Installation
(1) Remove all remains of the old gasket.
(2) Check the injector fuel leak-off pipe for
leaks.
(3) Clean the valve cover thoroughly in clean
diesel fuel.
(4) Replace the valve cover with its new
gasket.
(5) Tighten the attachment bolts.
Fig. 3.4.5 Valve cove
3.4.5 VALVE CLEARANCE ADJUSTMENT (FIG. 3.4.6. and 3.4.7)
NOTE: Setting the valve clearance must be performed when the engine is stationary. The engine may
be cold or warm. "Overlap" is the moment at which the inlet valve starts opening and the exhaust
valve is not yet closed.
The engine can be rotated by placing a socket (36 mm) with a ratchet handle on the attachment
bolt of the alternator pulley.
The stop lever of the fuel injection pump must be blocked in the rest zero position using the stop
lever.
a. Tilt the cab.

b. Remove the valve cover, see item 3.4.4.
c. Crank the engine anti-clockwise seen from the flywheel side until the valves of the 6th cylinder are in
overlap position.
d. Adjust the valve clearance of the inlet and exhaust valve (1i and 1u) of the 1st cylinder.
(1) Loosen the lock nut (1).
(2) Screw the adjustment (2) bolt in or out until
the feeler gauge indicates the correct
clearance.
(3) Tighten the lock nut properly; make sure
that the adjusting bolt does not turn by
using a screwdriver.
e. Set the valve clearance of the other valves:
(1 ) Crank the engine further until valve 2i
3-4-2
2 TH 9-3900
opens and set the clearance for valves 5i

and 5u.
(2) Crank the engine further until valve 4i
and 3u.
and 6u.
and 2u.
and 4u.
3.4.6 VALVE ADJUSTMENT BOLTS (FIG. 3.4.6.).
a. Removal
(1) Tilt the cab.
(2) Remove the valve cover, see item 3.4.4.
(3) Remove the lock nut (1).
(4) Remove the valve adjustment bolt (2) from
the valve rocker.
Fig. 3.4.6 Setting valve clearanc
(5) Check the rocker and valve cover.
1. Lock nut
2. Adjusting bolt
b. Installation
(1) Screw the adjustment bolt into the rocker.
(2) Fit the lock nut.
(3) Adjust the valve play, see item 3.4.5.
Fig. 3.4.7 Valve configuration
3-4-3
2 TH 9-3900
3.4.7 OIL SUMP (SEE FIG. 3.4.8.).
a. Removal
(1) Drain the engine oil (see point 3.4.1).
(2) Remove the lower guide ring support (1).
(3) Remove the support for the air blow-off
valve (2).
(4) Remove the filler / bleeder pipe, see item
3.4.3.
(5) Remove the attachment bolts from the oil
sump and remove the oil sump.
(6) Remove all remains of the old gasket.
b. Installation
(1) Fit a new gasket.
(2) Fit the oil sump in place and tighten the
attachment bolts to the prescribed torque.
(3) Reinstall the parts which were removed.
Fig. 3.4.8 Oil sump

1. Guide ring support
2. Air blow-off valve
3.4.8 REMOVAL / INSTALLATION OF THE INSPECTION COVER OF THE FLYWHEEL HOUSING (FIG.
3.4.9.).
a. Removal
(1) Detach the attachment bolts of the
inspection cover.
(2) Put the cover (1 ) complete with the fitted
electrical cable box on one side so that the
flywheel (4) and the indicator needle (3) are
visible.
(3) Use a new gasket (2) when fitting the cover.
b. Installation
(1) Installation in reverse order.
(2) Use a new gasket when fitting the cover.
Fig. 3.4.9
1. Inspection cover
2. Gasket
3. Indicator needle
4. Flywheel
3-4-4
2 TH 9-3900
3.4.9 SIDE COVER
a. Left-rear side cover (Fig. 3.4.10.).

(1) Removal
a. Tilt the cab.
b. Open the drain cock of the engine block
(right rear) and tap off the coolant (see
item 3.8.4.).
c. Disconnect the cylinders of the fuel
pump stop control and of the engine
brake operation.
d. Disconnect the connection of the air
hoses.
e. Remove the side cover.
(2) Installation Fig. 3.4.10
(a) Remove all remains of the old gasket. 1. Heat shield (turbocharger)
(b) Fit the side cover with a new gasket and 2. Heat shield (engine-brake housing)
with new gaskets under the bolt heads.
(c) Attach all the parts which were removed.
b. Right-front side cover (Fig. 3.4.11. ).

(1) Removal
(a)Tilt the cab.
(b)Disconnect the alternator, see item 3.9.1.
(c) Remove the side cover
(d) Remove all remains of the old gasket.
(2) Installation
(a) Fit the side cover with a new gasket and
with new gaskets under the bolt heads.
(b) Fit the alternator in position.
(c) Adjust the tension of the V-belts (see
item 3.8.8.)
Fig. 3.4.11
c. Right-rear side cover (Fig. 3.4.12.).

(1) Removal
(a) Tilt the cab.
(b) Disconnect the reservoir of the hydraulic
steering assistcomplete with bracket
and connected hoses.
(c) Disconnect the electrical wiring pipe.
(d) Remove the side cover.
(e) Remove all remains of the old gasket.
Fig. 3.4.12
3-4-5
2 TH 9-3900
(2) Installation
(a) Fit a new gasket to the cover and fit the cover.
(b) Tighten the bolts.
(c) Reinstall the parts which were removed.
Fig. 3.4.13
1. Heat shield bracket 8. Engine brake housing
2. Turbocharger 9. Heat shield bracket
3. Spacer ring 10. Stop lever
4. Nut 11. Air cylinder
5. Heat shield bracket 12. Adapter
6. Sealing rings 13. Seal ring
7. Heat shield bracket 14. Exhaust pipe
15. Gasket
3.4.10 ENGINE BRAKE (FIG. 3.4.11).
a. Removal
(1) Tilt the cab.
(2) Loosen the connection between the air cylinder (11) and the stop lever (10).
(3) Remove the heat shields (Fig. 3.4.10.)
(4) Remove the front exhaust pipe (14).
(5) Remove the steel sealing ring (13) between the flange of the exhaust pipe and the cast-iron
adapter(12).
(6) Remove the nuts (4) and the spacer rings (3); remove the engine-brake housing (8) together with the
adapter from the turbocharger (2).
(7) Separate the engine-brake housing and adapter from one another.
(8) Check the sealing rings (6).
b. Installation
(1) Fit the removed parts in the reverse order.
There are arrows on the sealing ring; these must point in the direction of the exhaust gas flow.
When assembling the engine-brake housing and the adapter make sure that these parts can be
attached in place without twisting them.
3-4-6
2 TH 9-3900
3.4.11 ENGINE BRAKE OPERATING MECHANISM (FIG. 3.4.14.- 3.4.15. - 3.4.16.).
a. Removal
(1) Tilt the cab.
(2) Mark the pipes of the engine brake valve
(Fig. 3.4.14.) and remove the pipes. The
valve is located bottom left of the cab floor.
(3) Remove the attachment nut from the
engine brake valve. The nut is located in
the cab on the floor plate. Remove the
valve.
(4) Take the connection cables of the pressure
switch against the left chassis member
(Fig. 3.4.15.).
(5) Remove the air cylinders (1) and (2), see
Fig. 3.4.16.
(6) Remove all lines.
b. Installation Fig. 3.4.14 Engine brake valve

1. Nipple
NOTE: Each part can be replaced separately 2. Engine brake valve
so there is no assembly sequence with 3. Nut
the exception of the first three items.
Turn the ball coupling on the adapter
until the centre-to-centre distance from
the ball coupling to the pivoting point of
the cylinder is 319 ± 1 mm.
(1) Always use new gaskets.
Fig. 3.4.15
Fig. 3.4.16
1. Air cylinder for fuel pump
2. Air cylinder for engine brake valve
3-4-7
2 TH 9-3900
3.4.12 ENGINE MOUNTS AND RUBBER HANGERSS
NOTE: Never remove more than one engine

bracket and/or rubber hangers at once.
a. Front (Fig. 3.4.17.).

(1) Removal
(a) Tilt the cab.
(b) Remove the bolts (1) of both the left
and the right rubber hangers.
(c) Place a jack under the oil sump with a
heavy piece of wood between the jack
and the sump.
(d) Jack the engine up carefully until the
tension is removed from the rubber
hangers (5).
(e) Remove the bolt (4) and take off the
bracket (3) and the rubber.
(f) Loosen the nut (2) and take the rubber
hangers from the bracket.
(2) Installation
(a) Place the rubber hangers on the engine Fig. 3.4.17 Engine mount, front
bracket but do not yet tighten the bolt. 1. Bolt
(b) Attach the bracket and rubber in 2. Support
reverse order to removal. 3. Bolt
4. Rubber hangers
(c) Tighten the bolt of the opposite rubber
hangers again.
b. Rear (Fig. 3.4.18.).

(1) Removal
(a) Tilt the cab.
(b) Remove the bolt (6) of both the left and
the right rubber hangers (4).
(c) Place a jack under the flywheel housing
with a heavy piece of wood between the
jack and the flywheel housing.
(d) Remove the four bolts (2) in the flange
of the rubber hangers to be removed.
(e) Jack the engine up carefully until the
rubber hangers is loose.
(f) Remove the four nuts (1) and then the
bracket (5) and the rubber hangers.
(2) Installation
(a) Attach the engine bracket and the
rubber hangers in reverse order to
removal; the stop plate (3) with the
double breast goes underneath.
(b) Tighten the bolt of the opposite rubber
hangers again.
Fig. 3.4.18 Engine bracket rear

1. Nut
2. Bolt
3. Stop plate
4. Rubber hangers
5. Support
6. Bolt
7. Sealing ring
8. Nut
3-4-8
2 TH 9-3900
3.5 CLUTCH ASSEMBLY
3.5.1 CLUTCH HOUSING INSPECTION COVER (if present) (FIG. 3.5.1.).
a. Removal
(1) Detach the two bolts.
(2) Remove the cover (and gasket),
b. Installation
(1) Install in reverse order.
Fig. 3.5.1 Clutch housing inspection cover
3.5.2 DECLUTCHING LEVER (FIG. 3.5.2).
a. Removal
(1) Remove the spring (1).
(2) Loosen the connection between the
operating cylinder and the lever (3).
(3) Remove the bolt from the lever (2).
(4) Remove the lever.
b. Installation
Fig. 3.5.2
1. Spring
2. Bolt
3. Lever
3.5.3 CLUTCH PEDAL SUSPENSION (FIG. 3.5.3).
a. Removal
(1) Undo the spring (1).
(2) Remove the pin (3) from the pivot point of
the pedal and the push rod.
(3) Remove the circlip from the pivoting point
(2) of the pedal and push rod.
(4) Remove the pedal.
(5) Remove the yoke (4) on the push rod.
b. Installation
(2) For adjustment see item 3.5.9.
Fig. 3.5.3
1. Spring
2. Axle
3. Pin
4. Yoke
3-5-1
2 TH 9-3900
3.5.4 OPERATING CYLINDER (SEE Fig. 3.5.4.).
a. Removal
(1) Disconnect the connection between the
fluid reservoir and the operating cylinder.
(2) Catch the fluid which flows out in a clean
reservoir.
(3) Undo the connection between the
operating cylinder and the pressure pipe to
the actuating cylinder.
(4) Remove the two bolts and take away the
cylinder; the push rod stays behind.
b. Installation
(1) To install, carry out the operations in
reverse order.
(2) Fill the reservoir and bleed the system (see
item 3.5.8.).
Fig. 3.5.4 Operating cylinder

3.5.5 3.5.5.ACTUATING CYLINDER(SEE Fig. 3.5.5.). 1. Reservoirr 5. Brake pedal
2. Steering column 6. Engine brake button
a. Removal 3. Clutch pedal 7. Fuse boxes
(1 ) Drain the cylinder and line by undoing the 4. Operating cylinder
bleed screw.
(2) Catch the fluid in a clean reservoir.
(3) Undo the connection between the actuating
cylinder and the clutch lever.
(4) Undo the two bolts and remove the
actuating cylinder.
b. Installation
reverse order.
3.5.6 PIPES AND BRACKETS
a. Removal
(1) Tilt the cab if necessary for access to the
pipes.
(2) Pipes can be removed complete by
detaching the couplings. Fig. 3.5.5 Actuating cylinder
(3) Catch the fluid which flows out in a clean 1. Spring
reservoir. 2. Nut
(4) Plug the pipes. 3. Clutch lever
4. Actuating cylinder
b. Installation 5. Bleed screw
(1) To install, carry out the operations in 6. Fluid hose
reverse order.
(2) Fill the reservoir and bleed the system (see
item 3.5.83.
3-5-2
2 TH 9-3900
3.5.7 FLUID RESERVOIR (SEE Fig. 3.5.6.)
a. Removal
(1) Remove the line to the operating cylinder.
(2) Catch the fluid in a clean reservoir.
(3) Remove the fluid reservoir and pipe.
b. Installation
reverse order.
(2) Fill and bleed the system.
(see item 3.5.8.).
Fig. 3.5.6 Clutch fluid reservoir
3.5.8 FILLING AND BLEEDING THE HYDRAULIC SYSTEM (SEE FIG. 3.5.6. AND 3.5.7.)
a. Inspect the whole system for any leaks (damp patches).

b. Check the smooth operation of the clutch pedal, the operation of the return spring, pedal height, pedal
travel and the adjustment of the thrust pin (pedal free travel).
c. The routing of the lines.
NOTE: For the proper operation of the system it is necessary that the lines are not kinked and that they
run directly from low to high. In general terms, the less favourable the lie of the lines is, the more
difficult they are to bleed.
d. Connect the ventilating tank (see Table 3.1.1) to

the bleed nipple of the actuating cylinder. Open
the nipple.
e. Fill / bleed the clutch control with the ventilating
tank, be aware that if filling is too rapid then
foaming will occur making bleeding impossible.
f. Fill / bleed the clutch operation to the correct
level in the fluid reservoir. Close the nipple.
WARNING: ENSURE THAT NO LIQUID IS

SPILT IN THE CAB DURING THE
FILLING / BLEEDING
OPERATION.
Fig. 3.5.7
1. Bleed nipple
3-5-3
2 TH 9-3900
3.5.9 ADJUSTMENT OF THE PEDAL TRAVEL AND THE FREE TRAVEL (SEE FIG. 3.5.8.).
(only after repair of the operating mechanism in the cab)
a. Remove the pedal rubber.

b. Use the adjusting bolt to set a distance of 181
mm between the floor mat and the upper side of
the clutch pedal (without rubber).
c. Use the adjusting bolt (2) to set the total pedal
travel to 200 mm.
d. Now check whether the pedal can be moved
about 6 mm down before resistance is felt.
e. If necessary set the distance of 6 mm by
loosening the lock nut (3) and turning the push
rod in or out as required.
Fig. 3.5.8
1. Adjusting bolt
2. Adjusting bolt
3. Lock nut
3-5-4
2 TH 9-3900
3.6 FUEL SYSTEM
3.6.1 FUEL INJECTOR PIPE (SEE FIG. 3.6.1.).
a. Removal
(1) Tilt the cab.
(2) Loosen the union nut (4) on the injection
pipe at the fuel pump.
(3) Loosen the union (2) from the connector of
the injector; prevent the connector from
turning as well (1) using a open-ended
spanner.
(4) Disconnect the clamping pieces (3) from
the pipe. Fig. 3.6.1
(5) Remove the line. 1. Connecting piece
(6) Plug the openings. 2. Union
3. Clamping piece
4. Union
b. Installation
3.6.2 FUEL LEAK-OFF PIPE FROM THE INJECTOR (SEE FIG. 3.62).
a. Removal
(1) Tilt the cab.
(2) Remove the valve cover, see item 3.4.4.
(3) Loosen the banjo bolts (1) on the injectors
and on the valves casing.
(4) Remove the pipe (2).
b. Installation
(1) Refit the fuel pipe; fit new gaskets.
(2) Check the fuel leak-off pipe for leakage
while the engine is idling.
Fig. 3.6.2
1. Banjo bolt
2. Fuel leak-off pipe
3.6.3 AIR PIPES AND HOSES. (SEE Fig. 3.6.1).
a. Removal
(1) Tilt the cab.
(2) Remove the air hose (3) between the air
filter (4) and air pipe (1 ).
(3) Remove the air hose between the
turbocharger and the air pipe.
(4) Remove the underpressure switch from the
air pipe.
(5) Remove the air pipe.
b. Installation
- Installation in random order.
Fig. 3.6.3
1. Air pipe
2. Underpressure switch
3. Air hose
4. Air filter
3-6-1
2 TH 9-3900
Fig. 3.6.4
1. Filter housing
2. Vane ring
3. Filter element
4. Nut
5. Lid
6. Dust container
3.6.4 AIR FILTER AND AIR FILTER ELEMENT (SEE FIG. 3.6.4.).
a. Removal
(1) Detach the two clamping brackets and remove the dust container (6).
(2) Unscrew the nut (4) in the centre of the filter.
(3) Remove the filter element (3) from the filter housing.
(4) Take out the vane ring (2).
(5) Disconnect the clamping strip from the air intake hose.
(6) Disconnect the clamping strips from the air filter housing (1).
(7) Remove the air filter housing.
b. Cleaning
(1) Remove the cover (5) from the dust container (6) and remove the collected dirt out of the dust
container.
(2) Clean the filter element by blowing compressed air through it from the inside out and carefully tapping
it on a surface which is not too hard.
c. Installation
(1). To install, carry out the operations in reverse order. Remember the correct position of the dust
container: position the mark TOP at the top.
3-6-2
2 TH 9-3900
3.6.5 FUEL RESERVOIR (SEE Fig. 3.6.5.).
a. Removal
(1) Remove the drain plug (5) with the filter;
drain the fuel.
(2) Disconnect the connection cable from the
fuel gauge sender.
(3) Disconnect the three pipes above the
reservoir; plug the pipes.
(4) Remove the two attachment rods (2) which
keep the reservoir in position.
(5) Remove the reservoir from its holders (4);
do not remove the felt strips (3).
b. Cleaning
(1) Clean the drain plug and filter in clean fuel.
(2) Clean the reservoir in clean fuel. It is not
permitted, for example, to use a steam Fig. 3.6.5
cleaner or chemical agents for cleaning. 1. Rubber strip
2. Attachment rod
3. Felt strip
c. Installation 4. Support
(1) To install, carry out the operations in 5. Copper ring
reverse order. 6. Plug and filter
NOTE: When fitting the drain plug always use

a new copper ring and make sure that
the filter slides round the suction pipe
in the reservoir.
(2) Fill the reservoir.
3.6.6 BLEEDING THE FUEL SYSTEM (SEE FIG. 3.6.6.).
a. Tilt the cab.

b. Unscrew the knurled knob of the fuel lift pump.
c. Move the knob up and down until a great pressure is felt.
d. Move the knob down and turn it tight again.
e. Check for leaks.
Fig. 3.6.6 Fuel lift pump control button
3-6-3
2 TH 9-3900
3.6.7 FUEL PIPES
NOTE: Take the necessary precautions to prevent fuel splashing.
a. Removal
(1) Tilt the cab if necessary.
(2) Disconnect the connections from the pipe and plug the openings.
(3) Disconnect the clamps and remove the pipe.
b. Checking and cleaning.

(1) Always clean (including new pipes! ) internally by blowing compressed air through them.
(2) Check whether the sealing surfaces of the banjo's are completely flat and undamaged.
c. Installation
NOTE: Fuel pipes must always be fitted without any tension. Never twist a pipe into place but bend it as
necessary. Always use new gaskets.
(1) Hand tighten union nuts and banjo bolts as tight as possible.
(2) Secure the pipe with the attachment clamp(s).
(3) Tighten the union nuts and banjo bolts to the specified tightening torque.
NOTE: Assembly of a new plastic pipe:

NOTE: Heat a plastic hose of the desired length in hot water (c. 700C.) and slide the hose onto the
banjo.
(4) Bleed the fuel system see item 3.6.6.

(5) Check for leakage.
3.6.8 FUEL RESERVOIR FILLER CAP, PIPE AND FILTER (SEE FIG. 3.6.7.).
NOTE: The filler cap is attached to the filler

pipe by a chain. Filler pipe and filter
are a single unit.
a. Removal
(1) Remove the filler cap.
(2) Pull the filler cap until the filler pipe knocks
against its stop.
(3) Turn the pipe until it can be completely
removed.
b. Cleaning and checking.

(1) Wash the filter in clean fuel.
(2) Check the filler cap, filler opening and
gasket for damage.
c. Installation
(1) Installation in reverse order. Fig. 3.6.7
3-6-4
2 TH 9-3900
3.6.9 FUEL FINE FILTER (SEE Fig. 3.6.8.).
NOTE: Take the necessary precautions to

prevent fuel splashing.
a. Removal
(1) Tilt the cab.
(2) Turn the filter anti-clockwise.
(3) Remove the filter and dispose of it.
b. Installation
(1) Install a new filter.
NOTE: The filter may only be tightened by

hand.

(3) Check for fuel leaks.
Fig. 3.6.8 Fuel filter

3.6.10 FUEL COARSE FILTER (SEE Fig. 3.6.9.).
NOTE: Take the necessary precautions to

prevent fuel splashing.
a. Removal
(1) Remove the drain plug (8).
(2) Loosen the central bolt (7).
(3) Remove the reservoir (6) and clean it
internally.
(4) Unscrew the plastic round nut (5).
(5) Remove the filter element (4).
(6) Clean the filter element in clean fuel.
b. Installation
(1) Check the 0-ring (3); replace if necessary.
(2) Mount in reverse order.
(4) Check for fuel leaks.
Fig. 3.6.9
1. Bolt
2. Banjo bolt
3. O-ring
4. Filter element
5. Round nut
6. Reservoir
7. Central nut
8. Drain plug
3-6-5
2 TH 9-3900
Fig. 3.6.10
1. Cold start lever
2. Lever linkage
3.6.11 COLD START CONTROL CABLE (SEE Fig. 3.6.10.).
a. Removal
(1) Tilt the cab.
(2) Disconnect the outer cable from the cold
start lever (1).
(3) Detach the inner cable from the lever
linkage (2).
(4) Detach the cold start knob from the
attachment bracket under the air filter (see
fig. 3.6.11.).
(5) Detach the other attachment points.
(6) Remove the cold start control cable.
b. Installation
(1) Assemble in the reverse order.
NOTE: When assembling the inner cable to

the lever linkage (2) make sure that the
cable is tight but hat the still has a
slight play.
Fig. 3.6.11
3-6-6
2 TH 9-3900
3.6.12 GLOW PLUGS
a. Removal (see Fig. 3.6.12.).

(1) Switch the main battery switch off.
(2) Tilt the cab.
(3) Remove the wiring from the glow plug that
is to be replaced; note the connections.
(4) Unscrew the glow plug from the inlet
manifold.
b. Installation (see Fig. 3.6.13.)

(1) Screw the glow plug into the inlet manifold.
(2) Connect the wiring again.
NOTE: The cable sleeve with the large eye is

fitted below at the ring (2).
Fig. 3.6.12 Connection sequence for the glow
NOTE: The cable sleeve with the small eye is plugs
fitted immediately under the union nut
(1).
NOTE: When assembling make sure that ring
(2) is not bent causing an earth
connection.
NOTE: If all the glow plugs are replaced
together then make sure when
connecting the wiring that the cables
are connected again in accordance
with the diagram.
Fig. 3.6.13
1. Union nut
2. Washer
3-6-7
2 TH 9-3900
Fig. 3.6.14
1. Manual throttle cable
2. Attachment rod
3. Lever
4. Attachment rod
5. Tension spring
6. Lever
7. Bearing
8. Lever
9. Lever
10.Lever axle
11.Bearing
12.Lever
13.Attachment rod
14.Lever
3.6.13 HROTTLE MECHANISM
a. Removal, levers and linkage system, see fig. 3.6.14.

(1) Tilt the cab.
(2) disconnect the tension spring (5) (mounted on the left side of the radiator).
(3) Disconnect all connections from the attachment rods (2), (13) and (4) and remove the attachment
rods.
(4) Detach the complete lever axle (10) and its bracket from the radiator.
(5) Remove the lower lever (6) and then take the lever axle upwards out of the bracket.
(6) Remove the plastic bearings (7) and (11).
(7) Remove the lever (3).
(8) Detach the manual throttle cable (1) from the lever (9).
(9) Remove the lever (9).
(10)Detach the manual throttle cable connection (1) to the lever.
(11) Pull the manual throttle cable through the cab floor.
3-6-8
2 TH 9-3900
b. Accelerator pedal removal, see Fig. 3.6.15.

(1) Tilt the cab.
(2) Remove the stop bolt (10).
(3) Tap the clamping pin (2) out of the pedal
(1); the connection between the lever (8,
fig. 3.6.14.) and the attachment rod (2, fig.
3.6.14.) must be loose.
- Remove the spindle (6); take the spindle
out from outside the cab.
c. Cleaning, checking and lubricating.

(1) Clean all parts thoroughly.
(2) Check whether the ball couplings still
operate smoothly; these do not require
lubrication.
(3) Grease all hinge points with M D2 grease.
d. Installation (Fig. 3.6.13.).

(1) Installation is done in reverse order. Fig. 3.6.15
(2) Attachment rod (13, fig. 3.6.14.) is the last 1. Accelerator pedal
to be fitted. 2. Clamping pin
e. Adjustment (Fig. 3.6.13.). 3. Ring
(1) Set the throttle lever of the fuel pump in the 4. Bolt
idling position. 5. Spring washer
(2) Set the accelerator pedal in the idling 6. Pedal axle
position; the angle to the floor is then 38° or 7. Dust cover
c. 22 mm. Under the heel without floor mat, 8. Pedal bracket
see fig. 3.6.16. 9. Lock nut
10.Stop bolt
(3) Adjust the attachment rod (13, fig. 3.6.14.)
such that the rod fits exactly between the
lever (12, fig. 3.6.14.) and the throttle lever
(14).
(4) Tilt the cab back into the driving position.
(5) Press the accelerator pedal as far in as
possible; the throttle lever (14) is at its
maximum position.
(6) Unscrew the stop bolt (10, Fig. 3.6.15.) until
it hits the pedal.
(7) Screw the bolt one turn back and secure it
using the lock nut (9).
Fig. 3.6.16 Accelerator pedal adjustment
3-6-9
2 TH 9-3900
3.6.14 STOP CONTROL MECHANISM (SEE Fig. 3.6.17.).
a. Removal
(1) Remove the stop cable from the stop lever.
(2) Tilt the cab.
(3) Remove the stop cable from the various
attachment points.
(4) Undo the connection between the stop
lever on the fuel pump and the stop inner
cable.
(5) Remove the cable through the duct.
b. Installation.
(2) Adjust the tension of the inner cable such
that it is not loose and also not so tight that
the stop cable is pulled from its stop.
Fig. 3.6.17
3-6-10
2 TH 9-3900
3.7 EXHAUST SYSTEM
3.7.1 EXHAUST PIPES (SEE Fig. 3.7.1. AND 3.7.2.).
a. Removal
(1) Support the silencer.
(2) Disconnect the flange connection between
the cast-iron exhaust pipe (1) and the front
exhaust pipe (3), fig. 3.7.1.
(3) Remove the sealing ring (2) between the
cast-iron exhaust pipe and the front
exhaust pipe.
(4) Undo the connection between the pipe and
the damper.
(5) Remove the foremost exhaust pipe.
(6) Remove the clamping bracket (1, Fig. 3.72)
from the rear exhaust pipe (2, fig. 3.7.2.)
and remove the flange connection.
(7) Remove the rear exhaust pipe.
b. Installation
(1) Installation is done in reverse order. Fig. 3.7.1
1. Exhaust pipe
NOTE: Watch out for the position of the 2. Seal ring
sealing ring (2, fig. 3.7.1.). 3. Exhaust pipe
3.7.2 EXHAUST SILENCER
a. Removal
(1) Support the silencer.
(2) Remove both flange connections.
(3) Remove the damper.
b. Installation
(1) Installation is done in reverse order.
3.7.3 ATTACHMENT OF EXHAUST SYSTEM Fig. 3.7.2

1. Clamping bracket
a. Removal 2. Exhaust pipe
(1) make a temporary hanger for pipes and 3. Saddle
exhaust. 4. Sealing ring
(2) Slacken the upper bolts (2) of the flange 5. Nut
connections. 6. Lock nut
(3) Loosen the nut (6).
(4) Remove the suspension bracket (1) and
the rubbers (7) with metal ring.
(5) See Fig. 3.72: remove the locking nuts (6),
the nuts (5) and the lock washers (4).
(6) See Fig. 3.7.2.: remove the saddle (3) and
the clamping bracket (1).
3-7-1
2 TH 9-3900
b. Installation
NOTE: Tighten the nut (6) in fig. 3.7.3. until

the distance between the underside of
the bolt head and the mating surface
of the nut is 26 mm.
Fig. 3.7.3
1. Mounting bracket5.Muffler
2. Nut6.Nut
3. Exhaust pipe7.Rubbers
4. Gasket
3-7-2
2 TH 9-3900
3.8 COOLING SYSTEM
3.8.1 FAN
a. Removal
(1) Tilt the cab.
(2) Loosen the attachment bolts of the
alternator.
(3) Remove the V-belts from the pulleys.
(4) Remove the upper bracket (1) from the
guide ring (2), see fig. 3.8.1.
(5) See Fig. 3.8.2.: take the fan (2) and the
assembly disks (1) and (3) off the
connector flange (4).
b. Installation
(1) Install the assembly disk (3).
(2) Fit the fan (2).
(3) Fit the second assembly disk (1).
(4) Assemble the other parts in reverse
sequence.
(5) Adjust the V-belt, see item 3.8.8).
Fig. 3.8.1 t
1. Guide ring support, upper
2. Guide ring
3. Clamping strips
4. Sleeve
5. Wind tunnel
6. Fan
7. Alternator pulley
Fig. 3.8.2
1. Assembly disk
2. Fan
3. Assembly disk
4. Connector flange
3-8-1
2 TH 9-3900
3.8.2 WIND TUNNEL (SEE Fig. 3.8.1).
a. Removal
(1) Tilt the cab.
(2) Remove the filler cap from the expansion
reservoir.
(3) Open the radiator tap (7) and drain off c. 15
litres of coolant.
(4) Remove the coolant hose upper right of the
radiator.
(5) Remove the fan (see item 3.8.1).
(6) Undo the lower support (6) of the guide
ring (3).
(7) Loosen both the clamping strips (5).
(8) Remove the guide ring (4) and both
clamping strips.
(9) Undo the throttle connecting rods from the
levers (1) and (11).
(10)Remove the lever axle bracket (12).
(11) Remove the nuts and take out the wind
tunnel (8) from the radiator.
b. Installation
(2) Adjust the throttle mechanism (see item
3.6.13).
(3) Fill the cooling system, run the engine for a Fig. 3.8.3
while and top up if necessary (see 1TH). 1. Lever
2. Guide ring support, upper
3.8.3 RADIATOR (SEE Fig. 3.8.3.). 3. Guide ring
4. Sleeve
a. Removal 5. Clamping strap
(1) Tilt the cab. 6. Guide ring support, lower
7. Drain tap
(2) Remove the filler cap from the expansion 8. Wind tunnel
reservoir. 9. Adjustment rod (l + r)
(3) Drain the radiator completely. 10.Support
(4) Remove the three coolant hoses. 11.Lever
(5) Remove the fan (see item 3.8.1). 12.Lever axle bracket
(6) Disconnect the bottom support of the guide
ring.
(7) Unscrew the clamping strips.
(8) Remove the guide ring, sleeve and both
clamping strips.
(9) Disconnect the throttle connection rods
from the levers.
(10)Remove the lever axle bracket.
(11) Disconnect the attachment rod at the left-
hand radiator bracket.
(12)Disconnect the adjustment rod left and
right under.
(13)Support the radiator.
(14)Remove the rubber hangers and brackets
on both sides of the radiator.
(15)Remove the radiator by allowing it to drop
Fig. 3.8.4 Radiator rubber hanger
downwards.
b. Installation
(1) Installation is in reverse order but do not yet fasten the rubber hangers and adjustment rods.
(2) Mount the rubber hangers as in fig. 3.8.4.
(3) Adjust the adjustment rods such that the radiator is positioned evenly with respect to the blades of the
fan.
(4) Fasten the rubber hangers and adjustment rods.
(5) Adjust the throttle mechanism (see item 3.6.13).
(6) Fill the cooling system, run the engine for a while and top up if necessary (see 1TH).
3-8-2
2 TH 9-3900
3.8.4 COOLANT REPLACEMENT

reservoir.
(2) Set the operating lever of the cab heater to
"warm".
(3) Drain the coolant both in the engine block
(fig. 3.8.53) and in the radiator.
(4) Close the drain cock.
(5) Fill the system with coolant via the
expansion reservoir.
(6) Allow the engine to run briefly and top up if
necessary (see 1TH).
3.8.5 EXPANSION RESERVOIR (SEE FIG. 3.8.63.
a. Removal
reservoir. Fig. 3.8.5 Coolant drain cock in engine block
(2) Drain approximately 10 litres of coolant
1. Fuel filter 3. Starter motor
from the radiator, see item 3.8.2. 2. Drain tap
(3) Disconnect the rubber hoses from the
reservoir; make sure that the ends of the
hoses are kept higher than the engine or
coolant will be lost.
(4) Remove the attachment bracket.
(5) Remove the reservoir.
b. Installation
(1) Fit the expansion reservoir and its
connections again.
(2) Top up the coolant (see 1TH).
3.8.6 THERMOSTATS (SEE Fig. 3.8.7.).
a. Removal Fig. 3.8.6

(1) Tilt the cab. 1. Clamping strap 3. Bleed hose
(2) Drain approximately 10 litres of coolant 2. Fluid hose 4. Bleed hose
from the radiator.
(3) Remove the coolant hose to the radiator.
(4) Loosen the four bolts of the thermostat
housing cover and remove the cover.
- Take out both thermostats and 0-rings.
b. Checking
(1) Lay the thermostat to be checked in a basin
of water (see fig. 3.8.7.)
(2) Heat the water to a temperature of 80-85
°C.
(3) Check whether the thermostat (min. 8 mm)
is open.
If this is not the case, the thermostat must
be replaced.
c. Installation
(1) Fit the thermostats with new O-rings in the
thermostat housing.
(2) Put a new gasket in the housing.
(3) Fasten the cover.
(4) Reconnect the hose.
(5) Top up the coolant (see 1TH).
Fig. 3.8.7
1. Thermostat
3-8-3
2 TH 9-3900
3.8.7 COOLANT PUMP (SEE Fig. 3.8.9.).
a. Removal
(1) Tilt the cab.
reservoir.
(3) Open de drain cocks of the engine block
and the radiator.
(4) Remove the thermostat housing cover (see
item 3.8.6).
(5) Remove the V-belts from the pump pulley
(see point 3.8.1).
(6) Undo the five attachment bolts and remove
the pump.
(7) Place the pump on a flat surface.
(8) Block the pulley using two V-belts and undo
the central bolt three or four turns.
(9) Pull the pulley from the axle using a pulley
puller (d, fig 3.1.1.).
Fig. 3.8.8
NOTE: If only the pulley is to be replaced then
this can be done without taking the
pump from the engine.
b. Installation
(2) Fill the cooling system, run the engine for a
while and top up if necessary (see 1TH).
3.8.8 V-BELTS (SEE FIG. 3.8.3. AND 3.8.8.).
a. Removal
(1) Tilt the cab.
(2) Loosen the attachment bolts of the alternator.
(3) Tilt the alternator as close as possible against the engine block.
(4) Remove the V-belts from the pulleys.
(5) Undo the guide ring from its lower and upper bracket, see item 3.8.2.
(6) Push the guide ring forwards and pull the V-belts through between the guide ring and fan blades.
(7) Remove the V-belts.
b. Installation
(2) Adjust the V-belt, see C. item 3.8.8).
c. Tensioning
NOTE: The V-belts must be tensioned such

that they can be pressed 10 to 15 mm
downwards between the alternator
pulley and the coolant pump pulley,
see fig. 3.8.9.
(1) Tilt the cab.

(2) Loosen the attachment bolts of the
alternator.
(3) Adjust the tension of the V-belts by moving
the alternator.
(4) Tighten the attachment bolts.
(5) Check the V-belt tension
(6) If necessary correct by repeating the above
Fig. 3.8.9
actions.
3-8-4
2 TH 9-3900
3.9 ELECTRICAL SYSTEM
3.9.1 ALTERNATOR (SEE FIG. 3.9.1.).
a. Removal
(1) Make sure the main battery switch is off.
(2) Tilt the cab.
(3) Remove the V-belts (see point 3.8.8).
(4) Disconnect the electrical plug (2) by turning
the union anti-clockwise.
(5) Remove the attachment bolts and take off
the alternator.
b. Installation
(2) Adjust the V-belt, see item 3.8.8).
Fig. 3.9.1
1. Alternator
2. Connecting plug
3.9.2 ALTERNATOR PULLEY (SEE FIG. 3.9.2.).
a. Removal
(2) Tilt the cab.
(3) Remove the alternator (see item 3.9.1).
(4) Use a V-belt to block the pulley (3).
(5) Loosen the nut (1).
(6) Remove the pulley (3).
NOTE: The fan (4) can now be taken off if

desired.
b. Installation
(2) Adjust the V-belt, see item 3.8.8). Fig. 3.9.2
1. Nut
2. Spring washer
3. Pulley
4. Fan
5. Alternator
3.9.3 VOLTAGE REGULATOR (SEE Fig. 3.9.3.).
a. Removal
(2) Remove the cover on the inside of the main
switch cabinet.
(3) Detach the socket.
(4) Remove the attachment screws and take
the voltage regulator out.
b. Installation
Fig. 3.9.3 Main switch cabinet inside
3-9-1
2 TH 9-3900
3.9.4 STARTER MOTOR
a. Removal
(2) Tilt the cab.
(3) Disconnect the wiring from the starter
motor.
(4) Remove the three attachment nuts.
(5) Take off the starter motor.
b. Installation
Fig. 3.9.3a
1. Attachment nut
2. Starter moto
3.9.5 SWITCHES ON THE INSTRUMENT PANEL (SEE FIG. 3.9.4.).
a. Switches for windshield wipers and washers and heater fan
(1) Removal
(a) Make sure the main battery switch is
off.
(b) Use a screwdriver to flip up the switch.
(c) Depress the two plastic lips and
remove the switch from the
instrument panel.
(d) Mark the connections and disconnect
them.
(2) Installation
(a) Installation in reverse order.
b. Main beam and turn-signal switch (see fig. 3.9.4.).
(1) Removal Fig. 3.9.4

(a) Make sure the main battery switch is 1. Cap
off. 2. Main-beam and turn-signal switch knob
(b) Remove the trim under the instrument 3. Switch arm
panel. 4. Dust cover
(c) Unscrew the cap (1) of the knob (2). 5. Blower switch
(d) Remove the locking ring and remove 6. Windshield wiper switch
the knob. 7. Windshield sprayer switch
(e) Remove the cross head screws at the 8. Odometer / Speedometer
switch.
(f) Push the switch and arm (3) inward.
(g) Mark the connections and disconnect
them.
(h) Remove the switch.
(2) Installation
3-9-2
2 TH 9-3900
c. Turn-signal and horn switch (see fig. 3.9.5.).
(1) Removal
off.
(b) Remove the trim under the instrument
panel.
(c) Unscrew the knob of the handle.
(d) Remove the screws at the switch.
(e) Push the switch and arm inward.
(f) Mark the connections and disconnect
them.
(g) Remove the switch.
(2) Installation
d. Hot start switch (see fig. 3.9.5.).

(1) Removal
off.
panel.
(c) Remove the attachment ring from the
hot start switch.
(d) Press the lock inwards. Fig. 3.9.5
(e) Mark the connections and disconnect 1. Turn-signal and horn switch
them. 2. Hot start switch
(f) Remove the hot start switch. 3. Warning lamps switch
4. Combi-instrument
(2) Installation
e. Warning lights switch (See fig. 3.9.5.).

(1) Removal
off.
panel.
(c) Unscrew the retaining nut under the
instrument panel.
(d) Pull out the switch.
(e) Mark the connections and disconnect
them.
(f) Remove the switch.
(2) Installation
3-9-3
2 TH 9-3900
f. Switches for rotating beam and rear fog light

(see fig. 3.9.6.).
(1) Removal
a) Make sure the main battery switch is
off.
(b) Pull out the switch knob.
(c) Turn the knob about a quarter turn
anti-clockwise and pull the knob out of
the panel (bayonet fitting).
(d) Remove the retaining nut.
(e) Remove the trim under the instrument
panel.
(f) Push the switch inward.
(g) Mark the connections and disconnect
them.
(h) Remove the switch.
(2) Installation
(a) Installation in reverse order. Fig. 3.9.6
1. Rotating beam switch
g. Battery main switch operating switch 2. Rear fog light switch
(see fig. 3.9.6.). 3. Battery main switch operating switch
4. Rev counter
5. Variable resistance switch for instrument panel
(1) Removal lighting
(a) Remove the connecting cables from
the batteries, see item 3.9.19.
(b) Remove the retaining nut from the
operating switch.
(c) Push the switch inward.
(d) Remove the trim under the instrument
panel.
(e) Mark the connections and disconnect
them.
(2) Installation
- Installation in reverse order.
h. Variable resistor for instrument lighting (see fig. 3.9.7.).
(1) Removal
off.
(b) Via the rectangular opening in the
knob press the spring down and
remove the knob.
(c) Remove the retaining nut.
(d) Push the switch inward.
(e) Remove the trim under the instrument
panel.
(f) Mark the connection and disconnect it.
(g) Remove the switch.
(2) Installation
3-9-4
2 TH 9-3900
3.9.6 WARNING LIGHTS ON THE INSTRUMENT PANEL (SEE FIG. 3.9.8.).
a. Warning lights with symbol.

(1) Removal
off.
(b) Pop the symbol cover plate out of the
panel.
(c) Pull out the lamp and fitting.
them.
(2) Installation
b. Bulb in switches of the rotating beam and rear

fog light (see fig. 3.9.8.).
(1) Removal Fig. 3.9.7

(a) Make sure the main battery switch is 1. Warning lamps
off. 2. Rear fog light switch
(b) Turn the knob of the switch a quarter 3. Rotating beam switch
turn anti-clockwise and pull the knob
out.
(c) Remove the bulb.
(2) Installation
c. Bulb for warning lights switch (see fig. 3.9.9.).
(1) Removal
off.
(b) Remove the axial retainer ring.
(c) Remove the protective cover.
(d) Pull out the Perspex cap.
(e) Remove the bulb.
(2) Installation
Fig. 3.9.8 Warning lamps switch
d. arning light front wheel drive (see fig. 3.9.10.).
(1) Removal
off.
(b) Pop the symbol cover plate out of the
panel.
them.
(2) Installation
Fig. 3.9.9 Warning light front wheel drive
3-9-5
2 TH 9-3900
Fig. 3.9.10
A. Air pressure gauge
B. Fuel gauge
C. Oil pressure gauge
D. Temperature gauge
E. Turn signal/ main-beam indicator
1. Clamping piece
2. Nut
3. Threaded bush
4. Clamping piece
5. Air connection
e. Warning lights for main beam and turning lights

(see fig. 3.9.11.).
(1) Removal
(a) Make sure the main battery switch is off.
(b) Remove the combi-instrument from the instrument panel (see item a, 3.9.7).
(2) Installation
3-9-6
2 TH 9-3900
3.9.7 INSTRUMENTS ON THE INSTRUMENT PANEL
a. Combi-instrument (see fig. 3.9.11. and 3.9. 12.).
(1) Removal
off.
panel.
(c) Disconnect the air connections under
the instrument panel (5, fig. 3.9.11.).
from the air pressure gauge A.
(d) Undo the two threaded bushes (3) and
remove the clamping pieces (4).
(e) Push the gauge from the instrument
panel.
(f) Remove the wiring from the gauge.
(g) Remove the nuts (2) and the nuts
under the threaded bushes (3).
(h) Remove the clamping pieces (1).
(i) Remove the five constituent parts of
the combi-instrument.
(2) Installation Fig. 3.9.11

(a) Installation in reverse order. 1. Combi-instrument
(b) For the connection of the wiring see 2. Dimmer switch for instrument lighting
fig. 3.9.11. 3. Rear fog light switch
3.9.7 .a INSTRUMENTS NOT ON THE INSTRUMENT PANEL
1. Hour meter (only YAK)
a. Removal
(1) Switch the main battery switch off.
(2) Remove the two threaded bushes and
the clamping piece.
(3) Pull out the gauge.
(4) Disconnect the wiring.
(5) Remove the gauge.
b. Installation
(1) Fit in the reverse order to removal.
3.9.8 SWITCHES NOT ON THE INSTRUMENT PANEL
a. Cab lighting switch (see fig. 3.9.13.).
(1) Removal Fig. 3.9.12a

1. Hour meter
off.
(b) Remove the screws in the switch.
(c) Pull out the switch.
them.
(e) Remove the switch.
(2) Installation
3-9-7
2 TH 9-3900
b. Trailer stop lights switch. (See Fig. 3.9.11).
(1) Removal
off.
(b) Remove the retaining nut.
(c) Push the switch inward.
them.
(2) Installation
Fig. 3.9.13
1. Trailer stop lights switch.
c. Headlight switch (See Fig. 3.9.14.). 2. Cab lighting switch
(1) Removal
off.
(b) Remove the retaining nut.
(c) Press the switch inwards complete
with the handle.
them.
(2) Installation
d. P.T.O. switch (see fig. 3.9.14.a.)

Fig. 3.9.14
(1) Removal
(a) Switch the main battery switch off.
(b) Remove the switch knob and the bulb.
(c) Remove the retaining nut.
(d) Push the switch inward.
(e) Disconnect the connections.
(2) Installation
(a) Fit in the reverse order to removal.
Fig. 3.9.14.a 1.P.T.O. switch
3-9-8
2 TH 9-3900
3.9.9 FUSE HOLDERS (SEE Fig. 3.9.15.).
a. Removal
(2) Remove the fuses, see 1 TH.
(3) Mark the connections and disconnect
them.
(4) Unscrew the holders and remove them.
b. Installation
Fig. 3.9.15
3.9.10 BATTERY MAIN SWITCH (see fig. 3.9.16.).
a. Removal
(1) Remove the covers from the main switch
cabinet.
(2) Disconnect the connection cables to the
starter batteries.
(3) Mark the connections on the battery main
switch and disconnect them.
(4) Remove the attachment screws.
(5) Remove the switch from the cabinet.
a. Installation
3.9.11 RELAY
a. Removal
(1) Remove the covers from the main switch
cabinet.
(3) Use the circuit diagram and the wiring
diagram to decide which relays must be
replaced.
(4) Mark the connections and disconnect Fig. 3.9.16 Main battery switch
them.
(5) Remove the relay.
b. Installation
3-9-9
2 TH 9-3900
3.9.12 HEADLIGHTS
a. Removal
(2) Remove the bulb, see 1TH.
(3) Mark the electrical connections and
disconnect them.
(4) Remove the attachment nut.
(5) Remove the headlight from the bumper.
b. Installation
c. Adjustment (See Fig. 3.9.17.).
NOTE: The position of the headlight can be

adjusted by loosening the central
attachment nut and tilting the lamp in
its ball joint to the desired angle. Fig. 3.9.17
(1) Place the vehicle on a flat surface, approx.

10 metres from a wall or screen.
(2) Measure the distance from the centre of the
headlight to the floor.
(3) Draw a horizontal line (A) at that height on
the wall.
(4) Draw a parallel line (B) 10 cm under line A.
(5) Draw vertical lines (C and D) directly in
front of the vertical centre line through the
headlights.
(6) Turn on the dipped beam.
(7) Cover one of the lights.
(8) Adjust the other light so the upper edge of
the beam is even with the intersection of
lines B and C or B and D.
(9) Repeat the previous two steps for the other
light.
3.9.13 INDICATOR LIGHTS, FRONT (SEE FIG. 3.9.18.).
a. Removal
(1) Remove the glass and the bulb, see 1TH.
(2) Remove the attachment screws.
(3) Mark the connections and disconnect them.
(4) Remove the lamp.
b. Installation
3.9.14 PARKING LIGHTS (SEE Fig. 3.9.18.).
a. Removal
(1) Remove the cover and the bulb, see 1TH.
b. Installation
Fig. 3.9.18
1. Darkened searchlight
2. Parking light
3. Reflector
4. Direction indicator
3-9-10
2 TH 9-3900
3.9.15 DARKENED SEARCHLIGHT, FRONT

(SEE FIG. 3.9.18.).
a. Removal
(1) Remove the cover with glass and bulb, see
1 TH.
them.
b. Installation
3.9.16 MARKER LIGHTS (SEE Fig. 3.9.19.).
a. Removal
(1) Remove the glass and the bulb, see 1TH.
them.
b. Installation
Fig. 3.9.19 Marker lighting
3.9.17 VARIOUS LIGHTS, REAR (SEE FIG. 3.9.20 and 3.9.21.).
a. Removal
(1) Remove the cover and the bulb, see 1TH.
them.
(3) Remove the lamp in question.
b. Installation
Fig. 3.9.20
1. Darkened brake lights
2. Registration plate light
3. Socket
Fig. 3.9.21
3-9-11
2 TH 9-3900
3.9.18 HORN (SEE Fig. 3.9.22.).
a. Removal
(3) Remove the horn.
b. Installation
Fig. 3.9.22
3.9.19 BATTERIES (SEE Fig. 3.9.23).
NOTE: Specific gravity (s.g.) of the electrolyte

for a charged battery: 1.280 Charge
battery if the s.g. drops to 1.118. Never
disconnect the battery clamps when
the engine is running.
a. Charging
(1) Measure the s.g. of the electrolyte.
(2) Disconnect the cable connections from the
battery (batteries).
(3) Connect the battery or batteries to a
charger.
Fig. 3.9.23
3.9.19 .a RADIO - BATTERIES (SEE FIG 3.9.23 a)
a. General
(1) The batteries can be obtained from the
communication unit or with an installation
package.
(2) If the vehicle does not have a radio-support
function, a wooden chest is located in the
place of the batteries.
(3) This chest contains a plastic bag with 3
battery clamps and 3 cable assemblies:
- Cable 1: a short cable marked 2A-
2B+.
- Cable 2: a longer cable, marked on
one side with 199 - 31A and on the
other side with 2B Fig. 3.9.23a
- Cable 3: a longer cable, marked on
one side with 199- 2 and on the other
side with 2A+
(4) The wooden chest must be stored by the
operator of the vehicle and must be
reinstalled if the vehicle looses its radio-
support function.
3-9-12
2 TH 9-3900
b. Placement
(1) Remove the cover from the battery pack.
(2) Remove the wooden chest.
(3) Place the radio batteries in the battery pack
(see fig. 3.9. 23.a)
(4) Remove the cover from the clamps cabinet.
(5) Connect the batteries as indicated in fig.
3.9.23a and 3.9.23b.
(6) Re-install the covers of the battery pack
and clamps cabinet.
c. Removal
(1) The order of removal is opposite that of
installation.
Fig. 3.9.23 b
3.9.20 COUPLE SOCKET (SEE FIG. 3.9.24.).
a. Removal
(1) Disconnect the connection cables from the
start-assistance socket to the batteries.
(2) Remove the attachment bolts and take off
the socket.
(3) Mark the connections and disconnect the
cables.
b. Installation
Fig. 3.9.24
3-9-13
2 TH 9-3900
3.9.21 SOCKETS, GENERAL (SEE FIG. 3.9.25. - 3.9.26. - 3.9.27.).
a. Removal
(3) Remove the attachment bolts/nuts and
remove the socket.
b. Installation
Fig. 3.9.25
1. 12-pin socket
2. General purpose socket (cross light)
Fig. 3.9.26 Coolant heater socket Fig. 3.9.26 a Coolant heater socket (YAK)
Fig. 3.9.27
1. Branch guard
2. Direction indicator
3. Socket
4. Stepwell
3-9-14
2 TH 9-3900
3.9.22 SENDING UNITS
a. Sending unit, coolant temperature gauge

(see fig. 3.9.28.).
(1) Removal
off.
(b) Tilt the cab.
(c) Drain the coolant as required.
them.
(e) Remove the sending unit.
(2) Installation
b. Sending units, oil-pressure gauge and indicator lamp

(see fig. 3.9.29.).
Fig. 3.9.28
(1) Removal
off.
(b) Tilt the cab.
(c) Disconnect the connection of the oil
line.
(d) Mark the electrical connections and
disconnect them.
(e) Remove the sending unit for the oil-
pressure gauge (2).
(f) Remove the sending unit for the
warning light (1).
(2) Installation
Fig. 3.9.29
1. Sending unit for oil-pressure warning lamp
2. Sending unit for oil-pressure gauge
3-9-15
2 TH 9-3900
3.9.23 WIRING HARNESS, BATTERY MAIN SWITCH YA 4440 - Project 1952, (see figs. 3.9.30 and
3.9.31)
a. Removal
(1) Set the main switch to the "Off" position.
(2) Remove the cover from the battery holder.
(3) Disconnect the battery clamps.
NOTE: The earth clamp must always be

removed first and connected last.
( 4) Slide the dust cap back.

( 5) Unscrew the attachment bolt from the
battery clamp and disconnect the cable.
( 6) Remove the four attachment screws from
the cover of the main switch.
( 7) Remove the cover.
( 8) Slide the rubber dust cap onto the contact
again. Fig. 3.9.30
( 9) Remove the attachment nut and washer.
(10)Take the cable from the contact and 1. Attachment bolt
remove the dust cap. 2. Cable
(11) Unscrew the union nut and pull the cable 3. Battery clamp
out of the main switch cabinet.
(12)Remove the tie rods and take the cable
from the vehicle.
b. Installation
( 1) Set the main switch to the "Off" position.
( 2) Stick the cable through the union in the
main switch cabinet.
( 3) Fit the rubber dust cap onto the cable.
( 4) Fasten the cable to the contact using the
attachment nut and washer.
( 5) Slide the rubber dust cap onto the contact.
( 6) Screw on the union nut.
( 7) Fit the cover of the main switch using the
four attachment screws.
( 8) Fasten the other connection of the cable
and the dust cap to the battery clamp using
the attachment bolt.
( 9) Lubricate both battery terminals with
Vaseline.
(10)Connect the battery clamps. Fig. 3.9.31
(11) Fit the cover of the battery pack. 1. Attachment nut
(12)Secure the cable with tie rods. 2. Sealing ring
3. Cable
4. Attachment screw
5. Lid
6. Contact
7. Union nut
8. Dust cover
3-9-16
2 TH 9-3900
3.9.24 MAIN SWITCH YA 4440 - Project 1952
See 3.30.32 and 3.30.33)

a. Remove main switch
(2) Disconnect the earth clamp from the
battery.
(3) Remove the four attachment screws from
the cover of the main switch.
(4) Remove the cover.
(5) Slide both dust caps back onto the
contacts.
(6) Remove both cables.
(7) Remove the switch handle and associated
dust cap.
(8) Remove both attachment bolts and nuts
from the main switch.
(9) Remove the main switch.
Fig. 3.9.32
1. Attachment nut 5. Attachment screw
2. Sealing ring 6. Attachment bolt
3. Main switch 7. Switch handle
4. Lid 8. Dust cover
b. Install main switch

c. Removal of the main switch box and mounting

plate.
(1) If necessary remove the main switch
(see a.).
(2) Undo both union nuts.
(3) Remove the dust caps from the cables.
(4) Take both cables out of the main switch
box. Fig. 3.9.33
(5) Remove the four nuts and lock washers on 1. Union nut 4. Sealing ring
the front of the mounting plate. 2. Cable 5. Mounting plate
(6) Remove the mounting plate and main 3. Attachment nut 6. Attachment screw
switch box from the vehicle.
(7) Remove the four bolts behind the mounting
plate and the nut and washer.
(8) Remove the main switch box from the
mounting plate.
d. Installation of the main switch box and

mounting plate.
Fig. 3.9.34
1. Union nut 4. Dust cover
2. Cable 5. Contact
3. Lid
3-9-17
2 TH 9-3900
3.9.25 WIRING HARNESS, MAIN SWITCH - SOCKET YA 4440 - Project 1952, (see figs. 03.09.34 and
03.09.35)
a. Removal
( 1) Set the main switch to the "Off" position.
( 2) Disconnect the earth clamp from the
battery.
( 3) Remove the cover from the main switch.
( 4) Remove the cable from the contact.
( 5) Remove the dust cap from the cable.
( 6) Unscrew the union nut.
( 7) Take the cable out of the main switch box.
( 8) Slide the dust cap back behind the socket.
( 9) Disconnect the cable from the socket.
(10)Remove the tie rods and take the cable
from the vehicle.
b. Installation Fig. 3.9.35

(1) Fit in the reverse order to removal. 1. Dust cover
(2) After mounting secure the cable with tie 2. Socket
rods.
3.9.26 SOCKET AND DUST CAP YA 4440 - Project 1952 (see Fig. 3.9.36)
a. Removal
(2) Remove the four bolts and nuts from the
socket.
NOTE: The bottom-right bolt is also for the

attachment of: chain, dust cap and
earth socket.
(3) Take the socket from the attachment

bracket.
(4) Slide the dust cap back on the rear of the

socket.
(5) Disconnect both electrical connections.
b. Installation
(1) Fit in the reverse order to removal. Fig. 3.9.36
1. Dust cover
2. Socket
3. Dust cap
3-9-18
2 TH 9-3900
3-9-19
2 TH 9-3900
3.9.27 LEGEND (FOR WIRING 88. Battery socket socket

DIAGRAM 634764 AND 89. Load platform socket 148.Door switch for cab lighting
CIRCUIT DIAGRAM 90. General purpose socket 150.Rotating beam switch +
632802) 92. Radio supply socket indicator lamp
93. Coolant pre-warming socket 152.Cross light socket
1. Vehicle battery 94. 7-pin trailer socket 153.Cross light plug
2. Radio battery 97. Fuses (12 x 8A) 154.Indicator lamp, front wheel
3. Starter motor 98. Fuses (12 x 8A) drive
4K. Alternator + rectifier 99. Fuses (2 x 8A) 155.Switch, indic. lamp, front
5. Voltage regulator 102K.Speedometer wheel drive
10. Control switch, relay main 105.Rev counter 162.Socket, intercom buzzer
battery switch 106K.Combi-instrument 163.Phone holder
11K.Main battery switch 1.Temperature gauge 166.Warning lamp, air filter
13A.Separation relay 2.Oil pressure gauge 167.Switch, warning lamp, air
13B.Control relay 3.Fuel gauge filter
15. Glow plug relay 4.Brake pressure gauge 168.Protection relay, alternator
22. Test coil, glow plug 5.Main beam warning lamp 170.Cable contact blade (in cab
24. Glow plug 6.Indicator lamp, direction behind door pillar L + R)
32K.Dipped beam + main beam indicators 171.Cable contact blade
33. Darkened driving lamp 7.Indicator lamp, direction (distribution box under cab
35V.Front direction-indicator indicators, trailer R)
lamp 8.Instrument lighting 172.Cable contact box
36. Parking lights 9.Instrument lighting (distribution box under cab
37K.Tail light W.Switch, brake pressure L)
39. Stop light, darkened buzzer 174.Cable contact blade (main
40. Cross light, removable 110 K.Sending unit, coolant switch cabinet)
41. Registration plate light temperature 180.Cable contact clamp (in cab
43. Warning lamp, charging 111.Horn behind door pillar L + R)
current 112.Windscreen wiper motor 181.Cable contact clamp
44. Indicator lamp, direction 113.Warning lamp, coolant (distribution box under cab
indicator (only in training temperature R)
vehicle) 116.Over-voltage protection unit 182.Cable contact clamp
47. Map reading lamp 119A.Interference filter B+ (distribution box under cab
49K.Cab lighting 119B.Interference filter D+ L)
53. Contour lighting 120.Direction indicator device 183.Cable contact clamp
54. Rear fog light interference suppression (distribution box, rear of
59K.Glow plug switch unit chassis)
60. Headlight switch 122.Warning lamp, oil pressure 184.Cable contact clamp (main
61K.Dipped beam switch 125.Fan witch cabinet)
62K.Direction indicator switch 126.Windscreen sprayer motor 190.Warning lamp, cab lock
63. Flasher, direction indicator 127.Sending unit, oil pressure 191.Switch, warning lamp, cab
64. Brake light switch 129A.Relay, main beam lock
65. Oil pressure switch 129B.Relay, dipped beam 199.Terminal cabinet, radio
66. Windscreen wiper switch 130.Trailer stop light blocking 201.Insulator
67. Switch for "engine brake for switch 202.Earth connection
trailer" 131.Separation relay, trailer 203.Earth connection
71. Switch for instrument hazard lights 204.Insulator
lighting 132.Switch, intercom buzzer 205.Earth connection
73. Hazard light switch + 133.Intercom buzzer 206.Earth connection
indicator lamp 135.Warning light, parking brake 207.Earth connection
75. Fog lamp switch + indicator 137.Sending unit, fuel level 208.Earth connection
lamp 138.Switch, parking brake 209.Earth connection
76. Fan switch warning light Alternative for the YAK 4440
78B.Diode 140.Warning buzzer, brake 141.P.T.O. valve
78C.Triple diode pressure 143.P.T.O. switch
79. Triple diode 142.Horn relay 147.Lighting, crane erection
83. Circuit breaker 25A 144.Switch, windshield washer 165.Hour meter
85. Trailer socket 145.Mast for rotating beam and
3-9-20
Batteries main switch Main switch operation + protection Generator + voltage regulator + overvoltage protection + suppressor filters Starter motor Glow start switch Glow device Windscreen wiper motor – switch Windshield PTO Hour meter Heater fan Fuel gauge Temp. gauge switch Oil pressure gauge Brake pressure Oil pressure Hand brake Cab lock Air filter Front-wheel drive
washer buzzer + switch warning light warning light warning light warning light warning light
Normal driving lighting

Parking lighting
Indicator lighting
Convoy lighting
Darkened driving light
Darkened driving lighting
Radio batteries Socket – Map-reading lights Intercom buzzer Engine brake – brake light – Brake light Brake lights Direction device – redirector Direction control Direction indicators Main lights Dipped headlights Driver lights Rear lights Cross light Parking/position/rear/numberplate lights Fogglamp switch Interior lights Flashing lights Horn Instrument lighting
radio power supply switch distributor darkened darkened
Telephone
Sockets
2 TH 9-3900
3.9.28 LEGEND (FOR WIRING 88. Battery socket socket

DIAGRAM 634764 AND 89. Load platform socket 148.Door switch for cab lighting
CIRCUIT DIAGRAM 90. General purpose socket 150.Rotating beam switch +
632802) 92. Radio supply socket indicator lamp
93. Coolant pre-warming socket 152.Cross light socket
1. Vehicle battery 94. 7-pin trailer socket 153.Cross light plug
2. Radio battery 97. Fuses (12 x 8A) 154.Indicator lamp, front wheel
3. Starter motor 98. Fuses (12 x 8A) drive
4K. Alternator + rectifier 99. Fuses (2 x 8A) 155.Switch, indicator lamp, front
5. Voltage regulator 102K.Speedometer wheel drive
10. Control switch, relay main 105.Rev counter 162.Socket, intercom buzzer
battery switch 106K.Combi-instrument 163.Phone holder
11K.Main battery switch 1.Temperature gauge 166.Warning lamp, air filter
13A.Separation relay 2.Oil pressure gauge 167.Switch, warning lamp, air
13B.Control relay 3.Fuel gauge filter
15. Hot-start relay 4.Brake pressure gauge 168.Protection relay, alternator
22. Test coil, glow plug 5.Main beam warning lamp 170.Cable contact blade (in cab
24. Glow plug 6.Indicator lamp, direction behind door pillar L + R)
32K.Dipped beam + main beam indicators 171.Cable contact blade
33. Darkened driving lamp 7.Indicator lamp, direction (distribution box under cab
35V.Front direction-indicator indicators, trailer R)
lamp 8.Instrument lighting 172.Cable contact box
36. Parking lights 9.Instrument lighting (distribution box under cab
37K.Tail light W.Switch, brake pressure L)
39. Stop light, darkened buzzer 174.Cable contact blade (main
40. Cross light, removable 110K.Sending unit, coolant switch cabinet)
41. Registration plate light temperature 180.Cable contact clamp (in cab
43. Warning lamp, charging 111.Horn behind door pillar L + R)
current 112.Windscreen wiper motor 181.Cable contact clamp
44. Indicator lamp, direction 113.Warning lamp, coolant (distribution box under cab
indicator (only in training temperature R)
vehicle) 116.Over-voltage protection unit 182.Cable contact clamp
47. Map reading lamp 119A.Interference filter B+ (distribution box under cab
49K.Cab lighting 119B.Interference filter D+ L)
53. Contour lighting 120.Direction indicator device 183.Cable contact clamp
54. Rear fog light interference suppression (distribution box, rear of
59K.Glow plug switch unit chassis)
60. Headlight switch 122.Warning lamp, oil pressure 184.Cable contact clamp (main
61K.Dipped beam switch 125.Fan switch cabinet)
62K.Direction indicator switch 126.Windscreen sprayer motor 190.Warning lamp, cab lock
63. Flasher, direction indicator 127.Sending unit, oil pressure 191.Switch, warning lamp, cab
64. Brake light switch 129A.Relay, main beam lock
65. Oil pressure switch 129B.Relay, dipped beam 199.Terminal cabinet, radio
66. Windscreen wiper switch 130.Trailer stop light blocking 201.Insulator
67. Switch for "engine brake for switch 202.Earth connection
trailer" 131.Separation relay, trailer 203.Earth connection
71. Switch for instrument hazard lights 204.Insulator
lighting 132.Switch, intercom buzzer 205.Earth connection
73. Hazard light switch + 133.Intercom buzzer 206.Earth connection
indicator lamp 135.Warning light, parking brake 207.Earth connection
75. Fog lamp switch + indicator 137.Sending unit, fuel level 208.Earth connection
lamp 138.Switch, parking brake 209.Earth connection
76. Fan switch warning light Alternative for the YAK 4440
78B.Diode 140.Warning buzzer, brake 141.P.T.O. valve
78C.Triple diode pressure 143.P.T.O. switch
79. Triple diode 142.Horn relay 147.Lighting, crane erection
83. Circuit breaker 25A 144.Switch, windshield washer 165.Hour meter
85. Trailer socket 145.Mast for rotating beam and
3-9-22
2 TH 9-3900
ADDITIONAL WIRING DIAGRAM (YA 4440 - Project 1952)
Fig. 3.9.37
1.Battery
2. Main switch, roller brush system
3.Socket (under front bumper)
3-9-24
2 TH 9-3900
3.10 GEARBOX
3.10.1 REPLACE LUBRICATING OIL (SEE FIG. 3.10.1.).
NOTE: Preferably drain the oil while it is still

warm. Ensure that the vehicle is
horizontal.
(a) Position a ± 10 litre reservoir under the

drain plug.
(b) Undo the drain plug (1).
(c) Screw in the drain plug (1).
(d) Undo the filler / level check plug (2).
(e) Fill the gear box with the prescribed oil to
the bottom of the level plug hole.
(f) Fit the filler plug.
(g) Check for leakage.
Fig. 3.10.1
1. Drain plug
2. Level check/filler plug
3.10.2 SELECTOR MECHANISM (SEE Fig. 3.10.23.
a. Removal
(1) Check whether the gear lever is in neutral.
(2) Tilt the cab.
(3) Remove the reaction rod (10).
(4) Disconnect the ball coupling (12) from the
selector shaft lever (1 l).
(5) Remove the spring (7) from the guide
bracket (8) and the selector rod (9).
(6) Loosen the connection between the lever
(1) and the universal joint (2).
(7) Remove the selector rod.
(8) Undo the knob from the gearbox lever (1).
(9) Remove the gearbox lever.
(10)Remove the selector shaft lever (11) from
the clutch shaft (14).
(11) Remove the bearing bracket (4).
(12)Remove the bearing bush (5) and the ring
(6); check these parts for wear and replace
if necessary.
(13)Remove the dust cap.
b. Installation
c. Adjustment
NOTE: Adjustment must be carried out while

the internal selector mechanism is in
neutral.
(1) Position the gearbox lever (1) with the

lower section straight on the cab floor.
(2) Position the selector shaft lever (11)
3-10-1
2 TH 9-3900
straight on the centre line of the gearbox.

(3) Adjust the gearbox lever if necessary by
turning the torque rod "in" or "out".
NOTE: To the left: shorten the torque rod (10).

To the right: lengthen the torque rod (10).
To the front: turn out the ball coupling (12).
To the rear: turn in the ball coupling (12).
Fig. 3.10.2
1. Gearbox lever
2. Universal joint
3. Dust cover
4. Bearing bracket
5. Bearing bush
6. Ring
7. Spring
8. Guide bracket
9. Selector rod
10.Torque rod
11.Selector shaft lever
12.Ball coupling
13.Lock nut
14.Switch
3-10-2
2 TH 9-3900
WIRING DIAGRAM 63476419

(for circuit diagram see drawing 63280214)
3-10-3
2 TH 9-3900
3-10-4
2 TH 9-3900
3.11 TRANSFER BOX
3.11.1 RUBBER HANGERS
a. Front bracket
(1) Removal, see Fig. 3.11.1.

(a) Remove the intermediate shaft between
the front axle and the transfer box, see
item 3.12.2.
(b) Position a jack under the transfer box.
(c) Undo the connection between the
operating cylinder and the air hose.
(d) Loosen the bolts of the operating
cylinder bracket.
(e) Loosen the bolts of the suspension
bracket.
(f) Undo the nut (1).
(g) Remove washer (2).
(h) Remove the bolt (3).
(i) Remove the bracket (5).
(j) Remove the rubber (4) from the bracket
(5).
Fig. 3.11.1
(2) Installation
1. Nut
(a) Installation in reverse order. 2. Ring
3. Bolt
NOTE: Turn the nut (1) until the bolt sticks out 4. Rubber
4.5 mm beyond the nut. 5. Support
b. Rear brackets
(1) Removal, see Fig. 3.11.2.

(a) Suspension bracket left: remove the
exhaust silencer, see item 3.7.2.
(b) Suspension bracket right: remove the
spare wheel (see 1TH).
(c) Position a jack under the transfer box.
(d) Undo the connection between the
bracket and the attachment beam.
(e) Undo the nut (1).
(f) Remove the bolt (2).
(g) Remove the bracket and rubber hanger
(3).
(2) Installation
NOTE: Turn the nut (1) until the bolt sticks out
3.5 mm beyond the nut.
Fig. 3.11.2
1. Nut
2. Bolt
3. Rubber
3.11.2 REPLACE LUBRICATING OIL (SEE FIG. 3.11.1).

horizontal.
(a)Position a ± 5 litre reservoir under the drain plug.

(b) Unscrew the drain plug (3) or (4), one is
sufficient.
(c) Screw the drain plug in.
3-11-1
2 TH 9-3900
(d) Undo the filler (1) and the level check plug
(2).
(e) Fill the transfer box with the prescribed oil
to the bottom of the level plug hole.
(f) Fit the filler plug.
(g) Check for leakage.
Fig. 3.11.3
1. Filler plug
2. Level check plug
3. Drain plug
4. Drain plug
3-11-2
2 TH 9-3900
3.12 INTERMEDIATE SHAFTS
NOTE: If both parts of the intermediate shaft, meaning the section with the universal joint and the section
with the slide coupling have separated then attention must be paid when assembling them that
the arrows on both sections are opposite one another. See Fig. 3.12.1.
3.12.1 iNTERMEDIATE SHAFT, GEAR BOX/TRANSFER BOX
a. Removal
(2) Remove the intermediate shaft.
b. Installation
(1) Degrease the bolts and nuts.
(2) Position the intermediate shaft.
(3) Apply locking liquid, Loctite 242 or a similar
product, to the screw threads of the bolt.
(4) Fit the bolts, lock washers and nuts.
NOTE: Tighten the bolts to the specified torque.
3.12.2 INTERMEDIATE SHAFT, TRANSFER BOX/FRONT AXLE
a. Removal
b. Installation
NOTE: Tighten bolts to the prescribed torque using the special tool (e, fig. 3.1.1.).
3.12.3 INTERMEDIATE SHAFT, TRANSFER BOX/REAR AXLE
a. Removal
b. Installation
NOTE: Tighten bolts to the prescribed torque using the special tool (e, fig. 3.1.1.).
Fig. 3.12.1 Intermediate shaft

1. Universal joint section
2. Slide coupling section
3-12-1
2 TH 9-3900
3.12.4 INTERMEDIATE SHAFT, POWER TAKE OFF / HYDRAULIC PUMP
a. Removal
(1) Undo the flange connection on the side of
the power take off.
(2) Remove the clamping pin on the side of the
hydraulic pump.
b. Installation
NOTE:Tighten the bolts to the specified torque.
Fig. 3.12.2
1. Hydraulic pump
2. Pump seat
3. Intermediate shaft
4. Power take off flange
5. Cord
3-12-2
2 TH 9-3900
3.13 FRONT AXLE

horizontal.

drain plug (2).
(b) Unscrew the drain plug.
(c) Lubricate the drain plug with grease
extremely high temp.
(d) Screw in the drain plug (2).
(e) Undo the filler / level check plug (1).
(f) Fill the front axle with the prescribed oil to
(g) Fit the level check/filler plug.
(h) Check for leaks
3.13.2 BLEEDING (SEE FIG. 3.13.20. Fig. 3.13.1

a. Removal 2. Drain plug
(1) Remove the air-bleed pipe (1).
(2) Open the bleed nipple (2).
(3) Check the pipe and nipple for blockage:
blow through with compressed air if
necessary.
b. Installation
Fig. 3.13.2
1. Bleed pipe
2. Bleed nipple
3. Front axle
3-13-1
2 TH 9-3900
3-13-2
2 TH 9-3900
3.14 REAR AXLE

horizontal.

drain plug (2).
(b) Unscrew the drain plug.
(c) Lubricate the drain plug with grease
extremely high temp.
(d) Screw in the drain plug (2).
(e) Undo the filler / level check plug (1).
(f) Fill the front axle with the prescribed oil to
(g) Fit the level check/filler plug.
(h) Check for leakage.
Fig. 3.14.1
2. Drain plug
3.14.2 .BLEEDING (SEE FIG. 3.14.2.).
a. Removal
(1) Remove the air-bleed pipe (1).
(2) Open the bleed nipple (2).
(3) Check the pipe and nipple for obstructions
and blow through with compressed air if
necessary.
b. Installation
Fig. 3.14.2
1. Bleed pipe
2. Bleed nipple
3. Rear axle
3-14-1
2 TH 9-3900
3.14.3 BALL RACE OF THE WHEEL HUB OIL SEAL (SEE FIG. 3.14.3 and 3.1 4.4.).
a. Removal
(1) Detach the axle shaft nuts.
(2) Pull the axle shaft from the axle housing.
(3) Remove the gasket (1).
(4) Take the grease seal plate and oil sealing
ring (2) out of the wheel hub.
(5) Remove the rear gasket (3).
(6) Remove the bearing race (10) and the
gasket (8) using, for example, two
screwdrivers.
b. Installation
(1) Check the oil seal for damage and replace
if necessary.
(2) Press a new bearing race and gasket onto
the axle journal (11).
(3) Lay a new gasket on the axle shaft studs.
(4) Fit the grease seal plate and oil seal in the Fig. 3.14.3
wheel hub. 2. Grease seal plate and oil seal
(5) Lay a new gasket on the grease seal plate 10.Bearing race
and oil seal. 11. Axle journal
(6) Fit the axle shaft.
3.14.4 AXLE SHAFT GASKET
a. Removal
(1) Detach the axle shaft nuts.
(2) Pull the axle shaft about 25 cm from the
axle housing.
(3) Remove the oil seal from the wheel hub.
(4) Remove both old gaskets.
b. Installation
(1) Pull a gasket carefully over the axle shaft
flange and over the grease seal plate.
(2) Lay the gasket on the axle shaft studs.
(3) Fit the grease seal plate and oil seal in the
wheel hub.
(4) Pull a gasket carefully over the axle shaft
flange and lay the gasket over the studs.
(5) Fit the axle shaft. Fig. 3.14.4
1. Gasket
2. Grease seal plate and oil seal
3. Gasket
4. Lock nut
5. Circlip
6. Wheel hub nut
7. Bearing, outer
8. Gasket ring
9. Axle shaft
10.Bearing race
11. Axle journal
3-14-2
2 TH 9-3900
3.15 BRAKE SYSTEM There are also two coupling heads (16b
and 17b) on the front of the truck with
3.15.1 DESCRIPTION OF THE AIR respectively a shut-off valve (15c) and a
PRESSURISED DUAL CIRCUIT line filter (28). When there is a trailer
DUAL LINE BRAKE SYSTEM. connected then the brake system of the
trailer can be connected via these
(SEE Fig. 3.15.1.). connections. The wheel brakes of the
trailer are unloaded via the supply line so
The compressor (1) pushes air via the
that the trailer can be moved. The trailer
pressure regulator (4) and the anti-frost
can now however no longer be braked by
device (5) to the so-called wet air reservoir
the brake system of the truck.
(2a) and from there via the four-circuit
If the truck has to be towed then the brake
safety valve (20) to the two air reservoirs
system of the towing vehicle can be
(2b). The pressure regulator also acts as
connected.
an oil and water separator.
If the towing vehicle then brakes then the
The purpose of the wet reservoir is to allow
brakes of the vehicle being towed also
a large part of the water vapour which is still
operate.
present in the compressed air to condense
If the foot brake valve (22) is operated then
through cooling.
compressed air flows into circuit 1 to the
This reservoir is equipped with an
service brake chamber of the spring brake
automatic blow-off valve (3).
cylinders on the front axle and in circuit 2
via the automatic load-independent control
The central supply line splits via the four-
valve (13) to the brake chambers on the
circuit safety valve (20) into four circuits;
rear axle so that via the brake camshafts all
two circuits for the operating brake (circuits
the wheels are braked. From both circuits
1 and 2), one for the parking brake valve
compressed air also flows to the dual
(circuit 3) and one for the trailer vehicle
circuit reaction valve (11) on the truck so
brake valve (circuit 4). Due to the use of
that the service line is inflated via the
this four-circuit safety valve, in the event of
shut-off valve (15b) and the coupling head
a leak in one of the circuits the air supply in
(17a) to the trailer. Breakage or
the other circuits is protected against being
disconnection of the supply line to the
lost.
trailer results in braking of the trailer.
In addition the circuits which are not faulty
Breakage of the service line has no
are filled up to a particular pressure. The
immediately discernible effects; in the
foot brake valve (22) consists of two
event of braking however compressed air
sections.
will escape up to the value set for circuit 3
of the four-circuit safety valve.
One section is linked to circuit 1, the other
section is linked to circuit 2.
Compressed air also flows out of these two If one or both of the trailer connections is
circuits to the air pressure gauge where the broken then full braking of the truck
supply pressure of each circuit is indicated continues to be possible although up to a
by one of the two red pointers. The buzzer little less maximum pressure.
activates when the supply pressure is too The parking and emergency brake are
low. operated using the controllable parking
brake valve (27) next to the driver's seat in
Air flows from circuit 1 via the overflow the cab.
valve (24) to the operating vale for the
independent braking of the trailer (25) and If the handle of the valve is turned then the
to the blocking brake. The front axle and emergency brake will operate. The from
any trailer is connected to circuit 1; the rear the parking brake valve (27) to the spring
axle of the truck and of any trailer is brake cylinders (7) will be vented.
connected to circuit 2. The brake camshafts are operated using
the heavy spring in the spring brake
The brake system of the truck is linked at cylinders. The line from the parking brake
the rear using two shut-off valves (15a and valve to the reaction valve is also vented so
15b) and two coupling heads (16a and 17a) that the service line to the trailer is also
to the trailer where one line provides the vented and this also brakes.
power and the other line passes the brake
command.
3-15-1
2 TH 9-3900
If the handgrip on the parking brake valve

is pulled out and turned further then the
parking brake is operated.
The spring brake cylinders on the front axle
continued to be vented.
In this position in which the handgrip is
blocked the line to the reaction valve (11)
is also vented. This means that the service
line to the trailer is vented so that the trailer
brakes are unloaded again.
In the line to the spring brake cylinders
there is a double-check valve (9a), which
prevents the parking brake (= spring brake
cylinders) and the operating brake (= brake
chambers) operating together on the brake
camshafts.
Via the overflow valve (24) on circuit 1
there is a connection to the engine brake,
the blocking brake valve (26) and the
independent trailer brake operating valve
(25).
If this last valve which is attached to the
steering column is operated via the two-
way valve (9b) to send a command to the
response valve so that only the trailer is
braked.
The stop light switch (19) is in the service
line to the trailer so that the stop lights can
be operated from both circuits. If the
blocking brake valve (26) is operated then
the max. air flow flows via the two-way
valves (9b) to the brake chambers and any
trailer. The blocking brake valve may only
be operated when the vehicle is stationary.
Both axles are then fully braked.
The blocking brake valve may not be used
for parking as if the air pressure falls off
then the wheel brakes unload again.
3-15-2
2 TH 9-3900
Fig. 3.15.1
1. Compressor 29. Locking cylinder 35. Engine brake cylinder

15a. Air cock 6. Test connection 10. Test connection
27. Parking brake valve 17b. Coupling head 11. Reaction valve
2a. Wet air reservoir 30. 3-Position cylinder 22. Foot brake valve
2b. Air reservoirs 7. Spring brake cylinder 36. Engine brake valve
15b. Air cock 18. Emergency filling 12. Spring lever
28. Line filter connection 23. Foot pressure switch
3. Automatic blow-off valve 31. 2-Position cylinder 37. Coupling valve (YAL)
15c. Air cock 32. 3-Position valve 13. Load-dependent control
A. Engine brake operating 8. Fast relief valve valve
16a. Coupling head 19. Stop light switch 24. Overflow valve
4. Pressure regulator 33. 2-Position valve 38. Foot brake valve (YAL)
16b. Coupling head 9a. Double check valve 25. Independent trailer brake
B. Intermediate box 20. Four-circuit safety valve valve
operation 34. Engine brake cylinder 39. Air cylinder, coupling
5. Anti-frost device 9b Two-way valve (YAL)
17a. Coupling head 21. Non-return valve 14. Brake chamber
26. Blocking brake valve
40 Relay valve
3-15-3
2 TH 9-3900
3.15.2 BRAKE SHOES COMPLETE WITH SPRINGS
a. Removal
(1) Take the wheel off, see 1 TH.
(2) Take off the brake drum complete with hub,
see item 3.16.1/2/4.
(3) See Fig. 3.15.2.: Remove the locking wire
(4) and the two locking bolts (3) from the
anchor pins.
(4) See Fig. 3.15.3.: Remove the two spring
clips (2), the felt rings (4) and the lock
washers (3).
(5) Remove the anchor pins.
(6) Take off the brake shoes and draw springs.
b. Checking
(1) Check the brake lining for: thickness
(minimum 1 mm up to the rivet head) -
unequal wear - surface (greasy, glazed).
(2) If necessary fit complete new brake shoes
with the accompanying brake drum.
Fig. 3.15.2
c. Installation
1. Spring
(1) Lubricate all pivot points with grease 2. Anchor pin
extremely high temp. 3. Locking bolt
(2) Installation in reverse order. 4. Locking wire
Fig. 3.15.3
1. Brake shoe
2. Spring clip
3. Sealing ring
4. Felt ring
5. Pin
3-15-4
2 TH 9-3900
d. Adjustment (See Fig. 3.15.4. and 3.15.5.).

(1) Check the distance between the centre line
of the brake lever and the cover of the
brake cylinder.
Front axle, 162 mm
Rear axle: 85 mm
(2) Undo the connection between the yoke and
the brake lever.
(3) Loosen the lock nut on the yoke.
(4) Turn the yoke in or out as required.
(5) Fasten the yoke and secure it with a split
pin.
(6) Tighten the locknut.
(7) Check the distance again.
e. Adjustment of the wheel brakes

(1). Jack up the axle in question.
(2). Turn the bush of the adjusting nut (A) on
the brake lever using the key after which
the nut is turned clockwise until the wheel
in question blocks.
(3). Then turn the adjustment nut slowly anti-
clockwise until the brakes are just free.
(4) Finally check the travel of the brake lever at
travel ,±3cm
the yoke. At maximum brake pressure this
will be about 3 cm.
3.15.3 BRAKE PIPES, HOSES AND COUPLINGS Fig. 3.15.4 Brake lever, front axle
NOTE: The following generally applies to

brake pipes, hoses and couplings. travel ,±3cm
a. Removal
(1) If necessary tilt the cab.
(2) Disconnect the pipe, hose or coupling to be
removed on both sides.
(3) Disconnect the fastenings.
(4) Remove the pipe, hose or coupling.
(5) Close the end of the line etc which has not
been taken off.
b. Installation
(1) Check that the lines etc. To be fitted are
clean.
Fig. 3.15.5 Brake lever, rear axle
3-15-5
2 TH 9-3900
3.15.4 ANTI-FROST DEVICE (SEE FIG. 3.15.6.).
WARNING: Position the handle of the anti-frost

device in the summer position (=
handle downwards) before
opening the filler cap and the drain
plug. Being careless can cause
fluid to get into the eyes when
opening the filler cap.
a. Checking
(1) Press the handle (2) down and turn it a
quarter turn to the right (= summer position,
the anti-frost device has then been put out
of operation).
(2) Remove the filler cap (1).
(3) Check the coolant level.
b. Topping up
(1) Fill the reservoir with fluid to the prescribed Fig. 3.15.6
level. 1. Filler cap
(2) Check the gasket of the filler cap. 2. Handgrip
(3) Tighten the filler cap firmly. 3. Drain plug
(4) Position the handle of the anti-frost device,
if necessary, in the winter position (= turn
handle a quarter turn to the left and allow to
rise up).
c. Cleaning
(1) Position the handle in the summer position.
(2) Screw out the drain plug (3).
(3) Collect any fluid.
(4) Remove the spring and the sleeve.
(5) Clean or replace the sleeve.
d. Removal
(1) Tilt the cab.
(2) Connect the tyre inflating hose to the test
connection so that the wet air reservoir
pressure is gone.
(3) Undo the connections to the anti-frost
device.
(4) Remove the attachment bolts.
(5) Remove the anti-frost device from the
vehicle.
Fig. 3.15.6 a
e. Installation
1. Air pipe
(1) Fit in the reverse order to removal. 2. Nut
(2) Start the engine and allow the brake system 3. Air pipe
to come up to pressure. 4. Anti-frost device
(3) Check the connections for leaks using a
soapy solution.
(4) If necessary fill the anti-frost device with
coolant
(5) Use the anti-frost device if circumstances
require this
3-15-6
2 TH 9-3900
3.15.5 TRAILER VEHICLE AIR CONNECTIONS
a. Removal (See Fig. 3.15.1.).

(1) Apply the parking brake.
(2) Turn the air cock to be removed open.
NOTE:If the left rear cock is opened then air will

escape to a pressure of ± 4.5 bar (kg/cm2).
No air may escape from the other cocks.
(3) Undo the attachment clamping bolt on the
line side.
(4) Undo the air cock and coupling head from
the line.
b. Take apart (see fig. 3.15.7.).

(1) Remove the spring clip (14) under the air
cock.
(2) Remove the complete insides.
(3) Detach the lever (2) by removing the pin (4)
from the cock housing.
c. Assembly
NOTE: When assembling check the rubber

sealing rings (3), (10) and (12).
NOTE: Check that the lid (9) can still close
properly.
NOTE: Use "Parker-O-Lube" grease to
lubricate the moving parts lightly
before assembling them.
(1) Assembly is done in reverse order.
d. Installation
(1) Install in reverse order (See a, item 3.15.5)
Fig. 3.15.7
1. Air cock
2. Lever
3. O-ring
4. Pin
5. Ring
6. Ball
7. Piston
8. Spring
9. Valve
10.O-ring
11.Spring
12.O-ring
13.Lid
14.Spring clip
3-15-7
2 TH 9-3900
3.15.6 BRAKE CAMSHAFT LEVER (See fig. 3.15.8. and 9.).
a. Removal
(1) Switch off the battery main switch.
(2) If it is a front wheel then turn the spindle in
the spring brake cylinder as far as possible.
(3) Remove the heads.
(4) Remove the split pin and the castle nut.
(5) Press the brake camshaft in a little if it is a
rear wheel.
(6) Take the washer, brake lever and shim from
the brake camshaft.
b. Installation
(1) Fit a shim with the right thickness to the
brake camshaft.
(2) Fit the brake lever.
(3) Fit the washer and the castle nut and
tighten the castle nut.
(4) Fit the split pin. Fig. 3.15.8
(5) Fit the heads and the split pin. 1. Split pin
(6) Fully turn the spindle into the spring brake 2. Castle nut
cylinder, if this is a front wheel, and tighten 3. Fill ring
it. 4. Brake lever
(7) Adjust the brakes (item 3.15.2). 5. Brake camshaft
(8) Lubricate the brake camshaft. 6. Fill ring
Fig. 3.15.9
1. Split pin
2. Castle nut
3. Fill ring
4. Brake lever
5. Brake camshaft
6. Fill ring
3-15-8
2 TH 9-3900
3.15.7 BRAKE PEDAL RUBBER (Fig. 3.15.10.)
a. Removal
(1) Set the parking brake lever to the parking
position.
(2) Tilt the cab.
(3) Remove the pin (1) from the yoke of the
long rod (2) which connects the brake valve
and the equaliser.
(4) Remove the four bolts (3) from the plate on
which the brake pedal is mounted.
(5) Remove the plate complete with the brake
pedal.
(6) Remove the control rod (4) and remove the
pedal rubber (5) and the 2 rings which be
present (6).
b. Installation
(1) Fit the new pedal rubber using a lubricant
(G-392) to the control rod (4).
(2) Fit the new pedal rubber (this has a groove
on the bottom) to the plate. The metal ring
can now remain behind.
(3) Carry out operations 3 to 5 of removal, in
reverse order.
(4) Adjust the length of the tie bar (2) such that
the bolt can be put in.
(5) Fit pin, ring and split pin.
(6) Check and correct if necessary the play of Fig. 3.15.10
the push rod in the service brake valve (Fig 1. Pin
3.15.11) by changing the length of the push 2. Push rod
rod. 3. Bolt
4. Control rod
5. Pedal rubber
6. Ring
Play
Fig. 3.15.11
1. Service brake valve
3-15-9
2 TH 9-3900
3-15-10
2 TH 9-3900
3.16 BRAKE DRUMS, WHEEL HUBS AND WHEELS
3.16.1 BRAKE DRUM (SEE FIG. 3.16.1.).
a. Removal
(1) Block the front wheels and back wheels
using the chocks.
(2) Remove the wheel, see 1TH.
(3) Remove the four sunken bolts (3).
(4) Insert two jack screws in the threaded
holes.
MAKE SURE that the air reservoirs have

sufficient pressure, at least 5.5bar.
(5) Screw in the jack plugs and press the brake

drum off.
b. Check
(1) Check the braking surface for grooves. The
grooves may be a maximum of c. 0.7 mm Fig. 3.16.1
broad and/or c. 50 mm long. If necessary 1. Jacking screw
the drums must be unscrewed (3TH). 2. Wheel hub
(2) Inspect the brake lining, see item 3.15.2. 3. Sunken bolt
(3) If necessary, clean the wheel brake.
Temporarily remove the separated dust
cover at the back of the wheel brake.
(4) Check and clean if necessary the mating
surfaces of the brake drum and the wheel
hub.
c. Installation
(1) Remove the jack screws from the brake
drum.
(2) Fit the four sunken bolts and tighten them.
(3) Fit the two wheel nuts opposite one
another.
(4) Tighten the two wheel nuts alternately until
the brake drum is correctly on the hub.
(5) Tighten the four sunken bolts again and
remove the wheel nuts.
(6) Fit the wheel, see 1 TH.
3.16.2 WHEEL HUB, FRONT AXLE (SEE FIG. 3.16.2).
a. Removal
(1) Block the rear wheels.
(2) Remove the wheel, see 1TH. Fig. 3.16.1 a Brake drum rejection norm
(3) Remove the brake drum, see item 3.16.1.
(4) Undo the nuts on the drive flange (2) and also the bolts in the middle of the flange.
(5) Remove the drive flange using the jacking screws (7) if necessary, and also the gasket (1).
(6) Remove the wheel hub nut (6), circlip (5) and lock nut (4) using the hub nut wrench.
(7) Remove the hub complete with bearings and sealing ring.
b. Installation
(2) Adjust the bearings, see item c.
c. Adjustment
(1)Tighten the wheel hub nut (6) to the specified tightening torque.
(2)Turn the wheel hub nut one quarter turn back.
(3)Fit the circlip (5).
(4)Tighten the lock nut (4) to the specified tightening torque.
3-16-1
2 TH 9-3900
3.16.3 BEARINGS AND OIL SEALING RING, FRONT AXLE (SEE FIG. 3.16.2).
a. Removal
(2) Remove the wheel hub complete with bearings
and sealing ring, see item3.16.1).
(3) Remove the bearing cones from the hub.
(4) Tap the outer ring from the inside of the rear
bearing out of the hub; the grease sealing ring
will also come.
(5) Tap the outer ring of the front bearing out of
the hub in the same way.
b. Installation
(1) Fit the complete bearings into the wheel hub.
Grease the fitting edge lightly with G-403
grease.
(2) Fit the grease sealing ring.
(3) Mount the wheel hub on the axle journal and
adjust the bearings, see item 3.16.2.
(4) Install in reverse order from item 3.16.2.
3.16.4 WHEEL HUB, REAR AXLE (SEE FIG.3.16.3).
a. Removal
(1) Block the front wheels. Fig. 3.16.2 Front wheel hub
(2) Remove the wheel, see 1 TH. 1. Gasket 5. Circlip
(3) Remove the brake drum, see item 3.16.1. 2. Drive flange 6. Wheel hub nut
(4) Remove the axle shaft from the axle housing, 3. Retaining flange 7. Jacking screw
see item 3.14.3. 4. Lock nut 8. Bearing
(5) Remove the grease sealing ring (2).
(6) Remove the wheel hub nut (6), circlip (5) and
lock nut (4) using the hub nut wrench.
(7) Remove the hub complete with bearings and
sealing ring.
b. Installation
(1) Carry out items a.6 and a.7
in reverse order.
(2) Adjust the bearings, see
item c.
(3) Carry out items a.1 to a.5 in
reverse order.
c. Adjustment
(1) Tighten the wheel hub nut
(6) to the specified
tightening torque.
(2) Turn the wheel hub nut one
quarter turn back.
(3) Fit the circlip (5).
(4) Tighten the lock nut (4) to
the specified tightening
torque.
Fig. 3.16.3 Rear wheel hub

1. Gasket 5. Circlip 9. Grease sealing ring
2. Grease seal plate and oil seal 6. Wheel hub nut 10. Gasket ring
3. Gasket 7. Bearing, outer 11. Axle shaft
4. Lock nut 8. Bearing, inner 12. Bearing race
3-16-2
2 TH 9-3900
3.16.5 BEARINGS AND OIL SEALING RING, REAR AXLE (SEE FIG. 3.16.4).
a. Removal
(1) Block the front wheels.
(2) Remove the wheel hub complete with
bearings and sealing ring, see item 3.16.4.
(3) Remove the bearing cones from the hub.
(4) Tap the outer ring of the rear bearing out of
the hub from the inside: the grease sealing
ring will also come out.
(5) Tap the outer ring of the front bearing out of
the hub in the same way.
b. Installation
(1) Fit the complete bearings into the wheel
Fig. 3.16.4
hub. Grease the fitting edge lightly with G-
403 grease. 1. Rim ring
2. Sealing ring
(2) Fit the oil seal. 3. Rim
(3) Mount the wheel hub on the axle journal 4. Brake drum
and adjust the bearings, see item 3.16.4. 5. Wheel nut
(4) Installation is then in accordance with item 6. Wheel stud
3.16.4. 7. Wheel hub
3.16.6 RIMS AND WHEEL RIMS (SEE FIG. 3.16.4).
a. Removal
(1)Remove the wheel, see 1TH.
(2) Lay the wheel flat on the ground with the
valve upwards.
(3) Remove the valve cap and the valve and
allow the tyre to deflate fully.
(4) Tap with a hammer round the rim ring (1).
(5) Twist the lock washer (2) loose using a tyre
iron.
(6) Remove the rim ring and lock washer.
(7) Turn the wheel over.
(8) Tap the tyre loose from the rim using an
iron placed between the tyre and the rim.
(9) Remove the rim.
b. Installation
(1) Lubricate the tyre heels.
(2) Position the tyre complete with inner tyre
and flap over the rim with the valve straight
immediately in front of the valve opening.
(3) Position the rim ring and lock washer in the
correct position.
(4) Tap the lock washer into place.
(5) Fit the valve.
(6) Position the wheel in a tyre cage and pump
the tyre up a little.
(7) Check the locking washer and rim rings are
positioned correctly.
(8) Pump up the tyre to the correct pressure in
the tyre cage.
(9) Fit the valve cap on to the valve.
(10)Fit the wheel nuts and tighten them to the
specified tightening torque.
3-16-3
2 TH 9-3900
3.16.7 TYRES (SEE Fig. 3.16.5.).
a. Removal
(1) Remove the rim, see item 3.16.6.
(2) Remove the flap.
(3) Take the inner tyre out of the outer tyre.
b. Repair
(1) Pump up the tyre a little.
(2) Localise the leak.
(3) Sand off the place properly.
(4) Allow the tyre to empty.
(5) Apply solution to the tyre and to the repair
plaster.
(6) Wait until the solution is almost dry and Fig. 3.16.5
press the plaster on to the tyre firmly. 1. Outer tyre
2. Inner tyre
c. Installation 3. Flap
(1) Carefully check the inside of the outer tyre. 4. Rim
(2) Apply copious amounts of talcum powder 5. Rim ring
onto the inner tyre. 6. Sealing ring
(3) Place the inner tyre in the outer tyre. 7. Valve
(4) Fit the flap; the edges must be caught
between the inner and outer tyres.
(5) Lightly lubricate the tyre heels and flap with
the prescribed grease.
(6) Mount the complete unit on the rim, see
item 3.16.6.
3-16-4
2 TH 9-3900
3.17 STEERING GEAR
3.17.1 STEERING ROD COMPLETE WITH BALL ENDS
a. Removal, see Fig. 3.17.1. and 3.17.2.

(1) Tilt the cab.
(2) Jack up the front axle until the wheels are
just clear of the floor.
(3) Turn the steering wheel to the left until the
wheel stop is reached.
(4) Remove the split pins and castle nuts on
both sides of the steering rod.
(5) Pull the ball ends out of the Pitman arm and
the steering rod arm using a puller.
(6) Remove the steering rod and the ball ends.
b. Installation
(1) Fasten the complete steering rod (1) to the
Pitman arm (2) and to the control arm; do
not yet tighten the castle nuts. Fig. 3.17.1
(2) Count the number of steering wheel turns 1. Steering rod
from the left stop to the right stop. 2. Clamping piece
(3) Turn the steering wheel half the number of 3. Ball end
turns back; the Pitman arm will then be 4. Control arm
about central.
(4) Turn the steering wheel until the marks on
the steering box and the steering axle are
opposite one another, see fig. 3.17.3. The
Pitman arm is exactly in the centre position.
(5) Allow the jack to go down until the wheels
are on the floor.
(6) Draw a cord over the flanks of the left hand
front tyre and the left h and rear tyre, see
fig. 3.17.4.
(7) Turn the steering wheel if necessary until
the cord touches the left hand tyres at all
four points. The front wheels are now in the
straight-ahead position.
(8) Remove the clamping bolts from the
steering rod.
(9) Adjust the desired steering rod length as
required by turning the ball end in or out.
(10)Fasten the steering rod to the steering rod
arm. If necessary correct the length of the
steering rod.
(11)Tighten the clamp bolts and the castle nuts
to the specified torque.
(12)Fit new split pins. Fig. 3.17.2
(13)Tilt the cab back into the driving position. 1. Steering rod
2. Pitman arm
3.17.2 STEERING ROD BALL ENDS (SEE FIG. 3.17.1).
a. Removal
(1)Tilt the cab.
(2)Remove the complete steering rod (1), see item 3.17.1.
(3)Undo the clamping bolts and unscrew the ball ends from the steering rod.
b. Installation
(1)Screw the ball ends into the steering rod.
(2)Adjust the length of the steering rod, see item 3.17.1.
(3)Fit the steering rod in position.
(4)Tighten the clamp bolts and the castle nuts to the specified torque.
(5)Fit new split pins.
(6)Tilt the cab back into the driving position.
3-17-1
2 TH 9-3900
3.17.3 STEERING ROD COMPLETE WITH BALL ENDS (SEE FIG. 3.17.5).
a. Removal
(1) Turn the steering wheel to the left until the
wheel stop is reached.
(2) Remove the split pins and castle nuts on
both sides of the track rod.
(3) Pull the ball ends from the track rod arms
using a puller.
(4) Remove the complete track rod.
b. Installation
(1) Position the wheels in the straight-ahead
position (see item 3.17.1).
(2) Adjust the track rod to be fitted to the
desired length by undoing the clamp bolts
and turning the hexagon of the ball ends
clockwise or anti-clockwise.
(3) Fit the track rod in position.
(4) Check the toe-in and correct if necessary.
c. Check/adjust toe-in
(1) Position the left front wheel in the straight-
ahead position (see item 3.17.1).
(2) Position a track rod at the front at wheel
hub height between the flanks of the front
tyres, see fig. 3.17.6
(3) Move the truck forwards until the track rod Fig. 3.17.3
has reached the same height at the back.
The difference between the front and rear
must comply with the prescribed value.
(item 2.2.3.h.)
(4) If necessary correct the toe-in by
shortening or lengthening the track rod.
(5) Tighten the clamp bolts and the castle nuts
to the specified torque.
(6) Fit new split pins. Good
Wrong
Fig. 3.17.4
3-17-2
2 TH 9-3900
3.17.4 TRACK ROD BALL ENDS (SEE FIG. 3.17.5.).
a. Removal
(1) Remove the track rod, see item 3.17.3.
(2) Undo the clamping bolts and unscrew the
ball ends from the track rod.
b. Installation
(1) Screw the ball ends into the track rod.
(2) Adjust the toe-in, see item 3.17.3 c.
Fig. 3.17.5
1. Ball end
2. Clamping piece
3. Track rod
4. Track rod arm
Fig. 3.17.6
3-17-3
2 TH 9-3900
3.17.5 HOSES AND LINES (SEE FIG. 3.17.7. and 3.17.8).
a. Removal
(1) Tilt the cab if necessary.
(2) Drain the steering box; catch the oil in a
reservoir.
(3) Disconnect the connections.
(4) Remove the relevant line or hose.
(5) Protect lines, hoses and steering parts
against dirt and dust.
b. Installation
(1) Remove the drain plugs from lines, hoses
and steering parts.
(2) Blow the lines and hoses clean carefully
before fitting them.
NOTE: Make sure that all lines, hoses and

connection pieces are fitted free of Fig. 3.17.7
stress.
(3) Re-fit the connections.

(4) Fill and bleed the system.
c. Bleeding (See Fig. 3.17.8.).

(1) Completely fill the steering oil reservoir.
(2) Place the stop lever in the stop position.
(3) Start the engine for more than + 10
seconds without allowing it to catch (stop
lever at "stop"! ) while checking that the
reservoir remains filled; top up if necessary.
(4) Jack up the front axle until the front wheels
are just clear from the floor.
(5) Open the bleed nipple on the steering box.
(6) Position the stop lever in the operating
position and start the engine.
(7) Run the engine at idling speed.
(8) Turn the steering wheel a number of times
quickly from stop to stop until no more air
escapes from the bleed nipple.
(9) Continue to top up the oil if necessary.
(10)Close the bleed nipple.
(11)Switch the engine off.
(12)Check the oil level in the reservoir; this
should be 1 or 2 cm above the max. mark
on the dipstick.
(13)Top up the oil if necessary.
(14)Tilt the cab back into the driving position. Fig. 3.17.8
1. Bleed nipple
2. Steering box
3. Drain plug
3-17-4
2 TH 9-3900
3.17.6 OIL RESERVOIR (SEE FIG. 3.17.9).
a. Removal
(1) Tilt the cab.
(2) Remove the hose and collect the escaping
oil.
(3) Hold the hose at the same height or a little
higher; this avoids the system having to be
bled afterwards.
(4) Remove the reservoir including the bracket.
(5) Remove the filter element (see item
3.17.7).
b. Installation
(1) Fit the reservoir.
(2) Connect the hoses.
(3) Position the filter element in the reservoir
(see item 3.17.7).
(4) Check the oil level, see item 3.17.8.
Fig. 3.17.9
3.17.7 FILTER ELEMENT (SEE Fig. 3.17.10.).
a. Removal
(1) Tilt the cab.
(2) Remove the wing nut from the cover.
(3) Remove the cover.
(4) Remove the rubber bush and centring ring.
(5) Remove the filter element (1) from the oil
reservoir (2).
b. Installation
(2) Check the rubber sealing ring for usability.
Fig. 3.17.10
1. Filter element
2. Reservoir
3-17-5
2 TH 9-3900
3.17.8 OIL LEVEL CHECK (SEE FIG. 3.17.11.).
NOTE: NOTE:Ensure that the vehicle is

horizontal.
(a) Tilt the cab.

(b) Start the engine and run it at idling speed.
(c) Check the oil level. The oil level must be
between the max. and min. markings on the
dipstick.
(d) Switch the engine off.
NOTE: With the engine at a standstill the oil

level is 1 to 2 cm above the max. mark
on the dipstick.
(e) Tilt the cab back.
Fig. 3.17.11 Oil level check
3-17-6
2 TH 9-3900
3.18 CHASSIS
3.18.1 TOWING HOOK (SEE FIG. 3.18.1.).
a. Removal
(1) Remove the split pin (9).
(2) Remove the nut (8).
(3) Remove the washer (7), lock washer (6)
and rubber ring (5).
(4) Remove the towing hook.
(5) Remove the conical ring (3) and the rubber
ring (2).
b. Installation
(1) Check whether the rubber rings are still in
good condition.
(2) Installation in reverse order. (Torque, see
table). Fig. 3.18.1
1. Towing hook
2. Rubber ring
3.18.2 SPARE WHEEL CARRIER 3. Conical ring
4. Attachment plate
5. Rubber ring
c. Removal 6. Sealing ring
(1) Take the spare wheel out of the carrier, see 7. Washer
1TH. 8. Nut
(2) Remove the attachment bolts and take off 9. Split pin
the carrier.
d. Installation
Fig. 3.18.2
3-18-1
2 TH 9-3900
3-18-2
2 TH 9-3900
3.19 SUSPENSION AND SHOCK ABSORBERS
Fig. 3.19.1 Front spring

1. Spring assembly 4. Shock absorber 6. Nut
2. Shock absorber seat 5. U-bolt 7. Lower spring seat
3. Fenders
3.19.1 FRONT SPRINGS (SEE FIG. 3.19.1. AND 3.19.2).
a. Removal
(2) Hoist the vehicle up or jack it up under the
chassis side members until the front
wheels (or the brake drums if the wheels
have been removed for convenience) are
just free of the ground.
shock absorber seating (2) and the shock
absorber (4).
(4) Remove the U-bolts (5), the lower spring
seat (7) and the shock absorber seating
(2).
NOTE: For the removal of the front U-bolts

from the right front spring, the lifting
cylinder of the cab must first be
removed. For the removal of the rear
spring pin from the left-hand front Fig. 3.19.2
spring the exhaust pipe before the 1. Lifting cylinder 4. Clamping bolt
silencer must first be removed(see 2. Nut 5. Spring seat
3. Shackle pin 6. Spring assembly
item 3.7.1).
(5) Remove the clamping bolts (4, Fig. 3.19.2.) from the spring seats (5).
(6) Tap the shackle pins (3) from inside to outside from the spring eyes.
(7) Remove the spring assembly (6).
b. Installation
(1) Position the spring assembly in the correct position (see Fig. 3.19.1.) on the front axle housing.
(2) Lay the shock absorber on the spring assembly.
(3) Fit the U-bolts and the lower spring seat but do not yet tighten the nuts.
(4) Install the shackle pins in such a way that the clamping bolts can be fitted.
(5) Attach the shock absorber to the shock absorber seat, see item 3.19.5.
(6) Tighten all the bolts and nuts to the prescribed torque.
(7) Fit all other parts back in place.
(8) Lubricate the shackle pins.
3-19-1
2 TH 9-3900
Fig. 3.19.3 Rear spring

1. Spring assembly
2. Upper spring seat
3. U-bolt
4. Lower spring seat
5. Shock absorber seat
6. Nut
7. Shock absorber
3.19.2 REAR SPRINGS (SEE FIG. 3.19.3.).
a. Removal
(1) Block the front wheels.
(2) Hoist the vehicle up or jack it up under the chassis side members until the rear wheels (or the brake
drums if the wheels have been removed for convenience) are just free of the ground.
(3) Loosen the connection between the shock absorber seat (5) and the shock absorber (7).
(4) Remove the shock absorber seat (5), lower spring seat (4), U-bolts (3) and upper spring seat (2).
(5) Remove the clamp bolts of the spring seats.
(6) Remove the shackle pins.
(7) Remove the spring assembly.
b. Installation
(1) Position the spring assembly on the rear axle housing.
(2) Lay the upper spring seat on the spring assembly.
(3) Fit the U-bolts and the lower spring seat and the shock absorber seat but do not yet tighten the nuts.
(4) Install the shackle pins in such a way that the clamping bolts can be fitted.
(5) Attach the shock absorber to the shock absorber seat, see item 3.19.6.
(6) Tighten all the bolts and nuts to the prescribed torque.
3-19-2
2 TH 9-3900
3.19.3 SPRING SHACKLES (SEE FIG. 3.19.4.).
a. Removal
(1) Block the wheels.
(2) Hoist the vehicle up or jack it up under the
chassis side members until the wheels in
question (or the brake drums if the wheels
have been removed for convenience) are
just free of the ground.
(3) Remove the four clamp bolts (1).
(4) Tap the shackle pins out of the spring
shackle.
NOTE: In the left front spring shackle the front

exhaust pipe must be removed first,
see item 3.7.1.
For right rear spring shackle the
vehicle tool kit and the cover of the
toolbox must be removed. (see Fig.
3.19.4)

(1) Installation in reverse order. 1. Clamping bolt
(2) Install the shackle pins in such a way that 2. Spring shackle
the clamping bolts can be fitted. 3. Lubricating nipple
(3) Tighten the clamp bolts to the specified
tightening torque.
3.19.4 FENDERS
a. Removal
(1) Front fenders:

(a)Disconnect the nut.
(b)Remove the ring and the fenders.
(2) Rear fenders:

(a)Remove the two bolts and nuts.
(b)Remove the fenders.
b. Installation
3-19-3
2 TH 9-3900
3.19.5 SHOCK ABSORBERS, FRONT
a. Removal
(1) Tilt the cab.
(2) Remove the dust cap (1, Fig. 3.19.5.).
(3) Unscrew the nut (2) and remove it together
with the spring washer (3), plate (4), rubber
rings (5 and 8) and bush (6).
(4) Unscrew the self-locking attachment nut on
the underside of the shock absorber (1, Fig.
3.19.6.) .
(5) Remove the nut together with the retainer
ring (2) and the rubber ring (3).
(6) Remove the shock absorber.
(7) Remove the other rubber ring (3).
NOTE: The pin is pressed into the shock

absorber seat and can not be removed
from the seat.
(8) Check the shock absorber rubber rings for

usability.
b. Installation
Fig. 3.19.5
1. Dust cap 6. Bush
2. Nut 7. Bracket
3. Spring washer 8. Rubber ring
4. Disc 9. Pin
5. Rubber ring 10 Shock absorber, front
Fig. 3.19.6 Front shock absorber attachment,

under
1. Nut
2. Retainer ring
3. Rubber rings
3-19-4
2 TH 9-3900
3.19.6 SHOCK ABSORBERS, REAR
a. Removal
(1) Remove the dust cap (10, Fig. 3.19.7.).
(2) Unscrew the nut (9) and remove it together
with the spring washer (8), plate (7), rubber
rings (6 and 3) and bush (5).
(3) Unscrew the self-locking attachment nut on
the top side of the shock absorber (1, Fig.
3.19.8).
(4) Remove the rubber ring (2).
(5) Remove the shock absorber.
(6) Remove the other rubber ring (2) together
with the retainer ring (3).
(7) Check the shock absorber rubbers for
usability.
b. Installation
3.19.7 SPRING SEATS
a. Removal
(1) Remove the shackle pins, see items
3.19.1. and 3.19.2.
(2) Remove the spring seat.
a. Installation
Fig. 3.19.7
1. Shock absorber
2. Pin
3. Rubber ring
4. Bracket
5. Bush
6. Rubber ring
7. Plate
8. Spring washer
9. Nut
10.Dust cap
Fig. 3.19.8 Rear shock absorber attachment,

upper
1. Nut
2. Rubber rings
3. Retainer ring
4. Pin
3-19-5
2 TH 9-3900
3-19-6
2 TH 9-3900
3.20 CAB
3.20.1 DROP GLASS MECHANISM (SEE FIG. 3.20.1.).
a. Removal
(1) Remove the cover plates on the window
crank and on the door handle.
(2) Unscrew the attachment screws from the
window crank, door handle, rotary knob
and door return handle.
(3) Remove the window crank, door handle,
rotary knob and door return handle.
(4) Remove the door trimming panel.
(5) Remove the window mechanism
attachment bolts.
(6) Raise the glass a little so that the roller
comes out of the guide rail.
(7) Remove the window mechanism.
b. Installation
Fig. 3.20.1
3.20.2 DROP GLASS
a. Removal
(1) Remove the drop glass mechanism (see
item 3.20.1+).
(2) Remove the trimming panel above the door
return handle, see Fig. 3.20.2. and 3.20.3.
(3) Remove the bolt from the rearmost guide
rail, see Fig. 3.20.4.
(4) Remove the rubber strip from the rearmost
guide rail.
(5) Pull the guide rail down and remove it.
(6) Lower the drop glass fully and move it a
little towards the lock; it will then come out
of the frame.
(7) Push the drop glass up and remove it, see
Fig. 3.20.5.
(8) Remove the guide strip at the bottom of the
drop glass by tapping it off the drop glass.

(1) Tap the guide rails and strip into place on
the drop glass.
Fig. 3.20.3
3-20-1
2 TH 9-3900
3.20.3 ROTATION MECHANISM OF THE VENTILATION WINDOW (SEE FIG. 3.20.6.).
a. Removal
(1) Remove the door return handle, crank and
doorknob.
(2) Remove the door trimming panel.
(3) Remove the connection bolt (1), which
connects the rotation mechanism to the
ventilation window.
(4) Remove the three cross head screws (2).
(5) Take the rotation mechanism (3) out of the
door.
b. Installation
Fig. 3.20.4
Fig. 3.20.5
Fig. 3.20.6
1. Connection bolt
2. Cross head screw
3. Rotation mechanism
3-20-2
2 TH 9-3900
3.20.4 VENTILATION WINDOW (SEE FIG. 3.20.7. and 3.20.8.).
a. Removal
(1) Remove from the door the rubber caps at
the top and bottom of the drop glass.
(2) Remove the bolt which connects the

window and the rotation mechanism, see
Fig. 3.20.6.
(3) Undo the lock nut and screw back the pin in
door a little, see Fig. 3.20.7.
(4) Remove the closed window from the door,
see Fig . 3.20.8.
b. Installation
Fig. 3.20.7
3.20.5 DOOR HINGES (SEE FIG. 3.20.9).
NOTE: When removing and installing the

cross head screws of the hinges
always use an impact screwdriver.
a. Removal
(1) Support the door.
(2) Disconnect the connection (1) to the
adjuster of the exterior mirror.
(3) Unscrew bolts (3) and cross head screws
(2) from the hinge.
(4) Remove the hinge.
b. Installation
Fig. 3.20.8
Fig. 3.20.9
1. Cross head screw, adjuster
2. Bolt
3. Cross head screw, hinge
3-20-3
2 TH 9-3900
3.20.6 DOOR LIMITER (SEE FIG. 3.20.10. and 3.20.11.).
a. Removal
(1) Remove the cover plate at the bottom of
the door.
(2) Remove the pin in the door.
(3) Remove the cover plate in the floor of the
cab.
(4) Roll removed plastic.
(5) Remove the rod.
b. Installation
3.20.7 DOOR CLOSING (SEE FIG. 3.20.12.).
a. Removal
(1) Remove the door covering, see item
3.20.1.
(2) Undo the connection between the tie bar
and the door lock. Fig. 3.20.10
(3) Unscrew the two cross head screws and
remove the tie rod.
(4) Remove the spring.
(5) Remove the two cross head screws on the
lock side.
(6) Remove the screw on the inside of the
door.
(7) Remove the door lock.
(8) Remove the nut on the inside of the handle
on the outside of the door.
(9) Remove the handle.
b. Installation
3.20.8 DOOR SEALS
a. Removal Fig. 3.20.11

(1) Remove the old seals.
(2) Carefully remove all old remains of glue or
profiles.
b. Installation
WARNING: Contact cement is used for

installing seals. This cement is
highly inflammable.
(1) Apply contact cement to both the door

edges and the seals.
(2) Wait for about ten minutes before applying
the seal.
Fig. 3.20.12
3-20-4
2 TH 9-3900
3.20.9 CAB WINDOWS (EXCEPT FOR THE WINDSHIELD)
a. Removal
(1) Pull the filler strip out of the rubber profile.
(2) Push the (remnants of the) window
outwards.
(3) Remove the rubber profile.
(4) Remove sealant remains using cleaning
spirit.
b. Installation
(1) Fit the rubber profile around the window,
Fig. 3.20.13
see Fig. 3.20.13.
(2) Apply talcum powder to the rubber profile
so as to facilitate fitting.
(3) Fit a cord in the rubber profile, see Fig.
3.20.14.
(4) Place the window in the slot so that the
cord ends are in the cab and the groove for
the filler strip is on the outside.
(5) Press the window as firmly as possible
inwards and at the same time pull one of
the cord ends; the rubber edge will then
pop over the slot, see Fig. 3.20.15 and
3.20.16.
(6) Fit the string using a string press. When Fig. 3.20.14
fitting the string must not be over-stretched,
see Fig. 3.20.17.
(7) Apply sealant under the rubber profile, see
Fig. 3.20.18.
Fig. 3.20.15 Fig. 3.20.16 Fig. 3.20.17
3-20-5
2 TH 9-3900
3.20.10 GRILLE (SEE FIG. 3.20.19.).
a. Removal
(1) Remove the two bolts.
(2) Unhook the upper part of the grille from the
two hooks on the cab.
(3) Remove the upper part.
(4) Remove the bolts.
(5) Remove the underside from the grille.
b. Installation
NOTE:The underside and upper side of the

grille can be fitted in any order.
3.20.11 BRANCH GUARD
a. Removal
(1) Remove the attachment bolts. Fig. 3.20.18
(2) Remove the branch guard.
b. Installation
3.20.12 CAB SEATS
a. Removal
(1)Remove the four attachment bolts from the underside of the mudguard.
(2)Remove the seat from the cab.
b. Installation
3.20.13 CORROSION INHIBITOR (SEE FIG. 3.20.20,3.20.21 and 3.20.22)
Corrosion inhibitors of various brands are on the market for a ML treatment. Each brand has developed its
own spray equipment and methods of spraying.
For the method of handling we refer you to the detailed instructions as provided by the suppliers of the
various corrosion inhibitors. Through which holes and openings in the various box girders of the YA 4440
and YAL 4440 cabs there should be sprayed to complete the ML process will also be determined by DAF
and is indicated in this section.
3-20-6
Treatment with
Dinitrol-m
All bolts
Underside wing
treatment eg coating
Legend
Exterior side Interior rear
Interior side
Plugged hole Ø8
Open hole Ø8 Dual gard 3651
Holes ≠ Ø8
Boltconnections
Inner side Scams Dinitrol-ml
Outer side
Underside cabin-treatment
dual gard 3651
Treatment with
Dinitrol-m
Fig. 3.20.20
All bolts
Underside wing
3-20-8
treatment eg coating
2 TH 9-3900
Legend
Exterior side Interior rear
Interior side
Plugged hole Ø8
Open hole Ø8 Dual gard 3651
Holes ≠ Ø8
Boltconnections
Scams Dinitrol-ml
Inner side
Outer side
Underside cabin-treatment
dual gard 3651
2 TH 9-3900
Fig. 3.20.21
3-20-9
2 TH 9-3900
3.20.14 Dobli mirror / mirror bracket (Fig. 3-20-23 to 3-20-26)
a. Removal
1. Fold the branch rack down.
2. Remove the socket head screws (1, Fig. 3-
20-23).
3. Remove the cover (3) and at the same time
take the mirror (8) off the mirror bracket (5).
4. Remove the plastic caps (14).
5. Remove the Allen screws (13) and at the
same time take the mirror bracket (5) off the
cab.
b. Preparation (if necessary)

1. At a distance of 110 mm from the top of the
rubber seal, mark off a horizontal line (1,
Fig. 3-20-24).
2. At a distance of 50 mm from the folded
seam, mark a vertical line (2).
3. Attach the marking sticker along the
horizontal and vertical lines.
4. Mark the position of the holes to be bored
using a centre punch.
5. Pre-drill the holes using a 3 mm twist drill.
Set the boring machine depth stop to 10
mm.
6. Finish-bore the holes using a 7 mm twist
drill. Set the boring machine depth stop to
10 mm. Fig. 3.20.22
7. Remove the sticker from the cab. 1. Allen screw
8. Treat the blank sheet steel in the bore holes 2. Washer
with an anti-corrosion agent (e.g. clear 3. Cover
Tectyl). 4. Cap
9. Fit a blind rivet nut (9, Fig. 3-20-23) in one 5. Mirror bracket
of the bored holes. 6. Ball joint
10. Tighten the blind rivet nut (9) with the 7. Cross head screw
special blind rivet nut pliers. 8. Mirror
11. Repeat operations 9 and 10 for the other 9. Blind river nut
10.Gasket
three bore holes. 11.Plastic ring
12.Washer
c. Fitting mirror bracket 13.Allen screw
1. Stick the self-adhesive gaskets (10) onto 14.Cap
the attachment foot of the mirror bracket
(5).
2. Slide the washers (12) and the plastic rings
(11) onto the Allen screws (13) in that order.
3. Fit the mirror bracket (5) onto the cab with
the Allen screws (13). Tighten the Allen
screws (13) evenly.
4. Fit the plastic caps (14) onto the heads of
the Allen screws (13).
5. Fit the cap (4) into the end of the mirror
bracket (5).
Fig. 3.20.23 Marking position of mirror bracket
3-20-10
2 TH 9-3900
d. Fitting Dobli mirror

1. Check the adjustability of the mirror (8). To
do this, move the ball joint (6) by hand. A
correctly adjusted ball joint (6) is difficult to
move backwards and forwards by hand. If
necessary, adjust the ball joint (6) using the
three cross head screws (7).
2. Make sure that the ball joint (6) is at right
angles to the mirror (8).
3. Fit the mirror straight ahead of the window
protection bar on the mirror bracket (Fig. 3-
20-25).
4. Evenly turn the mirror without adjusting the
ball joint on the window protection bar (Fig.
3-20-26). The ball joint is now at right
angles to the window protection bar.
5. Tighten the socket head screws (1, Fig. 3-
20-23) hand tight.
6. Turn the mirror towards the outside of the
vehicle until the window protection bar is
just not visible in the mirror from the driver's
seat.
7. From the driver's seat, check whether both
the horizon and the ground immediately Fig. 3.20.24 Fitting mirror
next to the cab are visible.
8. Tighten the Allen screws (1).
9. Check the setting of the mirror using
IK013551.
10. Fold the branch rack up.
Treat roof edge on the interior side completely

with dinitrol ml
Fig. 3.20.25 Adjusting mirror
3-20-11
2 TH 9-3900
3-20-12
2 TH 9-3900
3.21 AMMUNITION RACK
3.21.1 AMMUNITION RACK
a. Removal
(1) Remove the attachment bolts.
(2) Remove the ammunition rack.
b. Installation
Fig. 3.21.1
3-21-1
2 TH 9-3900
3-21-2
2 TH 9-3900
3.22 BUMPERS, TOWING EYES AND BUFFER BEAM
3.22.1 FRONT BUMPER (see Fig. 3.22.1.).
a. Removal
(1) Remove the headlights and the socket (left
behind the bumper, see item 3.9.12.
(2) Disconnect the rev counter cable on the
bumper.
(3) Remove the attachment bolts and nuts.
(4) Take of the front bumper.
b. Installation
Fig. 3.22.1
3.22.2 REAR BUMPER, TOWING EYES AND BUFFER BEAM (see Fig. 3.22.2.).
c. Removal
(1) Remove the attachment bolts as required
from the rear bumpers, towing eyes and/or
buffer beam.
(2) Remove the parts to be replaced.
d. Installation
3.22.3 DIN PLATE FRONT BUMPER YA 4440 -

Project 1952 (see Fig. 3.22.3)
a. Removal
(1) Remove the four spring clips from the
locking pins of the DIN plate.
(2) Pull the four locking pins from the DIN plate Fig. 3.22.2
and take them from the vehicle.
b. Installation
Fig. 3.22.3
1. Spring clip
2. Locking pin
3. DIN plate
3-22-1
2 TH 9-3900
3.22.4 ATTACHMENT BRACKET, SOCKET YA 4440 - Project 1952 (see Fig. 3.22.4)
a. Removal
(1) Remove the complete socket see section
3.9.26.
(2) Remove both attachment bolts and lock
washers from the attachment bracket.
(3) Remove the attachment bracket from the
front bumper of the vehicle.
b. Installation
NOTE: Fix both attachment bolts in

accordance with table 1-8 torque
moments from 1 TH9-1951 / 1952
quality 8-8.
Fig. 3.22.4
1. Attachment bolt
2. Sealing ring
3. Attachment bracket
4. Socket (complete).
3.22.5 ATTACHMENT BRACKET QUICK-RELEASE COUPLINGS YA 4440 - Project 1952 (see Fig.
3.22.5).
a. Removal
(1) Remove both hydraulic quick-release
couplings (see section 3.25.4) completely.
(2) Remove the water pipe quick-release
coupling (see section 3.26.2) completely.
(3) Remove both attachment bolts and lock
washers from the attachment bracket.
bumper of the vehicle.
b. Installation
Fig. 3.22.5
1. Attachment bolt
2. Sealing ring
3-22-2
2 TH 9-3900
3.23 TILTED LOADING PLATFORM AND SECONDARY EQUIPMENT
3.23.1 TILTED LOADING PLATFORM
For removal and installation see 1TH.
3.23.2 WINDSCREEN WIPER MOTOR
a. Removal
(2) Pull the buttons of the heating control
handles off, see Fig. 3.23.1.
Fig. 3.23.1
(3) Remove the nut located immediately next
to the instrument panel behind the bottom
trim, see Fig. 3.23.2.
(4) Remove the attachment bolt from the
storage compartment, see Fig. 3.23.3.
(5) Remove the cross head screws.
(6) Remove the panel and at the same time
loosen the electrical connections.
Fig. 3.23.2
Fig. 3.23.3
3-23-1
2 TH 9-3900
(7) Pull the five-pin plug (3) out of the

windscreen wiper motor, see Fig. 3.23.4.
linkage system and the motor.
(9) Loosen the two rearmost attachment bolts
(2) a few turns and do not remove it!
(10)Remove the two front attachment bolts (1).
(11) Remove the windshield wiper motor (4) by
shifting its suspension bracket (5) so that
the bolt heads (2) can pass the slotted
holes in the bracket.
(12)Remove the crank and bracket from the
windshield wiper motor.
b. Installation
(1) Fasten the suspension bracket to the
windscreen wiper motor.
(2) Connect the plug.
(3) Switch the main battery switch on.
Fig. 3.23.4
(4) Turn on the windshield wiper switch for a
moment; the motor stops in the rest 1. Attachment bolt, front
2. Attachment bolt, rear
position. 3. Five-pin plug
(5) Switch the main battery switch off again. 4. Windscreen wiper motor
(6) Remove the plug. 5. Mounting bracket
(7) Place the crank on the shaft in such a way
that the crank is parallel to the top of the
bracket.
(8) Fit the motor.
NOTE: If the fastening of the knobs on the

control levers is inadequate, they must
be glued with a permanently plastic
type of adhesive such as Bisonkit or
an equivalent product.
(9) Carry out the other operations in reverse

order to removal.
3.23.3 WIPERS AND LINKAGE
a. Removal
(2) Remove the windshield wiper blades with
arms and steering rod arm, see Fig. 3.23.5.
(3) Remove the cover and the attachment bolt
from the pivot shaft bearing and from the
wiper bearing (see Fig. 3.23.6.).
(4) Pull off the heads of the heating operating
handles.
(5) Remove the nut located immediately next
to the instrument panel behind the bottom
trim, see item 3.23.2).
(6) Remove the attachment bolt from the
storage compartment.
(7) Remove the cross head screws. Fig. 3.23.5
(8) Remove the panel. 1. Windshield wiper arm
(9) Remove the windscreen wiper motor see 2. Control arm
point 3.23.2.
(10)Remove the complete linkage system
including wiper and pivot shaft bearings.
3-23-2
2 TH 9-3900
b. Installation
(1) Fit the windscreen wiper motor see item
3.23.2.
NOTE: Before assembly lubricate the pivot

point of the control arm with anti-seize
grease molybdenum disulfide no.2
View x
Adjustable
Fig. 3.23.6
1. Nut
2. Wiper bearing
3. Pivot shaft bearing
4. Rod
5. Adjustable link
6. Crank
7. Adjusting bolt
(2) Fit the wiper and pivot shaft bearings.

(3) Fit the linkage system; do not yet fit the
connection to the motor. See Fig. 3.23.6.
(4) Fit the windscreen wiper motor in the rest
position, see item 3.23.2.
(5) Connect the windshield wiper motor
3-23-3 to the linkage system.
(6) Adjust the linkage (5) using an adjustment
bolt (7) so that the angle between the
tandem axle and the rod is 390; use a jib
for this. See Fig. 3.23.7. and Fig. 3.1.1. C.
(7) Carry out the other operations in reverse
order to removal.
Fig. 3.23.7
3-23-3
2 TH 9-3900
3.23.4 HEATING
a. Removal
(2) Take the upper piece of the grille off, see
item 3.20.10.
(3) Drain the coolant, see item 3.8.4.
(4) Remove the coolant hoses.
(5) Remove the air funnel, see Fig. 3.23.8.
(6) Disconnect the control cable from the tap.
Fig. 3.23.8
(7) Remove the six bolts which are

immediately behind the grille, see Fig.
3.23.9.
(8) Remove the heater radiator.
(9) Disconnect the wiring of from the heater.
(10)Remove the throttle and stop levers.
(11) Remove the panel, see point 3.23.2.
Fig. 3.23.9
(12)Remove the attachment screws from the
heater on the cab floor, see Fig. 3.23.10.
(13)Disconnect the rubber coupling sleeves
and clamps.
Fig. 3.23.10
3-23-4
2 TH 9-3900
(14)Separate the constituent parts of the heater

including the fan. Fig. 3.23.11).
b. Installation
NOTE: The electric motor of the heater fan

has been modified. The electric motor
is broader and the bearings are further
apart. This means that the middle
piece of the heater housing has been
modified as well. If a new electric
motor (fan) has to be fitted in an old
housing this must be done using a
special clip (DAF no. 689461). In order
to avoid imbalance in the motor the
blades of the fan are no longer
supplied separately.
Fig. 3.23.11
c. Installation
(new electric motor in an old housing)
(1) Cut the raised edges off one old
suspension rubber.
(2) Fit this rubber on the middle box.
(3) Fit the electric motor such that it is
precisely in the middle.
(4) Fit the (special) bracket.
(5) Fasten the clip using two bolts.
(6) Then replace the constituent parts together
again.
Fig. 3.23.13 Fig. 3.23.12
3-23-5
2 TH 9-3900
3.23.5 SUSPENSION BRACKET, FIG. 3.23.14.
NOTE: Height of rubber (3) in unloaded state

45 - 50 mm.
The height of the rubber in loaded
state depends on the load. Play is
permitted on the central bolt (4) in a
correctly-assembled condition both
when the vehicle is loaded and
unloaded.
Fig. 3.23.14
1. Nut
2. Slide block
3. Rubber
4. Central bolt
5. Bolt
6. Bracket, lower
7. Nut
3-23-6
2 TH 9-3900
3.24 INSTRUMENTS (NOT ELECTRIC)
3.24.1 ODOMETER/SPEEDOMETER (SEE FIG. 3.24.1.).
a. Removal
(2) Remove the trim under the instrument
panel.
(3) Unscrew the union nut from the odometer/
speedometer cable.
odometer/speedometer.
disconnect them.
(6) Take the odometer/speedometer out of the
instrument panel.
b. Installation
Fig. 3.24.1
3.24.2 REV. COUNTER (SEE FIG. 3.24.2.).
a. Removal
(2) Remove the trim under the instrument
panel.
(3) Unscrew the union nut from the rev.
counter cable.
rev counter.
disconnect them.
(6) Remove the rev. counter from the
instrument panel.
b. Installation
Fig. 3.24.2
3.24.3 ODOMETER/SPEEDOMETER CABLE AND REV COUNTER CABLE
a. Odometer / Speedometer cable

(1) Removal
off.
(b) Unscrew the union nut from the gauge,
see item 3.24.1.
(c) Tilt the cab, see 1TH.
(d) Unscrew the union nut from the
transfer box.
(e) Disconnect the fastenings.
(f) Pull the cable through the cab floor.
(2) Installation
3-24-1
2 TH 9-3900
b. Rev counter cable

(1) Removal
off.
(b) Unscrew the union nut from the gauge.
(c) Tilt the cab.
(d) Disconnect the fastenings.
(e) Pull the cable through the cab floor.
(f) Unscrew the union nut from the engine.
(2) Installation
3.24.4 RIGHT-ANGLED TRANSMISSION, REV COUNTER (SEE FIG. 3.24.3).
a. Removal
(1) Tilt the cab.
(2) Loosen the union nut on the rev counter
cable at the right-angled transmission.
(3) Loosen the union nut so that the right-
angled transmission is clamped in the
cover.
(4) Remove the right-angled transmission.
b. Installation
3.24.5 AIR PRESSURE GAUGE
See item 3.9.7. 3-24-2
Fig. 3.24.3
1. Rev counter cable union nut
2. Right-angled transmission
3. Fastening union nut
3-24-2
2 TH 9-3900
3.25 HYDRAULIC SYSTEM (YA 4440 - Project 1952)
3.25.1 CURRENT CONTROL VALVE YA 4440 - Project 1952 (see Fig. 3.25.1).
a. Removal
(1) Disconnect both hydraulic quick-release
couplings from the tank unit at the left rear
of the cab.
(2) Remove all three of the hydraulic lines and
catch any leaked oil.
(3) Unscrew both attachment bolts from the
current control valve and remove them
together with the lock washers.
(4) Take the current control valve from the
attachment bracket.
b. Installation
c. Checks
Also refer to 1 TH9-1951 / 1952.
(1) Test run the sweeping attachment.

Fig. 3.25.1
(2) Check for any leaks from the current
control valve. 1. Attachment bolt
2. Sealing ring
(3) Check the operation of the current control 3. Attachment bracket
valve. 4. Current control valve
(4) After the test run check the oil level in the 5. Hydraulic line
hydraulic reserve tank and top up if
necessary.
3.25.2 ATTACHMENT BRACKET, CURRENT CONTROL VALVE (YA 4440 - Project 1952) (see Fig.
3.25.2).
a. Removal
(1) Remove both attachment bolts from the
current control valve.
(2) Remove the current control valve complete
with the hydraulic lines from the attachment
bracket.
(3) Remove the four attachment bolts from the
attachment bracket together with the lock
washers.
vehicle.
b. Installation
Fig. 3.25.2
2. Current control valve
3-25-1
2 TH 9-3900
3.25.3 HYDRAULIC LINES YA 4440 - Project 1952 (see Fig. 3.25.3 to 3-25-6).
a. Removal
(1) Disconnect the hydraulic quick-release
couplings from the roller brush system at
the front of the bumper if present.
couplings from the tank unit behind the cab
if present.
(3) Unscrew the hydraulic line coupling and
catch the oil.
NOTE: Always unscrew the lowest coupling

first.
Sequence: bumper connections - hydraulic

pump - quick-release couplings behind the Fig. 3.25.3
cab - current control valve connections. 1. Hydraulic return line
2. Hydraulic pressure line
(4) Remove all the tie rods on the hydraulic
line.
(5) Remove the hydraulic line from the vehicle.
b. Installation
Avoid twisting of the line(s).
(2) Unscrew the air-bleeder plugs from the
hydraulic pump.
(3) Tighten the air-bleeder plugs again once oil
without air comes out.
c. Checks

(2) Check for any leaks in the couplings of the
hydraulic lines.
(3) After the test run check the oil level in the
necessary. Fig. 3.25.4
1. Hydraulic supply line
2. Hydraulic pressure line
Fig. 3.25.5 Fig. 3.25.6

1. Hydraulic supply lines 1. Hydraulic supply lines
2. Hydraulic return line 2. Hydraulic pressure line
3-25-2
2 TH 9-3900
3.25.4 HYDRAULIC QUICK-RELEASE COUPLINGS AND DUST CAP (YA 4440 - Project 1952)
(see Fig. 3.25.7 and 3.25.8).

a. Removal
couplings (of the roller brush attachment
and the tank unit) from the vehicle.
(2) Remove the hydraulic line from the
hydraulic quick-release coupling and catch
the oil.
couplings and remove them from the
attachment bracket together with the dust
cap.
b. Installation
Avoid twisting the line.
(2) Unscrew the air-bleeder plugs from the
Fig. 3.25.7
hydraulic pump.
(3) Tighten the air-bleeder plugs again once oil 1. Hydraulic line
2. Hydraulic quick-release coupling
without air comes out. 3. Dust cap
c. Checks

(2) Check for any leaks in the quick-release
couplings of the hydraulic lines.
(3) After the test run check the oil level in the
necessary.
Fig. 3.25.8
2. Sealing ring
3. Attachment nut
4. Attachment bolt
3-25-3
2 TH 9-3900
3.25.5 QUICK-RELEASE ATTACHMENT BRACKET BEHIND THE CAB YA 4440 - Project 1952
(see Fig. 3.25.9).
a. Removal
(1) Remove both hydraulic quick-release
couplings, see section 3.25.4.
(2) Remove the water hose quick-release
coupling, see section 3.26.2.
(3) Remove both attachment bolts and the lock
washers and nuts.
vehicle.
b. Installation
Fig. 3.25.9
3-25-4
2 TH 9-3900
3.26 WATER SUPPLY SYSTEM (YA 4440 - Project 1952))
3.26.1 HOSES
YA 4440 - Project 1952 (see Fig. 3.26.1).
a. Removal
(1) Remove the hose clamps which attach the
hose to the two quick-release couplings.
(2) Pull the hose from both quick-release
couplings.
(3) Remove the tie rods with which the hose is
attached to the vehicle.
(4) Remove the hose from the vehicle.
b. Installation
(2) Check the connections for leakage. Fig. 3.26.1
1. Water hose
2. Hose clamp
3. Quick-release coupling
3.26.2 QUICK-RELEASE COUPLINGS AND DUST CAP
YA 4440 - Project 1952 (see Fig. 3.26.2 and

3.26.3).
a. Removal
(1) Remove the water hose, see 3.26.1.
(2) Remove locking bolts and lock nuts.
(3) Take off the quick-release coupling and
dust cover from the attachment bracket.
b. Installation
c. Gasket replacement
(1) Remove the dust cover from the quick-
release coupling.
(2) Flip the old gasket out of the quick-release
coupling using a screwdriver.
(3) Clean the quick-release coupling on the
Fig. 3.26.2
inside and press a new gasket in.
(4) Check the connection for leaks. 1. Water hose
3. Dust cap
4. Chain dust cap
5. Locking bolt
6. Lock nut
Fig. 3.26.3
2. Gasket
3-26-1
2 TH 9-3900
3-26-2
2 TH 9-3900
4 FAULTS.
4.1 IDENTIFICATION OF FAULTS.
4.1.1 General.
a. This section provides information related to the identification and remedy of faults that can occur during
use of the YA (L) 4440.
b. The identification of faults is the systematic search for defective parts through analysis of failure
symptoms. The search can often be simplified and shortened by carrying out one or more tests. The more
symptoms that are identified the easier it will be to find the fault.
c. Fault-finding table.
d. The following table contains faults which occur the possible causes and the action to be taken by the
technicians.
e. Failures that may not be repaired at the 2nd level personnel must be reported to the direct support repair
unit.
FAULT-FINDING TABLE.
NOTE: In this table it is assumed that the normal actions for the proper functioning of the vehicle have
been carried out and that the cause is a defect.
Fault Possible cause Repair

ENGINE
1. Starter motor does not function a. Batteries not charged or faulty a. Charge or replace batteries
b. Battery cables are loose or b. Clean the cables and terminal

corroded clamps and tighten them
c. Start switch defective c. Replace the start switch
d. Faulty starter motor d. Replace starter motor
e. Other causes e. Report
2. Engine does not turn during a. Starter pinion gear or starter a. Report
starting. ring gear faulty.
b. Engine stuck b. Report
c. Other causes c. Report
3. Engine turns slowly during a. Poor cable connections from a. Check the cable connections
starting. the batteries and/or the starter from the batteries and starter
motor. motor. Clean and tighten them.
b. Batteries not charged or faulty. b. Charge or replace batteries
c. Faulty starter system. c. Replace starter motor
4. Engine will not fire a. Insufficient pre-glowing. a. Start again.
b. Glow plug faulty. b. Replace glow plug
c. Air in the fuel system. c. Bleed the fuel system.
d. Water separator full of water. d. Drain the sediment reservoir.
e. Fuel lift pump e. Report
f. Injector pump faulty or wrongly f. Report

adjusted.
g. Fuel filter clogged g. Replace filter.
4 -1-1
2 TH 9-3900
h. No fuel supply h. Check the fuel system for leaks

and report if necessary.
i. Throttle control sticks or is i. Repair and/or adjust the

wrongly adjusted. throttle control.
j. Injectors dirty or out of j. Report

adjustment.
k. Other causes K Report
5. Engine has insufficient power a. Air intake is partially or fully a. Clean the air filter.
runs badly and/or cuts out blocked (black smoke from the
often. exhaust).
b. Fuel filter clogged b. Replace the filter.
c. Loose or faulty fuel lines. c. Tighten them or repair them.
d. Air in the injection system. d. Bleed the fuel system.
e. Injectors dirty or out of e. Report.

adjustment.
f. Throttle control out of f. Repair the throttle control.

adjustment.
g. Other causes g. Report
6. Engine uses too much oil. a. External oil leakage a. Do a visual check for leaks and
tighten any loose connections.
If there is too much oil leakage
from the engine gasket then
report it.
b. Internal oil leakage. b. Check the coolant for the

presence of oil. If this is the
case then report it.
c. Oil sump bleed filter clogged c. Clean or replace

both on the cover and the filter
in the bleed pipe.
7. Engine smoke from the a. Dirty air filter or air inlet system a. Replace the air filter element
exhaust (black smoke)
b. Injectors dirty or out of b. Report

adjustment
c. Water in the compression c. Report

space or exhaust system
(white system)
d. Other causes d. Report
8. Engine oil pressure too low. a. Oil level too low a. Top up the engine oil
TURN THE ENGINE OFF
IMMEDIATELY
b. Faulty oil pressure sensor b. Replace the oil pressure

sensor
c. Faulty oil pump c. Report
d. Oil filter clogged d. Replace the filter
4 -1-2
2 TH 9-3900
9. Engine oil pressure too high a. Oil pressure control valve faulty a. Report
FUEL SYSTEM
10.Engine gets insufficient fuel a. Fuel filter clogged a. Replace fuel filter
b. Loose or faulty fuel lines b. Repair or replace
c. Not enough fuel in the reservoir c. Fill fuel reservoir
EXHAUST SYSTEM
11.Burns near the exhaust a. Blown exhaust gasket a. Fit a new gasket
manifold and exhaust pipes
b. Split exhaust manifold or b. Replace faulty parts

exhaust pipes
12.Engine makes abnormal a. Engine is too cold a. Run the engine at idling speed
noises
b. Injector pump is not functioning b. Report

properly
c. Valve clearance incorrect c. Adjust the valves
d. Turbocharger whistles d. Report
COOLANT SYSTEM
13.Engine stays too cold a. Incorrect type of thermostat a. Fit the right thermostat
14.Engine is too hot a. Insufficient coolant a. Top up the coolant. Check the
system for leaks and check the
oil for the presence of coolant.
Report if necessary
b. Slipping or faulty V-belt b. Replace or adjust the V-belt.
c. Faulty thermostat c. Fit a new thermostat
d. Coolant pump defective d. Fit a new coolant pump
e. Temperature gauge faulty e. Fit a new temperature gauge
f. Other causes f. Report
ELECTRICAL SYSTEM
15.Engine does not turn during a. Battery terminals corroded a. Clean the battery terminals
starting
b. Earth cables are loose b. Tighten the earth cables
c. Batteries not charged or faulty c. Charge or replace batteries
d. Battery main switch faulty d. Replace the main battery

switch
16.Batteries become discharged a. Slipping or faulty belt a. Replace or adjust the V-belt
4 -1-3
2 TH 9-3900
b. Electrolyte level too low b. Top up
c. Defective alternator c. Replace the alternator
17.Windshield wipers do not work a. Faulty fuse a. Replace fuse
b. Windshield wiper switch is b. Replace the switch

faulty
18.One light does not go on a. Bulb is burnt out a. Replace the bulb
b. Loose connection b. Tighten the connection
19.All lights do not light a. Faulty fuse a. Replace fuse
b. Loose connections b. Tighten the connections
CLUTCH AND GEARBOX
20.Difficult gear changing a. Worn clutch plate a. Report
b. Selector mechanism in the b. Report

gearbox is faulty
21.Gear selection is not possible a. Clutch plate is worn a. Report
b. Selector mechanism does not b. Report

work
c. Air in the declutching system c. Bleeding
TRANSFER BOX
22.Transfer box makes abnormal a. Oil level too low a. Top up the oil
noises
b. Other causes b. Report
INTERMEDIATE SHAFTS
23.Intermediate shafts vibrate or a. Not lubricated a. Lubricate

swing about
b. Joint or bearings of the b. Report

universal joint are faulty or
worn
FRONT AND REAR AXLE
24.Axles make abnormal noises a. Oil level too low a. Top up the oil to the correct
level
b. Wheel bearing damaged b. Replace the wheel bearing
WHEELS AND TYRES
4 -1-4
2 TH 9-3900
25.Excess play in the wheel a. Wheel is loose a. Tighten
b. Rim is bent b. Replace rim and tyre
26.Abnormal or uneven tyre wear a. Unequal tyre pressures a. Increase tyre pressure to the
specified value
b. Tracking is incorrect b. Adjust the tracking
BRAKE SYSTEM
27.Brake system does not - Repair if possible otherwise

function or functions poorly report it
STEERING SYSTEM
28.Steering system does not a. Oil level too low a. Top up the oil to the correct
function or functions poorly level
b. Other causes b. Repair if possible otherwise

report it
4 -1-5
2 TH 9-3900
4 -1-6
2 TH 9-3900
5 FAULTS.
5.1 INTRODUCTION
5.1.1 Explanation
a. This maintenance schedule is organised in various groups in accordance with the Standard NATO
Functional Group Organisation. (Derived from TB 750-93-1).
b. The schedule is intended as a guideline for personnel that are responsible for compiling supply and
maintenance documentation as well as those responsible for training.
c. In columns 1e through 5e "echelon", an "X" indicates which echelon is to carry out the operations.
d. Articles that are to be exchanged are indicated with an "XX".
e. Operations that are not included in this schedule are to be carried out by the echelon for which,
considering the nature of the operation, the work is deemed to be most suitable.
f. The echelon columns are defined as follows:

(1) Operations to be carried out by the user/crew.
(2) Operations to be carried out by the maintenance units of the unit to which the equipment has been
assigned.
(3) Operations to be carried out by the directly supporting units.
(4) Operations to be carried out by the general supporting units.
(5) Operations to be carried out by the overhaul units (sent out to civilian companies).
5.1.2 Standard group organisation
01 ENGINE
02 CLUTCH ASSEMBLY
03 FUEL SYSTEM
04 EXHAUST SYSTEM
05 COOLING SYSTEM
06 ELECTRICAL SYSTEM
07 TRANSMISSION
09 INTERMEDIATE SHAFTS
10 FRONT AXLE
11 REAR AXLE
12 BRAKE SYSTEM
13 WHEELS, HUBS, BRAKE DRUMS
14 STEERING GEAR
15 CHASSIS
16 SUSPENSION AND SHOCK
ABSORBERS
18 CHASSIS
19 TURRET (ROTATING GUN MOUNT)
21. BUMPERS
22 SECONDARY EQUIPMENT
47. INSTRUMENTS (non-electric)
5 -1 - 1
2 TH 9-3900
5.1.3 Maintenance schedule
OPERATIONS ECHELON
1 2 3 4 5
GROUP 01 - ENGINE
0100 - Engine assembly

ENGINE, cpl. replacement XX
ENGINE, overhaul X
ENGINE MOUNTS, replace X
SILENTBLOCS, replace X
OIL LEVEL check; top up as required X
OIL, change X
ATTACHMENT BOLTS, engine, inspect X
ATTACHMENTS, CONNECTIONS, HOSES and LINES X
visual inspection for leaks
0101 - Cylinder block - Cylinder head

CYLINDER BLOCK, recondition/replace X
CYLINDER HEAD GASKET, replace X
CYLINDER HEAD, replace X
CYLINDER HEAD, recondition X
CYLINDER LINERS, replace X
SIDE COVER ENGINE and GASKET, front left, replace X
SIDE COVER ENGINE and GASKET, rear left, replace X
COVER for VALVE PUSH RODS, front and rear, replace X
0102 - Crankshaft
CRANKSHAFT, recondition/replace X
CRANKSHAFT BEARINGS, replace X
PULLEY, replace (with vibration damper) X
OIL SEAL, flywheel side, replace X
0103 - Flywheel assembly

FLYWHEEL with STARTER RING GEAR, replace X
FLYWHEEL with STARTER RING GEAR, recondition X
STARTER RING GEAR, replace X
FLYWHEEL HOUSING, replace X
FLYWHEEL HOUSING, recondition X
INSPECTION COVER and GASKET, replace X
0104 - Pistons - Connecting rods

PISTONS with rings and wrist pins, replace X
CONNECTING RODS and ROD BEARINGS, replace X
CONNECTING ROD BOLTS, replace X
0105 - Valve timing system

VALVES, replace X
VALVES, adjust X
TIMING COVER, OIL SEAL and GASKET, replace X
VALVE TAPPETS and VALVE SPRINGS, replace X
VALVE ADJUSTMENT BOLTS, replace (incl. nuts) X
VALVE GUIDES inlet/exhaust, replace X
VALVE SEATS inlet/exhaust, replace/recondition X
VALVE COVER, replace/clean X
VALVE SLEEVE, replace X
VALVE PUSH RODS and ROCKER ARMS, replace X
VALVE ROCKER SHAFT and SPRINGS, replace X
CAMSHAFT and TIMING GEARS, replace X
CAMSHAFT BEARINGS, replace X
5-1-2
2 TH 9-3900
OPERATIONS ECHELON
1 2 3 4 5
0106 - Lubrication system
OIL PUMP with GEARS, replace/recondition X
FILTER and LINES, replace/recondition X
OIL PUMP DRIVE, replace X
OIL FILTER and GASKET, replace X
OVER-PRESSURE VALVE (oil), adjust/replace X
CRANKCASE BREATHER, clean/replace X
OIL SUMP with GASKETS, replace X
OIL DIPSTICK, replace X
OIL LINES, external, replace/recondition X
OIL LINES, flexible, external, replace X
DRAIN PLUGS and GASKET RINGS, replace X
OIL FILL CAP, replace X
0108 - Inlet and exhaust manifold

INLET/EXHAUST MANIFOLD, replace X
GASKETS, replace X
EXHAUST BRAKE, replace X
OPERATING MECHANISM, exhaust brake, recondition/replace X
GROUP 02 - CLUTCH ASSEMBLY
0200 - Clutch
CLUTCH HOUSING, replace X
CLUTCH PLATE, replace XX
CLUTCH PLATE, recondition X
CLUTCH RELEASE ASSEMBLY, complete, replace X
CLUTCH HOUSING, recondition X
INSPECTION COVER and GASKET, replace X
PILOT BEARING, replace X
0202 - Clutch control system

CLUTCH RELEASE MECHANISM external, replace and adjust/ X
recondition
CONTROL MECHANISM, clean/replace X
CLUTCH RELEASE MECHANISM, internal, replace adjust and X
recondition
0207 - Hydraulic clutch controls

HYDRAULIC OPERATING CYLINDER, replace XX
HYDRAULIC OPERATING CYLINDER, recondition X
FLUID RESERVOIR, replace X
FLUID LEVEL in reservoir, inspect X
FLUID in reservoir, top up X
CLUTCH CYLINDER, replace XX
CLUTCH CYLINDER, recondition X
LINES, SUPPORTS and BLEED NIPPLES, replace/recondition X
5 -1 - 3
2 TH 9-3900
OPERATIONS ECHELON
1 2 3 4 5
GROUP 03 - FUEL SYSTEM
0301 - Injectors
INJECTORS cpl., replace X
INJECTORS, inspect/recondition X
GASKET RINGS, replace X
GROMMETS, replace X
0302 - Fuel injection pump and lines

FUEL INJECTION PUMP, cpl., replace XX
FUEL INJECTION PUMP, cpl. (incl. boost pres. reg.), recondition X
FUEL LIFT PUMP, replace/recondition X
FUEL INJECTION LINES, RETURN LINES, replace X
0304 - Air filter

AIR FILTER ELEMENT, clean/replace X
AIR FILTER, recondition/replace X
LINES and CONNECTIONS, replace/recondition X
GASKETS, replace X
HOSES, replace X
0305 - Turbocharger
TURBOCHARGER, replace XX
TURBOCHARGER, recondition X
0306 - Fuel tank with lines

FUEL TANK, clean/replace X
FUEL TANK, recondition X
LINES and CONNECTIONS, replace/recondition X
FUEL TANK FILL CAP, replace X
0308 - Regulator
REGULATOR, adjustment at idle X
0309 - Fuel filters

FINE FUEL FILTER cpl., replace X
TANK FILTER, clean/replace X
COARSE FUEL FILTER, clean/replace X
COARSE FILTER ELEMENT, replace X
GASKETS, replace X
0311 - Cold-start assembly

COLD START CONTROL, replace X
GLOW PLUGS, replace X
0312 - Throttle- and stop-control mechanism

THROTTLE/STOP CONTROL, clean/replace X
GROUP 04 - EXHAUST SYSTEM
0401 - Exhaust pipes and Mufflers

EHAUST PIPES and MUFFLERS, replace X
HANGERS, exhaust system, replace X
5-1-4
2 TH 9-3900
OPERATIONS ECHELON
1 2 3 4 5
GROUP 05 - COOLING SYSTEM
0501 - Radiator
RADIATOR, replace XX
RADIATOR, recondition X
EXPANSION TANK, replace X
FILLER CAP, EXPANSION TANK, replace X
RADIATOR SUPPORTS, replace X
COOLANT LEVEL, inspect; fill as required X
COOLANT, replace X
0502 - Wind tunnel (cladding)

WIND TUNNEL, replace X
CLAMPING STRIP, replace X
SLEEVE, replace X
GUIDE RING, replace X
0503 - Thermostats
THERMOSTATS, LINES, HOSES and CONNECTIONS X
replace
0504 - Coolant pump

COOLANT PUMP, without pulley cpl., replace XX
COOLANT PUMP, repair X
PULLEY, replace X
0505 - Fan
FAN, replace X
V-BELTS, replace/adjust X
5 -1 - 5
2 TH 9-3900
OPERATIONS ECHELON
1 2 3 4 5
GROUP 06 - ELECTRICAL SYSTEM
0601 - Alternator
ALTERNATOR (with pulley), replace XX
ALTERNATOR, recondition X
PULLEY and SUPPORTS, replace X
DUST CAP, replace X
0602 - Voltage regulator

VOLTAGE REGULATOR, replace XX
VOLTAGE REGULATOR, recondition X
0603 - Starter motor

STARTER MOTOR, replace XX
STARTER MOTOR, recondition X
DUST CAP, replace X
0607 - Switches, indicator lamps and sockets on the instrument

panel
SWITCHES, INSTRUMENTS, SOCKETS and INDICATOR LAMPS,
check for proper operation X
BULBS FOR INDICATOR LAMPS, replace X
SWITCHES, INSTRUMENTS, SOCKETS and INDICATOR LAMPS,
replace X
HOUR METER, replace (only for YAK) X
0608 - Switches, indicator lamps and sockets not on the instrument

panel
SWITCHES, INSTRUMENTS, SOCKETS and INDICATOR LAMPS, X
check for proper operation
SWITCHES, INSTRUMENTS, SOCKETS and BULBS for
INDICATOR LAMPS, replace X
INDICATOR LAMPS, replace X X
FUSES, replace
FUSE BOXES, replace X
MAIN BATTERY SWITCH, replace X
RELAY, replace X
RADIO SOCKET, replace/recondition X
INTERCOM BUZZER, replace X
TELPHONE CONNECTION TERMINALS, replace X
0609 - Lighting
HEADLIGHTS, adjust/repair/replace X
TAIL LIGHTS, BRAKE LIGHTS, DIRECTION INDICATOR LAMPS X
AND PARKING LIGHTS, replace/recondition
CLEARANCE/DARKENED LAMPS, replace/recondition X
BULBS, replace X
0610 - Electrical components and sending units

COMPONENTS and SENDING UNITS, test/replace X
GASKETS, replace X
0611 - Horn
HORN cpl., replace X
0612 - Batteries
BATTERIES, charge/replace X
POLES and CLAMPS, inspect/grease X
BATTERIES and HOLDERS, clean X
FLUID LEVEL check; top up as required X
CABLES, replace X
CABLES, repair/fabricate X
HOLDERS, repair X
5-1-6
2 TH 9-3900
OPERATIONS ECHELON
1 2 3 4 5
0613 - Wiring
WIRING HARNESSES, replace X
WIRING HARNESSES, repair (minor repairs) X
12-PIN SOCKET, replace X
START-ASSISTANCE SOCKET, replace X
START-ASSISTANCE SOCKET, recondition X
EARTH CABLES, replace X
GROUP 07 - GEARBOX
0700 - Gearbox
GEARBOX cpl., replace XX
GEARBOX cpl., recondition X
HOUSING, GEARBOX, recondition X
PLUGS and GASKET RINGS, replace X
OIL LEVEL, check X
OIL, top up/ replace X
0701 - Main shaft, input shaft, auxiliary shaft, reverse shaft and
gears
INPUT SHAFT w/ BEARINGS and GEARS, replace/recondition X
BEARING COVERS, replace X
GASKETS and OIL SEALS, replace X
MAIN SHAFT w/ BEARINGS and GEARS, replace/recondition X
FLANGE, replace X
AUXILIARY SHAFT and REVERSE GEAR SHAFT w/ BEARINGS X
and GEARS replace/recondition
0704 - Gear shift mechanism (internal)

GEARSHIFT COVER and MECHANISM, replace X
GEARSHIFT COVER and MECHANISM, recondition X
0705 - Gear shift mechanism (external)

GEARSHIFT MECHANISM, replace X
GEARSHIFT MECHANISM, recondition X
GROUP 08 - TRANSFER BOX
0801 - Transfer box

TRANSFER BOX, replace XX
TRANSFER BOX, recondition X
SUSPENSION, chassis side, replace X
SILENTBLOCS, replace X
HOUSING, recondition X
PLUGS and GASKET RINGS, replace X
OIL LEVEL, check X
SHAFTS w/ BEARINGS and GEARS, replace/recondition X
BEARING COVERS, replace X
OIL SEALS, replace X
FLANGES, replace X
0803 - Shift mechanism

SHIFT MECHANISM (internal) TRANSFER BOX and FRONT X
WHEEL DRIVE, replace/recondition
OPERATING MECHANISM (external) replace/recondition X
5 -1 - 7
2 TH 9-3900
OPERATIONS ECHELON
1 2 3 4 5
GROUP 09 - INTERMEDIATE SHAFTS
0900 - Intermediate shafts

INTERMEDIATE SHAFT (GEARBOX/TRANSFER BOX), replace XX
INTERMEDIATE SHAFT (GEARBOX/TRANSFER BOX), X
recondition
INTERMEDIATE SHAFT (GEARBOX/FRONT AXLE), replace XX
INTERMEDIATE SHAFT (GEARBOX/FRONT AXLE), recondition X
INTERMEDIATE SHAFT (GEARBOX/REAR AXLE), replace XX
INTERMEDIATE SHAFT (GEARBOX/REAR AXLE), recondition X
INTERMEDIATE SHAFT (PTO/hydraulic pump, only for YAK), XX
replace
INTERMEDIATE SHAFT (PTO/hydraulic pump, only for YAK), X
recondition
INTERMEDIATE SHAFT and JOINTS, lubricate X
DUST SEAL, replace X
LUBRICATION NIPPLES, replace X
GROUP 10 - FRONT AXLE
1000 - Front axle

FRONT AXLE cpl., replace X
FRONT AXLE cpl., recondition X
SEAL RINGS and PLUGS, replace X
OIL LEVEL, check X
BREATHERS, replace X
1002 - Differential and drive axles, front axle

DIFFERENTIAL, replace XX
DIFFERENTIAL, recondition X
FLANGE and OIL SEAL, replace X
GASKETS, replace X
DRIVE SHAFTS cpl., replace XX
DRIVE SHAFTS cpl., recondition X
1004 - Swivel axles

SWIVEL AXLE CARRIER, replace X
SWIVEL AXLES, replace X
STEERING ARM and TRACK ARMS, replace X
BEARING HOLDERS for SWIVEL AXLE PIVOTS cpl., replace X
THRUST BEARINGS and SWIVEL AXLE COVERS, replace X
AXLE JOURNAL, replace X
SEALS and BEARINGS for drive axles, replace X
SWIVEL AXLES, replace
WHEEL DEFLECTION, check/adjust X X
5-1-8
2 TH 9-3900
OPERATIONS ECHELON
1 2 3 4 5
GROUP 11 - REAR AXLE
1100 - Rear axle

REAR AXLE cpl., replace X
REAR AXLE cpl., recondition X
OIL LEVEL, check X
BREATHER, replace X
1101 - Axle housing

X
AXLE HOUSING, recondition
X
PLUGS/SEALS and BREATHERS, replace
X
HUB OIL SEAL BEARING RACE, replace
1102 - Differential rear axle and axle shafts

DIFFERENTIAL, replace XX
DIFFERENTIAL, recondition X
FLANGE and OIL SEAL, replace X
AXLE SHAFTS, replace X
AXLE SHAFT SEAL, replace X
GROUP 12 - BRAKE SYSTEM
1201 - Parking brake

BLOCKING/PARKING BRAKE VALVE, replace X
PARKING BRAKE, check for proper operation X
1202 - Service brake system

BRAKE SHOES with lining and SPRINGS, replace XX
BRAKE SHOES, recondition X
BRAKE BACK PLATES, replace X
BRAKE CAMSHAFT, replace X
BEARINGS and SEALS, BRAKE CAMSHAFT, replace X
1208 - Air brake system

BRAKE CAMSHAFT, replace/recondition X
BRAKE PEDAL cpl. w/ RODS, replace X
SERVICE BRAKE VALVE, replace X
SERVICE BRAKE VALVE, recondition X
SPRING BRAKE CYLINDERS (FRONT AXLE), replace XX
SPRING BRAKE CYLINDERS (FRONT AXLE), recondition X
BRAKE CYLINDERS (REAR AXLE), replace XX
BRAKE CYLINDERS (REAR AXLE), recondition X
BRAKE REGULATING VALVES, replace X
BRAKE REGULATING VALVES, recondition X
AIR RESERVOIRS, replace X
BRAKE LINES, HOSES and COUPLINGS, replace X
ANTI-FROST DEVICE, inspect/top up X
ANTI-FROST DEVICE, replace XX
AUTOMATIC WATER SEPARATOR, replace/recondition X
1209 - Air compressor

AIR COMPRESSOR, replace X
AIR COMPRESSOR, recondition X
1211 - Connections for trailer

COCKS for the TRAILER, replace/recondition X
CONTROL VALVE for independent TRAILER BRAKE, replace X
CONTROL VALVE for independent TRAILER BRAKE, recondition X
5 -1 - 9
2 TH 9-3900
OPERATIONS ECHELON
1 2 3 4 5
GROUP 13 - HUBS, BRAKE DRUMS, WHEELS and TYRES
1311 - Hubs, brake drums and wheels

RIM RINGS and RIMS, replace X
RIM RINGS and RIMS, recondition X
WHEELS cpl., replace X
BRAKE DRUMS, replace XX
BRAKE DRUMS, recondition X
BEARINGS and SEALS, replace X
HUBS, replace X
HUBS, recondition X
1313 - Tyres
TYRES, recondition/replace X
GROUP 14 - STEERING GEAR
1401 - Steering column, track arms and steering arms

STEERING COLUMN, replace/recondition X
PITMAN ARM, replace X
BEARINGS for STEERING COLUMN cpl., replace X
STEERING WHEEL, replace X
STEERING UNIVERSAL JOINT, replace X
STEERING ROD and STEERING ROD END, replace X
TRACK ARM and TRACK ARM ENDS, replace X
TOE-IN, check X
1407 - Steering box and hydraulic power steering

STEERING BOX w/POWER STEERING, replace XX
STEERING BOX w/POWER STEERING, recondition X
STEERING LOCK PRESSURE, check/adjust X
STEERING BOX w/POWER STEERING, check for leaks X
1410 - Hydraulic steering pump

HYDRAULIC STEERING PUMP, replace X
1411 - Hydraulic lines for steering system

FLEXIBLE LINES, replace X
CONNECTIONS and other LINES, replace/recondition X
1413 - Hydraulic reservoir for steering pump

HYDRAULIC RESERVOIR, replace X
FILTER ELEMENT, replace X
OIL LEVEL, inspect/replace X
GROUP 15 - CHASSIS
1501 - Chassis
CHASSIS FRAME, align/repair X
AUXILIARY CHASSIS FRAME (only for YAK), replace/repair X
1503 - Towing hook and towing eyes

TOWING EYES and PINS, replace X
TOWING HOOK, replace/repair X
1504 - Spare wheel carrier

SPARE WHEEL CARRIER, replace/recondition X
5 - 1 - 10
2 TH 9-3900
OPERATIONS ECHELON
1 2 3 4 5
GROUP 16 - SUSPENSION and SHOCK ABSORBERS
1601 - Springs with attachments

FRONT SPRINGS cpl., replace X
SPRING ASSEMBLIES, recondition X
DAMPING BUFFERS, replace X
SPRING BOLTS, replace X
SHACKLE BUSHES, replace X
CENTRE BOLTS, replace X
SPRING SHACKLES, replace X
SPRING SHACKLE BUSHES, replace X
REAR SPRINGS cpl., replace X
SPRING SEATS, replace X
BOLT CONNECTIONS for SPRING SEATS, check tightening torque X
SPRING U-BOLTS, replace X
1604 - Shock absorbers

SHOCK ABSORBERS, check for proper attachment and leaks X
SHOCK ABSORBER RUBBERS, replace X
SHOCK ABSORBERS, replace XX
SHOCK ABSORBERS, adjust X
5 -1 - 11
2 TH 9-3900
OPERATIONS ECHELON
1 2 3 4 5
GROUP 18 - BODY WORK
1801 - Cab
CAB cpl., replace XX
CAB, repair (heavy damage) X
CAB, repair X
CAB SUSPENSION and TILT MECHANISM, replace/recondition X
DOORS, replace X
DOORS, repair (heavy damage) X
WINDOW MECHANISM X
DOOR HINGES and LATCHES, replace/recondition X
SEALS, replace/recondition X
MONHOLE COVER, replace/recondition X
GRILLE, replace X
INSTRUMENT PANEL/ STORAGE COMPARTMENT, recondition X
BRANCH GUARD, replace/recondition X
1802 - Mudguards, inner shields and windscreens

WINDSCREEN and SIDE WINDOWS, replace X
RUNNING BOARDS with STEPWELL, repair X
WINDOWS, DOOR and REAR, replace X
1806 - Interior
CAB SEATS, repair X
CAB SEATS, recondition X
INTERIOR TRIM, replace X
SUN VISORS, replace X
SHOOTING PLATFORM, replace X
1808 - Storage facilities

MOUNTING BRACKET for FIRE EXTINGUISHER, replace X
HOOK PLATE for GAS DECONTAMINATION TUBE and WEAPON X
RACK, replace
STORAGE CABINET for ROOF CANOPY, replace/recondition X
PIONEER RACK, replace/recondition X
1810 - Load platform

LOAD PLATFORM, repair (heavy damage) X
LOAD PLATFORM, recondition X
LOAD PLATFORM, replace X
SIDE and REAR HATCHES, replace X
SIDE and REAR HATCHES, recondition X
HINGES & LOCKS, replace/recondition X
GROUP 19 - TURRET (ROTATING GUN MOUNT)
1901 - Turret (rotating gun mount)

TURRET (ROTATING GUN MOUNT) cpl., replace X
TURRET (ROTATING GUN MOUNT) cpl., recondition X
1907 - Ammunition rack

AMMUNITION RACK, replace X
AMMUNITION RACK, recondition X
GROUP 20 - PTO FOR TRUCK-MOUNTED CRANE
2004 - PTO (only for YAK)

PTO, check for leaks X
PTO, replace X
PTO, recondition X
OPERATING MECHANISM, external, replace/recondition X
5 - 1 - 12
2 TH 9-3900
OPERATIONS ECHELON
1 2 3 4 5
GROUP 21 - BUMBERS and BUFFER BEAM
2101 - Bumpers and buffer beam

BUMPERS, replace X
BUMPERS, recondition X
BUFFER BEAM, replace X
BUFFER BEAM, recondition X
GROUP 22 - LOAD PLATFORM CANOPY SYSTEM and SECONDARY

EQUIPMENT
2201 - Roof canopy, supports, retainers and belts

CANOPY CLOTH, SUPPORTS and RETAINERS, replace X
CANOPY CLOTH, SUPPORTS and RETAINERS, recondition X
BELTS, replace X
2202 - Mirrors, windscreen wipers, ventilation and heater system

MIRRORS, MIRROR SUPPORTS and REFLECTORS, replace/ X
recondition
WINDSCREEN WIPER MOTOR, replace XX
WINDSCREEN WIPER MOTOR, recondition X
LINES and CONNECTIONS for the heater radiator, replace/ X
recondition
WIPERS and WIPER ARMS, replace X
HEATER RADIATOR cpl., replace XX
HEATER RADIATOR, recondition X
PARTS OF WINDSCREEN WASHER SYSTEM, replace X
HEATER FAN, replace XX
HEATER FAN, recondition X
ROTATING BEAM SUPPORT, replace/recondition X
ANTENNA SUPPORT, replace/recondition X
2207 - Engine heater system

QUICK-RELEASE COUPLING, LINES and HOSES, replace X
2210 - Instruction and identification plates

INSTRUCTION AND IDENTIFICATION PLATES, replace X
GROUP 24 - HYDRAULIC SYSTEM
2401 - Hydraulic pump

PUMP SEAT, replace X
DUST RING, hydraulic pump, replace X
GROUP 47 - INSTRUMENTS (NON-ELECTRIC)
4701 - Speedometer and rev counter

SPEEDOMETER and REV COUNTER, replace X
SPEEDOMETER and REV COUNTER, recondition X
DRIVE CABLES, replace X
RIGHT-ANGLE TRANSMISSION for REV COUNTER DRIVE, X
replace
4702 - Air pressure gauge

AIR PRESSURE GAUGE, replace X
AIR PRESSURE GAUGE, recondition X
5 -1 - 13
2 TH 9-3900
5 - 1 - 14
3 TH 9-3900
6 MAINTENANCE SCHEDULE (PROJECT NUMBER 1952)

6.1 INTRODUCTION
6.1.1 Explanation
a. This maintenance schedule is organised in various groups and subgroups in accordance with the
Standard Functional Group Organisation.
b. In columns 1e through 5e "echelon", an "X" indicates which echelon is to carry out the operations.
c. If an "XX" is shown, components that require service must be exchanged.
d. If an "XU" is shown in columns "5" or 5, these items must be sent out to a civilian company and/or
other Army companies.
e. The echelon columns are defined as follows:

(1) Operations to be carried out by the user/crew.
(2) Operations to be carried out by the maintenance personnel of the unit to which the equipment has
been assigned. .
(3) Operations to be carried out by personnel of the directly supporting unit (1 LK and NLC).
(4) Operations to be carried out by personnel of 4th echelon units of the NLC.
("5") 4th echelon operations to be carried out by personnel of base maintenance facilities.
(5) Operations to be carried out by the personnel of the base maintenance facility.
– Man hours The man hours are shown in time units (T.U.)
1 T.U. = 6 minutes.
– Frequency The frequency is shown in number of times per year (Preventative).
f. The schedule is intended as a guideline for compiling descriptive and supply documentation.
g. The schedule gives the staff insight into the manner in which maintenance is intended to be
performed.
h. Essential (spare) parts are indicated with a "+".
6.1.2 Standard group organisation
06 ELECTRICAL SYSTEM
09 INTERMEDIATE SHAFTS
20 PTO
21 BUMPER/ BUFFER BEAM
22 SECONDARY EQUIPMENT
24 HYDRAULIC SYSTEM
90 WATER TREATMENT INSTALLATION
6 -1-1
3 TH 9-3900
6.1.3 Maintenance schedule
Description Echelon Man freq.

hours
1 2 3 4 “5” 5
A B
Group 06 - ELECTRICAL SYSTEM

0607 - Switches, indicator lamps and sockets
on the instrument panel
HOUR METER, replace X 2
SWITCH, OPERATING MECHANISM
PTO, inspect X 0,1
SWITCH, OPERATING MECHANISM
PTO, replace X 2
INDICATOR LAMP, OPERATING
MECHANISM PTO, inspect X 0,1
INDICATOR LAMP, OPERATING
MECHANISM PTO, replace X 0,2
0608 - Switches, indicator lamps and sockets

not on the instrument panel
MAIN SWITCH, inspect X 0,1 Day
MAIN SWITCH, replace X 15
RELAY, replace X 0,1
SOCKER, replace X 15
DUST CAP, replace X 2
0613 - Wiring
WIRING HARNESS, HOUR METER, replace X 30
WIRING HARNESS, MAIN SWITCH- X 20
SOCKET, replace
WIRING HARNESS, BATTERIES - MAIN X 10
SWITCH, replace
Group 09 - INTERMEDIATE SHAFTS

0900 - Intermediate shafts
INTERMEDIATE SHAFT (PTO / hydraulic XX 6
pump), replace
INTERMEDIATE SHAFT (PTO / hydraulic X 11
pump), recondition
INTERMEDIATE SHAFT and JOINTS, X 1
lubricate
DUST SEAL, replace X 5
LUBRICATION NIPPLES, replace X 1
Group 20 - PTO
2004 - Power take off
PTO, check for leaks X 0,1
PTO, replace X 8,5
PTO, recondition X 10
OPERATING MECHANISM, replace/ X 5
recondition
6 -1-2
3 TH 9-3900
Description Echelon Man freq.

hours
1 2 3 4 “5” 5
A B
Group 21 - BUMPER/ BUFFER BEAM

2101 - Bumper/ buffer beam
BUMPER, replace/recondition X 10
FLAG MASTS, replace X 0,1
REINFORCEMENT PROFILES, replace X 40
CLUTCH PLATE, inspect attachments X 0,1
CLUTCH PLATE, replace X 3
CLUTCH PLATE, LOCK NUTS, replace X 30
SUPPORT, QUICK-RELEASE X 20
CONNECTIONS, replace
SUPPORT, SOCKET, replace X 15
Group 22 - SECONDARY EQUIPMENT

2202 - Rotating beam mast
ROTATING BEAM MAST, replace X 2
INTERNAL PIPE, ROTATING BEAM MAST, X 1
replace
2210 - Instruction and identification plates

INSTRUCTION STICKER, check legibility X 0,1 day
INSTRUCTION STICKER, replace X 2
Group 24 - HYDRAULIC SYSTEM

2401 - Hydraulic pump
HYDRAULIC INSTALLATION, check for leaks X 2
HYDRAULIC PUMP cpl., replace 10
HYDRAULIC PUMP, recondition X
PUMP SEAT, replace X 10
DUST SEAL, replace X 4
2402 - Operating valve, speed limiter

OPERATING VALVE, SPEED LIMITER, X 15
replace
SUPPORT, replace X 15
2406 - Hydraulic lines day

HYDRAULIC HOSE, inspect X 2
HYDRAULIC HOSE, replace X 20
QUICK-RELEASE COUPLING, inspect X 2 day
QUICK-RELEASE COUPLING, replace X 5
SUPPORT, replace X 15
Group 90 - WATER TREATMENT

INSTALLATION
9001 - Water line with couplings
HOSES and QUICK-RELEASE COUPLINGS, X 2 day
inspect
HOSE, replace X 20
QUICK-RELEASE COUPLING, replace X 5
SEAL RING, QUICK-RELEASE COUPLING, X 2
replace
6 -1-3
3 TH 9-3900
6 -1-4
2 TH 9-3900
APPENDIX 1. HYDRAULIC DRIVE SWEEPING ATTACHMENT DIAGRAM

(YA 4440 - Project 1952)
DAF YA 4440
1.Current control valve

2.Safety valve
3.Hydraulic pump
4.Quick- release
5.Hydraulic couplings
reserve tank
6.Return filter
7.Hydraulic motor
App.1 -1
2 TH 9-3900
APPENDIX 2. DIAGRAM, WATER SUPPLY SYSTEM SWEEPING ATTACHMENT

(YA 4440 - Project 1952)
1.Water tank
2.Shut-off tap
3.Quick-release couplings
4.Filter
5.Water pump
6.Spray bar
App 2-1
2 TH 9-3900
APPENDIX 3. STORAGE INSTRUCTION
ROYAL DUTCH ARMY EQUIPMENT DIRECTORATE
Storage instruction Y-4440 vehicles
Type NSN
YAS 4440 2320-17-049-2854
YAD 4440 2320-17-054-9576
YAL 4440 2320-17-049-2855
YAJ 4440 2320-17-054-9577
YAK 4440 2320-17-051-0589
YAI 4440 2320-17-101-9400
YAV 4440 2320-17-053-8162
Table of contents:
Introduction App. 3 -2
Overview of activities App. 3 -2
Overview of preserving agents App. 3 -3
Instructions for making ready for storage App. 3 -4
Instructions for maintenance App. 3 -5
Activities on putting into operation App. 3 -5
Appendices:
1 Consumables of vehicles in storage
2 Brake system of vehicles in storage
3 Clutch plates of vehicles in storage
4 Batteries of vehicles in storage
5 Instruction card + label for vehicles in storage
App 3 - 1
2 TH 9-3900
1.1 Introduction
These instructions specify the activities to be carried out if a Y-4440 is taken out of use for a period of more
than six months in the event of MOB, park or KV storage.
A diagram on the following page shows who should carry out the work and when. The preserving agents to be
used are shown with, where possible, their NATO designation on pages 5 and 6.
1.2 Overview of activities
Work To be carried out by When:
Ready for operational use + Maintenance personnel area vehicle placed out of use for
making roadworthy workshop (user unit) longer than 6 months
ML/tectyl coating the designated preservation at the beginning of the storage

equipment period, then every 5 years
Preparation for storage Maintenance personnel area at the start of the storage period
workshop (user unit)
Maintenance during the storage Maintenance personnel area yearly (function test), 5-yearly
period workshop (user unit) (maintenance service)
Preparation for use Mobilised personnel or in the event of mobilisation,

maintenance personnel area refresher training exercises
workshop (user unit) maintenance and transfer
NOTE: The above also applies to vehicles which are stored for Royal Dutch Army platoons with their
own unit (user unit).
These instructions are not intended for vehicles that have been placed at 573 Vzpl Coy. The vehicles
there must be handled such that no worsening takes place of the condition of the vehicles as it was at the
time they were presented.
App 3 - 2
2 TH 9-3900
1.3 Overview of preserving agents
Seq NATO Description NSN Issuing unit

No. Code
1 Al-39 Antifreeze Mixed -30° 6850-17-605-4970 can 20 1

6850-17-605-4950 drum 200 1
2 G-460 Grease, seawater-resistant 9150-17-700-2982 can 5 kg
3 C-642 Lubricating oil, engine preservatives 9150-17-622-0050 can 20 1

grade 30 9150-17-622-005 drum 200 1
4 C-640 Lubricating oil, engine preservatives 9150-17-622-0048 can 20 1

grade 10
5 S-736 Insulating compound electrical 6850-00-880-7617 tube of 8 oz
6 S-734 Petrolatum, Technical 9150-12-124-5785 can 1 kg
7 H-542 Brake fluid automotive 9150-17-622-0035 can 1 1
8 Corrosion-inhibiting agent internal 8030-14-051-4421 drum 205 1
9 Corrosion-inhibiting agent undercoating 8030-17-051-7700 drum 205 1
10 Corrosion-inhibiting agent seams 8030-17-051-7701 drum 60 1
11 Corrosion-inhibiting agent CRC-2.26 6850-00-988-7068 spray can 0.5 l
12 Silicon spray 9150-00-823-7860 spray can 450 g
13 Varnish, oil preservation 8010-17-003-3802 can 5 1
14 G-403 Grease Automotive and Artillery 9150-17-049-4580 filler cartridge 400 g

9150-17-622-0061 can 20 kg
15 Primer rust inhibiting zinc chromate 8010-17-003-1919 can 1 1

green
16 Paint army green RAL 6014 MT 8010-17-007-7052 can 1 1

8010-17-007-7049 can 5 1
17 Paint, black RAL 9005 SG. 8010-17-007-8759 can 1 1
18 Paint, yellow RAL 1007 SG 8010-17-007-6459 can 1 1
19 Paint, red RAL 3000 SG 8010-17-007-7074 can 1 1
20 Paint, white RAL 9010 SG. 8010-17-007-8710 can 1 1
21 Paint rapid drying army green RAL 8010-17-708-3277 can 25 1

6014 MT
22 Primer, rust inhibiting zinc chromate 8010-17-708-4644 can 25 1

green, rapid drying
23 Red lead 50/50 8010-17-003-1907 can 1 1
24 Sulphuric acid electrolyte 37% for 6810-17-051-3666 can 20 1

batteries
25 Water demineralised 6810-17-051-6628 can 25 1
26 Windscreen wiper fluid 7930-17-047-2005 can 1 1

7930-17-047-2006 can 20 1
27 Frost protection agent Pneumatic 6850-17-053-6606 bus 5 1

braking system-
App 3 - 3
2 TH 9-3900
1.4 Making ready for storage
1.4.1 general
Before making the vehicle ready for storage a complete inspection should first be carried out and faults which
are observed should be put right.
Specifically:
a. in the event of mobilisation storage:

compliance with the requirements as stated for category 2 vehicles (ready for active service and roadworthy).
b. in the event of park storage:

compliance with the requirements as stated for category 1 vehicles (1st to 3rd level ready and complete).
The ML/Tectyl repeat treatment should then be applied by the designated preservation unit.
1.4.2 Implementation
1. Cleaning
If necessary clean the vehicle inside and outside. When cleaning do not use a steam cleaner, diesel
oil, petrol or solvent because these affect the ML layer. A high-pressure spray is also not permitted but
normal water supply pressure is. Make sure during spraying that no water gets into the cab (shut the
doors and windows).
2. Exposed parts
Immediately after cleaning, coat the unpainted areas of the vehicle, such as wheel nuts and threaded
ends of the wheel bolts, plunger rod of the hydraulic lifting cylinder and the moving parts of the cab
pump, with G 460.
3. Paintwork
Damaged paintwork should be restored:
a. remove dirt and grease
b. remove rust and any loose paint with a steel brush and/or sandpaper.
c. remove the abrasive on areas cleaned of rust by blasting clean with compressed air if possible.
The battery pack, the battery cover and the battery clips must be cleaned with hot soda water,
thoroughly flushed with water and then dried.
d.apply a layer of primer, anti-corrosion, zinc chromate, green immediately to the areas cleaned of
rust. Once dried then 2 layers of finishing paint, Army green RAL 6014 MT should be applied.
Finishing paint, black RAL 9005 SG, should be applied to the inside of the battery pack, cover and
clips.
4. Door rubbers
Spray the door rubbers lightly with silicon spray.
5. Relay box
Remove both covers and spray all electrical parts with CRC 2.26.
6. Consumables
Change the consumables as described in Appendix 1.
7. Brake system
Treat the brake system as described in Appendix 2.
8. Coupling
Treat the coupling as described in Appendix 3.
9. Batteries
Treat the batteries as described in Appendix 4.
10. Windshield wipers

Make sure that the windshield wipers are a little bit free of the windscreen to prevent the blades
sticking. This is done by, for example, placing a piece of wood between the windshield wiper arms and
the windshield.
App 3 - 4
2 TH 9-3900
11. Canvas
Stretch the canvas straps over the uprights in such a way that as little rainwater as possible will collect
on it.
12. Cab ventilation

- For outdoor storage
a. Close the doors, windows and manhole properly.
b. The cab rear wall has a cable feed-through opening.
Open the hatch of the cable feed-through opening (on the outside of the cab) and place a block
between the hatch and the rear wall of the cab so that the hatch stays open.
c. Place the control lever for heating and ventilation on the instrument panel as follows:
(1) Both upper levers in the left-hand position (open).
(2) The bottom lever in the right-hand position (cold air).
Turn the grids on the instrument panel left and right in the "open" position
- For inside storage:

Wind down the side windows in the doors almost fully.
13. Instruction card

Fit the instruction card and label "engine sump filled with preservation oil C-642" in a clearly visible
position (Appendix 5).
1.5 Maintenance during the storage period
During the storage period preventive maintenance should be carried out in accordance with "IWK-NS" for
stored equipment in accordance with the following intervals:
- a yearly function test
- a maintenance service every 5 years in combination with the changing of the consumables and a ML/
tectyl repeat treatment.
1.6 Activities on putting into operation
a. Brake system
Deblock the brake installation as described in Appendix 2.
b. Coupling
Deblock the coupling as described in Appendix 3.
c. Batteries
Place the batteries as described in Appendix 4.
d. Windshield wipers
Remove the wooden blocks under the wiper arms.
e. Start engine
Start the engine with the stop lever downwards until the oil pressure warning lamp goes out.
Move the stop handle up and start the engine. Allow the engine to run at c. 900 rpm.
Check the operation of the instruments (oil pressure, charging current, air pressure, etc.).
App 3 - 5
2 TH 9-3900
App 3 - 6
2 TH 9-3900
ATTACHMENT 1. CONSUMABLES OF VEHICLES IN STORAGE

1.1 Preparation for storage:
a. Remove the consumables and refill,

- engine sump with C-642
- gearbox and reduction gearbox with 0-236
- front and rear axles with 0-226
- steering system with * DONAX-TM
- cooling system with ANTI-FREEZE MIXED -30°
- coupling operating system with H-542
* only change if the steering system is filled with 0-237
b. Check the fluid level and top up if necessary,

- brake system anti-frost device with anti-freeze, pneumatic brake system
- windshield sprayer with windshield wiper fluid
- cab tilting mechanism pump with DONAX-TM
- steering system with DONAX-TM
- fuel tank with fuel
c. Lubrication
- lubricate all lubrication points with G-403
d. Label
- place a label "engine sump filled with preservation oil C-642" in the cab.
1.2 Maintenance during the storage period
The consumables should be replaced every 5 years with the exception of the brake system anti-frost
device, windshield sprayer, tilting mechanism pump and steering system. The vehicle may ride 2500 km
with the preservation oil C-642.
1.3 Putting into operation
In the event of final placing into operation the preservation oil C-642 should be replaced with engine oil 0-
236/0-237.
ATT-1
2 TH 9-3900
ATTACHMENT 2. BRAKE SYSTEM OF VEHICLES IN STORAGE

a. Place chocks in front of and behind wheels.

b. Drain the water from the air reservoirs (see fig. 1 and 2).
c. Pressurise the whole system (release the parking brake).
d. Completely unscrew the bolt on the rear of the spring brake cylinders. (see fig. 3) The spring in the
cylinder is mechanically pressed in
e. Bleed the whole system (see fig. 1 and 2). This is intended to get the moisture out of the pipes, valves,
etc.
f. Fill the anti-frost device with fluid and then position the handle in the winter position (see fig. 4).
Figure 1.
Press against the pawl until no more water

comes out.
Fig. II.1
Figure 2.
Check the automatic operation of the blow-off

valve by pressing pin 2 on the underside of the
valve upwards.
There may be a difference of no more than half
a litre of water.
If the difference is more than half a litre of water
then the automatic blow-off valve should be
replaced.
Fig. II.2
Figure 3.
Unscrew bolt 4 which is on the back of the

spring brake cylinders 3 as far as possible.
Fig. II.3
ATT-2
2 TH 9-3900
Figure 4.
Position the handle in the summer position.

Check the fluid level and top up if necessary to
the max. with anti-freeze for pneumatic brake
systems.
Position the handle in the winter position (anti-
frost device is now activated).
Putting into operation

Pressurise the system fully.
Tighten the bolt on the rear of the brake
cylinders completely (see figure 3). Engage the
parking brake. Remove the chocks in front of
and behind the wheels. Then carry out a brake
test at low speed. Fig. II.4
1. Filler cap
2. Handle
3. Drain plug
ATT-3
2 TH 9-3900
ATTACHMENT 3. CLUTCH PLATES OF VEHICLES IN STORAGE

To avoid the clutch plate sticking a block must be placed, after the clutch pedal has been fully depressed,
between the lever and the clutch housing (see the figures) (dimensions of the block lxbxds 4.5x2.8x2.8 cm;
colour red).
The gearbox lever must be positioned in neutral.
Fig. <III>.1
Remove the block between the lever and the clutch housing (see the figure).
ATT-4
2 TH 9-3900
ATTACHMENT 4. BATTERIES OF VEHICLES IN STORAGE

1. Remove the batteries from the vehicle

2. Insulate the connection terminals so that no short-circuit can occur when the auxiliary socket is used.
3. The removed wet batteries should be handed in.
The dry batteries which are received may not be unpacked and should be stored in a cool, dry place. Both
the dry batteries and the electrolyte are frost-resistant.
4.2 Maintenance
No maintenance needs to be done on the dry batteries and the electrolyte other than a periodic check for
damage and breakage of the packaging materials.
Filling dry batteries.

Only in the event of mobilisation and the actual use of stored materials or at the orders of the competent
authorities should dry batteries be filled.
WARNING: Be careful with the sulphuric acid 37% required for filling, do not spill it as it attacks the skin,
clothing and footwear. Spilled sulphuric acid 37% should be flushed away with copious water.
The batteries must be filled as follows:

1. Carefully remove the battery packaging.
2. Unscrew the cell caps.
3. Remove the seal from the bleed holes in the cell caps and from the filler openings in the battery
compartment.
4. Fill the battery cells to about 5 mm above the plates with sulphuric acid 37% unless otherwise
indicated in filling instructions for the battery. Before the filling the appropriate spout should be fitted
on the bottle filled with sulphuric acid 37%.
5. Position the cell caps loosely on the filler openings.
6. Allow the sulphuric acid 37% at least 30 minutes to work in.
7. Check the level of the sulphuric acid 37% in all the cells of the battery and top up if necessary with
sulphuric acid 37% to about 5 mm above the plates.
8. Close the filler openings off properly with the cell caps.
9. If necessary rinse the battery with clean water and dry it. The battery is now ready for use.
Fit the batteries in the vehicle. Ensure the battery clamps are not above the battery terminals Lubricate the
battery terminals lightly with S-743 and ensure the protective covers are properly positioned.
ATT-5
2 TH 9-3900
ATTACHMENT 5. INSTRUCTION CARD

5.1 Actions to be taken when making the Y-4440 operational
1. Batteries
Position the batteries in the vehicle. (for the filling of the batteries see the instructions given with the
batteries)
2. Brakes
Pressurise the brake system.
Completely screw in the bolt on the rear of the front 2 brake cylinders.
Engage the parking brake.
Remove the chocks in front of and behind the wheels.
3. Coupling
Remove the red wooden block between the lever and the clutch housing. (accessible from the
underside of the vehicle)
4. Remove the wooden blocks under the wiper arms.
5. Start the engine

Start the engine with the stop lever downwards until the oil pressure warning lamp goes out (the
engine does not fire). Move the stop handle up and start the engine. Allow the engine to run at c. 900
rpm.
Check the operation of the instruments (oil pressure, charging current, air pressure, etc.).
lf 16164
IN THIS VEHICLE THE
ENGINE SUMP IS FILLED WITH
PRESERVATIVE OIL C-642
WITH THIS OIL THE VEHICLE MAY RIDE A MAX. OF 1500 KM

DURING THE STORAGE PERIOD AND ANOTHER 100 KM
AFTER THE PERIOD OF NOTICE FOR MAKING
OPERATIONAL
ATT-6

Eng 2TH9-3900

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ROYAL DUTCH ARMY

YAK 4440 DAF

Modification YA 4440 DAF

2nd Maintenance level

SER.NO. CHANGED BY (in capitals): DATE INITIALS

SUGGESTIONS? TRANSPORT MATERIAL DIRECTORATE

Publication date: Number of last change: W

Page/Fig. My proposal is:

CARBON MONOXIDE IS DEADLY

CARBON MONOXIDE IS A COLOURLESS AND ODOURLESS GAS.

DO NOT START ENGINES IN A POORLY-VENTILATED AREA.

INHALATION OF CARBON MONOXIDE CAN CAUSE DEATH.

IF ANYONE EXHIBITS THESE SYMPTOMS, PROCEED AS FOLLOWS:

(a) The numbering of the chapters, sections and items

Section 3.5. Clutch assembly 3-5-1

Section 3.6. Fuel system 3-6-1

Section 3.11. Transfer box 3-11-1

3.20.8. Door seals 3-20-4

CHAPTER 4 IDENTIFICATION OF FAULTS

CHAPTER 5 MAINTENANCE SCHEDULE (Project number 3900)

CHAPTER 6 MAINTENANCE SCHEDULE (Project number 1952)

APPENDIX 1. HYDRAULIC DRIVE SWEEPING ATTACHMENT DIAGRAM

ATTACHMENT 1 Consumables of vehicles in storage

1.1.2 Regulations and publications

1.1.5 Corrections and shortcomings

2 IDENTIFICATION, DESCRIPTION AND DATA

2.1.2 Component overview

2.2 DESCRIPTION AND DATA

2.2.2 General data

For the general data, see the related 1 TH

2.2.3 Detailed data

Make : Fichtel and Sachs

(1) Fuel injection

(2) Regulator : R. Bosch

(2) Starter motor

(3) Glow plugs

Intermediate shaft, PTO : Willi Elbe

Make : Clayton Dewandre

l. Springs and shock absorbers

(2)Rear springs Make

(3)Shock absorbers : KONI

2.2.4 Tightening torque

Description Tightening torque [Nm]

Oil sump, drain plug 78-88 Nm

3.1.1 2nd Level Maintenance

3.1.2 Preventive maintenance

3.1.3 Corrective maintenance

The purpose of modifications to the equipment is:

3.1.8 Spare parts

TABLE 3.1.1. SPECIAL TOOLS

Fig. no. Description Intended for

Fig. 3.1.3 c.Jig Fig. 3.1.4 d .Puller

Fig. 3.1.5 e. Ancillary torque wrench

3.2 ACTIONS TO BE TAKEN ON RECEIPT OF THE EQUIPMENT

3.2.2 Test drive

Carry out maintenance in accordance with 0K9.3900

3.2.3 Inspection and maintenance during the break-in period

a. At 500 km and/or 12.5 running hours.

b. At 2500 km and/or 62.5 running hours.

3.2.4 Service prior to transfer

3.3 PREVENTIVE MAINTENANCE

3.3.2 Inspection and test drive

3.3.3 Maintenance in accordance with the Inspection Work Card.