Original instructions

BG00201148 A.2 2013-07-11

Drill carrier TC7-TC12, NC7 Series

Drill carrier TC7-TC12, NC7 Series

Table of Contents

1. Introduction ................................................................... 1
1.1. The Purpose of these instructions ......................................................1
1.1.1. Validity of the manuals ................................................................ 1

2. Safety and Environmental Instructions ...................... 3

2.1. Safety precautions ................................................................................3
2.2. Servicing safety precautions ...............................................................3
2.3. Hydraulic system safety precautions ................................................. 4
2.4. Lubrication safety and other precautions .......................................... 5

3. Main components ..........................................................7

3.1. Main components ................................................................................. 7
3.2. Diesel engine (MB 904 LA) ...................................................................12
3.3. Diesel engine (MB 906 LA) ...................................................................13
3.4. Transmission (T20000) .........................................................................14
3.5. Transmission (HR32000) ......................................................................14
3.6. Frame ..................................................................................................... 15
3.7. Front axles .............................................................................................15
3.8. Rear axles ..............................................................................................16
3.9. Oscillation (rear) ................................................................................... 17

4. Drill carrier operation ....................................................19

4.1. Wiggins service system for automatic refueling and lubrication
(option for TC7/TC8/NC7 carriers) .......................................................19

5. Operator's maintenance procedures ...........................25

5.1. Carrier .................................................................................................... 25
5.1.1. Checking the tire condition, pressure and nut tightness ..............25
5.1.2. Checking the transmission oil level ............................................. 29
5.1.3. Checking the hydraulic oil level ................................................... 30
5.2. Diesel engine MB .................................................................................. 31
5.2.1. Cleaning the coarse filter .............................................................31
5.2.2. Checking the fuel level and filling the tank .................................. 32
5.2.3. Emptying the fuel water separator ...............................................35
5.2.4. Checking the engine oil level .......................................................36
5.2.5. Checking the coolant level .......................................................... 37

6. Periodic maintenance procedures .............................. 39

6.1. Carrier .................................................................................................... 39
6.1.1. Machine greasing points ............................................................. 39
6.1.2. Checking the planetary gear oil level .......................................... 39

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6.1.3. Checking the differential oil level .................................................40

6.1.4. Checking the battery electrolyte level ..........................................40
6.1.5. Checking the pressure of the brake accumulators ...................... 41
6.1.6. Releasing the pressure from the brake accumulators .................41
6.1.7. Filling the brake accumulators .....................................................42
6.1.8. Bleeding the brakes .....................................................................44
6.1.9. Checking the tightness of boom support bolts ............................ 48
6.1.10. Replacing the transmission oil filter .............................................51
6.1.11. Changing the differential oil .........................................................52
6.1.12. Changing the hydraulic oil ........................................................... 53
6.1.13. Spicer axle types 37R, 43R .........................................................54
6.1.14. Spicer axle types 113, 123, 213 .................................................. 54
6.1.15. Checking the middle-joint bearings ............................................. 54
6.1.16. Checking the oscillation axle bearings ........................................ 55
6.1.17. Changing the transmission oil ..................................................... 56
6.1.18. Changing the planetary gear oil .................................................. 58
6.1.19. Checking the specific gravity of the electrolyte and cleaning the
battery terminals ..........................................................................58
6.1.20. Servicing the Ansul fire suppression system (optional) ...............58
6.1.21. Maintenance procedures done as required .................................59
6.2. Diesel engine MB .................................................................................. 61
6.2.1. Replacing the engine oil and filter ............................................... 61
6.2.2. Replacing the fuel filter ................................................................64
6.2.3. Replacing the fuel water separator filter ......................................65
6.2.4. Checking the condition of poly V-belt .......................................... 66
6.2.5. Checking the engine for leaks and general condition ..................70
6.2.6. Checking the lines and hoses of the engine ................................70
6.2.7. Checking the intake pipe between air cleaner and engine ..........70
6.2.8. Checking the engine cooling system ...........................................71
6.2.9. Replacing the intake air cleaner filter .......................................... 72
6.2.10. Adjusting the valve clearances ....................................................73
6.2.11. Cleaning the fuel pre-filter ........................................................... 77
6.2.12. Checking the general condition of cooling and heating system .. 78
6.2.13. Renewing the coolant ..................................................................79

7. Lubrication specifications and filling capacities ....... 81

7.1. Lubrication specifications ................................................................... 81
7.1.1. Diesel engine ...............................................................................81
7.1.2. Axles and planetary reduction oils ...............................................86
7.1.3. Power shifted transmission and torque converter ....................... 87
7.1.4. Hydraulic system ......................................................................... 87
7.1.5. Greasing ......................................................................................87

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7.2. Filling capacities ...................................................................................87

8. Drill carrier troubleshooting .........................................91

8.1. Troubleshooting guide for hydraulics ................................................ 91
8.2. Troubleshooting guide for the power shift transmission ................. 92
8.3. Troubleshooting guide for the axle .....................................................95

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Drill carrier TC7-TC12, NC7 Series

1. INTRODUCTION
1.1. The Purpose of these instructions
This manual contains supplementary information for operation,
maintenance and repair of a component.
Before operating, or performing maintenance or repair procedures for the
component or system described in this manual, read and understand the
information in operator´s and maintenance manuals supplied with the
machine. Pay special attention to the safety information in chapter "2 Safety
and environmental instructions" of those manuals.
1.1.1. Validity of the manuals

This manual, and especially the safety information, is valid only if no

unauthorized changes to the product are made.
Continuing improvement and advancement of product design might have
caused changes to your product which are not included in this publication.
Note also that if a third party has made changes to the product after
delivery from the manufacturer, this publication does not include
information on these changes or their influences on the product.
Whenever a question arises regarding your product, or this manual, please
consult your local Sandvik representative for the latest available
information.

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2. SAFETY AND ENVIRONMENTAL INSTRUCTIONS

2.1. Safety precautions
Take all safety factors into consideration and perform your work with
care. Follow all drilling site safety regulations.

Operating, service and adjustment procedures must be carried out

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

HIGH PRESSURE INJECTION HAZARD!

Compressed air jets can cause serious injury.
Allow the pressure to be released from the hydraulic circuit before
opening the plugs or connectors.
WARNING! PERSONAL INJURY HAZARD!
Hazardous moving parts and dangerous rig movements (boom, feed,
rock drill, hatches, and gratings) could result in death or severe
injury.
Make sure there are no unauthorized persons in the danger areas
during drilling, tramming, setting up or servicing the rig.

2.2. Servicing safety precautions

When servicing or repairing the vehicle, shut down the engine unless
it is required to be running for adjustment purposes.

Keep your head, hands, feet and loose clothing away from power-
driven parts.

Do not grab the steering wheel when mounting the vehicle.

Accumulated grease or oil on the vehicle is a fire hazard. Remove

debris any time a significant quantity oil is spilled on the vehicle.

Do not arc weld on this vehicle without first disconnecting the

alternator.

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Before performing maintenance or repair work on any equipment,

consult the manufacturer’s instruction manual and follow the
recommended procedures.

• Inspect equipment daily for signs of failure or beginning of failure.

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

2.3. Hydraulic system safety precautions

WARNING
HIGH-PRESSURE FLUID HAZARD!
High-pressure fluid remaining in hydraulic lines can cause serious
injury.
Never carry out maintenance or repair work on a pressurized system.
Relieve pressure before opening fittings, plugs or hydraulic valve
cartridges. Always make sure the parts are not pressurized. Use a
bleeder screw to relieve the pressure behind the valves or
cartridges, or wait until the unit is depressurized, before removing
the components.

WARNING
HYDRAULIC FLUID INJECTION HAZARD!
High-pressure hydraulic fluid spray can penetrate under the skin,
causing serious injury.
Search for leaks with a piece of cardboard or wood. Never try to
locate a leak by feeling with your hand. Immediate medical attention
is required after injection.

Before performing service or maintenance work under the raised

boom (equipments) perform the following operations:
• Empty the boom.
• Place adequate support under the boom.
• Shut down the engine.

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WARNING
BURN HAZARD!
The oil circulating in the hydraulic systems is hot. It can cause
severe burns to the skin.
Let the oil cool down before starting any maintenance work.

When washing parts do not use corrodents.

• Do not change the pressure setting of any hydraulic valves unless

authorized instruction has been obtained.
• Clean the area around the component to be repaired before starting
work. If possible, change the complete component.
• Ensure that all the connections will be made according to the hydraulic
diagram.
• Check the movements of the rig before use.
• Hydraulic components and hoses should be stored with all connections
well plugged. Do not remove the plugs until the components are mounted
on the rig.
• Hydraulic pumps and motors are heavy. Before detachment you must
have equipments to lift them up safely.

2.4. Lubrication safety and other precautions

When lubricating the vehicle, shut down the engine unless it is
required, see the lubrication instructions.

Keep your head, hands, feet and loose clothing away from power-
driven parts.

Do not grab the steering wheel when lubricating the vehicle.

Use caution when draining hot fluids from the vehicle, splashing hot
fluid can cause serious burns.

Accumulated grease or oil on the vehicle is a fire hazard. Remove

debris any time a significant quantity oil is spilled on the vehicle.

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Before performing lubrication work on any equipment, consult the

manufacturer’s instruction manual and follow the recommended
procedures.

Never attempt to clean or lubricate the vehicle while it is in motion.

Note! Always comply with your company’s regulations and practices for
the safe lubrication of this vehicle.

• Avoid mixing lubricants. Please use oils recommended or oils with

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

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3. MAIN COMPONENTS
3.1. Main components
Carrier TC 7

4 2
4
5

5 3 3

1 Diesel engine 2 Transmission

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

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Carrier NC 7 -series

4 2
4
5

5 3 3

1 Diesel engine 2 Transmission

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

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Carrier TC 8

1
2
4
4

5 3 3

1 Diesel engine 2 Transmission

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

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Carrier TC 9

4 1

2 5

5
3 3
2

1 Diesel engine 2 Transmission

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

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Carrier TC 10-12

4
1

2 4

5 3 3

1 Diesel engine 2 Transmission

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

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3.2. Diesel engine (MB 904 LA)

3
16

7
11

15

9 13

12
4

1
11
17
10

5
2
14

1 Fuel filters 2 Oil drain plug

3 Engine oil filter 4 Engine oil filling cap
5 Dipstick of engine oil level 6 Contamination indicator for
air filter
7 Pumps for steering and 8 Radiator (air, oil, water)
brakes
9 Expansion vessel (cooler) 10 Air filter (dry)
11 Poly V-belts 12 Level sensor
13 Exhaust catalyzer (option) 14 Muffler
15 Charger guard 16 Warning sign, finger cover
17 MR2 Engine control unit

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3.3. Diesel engine (MB 906 LA)

8
7

10
9
3

6
1

11

5
4

1 Fuel filters 2 Oil drain plug

3 Engine oil filter 4 Engine oil filling cap
5 Dipstick of engine oil level 6 Radiator (air, oil, water)
7 Expansion vessel (cooler) 8 Poly V-belts
9 Charger guard 10 Warning sign, finger cover
11 MR2 Engine control unit

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3.4. Transmission (T20000)

2 1

1 Gear pump for steering 2 Gear pump for brakes

3 Transmission oil filter 4 Dipstick of transmission oil
level / transmission oil filling
cap
5 Transmission oil drain plug

3.5. Transmission (HR32000)

3 1

5
2

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1 Transmission oil filling cap 2 Transmission oil drain plug

3 Transmission oil filter 4 Checking mark of
transmission oil level (FULL)
5 Checking mark of
transmission oil level (LOW)

3.6. Frame
Carrier TC 7-8 / NC 7 -series

1 Hinge pins

3.7. Front axles

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

2
1

1 Planetary gear units

2 Brakes

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

1
2
1

1 Planetary gear units

2 Brakes

3.8. Rear axles

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

1
2
1

1 Planetary gear units

2 Brakes

Carrier TC 9-12 (axle 213)

1
2
1

1 Planetary gear units

2 Brakes

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3.9. Oscillation (rear)

1 The rear axle oscillation allows the carrier to be turned ±10° (TC 7,
NC 7 - NC 7S) or ±8° (TC 8-12 / NC 7W) along the longitudinal
axis.
2 The front axle is mounted rigidly to the frame.

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4. DRILL CARRIER OPERATION

4.1. Wiggins service system for automatic refueling and lubrication
(option for TC7/TC8/NC7 carriers)
Filling engine fuel tank
The fast fuel system is based on the simple concept of using a sealed
vehicle tank to allow a small amount of back pressure to build and
automatically shut off the nozzle. A receiver is located near the bottom of
the tank for bottom filling which helps to eliminate foaming that occurs
during the traditional ”splash fill” method at the top of the tank.

2
1

Figure: Fast filling system

1 Nozzle
2 Fuel

The nozzle is attached to the receiver, the handle is turned to the ”ON”
position and the diesel pumping module automatically starts filling the
vehicle fuel tank at a rate of 100 G.P.M. As fuel enters the tank, it forces
the air inside the tank through the hollow stem in the vent. When the fuel
level in the tank nears the top, two hollow floating balls force the third
ground ball against an O-Ring seal and stops the flow of air from the tank.
Fuel continues to flow into the tank and pressure begins to build. At
approximately 5.5 PSI, a diaphragm operated piston inside the nozzle
starts to shut off the flow of fuel and system line pressure picks up and
brings the nozzle to the OFF-position and the diesel pumping module is
automatically shut off. The nozzle is disconnected and the next vehicle is
ready to refuel.

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Filling motor, transmission and drilling oil (TC 7-8 carrier)

1 Crankcase oil evacuation and 2 Transmission oil evacuation

fill and fill
3 Hydraulic oil evacuation and 4 Collector piece
fill
5 Connection to Wiggins
evacuation and filling system
Adding and changing of engine, transmission and hydraulic oils is
described in separate instructions: Wiggins Service Systems, automatic
refueling and lubrication service for construction and mining equipment.

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Filling motor, transmission and drilling oil (NC 7 -series carriers)

1 Crankcase oil evacuation and 2 Transmission oil evacuation

fill and fill
3 Hydraulic oil evacuation and 4 Left distributor in front frame
fill
5 Connection to Wiggins
evacuation and filling system
Adding and changing of engine, transmission and hydraulic oils is
described in separate instructions: Wiggins Service Systems, automatic
refueling and lubrication service for construction and mining equipment.

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Hydraulic diagram, Wiggins evacuation (NC 7 -series)

EVACUATION
ENGINE OIL

ENGINE
DIESEL
8

SERIE
32000
SPICER
SERIE/
20000
CLARK
CRANCASE OIL
EVACUATION AND FILL

12
TRANSMISSION OIL
EVACUATION AND FILL

HYDRAULIC OIL
EVACUATION AND FILL
12

12
L5

LEFT

FROM PUMP OF ROTATION

PORT L1
12
F

OUT

L5
L4

L3
IN

24

L1

L2
T1 S5

PIPE 38X3
L7

L6
L8

PIPE 38X3
T2

X31
K425
M1

2.5bar

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Figure: Crankcase oil evacuation

1 Connection to Wiggins evacuation and filling system

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5. OPERATOR'S MAINTENANCE PROCEDURES

5.1. Carrier
5.1.1. Checking the tire condition, pressure and nut tightness

WARNING
FLYING MATERIAL HAZARD!
Failure to follow proper safety precautions could cause death or
severe injury.
Do not attempt to repair disc wheel assembly parts. Replace them
with new parts of the same size, type, and make. Ensure that all tire
and rim parts are undamaged and correctly assembled before
inflating the tires.

DANGER
TIRE EXPLOSION HAZARD!
In the event of tire explosion, the resulting power shock and ejected
tire/tool debris will cause death or severe injury.
Always use restraining devices (safety cage or similar protective
enclosure) when inflating tires.
Never stand in front of the assembly while inflating the tire. Use an
extended hose that allows you to stand to the side.
Do not exceed the tire manufacturer's recommended maximum
pressure.
Unauthorized people are not allowed in the vicinity of the wheel
during the tire is being inflated.
Always check after pressurization that the tire sits on the rim
correctly before removing the wheel from the cage.

See separate instructions in manual "Tire change and rim

inspection".

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Checking the tire condition

Check that the tires are undamaged and properly mounted.

When the tire damage is detected early enough, it may be possible to
repair the tire, which increases its service life, or remove the need to
replace the tire in difficult conditions.

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Checking the tire pressure

Check the pressure of the tires using a pressure gauge. The tire filling
pressures are:

Carrier Front wheels Rear wheels Wheel size

DC302R
2,5 bar 2,5 bar 11.5/80 - 15.3
• DB120
NC4
9,5 bar 9,5 bar 8.00 - 15
• DD211
NC5
10 bar 10 bar 12.00 - 20
• DL311 / DL321
NC7
• DD321
• DD411
10 bar 10 bar 12.00 - 20
• DL411 / DL431
• DS411 / DS421
• DT610 / DT611
NC7W
• DD421 8 bar 8 bar 14.00 - 24
• DL421
TC7
• DD410 / DD420
• DL410 / DL420 / 10 bar 10 bar 12.00 - 20
DL430
• DS410 / DS420
TC8
• DD530 / DD531
10 bar 10 bar 14.00 - 24
• DS510 / DS520
• DT820 / DT821
TC9
10 bar 10 bar 14.00 - 24
• DT920i / DT921i
TC10-12
• DT112x - DT123x
• DT112xi - DT123xi 10 bar 10 bar 14.00 - 24
• DT1130-JP
• DT1131-SC

Ensure that the protective caps are reinstalled on the valve steams after
pressure checks and filling procedures have been performed.
Use of lower tire pressure than presented above may lead to
NOTICE premature tire wear and possible tire damage.

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Checking the tire nut tightness

Check the tightening torque of the nuts (lubricated). The tightening torques
are:

Carrier Front wheels Rear wheels Wheel size

DC302R
300 Nm 300 Nm 11.5/80 - 15.3
• DB120
NC4
535 Nm 535 Nm 8.00 - 15
• DD211
NC5
630 Nm 630 Nm 12.00 - 20
• DL311 / DL321
NC7
• DD321
• DD411
630 Nm 630 Nm 12.00 - 20
• DL411 / DL431
• DS411 / DS421
• DT610 / DT611
NC7W
• DD421 630 Nm 630 Nm 14.00 - 24
• DL421
TC7
• DD410 / DD420
• DL410 / DL420 / 630 Nm 630 Nm 12.00 - 20
DL430
• DS410 / DS420
TC8
• DD530 / DD531
740 Nm 740 Nm 14.00 - 24
• DS510 / DS520
• DT820 / DT821
TC9
740 Nm 630 Nm 14.00 - 24
• DT920i / DT921i
TC10-12
• DT112x - DT123x
• DT112xi - DT123xi 450 Nm 630 Nm 14.00 - 24
• DT1130-JP
• DT1131-SC

If any of the nuts is missing, machine shall not be used before all
nuts are in place and correctly fastened.

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5.1.2. Checking the transmission oil level

T20000

2 1

1. Let the engine idle. The oil temperature should be 80–90 °C.
2. Move the drive selector to the middle position.
3. Check the oil level from the dipstick (4). The oil level should be between
the min. and max. levels (preferably closer to the max. level).

HR32000

3 1

5
2

1. Start the engine and let it idle (at 500–600 rpm). Keep the drive selector
in the middle position.

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

Note! Check the hydraulic oil level according to the periodic maintenance
instructions in the maintenance manual.

Note! Observe strict cleanliness replenishing oil. Contaminated oil is a

major cause of premature component failure.

Note! The oil level of the hydraulic oil tank should be checked when all of
the cylinders are retracted and the boom is in transportation
position.

If replenishing is required, use only the same type of oil as already

contained in the system.

MAX

MIN

An indicator (H602B) on the driving panel lights up if the hydraulic oil level
is too low.
Fill up the correct level by looking through the level glass on the side of the
tank. Do not overfill the tank. Avoid mixing oils of different make.

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5.2. Diesel engine MB

5.2.1. Cleaning the coarse filter

The service life of the disposable paper cartridge used in the filter depends
on the coarse filter being emptied regularly. If the coarse filter is not
emptied often enough, the cartridge becomes clogged very quickly. For this
reason, the coarse filter must never be more than half full and so must be
emptied daily. An indicator light (H5) on the gauge panel comes on if the air
filter has become clogged.

1. Empty the coarse filter by pressing the drain valve at the locations
indicated by arrows.
2. Remove any caked dirt by pressing the upper section of the drain valve
together.

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5.2.2. Checking the fuel level and filling the tank

1. Read the fuel level from the fuel gauge (P2). An indicator on the gauge
(P2) lights up if the fuel level is too low.
2. Fill the tank with suitable diesel fuel each day at the end of the shift. This
prevents condensation in the tank when the rig is not in use.

Figure: Vehicle refueling NC7

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Figure: Vehicle refueling TC8

Figure: Vehicle refueling TC11-TC12

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Filling the fuel tank

Handle fuel with care: it is highly flammable.

WARNING
FIRE HAZARD!
Smoking, open flames, and sparks during refueling or handling of
the fuel tank could cause death or severe injury.
Do not refuel the machine while smoking or when near open flame or
sparks.

WARNING! FUEL SPLASHING HAZARD!

The fuel splashing into the eyes could cause severe injury.
Wear eye protectors when refueling the machine.

When filling the fuel tank, follow these instructions:

• Always stop the engine before refueling the machine.
• In addition, switch the cabin heater / air conditioning off.
• Keep the fuel gun in contact with the filling tube.
If this is not possible, arrange for the gun to be earthed in some other
way.
This eliminates possible sparks caused by static electricity.
• Ensure that no fuel is spilled onto hot surfaces.
• Never lock the nozzle lever in motion without looking after it.
• Wipe spilled fuel off before starting the engine.
• Prevent fires by keeping the machine clean of accumulated trash,
grease, and debris.

Note! See separate instructions if the rig is equipped with the Wiggins
fast fuel system.

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5.2.3. Emptying the fuel water separator

An indicator light (H67) on the gauge panel comes on if too much water has
been collected in the water separator.
2

1 5
6

1. Place a receptacle under the separator.

2. Open the drain valve (1).
3. Pump the water out with the hand pump (2).
4. Close the drain valve (1).

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5.2.4. Checking the engine oil level

PROPERTY DAMAGE RISK!

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

The engine must be level when checking the oil level to make sure the
measurement is correct.

Figure: MB904

Figure: MB906

1. Engage the parking brake and shut down the engine.

2. Check the oil level from the dipstick. The oil level must be between the
MIN and MAX marks. An indicator light (H65) on the gauge panel goes
on if the oil level is too low.
3. If the oil level is too low, add oil through the filler opening up to the MAX
mark on the dipstick.

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5.2.5. Checking the coolant level

WARNING
SPLASHING HAZARD!
Explosive release of fluids from pressurized cooling system can
cause serious burns.
Shut off engine. Only remove filler cap when cool enough to touch
with bare hands. Slowly loosen cap to first stop to relieve pressure
before removing completely. Always wear safety gloves and safety
glasses when adding coolant.

WARNING
FALLING HAZARD!
Falling could cause death or severe injury.
Be careful when climbing on the machine.

RISK OF PROPERTY DAMAGE!

Coolant added to the engine must be mixed with the correct
NOTICE proportions of antifreeze, supplemental coolant additive, and water
to avoid engine damage.

Use a mixture of 50-percent water and 50-percent ethylene glycol or

propylene glycol-base antifreeze to protect the engine to -32°C [-25°F]
year-around. Antifreeze is essential in every climate. It broadens the
operating temperature by lowering the coolant freezing point and by raising
its boiling point. The corrosion inhibitors also protect the cooling system
components from corrosion and provides longer component life.
1. Switch the engine off and allow the system to cool.

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2. Check the coolant level on the expansion tank sight glasses.

The coolant level must be between the "MIN" and "MAX" marks. If the
level is below the "MIN" mark, coolant must be added.

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6. PERIODIC MAINTENANCE PROCEDURES

6.1. Carrier
6.1.1. Machine greasing points

Use a grease gun with recommended grease.

FIRE HAZARD!
Accumulated grease or oil on the carrier is a fire hazard.
Remove debris any time a significant quantity oil is spilled on the
carrier.

Lubricate the propeller shaft fittings. All drive line sections are furnished
with grease nipples on universal joints and telescopic sections. Lubrication
must be done carefully to avoid damage of the seals.
Greasing points:
• Propeller shaft fittings
• Seat hinge pins
• Transmission
• Center hinge
• Support bearings
• Rear oscillation
• Cable reel hinges
• Switchgear hinges
• Steering cylinder pins
6.1.2. Checking the planetary gear oil level

1. Rotate the wheel hub so that the center point of the oil filler opening is at
the same horizontal level than the center point of the axle.
2. Remove the oil plug.
3. Check the oil level. The oil level must be at the lower level of the filler
opening.
4. Add oil if necessary. Allow the oil to settle for a few minutes. There is
enough oil when a drop of oil comes out of the opening during filling.
5. Reinstall the oil plug.

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6.1.3. Checking the differential oil level

1. Set the axle and its components in a horizontal position.

2. Clean the breathers.
3. Remove the inspection/filler plugs (A) from the cover of the axle housing.
4. Check the oil level The oil level must be at the bottom of the inspection/
filler plug (A).
5. Add oil if necessary. Allow the oil to settle for a few minutes.
6. Reinstall the inspection/filler plugs (A).
6.1.4. Checking the battery electrolyte level

1. Check the battery electrolyte level.

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6.1.5. Checking the pressure of the brake accumulators

B
A

The pressure should be about 65 bar in TC 7-8 / NC 7 -series carriers.

The pressure should be about 80 bar in TC 9-12 carriers.
The pressure should be about 100 bar in NC 4 carrier.
Check the pressure as follows:
1. Remove the cap (A).
2. Screw the pressure gauge to the filling valve.
3. Undo the lock nut (B).
4. Wait until the needle of the gauge stops and then read the gauge
indication.
5. Close the lock nut (B).
6. Unscrew the gauge from the filling valve and fit the cap (A) in place.
6.1.6. Releasing the pressure from the brake accumulators

To release pressure from the brake accumulators, proceed as follows:

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

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6.1.7. Filling the brake accumulators

The only allowable filling gas is nitrogen (N2 ).

Repair of a pressure accumulator by welding or by other means is

strictly forbidden.

Do not fill an unchecked or a too worn accumulator.

9 7 6 5 4 2 1

10

N2 8 3

If the pressure accumulators need to be filled, do as follows:

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

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13. Release the elbow adapter (10) from the filling valve (1).
14. Tighten the locking nut (2) to 20 Nm.
15. Refit the cap (3).
16. After filling the pressure accumulators, check the brakes as follows:
a) Put the parking brake on.
b) Check that the drive selector is in the middle position (neutral).
c) Start the diesel engine and let it run for at least three minutes and
that you can see the warning lights are turned off.
d) Turn off the diesel engine.
e) Switch the power on by turning the ignition switch to the middle
position.
f) Pump the brake pedal all the way down at least five times and
make sure the brake pressure stays over 80 bars (gauges P3 and
P4).

1 2

1 Pressure gauge and indicator light of front brake circuit (P3)

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

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6.1.8. Bleeding the brakes

WARNING
PERSONAL INJURY HAZARD!
Uncontrolled movement of the brakeless rig could cause death,
severe injury or property damage.
Park the rig on a level surface if possible. Lock the wheels before
bleeding the brakes.

For the trouble-free operation of the parking brakes it is important that the
hydraulic system is entirely free from air. Air may enter the system for
example in connection with component replacements or repairs and as a
result of possible oil leaks. The brake is released through hydraulic
pressure. If the system contains air, this causes the pressure to decrease
and the brake is not released properly, or it will engage after a while. For
this reason the brake circuit must be bled after every repair operation and
also at other times if malfunctions occur.

Bleeding the parking brakes

1. With the engine running and parking brake engaged off.
2. Open the hose connector (B1, inner) slightly and let oil flow out until the
air comes out.
3. Close the connector.
When necessary the above measures must be carried out several times.
After bleeding check the operation of the brakes and adjust them.

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B1 B1

Figure: Bleeding the parking brakes (TC7-TC9, NC 7 -Series)

B1

Figure: Bleeding the parking brakes (TC10-TC12 front axle)

Bleeding the service brakes

If full braking effect is to be achieved, the oil in the centre gears, where the
brakes are located, must not contain any air. The brakes must be bled if air
has for some reason entered the system and the effect of the brakes has
diminished. Make sure the carrier is levelled, and that the wheels are
blocked against movement, before bleeding the brakes.
1. Install plastic tubes on the nipples.
2. Start the engine.

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3. Open the nipples (B2, outer) about half a turn.

4. Press the brake pedal fully down (do not pump it).
5. Close the nipples when the oil is free of air.
Bleed the axle at the other end in the same way.

B2
B2

Figure: Bleeding the service brakes (TC7-9 / NC7-series axles, TC10-12 rear axle)

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B2 B2

Figure: Bleeding the service brakes (TC10-TC12 front axle)

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6.1.9. Checking the tightness of boom support bolts

Boom support fixing bolts may break down and boom support with
booms may fall down if the bolts tightness is not regularly inspected.

Units with canopy

• Disconnect all necessary covers to get access to the bolts.

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

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Units with cabin

Checking the front side bolts

Front side bolts can be checked with the following procedure:
• Disconnect all necessary covers to get access to the bolts.
• Correct tightness of the bolt is 1100 Nm.
• If any of the bolts are missing, slackened or stretched, replace them
immediately with new ones.
• When using new bolts, lubricate the bolts and tighten them to specified
torque.

Checking the rear side bolts (TC7-TC12)

To gain access to tighten the rear bolts properly, the cabin must lift up for
200-350 mm according to following instructions:
• Support the unit to the ground with the jacks.
• With help of crane, support the cabin from the lifting points

• Untighten the rear (2) and front (2) cabin mounting bolts M16x110.
• Disconnect all necessary cables and hoses in order to lift the cabin for
250-350 mm.
- Especially in electrically controlled jumbos disconnect the cable for
the diesel engine.
- Especially in hydraulically controlled jumbos disconnect the cable for
the diesel engine and the boom and drilling hoses from the THC.
• Lift the cabin for 250-350 mm up in order to get access to rear side bolts
• Correct tightness of the bolt is 1100 Nm.
• If any of the bolts are missing, slackened or stretched, replace them
immediately with new ones.
• When using new bolts, lubricate the bolts and tighten them to specified
torque.
• After replacing and tightening the bolts, reconnect all the cables and
hoses.

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• Lower the cabin and refit the bolts and tighten them with correct
tightness.

Checking the rear side bolts (NC7)

To gain access to tighten the rear bolts properly, there is no need to lift the
cabin

• Tighten the bolts via the service hatch.

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

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6.1.10. Replacing the transmission oil filter

Extreme high temperature conditions, extended periods of high

temperature, or difficult climatic conditions will accelerate deterioration and
contamination of the oil.
The normal filter replacement frequency is intended for average
environmental and operational conditions. In extreme conditions, assess
and alter the maintenance frequency according to the conditions.

2 1

Figure: T20000

3 1

5
2

Figure: HR32000

Replace the filter as follows:

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1. Turn off the engine.

2. Open the filter (3) by turning it.
3. Clean the filter housing.
4. Lubricate the rubber seal and install a new filter.
5. Tighten the filter to 2.8–3.4 kpm.
6.1.11. Changing the differential oil

Change the oil while it is warm.

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

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6.1.12. Changing the hydraulic oil

Note! Change the oil according to the periodic maintenance instructions in

the maintenance manual.

To avoid contamination, clean the top of the reservoir before servicing.

Change the oil while it is warm.
Note! Cleanliness is of extreme importance. Before changing oil, the
exterior or the tank must be thoroughly cleaned to prevent the
possibility of dirt and foreign matter entering the system.

Note! Observe strict cleanliness replenishing oil. Contaminated oil is a

major cause of premature component failure.

Note! The oil level of the hydraulic oil tank should be checked when all of
the cylinders are retracted and the boom is in transportation
position.

MAX

MIN

1. Remove the reservoir fill cap and empty the hydraulic reservoir by
removing the drain plug (1).
2. Fill the tank with fresh oil. Use oil as specified in oil recommendation.
3. Remove the tank cover and clean the tank. Check hydraulic reservoir
sight gauges and add fluid as needed.

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6.1.13. Spicer axle types 37R, 43R

This check is recommended to be carried out when the oil in the centre
gear is to be changed.
The operation must be carried out for both sides of the axle.
1. Remove the plug from side of the trumpet arm, next to the center section.
The brake discs can be seen through the hole.
2. Have assistant to start the engine and fully apply the brakes.
3. While keeping the pressure up, check the clearance between the
reaction plates.
4. If the clearance between the reaction plate ears is less than 4,5mm
(0.177 in), replace the friction plates and reaction plates on the both
sides of the axle.

Figure: Checking the brake discs for wear (Spicer axle types 37R, 43R)

6.1.14. Spicer axle types 113, 123, 213

There is no need to check the brake discs.

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

Check the middle-joint bearings by turning the steering back and forth with
small movements. Check the play that may have developed in the middle-
joint bearings. If there is any play, replace the bearings.

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6.1.16. Checking the oscillation axle bearings

Rear-axle oscillation allows the carrier to turn in the longitudinal direction of

the axle.
Lift the rear axle off the ground and, using small movements, check the
play that may have developed in the oscillation bearings. If there is any
play, replace the bearings.

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6.1.17. Changing the transmission oil

Extreme high temperature conditions, extended periods of high

temperature or difficult climatic conditions will accelerate deterioration and
contamination of the oil.
Normal oil replacement frequency is intended for average environmental
and operational conditions. In extreme conditions, assess and alter the
maintenance frequency with consideration of the conditions.

T20000

2 1

1. Drain the oil from the transmission through the drain plug (5) when the oil
is warm.
2. Fill the transmission with fresh oil up to the upper mark on the dipstick
(4).
3. Start the engine and let it idle (at 500–600 rpm).
4. Check the oil level when the engine is running and add oil up to the lower
mark on the dipstick.
5. When the oil temperature is 82.2–93.3 °C, check the oil level and add oil
up to the upper mark on the dipstick.

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HR32000

3 1

5
2

1. Open the drain plug (2) and drain the oil from the transmission when the
oil is warm.
2. When oil has been drained, close the drain plug (2).
3. Open the filler plug (1).
4. Refill transmission to LOW mark (5). Pour fresh oil into the torque
converter through filling hole (1). Refer to table of oil recommendation for
appropriate oil type and quantity.
5. Run engine at 500...600 rpm to prime converter and lines.
6. Recheck level with engine running at 500...600 rpm and add oil to bring
level to LOW mark (5). When oil temperature is hot (82.2 ... 93.3 °C)
make final oil level check. Bring oil level to FULL mark (4).

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6.1.18. Changing the planetary gear oil

Change the oil while it is warm.

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

1. Check the specific gravity of the electrolyte and clean the battery
terminals.

6.1.20. Servicing the Ansul fire suppression system (optional)

Service shall be performed every 1000 hours or every 6 months (whichever

comes first).
Refer to the manufacturer's instructions.

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6.1.21. Maintenance procedures done as required

A B C D E F

SERVICE SERVICE PARKING PARKING CHARGING OF CLUTCH

BRAKE BRAKE BRAKE BRAKE ACCUMULATORS

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

SERVICE SERVICE PARKING PARKING CHARGING OF CLUTCH

BRAKE BRAKE BRAKE BRAKE ACCUMULATORS
NC7, TC7-8
FRONT REAR FRONT REAR
80 bar 80 bar 30 bar 30 bar 135-160 bar 17-19 bar

SERVICE SERVICE PARKING PARKING CHARGING OF CLUTCH

BRAKE BRAKE BRAKE BRAKE ACCUMULATORS
FRONT REAR FRONT REAR
70 bar 70 bar 30 bar 30 bar 135-160 bar 17-19 bar

Figure: Measuring point assembly (284)

Checking the service brake pressure

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

Checking the front axle's parking brake pressure

Follow these steps:
1. Attach a pressure gauge to the front axle's parking brake pressure
inspection point (C).
2. Start the engine.
3. Release the parking brake.

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4. The release pressure should be 100 bar (TC10-12) / 30 bar (TC7–9,

NC7).

Checking the rear axle's parking brake pressure

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

Checking the brake circuit pressure accumulator pressure

Follow these steps:
1. Attach a pressure gauge to the pressure accumulator's pressure
inspection point (E).
2. Start the engine.
3. The pressure should rise quickly to a maximum of 135 bar.

Checking the steering pressure

The pressure must be checked when the oil is at operating temperature
and the engine is running at full speed.

1. Connect the manometer to the checking point (A).

2. Turn the machine to the full turning angle against the end stops.
3. The maximum allowed pressure is 140 bar.
4. If the desired pressure differs from the given value, adjust it by turning
the adjustment screw (B, 263.01) to the desired direction.

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6.2. Diesel engine MB

6.2.1. Replacing the engine oil and filter

Note! Change the engine oil while the engine is warm.

WARNING! BURN HAZARD!

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

Special tool: oil filter opener

Open the oil filter cover with the
oil filter opener. Empty the filter
housing of oil.

Remove the cover (1) and the

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

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Siphoning/draining engine oil

Suction the engine oil off

through the dipstick tube.
Remove the dipstick
(arrow) and push the
suction device (cup) with
the O-ring seal to the
dipstick tube.

Alternative method:
Place a suitable
receptacle under the oil
drain plug in the oil pan.
Open the drain plug
carefully, and let the oil
flow out.

Dispose of the engine oil and filter in accordance with the applicable
regulations.

Replace the cover seal

(2).
Place a new filter
element to the cover and
press the filter until it
clicks into place.
Screw the cover to the oil
filter housing and tighten
the cover to the correct
tightness. The tightening
torque is 25 Nm.

If the engine oil is drained through the oil pan, replace the drain plug with
a new seal and tighten the plug to the correct tightness. The tightening
torque is 80 Nm.

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Add new engine oil

through the filler opening
neck (arrow) until the oil
level is in the level of the
max mark in the dipstick.

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

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6.2.2. Replacing the fuel filter

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

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6.2.3. Replacing the fuel water separator filter

5
1

1. Place a receptacle under the separator.

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

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6.2.4. Checking the condition of poly V-belt

Special tool (turning tool) required.

Figure: Inspection hole, flywheel housing

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

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Figure: Damage patterns

1 Condition as new 2 Wear on one side (wedge-
(trapezoidal ribs) shaped ribs)
3 Cord visible in base of ribs 4 Ribs split
5 Transverse cracks in several 6 Nodules of rubber in base of
ribs belt
7 Deposits of dirt/stones 8 Rips separated from base of
belt
9 Cord torn out to the side 10 Outer cords frayed
11 Transverse cracks on the 12 Transverse cracks in several
reverse of belt ribs

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Removing/installing poly V-belt

ENTANGLEMENT HAZARD!
The tensioning mechanism is springloaded and could cause severe
injury.
Use proper service tools and be careful.

Figure: Removing/installing poly-V-belt

1. Plug the spanner (2) with a 17 mm socket insert onto the hexagonal bolt
on the tensioner pulley (1).
2. Turn the tensioner pulley upwards and remove the poly-V-belt.
3. Turn the tensioning mechanism back.
4. Check the tensioning mechanism and pulleys for damage (e.g. worn
bearing on tensioning mechanism, tensioner and deflector pulleys, or
pattern wear on poly-V-belt pulleys). If necessary, renew parts.
5. Lay the poly-V-belt (new) on all the pulleys except for the tensioner pulley
(see illustrations for correct routing of the poly-V-belt).
6. Turn the idler pulley upward with the handle, place the poly-V-belt onto
the idler pulley and turn the idler pulley downward.
7. Remove the handle and check that the poly-V-belt is seated correctly on
the pulleys.

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Figure: Routing of poly-V-belt (engine without refrigerant compressor)

1 Crankshaft
2 Generator
3 Coolant pump
4 Tensioner pulley

Figure: Routing of poly-V-belt (engine with refrigerant compressor)

1 Crankshaft
2 Generator
3 Coolant pump
4 Tensioner pulley
5 Refrigerant compressor
6 Deflector and guide pulley

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Figure: guard for alternator

When installing the body V-belt, make sure that the guard for alternator is
installed back on its place.
6.2.5. Checking the engine for leaks and general condition

Check the engine visually for signs of leakage. Slight dampness at sealing
points is acceptable.
Cause for more severe leaks must be identified and repaired without delay.
6.2.6. Checking the lines and hoses of the engine

1. Check for leaks and general condition.

2. Visually inspect lines and hoses. At the same time, check that all pipes
and hoses are undamaged, correctly positioned to avoid abrasion, and
properly secured.
6.2.7. Checking the intake pipe between air cleaner and engine

1. Check that rubber boots, intake pipes and connecting hoses are
undamaged and free from leaks.
2. Check tightness of hose clips, flange connections and the intake
manifold.

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6.2.8. Checking the engine cooling system

Check fluid level and corrosion inhibitor/antifreeze concentration, and

correct if necessary.
Only use service products approved by engine manufacturer.

WARNING
BURN HAZARD!
Hot and pressurized coolant can cause serious burns.
Never open the cap of the engine cooling system if the coolant is at
normal operating temperature. Only check and correct coolant level
when the coolant temperature is below 50 °C. Remove cap slowly.
Use safety gloves.

Before correcting the coolant level, check the corrosion inhibitor/antifreeze

concentration. When topping up, use only a pre-prepared coolant mixture
containing 50% corrosion inhibitor/antifreeze by volume.
1. Open the cap of the engine cooling system slowly to allow excess
pressure to escape.
2. Check the concentration of corrosion inhibitor/antifreeze with a suitable
tester. The correct concentration of corrosion inhibitor/antifreeze, that is
50% by volume, protects the system down to a temperature of -37 °C. If
a lower level of antifreeze protection is shown, correct the concentration.
If the concentration is too low, there is a risk of corrosion/cavitation in the
cooling system. Concentrations of more than 55% by volume should not
be used, as this is the level which affords maximum antifreeze protection
(down to -45 °C), when higher concentrations adversely affect heat
dissipation.
3. Check the coolant level. The cooling system is correctly filled when the
coolant has reached the mark in the filler neck.

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6.2.9. Replacing the intake air cleaner filter

3 4 1

1. Undo clip fasteners (1).

2. Take off hood (2) and remove cartridge (3).
3. Clean cartridge (replace at least once a year).
4. Clean cartridge (3).
a) Using dry compressed air (max. 5 bar), blow out from inside
outwards, or
b) Tap out (in emergencies only). Do not damage the cartridge, or
c) Wash out according to manufacturer’s specifications
5. Check paper filter (light showing through) and gaskets for damage.
Replace if necessary.
6. After five filter services or after two year at the latest, replace safety
cartridge (4) (never clean!).
7. Install cartridge (3), replace hood (2) and do up clip fasteners (1).

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6.2.10. Adjusting the valve clearances

Layout of cylinders and valves

Figure: Valve clearance adjustment

WHITE ARROW = Inlet valve

BLACK ARROW = Exhaust valve
X = Flywheel end
Special tool (turning tool) required.

Valve clearance
Inlet valves = 0,40 mm
Exhaust valves = 0,60 mm
Note! Adjust the valve clearance when the engine is cold (at least 30
minutes after it was switched off, even if it was only run for a short
time). Clean a heavily soiled cylinder head cover before removing it.

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Removing/installing cylinder head cover

Figure: Removing/installing cylinder head cover

1. Remove the cover.

2. Remove the crankcase breather hose (6) from the cylinder head cover.
3. Unscrew the hexagon socket-headed bolt (2) from the cylinder head
cover, together with its sealing washer (3). To install: Insert the hexagon
socket-headed bolt with a new sealing washer and tighten with a
tightening torque of 30 Nm.
4. Remove cylinder head cover.
To install: Clean the sealing surfaces of the cylinder head and the cylinder
head cover as necessary. Check the gasket between the cylinder head
cover and the charge air manifold (1). Renew as necessary. The gasket (5)
between the cover and the cylinder head must always be renewed.
The cylinder head cover is installed in reverse order.
Fit the turning tool into the inspection hole on the flywheel housing.

Valve clearance adjustment - method 1

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

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Engine
OM 906 LA Injection sequence 1 5 3 6 2 4
OM 906 LA Overlap 6 2 4 1 5 3

Figure: Inspection hole, flywheel housing

Valve clearance adjustment - method 2

All valves can be adjusted in two crankshaft positions.
• Use the turning tool to turn the crankshaft until No. 1 cylinder is at the
ignition TDC position or at the overlap TDC position (at ignition TDC, all
valves are closed and the valves of No. 4 cylinder overlap).
• Check and adjust valves in accordance with the following table.
Crankshaft position Cylinders/valves to be
Engine
No. 1 cylinder adjusted
1 2 3 4 5 6
OM 904 LA Ignition TDC I/E I E -
OM 904 LA Overlap TDC - E I I/E
OM 906 LA Ignition TDC I/E I E I E -
OM 906 LA Overlap TDC - E I E I I/E

I - Inlet valve
E - Exhaust valve

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Checking/adjusting valve clearance

Figure: Peephole, flywheel housing

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

Concluding operations
1. Reinstall cylinder head cover.
2. Remove the turning tool from the inspection hole in the flywheel housing.

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6.2.11. Cleaning the fuel pre-filter

1. Clean the outside of the fuel pre-filter and cover over any hoses or pipes
located beneath it.
2. Unscrew the filter bowl (1).
3. Clean the filter bowl (1) and filter element (2). Note! If the filter element is
heavily soiled or damaged, it should be renewed. Dispose of the used
filter and of residual fuel in accordance with applicable rules and
regulations.
4. Check the seal (3) for the filter casing and renew if necessary.
5. Insert the filter element (2) into the filter bowl (1) and screw the filter bowl
onto the filter casing with a tightening torque of 10 Nm.

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6.2.12. Checking the general condition of cooling and heating system

Check the general condition and look for possible leaks.

Special tool (pressure tester) required.
Note! The fluid level and corrosion inhibitor/antifreeze concentration
(correcting if necessary) must be checked first.

Note! A safety valve is incorporated into the tester to prevent the pressure
from exceeding 1,2 bar.

Figure: Compressed air valve

1. On heating systems, open the regulating and cut-off valves.

2. Remove the cap from the coolant expansion tank.
3. Connect up the tester.
4. Connect the compressed air hose with the tyre inflation union to the valve
and allow pressure to build up to a level corresponding to the opening
pressure of the cooling system. The opening pressure of the cooling
system can be identified from the code on the cap or on the pressure
relief valve. Example: Code 70 = 0.7 bar gauge pressure.
5. Check all radiators, the coolant pump, the engine oil cooler, the engine
covers (corehole covers) and the heat exchanger for leaks.
6. Check all pipes and hoses for the cooling and heating system for
freedom from leaks and damage, correct positioning to avoid abrasion
and secure fastening in the specified manner.
7. Check the radiator for external contamination. The fins must not be
clogged with dirt.
8. Relieve pressure in the cooling and heating system at the valve on the
tester. Remove and re-attach the cap.
9. Close the heating system regulating valves.

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6.2.13. Renewing the coolant

Only use a corrosion inhibitor/antifreeze approved by Mercedes-Benz.

WARNING
BURN HAZARD!
Hot and pressurized coolant could cause serious burns.
Never open the cap of the engine cooling system if the coolant is at
normal operating temperature. Only check and correct coolant level
when the coolant temperature is below 50 °C. Remove cap slowly.
Use safety gloves.

Note! Before renewing the coolant, check that the cooling and heating
system is in good condition and free from leaks. Confirm the coolant
renewal with an entry in the Maintenance Booklet.

Note! There are other drain plugs, for example on the radiator. Pipes etc.
below the drain plugs should first be covered over and a receptacle
suitable for the quantity of coolant should be placed underneath.

Figure: Coolant drain plug

1. Open the cap of the engine’s cooling system slowly to allow excess
pressure to escape and remove the cap.
2. On heating systems: Open the heating system regulating valves.
3. To drain the coolant from the engine, attach the hose (interior diameter
approx. 12,5 mm) to the drain plug on the engine. The coolant will drain
off after the plug has been turned through 1 to 2 turns.
Dispose of the used coolant in accordance with applicable legal
stipulations.
4. Free drain apertures if blocked by deposits.
5. Screw in the coolant drain plug on the engine tight again and remove the
drain hose.
6. Screw in other drain plugs (without hose connection) with new seals.

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7. Add coolant in the specified concentration until the mark in the filler neck
is reached. Seal the cooling system again.
8. Start the engine and run it for about 1 minute at varying speeds.
9. Stop the engine and check the coolant level. Top up if necessary.

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7. LUBRICATION SPECIFICATIONS AND FILLING

CAPACITIES
7.1. Lubrication specifications
WARNING! HEALTH AND ENVIRONMENTAL HAZARD!
Skin contact and inhalation of vapors when handling fluids could
cause damage to human health.
Incorrect disposal of fluids and greases could cause damage to the
environment.
Use personal protective equipment when handling fluids and
greases, and dispose of all fluids and greases in accordance with
local regulations.

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

WARNING! POISONING HAZARD!

Risk of severe injury or death.
Consult a doctor immediately if any service product is swallowed.
Keep service products out of the reach of children.

Components of the engine and the lubricants must be carefully matched

together. For this reason, only brands which have been tested and
approved by Mercedes-Benz should be used. These are stated in the
Mercedes-Benz Specifications for Service Products.
No special lubricant additives are needed. The use of additives could affect
warranty rights.
Information is available from any Mercedes-Benz Service Station.
Dispose of service products and parts which have been in contact with
lubricants (e.g. filters) in an environmentally responsible manner. Comply
with legal requirements.

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Diesel fuels

Only use commercially available vehicle diesel fuel (DIN EN590). Grades
such as marine diesel fuel, heating oil etc are not permissible.
No fuel additives are needed. The use of fuel additives could affect
warranty rights.
If diesel fuel with a sulphur content exceeding 0.3% by weight is used,
change the engine oil at shorter intervals. Comply with the instructions in
the Maintenance Booklet.
Note! If the Telligent maintenance system is used, the sulphur content of
the diesel must be entered in the system or adapted to the current
value.

Fuel added from drums or cans could be contaminated. This could lead to
malfunctions in the fuel system. Always filter the fuel before adding it to the
tank.

Diesel fuel in extreme cold

At low ambient temperatures, paraffin may separate from the diesel and
affect its ability to flow freely.
To avoid breakdowns caused by this problem (e.g. blocked filters), diesel
fuel with improved low-temperature flow characteristics is sold during the
winter months. Differences are possible in different countries and in the
transitional periods before and after the cold season. In Germany,
particularly cold-resistant winter diesel fuels keep the engine operational
down to a temperature of approximately -20 °C. In most cases, winter-
grade diesel can be used without problems at the ambient temperatures
encountered locally.
If summer-grade diesel, or a less cold-resistant winter-grade diesel is in
use, a flow improver or kerosene can be added to it, the actual quantity
being dependent on the ambient temperature.
Do not add petrol (gasoline) to the diesel.
Mix the flow improver or kerosene with the diesel in good time, before the
fuel’s flow characteristics have been adversely affected by paraffin
separation. If faults have already been caused by paraffin separation, they
can only be rectified by heating the entire fuel system. Do not add anything
to cold-resistant winter-grade diesel fuels. The fuel’s low-temperature flow
characteristics could actually deteriorate with such an additive.

Flow improver
The effectiveness of flow improver is not guaranteed with all fuels. Comply
with the product manufacturer’s recommendations. Any Mercedes-Benz
Service Station can provide information on approved flow improver.

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Kerosene
Keep the quantity added as low as possible, bearing in mind the ambient
temperature. The addition of 5 % by volume of kerosene will improve the
fuel’s resistance to cold by about 1°C. Never add more than 50 % kerosene
to the fuel.
For reasons of safety, add the kerosene to the diesel only in the fuel tank.
Add the kerosene first, then the diesel. Run the engine for a short time to
allow the mixture to reach all parts of the fuel system.
FIRE AND EXPLOSION HAZARD!
Diesel fuel is combustible and could cause severe personal injury or
death.
The addition of kerosene lowers the flash point of the diesel. This
increases the risk involved when handling the fuel mixture.
Comply with appropriate safety regulations.

The use of fuel that is approved by Daimler Chrysler AG and published in

the applicable fuel specifications is an integral part of Daimler Chrysler
warranty conditions.
Note! If Daimler Chrysler fuel specifications are not observed or if products
are used that have not been approved in writing by Daimler Chrysler
AG, serious engine damage is to be expected.

Customers, Customer Care and Manufacturing are to be informed (e.g. by

means of the Equipment Operating Instructions or a separate memo) of
Daimler Chrysler fuel specifications, in order that they can be adhered to.

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Engine oils

Engine oils are specially tested to ensure their suitability for Mercedes-
Benz engines. For this reason, use only engine oil brands which Mercedes-
Benz has approved. These are stated in the Mercedes-Benz Specifications
for Service Products. Comply with the instructions in the Maintenance
Booklet.
The use of non-approved engine oils could affect warranty rights.
Information is available from any Mercedes-Benz Service Station.
Select the SAE classification of the engine oil in accordance with ambient
temperatures.
When maintenance work is performed, engine oil changes will be recorded
in the Maintenance Booklet, together with details of the brand, quality
category and SAE classification of the oil.
When topping up, only use engine oils of the same quality and SAE
classification.
Note! If an oil of a lower quality grade is added, the characteristics of the
oil will be adversely affected. Oil change and filter replacement
should then be performed earlier.

Note! For detailed information on oil recommendations, refer to the

"Lubricant and coolant recommendation" instructions.

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Coolant

The coolant is a mixture of water and a combined corrosion inhibitor/

antifreeze. For reasons of anti-corrosion protection and to raise the boiling
point the coolant must remain in the cooling system all year round.
Renew the coolant every three years as the degree of corrosion protection
gradually drops with time.

Water
Water containing no additives is not suitable as a coolant, even if no
antifreeze protection is needed.
The water used in the coolant must comply with certain requirements,
which are not always satisfied by drinking water.
If water quality is inadequate, the water must undergo suitable treatment.
Information is available from any Mercedes-Benz Service Station.

Corrosion inhibitor / antifreeze

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

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Coolant mixing ratio

Refer to the "Lubricant and coolant recommendation" instructions.

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

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

Note! Refer to the "Lubricant and coolant recommendation" instructions.

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7.1.3. Power shifted transmission and torque converter

Oil specification
Recommended lubricants:

1. Caterpillar TO-4
2. John Deere J20 C, D
3. Military MIL-PRF-2140G
4. Allison C-4
5. Dexron II Equivalent - see note below

Note! Dexron II equivalent is acceptable; however it is not compatible with

torque converters or transmissions equipped with graphitic friction
material clutch plates.

Note! Dexron III, engine oil or GL-5 oils are not recommended

Preferred oil viscosity

It is recommended that the highest viscosity monograde lubricant available
be used for the anticipated ambient temperature. Typically this will be a
CAT TO-4 qualified lubricant. When large swings in ambient temperature
are probable, J20 C, D multigrades are recommended. Multigrades
lubricants should be applied at the lower viscosity rating for the prevailing
ambient temperature, i.e. a 10W20 should be used where a 10W
monograde is used. If a C-4 multigrades is used in stead of J20 lubricant it
is recommended that the viscosity span no more than 10 points, i.e.
10W20.
Note! Synthetic lubricants are approved if qualified by one of the above
specifications. Oil viscosity quidelines apply, but synthetic
multigrades may span more than 10 points.

7.1.4. Hydraulic system

Note! Refer to the "Lubricant and coolant recommendation" instructions.

7.1.5. Greasing

Note! Refer to the "Lubricant and coolant recommendation" instructions.

7.2. Filling capacities

For further information and fluid specific environmental, safety and health
instructions, refer to the technical data and material safety data sheets in
the appendix Factory filled oils, lubricants and coolants for underground
rigs.

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CLASSIFICATION
FIRST FILLING
ITEM CAPACITY RECOMMENDATI NOTE!
OIL/FLUID
ON
CF, CF-4, CG-4,
Diesel engine ACEA E3, Shell Rimula R3 First filling with oil
15 l
(MB 904 LA) MB228.4, X 15W-40 filter
Caterpillar ECF-1
CF, CF-4, CG-4,
Diesel engine ACEA E3, Shell Rimula R3 First filling with oil
28 l
(MB 906 LA) MB228.4, X 15W-40 filter
Caterpillar ECF-1
Driveline
gearbox 22 l GM Allison C-4 Shell Donax TM
(T20000)
Driveline
gearbox 25 l GM Allison C-4 Shell Donax TM
(HR32000)
1.7 l / planetary
Front/rear axle
gear Shell Donax TD
(Axle 123, wet API GL-4
8 l / differential 10W-30
brake)
gear
2.3 l / planetary
Front/rear axle
gear Shell Donax TD
(Axle 113, wet API GL-4
16 l / differential 10W-30
brake)
gear
1.6 l / planetary
Front/rear axle
gear Shell Donax TD
(Axle 213, wet API GL-4
14 l / differential 10W-30
brake)
gear
Front/rear axle
Shell Donax TD
(Axle 37R/43R, 45 l API GL-4
10W-30
wet brake)
Hydraulic oil Viscosity class is
DIN 51524 part 2
tank, drilling Shell Tellus Oil S chosen according to
210 l (HLP), ISO 6743-4
TC7/TC8 (DS 68 or 100 the operating
(HM)
rigs) conditions
Hydraulic oil Viscosity class is
DIN 51524 part 2
tank, drilling Shell Tellus Oil S chosen according to
290 l (HLP), ISO 6743-4
(TC8 and NC7- 68 or 100 the operating
(HM)
series) conditions
Viscosity class is
Hydraulic oil DIN 51524 part 2
Shell Tellus Oil S chosen according to
tank, drilling 380 l (HLP), ISO 6743-4
68 or 100 the operating
(TC9) (HM)
conditions

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Drill carrier TC7-TC12, NC7 Series

CLASSIFICATION
FIRST FILLING
ITEM CAPACITY RECOMMENDATI NOTE!
OIL/FLUID
ON
Viscosity class is
Hydraulic oil DIN 51524 part 2
Shell Tellus Oil S chosen according to
tank, drilling 470 l (HLP), ISO 6743-4
68 or 100 the operating
(TC10–TC12) (HM)
conditions
SAE 75 W / 90 API
Cable reel GL5 Esso GX 85
2.7 l
gearbox SAE 80 W / 90 API W-140
GL5
Compressor Shell AEON
5l API CE/CF
(CT10/16) 3000
Compressor Shell AEON
8l API CE/CF
(CT28) 3000
Compressor Shell AEON
11 l API CE/CF
(CT40) 3000
Shank
lubrication Shell Torcula Oil
14 l Sandvik
(Rig with 1 or 2 100
booms)
Shank
lubrication Shell Torcula Oil
22 l Sandvik
(Rig with 3 100
booms)
Air conditioner
refrigerant 1900 g Sandvik R-134a
(TC7 carrier)
Air conditioner
refrigerant
2000 g Sandvik R-134a
(TC8 and NC7-
series carriers)
Air conditioner
refrigerant 1900 to 2000 g Sandvik R-134a
(TC9–12 carrier)
Refer to the
separate air ISO-100 (high
Air conditioner conditioner viscosity) or Sanden PAG
oil level manual, ID 463, ISO-46 (low SP-20 / SP-10
for the viscosity)
capacities.
Fuel, diesel Thermoshell
150 l EN 590
engine Winter 1202

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CLASSIFICATION
FIRST FILLING
ITEM CAPACITY RECOMMENDATI NOTE!
OIL/FLUID
ON
Diesel engine
BS 6580, AFNOR, GlycoShell
coolant 22 l
ASTM D 3306 consentrate
(MB 904 LA)
Diesel engine
BS 6580, AFNOR, GlycoShell
coolant 27 l
ASTM D 3306 consentrate
(MB 906 LA)

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Drill carrier TC7-TC12, NC7 Series

8. DRILL CARRIER TROUBLESHOOTING

8.1. Troubleshooting guide for hydraulics
Trouble Location Probable cause(s) Remedy
The relief valve is Check and adjust the
Steering
Steering is very stiff damaged or the pressure. Change a new relief
hydraulics
adjustment has altered. valve when necessary.
Hydraulic pump has
Steering is very stiff Engine side Change a new pump.
damaged.
The cylinder leakage can be
ascertained by operating the
The steering cylinder steering several times to see
Steering is very stiff Engine side
seals are leaking. whether the cylinder heats up
in abnormal way. Change the
cylinder seals.
Steering valve is Change a new steering unit.
Steering is very stiff Engine side
damaged. Maintain strict cleanness.
Carry out bleeding by driving
Steering is sticking Air in the steering the steering to extreme
Steering
and unsteady system. positions a few times. Check
the inlet side of the pump.
Steering is sticking
Steering Steering valve worn. Change the steering valve.
and unsteady
Steering is sticking Steering column bearing
Steering Change the bearing.
and unsteady worn.
Service brake does Service brake Internal leak in the brake
Change the cylinder seals.
not hold system cylinders.
Check the brake valve spring,
Service brake does Service brake and change if necessary.
Too low brake pressure.
not hold system Check and adjust the pressure
in the hydraulic system.
Service brake does Service brake
Air in the brake system. Bleed the system.
not hold system
Service brake does Service brake Brake plates are worn Check the brake plates, and
not hold system out. change if necessary.
Parking brake does Parking brake Brake plates are worn
Renew the brake plates.
not hold system out.
Parking brake does Parking brake Lack of power of parking
Renew the springs.
not hold system brake cylinder springs.
Oil leak in the parking
Parking brake does Parking brake brake valve, thus
Change the brake valve.
not hold system pressure in the spring
brake.

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Trouble Location Probable cause(s) Remedy

Parking brake does Parking brake
Air in the system. Bleed the system.
not release (open) system
Check the pressure, adjust
Parking brake does Parking brake Releasing pressure too
according to the workshop
not release (open) system low.
manual.
Parking brake does Parking brake Oil leak in the brake
Change the seals.
not release (open) system cylinder.

8.2. Troubleshooting guide for the power shift transmission

The following information is presented as an aid ti isolating and determining
the specific problem area in a transmission that is not functioning correctly.
When troubleshooting a “transmission” problem, it should be kept in mind
that the transmission is only the central unit of a group of related power
train components. Proper operation of the transmission depends on the
condition and correct functioning of the other components of the group.
Therefore, to properly diagnose a suspected problem in the transmission, it
is necessary to consider the transmission fluid, charging pump, torque
converter, transmission assembly, oil cooler, filter, connecting lines, and
controls, including the engine, as a complete system.
By analyzing the principles of operation together with the information in this
section, it should be possible to identify and correct any malfunction which
may occur in the system.
Transmission (power shift with torque converter transmission) troubles fall
into three general categories:
• Mechanical problems
• Hydraulic problems
• Electrical problems
In addition to the mechanical and electrical components, all of which must
be in the proper condition and functioning correctly, the correct functioning
of the hydraulic circuit is most important. Transmission fluid is the “life
blood” of the transmission. It must be supplied in an adequate quantity and
delivered to the system at the correct pressures to ensure converter
operation, to engage and hold the clutches from slipping, and to cool and
lubricate the working components.

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Stall test
A stall test to identifies transmission, converter, or engine problems. Use
following procedure:
1. Put the vehicle against a solid barrier, such as a wall, and/or apply the
parking brake and block the wheels.
2. Put the directional control lever in FORWARD (or REVERSE, as
applicable).
3. Select the highest speed. With the engine running, slowly increase
engine speed to approximately one-half throttle and hold until
transmission (converter outlet) oil temperature reaches the operating
range.
Note! Do not operate the converter at stall condition longer than 30
seconds at one time, shift to neutral for 15 seconds and repeat the
procedure until desired temperature is reached. Excessive
temperature 120 °C (250 °F) maximum will cause damage to
transmission clutches, fluid, converter, and seals.

Pressure checks
Transmission problems can be isolated by the use of pressure tests. When
the stall test indicates slipping clutches, then measure clutch park pressure
to determine if the slippage is due to low pressure or clutch plate friction
material failure.
In addition, converter charging pressure and transmission lubrication
pressure can also be measured.

Mechanical and electrical checks

Prior to checking any part of the system for hydraulic function (pressure
testing), the following mechanical and electrical checks should be made:
• Check the parking brake and inching pedal for correct adjustment.
• Be sure all lever linkage is properly connected and adjusted in each
segment and at all connecting points.
• The controls are actuated electrically. Check the wiring and electrical
components.
• Be sure that all components of the cooling system are in good condition
and operating correctly. The radiator must be clean to maintain the
proper cooling and operating temperatures for the engine and
transmission. Air clean the radiator, if necessary.
• The engine must be operating correctly. Be sure that it is correctly tuned
and adjusted to the correct idle and maximum no-load governed speed
specifications.

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Hydraulic checks
Also, before checking the transmission clutches, torque converter, charging
pump, and hydraulic circuit for pressure and rate of oil flow, it is important
to make the following transmission fluid check:
Check oil level in the transmission. The transmission fluid must be at the
correct (full level). All clutches and the converter and its fluid circuit lines
must be fully charged (filled) at all times.
The transmission fluid must be at operating temperature of 82...93 °C
(180...200 °F) to obtain correct fluid level and pressure readings. Do
not attempt to make these checks with cold oil.

To raise the oil temperature to this specification it is necessary to either

operate (work) the vehicle or run the engine with converter at “stall” (Refer
to “Stall test”).
Be careful that the vehicle does not move unexpectedly when
operating the engine and converter at stall rpm.

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Troubleshooting guide
Refer to the following troubleshooting guide for the diagnosis of typical
transmission troubles.

Trouble Probable cause Remedy

Low clutch pressure Low oil level Fill to proper level.
Clutch pressure regulating valve
Low clutch pressure Clean valve spool and housing.
stuck open
Low clutch pressure Faulty charging pump Replace pump.
Broken or worn clutch shaft or
Low clutch pressure Replace sealing rings.
piston sealing rings
Clutch piston bleed valve stuck
Low clutch pressure Clean bleed valves thoroughly.
open
Low charging pump
Low oil level Fill to proper level.
output
Low charging pump
Suction screen plugged Clean suction pump.
output
Low charging pump
Defective charging pump Replace pump.
output
Remove, disassemble, and rebuild
Overheating Worn oil sealing rings
converter assembly.
Overheating Worn charging pump Replace charging pump.
Overheating Low oil level Fill to proper level.
Overheating Dirty oil cooler Clean cooler.
Overheating Restriction in cooler lines Change cooler lines.
Noisy converter Worn charging pump Replace charging pump.
A complete disassembly will be
Noisy converter Worn or damaged bearings necessary to determine which
bearings is faulty.
Lack of power Low engine RPM at converter stall Tune engine check governor.
See “Overheating” and make Make corrections as explained in
Lack of power
same checks. “Overheating”.

8.3. Troubleshooting guide for the axle

Most operating problems are due to improper operation or maintenance of
the axle.
In the event of trouble, always check whether the operating instructions
have been strictly followed.

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Problem Possible cause Repair

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

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 Original instructions
BG00201574 A.1 2013-07-12

Steering and braking system, TC7-

TC12, NC7
Steering and braking system, TC7-TC12, NC7

Table of Contents

1. Introduction ................................................................... 1
1.1. The Purpose of these instructions ......................................................1
1.1.1. Validity of the manuals ................................................................ 1

2. Main components ..........................................................3

2.1. Components ..........................................................................................3
2.1.1. Double pressure relief valve (261) .............................................. 3
2.1.2. Priority valve (262) ...................................................................... 3
2.1.3. Steering valve (263) .................................................................... 4
2.1.4. Integrated brake valve (267) ....................................................... 5
2.1.5. Parking brake control valves (270, 344) ......................................6
2.1.6. Middle-joint locking valves (288, 289), TC7-TC8, NC7 rigs with
frame ........................................................................................... 7
2.1.7. Steering reversing valve (290), TC9-TC12 (optional) ..................8
2.1.8. Emergency steering control valve (295) ......................................9
2.1.9. Pressure accumulator (296) ........................................................ 9
2.1.10. Charging valve (297) ................................................................... 10
2.1.11. Release valve of the pressure accumulator (299) .......................10
2.1.12. Service brake testing valves (281, 282) ...................................... 11
2.2. Parking and service brakes ................................................................. 11
2.2.1. Parking and service brake cylinders TC7-TC9/NC7 axles,
TC10-TC12 rear axle ...................................................................12
2.2.2. Parking brake cylinder, TC10-TC12 front axle ............................ 13

3. Steering and brake circuit diagrams ........................... 15

3.1. Steering circuit diagram, NC7 ............................................................. 15
3.1.1. Components for NC7 ...................................................................16
3.2. Steering circuit diagram, TC7-TC8 ......................................................17
3.2.1. Components for TC7-TC8 ........................................................... 18
3.3. Steering circuit diagram, TC9-TC12 ....................................................19
3.3.1. Components for TC9-TC12 ......................................................... 20
3.4. Brake circuit diagram, NC7 ..................................................................21
3.4.1. Components for NC7 ...................................................................22
3.5. Brake circuit diagram, TC7-TC8 .......................................................... 25
3.5.1. Components for TC7-TC8 ........................................................... 26
3.6. Brake circuit diagram, TC9 .................................................................. 29
3.6.1. Components for TC9 ................................................................... 30
3.7. Brake circuit diagram, TC10-TC12 ...................................................... 33
3.7.1. Components for TC10-TC12 ....................................................... 34

4. Parking and service brakes operation ........................ 37

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4.1. Parking brake circuit, TC7-TC12, NC7 ................................................ 37

4.1.1. Engaging and releasing the parking brakes ................................ 38
4.1.2. Parking brake circuit functional diagram (engaging), NC7 .......... 40
4.1.3. Parking brake circuit functional diagram (engaging), TC7/TC8 ...42
4.1.4. Parking brake circuit functional diagram (engaging), TC9 .......... 44
4.1.5. Parking brake circuit functional diagram (engaging), TC10-TC12
.................................................................................................... 46
4.1.6. Parking brake circuit functional diagram (releasing), NC7 .......... 48
4.1.7. Parking brake circuit functional diagram (releasing), TC7/TC8 ...50
4.1.8. Parking brake circuit functional diagram (releasing), TC9 ...........52
4.1.9. Parking brake circuit functional diagram (releasing), TC10-TC12
.................................................................................................... 54
4.2. Service brake circuit, TC7-TC12, NC7 .................................................55
4.2.1. Service brake circuit functional diagram, NC7 ............................ 56
4.2.2. Service brake circuit functional diagram, TC7-TC8 .....................60
4.2.3. Service brake circuit functional diagram, TC9 .............................64
4.2.4. Service brake circuit functional diagram, TC10-TC12 .................68
4.2.5. Operation of the ABA-system ......................................................70
4.3. Testing the brakes ................................................................................ 71
4.3.1. Service brake testing system, TC7-TC12, NC7 (optional) .......... 73
4.4. Emergency steering, TC7-TC8, NC7 (optional) .................................. 82
4.4.1. Functional diagram of emergency steering, TC7-TC8, NC7 ....... 82
4.4.2. Components ................................................................................ 83
4.4.3. Operation of the emergency steering .......................................... 84

5. Steering and brake system troubleshooting .............. 85

5.1. Steering ................................................................................................. 85
5.2. Brakes ....................................................................................................86

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1. INTRODUCTION
1.1. The Purpose of these instructions
This manual contains supplementary information for operation,
maintenance and repair of a component.
Before operating, or performing maintenance or repair procedures for the
component or system described in this manual, read and understand the
information in operator´s and maintenance manuals supplied with the
machine. Pay special attention to the safety information in chapter "2 Safety
and environmental instructions" of those manuals.
1.1.1. Validity of the manuals

This manual, and especially the safety information, is valid only if no

unauthorized changes to the product are made.
Continuing improvement and advancement of product design might have
caused changes to your product which are not included in this publication.
Note also that if a third party has made changes to the product after
delivery from the manufacturer, this publication does not include
information on these changes or their influences on the product.
Whenever a question arises regarding your product, or this manual, please
consult your local Sandvik representative for the latest available
information.

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2. MAIN COMPONENTS
2.1. Components
2.1.1. Double pressure relief valve (261)

The double pressure relief valve limits the maximum pressure of gear
pumps (251) and (252).

.01 .02

.01 Pressure relief valve

.02 Pressure relief valve
.03 Anti-cavitation valve
.04 Anti-cavitation valve

2.1.2. Priority valve (262)

The priority valve distributes the oil delivered from the gear pump (251)
primarily to the steering or secondarily to the carrier auxiliary functions.

.01 Orifice
.02 Orifice
.03 Orifice

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2.1.3. Steering valve (263)

The steering valve distributes oil to the steering as necessary.

The steering unit consists of a rotary valve and a rotary meter. When the
steering wheel is turned, oil is directed via the rotary valve and rotary meter
to cylinder port L or R. The rotary meter measures the oil flow to the
steering cylinder in proportion to the angular rotation of the steering wheel.

.01

.02

.03 .05

.06 .04

.01 Pressure relief valve .02 Non-return valve

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

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2.1.4. Integrated brake valve (267)

The brake pedal adjusts the hydraulic pressure to the service brake
cylinder proportionally in accordance with the brake pedal angle.

.01 .04 .07

.05 .02
.06

.03

.01 Priority valve .02 Control valve

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

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2.1.5. Parking brake control valves (270, 344)

The parking brake control valves control the operation of the rear and front
axle parking brake cylinder. The pressure reducing/relieving valve (.01)
adjusts the rear axle control pressure to 30 bar (TC7- TC12, NC7) and front
axle control pressure to 30 bar (TC7–TC9, NC7) / 100 bar (TC10-TC12).
Directional valve (.02) directs the oil flow to the parking brake or receiver.

.01 .02

270

344

100 bar
(TC10-12)
30 bar
(TC7-9, NC7)

.01 Pressure reducing/relieving valve

.02 3/2 directional valve

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2.1.6. Middle-joint locking valves (288, 289), TC7-TC8, NC7 rigs with frame

During drilling middle-joint movements are prevented with locking valves

(288).

40 Nm

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2.1.7. Steering reversing valve (290), TC9-TC12 (optional)

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2.1.8. Emergency steering control valve (295)

295

.02

.01

2.1.9. Pressure accumulator (296)

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2.1.10. Charging valve (297)

N S1
T

.03
P .02

.01

.04

297 T

Charging the pressure accumulator

The charging valve (297) allows the oil to flow to the pressure accumulator
(296) through the port (S1). When the pressure accumulator is full, the
charging valve changes position, and the oil flows through the brake circuit
port (N).
2.1.11. Release valve of the pressure accumulator (299)

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Steering and braking system, TC7-TC12, NC7

2.1.12. Service brake testing valves (281, 282)

2.2. Parking and service brakes

The TC10-12 brakes only differ from the TC7-9 / NC7 brakes in regards to
the front axle parking brake.
The integrated brake valve (267) is used for three different purposes:
priority function, charging and control.
The priority function takes care of the priority of the oil flow. Valves (267.01)
and (267.05) control the priority function. Priority is always given to the
service and parking brake circuits.
Control takes place when the service brake pedal is used.

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2.2.1. Parking and service brake cylinders TC7-TC9/NC7 axles, TC10-TC12 rear axle

2 1 3

5
6
9
8 P1

B1 B2

P2

1 Parking brake control 2 Parking brake operating

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

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Steering and braking system, TC7-TC12, NC7

2.2.2. Parking brake cylinder, TC10-TC12 front axle

2 3 4

1 Parking brake washer

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

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3. STEERING AND BRAKE CIRCUIT DIAGRAMS

3.1. Steering circuit diagram, NC7
283 283

288 289

.06 .05

.04 .03

263

.07

.01
.02

.03
262
.01
.02

.03 .04

261

.01 .02

257 252
251

312

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3.1.1. Components for NC7

251 Gear pump Feeds oil to the steering circuit and carrier circuit
252 Gear pump Feeds oil to the service and parking brake circuits
257 Diesel engine
Double pressure
261 Limits the maximum pressure of gear pumps (251) and (252)
relief valve
.01 Pressure relief valve Limits the pressure of gear pump (251) (220 bar)
.02 Pressure relief valve Limits the pressure of gear pump (252) (200 bar)
.03 Anti-cavitation valve Prevents cavitation in steering and carrier circuits
.04 Anti-cavitation valve Prevents cavitation in service and parking brake circuits
Distributes the oil delivered from the gear pump (251) primarily to
262 Priority valve
the steering or secondarily to the carrier auxiliary functions
.01 Orifice Stabilizes the priority valve (262) spool
.02 Orifice Stabilizes the priority valve (262) spool
.03 Orifice Stabilizes the priority valve (262) spool
Steering valve Distributes oil from the priority valve (262) to the steering
263
(orbitrol) cylinders (283)
.01 Pressure relief valve Adjusts the maximum pressure of the steering valve (263)
Prevents the pilot pressure from being released from the steering
.02 Non-return valve
circuit
.03 Non-return valve Anti-cavitation valve for the steering valve (263)
.04 Non-return valve Anti-cavitation valve for the steering valve (263)
.05 Pressure relief valve Shock valve
.06 Pressure relief valve Shock valve
.07 Orifice Stabilizes the pressure relief valve (263.01)
283 Steering cylinders
Middle-joint lock
288
valve (optional)
Middle-joint lock
289
valve (optional)
312 The hydraulic oil tank

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3.2. Steering circuit diagram, TC7-TC8

LEF T RI GHT LEF T RI GHT
283 283

Y3 7 9 . 1 Y3 7 9 . 2
288 289

R L R L
190ba r 190ba r
.06 .05
ARTI CULATI ON LOCKI NG
OP TI ON
.04 .03

263

.07 LS

.01
.02
140ba r

P T

Ca r r i e r h o s i n g a n d
X9 r e t u r n f i l t e r s

X8 Ca r r i e r h o s i n g a n d
CF

EF

X7 r e t u r n f i l t e r s
.03 X2 3 Ca r r i e r h o s i n g a n d
262 r e t ur n f i l t e r s
LS

.01
.02
P

X1

B2 T A2

.03 .04

220 ba r 200 ba r
261

.01 .02

B1 T A1
X1 3 Ca r r i e r h o s i n g a n d
r e t ur n f i l t e r s

P P
16c c 16c c
257 M 252
251 S S
From port B1 when
TC8 2-boom jumbo

( B1 )
S1 S2

312

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3.2.1. Components for TC7-TC8

251 Gear pump Feeds oil to the steering circuit and carrier circuit
252 Gear pump Feeds oil to the service and parking brake circuits
257 Diesel engine
Double pressure
261 Limits the maximum pressure of gear pumps (251) and (252)
relief valve
.01 Pressure relief valve Limits the pressure of gear pump (251) (220 bar)
.02 Pressure relief valve Limits the pressure of gear pump (252) (200 bar)
.03 Anti-cavitation valve Prevents cavitation in steering and carrier circuits
.04 Anti-cavitation valve Prevents cavitation in service and parking brake circuits
Distributes the oil delivered from the gear pump (251) primarily to
262 Priority valve
the steering or secondarily to the carrier auxiliary functions
.01 Orifice Stabilizes the priority valve (262) spool
.02 Orifice Stabilizes the priority valve (262) spool
.03 Orifice Stabilizes the priority valve (262) spool
Steering valve Distributes oil from the priority valve (262) to the steering
263
(orbitrol) cylinders (283)
.01 Pressure relief valve Adjusts the maximum pressure of the steering valve (263)
Prevents the pilot pressure from being released from the steering
.02 Non-return valve
circuit
.03 Non-return valve Anti-cavitation valve for the steering valve (263)
.04 Non-return valve Anti-cavitation valve for the steering valve (263)
.05 Pressure relief valve Shock valve
.06 Pressure relief valve Shock valve
.07 Orifice Stabilizes the pressure relief valve (263.01)
283 Steering cylinders
Middle-joint lock
288 valve (frame-steered
rigs, optional)
Middle-joint lock
289 valve (frame-steered
rigs, optional)
312 The hydraulic oil tank

18 Copyright © Sandvik Mining and Construction

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

3.3. Steering circuit diagram, TC9-TC12

ATTENTI ON! ! !
DRI LLI NG DI RECTI ON

Note! Hosing is different comparing to the basic version.

LEF T RI GHT RI GHT LEF T
283 ( S h a f t R) 283 ( S h a f t L)

Y3 7 8 2 4
290
3 1

R L R L
190ba r 190ba r
.06 .05
OP TI ON

.04 .03

263

LS

.01
.02
140ba r

P T

Ca r r i e r p i p i n g a n d
X9 r e t u r n h o s e s

X8 Ca r r i e r p i p i n g a n d
r e t ur n hos e s
CF EF
.03 Ca r r i e r p i p i n g a n d
262 .01 X1 3 r e t u r n h o s e s
LS
.02
P

X1
2/ 11

B2 T A2

.03 .04

220 ba r 200 ba r
261

.01 .02

B1 T A1

16c c P P 16c c
257 M 252
251 S S

S1 S2

312

Copyright © Sandvik Mining and Construction 19

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

3.3.1. Components for TC9-TC12

251 Gear pump Feeds oil to the steering circuit and carrier circuit
252 Gear pump Feeds oil to the service and parking brake circuits
257 Diesel engine
Double pressure
261 Limits the maximum pressure of gear pumps (251) and (252)
relief valve
.01 Pressure relief valve Limits the pressure of gear pump (251) (220 bar)
.02 Pressure relief valve Limits the pressure of gear pump (252) (200 bar)
.03 Anti-cavitation valve Prevents cavitation in steering and carrier circuits
.04 Anti-cavitation valve Prevents cavitation in service and parking brake circuits
Distributes the oil delivered from the gear pump (251) primarily to
262 Priority valve
the steering or secondarily to the carrier auxiliary functions
.01 Orifice Stabilizes the priority valve (262) spool
.02 Orifice Stabilizes the priority valve (262) spool
.03 Orifice Stabilizes the priority valve (262) spool
Steering valve Distributes oil from the priority valve (262) to the steering
263
(orbitrol) cylinders (283)
.01 Pressure relief valve Adjusts the maximum pressure of the steering valve (263)
Prevents the pilot pressure from being released from the steering
.02 Non-return valve
circuit
.03 Non-return valve Anti-cavitation valve for the steering valve (263)
.04 Non-return valve Anti-cavitation valve for the steering valve (263)
.05 Pressure relief valve Shock valve
.06 Pressure relief valve Shock valve
.07 Orifice Stabilizes the pressure relief valve (263.01)
283 Steering cylinders
Steering reversing
290
valve (optional)
312 The hydraulic oil tank

20 Copyright © Sandvik Mining and Construction

ID: BG00201574 A.1 2013-07-12
 ID: BG00201574 A.1 2013-07-12
21 Copyright © Sandvik Mining and Construction
Figure: Brake circuit diagram, NC7
.01
.07

.06

.02

.05
.04
.03

275
267

.01
276

281
.02
293

272
271
344
.01

.02
.01
.01

270

282
277
.02
.02
285

.01
274
.02

345
280

279

.05
.06

.03
SERVICE BRAKE PRESSURE FRONT (80 bar)
SERVICE BRAKE PRESSURE REAR (80 bar)
PARKING BRAKE PRESSURE FRONT (30 bar)

.04
PARKING BRAKE PRESSURE REAR (30 bar)
CHARGING PRESSURE OF ACCUMULATORS (135-160 bar)
CLARK CLUTCH PRESSURE (17-19 bar)

291
284

.02
.01

.07

.08
294

.01
286

347

278
.02
Brake circuit diagram, NC7 3.4.
Steering and braking system, TC7-TC12, NC7
Steering and braking system, TC7-TC12, NC7

3.4.1. Components for NC7

Directs the oil to parking/service brake circuit or secondary

267 Integrated brake valve
control circuit (port S).
Directs the oil to parking/service brake circuit or secondary
.01 Priority valve
control circuit (port S).
Controls the operation of the priority valve (267.01) in the
brake circuit When the pressure in the brake circuit rises to
160 bar, the valve changes position and directs the pilot
control oil of the priority valve (267.01) to the receiver. The
priority valve (267.01) changes position and directs the oil to
.02 Control valve
the secondary control circuit (port S). When the pressure in
the brake circuit descends to 135 bar, the valve changes
position and directs the pilot control oil to the priority valve
(267.01). The priority valve (267.01) changes position and
directs the oil to the parking/service brake circuit.
Ensures the functioning of the rear service brake circuit in
case of a hose rupture in the front service brake circuit.
.03 Pressure relief valve
Adjusts the operating pressure of the rear service brake
circuit to approximately 120 bar.
Ensures the functioning of the front service brake circuit in
case of a hose rupture in the rear service brake circuit.
.04 Pressure relief valve
Adjusts the operating pressure of the front service brake
circuit to approximately 120 bar.
Prevents the pilot pressure from being released from the
.05 Non-return valve
parking/service brake circuit.
Pressure reducing/ Adjusts the service brake pressure to the rear axle according
.06
relieving valve to the pedal
Pressure reducing/ Adjusts the service brake pressure to the front axle
.07
relieving valve according to the pedal
Parking brake control Directs the oil flow to the rear axle parking brake. Adjusts
270
valve pressure to the parking brake circuit.
Pressure reducing/
.01 Adjusts the maximum pressure of the parking brake.
relieving valve
.02 3/2 directional valve Directs the oil flow into the receiver, parking brake.
271 Pressure accumulator Acts as an oil storage for the rear service brake circuit.
272 Pressure accumulator Acts as an oil storage for the front service brake circuit.

22 Copyright © Sandvik Mining and Construction

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

Monitors the minimum charging pressure of the front service

brake circuit. Causes an indicator light to light up in gauge
(P3) (on the driving panel) when the pressure of the front
service brake drops below 100 bar. When using the ABA
274 Pressure transducer
system (optional), the transducer monitors the minimum
charging pressure of the front service brake circuit and
causes the indicator light (H20) to light up on the driving
panel when the pressure drops below 110 bar.
Monitors the minimum charging pressure of the rear service
brake circuit. Causes an indicator light to light up in gauge
(P4) (on the driving panel) if the pressure drops below 100
275 Pressure transducer bar. When using the ABA system (optional), the transducer
monitors the minimum charging pressure of the rear service
brake circuit and causes the indicator light (H20) to light up
on the driving panel when the pressure drops below 110 bar.
Pressure switch (ABA Monitors the brake pressure. If the pressure drops below 75
276
system, optional) bar, the parking brake engages.
Pressure switch (ABA Monitors the brake pressure. If the pressure drops below 75
277
system, optional) bar, the parking brake engages.
Monitors the pressure of the rear axle parking brake. If the
278 Pressure switch pressure drops below 5 bar, the indicator light (H15)
switches on.
Directs the pressure from the rear or front service brake
279 Shuttle valve
circuit to pressure switch (280).
280 Pressure switch Brake light switch (5 bar)
Front axle service brake
testing valve (service
281
brake testing system,
optional)
.01 4/2 directional valve
Pressure reducing/
.02 Restricts the hydraulic oil pressure to 80 bar.
relieving valve
Rear axle service brake
testing valve (service Directs the oil flow from the testing circuit to the rear axle
282
brake testing system, brake. Adjusts the testing circuit pressure.
optional)
.01 4/2 directional valve
Pressure reducing/
.02 Restricts the hydraulic oil pressure to 80 bar.
relieving valve
284 Measuring point assembly
Front axle service and
285
parking brake cylinders
Front service brake
.01 Controls the braking power of the front service brakes.
cylinders

Copyright © Sandvik Mining and Construction 23

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

Front parking brake

.02 Front parking brakes engaged/released.
cylinders
Rear axle service and
286
parking brake cylinders
Rear service brake
.01 Controls the braking power of the rear service brakes.
cylinders
Rear parking brake
.02 Rear parking brakes engaged/released.
cylinders
291 Transmission
Transmission oil cooler
.01
(optional)
.02 Gearbox
Monitors the pressure of the gear box of the feed pump.
Pressure switch (ABA When the pressure drops below 4 bar, the parking brake
.03
system, optional) engages and the indicator light (SH2) of the parking brake
button lights up.
Consists of two separate components: collector and
.04 Manifold
pressure distributor.
Monitors the minimum clutch thrust of the gear box (14.3
.05 Pressure transducer
bar).
.06 The breather Takes care of the ventilation of the brakes.
Monitors the maximum oil temperature of the gear box (110
.07 Temperature transducer
°C).
.08 Manifold
Shuttle valve (service
293 brake testing system,
optional)
Shuttle valve (service
294 brake testing system,
optional)
Parking brake control Directs the oil flow to the front axle parking brake. Adjusts
344
valve pressure to the parking brake circuit.
Pressure reducing/
.01 Adjusts the maximum pressure of the parking brake.
relieving valve
.02 3/2 directional valve Directs the oil flow into the receiver, parking brake.
345 Pressure switch (optional)
Monitors the pressure of the front axle parking brake. If the
347 Pressure switch pressure drops below 5 bar, the indicator light (H15)
switches on.

24 Copyright © Sandvik Mining and Construction

ID: BG00201574 A.1 2013-07-12
 3.5.

285 286
FRONT AXLE REAR AXLE
SERVICE PARKING SERVICE PARKING
LEFT RIGHT LEFT RIGHT LEFT RIGHT LEFT RIGHT

.01 .02 .01 .02

267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293
H H

(REAR SERVICE
.07 F2 S15.1 BRAKE LIGHTS) 5 bar
F1 280 S19
.06 347 5 bar
MF1
344
X12 Y295.1 .02
T
SERVICE BRAKE PRESSURE FRONT (80 bar)
SERVICE BRAKE PRESSURE REAR (80 bar)
PARKING BRAKE PRESSURE FRONT (30 bar)
PARKING BRAKE PRESSURE REAR (30 bar)
CHARGING PRESSURE OF ACCUMULATORS (135-160 bar)
CLARK CLUTCH PRESSURE (17-19 bar)

TO CARRIER CIRCUIT T X 294

.03 A1
P .01 279
.02 30 bar
284
Brake circuit diagram, TC7-TC8

TO CARRIER CIRCUIT
X11
135-
LS 160 bar
A2 Y295 .02

Figure: Brake circuit diagram, TC7-TC8

.04
.05 T X

ID: BG00201574 A.1 2013-07-12

B3
X1 P .01
P .01
Steering and braking system, TC7-TC12, NC7

30 bar
S15.2
270
S MS MA X14 278
TO CARRIER CIRCUIT 5 bar

Copyright © Sandvik Mining and Construction

TO CARRIER CIRCUIT
X10
PRESSURE CONTROL OF PRESSURE CONTROL OF
BRAKE CIRCUIT BRAKE CIRCUIT
TO DRILLING CIRCUIT S13B S14B T2
276 277 BR .07
T3 .04 T1 110° C
.06
75 bar 75 bar C1
.05 291
P3 P1 C4 C3
275 274 B2 P / I 31 11 .08
P4 OUT IN
B1 3 P / I P/I B1 4 14,3 bar
P2 C2
100 bar 100 bar .01
(ABA 110 bar) (ABA 110 bar)
S16 OUT
GEARBOX

FRONT 65 bar 65 bar REAR 12

272 271 .03 IN
281 282 OPTION OPTION
.01 Y296 Y297 .01 Test valve of 4 bar ENGINE
80bar 80bar rear brake OPTION FAN
.02 P P .02
A A ABA
B B
Carrier hosing
OPTION and return
T T filters
Test valve of front brake X25

25
Steering and braking system, TC7-TC12, NC7

3.5.1. Components for TC7-TC8

Directs the oil to parking/service brake circuit or secondary

267 Integrated brake valve
control circuit (port S).
Directs the oil to parking/service brake circuit or secondary
.01 Priority valve
control circuit (port S).
Controls the operation of the priority valve (267.01) in the
brake circuit When the pressure in the brake circuit rises to
160 bar, the valve changes position and directs the pilot
control oil of the priority valve (267.01) to the receiver. The
priority valve (267.01) changes position and directs the oil to
.02 Control valve
the secondary control circuit (port S). When the pressure in
the brake circuit descends to 135 bar, the valve changes
position and directs the pilot control oil to the priority valve
(267.01). The priority valve (267.01) changes position and
directs the oil to the parking/service brake circuit.
Ensures the functioning of the rear service brake circuit in
case of a hose rupture in the front service brake circuit.
.03 Pressure relief valve
Adjusts the operating pressure of the rear service brake
circuit to approximately 120 bar.
Ensures the functioning of the front service brake circuit in
case of a hose rupture in the rear service brake circuit.
.04 Pressure relief valve
Adjusts the operating pressure of the front service brake
circuit to approximately 120 bar.
Prevents the pilot pressure from being released from the
.05 Non-return valve
parking/service brake circuit.
Pressure reducing/ Adjusts the service brake pressure to the rear axle according
.06
relieving valve to the pedal
Pressure reducing/ Adjusts the service brake pressure to the front axle
.07
relieving valve according to the pedal
Parking brake control Directs the oil flow to the rear axle parking brake. Adjusts
270
valve pressure to the parking brake circuit.
Pressure reducing/
.01 Adjusts the maximum pressure of the parking brake.
relieving valve
.02 3/2 directional valve Directs the oil flow into the receiver, parking brake.
271 Pressure accumulator Acts as an oil storage for the rear service brake circuit.
272 Pressure accumulator Acts as an oil storage for the front service brake circuit.

26 Copyright © Sandvik Mining and Construction

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

Monitors the minimum charging pressure of the front service

brake circuit. Causes an indicator light to light up in gauge
(P3) (on the driving panel) when the pressure of the front
service brake drops below 100 bar. When using the ABA
274 Pressure transducer
system (optional), the transducer monitors the minimum
charging pressure of the front service brake circuit and
causes the indicator light (H20) to light up on the driving
panel when the pressure drops below 110 bar.
Monitors the minimum charging pressure of the rear service
brake circuit. Causes an indicator light to light up in gauge
(P4) (on the driving panel) if the pressure drops below 100
275 Pressure transducer bar. When using the ABA system (optional), the transducer
monitors the minimum charging pressure of the rear service
brake circuit and causes the indicator light (H20) to light up
on the driving panel when the pressure drops below 110 bar.
Pressure switch (ABA Monitors the brake pressure. If the pressure drops below 75
276
system, optional) bar, the parking brake engages.
Pressure switch (ABA Monitors the brake pressure. If the pressure drops below 75
277
system, optional) bar, the parking brake engages.
Monitors the pressure of the rear axle parking brake. If the
278 Pressure switch (S15.2) pressure drops below 5 bar, the indicator light (H15)
switches on.
Directs the pressure from the rear or front service brake
279 Shuttle valve
circuit to pressure switch (280).
280 Pressure switch (S19) Brake light switch (5 bar)
Front axle service brake
testing valve (service
281
brake testing system,
optional)
.01 4/2 directional valve
Pressure reducing/
.02 Restricts the hydraulic oil pressure to 80 bar.
relieving valve
Rear axle service brake
testing valve (service Directs the oil flow from the testing circuit to the rear axle
282
brake testing system, brake. Adjusts the testing circuit pressure.
optional)
.01 4/2 directional valve
Pressure reducing/
.02 Restricts the hydraulic oil pressure to 80 bar.
relieving valve
284 Measuring point assembly
Front axle service and
285
parking brake cylinders
Front service brake
.01 Controls the braking power of the front service brakes.
cylinders

Copyright © Sandvik Mining and Construction 27

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

Front parking brake

.02 Front parking brakes engaged/released.
cylinders
Rear axle service and
286
parking brake cylinders
Rear service brake
.01 Controls the braking power of the rear service brakes.
cylinders
Rear parking brake
.02 Rear parking brakes engaged/released.
cylinders
291 Transmission
Transmission oil cooler
.01
(optional)
.02 Gearbox
Monitors the pressure of the gear box of the feed pump.
Pressure switch (S16, When the pressure drops below 4 bar, the parking brake
.03
ABA system, optional) engages and the indicator light (SH2) of the parking brake
button lights up.
Consists of two separate components: collector and
.04 Manifold
pressure distributor.
Monitors the minimum clutch thrust of the gear box (14.3
.05 Pressure transducer
bar).
.06 The breather Takes care of the ventilation of the brakes.
Monitors the maximum oil temperature of the gear box (110
.07 Temperature transducer
°C).
.08 Manifold
Shuttle valve (service
293 brake testing system,
optional)
Shuttle valve (service
294 brake testing system,
optional)
Parking brake control Directs the oil flow to the front axle parking brake. Adjusts
344
valve pressure to the parking brake circuit.
Pressure reducing/
.01 Adjusts the maximum pressure of the parking brake.
relieving valve
.02 3/2 directional valve Directs the oil flow into the receiver, parking brake.
Monitors the pressure of the front axle parking brake. If the
347 Pressure switch (S15.1) pressure drops below 5 bar, the indicator light (H15)
switches on.

28 Copyright © Sandvik Mining and Construction

ID: BG00201574 A.1 2013-07-12
 3.6.

285 FRONT AXLE 286 REAR AXLE

SERVICE PARKING SERVICE PARKING
LEFT RIGHT LEFT RIGHT LEFT RIGHT LEFT RIGHT
.01 .02 .01 .02

267 MF2 P2 P2 P1 P1 P2 P2 P1 P1

293 H H

(REAR SERVICE
F2 BRAKE LIGHTS) 5 bar
.07
280 B968P
F1
.06 294
MF1
344 0.2
TO CARRIER CIRCUIT Y960
SERVICE BRAKE PRESSURE FRONT (70 bar)
SERVICE BRAKE PRESSURE REAR (70 bar)
PARKING BRAKE PRESSURE FRONT (30 bar)
PARKING BRAKE PRESSURE REAR (30 bar)
CHARGING PRESSURE OF ACCUMULATORS (135-160 bar)
CLARK CLUTCH
PRESSURE (17-19 bar)
Brake circuit diagram, TC9

X12 T T X
.03 A1 278
P B961P
0.1 279 284
.02

Figure: Brake circuit diagram, TC9

30 bar
TO CARRIER CIRCUIT 5 bar
X11
135- 347
LS A2 Y961 0.2 B960P
160 bar
.04
T X 5 bar

ID: BG00201574 A.1 2013-07-12

.05 B3
X1 P .01
P .01
Steering and braking system, TC7-TC12, NC7

30 bar
270
X19
TO CARRIER CIRCUIT

Copyright © Sandvik Mining and Construction

S MS MA
X10

TO AIR CONDITION CIRCUIT PRESSURE CONTROL OF PRESSURE CONTROL OF

BRAKE CIRCUIT BRAKE CIRCUIT T2 B970T
BR T1 .07 110° C
T3
.06
B966P B967P .04
291 C1
276 277 .05
P3 P1 C4 C3
P/I 31 11 .08
75 bar 75 bar B970P P4 OUT IN
14,3 bar
P2 C2
.01
OPTION
275 274 Test valve of B975P
281 OUT
GEARBOX

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

12
OPTION 100 bar 100 bar Y297 .01 4 bar IN ENGINE
Test valve of front brake (ABA 110 bar) (ABA 110 bar) 70bar FAN
OPTION
P .02
Y296 A ABA
80 bar 80 bar
70bar 272 271
.02 FRONT REAR B
P
A
B Carrier hosing T
and return 282
.01 T X25
filters

29
Steering and braking system, TC7-TC12, NC7

3.6.1. Components for TC9

Directs the oil to parking/service brake circuit or secondary

267 Integrated brake valve
control circuit (port S).
Directs the oil to parking/service brake circuit or secondary
.01 Priority valve
control circuit (port S).
Controls the operation of the priority valve (267.01) in the
brake circuit When the pressure in the brake circuit rises to
160 bar, the valve changes position and directs the pilot
control oil of the priority valve (267.01) to the receiver. The
priority valve (267.01) changes position and directs the oil to
.02 Control valve
the secondary control circuit (port S). When the pressure in
the brake circuit descends to 135 bar, the valve changes
position and directs the pilot control oil to the priority valve
(267.01). The priority valve (267.01) changes position and
directs the oil to the parking/service brake circuit.
Ensures the functioning of the rear service brake circuit in
case of a hose rupture in the front service brake circuit.
.03 Pressure relief valve
Adjusts the operating pressure of the rear service brake
circuit to approximately 120 bar.
Ensures the functioning of the front service brake circuit in
case of a hose rupture in the rear service brake circuit.
.04 Pressure relief valve
Adjusts the operating pressure of the front service brake
circuit to approximately 120 bar.
Prevents the pilot pressure from being released from the
.05 Non-return valve
parking/service brake circuit.
Pressure reducing/ Adjusts the service brake pressure to the rear axle according
.06
relieving valve to the pedal
Pressure reducing/ Adjusts the service brake pressure to the front axle
.07
relieving valve according to the pedal
Parking brake control Directs the oil flow to the rear axle parking brake. Adjusts
270
valve pressure to the parking brake circuit.
Pressure reducing/
.01 Adjusts the maximum pressure of the parking brake.
relieving valve
.02 3/2 directional valve Directs the oil flow into the receiver, parking brake.
271 Pressure accumulator Acts as an oil storage for the rear service brake circuit.
272 Pressure accumulator Acts as an oil storage for the front service brake circuit.

30 Copyright © Sandvik Mining and Construction

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

Monitors the minimum charging pressure of the front service

brake circuit. Causes an indicator light to light up on the
gauge (P3) (on the driving panel) when the pressure of the
front service brake drops below 100 bar. When using the
274 Pressure transducer
ABA system (optional), the transducer monitors the
minimum charging pressure of the front service brake circuit
and causes the indicator light (H20) to light up on the driving
panel when the pressure drops below 110 bar.
Monitors the minimum charging pressure of the rear service
brake circuit. Causes an indicator light to light up in gauge
(P4) (on the driving panel) if the pressure drops below 100
275 Pressure transducer bar. When using the ABA system (optional), the transducer
monitors the minimum charging pressure of the rear service
brake circuit and causes the indicator light (H20) to light up
on the driving panel when the pressure drops below 110 bar.
Pressure switch (ABA Monitors the brake pressure. If the pressure drops below 75
276
system, optional) bar, the parking brake engages.
Pressure switch (ABA Monitors the brake pressure. If the pressure drops below 75
277
system, optional) bar, the parking brake engages.
Monitors the pressure of the rear axle parking brake. If the
278 Pressure switch pressure drops below 5 bar, the indicator light (H15)
switches on.
Directs the pressure from the rear or front service brake
279 Shuttle valve
circuit to pressure switch (280).
280 Pressure switch Brake light switch (5 bar)
Front axle service brake
testing valve (service
281
brake testing system,
optional)
.01 4/2 directional valve
Pressure reducing/
.02 Restricts the hydraulic oil pressure to 70 bar.
relieving valve
Rear axle service brake
testing valve (service Directs the oil flow from the testing circuit to the rear axle
282
brake testing system, brake. Adjusts the testing circuit pressure.
optional)
.01 4/2 directional valve
Pressure reducing/
.02 Restricts the hydraulic oil pressure to 70 bar.
relieving valve
284 Measuring point assembly
Front axle service and
285
parking brake cylinders
Front service brake
.01 Controls the braking power of the front service brakes.
cylinders

Copyright © Sandvik Mining and Construction 31

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

Front parking brake

.02 Front parking brakes engaged/released.
cylinders
Rear axle service and
286
parking brake cylinders
Rear service brake
.01 Controls the braking power of the rear service brakes.
cylinders
Rear parking brake
.02 Rear parking brakes engaged/released.
cylinders
291 Transmission
Transmission oil cooler
.01
(optional)
.02 Gearbox
Monitors the pressure of the gear box of the feed pump.
Pressure switch (ABA When the pressure drops below 4 bar, the parking brake
.03
system, optional) engages and the indicator light (SH2) of the parking brake
button lights up.
Consists of two separate components: collector and
.04 Manifold
pressure distributor.
Monitors the minimum clutch thrust of the gear box (14.3
.05 Pressure transducer
bar).
.06 The breather Takes care of the ventilation of the brakes.
Monitors the maximum oil temperature of the gear box (110
.07 Temperature transducer
°C).
.08 Manifold
Shuttle valve (service
293 brake testing system,
optional)
Shuttle valve (service
294 brake testing system,
optional)
Parking brake control Directs the oil flow to the front axle parking brake. Adjusts
344
valve pressure to the parking brake circuit.
Pressure reducing/
.01 Adjusts the maximum pressure of the parking brake.
relieving valve
.02 3/2 directional valve Directs the oil flow into the receiver, parking brake.
Monitors the pressure of the front axle parking brake. If the
347 Pressure switch pressure drops below 5 bar, the indicator light (H15)
switches on.

32 Copyright © Sandvik Mining and Construction

ID: BG00201574 A.1 2013-07-12
 3.7.

.01 .02 .01 .02

OPTION
ONLY WITH BRAKE P2 P2 P1 P1 P2 P2 P1 P1
TEST VALVES
MF2 285
293 286

(REAR SERVICE 5 bar

BRAKE LIGHTS) OPTION
.07 F2 280 S19 ONLY WITH BRAKE
TEST VALVES
F1
.06
MF1
TO CARRIER CIRCUIT Y295.1
SERVICE BRAKE PRESSURE FRONT (70 bar)
SERVICE BRAKE PRESSURE REAR (70 bar)
PARKING BRAKE PRESSURE FRONT (100 bar)
PARKING BRAKE PRESSURE REAR (30 bar)
CHARGING PRESSURE OF ACCUMULATORS (135-160 bar)
CLARK CLUTCH
PRESSURE (17-19 bar)

.02 294
X12 T T 344
267
X
P
.03 A1
.01 279 284
.02 100 bar S15.1
TO CARRIER CIRCUIT
347
X11 50 bar
LS 135- A2 Y295.2
160bar .02 S15.2
.04

Figure: Brake circuit diagram, TC10-TC12

T 278
X
Brake circuit diagram, TC10-TC12

X1 .05 5 bar
B3
1/21 P .01
P .01
30 bar

ID: BG00201574 A.1 2013-07-12

270
Steering and braking system, TC7-TC12, NC7

S MS MA
X10 PRESSURE CONTROL OF
S13 B S14B BRAKE CIRCUIT

Copyright © Sandvik Mining and Construction

TO AIR CONDITION/
CARRIER CIRCUIT T2
276 277 B1
PRESSURE CONTROL OF BR
BRAKE CIRCUIT 75 ba r 75 bar .06
T3 T1 .07
.04 110° C
.08 C1
B2 291
275 274 P3 P1 C4 C3
.05 P / I 31 11 OUT
B13 P/I P/I B14 IN
14,3 bar
100 bar 100 bar
S16 20000/ .01
(ABA 110 bar) (ABA 110 bar) 32000
FRONT REAR .03 SERIE
272 271 .02 OUT
4 bar 12
80 bar 80 bar IN
OPTION
ABA ENGINE
Y296 Y297 FAN
.02 .01
70bar 70bar
A .01 P P .02 A
B 281 282 B

T T Carrier hosing and

OPTION return filters
X14
BRAKE TEST
VALVES

33
Steering and braking system, TC7-TC12, NC7

3.7.1. Components for TC10-TC12

Directs the oil to parking/service brake circuit or secondary

267 Integrated brake valve
control circuit (port S).
Directs the oil to parking/service brake circuit or secondary
.01 Priority valve
control circuit (port S).
Controls the operation of the priority valve (267.01) in the
brake circuit When the pressure in the brake circuit rises to
160 bar, the valve changes position and directs the pilot
control oil of the priority valve (267.01) to the receiver. The
priority valve (267.01) changes position and directs the oil to
.02 Control valve
the secondary control circuit (port S). When the pressure in
the brake circuit descends to 135 bar, the valve changes
position and directs the pilot control oil to the priority valve
(267.01). The priority valve (267.01) changes position and
directs the oil to the parking/service brake circuit.
Ensures the functioning of the rear service brake circuit in
case of a hose rupture in the front service brake circuit.
.03 Pressure relief valve
Adjusts the operating pressure of the rear service brake
circuit to approximately 120 bar.
Ensures the functioning of the front service brake circuit in
case of a hose rupture in the rear service brake circuit.
.04 Pressure relief valve
Adjusts the operating pressure of the front service brake
circuit to approximately 120 bar.
Prevents the pilot pressure from being released from the
.05 Non-return valve
parking/service brake circuit.
Pressure reducing/ Adjusts the service brake pressure to the rear axle according
.06
relieving valve to the pedal
Pressure reducing/ Adjusts the service brake pressure to the front axle
.07
relieving valve according to the pedal
Parking brake control Directs the oil flow to the rear axle parking brake. Adjusts
270
valve pressure to the parking brake circuit.
Pressure reducing/
.01 Adjusts the maximum pressure of the parking brake.
relieving valve
.02 3/2 directional valve Directs the oil flow into the receiver, parking brake.
271 Pressure accumulator Acts as an oil storage for the rear service brake circuit.
272 Pressure accumulator Acts as an oil storage for the front service brake circuit.

34 Copyright © Sandvik Mining and Construction

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

Monitors the minimum charging pressure of the front service

brake circuit. Causes an indicator light to light up on the
gauge (P3) (on the driving panel) when the pressure of the
front service brake drops below 100 bar. When using the
274 Pressure transducer
ABA system (optional), the transducer monitors the
minimum charging pressure of the front service brake circuit
and causes the indicator light (H20) to light up on the driving
panel when the pressure drops below 110 bar.
Monitors the minimum charging pressure of the rear service
brake circuit. Causes an indicator light to light up in gauge
(P4) (on the driving panel) if the pressure drops below 100
275 Pressure transducer bar. When using the ABA system (optional), the transducer
monitors the minimum charging pressure of the rear service
brake circuit and causes the indicator light (H20) to light up
on the driving panel when the pressure drops below 110 bar.
Pressure switch (ABA Monitors the brake pressure. If the pressure drops below 75
276
system, optional) bar, the parking brake engages.
Pressure switch (ABA Monitors the brake pressure. If the pressure drops below 75
277
system, optional) bar, the parking brake engages.
Monitors the pressure of the rear axle parking brake. If the
278 Pressure switch pressure drops below 5 bar, the indicator light (H15)
switches on.
Directs the pressure from the rear or front service brake
279 Shuttle valve
circuit to pressure switch (280).
280 Pressure switch Brake light switch (5 bar)
Front axle service brake
testing valve (service
281
brake testing system,
optional)
.01 4/2 directional valve
Pressure reducing/
.02 Restricts the hydraulic oil pressure to 70 bar.
relieving valve
Rear axle service brake
testing valve (service Directs the oil flow from the testing circuit to the rear axle
282
brake testing system, brake. Adjusts the testing circuit pressure.
optional)
.01 4/2 directional valve
Pressure reducing/
.02 Restricts the hydraulic oil pressure to 70 bar.
relieving valve
284 Measuring point assembly
Front axle service and
285
parking brake cylinders
Front service brake
.01 Controls the braking power of the front service brakes.
cylinders

Copyright © Sandvik Mining and Construction 35

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

Front parking brake

.02 Front parking brakes engaged/released.
cylinders
Rear axle service and
286
parking brake cylinders
Rear service brake
.01 Controls the braking power of the rear service brakes.
cylinders
Rear parking brake
.02 Rear parking brakes engaged/released.
cylinders
291 Transmission
Transmission oil cooler
.01
(optional)
.02 Gearbox
Monitors the pressure of the gear box of the feed pump.
Pressure switch (ABA When the pressure drops below 4 bar, the parking brake
.03
system, optional) engages and the indicator light (SH2) of the parking brake
button lights up.
Consists of two separate components: collector and
.04 Manifold
pressure distributor.
Monitors the minimum clutch thrust of the gear box (14.3
.05 Pressure transducer
bar).
.06 The breather Takes care of the ventilation of the brakes.
Monitors the maximum oil temperature of the gear box (110
.07 Temperature transducer
°C).
.08 Manifold
Shuttle valve (service
293 brake testing system,
optional)
Shuttle valve (service
294 brake testing system,
optional)
Parking brake control Directs the oil flow to the front axle parking brake. Adjusts
344
valve pressure to the parking brake circuit.
Pressure reducing/
.01 Adjusts the maximum pressure of the parking brake.
relieving valve
Parking brake control
.02 Directs the oil flow into the receiver, parking brake.
valve
Monitors the pressure of the front axle parking brake. If the
347 Pressure switch pressure drops below 5 bar, the indicator light (H15)
switches on.

36 Copyright © Sandvik Mining and Construction

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

4. PARKING AND SERVICE BRAKES OPERATION

4.1. Parking brake circuit, TC7-TC12, NC7

1 2 3

Figure: With Mercedes Benz engine

1 2

Figure: With Cummins engine

1 Parking brake engagement button (S21)

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

Copyright © Sandvik Mining and Construction 37

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

4.1.1. Engaging and releasing the parking brakes

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

38 Copyright © Sandvik Mining and Construction

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

This page is intentionally left blank

Copyright © Sandvik Mining and Construction 39

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

4.1.2. Parking brake circuit functional diagram (engaging), NC7

.02

278
347
286

.01
294

.08
.07
.01

.02
284

291
CLARK CLUTCH PRESSURE (17-19 bar)

CHARGING PRESSURE OF ACCUMULATORS (135-160 bar)

PARKING BRAKE PRESSURE REAR (30 bar)

.04
PARKING BRAKE PRESSURE FRONT (30 bar)

SERVICE BRAKE PRESSURE REAR (80 bar)

SERVICE BRAKE PRESSURE FRONT (80 bar)

.03
.06
.05
279
280

345
.02

274

.01
285

.02

.02

277

282
270
.01

.01

.02
.01

344

271
272
293

.02

281
276

.01
267

275
.03

.04
.05
.02
.06
.07

.01

Figure: Parking brake circuit functional diagram (engaging), NC7

40 Copyright © Sandvik Mining and Construction

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

Parking brake circuit operation (engaging)

The oil flows from the parking brake circuit gear pump (252). From the
pump (252) the oil flows through the double pressure relief valve assembly
(261) to the integrated service brake valve (267) connection (P). From the
port (P) the oil flows through the control valve (267.01) and non-return
valve (267.05) to the integrated service brake valve (267) connection (B3).
From there the oil flows to the parking brake valves (270) and (344)
connection (P) and then to the pressure reducing/relieving valves (270.01)
and (344.01). The pressure reducing/relieving valves (270.01) and (344.01)
adjust the operating pressure of the parking brake circuits. When the
operator engages the parking brake (with the parking brake button or an
emergency stop button), the directional valves (270.02) and (344.02) direct
the oil flow from the front and rear parking brake cylinders (chambers
285.02 and 286.02) to the receiver and the parking brake cylinder springs
engage the parking brakes. The indicator light (H15) on the tramming panel
lights up when the control pressure of both parking brake circuits has fallen
below the 5bar (pressure switches 278 and 347).

Copyright © Sandvik Mining and Construction 41

ID: BG00201574 A.1 2013-07-12
 42
4.1.3.

285 286
FRONT AXLE REAR AXLE
SERVICE PARKING SERVICE PARKING
LEFT RIGHT LEFT RIGHT LEFT RIGHT LEFT RIGHT

.01 .02 .01 .02

267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293
H H

(REAR SERVICE
.07 F2 S15.1 BRAKE LIGHTS) 5 bar
F1 280 S19
.06 347 5 bar
MF1
344
X12 Y295.1 0.2
T
SERVICE BRAKE PRESSURE FRONT (80 bar)
SERVICE BRAKE PRESSURE REAR (80 bar)
PARKING BRAKE PRESSURE FRONT (30 bar)
PARKING BRAKE PRESSURE REAR (30 bar)
CHARGING PRESSURE OF ACCUMULATORS (135-160 bar)
CLARK CLUTCH PRESSURE (17-19 bar)

TO CARRIER CIRCUIT T X 294

.03 A1
P 0.1 279
.02 30 bar
284

ID: BG00201574 A.1 2013-07-12

TO CARRIER CIRCUIT
X11
135-
A2
Steering and braking system, TC7-TC12, NC7

LS 160 bar Y295 .02

.04
.05 T X
B3

Copyright © Sandvik Mining and Construction

X1 P .01
P .01
30 bar
S15.2
270
S MS MA X14 278
TO CARRIER CIRCUIT 5 bar
TO CARRIER CIRCUIT
X10
PRESSURE CONTROL OF PRESSURE CONTROL OF
Parking brake circuit functional diagram (engaging), TC7/TC8

BRAKE CIRCUIT BRAKE CIRCUIT

TO DRILLING CIRCUIT S13B S14B T2
276 277 BR .07
T3 .04 T1 110° C
.06
75 bar 75 bar C1
.05 291
P3 P1 C4 C3
275 274 B2 P / I 31 11 .08
P4 OUT IN
B1 3 P / I P/I B1 4 14,3 bar 20000/
P2 32000 C2
100 bar 100 bar SERIE .01
(ABA 110 bar) (ABA 110 bar)
S16 OUT

Figure: Parking brake circuit functional diagram (engaging), TC7/TC8

FRONT 65 bar 65 bar REAR 12
272 271 .03 IN
281 282 OPTION OPTION
.01 Y296 Y297 .01 Test valve of 4 bar ENGINE
80bar 80bar rear brake OPTION FAN
.02 P P .02
A A ABA
B B
Carrier hosing
OPTION T and return
T filters
Test valve of front brake
Steering and braking system, TC7-TC12, NC7

Parking brake circuit operation (engaging)

The oil flows from the parking brake circuit gear pump (252). From the
pump (252) the oil flows through the double pressure relief valve assembly
(261) to the integrated service brake valve (267) connection (P). From the
port (P) the oil flows through the control valve (267.01) and non-return
valve (267.05) to the integrated service brake valve (267) connection (B3).
From there the oil flows to the parking brake valves (270) and (344)
connection (P) and then to the pressure reducing/relieving valves (270.01)
and (344.01). The pressure reducing/relieving valves (270.01) and (344.01)
adjust the operating pressure of the parking brake circuits. When the
operator engages the parking brake (with the parking brake button or an
emergency stop button), the directional valves (270.02) and (344.02) direct
the oil flow from the front and rear parking brake cylinders (chambers
285.02 and 286.02) to the receiver and the parking brake cylinder springs
engage the parking brakes. The indicator light (H15) on the tramming panel
lights up when the control pressure of both parking brake circuits has fallen
below the 5bar (pressure switches 278 and 347).

Copyright © Sandvik Mining and Construction 43

ID: BG00201574 A.1 2013-07-12
 44
4.1.4.

285 FRONT AXLE 286 REAR AXLE

SERVICE PARKING SERVICE PARKING
LEFT RIGHT LEFT RIGHT LEFT RIGHT LEFT RIGHT
.01 .02 .01 .02

267 MF2 P2 P2 P1 P1 P2 P2 P1 P1

293 H H

(REAR SERVICE
F2 BRAKE LIGHTS) 5 bar
.07
280 B968P
F1
.06 294
MF1
344 0.2
TO CARRIER CIRCUIT Y960

SERVICE BRAKE PRESSURE FRONT (70 bar)

SERVICE BRAKE PRESSURE REAR (70 bar)
PARKING BRAKE PRESSURE FRONT (30 bar)
PARKING BRAKE PRESSURE REAR (30 bar)
CHARGING PRESSURE OF ACCUMULATORS (135-160 bar)
CLARK CLUTCH
PRESSURE (17-19 bar)

X12 T T X
.03 A1 278
P B961P
0.1 279 284
.02 30 bar
TO CARRIER CIRCUIT 5 bar
X11
135- 347
LS A2 Y961 0.2 B960P
160 bar
.04
T X 5 bar

ID: BG00201574 A.1 2013-07-12

.05 B3
X1 P .01
P .01
Steering and braking system, TC7-TC12, NC7

30 bar
270
X19
TO CARRIER CIRCUIT

Copyright © Sandvik Mining and Construction

S MS MA
X10

TO AIR CONDITION CIRCUIT PRESSURE CONTROL OF PRESSURE CONTROL OF

BRAKE CIRCUIT BRAKE CIRCUIT
Parking brake circuit functional diagram (engaging), TC9

T2 B970T
BR T1 .07 110° C
T3
.06
B966P B967P .04
291 C1
276 277 .05
P3 P1 C4 C3
P/I 31 11 .08
75 bar 75 bar B970P P4 OUT IN
14,3 bar

Figure: Parking brake circuit functional diagram (engaging), TC9

P2 C2
.01
OPTION
275 274 Test valve of B975P
281 OUT
GEARBOX

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

12
OPTION 100 bar 100 bar Y297 .01 4 bar IN ENGINE
Test valve of front brake (ABA 110 bar) (ABA 110 bar) 70bar FAN
OPTION
P .02
Y296 A ABA
80 bar 80 bar
70bar 272 271
.02 FRONT REAR B
P
A
B Carrier hosing T
and return 282
.01 T X25
filters
Steering and braking system, TC7-TC12, NC7

Parking brake circuit operation (engaging)

The oil flows from the parking brake circuit gear pump (252). From the
pump (252) the oil flows through the double pressure relief valve assembly
(261) to the integrated service brake valve (267) connection (P). From the
port (P) the oil flows through the control valve (267.01) and non-return
valve (267.05) to the integrated service brake valve (267) connection (B3).
From there the oil flows to the parking brake valves (270) and (344)
connection (P) and then to the pressure reducing/relieving valves (270.01)
and (344.01). The pressure reducing/relieving valves (270.01) and (344.01)
adjust the operating pressure of the parking brake circuits. When the
operator engages the parking brake (with the parking brake button or an
emergency stop button), the directional valves (270.02) and (344.02) direct
the oil flow from the front and rear parking brake cylinders (chambers
285.02 and 286.02) to the receiver and the parking brake cylinder springs
engage the parking brakes. The indicator light (H15) on the tramming panel
lights up when the control pressure of both parking brake circuits has fallen
below the 5bar (pressure switches 278 and 347).

Copyright © Sandvik Mining and Construction 45

ID: BG00201574 A.1 2013-07-12
 46
4.1.5.

.01 .02 .01 .02

OPTION
ONLY WITH BRAKE P2 P2 P1 P1 P2 P2 P1 P1
TEST VALVES
MF2 285
293 286

(REAR SERVICE 5 bar

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

SERVICE BRAKE PRESSURE FRONT (70 bar)

SERVICE BRAKE PRESSURE REAR (70 bar)
PARKING BRAKE PRESSURE FRONT (100 bar)
PARKING BRAKE PRESSURE REAR (30 bar)
CHARGING PRESSURE OF ACCUMULATORS (135-160 bar)
CLARK CLUTCH
PRESSURE (17-19 bar)

.02 294
X12 T T 344
267
X
P
.03 A1
.01 279 284
.02 100 bar S15.1
TO CARRIER CIRCUIT
347
X11 50 bar
LS 135- A2 Y295.2
160bar .02 S15.2
.04
T 278
.05 X 5 bar
X1 B3
1/21 P .01
P .01

ID: BG00201574 A.1 2013-07-12

30 bar
270
Steering and braking system, TC7-TC12, NC7

S MS MA
X10 PRESSURE CONTROL OF
S13 B S14B BRAKE CIRCUIT

Copyright © Sandvik Mining and Construction

TO AIR CONDITION/
CARRIER CIRCUIT T2
276 277 B1
PRESSURE CONTROL OF BR T3 T1
BRAKE CIRCUIT 75 ba r 75 bar .06 .04 .07 110° C
.08 C1
B2 291
275 274 P3 P1 C4 C3
.05 P / I 31 11 OUT
B13 P/I P/I B14 IN
14,3 bar
100 bar
100 bar S16 20000/ .01
(ABA 110 bar) 32000
(ABA 110 bar)
Parking brake circuit functional diagram (engaging), TC10-TC12

REAR .03 SERIE

FRONT 272 .02 OUT
271 4 bar
80 bar 80 bar 12
IN
OPTION
ABA ENGINE
Y296 Y297 FAN
.02 .01
70bar 70bar

Figure: Parking brake circuit functional diagram (engaging), TC10-TC12

A .01 P P .02 A
B 281 282 B

T T Carrier hosing and

OPTION return filters
BRAKE TEST X14
VALVES
Steering and braking system, TC7-TC12, NC7

Parking brake circuit operation (engaging)

The oil flows from the parking brake circuit gear pump (252). From the
pump (252) the oil flows through the double pressure relief valve assembly
(261) to the integrated service brake valve (267) connection (P). From the
port (P) the oil flows through the control valve (267.01) and non-return
valve (267.05) to the integrated service brake valve (267) connection (B3).
From there the oil flows to the parking brake valves (270) and (344)
connection (P) and then to the pressure reducing/relieving valves (270.01)
and (344.01). The pressure reducing/relieving valves (270.01) and (344.01)
adjust the operating pressure of the parking brake circuits. When the
operator engages the parking brake (with the parking brake button or an
emergency stop button), the directional valves (270.02) and (344.02) direct
the oil flow from the front and rear parking brake cylinders (chambers
285.02 and 286.02) to the receiver and the parking brake cylinder springs
engage the parking brakes. The indicator light (H15) on the driving panel
lights up when the control pressure of both parking brake circuits has fallen
below the set limits (front brake circuit 50 bar / rear brake circuit 5 bar)
(pressure switches 278 and 347).

Copyright © Sandvik Mining and Construction 47

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

4.1.6. Parking brake circuit functional diagram (releasing), NC7

.02

278
347
286

.01
294

.08
.07
.01

.02
284

291
CLARK CLUTCH PRESSURE (17-19 bar)

CHARGING PRESSURE OF ACCUMULATORS (135-160 bar)

PARKING BRAKE PRESSURE REAR (30 bar)

.04
PARKING BRAKE PRESSURE FRONT (30 bar)

SERVICE BRAKE PRESSURE REAR (80 bar)

SERVICE BRAKE PRESSURE FRONT (80 bar)

.03
.06
.05
279
280

345
.02

274

.01
285

.02

.02

277

282
270
.01

.01

.02
.01

344

271
272
293

.02

281
276

.01
267

275
.03

.04
.05
.02
.06
.07

.01

Figure: Parking brake circuit functional diagram (releasing), NC7

48 Copyright © Sandvik Mining and Construction

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

Parking brake circuit operation (releasing)

When the parking brake is released, the 3/2 directional valves (270.02) and
(344.02) of the parking brake control valves (270) and (344) are activated
and the oil flows to the front parking brake cylinders (285), the rear parking
brake cylinders (286), the pressure switches (278) and the measuring point
assembly (284). When the control pressure of both parking brake circuits
has risen over the 5 bar, the parking brake indicator lamp (H15) on the
tramming panel turns off. The springs in cylinders (285) and (286) are
compressed and the parking brakes are released.

Copyright © Sandvik Mining and Construction 49

ID: BG00201574 A.1 2013-07-12
 50
4.1.7.

285 286
FRONT AXLE REAR AXLE
SERVICE PARKING SERVICE PARKING
LEFT RIGHT LEFT RIGHT LEFT RIGHT LEFT RIGHT

.01 .02 .01 .02

267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293
H H

(REAR SERVICE
.07 F2 S15.1 BRAKE LIGHTS) 5 bar
F1 280 S19
.06 347 5 bar
MF1
344
X12 Y295.1 .02
T
SERVICE BRAKE PRESSURE FRONT (80 bar)
SERVICE BRAKE PRESSURE REAR (80 bar)
PARKING BRAKE PRESSURE FRONT (30 bar)
PARKING BRAKE PRESSURE REAR (30 bar)
CHARGING PRESSURE OF ACCUMULATORS (135-160 bar)
CLARK CLUTCH PRESSURE (17-19 bar)

TO CARRIER CIRCUIT T X 294

.03 A1
P .01 279
.02 30 bar
284
TO CARRIER CIRCUIT
X11
135-
LS 160 bar
A2 Y295 .02
.04
.05 T X

ID: BG00201574 A.1 2013-07-12

B3
X1 P .01
P .01
Steering and braking system, TC7-TC12, NC7

30 bar
S15.2
270
S MS MA X14 278
TO CARRIER CIRCUIT 5 bar

Copyright © Sandvik Mining and Construction

TO CARRIER CIRCUIT
X10
PRESSURE CONTROL OF PRESSURE CONTROL OF
BRAKE CIRCUIT BRAKE CIRCUIT
TO DRILLING CIRCUIT S13B S14B T2
276 277 BR .07
T3 .04 T1 110° C
.06
75 bar 75 bar C1
.05
Parking brake circuit functional diagram (releasing), TC7/TC8

P1
291 C4 C3
275 274 P3
B2 P / I 31 11 .08
P4 OUT IN
B1 3 P / I P/I B1 4 14,3 bar
P2 C2
100 bar 100 bar .01
(ABA 110 bar) (ABA 110 bar)
S16 OUT

Figure: Parking brake circuit functional diagram (releasing), TC7/TC8

GEARBOX

FRONT 65 bar 65 bar REAR 12

272 271 .03 IN
281 282 OPTION OPTION
.01 Y296 Y297 .01 Test valve of 4 bar ENGINE
80bar 80bar rear brake OPTION FAN
.02 P P .02
A A ABA
B B
Carrier hosing
OPTION T and return
T filters
Test valve of front brake X25
Steering and braking system, TC7-TC12, NC7

Parking brake circuit operation (releasing)

When the parking brake is released, the 3/2 directional valves (270.02) and
(344.02) of the parking brake control valves (270) and (344) are activated
and the oil flows to the front parking brake cylinders (285), the rear parking
brake cylinders (286), the pressure switches (278) and the measuring point
assembly (284). When the control pressure of both parking brake circuits
has risen over the 5 bar, the parking brake indicator lamp (H15) on the
tramming panel turns off. The springs in cylinders (285) and (286) are
compressed and the parking brakes are released.

Copyright © Sandvik Mining and Construction 51

ID: BG00201574 A.1 2013-07-12
 52
4.1.8.

285 FRONT AXLE 286 REAR AXLE

SERVICE PARKING SERVICE PARKING
LEFT RIGHT LEFT RIGHT LEFT RIGHT LEFT RIGHT
.01 .02 .01 .02

267 MF2 P2 P2 P1 P1 P2 P2 P1 P1

293 H H

(REAR SERVICE
F2 BRAKE LIGHTS) 5 bar
.07
280 B968P
F1
.06 294
MF1
344 0.2
TO CARRIER CIRCUIT Y960

SERVICE BRAKE PRESSURE FRONT (70 bar)

SERVICE BRAKE PRESSURE REAR (70 bar)
PARKING BRAKE PRESSURE FRONT (30 bar)
PARKING BRAKE PRESSURE REAR (30 bar)
CHARGING PRESSURE OF ACCUMULATORS (135-160 bar)
CLARK CLUTCH
PRESSURE (17-19 bar)

X12 T T X
.03 A1 278
P B961P
0.1 279 284
.02 30 bar
TO CARRIER CIRCUIT 5 bar
X11
135- 347
LS A2 Y961 0.2 B960P
160 bar
.04
T X 5 bar

ID: BG00201574 A.1 2013-07-12

.05 B3
X1 P .01
P .01
Steering and braking system, TC7-TC12, NC7

30 bar
270
X19
TO CARRIER CIRCUIT

Copyright © Sandvik Mining and Construction

S MS MA
X10

TO AIR CONDITION CIRCUIT PRESSURE CONTROL OF PRESSURE CONTROL OF

BRAKE CIRCUIT BRAKE CIRCUIT
Parking brake circuit functional diagram (releasing), TC9

T2 B970T
BR T1 .07 110° C
T3
.06
B966P B967P .04
291 C1
276 277 .05
P3 P1 C4 C3
P/I 31 11 .08
75 bar 75 bar B970P P4 OUT IN

Figure: Parking brake circuit functional diagram (releasing), TC9

14,3 bar
P2 C2
.01
OPTION
275 274 Test valve of B975P
281 OUT
GEARBOX

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

12
OPTION 100 bar 100 bar Y297 .01 4 bar IN ENGINE
Test valve of front brake (ABA 110 bar) (ABA 110 bar) 70bar FAN
OPTION
P .02
Y296 A ABA
80 bar 80 bar
70bar 272 271
.02 FRONT REAR B
P
A
B Carrier hosing T
and return 282
.01 T X25
filters
Steering and braking system, TC7-TC12, NC7

Parking brake circuit operation (releasing)

When the parking brake is released, the 3/2 directional valves (270.02) and
(344.02) of the parking brake control valves (270) and (344) are activated
and the oil flows to the front parking brake cylinders (285), the rear parking
brake cylinders (286), the pressure switches (278) and the measuring point
assembly (284). When the control pressure of both parking brake circuits
has risen over the 5 bar, the parking brake indicator lamp (H15) on the
tramming panel turns off. The springs in cylinders (285) and (286) are
compressed and the parking brakes are released.

Copyright © Sandvik Mining and Construction 53

ID: BG00201574 A.1 2013-07-12
 54
4.1.9.

.01 .02 .01 .02

OPTION
ONLY WITH BRAKE P2 P2 P1 P1 P2 P2 P1 P1
TEST VALVES
MF2 285
293 286

(REAR SERVICE 5 bar

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

SERVICE BRAKE PRESSURE FRONT (70 bar)

SERVICE BRAKE PRESSURE REAR (70 bar)
PARKING BRAKE PRESSURE FRONT (100 bar)
PARKING BRAKE PRESSURE REAR (30 bar)
CHARGING PRESSURE OF ACCUMULATORS (135-160 bar)
CLARK CLUTCH
PRESSURE (17-19 bar)

.02 294
X12 T T 344
267
X
P
.03 A1
.01 279 284
.02 100 bar S15.1
TO CARRIER CIRCUIT 347
X11 50 bar
LS 135- A2 Y295.2
160bar .02 S15.2
.04
T 278
.05 X 5 bar
X1 B3
1/21 P .01
P .01

ID: BG00201574 A.1 2013-07-12

30 bar

270
Steering and braking system, TC7-TC12, NC7

S MS MA
X10 PRESSURE CONTROL OF
S13 B S14B BRAKE CIRCUIT

Copyright © Sandvik Mining and Construction

TO AIR CONDITION/
CARRIER CIRCUIT T2
276 277 B1
PRESSURE CONTROL OF BR T3 T1
BRAKE CIRCUIT 75 ba r 75 bar .06 .04 .07 110° C
.08 C1
B2 291
275 274 P3 P1 C4 C3
.05 P / I 31 11 OUT
B13 P/I P/I B14 IN
14,3 bar
100 bar
100 bar S16 20000/ .01
(ABA 110 bar) 32000
(ABA 110 bar)
Parking brake circuit functional diagram (releasing), TC10-TC12

REAR .03 SERIE

FRONT 272 271 .02 OUT
80 bar 4 bar 12
80 bar IN
OPTION
ABA ENGINE
Y296 Y297 FAN
.02 .01
70bar 70bar

Figure: Parking brake circuit functional diagram (releasing), TC10-TC12

A .01 P P .02 A
B 281 282 B

T T Carrier hosing and

OPTION return filters
BRAKE TEST X14
VALVES
Steering and braking system, TC7-TC12, NC7

Parking brake circuit operation (releasing)

When the parking brake is released, the 3/2 directional valves (270.02) and
(344.02) of the parking brake control valves (270) and (344) are activated
and the oil flows to the front parking brake cylinders (285), the rear parking
brake cylinders (286), the pressure switches (278) and the measuring point
assembly (284). When the control pressure of both parking brake circuits
has risen over the set limits (front brake circuit 50 bar / rear brake circuit 5
bar), the parking brake indicator lamp (H15) on the driving panel turns off.
The springs in cylinders (285) and (286) are compressed and the parking
brakes are released.

4.2. Service brake circuit, TC7-TC12, NC7

1 2

1 Front brake circuit pressure gauge and indicator light (P3)

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

Copyright © Sandvik Mining and Construction 55

ID: BG00201574 A.1 2013-07-12
 ID: BG00201574 A.1 2013-07-12
Copyright © Sandvik Mining and Construction 56
Figure: Service brake circuit functional diagram, NC7
.01
.07

.06

.02

.05
.04
.03

275
267

.01
276

281
.02
293

272
271
344
.01

.02
.01
.01

270

282
277
.02
.02
285

.01
274
.02

345
280

279

.05
.06

.03
SERVICE BRAKE PRESSURE FRONT (80 bar)
SERVICE BRAKE PRESSURE REAR (80 bar)
PARKING BRAKE PRESSURE FRONT (30 bar)

.04
PARKING BRAKE PRESSURE REAR (30 bar)
CHARGING PRESSURE OF ACCUMULATORS (135-160 bar)
CLARK CLUTCH PRESSURE (17-19 bar)

291
284

.02
.01

.07

.08
294

.01
286

347

278
.02
Service brake circuit functional diagram, NC7 4.2.1.
Steering and braking system, TC7-TC12, NC7
Steering and braking system, TC7-TC12, NC7

Operation of the service brake circuit

The oil flows to the service brake circuit from the gear pump (252). From
the pump (252) the oil flows through the double pressure relief valve
assembly (261) to the integrated service brake valve (267) connection P.
If the brake pedal is not used and the service brake circuit pressure
accumulators (271) and (272) do not need extra oil, the oil pressure in the
service brake circuit starts to rise to 160 bar. When the control pressure
rises to 160 bar, the control valve (267.02) changes its position. The pilot
control oil from the control valve (267.01) is directed to the receiver. At the
same time, the control valve (267.01) changes position and directs the oil
from port P to port S of the integrated brake valve (267), and from there the
oil flows to the secondary circuits.
If the control pressure falls below 135 bar in the “charging circuit”, the
control valve (267.02) changes position and directs the oil flow from the
brake circuit main line to the spring side of the control valve's (267.01)
control spool. The control valve (267.01) spool changes position and directs
the main flow through the non-return valve (267.05) and pressure relief
valves (267.03) and (267.04) to ports A2 and A1 of the integrated brake
valve (267).
From port A2 the oil flows to the front brake cylinder pressure transducer
(275) and front brake cylinder pressure accumulator (272). From port A1
the oil flows to the rear brake cylinder pressure transducer (274) and rear
brake cylinder pressure accumulator (271). When the brake pedal is used,
the oil flows through the pressure reducing/relieving valves (267.06) and
(267.07) to port F1 and F2. From there the oil flows to the front service
brake cylinders (285.01), rear service brake cylinders (286.02), and
measuring point collector (284).
The control pressure value of pressure reducing/relieving valves (267.06)
and (267.07) is directly proportional to the change of the brake pedal angle.
The greater the change of angle, the greater control pressure and braking
force.
The function of the pressure accumulators (271) and (272) is to ensure a
sufficient amount of oil for brake pedal operation. Pressure transducers
(274) and (275) control the level of the service brake circuit charging
pressure. If the pressure drops below 100 bar, the warning light (P3) and/or
(P4) of the pressure gauge on the tramming panel lights up.
Normal brake circuit pressure is 135-160 bar. If the brake circuit pressure in
one or both brake circuits is below 75 bar, the brakes cannot be released.
The parking brake holding circuit will not be activated unless the pressures
at front brake circuit pressure switch (276) and rear brake circuit pressure
switch (277) are not within the permissible range. When the brake circuit
pressure in both circuits increases to above the 75 bar limit, the brakes can
be released and the rig can be taken into use by releasing the brakes with
parking brake button S21 on the tramming panel and acknowledging the
brake circuit as released with button SH2 (refer to section 3.3.1).

Copyright © Sandvik Mining and Construction 57

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

The pressures in the brake circuits are also monitored with front and rear
pressure transducers: (275) and B14 (274), respectively. The pressures in
the brake circuits are displayed on brake pressure gauges P3 and P4 on
the tramming panel.
If the brake circuit pressure drops below 100 bar on brake pressure gauges
P3 (front) and P4 (rear) on the tramming panel, the red low brake pressure
warning lights go on.
If the brake pressure in one or both brake circuits (front brake circuit, (276),
and/or rear brake circuit, (277)) drops below 75 bar, the pressure switch
deactivates the parking brake holding circuit and the brakes engage.

58 Copyright © Sandvik Mining and Construction

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

This page is intentionally left blank

Copyright © Sandvik Mining and Construction 59

ID: BG00201574 A.1 2013-07-12
 60
4.2.2.

285 286
FRONT AXLE REAR AXLE
SERVICE PARKING SERVICE PARKING
LEFT RIGHT LEFT RIGHT LEFT RIGHT LEFT RIGHT

.01 .02 .01 .02

267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293
H H

(REAR SERVICE
.07 F2 S15.1 BRAKE LIGHTS) 5 bar
F1 280 S19
.06 347 5 bar
MF1
344
X12 Y295.1 .02
T
SERVICE BRAKE PRESSURE FRONT (80 bar)
SERVICE BRAKE PRESSURE REAR (80 bar)
PARKING BRAKE PRESSURE FRONT (30 bar)
PARKING BRAKE PRESSURE REAR (30 bar)
CHARGING PRESSURE OF ACCUMULATORS (135-160 bar)
CLARK CLUTCH PRESSURE (17-19 bar)

TO CARRIER CIRCUIT T X 294

.03 A1
P .01 279
.02 30 bar
284
TO CARRIER CIRCUIT
X11
135-
LS 160 bar
A2 Y295 .02
.04
.05 T X

ID: BG00201574 A.1 2013-07-12

B3
X1 P .01
P .01
Steering and braking system, TC7-TC12, NC7

30 bar
S15.2
270
278
Service brake circuit functional diagram, TC7-TC8

S MS MA X14
TO CARRIER CIRCUIT 5 bar

Copyright © Sandvik Mining and Construction

TO CARRIER CIRCUIT
X10
PRESSURE CONTROL OF PRESSURE CONTROL OF
BRAKE CIRCUIT BRAKE CIRCUIT
TO DRILLING CIRCUIT S13B S14B T2
276 277 BR .07
T3 .04 T1 110° C

Figure: Service brake circuit functional diagram, TC7-TC8

.06
75 bar 75 bar C1
.05 291
P3 P1 C4 C3
275 274 B2 P / I 31 11 .08
P4 OUT IN
B1 3 P / I P/I B1 4 14,3 bar
P2 C2
100 bar 100 bar .01
(ABA 110 bar) (ABA 110 bar)
S16 OUT
GEARBOX

FRONT 65 bar 65 bar REAR 12

272 271 .03 IN
281 282 OPTION OPTION
.01 Y296 Y297 .01 Test valve of 4 bar ENGINE
80bar 80bar rear brake OPTION FAN
.02 P P .02
A A ABA
B B
Carrier hosing
OPTION and return
T T filters
Test valve of front brake X25
Steering and braking system, TC7-TC12, NC7

Operation of the service brake circuit

The oil flows to the service brake circuit from the gear pump (252). From
the pump (252) the oil flows through the double pressure relief valve
assembly (261) to the integrated service brake valve (267) connection P.
If the brake pedal is not used and the service brake circuit pressure
accumulators (271) and (272) do not need extra oil, the oil pressure in the
service brake circuit starts to rise to 160 bar. When the control pressure
rises to 160 bar, the control valve (267.02) changes its position. The pilot
control oil from the control valve (267.01) is directed to the receiver. At the
same time, the control valve (267.01) changes position and directs the oil
from port P to port S of the integrated brake valve (267), and from there the
oil flows to the secondary circuits.
If the control pressure falls below 135 bar in the “charging circuit”, the
control valve (267.02) changes position and directs the oil flow from the
brake circuit main line to the spring side of the control valve's (267.01)
control spool. The control valve (267.01) spool changes position and directs
the main flow through the non-return valve (267.05) and pressure relief
valves (267.03) and (267.04) to ports A2 and A1 of the integrated brake
valve (267).
From port A2 the oil flows to the front brake cylinder pressure transducer
(275) and front brake cylinder pressure accumulator (272). From port A1
the oil flows to the rear brake cylinder pressure transducer (274) and rear
brake cylinder pressure accumulator (271). When the brake pedal is used,
the oil flows through the pressure reducing/relieving valves (267.06) and
(267.07) to port F1 and F2. From there the oil flows to the front service
brake cylinders (285.01), rear service brake cylinders (286.02), and
measuring point collector (284).
The control pressure value of pressure reducing/relieving valves (267.06)
and (267.07) is directly proportional to the change of the brake pedal angle.
The greater the change of angle, the greater control pressure and braking
force.
The function of the pressure accumulators (271) and (272) is to ensure a
sufficient amount of oil for brake pedal operation. Pressure transducers
(274) and (275) control the level of the service brake circuit charging
pressure. If the pressure drops below 100 bar, the warning light (P3) and/or
(P4) of the pressure gauge on the tramming panel lights up.
Normal brake circuit pressure is 135-160 bar. If the brake circuit pressure in
one or both brake circuits is below 75 bar, the brakes cannot be released.
The parking brake holding circuit will not be activated unless the pressures
at front brake circuit pressure switch (276) and rear brake circuit pressure
switch (277) are not within the permissible range. When the brake circuit
pressure in both circuits increases to above the 75 bar limit, the brakes can
be released and the rig can be taken into use by releasing the brakes with
parking brake button S21 on the tramming panel and acknowledging the
brake circuit as released with button SH2 (refer to section 3.3.1).

Copyright © Sandvik Mining and Construction 61

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

The pressures in the brake circuits are also monitored with front and rear
pressure transducers: (275) and B14 (274), respectively. The pressures in
the brake circuits are displayed on brake pressure gauges P3 and P4 on
the tramming panel.
If the brake circuit pressure drops below 100 bar on brake pressure gauges
P3 (front) and P4 (rear) on the tramming panel, the red low brake pressure
warning lights go on.
If the brake pressure in one or both brake circuits (front brake circuit, (276),
and/or rear brake circuit, (277)) drops below 75 bar, the pressure switch
deactivates the parking brake holding circuit and the brakes engage.

62 Copyright © Sandvik Mining and Construction

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

This page is intentionally left blank

Copyright © Sandvik Mining and Construction 63

ID: BG00201574 A.1 2013-07-12
 64
4.2.3.

285 FRONT AXLE 286 REAR AXLE

SERVICE PARKING SERVICE PARKING
LEFT RIGHT LEFT RIGHT LEFT RIGHT LEFT RIGHT
.01 .02 .01 .02

267 MF2 P2 P2 P1 P1 P2 P2 P1 P1

293 H H

(REAR SERVICE
F2 BRAKE LIGHTS) 5 bar
.07
280 B968P
F1
.06 294
MF1
344 0.2
TO CARRIER CIRCUIT Y960

SERVICE BRAKE PRESSURE FRONT (70 bar)

SERVICE BRAKE PRESSURE REAR (70 bar)
PARKING BRAKE PRESSURE FRONT (30 bar)
PARKING BRAKE PRESSURE REAR (30 bar)
CHARGING PRESSURE OF ACCUMULATORS (135-160 bar)
CLARK CLUTCH
PRESSURE (17-19 bar)

X12 T T X
.03 A1 278
P B961P
0.1 279 284
.02 30 bar
TO CARRIER CIRCUIT 5 bar
X11
135- 347
LS A2 Y961 0.2 B960P
160 bar
.04
T X 5 bar

ID: BG00201574 A.1 2013-07-12

.05 B3
X1
Service brake circuit functional diagram, TC9

P .01
P .01
Steering and braking system, TC7-TC12, NC7

30 bar
270
X19
TO CARRIER CIRCUIT

Copyright © Sandvik Mining and Construction

S MS MA
X10

Figure: Service brake circuit functional diagram, TC9

TO AIR CONDITION CIRCUIT PRESSURE CONTROL OF PRESSURE CONTROL OF
BRAKE CIRCUIT BRAKE CIRCUIT T2 B970T
BR T1 .07 110° C
T3
.06
B966P B967P .04
291 C1
276 277 .05
P3 P1 C4 C3
P/I 31 11 .08
75 bar 75 bar B970P P4 OUT IN
14,3 bar
P2 C2
.01
OPTION
275 274 Test valve of B975P
281 OUT
GEARBOX

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

12
OPTION 100 bar 100 bar Y297 .01 4 bar IN ENGINE
Test valve of front brake (ABA 110 bar) (ABA 110 bar) 70bar FAN
OPTION
P .02
Y296 A ABA
80 bar 80 bar
70bar 272 271
.02 FRONT REAR B
P
A
B Carrier hosing T
and return 282
.01 T X25
filters
Steering and braking system, TC7-TC12, NC7

Operation of the service brake circuit

The oil flows to the service brake circuit from the gear pump (252). From
the pump (252) the oil flows through the double pressure relief valve
assembly (261) to the integrated service brake valve (267) connection P.
If the brake pedal is not used and the service brake circuit pressure
accumulators (271) and (272) do not need extra oil, the oil pressure in the
service brake circuit starts to rise to 160 bar. When the control pressure
rises to 160 bar, the control valve (267.02) changes its position. The pilot
control oil from the control valve (267.01) is directed to the receiver. At the
same time, the control valve (267.01) changes position and directs the oil
from port P to port S of the integrated brake valve (267), and from there the
oil flows to the secondary circuits.
If the control pressure falls below 135 bar in the “charging circuit”, the
control valve (267.02) changes position and directs the oil flow from the
brake circuit main line to the spring side of the control valve's (267.01)
control spool. The control valve (267.01) spool changes position and directs
the main flow through the non-return valve (267.05) and pressure relief
valves (267.03) and (267.04) to ports A2 and A1 of the integrated brake
valve (267).
From port A2 the oil flows to the front brake cylinder pressure transducer
(275) and front brake cylinder pressure accumulator (272). From port A1
the oil flows to the rear brake cylinder pressure transducer (274) and rear
brake cylinder pressure accumulator (271). When the brake pedal is used,
the oil flows through the pressure reducing/relieving valves (267.06) and
(267.07) to port F1 and F2. From there the oil flows to the front service
brake cylinders (285.01), rear service brake cylinders (286.02), and
measuring point collector (284).
The control pressure value of pressure reducing/relieving valves (267.06)
and (267.07) is directly proportional to the change of the brake pedal angle.
The greater the change of angle, the greater control pressure and braking
force.
The function of the pressure accumulators (271) and (272) is to ensure a
sufficient amount of oil for brake pedal operation. Pressure transducers
(274) and (275) control the level of the service brake circuit charging
pressure. If the pressure drops below 100 bar, the warning light (P3) and/or
(P4) of the pressure gauge on the tramming panel lights up.
Normal brake circuit pressure is 135-160 bar. If the brake circuit pressure in
one or both brake circuits is below 75 bar, the brakes cannot be released.
The parking brake holding circuit will not be activated unless the pressures
at front brake circuit pressure switch (276) and rear brake circuit pressure
switch (277) are not within the permissible range. When the brake circuit
pressure in both circuits increases to above the 75 bar limit, the brakes can
be released and the rig can be taken into use by releasing the brakes with
parking brake button S21 on the tramming panel and acknowledging the
brake circuit as released with button SH2 (refer to section 3.3.1).

Copyright © Sandvik Mining and Construction 65

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

The pressures in the brake circuits are also monitored with front and rear
pressure transducers: (275) and B14 (274), respectively. The pressures in
the brake circuits are displayed on brake pressure gauges P3 and P4 on
the tramming panel.
If the brake circuit pressure drops below 100 bar on brake pressure gauges
P3 (front) and P4 (rear) on the tramming panel, the red low brake pressure
warning lights go on.
If the brake pressure in one or both brake circuits (front brake circuit, (276),
and/or rear brake circuit, (277)) drops below 75 bar, the pressure switch
deactivates the parking brake holding circuit and the brakes engage.

66 Copyright © Sandvik Mining and Construction

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

This page is intentionally left blank

Copyright © Sandvik Mining and Construction 67

ID: BG00201574 A.1 2013-07-12
 68
4.2.4.

.01 .02 .01 .02

OPTION
ONLY WITH BRAKE P2 P2 P1 P2 P2 P1 P1
TEST VALVES
MF2 285
293 286

(REAR SERVICE 5 bar

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

SERVICE BRAKE PRESSURE FRONT (70 bar)

SERVICE BRAKE PRESSURE REAR (70 bar)
PARKING BRAKE PRESSURE FRONT (100 bar)
PARKING BRAKE PRESSURE REAR (30 bar)
CHARGING PRESSURE OF ACCUMULATORS (135-160 bar)
CLARK CLUTCH
PRESSURE (17-19 bar)

.02 294
X12 T T 344
267
X
P
.03 A1
.01 279 284
.02 100 bar S15.1
TO CARRIER CIRCUIT
347
X11 50 bar
LS 135- A2 Y295.2
160bar .02 S15.2
.04
T 278
.05 X 5 bar
X1 B3
1/21 P .01
P .01

ID: BG00201574 A.1 2013-07-12

30 bar
270
Steering and braking system, TC7-TC12, NC7

S MS MA
X10 PRESSURE CONTROL OF
BRAKE CIRCUIT

Copyright © Sandvik Mining and Construction

TO AIR CONDITION/ S13 B S14B
Service brake circuit functional diagram, TC10-TC12

CARRIER CIRCUIT T2
276 277 B1
PRESSURE CONTROL OF
BR T3 T1
BRAKE CIRCUIT 75 ba r 75 bar .06 .04 .07 110° C
.08 C1
B2 291
275 274 P3 P1 C4 C3
.05 P / I 31 11 OUT
B13 P/I P/I B14 IN
14,3 bar

Figure: Service brake circuit functional diagram, TC10-TC12

100 bar
S16 20000/ .01
100 bar (ABA 110 bar) 32000
(ABA 110 bar) .03 SERIE
REAR .02 OUT
FRONT 272 271 4 bar
80 bar 80 bar 12
IN
OPTION
ABA ENGINE
Y296 Y297 FAN
.02 .01
70bar 70bar
A .01 P P .02 A
B 281 282 B

T T Carrier hosing and

OPTION return filters
BRAKE TEST X14
VALVES
Steering and braking system, TC7-TC12, NC7

Operation of the service brake circuit

The oil flows to the service brake circuit from the gear pump (252). From
the pump (252) the oil flows through the double pressure relief valve
assembly (261) to the integrated service brake valve (267) connection P.
If the brake pedal is not used and the service brake circuit pressure
accumulators (271) and (272) do not need extra oil, the oil pressure in the
service brake circuit starts to rise to 160 bar. When the control pressure
rises to 160 bar, the control valve (267.02) changes its position. The pilot
control oil from the control valve (267.01) is directed to the receiver. At the
same time, the control valve (267.01) changes position and directs the oil
from port P to port S of the integrated brake valve (267), and from there the
oil flows to the secondary circuits.
If the control pressure falls below 135 bar in the “charging circuit”, the
control valve (267.02) changes position and directs the oil flow from the
brake circuit main line to the spring side of the control valve's (267.01)
control spool. The control valve (267.01) spool changes position and directs
the main flow through the non-return valve (267.05) and pressure relief
valves (267.03) and (267.04) to ports A2 and A1 of the integrated brake
valve (267).
From port A2 the oil flows to the front brake cylinder pressure transducer
(275) and front brake cylinder pressure accumulator (272). From port A1
the oil flows to the rear brake cylinder pressure transducer (274) and rear
brake cylinder pressure accumulator (271). When the brake pedal is used,
the oil flows through the pressure reducing/relieving valves (267.06) and
(267.07) to port F1 and F2. From there the oil flows to the front service
brake cylinders (285.01), rear service brake cylinders (286.02), and
measuring point collector (284).
The control pressure value of pressure reducing/relieving valves (267.06)
and (267.07) is directly proportional to the change of the brake pedal angle.
The greater the change of angle, the greater control pressure and braking
force.
The function of the pressure accumulators (271) and (272) is to ensure a
sufficient amount of oil for brake pedal operation. Pressure transducers
(274) and (275) control the level of the service brake circuit charging
pressure. If the pressure drops below 100 bar, the warning light (P3) and/or
(P4) of the pressure gauge on the tramming panel lights up.
Normal brake circuit pressure is 135-160 bar. If the brake circuit pressure in
one or both brake circuits is below 75 bar, the brakes cannot be released.
The parking brake holding circuit will not be activated unless the pressures
at front brake circuit pressure switch (276) and rear brake circuit pressure
switch (277) are not within the permissible range. When the brake circuit
pressure in both circuits increases to above the 75 bar limit, the brakes can
be released and the rig can be taken into use by releasing the brakes with
parking brake button S21 on the tramming panel and acknowledging the
brake circuit as released with button SH2 (refer to section 3.3.1).

Copyright © Sandvik Mining and Construction 69

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

The pressures in the brake circuits are also monitored with front and rear
pressure transducers: (275) and B14 (274), respectively. The pressures in
the brake circuits are displayed on brake pressure gauges P3 and P4 on
the tramming panel.
If the brake circuit pressure drops below 100 bar on brake pressure gauges
P3 (front) and P4 (rear) on the tramming panel, the red low brake pressure
warning lights go on.
If the brake pressure in one or both brake circuits (front brake circuit, (276),
and/or rear brake circuit, (277)) drops below 75 bar, the pressure switch
deactivates the parking brake holding circuit and the brakes engage.
4.2.5. Operation of the ABA-system

On rigs with ABA brakes, the transmission clutch pressure is monitored

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

70 Copyright © Sandvik Mining and Construction

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Steering and braking system, TC7-TC12, NC7

4.3. Testing the brakes

Figure: Instruction plate for brake testing

Copyright © Sandvik Mining and Construction 71

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Steering and braking system, TC7-TC12, NC7

Figure: Instruction plate for brake testing (USA / Canada option)

72 Copyright © Sandvik Mining and Construction

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Steering and braking system, TC7-TC12, NC7

4.3.1. Service brake testing system, TC7-TC12, NC7 (optional)

rpm

0
rpm

1
SH56

Figure: With Mercedes Benz engine

rpm

0
rpm

1
SH56

Figure: With Cummins engine

1 Service brake test switch (S29)

2 Parking brake test switch (S25)

Copyright © Sandvik Mining and Construction 73

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Steering and braking system, TC7-TC12, NC7

Functional diagram of the service brake testing system, NC7

.02

278
347
286

.01
294

.08
.07
.01

.02
284

291
CLARK CLUTCH PRESSURE (17-19 bar)

CHARGING PRESSURE OF ACCUMULATORS (135-160 bar)

PARKING BRAKE PRESSURE REAR (30 bar)

.04
PARKING BRAKE PRESSURE FRONT (30 bar)

SERVICE BRAKE PRESSURE REAR (80 bar)

SERVICE BRAKE PRESSURE FRONT (80 bar)

.03
.06
.05
279
280

345
.02

274

.01
285

.02

.02

277

282
270
.01

.01

.02
.01

344

271
272
293

.02

281
276

.01
267

275
.03

.04
.05
.02
.06
.07

.01

Figure: Functional diagram of the service brake testing system, NC7

74 Copyright © Sandvik Mining and Construction

ID: BG00201574 A.1 2013-07-12
Steering and braking system, TC7-TC12, NC7

Operation of the service brake testing system, TC7-TC8, NC7

Testing of the front axle service brake

When the service brake testing valve's (281) spool Y296 is activated, the
valve allows oil to flow from port P to port B. The oil flows to the front axle
service brake through the shuttle valve (293). The pressure reduction valve
decreases the oil pressure to the brakes to 80 bar.

Testing of the rear axle service brake

When the service brake testing valve's (282) spool Y297 is activated, the
valve allows oil to flow from port P to port B. The oil flows to the rear axle
service brake through the shuttle valve (294). The pressure reduction valve
decreases the oil pressure to the brakes to 80 bar.

Copyright © Sandvik Mining and Construction 75

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 76
285 286
FRONT AXLE REAR AXLE
SERVICE PARKING SERVICE PARKING
LEFT RIGHT LEFT RIGHT LEFT RIGHT LEFT RIGHT

.01 .02 .01 .02

267 MF2 P2 P2 P1 P1 P2 P2 P1 P1
293
H H

(REAR SERVICE
.07 F2 S15.1 BRAKE LIGHTS) 5 bar
F1 280 S19
.06 347 5 bar
MF1
344
X12 Y295.1 .02
T

SERVICE BRAKE PRESSURE FRONT (80 bar)

SERVICE BRAKE PRESSURE REAR (80 bar)
PARKING BRAKE PRESSURE FRONT (30 bar)
PARKING BRAKE PRESSURE REAR (30 bar)
CHARGING PRESSURE OF ACCUMULATORS (135-160 bar)
CLARK CLUTCH PRESSURE (17-19 bar)

TO CARRIER CIRCUIT T X 294

.03 A1
P .01 279
.02 30 bar
284
TO CARRIER CIRCUIT
X11
135-
LS 160 bar
A2 Y295 .02
.04
.05 T X

ID: BG00201574 A.1 2013-07-12

B3
X1 P .01
P .01
30 bar
Steering and braking system, TC7-TC12, NC7

S15.2
270
S MS MA X14 278
TO CARRIER CIRCUIT 5 bar

Copyright © Sandvik Mining and Construction

TO CARRIER CIRCUIT
X10
PRESSURE CONTROL OF PRESSURE CONTROL OF
BRAKE CIRCUIT BRAKE CIRCUIT
TO DRILLING CIRCUIT S13B S14B T2
276 277 BR .07
T3 .04 T1 110° C
.06
75 bar 75 bar C1
.05 291
P3 P1 C4 C3
275 274 B2 P / I 31 11 .08
P4 OUT IN
B1 3 P / I P/I B1 4 14,3 bar
Functional diagram of the service brake testing system, TC7-TC8

P2 C2
100 bar 100 bar .01
(ABA 110 bar) (ABA 110 bar)
S16 OUT
GEARBOX

FRONT 65 bar 65 bar REAR 12

272 271 .03 IN
281 282 OPTION OPTION
.01 Y296 Y297 .01 Test valve of 4 bar ENGINE

Figure: Functional diagram of the service brake testing system, TC7-TC8

80bar 80bar rear brake OPTION FAN
.02 P P .02
A A ABA
B B
Carrier hosing
OPTION T T and return
filters
Test valve of front brake X25
Steering and braking system, TC7-TC12, NC7

Operation of the service brake testing system, TC7-TC8, NC7

Testing of the front axle service brake

When the service brake testing valve's (281) spool Y296 is activated, the
valve allows oil to flow from port P to port B. The oil flows to the front axle
service brake through the shuttle valve (293). The pressure reduction valve
decreases the oil pressure to the brakes to 80 bar.

Testing of the rear axle service brake

When the service brake testing valve's (282) spool Y297 is activated, the
valve allows oil to flow from port P to port B. The oil flows to the rear axle
service brake through the shuttle valve (294). The pressure reduction valve
decreases the oil pressure to the brakes to 80 bar.

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 78
285 FRONT AXLE 286 REAR AXLE
SERVICE PARKING SERVICE PARKING
LEFT RIGHT LEFT RIGHT LEFT RIGHT LEFT RIGHT
.01 .02 .01 .02

267 MF2 P2 P2 P1 P1 P2 P2 P1 P1

293 H H

(REAR SERVICE
F2 BRAKE LIGHTS) 5 bar
.07
280 B968P
F1
.06 294
MF1
344 0.2
TO CARRIER CIRCUIT Y960

SERVICE BRAKE PRESSURE FRONT (70 bar)

SERVICE BRAKE PRESSURE REAR (70 bar)
PARKING BRAKE PRESSURE FRONT (30 bar)
PARKING BRAKE PRESSURE REAR (30 bar)
CHARGING PRESSURE OF ACCUMULATORS (135-160 bar)
CLARK CLUTCH
PRESSURE (17-19 bar)

X12 T T X
.03 A1 278
P B961P
0.1 279 284
.02 30 bar
TO CARRIER CIRCUIT 5 bar
X11
135- 347
LS A2 Y961 0.2 B960P
160 bar
.04
T X 5 bar
.05 B3

ID: BG00201574 A.1 2013-07-12

X1 P .01
P .01
30 bar
Steering and braking system, TC7-TC12, NC7

270
X19
TO CARRIER CIRCUIT
S MS MA

Copyright © Sandvik Mining and Construction

X10

TO AIR CONDITION CIRCUIT PRESSURE CONTROL OF PRESSURE CONTROL OF

BRAKE CIRCUIT BRAKE CIRCUIT T2 B970T
BR T1 .07 110° C
T3
.06
B966P B967P .04
291 C1
Functional diagram of the service brake testing system, TC9

276 277 .05

P3 P1 C4 C3
P/I 31 11 .08
75 bar 75 bar B970P P4 OUT IN
14,3 bar
P2 C2
.01
OPTION

Figure: Functional diagram of the service brake testing system, TC9

275 274 Test valve of B975P
281 OUT
GEARBOX

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

12
OPTION 100 bar 100 bar Y297 .01 4 bar IN ENGINE
Test valve of front brake (ABA 110 bar) (ABA 110 bar) 70bar FAN
OPTION
P .02
Y296 A ABA
80 bar 80 bar
.01 70bar
.02 FRONT 272 271 REAR
P B
A
B Carrier hosing T
T and return 282
filters X25
Steering and braking system, TC7-TC12, NC7

Operation of the service brake testing system, TC9-TC12

Testing of the front axle service brake

When the service brake testing valve's (281) spool Y296 is activated, the
valve allows oil to flow from port (P) to port (B). The oil flows to the front
axle service brake through the shuttle valve (293). The pressure reduction
valve decreases the oil pressure to the brakes to 70 bar.

Testing of the rear axle service brake

When the service brake testing valve's (282) spool Y297 is activated, the
valve allows oil to flow from port (P) to port (B). The oil flows to the rear
axle service brake through the shuttle valve (294). The pressure reduction
valve decreases the oil pressure to the brakes to 70 bar.

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 80
.01 .02 .01 .02
OPTION
ONLY WITH BRAKE P2 P2 P1 P2 P2 P1 P1
TEST VALVES
MF2 285
293 286

(REAR SERVICE 5 bar

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

SERVICE BRAKE PRESSURE FRONT (70 bar)

SERVICE BRAKE PRESSURE REAR (70 bar)
PARKING BRAKE PRESSURE FRONT (100 bar)
PARKING BRAKE PRESSURE REAR (30 bar)
CHARGING PRESSURE OF ACCUMULATORS (135-160 bar)
CLARK CLUTCH
PRESSURE (17-19 bar)
.02 294
X12 T T 344
267
X
P
.03 A1
.01 279 284
.02 100 bar S15.1
TO CARRIER CIRCUIT
347
X11 50 bar
LS 135- A2 Y295.2
160bar .02 S15.2
.04
T 278
.05 X 5 bar
X1 B3
1/21 P .01
P .01
30 bar

ID: BG00201574 A.1 2013-07-12

270
Steering and braking system, TC7-TC12, NC7

S MS MA
X10 PRESSURE CONTROL OF
S13 B S14B BRAKE CIRCUIT
TO AIR CONDITION/

Copyright © Sandvik Mining and Construction

CARRIER CIRCUIT T2
276 277 B1
PRESSURE CONTROL OF BR
BRAKE CIRCUIT 75 ba r 75 bar .06
T3 T1 .07
.04 110° C
.08 C1
B2 291
275 274 P3 P1 C4 C3
.05 P / I 31 11 OUT
B13 P/I P/I B14 IN
14,3 bar
100 bar
100 bar S16 20000/ .01
(ABA 110 bar) 32000
(ABA 110 bar) SERIE
REAR .03
FRONT 272 271 .02 OUT
80 bar 80 bar 4 bar 12
IN
OPTION
Functional diagram of the service brake testing system, TC10-TC12

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

Figure: Functional diagram of the service brake testing system, TC10-TC12

T T
OPTION X14
BRAKE TEST Carrier hosing and
return filters
VALVES
Steering and braking system, TC7-TC12, NC7

Operation of the service brake testing system, TC9-TC12

Testing of the front axle service brake

When the service brake testing valve's (281) spool Y296 is activated, the
valve allows oil to flow from port (P) to port (B). The oil flows to the front
axle service brake through the shuttle valve (293). The pressure reduction
valve decreases the oil pressure to the brakes to 70 bar.

Testing of the rear axle service brake

When the service brake testing valve's (282) spool Y297 is activated, the
valve allows oil to flow from port (P) to port (B). The oil flows to the rear
axle service brake through the shuttle valve (294). The pressure reduction
valve decreases the oil pressure to the brakes to 70 bar.

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Steering and braking system, TC7-TC12, NC7

4.4. Emergency steering, TC7-TC8, NC7 (optional)

4.4.1. Functional diagram of emergency steering, TC7-TC8, NC7

LEF T RI GHT
283

R L
190ba r 190ba r
.06 .05 295

.01
.04 .03 1

263
.02

Y398 EMERGENCY STEERING

.07 LS OPTION
2
.01 299
80bar
.02 10L
140ba r

P T 296 2 1

Ca r r i e r h o s i n g a n d X1 Y399
X9 r e t u r n f i l t e r s
ONLY WITH EMERGENCY 298
STEERING X8 Ca r r i e r h o s i n g a n d
CF

EF

X7 r e t u r n f i l t e r s N S1
.03 T
X2 3 Ca r r i e r h o s i n g a n d
262 r e t ur n f i l t e r s S2
LS

.01 .03
.02 P
P

297

X1 .01

.02

.04 T
B2 T A2

.03 .04

220 ba r 200 ba r
261 X15
Carrier hosing and
.01 .02 return filters

B1 T A1
X1 3 Ca r r i e r h o s i n g a n d
r e t ur n f i l t e r s

P P
16c c 16c c
257 M 252
251 S S
From port B1 when
TC8 2-boom jumbo

( B1 )
S1 S2

312

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Steering and braking system, TC7-TC12, NC7

4.4.2. Components

Emergency steering Directs oil from the pressure

295 control valve (emergency accumulator (296) to the
steering, optional) steering valve (263).
Directs oil from the pressure
.01 Directional valve accumulator (296) to the
steering valve (263).
.02 Flow control valve
Pressure accumulator Functions as the oil reserve for
296
(emergency steering) the emergency steering.
Charging valve Charges the pressure
297
(emergency steering) accumulator (296).
.01 Priority valve
.02 Charging valve
.03 Check valve
.04 Restrictor
Non-return valve
298
(emergency steering)
Releases the pressure from the
Release valve for
299 accumulator of the emergency
emergency steering
steering.

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Steering and braking system, TC7-TC12, NC7

4.4.3. Operation of the emergency steering

If the rig voltage drops below 26.5 V, the 2/2 directional valve (295.01)
opens and releases the oil from the pressure accumulator (296) to the
steering circuit.
When the carrier main switch is on, the coil of valve Y399 (299) is activated
and the valve close the connection from the pressure accumulators to the
tank. When the engine is started, charging of the pressure accumulators
begins.
Note! When the carrier main switch is on, the coils of valves Y398 and Y399
remain continuously activated and keep discharging the rig batteries
if the rig is not connected to an external network.

WARNING
HIGH-PRESSURE FLUID HAZARD!
High-pressure fluid remaining in hydraulic lines could cause serious
injury.
Never carry out maintenance or repair work on a pressurized system.
Relieve pressure before opening fittings, plugs or hydraulic valve
cartridges. Always make sure the parts are not pressurized. Use a
bleeder screw to relieve the pressure behind the valves or
cartridges, or wait until the unit is depressurized, before removing
the components.

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Steering and braking system, TC7-TC12, NC7

5. STEERING AND BRAKE SYSTEM TROUBLESHOOTING

5.1. Steering
Fault Cause Action
The wheels do not stay turned in the
desired direction but move forward and
Air in the steering cylinder or in
backward when the steering wheel is not Bleed the steering
the piping between the cylinder
turned. The steering wheel must be system.
and the steering valve.
turned quite a distance (e.g., 1/4 of a
turn) before the wheels start turning.
The wheels do not stay turned in the
desired direction but move forward and
backward when the steering wheel is not Worn connections in the Change the worn
turned. The steering wheel must be steering system controls. connections.
turned quite a distance (e.g., 1/4 of a
turn) before the wheels start turning.
The wheels do not stay turned in the
desired direction but move forward and Air in the steering system – e.g.,
Check the oil level
backward when the steering wheel is not if the oil level in the tank is too
and check for oil
turned. The steering wheel must be low or the suction hose of the
leaks.
turned quite a distance (e.g., 1/4 of a hydraulic pump leaks.
turn) before the wheels start turning.
Oil leaks in the hydraulic circuit
The wheels turn during tramming, usually between the steering valve and
slowly, even though the steering wheel is cylinder because of:
not turned. When the steering wheel is • a faulty steering cylinder Replace the parts.
turned, the wheels do not turn or they • a worn ORBITROL steering
turn slowly. valve
• a faulty surge damping valve
Clean the steering
Steering is unstable and the steering
valve, and check the
wheel is stiff when turned. The turning Dirt in the ORBITROL steering
cleanliness of the oil
movement of the steering wheel valve causes the adjusting valve
using an oil
continues – e.g., when the steering wheel spools to stick.
analyzer. Change
is released.
the oil.
There is no oil in the steering Check the pump
The steering wheel turns lightly system due to, for example: output pressure
approximately 8 degrees in either • a faulty hydraulic pump from the pressure
direction from the middle position, but • a faulty safety relief valve or gauge in the
after this turning feels heavy. Power flow regulator valve measuring point.
steering is not working. • a faulty non-return valve in Replace faulty/worn
the ORBITROL control valve components.

A jammed steering wheel arm

The steering wheel is heavy when turned Replace faulty/worn
bearing or faulty ORBITROL
or does not turn at all. components.
control valve.

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Steering and braking system, TC7-TC12, NC7

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

86 Copyright © Sandvik Mining and Construction

ID: BG00201574 A.1 2013-07-12
www.sandvik.com
 Instrucciones originales
498 2 es 2009-12-14

CAMBIO DEL NEUMÁTICO E INSPECCIÓN DE

LLANTA
Índice de contenidos

1. EXTRACCIÓN SEGURA DE UNA RUEDA DE LA MÁQUINA ..................................................... 3

2. MARCAS EN EL NEUMÁTICO ..................................................................................................... 5

3. LLANTAS ....................................................................................................................................... 6
3.1. Marcas en la llanta ........................................................................................................................................... 7

4. INSPECCIONES EN LOS COMPONENTES DE LA RUEDA ....................................................... 8

4.1. Inspecciones previas al montaje de un neumático en una llanta ....................................................... 8
4.2. Inspección magnética de la llanta ............................................................................................................... 9

5. MONTAJE DE UN NEUMÁTICO EN UNA LLANTA ..................................................................... 10

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

Copyright © Sandvik Mining and Construction 1 (14)

ID: 498 2 es 2009-12-14
2 (14) Copyright © Sandvik Mining and Construction
ID: 498 2 es 2009-12-14
 CAMBIO DEL NEUMÁTICO E INSPECCIÓN DE LLANTA

1. EXTRACCIÓN SEGURA DE UNA RUEDA DE LA MÁQUINA ID: 11151

Siga siempre las normativas de seguridad locales y específicas

para minas cuando manipule las ruedas o los neumáticos de los
equipos de perforación de roca.

Nunca se posicione bajo un equipo que esté elevado sobre los

gatos.

Apoye siempre de forma adecuada el equipo de perforación de

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

Cuando manipule las ruedas, tenga en cuenta las cargas extra

provocadas por el inflado de los neumáticos.

Cuando extraiga la rueda del eje de oscilación, preste atención

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

Se recomienda encargar a personal cualificado la inspección y

el montaje de los neumáticos y las llantas.

La extracción de una rueda es una operación especializada, que requiere conocimientos y equipos
especializados.
Antes de extraer una rueda, asegúrese siempre de que puede trabajar de forma segura y según lo
indicado por las normativas de seguridad locales y específicas para minas.
Deberá disponerse de herramientas adecuadas para una extracción segura de las ruedas.
Antes de aflojar ninguna de las tuercas de la rueda, compruebe siempre lo siguiente:
1. ¿Se ha estado conduciendo con el neumático desinflado (80% o más por debajo de la presión
de funcionamiento recomendada)? En caso de duda, compruebe la presión.
2. ¿Existen sospechas de deterioro o daños evidentes en el neumático o los componentes de la
rueda?

Si se cumplen estas condiciones, antes de aflojar las tuercas de la rueda, el neumático deberá
desinflarse completamente extrayendo el núcleo de la válvula.
Si la llanta y el neumático están en buenas condiciones, desinfle el neumático a una presión de 35
kPa (0,35 bares, 5 psi), antes de aflojar las tuercas de la rueda.

Copyright © Sandvik Mining and Construction 3 (14)

ID: 498 2 es 2009-12-14
CAMBIO DEL NEUMÁTICO E INSPECCIÓN DE LLANTA

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

4 (14) Copyright © Sandvik Mining and Construction

ID: 498 2 es 2009-12-14
 CAMBIO DEL NEUMÁTICO E INSPECCIÓN DE LLANTA

2. MARCAS EN EL NEUMÁTICO ID: 11146

2
1
3

5
6

ID: 30003

1 Ancho del neumático 2 Diámetro de la llanta

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

Copyright © Sandvik Mining and Construction 5 (14)

ID: 498 2 es 2009-12-14
CAMBIO DEL NEUMÁTICO E INSPECCIÓN DE LLANTA

3. LLANTAS ID: 11149

Existen tres tipos principales de llanta: llantas de una pieza, llantas segmentadas y llantas multipieza.
Los equipos de perforación Sandvik suelen usar llantas multipieza.

1 1 4
2
3 5
3

ID: 30015

1 Anillo lateral 2 Anillo de bloqueo

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

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3.1. Marcas en la llanta ID: 11150

Las ruedas de disco están marcadas con la siguiente información:

• Designación del tamaño de la llanta
• Identificación del fabricante de la llanta
• Fecha de fabricación

Los anillos están marcados con la siguiente información:

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

Designación del tamaño de la llanta

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

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4. INSPECCIONES EN LOS COMPONENTES DE LA RUEDA ID: 29718

4.1. Inspecciones previas al montaje de un neumático en una llanta ID: 29720

El desmontaje de las ruedas y la inspección de los componentes de las ruedas son operaciones
especializadas, que requieren conocimientos y equipos especializados.
Todos los componentes de las ruedas multipieza deben inspeccionarse antes de su ensamblaje.
Realice una inspección y asegúrese de que los componentes de la llanta y el neumático coinciden.
No reutilice una llanta o un componente de una llanta que esté:
• doblado o encorvado
• corroído
• roto
• partido

ID: 29739

1. dado de sí

Nunca use un anillo de bloqueo (anillo de cierre) que haya dado

de sí.

No utilice las llantas si:

• Los orificios de los tornillos están desgastados o presentan una forma elíptica.
• La llanta se ha reparado mediante soldadura.
• La llanta presenta un desgaste avanzado en el área del asiento del talón.

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Las bridas de la llanta, los anillos y las superficies del asiento del talón del neumático de la llanta
deben estar limpias y libres de óxido.

No reutilice los neumáticos si:

• La máquina se ha conducido con neumáticos vacíos o despresurizados casi por completo.

• Existen signos de desgaste en el neumático o el neumático tiene más de 10 años.
• El estado general del neumático no es adecuado, por ejemplo: existen fracturas o queda muy poca
superficie de rodamiento.
• El neumático presenta daños irreparables.
• El neumático ha estado en funcionamiento reparado.

Compruebe que el neumático está limpio y seco y que no contiene materiales extraños.
Los componentes de ruedas multipieza no deben intercambiarse. Use exclusivamente las piezas de
recambio incluidas en el paquete de piezas de recambio suministrado por Sandvik para la llanta en
cuestión.

4.2. Inspección magnética de la llanta ID: 30027

Cuando la llanta alcance de 12000 a 15000 horas de servicio, debe realizarse una inspección de
partículas magnéticas. Si la inspección no se lleva a cabo, la llanta y sus piezas deben retirarse del
servicio.
Consulte al fabricante de la llanta los intervalos de horas recomendados para la realización de
inspecciones magnéticas en las llantas.
La inspección siempre debe repetirse en intervalos de 12000 a 15000 horas de servicio.
Si se detectan deterioros durante las inspecciones visuales, la inspección de partículas magnéticas
debe realizarse inmediatamente, antes de seguir usando la llanta. Si la inspección no se lleva a cabo,
la llanta debe retirarse del servicio.
Para realizar una inspección de partículas magnéticas en un ensamblaje de llanta, el neumático debe
extraerse primero.
Esta instrucción es una directriz. Respete siempre las normas
de agencia, obligatorias, indicadas por las autoridades, o
específicas de la mina, relativas a las inspecciones magnéticas
en llantas.

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5. MONTAJE DE UN NEUMÁTICO EN UNA LLANTA ID: 30030

5.1. Seguridad en la colocación de neumáticos ID: 30032

Cuando presurice un neumático, tome siempre las siguientes precauciones de seguridad:

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

5.2. Presurización del neumático ID: 30036

La colocación de neumáticos es una operación especializada, que requiere conocimientos y equipos

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

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5.3. Jaula de seguridad ID: 26731

Siempre que sea posible, use la jaula de seguridad.

La jaula de seguridad es un dispositivo de seguridad para la presurización de neumáticos, diseñado
para minimizar las consecuencias derivadas de una posible explosión de un neumático. La red de
seguridad alrededor de la jaula de seguridad detendrá los componentes de la llanta o las partes del
neumático que salgan disparados en caso de explosión del neumático.

ID: 26763

Figura: Jaula de seguridad con un inflador de neumáticos automático.

Tras el inflado, los componentes de la rueda y el neumático deben inspeccionarse aún dentro de la
jaula de seguridad para garantizar que están correctamente posicionados y sujetos.
Si es necesario realizar ajustes adicionales en los componentes de la rueda o el neumático, el
neumático debe desinflarse extrayendo el núcleo de la válvula, antes de realizar el ajuste.
Cuando presurice un neumático, tome siempre las siguientes precauciones:
Trabaje con cuidado y precaución.

Antes de inflar el neumático, asegúrese de que los

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

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Use siempre una jaula de seguridad o dispositivos similares

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

Levante la rueda acoplada a la máquina de montaje o al

vehículo. La rueda seguirá puesta aunque el neumático explote
mientras se está inflando.

Use siempre protectores auditivos. Incluso al retirar la válvula,

se excede el límite de ruido de 90 dB. Si no se usan protectores
auditivos, en caso de explosión de un neumático, se sufrirán
lesiones auditivas permanentes.

Nunca se coloque junto a la rueda, se siente en el neumático ni

se apoye en el neumático mientras se está inflando. Infle el
neumático desde una distancia adecuada.

Colóquese a una distancia prudencial (al menos 1.5 m) y en lado

de la superficie de rodamiento. Use el tipo de pieza de entrada
para la manguera de aire que pueda acoplarse a la válvula.

Observe el neumático mientras se está inflando. Supervise la

presurización y compruebe que los talones del neumático se
elevan correctamente en la llanta. Asegúrese de que las piezas
de la llanta de tipo multipieza se han colocado correctamente.
Lleve el neumático con la llanta multipieza a la jaula de
seguridad tras la presurización a 150 kPa (22 psi, 1,5 bares).

Está prohibida la presencia de personal no autorizado cerca de

la rueda mientras se esté inflando el neumático.

Si detecta algún tipo de anomalía, vacíe y compruebe el

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

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www.sandvik.com
 Original instructions
BG00201664 A.2 2013-09-10

Mercedes Benz engine fault codes

Mercedes Benz engine fault codes

Table of contents

1. Engine control fault codes ........................................... 1

1.1. Fault codes of engine control (PLD-MR) via SAE J1939 ...................1

2. Vehicle control fault codes .......................................... 27

2.1. Fault codes of vehicle control (ADM2) via SAE J1939 ...................... 27

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Mercedes Benz engine fault codes

1. ENGINE CONTROL FAULT CODES

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

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Mercedes Benz engine fault codes

Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
• check oil level, correct if necessary.
• check wire for short circuit to
battery, repair or replace if
oil level sensor necessary.
measured value
02517 (up to diagnosis
not plausible • check oil level sensor, replace if
version 4)
necessary. nominal value: 20...25
Ohm
• perform functional check.
• check oil level, correct if necessary.
• check wire for short circuit to
ground, repair or replace if
measuring necessary.
oil level sensor
98/4 02515 range
** • check oil level sensor, replace if
exceeded
necessary. nominal value: 20...25
Ohm
• perform functional check.
• check oil level, correct if necessary.
• check wire for short circuit to
ground, repair or replace if
oil level sensor measured value necessary.
98/3 02516
** not plausible • check oil level sensor, replace if
necessary. nominal value: 20...25
Ohm
• perform functional check.
• check oil level sensor , replace if
necessary.
oil level sensor open circuit
98/5 02509 • check wire for open circuit fault,
** fault
repair or replace if necessary.
• perform functional check.
• check oil level, correct if necessary.
• check wire for open circuit fault,
oil pressure signal not repair or replace if necessary.
100/2 11617
sensor plausible • check oil pressure sensor, replace
if necessary.
• perform functional check.

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Mercedes Benz engine fault codes

Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
• check oil pressure sensor, replace
if necessary.
measuring
oil pressure • check wire for open circuit fault or if
100/3 11615 range
sensor shortened to batteryvoltage, repair
exceeded
if necessary.
• perform functional check.
• check oil pressure sensor, replace
remains under if necessary.
oil pressure
100/4 11616 measuring • check wire for short circuit to
sensor
range ground, repair if necessary.
• perform functional check.
engine oil pressure too • message via CAN: oil pressure
100/14 02020
circulation ** low advance warning or warning
• if fault codes 11415 or11417 are
also present, process them first.
boost pressure • boost pressure system (boost air
102/0 11820 booster path *
too high tubes, boost air cooler) visual
check.
• perform functional check.
• check tubes and connections
between turbocharger, boost air
booster path cooler and the boost air tubes for
102/1 11818 booster path * leakage.
defective
• check boost air cooler.
• perform functional check.
• check wire for open circuit fault,
repair if necessary.
• check boost pressure sensor,
boost pressure measured value replace if necessary.
102/2 11417
sensor not plausible • perform functional check.
• if fault code 01315 or 01316 also
actual: replace and calibrate ECU
engine control (e.g. MR-PLD).

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Mercedes Benz engine fault codes

Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
• check boost pressure, replace if
necessary.
measuring
boost pressure • check wire for open circuit fault and
102/3 11415 range
sensor if shorted to battery voltage, repair
exceeded
if necessary.
• perform functional check.
• unplug the connector from
combination sensor. fault codes
remains under 01215 and 11415 actual: replace
boost pressure combination sensor.
102/4 11416 measuring
sensor
range • check wire for short circuit to
ground, repair if necessary.
• perform functional check.
max. output of
booster path /
booster speed
102/13 11873 boost pressure
balancing
control **
governor
booster path / set value (with power reduction)
11874ord
102/13 boost pressure deviation too • check booster path fault codes
er 01874
control high 11874* , 01874**
booster path / boost pressure
102/13 11875 boost pressure deviation too
control * high
booster path /
braking power
102/13 11876 boost pressure
too low
control *
(boost
scavenging pressure ) • check sensor, replace if necessary.
102/13 12415 gradient sensor measuring
(P2S-P3) ** range • check wire for open circuit
exceeded
(boost
scavenging pressure ) • check sensor, replace if necessary.
102/13 12416 gradient sensor remains under
(P2S-P3) ** measuring • check wire for open circuit
range
no speed no engine
103/7 12612
booster 1 ** speed

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Mercedes Benz engine fault codes

Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
no speed no engine
103/14 12712
booster 2 ** speed
temperature to • temperature of boost pressure too
105/0 01822 booster path **
high high
• check temperature sensor, replace
if necessary.
• nominal value: 2.4 k Ohm
boost measuring (corresponds to 215C)
105/3 11215 temperature range
sensor exceeded • check wire if connected to battery
voltage and if open circuit fault,
repair if necessary.
• perform functional check.
• check temperature sensor, replace
if necessary.
boost remains under • nominal value: 2.4 kOhm
105/4 11216 temperature measuring (corresponds to 215C)
sensor range • check wire for short circuit to
ground, repair if necessary.
• perform functional check.
coolant
temperature too
110/0 02122 temperature
high
sensor *
• check sensor, repair or replace if
necessary.
• nominal value: 2.4 kOhm
coolant measuring (corresponds to 215C)
110/3 11515 temperature range
sensor exceeded • check wire for open circuit fault or if
shortened to battery voltage, repair
if necessary.
• perform functional check.
• check sensor, repair or replace if
necessary.
coolant remains under • nominal value: 2.4 kOhm
110/4 11516 temperature measuring (corresponds to 215C)
sensor range • check wire for open circuit fault,
repair or replace if necessary.
• perform functional check.

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Mercedes Benz engine fault codes

Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
• check fuse, replace if necessary.
inconsistency • check wires and plug connectors
terminal 15
158/2 12219 MR<->FR for open circuit fault, repair or
detection *
terminal 15 replace if necessary.
• perform functional check.
• check wires and plug connectors
for open circuit fault, repair if
inconsistency necessary.
terminal 50
158/2 12319 MR<->FR
detection * • check wires and plug connectors
terminal 50
for open circuit fault, repair if
necessary.
terminal 30, nominal range • 24 V-Mode: 30 V, 12 V-Mode: 16 V
168/3 07542
battery voltage exceeded • alternator or governer defect
• 24 V-Mode: 22 V, 12 V-Mode: 10 V
terminal 30, remains below
168/4 07543 • battery defect
battery voltage nominal range
• alternator, governor or fuse defect
• check wire, repair or replace if
necessary.
• nominal value: 2.4 kOhm
fuel measuring (corresponds to 215C).
174/3 11115 temperature range
sensor exceeded • check wire if shortened to battery
voltage and if open circuit fault,
repair if necessary.
• perform functional check.
• check sensor, repair or replace if
necessary.
fuel remains under • nominal value: 2.4 kOhm
174/4 11116 temperature measuring (corresponds to 215C).
sensor range • check wire for short circuit to
ground, repair if necessary.
• perform functional check.

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Mercedes Benz engine fault codes

Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
• check oil temperature sensor and
replace if necessary.
measuring • nominal value: 2.4 kOhm
oil temperature (corresponds to 215C).
175/3 01015 range
sensor
exceeded • check wire for ground short, repair
if necessary.
• perform functional check.
• check oil temperature sensor B11
and replace if necessary.
remains under • nominal value: 2.4 kOhm
oil temperature (corresponds to 215C).
175/4 01016 measuring
sensor
range • check wire for ground short, repair
if necessary.
• perform functional check.
• inform about authorized engine
engine speed speed
190/0 10530 engine speed
too high
• delete fault memory
• check all affected connectors, plug
connections and electrical
components for damage, loose
backup control contact, corrosion etc. and repair if
609/11 04056 internal fault * necessary.
defective*
• if fault code is still present, renew
and program control unit.
• perform functional check.
• if fault codes 11415 or 11416 are
present, remove them first.
• fault code 01315 remains present:
measuring
ambient read out actual values 014 and 015
609/12 01315 range
pressure sensor and compare with each other.
exceeded
• actual value should be inside
tolerance band (+/- 10%) while
engine stops.

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Mercedes Benz engine fault codes

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

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Mercedes Benz engine fault codes

Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
• check all affected plugs, plug
connectors and electrical
starter driver components for damage, loose
609/12 14038 internal fault ** high-resistance contact, corrosion etc. and repair if
(main path) necessary.
• perform functional check.
• check all affected plugs, plug
14039 starter connectors and electrical
driver low- components for damage, loose
609/12 14039 internal fault * resistance contact, corrosion etc. and repair if
(main path or necessary.
auxiliary path)
• perform functional check.
• check all affected plugs, plug
connectors and electrical
level detection components for damage, loose
609/12 04040 internal fault starter defec- contact, corrosion etc. and repair if
tive necessary.
• perform functional.
• check all affected plugs, plug
connectors and electrical
internal fault (till PV- Highside- components for damage, loose
609/12 14041 diagnosis transistor contact, corrosion etc. and repair if
version 4) defective necessary.
• perform functional check.
• check all affected plugs, plug
connectors and electrical
components for damage, loose
CAN-data area contact, corrosion etc. and repair if
609/12 14054 internal fault necessary.
defective
• if fault code is still present, replace
and program control unit.
• perform functional check.

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Mercedes Benz engine fault codes

Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
Main branch: During the controller
Starter output initialization the two transistors of the
stage with low main branch are alternating switched
impedance on briefly. The level at the starter
(main branch or output changes thereby on "High", the
branch of main branch is classified as low
609/12 18039 internal fault ** emergency) or impedance.
load (relay) also Backup branch: If that changes for
to high clamp 50 signal on "High" and follows
resistance this level change a change of the level
and/or to high at the starter output before the starter
inductance. output stage was activated, the backup
branch is classified as low impedance.
• check all affected connectors, plug
connections and electrical
cylinder number components for damage, loose
609/14 04037 internal fault contact, corrosion etc. and repair if
implausible
necessary.
• perform functional check.
• check all affected connectors, plug
connections and electrical
characteristic components for damage, loose
609/14 04047 internal fault data map de- contact, corrosion etc. and repair if
fective necessary.
• perform functional check.
• check all affected connectors, plug
connections and electrical
cylinder number components for damage, loose
609/14 04048 internal fault contact, corrosion etc. and repair if
implausible
necessary.
• perform functional check.
• check all affected plugs, plug
connectors and electrical
parametrization components for damage, loose
609/14 14049 internal fault ** contact, corrosion etc. and repair if
fault
necessary.
• perform functional check.

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Mercedes Benz engine fault codes

Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
• check all affected connectors, plug
connections and electrical
incorrect components for damage, loose
609/14 04050 internal fault hardware contact, corrosion etc. and repair if
detection necessary.
• perform functional check.
• check all affected connectors, plug
connections and electrical
EEPROM: components for damage, loose
Checksum contact, corrosion etc. and repair if
609/14 04051 internal fault necessary.
failure1
(memory fault) • if fault code is still present, renew
and program control unit.
• perform functional check.
• check all affected plugs, plug
connectors and electrical
EEPROM: components for damage, loose
CKS- fault 2 contact, corrosion etc. and repair if
609/14 14052 internal fault necessary.
(groups vehicle
parameters) • if fault code is still present, replace
and program control unit.
• perform functional check.
• check all affected connectors, plug
connections and electric
EEPROM: components for damage, loose
Checksum- contact, corrosion etc., and repair if
609/14 24053 internal fault ** fault 3 (block necessary.
production or
• if fault code still present, renew and
immobilizer).
calibrate control unit.
• perform functional check.
short circuit to
611/4 06506 oil separator * ground
diagnostic line.
oil separator
611/12 06564 oil separator *
defective
• work off actual faults of SG FRE
CAN CAN data not apart from CAN data bus fault
625/2 10102 codes 10201, 00202 and 10203.
connection plausible
• perform functional check.

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Mercedes Benz engine fault codes

Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
• check CAN connection to SG FRE.
• check cables, connectors, plug
connectors and electrical
components for damage, correct
connection, loose contact and
corrosion, repair if necessary.
CAN no connection • remove engine CAN bus fault in the
625/2 10104
connection to CAN SG FRE.
• perform functional check
• communication with the ECU
engine control (e.g. MR-PLD)
restored: check calibration of ECU
engine control (e.g. MR-PLD) for
one wire capability.
• check for open circuit fault, repair or
replace if necessary.
• switch on ignition.
CAN CAN-High
625/14 10100 • delete fault memory in ECU engine
connection defective
control (e.g. MR-PLD).
• delete fault memory in SG FRE.
• perform functional check.
• check wire for open circuit fault,
repair of replace if necessary.
• switch on ignition.
CAN CAN-Low
625/14 10101 • delete fault memory in ECU engine
connection defective
control (e.g. MR-PLD).
• delete fault memory in SG FRE.
• perform functional.
CAN parameter fault • check parameters and
625/14 10149
connection CAN • perform functional check.

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Mercedes Benz engine fault codes

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

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Mercedes Benz engine fault codes

Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
• press in speed (position) sensor
during engine standstill until
mechanical limit stop.
crankshaft • fault code 10309 actual: work off
crankshaft timeout - this fault code.
636/8 10312
position nocrankshaft
signal Timeout • fault code 10312 actual: check
crankshaft position sensor, replace
if necessary.
• nominal value 1.2 kOhm
crankshaft • connect the position sensor
crankshaft correctly.
636/14 10313 sensor wrong
position
polarity • perform functional check.
shortened to
control solenoid battery • shortened to battery
651/3 24805
valve ** voltageHighside voltageHighside bank 1
bank 1
shortened to
control solenoid battery
651/3 24905 • switch off solenoid valves bank 2
valve ** voltageHighside
bank 2
ground short
control solenoid
651/4 24806 Low side bank • switch off solenoid valves bank 1
valve **
1
control solenoid ground short
651/4 24906 • switch off solenoid valves bank 2
valve ** Lowside bank 2
important note:
control failure • upon removing mechanical or
control cylinder
651/5 15027 injector-/ electrical faults at the injector
1 disturbed
solenoid valve valves, the engine-smoothness
control has to be set to zero.
important note:
short circuit
• upon removing mechanical or
solenoid valve injector
651/6 25028 electrical faults at the injector
cylinder 1 ** solenoid valve
valves, the engine smoothness
cylinder 1
control has to be set to zero.

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Mercedes Benz engine fault codes

Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
important note:
contact
• upon removing mechanical or
recognition no contact
651/7 15026 electrical faults at the injector
injector-/ cylinder 1
valves, the engine smoothness
solenoid valve
control has to be set to zero.
important note:
engine- • upon removing mechanical or
LRR-limitation
651/12 09044 smoothness electrical faults at the injector
cylinder 1
cylinder 1 valves, the engine smoothness
control has to be set to zero.
important note:
individual • upon removing mechanical or
EZA-limitation
651/14 09045 cylinder electrical faults at the injector
cylinder 1
adaption valves, the engine smoothness
control has to be set to zero
• upon removing mechanical or
electrical faults at the injector
valves, the engine-smoothness
injector-/ control cylinder control has to be set to zero.
652/5 15127 solenoid valve 2 disturbed /
cylinder 2 failure • the engine-smoothness control can
be set to zero in the menu
"controls" at the menu level "check
engine-smoothness control".
• check electrical screw connections
short circuit of the affected injector valve for
solenoid valve injector-/ short circuit.
652/6 25128
cylinder 2 ** solenoid valve • disconnect electrical screw
cylinder 2 connections of the affected injector
valve.
• upon removing mechanical or
electrical faults at the injector
contact valves, the engine-smoothness
recognition control has to be set to zero.
no contact
652/7 15126 injector-/
cylinder 2 • the engine-smoothness control can
solenoid valve
cylinder 2 be set to zero in the menu
"controls" at the menu level "check
engine-smoothness control".

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Mercedes Benz engine fault codes

Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
engine- important note:
injector-/ smoothness • upon removing mechanical or
652/12 09144 solenoid valve control: LRR- electrical faults at the injector
cylinder 2 limitation valves, the engine smoothness
cylinder control has to be set to zero.
individual important note:
injector-/ cylinder • upon removing mechanical or
652/14 09145 solenoid valve adaptation: electrical faults at the injector
cylinder EZA-limitation valves, the engine smoothness
cylinder control has to be set to zero.
important note:
injector-/ control cylinder • upon removing mechanical or
653/5 15227 solenoid valve 3 disturbed / electrical faults at the injector
cylinder 3 failure valves, the engine-smoothness
control has to be set to zero.
• check electrical screw connections
short circuit of the affected injector valve for
injector-/ short circuit.
injector-/
653/6 25228 solenoid valve
solenoid valve • disconnect electrical screw
cylinder 3 **
cylinder 3 connections of the affected injector
valve.
contact
important note:
recognition
injector-/ • upon removing mechanical or
injector-/
653/7 15226 solenoid valve electrical faults at the injector
solenoid valve:
cylinder 3 valves, the engine smoothness
no contact
control has to be set to zero.
cylinder 3
engine- important note:
injector-/ smoothness • upon removing mechanical or
653/12 09244 solenoid valve: control: LRR- electrical faults at the injector
cylinder 3 limitation valves, the engine smoothness
cylinder control has to be set to zero.
individual important note:
injector-/ cylinder • upon removing mechanical or
653/14 09245 solenoid valve: adaptation: electrical faults at the injector
cylinder 3 EZA-limitation valves, the engine smoothness
cylinder 3 control has to be set to zero.

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Mercedes Benz engine fault codes

Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
contact
important note:
recognition
control failure • upon removing mechanical or
injector-/
654/5 15327 injector-/ electrical faults at the injector
solenoid valve:
solenoid valve valves, the engine smoothness
no contact
control has to be set to zero.
cylinder 4
• check electrical screw connections
short circuit of the affected injector valve for
injector-/ short circuit.
injector-/
654/6 25328 solenoid valve
solenoid valve • disconnect electrical screw
cylinder 4 **
cylinder 4 connections of the affected injector
valve.
contact
important note:
recognition
injector-/ • upon removing mechanical or
injector-/
654/7 15326 solenoid valve electrical faults at the injector
solenoid valve:
cylinder 4 valves, the engine smoothness
no contact
control has to be set to zero.
cylinder 4
engine- important note:
injector-/ smoothness • upon removing mechanical or
654/12 09344 solenoid valve control: LRR- electrical faults at the injector
cylinder 4 limitation valves, the engine smoothness
cylinder 4 control has to be set to zero.
individual important note:
injector-/ cylinder • upon removing mechanical or
654/14 09345 solenoid valve adaption: EZA- electrical faults at the injector
cylinder 4 limitation valves, the engine smoothness
cylinder 4 control has to be set to zero.
contact
important note:
recognition
injector-/ • upon removing mechanical or
injector-/
655/5 15427 solenoid valve electrical faults at the injector
solenoid valve:
cylinder 5 valves, the engine smoothness
no contact
control has to be set to zero.
cylinder 5
• check electrical screw connections
short circuit of the affected injector valve for
injector-/ short circuit.
injector-/
655/6 25428 solenoid valve
solenoid valve • disconnect electrical screw
cylinder 5 **
cylinder 5 connections of the affected injector
valve.

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Mercedes Benz engine fault codes

Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
contact
important note:
recognition
injector-/ • upon removing mechanical or
injector-/
655/7 15426 solenoid valve electrical faults at the injector
solenoid valve:
cylinder 5 valves, the engine smoothness
no contact
control has to be set to zero.
cylinder 5
engine- important note:
injector-/ smoothness • upon removing mechanical or
655/12 09444 solenoid valve control: LRR- electrical faults at the injector
cylinder 5 limitation valves, the engine smoothness
cylinder 5 control has to be set to zero.
individual important note:
injector-/ cylinder • upon removing mechanical or
655/14 09445 solenoid valve adaptation: electrical faults at the injector
cylinder 5 EZA-limitation valves, the engine smoothness
cylinder 5 control has to be set to zero.
control failure important note:
injector-/ injector-/ • upon removing mechanical or
656/5 15527 solenoid valve solenoid valve: electrical faults at the injector
cylinder 6 control cylinder valves, the engine smoothness
6 disturbed control has to be set to zero.
• check electrical screw connections
short circuit of the affected injector valve for
injector-/ short circuit.
injector-/
656/6 25528 solenoid valve
solenoid valve • disconnect electrical screw
cylinder 6 **
cylinder 6 connections of the affected injector
valve.
contact
important note:
recognition
injector-/ • upon removing mechanical or
injector-/
656/7 15526 solenoid valve electrical faults at the injector
solenoid valve:
cylinder 6 valves, the engine smoothness
no contact
control has to be set to zero.
cylinder 6
engine- important note:
injector-/ smoothness • upon removing mechanical or
656/12 09544 solenoid valve control: LRR- electrical faults at the injector
cylinder 6 limitation valves, the engine smoothness
cylinder 6 control has to be set to zero.

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Mercedes Benz engine fault codes

Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
individual important note:
injector-/ cylinder • upon removing mechanical or
656/14 09545 solenoid valve adaption: EZA- electrical faults at the injector
cylinder 6 limitation valves, the engine smoothness
cylinder 6 control has to be set to zero.
important note:
injector-/ control failure • upon removing mechanical or
657/5 15627 solenoid valve injector-/ electrical faults at the injector
cylinder 7 solenoid valve valves, the engine smoothness
control has to be set to zero.
• check electrical screw connections
short circuit of the affected injector valve for
injector-/ short circuit.
injector-/
657/6 25628 solenoid valve
solenoid valve • disconnect electrical screw
cylinder 7 **
cylinder 7 connections of the affected injector
valve.
contact
important note:
recognition
injector-/ • upon removing mechanical or
injector-/
657/7 15626 solenoid valve electrical faults at the injector
solenoid valve:
cylinder 7 valves, the engine smoothness
no contact
control has to be set to zero.
cylinder 7
engine- important note:
injector-/ smoothness • upon removing mechanical or
657/12 09644 solenoid valve control: LRR- electrical faults at the injector
cylinder 7 limitation valves, the engine smoothness
cylinder 7 control has to be set to zero.
individual important note:
injector-/ cylinder • upon removing mechanical or
657/14 09645 solenoid valve adaptation: electrical faults at the injector
cylinder 7 EZA-limitation valves, the engine smoothness
cylinder 7 control has to be set to zero.
control failure important note:
injector-/ injector-/ • upon removing mechanical or
658/5 15727 solenoid valve solenoid valve: electrical faults at the injector
cylinder 8 control cylinder valves, the engine smoothness
8 disturbed control has to be set to zero.

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Mercedes Benz engine fault codes

Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
• check electrical screw connections
short circuit of the affected injector valve for
injector-/ short circuit.
injector-/
658/6 25728 solenoid valve
solenoid valve • disconnect electrical screw
cylinder 8 **
cylinder 8 connections of the affected injector
valve.
contact
important note:
recognition
injector-/ • upon removing mechanical or
injector-/
658/7 15726 solenoid valve electrical faults at the injector
solenoid valve:
cylinder 8 valves, the engine smoothness
no contact
control has to be set to zero.
cylinder 8
engine- important note:
injector-/ smoothness • upon removing mechanical or
658/12 09744 solenoid valve control: LRR- electrical faults at the injector
cylinder 8 limitation valves, the engine smoothness
cylinder 8 control has to be set to zero.
individual important note:
injector-/ cylinder • upon removing mechanical or
658/14 09745 solenoid valve adaptation: electrical faults at the injector
cylinder 8 EZA-limitation valves, the engine smoothness
cylinder 8 control has to be set to zero.
• check wire - terminal 50 input of
starter relay if shortened to battery
starter relay voltage, repair or replace if
starter control necessary.
677/3 18005 external current
(PLD-MR) **
supply • check starter relay, replace if
necessary.
• restore electrical connection(s)
• check of starter relay if shortened to
battery voltage, repair or replace if
starter relay necessary.
starter control
677/5 18009 external current
(PLD-MR) ** • check starter relay, replace if
supply
necessary.
• restore electrical connection(s)

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Mercedes Benz engine fault codes

Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
• check wire - terminal 50 input of the
starter relay for short circuit to
starter control short circuit to ground, repair or replace if
677/6 18008 necessary.
(PLD-MR) ** ground
• check starter relay, replace if
necessary.
• check starter electrically and
starter control starter does not mechanically.
677/7 18086
(PLD-MR) ** engage
• perform functional check.
starter control starter relay • check starter relay, replace if
677/14 18033 Starter relay is fixed in closed necessary.
(PLD-MR) ** position • perform functional
shortened to
proportional
697/3 17007D) battery voltage • set output off
valve (MBR-BK)
(-lead)
proportional shortened to
17705 valve bank battery voltage • set output off 1 2 3 4
1PVB (+lead)*
proportional short circuit to
697/4 17708 valve bank 1 ground • set output off 1 2 3 4
(PVB 1) (+lead)**
• check parametrization.
• parameter 06 has to be set to NOT
open circuit ACTIVE
fault** ECU
proportional • if not, then the data set of ECU
engine control
697/5 17009 valve 1 (MBR- engine control (e.g. MR-PLD) is
(e.g. MR-PLD)
BK) wrong
wrong
calibration. • replace and program ECU engine
control (e.g. MR-PLD).
• perform functional check.

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Mercedes Benz engine fault codes

Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
• check parametrization.
• parameter 06 has to be set to NOT
short circuit to ACTIVE
ground (-lead)
proportional • if not, then the data set of ECU
ECU engine
697/6 17006 valve 1 (MBR- engine control (e.g. MR-PLD) is
control (e.g.
BK) wrong
MR-PLD) wrong
calibration. • replace and program ECU engine
control (e.g. MR-PLD).
• perform functional check.
shortened to
proportional
17305C) battery voltage
698/3 valve 2 (MBR- • set output off
17307D) (-lead) High
KD)
Side
proportional
17317C) open circuit
698/5 valve 2 (MBR- • set output off
17309D) fault Low Side
KD)
• check calibration, correct if
proportional necessary. Parameter 007 has to
valve 2 short circuit to be set to NOT ACTIVE.
Activation: ground (-lead) • if not, then the data set of the
698/6 17306 engine brake High Side control unit MR is wrong.
reecompression wrong
valve (MBR- calibration • replace and program ECU engine
KD) control (e.g. MR-PLD).
• perform functional check.
shortened to
proportional
699/3 17107D) battery voltage • set output off
valve 3
(-lead)*
• check calibration, correct if
necessary. Parameter 008 has to
be set to NOT ACTIVE.
note:
open circuit • if a Linig-fan is installed, the
proportional
699/5 17109 fault wrong following calibration applies:
valve 3
calibration
a) parameters 8 and 9 have to be
set to ACTIVE.
b) parameter 14 has to be set to
"Type 0".

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Mercedes Benz engine fault codes

Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
• check calibration, correct if
necessary. Parameter 008 has to
short circuit to
be set to NOT ACTIVE.
ground (-lead)
ECU engine • if the calibration is OK, check wire
proportional control (e.g. for short circuit to ground, repair or
699/6 17106 replace if necessary.
valve 3 MR-PLD) wrong
calibration / • if still no fault can be detected,
short circuit to replace and program ECU engine
ground control (e.g. MR-PLD).
• perform functional check.
shortened to
proportional
700/3 17207** battery voltage • set output off
valve 4
(-lead)*
note: ECU engine control (e.g. MR-
PLD) wrong calibration / open circuit
fault
• check calibration, correct if
necessary. Parameter 009 has to
be set to NOT ACTIVE.
note:
• if a Linnig-fan is installed, the
following calibration applies:
a) parameters 8 and 9 have to be
proportional open circuit set to ACTIVE
700/5 17209
valve 4 fault
b) parameter 14 has to be set to
"Type 0".
• fault code17209 remains actual:
check wires for open circuit fault,
repair or replace if necessary.
• if no fault can be detected, replace
and program ECU engine control
(e.g. MR-PLD)
• perform functional check.
• set output off

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Mercedes Benz engine fault codes

Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
note: ECU engine control (e.g. MR-
PLD) wrong calibration / short circuit to
ground
• check calibration, correct if
necessary. Parameter 009 has to
be set to NOT ACTIVE.
• check calibration, correct if
proportional short circuit to necessary. Parameter 009 has to
700/6 17206 be set to NOT ACTIVE. if the
valve 4 ground (-lead)
calibration is OK, check wire for
short circuit to ground, repair or
replace if necessary.
• if still no fault can be detected,
replace and program ECU engine
control (e.g. MR-PLD).
• perform functional check.
shortened to
proportional
705/3 17405 battery voltage • set output off
valve 5
(+lead)*
proportional short circuit to
705/4 17408 • set output off for valve 6 and 5.
valve 5 ground (+lead)*
proportional shortened to
705/11 17805 valve bank 2 battery voltage • set output off for valve 6 and 5.
PVB 2 (+lead)*
proportional
short circuit to
705/11 17808 valve bank 2 • set output off for valve 6 and 5.
ground (+lead)*
PVB 2
proportional open circuit
706/3 17609 • set output off for valve 6
valve 6 fault *
camshaft • check wire for open circuit, replace
camshaft if necessary.
723/3 10409 sensor open
position
circuit fault • nominal value: 1.2 kOhm
• check wire and position sensor for
camshaft ground short, replace if necessary.
camshaft
723/4 10408 sensor ground
position sensor • nominal value: 1.2 kOhm
short
necessary.

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Mercedes Benz engine fault codes

Fault
codes Fault
SAE codes
Description Repair instructions
J1939 PLD-MR
SPN/FMI ***
****
• if fault codes 10408 and 10409 are
current, remove them first
• pull out position sensor during
engine standstill and perform visual
check
camshaft time- • remove metal pieces/shavings if
camshaft out (no cam necessary.
723/8 10412
position sensor shaft signal) • replace position sensor in the case
Timeout of mechanical damage (clear stress
marks).
• press in speed (position) sensor
during engine standstill until
mechanical limit stop.
• perform functional check.
camshaft • position sensor correctly with pin of
camshaft sensor wrong the ECU engine control (e.g. MR-
723/14 10413 PLD)
position polarity Sensor
verpolt • perform functional check.
currently not fan speed detection
no signal installed.
986/8 17112 fan speed (timeout) • check calibration, correct if
Timeout necessary. Parameter 14 has to be
set to "Type 0".

* diagnosis version 5 D)=only for the D-Model of PLD-MR control units

(diagnosis version 6)
** diagnosis version 6 and newer
*** Minidiag 2 Diagnostic unit
**** Driving panel master gauge (P1)

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Mercedes Benz engine fault codes

2. VEHICLE CONTROL FAULT CODES

2.1. Fault codes of vehicle control (ADM2) via SAE J1939
ADM2
fault ADM2
codes fault
Description Remedial action Pin
(J1939) codes (k-
SPN/FMI line) ***
****
decom- • check wiring
45/3 10003 pression valve open circuit 15/10
MBR_KD • check solenoid valve

decom- • check wiring

shorted to
45/4 10004 pression valve 15/10
ground • check solenoid valve
MBR_KD
vehicle speed • check wiring
84/3 10103 open circuit 15/03
signal C3 • check parameter 08/01
vehicle speed shorted to
84/4 10104 • check wiring 15/03
signal C3 ground
vehicle speed value not
84/14 10114 • check parameter 08/01 15/03
signal C3 plausible
• restart accelerator
pedal adjustment
routine
analog accelerator • check wiring
91/0 10200 accelerator pedal not • Limit value idle 21/11
pedal adjusted operation position: 5,0
V
• Limit value kick down
position: 4,9 V
• Pedal unit exchange, if
defective
• check wiring
analog
voltage not • Limit value idle
91/2 10202 accelerator
plausible operation position: 5,0
pedal
V
• Limit value kickdown
position: 4,9 V

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Mercedes Benz engine fault codes

ADM2
fault ADM2
codes fault
Description Remedial action Pin
(J1939) codes (k-
SPN/FMI line) ***
****
• Pedal unit exchange, if
defective
• check wiring
analog voltage too high
91/3 10203 accelerator or shorted to • Limit value idle 21/11
pedal battery voltage operation position: 5,0
V
• Limit value kickdown
position: 4,9 V
• Pedal unit exchange, if
defective
• check wiring
analog voltage too low
91/4 10204 accelerator or shorted to • Limit value idle 21/11
pedal AFPS ground operation position: 5,0
V
• Limit value kickdown
position: 4,9 V
• Oil discharge with to
strong overstocking.
• remark: This problem
98/0 10400 oil level oil level to high can occur also if in PLD-MR
PLD-MR the false type
of oil pan were
programmed.
98/1 10401 oil level low oil level • refill oil PLD-MR
• refill oil
• remark: This problem
98/14 10414 oil level oil level too low can occur also if in PLD-MR
PLD-MR the false type
of oil pan were
programmed.
oil pressure • check oil pump and oil
100/1 10501 low oil pressure PLD-MR
sensor circuit
oil pressure oil pressure too • check oil pump and oil
100/14 10514 PLD-MR
sensor low circuit.
air pressure too
107/0 10800 air filter sensor • check wiring. 15/08
high
107/3 10803 air filter sensor open circuit • check wiring. 15/08

28 Copyright © Sandvik Mining and Construction

ID: BG00201664 A.2 2013-09-10
Mercedes Benz engine fault codes

ADM2
fault ADM2
codes fault
Description Remedial action Pin
(J1939) codes (k-
SPN/FMI line) ***
****
shorted to
107/4 10804 air filter sensor • check wiring. 15/08
ground
coolant high coolant • cooling-water level and
110/0 10900 PLD-MR
temperature temperature cooling circuit check.
coolant
coolant • cooling-water level and
110/14 10914 temperature too PLD-MR
temperature cooling circuit check.
high
low coolant • refill coolant
111/1 11001 coolant level 15/07
level • check wiring
• check wiring
111/3 11003 coolant level open circuit • Voltage must be larger 15/07
than 2,0 V.
shorted to
111/4 11004 coolant level • check wiring. 15/07
ground
• check battery voltage
terminal 15
158/0 11100 over voltage • check parameter 2/08 21/02
(ignition)
(24V/12V selection)
• check battery voltage
terminal 15
158/1 11101 under voltage • check parameter 2/08 21/02
(ignition)
(24V/12V selection)
Wiring idle
validation
switch GAS1 • check wiring 21/12 and
idle switch and GAS2
558/1 11701 • Pedal unit exchange, if 21/13 or
(analog pedal) twisted or open
defective 21/14
circuit at
potentiometer
ground FP-
both switches • check wiring
idle switch open circuit 21/12 and
558/5 11705 • Pedal unit exchange, if
(analog pedal) (GAS2 + GAS1 21/13
open) defective

both switches • check wiring

idle switch 21/12 and
558/12 11712 closed (GAS2 + • Pedal unit exchange, if
(analog pedal) 21/13
GAS1 closed) defective

Copyright © Sandvik Mining and Construction 29

ID: BG00201664 A.2 2013-09-10
Mercedes Benz engine fault codes

ADM2
fault ADM2
codes fault
Description Remedial action Pin
(J1939) codes (k-
SPN/FMI line) ***
****
cruise control • check wiring
both switches 18/04 and
599/12 11812 switch CC+ and • check cruise control
closed 18/05
CC- switch
cruise control • check wiring
both switches 18/04 and
601/12 11912 switch CC+ and • check cruise control
closed 18/05
CC- switch
power supply
620/3 12103 analog pedal voltage too high • supply voltage > 5,2 V. 21/09
(AFP+)
power supply
620/4 12104 analog pedal voltage too low • supply voltage < 4,8 V. 21/09
(AFP+)
• check wiring (engine
CAN)
no • check configuration:
CAN link ADM2 MR parameter (../..) and
625/2 12202 communication
- MR ADM2 parameter 1/01
with MR
to be set to equal
functionality (0ne wire
capability)
• check wiring (engine
CAN)
• check configuration:
CAN link ADM2 MR parameter (../..) and
625/14 12214 one wire mode
- MR ADM2 parameter 1/01
to be set to equal
functionality (0ne wire
capability)
629/12 12312 ADM2 internal error
• check wiring
677/5 13305 output relay 1 open circuit 15/12
• check relay 1
shorted to • check wiring
677/6 13306 output relay 1 15/12
ground • check relay 1
grid heater: no
increasing • check wiring
730/0 13900 output relay 2 boost • check relay 2 15/09
temperature • check grid heater
after activation

30 Copyright © Sandvik Mining and Construction

ID: BG00201664 A.2 2013-09-10
Mercedes Benz engine fault codes

ADM2
fault ADM2
codes fault
Description Remedial action Pin
(J1939) codes (k-
SPN/FMI line) ***
****
grid heater:
relay • check wiring
730/1 13901 output relay 2 15/09
permanently • check relay 2
closed
grid heater:
relay • check wiring
730/2 13902 output relay 2 15/09
permanently • check relay 2
closed
voltage too high
730/3 13903 output relay 2 or shorted to • check wiring 15/09
battery voltage
voltage too low • check wiring
730/4 13904 output relay 2 or shorted to 15/09
ground • check relay 2

• limit values for the

supply voltage of the
remote pedal supply voltage
974/2 14202 HFG: 18/17
HFG out of range
Minimum value: 4,8 V and
maximum value: 5,2 V.
voltage too high • check wiring
remote pedal
974/3 14203 or shorted to 18/18
HFG • check remote pedal
battery voltage
voltage too low • check wiring
remote pedal
974/4 14204 or shorted to 18/18
HFG • check remote pedal
ground
• check wiring
1004/3 14403 output relay 4 open circuit 18/01
• check relay 4
shorted to • check wiring
1004/4 14404 output relay 4 18/01
ground • check relay 4
output PWM
1005/3 14503 pedalsupply or open circuit • check wiring. 15/05
transmission
output PWM
shorted to
1005/4 14504 pedalsupply or • check wiring. 15/05
ground
transmission
• check wiring
exhaust brake
1006/3 14603 open circuit • check exhaust brake 15/06
valve MBR_BK
valve

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ID: BG00201664 A.2 2013-09-10
Mercedes Benz engine fault codes

ADM2
fault ADM2
codes fault
Description Remedial action Pin
(J1939) codes (k-
SPN/FMI line) ***
****
• check wiring
exhaust brake shorted to
1006/4 14604 • check exhaust brake 15/06
valve MBR_BK ground
valve
CAN identifiers • PGN ETC1 was
J1939 CAN-
639/2 14902 ETC#1 or received only once and
interface
ACC#1 missing did not disappear.
PWM
no supply
1015/1 15001 accelerator • check wiring 15/05
voltage
pedal
PWM both signals • check wiring
1015/2 15002 accelerator missing (GAS1 • Pins 21/13, 21/12,
pedal and GAS2) 15/05 , 21/14.
PWM • check wiring
signal GAS2,
1015/3 15003 accelerator • Pins 21/13, 15/05 ,
not available
pedal 21/14.
PWM • check wiring
signal GAS1,
1015/4 15004 accelerator • Pins 21/12, 15/05 ,
not available
pedal 21/14.
PWM accelerator • restart accelerator
1015/5 15005 accelerator pedal not pedal adjustment
pedal adjusted routine
PWM idle position out • restart accelerator
1015/6 15006 accelerator of adjusted pedal adjustment
pedal range routine
PWM accelerator • restart accelerator
1015/7 15007 accelerator pedal out of pedal adjustment
pedal adjusted range routine

* diagnosis version 5 D)=only for the D-Model of PLD-MR control units

(diagnosis version 6)
** diagnosis version 6 and newer
*** Minidiag 2 Diagnostic unit
**** Driving panel master gauge (P1)

32 Copyright © Sandvik Mining and Construction

ID: BG00201664 A.2 2013-09-10
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