NMC 60
NMC 60
AIRCRAFT/INDUSTRIAL
TOW TRACTOR
MODEL 60
OPERATION, MAINTENANCE AND
PARTS MANUAL
NMC-WOLLARD, Inc.
2021 Truax Blvd.
Eau Claire, WI 54702
715-835-3151
Fax 715-835-6625
nmc-wollard.com
General Email [email protected]
NMC-WOLLARD 2021Truax Blvd., Eau Claire, WI 54703, Phone (715) 835-3151, Fax (715) 835-6625
M60 Tow Tractor Manual No. 46050
INTRODUCTION
Congratulations on the purchase of your new Tow Tractor from NMC-Wollard, Inc. With
its optional equipment this is the simplest, most flexible system on the market today.
With proper operation and preventative maintenance it will last for years.
This SAFETY ALERT SYMBOL indicates important safety messages in the
manual. When you see this symbol, be alert to the possibility of PERSONAL INJURY
and carefully read the message that follows.
Never operate without all covers, shields and guards in place. Body,
hair or clothing can become entangled in exposed, moving parts and can cause serious
injury or death.
Some covers and guards have been removed for illustrative/photographic purposes only
in this manual.
The Warranty appears in the front of this book. The order number and serial number
are recorded on the cover. These numbers should be recorded on the Registration and
Inspection Certificate for your reference and for proper identification of your machine by
NMC-Wollard, Inc.
For information on ordering repair parts, refer to the Repair Parts chapter at the back of
this book.
You are urged to study this manual and follow the instructions carefully. Your efforts
will be repaid in better operation and service as well as a savings in time and repair
expense. Failure to read and understand the machine or the system could lead to
serious injury. If you do not understand the instructions in this manual contact the
manufacturer.
If figures or paragraphs from the current section are referred, the chapter and section
may not be referenced.
Keep a copy of your NMC-Wollard, Inc. manuals on your computer or CD-ROM! You will
be able to view and print pages and search for words or numbers. CD-ROM manuals
include a linked table of contents. Mouse click on a table of contents entry to display the
page containing that item.
For availability and pricing, contact NMC-Wollard, Inc. customer service at:
Phone (715) 835-3151
Fax (715) 835-6625
Email [email protected]
NMC-Wollard, Inc. warrants to the original owner that all components of the equipment are free
from defects in material and workmanship under normal use and service for 12 months or 1,000
hours, whichever comes first, from the date of shipment.
This warranty provides for NMC-Wollard, Inc. equipment components that fail because of
defects in material or workmanship during the warranty period, without charge to the owner for
parts or labor. The owner must provide prompt notice of the defect and allow a reasonable time
for replacement or repair.
This warranty applies only to parts manufactured by NMC-Wollard, Inc. Components installed
on NMC-Wollard, Inc. equipment but not manufactured by NMC-Wollard, Inc. shall be covered
under the original manufacturer’s warranty. NMC-Wollard, Inc. will assist in administering all
such warranties, with the exception of tires, battery, and other expendable parts, for which
the owner will be required to deal directly with the original manufacturer for warranty service.
Neither tune-ups, normal maintenance and repair or replacement of expendable parts (such as
oil, lubricants, belts, filters, tires, battery, etc.) are covered by this warranty.
This warranty does not cover damage resulting from carelessness or neglect; accidents,
fire, or other casualties; improper repair, operation, transportation, or storage; or failure to
provide necessary or appropriate maintenance. This warranty does not cover deterioration or
failure caused by chemicals, falling objects, dirt and sand, or excessive heat or moisture. The
NMC-Wollard, Inc. equipment must be maintained according to the instructions provided with it
or this warranty may be considered void. Warranted components must be replaced with parts
manufactured or approved by NMC-Wollard, Inc. Warranty determination will be made after
NMC-Wollard, Inc. inspects the failed part.
NMC-Wollard, Inc. is not liable for damage or injury resulting from improper installation, use,
abuse, inability to use or misapplication of NMC-Wollard, Inc. equipment, nor is NMC-Wollard,
Inc. liable for damage resulting from equipment repaired or modified by persons not authorized
by NMC-Wollard, Inc. NMC-Wollard, Inc. does not warrant any part or product to meet local,
municipal, state, provincial, or national laws or regulations.
This Limited Warranty is in lieu of all other warranties, whether express, implied, or statutory.
No other express warranty is given or authorized by NMC-Wollard, Inc. NMC-Wollard, Inc.
expressly disclaims any implied warranty of merchantability or fitness for a particular purpose or
otherwise. NMC-Wollard, Inc. shall not be liable for loss of use of equipment, loss of time, loss
of business, or for any other incidental, or consequential damages. No authorized NMC-Wollard,
Inc. representative has the right to change or modify this warranty in any respect.
Check that you have received all the equipment ordered. Check inside the product
manual for engine warranties. Some OEM manufacturers supply a registration card that
must be filled out and returned immediately to initiate the warranty. If a survey card or
delivery checklist is enclosed from NMC-Wollard, Inc. please return it.
Call NMC-Wollard, Inc. (715-835-3151). We will require the serial number, number
of hours on the unit, and a description of the problem. You will be given a warranty
authorization number and assistance in troubleshooting.
IMPORTANT!
Clear and immediate communication with the factory is the key to obtaining a
satisfactory and timely resolution of your warranty problem.
Every warranty situation is different and so there are no hard rules. We will work with
your maintenance personnel and service managers to equitably resolve all claims.
Complete and return the warranty claim form within 10 days. Place the assigned
warranty authorization number we gave you when you first called us with the problem
on your claim.
Return defective parts immediately. Your claim cannot be processed until all defective
parts have been returned to NMC-Wollard, Inc. Identify returned parts with the assigned
warranty authorization number.
What should you use for labor rate and labor time?
Labor rate are reviewed annually, if you do not have an established rate, call
NMC-Wollard, Inc. We do not publish a rate book; instead, we have accumulated
average times for repairs. We will authorize repair time once we have approved the
repair. If unforeseen circumstances cause a significantly greater repair time than
originally approved, please contact us before submitting your claim.
TABLE OF CONTENTS
INTRODUCTION..............................................................................................................2
1 YEAR LIMITED WARRANTY..............................................................................4
REVISION RECORD..............................................................................................7
REVISION HIGHLIGHTS........................................................................................8
PAGE EFFECTIVITY............................................................................................18
CONFIGURATION................................................................................................25
EFFECTIVITY CODE...........................................................................................27
REVISION RECORD
Rev Issue Date Initial Rev Issue Date Initial
No. Date Inserted No. Date Inserted
1 01/31/07 1/31/07 NMC- 19 05/25/16 05/25/16 NMC-
Wollard Wollard
2 07/31/07 07/31/07 NMC- 20 06/01/16 06/01/16 NMC-
Wollard Wollard
3 08/31/08 08/31/08 NMC-
Wollard
4 08/15/11 08/15/11 NMC-
Wollard
5 02/04/13 02/04/13 NMC-
Wollard
6 12/15/13 12/15/13 NMC-
Wollard
7 03/31/14 03/31/14 NMC-
Wollard
8 06/25/14 06/25/14 NMC-
Wollard
9 07/31/14 07/31/14 NMC-
Wollard
10 08/20/14 08/20/14 NMC-
Wollard
11 09/25/14 09/25/14 NMC-
Wollard
12 12/01/14 12/01/14 NMC-
Wollard
13 04/03/15 04/03/15 NMC-
Wollard
14 07/01/15 07/01/15 NMC-
Wollard
15 09/15/15 09/15/15 NMC-
Wollard
16 11/02/15 11/02/15 NMC-
Wollard
17 01/13/16 01/13/16 NMC-
Wollard
18 04/26/16 04/26/16 NMC-
Wollard
REVISION HIGHLIGHTS
TO: HOLDERS OF NMC-Wollard, Inc. OPERATION AND MAINTENANCE MANUAL
number 46050, M60 Tow Tractor.
Pages that have been revised are outlined below, together with highlights of the
revision. Please delete the affected pages and enter Revision No.and date to the
Revision Record page.
4/4/164-165 48311+ D
4/4/181. 183 Hyd ftgs revised. 47919 added for Cummins 4.5NA
4/4/193. 209 50441 added. 43362 added. H
4/4/200-201 Deutz Exhaust updated Deutz 2011
4/4/225 49128+, 46744-8 was 46738-8 Z2.8LP
4/4/233. 237 46744-7 added, 46738-7 updated. Exh key#’s updated Z2.8
4/4/244-264 B3.3NA/C6 T3 pak added C
PAGE EFFECTIVITY
Chapter/Section Page Date Chapter/Section Page Date
Cover 1 08/31/08 1-3 2 08/15/11
Introduction 2 08/31/08 1-3 3 09/15/15
Introduction 3 08/31/08 1-3 4 08/31/08
Limited Warranty 4 08/31/08 1-3 5 08/31/08
Limited Warranty 5 08/31/08 1-3 6 08/31/08
Table of Contents 6 07/01/15 1-4 1 08/31/08
Revision Record 7 06/01/16 1-4 2 08/31/08
Revision Highlights 9 08/31/08 1-5 1 08/31/08
Revision Highlights 10 08/15/11 1-5 2 08/31/08
Revision Highlights 11 03/31/14 2-TOC 1 05/25/16
Revision Highlights 12 07/31/14 2-TOC 2 05/25/16
Revision Highlights 13 12/01/14 2-TOC 3 05/25/16
Revision Highlights 14 07/01/15 2-TOC 4 05/25/16
Revision Highlights 15 01/13/16 2-1 1 08/15/11
Revision Highlights 16 05/25/16 2-1 2 08/15/11
Revision Highlights 17 06/01/16 2-1 3 08/15/11
Page Effectivity 18 06/01/16 2-1 4 09/15/15
Page Effectivity 19 06/01/16 2-1 5 07/01/15
Page Effectivity 20 06/01/16 2-1 6 08/15/11
Page Effectivity 21 06/01/16 2-1 7 01/13/16
Page Effectivity 22 06/01/16 2-1 8 01/13/16
Page Effectivity 23 06/01/16 2-1 9 08/15/11
Page Effectivity 24 06/01/16 2-1 10 08/15/11
Configuration 25 09/15/11 2-1 11 08/15/11
Configuration 26 09/15/15 2-1 12 08/15/11
Effectivity Code 27 04/26/16 2-1 13 08/15/11
Effectivity Code 28 09/15/15 2-1 14 08/15/11
1-TOC 1 05/25/16 2-1 15 09/15/15
1-TOC 2 05/25/16 2-1 16 08/15/11
1-1 1 08/31/08 2-1 17 08/15/11
1-1 2 07/01/15 2-1 18 08/15/11
1-1 3 08/31/08 2-1 19 08/15/11
1-1 4 08/31/08 2-1 20 08/15/11
1-1 5 07/31/14 2-1 21 08/15/11
1-1 6 08/31/08 2-1 22 08/15/11
1-1 7 08/31/08 2-1 23 08/15/11
1-1 8 08/31/08 2-1 24 08/15/11
1-1 9 08/31/08 2-1 25 08/15/11
1-1 10 09/15/15 2-1 26 08/15/11
1-1 11 09/15/15 2-1 27 08/15/11
1-1 12 08/31/08 2-1 28 08/15/11
1-2 1 08/31/08 2-1 29 08/15/11
1-2 2 09/15/15 2-1 30 08/15/11
1-2 3 09/15/15 2-1 31 08/15/11
1-2 4 08/31/08 2-1 32 08/15/11
1-2 5 08/31/08 2-1 33 08/15/11
1-2 6 08/31/08 2-1 34 08/15/11
1-2 7 08/31/08 2-1 35 01/13/16
1-2 8 08/31/08 2-1 36 08/15/11
1-2 9 05/25/16 2-1 37 08/15/11
1-2 10 05/25/16 2-1 38 08/15/11
1-3 1 07/01/15 2-1 39 08/15/11
2-1 40 08/15/11
JUNE 01, 2016 INTRODUCTION
PAGE 18 PAGE EFFECTIVITY
NMC-WOLLARD 2021Truax Blvd., Eau Claire, WI 54703, Phone (715) 835-3151, Fax (715) 835-6625
M60 Tow Tractor Manual No. 46050
Chapter/Section Page Date Chapter/Section Page Date
2-1 41 08/15/11 2-3 6 08/15/11
2-1 42 08/15/11 2-3 7 08/15/11
2-1 43 08/15/11 2-3 8 08/15/11
2-1 44 08/15/11 2-3 9 08/15/11
2-2 1 08/31/08 2-3 10 08/15/11
2-2 2 08/31/08 2-3 11 08/15/11
2-2 3 01/31/07 2-3 12 08/15/11
2-2 4 01/31/07 2-3 13 08/15/11
2-2 5 08/31/08 2-3 14 08/15/11
2-2 6 08/31/08 2-3 15 08/15/11
2-2 7 08/31/08 2-3 16 08/15/11
2-2 8 08/31/08 2-3 17 08/15/11
2-2 9 08/31/08 2-3 18 08/15/11
2-2 10 08/31/08 2-3 19 08/15/11
2-2 11 08/31/08 2-3 20 08/15/11
2-2 12 09/15/15 2-3 21 08/15/11
2-2 13 05/25/16 2-3 22 08/15/11
2-2 14 08/31/08 2-3 23 08/15/11
2-2 15 08/31/08 2-3 24 08/15/11
2-2 16 08/31/08 2-3 25 08/15/11
2-2 17 08/31/08 2-3 26 08/15/11
2-2 18 08/31/08 2-4 1 08/31/08
2-2 19 03/31/14 2-4 2 08/31/08
2-2 20 03/31/14 2-4 3 08/31/08
2-2 21 03/31/14 2-4 4 08/31/08
2-2 22 03/31/14 2-4 5 08/31/08
2-2 23 09/15/15 2-4 6 08/31/08
2-2 24 09/15/15 2-4 7 07/01/15
2-2 25 09/15/15 2-4 8 08/31/08
2-4 9 08/31/08
2-2 26 09/15/15
2-4 10 12/15/13
2-2 27 09/15/15 2-4 11 12/15/13
2-2 28 09/15/15 2-4 12 08/15/11
2-2 29 09/15/15 3-TOC 1 08/31/08
2-2 30 05/25/16 3-TOC 2 08/31/08
2-2 31 05/25/16 3-1 1 08/31/08
2-2 32 05/25/16 3-1 2 08/31/08
2-2 33 05/25/16 3-1 3 08/31/08
2-2 34 05/25/16 3-1 4 08/31/08
2-2 35 05/25/16 3-1 5 08/31/08
2-2 36 05/25/16 3-1 6 08/31/08
2-2 37 05/25/16 3-1 7 08/31/08
2-2 38 05/25/16 3-1 8 08/31/08
2-2 39 05/25/16 3-1 9 08/31/08
2-2 40 05/25/16 3-1 10 08/31/08
3-1 11 08/31/08
2-2 41 05/25/16
3-1 12 08/31/08
2-2 42 05/25/16 3-1 13 08/31/08
2-2 43 05/25/16 3-1 14 08/31/08
2-2 44 05/25/16 3-1 15 08/31/08
2-3 1 07/01/15 3-1 16 08/31/08
2-3 2 08/15/11 4-TOC 1 06/01/16
2-3 3 08/15/11 4-TOC 2 06/01/16
2-3 4 08/15/11 4-TOC 3 06/01/16
2-3 5 08/15/11 4-TOC 4 06/01/16
INTRODUCTION JUNE 01, 2016
PAGE EFFECTIVITY PAGE 19
NMC-WOLLARD 2021Truax Blvd., Eau Claire, WI 54703, Phone (715) 835-3151, Fax (715) 835-6625
M60 Tow Tractor Manual No. 46050
CONFIGURATION
The NMC-Wollard, Inc. sales order number for this unit is _____________________
The serial number placard for this unit is located on the inside firewall. For your
convenience, record the serial number (or range of numbers for multiple orders)
below.
Serial Number(s)
____________________ ____________________
____________________ ____________________
____________________ ____________________
____________________ ____________________
____________________ ____________________
____________________ ____________________
____________________ ____________________
____________________ ____________________
____________________ ____________________
____________________ ____________________
____________________ ____________________
Both the sales order and serial numbers are required for proper identification by
NMC-Wollard, Inc. whenever you call for service parts or other technical support.
The unit shipped with this operator’s manual was equipped with the items indicated on
the following available options listing.
EFFECTIVITY CODE
This manual is effective on units having the following serial numbers:
Effectivity Code Serial Numbers
None 07-C-2993+
A 07-C-1086-
B 07-C-1087+
C 08-C-3156+
D 08-C-3171-
E 08-C-3170-
F 11-C-3806+
G 11-C-3805-
H 11-C-3784+
I 11-C-3783-
J 09-C-3184+
K 09-C-3183-
L 12-C-3934+
M 14-C-3994+
N 14-C-4021
O 14-C-4022
P 14-C-4023+
Q 15-C-4057+
R 16-C-4105+
S 16-C-4108,4109+
NOTE: Your tow tractor may have additional specific decals. See Decals/Placards in
the Parts chapter.
For your protection, read all safety decals on the machine and in this
manual. Replace any missing or illegible decals by ordering the part numbers shown on
the safety decals page.
CHAPTER 1 GENERAL INFORMATION AND OPERATING INSTRUCTIONS AUGUST 31, 2008
1 DESCRIPTION PAGE 1
NMC-WOLLARD 2021Truax Blvd., Eau Claire, WI 54703, Phone (715) 835-3151, Fax (715) 835-6625
M60 Tow Tractor Manual No. 46050
1.2 SAFETY DECALS
Safety Sign Care
• Keep Safety Signs Clean And Legible At All Times.
• Replace Safety Signs That Are Missing Or Have Become Illegible.
• Replaced Parts That Displayed A Safety Sign Should Also Display The
Current Sign.
• Safety Signs Are Available From Your Dealer.
DECAL F.
DECAL D. DECAL E. PART NO. 305732
PART NO. 1018145 PART NO. 204594
There are inherent hazards associated with the operation and servicing of this
machine. For your protection please read and understand the following
precautions before operating or servicing this machine.
• Never approach overhead power lines or cables with any part of your machine.
Contact with or getting close to any power lines or cables can result in electrocution.
• Fuel vapors create fire and explosion hazards. Do not allow any open flame,
smoking materials or other potential ignition sources near fuel or the fuel system.
• Never operate without all covers, shields and guards in place. Body, hair or
clothing can become entangled in exposed, moving parts and can cause
serious injury or death.
• Keep hands, loose clothing, long hair and loose jewelry away from moving parts.
You may become entangled in moving parts that can cause serious injury or death.
• Perform lockout/tagout procedures before adjusting, lubricating, cleaning or
otherwise servicing. Failure to do so could result in unexpected startup and
could cause serious injury or death.
• Use seat belts, approved headgear, eye protection and other protective
equipment as required by federal, state, local or employer regulations.
• Do not operate or service this machine while under the influence of any drugs
or alcohol.
• Do not indulge in stunt driving or other reckless operation.
• Limit travel speed. Ground conditions, congestion, slope, location of personnel
and other factors increase risk of collision or injury to personnel.
• Operator must be present while this machine is in use.
• California Proposition 65 Warning: Diesel engine exhaust and some of its
constituents are known to the State of California to cause cancer, birth defects,
and other reproductive harm.
• To minimize risk of serious injury or death, follow these hydraulic servicing
precautions:
• Follow all necessary lockout/tagout procedures.
• Before starting repairs which do not require battery power, always turn off the
key switch, then disconnect the battery connector from the battery to prevent
accidental short circuit.
• Be certain area is clear of people and other equipment before starting operation.
• Keep machine clear of foreign objects and clean of grease/oil and other lubricants.
In addition to these general safety precautions you will find specific safety
messages embedded in the Operating and Maintenance Chapters of this
manual.
Please review them for your protection.
1.4.3 Frame
The frame is a welded-steel one-piece unit, cross-braced to prevent
misalignment. Ballast weight is on the frame over the rear axle. An adjustable
driver’s seat is on the left side of the tractor. A seat may also be provided on
the passenger side.
1.4.4 Engine
A diesel or gas engine powers the rear wheels through a transmission, drive
shaft, and rear axle assembly. The engine is a valve-in-head, four-cycle,
liquid-cooled, pressure-lubricated, with crankcase ventilation.
1.4.6 Transmission
The automatic transmission and torque converter housing are together in an
aluminum casting. Gear selection is done by using a conveniently located
manual shift lever. On most tractors, the lever has five detent positions; R
(reverse), N (neutral), D (drive), 2 (second), and 1 (low).
CHAPTER 1 GENERAL INFORMATION AND OPERATING INSTRUCTIONS JULY 31, 2014
1 DESCRIPTION PAGE 5
NMC-WOLLARD 2021Truax Blvd., Eau Claire, WI 54703, Phone (715) 835-3151, Fax (715) 835-6625
M60 Tow Tractor Manual No. 46050
There is no P (Park) position. The gear shift control is linked to the
transmission by a cable. The transmission is cooled by hydraulic fluid
circulated through a heat exchanger attached to the engine radiator.
The screw-on oil filter is mounted on the oil pump (or auxiliary cooler where
provided). If the element becomes clogged, a relief valve in the filter permits
oil to bypass the filter.
Engine oil flows through the oil cooler cavity to be cooled by coolant which
flows through plates inside the oil cooler.
Vent Valve
The vent valve should be used only when filling or cleaning the inside of the
tank. It is opened manually.
Fuel Gauge
The fuel gauge is a float level type that indicates percentage of fuel remaining
in the tank.
Shut-Off Valve
The shut-off valve is operated manually to control fuel flow from tank. The
valve opens counterclockwise and closes clockwise.
Threaded into the base of the valve is a maximum withdrawal valve that
closes automatically when a surge of fuel, such as that caused by a bursting
hose, exceeds engine demand by 10%.
NOTICE! Close the shut-off valve no more than hand tight to avoid crushing
the valve seat.
Disconnect Coupling
A disconnect coupling is attached to the shut-off valve. It requires no tools to
operate. When disconnecting, it automatically seals off any flow through the
valve and hose.
1.4.14 Battery
The battery is a conventional 12-volt type with a positive cable and a negative
ground cable. The cables have protective boots at the battery end.
1.4.15 Alternator
Electrical power is supplied by a belt-driven alternator mounted on the right
front of the engine. It produces three-phase alternating current and voltage,
rectified to DC by a full-wave rectifier bridge using six diodes. The alternator
does not require a cutout relay.
1.4.17 Starter
The starter motor is a gear-reduction type mounted on the automatic
transmission housing at the rear of the engine. The starter motor is used to
turn the engine fast enough to start the engine.
a. Voltmeter
b. Engine coolant temperature gauge
c. Oil pressure gauge
d. Transmission oil temperature gauge
e. Fuel gauge
f. Ignition switch
g. Hour meter
h. Rear work light switch
i. Head and tail light switch
j. Glow switch/indicator, some diesels
1,2,3,5 20
4
11
10
9
14
18
6
The front and rear brakes are non-adjustable, sliding caliper-type disc
brakes.
The optional dual-wheel rear axle has brakes that are self-adjusting,
expanding, shoe-type. Adjustment occurs when the brake pedal is pushed.
The master cylinder has a brake fluid reservoir and a mechanically actuated
piston that pressurizes the system when the brake pedal is applied.
The power booster unit provides a power assist to operate the dual master
cylinder system.
The equalizing valve proportions the brake fluid between the front and rear
wheel cylinders to provide braking force at each wheel.
The check valve in the rear brake circuit slows down the shoe (drum
brakes) return, thus preventing the rear wheel cylinders form collapsing and
introducing air into the system when the brakes are released.
Parking Brake
The parking brake lever is on the operator’s right. When pulled, the lever
pulls a cable which applies pressure to brake bands which press against the
parking brake drum or disk (attached to the transmission output shaft). The
parking brake is completely mechanical.
To prevent serious injury, all riders must ride in a passenger seat with
the safety belt fastened.
NOTICE! If the tractor still will not start, allow the starter motor to cool before
repeating the procedure. This will prevent battery drain and starter motor
overheating.
8. After the engine is running smoothly, tap the accelerator pedal to reduce
the fast idle speed. Allow engine to warm up for 2 minutes.
9. Observe instruments to be sure each is working. Do not operate engine if
oil pressure fails to rise or if voltmeter does not show any charge.
If the tractor fails to start in the normal way, the engine probably needs
service.
NOTICE! When using a battery booster, observe proper polarity or you may
damage the electrical system and battery.
A worn out or badly sulfated battery will produce numerous problems that
cannot be corrected until the battery is replaced.
Always check battery condition and connections before condemning other
tractor systems.
Fast Charging
Fast charging sends a relatively heavy initial current (50-60 amps) through the
battery. This will impart a fairly good charge in one to two hours.
• Keep sparks and flame away from battery to avoid battery gas explosion.
• Do not allow the booster and dead vehicles to touch. Set park brakes and
turn both vehicle ignitions OFF.
• Connect one end of the positive (red) booster cable to the positive (+)
terminal on the dead battery and then the other end of this red cable to the
positive (+) terminal of the booster vehicle battery.
• Connect the end of the negative (black) booster cable to the negative
(-) terminal of the booster vehicle battery and the other end of this black
cable to a unpainted bolt or bracket on the dead vehicle (good ground)
located as far as possible from the dead battery to minimize the possibility
of igniting any hydrogen gas.
• Start the booster vehicle and let it idle for several minutes, then start the
dead vehicle. If the vehicle fails to start in a normal manner, discontinue
jump starting and service the vehicle for other problems.
• Once the dead vehicle is running, disconnect the booster cables in the
reverse order they were installed.
• Never allow booster cable ends to touch while connected to a battery.
BREAK-IN
Gradual new-engine break-in is not recommended because prolonged
operation at light loads during the early life of the engine can cause excessive
carbon build-up.
As soon as the engine is put into service and coolant temperature has
reached at least 140F, you can apply maximum load to the engine.
Do not operate the engine at high speeds without a load and do not overload
the engine.
ALTITUDE (diesel)
If the engine is to run at an altitude above 2,000 ft., fuel delivery can be
adjusted to reduce fuel consumption and smoke. NMC-Wollard, Inc. can
advise as to fuel reduction necessary if details of engine application and
ambient conditions are given. Changes to settings of the fuel injection pump
must be made by authorized personnel.
3. Release the foot brake and depress the accelerator pedal slowly and evenly.
As the tractor starts to move and increase speed, the transmission will up shift
automatically, unless you are in “1” or ”R”.
NOTICE! Do not shift from a forward gear (D, 2, or 1) to reverse (R) or from
reverse to a forward gear unless the tractor is at a complete stop. Failure to do this
will damage the transmission and void the warranty.
Secure all hitch pins and pintle hitches with a safety retainer pin to
prevent accidental unhooking, which can result in a run away load.
5. When driving or towing, avoid the tendency to oversteer and turn too sharply.
Allow enough clearance for the towed load.
Be sure that the shift control lever is secure in the neutral detent
and the parking brake is applied to prevent unintended movement that could result
in serious injury or death.
Always set the parking brake when parking the machine. The
transmission does not have an internal parking lock and failure to apply the parking
brake could allow unexpected movement resulting in crushing injury or death.
Tires:
Front:.............................................................................See chapter 4 for tire options
Rear:..............................................................................See chapter 4 for tire options
Alternator....................................................................................................... 66 amps
Battery................................................................................................. 625CCA diesel
FLUIDS
Engine Oil............................................................................................15W-40 CD/SF
Trans. Fluid............................................................................................ATFDexron III
Power Steering......................................................................................ATFDexron III
Coolant................................................................ 50-50 Water/Ethylene Glycol-Base
Brake Fluid....................................................................................................... DOT-3
Fuel (for diesel models).........................................................................JP5-DF1-DF2
Fuel (for gas models)................................................................................... Unleaded
Drive Axle.............................................. APIGL-5 lubricant SAE 80W-90 or 85W-140
Capacity................... 4 Pints (2 Liters)/wheel end, 9.5 Pints (4.5 Liters)/housing bowl
NOTE: * Gross vehicle weight may vary by 5% and is dependent on optional
equipment installed
3.7 TRANSMISSION
Make/Model .................................................................... GM 4L70 or Ford C6
Type..................................................................Automatic w/Torque Converter
3.9 ELECTRICAL
550/680 amp hour battery and 66 amp alternator with internal regulator. Has starter
lock out switch (prevents starter and ring gear damage when engine is running).
Tractor starts only in neutral.
Never work beneath a machine that is not raised and set securely
on blocks or jack stands, front and back, having capacity for the weight of the
machine. If the machine falls on you, serious injury or death will occur.
If you need to keep your machine idle for more than 30 days, or you are putting it into
indefinite storage, first prepare it according to the following procedures:
NOTICE! The following steps will help minimize corrosion and deterioration while your
machine is in storage
The recommendations below are designed to prevent damage to the engine when
it is withdrawn from service for a prolonged period. Perform in addition to 30-90
day procedure.
1. Clean engine breather pipe and seal end of pipe.
2. Drain fuel system and fill with clean fuel. The fuel must be drained and filters
discarded at end of storage period. If you add a fuel preservative to the fuel,
the fuel and filters may not need to be discarded at the end of the storage
period.
3. Operate engine until it is warm. Stop engine and fix any fuel, oil, or air leaks.
4. Drain the cooling system. In order to protect the cooling system against
corrosion, fill with a coolant that has a corrosion inhibitor. If protection against
frost is necessary, use an antifreeze mixture.
5. Operate engine for a short period in order to circulate lubricating oil and
coolant in engine.
CHAPTER 1 GENERAL INFORMATION AND OPERATING INSTRUCTIONS AUGUST 31, 2008
5 STORAGE PAGE 1
NMC-WOLLARD 2021Truax Blvd., Eau Claire, WI 54703, Phone (715) 835-3151, Fax (715) 835-6625
M60 Tow Tractor Manual No. 46050
6. Remove injectors and spray an internal engine preservative into each cylinder
bore. If this is not available, clean engine oil will offer some protection. Two to
three ounces of oil should be placed in each cylinder.
7. Slowly turn crankshaft one revolution and then fit injectors with new seat
washers and new dust seals.
8. Remove pipes installed between air filter and intake manifold. Spray
preservative into intake manifold. Seal manifold with waterproof tape.
9. Remove exhaust pipe. Spray preservative into exhaust manifold. Seal manifold
with waterproof tape.
10. Remove oil filler cap. Spray preservative into oil filler hole to protect rocker
shaft assembly. Install filler cap.
11. Seal vent pipe of fuel tank or filler cap with waterproof tape.
12. Remove drive belts and put into storage.
13. Spray engine with external engine preservative to prevent corrosion. Do not
spray area inside alternator cooling fan.
If engine protection is done correctly, corrosion damage normally will not occur.
NMC-WOLLARD, Inc. is not responsible for corrosion damage which may occur
when a vehicle is in storage after a period in service.
NOTICE! If the unit has been stored for more than 120 days, you can expect some
deterioration of the hydraulic seals. Replace defective seals before operating
machine
5. Install all parts that were removed when vehicle was being prepared for
storage.
6. Perform “Daily” checks as described in Maintenance, Chapter 2.
7. After the hydraulic system has warmed up to operating temperature, remove
hydraulic tank fill cap and check appearance of hydraulic fluid. A milky
appearance indicates that there is water in the system and that the system
should be drained and re-filled with fresh oil.
CHAPTER 2 MAINTENANCE
1. SERVICING...................................................................................................................1
1.1 CHAPTER CONTENTS........................................................................................1
1.2 BOLT TIGHTENING DATA..................................................................................2
1.3 FLUIDS, CAPACITIES, AMBIENT TEMPERATURE RANGES........................4
1.4 PERIODIC MAINTENANCE AND INSPECTION................................................6
1.4.1 Preventative Maintenance Schedule............................................................7
1.5 DAILY SERVICE...................................................................................................9
1.5.1 Coolant Level.................................................................................................9
1.5.2 Coolant Leaks................................................................................................9
1.5.3 Engine Oil Level.............................................................................................9
1.5.4 Empty Air Cleaner Dust Cup (If Conditions are Extremely Dusty).................9
1.5.5 Inspect for Transmission Oil Leaks................................................................9
1.5.6 Lights.............................................................................................................9
1.5.7 Fuel Leaks.....................................................................................................9
1.5.8 Brake Pedal Free Play.................................................................................10
1.5.9 Tire Condition and Pressure........................................................................10
1.5.10 Rear Axle Oil Leaks...................................................................................10
1.5.11 Water Separator.........................................................................................10
1.5.12 Cummins Diesels - Specific Procedures....................................................10
1.6 EVERY100 OPERATING HOURS - GAS MODELS......................................... 11
1.6.1 Change Engine Oil and Oil Filter................................................................. 11
1.6.2 Clean Crankcase Inlet Air Cleaner.............................................................. 11
1.7 EVERY 250 OPERATING HOURS OR 3 MONTHS......................................... 11
1.7.1 Transmission Oil.......................................................................................... 11
1.7.2 Lubricate Grease Fittings.............................................................................12
1.7.3 Inspect Drive Shaft, Steering, Suspension, and Front Axle Components...12
1.7.4 Inspect Brakes.............................................................................................13
1.7.5 Inspect Muffler, Exhaust, and Tail Pipe........................................................14
1.7.6 Instructions For Cleaning Spark Arrester/Exhaust System..........................14
1.7.7 Change Engine Oil and Oil Filter - Diesel....................................................15
1.7.8 Check Air Cleaner Restriction......................................................................15
1.7.9 Replace Spark Plugs - Gas Models, Zenith, Kubota...................................15
1.7.10 Clean Fuel Pump Strainer - Perkins..........................................................15
1.7.11 Change Fuel Filter Element - Perkins........................................................16
1.7.12 Replace Air Cleaner Element....................................................................16
1.7.13 Batteries.....................................................................................................17
1.7.14 A Sound Battery Is A Must.........................................................................19
1.7.15 Voltmeter....................................................................................................19
1.7.16 Alternator...................................................................................................19
1.8 EVERY 500 OPERATING HOURS OR 6 MONTHS.........................................20
1.8.1 Belt Tension And Condition..........................................................................20
Keep maintenance area clean and dry. Oily and wet spots are
slippery, greasy rags are a fire hazard, and wet spots are dangerous around electrical
equipment.
Before attempting to repair the tractor, be familiar with the information on these
pages.
1.5.4 Empty Air Cleaner Dust Cup (If Conditions are Extremely Dusty)
Remove retaining strap securing dust cup to canister. Remove dust cup.
Remove wing nut securing filter element to canister. Remove and inspect
element. Clean out dust from canister and dust cup with a damp, lint-free
cloth. Install element and dust cup. Replace element if necessary.
1.5.6 Lights
Check operation of all tractor lights. Replace any burned-out lights.
NOTICE! Always check fluid level with tractor on a level surface and with fluid
at normal operating temperature for hot check. Do not overfill transmission.
Overfilling can result in transmission damage. To avoid overfilling, add fluid
in small amounts and recheck level frequently. See Section 1.3, Fluids And
Capacities.
3. Examine fluid for discoloration and a foul (burned) smell. This would
indicate damaged bands or clutches. If oil has a milky look, water has
entered the transmission. Air bubbles mean there is an air leak in the
suction lines. Report any of these conditions to your supervisor.
Keep head and face away from possible hot or toxic muffler
drainage. Exposure to this drainage can result in serious injury.
1. Remove the plug (pipe plug) on the bottom half or side of the spark
arrester (muffler). Some particles may begin to drain out at this time. Soot
mixed with condensation or other oily liquids may also empty out.
2. Without causing deformation (or any type of damage to the spark arrester)
repeatedly tap on the arrester near the plug. This may be enough to begin
drainage of the spark trap.
Gauze
Strainer
Fuel Filter
Drain Tap
1.7.13 Batteries
To minimize risk of fire or explosion, follow these battery
servicing safety precautions:
• Sulfuric battery acid is poisonous. Avoid breathing battery fumes.
• Battery acid is strong enough to burn skin and cause blindness if splashed
into the eyes. Protect eyes and skin from contact. In the event of contact
with battery acid, immediately rinse in large amounts of water. Obtain
medical care if the eyes are burned.
• Battery gas can explode. Keep sparks and flame away from battery.
• Never check battery charge by placing a metal object across the battery
posts.A spark will occur and cause possible explosion. Use a voltmeter or
hydrometer.
Maintenance
The 12-volt battery supplied with your loader will provide long service if given
proper
care. Clean and inspect your battery every 3-4 months.
• The battery requires little maintenance.
• If the electric system has a defect, i.e., regulator damage, compensate for
increased water consumption of battery.
• Unscrew the sealing caps and replenish distilled water until battery acid
level is 1/2” above the lead plates. Screw on caps hand-tight.
Keep battery clean by wiping it with a damp cloth. Keep all connections clean
and tight. Remove any corrosion, and wash terminals with a solution of 1 part
baking soda and 4 parts water.
If the battery was just charged, crank the engine for several seconds to
reduce the “surface charge.”
Draw electrolyte into hydrometer, then squirt it back out several times to bring
float to electrolyte temperature.
Correct reading by subtracting .004 for each 10F BELOW 80F, and add .004
for each 10F ABOVE 80F
A difference of more than .025 between cells means the battery is starting to
fail due to internal shorts, or normal deterioration.
1.7.15 Voltmeter
The voltmeter indicates voltage across the battery terminals. When the
ignition and lights are off, the voltmeter needle should be at the 12V mark.
When the engine is running, the voltmeter needle should show 14V.
If the voltmeter does not jump to 14V after starting the engine, this indicates
that the battery is not being charged by the alternator.
1.7.16 Alternator
The alternator used is a 60-amp type.
The alternator requires no special care except to keep the drive belt properly
tensioned. It is not a user-repairable item.
If you suspect a problem with the alternator, most alternator problems can be
traced to one of the following causes:
An electrical schematic is shown on the next two pages for reference and an
aid to troubleshoot and repair problems.
• Do not over tighten brake tube fittings. Over tightening may crack the
fitting or damage the seat in the cylinder fitting.
• Compressed air used to service brake components must be oil-free or
rubber parts may be damaged.
• Always replace brake lines that are questionable.
• Never allow brake system rubber parts to come in contact with gasoline,
diesel fuel, or any type of cleaner other than an approved brake cleaner.
Wash hands before handling brake components.
• Brake linings that contact oil or grease can become contaminated, lose
braking friction and then must be discarded.
Periodic brake inspections are a must for safe and efficient brake operation.
Your inspection should be thorough.
4. Pads should be replaced if any pad has 1/8 inch or less friction material
remaining.
5. Inspect brake disc for rust, scoring, ridges, and distortion. Light rust is
not harmful. Disc should be free of excessive or heavy scoring, but some
scoring is natural. If scoring is deeper than .080-in., replace both discs.
Any cracks require disc replacement.
6. Clean up minor roughness with an emery cloth. Discs can be repaired by
honing to a minimum thickness of 0.85”.
7. If brake disc has heavy scoring, ridges, or blue heat spots, machining the
disc may eliminate these problems.
8. Maximum friction surface lateral (side-to-side wobble) allowed is 0.030"
total.
9. Replace disc if wear or distortion exceeds these values.
Stoplight Switch
Check switch operation according to 2-2 - 2.4.
Road Test
After performing the above checks and any necessary repairs, drive the
tractor to test brake action. The tractor should stop quickly and smoothly with
no tendency to dive or pull to one side.
An improper toe-in can grind off tire tread in a short period of driving. Toe-in
should be checked using a toe gauge or trammel.
1. Jack up each front wheel and chalk a band near center of tire while
spinning the wheel.
2. Use a sharp-nosed scriber to form a thin line near the center of the chalk
band while spinning the wheel. Keep the line THIN.
3. Lower wheels to floor. Roll tractor forward until wheels have made one
complete turn. Wheels should point straight ahead. This will impart a
rearward thrust to the wheels and will provide an accurate toe-in reading.
6. Remove grease seal. Inspect inner bearing cone and cup. Remove
bearing cone and cup if they appear damaged in any way. (Always replace
cup and cone as a set.)
7. Using a clean rag, wipe old grease from spindle, hub, and bearings.
8. Install new outer bearing cup, if removed.
9. Install new inner bearing cup, if removed.
10. Install new grease seal, if removed, using a plug to place pressure evenly
around seal. If you bend or otherwise damage seal, discard and use a
new one.
NOTICE! Do not overfill with grease because too much grease can cause
seal to fail or grease cap to pop loose after assembly.
NOTICE! Always check fluid level with tractor on a level surface and with fluid
at normal operating temperature for hot check. Do not overfill transmission.
Overfilling can result in transmission damage. To avoid overfilling, add fluid in
small amounts and recheck level frequently.
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NMC-WOLLARD 2021Truax Blvd., Eau Claire, WI 54703, Phone (715) 835-3151, Fax (715) 835-6625
M60 Tow Tractor Manual No. 46050
3. Withdraw dipstick and examine fluid for discoloration and a foul (burned)
smell. This would indicate damaged bands or clutches. If oil has a milky
look, water has entered the transmission. Air bubbles mean there is an air
leak in the suction lines. Report any of these conditions to your supervisor.
4. Check level indicated on dipstick. Add fluid as needed to maintain level
between “FULL” and “ADD 1 PINT” marks on the dipstick. See 1.3, Fluids
And Capacities.
NOTICE! The torque converter does not drain when transmission pan is
removed.
8. Install a new transmission filter on control valve body and secure with
capscrews. Tighten to 150 in/lbs torque.
9. Clean oil pan with solvent and dry it with compressed air.
NOTICE! Use care to prevent entry of dirt and other foreign matter into
transmission.
10. Install a new gasket on pan and install pan on transmission. Tighten pan
capscrews to 150 in/lbs torque.
NOTICE! Always check fluid level with tractor on a level surface and with fluid
at normal operating temperature for hot check. Do not overfill transmission.
Overfilling can result in transmission damage. To avoid overfilling, add fluid in
small amounts and recheck level frequently.
14. Check level indicated on dipstick. Add fluid as needed to maintain level
between “FULL” and “ADD” marks on dipstick.
Transmission Service - C6
The Ford C6 transmission combines a torque converter with a two-speed or
three-speed, fully automatic unit for transmitting engine torque to the drive
axle via a drive shaft. Maintenance is limited to changing the fluid and filter at
the recommended service intervals and adjusting the linkage, intermediate
band and the neutral start switch.
Malfunctions
Automatic transmission malfunctions may be caused by poor engine
performance or improper transmission adjustments.
If the problem exists after these checks and adjustments are completed,
remove tractor from service and refer the transmission to a transmission
repair facility.
NOTICE! If you ever notice unusual noises such as gear noise or grinding,
a buzz or whine, knocks, scraping, clicking, etc., remove the tractor from
service and refer it to a transmission repair facility.
Gearshift Cable
1. Disconnect the shift cable from the shift control on the transmission.
(Driver’s side of transmission).
2. Place gearshift lever on dash in N (neutral).
3. Move the control lever on transmission to the rearmost position detent.
Move the control lever on transmission ahead 2 detents. This is neutral.
4. Adjust cable length by turning clevis in or out until clevis will slide through
clevis and shift lever without movement of shift lever or control lever.
5. Move control lever through the entire shift range one position at a time,
checking shift lever detent at each position.
6. Tighten the clevis lock nut. Install the clevis and a new self-locking nut.
Tighten the nut firmly.
NOTE: Be sure the switch packing is properly installed to prevent oil leakage.
NOTE: If the transmission vacuum modulator pin comes out the pin must be
reinstalled into the transmission for the mechanical modulator to function. See
figure 5.
NOTICE! Unit is factory adjusted and disassembly of the modulator lid should
not be required. Disassembly could result in unequal of screws causing
gasket leakage and/or loss of the internal parts.
a. Remove plastic plug from transmission base and protective cap form
modulator body. Make sure that the modulator valve actuating rod is in
place inside transmission case. (On some models, the rod is retained
within the transmission.) Lubricate the “O” ring with transmission fluid
and fit it on the neck of the modulator. Insert neck into transmission
opening.
b. The necessary clip and fastener are provided with the transmission. Fit
the retaining clip to the groove in the neck of the modulator as shown
in (Figure 5). Fit fastener and tighten to 180 - 240 lb. ins. (20.3 - 27.1
Nm).
c. Route cable and secure cable hub to mounting bracket at fuel control
lever. Make sure that the cable bend radius is not less than 4 ins.
(101.6 mm) and that the cable is clear of exhaust system and other
engine hot spots. Support cable if necessary but do not crush conduit.
Some cable adjusting may be required to obtain full travel of the modulator
cable, as follows:
a. Move fuel control lever to wide open throttle (W.O.T.) position. Pull
(figure 7) or Push (figure 8) threaded cable rod end until it bottoms on
its internal stop. Adjust cable terminal to provide a free pin condition to
the fuel lever as shown in figure 7 or 8.
NOTICE! The Felsted Modulator is designed with positive stop at both ends of
1.5 ins. (38.1 mm) travel. Therefore, cable terminal (slip-link) must allow lever
to return to idle regardless of cable position.
5. Engine full throttle transmission line pressure check. With brakes engaged
and non drive wheels blocked gradually accelerate engine to full throttle.
Pressure should increase to the following at full throttle.
NOTICE! Do not stall transmission and run engine at wide open throttle for
more than ten seconds at a time. Extended operation in a transmission stall
mode at full or partial throttle will cause overheating and transmission failure.
After each full throttle check, move the selector to neutral and run the engine
at fast idle for about fifteen seconds to cool the converter before continuing to
the next check.
If the line pressure obtained is too low repeat step five adjusting the line
pressure closer to the higher pressure of the specification. If the pressure
obtained is too high repeat step five adjusting the pressure closer to the lower
pressure of the specification.
NOTICE! Pressure below 110 PSI for drive and 175 PSI for reverse may
cause band and clutch slippage and damage the transmission.
6. Remove wheel blocks and up shift test the vehicle with brakes not
engaged. From a stop “floor board” the accelerator and hold down the
accelerator until automatic up shift which will be a harsh change. If the up
shift does not occur repeat step five setting line pressure lower but not
below the minimum specified line pressure.
7. Remove hydraulic pressure gauge and reinstall pipe plug. Test vehicle
under normal driving conditions.
1. Remove radiator fill cap. Place suitable catch pans under the radiator and
engine drain plugs.
2. Drain radiator by opening tap at bottom of radiator.
3. Remove the drain plug from side of cylinder block to drain engine. Make
sure drain hole is not plugged.
4. Dispose of old coolant in an approved manner.
5. Flush system with clean water.
6. Install drain plugs and close radiator tap.
7. Remove one of the plugs from the thermostat housing to allow air to
escape the engine. Fill radiator with clean engine coolant. Fill coolant
reservoir to the recommended level. See 1.3, Fluids And Capacities.
1. The rear axle has two fill plugs: one on the differential bowl and one on the
input gearbox.
2. Park tractor on a level surface. Shut off engine and set parking brake.
3. Using a rag and wire brush, thoroughly clean dirt and rust from around fill plugs
and the drain plug on the lower side of the differential bowl. The axle housing fill
plug is the upper plug.
4. Remove, clean, and reinstall drive axle breather. Replace if corroded.
5. Place a catch pan under the differential drain plug.
6. Remove the drain plug. Inspect and remove metal particles from the plug.
Normally, these particles are very fine. If they appear to be irregular or of a
large size, there may be damage inside the axle. Notify your supervisor of this
condition.
7. When oil has drained, apply a non-hardening sealing compound (like #51 or
equivalent) to differential drain plug and install and tighten plug.
8. It is suggested to slowly add oil to both the gearbox and differential because it
shortens the time for the oil to evenly disperse into the axle.
9. See 1.3, Fluids And Capacities.
10. Apply a non-hardening sealing compound (like #51 or equivalent) to the fill
plugs and install them.
If you are not using a pressure bleeding system, use the standard method as
follows in steps 6 and 7:
NOTE: Bleeding the brakes without pressure bleeding equipment requires two
persons, one to observe the fluid being bled, and one to depress the brake pedal.
6. With a bleeder hose set up as in step 4, loosen bleeder screw and depress
brake pedal several times until air bubbles can no longer be seen and fluid runs
clear. Close bleeder screw. Repeat this procedure on the left rear, right front,
and left front wheel cylinders, in that order. (Remember to check fluid level in
master cylinder frequently.)
7. Replace caliper to original position.
8. After all four brakes have been bled, fill reservoir and install cover on master
cylinder.
IMPORTANT! Do not let reservoir run empty. If you let the reservoir run empty, air
will enter the system and you will have to begin the procedure all over again.
Jar with
brake fluid
FIGURE 9. TYPICAL SETUP FOR BLEEDING AIR FROM THE BRAKE SYSTEM
1.13 BLEEDING THE POWER STEERING SYSTEM
Any time a hose, pump, or steering gear unit is removed, replaced, or opened, air
in the system will have to be eliminated.
1. Fill power steering pump to proper level and let fluid stand for at least two
minutes.
2. Start engine and run momentarily. Add power steering fluid if necessary.
3. Repeat above procedure until fluid level remains constant after running engine.
4. Raise front of vehicle so that wheels are off ground. Turn steering wheel back
and forth, lightly contacting wheel stops. Add fluid if necessary.
5. Lower vehicle and turn wheels back and forth on ground. Check fluid level and
refill as required.
6. If fluid is foamy, allow vehicle to stand for a few minutes with engine off. Repeat
steps 1-6 as necessary.
7. Trapped air in system will cause fluid level in pump to rise when engine is off.
Repeat steps above until this condition no longer occurs.
Keep alcohol and other flammable solvents away from open flame
or lit cigarettes to prevent explosion or fire.
Every 30 Days
Clean and Check for Leaks
1. Clean surface of tank, hoses and fittings with a clean cloth and kerosene or
equivalent petroleum solvent. Carefully check for frosted areas and gas odor
which would indicate leakage. Open the shut-off valve and again check for
leakage at the shut-off and quick disconnect valves.
2. Check fuel, water, and fuel vapor hose connections and major LP components
for evidence of leakage. Look for stains or frost caused by evaporation. Check
if there is gas odor indicating leakage. Tighten cover screws as required.
Reseal fitting threads if necessary.
3. Apply soapy water or a leak detector solution to hoses, connections, and
assemblies while system pressure is at least 90 PSI (620 kPa) to verify
leakage.
4. The LPG system requires tight vacuum connections. If hose ends are belled,
split, or loose, cut off damaged part and reconnect to the fitting.
5. Water hoses between the engine and vaporizer are clamp on type with
reusable clamps. Replace any hose that shows signs of deterioration.
• Hand tighten.
5. Keep fuel hoses at least 2 inches from exhaust system parts. Hoses must be
supported by clamps, straps, or tape to minimize chafing or wear.
Pressurized oil from the pump flows to the steering gear unit via the brake power
boost assembly.
NOTICE! Do not leave the shut-off valve closed for more than 5 seconds.
Excessive heat may build up, damaging the power system components.
10. Turn engine off, remove test gauge, valve, and extra hose. Reconnect pressure
hose to the booster, make necessary repairs, and check fluid level.
Pump-to-Booster
Hose
Spare
to Hose to
Pump Booster
FIGURE 1. TEST GAUGE
2.3 DIAGNOSTICS, STEERING AND BRAKES
Use Table 2.4 for assistance in diagnosing brake problems.
If one light does not come on, check for a burned-out bulb or a poor electrical
connection. If both lights do not come on, check the fuses.
If bulbs, fuses, and connections are good, check the stop light switch: Unplug
the two wires from the switch and test for 12VDC. Voltage should be present.
If not, the problem is in the wiring. If voltage is present, the switch is not
working and should be replaced.
If care is taken, a new switch may be installed without allowing air into the
brake system. To replace the switch, unscrew the switch from the hydraulic
fitting. Apply a very small amount of pressure on the brake pedal, just enough
to cause brake fluid to fill the opening in the hydraulic fitting, then install the
new switch. Plug in the wires and re-check the brake light operation.
If brakes feel spongy after replacing the stoplight switch, bleed the brakes
according to paragraph 2-1 - 1.12.
The pipe fitting (Figure 2) uses a tapered thread that produces leakproof
joints.
Pipe threads will leak if or over-torqued.
Use a good pipe dope such as teflon tape on pipe threads. Do not put dope
on the first two threads from the end. Always put dope on the male thread,
never on the female thread.
After firm hand tightening, give the fitting 2-1/2 to 3 additional turns. This will
lock the threads. Tightening beyond this point will be of no value and could
even split the fitting.
48483
FIGURE 4.
STARTER/ INDICTOR LIGHTS DIAGRAM, ZENITH Z4.4L/Z2.8L
SEPTEMBER 15, 2015 CHAPTER 2 MAINTENANCE
PAGE 12 2 TROUBLESHOOTING
NMC-WOLLARD 2021Truax Blvd., Eau Claire, WI 54703, Phone (715) 835-3151, Fax (715) 835-6625
M60 Tow Tractor Manual No. 46050
FIGURE 10. ELECTRIC SCHEMATIC - ZENITH /C6 WITH CANBUS GAUGES (2 OF 4) 53201-2
48483-4
Breather
3.1.2 Removal
If you need to disassemble or replace the axle, first remove axle from tractor.
See Chapter 4, figure 15.
1. Remove rear wheels, according to 2-4 - 4.2.1.
2. Remove pipe clamps holding exhaust pipe and tail pipe to frame.
Disconnect and remove exhaust components as necessary.
3. Remove U-bolts securing rear universal joint to input yoke of differential
and swing drive shaft out of the way. Tape bearing to universal joint spider
to prevent losing bearings.
4. Remove calipers, according to Chapter 3.
5. (Drum-brake axles only) Disconnect brake lines from wheel cylinders and
remove hardware securing tee to differential housing. Plug lines to prevent
system contamination. Move brake lines and secure to frame to prevent
damage to lines.
6. Drain axle lubricant.
7. Position an axle jack or other mobile lifting device under axle and raise it
enough to relieve tension.
8. Remove the frame-to-axle capscrews and lower the axle.
9. Raise tractor until axle can be moved from under tractor. If sufficient
clearance cannot be obtained at the rear, slide unit out side of tractor.
8. Remove snap ring, two bearings and input pinion shaft from the reducer.
AUGUST 15, 2011 CHAPTER 2 MAINTENANCE
PAGE 2 3 REMOVAL AND INSTALLATION
NMC-WOLLARD 2021Truax Blvd., Eau Claire, WI 54703, Phone (715) 835-3151, Fax (715) 835-6625
M60 Tow Tractor Manual No. 46050
9. If removal from of the front reducer housing from the carrier assembly
(differential housing) is required. Remove the six locknuts and washers
that secure the housing to the carrier.
10. If pinion or pinion cage removal is desired, refer to 3.1.10
11. Clean, inspect, and repair components according to 3.1.5 and 3.1.6.
Immediately after cleaning, coat parts with a light film of oil to protect from
corrosion and then reassemble. If parts are to be stored for any length of time,
they should be treated with a good rust preventive and wrapped in special
paper or other material designed to prevent corrosion.
NOTE: Do not clean bearings in gasoline. Never place ground and polished
surfaces in a hot cleaning solution tank.
1. Inspect all bearing cups and cones, including those not removed from
parts of the carrier. Replace if pitted or damaged in any way.
NOTE: When necessary to replace either the bevel pinion or gear, replace the
gears as a set. These gears are matched to assure quietness and satisfactory
service.
NOTE: Replace thrust washers in sets because using old and new
washers together can result in premature failure.
3.1.6 Repair
Replace all worn or damaged parts. Replace hex nuts with rounded corners,
all lock washers, oil seals, and gaskets.
NOTE: When removing hub and drum assembly, always replace hub oil seal.
NOTICE! There is no shim pack or shims necessary for adjusting bevel gears
or differential bearing pre-load because housing and gears are machined
within limits that impose the correct pre-load and gear lash when unit is
assembled.
Repair of the drive shaft assembly is limited to replacing universal joints, the slip
joint components, or the complete drive shaft.
3.2.2 Installation
1. Install drive shaft assembly on transmission and secure with capscrews
and lock washers. Tighten U-bolt style nuts to 20-24 ft-lbs or strap design
bolts to 30-35 ft-lbs.
2. Position slip yoke on differential gear case yoke and loosely install “U”
bolts. Remove tape securing bearings to yoke and tighten “U” bolt nuts to
70 ft./lbs.
3. Grease universal joints with a high-quality grease.
3.3.2 Installation
Install in reverse of removal sequence. Refer to Section 1 for torque
specifications.
When installing u-bolts over springs and rear axle, torque nuts to 175 ft.-lbs
The recommended way to fix a radiator is to either replace it with a new one or
take it to a qualified radiator repair facility.
19. Attach a suitable hoisting bracket to transmission and/or engine assembly for
support and lifting.
20. Steps 20-25 apply if it is possible to remove the engine without the
transmission.
21. Remove converter drain plug access cover from lower end of converter
housing. Matchmark torque converter with drive plate (for easier installation).
22. Remove converter-to-flywheel attaching nuts.
23. Remove converter housing-to-engine attaching bolts.
24. Lower tractor for easier engine removal, if necessary.
25. Remove engine mount capscrews.
NOTICE! The transmission and torque converter must be removed and installed as
an assembly to prevent damage to the front bushing or front oil seal.
NOTICE! The drive plate (flywheel) will not support a load. Transmission should
not rest on the drive plate during removal or installation. Before removing
transmission support, use a jack to support the transmission.
NOTICE! The transmission and torque converter must be removed and installed as
an assembly to prevent damage to the front bushing or front oil seal.
1. Put tractor on hoist, but do not raise at this time. Disconnect neutral switch wire
at plug connector.
2. Raise tractor on hoist or stands.
3. Place drain pan under transmission fluid pan. Starting at rear of pan and
working toward front, loosen attaching bolts and allow fluid to drain. Finally
remove all of pan attaching bolts except two at front to allow fluid to further
drain. With fluid drained, install two bolts on rear side of pan to temporarily hold
it in place.
4. Remove converter drain plug access cover from lower end of converter
housing. torque converter with drive plate (for easier installation).
5. Remove converter-to-flywheel attaching nuts. Place a wrench on crankshaft
pulley attaching bolt to turn converter to gain access to bump switch.
6. With wrench on crankshaft pulley attaching bolt, turn converter to gain access
to converter drain plug. Place a drain pan under converter to catch fluid and
remove plug. After fluid has been drained, re-install plug.
7. Disconnect park brake cable. Disconnect from transmission park brake disk
and slide shaft rearward from transmission. Install a seal installation tool in
extension housing to prevent fluid leakage.
8. Disconnect downshift and manual linkage rods or cable controls from levers at
transmission.
9. Disconnect oil cooler lines from transmission. Disconnect temperature sender
wire.
10. Remove vacuum hose from vacuum diaphragm unit. Remove vacuum line from
retaining clip.
11. Disconnect cable from terminal on starter motor. Remove the three attaching
bolts and remove starter motor.
12. Remove transmission rear support and insulator assembly attaching bolts at
bottom rear of transmission.
13. Raise transmission with transmission jack to take pressure off rear.
14. Remove bolts securing transmission to frame and remove cross member.
15. Secure transmission to jack with safety chain.
16. Remove converter housing-to-engine attaching bolts.
17. Move transmission away from engine.
18. Lower transmission jack and move transmission and converter assembly from
under vehicle.
NOTICE! The engine and transmission must be assembled to each other before
bolting the engine to the torque converter adapter.
10. Working through the access opening in the engine bell housing, bolt the (2) to
the torque converter adapter (4) using four flange head hex screws (6). Use
blue loctite and torque to 101-105 ft-lbs
Fuel vapors create fire and explosion hazards. Do not allow any
open flame, smoking materials or other potential ignition sources near fuel or the
fuel system.
Disconnect the negative battery cable before servicing the fuel tank
or fuel system. An electrical arc at the fuel tank sending unit can act as an igniter
creating a fire and explosion hazard.
NOTICE! Use care when handling the sending unit to prevent damaging it.
3.8.4 Reassembly
1. Install new gasket on sending unit opening on tank, then carefully lower
sending unit into tank. Do not use gasket cement.
2. Secure sending unit with its hardware.
3. Temporarily tape or cover tank filler opening to prevent entry of dirt when
installing tank.
4. Apply thread sealer to drain plug threads and install drain plug.
3.8.5 Installation
1. When ready to install tank, place a quart of fuel in the tank, slosh around,
and pour out.
2. Install hoses and sending unit wire.
3. Position tank under frame and raise into position.
4. Install tank supports and straps. Tighten mounting hardware to 30 ft-lbs
torque.
5. Install battery and connect battery cables.
6. Fill tank with fuel and check for leaks.
3.9.1 Removal
1. Loosen hose clamp at power steering pump and disconnect hose. Drain
fluid into suitable container.
2. Remove steering column cover and pitman arm cover, if applicable.
3. Remove hose clamp and hose from return fitting at steering gear. Remove
hose assembly, union and pressure fitting from steering gear.
4. Loosen pinch bolt on coupling on lower end of steering column.
5. Disconnect drag link at steering gear end.
6. Remove pitman arm nut and washer. Remove arm from steering gear.
7. Remove capscrews and washers securing steering gear to frame mounting
bracket. Disconnect steering gear from coupling on column and remove
from vehicle.
3.9.2 Installation
1. Position steering gear assembly on frame bracket and engage gear
shaft with coupling on lower end of steering column. Secure to bracket with
capscrews and washers. Tighten capscrews to 45 ft./lbs.
2. Tighten pinch bolt on steering gear coupling.
3. Install hose assembly, union and pressure fitting. Connect hose assembly
to power steering pump.
4. Connect hose to return fitting and power steering pump and secure with
hose clamps.
5. Install pitman arm on gear shaft. Install hex nut and washer. Tighten hex
nut to 188 ft./lbs.
6. Install drag link and grease the link.
7. Bleed the system according to 2-1 - 1.12.
8. Install steering column cover and pitman arm cover, if applicable.
3.10.2 Installation
1. Position pump-to-pivot bracket with capscrews and washers.
2. Install pulley-to-pump shaft.
3. Install capscrews that allow pump to pivot.
4. Install belt and adjust tension to approx. 3/8" deflection.
5. Uncap hoses and pump connections. Connect hoses to pump. Tighten
hose fittings to 30-40 ft./lbs.
6. Bleed system as described in 2-1 - 1.12.
7. Install cap on power steering pump.
3.12.3 Installation.
1. Work rear of spring into seating slot in the rear spring mounting plate.
2. Align front of spring bushing bore with hole in frame and install spring front
mounting hardware. Tighten nut to 135 ft-lbs torque.
3. Install U-bolts over front axle and springs and install mounting plates,
washers, and nuts. Torque nuts to 105 ft-lbs.
4. Remove jack stands and jack from beneath axle and frame.
3.13.2 Disassembly
1. Remove cotter pins and caliper retaining bolts holding caliper to mounting
bracket and remove caliper. If necessary, loosen a bleeder to relieve
pressure (This will necessitate bleeding the brakes later.). Place a block
between the friction pads to secure the pistons.
2. Remove grease cap from hub.
3. Remove cotter pin, nut, and washer from wheel hub and pull off wheel hub
and brake disk. Protect bearings from contamination.
4. Remove brake disc from wheel hub, if necessary, by removing socket
head capscrews. Do not remove wheel studs unless replacement is
necessary.
5. Remove cotter pins and locknuts securing lower steering arms to tie rod
end assemblies. Remove tie rod. If tie rod ends need replacing, loosen
jam nuts on tie rod and remove end assemblies.
6. Disassemble knuckles and push out the king pins.
7. Remove knuckles from axle weldment. Remove knuckle bushings and/or
thrust bearings.
AUGUST 15, 2011 CHAPTER 2 MAINTENANCE
PAGE 20 3 REMOVAL AND INSTALLATION
NMC-WOLLARD 2021Truax Blvd., Eau Claire, WI 54703, Phone (715) 835-3151, Fax (715) 835-6625
M60 Tow Tractor Manual No. 46050
8. If necessary to remove tie rod and/or caliper brackets, remove the socket
head capscrews.
9. Remove steering arm, if necessary.
10. Inspect hub bearings. Remove bearing cups, if necessary. Always replace
cup and cone as a set.
3.13.3 Assembly
1. Install new thrust bearings, bushings, and king pins into the knuckles and
axle weldment.
2. Re-assemble king pins.
3. Install ball stud and secure with nut and cotter pin, if previously
disassembled. Place on socket head screw threads and tighten to 85 ft-lbs
torque.
4. If inner and outer bearings are to be replaced, install new cups into hub.
Make sure cups are seated well.
5. Install wheel studs, if removed.
6. Grease inner cone and cup and install inner cone.
7. Install grease seal using a plug to place pressure evenly around seal. If
you bend or otherwise damage seal, discard and use a new one.
8. Install brake disc on wheel hub, if removed. Tighten bolts to 85 ft-lbs
torque (axle) or 105 ft/lbs (Brierton Axle)
9. Install tie rod assembly to tie rod arms. Adjust toe-in of front wheels
according to 2-1 - 1.9.1. Tighten tie rod lock nuts to 20 ft-lbs torque.
NOTICE! Do not overfill with grease because too much grease can cause
seal to fail or grease cap to pop loose after assembly.
NOTE: If the tie rod ball joints were replaced or adjusted in any way, check
toe-in and adjust if necessary.
3.13.4 Installation
1. Position axle under tractor and raise axle using an axle jack.
2. Install U-bolts over front axle and springs and install mounting plates,
washers, and nuts. Torque nuts to 70 ft.-lbs
3. Position drag link so opening in end engages ball on steering arm.
4. Tighten plug until plug is flush with end of tube.
5. Align holes in ends of drag link tube with holes in plugs and install cotter
pins to secure.
6. Untie brake lines from frame and unplug lines. Connect brake lines and
bleed the brakes, see 1.12 of Maintenance manual for bleeding
instructions.
7. Install front wheels and tighten mounting nuts to 120 ft-lbs torque.
NOTE: If stop bolt supplied with axle is not long enough to make adjustment,
replace it with a 1/2-13x2.50 hex bolt.
6. Make adjustment at both ends. If correct, the steering arm will just clear
the axle tube when the stop bolts stop the hub from turning. See figure 4.
3.14.1 Removal
1. Remove cotter pins from ends of drag link.
2. Unscrew drag link plugs enough to free pitman arm and steering arm.
Remove drag link.
3.14.2 Installation
1. Position drag link so openings in ends engage balls on pitman arm and
steering arm.
2. Tighten plugs until plugs are flush with ends of tube.
3. Align holes in ends of drag link tube with holes in plugs and install cotter
pins to secure.
3.15 ALTERNATOR
The alternator requires no special care except to keep the drive belt properly
tensioned. It is not a user-repairable item.
If you suspect a problem with the alternator, most alternator problems can be
traced to one of the following causes:
NOTICE! When welding on the tractor, disconnect the battery to prevent damage
to the alternator.
After initially mounting wheel and tire assembly, recheck lug nut
torque after the first hour of operation and after the first 8 hours of operation. After
this, check monthly or every 250 hours, whichever comes first. Do not lube wheel
studs as it will result in inaccurate tightening torque. Failure to follow these
procedures could result in wheel mounting failure and loss of vehicle control.
The front and rear wheels are similar in maintenance, cleaning, and inspection.
4.2.1 Removal
1. Move tractor to a level surface. Shut off engine and set parking brake.
2. Using a jack, overhead crane, or some other suitable lifting device
(minimum 5 ton), raise end of tractor. Before tires leave the ground, loosen
the lug nuts. Then continue raising the tractor until the tire comes off the
ground. See Chapter 1 for jack stand locations.
3. Place jack stands under tractor to support it while wheel is off.
4. Remove lug nuts, valve stem bracket (rear wheels), and tire and wheel
assembly.
4.2.2 Disassembly
1. Let air out of tire and remove valve core.
2. Remove tire from wheel using standard safety equipment, tire changing
equipment, and safety practices.
3. Remove valve stem, if damaged or defective.
4.2.6 Installation
1. Assemble valve stems, if not already done.
2. Tires on dual sets must be replaced together. Unequal tire tread wear will
result in uneven weight distribution.
3. Proper installation when wheels are reinstalled. See figure 1:
a. Clean and dry wheel, studs, and mating surfaces before assembly. See
4.2.3
b. Install wheel and tire assembly on axle. Rear dual wheels are installed
with clamp plates over the studs, see figure 1. Thread the flange nuts
on. DO NOT use lock washers under flange nuts. Tighten gradually in
an alternating pattern.
c. The axle hub cover is provided with jack screw holes so when you
remove the cover bolts, you can thread them into these holes and
uniformly torque them to remove the press fitted cover.
d. When reinstalling this cover, it is very important to center the jack
screw holes over the solid parts of the hub. DO NOT position them
over the scallops in the hub. If you do, the next time you use the jack
screw holes to remove the cover, the bolts will ride up on the scallops
and break the hub. IMPORTANT: When using jackscrews to remove
cover be sure all the mounting bolts have been removed or cover
breakage will result.
e. When mounting the wheels, position the valve stem hole in line with
the “V” notch on the axle hub. The valve stem extension must pass
through this notch. If you do not, the valve stem will wear through.
f. Position the wheel clamps so the joint is in line with the valve stem and
doesn’t cover the passage way for the valve stem extension.
g. Torque using the criss cross tightening sequence shown on figure 2.
Torque to specifications on decal located on frame above tire.
4.3.2 Installation
Install in reverse of removal sequence. Refer to Table in Section 1 for torque
specifications.
When installing u-bolts over springs and rear axle, torque nuts to 175 ft.-lbs
IMPORTANT! Seal must be pressed into the hub bore until it bottoms out, even if
the original seal was only pressed in flush to the bore.
14. Apply a light coat of grease or oil to seal lip and spindle seal journal.
15. Install hub and bearing on spindle.
16. Install outer bearing cone.
17. Assemble nut and torque to 200 ft-lbs.
18. Rotate hub forward and back several revolutions to seat the bearings.
19. Retorque to 200 ft-lbs.
20. Back nut off slightly to relieve the torque, then to 100 ft-lbs. This is your
adjustment.
21. Make a mark on the spindle spline lining up the roll pin in the nut.
22. Mark the ring gear spline to line up with hole in the back face.
23. Assemble the ring gear by aligning the marks so the hole and the roll pin
go together. This locks the nut in place.
24. Assemble axle shaft and sun gear.
25. Apply silicone sealer to mounting surface of planetary spider. Assemble
planetary, install capscrews and torque to 85-115 ft-lbs.
26. Fill with oil to proper level.
MOUNTING SLOTS
SWITCH
ALIGNMENT
CHAPTER 3 OVERHAUL
TABLE OF CONTENTS
1 GENERAL REPAIR.........................................................................................................1
1.1 GUIDELINES FOR REPAIRING THE TRACTOR..................................................1
1.1.1 Special Tools..................................................................................................1
1.1.2 Removal and Disassembly............................................................................1
1.1.4 Using Compressed Air...................................................................................2
1.1.5 Frame, Engine, and Transmission.................................................................2
1.1.6 Metal Parts.....................................................................................................2
1.1.7 Bearings.........................................................................................................2
1.1.8 Gears.............................................................................................................2
1.1.9 Inspecting Parts.............................................................................................2
1.2 REPAIR AND REPLACEMENT..............................................................................2
1.2.1 Structural Parts..............................................................................................2
1.2.2 Wiring.............................................................................................................3
1.2.3 Gaskets and Seals.........................................................................................3
1.2.4 Reassembly and Installation..........................................................................3
1.3 ENGINE REPAIR AND MAINTENANCE................................................................3
1.3.1 Ordering Parts...............................................................................................3
1.4 FRONT BRAKES....................................................................................................3
1.4.1 Friction Pad Removal and Installation (Front)...............................................3
1.4.2 Disc Replacement (Front)..............................................................................5
1.4.3 Caliper Repair (Front)....................................................................................5
1.5 REAR BRAKES (STANDARD SINGLE-WHEEL AXLE).........................................6
1.5.1 Friction Pad and Caliper Service (Rear)........................................................6
1.5.2 Disc Replacement (Rear)..............................................................................7
1.6 REAR BRAKES (OPTIONAL DUAL-WHEEL AXLE)..............................................8
1.6.1 Adjustment.....................................................................................................8
1.6.2 Rear Drum Brake Removal and Disassembly...............................................8
1.6.3 Cleaning and Inspection................................................................................9
1.6.4 Rear Drum Brake Assembly and Installation.................................................9
1.7 WHEEL CYLINDERS...........................................................................................10
1.7.1 Removal.......................................................................................................10
1.7.2 Disassembly................................................................................................10
1.7.3 Cleaning and Inspection..............................................................................10
1.7.4 Assembly..................................................................................................... 11
1.7.5 Installation.................................................................................................... 11
1.8 POWER BOOSTER/MASTER CYLINDER.......................................................... 11
1.8.1 Removal.......................................................................................................12
1.8.2 Repair..........................................................................................................13
1.8.3 Installation....................................................................................................13
1.9 PARKING BRAKE (C-6 TRANSMISSION)...........................................................14
• Do not over tighten brake tube fittings. Over tightening may crack the fitting or damage
the seat in the cylinder fitting.
• Compressed air used to service brake components must be oil-free or rubber parts
may be damaged.
• Always replace brake lines that are questionable.
• Never allow brake system rubber parts to come in contact with gasoline, diesel fuel, or
any type of cleaner other than an approved brake cleaner. Wash hands before
handling brake components.
• Brake linings that contact oil or grease can become contaminated, lose braking friction
and then must be discarded.
1.1.3 Cleaning
When cleaning, keep related parts together so reassembly is easier. Valves,
pistons, sleeves and other internal parts that have close tolerance fits in
mating bores should be cleaned individually to prevent surface scoring and
marking. Special cleaning instructions are given where required.
Structural parts are best cleaned using soap and water and suitable brushes.
Steam cleaning may also be done before disassembly to remove heavy
accumulations of grease, oil, and dirt from exterior of engine, transmission
and rear axle assembly.
1.1.7 Bearings
Wash bearings in a bearing washer or immerse in solvent and scrub clean
with a soft brush. Remove all grease and oil from bearing recesses. Allow
to air dry. Apply a thin film of lubricating oil to bearings and check for free
movement between inner and outer race. Worn bearings must be replaced.
1.1.8 Gears
Clean gears using a soft bristle brush and cleaning solvent. Remove foreign
matter from the gears.
NOTICE! Small metal tabs project through the mounting holes of the outboard
brake pads on the outside of the caliper. To keep the pads from floating, peen
the tabs over the edge of the hole. This should extend the life of the outer pad
and eliminate premature rotor wear. Do this in assembly with the rotor while
applying pressure to the caliper to prevent the mounting bolts from bending.
To insure that the caliper floats check for adequate grease in the caliper
mounting sleeves, we recommend Stalube #3303 synthetic brake caliper
grease with added graphite and teflon.
12. If air was allowed to enter the hydraulic system, bleed brakes according to
2-1.10.
13. Pump brake pedal to force pads against disc. Check fluid reservoir and
bring to correct level.
14. Road test the tractor to test brake action. The tractor should stop quickly
and smoothly with no tendency to dive or pull to one side.
Installation
1. Connect brake line to housing assembly.
2. Bleed brake system as described in 2-1.10.
3. Install caliper in reverse order of disassembly.
10. Install wheel and tire assembly. Tighten 9/16 lug nuts (rear) to 130 ft./lbs.
torque. Remove jack stand and lower tractor.
4. Assemble the retainer rods, springs, and retainers. Lock the rods by
pushing down on the retainers while you twist the nails 1/4-turn with pliers.
5. To assemble the shoe return spring, put one hook in position in a brake
shoe. Pull the spring open to install the opposite hook in the other shoe.
6. Install the retainer spring into the shoes.
7. Install the hub and drum.
8. Install the washer and axle shaft nut. Tighten nut to 400-450 ft/lbs torque.
Install cotter pin.
9. If hydraulic line to wheel cylinder was removed, bleed brake system.
10. Install wheel and tire assembly. Tighten 9/16 lug nuts to 130 ft./lbs. torque.
Remove jack stand and lower tractor.
NOTICE! If the wheel cylinder is leaking or has failed, it is better to install a new
one rather than repair the old one. The time and cost involved to recondition a
cylinder is usually greater than its replacement cost.
1.7.1 Removal
1. Remove brake drum. Refer to paragraph 1.5.1.
2. Back off brake adjusting bolts if necessary to get clearance between drum
and brake shoes.
3. Disconnect brake line at cylinder. Plug brake line or secure clean rag
around open brake line to keep brake fluid from contaminating brake
linings and work area.
4. Remove brake return spring.
5. Remove securing wheel cylinder to brake. Spread brake shoes apart until
ends of shoes clear cylinder. Remove cylinder.
1.7.2 Disassembly
1. Remove rubber boots from wheel cylinders.
2. Apply low-pressure compressed air to cylinder inlet (if needed) and force
pistons and cups from cylinder bores. Remove spring.
3. If needed, remove bleeder screw from cylinder.
3. Inspect pistons, cups, and cylinder bores for scratches, scoring, pitting and
corrosion.
4. Use crocus cloth or a hone to remove deposits or minor surface
irregularities. If bore does not clean up readily, replace cylinder.
5. Inspect tapped holes of cylinder for thread damage. Use a tap to
clean up minor damage. Replace cylinder if threads are damaged due to
cross-threading of capscrews or fittings.
1.7.4 Assembly
1. Lubricate cylinder bore, spring, cups, and pistons with clean brake fluid.
Install into cylinder. Open side of cups and flat side of piston must be
toward inside of cylinder.
2. Install rubber boots making sure they engage grooves on cylinder.
3. Install bleeder screw into cylinder but do not tighten.
1.7.5 Installation
1. Position wheel cylinder, install capscrews and lock washers, and tighten to
15-20 ft-lbs torque.
2. Spread brake shoes apart enough to allow projections of brake shoes to
engage cylinder properly.
3. Connect brake line to wheel cylinder. Tighten tube fitting firmly. Do not
overtighten.
4. Bleed brake system as described in paragraph 2-1.10. Check for leaks
when bleeding system.
5. Install brake drum as described in paragraph 1.6.4.
6. Install wheel assembly and tighten 9/16 lug nuts (rear) to 130 ft-lbs torque.
Remove safety stands and lower tractor.
An accumulator is filled with brake fluid each time the brakes are applied. If the
power steering pump fails for some reason, the accumulator will provide around
three
Above-normal pedal pressure may cause the booster to hiss. Loud hissing sounds
at or below normal pedal effort indicates a possible problem.
Clunk, chatter, or clicking noises may be heard when the brake pedal is quickly
released from hard pedal efforts.
1.8.1 Removal
1. With engine off, depress brake pedal several times to discharge
accumulator.
2. Remove deck plate (located to right of operator’s seat).
a. Disconnect parking brake cable from parking brake lever.
b. Remove round head screws from both brake access plates and
remove access plates.
c. Remove deck plate fasteners and deck plate.
3. Disconnect brake pedal linkage from power booster by removing linkage
locknuts and capscrews.
4. Place rags under booster and master cylinder assembly. Disconnect all
hoses and pipes from booster and master cylinder.
5. Plug hoses, pipes, and booster ports to prevent entry of dirt, water or other
contaminants.
6. Remove hardware securing power booster to bracket and remove booster
assembly.
1.8.2 Repair
Repair of the power booster/master cylinder assembly is not recommended. If
faulty, replace entire unit.
1.8.3 Installation
1. Position power booster assembly on bracket and secure booster with its
mounting hardware. Tighten capscrews to 30 ft-lbs torque.
2. Bleed air from master cylinder.
a. Fill reservoir with DOT 3 brake fluid.
b. Using two plastic or rubber tubes, each approx. 5 inches long, place
one end of each tube into one of the master cylinder ports and place
other end in reservoir.
c. Move booster piston back and forth until no more bubbles appear.
d. Remove tubes and connect brake lines to master cylinder.
3. Connect brake lines to master cylinder and tighten.
4. Connect fittings to power booster and tighten.
5. Bleed air from Hydro-boost unit as follows:
a. Fill pump reservoir.
b. Crank engine for several seconds with coil wire or fuel pump wire
c. disconnected. DO NOT START ENGINE.
d. Check fluid level and add if necessary.
e. Start engine.
f. Turn wheels, lock-to-lock, twice.
g. Stop engine.
h. Discharge accumulator by depressing brake pedal five times.
i. Repeat steps (a) through (g).
j. If foaming occurs, stop engine and wait for 1 hour for foam to dissipate.
k. Repeat steps (a) through (g).
6. Re-connect pedal linkage. Tighten locknuts to 70 ft-lbs torque.
7. Adjust brake pedal. Refer to 2-1.12.
8. Bleed brake system. Refer to 2-1.10.
9. Road test the tractor.
1.9.4 Reassembly
1. Position brake shoes in drum and fasten with springs.
2. Put cover over brake assembly and fasten with attaching screws.
3. Slide drive shaft forward and attach to park brake assembly.
4. Turn knob on park brake handle out as far as possible without removing it.
1.10 RADIATOR
1.10.1 Removal
1. When engine is cool, remove transmission oil cooler from radiator.
2. Drain cooling system.
3. Disconnect upper and lower hoses. Replace if bulged, cracked, or leaky.
4. Remove radiator mounting fasteners and remove radiator.
VENDOR PART NUMBER column lists the original manufacturers’ part numbers of
items purchased by NMC-Wollard, Inc.. Although these parts may be purchased from
NMC-Wollard, Inc. by using the NMC-Wollard, Inc. part number, you may wish to
purchase directly from the original manufacturer.
EFF (Effectivity) column identifies by code the model or serial number/s on which a
particular part is used. Absence of the code in the “EFF” column indicates that the part
or assembly is used on all models with Ser #001 and on.
FIGURE 1.
AXLE-FRONT
1 OF 2
APRIL 3, 2015 CHAPTER 4 REPAIR PARTS
PAGE 2 4 ILLUSTRATED PARTS LIST
NMC-WOLLARD 2021Truax Blvd., Eau Claire, WI 54703, Phone (715) 835-3151, Fax (715) 835-6625
M60 Tow Tractor Manual No. 46050
FIGURE 1.
AXLE- FRONT
2 OF 2
FIGURE 2.
BRAKE, CALIPER, GM, FRONT
FIGURE 3.
AXLE-FRONT SPRING
FIGURE 4.
AXLE, REAR
1 OF 3
FIGURE 4.
AXLE, REAR
2 OF 3
FIGURE 4.
AXLE, REAR
3 OF 3
FIGURE 5.
AXLE, REAR SHAFT ASSY
AXLE, REAR, CALIPER ASSY
AXLE, REAR, BRAKE DRUM
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
PAGE 16 4 ILLUSTRATED PARTS LIST
NMC-WOLLARD 2021Truax Blvd., Eau Claire, WI 54703, Phone (715) 835-3151, Fax (715) 835-6625
M60 Tow Tractor Manual No. 46050
Note: Long Axle Shaft extends toward RH wheel. Short Axle Shaft extends toward LH
wheel.
3
2
FIGURE 6.
AXLE ASSY REAR, NEWAGE
MAY 25, 2016 CHAPTER 4 REPAIR PARTS
PAGE 18 4 ILLUSTRATED PARTS LIST
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M60 Tow Tractor Manual No. 46050
FIGURE 7
12
11
7
10
9
13
8
6
7 5
2
1
FIGURE 8.
BRAKE, CALIPER REAR
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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NOTE: The quantities are for one wheel assembly, except for item #3.
12 13
9
4
3 7
14
16
17
2
18
1
19
20
21
FIGURE 9.
BRAKE, DRUM - REAR WITH DUAL WHEELS
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 10
AXLE-REAR SPRING
FIGURE 11
BRAKE PEDAL & MASTER CYL, HYD TUBES, HOSES & CONN
1 OF 2
45
46
FIGURE 11
BRAKE PEDAL & MASTER CYL, HYD TUBES, HOSES & CONN
2 OF 2
FIGURE 12.
BRAKE C6 - PARKING
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 13.
BRAKE, PARK LEVER ASSEMBLY
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 14.
HYDRAULIC POWER SYSTEM C6
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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Fig.- NMC Vendor Nomenclature Eff Units
Item Wollard Part No. Per
Part No. Assy
14- Hydraulic Power System, C6 Ref
1 F102526 Power Steering Pump 1
NW031646 HHCS, M10 x 1.6 x 30MM, GR8.8 2
2 F100979 Hose Clamp, #6 (3/8-7/8) 6
3 45811 Relief Valve, PS Pump, 800-900,
Perkins 1104
45812 O-ring, PS Relief Valve
4 NW034570 Hose, 3/8 x 32", Tee - Pump(Used with 1
diesel engines.)
5 F104418 29T6 Tee, Union (Thompkins) 1
6 NW029964 Hose Assy, 12", Tee - Str. Gear 1
7 NW026800 FF5300-0646 Elbow (01276) 1
8 NW029966 Hose Assy, 30.50", Str. Gear-Booster 1
9 NW026799 FF5300-0645 Elbow (01276) 2
10 NW023510 Steering Gear (See Steering Column) Ref
11 NW029965 Hose Assy, 29", Pump - Booster 1
(Cummins 4B4.5)
37695 Hose Assy, 27", Pump - Booster(Used 1
with diesel engines. W/ Cummins
40278)
NW030042 Hose Assy (Cummins) 1
38387 Hose, Assy, PS, #6M, 56”, ST90 1
(Perkins)
12 NW029878 Hose Assy, 3/8 x 21", Tee - 1
Booster(Used with diesel engines.)
13 F104286 2771072 Master Cylinder/Power Booster (14894) 1
14 F101156 Clamp, Hose, #12 2
NS F101146 Clip, Insulated, 1.25" ID 2
FIGURE 15.
STEERING COLUMN, C6
1 2 3 4 5
6 7 8 9
10 11 12 13
14 15 16 17
18 19 20 21
22 23 24 25 26
FIGURE 16.
DECALS AND PLACARDS
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27
FIGURE 17.
FRAME
FIGURE 18.
SHEET METAL
1 OF 2
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19
18
FIGURE 18.
SHEET METAL SOUND SUPPRESSION
2 OF 2
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FIGURE 19.
COUNTERWEIGHTS
ZENITH
FIGURE 20.
FUEL SYSTEM
1 OF 2
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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ZENITH
FIGURE 20.
FUEL SYSTEM
2 OF 2
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 21.
FUEL SYSTEM, LP OPTION, ZENITH 2.8L/C6
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 22.
LIGHTS-HEADLIGHT
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 23.
LIGHTS-REAR & 9 PIN RECEPTACLE
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FIGURE 24.
LIGHT- AMBER STROBE W/ POLE
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 25.
LIGHTS-PONY LIGHTS, OPTION
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 26.
LIGHTS- SPOTLIGHT, OPTION
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 27.
LIGHTS - WORKLIGHT ASSEMBLY, OPTION
FIGURE 28.
LIGHTS- TURN SIGNALS, OPTION
LIGHTS - 4 WAY FLASHERS, OPTION
BOSTROM T-BAR
FIGURE 30.
SEAT ASSEMBLY
FIGURE 31.
SEAT, SUSPENSION, GRAMMAR, OPTION
FIGURE 32.
WHEELS AND TIRES - FRONT
FIGURE 33.
WHEELS AND TIRES - REAR
FIGURE 34.
WHEELS AND TIRES, DUAL OPTION
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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NOTE: 43961 includes standard coolant temperature and oil pressure gauge.
FIGURE 35.
INSTRUMENT PANEL
SHUTDOWN, LO OIL/HI TEMPERATURE
BRAKE INDICATOR LIGHT
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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5 6 7
FIGURE 36.
INSTRUMENT PANEL, BRAKE CONTROLLER
1 of 2
NOVEMBER 02, 2015 CHAPTER 4 REPAIR PARTS
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M60 Tow Tractor Manual No. 46050
1 2
4
12
5
6
7
8
9
3 10
11
53512
FIGURE 36.
INSTRUMENT PANEL, BRAKE CONTROLLER
2 of 2
MAY 25, 2016 CHAPTER 4 REPAIR PARTS
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FIGURE 37.
RELAYS, FIREWALL
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 38.
BATTERY SYSTEM
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 39.
SPEEDOMETER, CHARGE WARNING
EMERGENCY SHUT DOWN, OPTION
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 40.
SWITCH, TOGGLE, MILITARY SPEC., OPTION
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FIGURE 41.
HARNESS, REAR
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FIGURE 42.
HARNESS ASSEMBLY, DASH
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FIGURE 43.
HARNESS, DASH, GAUGES & LIGHTS
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M60 Tow Tractor Manual No. 46050
1A
1C
1E
1B
2A 2B
2A
3A
2 3
FIGURE 44.
HARNESS, WIRING, VARIOUS
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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1 2
3 4
5
6
8 9
FIGURE 45.
HARNESS, WIRING, VARIOUS
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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53583
FIGURE 46.
HITCH, SPRING-LOADED & ADAPTER COUPLER
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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M60 Tow Tractor Manual No. 46050
Fig.- NMC Vendor Nomenclature Eff Units
Item Wollard Part No. Per
Part No. Assy
46- 39138 Hitch, Pin/Eye, Spring-Loaded, Ref
Option
1 39140 Pin Assembly 1
2 39139 Hitch Weldment 1
3 39141 Spring 1
4 39487 Washer 1
5 SWXRP202 Pin 1
6 F016829 Lock Washer, 5/8 4
7 Comm Nut, Hex, 5/8-11, GR8 4
8 Comm HHCS, /58-11 x 3.00 GR8 4
FIGURE 47.
HITCH, FRONT, W/ RELEASE, OPTION
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 48.
HITCH, PIN/EYE, .69 DIAMETER, OPTION
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 49.
HITCH, COUPLER, PINTLE HOOK, OPTION
3, 4, 5
FIGURE 50.
HITCH, HOLLAND 400 CA ( FRONT AND REAR), OPTION
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 51.
HITCH, 3 POSITION TOW, REAR, OPTION
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 52.
HITCH, PIN & EYE COUPLER, OPTION
2
3,4,5,6
52511
FIGURE 53.
HITCH ASSEMBLY, PIN & EYE
FIGURE 54.
HITCH OPTION
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 55.
HITCH, COUPLER, HOLLAND 400CA, QUICK RELEASE, OPTION
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52475
FIGURE 56.
HITCH, RECEIVER W/ TRIBALL, OPTION
TRAILER CONNECTOR
Tape
FIGURE 57.
WIRE THROUGH IGNITION, OPTION
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 58.
CAB, 8” TUB, DIESEL, OPTION
1 OF 2
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FIGURE 58.
CAB, 8” TUB, DIESEL, OPTION
2 OF 2
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FIGURE 59.
CAB, 8” TUB, DIESEL OPTION
1 OF 2
FIGURE 59.
CAB, 8” TUB, DIESEL OPTION
2 OF 2
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FIGURE 60
CAB, DOORS, CANVAS, GREY, 8”, KIT OPTION
FIGURE 61.
GUARD, OVERHEAD, 8” TUB, OPTION
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 62.
CAB, ECONO OPTION
JULY 1, 2015 CHAPTER 4 REPAIR PARTS
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FIGURE 63.
PADS, RUBBER PUSH, OPTION
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 64.
GUARD, HIP OPTION AND MASTER DISCONNECT
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 65.
BACK-UP ALARM, OPTION
FIRE EXTINGUISHER, OPTION
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1 2 3 5 4 6
To oil
sender
Temp. sender
on engine I
S G
T N
7 BAT To fuse
panel
Ign. Switch
FIGURE 66.
SAFETY SHUTDOWN, OPTION
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FIGURE 67.
HEATER/DEFROSTER, OPTION
FIGURE 68.
AIR COMP, OPT, 60DCC6, TRAILER CONNECTION
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 69.
SHUTDOWN, LOW OIL/HIGH TEMPERATURE
NO SHUTDOWN OPTION, DEUTZ 2011
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10
11
FIGURE 70.
SHIFTER ASSEMBLY/C6/GM, QUADRASTAT
FIGURE 71.
SHIFTER ASSEMBLY, MORSE IN DASH
FIGURE 72.
SHIFT INHIBITOR, OPTION, C6
37
38
18 9
27,28 19
24
1
20
12
26
4
16
6
3 ,7 8
14
2
5
10
13
17
FIGURE 73A.
AIR CONDITIONER FIREWALL MOUNT
FIGURE 74.
ENGINE PACK, CUMMINS 4B4.5 NA/C6
FIGURE 75.
ENGINE/TRANSMISSION ASSEMBLY, CUMMINS 4B4.5 NA/C6
1 OF 2
FIGURE 75.
ENGINE/TRANSMISSION ASSEMBLY, CUMMINS 4B4.5 NA/C6
2 OF 2
FIGURE 76.
OEM PARTS, CUMMINS 4B4.5NA/C6
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FIGURE 77.
DRIVESHAFT, CUMMINS 4B4.5NA/C6
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FIGURE 78.
LINKAGE SYSTEM, CUMMINS 4B4.5NA/C6
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FIGURE 79.
COOLING SYSTEM, CUMMINS 4B4.5NA/C6
DECEMBER 01, 2014 CHAPTER 4 REPAIR PARTS
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FIGURE 80.
STEERING SYSTEM, CUMMINS 4B4.5NA/C6
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FIGURE 81.
EXHAUST SYSTEM, CUMMINS 4B4.5NA/C6
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FIGURE 82.
AIR INTAKE SYSTEM, CUMMINS 4B4.5NA/C6
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FIGURE 83.
ELECTRIC SYSTEM, CUMMINS 4B4.5NA/C6
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FIGURE 84.
STEERING ASSEMBLY, CUMMINS 4B4.5NA/C6
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 85.
ENGINE PACK, DEUTZ 2011/C6
AUGUST 15, 2011 CHAPTER 4 REPAIR PARTS
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FIGURE 86.
ENGINE/TRANSMISSION ASSEMBLY, DEUTZ 2011/C6
(1 OF 2)
FIGURE 86.
ENGINE/TRANSMISSION ASSEMBLY, DEUTZ 2011/C6
(2 OF 2)
FIGURE 87.
DRIVESHAFT, DEUTZ 2011/C6
FIGURE 88.
LINKAGE SYSTEM, DEUTZ 2011/C6
FIGURE 89.
EXHAUST SYSTEM, DEUTZ 2011/C6
FIGURE 90.
AIR INTAKE SYSTEM, DEUTZ 2011/C6
FIGURE 91.
ENGINE PACK, PERKINS 1104-44/C6
FIGURE 92.
ENGINE / TRANS ASSY, PERKINS 1104-44/C6
(1 OF 2)
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Fig.- NMC Vendor Nomenclature Eff Units
Item Wollard Part No. Part No. Per
Assy
92- 44826 Engine/Trans., Perkins 1104C-44/C6, Tier 2 Ref
46382 Engine/Trans, 1104/C6, T2, Hyd Steer
44842 Pump Assy, Hyd, 1104 (Also See Fig 14)
1 44827 Engine, Perkins 1104C-44, C6, T2 1
2 38733 Fitting, Pipe, Nipple, 1/8-27 w/Hex 1
3 3.1820 Fitting, Pipe, Tee, 1/8 NPT 1
4 F101526 Sender, Temp 1
5 F101527 02025-00 Sender, Oil Pressure (V00542) 1
6 NW021649 8647 Switch, Pressure (13445) 1
13 43258 Pivot Weldment, PS Pump 1
F100196 HHCS, 3/8-24 x 1.25 2
F009665 Lockwasher, 3/8 2
14 45811 Valve, Relief, PS, 800-900 PSI 1
45812 O-Ring, PS, 800-900 PSI 1
15 F102526 Pump, Power Steering 1
46229 Cap, Power Steering 1
F103926 HHCS, M10 x 1.5 x 25mm DN 933 2
F018486 Lock Washer, 7/16 3
16 38334 Plate, Adjuster, PS Pump 1
17 NW023994 3830967 Pulley, Steering Pump (1HS72) 1
18 37678 412505 Fan, 16" Puller (V00547) 1
19 44941 Adjuster, Power Steer Pump, 1104 1
20 NW010518FB Strap, Ground 1
21 F100780 Reducer, Bushing, 1/2 NPT to 1/8 1
22 45093 7355 Belt V, G 7355, 3/8 x 36 1/4 1
27 40480 Spacer, PS Pump 1
28 NW031646 HHCS, 10mm x 30mm GR 8 2
29 38321 HHCS, M16 x 40mm 2
30 F103926 HHCS, M10 x 1.5 x 20mm DN 933 2
37 NW03461 Socket Head Bolt 1
39 F104348 HHCS, 12mm x 1.75 12
40 F100405 HHCS, 5/8-11 x 4, GR5 2
41 204714 FW, 5/8 SAE, Hard 2
42 F018701 HHCS, 1/2 x 1-3/4 6
43 F100064 Washer, 1/2 Flat 6
44 F015973 Washer, 1/2 Lock 14
45 F016825 Nut 1/2-13 Hex 6
46 37535 FW, .66 ID, 3.12 OD, .19 thk 4
47 3.0391 Nut, Hex, 5/8-11 Lock, Esna 2
65 44631 Engine Mount, Perkins RH 1
66 44670 Engine Mount, Perkins LH 1
67 44514 Isolator 2
68 44634 Mount Wldmt, M60, Engine-Frame 2
69 42031-20 4126X091 Tube, Dipstick 1
85 44859 Brkt Wldmnt, Fuel Filter, P1104 1
86 204783 Spacer, Brake Lever, P1104 1
87 44940 Angle, Dipstick Mnt, C6 1
88 44888 Plate, Mnt, fuel Filter, P1104 1
89 44942 Spacer, Power Steer Pump, 1104 1
90 400906 Spacer, Cut, 4009, 1.00 1
NS 42265 Heater, Block, Option 1
NS F104343 Clip, Insulated, 3/4” ID 1
NS 39981 Brkt, Dipstick 1
FIGURE 92.
ENGINE/TRANSMISSION ASSEMBLY, PERKINS 1104-44/C6
(2 of 2)
FIGURE 93.
OEM PARTS, PERKINS 1104-44/C6
FIGURE 94.
DRIVESHAFT, PERKINS 1104-44/C6
FIGURE 95.
LINKAGE SYSTEM, PERKINS 1104-44/C6/GM
FIGURE 96.
COOLING SYSTEM, PERKINS 1104-44/C6 OR GM4L70
FIGURE 97.
EXHAUST SYSTEM, PERKINS 1104-44/C6
FIGURE 98.
AIR INTAKE SYSTEM, PERKINS 1104-44/C6 OR GM4L70
FIGURE 99.
ELECTRICAL ASSEMBLY, PERKINS 1104-44/C6
FIGURE 100.
ENGINE PACK, ZENITH 2.8L/C6
4 5
FIGURE 101.
ENGINE/TRANS ASSEMBLY, ZENITH 2.8L/C6
FIGURE 102.
ENGINE/TRANS OEM PARTS, ZENITH 2.8L/C6
FIGURE 103.
DRIVESHAFT ASSEMBLY, ZENITH 2.8L/C6
9 9
49683 51520
FIGURE 104.
COOLING SYSTEM, ZENITH 2.8L/C6
FIGURE 105.
STEERING ASSEMBLY, HYDRAULIC, ZENITH 2.8L
FIGURE 106.
EXHAUST SYSTEM, ZENITH 2.8L/C6
FIGURE 107.
AIR INTAKE SYSTEM, ZENITH 2.8L/C6
FIGURE 108.
ELECTRICAL SYSTEM, ZENITH 2.8L/C6
FIGURE 109.
HARNESS ENGINE, ZENITH 2.8L/C6
FIGURE 110.
GRP, ENG, B3.3NA/C6, T3
FIGURE 111.
ENGINE/TRANS ASSEMBLY, B3.3 TURBO,T3
(1 OF 2)
FIGURE 111.
ENGINE/TRANSMISSION ASSEMBLY, B3.3 TURBO,T3
(2 OF 2)
FIGURE 112.
ELECTRICAL ASSEMBLY, B3.3 NA C6,T3
FIGURE 113.
DRIVE SHAFT, B3.3 NA C6,T3
FIGURE 114.
LINKAGE SYSTEM, B3.3 NA C6,T3
FIGURE 115.
EXHAUST SYSTEM, B3.3 NA C6,TT AND GM4L70
FIGURE 116.
AIR INTAKE, B3.3 NA C6,T3 AND GM4L70
FIGURE 117.
COOLING SYSTEM, B3.3/C6,T3 AND GM4L70
FIGURE 118.
STEERING ASSEMBLY, HYDRAULIC, B3.3/C6,T3
FIGURE 119.
LINKAGE SYSTEM, B3.3 NA, GM4L70,T3
FIGURE 120.
ELECTRICAL ASSEMBLY, B3.3 NA, GM4L70,T3
FIGURE 121.
ELECTRICAL ASSEMBLY, CHASSIS PERKINS 1104C-44/GM4L70
FIGURE 122.
ENG/TRAN/PERKINS 1104C-44/GM4L70
(1 of 2)
FIGURE 122.
ENG/TRAN/PERKINS 1104C-44/GM4L70
(2 of 2)
FIGURE 123.
GROUP, M60 ENGINE, KUBOTA WG2503, GAS/LP
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3 4
2
5 6
FIGURE 124.
ENGINE/TRANSMISSION ASSEMBLY, KUBOTA WG2503
1 OF 2
90
FIGURE124.
ENGINE/TRANSMISSION ASSEMBLY, KUBOTA WG2503/C6
2 OF 2
2 3 7
1
8
17
9
BUSS
19
21
25
24
FIGURE125.
ELECTRICAL ASSEMBLY, KUBOTA WG2503 (1 OF 2)
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1 3
FIGURE125.
ELECTRICAL ASSEMBLY, KUBOTA WG2503 (2 OF 2)
NOVEMBER 02, 2015 CHAPTER 4 REPAIR PARTS
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FIGURE126.
LINKAGE ASSEMBLY, KUBOTA WG2503
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3
4
1
FIGURE127.
EXHAUST SYSTEM, KUBOTA WG2503
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2 or 3
1
4 or 5
FIGURE128.
AIR INTAKE SYSTEM, KUBOTA WG2503
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8
9
FIGURE129.
COOLING SYSTEM, KUBOTA WG2503
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FIGURE130.
FUEL SYSTEM, KUBOTA WG2503
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FIGURE131.
HYDRAULIC ASSY, KUBOTA WG2503
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7
1
5 2
3
4
FIGURE132.
DRIVESHAFT, KUBOTA WG2503
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C6
FIGURE 133.
LOCKOUT 3RD GEAR, OPTION
JULY 01, 2015 CHAPTER 4 REPAIR PARTS
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FIGURE 134.
BASE GRP., M60 W/HYD. STEER, CONTAINER SHIP, OPT
CHAPTER 4 REPAIR PARTS APRIL 26, 2016
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Product Family
2” CAN Display
Operation
Manual
Contact Beede
Beede Electrical
Instrument Company, Inc.
88 Village Street
Penacook, NH 03303
(603) 753-6362
Toll-free 800-451-8255
Fax (603) 753-6201
W W W . B E E D E . C O M
Table of Contents
About � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � iii
Scope � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � iii
Preconfigured Instruments � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � iv
Stand-Alone and Master Node Configurations � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � iv
Product Outline Drawing � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � v
Menu Navigation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1
Menu/Enter/Reset Switch � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1
Up Switch � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1
Down Switch � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1
Switch Icon Conventions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1
Selection Arrow Cursor � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2
Menu Scrolling Icons� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2
Blinking Bar Cursor � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3
Start-up Routine � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
Default CAN Parameter Screen � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
Viewing CAN Parameters � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
Main Menu � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
Maintenance Hours or Vehicle Trip � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5
Faults Active � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 6
Viewing Active Faults � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7
Warnings Active � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8
Viewing Active Warnings � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9
Faults Stored � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �10
Alarms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �11
Alarms Menu � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �12
Enabling/Disabling Alarms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �13
Viewing Alarms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �14
Alarm Configuration� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �15
Adding an Alarm or Alarms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �16
Editing Alarms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �18
Deleting Alarms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �19
Mute � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �20
Setup Menu � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 21
Backlight � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �22
Lamp On & Lamp Off � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �22
Setting Units � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �23
Popups Notification Screens � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �24
Setting Popups � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �25
Display � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �26
1 or 2 Parameter Display � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �27
Set Contrast � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �28
Video Mode Formats � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �29
Set Video � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �30
Trip Mode � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �31
Alarm Output � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �32
Firmware Information� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �33
Implementation of SAE J1939 Parameters � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 34
Parameter Icons & Descriptions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 35
Menu Navigation Icon Descriptions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 36
CHAPTER 5 MAUFACTURER’S INFORMATION SEPTEMBER 15, 2015
CAN DISPLAY MANUAL PAGE 3
NMC-WOLLARD 2021Truax Blvd., Eau Claire, WI 54703, Phone (715) 835-3151, Fax (715) 835-6625
M60 Tow Tractor Manual No. 46050
ii
List of Figures
Figure 1-1: Menu Scrolling and Option Selection � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2
Figure 1-2: Blinking Bar Cursor � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3
Figure 1-3: Accessing the Main Menu � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
Figure 1-4: Accessing and Resetting Maintenance Hours and Vehicle Trip Logs � � � 5
Figure 1-5: Fault Notification and Information Screens � � � � � � � � � � � � � � � � � � � � � � � � � � � 6
Figure 1-6: Viewing Active Faults � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7
Figure 1-7: Warning Notification and Information Screens � � � � � � � � � � � � � � � � � � � � � � � 8
Figure 1-8: Viewing Active Warnings � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9
Figure 1-9: Faults Stored Information Screens � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 10
Figure 1-10: Alarms Menu Functions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 12
Figure 1-11: Enabling/Disabling Alarms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 13
Figure 1-12: Alarm Screen Details � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 14
Figure 1-13: Viewing Alarms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 14
Figure 1-14: Add & Edit Alarm CAN Parameter Screen Details � � � � � � � � � � � � � � � � � � � 15
Figure 1-15: Menu Prompt Sequence with No Configured Alarms � � � � � � � � � � � � � � � 16
Figure 1-16: Menu Prompt Sequence with Previously Configured Alarms � � � � � � � 17
Figure 1-17: Editing an Alarm � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 18
Figure 1-18: Deleting an Alarm � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 19
Figure 1-19: Muting Faults, Warnings & Alarms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 20
Figure 1-20: Setup Menu Functions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 21
Figure 1-21: Setting Backlight Intensity � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 22
Figure 1-22: Setting Units � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 23
Figure 1-23: Popup Fault, Warning & Alarm Screens � � � � � � � � � � � � � � � � � � � � � � � � � � � � 24
Figure 1-24: Setting Popup Status � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 25
Figure 1-25: Display Menu � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 26
Figure 1-26: 1 and 2 CAN Parameter Display Formats � � � � � � � � � � � � � � � � � � � � � � � � � � � 27
Figure 1-27: Setting 1 or 2 Parameter Display Lines � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 27
Figure 1-28: Setting LCD Contrast � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 28
Figure 1-29: Video Mode Formats � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 29
Figure 1-30: Setting LCD Background Color Scheme (Video Mode) � � � � � � � � � � � � � � 30
Figure 1-31: Setting Hours or Miles for Main Menu Display � � � � � � � � � � � � � � � � � � � � � 31
Figure 1-32: Setting Alarm Output Pin Status � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 32
Figure 1-33: Viewing Firmware Revision � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 33
SEPTEMBER 15, 2015 CHAPTER 5 MANUFACTURER’S INFORMATION
PAGE 4 CAN DISPLAY MANUAL
NMC-WOLLARD 2021Truax Blvd., Eau Claire, WI 54703, Phone (715) 835-3151, Fax (715) 835-6625
M60 Tow Tractor Manual No. 46050
iii NexSysLink 2" Stand-Alone CAN Display Operation Manual · SAe J1939
®
• About
This instrument directly reads SAE J1939 compliant CAN messages and
displays the message information on a sunlight visible, transflective dot-
matrix LCD� Like all NexSysLink® instruments, this product eliminates the
need for a translation “black box” between an ECM/ECU and the instrument
itself making wiring and installation simple and fast�
Three discrete alert LEDs provide users with visual notification of engine/
vehicle/vessel parameter faults, warnings and malfunctions�
Built-in, sealed, tactile switches allow users to easily navigate the intuitive
menu driven user interface� The integration of the switches also reduces
wiring to further reduce installation time and costs; essentially providing a
plug-and-play product�
• Scope
This manual describes how to navigate the LCD interface and use the many
features the instrument provides� Although the interface is intuitive and
easy to navigate, this operation manual provides users with a resource to
realize the full potential and capabilities of the instrument�
Covered in this manual are display options, menu navigation and menu
function usage�
Although some wiring connections are noted for easy reference, this
manual does not cover complete installation mounting and wiring
requirements� Please refer to the installation instruction sheet for proper
installation�
CHAPTER 5 MAUFACTURER’S INFORMATION SEPTEMBER 15, 2015
CAN DISPLAY MANUAL PAGE 5
NMC-WOLLARD 2021Truax Blvd., Eau Claire, WI 54703, Phone (715) 835-3151, Fax (715) 835-6625
M60 Tow Tractor Manual No. 46050
iv
• Preconfigured Instruments
PAGE 7
SEPTEMBER 15, 2015
NMC-WOLLARD 2021Truax Blvd., Eau Claire, WI 54703, Phone (715) 835-3151, Fax (715) 835-6625
M60 Tow Tractor Manual No. 46050
1
• Menu Navigation
Menu navigation is accomplished through three built-in momentary switches� The switch functions are
MENU/ENTER/RESET, UP and DOWN�
• Menu/Enter/Reset Switch
As its name suggests, this switch serves several purposes when navigating the user interface� The
function depends upon the context of the menu option but is labeled ENTER on the instrument�
Menu Function: Pressing and holding this switch for approximately three seconds when any parameter
screen is displayed brings up the main menu�
Enter Function: Pressing and releasing this switch provides enter functionality when the operator is
required to choose a menu item, parameter, or value�
Reset Function: Pressing and holding this switch resets the selected trip miles or maintenance hour
value to zero�
• Up Switch
Pressing and releasing the Up switch scrolls up through the CAN parameter list, menu choices or
increases a value one item/unit at a time�
Pressing and holding the Up switch continuously scrolls up through the CAN parameter list, menu
choices or increases a value until the end of the menu choices or maximum value is reached�
• Down Switch
The Down switch functions identical to the Up switch with the exception that its direction for all lists,
menu choices and values is down or decreasing�
• Switch Icon Conventions
Throughout this manual, icons are used to indicate actions required by the user to navigate the menus�
Below are descriptions and the corresponding action to be taken when they appear�
The presence of this icon in the manual indicates when to press and release
the Menu/Enter/Reset switch�
The presence of this icon in the manual indicates when to press and hold
the Menu/Enter/Reset switch for approximately three seconds�
The presence of this icon in the manual indicates when to press and release the Up switch�
Users may also choose to press and hold the Up switch if necessary�
The presence of this icon in the manual indicates when to press and release the Down
switch� Users may also choose to press and hold the Down switch if necessary�
Pressing and releasing an Up or Down switch moves the selection arrow up or down a
menu list one item at a time until the beginning or end of the list is reached� Pressing and
holding the Up or Down switch continuously moves the selection arrow up and down a menu list until
the switch is released or the beginning or end of the list is reached�
• Menu Scrolling Icons
A menu scrolling icon appears in the lower right corner of the display to
indicate if more menu options appear only above, only below or above and
below the menu option or options currently displayed�
Maintenance Hours
Faults Active
Note: Many menu screen diagrams
To scroll up and down Warnings Active in this manual only show the first
a menu option list Faults Stored two options of the entire menu�
Alarms If more than two options are
Mute Audio Alarm available within a menu, a listing
of all the options will appear
Setup below the menu diagram�
Information
To select option Exit
adjacent to
selection arrow cursor Complete Main Menu
Function List
3
• Blinking Bar Cursor
A blinking bar cursor appearing beneath a numeric value or CAN parameter indicates the item may be
changed by pressing or pressing and holding either the Up or Down switches�
When a numeric value appears above a blinking bar cursor, pressing or pressing and holding the Up or
Down switch increases or decreases the value until the maximum value limits are reached�
When a CAN parameter appears above a blinking bar cursor, pressing or pressing and holding either the
Up or Down switch scrolls through the list of CAN parameters until the end of the list is reached�
A1 Coolant Pressure
0.0 bar
Blinking Bar Cursor
located under parameter name
A1 Battery Current
0A
Blinking Bar Cursor
located under amperage value
• Start-up Routine
Upon Instrument start-up, the three alert LEDs will flash then the Beede logo followed by the SAE logo
appear for approximately three seconds�
• Main Menu
The Main Menu contains functions to configure the LCD (Liquid Crystal Display), set alarms or view ECM
faults and warnings� Access the Main Menu by pressing and holding the Menu/Enter/Reset switch for
approximately three seconds while any CAN parameter screen is displayed�
Like all menus with multiple functions/options, only the first two Main Menu functions/options appear
on the screen� Access the other functions/options by scrolling down the menu list using the Down
switch� Use the Up switch to scroll back up the Main Menu function/option list�
The Main Menu and all the functions within it except Maintenance Hours and Vehicle Trip functions will
display for approximately 30 seconds if no user activity is detected� The previously displayed parameter
reappears after 30 seconds of inactivity�
*Maintenance Hours
* Either Maintenance Hours or
Faults Active Vehicle Trip appears as the first
Warnings Active Main Menu function depending
To scroll up and down Faults Stored upon the Main Menu-Setup-Trip Mode
configuration�
the Main Menu list Alarms
Mute Audio Alarm Main Menu-Setup-Trip-Hours
Mute-Temporary displays Maintenance Hours�
Setup
Main Menu-Setup-Trip-Distance
Information
displays Vehicle Trip�
To select a Main Menu Exit
function adjacent to the
selection arrow cursor Complete Main Menu
Function List
5
• Maintenance Hours or Vehicle Trip
Depending upon the configuration of the instrument, either Maintenance Hours or Vehicle Trip appears
as the first Main Menu function� See "Trip Mode" on page 31 for setting hours or trip as the first Main
Menu function�
The instrument provides two resettable maintenance hour and vehicle trip logs� The Maintenance
Hours or Vehicle Trip function allows users to view and reset any of the hour or trip logs�
Figure 1-4: Accessing and Resetting Maintenance Hours and Vehicle Trip Logs
• Faults Active
Faults are an indicator of a severe vehicle problem as reported by the ECM/ECU that warrants stopping
the engine/vehicle/vessel� Users should consult the owners manual or a service technician to correct
the fault condition or conditions�
When a fault condition occurs, the instruments internal audible alarm and Fault LED are activated�
The internal audible alarm is temporarily muted by pressing the Enter switch�
An external audible device connected to output pin 3 of the six pin connector will also be muted if the
setup option Alarm Output, Main Menu-Setup-Alarm Output, is set to Audio� See "Alarm Output" on
page 32 to configure alarm output pin�
The Main Menu-Faults Active option allows users to view the parameter or parameters causing fault
notification� If popups for fault conditions is enabled, a fault notification screen appears� Refer to
"Setting Popups" on page 25�
The Faults Active function within the Main Menu allows users to view details for all currently active
faults�
DM1 (Diagnostic Message) for active faults or DM2 for stored faults
Fault number and total fault quantity, e�g�, 1 of 3
SPN (Suspect Parameter Number) numerically identifies the parameter per the CAN protocol
FMI (Fault Mode Indicator) number to further identify the faults characteristic
Fault Name� Appears if the CAN parameter is implemented in the instruments firmware�
See"Implementation of SAE J1939 Parameters" on page 34
The active fault display will not time out after 30 seconds� Press the Enter switch to exit viewing faults
and return to the Faults Active option of the Main Menu�
7
• Viewing Active Faults
If a fault information screen is cleared after it initially appears and the fault is still active, users can view
all the active fault information screens by using the Faults Active function of the Main Menu, Main Menu-
Active Faults�
• Warnings Active
Warnings are an indicator of a vehicle problem as reported by the ECM/ECU that does not warrant
immediately stopping the vehicle or vessel� Users should consult the owners manual or a service
technician to correct the warning condition or conditions�
When a warning condition occurs, the instruments internal audible alarm and Warn LED are activated�
The internal audible alarm may be temporarily muted by pressing the Enter switch�
An external audible device connected to output pin 3 of the six pin connector will also be muted if the
setup option Alarm Output, Main Menu-Setup-Alarm Output, is set to Audio� See "Alarm Output" on
page 32 to configure alarm output pin�
The Main Menu-Warnings Active option allows users to view the parameter or parameters causing the
warning� If popups for warning conditions is enabled, a warning notification screen appears� Refer to
"Setting Popups" on page 25�
The built-in audible device will sound when a warning condition occurs if the Mute setting, Main Menu-
Mute Audio Alarm, is not set to Permanent� See "Mute" on page 20 for enabling the internal audible
device�
The active warning display will not time out after 30 seconds� Press the Enter switch to exit viewing
warnings and return to the Warnings Active option of the Main Menu�
9
• Viewing Active Warnings
If a warning information screen is cleared after it initially appears and the warning is still active, users
can view all the active warning information screens by using the Warnings Active function of the Main
Menu, Main Menu-Warnings Active�
• Faults Stored
The instrument will display all DM2 (Diagnostic Mode) faults stored by the ECU� DM2 faults are
previously active diagnostic trouble codes�
11
• Alarms
Alarms are user configured limits for CAN parameters used to alert operators when the parameter or
parameters exceeds those limits� Alarms help users protect a vehicle, vessel or equipment from damage
by providing an option to set operating notification limits for CAN parameters critical to the application�
Alarm settings are written to non-volatile memory and retained when power is removed from the
instrument�
If alarms are configured and enabled, a blinking "Bell" icons appears in the upper left corner of the
current CAN parameter display screen once a parameter exceeds the set alarm limits� If popups for
alarm conditions is enabled, an alarm notification screen appears� Refer to "Setting Popups" on page
25�
The built-in audible device will sound when an alarm occurs if the Mute setting, Main Menu-Mute Audio
Alarm, is not set to Permanent� See "Mute" on page 20 for enabling the internal audible device�
• Alarms Menu
The Main Menu-Alarms function allows users to enable alarm notification, view the parameter or
parameters causing the alarm, edit existing alarms and add new alarms�
Alarms-Enabled (Disabled)
View Alarms Alarms Menu Function List�
Edit Alarms Note: Pressing the Enter switch toggles between
Return Alarms Enabled and Alarms-Disabled�
Exit
13
• Enabling/Disabling Alarms
Alarms-Enabled/Disabled turns on or off notification when an alarm condition occurs� This function
does not delete alarms or their settings from the alarm list�
Enabling or disabling alarms is a toggle function� When the Alarm menu is opened the current setting,
enabled or disabled, is shown� To change the current setting, simply press the Enter switch�
To protect against operating the vehicle unaware of potentially damaging conditions, always use
caution when deciding to turn off alarm notification�
• Viewing Alarms
View Alarms allows users to scroll through all CAN parameters configured for alarm notification�
Users are shown the alarm number, parameter name, measured value for the parameter and the alarm
trigger conditions for the parameter�
Alarms-Enabled Once in the Alarms menu, scroll down to place the selection
View Alarms arrow cursor next to the View Alarms option�
View Alarms With the selection arrow cursor next to the View Alarms option,
Edit Alarms press the Enter switch to view any current alarms�
15
• Alarm Configuration
When adding a new alarm parameter or editing an existing alarm parameter with the Edit Alarms
option, users must set the following:
Figure 1-14: Add & Edit Alarm CAN Parameter Screen Details
To select a CAN parameter, scroll through the parameter list with the Up and Down switches until the
desired parameter appears� Press the Enter switch to add the parameter to the alarm list�
After selecting a parameter, the blinking bar cursor appears under the Higher/Lower than arrow icon�
Users must choose if the alarm notification will occur when the actual parameter value is either higher
or lower than the desired trigger value� Pressing either the Up or Down switch toggles the indicator
between the higher than arrow (pointing up) and lower than arrow (pointing down)� Press the Enter
switch to accept direction of the arrow icon�
Once higher or lower is chosen, the blinking bar cursor moves to the alarm notification trigger value�
The units of this value change depending on the type of parameter chosen� Use the Up or Down
switches to change the value then press the Enter switch to accept the displayed value�
After configuring all the alarm parameters, users can choose to save or discard the alarm configuration�
The Edit Alarms menu screens differ if no alarms are set as compared to when previously configured
alarms exist� If no previously configured alarms exist, the Add Alarm menu option appears after
selecting Edit Alarms� If previously configured alarms exist, the configured alarms appear before the
Add Alarm menu option� To add an additional alarm when previously alarms exist, users must scroll
down thru all the previously configured alarms before reaching the Add Alarm menu option�
Edit Alarms With the selection arrow cursor next to the Edit Alarms
Return option, press the Enter switch to begin editing alarms�
17
Figure 1-16: Menu Prompt Sequence with Previously Configured Alarms
Edit Alarms With the selection arrow cursor next to the Edit Alarms
Return option, press the Enter switch to begin editing alarms�
Add Alarm Press the Enter switch to add a new alarm or select
Return Return to bring back the Edit Alarms menu option�
• Editing Alarms
The Edit Alarms function is used to change an alarms existing CAN parameter, higher/lower than
threshold indicator or trigger value�
Figure 1-17: Editing an Alarm
From the Alarms Menu place the selection arrow cursor
Edit Alarms next to the Edit Alarms option, Main Menu-Alarms-Edit Alarms,
Return then press the Enter switch to begin editing alarms�
Save Alarm With the selection arrow cursor next to the Save Alarm option,
press the Enter switch to save alarm changes�
19
• Deleting Alarms
The Edit Alarms function is also used to delete existing alarms�
A1 Alternator Volts The prompt “Change?” appears in the lower left corner of the display�
Change? 10.0 V To delete the displayed alarm configuration, press the Enter switch
to accept the prompt to change the alarm� Otherwise, press the
down switch until the desired alarm to delete appears on the
display then press the Enter switch to accept the change prompt�
Delete Alarm With the selection arrow cursor next to the Delete Alarm option,
press the Enter switch�
After selecting Delete Alarm, users must either cancel the delete
No Change request by selecting No Change or confirm the deletion by selecting
Confirm Delete Confirm Delete�
A1 Battery Volts
Change? 10.0 V If No Change is selected above, the previously displayed
Alarm configuration screen appears�
Or If Confirm Delete is selected, the next configured alarm appears�
If no other alarms were configured, the Add Alarm and Return
Add Alarm menu options appear�
Return
• Mute
The instrument is equipped with an internal audible device to alert users when a Fault, Warning or
Alarm condition occurs� Pressing the Enter switch after a Fault, Warning or Alarm condition occurs
either temporarily or permanently mutes the audible device for that condition depending upon the
setting of Mute Audio Alarm, Main Menu-Mute Audio Alarm�
Note: Regardless of the Mute Audio Alarm setting, the first occurrence of a Fault, Warning or Alarm
condition always activates the audio alarm� Subsequent occurrences of the same Fault, Warning or
Alarm condition is controlled by the Mute Audio Alarm setting�
If an external audible device is connected to the switched output pin 3 of the connector, the device is
muted as well� For muting external devices, see "Alarm Output" on page 32�
Mute Audio Alarm - Permanent setting turns off the audible device for subsequent occurrences of the
specific Fault, Warning or Alarm�
Mute Audio Alarm - Temporary setting disables the audible device for twenty seconds�
Faults are muted for 20 seconds� Warnings and Alarms are muted for 2 minutes� Faults are muted
for a shorter period of time because they are considered critical conditions that require immediate
attention� A Fault condition sounds a steady audible tone while Warning and Alarms conditions sound
an intermittent audible tone�
Alarms From the Main Menu, scroll to place the selection arrow cursor
Mute Audio Alarm next to the Mute Audio Alarm option, Main Menu-Mute Audio Alarm�
After setting the mute status, scroll down to the Exit option then
Exit press the Enter switch to return to the last displayed CAN parameter
or simply wait 30 seconds for the last displayed CAN parameter
to appear�
21
• Setup Menu
The Setup Menu contains all the functions necessary to configure the instrument to satisfy user
preferences and application requirements� This section of the manual describes those functions�
Figure 1-20: Setup Menu Functions
Backlight
Units
Popup
Display
Setup Menu Function List�
Trip Mode
Alarm Output
Return
Exit
• Backlight
The instrument offers two levels of illumination control; external lamp switch on and lamp switch off�
Backlight intensity is set using the Backlight option from the Setup Menu, Main Menu-Setup-Backlight�
Backlight intensity values range from 0 or off to 100% or maximum by increments of 10%�
Lamp Off: The Lamp Off function sets the backlight illumination brightness when no external lamp
switch is used or when an external lamp switch is wired to pin 4 of the instruments 6 pin connector
and the lamp switch is turned off� This feature allows users to turn on and control the instruments
backlighting independent of the vehicle's or equipment's light switch�
Note: Standard factory hardware configuration for the instrument uses Pin 4 of the 6 pin connector
to connect to an external lamp switch� Some factory configured instruments use pin 4 for serial data
communication to Beede NexSysLink® instruments� See "Stand-Alone and Master Node Configurations"
on page iv for more information�
From the Setup Menu place the selection arrow cursor next to
Backlight Backlight, Main Menu-Setup-Backlight, then press the
Units Enter switch to begin adjusting the LCD backlight intensity.
23
• Setting Units
Users may select to display CAN parameters in either English or SI-Metric units�
Backlight From the Setup menu, scroll to place the selection arrow
Units cursor next to the Units option, Main Menu-Setup-Units�
Exit Scroll down to the Exit option and press the Enter switch or
wait 30 seconds for the last displayed CAN parameter to appear�
FAULT
ALARM
Fault, Warning and Alarm popup screens remain displayed until acknowledged by pressing the Enter
switch� Pressing the Enter switch returns the last displayed CAN parameter prior to the occurrence of
the Fault, Warning or Alarm condition�
For Faults and Warnings, the Fault LED and Warning LED remain illuminated after pressing the Enter
switch to acknowledge and clear the notification screen�
After pressing the Enter switch for Alarms, a blinking "bell" icon appears in the upper left corner of the
CAN parameter display screen to indicate an alarm condition exists�
Pressing the Up or Down switch when a notification screen appears brings up the Fault, Warning or
Alarm detail information display�
Note: If the condition that caused the Fault, Warning or Alarm clears, the notification screens and bell
icon disappears and the alert LEDs turn off�
25
• Setting Popups
Enabling popups allows the Fault, Warning and Alarm screens to appear when a when a System Fault,
Warning or Alarm condition occurs�
Units-English From the Setup menu, scroll to place the selection arrow
Popup cursor next to the Popup option, Main Menu-Setup-Popup�
Exit Scroll down to the Exit option and press the Enter switch or
wait 30 seconds for the last displayed CAN parameter to appear�
• Display
The Display Menu functions provide users the ability to configure the LCD� Options for configuring
the display include either 1 or 2 parameter display mode, LCD contrast and positive or negative image
mode� Each function is detailed in the following pages�
27
• 1 or 2 Parameter Display
Users can set whether 1 or 2 CAN parameters appear on the LCD screen�
35 PSI
Eng Oil Pressure
From the Setup Menu place the selection arrow cursor next to
Display the Display option, Main Menu-Setup-Display, then press
Trip Mode the Enter switch to view the Display Menu functions�
2-Parameter Pressing the Enter switch toggles the paramater display mode
Contrast to two 2-Parameter�
Exit Scroll down to the Exit option and press the Enter switch or
wait 30 seconds for last displayed CAN parameter to appear�
• Set Contrast
Contrast sets the difference between the white and black colors of the LCD�
From the Setup Menu place the selection arrow cursor next to
Display the Display option, Main Menu-Setup-Display, then press
Trip Mode the Enter switch to view the Display menu functions�
1-Parameter The first two Display Menu functions appear� Scroll to place
Contrast the selection arrow cursor next to the Contrast option�
Exit Scroll down to the Exit option and press the Enter switch or
wait 30 seconds for the last displayed CAN parameter to appear�
29
• Video Mode Formats
Setting the video mode changes the color scheme of the LCD from white graphics on a black
background (Normal) to black graphics on a white background (Reverse)�
Video-Normal
Return
Video-Reverse
Return
• Set Video
The menu sequence below shows how to set the video mode to either normal or reverse�
From the Setup Menu place the selection arrow cursor next to
Display the Display option, Main Menu-Setup-Display, then press
Trip Mode the Enter switch to view the Display Menu functions�
1-Parameter The first two Display Menu functions appear� Scroll to place
Contrast the selection arrow cursor next to the Video Mode option�
Exit Scroll down to the Exit option and press the Enter switch or
wait 30 seconds for the last displayed CAN parameter to appear�
31
• Trip Mode
The Trip mode setting determines whether distance or hours appear as the first item upon entering the
Main Menu�
The decision to set the Trip Mode function to either hours or distance depends upon which of the two
parameters is viewed more frequently in the application�
From the Main Menu, scroll to place the selection arrow cursor
Setup next to the Setup option�
Information Press the Enter switch to view the Setup Menu functions�
Exit Scroll down to the Exit option and press the Enter switch or
wait 30 seconds for last displayed CAN parameter to appear�
• Alarm Output
The alarm output setting controls whether the alarm output pin is turned off when an alarm condition
occurs and the Enter switch is pressed� This function is also dependant upon the Mute setting for the
audible output�
If Mute is set to Temporary and Alarm Output is set to Audible, the internal and external audible devices
will temporarily turn off� If Mute is set to Permanent and the Alarm Output is set to Audible, the internal
and external audible devices will remain off until a new alarm condition occurs�
If Alarm Output is set to light, the output pin remains on regardless of the current mute setting when
the Enter switch is pressed�
From the Main Menu, scroll to place the selection arrow cursor
Setup next to the Setup option�
Information Press the Enter switch to view the Setup Menu functions�
Exit Scroll down to the Exit option and press the Enter switch or
wait 30 seconds for last displayed CAN parameter to appear�
33
• Firmware Information
Firmware part number, revision and release date are available when selecting the Information option
from the Main Menu�
With a CAN parameter displayed, press and hold the Enter switch
1049.3 to open the Main Menu�
Engine Hours Engine Hours parameter shown as an example only�
First two Main Menu options appear with the selection arrow
Maintenance Hours cursor next to the Maintenance Hours option�
Faults Active Note: Instrument configuration may show vehicle trip�
Information Pressing the Enter switch returns the Information Main Menu
Exit option�
Exit Scroll down to the Exit option and press the Enter switch or
wait 30 seconds for the last displayed CAN parameter to appear�
35
• Parameter Icons & Descriptions
Accelerator Pedal
Engine RPM/Speed
Position
Alternator Current
Fuel Level
or Voltage
Average Fuel
Fuel Level 2
Economy
Battery Voltage
Fuel Pressure
or current
Fuel Rate/Flow
Boost Pressure
Total
Engine Coolant
Fuel Temperature
Level
Engine Coolant
Hydraulic Oil Level
Pressure
Engine Intercooler
Percent Load
Temperature
Speed,
Engine Oil
Wheel or Water
Temperature
Based
© 2011 Beede electrical Instrument Co., Inc.
Transmission Oil
Total Engine Hours
Pressure
37
• Notes
WARRANTY
Beede Electrical Instrument Co., Inc warrants all
instruments and accessories free from all defects in
workmanship and materials on gauges that are less than
three (3) years old or have been in service fewer than
two (2) years and, at no charge, will replace or repair at
Beede’s option all instruments that fail.
Contact Beede for complete details.
THANK YOU!
Thank you for purchasing a Beede® Instrument.
Our instruments are designed and manufactured for you in the U.S.A.
Visit our web site at www.beede.com or contact customer service for
information on this or other Beede® instruments.
TRIFLEX
TRIFLEX BRAKE CONTROL
INSTALLATION AND USER GUIDE
For use with 12 volt negative ground systems only
For trailers with two to eight brakes
Read, follow and save this guide for future reference
51140-INS-RB • PAGE 1
WARNING: The brake control unit's positive (with 30 amp circuit breaker) and ground
wires must be connected directly to the tow vehicle's battery using 10 gauge minimum
stranded wire. Connecting to existing wiring or an alternate ground may damage
vehicle circuits, lead to failure of the brake control module, loss of trailer brakes or
vehicle fire.
NOTICE: Removal of the factory supplied quick plug can void warranty.
Key Features
• Digital display provides detailed brake force output and sensitivity position
• Provides automatic and manual trailer braking
• Switchable manual control output, 100% or limited to output setting
• Switchable manual control brake light activation or no brake light activation
• Compatible with electronic systems (anti-lock brakes and cruise control)
• Protected against reverse voltage, voltage spikes, shorts and overloads
• Power conservation mode after 30 min. of inactivity, wakes when brake pedal is pushed
• Display is capable of communicating operational errors
• Reduced output when sitting still (railroad crossing, stoplight, etc…)
• Automatically compensates for uphill and downhill road conditions
• Will work with most electrically activated hydraulic trailer brake systems
• Connects to vehicle with CURT 55515 quick plug, available separately
(see CURT catalog for a list of application specific quick plug harnesses) PAGE 3
5 3 4 PAGE 4
Digital Display
The digital display shows the output setting when the control is activated. It is used
to setup and monitor the brake control and can be used when trouble shooting.
Accelerometer error,
Flashing, output adjustment mode
powers brakes using default values
INSTALLATION
Set Manual Control Output and Brake Light Switches
There are two small switches
located at the rear of the unit
that can be accessed by
removing the rectangular cover.
Once accessed, the switch
positions can be changed
using a small pointed tool.
In the illustration above, the switch on the right (#2) controls the level of output
available to the trailer brakes when using the manual control. The factory default
setting is the 'ON' position with the switch down. This setting limits the manual
control output to the level set using the output control thumb wheel. Moving this
switch up to the 'OFF' position allows 100% of the output to the brakes when the
manual control is actuated regardless of the output control setting.
In the illustration above, the switch on the left (#1) controls the unit's brake light
activation feature. The factory default setting is the 'ON' position with the switch
down. This setting activates the tow vehicle and trailer brake lights
when the manual control is actuated. Moving the switch up to the 'OFF'
position turns off the brake light activation feature and the brake lights are
not activated when the manual control is actuated.
PAGE 8
Mounting
1. Determine a suitable mounting location.
A) The unit must be mounted securely to a solid surface
B) The unit must be easily reached by the driver
C) The area behind mounting location must be
clear so no damage will be done when drilling
70°
20°
20° 20°
TM
LEX
TRIF
TRTIRI
F FLEX
TM
LEX TM
WIRING DIAGRAM
Feed two 10 gauge wires, one white and black, from the mounted brake control to
the battery area. Using a ring terminal, connect the black wire to the ‘AUX’ side of
the 30 amp circuit breaker. Leave the white wire to be connected later.
Using a 10/12 gauge butt connector, attach the black wire from the ‘AUX’ side of
the 30 amp circuit breaker to the brake control's black wire. Again using a 10/12
gauge butt connector, attach the white wire from the battery area to the brake
control's white wire. Run a 10 gauge blue wire from the tow vehicle's trailer plug
"brake" terminal to the brake control. Using a 10/12 butt connector, connect this
wire to the brake control's blue wire PAGE 11
SETUP
Once all electrical connections are complete and the single decimal point is seen,
while parked on a level surface, plug the trailer's electrical connector into the tow
vehicle's plug.
Making the trailer connection initiates the mounting position calibration mode.
may be seen on the display followed by either or . If appears,
recalibration is needed. To recalibrate, unplug and replug the trailer's electrical
connector. While calibrating, the display will show or may flash the Output
setting. When appears, the unit is calibrated and ready for setup.
Make the following preliminary adjustments with the trailer connected and engine
running to ensure proper charge voltage. The vehicle must be in park or neutral
with the parking brake applied, foot off the brake pedal, and no manual control
actuation:
Adjust output to by turning the output control wheel left or right as needed.
Adjust sensitivity to by moving the sensitivity control forward or back.
Test Drive and Adjustment
Both output and sensitivity can be adjusted to achieve smooth firm stops.
Output and sensitivity adjustments should only be made while stopped, with the
transmission in park or neutral, parking brake applied, foot off the brake pedal,
and no manual control actuation. Output and sensitivity settings will flash while
adjustments are made and for a few seconds after.
PAGE 13
Start with the output adjustment. Drive forward on a paved or concrete surface that
is dry and level. At approximately 25 mph, apply the tow vehicle brakes. If trailer
braking is insufficient, adjust the output control to the right. If the trailer brakes
lockup adjust the output control to the left. Repeat this step until stops are firm,
just short of lockup.
Once the output is set, adjust sensitivity. Drive forward to approximately 25 mph
and press the brake pedal. Tow vehicle and trailer should make smooth stops. If
the stops seems slow and more aggressive braking is desired, move the sensitivity
control toward the driver. If the stop seems too aggressive adjust the sensitivity
control away from the driver.
Make several stops at various speeds and adjust sensitivity until stops are smooth
and firm. Slight adjustment the output control may also be desirable.
NOTE: If any problems occur during setup, refer the trouble shooting section.
HELPFUL TIPS
Light pressure on the manual control will activate the trailer's brakes with no effect on
the vehicle's brakes. This is useful for gradual slowing on steep grades or before stops.
Periodic adjustment of the output and sensitivity controls may be necessary to
correct for changing road conditions, trailer loading, brake wear or driver preference.
In some applications, when towing with hazard flashers on, the digital display will
flash with the hazard flashers. If the brake control is set aggressively pulsing may
be felt in the trailer brakes.
PAGE 14
The TriFlex will display that it's checking calibration , that it's calibrating , or
that it needs recalibration . If the indication appears, disconnect and reconnect
the bulb from the blue wire to recalibrate. It will show when disconnected,
and / or during calibration, followed by two decimal points when complete.
Manual Control Testing
Rotate the output control thumb wheel right to its maximum setting ,
move the sensitivity adjustment toward the front of the unit to its most aggressive
setting , and slowly activate the manual control up to its full output.
While actuating the manual control the brightness of the bulb will correspond with
the output shown by the brake controller. Release the manual control to deactivate.
Accelerometer Testing
While keeping the brake control level, connect the red brake input wire of the TriFlex to
the positive terminal of the 12V battery. The brake control output will activate and the
bulb may be dimly lit.
Slowly tilt the front of the TriFlex to about 45° and the brightness of the bulb will
increase corresponding with the output shown by the brake controller. Slowly tilt
the front of the TriFlex back to level and the brightness of the bulb will decrease
corresponding with the output shown by the brake controller.
When finished testing disconnect the wiring from the positive terminal of the 12V
battery ensuring the exposed contacts to not make contact. If the TriFlex does not
function as described during the above test steps return the brake controller for
service or replacement. PAGE 16
PAGE 17
PAGE 18
* This guide is for reference only. If problems persist, see a professional installer. PAGE 19
NOTES
PAGE 20
CONTROL CABLES
Malfunctions
Automatic transmission malfunctions may be caused by poor engine perfor mance or
improper transmission adjustments.
You should always begin by checking engine performance, then fluid level and
condition, and gearshift cable adjustment.
If the problem exists after these checks and adjustments are completed,
remove unit from service and refer the transmission to a transmission repair facility.
If you ever notice unusual noises such as gear noise or grinding, a buzz or whine,
knocks, scraping, clicking, etc., remove the unit from service and refer it to a
transmission repair facility.
Tow the unit with the rear end picked up or with the drive shaft
disconnected or the transmission will be damaged.
IN AN EMERGENCY, the unit may be towed without lifting the wheels or discon necting
the drive shaft IF:
• Engine is running AND transmission is in neutral.
• Towing distance must be LESS THAN 1 MILE and travel speed LESS THAN 5 M.P.H.
Always check oil level with unit on a level surface and WITH FLUID AT
NORMAL OPERATING TEMPERATURE. DO NOT OVERFILL TRANSMISSION.
Overfilling can result in transmission damage. It is easy to overfill the transmission. To
avoid overfilling, add oil in small amounts and recheck level frequently.
3. Withdraw dipstick and examine fluid for discoloration and a foul (burned) smell. This
would indicate damaged bands or clutches. If oil has a milky look, water has entered
the transmission. Air bubbles mean there is an air leak in the suction lines. Report
any of these conditions to your supervisor.
4. Check level indicated on dipstick. Add fluid as needed to maintain level between
“FULL” and “ADD 1 PINT” marks on the dipstick. Use type Dexron R2.
Most repair facilities can perform intermediate band and neutral start switch
adjustments.
The neutral start switch is a safety device that prevents the engine from starting if the
transmission is in any shift position other than NEUTRAL.
NOTE: The neutral start switch may also be checked by attempting to start the engine
with the gear shift lever in each shift position.
This switch is a combination unit located on the automatic transmission shifter shaft in
the engine package.
1. Remove clevis pin holding shifter arm to cable clevis.
2. Connect a volt-ohm meter (on resistance range) or a continuity tester across both
Red/Blue wires coming out of the switch.
3. Loosen hold-down bolts on switch and rotate switch until contact opens for the same
throw of shifter arm either side of Neutral.
4. Retighten switch bolts and recheck adjustment.
5. Replace clevis pin.
IMPORTANT! Be sure the switch packing is properly installed to prevent oil leakage.
The drive plate (flywheel) will not support a load. None of the weight of the transmission
must be allowed to rest on the drive plate during removal or installation.
1. Raise transmission with transmission jack to take pressure off rear cross member.
2. Secure transmission to jack with safety chain.
3. Remove converter housing-to-engine attaching bolts.
4. Move transmission away from engine.
5. Lower transmission jack and move transmission and converter assembly from under
vehicle.
NOTE: This manual does not cover transmission disassembly. Disassembly must be
done by specialized personnel.
Do not allow the weight of the transmission to rest on the drive plate during
installation. The drive plate will not support a load.
Figure 1
CASE, COVERTER, EXTENSION HOUSING
Figure 2
INTERMEDIATE SERVO AND BAND
Fig.- NMC Vendor Nomenclature Eff Units
Item Wollard Part No. Per
Part No. Assy
1 302314 C8SZ-TD028-B Spring, Inter. Band Servo (Yellow) 1
302315 D1AZ-7D028-A Spring, Inter. Band Servo (Brown)
302316 D6OZ-7D028-A Spring, Inter. Band Servo (Pink)
7 6
PARTS LIST,
HYDRAULIC POWER SECTION
NOT AVAILABLE AT TIME OF PUBLICATION
512
WORKSHOP
MANUAL
512 Manual
Issue: 2.1
Created By: M. Crane
Date: September 2014
PRM Newage Ltd operates a policy of product improvement and therefore reserves the right to change specifications without
prior notification. Whilst every effort is made to ensure complete accuracy of the information in this manual no liabilities for
inaccuracies or the consequences thereof can be accepted by the manufacturer or the distributor who supplied the manual.
CONTENTS
INTRODUCTION........................................................................................................................................................................... 5
GENERAL DATA ........................................................................................................................................................................... 5
Description ............................................................................................................................................................................. 5
Specification ........................................................................................................................................................................... 5
Installation Drawing ................................................................................................................................................................ 6
IDENTIFICATION .......................................................................................................................................................................... 7
GENERAL SERVICE INFORMATION ............................................................................................................................................... 8
Routine Maintenance .............................................................................................................................................................. 8
Lubricants ............................................................................................................................................................................... 8
Greases ................................................................................................................................................................................... 8
Brake Fluid .............................................................................................................................................................................. 8
Liquid Sealant.......................................................................................................................................................................... 8
Fastener Tightening Torques ................................................................................................................................................... 9
Axle Backlash .......................................................................................................................................................................... 9
Tooling.................................................................................................................................................................................... 9
SERVICING AND REPAIRS ........................................................................................................................................................... 10
Seals ..................................................................................................................................................................................... 10
Bearings ................................................................................................................................................................................ 10
Cleaning ................................................................................................................................................................................ 10
INSPECTION .............................................................................................................................................................................. 11
Main Case and Arms.............................................................................................................................................................. 11
Gears .................................................................................................................................................................................... 11
Bearings ................................................................................................................................................................................ 11
Threaded Parts...................................................................................................................................................................... 11
PROCEDURES ............................................................................................................................................................................ 11
512 Axle Assembly ................................................................................................................................................................ 12
Section ‘A’ – Transfer Case Assembly ..................................................................................................................................... 12
Removing and Servicing the Transfer Case Assembly.......................................................................................................... 14
Reassembling the Transfer Case Assembly ......................................................................................................................... 15
Pinion Shimming Procedure............................................................................................................................................... 16
Solid Spacer Shimming Procedure...................................................................................................................................... 16
Section ‘B’ – Main Case and Differential Assembly ................................................................................................................. 17
Servicing the Main Case and Differential Assemblies .......................................................................................................... 18
Removing the Differential .................................................................................................................................................. 18
Servicing the Differential Assembly .................................................................................................................................... 18
Section ‘C’ – Planet Carrier Assembly..................................................................................................................................... 19
Servicing the Planet Carrier Assemblies.............................................................................................................................. 20
Removing the Annulus Gear .............................................................................................................................................. 20
INTRODUCTION
Spare parts for Newage axles may only be obtained from the original equipment manufacturer and not directly from
Newage. Always quote your vehicle/machine serial number and axle serial number – see section titled 'Identifica-
tion'.
If possible, the repair/service should be carried out in a clean environment. Where this is not possible and the work
must be completed on site, appropriate measures must be taken to ensure that dirt or foreign matter does not enter
the unit. Newage axles are designed to operate in the arduous conditions found in the construction industry; provid-
ing they are maintained regularly they will provide the service our customers expect from Newage products.
GENERAL DATA
Description
The 512 series axle is a triple reduction unit featuring a Hydraulic Disc Braking system.
The Transfer Casing houses the 1st reduction Input Pinion and Wheel. This is fixed to the 2nd reduction Spiral Bevel
Pinion and Crown Wheel driving a 4 Pinion Differential. Final drive is transmitted via the 3rd reduction in-board Plan-
etary Assemblies. The Axle Shafts are fully floating (i.e. not subjected to wheel loads) with each Wheel Hub support-
ed on opposed taper Roller Bearings.
Specification
Overall Ratio
9.24:1 / 12.33:1 / 15.79:1 / 19.90:1
Input Flange
To suit Hardy Spicer 1310 Coupling
Wheel Fixing
8 studs: 9/16” x 18 UNF-3A on 165.1mm (6.5”) PCD
Service Brake
See Torque/Pressure Graph
Park Brake
Optional (disc mounted). See Torque / Lever Force Graph
Approximate weight
300kg (661lb) dry
Oil Capacity
10 litres (2.6 US Gallons)
Installation Drawing
IDENTIFICATION
If spares are required, please quote the axle model, the vehicle/machine model and serial number from the blue
plate. 512 Axles are produced in a variety of configurations for individual customer requirements; therefore it is
important to identify the Axle correctly.
The part number allocated to each Axle describes the basic specification as below:
AXLE SERIES
REDUCTION REVISION No.
RATIO
BRAKE CONFIGURATION
CUSTOMER CODE
Check Frequency
After initial 300 Hrs
Axle Oil change
then every 1,000 Hrs
Axle Oil Level check Monthly
Axle Shaft Bolts Monthly
Brake Fluid change Annually
Brake Fluid Level check Monthly
Check Axle Arm/Main Case joint securing Bolts Monthly
Check Wheel Hub Bearing adjustment 1,000 Hrs
Check Wheel Nut Weekly
Visual check for oil leaks around joints and Seals Weekly
Prop Shaft Nut Monthly
Lubricants
Only those lubricants shown below or their direct equivalents must be used:
SAE 80W-90 Q8 T55 Heavy Duty Gear oil for operation in ambient temperatures as low as -25°C (32-86°F)
ambient.
NOTE: An alternative engineering approved Gear oil may be used. Consult ‘PRM Newage’ before filling the axle.
The oil is added via the combined Filler/Level Plug positioned on the front of the axle Main Case. The Filler/Level Plug
on the rear of the Transfer Case Assembly can also be used. Apply P-80 oil seal lubricant to clean wheel hub stub axle
when installing new hub Seals.
Greases
Smear grease between Oil Seal lips and ‘O’ Rings at major overhauls, or whenever a repair to these areas is
performed.
Only those greases shown below, their direct equivalents or alternative engineering approved grease must be used:
Texaco Multifak EP2
Brake Fluid
The Axle Brakes operate with the fluid specification:
FMVSS 116 DOT 4, SAEJ1703 and ISO4925 Brake Fluid
NOTE: An ISO VG32 Mineral Hydraulic Fluid Should NOT be used under any circumstance.
Liquid Sealant
The Main Case/Axle Arm/Transfer Case/End Cover joint faces must be sealed with either of the following:
Threebond 1207D Silicone Liquid Gasket
NOTE: An alternative engineering approved silicon sealant may be used.
Axle Backlash
Tooling
The following tooling is used to aid in the servicing of the axle. These are available from the Original Equipment
Manufacturer.
TMFS10 SKF M70 Stub Axle Locknut socket 19mm (3/4”) drive fitment
PR40004 Press Pin for Wheel Studs
PR40005 Support Plate for use with Press Pins
Before removal of the Axle for repair or overhaul, carefully study the following procedures. Use proper hand tools,
slings and hoists for the job. WORK SAFELY
Keep all work areas, tools and Axle clean. All oil should be drained into a suitable container. Wipe up any spilled oil
or fluids to prevent accidents. Wear correct safety equipment I.e. safety glasses and safety shoes to guard against
personal injury
Remember HOT OIL CAN CAUSE BURNS – WORK SAFELY – USE COMMON SENSE
CAUTION: The above operations should be carried out by suitably qualified personnel and strictly in accordance with
the procedures detailed in the workshop manual.
Drawings showing all internal components are contained in the parts lists at the back of this manual.
Seals
Remove Oil Seals carefully to prevent damage if they are to be re-used, however to prolong the life of the axle, it is
best to replace these items.
Bearings
If removing taper roller Bearings for re-use keep them in matched sets and protect all Bearings from contamination.
Cleaning
WARNING: If using cleaning solvents these can be toxic, flammable, a skin irritant or give off harmful fumes. Avoid
prolonged contact, vapour inhalation, or smoking. Failure to take care can result in injury or death.
Rinse all metal parts in solvent to remove dirt, grease and oil.
10
INSPECTION
Main Case and Arms
Inspect for cracks. Check sealing surfaces for any imperfections, damage, etc. which will lead to oil leaks. Check all
threads for damage.
Gears
Inspect for any chipped, broken or cracked gear teeth, also for any excessive wear i.e. initial or progressive gear
pitting.
Bearings
Inspect for any damage, denting, initial or progressive pitting and over-heating. Each time a Bearing is removed for
inspection, or replacement it will be necessary to recalculate the required solid spacer shim thickness to pre-load the
Bearings correctly, see Procedures for more information.
Threaded Parts
Inspect for stripped or damaged threads.
PROCEDURES
CAUTION: When re-assembling the Axle all threaded fasteners must be tightened to the specified torques to prevent
premature failure. Refer to Fastner Tightening Torque on page 9.
Some servicing operations can be carried out with the Axle still mounted to the vehicle (provided, of course, that
there is sufficient space); an example of this is the replacement or repair of the brake assemblies. The repair or
replacing the Differential, Planetaries or Arm assemblies however will require the complete removal of the Axle from
the vehicle.
If the details outlined below are carefully followed no difficulty will be found in stripping and rebuilding the Axle. It is
most important that all components are perfectly clean and in good condition before reassembly.
CAUTION: All gears are supported by taper roller Bearings. Each time a bearing has been removed for inspection,
component repair or replacement it will be necessary to recalculate the number of Shims or adjust the Wheel and
Differential Bearing to give the required pre-load. Re-Shimming of the Axle is detailed under the Axle Shimming
procedure.
11
12
13
For the following steps, it is advisable to have the Transfer Case mounted in a horizontal position to retain the inter-
nals within the Transfer Case.
2. Remove Nut (A1) and Washer (A3). Gently pull the Coupling (A4) off of the Input Gear spline (A7). Examine
the Oil Seal (A5) within the front Transfer Case (A24) bore for damage.
3. 512B only - Remove 4 Bolts (A13) and Upper End Cover (A12) using the 2off M8 extraction holes.
NOTE: Keep the shims separate and note from where they came within the axle.
4. Remove 4 Bolts (A14) and remove the Lower End Cover (A15) using the 2off M8 extraction holes.
5. 512B Only - Remove 2 Bolts (A10) and 2 Nuts (A2).
6. Remove 13 Bolts (A11), Nut (A16) and Spacer (A19) from the end of the Pinion (A25).
NOTE: Bolts A10 are longer than A11 and so should be kept separate to avoid confusion during reassembly (512B
only)
14
CAUTION: 055CU024T and 055CU024H ARE NOT interchangeable. Mixing these bearings could severally damage the
axle. Ensure that these are marked and kept separate to avoid confusion.
8. Remove the Input Pinion (A7) with it’s respective Bearing cones. Remove the Solid Spacer Shim (A21), Input
Wheel (A22) and Pinion Spacer (A23).
9. Loosen and remove the seven bolts which clamp the Transfer Case to the Main Case (A11).
10. The Transfer Case (A24), Pinion (A25) with Bearing (A20) can then be retracted from the Maincase mounting
along with the Shims.
11. If the Oil Seals (A5) were damaged, drift out from inside of the Transfer Case (A24) bore.
15
If the Crown Wheel and Pinion (A25) or Pinion Head Bearing (A13) are replaced, the following procedure needs to be
carried out for correct contact of the Bevel Gear set:
1. Note the new Bevel Pinion (A25) mounting distance (etched as MD) on the bottom of the head. (Approxi-
mately 102.00mm)
2. Measure the new overall width of Pinion Head Bearing (A13). (Approximately 29.37mm)
3. Note the Case Constant, which is 132.27mm .
4. The required Shim thickness can then be calculated by using the following calculation:
= Case Constant – (Mounting Distance + Bearing Width)
= 132.27mm - (1. + 2.)
CAUTION: If the components are therefore replaced, a new Solid Spacer Shim (A23) must be used and the Crown
Wheel/Pinion Bearing pre-load reset as detailed below:
1. The Transfer Case (A24) must not be built on the axle Maincase (B4)
2. With the Shims for the tooth contact for the Bevel Pinion (A25) set in place, fit the Pinion Spacer (A23), Input
Wheel (A22) & Slave Solid Spacer Shim (A21) of pre-determined length of 17.10mm & Bearing (A20a) fitted
ino the Rear Transfer Case (A9).
3. Clamp both Transfer Case halves (A9 & A24) together to a specified tightening torque without sealant &
without the mating Input Pinion (A7).
4. Fit Pinion Washer (A19) and used Nylock Nut (A16). Tighten to recommended tightening torque.
5. Magnetise a dial test indicator (DTI) base to the Transfer Case & fit plunger to the end of the Spiral Bevel Pin-
ion (A25).
6. Push & pull the Spiral Bevel Pinion (A25) to record the max movement of the Spiral Bevel Pinion between the
bearings.
7. Remove this amount from the Slave Solid Spacer (A21) +0.05mm for the Bearing pre-load.
8. Strip & rebuild with the sealant & a new Nylock Nut (A16) and the mating Input Pinion (A7).
9. The Input Pinion shimming is carried out by fitting excessive shims, for example 2mm thick.
10. Clamp End Cover (a12) with 4off Bolts (A13) uniformly tightened to 7Nm.
11. Measure gap between Transfer Case face (A9) and End Cover (A12) with Feeler Gauge.
12. Subtract this distance from the shims fitted and refit the current shim stack.
CAUTION: If any components are replaced a new Collapsible Spacer (A7) must be used and the Crown Wheel/Pinion
marking and backlash reset.
16
17
CAUTION: Great care must be taken when removing the Differential Assembly from Main Case. Any damage to the
Crown Wheel would be detrimental to the axles’ performance.
WARNING: The space constraints around the differential are very tight. The Differential Assembly weights 20Kg, so
ensure that you have a good grip on the casing before attempting to remove the assembly from the case.
NOTE: To reset the backlash, see page 15 for the procedure. The acceptable range can be found on page 9.
18
19
NOTE: This procedure assumes the Axle has had both arms removed - see section D.
1. The Planet Carrier assembly can now be removed from the Centre Casing. Take care not to withdraw the
floating Sun Gear (C9).
2. Check the Planet Gears (C4) and the mating gear teeth on the Annulus (C10) and Sun Gear (C9) for damage
and wear. The Planet Gears (C4) should run free in the Planet Pins (C1), without excessive radial “play”. Re-
place if worn.
NOTE: When servicing the Planet assembly we recommend all three Planet Gears (C4), Planet Pins (C1), Needle
Roller Bearings (C3), Spring Dowels (C6), Annulus (C10) & Sun Gear (C9) are replaced together.
Dowels are replaced together.
3. To replace the Planet Gears, Pins or Bearings, drift each Spring Dowel (C6) through its hole, which locates the
Planet Pins (C1) through the Planet Carrier (C5). Once the Dowels have been removed, lightly drift each Plan-
et Pin (C1) through the Planet Gear (C4) and Planet Carrier (C5). Remove the loose Planet Gears (C4), Thrust
Washers (C2) and Needle Roller Bearings (C3). Remove Circlip (C8), which secures the Spacer (C7).
NOTE: The Spacer (C7) is fitted with the large central chamfer facing outwards towards the Spline in the Planet
Carrier (C5).
To reassemble:
1. Replace the Spacer & Circlip (C7 & C8) and slide the Needle Roller Bearings (C3) into the Planet Gears (C4).
Fit the bottom Thrust Washer (C2) over the machined boss within the Planet Carrier (C5), place the Planet
Gear (C4) with the Needle Roller Bearing (C3) on top of the bottom Thrust Washer and from the underside
gently tap the Planet Pin (C1) through the Carrier (C5), bottom Thrust Washer (C2) & Planet Gear (C4).
NOTE: When you begin this procedure, the cross hole in the Planet Pin (C1) must be aligned with the cross hole in
the Planet Carrier (C5).
2. When part way through fit the top Thrust Washer (C2) and continue to drift the Planet Pin (C1) all the way
through the Planet Carrier until it is flush with the Planet Carrier machined face (C5).
3. Secure by fitting a new Spring Dowel (C1) in the Planet Carrier (C5). To prevent the Spring Dowel (C1) from
drifting out of position. The end should be peined into the Planet Carrier (C5). Failure to do this can cause
the Planet Gear (C4) to work loose.
4. Check for free rotation of the Planet Gears (C4) & their respective Planet Pin (C1).
5. This process is repeated for all three Planet Gear fitment (C4).
6. To refit, engage the Teeth of the Sun Gear (C9) with those of the Planet Gears (C4). Mesh the Planet Gears
with the Annulus (C10) and push into position.
1. To remove Annulus (C10), use a special purpose extractor tool or pinch bars, located behind the Annulus
(C10) diametrically opposed, in a scissor fashion to prise the Annulus clear of the Maincase bore (B4).
2. To refit, reverse procedure ensuring that the Dowel (C11) is aligned with the slot at the bottom of the An-
nulus (C10).
20
21
1. Remove 8off Bolts (D10) that secures the Axle Shaft (D11) to the Wheel Hub/Brake Disc. Withdraw the Axle
Shaft (D11) using the extractor screws, and inspect the Spline form for damage and wear.
2. Straighten locking tab ears on Lockwasher (D2), unscrew & remove the Lock Nut (D1) using a special tool. A
gentle tap with a soft mallet on opposing sides of the Brake Disc will assist on pulling the assembly off the
axle arm stub. Remove Lockwasher (D2) (note the keyway lines) and Bearing Spacer (D3).
3. The Wheel Hub (D14) can now be withdrawn from the Axle Arm stub.
NOTE: Care must be taken not to drop the loose Bearing Cones.
4. Examine all Bearing Cups & Cones for wear or damage, replace as necessary.
NOTE: We recommend the Hub Oil Seals are always changed when the Hub has been removed.
5. The Bearing Cup (D4) can be drifted out of the Hub (D14) if they need replacing. When fitting new Bearing
cups (D4) ensure that they are aligned squarely to the bores before pressing in.
NOTE: If the Rear Bearing (D4) is replaced Oil Seal (D15) will also need replacing.
6. To reassemble the Hub assembly, reverse the above procedure using a new Lockwasher (D2).
7. To adjust the Hub Bearings:
i. Tighten the Lock Nut (D1) to the tightening torque of 135 Nm (100 lb.ft). When checking the torque
setting, rotate the Wheel Hub 3 turns in each direction to ensure the Bearings have "seated" cor-
rectly and recheck tightening torque. Repeat this procedure 3 times.
ii. Slacken the Lock Nut (D1) back a distance equal to 1 tab of the new Lock Washer (D4).
iii. Bend ear of Lock Washer over to secure the Nut.
NOTE: Never re-use a Lock Washer (D4).
NOTE: 512-2510-KIT consists of 2 Brake Pads, and we recommend replacing all the Brake Pads (D6) at the same
time.
22
23
CAUTION: Great care must be taken when realigning the Caliper with the Park Brake Disc. The Caliper is self-
positioning and so should have sufficient movement to slide along the Bolts.
1. Loosen the Nut (E9.1) and slide the Bolt (E9.2) out through the Caliper body.
2. Remove the Spring (E9.3) once the Bolt (E9.2) has pass all the through the body.
3. The old Pads (E9.4) will slide out of the Caliper body.
4. Insert the new Pads and reposition the Spring (E9.3) so that it is reacting on the inside face of both Pads.
5. Reinsert the Bolt (E9.2) and tighten the Nut (E9.1).
24
SPARES KITS
To ease the procurement of spares, we offer a catalogue of Kits that group common parts together to simplify the
ordering process. These Kits are detailed below:
512-9630-KIT
Differential Kit (1 kit per axle)
Item Part No Qty Description
B8 616-2160 1 Lock Plate
B10 0041024HT 8 M10 x 120mm Bolt
B11 055CO28UO49H 2 Taper Roller Bearing
B12 615-9520 1 Differential Case
B13 400-2110 2 Diff Wheel Thrust Washer
B14 400-2120 4 Diff Pinion Thrust Washer
B15 410-2100 4 Diff Pinion
B16 413-2130 2 Diff Spider
B17 410-2090 2 Diff Wheel
B18 0051006HT 8 M10 Nut
512-9820-KIT
Differential Kit inc. Crown Wheel & Pinion (1 kit per axle)
Item Part No Qty Description
B8 616-2160 1 Lock Plate
B10 0041024HT 8 M10 x 120mm Bolt
B11 055CO28UO49H 2 Taper Roller Bearing
B12 615-9520 1 Differential Case
B13 400-2110 2 Diff Wheel Thrust Washer
B14 400-2120 4 Diff Pinion Thrust Washer
B15 410-2100 4 Diff Pinion
B16 413-2130 2 Diff Spider
B17 410-2090 2 Diff Wheel
B18 0051006HT 8 M10 Nut
A26 513-9820 1 Crown Wheel & Pinion
512-2891-KIT 1 Transfer Case Shim Kit
512-9580-KIT
Long Arm Planet Kit (1 kit per axle)
Item Part No Qty Description
C1 400-0250 3 Planet Pin
C2 400-0270 6 Thrust Washer
C3 0562005 3 Needle Roller Bearing
C4 400-0080 3 Planet Gear
C5 512-0060 1 Planet Carrier
C6 010-0030 3 Spring Pin
C7 400-1320 1 Spacer
C8 003-0120 1 Circlip
C9 512-0093 1 Long Arm Sun Gear
C10 512-0070 1 Annulus
25
512-2500-KIT
Universal Brake Caliper Kit (2 kits per axle)
Item Part No Qty Description
D5 512-2500 2 Brake Caliper
512-2510-KIT
Universal Brake Caliper Pad Kit (2 kits per axle)
Item Part No Qty Description
D6 512-2510 2 Pack of 2 Brake Pads
512-0040-KIT
Wheel Hub Kit (2 kits per axle)
Item Part No Qty Description
D2 009-0230 1 Lock Washer
D4 0540751H 2 Taper Roller Bearing
D12 0431303 1 O-Ring
D13 512-0450 8 9/16 UNF x 18 Wheel Stud
D14 512-0040 1 Wheel Hub / Brake Disc
512-2520-KIT
512B 512PB Park Brake Conversion Kit (1 kit per axle)
Item Part No Qty Description
E1 512-2372 1 Seal Housing
E2 0400483 1 Oil Seal
E3 0081420 4 M8 x 20mm Cap Bolt
E4 512-2181 1 Park Brake Flange
E5 512-0750 1 Park Brake Disc
E6 512-2191 1 Flange Washer
E7 007-0130 1 M20 Nut
E8 0041006 4 M10 x 16mm Bolt
E9 512-2520 1 Park Brake Caliper
26
512-2891-KIT
Transfer case Shim Kit(1 kit per axle)
Item Part No Qty Description
057313A 2 .002” Shim
057313B 2 .005” Shim
057313C 4 .010” Shim
360-2350 2 0.25mm Shim
360-2210 2 0.30mm Shim
360-2290 2 0.40mm Shim
A21 512-2891/Q1 1 Solid Spacer Shim
NOTE: 512-2891/Q1 must be machined to length to achieve 17/22
lbin Bearing Preload
All spares are available from your local Newage distributor. Check our website to find your closest distributor.
Other spares are available upon request; however these may not be carried by the distributor as standard stock and may incur a
delivery lead-time.
27
Contact may vary, but generally is approximately in the tooth centre, equi-spaced between root and tip. The marking
may be towards toe on some gears on both flanks, or marking crossed slightly i.e. towards toe on convex flank and
heel on concave flank or vice versa.
If, compared to the factory tooth contact, the contact appears as shown below, then corrective action should be
taken as follows:
CONVEX FLANK
CONCAVE FLANK
ACTION: Recheck and decrease shims behind Pinion Head Bearing (A20a).
28
CONCAVE FLANK
ACTION: Recheck and increase shims behind Pinion Head Bearing (A20a).
29
NOTES
30
Maintenance / On 2013
Vehicle Service
4L6XE/70E
GM 4L70 TRANSMISSION
CHAPTER 5 MAUFACTURER’S INFORMATION DECEMBER 15, 2013
GM 4L70 TRANSMISSION PAGE 171
NMC-WOLLARD 2021Truax Blvd., Eau Claire, WI 54703, Phone (715) 835-3151, Fax (715) 835-6625
M60 Tow Tractor Manual No. 46050
Model 4L6XE/4L70E
Always Use
When you diagnose any condition of the 4L60x/4L70E transmission, begin with a
Diagnostic Starting Point. This procedure indicates the proper path of diagnosing
the transmission by describing the basic checks. This procedure will then refer
you to the locations of specific checks. After you have determined the cause of a
condition, refer to Repair Instructions for repair procedures.
Basic Knowledge
You must be familiar with some basic electronics in order to use this section of
the service manual. You should also be able to use the following special tools:
This service manual uses various symbols in order to describe different service operations.
The diagnosis and repair procedures in a GM Service Manual contain both general and
specific Dangers, Warnings, Cautions, Notes or Importants. GM is dedicated to the
presentation of service information that helps the technician to diagnose and repair the
systems necessary for the proper operation of the vehicle; however, certain procedures
may present a hazard to the technician if they are not followed in the recommended
manner. Dangers, Warnings, Cautions and Notes or Importants are elements designed
to prevent these hazards, however, not all hazards can be foreseen. This information is
placed at strategic locations within the service manual. This information is designed to
prevent the following from occurring:
DANGER Defined
WARNING Defined
CAUTION Defined
Clarify a procedure
Present additional information for accomplishing a procedure
Give insight into the reason or reasons for performing a procedure in the
manner recommended
Present information that will help to accomplish a procedure in a more
effective manner
Present information that gives the technician the benefit of past
experience in accomplishing a procedure with greater ease
Warnings
Battery Disconnect Warning
Warning: Unless directed otherwise, the ignition and start switch must be in the OFF
position, and all electrical loads must be OFF before servicing any electrical component.
Disconnect the negative battery cable to prevent an electrical spark should a tool or
equipment come in contact with an exposed electrical terminal. Failure to follow these
precautions may result in personal injury and/or damage to the vehicle or its
components.
Warning: Avoid taking the following actions when you service wheel brake parts:
Some models or aftermarket brake parts may contain asbestos fibers which can
become airborne in dust. Breathing dust with asbestos fibers may cause serious bodily
harm. Use a water-dampened cloth in order to remove any dust on brake parts.
Equipment is available commercially in order to perform this washing function. These
wet methods prevent fibers from becoming airborne.
Cautions
Fastener Caution
Caution: Use the correct fastener in the correct location. Replacement fasteners must
be the correct part number for that application. Do not use paints, lubricants, or
corrosion inhibitors on fasteners, or fastener joint surfaces, unless specified. These
coatings affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners in
order to avoid damage to parts and systems. When using fasteners that are threaded
directly into plastic, use extreme care not to strip the mating plastic part(s). Use hand
tools only, and do not use any kind of impact or power tools. Fastener should be hand
tightened, fully seated, and not stripped.
This procedure checks the transmission fluid level, as well as the condition of the fluid
itself.
Caution: Always use the proper automatic transmission fluid listed. Using incorrect
automatic transmission fluid may damage the vehicle.
1. Start the engine and park the vehicle on a level surface. Keep the engine
running.
2. Apply the parking brake and place the shift lever in PARK (P).
3. Depress the brake pedal and move the shift lever through each gear range,
pausing for about 3 seconds in ea ch range. Then, move the shift lever back to
PARK (P).
4. Allow the engine to idle 500–800 RPM for at least 1 minute. Slowly release the
brake pedal.
o Use this cold check procedure to check fluid level when the
transmission fluid temperature is between 27–32°C (80–90°F).
2. Start the engine and locate the transmission dipstick at the rear of the
engine compartment, on the passenger's side of the vehicle.
3. Flip the handle up, and then pull out the dipstick and wipe the dipstick end
with a clean rag or paper towel.
4. Install the dipstick by pushing it back in the dipstick tube all the way, wait
three seconds and then pull it back out again.
Note: Always check the fluid level at least twice. Consistent readings are
important to maintaining proper fluid level. If inconsistent readings are
noted, inspect the transmission vent assembly to ensure it is clean and
unclogged.
5. Keep the dipstick pointing down and check both sides of the dipstick, and
read the lower level. Repeat the check procedure to verify the reading.
6. Inspect the color of the fluid on the dipstick. Refer to Fluid Condition
Inspection in this procedure.
7. If the fluid level is below the COLD check line, add only enough fluid as
necessary to bring the level into the COLD line. It does not take much
fluid, generally less than one pint (0.5L). Do not overfill.
8. If the fluid level is in the acceptable range, push the dipstick back in all the
way, then flip the handle down to lock the dipstick in place.
9. Perform a hot check at the first opportunity after the transmission reaches
a normal operating temperature between 82–93°C (180–200°F).
Note: Use this procedure to check the transmission fluid level when the
transmission fluid temperature is between 82–93°C (180–200°F). The hot
check procedure is the most accurate method to check the fluid level. The
hot check should be performed at the first opportunity in order to verify the
cold check. The fluid level rises as fluid temperature increases, so it is
important to ensure the transmission temperature is within range.
1. Start the engine and locate the transmission dipstick at the rear of the
engine compartment, on the passenger side of the vehicle.
2. Flip the handle up, and then pull out the dipstick and wipe the dipstick end
with a clean rag or paper towel.
3. Install the dipstick by pushing it back in the dipstick tube all the way, wait
three seconds and then pull it back out.
Note: Always check the fluid level at least twice. Consistent readings are
important to maintaining proper fluid level. If inconsistent readings are
4. Keep the dipstick tip pointing down and check both sides of the dipstick.
Read the lower level. Repeat the check procedure to verify the reading.
5. Inspect the color of the fluid on the dipstick. Refer to Fluid Condition
Inspection.
6. A safe operating fluid level is within the HOT crosshatch band on the
dipstick. If the fluid level is not within the HOT band, and the transmission
temperature is between 82–93°C (180–200°F), add or drain fluid as
necessary to bring the level into the HOT band. If the fluid level is low, add
only enough fluid to bring the level into the HOT band.
7. If the fluid level is low, add only enough fluid to bring the level into the
HOT band. It does not take much fluid, generally less than one pint (0.5L).
Do not overfill. Also, if the fluid level is low, inspect the transmission for
leaks. Refer to Fluid Leak Diagnosis.
8. If the fluid level is in the acceptable range, push the dipstick back into the
dipstick tube all the way, and then flip the handle down to lock the dipstick
in place.
Inspect the fluid color. The fluid should be red or dark brown.
If the fluid color is very dark or black and has a burnt odor, inspect the fluid
and inside of the bottom pan for excessive metal particles or other debris.
A small amount of “friction” material in the bottom pan is a “normal”
condition. If large pieces and/or metal particles are noted in the fluid or
bottom pan, flush the oil cooler and cooler lines and overhaul the
transmission. If there are no signs of transmission internal damage noted,
replace the fluid filter assembly, repair the oil cooler, and flush the cooler
lines.
bushing wear
• Steel particles
15. Clean the transmission
case and the oil pan
gasket surfaces with
solvent, and air dry. You
must remove all traces of
the old gasket material.
Installation Procedure
Installation Procedure
Installation Procedure
Special Tools
Removal Procedure
Removal Procedure
Caution: Refer to
Fastener Caution.
Removal Procedure
Caution: Refer to
Fastener Caution.
Installation Procedure
flange of seal should contact the 6. Fill the transmission to the proper
extension housing. level with DEXRON® VI
transmission fluid. Refer to
Transmission Fluid Level and
Condition Check.
Removal Procedure
5 Remove the transmission oil cooler
pipes. Refer to Transmission Fluid
Cooler Hose/Pipe Replacement.
Warning: Refer to Battery
Disconnect Warning.
6. Remove the rear propeller shaft.
7. Support the transmission with a
Caution: The drive plate transmission jack.
(flywheel) will not support a load. 8. Remove the transmission rear
None of the weight of the support and insulator assembly
transmission must be allowed to attaching bolts at the bottom rear of
rest on the drive plate during the transmission.
removal or installation.
9. Remove exhaust pipe, manifolds or
exhaust components as necessary
Caution: The transmission and
torque converter must be
removed and installed as an
assembly to prevent damage to
the front bushing or front oil seal.
the vehicle.
19 Raise the transmission with the
transmission jack to take pressure
off of the rear cross member.
20 Secure transmission to the jack
with safety chain
18. Remove all vehicle harness wires, Caution: The drive plate
harness clips, tubes, brackets, and (flywheel) will not support a load.
lines that may interfere with the None of the weight of the
removal of the transmission from transmission must be allowed to
Special Tools
Tool
Number/Descripti
Illustration on
J 43909
Selector Shaft
J 29714 -A Seal Installer
Servo Cover
Depressor
J 35944 -22
J 35944 -200
Cooler Flushing
Adapters
J 36850
Transjel Lubricant
Removal Procedure
Warning: Avoid taking the following actions when you service wheel brake parts:
Some models or aftermarket brake parts may contain asbestos fibers which can become
airborne in dust. Breathing dust with asbestos fibers may cause serious bodily harm. Use
a water-dampened cloth in order to remove any dust on brake parts. Equipment is
available commercially in order to perform this washing function. These wet methods
prevent fibers from becoming airborne.
7. Remove caliper assembly
Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it
is separated from its mount.
8. Remove the flange yoke bolts (6), flange yoke (7), rotor (5), flange cap (4).
9. Remove the case extension bolts (2).
10. Remove the case extension (3).
11. Remove and discard the case extension O-ring sealௗ(1).
Installation Procedure
2. Install the case extension (3). Rotate flange as required to align flange and output
shaft splines.
3. Install the case extension bolts (2) and tighten to 45ௗN·m (33ௗlbௗft).
4. Install the flange cap (4), rotor (5), flange yoke (7).
8. Install the brake caliper guide pin bolts (1) and tighten to 35ௗNm (26ௗlbௗft).
9. Remove the drain pan and the transmission jack.
10. Install the propeller shaft
11. Lower the vehicle.
12. Fill the transmission to the proper level with DEXRON® VI transmission fluid. Refer
to Transmission Fluid Level and Condition Check.