truck, cargo, heavy, mc3 – mack · 2018-03-28 · electrical and mechanical engineering...

ELECTRICAL AND MECHANICALENGINEERING INSTRUCTIONS

VEHICLE G 709Issue 10, Jun 14

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TRUCK, CARGO, HEAVY, MC3 – MACK

ALL VARIANTS

SERVICING INSTRUCTION

This instruction is authorised for use by command of the Chief of Army. It provides direction, mandatory controls and procedures for the operation, maintenance and support of equipment. Personnel are to carry out any action required by this instruction in accordance with EMEI General A 001.

INTRODUCTION

1. This EMEI lists the requirements for each level of servicing for the Truck, Cargo, Heavy, MC3 – Mack – All Variants, except:

a. Truck, Wrecker, Heavy (HRV);

b. Launch Recovery Vehicle (LRV);

c. Truck, Tanker, Fuel, Aviation, Heavy, MC3:

(1) MKI, NSN 2320-66-150-7876; and

(2) MKII, NSN 2320-66-153-3721.

NOTE

Whilst this EMEI excludes the LRV, it may be used to complete a service/Technical Inspection (TI) on the cab/chassis for the vehicle. For details specific to the LRV sub-frame, refer to EMEI Vehicle G 78 Decade.

2. The servicing sequence is detailed at Para 5. The actions to be performed at each level of servicing by both the operator and tradesperson are detailed at Table 3.

All industrial safety, work practices and equipment operating and maintenance instructions pertaining to this EMEI are to be adhered to.

The handling, storage and use of chemical substances are to be in accordance with SAFETYMAN, MSDS and EMEI Workshop E series requirements.

WORKING ON FUEL TANKERS - GENERAL HAZARD. The requirements of AS 2809 are to be adhered to prior to any maintenance work being conducted on the vehicle or serious injury and death could occur. This includes:

The tank has to be gauged to ensure it is not over the maximum filling level.

No hot working is to be conducted either indoors or outdoors unless the tank has been made gas free and a certificate issued.

The vehicle is not to be parked near a source of heat that could heat the cargo causing the cargo to vent.

Associated Publications

3. Reference may be necessary to the latest issue of the following documents for maintenance and repair procedures:

a. EMEI Misc Equip Q 208 – Inspection of Portable Fire Extinguishers – Equipment Inspection and Examination Data;

http://vbmweb.sor.defence.gov.au/TECHDATA/dofa/emei/Misc%20Equip/q208.pdf











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b. EMEI Misc Equip P 009-1 – POL Storage and Fuel Transfer Equipment – Regulatory Testing Requirements For Bulk Fuel Tankers – General Instruction;

c. EMEI Misc Equip P 009-2 – POL Storage and Fuel Transfer Equipment – Truck and Skid Mounted, Unfired Pressure Vessels with Quick Actuating Closures – General Instruction;

d. EMEI Misc Equip P 009-3 – POL Storage and Fuel Transfer Equipment – Truck and Skid Mounted, Unfired Pressure Vessel Hydraulic Accumulators/Shock Alleviators – General Instruction;

e. EMEI Misc Equip P 009-4 – POL Storage and Fuel Transfer Equipment – Regulatory Requirements for Testing Bulk Fuel Hose and Assemblies – General Instruction;

f. EMEI Vehicle A 028-1 – Vehicles – General – B Vehicle Mounted Cranes – Technical Inspection Requirements – Inspection for Useability;

g. EMEI Vehicle A 029-2 – Vehicles – General – Road Testing of Medium and Heavy B Vehicles and Combinations – General Instruction;

h. EMEI Vehicle A 049-1 – Towing Pintle Hooks – Medium and Heavy General Services B Vehicles - Inspection And Repair – Miscellaneous Instruction;

i. EMEI Vehicle A 291-1 – Tyres and Tubes – Care and Maintenance of B Vehicles – General Instruction;

j. EMEI Vehicle A 291-5 – Tyres and Tubes – General Service B Vehicle Tyre Guide – Operator Instructions;

k. EMEI Vehicle A 298-2 – Tyres and Tubes – General Service B Vehicle Tyres – Inspection for Useability;

l. EMEI Vehicle A 429-1 – Brake Systems – B Vehicles General – Brake Shoe Re-lining Policy – General Instruction;

m. EMEI Vehicle A 548-1 – Vehicle Seat Belts – Inspection Data – Inspection for Useability;

n. EMEI Vehicle A 591-1 – Miscellaneous – Inspection and Cleaning of Dry Type Air Cleaners – Miscellaneous Instruction;

o. EMEI Vehicle D 108 – Recovery Equipment – Inspection of Recovery Equipment – Inspection for Useability;

p. EMEI Vehicle G 700 – Truck, Cargo, Heavy, MC3 – Mack – Including Truck, Cargo, Winch, Heavy, MC3 – MACK – Data Summary;

q. EMEI Vehicle G 703 – Truck, Cargo, Heavy, MC3 – Mack – Including Truck, Cargo, Winch, Heavy, MC3 – MACK – Light Grade Repair;

r. EMEI Vehicle G 704 – Truck, Cargo, Heavy, MC3 – Mack – Medium Grade Repair;

s. EMEI Vehicle G 704-1 – Truck, Cargo, Heavy, MC3 – Mack – Heavy Grade Repair;

t. EMEI Vehicle G 708-1 – Truck, Cargo, Heavy, MC3 – Mack – Technical Inspection – Inspection for Useability;

u. EMEI Vehicle G 713 – Truck, Cargo, With Crane, Heavy, MC3 – Mack – Light Grade Repair;

v. EMEI Vehicle G 714 – Truck, Cargo, With Crane, Heavy, MC3 – Mack – Medium and Heavy Grade Repair;

w. EMEI Vehicle G 737-11 – Truck, Dump, Heavy, MC3 – Mack – Dump Hoist Hydraulic Filter Installation – Modification Instruction;

x. EMEI Vehicle G 737-12 – Truck, Dump, Heavy, MC3 – Mack – Replacement of Hydraulic Tank Filler Cap – Modification Instruction;

y. EMEI Vehicle G 759-1 – Truck, Heavy, MC3 – Mack – All Types – Wear Limits and Inspection of the Tanker Barrel Bearing Mounts – Miscellaneous Instruction;

z. EMEI Vehicle G 794-1 – Truck, Heavy, MC3 – Mack – All Types – Crisp-Air Airconditioner – Medium Grade Repair;

aa. EMEI Vehicle G 797-7 – Truck, Heavy, MC3 – Mack – All Types – Fuel Tank Support Brackets – Modification Instruction;

http://vbmweb.sor.defence.gov.au/TECHDATA/dofa/emei/Misc%20Equip/p009-1.pdf




































http://vbmweb.sor.defence.gov.au/TECHDATA/dofa/emei/Vehicle/a028-1.pdf


































































http://vbmweb.sor.defence.gov.au/TECHDATA/dofa/emei/Vehicle/d108.pdf







http://vbmweb.sor.defence.gov.au/TECHDATA/dofa/emei/Vehicle/g700.pdf





















http://vbmweb.sor.defence.gov.au/TECHDATA/dofa/emei/Vehicle/g704-1.pdf










































http://vbmweb.sor.defence.gov.au/TECHDATA/Dofa/Emei/Vehicle/G759-1.pdf























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bb. EMEI Vehicle G 797-28 – Truck, Heavy, MC3 – Mack – All Types – Replacement of Wheel Studs and Nuts – Modification Instruction;

cc. EMEI Vehicle G 798-10 – Truck, Heavy, MC3 – Mack – All Types – Air Bag Suspension Inspection Criteria and Periodic Preventative Maintenance – Inspection for Serviceability;

dd. EMEI Vehicle G 799-23 – Truck, Heavy, MC3 – Mack – All Types – Identification of Rims and Approved Rim and tyre Configurations – Miscellaneous Instruction;

ee. EMEI Vehicle G 799-27 – Truck, Heavy, MC3 – Mack – All Types – Inspection/ Repair/ Replacement of Tailgate/ Sidegate Hinges And Hinge Mounts – Miscellaneous Instruction;

ff. EMEI Vehicle G 816-1 – Truck, Tank, Water, Heavy, MC3, 8 Tonne, T/Charged Diesel Engine, Man Trans, 6 x 6, Air Brakes, Mack RM6866RS Chassis, C/W Spray Bar, Water Pump, S/Steel Tank, NSN 2320-66-150-7875 – Light Grade Repair;

gg. EMEI Workshop E 410 – Hazardous Substances – Occupational Health and Safety Instruction – Asbestos – General Instruction;

hh. EMEI Workshop H 149-1 – Vehicle Jacks – Mechanical and Hydraulic – General Instruction;

ii. Defence Safety Manual (SAFETYMAN);

jj. EMEI Vehicle A 598 – Total Restraint Access Module (TRAM) System – ADF Fuel and Water Tankers – All applicable variants – Equipment Inspection and Examination Data;

kk. Equipment User/Operator and Servicing Handbooks; and

ll. DEF (AUST) 206E – Petroleum, Oils and Lubricants Manual.

Servicing Points

4. Servicing points for the Mack are identified as follows:

a. Figure 1 – Power Train Servicing Points – Front;

b. Figure 2 – Driveline Servicing Points;

c. Figure 3 – Driveline Servicing Points – Rear;

d. Figure 4 – Crisp-Air Conditioner Servicing Points;

e. Figure 5 – Air Spring Servicing Points;

f. Figure 6 – HIAB 090 Crane Servicing Points;

g. Figure 7 – Dump Servicing Points;

h. Figure 8 – Fuel Tanker Servicing Points;

i. Figure 9 – MKI Water Tanker Servicing Points; and

j. Figure 10 – MKII Water Tanker Servicing Points.

Servicing Sequence

5. The following servicing sequence is to be applied:

a. Technical Inspection (TI) – 10 000 km or 12 months after the last service;

b. Minor Service – 10 000 km or 12 months after the last TI;

c. TI – 10 000 km or 12 months after the last Minor Service;

d. Major Service – 10 000 km or 12 months after the last TI;

e. TI – 10 000 km or 12 months after the last Major Service;

f. Minor Service – 10 000 km or 12 months after the last TI;

g. TI – 10 000 km or 12 months after the last Minor Service;

h. Alternate Major Service – 10 000 km or 12 months after the last TI; and

i. the servicing sequence commences again after the Alternate Major Service with a Technical Inspection being carried out after a further 10 000 km or 12 months.




































http://vbmweb.sor.defence.gov.au/TECHDATA/dofa/emei/Workshop/e410.pdf









http://vbmweb.sor.defence.gov.au/TECHDATA/dofa/emei/Workshop/h149-1.pdf







http://ohsc.defence.gov.au/SAFETYMAN/default.htm









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NOTE

Due to statutory servicing requirements, all fuel tankers will be serviced on calendar time only and not distance travelled.

6. Servicing is based on distance travelled or time elapsed with all vehicles being serviced at least once every 24 months. Unit commanders may reduce the periods between services or add servicing tasks to meet operational or exercise requirements. A scheduled service may be anticipated or delayed within a limit of plus or minus 10 percent of the interval between services to meet operational needs and to permit workload planning.

NOTE

When any equipment exceeds the 10 percent maximum limit of the servicing interval (Para 5), it is to be classified ‘DO NOT USE – XX’ until the outstanding service is completed.

Authorised Personnel

7. All operator tasks listed in Table 3 are to be carried out by a qualified operator under the supervision of personnel nominated at Para 8.

8. All tradesperson tasks are to be carried out by the following tradesperson as applicable to the task:

a. Vehicle:

(1) Vehicle Mechanic (ECN 229);

(2) Recovery Mechanic (ECN 226);

(3) Technician Electrical (ECN 418);

(4) Fitter Armourer (ECN 146); or

(5) Tri-service/civilian equivalent.

b. Tanker System:

(1) Army: Fitter Armament ECN 146;

(2) RAAF: Ground Support Equipment Fitter; or

(3) civilian equivalent of the above.

c. Qualified Operator Petroleum:

(1) to assist with servicing under the supervision of the tradespersons; and

(2) to operate the equipment during inspections and testing.

Standard Job

9. Standard job numbers have been raised to detail the vehicle servicing/TI procedures. Table 1 details the standard job numbers allocated for the Truck, Cargo, Heavy, MC3 – Mack variants detailed in this instruction.

Table 1 Standard Job Numbers

SerialStandard

Job Number

Standard Job Description Applicability

1 00300 MACK MIN SVC & TI All variants less TTW MKI & TTF

2 00301 MACK MAJ SVC & TI All Cargo Variants

3 00302 MACK ALT MAJ SVC & TI All Cargo Variants

4 06508 MACK TI All Variants less TTW MKI & MKII & TTF

5 00210 MACK DUMP MIN SVC & TI Dump & Dump W/Winch

6 00298 MACK DUMP MAJ SVC & TI Dump & Dump W/Winch

7 00306 MACK DUMP ALT MAJ SVC & TI Dump & Dump W/Winch

8 06450 MACK W/C & GUN TRACTOR MAJ SVC & TI Cargo W/C & Gun Tractor



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SerialStandard

Job Numbers

Standard Job Description Applicability

9 06451 MACK W/C & GUN TRACTOR ALT MAJ SVC & TI Cargo W/C & Gun Tractor

10 00088 MACK TTF MIN SVC & TI TTF only

11 00089 MACK TTF MAJ SVC & TI TTF only

12 00090 MACK TTF ALT MAJ SVC & TI TTF only

13 01030 MACK TTF & TTFA 6M SVS TTF only

14 06646 MACK TTF TI ONLY TTF only

15 00323 MACK TTW MKI MIN SVC & TI TTW MKI only

16 06642 MACK TTW MAJ SVC & TI TTW MKI only

17 06643 MACK TTW ALT MAJ SVC & TI TTW MKI only

18 06644 MACK TTW TI ONLY TTW MKI only

19 00587 MACK FALL RESTRAINT SYSTEM TTW

19 00220 MACK TTW MKII MAJ SVC & TI TTW MKII only

20 00221 MACK TTW MKII ALT MAJ SVC & TI TTW MKII only

21 06644 MACK TTW MKII TI ONLY TTW MKII only

22 06613 5-YEARLY CRANE INSPECTION (re-certification) Cargo W/C & Gun Tractor

Repair Parts Scales

10. Table 2 lists the Repair Parts Scale (RPS) for all vehicles listed in this EMEI.

Table 2 Repair Parts Scales

NIIN Description RPS

66-104-2875 Truck, Cargo, Heavy, MC3, 8 Tonne, GS, Turbocharged Diesel Engine, Manual Gearbox, 2 Speed Transfer, 6x6, Air Brakes, 24 Volt Electrical System, W/O Winch or Crane Mack RM6866RS Chassis

66-119-1557 Truck, Cargo, Heavy, W/Removable Cab, MC3, Mack RM6866RS Chassis, W/O Winch or Crane02160

66-104-2876 Truck, Cargo, Heavy, MC3, 8 Tonne, GS, Turbocharged Diesel Engine, Manual Gearbox, 2 Speed Transfer, 6x6, Air Brakes, 24 Volt Electrical System, W/Winch, W/O Crane, Mack RM6866RS Chassis

66-119-1558 Truck, Cargo, Heavy, W/Removable Cab, W/Winch, MC3 , Mack RM6866RS Chassis, W/O Crane02161

66-104-2877 Truck, Cargo, Heavy, MC3, 8 Tonne, GS, Turbocharged Diesel Engine, Manual Gearbox, 2 Speed Transfer, 6x6, Air Brakes, 24 Volt Electrical System, W/O Winch, W/Crane 02162

66-104-2878 Truck, Flatbed, Heavy, MC3, 8 Tonne, GS, Turbocharged Diesel Engine, Manual Gearbox, 2 Speed Transfer, 6x6, Air Brakes, 24 V Elec, Gun Tractor & Ammo Transporter, W/Winch & Crane, Mack 02164

66-112-8850 Truck, Dump, Heavy,MC3, 6x6, GS, Mack RM6866RS Chassis, Turbocharged Diesel Engine, 5 Speed Manual Transmission, 2 Speed Transfer, Air Brakes, 24 V Electrical System, W/O Winch 02165

66-112-8851Truck, Dump, Heavy, MC3, 6x6, GS, Mack RM6866RS Chassis, 8 Tonne, 8 cu m, Turbocharged Diesel Engine, 5 speed Manual Transmission, 2 Speed Transfer, Air brakes, 24 V Electrical System, W/Winch

02166

66-112-8852 Truck, Tank, Gasoline, Heavy, Mc3, 6x6, Mack RM6866RS Chassis, 8 Tonne, 6 Cyl, Turbocharged Diesel Engine, 5 Speed Manual Transmission, Air Brakes, 24 V Electric 02167

66-112-8853 Truck, Tank, Water, Heavy, MC3, 12 500 L Capacity, Pump Feed, W/Spray Bar and Hand Spray 02168

66-150-7875 Truck, Tank, Water, Heavy,MC3, 8 Tonne, T/Charged Diesel Engine, Manual Transmission, 6x6, Air Brakes, Mack RM6866RS Chassis, C/W Spray Bar, Water Pump, S/Steel Tank 02255

Additional Tasks

11. No additional tasks are to be added to scheduled maintenance work orders. A separate work order shall be raised to record additional maintenance tasks identified during the servicing and/or the Technical Inspection. These additional tasks may include, but not be limited to, the replacement of wheel bearings, brake pads/shoes, wheel cylinders etc, and outstanding modifications. The additional tasks are to be completed in conjunction with the scheduled maintenance.



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Table 3 Servicing Requirements

Serial Item or Assembly (1) 6 Mth 12 Mth MIN MAJ ALT/MAJ Capacity (Litres) Lubricant

Operator Tasks. Before an operator carries out any of the following tasks refer to Para 7.

All Variants (Ref Figures 1 , 2 and 3).

1 Transmission T D D 10.4 OEP-220

2 Transfer case cooling fins(if fitted with cooler/filter system)

C C C

3 Transfer case oilTransfer case oil (if fitted with cooler/filter system)

D

D

D

D

D

D

9.5

11OEP-220

4 Propeller shafts universal joints

L L L XG-291

5 Clutch release bearing L L L XG-291

6 Clutch cross shaft L L L XG-291

7 Engine oil filters R R R

8 Engine oil D D D 55.3 SAE Grade 40

9 Water pump housing L L L XG-291

10 Coolant (Para 13) T T D 54 Anti-freeze/ anti-boil

11 Coolant conditioner filter R R R

12 Front axle differential T D D 11.4 OEP-220

13 Mudguard hinge pivots L L L XG-291

14 Front spring shackle pins L L L XG-291

15 Steering drag link L L L XG-291

16 Steering box bearing cap L L L XG-291

17 Steering shaft (two fittings in cab)

L L L XG-291

18 Constant velocity joints L L L XG-291

19 Front wheel bearings (Para 14 & 15)

T D D OEP-220

20 Axles and front hub breathers C C C

21 Upper and lower drive hub pivots (Para 16)

L L L XG-291

22 Tie rod ends L L L XG-291

23 Air cleaners (Para 17) C C C

24 Transfer case selector L L L XG-291

25 Transfer case linkage support (vented fitting)

L L L XG-291

26 Spare wheel carrier pivots L L L SAE Grade 40

27 Winch rope guide roller(if fitted)

L L L XG-291

28 Transfer case cooler oil filter (if fitted)

– R R

29 Power steering filter – R R



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Table 3 Servicing Requirements (Continued)

Serial Item or Assembly (1) 6 Mth 12 Mth MIN MAJ ALT/MAJCapacity (Litres) Lubricant

Operator Tasks – Continued. Before an operator carries out any of the following tasks refer to Para 7.

All Variants - Continued (Ref Figures 1 , 2 and 3).

30 Winch cable rollers (if fitted) L L L XG-291

31 Fuel filters R R R

32 Power Take Off (PTO) shaft joints (Para 18 if applicable)

L L L XG-291

33 Winch drive chain (Para 19 if fitted) L L L Chain lube

34 Winch gearbox (if fitted) T D D 2.5 OEP-220

35 Intermediate axle (Para 20) T D D 12.0 OEP-220

36 Fuel tanks (Para 21) D D D

37 Winch rope pulleys (if fitted) L L L XG-291

38 Pintle hook L L L XG-291

39 Winch drum bearing (if fitted) L L L XG-291

40 Winch rope (Para 22 if fitted) C, L C, L C, LRocol

wire rope lube

41 Handles, locks and hinges L L L SAE Grade 40

42 Axle and transmission breathers C C C

43 Seat slide runners L L L SAE Grade 40

44 Battery terminals, cables and battery compartment I I I

45 Tyre wear and rim damage(Para 23) I I I

46 Panel damage I I I

47 Operation of lights, gauges, warning lights and horn I I I

48 Tray condition (if applicable) I I I

49 CES I I I

50 Vehicle jack classification tag I I I

51 Fire extinguisher inspection tag I I I I I

52 Vehicle general C C C C C

Air Conditioner (Ref Figure 4)

53 Air intake filter C C C

54 Return air filter C C C

55 Evaporator drain tube C, I C, I C, I

56 Condenser coil C C C

57 Compressor drive belt I I I

58 Hoses and pipes I I I

Crane (Ref Figure 6)

59 Hook and pivot C, L C, L C, LXG-291 and SAE Grade

40



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Serial Item or Assembly (1) 6 Mth 12 Mth MIN MAJ ALT/MAJCapacity (Litres) Lubricant


Crane - Continued (Ref Figure 6).

60 Crane control handle pivots (left and right sides)

L L L XG-291

61 Outrigger pivots L L L XG-291

62 Tilt cylinder pivots and tilt rotor assembly

L L L XG-291

63 Outrigger control handle pivots

C, L C, L C, L SAE Grade 40

64 Pressure reduction oil filter

R R

65 Loader body bearings (upper and lower)

L L L

66 Return oil filter – R R

67 Oil tank filler cap strainer (Para 24)

C C C

68 Oil tank reservoir T D D 105 OM-33

69 Crane C C C

70 Recertification due date (Para 25)

I I I

Dump (Ref Figure 7).

71 Rear body pivots C, L C, L C, L XG-291

72 Ram pivots C, L C, L C, L XG-291

73 Tailgate pivots C, L C, L C, L XG-291

74 Body tip lock assembly pivots

C, L C, L C, L XG-291

75 Hydraulic oil reservoir T D D 72 OM-65

76 Hydraulic oil filter – R R

77 Hydraulic tank filler cap C C C

Fuel Tanker (Diesel) (Ref Figure 8).

78 Hydraulic oil (Para 26) T D D 81 OM-65

79 Hydraulic oil filter R R

80 Hydraulic breather C C C

81 Manual cam lifters L L L

82 Emergency hatch hinge pins

L L L

83 Truck socket C,L C,L C,L

84 End of reel hose holders (nozzle receptacle)

I I I

85 Earth reel continuity U U U U U

86 Fuel hose hydrostatic U U U U U

87 General fuel hose continuity

U U U U U

88 Fuel pump bearings L L L XG-291

89 Hose reel bearings L L L



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Serial Item or Assembly (1) 6 Mth 12 Mth MIN MAJ ALT/MAJ

Capacity (Litres) Lubricant


90 TRAM system (Para 44) C,I,L C,I,L C,I,L C,I,L C,I,L

Water Tanker - MKI – NSN 2320-66-112-8853 (Ref Figure 9).

91 Hose reels drive shaft L C, L C, L XG-291

92 Hose reel locking latches

L L L

93 Rear tank mounting L C, L C, L XG-291

94 All hinges, pins and linkages not fitted with grease nipples

L L L

95 Hydraulic oil (Para 26) T D D 135 OM-65

96 Hydraulic oil tank, suction filter (Para 27)

– – R


98 Water tank mountings (Para 28)

L L L XG-291

99 Water pump L L L XG-291

100 Water pump outrigger bearing

L L L XG-291

101 Pump mounted grease cup

L C, L C, L XG-291

102 System Operation (Para 29)

AR AR AR

103 TRAM system (Para 44)

C,I,L C,I,L C,I,L C,I,L C,I,L

Water Tanker - MKII – NSN 2320-66-150-7875 (Ref Figure 10).


105 Hydraulic oil T D D 60 L OM-65

106 Hydraulic filler/breather C C C

107 Hose reel bearings L L L SAE Grade 40

108 Butterfly valve flanges including vent valves

I, Y I, Y I, Y

109 Butterfly valve actuators I, Y I, Y I, Y

110 Tank mounting bolts and fittings

Y Y Y

111 All hinges, pins and linkages without grease nipples

L L L SAE Grade 40

112 System operation (Para 29)

AR AR AR

113 Handrail – All hinges, pins and linkages not fitted with grease nipples

C,I,L C,I,L C,I,L C,I,L C,I,L

Tradesperson Tasks. Ensure tradesperson is suitably qualified in accordance with Para 8.

All Variants (Ref Figures 1 , 2 and 3)

114 Steering drag link I I I

115 Steering shaft – I I



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Tradesperson Tasks - Continued. Ensure tradesperson is suitably qualified in accordance with Para 8.

All Variants (Ref Figures 1 , 2 and 3)

116 Vehicle brakes (Para 30)

I I I

117 Front axle half-shaft retaining studs

– I I

118 Tie rod ends I I I

119 Air system for leaks I I I

120 Air bag filter R R R

121 Pintle hook I I I

122 Seat belts, mountings and inertia reel operation (Para 31)

I I I

123 Wheel nuts and studs I I I

124 Wheel alignment I I I

125 Clutch – I I

126 Power Take Off (PTO) shaft joints (Para 18)

I I I

127 Engine mounts I I I

128 Engine valve clearance (Para 32)

– A A

129 Rear wheel bearings – I I

130 Vehicle jack (Para 33) I I I

131 Tailgate/sidegate hinges and hinge mounts (Para 34)

I I I

Air Conditioner (Ref Figure 4 and Para 35).

132 Compressor oil – D D 0.135 Sanden SP-20

133 Refrigerant I D D R134a1.2 kg ±50 g

134 Operation of the system (Para 36)

AR AR AR

135 Receiver dryer (Para 37)

– R R

Air Bag Suspension (Ref Figure 5)

136 Air bags, upper and lower mounting plate

I I I

137 Internal bumper security

I I I

138 Equalising beams, transverse beams & hanger bkts (Para 43)

I I I

139 Pressure protection valve filter

I I I

140 Road test (Para 45) AR AR AR

141 Raise Technical Inspection Report (Para 46)

AR AR AR



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Tradesperson Tasks - Continued. Ensure tradesperson is suitably qualified in accordance with Para 8.

Crane (Ref Figure 6)

142 Boom cylinder pivot pins and bushes (Para 38)

L L L XG-291

143 Crane I I I

144 Re-certification (Para 25) AR AR AR

Dump (Ref Figure 7)

145 Rear body pivots I I I

146 Ram pivots I I I

147 Tailgate pivots I I I

148 Body tip lock assembly pivots I I I

149 Tank mounting bolts and fittings Y Y Y

Fuel Tanker (Diesel) (Ref Figure 8)

150 All hinges, pins and linkages without grease nipples

L L L SAE Grade 40

151 System operation (Para 29) AR AR AR

152 Hose reels drive shaft – I I

153 Rear tank mounting – I I

154 Fuel tank, fuel transfer equipment, safety equipment and bonding reels (Para 39)

I I I

155 TRAM system (Para 44) I I O O O

MKI Water Tanker (Ref Figure 9).

156 Water pump – I I XG-291

157 Water pump outrigger bearing – I I XG-291

158 Tanker barrel bearing mounts(Para 40)

I I I

159 TRAM system (Para 44) I I O O O

MKII Water Tanker (Ref Figure 10).

160 Pneumatic filter/regulator (Para 41)

I I I

161 Pneumatic system lubricator (Para 42)

AR AR AR

162 Handrail – All hinges, pins and linkages not fitted with grease nipples

- I I I I

Legend:A – Adjust, AR – Action Required, B – Bleed, C – Clean, D – Drain and Refill, I – Inspect, L – Lubricate, N/A – No Action, O – Overhaul, R – Replace, T – Top Up, U – Test, Y – Tighten, W – Record



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1. Engine mounts, front 2. Transmission 3. Transfer case4. Transfer case oil filler 5. Propeller shaft universal joint 6. Propeller shaft universal joints7. Clutch and clutch release bearing 8. Engine mounts, rear 9. Clutch cross shaft10. Engine oil filters 11. Engine oil filler 12. Water conditioner13. Water pump housing 14. Coolant

Figure 1 Power Train Servicing Points – Front

1. Front axle differential 9. Front wheel bearings 16. Transfer case selector2. Mudguard hinge pivots 10. Front hub breathers 17. Transfer case linkage support3. Front spring shackle pins 11. Drive hub pivots 18. Spare wheel carrier pivots4. Steering drag link 12. Tie rod ends 19. Winch rope guide roller5. Steering box bearing cap 13. Air cleaners 20. Power steering reservoir6. Steering shaft 14. Front springs 21. Power steering filter7. Constant velocity joints 15. Propeller shaft universal joints 22. Winch cable rollers8. Front brakes

Figure 2 Driveline Servicing Points



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1. Fuel filters 2. Power take off shaft joints 3. Transfer case oil cooler filter4. Winch overload device 5. Winch drive 6. Winch gearbox7. Intermediate axle 8. Rear wheel bearings 9. Rear brakes10. Air spring suspension system 11. Rear axle 12. Air bag filter13. Fuel tanks 14. Winch rope pulleys 15. Pintle hook16. Propeller shaft universal joints 17. Winch drum bearing 18. Winch rope

Figure 3 Driveline Servicing Points – Rear

1. Fresh air intake filter 2. Return air filter 3. Evaporator drain tube4. Receiver dryer 5. Condenser coil 6. Compressor drive belt7. Compressor

Figure 4 Crisp-Air Air Conditioner Servicing Points



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Figure 5 Air Spring Suspension Servicing Points

1. Boom cylinder pivot pins and bushes 2. Hook and pivot 3. Crane control handle pivots4. Outrigger pivots 5. Tilt cylinder pivots and tilt rocker assembly 6. Outrigger control handle pivots7. Pressure reduction oil filter 8. Loader body bearings

Figure 6 HIAB 090 Crane Servicing Points



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1. Rear body pivots 2. Ram pivots 3. Tailgate pivots4. Tip lock assembly pivots 5. Hydraulic oil reservoir

Figure 7 Dump Servicing Points

1. Hydraulic oil reservoir 2. Hydraulic oil filter 3. Fuel pump bearings4. Filling hose reel drive 5. Tank mounting

Figure 8 Fuel Tanker Servicing Points



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Figure 9 MKI Water Tanker Servicing Points



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1. Hydraulic oil filter 4. Tank vent air cleaner 7. Hose reel bearings

2. Hydraulic oil 5. Pneumatic filter/regulator 8. Butterfly valve flanges including vent valves

3. Hydraulic filter/breather 6. Pneumatic system lubricator 9. Butterfly valve actuators

Figure 10 MKII Water Tanker Servicing Points



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General Information

12. The universal joint yoke retaining bolts and washers are to be inspected for serviceability.

13. The mixing ratios for Castrol anti-freeze/anti-boil in the coolant system are as follows:

a. Ambient Temperatures of -12 ºC and Above. Add 15 L of Castrol anti-freeze/anti-boil to 39 L of water to fill the coolant system. To top up the coolant system, use a mixture of 28% of Castrol anti-freeze/anti-boil to 72% water.

b. Ambient Temperatures of -12 ºC to -17 ºC. Add 18 L of Castrol anti-freeze/anti-boil to 36 L of water to fill the coolant system. To top up the coolant system, use a mixture of 33% of Castrol anti-freeze/anti-boil to 67% water.

14. Front wheel bearing oil change:

a. To drain (best results are obtained when the oil is warm):

(1) remove the plug from the outer axle drive flange; and

(2) rotate the hub until the open threaded hole is at the lowest point of rotation.

b. To fill:

(1) rotate the hub until the open threaded hole is on the horizontal centreline of the axle;

(2) fill the hub with lubricant, level to the threaded hole; and

(3) install the plug in the outer axle drive flange.

15. In conjunction with the wheel bearing service at each Alternate Major Service, the front axle half shaft retaining studs are to be checked for security. When loose studs are detected, they are to be removed, inspected (replaced if worn or damaged), threads cleaned and refitted ensuring Loctite 271 is applied to the threads.

Ensure the front axle is supported on safety stands before greasing the drive hub pivots.

16. Jack up the front axle; ensure the wheels are clear of the ground and the axle is supported on safety stands before greasing the drive hub pivots.

17. If cleaning is required, the element is to be serviced in accordance with EMEI Vehicle A 591-1.

18. Check and tighten PTO drive shaft retaining grub screws at each service.

19. Lubricate the winch drive chain using Lubricating Oil, General Purpose, Chain, 250 g Spray Pack, Castrol NSN 9150-66-102-4439.

20. When filling the axle housings, the following procedure must be followed:

a. fill the power divider housing to the filler plug level (inset graphic, Figure 3, Item a) and install the plug;

b. fill both bevel gear housings to the filler plug level (inset graphic, Figure 3, Item b) and install the plugs; and

c. fill both axle housings to the filler plug level (inset graphic, Figure 3, Item c) to the filler plug hub level and install the plug; and

21. During Minor, Major and Alternate Major Services, the fuel tank drain plugs are to be loosened two to three turns and any water allowed to drain away. Re-tighten the drain plugs on completion.

22. The winch rope is to be cleaned using low-pressure fresh water, e.g. garden hose. The winch rope is not to be cleaned using high-pressure cleaners. Once cleaned, the winch rope is to be inspected by a Recovery Mechanic (ECN 226-2) in accordance with EMEI Vehicle D 108 prior to lubricating it with Lubricating Oil, Preservative, Corrosion Inhibited, NSN 9510-99-337-1498.



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When inspecting wheels and tyres, ensure that no JAMAK 1 rims are fitted to the vehicle. Ensure that rim and tyre combinations comply with EMEI Vehicle G 799-23.

23. Inspect the tyres in accordance with EMEI Vehicle A 298-2. Tyres should be changed from front to rear at each service. The spare wheel should be incorporated into the changes at the left rear position.

24. The crane oil filler cap may require replacement more often if the crane is operating in dusty conditions.

25. The crane is to be re-certified after 10 years from manufacture. Thereafter, the re-certification is to be carried out every five years. A copy of the re-certification certificate is to be inserted in the vehicle GM 120 logbook.

26. During the Alternate Major Service, before refilling the hydraulic oil tank with fresh oil, ensure that the hydraulic oil tank suction filter has been replaced.

27. The filter’s outer diameter is 80 mm, length 185 mm, a 50 mm internal thread and is secured internally to the tank at the outlet. The filter’s NSN is 99-528-4990. The filter is identified in RPS 02167-01-01, WDA 003, but not in RPS 02168-01-01.

28. The front and rear tank mountings are to be lubricated at every service. The front mounting has a grease nipple either side and the rear mounting is fitted with one grease nipple centrally located.

29. At every service, operate the tanker and water pump to ensure that all operating cycles are sound and working correctly. Check all O rings, hoses, couplings and nozzles. Report any defects.

30. During Major and Alternate Major Service, inspect the brake lining wear and overhaul the wedge brake assembly in accordance with EMEI Vehicle G 703.

31. Seat belts are to be inspected at every service in accordance with EMEI Vehicle A 548-1.

32. Valve clearance adjustments are to be completed at each Major Service in accordance with EMEI Vehicle G 703. During valve clearance adjustment procedure, the Mack Dynatard contact points are to be inspected for serviceability.

33. Inspect the vehicle jack in accordance with EMEI Workshop H 149-1.

34. Inspect the tailgate/sidegate hinges and hinge mounts in accordance with EMEI Vehicle G 799-27.

35. For maintenance and adjustment procedures of the Crisp-Air air conditioner, refer to EMEI Vehicle G 794-1. During Major Service, recover the refrigerant gas, change the compressor oil and receiver dryer, flush the system, recharge the system and check for leaks.

36. Operation/Integrity Test. Run the air conditioner for 15 minutes at full capacity and check the level of refrigerant in the system. Check the evaporator return air temperature to ensure proper operation. Any repairs required on the system are to be carried out in accordance with EMEI Vehicle G 794-1.

37. This task should only be undertaken after the system operation/integrity test (refer Para 36). Inspect the receiver dryer and replace if required.

38. The crane boom extension slides are to be checked for serviceability and adjusted as necessary.

39. The fuel tank module, fuel transfer equipment, safety equipment and bonding reels are to be inspected and serviced in accordance with EMEI Misc Equip P 009-1.

40. Inspect tanker barrel bearing mounts in accordance with EMEI Vehicle G 759-1.

41. Drain any water from the bowl. For maintenance and adjustment procedures, refer to EMEI Vehicle G 816-1.

42. Check the flow rate; refer to EMEI Vehicle G 816-1.

43. Inspect the equalising beams, transverse beams and hanger brackets as follows:

a. check for cracks or failed welds;

b. check the bushes for separated, extruded or perished rubber;

c. check for movement between the mounting bracket and the beam using a suitable lever (movement is not to exceed 5 mm);










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d. check that bushings are not bent, the rubber is not crushed or the inner tube is not worn or elongated; and

e. check that the scalloped washer on the front beam hanger is correctly aligned (scallop facing the beam) and is not worn. Check the security of the mounting hardware.

44. The TRAM system is subject to periodic servicing and inspection as detailed in EMEI Vehicle A 598. The TRAM system requires an overhaul service every two years.

45. Carry out a road test in accordance with EMEI Vehicle A 029-2.

46. Raise and complete a Technical Inspection (TI) report entering the details of the inspection in Part 2 of the vehicle’s GM 120, placing a copy of the report into the GM 120. The original TI is to be retained with the work order.

ENDDistribution List: VEH G 50.0 – Code 2 (Maint Level)

(Sponsor: CGSVSPO, Med/Hvy B Vehicles)(Authority: EC-006249)

truck, cargo, heavy, mc3 – mack · 2018-03-28 · electrical and mechanical engineering...

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