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TA40 G7
MAINTENANCE MANUAL
Issued by;
Customer Support Department
Terex Equipment Limited
Newhouse Industrial Estate
Motherwell, ML1 5RY
Scotland
www.terex.co.uk
MAINTENANCE MANUAL
SM865
revision 10/2006
THIS PAGE IS INTENTIONALLY LEFT BLANK
TEREX Equipment Limited Maintenance Manual - Introduction
For further information on the subject matter detailed within this Maintenance Manual,
please refer to Terex Equipment Limited Operator Handbooks and Product Parts
Books.
The illustrations, technical information, data and descriptive text in this manual, to the
best of our knowledge, were correct at the time of print. The right to change
specifications, equipment and maintenance instructions at any time without notice, is
reserved as part of the Terex Equipment Limited policy of continuous development
and improvement of the product.
* * * *
2 SM 2419 Rev7 10-06
Section 000-0000
Welding
WARNING
Welding and flame cutting cadmium plated
WARNINGS metals produce odourless fumes which are
Before any welding is done on a machine toxic. Recommended industrial hygiene
equipped with any electronic systems, practice for protection of the welding operator
disconnect the following (if applicable) in this from the cadmium fumes and metallic oxides
order: Battery earth cable, battery supply requires enclosure ventilation specifically
cable, alternator earth cables, alternator supply designed for the welding process. A
cables and electrical connections at the engine respiratory protective device such as the
ECM, transmission ECU, body control lever, M.S.A. 'Gasfoe' respirator with G.M.A. cartridge
hydraulics ECU and cab bulkhead to avoid will provide protection against cadmium,
damage to electrical components. Turn off fumes and metallic oxides. The 'Gasfoe'
battery master switch to isolate the batteries respirator has been approved by the U.S.
before disconnecting any components. Bureau of Mines: Approval number 23B-10,
After welding connect all of the above in the and is designed to protect against gases,
reverse order. vapours, and/or metal fumes.
SM 2172 11-05 1
General Information - Welding Procedure
Section 000-0010
3. Pre-heat area to 100° C (212° F), measured 3 - 4" 3 - 4" either side of repair prior to gouging. On
either side of repair. Avoid local overheating. completion of gouging grind to remove thin carbon
layer.
4. Weld completely using E-7016 electrodes. Care
must be taken to ensure electrodes are protected from 2. Apply dye-penetrant check to ensure crack has
moisture pick-ups at all times. been completely removed.
5. Allow repair weld to cool slowly. 3. Pre-heat area to 200° C (392° F), measured 3 - 4"
either side of repair. Avoid local overheating.
6. Grind and blend repair to original contour. Paint
heat damaged areas. 4. Weld completely using E-7016 electrodes. Care
must be taken to ensure electrodes are protected from
moisture pick-ups at all times.
The following general procedure should be used for
the repair of defects in alloy steel castings and in the 5. On completion of welding, post-heat repair area to
welds joining steel castings. 400° C (752° F), measure 3 - 4" either side of repair.
1. Completely ARC-AIR gouge or grind out the crack 6. If welding has to be interrupted for any reason, e.g.
until sound metal is reached. If ARC-AIR method is overnight, post-heat immediately as in Step 5.
employed, pre-heat area to 200° C (392° F), measure
* * * *
2 SM 2172 11-05
CHASSIS - Frames
Section 100-0010
SM - 3413
DESCRIPTION
The front and rear frames are all-welded high grade Note: For details on the articulation and oscillation
steel fabrications, with rectangular box section beams pivot and procedures for separating the front and rear
forming the main side and cross-members. These frames, refer to Section 100-0020, ARTICULATION
heavy duty structures are designed to withstand the AND OSCILLATION PIVOT.
severe loadings incurred when operating over rough
terrain.
MAINTENANCE
The front frame houses engine, transmission, Note: This section covers maintenance of the front
hydraulic and fuel tanks and carries the cab, front and rear frames only.
suspension and front drive axle. The rear frame
carries the body, body cylinders, rear suspension
system and the rear drive axles. Inspection
Inspect the frames and attached parts at intervals not
Inter-frame oscillation is provided by a robust exceeding 250 hours for cracked or broken welds and
cylindrical coupling, carried on large nylon bushes. bending of the frame. Any defects found should be
Steering is by frame articulation to 45 degrees either repaired before they progress into major failures.
side by two widely spaced vertical pivot pins in taper
roller bearings.
SM 2403 01-06 1
Chassis - Frames
Section 100-0010
* * * *
2 SM 2403 01-06
CHASSIS - Articulation and Oscillation Pivot
Section 100-0020
SM - 3533
25 52 56
50 51 29 56
16 5,6 55
19 7
20
14 27 53 54
8,9
56
17 DETAIL A
42 25
41
45,46,49 39
36,49
45,47,49
1
32
26,56 26,53
30
52,55 54,55 10,26
23
56
38 11
2,3,4 2,3,4
33 60
57,58,59
49,61,62 36,49 40 28 51 18
13
15 8,9
51
31 63
17
50 16
19
19 64-68
44,48,49 43 37,49 16
29
31
35 14 24 8,9
29 15
38
30,23 21,22
34 12
25
10,26
45,46,49 37,49 45,47,49
DESCRIPTION AND OPERATION connecting the drive between the front and rear frames.
The articulation and oscillation pivot allows the front
and rear frames to rotate horizontally (articulation) and Articulation bearings, oscillation bushes, pivot
tilt laterally (oscillation) with respect to each other. It is driveshaft bearing and associated parts can be
also the main load bearing coupling between the two removed, inspected and replaced or renewed by
frames. The pivot assembly houses the driveshaft following the procedures outlined in this section.
SM 2438 01-06 1
Chassis - Articulation and Oscillation Pivot
Section 100-0020
14. Prise out and discard seal (15) from front of the
Removal and Disassembly
housing.
1. Position the vehicle on a level work area and apply
parking brake. 15. Lift out front bearing assembly cup (8) from front
of the housing.
2. Raise body and install body safety prop to secure
body in partially raised position. 16. If bearing replacement is required, use a suitable
puller to remove front and rear bearing assembly
3. Shut down engine and block all wheels securely. cups (8) from the housing.
4. Identify the relationship of the driveline caps to the Note: If either bearing assembly cup or cone (8 or 9)
transmission yoke and front yoke (17). Remove need replacing, they must be replaced as a set.
capscrews and remove driveline from vehicle.
17. If retaining rings (31) need replacing, use a
Note: Take extra care when handling drivelines as suitable drift or puller to remove them from the housing.
any deformity on a rotating mass creates vibration
and excessive wear during any operation. 18.Temporarily install front yoke (17) fully onto front of
driveshaft (14) and suitably restrain to resist rotation.
5. Remove wheel blocks, start engine and steer
vehicle into a full left-hand lock. Shut down engine 19. Remove mounting hardware securing parking
and block all wheels securely. brake disc to brake yoke (18) and remove brake disc.
6. Remove Lockplate (16) , 2 0ff Front bolts (19) & 20. Remove Lockplate (16) , 2 off Rear bolts (19) ,
Front thrust collar (50). Rear Thrust collar (63) & Brake yoke (18) from
driveshaft (14). Identify front and rear ends of
7. Remove and discard 'O' rings (29 & 51) from Thrust driveshaft (14).
collar (50).
21. Remove and discard 'O' rings (29 & 51) from Rear
8. Place a suitable container under the front of the Thrust collar (63).
pivot and pull front yoke (17) from driveshaft (14).
2 SM 2438 01-06
Chassis - Articulation and Oscillation Pivot
Section 100-0020
9 SM - 3143
14
22. Remove and discard seal (15) from driveshaft (14).
Inspection
Note: If either bearing assembly cup or cone (8 or 9) 7. Insert driveshaft (14) into truck end of pivot casing
need replacing, they must be replaced as a set. until bearing assembly cone (9) seats firmly in the
bearing asembly cup (8).
3. Inspect splines of driveshaft (14) and yokes
(17 & 18) for nicks, burrs or excessive wear. Replace 8. Apply loctite (3) to new seal (15) and fit over the
if wear is excessive or splines are nicked. Burrs may driveshaft (14) with seal 'Lip' to bearing side.Press seal
be removed with a fine file or medium India stone. home using a mandrel.
4. Check yokes (17 & 18) for damage in region 9. Apply grease to splines of Front yoke (17) and slide
polished by oil seal lip; even slight damage in this onto the drive shaft (14).
area can cause leakage. Very slight marks may be
polished out with fine emery cloth but it is essential 10. Fit new 'O'-rings ( 29 & 51) to Front thrust collar
that polishing marks are parallel to the seal lip. (50) and fit collar over stub end of driveshaft (14) (align
mating holes). Fit 2 off front bolts (19).
5. Replace all seals and 'O' rings with new parts.
11. Tighten Front bolts (19) ; alternately 1/4 - 1/2 turns,
drawing driveshaft (14) hard against the inner face of
Assembly and Installation Front thrust collar (50). Shaft will be visible through
1. If removed, use a suitable driver and install retaining inspection hole on the collar.
rings (31) into housing, ensuring that they butt hard
against abutment shoulders. 12. Lock Front yoke (17) from rotation by a suitable
method / bar acting on the ground. Torque front bolts
2. Using a suitable driver, install front bearing cup (8) (19) to 54Nm/39 Ibf ft.
into tractor end of pivot casing. Ensure it is firmly
seated & that a 0.05mm (0.002") feeler gauge cannot 13. Using special mandrel (15270104) home locking
be inserted between cup and mating face. plate (16) onto Bolts (19). Remove the clamping bar.
3. Check rear bearing cup (8) is firmly seated in the 14. Slide Rear bearing asembly cone (9) onto rear end
body end of the pivot casing, again ensuring 0.05mm of drive shaft (14) until it seats in bearing assembly
(0.002") feeler gauge cannot be inserted between cup cup (8).
and mating face.
15. Position clamping bar assembly and screw central
4. Lightly oil both bearing assembly cones (9) with SAE bolt hard against bolts (19) of front thrust collar (50),
80W - 90 E. P. gear oil (24). enabling body end bearing to be fully seated home.
5. Support driveshaft (14) in a suitable fixture & tap one 16. Using mandrel and heavy hammer, drive Rear
Bearing assembly cone (9) onto driveshaft (14) using a bearing assembly cone, fully into cup. Now remove
tubular mandrel. clamp bar assembly from front end.
SM 2438 01-06 3
Chassis - Articulation and Oscillation Pivot
Section 100-0020
Sm 3144
'A'
'B' 'D' DEPTH
SHAFT MICROMETER
17. Take remaining seal (15), apply loctite (3) and fit
over drive shaft with seal 'Lip' to bearing side. Press 22. The actual free air space 'E' to be shimmed
seal home using a mandrel. between end of drive shaft (14) and compression face
of Thrust collar (63) equals:
18. Apply grease to splines of brake yoke (18) and
slide onto drive shaft (14). Ensure milled slots of E='D' - 'C'.
driving flanges are aligned with those of brake yoke.
23. Now add 0.6mm (0.024") to dimension 'E' to allow
Note : For Measurment letters- refer to fig. 3, unless for oversize shims. This value is dimension 'F'
otherwise stated. (End float will be determined by subtraction).
19. Before fitting of Rear Thrust collar (63) record 24. Remove Rear bolts (19) and Rear thrust collar (63)
Measurements as stated: from pivot body end and chap drive shaft (14) to free
bearing.
i) Measure total width 'A' of Rear thrust collar (63)
25. Calculate the nominal combination of minimum
ii) Using Depth micrometer, measure inner bore depth number if shims (64) to achieve the size nearest to
'B' of collar (63) and record value. dimension 'F'. Record the appropriate part numbers and
total nominal thickness value.
iii) Subtract 'B' from 'A' to determine recess dimension
'C'. 26. Select the shims (64) and measure the total actual
thickness of the combination. Record this value.
20. Fit Rear thrust collar (63) without 'O'-rings onto
Drive shaft (14) and tighten Rear bolts (19) to a nominal 27. Place the shim pack (64) in the rear thrust collar
torque of 15Nm/11Ibf ft. (63) , lock off the Brake yoke (18) from rotation by
suitable method / bar on ground. Torque bolts (19) to
Note : a gap should be visible between end of shaft full torque.
and inner face of collar.
28. Remove the clamp and spin the yoke (18) to
21. Using a Depth micrometer, measure distance 'D' ensure driveshaft (14) free rotation.
from collar (63) outer face to end face of drive shaft
(14) via the hole in the collar and record the value. 29. Take a magnetic clock gauge located on the flange
of pivot casing, needle acting on rear thrust collar (63)
4 SM 2438 01-06
Chassis - Articulation and Oscillation Pivot
Section 100-0020
end face. Check Brake yoke (18) float movement.
43. Remove plug (25) from underside of oscillation hub
30. Take reading obtained and subtract a figure to drain the cavity between the oscillation hub and
sufficient to give an end float in the range 0.05mm - pivot assembly (1) of any oil that entered while filling
0.15mm (0.002" - 0.006"), reduce shim pack (64) the driveshaft bearing housing.
accordingly.
44. Install plug (25) into filler/level hole on pivot
31. Remove Rear thrust collar (63) and shims (64) and assembly (1). Install gasket (5) and cover plate (6) on
re-assemble with the apporpriate shims. Ensure 'O'- side of oscillation hub, secure with bolts (7) and
rings (29 & 51) are now fitted. washers (20).
32. Lock Brake yoke (18) flange as before ,applying 45. Install plug (25) into cavity drain port on underside
alternate 1/4 -1/2 turns on bolts (19). Torque to 54 Nm of oscillation hub.
(39 Ibf ft).
46. Install parking brake disc protective guard (if fitted)
33. Remove the locking bar and confirm that the and secure with bolts, washers and nuts. Tighten nuts
driveshaft (14) end float is in the range 0.05mm - to a torque of 73 Nm (54 lbf ft).
0.15mm (0.002" - 0.006") by moving the brake yoke
(18) for and aft against the clock gauge. 47. Start engine, raise body, lower body safety prop
and lower body.
34. Adjust and refit the shim pack (63) as necessary.
48. Remove wheel blocks.
35. Float set correctly; Drive home locking plate (16)
using a mandrel (15270104) . Re-check the end float.
ARTICULATION COMPONENTS
36. Install parking brake disc on brake yoke (18) and Numbers in parentheses refer to Fig. 1, unless
secure with bolts and washers. Tighten bolts to a otherwise specified.
torque of 73 Nm (54 lbf ft).
Note: The following procedures assume that only
37. Install parking brake assembly to mounting components associated with articulation require repair.
brackets and secure with bolts, washers and nuts.
Refer to Section 170-0010, PARKING BRAKE AND Note: It is essential that the grease used for articulation
MOUNTING. components is Extreme Pressure Lithium Complex No. 2
(23), as specified in Section 300-0020, LUBRICATION
38. Apply parking brake by turning the hex-head on the SYSTEM.
parking brake actuator fully clockwise.
Note: Tighten all fasteners without special torques
39. Apply Loctite 638 to the threads of capscrews used specified to torques listed in Section 300-0080,
to mount driveline to brake yoke (18). Align match STANDARD BOLT AND NUT TORQUE
marks and install driveline. Tighten capscrews to a SPECIFICATIONS.
torque of 153 Nm (113 lbf ft).
SM 2438 01-06 5
Chassis - Articulation and Oscillation Pivot
Section 100-0020
SM - 008
9. Remove bolt (62), washer (61), large nut (42) and
washer (41) securing upper pin (40).
3. Shut down engine and block all wheels securely. 14. Remove spacer (39) noting orientation to ensure
correct installation.
4. Identify the relationship of the driveline caps to the
transmission yoke and front yoke (17). Remove
capscrews and remove driveline from vehicle. Disassembly
1. Identify seal housings (32, 33, 34 & 35) to ensure
5. Support tractor frame at front and rear with suitably correct location on assembly/installation.
placed stands or timbers so the frame will remain level
during and after pin removal. Note: Seal housings (32, 33, 34 & 35) are not
interchangeable.
6. Remove bolts, washers and pins securing steering
cylinders to pivot. Secure steering cylinders clear of 2. Remove bolts (46 & 47), washers (45), seal housings
pivot. (32, 33, 34 & 35) and upper and lower shims (38).
7. Release the parking brake by turning the hex-head 3. Prise out and discard seals (36 & 37) from the
on the parking brake actuator fully anticlockwise. housings.
6 SM 2438 01-06
Chassis - Articulation and Oscillation Pivot
Section 100-0020
and allow to dry. Connecting Front and Rear Frames
1. Install spacer (39) in upper outer seal housing (32),
2. Check bearing assemblies (30) and spacers, and as noted on removal.
pins (40 & 43) for wear or damage. Renew as
necessary. 2. Smear bearing and pin bores with Extreme Pressure
Lithium Complex No. 2 grease (23).
Note: Bearing assemblies (30) and spacers must be
renewed as a matched set. 3. Attach suitable lifting equipment to pivot/rear frame
assembly. Lifting equipment must prevent pivot from
3. Replace all seals with new parts. oscillating and be capable of pulling pivot/rear frame
assembly to align pivot bearing bores and front frame
Assembly pin bores. Raise lifting equipment to support pivot/rear
frame assembly.
1. Apply Loctite 243 (49) sparingly to bore of seal
housings (32, 33, 34 & 35). 4. Remove blocks from rear wheels and blocking from
pivot/rear frame assembly. Using lifting equipment, pull
2. Using a suitable driver, install seals (36 & 37) into pivot/rear frame assembly to align pivot bearing bores
seal housings (32, 33, 34 & 35) ensuring that the metal and front frame pin bores. Block wheels and block
ring on inside of the seals are not disturbed, and, that pivot/rear frame assembly to remain level and
they are located towards the inside of seal housing. stationary.
3. Apply Loctite 243 (49) to threads of outer seal 5. Freeze upper and lower pins (40 & 43) to ease
housing bolts (46). installation.
4. Place outer seal housings (32 & 34) in position 6. Smear lower pin (43) with Extreme Pressure Lithium
ensuring that grease relief hole in seal housings are Complex No. 2 grease (23) and install through front
directly opposite bearing grease port on pivot. Secure frame and bearing bores.
with bolts (46) and washers (45). Tighten bolts (46) to a
torque of 94 Nm (68 lbf ft). Note: It may be necessary to relieve binding between
the pin and pin bores by raising or lowering pivot/rear
Note: Bearing assemblies (30) and spacers are a frame assembly.
matched set, never interchange cups, cones or
spacers between sets. 7. Apply Loctite 243 (49) to threads of bolt (48) and
secure lower pin (43) with bolt (48) and hardened
5. Using Extreme Pressure Lithium Complex No. 2 washer (44). Tighten bolt (48) to a torque of 73 Nm
grease (23), pack bearing assemblies (30), including (54 lbf ft).
end faces, and install bearings.
8. Smear upper pin (40) with Extreme Pressure Lithium
6. Place inner seal housings (33 & 35) temporarily in Complex No. 2 grease (23) and install through front
position and secure with bolts (47) and washers (45). frame and bearing bores.
Tighten bolts (47) to a torque of 16 Nm (12 lbf ft).
9. Apply Loctite 243 (49) to threads of bolt (62). Secure
7. Using feeler gauges, as shown in Fig. 4, measure upper pin (40) with bolt (62), washer (61), large nut (42)
the dimension between the inner pivot faces and seal and washer (41). Tighten nut (42) to a torque of 1 425
housings (33 & 35). Measure at 3 positions equally Nm (1 050 lbf ft).
spaced around seal housings and determine average
dimension, this is the size of shims (38) required.
Final Assembly
8. Remove bolts (47), washers (45) and inner seal 1. Apply parking brake by turning the hex-head on the
housings (33 & 35). parking brake actuator fully clockwise.
9. Install shims (38) as calculated at Step 7, reinstall 2. Remove lifting equipment from pivot/rear frame
inner seal housings (33 & 35) and secure with bolts assembly.
(47) and washers (45). Tighten bolts (47) to a torque of
94 Nm (68 lbf ft). 3. Remove stands or timbers from front frame.
SM 2438 01-06 7
Chassis - Articulation and Oscillation Pivot
Section 100-0020
SM - 038
4. Apply Loctite 270 to the threads of capscrews used
to mount driveline between transmission yoke and front
yoke (17). Align match marks and install driveline.
Tighten capscrews to a torque of 153 Nm (113 lbf ft).
OSCILLATION COMPONENTS
Disconnecting Front and Rear Frames
Numbers in parentheses refer to Fig. 1.
1. Position the vehicle on a level work area and apply
Note: The following procedure assumes that only parking brake.
components associated with oscillation require repair.
2. Raise body and install body safety prop to secure
Note: It is necessary to disconnect the front and rear body in partially raised position.
frames at the articulation point to service the
oscillation components. 3. Shut down engine and block all wheels securely.
Note: It is essential that the grease used for 4. Depress and release brake pedal continuously to
oscillation components is Extreme Pressure relieve the pressure in the braking system.
Multipurpose Grease (26), as specified in Section 300-
0020, LUBRICATION SYSTEM. 5. Carefully loosen brake lines at base of both
accumulators to check that the pressure has
Note: Tighten all fasteners without special torques released. Re-tighten brake lines.
specified to torques listed in Section 300-0080,
STANDARD BOLT AND NUT TORQUE 6. Tag all hydraulic lines and electrical wiring between
SPECIFICATIONS. front and rear frames to ensure correct assembly/
installation. Disconnect all hydraulic lines and plug
openings to prevent ingress of dirt. Disconnect
WARNINGS electrical wiring and any other attachments which could
To prevent personal injury and property damage, be damaged on separation of front and rear frames.
be sure wheel blocks, blocking materials and
8 SM 2438 01-06
Chassis - Articulation and Oscillation Pivot
Section 100-0020
7. Identify the relationship of the driveline caps to the securing guard to the rear frame. Refer to
transmission yoke and front yoke (17). Remove Section 170-0010, PARKING BRAKE AND
capscrews and remove driveline from the vehicle. MOUNTING.
8. Support tractor frame at front and rear with suitably 2. Remove mounting hardware securing parking brake
placed stands or timbers to keep the frame level during assembly to mounting bracket on frame. Remove and
and after pin removal. secure parking brake assembly clear of brake disc.
9. Remove bolts, washers and pins securing steering 3. Identify the relationship of the driveline caps to
cylinders to pivot. Secure steering cylinders clear of brake yoke (18). Remove capscrews, disconnect
pivot. driveline and secure clear of brake yoke (18).
10. Release the parking brake by turning the hex- 4. Remove mounting hardware securing parking brake
head on the parking brake actuator fully anticlockwise. disc to brake yoke (18) and remove brake disc.
11. Attach suitable lifting equipment to pivot/rear frame 6. Remove Rear bolts (19), Lockplate (16) & Rear
assembly. Lifting equipment must prevent pivot from thrust collar (63). Pull brake yoke (18) from driveshaft
oscillating after separation, and, be capable of pulling (14) .
pivot/rear assembly clear of front frame. Raise lifting
equipment to support pivot/rear frame assembly. 7. Remove adaptor (57), connector (58), elbow (59)
and pipe assembly (60) from oscillation hub.
12. Remove bolt, washer, large nut (42) and washer
(41) securing upper pin (40). 8. Remove bolts (22) and washers (21) securing
locking plate (12). Remove locking plate (12).
13. Remove upper pin (40). If necessary tap upper pin
(40) to ease removal taking care to avoid damaging 9. Restrain pivot assembly (1) to prevent it oscillating,
the threads. by placing a heavy bar between the steering cylinder
mountings. Lock the bar in position using suitable
Note: It may be necessary to relieve binding between trestles or stands. See Fig. 5.
the pin and pin bores by raising or lowering the pivot/
rear frame assembly. 10. Using a suitable tool, remove thrust nut (11). If
wear area of thrust nut (11) is damaged, replace thrust
14. Remove bolt (48) and hardened washer (44) nut (11).
securing lower pin (43). 11. Insert an M20 eyebolt into tapped pad provided on
top of pivot assembly (1) and attach suitable lifting
15. Remove lower pin (43). If necessary tap lower pin equipment.
(43) to ease removal taking care to avoid damaging the 12. Remove pivot restraining bar.
pin.
13. Using lifting equipment, carefully pull pivot
16. Remove blocks from rear wheels and use lifting assembly (1) clear of oscillation hub. Place pivot
equipment to pull pivot/rear frame assembly clear of assembly (1) in a suitable work area for further
the front frame. After moving, block pivot/rear frame disassembly.
assembly and block the wheels.
14. Note position of front 'V' ring (10) to aid in
17. Remove spacer (39) noting orientation to ensure 'Installation'. Remove and discard 'V' ring (10).
correct installation. Cover articulation bearings to
prevent ingress of dirt. 15. Inspect nylon oscillation bushes (2) as described in
'Inspection'. If bushes are to be renewed, proceed with
step 16.
Disassembly
1. Remove protective guard (if fitted) from beneath 16. Remove nylon oscillation bushes (2) with hammer
parking brake disc by removing mounting hardware and chisel.
SM 2438 01-06 9
Chassis - Articulation and Oscillation Pivot
Section 100-0020
Note: The suggested method is to make an axial cut 7. Using suitable lifting equipment, and taking care to
along the bush then to lever the bush in order to prevent damaging bushes (2) or pivot threads, install
collapse it upon itself. pivot assembly (1) into rear frame.
2. Inspect nylon oscillation bushes for wear, scoring, 9 . a) Restrain pivot assembly (1) to prevent it
erosion and 'out of round'. Pay particular attention to oscillating, by placing a heavy bar between the steering
the thrust faces of the bushes which should also be cylinder mountings. Lock the bar in position using
inspected for cracking/splitting. Renew if required. suitable trestles or stands. See Fig. 5.
3. Replace all seals with new parts. b) Secure a suitable tool to pivot thrust nut (11) and
tighten thrust nut (11) until there is no end float/
Assembly clearance at thrust face of either bush. Slacken thrust
nut (11) until pin of the locking plate (12) can be
Numbers in parentheses refer to Fig. 1. inserted in the first available hole in the thrust nut (11).
Note: Tighten all fasteners without special torques c) Secure locking plate (12) with bolts (22) and
specified to torques listed in Section 300-0080, lockwashers (21). Torque tighten bolts (22) to 94 Nm
STANDARD BOLT AND NUT TORQUE (69 lbf ft).
SPECIFICATIONS.
10. Install adaptor (57), connector (58), elbow (59) and
pipe assembly (60) to oscillation hub.
WARNING
To prevent personal injury and property 11. Install brake yoke (18) on driveshaft (14) until it
damage, be sure wheel blocks are properly butts against bearing assembly cup and cone (8 & 9).
secured and of adequate capacity to do the job
safely. 12. Install parking brake disc on brake yoke (18) and
secure with bolts, washers and nuts. Tighten bolts to a
1. Wipe bush housing clean using a suitable solvent torque of 73 Nm (54 lbf ft).
and allow to dry.
13. Install rear of driveshaft (14).
2. Apply Loctite 648 (3) and Loc Quick Primer (4) and
align new bushes (2) to housing with grease holes 14. install Brake yoke (18) , Rear thrust collar (63)
aligned vertically and identification 'PAINT DOT' at Top ensuring 'O'-rings (29& 51) are in place , shim pack (64)
Dead Centre. Refer to Fig. 6. Drift bushes (2) into and bolts (19).
housing using hammer with soft packing for protection.
10 SM 2438 01-06
Chassis - Articulation and Oscillation Pivot
Section 100-0020
15. Lock off Brake yoke flange as before (18) with 8. Smear upper pin (40) with Extreme Pressure Lithium
suitable clamping method. Torque bolts (19) to 73 Nm Complex No. 2 grease (23) and install through front
(Ibf ft) frame and bearing bores.
Note: It may be necessary to relieve binding between 7. Align steering cylinder bores and mounting pin bores
the pin and pin bores by raising or lowering pivot/rear on pivot. Install pins and secure with bolts and washers.
frame assembly. Tighten bolts to a torque of 73 Nm (54 lbf ft).
6. Smear lower pin (43) with Extreme Pressure Lithium 8. Connect hydraulic lines and electrical wiring as
Complex No. 2 grease (23) and install through front noted on disassembly.
frame and bearing bores.
9. Remove bolts (7), washers (20), gasket (5) and
7. Apply Loctite 243 (49) to threads of bolt (48). Secure cover plate (6) from side of oscillation hub to gain
lower pin (43) with bolt (48) and hardened washer (44). access to filler/level plug (25) on pivot assembly (1).
Tighten bolt (48) to a torque of 73 Nm Remove filler/level plug (25).
(54 lbf ft).
SM 2438 01-06 11
Chassis - Articulation and Oscillation Pivot
Section 100-0020
(26) to oscillation bushing lube fittings (55) on top of
10. Add SAE 80W - 90 E. P. gear oil (24) through filler/ oscillation hub. Lube until excess grease in seen.
level hole in pivot assembly (1) until the oil is level with
the bottom of filler/level hole.
WARNING
11. Remove plug (25) from underside of oscillation hub To prevent personal injury and property
to drain the cavity between the oscillation hub and damage, be sure wheel blocks are properly
pivot assembly (1) of any oil that entered while filling secured and of adequate capacity to do the job
the driveshaft bearing housing. safely.
12. Install plug (25) in filler/level hole on pivot Every 250 hours, check the end float/clearance at the
assembly (1). Install gasket (5) and cover plate (6) on thrust face of the oscillation bushes. Any clearance
side of oscillation hub, secure with bolts (7) and found must be removed by adjustment of the thrust
washers (20). nut, as described in step 9 of 'Assembly' procedure.
13. Install plug (25) in cavity drain port on underside of Note: A practical method of establishing the effective
oscillation hub. adjustment of the thrust nut is to use movement of the
machines body in the raised position. Move the body
14. Remove plugs (28) from articulation bearing grease from fully raised to almost fully raised while watching
ports and replace with lube fittings (27). the effect of this action on the frame and pivot
arrangement. Any slackness between the thrust nut
Note: Lube fittings (27) are stored on pad on side of and thrust faces will be clearly visible movement of the
pivot assembly (1). frame.
15. Fill bearing housings with Extreme Pressure Every 1 000 hours (6 months), follow the procedure
Lithium Complex No. 2 grease (23) through lube fittings given below to check the oil level in the driveshaft
(27) until excess grease starts to escape from seal bearing housing, and, lubricate the articulation and
housings (32 & 34). oscillation bearings.
16. Remove lube fittings (27) and reinstall plugs (28). Note: It is essential that the grease used for
Store grease fittings (27) on pad on side of pivot articulation components is Extreme Pressure Lithium
assembly (1). Complex No. 2 grease (23), as specified in Section
300-0020, LUBRICATION SYSTEM.
17. Add Extreme Pressure Multipurpose grease (26) to
oscillation bushing lube fittings (55) on top of oscillation 1. Position the vehicle on a level work area and apply
hub. Lube until excess grease in seen. parking brake.
18. Install parking brake disc protective guard (if fitted) 2. Raise body and install body safety prop to secure
and secure with bolts, washers and nuts. Tighten nuts body in partially raised position.
to a torque of 73 Nm (54 lbf ft).
3. Shut down engine and block all wheels securely.
19. Start engine to charge hydraulic systems, raise
body, lower body safety prop and lower the body. 4. Remove protective guard (if fitted) from beneath
parking brake disc by removing nuts, washers and
20. Bleed the braking system as described in Section bolts securing guard to rear frame.
165-0010, BRAKE PARTS.
5. Remove bolts (7), washers (20), gasket (5) and
21. Remove wheel blocks. cover plate (6) from side of oscillation hub to gain
access to filler/level plug (25) on pivot assembly (1).
Remove filler/level plug (25).
MAINTENANCE
Numbers in parentheses refer to Fig. 1. 6. Add SAE 80W - 90 E. P. gear oil (24) through filler/
level hole in pivot assembly (1) until the oil is level with
Every 250 hours, oscillation bushes must be the bottom of filler/level hole.
lubricated. Add Extreme Pressure Multipurpose grease
12 SM 2438 01-06
Section 100-0020
SPECIAL TOOLS
Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of the thrust nut tool and general service tools
and adhesives required for procedures outlined in this
section. These tools and adhesives are available from
your dealer.
SM 2438 01-06 13
Chassis - Articulation and Oscillation Pivot
Section 100-0020
* * * *
14 SM 2438 01-06
Section 100-0040
SM 2383 05-06 1
Engine - Air Cleaner
Section 110-0050
SM - 3416
15
AIR FILTER ELEMENT
WARNING SYMBOL
12 20 19 18 17
11 9
10
8
14 16 13
7
6
1
2 5
4
3
5
2 SM 2404 01-06
Engine - Air Cleaner
Section 110-0050
10. Blank off all open ends with tape or cardboard to b. Check that air cleaner is mounted securely to the
prevent entry of dirt. RH fender support brackets.
Disassembly
Numbers in parentheses refer to Fig. 1, unless WARNING
otherwise specified. Always shutdown the engine before servicing
air cleaner.
Note: Air cleaner body (1) should be thoroughly
cleaned twice a year. Do not apply heat in any form to Check Visual display unit for air filter / element warning
air cleaner body (1). symbol. The air cleaner elements should be serviced
when the maximum allowable restriction has been
1. Release latches on cover assembly (6) and remove reached. The elements should not be serviced on the
cover assembly from air cleaner body (1). basis of visual observation as this would lead to over
service. When restriction readings finally indicate a
2. Remove primary element (2) and safety element (3) change, remove primary element (2) carefully and
from air cleaner body (1). clean/replace as required. Refer to 'Primary Element'.
3. Open mounting bands (5) and remove from air Never attempt to clean safety element (3). Change
cleaner body (1). safety element (3) after every third primary element (2)
service.
4. Slacken clamp (8), from the top port on the RH
fender and remove rain cap (8) from the RH fender. Make sure vacuator valve (4) is not damaged or
plugged and that the joint with cover assembly (6) is
5. Blank off air cleaner body (1) outlets with tape or not broken. If vacuator valve (4) is lost or damaged,
cardboard. Reach inside body with a compressed air replace it to maintain pre-cleaner efficiency and normal
nozzle or brush and remove dust from the body. filter element service life.
6. Remove all loose dust from air cleaner body (1) and Check condition of clamp (8), clamps (3,5 & 7, Fig. 2),
remove tape or cardboard from body outlets. elbow (4, Fig. 2) and air intake tube (1 Fig. 2). Tighten/
replace as necessary.
Assembly/Installation
Numbers in parentheses refer to Fig. 2, unless
otherwise specified. Primary Element
Numbers in parentheses refer to Fig. 1.
Note: Tighten all fasteners to standard torques listed in
Section 300-0080, STANDARD BOLT AND NUT Although a paper primary element (2) is used, it is
TORQUE SPECIFICATIONS. possible to remove excess dirt by tapping element.
Assembly and installation of the air cleaner assembly 1. Release latches on cover assembly (6) and remove
is the reverse of disassembly and removal. Reset air cover assembly from air cleaner body (1).
restriction gauge (17).
2. Remove primary element (2) from air cleaner body (1)
Following installation, but before starting the engine, and clean/replace. It is advised to replace the element
the following system checks should be carried out: rather than attempt to clean thoroughly.
a. Check air intake tube (1), elbow (4) and hose (2) for 3. Using a damp cloth and a suitable solvent, wipe out
defects and that clamps (3,5 & 7) (and those supplied all excess dust from air cleaner body (1) and allow to
with the engine) are securely tightened to ensure that dry.
there are no leaks in the system. 4. Install primary element (2) in air cleaner body (1).
SM 2404 01-06 3
Engine - Air Cleaner
Section 110-0050
* * * *
4 SM 2404 01-06
Transmission - Transmission and Mounting
Section 120-0010
SM - 3486
16 19
20
17 12
18 21
13 22
14 23
15
14
6
6
5
10 5
11 10
3 11
RH 2
LH
8
9 24
9
8
24
1
1
25
4
7 4
26 7
DESCRIPTION
secured via mounting brackets (2 & 3, Fig. 1) on either
Numbers in parentheses refer to Fig. 1.
side of the transmission. Isolation mounts (1) provide
sufficient flexibility to absorb varying transmission
For transmission make, model and specification, refer
vibration and torsional loads.
to Section 000-0000, GENERAL INFORMATION. For
transmission servicing and repair data refer to
The transmission consists of a number of major
transmission manufacturer service manual.
assembly 'modules'. Integral with the transmission
assembly are torque converter and planetary gearing
The transmission convertor housing module is close-
modules.There are six forward gears, one reverse gear
coupled to the engine output flywheel housing, as the
and a neutral position, with automatic lockup in all
engine is secured to the chassis frame via isolation
speed ranges. Operation of the transmission is
mounts at it's front, refer to Section 110-0030 ENGINE
signalled by the electric shift control via the 4th GEN
AND MOUNTING for specific arrangement details, this
CONTROL system.
in turn means that the front of the transmission is
secured in place. At its rear, the transmission is
SM 2416 05-06 1
Transmission - Transmission and Mounting
Section 120-0010
SM - 3487
4 5 6 7 10
8 9
1
11
12
2
20
3
13
17
14
x
18
16 15
19
2 SM 2416 05-06
Transmission - Transmission and Mounting
Section 120-0010
through which the turbine shaft passes to the rotating Output Retarder module
clutch assembly. The charging pump pressurizes the The output retarder module is to assist in stopping the
transmission fluid. Charging pump rotates with engine vehicle and controlling the downhill speed of the
to provide a constant flow of pressurized fluid for the vehicle.
transmission hydraulic system.
ELECTRO-HYDRAULIC CONTROL MODULE (15)
GEARBOX MODULES
The basic gearbox modules contain five clutch The control module houses the solenoids, sensors,
assemblies and three planetary gear sets to provide six valves and regulators that control the pressure and flow
forward speeds, neutral and one reverse. of the transmission fluid to the clutches, the torque
convertor and the lubricating/ cooling hydraulic circuits.
Rotating Clutch module The control module also houses the transmission fluid
The rotating clutch (16) hub assembly is spilined to the filters.
turbine shaft (17) and rotates with the turbine (1). The
rotating clutch module contains the turbine shaft
assembly, rotating clutch hub assembly, C1 and C2 (6 TRANSMISSION CONTROL MODULE
& 7) clutch assemblies, rotating clutch drum and sun (TCM).
gear drive hub assembly for the P1 planetary gear set.
Refer to Figures 3 & 4 unless otherwise stated.
Main Housing module SM - 3489
The main housing module consists of the C3, C4 and
C5 clutches (8,9 & 10), ring gear component of the P1
planetary gear set and the transmission main housing.
The clutches in the main housing are stationary clutch
assemblies and do not rotate when hydraulically
applied. The ECU signals solenoid valves in the control
module to apply and release clutches based on power
and speed requirements.
Fig. 3 - Transmission Control Module (TCM).
P1Planetary Gear module (11)
P1 is the first planetary gear set assembly, consisting WARNING
of - sun gear driven by the rotating clutch drum. P1
carrier assembly containing P1 pinion gears and the P1 Heatsink of the TCM must be electrically
ring gear housed in the C3 clutch assembly. isolated from all vehicle electrical systems
including chassis ground!
P2 Planetary Gear module (12)
P2 is the second planetary gear set assembly, The transmission control module is the "brain" of the
consisting of a sun gear splined to the main shaft. P2 system. The independent controller is configured to run
carrier assembly containing the P2 pinion gears and P2 off 24V. The TCM receives and processes signals from
ring gear splined to P1 carrier. various switches and sensors. These inputs are
processed and the TCM determines the optimum shift
Main Shaft module 13) sequences, timing and clutch apply / release
The main shaft module passes through the centre of pressures. This is done by controlling the transmission
the transmission gearbox. The P2 and P3 sun gears solenoids and valves.
are part of or splined to the main shaft, enabling it to SM - 3488
transmit torque to the rotating clutch module. Input SHIFT SELECTOR
shaft provides the primary path for transmitting torque THROTTLE POSITION SENSOR SOLENOIDS
through the various stages of the transmission. RETARDER MODULATION TCM DIAGNOSTIC PRESSURE SWITCH
VEHICLE/ENGINE
TEMPERATURE SENSOR
COMMUNICATION LINKS
(SUMP / RETARDER)
OUTPUT MODULES
The output modules contain components that transmit
power and torque to the vehicle driveline. The output INPUTS OUTPUTS
SM 2416 05-06 3
Transmission - Transmission and Mounting
Section 120-0010
SM - 3490
6
9
1
2 8
9
3 4
7
4 SM 2416 05-06
Transmission - Transmission and Mounting
Section 120-0010
SM - 3597
5
4
6
7 3
2
1
OPERATION SM - 3491
1
2
3
DE
4
CT
Generation controls and shift selector lever. The shift
MO
5
LE
D
SE
N
R
selector communicates with the transmission TCM via
OR
NIT
the J1939 datalink. The shift selector is a remote
MO
mounted lever type. The selector has a 2-digit LED 2
display, that during normal operation will display the 3
range selected and range attained.
4
5
There is a hold override button (1) that must be
pressed when shifting between R,N and D. The hold
override button (1) is released when the desired 1 - Hold/Override Button 4 - Range Attained
2 - Mode Button 5 - Display Mode Button
selector position is reached. The selector can move 3 - Range Selected
freely between D and the number ranges without
pressing the override button.
Fig. 7 - 4th Gen Gear Shift Lever
The transmission upshifts and downshifts
automatically between first range and the highest range
Failure to meet any of the conditions 1-4 previously
selected on the selector in direct response to throttle
listed, will stop the 2 minute countdown and the shift
position and transmission output speed. When reverse
lever will display one of the following codes-
range is selected, the reverse alarm sounds and the
reverse light illuminates at the rear of the truck.
oL0X Setting time too short.
oL50 Engine RPM too low.
The shift selector can be used to display a number of
oL59 Engine RPM too high.
parameters, including oil level information and
oL65 Neutral not selected.
transmission fault code information.
oL70 Sump fluid temperature too low.
oL79 Sump fluid temperature too high.
Displaying Oil Level Information (OLS) oL89 Output shaft rotation detected.
oL95 Oil level sensor failed.
To enter the oil information sequence, press the
display mode (5) button once on the gear shift lever. A Displaying Diagnostic Fault codes
2 minute countdown begins when the following Should there be a transmission fault, the check
conditions are met - 1.Engine at idle, 2. Oil at operating transmission warning light will illuminate at the top of
temp 82-104°C, 3. transmission in neutral and 4. the instrument panel bank of warning symbols,
transmission output shaft stationary. indicating that the TCM has registered a diagnostic
code. As many as five codes may be recorded in
The oil level will be displayed at the end of the 2
memory, listed in order of newest to oldest. In which
minute countdown (to facilitate constant oil drain back).
case, fault codes can be retrieved through the 4th Gen
During the countdown, the display flashes out a
shift selector lever.
numerical value starting at '8' in 15 second intervals,
decreasing in value by 1 each time in sequence i.e. To enter the diagnostic code sequence, press the
8,7,6,5,4,3,2 & 1. After the number sequence the display mode button (5), twice on the shift lever. Each
display will then sequentially flash the oil level code consists of 4 sequential elements; each being 1
information, 2 characters at a time; the following may or 2 characters. The display for each code will repeat
be displayed: continuously until the next code is displayed (if
oL ; oK Oil level OK present). To display the next code if present, press the
oL ; Lo Oil level low 1 quart- or as many as req. mode button (2). The following cycle illustrates the
oL ; HI Oil level high 1 quart- or as many as req. display cycle:
(1 US quart = 0.95Litre = 0.2 gallon).
6 SM 2416 05-06
Transmission - Transmission and Mounting
Section 120-0010
d1 Code list position (d1 newest, d5 oldest). The retarder may be used at any time to slow the
P Code type. vehicle down. If additional braking is required apply the
service brakes.
25 Main code.
34 Sub code. Note: The retarder is not meant for bringing the vehicle
Code repeats until the next code (d2) is accessed by to a stop, service brakes should be used for stopping.
pressing the mode button (5)
The retarder consists of a stator, rotor, housing and
Clearing Diagnostic Fault codes control valve body assembly. The rotor is splined to
the transmission output shaft and is driven at output
To clear active codes, press and hold the mode button
shaft speed. The retarder stator, rotor and housing all
(2) for 3 to five seconds. Similarly to clear inactive fault
have integral vanes. The rotor rotates between the
codes, press and hold the mode button (2) for 8 to 10
stationary stator and retarder housing.
seconds.
Exiting Diagnostic mode Retardation occurs when the retarder housing is filled
with transmission fluid and pressurized, thus impeding
Any of the following methods may be used to exit the and slowing the rotor, output shaft and vehicle.
diagnostic display mode -
\ Momentarily press the display mode button (5). For the retarder to engage, certain conditions must be
satisfied:
Move the gearshift lever to any other position that the
one selected when the diagnostic display mode was 1. Accelerator released.
activated. 2. Transmission 'STOP' warning light must be out.
4 Wait until time out (approx. 10 minutes). The system 3. Transmission must be in lockup.
automatically returns to normal operating mode.
Turn the vehicle off - Eliminating power to SM - 3492
transmission ECU.
L
The primary shift schedule is the default setting each Fig. 8 - Retarder Req. Sw / Percentage Lever.
time the vehicle is started. This is used for normal
operation. The secondary shift schedule can be
requested by pressing the Mode button. A small red To apply the retarder, the dash mounted retarder
light next to the mode button indicates that the function request switch must be on (1, Fig. 8). A signal is then
has been selected. sent to the TCM to request retarder operation, when all
conditions are met.
Transmission Retarder
The amount of retardation requested, is operator
The transmission retarder is used to assist in stopping dependant. This is done via the six-position lever on
the vehicle and reduce the need for service brake the right hand switch bank (2, Fig. 8). With maximum
applications, thus reducing service brake ware and retardation requested in the lowest position.
preventing overheating.
SM 2416 05-06 7
8
Section 120-0010
Transmission - Transmission and Mounting
Gear activation
The following table shows the condition of the individual solenoids, switched and latch valves to attain the full range of gears from the transmission. Note:
Intermediate stages i.e. neutral to reverse, have been ommitted, only the range attained is listed. For where to check pressure setting and measure
pressure values, see following detail.
Range Attained Solenoid Energised Latch Valve Position PS1 position Main Mod Press. Solenoid. SS1 Clutch apply
PCS1 PCS2 PCS3 PCS4 C1 C2 Open Closed Energised De-energized Energized
Neutral X X X Up Up X X C5
1st X X Down Up X X C1 + C5
6th X X Up Down X X C2 + C4
Reverse X X Up Up X X C3 + C5
Main pressure modulation is checked at idle in Neutral, reverse, 1st convertor and second convertor. Main modulation pressure is checked at high speed
in neutral only. RPM in range 1780 - 1820.
SM 2416 05-06
Transmission - Transmission and Mounting
Section 120-0010
SM - 3493
MAIN
C4 C5
C3
C1 C2
MAIN
LUBE
OIL FILTER
COVERS
PRESSURE CHECKS
Note: Check to see if there are diagnostic codes 2. Bring the transmission to normal operating
present that are related to the transmission temperature of 71 - 93 Deg. Celcius (160- 200 Deg F).
difficulty which is being experienced. Proceed to Check for fluid leaks in the circuit being checked. Be
make mechanical preparations for checking clutch sure that fluid level is correct.
pressures only after codes have been evaluated
first. 3. Compare clutch pressures recorder with those given
in the table. If clutch pressures are not within
Checking individual clutch pressures helps to specification take corrective action to redeem the fault.
determine if a transmission malfunction is due to a
mechanical or an electrical problem. Properly making 4. Main pressure modulation is checked in neutral,
these pressure checks requires transmission and reverse, 1st and 2nd converter.
vehicle preparation, recording of data and comparing
data against specifications provided. 5. Main pressure modulation is checked at high speed
in neutral only.
1. Remove plug from the pressure tap and install a
suitable hydraulic fitting and pressure gauge at location Refer to the following tables on pages 10 & 11, which
where measurement is desired. Pressure gauge set should be used as reference for checking pressures
J26417-A is available. and troubleshooting the system.
WARNING
Be sure that the transmission has enough fluid
for cold operation until an operating fluid level
can be set.
SM 2416 05-06 9
Transmission - Transmission and Mounting
Section 120-0010
SM - 3562A
Engine Range Clutches Main Press. Range Clutch Conv.Out Lube LU Clutch
RPM Applied Spec. Press. Spec* Press. Spec Press. Spec Press. Spec*
0 - 5.8 (C5)
0 - 5.8 (C4)
0 - 5.8 (C5)
0 - 5.8 (C4)
0 - 5.8 (C4)
0 - 5.8 (C3)
0 - 5.8 (C3)
0 -10 (C2)
0 -10 (C2)
0 - 5.8 (C3)
0 -5.8 (C3)
0 - 5.8 (C3)
0 - 5.8 (C4)
* Subtract clutch pressure from main pressure; the difference must fall within the specification given.
10 SM 2416 05-06
Transmission - Transmission and Mounting
Section 120-0010
SM - 3496
No. COLOUR WIRE# DESCRIPTION
61
41
21
1
15 W 115 Retarder Solenoid High
16 U 116 Oil Level Sensor Low
20 U 120 Turbine Speed Sensor Low
21 G 121 Anti Lock Brake Low
24 W 124 GPO5 - Retarder indicator
25 TAN 125 Speedometer Signal
26 Y 126 CAN 2 Controller termination (J1939)
27 G 127 CAN 2 Controller , Low (-) (J1939)
28 Y 128 CAN 1 Controller, High (+) (J1939)
29 G 129 Check Transmission Low
30 W 130 GPO1 - PTO Enable
31 Y 131 Retarder Solenoid
32 W 132 Diagnostic driver (J1708)
33 Y 133 PCS3 Solenoid Low
35 U 135 Engine Water temperature
36 O 136 PCS1 Solenoid Low
37 W 137 TCC Solenoid Low
39 O 139 Engine Speed Sensor Low
40 G 140 Output Speed Sensor Low
41 TN 141 Neutral Start High
42 W 142 GPI5 - Auxilliary Hold
43 U 143 GPI3 - PTO Enable
44 U 144 PWM Throttle signal
45 O 145 GPO3 - Engine Overspeed Indicator
47 G 147 CAN 2 Controller , Low (-) (J1939)
48 Y 148 CAN 1 Controller , High (+) (J1939)
49 - 149 CAN 1 Controller Shield
51 W 151 SS1 Shift Solenoid
52 G 152 PCS2 Solenoid
54 TN 154 Sump Temperature Signal
55 W 155 PCS4 Solenoid
56 Y 156 Retarder Modulation Request
57 W 157 Engine Brk enable / Preselect request
58 G 158 Analogue Return
59 TN 159 Engine Speed Sensor High
80
60
40
20
SM 2416 05-06 11
Transmission - Transmission and Mounting
Section 120-0010
12 SM 2416 05-06
Transmission - Transmission and Mounting
Section 120-0010
SM 2416 05-06 13
Transmission - Transmission and Mounting
Section 120-0010
14 SM 2416 05-06
Transmission - Transmission and Mounting
Section 120-0010
SM 2416 05-06 15
Transmission - Transmission and Mounting
Section 120-0010
SM - 3502
14. Disconnect driveline connected from transmission and attach a hoist to make sure lifting attachments are
to dropbox and secure clear of the transmission. Refer placed so that the transmission is balanced.
to Section 130-0010, DRIVELINES.
20. Remove bell-housing bolts. Loosen off two engine /
15. Disconnect pressure and suction hoses from main transmission mounts and retract transmission via
hydraulic pump. Identify and tag hydraulic lines holding bracket , approximately 3" to separate.
Note: Access to suction hose is limited; use a suitable 21. Lift transmission Clear of chassis frame and
10mm ball end allen key with extension for removal. engine.
17. Remove npt plug from engine 3/4" sq. drive, 1. Remove 8-off mounting bolts (1) securing PTO to
situated below starter motor to access 12 bolts holding transmission LHS.
flex plate damper, which connects the engine to
transmission. 2. Remove PTO (2) and gasket (3). Inspect PTO
studs for damage and remove if necessary.
18. Engine crank has to be turned, to allow access to
the 12-off bolts. Use special tool 15502496. 3. Remove bolts (16) retaining oil fill tube hose to
clamp over top of transmission. Remove bracket, fill
19. Mount holding bracket 15502498 to transmission tube, seal and dipstick from transmission.
SM 2416 05-06 17
Engine - Air Cleaner
Section 110-0050
SM - 3416
15
AIR FILTER ELEMENT
WARNING SYMBOL
12 20 19 18 17
11 9
10
8
14 16 13
7
6
1
2 5
4
3
5
2 SM 2404 01-06
Engine - Air Cleaner
Section 110-0050
10. Blank off all open ends with tape or cardboard to b. Check that air cleaner is mounted securely to the
prevent entry of dirt. RH fender support brackets.
Disassembly
Numbers in parentheses refer to Fig. 1, unless WARNING
otherwise specified. Always shutdown the engine before servicing
air cleaner.
Note: Air cleaner body (1) should be thoroughly
cleaned twice a year. Do not apply heat in any form to Check Visual display unit for air filter / element warning
air cleaner body (1). symbol. The air cleaner elements should be serviced
when the maximum allowable restriction has been
1. Release latches on cover assembly (6) and remove reached. The elements should not be serviced on the
cover assembly from air cleaner body (1). basis of visual observation as this would lead to over
service. When restriction readings finally indicate a
2. Remove primary element (2) and safety element (3) change, remove primary element (2) carefully and
from air cleaner body (1). clean/replace as required. Refer to 'Primary Element'.
3. Open mounting bands (5) and remove from air Never attempt to clean safety element (3). Change
cleaner body (1). safety element (3) after every third primary element (2)
service.
4. Slacken clamp (8), from the top port on the RH
fender and remove rain cap (8) from the RH fender. Make sure vacuator valve (4) is not damaged or
plugged and that the joint with cover assembly (6) is
5. Blank off air cleaner body (1) outlets with tape or not broken. If vacuator valve (4) is lost or damaged,
cardboard. Reach inside body with a compressed air replace it to maintain pre-cleaner efficiency and normal
nozzle or brush and remove dust from the body. filter element service life.
6. Remove all loose dust from air cleaner body (1) and Check condition of clamp (8), clamps (3,5 & 7, Fig. 2),
remove tape or cardboard from body outlets. elbow (4, Fig. 2) and air intake tube (1 Fig. 2). Tighten/
replace as necessary.
Assembly/Installation
Numbers in parentheses refer to Fig. 2, unless
otherwise specified. Primary Element
Numbers in parentheses refer to Fig. 1.
Note: Tighten all fasteners to standard torques listed in
Section 300-0080, STANDARD BOLT AND NUT Although a paper primary element (2) is used, it is
TORQUE SPECIFICATIONS. possible to remove excess dirt by tapping element.
Assembly and installation of the air cleaner assembly 1. Release latches on cover assembly (6) and remove
is the reverse of disassembly and removal. Reset air cover assembly from air cleaner body (1).
restriction gauge (17).
2. Remove primary element (2) from air cleaner body (1)
Following installation, but before starting the engine, and clean/replace. It is advised to replace the element
the following system checks should be carried out: rather than attempt to clean thoroughly.
a. Check air intake tube (1), elbow (4) and hose (2) for 3. Using a damp cloth and a suitable solvent, wipe out
defects and that clamps (3,5 & 7) (and those supplied all excess dust from air cleaner body (1) and allow to
with the engine) are securely tightened to ensure that dry.
there are no leaks in the system. 4. Install primary element (2) in air cleaner body (1).
SM 2404 01-06 3
Engine - Air Cleaner
Section 110-0050
* * * *
4 SM 2404 01-06
Transmission - Transmission and Mounting
Section 120-0010
SM - 3486
16 19
20
17 12
18 21
13 22
14 23
15
14
6
6
5
10 5
11 10
3 11
RH 2
LH
8
9 24
9
8
24
1
1
25
4
7 4
26 7
DESCRIPTION
secured via mounting brackets (2 & 3, Fig. 1) on either
Numbers in parentheses refer to Fig. 1.
side of the transmission. Isolation mounts (1) provide
sufficient flexibility to absorb varying transmission
For transmission make, model and specification, refer
vibration and torsional loads.
to Section 000-0000, GENERAL INFORMATION. For
transmission servicing and repair data refer to
The transmission consists of a number of major
transmission manufacturer service manual.
assembly 'modules'. Integral with the transmission
assembly are torque converter and planetary gearing
The transmission convertor housing module is close-
modules.There are six forward gears, one reverse gear
coupled to the engine output flywheel housing, as the
and a neutral position, with automatic lockup in all
engine is secured to the chassis frame via isolation
speed ranges. Operation of the transmission is
mounts at it's front, refer to Section 110-0030 ENGINE
signalled by the electric shift control via the 4th GEN
AND MOUNTING for specific arrangement details, this
CONTROL system.
in turn means that the front of the transmission is
secured in place. At its rear, the transmission is
SM 2416 05-06 1
Transmission - Transmission and Mounting
Section 120-0010
SM - 3487
4 5 6 7 10
8 9
1
11
12
2
20
3
13
17
14
x
18
16 15
19
2 SM 2416 05-06
Transmission - Transmission and Mounting
Section 120-0010
through which the turbine shaft passes to the rotating Output Retarder module
clutch assembly. The charging pump pressurizes the The output retarder module is to assist in stopping the
transmission fluid. Charging pump rotates with engine vehicle and controlling the downhill speed of the
to provide a constant flow of pressurized fluid for the vehicle.
transmission hydraulic system.
ELECTRO-HYDRAULIC CONTROL MODULE (15)
GEARBOX MODULES
The basic gearbox modules contain five clutch The control module houses the solenoids, sensors,
assemblies and three planetary gear sets to provide six valves and regulators that control the pressure and flow
forward speeds, neutral and one reverse. of the transmission fluid to the clutches, the torque
convertor and the lubricating/ cooling hydraulic circuits.
Rotating Clutch module The control module also houses the transmission fluid
The rotating clutch (16) hub assembly is spilined to the filters.
turbine shaft (17) and rotates with the turbine (1). The
rotating clutch module contains the turbine shaft
assembly, rotating clutch hub assembly, C1 and C2 (6 TRANSMISSION CONTROL MODULE
& 7) clutch assemblies, rotating clutch drum and sun (TCM).
gear drive hub assembly for the P1 planetary gear set.
Refer to Figures 3 & 4 unless otherwise stated.
Main Housing module SM - 3489
The main housing module consists of the C3, C4 and
C5 clutches (8,9 & 10), ring gear component of the P1
planetary gear set and the transmission main housing.
The clutches in the main housing are stationary clutch
assemblies and do not rotate when hydraulically
applied. The ECU signals solenoid valves in the control
module to apply and release clutches based on power
and speed requirements.
Fig. 3 - Transmission Control Module (TCM).
P1Planetary Gear module (11)
P1 is the first planetary gear set assembly, consisting WARNING
of - sun gear driven by the rotating clutch drum. P1
carrier assembly containing P1 pinion gears and the P1 Heatsink of the TCM must be electrically
ring gear housed in the C3 clutch assembly. isolated from all vehicle electrical systems
including chassis ground!
P2 Planetary Gear module (12)
P2 is the second planetary gear set assembly, The transmission control module is the "brain" of the
consisting of a sun gear splined to the main shaft. P2 system. The independent controller is configured to run
carrier assembly containing the P2 pinion gears and P2 off 24V. The TCM receives and processes signals from
ring gear splined to P1 carrier. various switches and sensors. These inputs are
processed and the TCM determines the optimum shift
Main Shaft module 13) sequences, timing and clutch apply / release
The main shaft module passes through the centre of pressures. This is done by controlling the transmission
the transmission gearbox. The P2 and P3 sun gears solenoids and valves.
are part of or splined to the main shaft, enabling it to SM - 3488
transmit torque to the rotating clutch module. Input SHIFT SELECTOR
shaft provides the primary path for transmitting torque THROTTLE POSITION SENSOR SOLENOIDS
through the various stages of the transmission. RETARDER MODULATION TCM DIAGNOSTIC PRESSURE SWITCH
VEHICLE/ENGINE
TEMPERATURE SENSOR
COMMUNICATION LINKS
(SUMP / RETARDER)
OUTPUT MODULES
The output modules contain components that transmit
power and torque to the vehicle driveline. The output INPUTS OUTPUTS
SM 2416 05-06 3
Transmission - Transmission and Mounting
Section 120-0010
SM - 3490
6
9
1
2 8
9
3 4
7
4 SM 2416 05-06
Transmission - Transmission and Mounting
Section 120-0010
SM - 3597
5
4
6
7 3
2
1
OPERATION SM - 3491
1
2
3
DE
4
CT
Generation controls and shift selector lever. The shift
MO
5
LE
D
SE
N
R
selector communicates with the transmission TCM via
OR
NIT
the J1939 datalink. The shift selector is a remote
MO
mounted lever type. The selector has a 2-digit LED 2
display, that during normal operation will display the 3
range selected and range attained.
4
5
There is a hold override button (1) that must be
pressed when shifting between R,N and D. The hold
override button (1) is released when the desired 1 - Hold/Override Button 4 - Range Attained
2 - Mode Button 5 - Display Mode Button
selector position is reached. The selector can move 3 - Range Selected
freely between D and the number ranges without
pressing the override button.
Fig. 7 - 4th Gen Gear Shift Lever
The transmission upshifts and downshifts
automatically between first range and the highest range
Failure to meet any of the conditions 1-4 previously
selected on the selector in direct response to throttle
listed, will stop the 2 minute countdown and the shift
position and transmission output speed. When reverse
lever will display one of the following codes-
range is selected, the reverse alarm sounds and the
reverse light illuminates at the rear of the truck.
oL0X Setting time too short.
oL50 Engine RPM too low.
The shift selector can be used to display a number of
oL59 Engine RPM too high.
parameters, including oil level information and
oL65 Neutral not selected.
transmission fault code information.
oL70 Sump fluid temperature too low.
oL79 Sump fluid temperature too high.
Displaying Oil Level Information (OLS) oL89 Output shaft rotation detected.
oL95 Oil level sensor failed.
To enter the oil information sequence, press the
display mode (5) button once on the gear shift lever. A Displaying Diagnostic Fault codes
2 minute countdown begins when the following Should there be a transmission fault, the check
conditions are met - 1.Engine at idle, 2. Oil at operating transmission warning light will illuminate at the top of
temp 82-104°C, 3. transmission in neutral and 4. the instrument panel bank of warning symbols,
transmission output shaft stationary. indicating that the TCM has registered a diagnostic
code. As many as five codes may be recorded in
The oil level will be displayed at the end of the 2
memory, listed in order of newest to oldest. In which
minute countdown (to facilitate constant oil drain back).
case, fault codes can be retrieved through the 4th Gen
During the countdown, the display flashes out a
shift selector lever.
numerical value starting at '8' in 15 second intervals,
decreasing in value by 1 each time in sequence i.e. To enter the diagnostic code sequence, press the
8,7,6,5,4,3,2 & 1. After the number sequence the display mode button (5), twice on the shift lever. Each
display will then sequentially flash the oil level code consists of 4 sequential elements; each being 1
information, 2 characters at a time; the following may or 2 characters. The display for each code will repeat
be displayed: continuously until the next code is displayed (if
oL ; oK Oil level OK present). To display the next code if present, press the
oL ; Lo Oil level low 1 quart- or as many as req. mode button (2). The following cycle illustrates the
oL ; HI Oil level high 1 quart- or as many as req. display cycle:
(1 US quart = 0.95Litre = 0.2 gallon).
6 SM 2416 05-06
Transmission - Transmission and Mounting
Section 120-0010
d1 Code list position (d1 newest, d5 oldest). The retarder may be used at any time to slow the
P Code type. vehicle down. If additional braking is required apply the
service brakes.
25 Main code.
34 Sub code. Note: The retarder is not meant for bringing the vehicle
Code repeats until the next code (d2) is accessed by to a stop, service brakes should be used for stopping.
pressing the mode button (5)
The retarder consists of a stator, rotor, housing and
Clearing Diagnostic Fault codes control valve body assembly. The rotor is splined to
the transmission output shaft and is driven at output
To clear active codes, press and hold the mode button
shaft speed. The retarder stator, rotor and housing all
(2) for 3 to five seconds. Similarly to clear inactive fault
have integral vanes. The rotor rotates between the
codes, press and hold the mode button (2) for 8 to 10
stationary stator and retarder housing.
seconds.
Exiting Diagnostic mode Retardation occurs when the retarder housing is filled
with transmission fluid and pressurized, thus impeding
Any of the following methods may be used to exit the and slowing the rotor, output shaft and vehicle.
diagnostic display mode -
\ Momentarily press the display mode button (5). For the retarder to engage, certain conditions must be
satisfied:
Move the gearshift lever to any other position that the
one selected when the diagnostic display mode was 1. Accelerator released.
activated. 2. Transmission 'STOP' warning light must be out.
4 Wait until time out (approx. 10 minutes). The system 3. Transmission must be in lockup.
automatically returns to normal operating mode.
Turn the vehicle off - Eliminating power to SM - 3492
transmission ECU.
L
The primary shift schedule is the default setting each Fig. 8 - Retarder Req. Sw / Percentage Lever.
time the vehicle is started. This is used for normal
operation. The secondary shift schedule can be
requested by pressing the Mode button. A small red To apply the retarder, the dash mounted retarder
light next to the mode button indicates that the function request switch must be on (1, Fig. 8). A signal is then
has been selected. sent to the TCM to request retarder operation, when all
conditions are met.
Transmission Retarder
The amount of retardation requested, is operator
The transmission retarder is used to assist in stopping dependant. This is done via the six-position lever on
the vehicle and reduce the need for service brake the right hand switch bank (2, Fig. 8). With maximum
applications, thus reducing service brake ware and retardation requested in the lowest position.
preventing overheating.
SM 2416 05-06 7
8
Section 120-0010
Transmission - Transmission and Mounting
Gear activation
The following table shows the condition of the individual solenoids, switched and latch valves to attain the full range of gears from the transmission. Note:
Intermediate stages i.e. neutral to reverse, have been ommitted, only the range attained is listed. For where to check pressure setting and measure
pressure values, see following detail.
Range Attained Solenoid Energised Latch Valve Position PS1 position Main Mod Press. Solenoid. SS1 Clutch apply
PCS1 PCS2 PCS3 PCS4 C1 C2 Open Closed Energised De-energized Energized
Neutral X X X Up Up X X C5
1st X X Down Up X X C1 + C5
6th X X Up Down X X C2 + C4
Reverse X X Up Up X X C3 + C5
Main pressure modulation is checked at idle in Neutral, reverse, 1st convertor and second convertor. Main modulation pressure is checked at high speed
in neutral only. RPM in range 1780 - 1820.
SM 2416 05-06
Transmission - Transmission and Mounting
Section 120-0010
SM - 3493
MAIN
C4 C5
C3
C1 C2
MAIN
LUBE
OIL FILTER
COVERS
PRESSURE CHECKS
Note: Check to see if there are diagnostic codes 2. Bring the transmission to normal operating
present that are related to the transmission temperature of 71 - 93 Deg. Celcius (160- 200 Deg F).
difficulty which is being experienced. Proceed to Check for fluid leaks in the circuit being checked. Be
make mechanical preparations for checking clutch sure that fluid level is correct.
pressures only after codes have been evaluated
first. 3. Compare clutch pressures recorder with those given
in the table. If clutch pressures are not within
Checking individual clutch pressures helps to specification take corrective action to redeem the fault.
determine if a transmission malfunction is due to a
mechanical or an electrical problem. Properly making 4. Main pressure modulation is checked in neutral,
these pressure checks requires transmission and reverse, 1st and 2nd converter.
vehicle preparation, recording of data and comparing
data against specifications provided. 5. Main pressure modulation is checked at high speed
in neutral only.
1. Remove plug from the pressure tap and install a
suitable hydraulic fitting and pressure gauge at location Refer to the following tables on pages 10 & 11, which
where measurement is desired. Pressure gauge set should be used as reference for checking pressures
J26417-A is available. and troubleshooting the system.
WARNING
Be sure that the transmission has enough fluid
for cold operation until an operating fluid level
can be set.
SM 2416 05-06 9
Transmission - Transmission and Mounting
Section 120-0010
SM - 3562A
Engine Range Clutches Main Press. Range Clutch Conv.Out Lube LU Clutch
RPM Applied Spec. Press. Spec* Press. Spec Press. Spec Press. Spec*
0 - 5.8 (C5)
0 - 5.8 (C4)
0 - 5.8 (C5)
0 - 5.8 (C4)
0 - 5.8 (C4)
0 - 5.8 (C3)
0 - 5.8 (C3)
0 -10 (C2)
0 -10 (C2)
0 - 5.8 (C3)
0 -5.8 (C3)
0 - 5.8 (C3)
0 - 5.8 (C4)
* Subtract clutch pressure from main pressure; the difference must fall within the specification given.
10 SM 2416 05-06
Transmission - Transmission and Mounting
Section 120-0010
SM - 3496
No. COLOUR WIRE# DESCRIPTION
61
41
21
1
15 W 115 Retarder Solenoid High
16 U 116 Oil Level Sensor Low
20 U 120 Turbine Speed Sensor Low
21 G 121 Anti Lock Brake Low
24 W 124 GPO5 - Retarder indicator
25 TAN 125 Speedometer Signal
26 Y 126 CAN 2 Controller termination (J1939)
27 G 127 CAN 2 Controller , Low (-) (J1939)
28 Y 128 CAN 1 Controller, High (+) (J1939)
29 G 129 Check Transmission Low
30 W 130 GPO1 - PTO Enable
31 Y 131 Retarder Solenoid
32 W 132 Diagnostic driver (J1708)
33 Y 133 PCS3 Solenoid Low
35 U 135 Engine Water temperature
36 O 136 PCS1 Solenoid Low
37 W 137 TCC Solenoid Low
39 O 139 Engine Speed Sensor Low
40 G 140 Output Speed Sensor Low
41 TN 141 Neutral Start High
42 W 142 GPI5 - Auxilliary Hold
43 U 143 GPI3 - PTO Enable
44 U 144 PWM Throttle signal
45 O 145 GPO3 - Engine Overspeed Indicator
47 G 147 CAN 2 Controller , Low (-) (J1939)
48 Y 148 CAN 1 Controller , High (+) (J1939)
49 - 149 CAN 1 Controller Shield
51 W 151 SS1 Shift Solenoid
52 G 152 PCS2 Solenoid
54 TN 154 Sump Temperature Signal
55 W 155 PCS4 Solenoid
56 Y 156 Retarder Modulation Request
57 W 157 Engine Brk enable / Preselect request
58 G 158 Analogue Return
59 TN 159 Engine Speed Sensor High
80
60
40
20
SM 2416 05-06 11
Transmission - Transmission and Mounting
Section 120-0010
12 SM 2416 05-06
Transmission - Transmission and Mounting
Section 120-0010
SM 2416 05-06 13
Transmission - Transmission and Mounting
Section 120-0010
14 SM 2416 05-06
Transmission - Transmission and Mounting
Section 120-0010
SM 2416 05-06 15
Transmission - Transmission and Mounting
Section 120-0010
SM - 3502
14. Disconnect driveline connected from transmission and attach a hoist to make sure lifting attachments are
to dropbox and secure clear of the transmission. Refer placed so that the transmission is balanced.
to Section 130-0010, DRIVELINES.
20. Remove bell-housing bolts. Loosen off two engine /
15. Disconnect pressure and suction hoses from main transmission mounts and retract transmission via
hydraulic pump. Identify and tag hydraulic lines holding bracket , approximately 3" to separate.
Note: Access to suction hose is limited; use a suitable 21. Lift transmission Clear of chassis frame and
10mm ball end allen key with extension for removal. engine.
17. Remove npt plug from engine 3/4" sq. drive, 1. Remove 8-off mounting bolts (1) securing PTO to
situated below starter motor to access 12 bolts holding transmission LHS.
flex plate damper, which connects the engine to
transmission. 2. Remove PTO (2) and gasket (3). Inspect PTO
studs for damage and remove if necessary.
18. Engine crank has to be turned, to allow access to
the 12-off bolts. Use special tool 15502496. 3. Remove bolts (16) retaining oil fill tube hose to
clamp over top of transmission. Remove bracket, fill
19. Mount holding bracket 15502498 to transmission tube, seal and dipstick from transmission.
SM 2416 05-06 17
Drivelines - Front Drivelines
Section 130-0010
Note: Access to driveline assembly (1) can be 3. Place the shaft end of driveline assembly (1) in a
obtained from underneath the vehicle. soft jawed vice.
4. Remove Locknuts (12), washers (13 & 18) and bolts 4. Remove screws (5) and universal joint from driveline
(18), securing Support plate (11) to anti-flail guard (10). assembly (1).
Remove support plate (11).
5. Repeat steps 1 to 4 for drivelines (2 & 3).
5. Remove bolt (15), locknut (16) and washer (17)
securing anti-flail guard (10) to cross-member (6).
Remove anti flail guard (10) clear of driveline assembly INSPECTION
(1).
1. Clean all metal parts in a suitable solvent, and dry
6. Match mark universal joints and their mating all parts with compressed air.
surfaces to ensure correct mating alignment when
installing driveline assembly (1). 2. Inspect splines of shaft and yoke for nicks, burrs
and excessive wear. Replace if wear is excessive or
7. Support driveline (1) with suitable lifting equipment splines are nicked. Burrs may be removed with a fine
and remove bolts (4) securing universal joints file or medium India stone.
to their mating components and remove driveline
2 SM 2385 01-06
Drivelines - Front Drivelines
Section 130-0010
SM - 088 INSTALLATION
APPLY PRESSURE MAXIMUM PERMISSIBLE
Numbers in parentheses refer to Fig. 1.
HERE BY HAND GAP IS 0.2 mm (0.008 in)
Note: Tighten all fasteners without special torques
specified to standard torques listed in Section
STRAIGHT EDGE
300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
WARNINGS
To prevent personal injury and property
Fig. 2 - Checking Parallelism damage, be sure wheel chocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
3. Check the surfaces of the components that universal safely.
joints mate against for parallelism. Refer to Fig. 2.
4. Check condition of mounting capscrews and replace To prevent serious injury or death, DO
if required. NOT go under the vehicle when the engine is
running. Rotating shafts can be dangerous. You
5. Check that anti-flail guard (10), support plate (11) can snag clothes, skin, hair, hands, etc..
and cross-member (6) are not damaged prior to
assembly.
1. If removed at disassembly stage. Secure cross-
ASSEMBLY member (6) to chassis frame, using bolts, locknuts and
washers (9,8 & 7). Tighten bolts to a torque of 921 Nm
Universal Joint (680 Ibf ft).
Numbers in parentheses refer to Fig. 1. 2. Position driveline assembly (3) on the vehicle as
shown in Fig. 1 and align match marks on universal
1. Place the yoke end of driveline assembly (1) in a joints with those on their mating surfaces.
soft jawed vice, clamping on the tube of shaft.
3. Apply Loctite 638 to the threads of bolts (4). Secure
Note: Do not distort the tube with excessive grip. universal joints to their mating surfaces with bolts (4).
Tighten bolts (4) to a torque of 153 Nm (113 lbf ft).
2. Install universal joint to yoke end of driveline
assembly (1) and secure with screws (5). 4. Position driveline assembly (2) on the vehicle as
shown in Fig. 1 and align match marks on universal
3. Place the shaft end of driveline assembly (1) in a joints with those on their mating surfaces.
soft jawed vice.
5. Apply Loctite 638 to the threads of bolts (4). Secure
4. Install universal joint to shaft end of driveline universal joints to their mating surfaces with bolts (4).
assembly (1) and secure with screws (5). Tighten bolts (4) to a torque of 153 Nm (113 lbf ft).
5. Repeat steps 1 to 4 for drivelines (2 & 3). 6. Position driveline assembly (1) on the vehicle as
shown in Fig. 1 and align match marks on universal
joints with those on their mating surfaces.
SM 2385 01-06 3
Drivelines - Front Drivelines
Section 130-0010
7. Apply Loctite 638 to the threads of bolts (4). Secure Every 2 000 Hours: Check drivelines for leaks and
universal joints to their mating surfaces with bolts (4). damage, and replace if required.
Tighten bolts (4) to a torque of 153 Nm (113 lbf ft).
* * * *
4 SM 2385 01-06
DRIVELINES - Rear Drivelines
Section 130-0020
SM - 2944
2,3
2,3 5,6 4 5,6
DESCRIPTION centre and rear axles to the drive supplied from the
transmission, through the pivot drive arrangement, as
Numbers in parentheses refer to Fig. 1.
follows:
The function of the driveline is to transmit rotating
Driveline assembly (1) is connected between the
power from one point to another in a smooth and
articulation and oscillation pivot and the centre axle.
continuous action while allowing a degree of
movement or misalignment of the components it
Driveline assembly (4) is connected between the centre
connects.
axle and the rear axle.
The drivelines must operate through constantly
changing relative angles between the components REMOVAL
they are mounted to and must also be capable of
Numbers in parentheses refer to Fig. 1, unless
changing length while transmitting torque.
otherwise specified.
A typical driveline consists of universal joints which
Note: Extra care should be taken when handling
allow some misalignment and permit the driveline to
drivelines since carelessness can result in premature
pivot in any direction, and, a light rigid hollow slip yoke
failure of the components. Chips, dents, burrs, or any
and splined shaft assembly forming a slip joint.
other deformity of universal joints will prevent accurate
mating. This will cause misalignment which is
The slip joint accommodates length variations
accompanied by vibration and excessive wear.
generated during operation, preventing tension or
compression loads from causing serious damage to
the components.
WARNINGS
To prevent personal injury and property
Note: Extra care should be taken when handling the
damage, be sure wheel blocks, blocking
drivelines since chips, dents, burrs or deformity on any
materials and lifting equipment are properly
rotating mass creates vibration and excessive wear
secured and of adequate capacity to do the job
during any operation.
safely.
There are two driveline assemblies connecting the
SM 2386 03-06 1
Drivelines - Rear Drivelines
Section 130-0020
4. Remove screws (3) and universal joint from driveline
To prevent serious injury or death, DO assembly (1).
NOT go under the vehicle when the engine is
running. Rotating shafts can be dangerous. You 5. Repeat steps 1 to 4 for driveline (4).
can snag clothes, skin, hair, hands, etc..
INSPECTION
Disconnecting or removing any of the
rear drivelines will make the parking brake 1. Clean all metal parts in a suitable solvent, and dry
ineffective. all parts with compressed air.
1. Position the vehicle in a level work area, apply the 2. Inspect splines of shaft and yoke for nicks, burrs
parking brake and switch off the engine. Depress the and excessive wear. Replace if wear is excessive or
brake pedal continuously to relieve any pressure in the splines are nicked. Burrs may be removed with a fine
braking circuit. Turn the steering wheel several times to file or medium India stone.
relieve any pressure in the steering circuit.
3. Check the surfaces of the components that universal
2. Block all road wheels and place the battery master joints mate against for parallelism. Refer to Fig. 2.
switch in the off position.
4. Check condition of mounting capscrews and replace
Note: Access to driveline assemblies (1 & 4) can be if required.
obtained from underneath the vehicle.
ASSEMBLY
3. Match mark universal joints and their mating
surfaces to ensure correct mating alignment when Universal Joint
installing driveline assembly (1).
Numbers in parentheses refer to Fig. 1.
4. Remove capscrews (2) securing universal joints to
their mating components and remove driveline 1. Place the yoke end of driveline assembly (1) in a
assembly (1). If necessary tap driveline assembly (1) soft jawed vice, clamping on the tube of shaft.
from its mating components with a soft faced hammer.
Note: Do not distort the tube with excessive grip.
5. Match mark universal joints and their mating
surfaces to ensure correct mating alignment when 2. Install universal joint to yoke end of driveline
installing driveline assembly (4). assembly (1) and secure with screws (3).
6. Remove capscrews (5) securing universal joints to 3. Place the shaft end of driveline assembly (1) in a
their mating components and remove driveline soft jawed vice.
assembly (4). If necessary tap driveline assembly (4)
from its mating components with a soft faced hammer. 4. Install universal joint to shaft end of driveline
assembly (1) and secure with screws (3).
Universal Joint
INSTALLATION
Numbers in parentheses refer to Fig. 1.
Numbers in parentheses refer to Fig. 1, unless
1. Place the yoke end of driveline assembly (1) in a otherwise specified.
soft jawed vice, clamping on the tube of shaft.
Note: Tighten all fasteners without special torques
Note: Do not distort the tube with excessive grip. specified to standard torques listed in Section
300-0080, STANDARD BOLT AND NUT TORQUE
2. Remove screws (3) and universal joint from driveline SPECIFICATIONS.
assembly (1).
Note: Extra care should be taken when handling
3. Place the shaft end of driveline assembly (1) in a drivelines since carelessness can result in premature
soft jawed vice. failure of the components. Chips, dents, burrs, or any
2 SM 2386 03-06
Drivelines - Rear Drivelines
Section 130-0020
MAINTENANCE
Universal Joints
REMOVE ALL Every 500 Hours: Check the universal joints for wear
BURRS AND
PAINT FROM and replace if required.
THESE SURFACES
Every 2 000 Hours: Check drivelines for leaks and
damage, and replace if required.
WARNINGS With the pry bar, check the universal joints for play. If
To prevent personal injury and property loose, replace the universal joints. Check the splines at
damage, be sure wheel blocks, blocking the slip joint and replace the yoke if excessively worn.
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely. SPECIAL TOOLS
There are no special tools required for procedures
To prevent serious injury or death, DO outlined in this section. Refer to Section 300-0070,
NOT go under the vehicle when the engine is SERVICE TOOLS, for part numbers of general service
running. Rotating shafts can be dangerous. tools and adhesives required. These tools and
You can snag clothes, skin, hair, hands, etc.. adhesives are available from your dealer.
SM 2386 03-06 3
Drivelines - Rear Drivelines
Section 130-0020
* * * *
4 SM 2386 03-06
CENTRE AXLE - Differential Drive Head
Section 150-0020
Note: Never engage or disengage the Differential 8. Support the weight of differential housings (2 & 31)
Lock when moving or when the wheels are spinning. and layshaft housing (3) with suitable lifting equipment.
Remove bolts securing differential housing (2) to axle
casing and carefully remove differential assembly clear
REMOVAL AND INSTALLATION of axle casing.
Numbers in parentheses refer to Fig. 1.
INSTALLATION
Installation is the reversal of the 'Removal' procedure.
WARNING
To prevent personal injury and property Note: Use sealing compound (Loctite 574) between the
damage, be sure wheel blocks, blocking axle housing and differential housing mounting faces.
materials and lifting equipment are properly
secured and of adequate capacity to do the job Tighten bolts securing differential assembly to axle
safely. casing to 375 Nm (277 lbf ft). Tighten nuts to 280 Nm
(207 lbf ft).
1. Position the vehicle in a level work area, raise the
body and install the body safety prop to secure the Note: Tighten all fasteners to standard torques listed in
body in the partially raised position. Section 300-0080, AXLE BOLT AND NUT TORQUE
SPECIFICATIONS.
2. Apply the parking brake and switch off the engine.
Fill the layshaft housing (3) and the differential housing
3. Block all road wheels, place the steering lock bar in (31) with 1.5 litres (0.4 US gallon) of gear oil of the type
the 'Locked' position and the battery master switch in specified in Section 300-0020, LUBRICATION
the 'Off' position. SYSTEM, through the differential filler/level hole. Fill
the axle casing with gear oil of the type specified in
4. Drain the gear oil out of the axle housing and both Section 300-0020, LUBRICATION SYSTEM, through
planetaries into a suitable container. the differential filler/level hole until the oil is level with
the bottom of the filler/level hole. Fill the planetary
5. Remove the planetary assemblies and axle shafts assemblies up to the 'Oil Level Check Line'. Check oil
from the axle housing. Note from which side the long levels after a few minutes to ensure level remains
constant.
SM 2249 9-03 1
Centre Axle - Differential Drive Head
Section 150-0020
SM - 3022
2 SM 2249 9-03
Centre Axle - Differential Drive Head
Section 150-0020
SM - 3023
SM 2249 9-03 3
Centre Axle - Differential Drive Head
Section 150-0020
4 SM 2249 9-03
Centre Axle - Differential Drive Head
Section 150-0020
SM - 2954 10. Remove both bearings (17 & 18) inner rings using
special tools (15272560 Puller, 15500887 Gripping
Insert, 15500888 Gripping Insert and 15500889
Reducer) as shown in Fig. 9.
SM 2249 9-03 5
Dropbox - Dropbox and Mounting
Section 125-0010
SM - 3392
1B 6
1A
10
4
2
1 - High Range Solenoid (A) 3 - Diff. Lock Relief Valve (CT5) 6 - Check Valve (CT6)
1 - Low Range Solenoid (B) 4 - Pressure Control Valve (CT1) 9 - Pressure Switch (SW5)
2 - Differential Lock Solenoid (CT4) 5 - Check Valve (CT3) 10 - Temperature Switch (SW6)
Gear selection and differential lock are operated via 5. Desired gear ratio will be activated.
switches in the vehicle by continuously rated 24V dc 6. Release the service brake pedal.
solenoids. These solenoids (1 & 2 Fig. 2) are located
on the externally mounted valve block (Fig. 2). 7. The park emergency brake will now automatically
disengage.
SWITCHES AND PRESSURE POINTS When either high or low ratio is selected, the
Numbers in parentheses refer to Fig. 2 & 3. corresponding solenoid (1A or 1B) will be energised.
On start up, the gear range the vehicle will be in is
Gear Selection dependant on the position that the gear selection switch
was left in, prior to leaving the vehicle.
High and low range gear selection is by face driven dog
engagement. To engage high or low gear ratio, the Numbers in parentheses refer to Fig. 2 unless otherwise
following steps must be adhered to: stated
1. Bring vehicle to a stop with the service brakes. Diff. lock solenoid (2) is energised to select the
Maintain pressure on service brakes. differential lock. The inter-axle differential lock is a
multi-plate clutch device that locks the front and rear
2. Engine RPM must be less than 750.
drives together (50/50 torque split) to provide more
3. Press the high / low ratio request switch into the traction in arduous conditions. It is selectable on the
desired gear range. move, provided the vehicle speed is not greater than 5
4. The park/emergency brake will now automatically km/hr. With the differential lock disengaged there is
apply. normal torque biasing of 2/3 to the rear and 1/3 to the
front axle.
SM - 3393
TP2
(12)
B
(13)
P1 GS1
(17) (4) GS2
(14)
(1)
T1
(18)
A
(15)
TP1 DL
(11)
(5)
(7)
OC1
(2)
(9)
SW5
(6) (8)
SW6 OC2
(10) (3)
(16)
P2
1 - Range Selector Solenoid (CT2) 7 - Oil Cooler Feed Port- OC1 13 - High Gear Range Port- GS1
2 - Differential Lock Solenoid (CT4) 8 - Oil Cooler Return Port- OC2 14 - Low Gear Range Port- GS2
3 - Differential Lock Relief Valve (CT5) 9 - Pressure Switch- SW5 15 - Differential Lock Port- DL
4 - Pressure Control Valve (CT1) 10 - Temperature Switch- SW6 16 - Supply Port - P2
5 - Check Valve (CT3) 11 - Differential Lock Test Point- TP1 17 - Supply Port - P1
6 - Check Valve (CT6) 12 - Pressure Test Point- TP2 18 - Return Port - T1
SM - 3563
1 LOW RANGE
INDICATOR SWITCH
80
SW2
2 - Input Gear 53 - Friction Plate
43 49,44
3 - Gear 54 - Plain Plate
86,96,101 4 - Gear 55 - Quad Ring
5 - Gear 56 - Quad Ring
95,87 95,87
6 - Gear 59 - Shim
81, 82,42 7 - Gear Differential 60 - Washer
48 40,49 82, 8 - Gear (Drop) 61 - Washer
39 41,100
32,115
HIGH RANGE
9 - Input Shaft 63 - Washer
INDICATOR SWITCH 10 - Countershaft 64 - Taper Roller
SW3
11 - Sleeve selector 65 - Needle Roller
16 - Oil Restrictor 66 - Washer
47, 116, 106 47, 51 18 - Oilseal housing 67 - Needle Roller
74,18, 2,63 117,11 4,63
9 16
59,102 23 - Splash guard LH 68 - Needle Roller
24 - Shaft (rear) 70 - Washer
73
25 - Sun Gearshaft 71 - Needle Roller
3 26 - Planet Carrier 72 - Taper Roller
73 - Oil Seal
K75x83x30 K75x83x30 K75x83x30 K75x83x30
27 - Planet Gear
TRANS PUMP 5
28 - Planet Spindle 74 - Oil Seal
29 88 29 - Annulus Gear 77 - 'O'-ring
27 10 30 - Clutch Basket 80 - Bush
37 6 31 - Piston (difflock) 82 - Piston Seal
52,7 32 - Fork Selector 84 - Piston Ring
45,71
33 - Splash guard RH 85 - Washer
93,28
61,68
34 - Oil distribution ring 86 - Locknut
53,54 35 - Output Shaft 87 - Locknut
25 36 - Front Gear 88 - Key
65,66 37 - Pressur Plate 89 - Key
K202617
64
34,77 39 - Rod Selector 91 - Bolt - flanged
24 40 - Switch Housing 93 - Pin
9RB 90 112 055
20
07
V-
53
34
0R
AR
Q
24T-10/20DP
56.52x5.33
97,98
REAR AXLE 41 - Primary Piston 95 - Grubscrew
67
31,56 42 - Piston (secondary) 96 - Stud
46
84
43 - Hydraulic Cylinder 97 - Locknut
QRAR04442-V7002
73
44 - Cover Plate 98 - Lockwasher
50 65,70,85 45 - Washer 100 - Dowty
55,31,56
46 - Oil Seal 101 - Washer
8
FRONT
56.52x5.33
24T-10/20DP
1. Position the vehicle in a level work area, ensure the 4. Place a suitable container under the dropbox drain
body is fully lowered, apply the parking brake and port. Remove drain plug (19) and drain oil through hose
switch off the engine. Operate steering right and left adaptor (20) into a suitable container . After draining,
several times to relieve any pressure in the steering reinstall drain plug and tighten securely.
system.
5. Remove cab from the machine. Refer to Section
2. Operate the treadle valve continuously to discharge 260-0010, CAB AND MOUNTING. Ensure all
the accumulators, block all road wheels, place the connections and lines connect to the cab are
steering lock bar in the 'Locked' position and the disconnected.
battery master switch in the 'Off' position.
6. Disconnect all drivelines connected to the dropbox
3. Disconnect the following cables and connectors in and secure clear of the dropbox. Refer to Section 130-
order to prevent damage to vehicle electrical 0010, DRIVELINES.
COLD COLD
FULL ADD WARNING
When checking the oil level, be sure that the
parking brake is applied and all road wheels are
securely blocked.
Troubleshooting:
Low Pressure Indication • Wiring or Pressure Switch • Check pressure on dropbox valve block- Pressure
(Engine Running). failure. at TP2 should be 15 bar (217 Ibf/in²). If OK check
wiring and switch.
• Partial/ Full blockage of • Check and replace filter element.
valve block filter.
• Failure of main hydraulic
• Check flow and pressure to dropbox from main
system.
hydraulic valve port 'DL'.
• Failure/ wear in dropbox • Replace pump unit- checks must be made to
pump unit. establish primary cause i.e. contaminated oil.
• Low oil level • Check oil level and unit for leaks.
High Temperature Warning.
• Vehicle cooler circuit • Check oil cooler circuit for failure, damage or
failure. radiator blockage.
Differential lock Inoperative • Wiring or solenoid failure. • Check for power to solenoid and that solenoid
energises when differential lock switch activated-
replace or repair as necessary.
• Low pressure • Check oil pressure at pressure point TP1 on
dropbox valve block - should be 27.5 ±2.5 bar (399
(399 ± 36 Ibf/in²) on activation of diff. lock switch -
Low pressure indicates either worn pump unit,
leaking valve (CT3) in the valve block or worn
differential piston and/ or shaft seals. Check and
replace as necessary. Verify and rectify primary
cause i.e. contaminated oil.
• Clutch plate wear • If pressure is within specification check oil line for
blockage. If oil flow is present examine and replace
clutch plates in the differential.
• Differential lock partially • Check oil pressure at pressure point TP1 on
Squeal from differential engaged. dropbox valve block- should be 0Bar with Diff. lock
with dif. lock not engaged.
off. If pressure is indicated, ensure solenoid (CT4) is
not being energised, check solenoid valve for
leakage. Replace as necessary.
• Clutch plates warped or • Examine and replace clutch plates in differential.
damaged
17 SM - 3439
2
26
4
11 15
33
18
27 12
21 31
20
5,6 3
23
13 29
32
8 7
24
28
34
22 25 14 30
19 10
16
The emergency steering pump is an axial piston, The variable displacement unit incorporates a
variable displacement (adjustable) pump, capable of mechanism that governs the angle of bearing swash
high pressure operation. It provides flow to steering plate (15) which, in turn controls the stroke length of
circuit in the event that the main pump can no longer each piston as rotating group (9) assembly and
function. Pump control valve (2) regulates system driveshaft (16) rotate. End cover (14) includes the inlet
pressure at 240 bar (3 480 lbf/in²). and outlet ports. Tapered bearing (21) in pump housing
(13) and tapered bearing (22) in end cover (14) support
The emergency steering pump is assembled for right driveshaft (16).
hand (clockwise) rotation, as viewed from driveshaft
(16) end.
SM 2369 05-06 1
Dropbox - Emergency Steering Pump
Section 125-0020
SM - 395
OUTLET
PORT
INLET
PORT DRIVESHAFT
SHOE PLATE
INTAKE VALVE
PLATE SLOT
CYLINDER BLOCK BORE
OPERATION SM - 553
2 SM 2369 05-06
Dropbox - Emergency Steering Pump
Section 125-0020
SM - 377
MAXIMUM SHOE PLATE ANGLE DECREASED SHOE PLATE ANGLE ZERO SHOE PLATE ANGLE
(MAXIMUM DISPLACEMENT) (PARTIAL DISPLACEMENT) (MINIMUM DISPLACEMENT)
VIEW A VIEW B VIEW C
REMOVAL
Numbers in parentheses refer to Fig. 5.
WARNING
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly 2,3 3,6 7
2. Turn steering wheel in both directions several times Fig. 5 - Plan View of Steering Pump Installation
to relieve pressure in accumulator and steering
system. Block all road wheels.
and, with suitable containers available to
3. With a suitable container in position, remove drain catch leakage, disconnect hydraulic lines. Fit blanking
plug from bottom of steering and brake control tank and caps and plugs to all hydraulic lines and tank ports.
drain the oil. Reinstall the drain plug and tighten
securely. 6. Support steering pump (1) with a suitable lifting
device and remove two mounting bolts (2) and
4. With a suitable container in position, remove drain lockwashers (3). Pull steering pump (1) rearward to
plug from underside of steering pump (1) housing and disengage pump driveshaft from drive coupling (8).
drain the oil.
7. Pull steering pump (1) and gasket (5) straight out
5. Ensure hydraulic lines connected to steering from the mounting flange of pump adaptor (4). Discard
pump (1) assembly are identified for ease of installation gasket (5). Do not remove pump adaptor (4) from its
mounting unless it is to be replaced.
SM 2369 05-06 3
Dropbox - Emergency Steering Pump
Section 125-0020
8. Wash the outside of steering pump (1) thoroughly Orientated with end cover (14) and screws (29) facing
with a suitable solvent and move to a clean work area upwards for disassembly.
for disassembly.
2. Match mark end cover (14) and pump housing (13)
OVERHAUL to aid at assembly stage.
In most cases, the pump will not require a complete
overhaul as described within this section of the 3. Remove control valve (2) by removal of screws (4).
manual. Repair of this unit is intricate and should not be Discard 'O'-rings (3). Refer to Fig 6.
attempted without proper tools.
4. Remove 4-off screws (29) from end cover (14).
Using suitable lifting equipment, remove end cover (14)
DISASSEMBLY from the pump assembly (1). Refer to Fig 7.
Numbers in parentheses refer to Fig. 1 unless
SM - 3432
otherwise stated.
SM - 3432
Pump
Numbers in parentheses refer to Fig 1 unless
otherwise stated.
1. Secure pump assembly in a suitable jig or fixture. Fig. 8 - End Cover Removal
4 SM 2369 05-06
Dropbox - Emergency Steering Pump
Section 125-0020
7. Remove bearing (22) inner race and shim (19) from 10. Remove piston rod (12) and swash plate (15) using
end of driveshaft (16). Take care not to damage sealing a suitable tool. Slight rotation of swash plate (15)
surfaces. Refer to Fig 9. through the z-axis may be required to aid in removal
from inner bore of the housing. Refer to Fig. 12.
SM - 3434
SM - 3437
13. Remove circlip (28) and shaft seal (24) from the
opposite end of the pump housing. Refer to Fig. 13.
SM - 3438
9. Remove plug (17) and 'o'-ring (26) from control piston Fig. 13 - Driveshaft Removal
(11). Prise control piston (11) out of pump housing (13)
using the flat surface with a suitable screwdriver. Refer 14. Using suitable lifting equipment, secure pump
to Fig. 11. housing (13) on the bench or fixture, in correct
orientation for removal of the bearing (21) outer race.
SM - 3436
16. Remove shim (20) and plug (33) from the housing
(13).
SM 2369 05-06 5
Dropbox - Emergency Steering Pump
Section 125-0020
2. If removal of spring (7) from rotating group (9, Fig. 1) Pump Housing and Associated Parts
is required, it is recommended that caution be taken
1. Inspect pump housing (13) for erosion, cracks and
during this step.
burrs. Clean up minor burrs with an India stone. If
erosion or cracks are noted, replace pump housing
SM - 3425 (13).
6
3. Inspect control plate (10) for erosion, excessive
Fig. 14 - Rotating Group Detail wear, heavy scratches and cracks. If any of the above
conditions are found, replace the valve plate.
Bearing Bush
INSPECTION
1. Inspect bearing bush (23) face for wear, roughness
Numbers in parentheses refer to Fig. 1 or scoring. Check the hubs and bearing surfaces for
wear and cracks. Replace if defective.
Note: Before inspection of parts, clean all parts with a 2. Inspect bearing bushes (23) for heavy wear and/or
suitable solvent. cracks. Replace if defective.
Note: Rotating group* (9) is made up of a cylinder
block (6, Fig. 14), shoe plate (3, Fig. 14.) and piston Driveshaft and associated parts
assemblies. 1. Inspect driveshaft (16) for wear, chipped splines and
burrs. Remove burrs with an India stone. Inspect
Rotating Group contact area of tapered bearings (21 & 22) and shaft
seal (24). Replace driveshaft (16) if wear or scoring is
1. Inspect cylinder block for wear, scratches and/or greater than 0.127 mm (0.005 in) total indicator reading
erosion. If cylinder block condition is questionable, (T.I.R.).
replace the entire rotating group.
2. Inspect inner and outer races of tapered bearings (21
2. Check each cylinder block bore for excessive wear. & 22) for roughness, pitting of rollers and excessive
Use piston and shoe assemblies for this purpose. The end play. Make sure the inner race turns freely within
pistons should be a very close fit and slide in and out the outer race. If the tapered bearing needs
of the cylinder block bores. No binding can be replacement, both the inner and outer races must be
tolerated. If binding occurs, clean cylinder block and replaced.
6 SM 2369 05-06
Dropbox - Emergency Steering Pump
Section 125-0020
3. Inspect pump housing (13) mounting flange for nicks SM - 3419
and burrs. Remove minor nicks and burrs with an India
stone. Also check pump housing (3) for damaged or
stripped threads. If any thread is damaged, replace the
pump housing.
ASSEMBLY
Numbers in parentheses refer to Fig. 1 unless
otherwise stated.
Fig. 16 - Driveshaft detail
Note: Obtain a new shaft seal kit and a new bearing kit,
3. Take driveshaft (16) and fit the shaft through the
if required. Refer to the vehicle Parts Book for kit part
pump housing (13), chapping lightly on the end face of
numbers. Apply a light film of clean hydraulic oil to all
the shaft till the bearing (21) is in position.
new seals to make assembly easier and provide initial
lubrication of moving parts.
4. Taking end cover (14), secure on the bench or
suitable jig fixture. Insert new 'o'-ring (25) into mating
Assembly of the pump is largely the reverse sequence
groove.
to disassembly, but note the following:
5. Press in outer race of rear bearing (22) onto end
1. Grease the sealing ring (20). Insert ring (20) into
cover (14). Using a suitable driver and plastic mallet.
open end of pump housing (13). Tap lightly to ensure
Refer to Fig. 17.
that stop ring sits on shoulder face. Refer to Fig. 15.
Locate bearing (21) outer race in correct orientation
SM - 3420
inside pump housing and chap home till fully seated on
shoulder.
SM - 3418
SM 2369 05-06 7
Dropbox - Emergency Steering Pump
Section 125-0020
necessary adjust the thickness of the shim (19) to SM - 3423
meet this requirement.
SM - 3421
8. Remove end cover (14), bearing (22) inner race and SM - 3424
1. Taking pins (5), spring (7) and circlip (8), fit into the
bore of the cylinder housing (6). Ensure orientation is
correct. Refer to Fig. 14.
Fig. 17 - Seal Retention.
2. Taking a suitable combination of bolt, nut and
12. Rotate pump housing (13) assembly in the fixture. washer type to allow the spring and pins to be enclosed
Grease the bushes (23). Insert spring (18) and bushes and compressed in tightening of the bolt / nut
(23) into the housing body, in the correct orientation. combination. Do so sufficiently enough to allow the
Refer to Fig. 18. circlip to be locked in place. On removal of assembly
aids, the spring face will be held against full extension
13. Assembly swash plate (15) and piston rod (12) into by the inner face of the circlip, similarly the pins will be
8 SM 2369 05-06
Dropbox - Emergency Steering Pump
Section 125-0020
held on the inner shoulder of the piston housing, thus 7. Assemble control valve (2) to pump housing (13),
retaining the assembly. ensuring 'o;-rings (3) are in place. Secure valve using
screws (4). Torque screws (4) to a value of 12-15.5 Nm
3. Lubricate piston group (9, Fig.1) and retaining plate (9-11.5 Ibf ft).
with oil. Fit tapered end cap, retaining plate and piston
SM - 3428
group in place (Refer to Fig.19) into piston housing
(13, Fig.1 ).
SM - 3426
SM - 3429
SM - 3430
Fig. 20 - Insert Rotating Group
SM 2369 05-06 9
Dropbox - Emergency Steering Pump
Section 125-0020
Note: Tighten all fasteners to standard torques listed in 1. Make sure the reservoir and circuit are clean and
Section 300-0080, STANDARD BOLT AND NUT free of dirt and debris prior to filling with hydraulic fluid.
TORQUE SPECIFICATIONS. Fill the reservoir with filtered oil to a level sufficient to
prevent vortexing at suction connection to pump inlet.
Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 220- Note: It is good practice to clean the system by
flushing and filtering the system using an external
0000, STEERING SYSTEM SCHEMATIC.
slave pump. Before starting the pump, fill with fluid
Renew all through one of the ports. This is particularly important
'O' rings where used. if the pump is above the fluid level of the reservoir.
Note: It is very important that the pump cavity is 2. Be sure the pump case drain line is free from
completely filled with hydraulic oil. This will ensure obstructions that restrict the pump case drain flow
proper lubrication of the internal parts of the pump when back to tank and cause high case drain pressure which
it is initially operated. can lead to an early pump failure.
4. Fill the steering and brake control tank with clean 3. Before starting the engine after pump installation,
hydraulic oil specified in Section 300-0020, remove the remaining case drain plug from the pump
LUBRICATION SYSTEM. Refer to Section 220-0040, and an appropriate plug from the hydraulic tank and
STEERING AND BRAKE CONTROL TANK for correct install 0 - 3.5 bar (0 - 50 lbf/in²) gauges in both ports,
oil level. as well as a gauge in the pressure circuit which can be
5. Refer to 'PUMP STARTING PROCEDURE' for proper read for setting the steering system pressure. Be sure
pump priming and start-up procedure. to back out adjusting screw in compensator assembly
(1) until it is flush with the compensator body.
10 SM 2369 05-06
Dropbox - Emergency Steering Pump
Section 125-0020
4. Start the engine and monitor the system pressure SPECIAL TOOLS
gauge. Pressure should register within 30 seconds. If
Details of recommended manufacturer tools to follow,
not, re-check to assure that the system is properly
once confirmation and approval has been given from
filled with oil and that there is no restriction to the pump
pump manufacturer.
inlet.
Refer to Section 300-0070, SERVICE TOOLS for part
With the engine at Maximum No Load rev/min, read the
numbers of special tools referenced in this section and
pressures on both the tank and the pump case. At no
general service tools and adhesives required. These
time should the case pressure be more than
tools and adhesives are available from your dealer.
0.07 - 0.14 bar (1 - 2 lbf/in²) above the tank pressure.
* * * *
SM 2369 05-06 11
THIS PAGE IS INTENTIONALLY LEFT BLANK
DRIVELINES - Front Drivelines
Section 130-0010
SM - 3414
10
12,13,14 15
9 17
11
8
7
6 9
1 16 8
7
4,5
4,5
TRAILER
2
TRANSMISSION
FRONT AXLE
3 4,5
4,5
4,5 4,5
DESCRIPTION
Numbers in parentheses refer to Fig. 1. compression loads from causing serious damage to the
components.
The function of the driveline is to transmit rotating
power from one point to another in a smooth and Note: Extra care should be taken when handling the
continuous action while allowing a degree of movement drivelines since chips, dents, burrs or deformity on any
or misalignment of the components it connects. rotating mass creates vibration and excessive wear
during any operation.
The drivelines must operate through constantly
changing relative angles between the components they There are three driveline assemblies installed between
are mounted to and must also be capable of changing various components in the tractor frame as follows:
length while transmitting torque.
Driveline assembly (1) is connected between the
A typical driveline consists of universal joints which transmission final drive and dropbox input drive.
allow some misalignment and permit the driveline to
pivot in any direction, and, a light rigid hollow slip yoke Driveline assembly (2) is connected between the front
and splined shaft assembly forming a slip joint. axle drive flange and dropbox final drive.
The slip joint accommodates length variations Driveline assembly (3) connects the rear final drive of
generated during operation, preventing tension or the dropbox to the articulation and oscillation pivot.
SM 2385 01-06 1
Drivelines - Front Drivelines
Section 130-0010
Note: Access to driveline assembly (1) can be 3. Place the shaft end of driveline assembly (1) in a
obtained from underneath the vehicle. soft jawed vice.
4. Remove Locknuts (12), washers (13 & 18) and bolts 4. Remove screws (5) and universal joint from driveline
(18), securing Support plate (11) to anti-flail guard (10). assembly (1).
Remove support plate (11).
5. Repeat steps 1 to 4 for drivelines (2 & 3).
5. Remove bolt (15), locknut (16) and washer (17)
securing anti-flail guard (10) to cross-member (6).
Remove anti flail guard (10) clear of driveline assembly INSPECTION
(1).
1. Clean all metal parts in a suitable solvent, and dry
6. Match mark universal joints and their mating all parts with compressed air.
surfaces to ensure correct mating alignment when
installing driveline assembly (1). 2. Inspect splines of shaft and yoke for nicks, burrs
and excessive wear. Replace if wear is excessive or
7. Support driveline (1) with suitable lifting equipment splines are nicked. Burrs may be removed with a fine
and remove bolts (4) securing universal joints file or medium India stone.
to their mating components and remove driveline
2 SM 2385 01-06
Drivelines - Front Drivelines
Section 130-0010
SM - 088 INSTALLATION
APPLY PRESSURE MAXIMUM PERMISSIBLE
Numbers in parentheses refer to Fig. 1.
HERE BY HAND GAP IS 0.2 mm (0.008 in)
Note: Tighten all fasteners without special torques
specified to standard torques listed in Section
STRAIGHT EDGE
300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
WARNINGS
To prevent personal injury and property
Fig. 2 - Checking Parallelism damage, be sure wheel chocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
3. Check the surfaces of the components that universal safely.
joints mate against for parallelism. Refer to Fig. 2.
4. Check condition of mounting capscrews and replace To prevent serious injury or death, DO
if required. NOT go under the vehicle when the engine is
running. Rotating shafts can be dangerous. You
5. Check that anti-flail guard (10), support plate (11) can snag clothes, skin, hair, hands, etc..
and cross-member (6) are not damaged prior to
assembly.
1. If removed at disassembly stage. Secure cross-
ASSEMBLY member (6) to chassis frame, using bolts, locknuts and
washers (9,8 & 7). Tighten bolts to a torque of 921 Nm
Universal Joint (680 Ibf ft).
Numbers in parentheses refer to Fig. 1. 2. Position driveline assembly (3) on the vehicle as
shown in Fig. 1 and align match marks on universal
1. Place the yoke end of driveline assembly (1) in a joints with those on their mating surfaces.
soft jawed vice, clamping on the tube of shaft.
3. Apply Loctite 638 to the threads of bolts (4). Secure
Note: Do not distort the tube with excessive grip. universal joints to their mating surfaces with bolts (4).
Tighten bolts (4) to a torque of 153 Nm (113 lbf ft).
2. Install universal joint to yoke end of driveline
assembly (1) and secure with screws (5). 4. Position driveline assembly (2) on the vehicle as
shown in Fig. 1 and align match marks on universal
3. Place the shaft end of driveline assembly (1) in a joints with those on their mating surfaces.
soft jawed vice.
5. Apply Loctite 638 to the threads of bolts (4). Secure
4. Install universal joint to shaft end of driveline universal joints to their mating surfaces with bolts (4).
assembly (1) and secure with screws (5). Tighten bolts (4) to a torque of 153 Nm (113 lbf ft).
5. Repeat steps 1 to 4 for drivelines (2 & 3). 6. Position driveline assembly (1) on the vehicle as
shown in Fig. 1 and align match marks on universal
joints with those on their mating surfaces.
SM 2385 01-06 3
Drivelines - Front Drivelines
Section 130-0010
7. Apply Loctite 638 to the threads of bolts (4). Secure Every 2 000 Hours: Check drivelines for leaks and
universal joints to their mating surfaces with bolts (4). damage, and replace if required.
Tighten bolts (4) to a torque of 153 Nm (113 lbf ft).
* * * *
4 SM 2385 01-06
DRIVELINES - Rear Drivelines
Section 130-0020
SM - 2944
2,3
2,3 5,6 4 5,6
DESCRIPTION centre and rear axles to the drive supplied from the
transmission, through the pivot drive arrangement, as
Numbers in parentheses refer to Fig. 1.
follows:
The function of the driveline is to transmit rotating
Driveline assembly (1) is connected between the
power from one point to another in a smooth and
articulation and oscillation pivot and the centre axle.
continuous action while allowing a degree of
movement or misalignment of the components it
Driveline assembly (4) is connected between the centre
connects.
axle and the rear axle.
The drivelines must operate through constantly
changing relative angles between the components REMOVAL
they are mounted to and must also be capable of
Numbers in parentheses refer to Fig. 1, unless
changing length while transmitting torque.
otherwise specified.
A typical driveline consists of universal joints which
Note: Extra care should be taken when handling
allow some misalignment and permit the driveline to
drivelines since carelessness can result in premature
pivot in any direction, and, a light rigid hollow slip yoke
failure of the components. Chips, dents, burrs, or any
and splined shaft assembly forming a slip joint.
other deformity of universal joints will prevent accurate
mating. This will cause misalignment which is
The slip joint accommodates length variations
accompanied by vibration and excessive wear.
generated during operation, preventing tension or
compression loads from causing serious damage to
the components.
WARNINGS
To prevent personal injury and property
Note: Extra care should be taken when handling the
damage, be sure wheel blocks, blocking
drivelines since chips, dents, burrs or deformity on any
materials and lifting equipment are properly
rotating mass creates vibration and excessive wear
secured and of adequate capacity to do the job
during any operation.
safely.
There are two driveline assemblies connecting the
SM 2386 03-06 1
Drivelines - Rear Drivelines
Section 130-0020
4. Remove screws (3) and universal joint from driveline
To prevent serious injury or death, DO assembly (1).
NOT go under the vehicle when the engine is
running. Rotating shafts can be dangerous. You 5. Repeat steps 1 to 4 for driveline (4).
can snag clothes, skin, hair, hands, etc..
INSPECTION
Disconnecting or removing any of the
rear drivelines will make the parking brake 1. Clean all metal parts in a suitable solvent, and dry
ineffective. all parts with compressed air.
1. Position the vehicle in a level work area, apply the 2. Inspect splines of shaft and yoke for nicks, burrs
parking brake and switch off the engine. Depress the and excessive wear. Replace if wear is excessive or
brake pedal continuously to relieve any pressure in the splines are nicked. Burrs may be removed with a fine
braking circuit. Turn the steering wheel several times to file or medium India stone.
relieve any pressure in the steering circuit.
3. Check the surfaces of the components that universal
2. Block all road wheels and place the battery master joints mate against for parallelism. Refer to Fig. 2.
switch in the off position.
4. Check condition of mounting capscrews and replace
Note: Access to driveline assemblies (1 & 4) can be if required.
obtained from underneath the vehicle.
ASSEMBLY
3. Match mark universal joints and their mating
surfaces to ensure correct mating alignment when Universal Joint
installing driveline assembly (1).
Numbers in parentheses refer to Fig. 1.
4. Remove capscrews (2) securing universal joints to
their mating components and remove driveline 1. Place the yoke end of driveline assembly (1) in a
assembly (1). If necessary tap driveline assembly (1) soft jawed vice, clamping on the tube of shaft.
from its mating components with a soft faced hammer.
Note: Do not distort the tube with excessive grip.
5. Match mark universal joints and their mating
surfaces to ensure correct mating alignment when 2. Install universal joint to yoke end of driveline
installing driveline assembly (4). assembly (1) and secure with screws (3).
6. Remove capscrews (5) securing universal joints to 3. Place the shaft end of driveline assembly (1) in a
their mating components and remove driveline soft jawed vice.
assembly (4). If necessary tap driveline assembly (4)
from its mating components with a soft faced hammer. 4. Install universal joint to shaft end of driveline
assembly (1) and secure with screws (3).
Universal Joint
INSTALLATION
Numbers in parentheses refer to Fig. 1.
Numbers in parentheses refer to Fig. 1, unless
1. Place the yoke end of driveline assembly (1) in a otherwise specified.
soft jawed vice, clamping on the tube of shaft.
Note: Tighten all fasteners without special torques
Note: Do not distort the tube with excessive grip. specified to standard torques listed in Section
300-0080, STANDARD BOLT AND NUT TORQUE
2. Remove screws (3) and universal joint from driveline SPECIFICATIONS.
assembly (1).
Note: Extra care should be taken when handling
3. Place the shaft end of driveline assembly (1) in a drivelines since carelessness can result in premature
soft jawed vice. failure of the components. Chips, dents, burrs, or any
2 SM 2386 03-06
Drivelines - Rear Drivelines
Section 130-0020
MAINTENANCE
Universal Joints
REMOVE ALL Every 500 Hours: Check the universal joints for wear
BURRS AND
PAINT FROM and replace if required.
THESE SURFACES
Every 2 000 Hours: Check drivelines for leaks and
damage, and replace if required.
WARNINGS With the pry bar, check the universal joints for play. If
To prevent personal injury and property loose, replace the universal joints. Check the splines at
damage, be sure wheel blocks, blocking the slip joint and replace the yoke if excessively worn.
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely. SPECIAL TOOLS
There are no special tools required for procedures
To prevent serious injury or death, DO outlined in this section. Refer to Section 300-0070,
NOT go under the vehicle when the engine is SERVICE TOOLS, for part numbers of general service
running. Rotating shafts can be dangerous. tools and adhesives required. These tools and
You can snag clothes, skin, hair, hands, etc.. adhesives are available from your dealer.
SM 2386 03-06 3
Drivelines - Rear Drivelines
Section 130-0020
* * * *
4 SM 2386 03-06
CENTRE AXLE - Differential Drive Head
Section 150-0020
Note: Never engage or disengage the Differential 8. Support the weight of differential housings (2 & 31)
Lock when moving or when the wheels are spinning. and layshaft housing (3) with suitable lifting equipment.
Remove bolts securing differential housing (2) to axle
casing and carefully remove differential assembly clear
REMOVAL AND INSTALLATION of axle casing.
Numbers in parentheses refer to Fig. 1.
INSTALLATION
Installation is the reversal of the 'Removal' procedure.
WARNING
To prevent personal injury and property Note: Use sealing compound (Loctite 574) between the
damage, be sure wheel blocks, blocking axle housing and differential housing mounting faces.
materials and lifting equipment are properly
secured and of adequate capacity to do the job Tighten bolts securing differential assembly to axle
safely. casing to 375 Nm (277 lbf ft). Tighten nuts to 280 Nm
(207 lbf ft).
1. Position the vehicle in a level work area, raise the
body and install the body safety prop to secure the Note: Tighten all fasteners to standard torques listed in
body in the partially raised position. Section 300-0080, AXLE BOLT AND NUT TORQUE
SPECIFICATIONS.
2. Apply the parking brake and switch off the engine.
Fill the layshaft housing (3) and the differential housing
3. Block all road wheels, place the steering lock bar in (31) with 1.5 litres (0.4 US gallon) of gear oil of the type
the 'Locked' position and the battery master switch in specified in Section 300-0020, LUBRICATION
the 'Off' position. SYSTEM, through the differential filler/level hole. Fill
the axle casing with gear oil of the type specified in
4. Drain the gear oil out of the axle housing and both Section 300-0020, LUBRICATION SYSTEM, through
planetaries into a suitable container. the differential filler/level hole until the oil is level with
the bottom of the filler/level hole. Fill the planetary
5. Remove the planetary assemblies and axle shafts assemblies up to the 'Oil Level Check Line'. Check oil
from the axle housing. Note from which side the long levels after a few minutes to ensure level remains
constant.
SM 2249 9-03 1
Centre Axle - Differential Drive Head
Section 150-0020
SM - 3022
2 SM 2249 9-03
Centre Axle - Differential Drive Head
Section 150-0020
SM - 3023
SM 2249 9-03 3
Centre Axle - Differential Drive Head
Section 150-0020
4 SM 2249 9-03
Centre Axle - Differential Drive Head
Section 150-0020
SM - 2954 10. Remove both bearings (17 & 18) inner rings using
special tools (15272560 Puller, 15500887 Gripping
Insert, 15500888 Gripping Insert and 15500889
Reducer) as shown in Fig. 9.
SM 2249 9-03 5
Centre Axle - Differential Drive Head
Section 150-0020
12. Using suitable lifting equipment, remove bolts (28 & SM - 3026
29) and separate layshaft housing (3) and differential
housing (31) from differential housing (2) as shown in
Fig. 11.
13. Using special tool (15269899 220V Hot Air Blower SM - 3027
or 15269900 110V Hot Air Blower) heat the slotted nut
(67) to around 120 oC before loosening using special
tools (15500890 Socket and 15270120 Clamping Yoke)
as shown in Fig. 12. Do not remove nut (67) at this
point.
15. Remove slotted nut (67), washer (66) and drive SM - 3029
6 SM 2249 9-03
Centre Axle - Differential Drive Head
Section 150-0020
SM - 3030 16. Separate flanges (45 & 62) and press out bearing (59).
Shims (60 & 99) should also be removed at this stage.
17. Pull off bearing inner race from differential case (37)
using special tool (15500906 Puller) as shown in Fig. 15.
SM - 3032 19. Loosen bolts (79) evenly and separate cylinder (78)
from the housing (31) as shown in Fig. 17.
SM - 1111 20. Remove switch (86), seal ring (85) and contact pin
(84) from housing (31) as shown in Fig. 18. Remove
both shifter fork lock pins (71).
SM 2249 9-03 7
Centre Axle - Differential Drive Head
Section 150-0020
21. Remove shifter fork assembly (69) and piston (74) SM - 1116
assembly as shown in Fig. 19.
25. Press out quill shaft (40) using special tool SM - 3034
(15269946 Puller Set) as shown in Fig. 21.
26. Remove adjusting ring (25) from shaft (40). Support SM - 3035
shaft (40) on sliding dog (68) and press off bearing (24)
inner race as shown in Fig. 22.
8 SM 2249 9-03
Centre Axle - Differential Drive Head
Section 150-0020
SM - 2962 27. Remove bearing (23) inner race and spacer ring
(26) from housing (3) as shown in Fig 23.
SM - 3037 29. Using special tool (15269899 220V Hot Air Blower
or 15269900 110V Hot Air Blower) heat slotted nut (22)
to around 120 oC before removing using special tool
(15500891 Socket). Block spur gear (98) with wooden
block, as shown in Fig. 25.
SM - 2965 30. Press pinion gear (96) out of bearing (12) using
special tool (15269946 Puller Set) as shown in Fig. 26.
Remove bearing (12) inner race from housing (3).
SM 2249 9-03 9
Centre Axle - Differential Drive Head
Section 150-0020
31. Pull off the bearing (15) inner race from the pinion SM - 2966
gear (96) using special tools (15500892 Gripping Insert
and 15272560 Bearing Puller).
32. Remove bush spacer (13) and adjusting ring (14) SM - 2967
from layshaft housing (3). Using special tool (15269946
Puller Set) press out bushing (10) as shown in Fig. 28.
33. Press out the bearing (15) outer ring from the
bushing (10) and remove the shim (16).
INSPECTION SM - 2968
10 SM 2249 9-03
Centre Axle - Differential Drive Head
Section 150-0020
SM - 2970 Note: If either ring gear or pinion gear is defective, both
gears must be replaced, because they are serviced
only as a matched set. Make sure the ring gear and
pinion gear have the same mating numbers.
SM - 2971 ASSEMBLY
Numbers in parentheses refer to Figs. 1 & 2 unless
specified otherwise.
Fig. 33 - Measuring Dimension 'A' 3. Insert spur gear (98) into housing (3) bore, ensuring
that inner diameter (85 mm) is facing down, as shown
SM - 2973 in Fig. 31.
SM 2249 9-03 11
Centre Axle - Differential Drive Head
Section 150-0020
Eg. Dimension 'A' = 29.70 mm SM - 2974
Example:
Dimension 'D' 42.70 mm
+ Dimension 'E' 197.90 mm
Example:
Dimension 'X' 241.45 mm
- Dimension 'Y' 240.60 mm
12 SM 2249 9-03
Centre Axle - Differential Drive Head
Section 150-0020
SM - 2977 11. Freeze bearing (15) outer race and install in
bushing (10), ensuring it is firmly home.
WARNING
To prevent personal injury, wear protective
gloves when handling bearing.
WARNING
To prevent personal injury, wear protective
gloves when handling bearing.
SM - 2979 14. The adjusting ring (14) is used to obtain the rolling
resistance of the pinion bearing. Rolling resistance
should be 3.5 - 4.0 Nm (2.6 - 2.9 lbf ft). This rolling
resistance is checked once pinion gear (96) is secured
in housing (3) (Step 17).
As shown in Fig. 42, install bush spacer (13) with the
small collar showing up (ref. arrow) into the bore of the
spur gear (98) and install adjusting ring (14).
SM 2249 9-03 13
Centre Axle - Differential Drive Head
Section 150-0020
15. Heat inner race of bearing (12) to approximately 90° SM - 2980
C (190° F) and press it on to the shaft of pinion gear
(96) until it is firmly home as shown in Fig. 43.
WARNING
To prevent personal injury, wear protective
gloves when handling bearing.
16. Coat threads of slotted nut (22) with Loctite 649. SM - 2981
Locate washer (21) and install slotted nut (22). Using
special tool (15500891 Socket) tighten slotted nut (22)
to a torque of 1200 Nm (885 lbf ft).
Note: When tightening nut (22), rotate the pinion gear (96)
in both directions several times.
14 SM 2249 9-03
Centre Axle - Differential Drive Head
Section 150-0020
SM - 3040 21. Insert the slotted pin (32) (ref. arrow) and new bolts
(64) as shown in Fig. 49. Torque bolts (64) to 155 Nm
(114 lbf ft).
SM - 3041 22. Install sliding dog (68) on quill shaft (40) with the
gearing showing downwards as shown in Fig. 50.
SM 2249 9-03 15
Centre Axle - Differential Drive Head
Section 150-0020
23. Press bearing (24) inner race onto quill shaft (40) SM - 3042
until it is firmly home as shown in Fig. 51.
26. The spacer ring (26) is used to obtain the rolling SM - 2985
resistance of the shaft (40) bearing. Rolling resistance
should be 0.5 - 2.0 Nm (0.37 - 1.48 lbf ft). This rolling
resistance (THo) is calculated once shaft (40) is
secured in housing (Step 29). As shown in Fig. 54,
install spacer ring (26) on shaft (40) with the collar
facing down.
16 SM 2249 9-03
Centre Axle - Differential Drive Head
Section 150-0020
WARNING
To prevent personal injury, wear protective
gloves when handling bearing.
Example:
Ttot e.g. 4.5 Nm
Tpinion e.g. - 3.5 Nm
Results in THo = 1.0 Nm
SM 2249 9-03 17
Centre Axle - Differential Drive Head
Section 150-0020
31. Place 'U' section ring (75) on piston (74) with SM - 3046
sealing lip towards outside. Slide spring (76) on the
piston stem. Locate the centering ring (77) in the
recess as denoted by arrow in Fig. 59. Insert the
assembled piston into its bore in differential housing
(31). Be sure the piston stem makes contact with
shifter fork (69).
32. Place new seals (73) on shifter fork lock pins (71). SM - 3047
Position the shifter fork assembly (69) and fix in place
with shifter fork lock pins (71) as shown in Fig. 60.
Secure lock pins (71) with bolts (72) and torque to 45
Nm (33 lbf ft).
18 SM 2249 9-03
Centre Axle - Differential Drive Head
Section 150-0020
SM - 3050 35. Install side gear (41) in differential case half (37).
SM - 3051 37. Install differential case half (37) and fasten with
capscrews (11). Tighten capscrews to 115 Nm (85 lbf
ft).
ZF-No.:
SM - 3053
39. On flange (45) measure Dimension 'B' from the
mounting face to the locating face as shown in Fig. 66.
Example:
Dimension 'B' 6.70 mm
Dimension 'A' - 5.00 mm
= 1.70 mm
Required End Float + 0.20 mm
Shim (99) Dimension = 1.90 mm
Fig. 66 - Measuring Dimension 'B' Place calculated shim (99) into the flange (45).
SM 2249 9-03 19
Centre Axle - Differential Drive Head
Section 150-0020
40. Press bearing (59) into flange (45) until firmly SM - 3054
home.
41. Install both bearing (59) inner rings. Place pre- SM - 3055
assembled flange (45) on inter-axle differential and
press until firmly home as shown in Fig. 68.
42. Using special tool (15269899 220V Hot Air Blower SM - 3056
or 15269900 110V Hot Air Blower) heat housing (31)
bore and coat mounting face with sealing compound
Loctite 574.
20 SM 2249 9-03
Centre Axle - Differential Drive Head
Section 150-0020
Example:
Dimension 'Y' 11.10 mm
Dimension 'X' - 10.40 mm
Shim (60) Dimension = 0.70 mm
SM - 3060 48. Press dust cap (95) onto drive flange (94) using
special tools (15500909 Driver and 15270121 Handle).
49. Install drive flange (94) and secure with washer (66)
and slotted nut (67). Using special tools (15500890
Socket and 15270120 Clamping Yoke) tighten nut to
1 000 Nm (738 lbf ft).
SM 2249 9-03 21
Centre Axle - Differential Drive Head
Section 150-0020
52. Install contact pin (84), seal ring (85) and contact SM - 3062
switch (86). Connect special tool (15500911 Indicator)
as shown in Fig. 75.
54. Install disc (83) and filter element (80) in bore SM - 3064
arrowed in Fig. 77. Cover port until final installation of
hose.
22 SM 2249 9-03
Centre Axle - Differential Drive Head
Section 150-0020
SM - 3074 56. Heat ring gear (46) and install it on the differential
housing (47) until it is firmly home as shown in Fig. 79.
WARNING
To prevent personal injury, wear protective
gloves when handling ring gear.
SM 2249 9-03 23
Centre Axle - Differential Drive Head
Section 150-0020
60. Install side gear (51) as shown in Fig. 83. Ensure SM - 3002
62. Install second side gear (51) as shown in Fig. 85. SM - 3004
63. Install second thrust ring (50) as shown in Fig. 86. SM - 3005
24 SM 2249 9-03
Centre Axle - Differential Drive Head
Section 150-0020
SM - 3006 64. Install disc set B (Fig. 2) beginning with internally
splined disc (49) as shown in Fig. 87.
SM - 3008 66. Measure Dimension 'B' from the contact face to the
mounting face of housing cover (57) using special tool
(15270114 Digital Depth Gauge) as shown in Fig. 89.
Example:
Dimension 'A' 4.30 mm
Dimension 'B' 4.00 mm
Results in clearance 0.30 mm
Fig. 90 - Installing Thrust Washers Note: If necessary to change the outer externally
SM 2249 9-03 25
Centre Axle - Differential Drive Head
Section 150-0020
68. Place both thrust washers (52 & 54) in the cover
(57), installing steel thrust washer (52) first as shown in
Fig. 90.
70. Heat bearings (17 & 18) inner races and install on SM - 3011
assembled differential, as shown in Fig. 91.
WARNING
To prevent personal injury, wear protective
gloves when handling bearing.
72. Install adjusting nuts (1 & 19) and locate bearing SM - 3012
caps using bolts and washers as shown in Fig. 93.
Coat thread of bearing cap bolts with Loctite 649.
Torque bolts to 390 Nm (288 lbf ft).
26 SM 2249 9-03
Centre Axle - Differential Drive Head
Section 150-0020
SM - 3014 74. Check the backlash between ring gear (46) and
pinion gear (96). Mount special tools (15500897
Magnetic Stands and 15500898 Dial Indicator) at right
angles to the outer diameter of the ring gear tooth flank
as shown in Fig. 95. Establish the backlash by
alternately setting both adjusting nuts (1 & 19). Rock
the ring gear back and forth being careful not to move
the pinion gear. Backlash should be 0.27 - 0.33 mm.
SM - 3015 75. Determine the bearing (17 & 18) rolling resistance
and bracket dimension by further tightening of both
adjusting nuts (1 & 19). The bearing rolling resistance
should be 3 - 4 Nm (2.2 - 2.9 lbf ft). Measure bracket
dimension as shown in Fig. 96 using 15500899
Micrometer. Dimension should be 358-0.1 mm.
SM - 891 76. To check the tooth pattern of ring gear (46), coat
about twelve ring gear teeth with prussian blue, oiled
red lead or some other easily removed print or dye.
When the pinion is rotated, the paint is squeezed away
by the contact of the teeth, leaving bare areas the
exact size, shape and location of the contacts as
shown in Fig. 97.
SM - 3016 77. Fasten adjusting nuts (1 & 19) with slotted pins (20)
as shown in Fig. 98.
SM 2249 9-03 27
Centre Axle - Differential Drive Head
Section 150-0020
28 SM 2249 9-03
Rear Axle Group - Axle Group (Hub)
Section 160-0030
WARNINGS
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly Fig. 2 - Install adjusting screws.
secured and of adequate capacity to do the job
safely.
9. Remove drain plugs and drain cooling oil from brake
packs into a clean container. Refit drain plugs.
To prevent personal injury and property
damage, the procedure for removing tyre and
10. Index mark planet carrier (16) and hub (8) to aid in
rim assembly described in Section 160-0050,
installation as shown in Fig. 2.
WHEEL, RIM AND TYRE, must be strictly
followed.
11. Loosen bolts (23) and install adjusting screws
When necessary to drive out components (15502331) to aid in removal of planet carrier (16) sub
assembly as shown in Fig. 2. Remove bolts (23) then
during disassembly, be sure to use a soft drift
prise planet carrier (16) from hub (8) and remove with
to prevent property damage and personal
suitable lifting equipment (15501178) as shown in
injury.
Fig. 3.
1. Before attempting to remove the road wheels, drive SM - 3451
the vehicle onto a level, solid concrete floor, preferably
after a short run to warm the oil.
SM - 3453 16. Remove two lock screws (13) and remove locking
plate (12) from the ring gear (10) as shown in Fig. 8.
17. Remove slotted nut (28) from hub carrier (1) with
the special tools (15500882, Socket and 15500883
Centering Bracket) as shown in Fig. 9.
SM - 3456
Fig. 5 - Extracting Planet Gears.
SM - 3455 SM - 3457
SM - 896 SM - 899
Fig. 107 - Drive Side (Convex) Fig. 110 - Drive Side (Convex)
SM - 897 SM - 900
Fig. 108 - Pinion Distance Must Be Decreased Fig. 111 - Pinion Distance Must Be Increased
SM - 898
SM 2249 9-03 31
Centre Axle - Differential Drive Head
Section 150-0020
DIFFERENTIAL DIAGNOSIS
Noises and vibrations originating in the tyres, WARNING
transmission, planetaries and drivelines are easily To prevent personal injury and property
transmitted and may be erroneously attributed to the damage, be sure wheel blocks, blocking
differential. Therefore, all possible sources of noise materials and lifting equipment are properly
should be investigated before the differential is taken secured and of adequate capacity to do the job
apart. safely.
DIAGNOSIS CHART
CONDITION REASON REMEDY
Vibration Broken gear teeth, worn bearings Replace gear or bearings
Continual noise Worn gear or bearings Replace gear or bearings
Noise on drive Ring or pinion gear adjustment tight Adjust
Noise on coast Bearings damaged Replace bearings
Ring and pinion gear adjustment loose Adjust
Excessive pinion gear end play Adjust
32 SM 2249 9-03
Centre Axle - Differential Drive Head
Section 150-0020
* * * *
SM 2249 9-03 33
THIS PAGE IS INTENTIONALLY LEFT BLANK
REAR AXLE GROUP - Differential Drive Head
Section 160-0020
SM - 849
SM 2248 8-03 1
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 2949
6
5
10 A
7 4
3
4
3
11 12
2
1 2
11
3
4
3
4 9
B
5
2 SM 2248 8-03
Rear Axle Group - Differential Drive Head
Section 160-0020
4. Drain the gear oil out of the axle housing and both Tighten bolts securing differential assembly to axle
planetaries into a suitable container. housing to 375 Nm (277 lbf ft). Tighten nuts to 280 Nm
(207 lbf ft).
5. Remove the planetary assemblies and axle shafts
from the axle housing. Note from which side the long Note: Tighten all fasteners without specified torques to
and short axle shafts are removed. Refer to Section standard torques listed in Section 300-0080,
160-0030, AXLE GROUP (HUB). STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
6. Identify the relationship of the driveline flange and
differential pinion flange with punch marks. Fill the layshaft housing (3) with 1.5 litres (0.4 US
gallon) of gear oil of the type specified in Section 300-
7. Disconnect the driveline from the differential drive 0020, LUBRICATION SYSTEM, through the differential
flange. The driveline can be removed if it is convenient filler/level hole. Fill the axle casing with gear oil of the
to do so. type specified in Section 300-0020, LUBRICATION
SYSTEM, through the differential filler/level hole until
8. Index mark differential housing (1) and the axle the oil is level with the bottom of the filler/level hole. Fill
housing to ensure that differential housing (1) is the planetary assemblies up to the 'Oil Level Check
installed in the same position. Line'. Check oil levels after a few minutes to ensure
level remains constant.
SM 2248 8-03 3
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 2950
42
1 43
39 40,41
5
12 10
44
11
10
38
8
9 14
13
18
23 26
19 21
24
22 25
32
33
20
34
2
3 35
27
4 28
29,30 15
6 36
7 16
31 37
17
4 SM 2248 8-03
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 3020 DISASSEMBLY
Numbers in parentheses refer to Fig. 3.
WARNING
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.
SM 2248 8-03 5
Rear Axle Group - Differential Drive Head
Section 160-0020
5. Using special tool (15269899 220V Hot Air Blower or SM - 2953
15269900 110V Hot Air Blower) heat the area around
the threaded holes and loosen bolts securing bearing
caps. Remove bearing caps.
7. Remove both bearings (12 & 44) inner rings using SM - 2954
special tools (15272560 Puller, 15500887 Gripping
Insert, 15500888 Gripping Insert and 15500889
Reducer) as shown in Fig. 10.
6 SM 2248 8-03
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 2957 10. Using special tool (15269899 220V Hot Air Blower
or 15269900 110V Hot Air Blower) heat the slotted nut
(2) to around 120 oC before loosening using special tool
(15500890 Socket) as shown in Fig. 13. Remove
slotted nut (2), washer (3) and drive flange (4).
SM - 2958 11. Remove bolts (39) and seal holder (5) from cover
(14) as shown in Fig. 14.
SM - 2959 12. Remove retainer (35) and shim support (34) from
layshaft housing (26) as shown in Fig. 15.
SM 2248 8-03 7
Rear Axle Group - Differential Drive Head
Section 160-0020
13. As shown in Fig. 16 use special tool (15269946 SM - 2960
Puller Set) to press quill shaft (11) out of the bearing.
14. Remove spacer (9) and press the bearing (8) inner SM - 2961
race from the shaft (11).
15. Remove bearing (33) inner race and spacer (32) SM - 2962
from housing (26).
16. Remove bolts (19) and separate cover (14) from SM - 2963
layshaft housing (26) as shown in Fig. 19. Remove
spur gear (13) at this time.
8 SM 2248 8-03
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 2964
17. Using special tool (15269899 220V Hot Air Blower
or 15269900 110V Hot Air Blower) heat slotted nut (21)
before removing using special tool (15500891 Socket)
as shown in Fig. 20.
SM - 2965 18. With the special tool (15269946 Puller Set) shown
in Fig. 21, press the pinion gear (17) out of the bearing
(23).
SM - 2966 19. Pull off the bearing (16) inner race from the pinion
gear (17) using special tools (15500892 Gripping Insert
and 15272560 Bearing Puller).
SM - 2967 20. Remove adjusting ring (24) and spacer bush (25)
from housing (26). Using special tool (15269946 Puller
Set) press out bushing (37) and spacing washer (15).
SM 2248 8-03 9
Rear Axle Group - Differential Drive Head
Section 160-0020
INSPECTION SM - 2968
ASSEMBLY
Numbers in parentheses refer to Fig. 3.
WARNING
SM - 2971
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.
10 SM 2248 8-03
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 2972 3. Insert spur gear (36) into housing (26) bore, ensuring
that inner diameter (85 mm) is facing down, as shown
in Fig. 26.
Example:
Dimension 'A' 29.70 mm
+ Dimension 'B' 196.75 mm
- Dimension 'C' (1/2 diameter of Measuring
Shaft) 15.00 mm
SM 2248 8-03 11
Rear Axle Group - Differential Drive Head
Section 160-0020
9. The arrow in Fig. 32 is pointing to a dimension SM - 2975
stamped on the face of pinion gear (17). Record as
Dimension 'E'.
Example:
Dimension 'D' 42.70 mm
+ Dimension 'E' 197.90 mm
Example:
Dimension 'X' 241.45 mm
- Dimension 'Y' 240.60 mm
WARNING
To prevent personal injury, wear protective
gloves when handling bearing.
WARNING
To prevent personal injury, wear protective
gloves when handling bearing.
12 SM 2248 8-03
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 2979 14. The adjusting ring (24) is used to obtain the rolling
resistance of the pinion bearing. Rolling resistance
should be 3.5 - 4.0 Nm (2.6 - 2.9 lbf ft). This rolling
resistance is checked once pinion gear (17) is secured
in housing (26) (Step 17).
As shown in Fig. 37, install spacer bush (25) with the
small collar showing up (ref. arrow) into the bore of the
spur gear (36) and install adjusting ring (24).
WARNING
To prevent personal injury, wear protective
gloves when handling bearing.
SM - 2981 16. Coat threads of slotted nut (21) with Loctite 649.
Locate washer (22) and install slotted nut (21). Using
special tool (15500891 Socket) tighten slotted nut (21)
to a torque of 1200 Nm (885 lbf ft).
Note: When tightening nut (21), rotate the pinion gear (17)
in both directions several times.
SM 2248 8-03 13
Rear Axle Group - Differential Drive Head
Section 160-0020
17. Check the rolling resistance of the pinion bearing SM - 2982
as shown in Fig. 40 by using special tool (15500895
Torque Spanner). If the rolling resistance is outwith
range (3.5 - 4.0 Nm), adjusting ring (24) thickness must
be changed.
19. Install quill shaft (11) into housing (26) using SM - 2984
special tool (15269946 Puller Set) as shown in Fig. 42.
Do not remove special tool at this point.
20. On the other side of shaft (11), install spacer (32) SM - 2985
with the collar facing down as shown in Fig. 43.
14 SM 2248 8-03
Rear Axle Group - Differential Drive Head
Section 160-0020
WARNING
To prevent personal injury, wear protective
gloves when handling bearing.
SM - 2987 22. Install shim support (34) and snap in the retainer
(35) as shown in Fig. 45.
SM - 2989 24. Press bearing (8) outer race into cover (14) until firmly
home, as shown in Fig. 47.
SM 2248 8-03 15
Rear Axle Group - Differential Drive Head
Section 160-0020
25. Apply Loctite 574 to mounting face of housing (26) SM - 2990
as shown in Fig. 48. Place the housing cover (14) on
housing (26) and secure using pin (20) and new bolts
(19). Torque bolts (19) to 155 Nm (114 lbf ft).
E
CTIT
LO
Fig. 48 - Applying Loctite 574
WARNING
To prevent personal injury, wear protective
gloves when handling bearing.
16 SM 2248 8-03
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 2994 29. Coat outer diameter of shaft seal (7) with Loctite
574 and install in seal holder (5) using special tool
(15500896 Driver). Ensure sealing lip faces inboard.
SM - 2995 30. Press dust shield (6) over drive flange (4) as shown
in Fig. 53.
SM - 2996 31. Coat threads of slotted nut (2) with Loctite 649.
Coat faces of washer (3) with Loctite 574. Assemble
drive flange (4), washer (3) and slotted nut (2) on shaft
(11). Using special tools (15500890 Socket and
15270120 Clamping Yoke) torque slotted nut (2) to 750
Nm (553 lbf ft) as shown in Fig. 54.
Example:
Ttot e.g. 5.5 Nm
Tpinion e.g. - 3.5 Nm
Results in TAn = 2.0 Nm
SM 2248 8-03 17
Rear Axle Group - Differential Drive Head
Section 160-0020
33. Coat mounting face of differential housing (1) with SM - 2998
35. Heat ring gear (18) and install it on the differential SM - 3074
WARNING
To prevent personal injury, wear protective
gloves when handling ring gear.
37. Install disc set A (Fig. 2) in housing (9, Fig. 2), SM - 3000
beginning with externally splined disc (3, Fig. 2) as
shown in Fig. 59.
18 SM 2248 8-03
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 3001 38. Install thrust ring (5, Fig. 2) as shown in Fig. 60.
SM - 3002 39. Install side gear (6, Fig. 2) as shown in Fig. 61.
Ensure both internally splined discs (4, Fig. 2) of set A
are located on side gear (6, Fig. 2).
SM - 3004 41. Install second side gear (6, Fig. 2) as shown in Fig.
63.
SM 2248 8-03 19
Rear Axle Group - Differential Drive Head
Section 160-0020
42. Install second thrust ring (5, Fig. 2) as shown in SM - 3005
Fig. 64.
45. Measure Dimension 'B' from the contact face to the SM - 3008
mounting face of housing cover (1, Fig. 2) using
special tool (15270114 Digital Depth Gauge) as shown
in Fig. 67.
20 SM 2248 8-03
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 3009 46. With reference to Steps 44 - 45, calculate
clearance as shown in the example below.
Example:
Dimension 'A' 4.30 mm
Dimension 'B' 4.00 mm
Results in clearance 0.30 mm
Fig. 68 - Installing Thrust Washers Note: If necessary to change the outer externally
splined discs (3, Fig. 2) to obtain correct clearance,
SM - 3010
these should be changed so that the overall thickness
of disc sets A and B (Fig. 2) are identical.
49. Heat bearings (12 & 44) inner races and install on
SM - 3011
assembled differential, as shown in Fig. 69.
WARNING
To prevent personal injury, wear protective
gloves when handling bearing.
SM - 3012 51. Install adjusting nuts (10) and locate bearing caps
using bolts and washers as shown in Fig. 71. Coat
thread of bearing cap bolts with Loctite 649. Torque
bolts to 390 Nm (288 lbf ft).
SM 2248 8-03 21
Rear Axle Group - Differential Drive Head
Section 160-0020
22 SM 2248 8-03
Brake Assembly - Oil Cooled Disc Brakes
Section 165-0015
27
26
25
24
X
23
22
SM - 3136 Fig. 27 - Retaining Support Shim in Piston
SM - 3134 Fig. 25 - Pin installation Detail 10. Insert the pre-assembled support shim into position
and fasten by means of Snap ring (27) as shown
8. Refer to fig. 25, Mount cup spring (24) onto the pin. in Fig. 27
12. Refer to fig. 29, Grease 'O' -ring (4) and insert into
pressure oil supply bore.
13. Grease the 'O' -ring (12) and insert into the annular
groove. Install plug (9) with a new 'O'- ring (10) as
SM - 3135 Fig. 26 - Locking pins to support shim
shown in fig. 29
14 27 X
1 22 25 28
8 SM 2390 01-06
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 893 SM - 896
SM - 894 SM - 897
24 SM 2248 8-03
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 898
SM - 899
SM - 900
SM 2248 8-03 25
Rear Axle Group - Differential Drive Head
Section 160-0020
DIAGNOSIS CHART
CONDITION REASON REMEDY
Vibration Broken gear teeth Replace damaged gear
Excessive run-out of pinion or flanged case Disassemble, correct or replace faulty
part
Continual noise Bearing worn Replace worn parts
Gears damaged or worn Replace gears
Noise on drive Ring or pinion gear adjustment tight Adjust
Noise on coast Bearings damaged Replace bearings
Loose ring and pinion gear adjustment Adjust
Excessive pinion gear end play Adjust
Noise on turns Normal limited slip differential operation Use an EP oil with limited slip
additives. Refer to Section 300-0020,
LUBRICATION SYSTEM
Worn pinion gears or side gears Replace gears
Worn or damaged axles (spiders) Replace axles (spiders)
Loss of lubricant Oil seals worn Replace seals
Loose nuts or bolts Tighten nuts or bolts to correct torque
Cracked housing/case Repair or replace housing/case
26 SM 2248 8-03
Rear Axle Group - Differential Drive Head
Section 160-0020
* * * *
SM 2248 8-03 27
THIS PAGE IS INTENTIONALLY LEFT BLANK
REAR AXLE GROUP - Axle Group (Hub)
Section 160-0030
SM - 3449
27 25
6 5
7
4
8 23
30
17 18
3
1 19
12
13 26
22
14
16 24
15
28
21 20,29
10
9
11
OPERATION
Numbers and letters in parentheses refer to Fig. 1. with sun gear shaft (14) rotate anticlockwise. Ring gear
(9) is splined to hub carrier (1) and does not rotate but
Power from the differential is transmitted through a causes planet gears (20), which are meshed with ring
fully floating axle shaft connected to sun gear shaft (14) gear (10), to move around it in a clockwise direction.
by driver (15). As sun gear shaft (14) rotates in a As planet carrier (16) is bolted to wheel hub (8) the
clockwise direction, the three planet gears (20) meshed wheel then rotates in a clockwise direction.
WARNINGS
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly Fig. 2 - Install adjusting screws.
secured and of adequate capacity to do the job
safely.
9. Remove drain plugs and drain cooling oil from brake
packs into a clean container. Refit drain plugs.
To prevent personal injury and property
damage, the procedure for removing tyre and
10. Index mark planet carrier (16) and hub (8) to aid in
rim assembly described in Section 160-0050,
installation as shown in Fig. 2.
WHEEL, RIM AND TYRE, must be strictly
followed.
11. Loosen bolts (23) and install adjusting screws
When necessary to drive out components (15502331) to aid in removal of planet carrier (16) sub
assembly as shown in Fig. 2. Remove bolts (23) then
during disassembly, be sure to use a soft drift
prise planet carrier (16) from hub (8) and remove with
to prevent property damage and personal
suitable lifting equipment (15501178) as shown in
injury.
Fig. 3.
1. Before attempting to remove the road wheels, drive SM - 3451
the vehicle onto a level, solid concrete floor, preferably
after a short run to warm the oil.
SM - 3453 16. Remove two lock screws (13) and remove locking
plate (12) from the ring gear (10) as shown in Fig. 8.
17. Remove slotted nut (28) from hub carrier (1) with
the special tools (15500882, Socket and 15500883
Centering Bracket) as shown in Fig. 9.
SM - 3456
Fig. 5 - Extracting Planet Gears.
SM - 3455 SM - 3457
SM - 3458 INSPECTION
Numbers in parentheses refer to Fig. 1.
WARNING
To prevent personal injury and property
damage, be sure lifting equipment is properly
secured and of adequate capacity to do the job
safely.
21. Unsnap snap ring (11) and separate the ring gear SM - 3122
carrier (9) from the ring gear (10) as shown in Fig. 13.
SM - 3460
3. Insert roller bearing (7), U-ring (4) and shaft seal (3)
22. Using a suitable pry bar 15270131, lever and press into hub (8). Shaft seal (3) should be inserted with
shaft seal (3) out of the hub carrier (1) bore and remove care, using special tools; mounting tool 15501177 and
U-ring (4). If required remove both bearing (5 & 7) outer handle 15269898. Refer to Fig. 14.
races from the bore of the hub (8).
SM - 3468 SM - 3471
28
30
15
SM - 3470
12
23. Insert sun gear shaft (14) into position over thrust
washer (22) as shown in Fig. 31. Note: Ensure o-ring
(19) is grease and fitted at this time as well.
SM - 3478
14
Fig. 28 - Measurement
20. Measure dimension from mounting face of planet Fig. 31 - Fit Sun Gear
gear (20) to contact surface of thrust washer (22) using
measuring equipment used in previous step, including 24. Using suitable lifting tackle 15502405 and adjusting
block gauges 15502404. Call this dimension 'B'. Refer screws 15502331 to aid in location, insert planet carrier
to Fig. 29. (16) sub-assembly into ring gear (10) bore and locate it
SM - 3476
in the hub (8) till fully home. Refer to Fig. 32.
SM - 3479
23
MAINTENANCE
Proper lubrication of the axle group is essential if axles
are to deliver the service intended. Section
300-0020, LUBRICATION SYSTEM gives full
information on the proper lubrication intervals and the
lubricant which should be used.
24 SPECIAL TOOLS
Fig. 34 - Torque Bolts
The special tools referenced throughout this section
are available from your dealer. Refer to Section
26. Secure plug screw (18), o-ring (17) and plug (26) in 300-0070, SERVICE TOOLS, for part numbers of
place on planet carrier (16) face as shown in Fig. 35. general service tools and sealants required.
Torque plug (18) to a value of 40 Nm (29.5 Ibf ft) and
torque plug (26) to a value of 150 Nm (111 Ibf ft).
SM - 3482
18
26
WARNING
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.
* * * *
SM - 1176
FROM MACHINE
Numbers in parentheses refer to Fig. 1.
WARNING
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.
3. Break outer tyre bead loose with pry bar shown in INSPECTION
Fig. 3.
Tyre
4. Insert flat hooked end of pry bar into breaking slots Check the interior surface of the tyre to determine its
between bead seat band (3) and outer flange (1) (See condition. Inspect for cuts or fabric breaks that have
Fig. 4). A pipe over the straight end of the pry bar will penetrated the tyre body. The casing should be
increase leverage. inspected closely for any sharp , pointed object that
may have penetrated the tyre body but is invisible from
5. Twist bar toward tyre to break bead. the outside. All dust, dirt, water or other foreign matter
should be cleaned from the inside of tyre.
6. A second bar may be inserted in space between
bead seat band (3) and outer flange (1). Twist second Rim Assembly
bar to maintain space gained by the first bar.
Overloading, improper tyre inflation, rough terrain, high
7. Move the first bar around the rim, twisting and speed, accidents, dirt accumulation, and corrosion all
following with the second bar, until the outer tyre bead tend to reduce the service life of rims and rim
is loose. components. It is recommended that rims be
inspected, as below, not less often than at every tyre
8. Pry bead seat band (3) away from lock ring (4) by change and that, as the warranty limit approaches,
placing hooked end of pry bar in groove of wheel rim consideration be given to periodic replacement.
(5), between ends of lock ring (4), and prying up with
bar. Using two bars, as in Step 7, work completely The rim and its components are designed with built-in
around wheel rim (5). safety factors, to prevent the components from flying
off with killing force during inflation. Check components
9. Pry lock ring (4) out in same manner by starting at for cracks, bends, distortion, or other damage. If
prying notch in rim assembly and work all the way damage is found, the component must be replaced.
around rim with two pry bars.
10. Remove and discard 'O' ring (2, Fig. 1). WARNING
Never mix components of one manufacturer's
11. Remove lock ring (4), pry out and remove bead rims with those of another. Using the rim base
seat band (3). of one manufacturer with the lock ring of
another or vice versa is dangerous. The lock
12. Breaking slots are provided inside the rims. The ring of one may not fully engage with the lock
inner bead may be broken as described in Steps 4 ring groove of the other. Always consult the
through 8. If tyre and rim assembly are on the rim manufacturer for proper matching and
machine, the following procedure may be used for assembly instructions. Also, use and servicing
breaking the inner bead. of damaged, worn out, or improperly
assembled rim assemblies is a very dangerous
13. Place jack between inner flange (6) and machine practice. Failure to comply with the above
frame. Extend jack until tyre bead is broken. Continue warnings could result in explosions from tyre
around rim until tyre bead is broken at all points. pressure causing serious personal injury and
property damage.
Clean all rust and dirt from the rim parts and wheel SM - 207
Rubber 'O' rings are air seals for tubeless tyre and rim
assemblies and therefore should be carefully handled
to provide an airtight seal when the tyre is remounted
on the rim. Always use new 'O' rings when mounting a
tubeless tyre. 1 - Lock Ring 2 - Drive Lug
Fig. 5 - Installing Typical Lock Ring
Note: Handle 'O' rings carefully, as damage will
prevent an airtight seal for tyre inflation. soft hammer to rotate lug. Use bar for installing lock
ring, as illustrated in Fig. 5.
MOUNTING TYRE ON RIM 8. Force bead seat band (3) past 'O' ring groove in
Numbers in parentheses refer to Fig. 2, unless wheel rim (5) by prying, or with lift truck forks. Use
otherwise specified. blocking between the forks and tyre to prevent
damage. Insert a new 'O' ring (2, Fig. 1) in groove of
For mounting a tyre with rim on or off machine, the the rim behind lock ring (4). Lubricate area of front
procedure is basically the same. taper of bead seat band adjacent to 'O' ring, with a thin
solution of soap and water or another approved
lubricant which is not harmful to rubber. Avoid using an
WARNING excessive amount of lubricant.
When lifting tyre onto rim, be sure the
equipment is of sufficient capacity and 9. Install driver (2). Make sure all rim components are
properly secured to do the job safely. correctly assembled.
1. For off-machine installation, lay rim on blocks or 10. Lift the tyre upwards to effect a seal between bead
mounting stand with 'O' ring groove up. Rim should be seat band (3) and 'O' ring (2, Fig. 1). In some cases
off floor enough to allow tyre to rest on rim and not on the tyre will automatically spring out, making this step
floor. Blocks are not to extend more than 13 mm unnecessary.
(0.50 in) beyond rim base.
11. Refer to 'Tyre Inflation' in this section for the proper
2. If removed, install inner flange (6) over wheel rim (5). procedure for inflating the tyre.
TYRE INFLATION D.
Do not charge batteries, either in or out of a
machine, near the air inlet of a compressor
WARNING used for inflating tyres. Charging batteries
To prevent personal injury and property produces highly explosive hydrogen gas
damage, the tyre and rim assembly should be which can be readily drawn into a nearby
placed in a safety cage before inflating. If no compressor inlet and pumped into the tyre.
safety cage is available or tyre is on the
machine, the tyre and rim assembly should be E.
wrapped with safety chains or with lash cables Never exceed the specified concentration of
before inflating. alcohol when adjusting the alcohol vaporizer,
or adding alcohol to the auxiliary air tank, used
Even with these precautions remember that on machine air systems to prevent freezing or
air-blast is a potential hazard. Tyre inflation moisture condensate in below-freezing
should be carried out away from busy working temperatures. Excessive alcohol, added to the
areas. machines air tanks in this manner can produce
flammable vapours that will be pumped into a
WARNING tyre when this air supply is used for tyre
To avoid personal injury and property damage, inflation if the tyre inflation kit is not equipped
never stand or sit in front of a mounted tyre with a moisture filter. Alcohol added to
during tyre inflation. Use a clip-on air chuck machine air systems in recommended
with a long hose and stand to one side while concentration to prevent condensate freezing
the tyre is being inflated. are below hazardous levels for tyre inflation.
WARNING F.
To prevent personal injury and property Another source of hazardous flammable
damage, always prevent flammable vapours vapours in tyres is the tyre bead lubricant.
that could produce tyre explosions, from being Always use bead lubricants that do not
pumped into tyres during inflation, by introduce flammable vapours into the tyre.
observing the following precautions:
A. Inflation
Use an air compressor and reservoir located Note: Always use tyre inflation equipment with an air
inside a heated building, when available, so filter that removes moisture from the air supply, when
that alcohol, methanol, or other flammable available, to prevent moisture corrosion of internal rim
antifreeze liquids are not needed in the air parts.
tanks to prevent moisture freezing in the tank
and lines in subfreezing outside temperatures. 1. Inflate tyre to 1 bar (15 lbf/in²) initially to seat
components and tap lock ring lightly to ensure correct
B. seating. Visually check that all components are in
Make sure that paints, lacquers, paint thinners, place, then continue inflation observing all safety
or similar materials that produce volatile, precautions. (See Step 2).
flammable vapours are not used or stored near
the air intake of the compressor that supplies 2. If the tyre is off the machine, place it in a safety
the air for inflating tyres. The compressor cage after initially inflating to 1 bar (15 lbf/in²) to seat
should be isolated from all such sources of components. See Fig. 6.
flammable vapours.
Nitrogen gas improves tyre pressure retention, Fig. 6 - Typical Safety Cage
increases tyre life by reducing carcass oxidation from
within, minimizes rim rust and has no detrimental
effects on the tyre. It also reduces the potential of a SM - 1040
WARNINGS
DO NOT USE charging assembly, Part No.
9359489, for tyre inflation because this
assembly does not include a pressure
regulator, safety relief valve, and adequate
pressure gauging which is mandatory for tyre
inflation purposes. Tyre volume is as much as
90 times greater than the average accumulator
volume and hence it takes very much longer to
inflate a tyre - up to 40 minutes or more for
very large tyres.
a. Connect nitrogen tyre inflation kit to nitrogen Note: Although a little more nitrogen gas is used to seat
compressed gas supply. DO NOT connect clip-on beads than that used for re-inflation of a mounted tyre,
chuck to the tyre valve at this time. refer to 'Re-inflation of a Mounted Tyre', its cost is
generally negligible in comparison to the time and labour
b. Open valve on nitrogen supply. saving and, longer tyre life achievable with the reduced
oxygen content which results.
c. With flexible hose and clip-on chuck connected to
nitrogen tyre inflation kit assembly but not connected
to the tyre, adjust pressure regulator so that its output TYRE EXPLOSION HAZARD
pressure is not more than 1.4 bar (20 lbf/in²) higher
than the desired tyre inflation pressure.
WARNINGS
d. Connect clip-on chuck to the tyre valve. The tyre will Whenever a machines tyre(s) is (are) exposed
now inflate. Tyre pressure can be monitored by to excessive heat such as a machine fire or
observing the gauge at the pressure regulator. STAY extremely hot brakes the hazard of a
AWAY FROM THE TYRE. subsequent violent tyre explosion must be
recognized. All persons must avoid
e. When desired inflation pressure has been achieved, approaching the machine so as not to be
back off the regulator or close the valve on the physically endangered in the event of an
compressed gas cylinder. explosion of the tyre and rim parts. The
machine should be moved to a remote area,
f. Remove the clip-on chuck and adjust the tyre but only when this can be done with complete
pressure with the tyre gauge in the usual manner. safety to the operator operating or towing the
machine. All other persons should stay clear of
the machine. The fire or overheated brakes,
Re-inflation of a Mounted Tyre wheel, etc. should be extinguished or cooled
To re-inflate a tyre with dry nitrogen gas which is now from a safe distance. Do not attempt to
inflated with air, proceed as follows: extinguish the fire or cool the machine by use
of hand-held fire extinguishers.
1. Exhaust the tyre until only air at atmospheric
pressure remains in the tyre. If it is absolutely necessary to approach a
machine with a suspect tyre, approach only
2. Re-inflate the tyre using only dry nitrogen gas to from the front or the back. Stay at least 15 m
4.15 bar (60 lbf/in²) gauge as a minimum, or to bead- (50 ft) from the tread area. Keep observers out
seating pressure as a maximum. of the area and at least 460 m (1 500 ft) from
the tyre sidewall. Refer to Fig. 8. The tyre(s)
3. Adjust to the service inflation pressure required: should be allowed at least eight (8) hours
cooling time after the machine is shut down or
a. If the required service inflation pressure is LESS the fire extinguished before approaching
than 4.1 bar (60 lbf/in²), remove the clip-on chuck and closer.
adjust the pressure with the tyre gauge in the usual
manner.
SM - 1041
TYRE AND WHEEL RIM MAINTENANCE Punctures 13 mm (0.50 in) or larger, large cuts, or
bruise breaks require sectional or reinforced
Tyre Repairs vulcanized repair. Cover the repair patch with a layer
Prompt repair of tyre injuries will prevent small injuries of cushion gum after application to the tubeless tyre to
from enlarging and causing tyre failure. Use the best ensure an airtight repair. Any cords of the inside ply
tyre facilities available. If good repair facilities are not that are exposed in buffing and are not covered with
available, have the nearest dealer make the necessary repair patch must be coated with cushion gum to
repairs. prevent air leakage into the carcass plies on tubeless
tyres.
Minor cuts, snags, or punctures should be repaired
upon discovery. Skive with a sharp pointed knife
around any cut in the tyre tread area that is of Recapping and Retreading
sufficient depth or shape to hold pebbles or dirt. The There are two general methods employed in restoring
angle of the skive should be no more than sufficient to the tread surface of off-the-highway tyres: recapping
expel all foreign material and should extend no deeper and retreading.
than the breaker. The skive should go to the bottom of
the hole. Tyres with shallow cuts, if treated promptly, A recapped tyre has a new tread cured right over the
may be allowed to continue in service. If the cut old tread surface.
extends deeper into the tyre carcass, the tyre should
be removed for repair. A retreaded tyre has the old tread removed entirely
and a new tread cured directly onto the body of the
The tyre must be removed from the rim to repair larger tyre. A tyre can be recapped or retreaded if the cord
punctures or cuts. Irregular shaped punctures or cuts body is free of cuts, bruises and separation, and is
thoroughly sound, including previous repairs.
'O' rings are seals and should be carefully stored in a Every 50 hours of operation (weekly), torque tighten
cool, dry place where they will not be injured or wheel rim nuts to 730 Nm (540 lbf ft).
damaged.
Check tyres regularly and replace or repair if required.
Valve cores should also be stored in a cool, dry and
clean place.
SERVICE TOOLS
Refer to Section 300-0070, SERVICE TOOLS for part
MAINTENANCE numbers of the nitrogen tyre inflation kit shown in
Check tyre pressures daily, preferably before the Fig. 7 and general service tools required.
Occasionally a tubeless off highway tyre/rim assembly may leak in field service. To determine cause of leakage,
the entire assembly including valve hardware, multi-piece rim assembly, 'O' ring and tyre should be checked using a
soap solution.
This table lists various causes of air loss and possible remedy.
CAUSE REMEDY
Defective valve Tighten parts. Replace defective parts. Use valve caps.
Cracked rim or weld Replace defective part
WARNING
Do not attempt repair of wheel components.
Twisted or damaged 'O' ring Replace 'O' ring (lubricate)
Tyre cuts and snags Repair tyre damage
Bead area awl holes Repair inner liner (preferred)
Leakage between tyre bead trim With tyre removed from rim:
Clean tyre beads in rim contact area
Clean rim with wire brush
Inspect 5 degree tapered bead seat band and the rim base
in the bead seating area to determine if the transverse weld
trims are flat or concave. Replace defective part(s). Note:
Weld trim should follow rim contour.
* * * *
When the treadle valve is actuated, hydraulic oil enters 2. Turn the steering wheel in both directions several
the brake assembly and forces the brake piston (14) times to relieve any pressure in the steering circuit.
against the rotating friction discs (20) which react with Operate the treadle valve continuously to relieve any
stationary reaction discs (21). The reaction discs (21) pressure in the braking system. Block all road wheels.
are retained by scalloped tangs at the outside
diameter, which in turn transfers the reaction torque to 3. Remove drain plug and drain cooling oil from brake
the rigid outside housing (1), slowing or stopping wheel packs into a clean container. Reinstall plugs.
rotation.
4. Drain oil from hubs and differentials. Refer to
In an emergency situation, application of the park/ Section 160-0030, AXLE GROUP (HUB) and Section
emergency valve will actuate the service brakes and 160-0020, DIFFERENTIAL DRIVE HEAD.
the parking brake to bring the machine to a halt. In this
condition, a restriction in the 'Px' line from the brake 5. Refer to Section 160-0030, AXLE GROUP (HUB) for
manifold valve will slow oil flow from the parking brake disassembly instructions.
allowing the service brakes to actuate momentarily
ahead of the parking brake. 6. Attach suitable lifting equipment to brake assembly
and support weight. Loosen and remove bolts securing
When the treadle valve or park/emergency brake is brake assembly and hub carrier to axle stub.
released, hydraulic pressure against piston (14) is
relieved and cup springs (24) force the piston (14) to 7. With brake assembly supported, remove brake
return to its original position, thus, relieving the assembly from axle stub.
pressure against the brake disc pack.
8. Place brake assembly on a clean work surface for
disassembly.
REMOVAL
9. Remove and discard all 'O' rings and oil seals from
brake assembly.
WARNINGS
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of sufficient capacity to do the job
safely.
SM 2390 01-06 1
Brake Assembly - Oil Cooled Disc Brakes
Section 165-0015
SM - 3099
INSTALLATION
1. Refer to Fig 33. Using suitable lifting equipment, 4. Refill brake coolant tank with oil as described in
offer Anchor plate (3), brake assembly (5) and hub Section 250-0025, BRAKE COOLANT TANK.
carrier (1) up to axle stub (8) and secure with washers
(7) and bolts (6); applying adhesive 15500690 to bolts
WARNINGS
(6) and torquing to a value of 460 Nm (339 Ibf ft).
To prevent personal injury and property
damage, be sure wheel blocks, blocking
2. Refer to Section 160-0030, AXLE GROUP (HUB) for
materials and lifting equipment are properly
assembly instructions.
secured and of sufficient capacity to do the job
safely.
3. Fill hubs and differentials with oil. Refer to Section
160-0030, AXLE GROUP (HUB) and Section 160-0020,
DIFFERENTIAL DRIVE HEAD.
2 SM 2390 01-06
Brake Assembly - Oil Cooled Disc Brakes
Section 165-0015
DISASSEMBLY 3 13
3
STEP 1 5
2. Lever the slide ring seal (5) out of the sealing holder
(3) using pry bar 15270132 and then remove the 'O'-ring
(4) from the holder (3). Shown in Fig 3.
4
STEP 2
3
3.Remove the 'disc set' (20 & 21) from the brake
housing (1).Now carefully remove the brake housing (1) 20,21
11
14
28
27
SM 2390 01-06 3
Brake Assembly - Oil Cooled Disc Brakes
Section 165-0015
5. Press out the support shims (25) by means of screws to aid in removal. Remove bolts (6, Fig 36)
automatic adjusting from the Brake piston (14). Shown and washers (7, fig 36) as shown in fig. 8.
Fig 6. using tool 15270132.
12. Remove hub carrier (1, fig 36) from axle housing
(8, fig 36) using suitable lifting straps 15501168 as
shown in Fig. 9.
6.Tap out the slotted pins (28) from the Shim support
(25) shown in Fig 7.
8. Pull the pin (22) out of the Shim support (25) and
remove released cup springs (24), then remove the
Gripping ring (23) from the pin (22).
10. Remove the guide ring (19), U-rings (15 & 17) and SM - 3512 fig. 10 - Separate Hub carrier
support rings (16 & 18) from the annular grooves of the
brake housing (1).
11. Loosen bolts (6, Fig 36) connecting hub carrier (1,
Fig 36) to axle housing (8), Fig 36). Install adjusting
4 SM 2390 01-06
Section 165-0015
ASSEMBLY 4. Refer to Fig. 14, FLUSH MOUNT SLOTTED PINS
(28)- install slots of pins in direction of force and by
Numbers in parentheses refer to Fig. 1, unless 180 Deg turned to each other.
otherwise stated.
SM 2390 01-06 5
Brake Assembly - Oil Cooled Disc Brakes
Section 165-0015
bearing (2) onto the hub carrier (3) until seated home. Rotate Hub in a clockwise directions several times to
ensure free rotation.
10. Refer to Fig 17. Insert the ring gear carrier (1) into
the ring gear (2) and fasten it by means of the retaining 12. Refer to fig. 19, Check the rolling moment by
ring (3). means of a spring balance 15501169. As follows:
3
Rolling moment 'Torque' must be within range :-
6 SM 2390 01-06
Section 165-0015
Secure the guide ring with Loctite (type No 415) at its 5. Refer to fig. 22, Insert the pins (28) into the
extremities. assembly fixture 15501174, until contact.
14
16
15
23
17
18
9 1
3. Refer to fig. 20, Insert the piston (14) into the Brake
housing, ensuring adequate levels of oil have been
applied to sliding /contact surfaces of the constituent
parts.
4. Refer to fig. 21, Mount the piston by means of SM - 3132 Fig. 23 - Gripping ring fitment
26
25
24
23
22
SM - 3130 Fig. 21 - Piston Mounting / tooling SM - 3133 Fig. 24 - Pin installation setup
SM 2390 01-06 7
Brake Assembly - Oil Cooled Disc Brakes
Section 165-0015
27
26
25
24
X
23
22
SM - 3136 Fig. 27 - Retaining Support Shim in Piston
SM - 3134 Fig. 25 - Pin installation Detail 10. Insert the pre-assembled support shim into position
and fasten by means of Snap ring (27) as shown
8. Refer to fig. 25, Mount cup spring (24) onto the pin. in Fig. 27
12. Refer to fig. 29, Grease 'O' -ring (4) and insert into
pressure oil supply bore.
13. Grease the 'O' -ring (12) and insert into the annular
groove. Install plug (9) with a new 'O'- ring (10) as
SM - 3135 Fig. 26 - Locking pins to support shim
shown in fig. 29
14 27 X
1 22 25 28
8 SM 2390 01-06
Section 165-0015
Y
21 1
14
3
11
20
SM - 3138 Fig. 29 - 'O'-Ring fitting X
14. Using Eye bolts 15270115, locate the brake carrier SM - 3141 Fig. 32 - Lined Disc Clearance details.
X......................................= 28.00mm
Y...................................= 26.60mm
Clearance -1.40mm.
SM - 3139 Fig. 30 - Fit Brake Housing to Axle hub If required , correct the clearance with an adequate
outer disc.
15. Take Adjusting screws 15501167 and locate on
Hub carrier (1, fig. 36). Using Spline mandrel 15501176, 17. Grease 'O'-ring (4) and insert into the annular
install Reaction & Friction Discs (20,21) alternately , groove of the sealing holder (3).
starting with a Reaction disc, as shown in fig. 31.
Note: Oil Disc to ZF list of Lubricants TE-ML 05 18. Wet the 'O'-ring of seal slide ring (5) and insert into
the seal slide ring.
19. Press the seal slide sing (5) into sealing holder (3)
ensuring the surface of the seal slide ring does not
show any profiled grooves, scratches or other damage,
which could affect the performance / integrity of the
sealing elements.
WARNINGS
SM 2390 01-06 9
Brake Assembly - Oil Cooled Disc Brakes
Section 165-0015
20. Mount sealing holder (3) on to the brake housing (1) 22. Remove the Mandrel 15501176 for aligning the Disc
until contact is obtained and fasten with hex screws set (20 & 21). As shown in Fig. 35.
(13) to 390Nm max, as shown in Fig. 33,
13
SM - 3169 Fig. 33 - Mounting Sealing Holder / Mandrel SM - 3171 Fig. 35 - Removing Mandrel
21. Install valve vent plug (8), new 'O'-ring (7) and
screw neck (6). Now install a suitable adaptor and MAINTENANCE
pressurize the piston with air to approximately 4 bar to
fasten the disc set. As shown in Fig. 34
WARNING
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.
SPECIAL TOOLS
Refer to Section 300-0070, SERVICE TOOLS, for
details of service tools and adhesives required. These
tools and adhesives are available from your dealer.
10 SM 2390 01-06
Section 165-0015
SM - 3172
4 5
13
2 14
12 15
11
10
16 24
25 26
9
20 22
6
7 21 27
31
32
33 23 28
35 34
30 29
19
18
17
* * * *
SM 2390 01-06 11
THIS PAGE IS INTENTIONALLY LEFT BLANK
PARKING BRAKE - Parking Brake and Mounting
Section 170-0010
SM - 3519
7,8
13 10
2
12 15 11
9
4,5
1
6
14
3
SM 2428 01-06 1
Parking Brake - Parking Brake and Mounting
Section 170-0010
REMOVAL DISASSEMBLY
Numbers in parentheses refer to Fig. 1, unless Numbers in parentheses refer to Fig. 2.
otherwise specified.
1. Remove calliper head assembly as described under
removal.
WARNINGS
To prevent personal injury and property 2. Remove snap ring (13) from power screw shaft (18),
damage, be sure wheel blocks, blocking and remove fasteners securing control strap (27) to
materials and lifting equipment are properly slack adjuster (14).
secured and of adequate capacity to do the job
safely. 3. Slide slack adjuster (14) from power screw shaft (18).
Hydraulic fluid pressure will remain 4. Remove and discard washer (16), wave spring
within the braking system after engine shut washer (15) and packing (17) from power screw
down. Operate the treadle pedal continuously shaft (18).
until the pressure has dissipated before
carrying out any work on the braking system or 5. Remove bolts (2) and washers (3) securing cap
serious injury could result. assembly (21) to calliper (6).
1. Position the vehicle on a level surface, apply the 6. Remove as a unit, power screw shaft (18),
parking brake, block all road wheels and place the piston (5) and cap assembly (19 through 22) from
steering lock bar in the 'Locked' position. calliper (6).
2. Raise the body and install body safety prop to 7. Slide power screw shaft (18) and piston (5) from cap
secure in partially raised position. assembly (21).
3. Pull out push control to release the parking brake. 8. Unscrew piston (5) from power screw shaft (18).
4. Release spring tension on slack adjuster clevis pin 9. Remove and discard thrust bearing (19) from power
(7) by unscrewing tensioning bolt on slack adjuster (3) screw shaft (18) and gasket (20) from cap
until clevis pin (7) feels loose. Remove cotter pin (8) assembly (21).
and clevis pin (7) from actuator (9).
10. Remove and discard piston seal (4) from calliper (6).
Note: On engine shutdown the parking brake will
automatically apply. Ensure there is sufficient
clearance for actuator rod travel. INSPECTION
Numbers in parentheses refer to Fig. 2.
5. Switch off the engine and place the battery master
switch in the 'Off' position. 1. Thoroughly clean all parts. Inspect journal bearing
(22) in cap assembly (21) for wear. Journal bearing (22)
6. Disconnect and plug hydraulic line from actuator (9). ID should not exceed 38.35 mm (1.51 in). Replace if
Cap actuator (9) to prevent ingress of dirt. necessary.
7. Remove nuts (10) and washers (11) securing 2. Replace cap assembly (21) if excessively worn.
actuator (9) to cap assembly (13). Remove actuator (9)
from cap assembly (13). 3. Inspect all brake parts for cracks, excessive wear or
scoring. Replace brake parts as required.
8. Support calliper head assembly (2) and remove bolts
(4 & 16), washers (5) and nuts (6) securing mounting
plates (1) to mounting bracket on the frame. ASSEMBLY
Numbers in parentheses refer to Fig. 2.
9. Remove mounting plates (1) and calliper head
assembly (2) from the vehicle. 1. Install new piston seal (4) into seal groove in calliper
(6).
2 SM 2428 01-06
Parking Brake - Parking Brake and Mounting
Section 170-0010
SM - 2802
18
19 20
21
6 3
2
12
'A'
11
22 26
24 25
17
10 15
14
16 7
1
'A'
27
4
8
23 5
9 13
AT POSITION 'A'
face of new thrust bearing (19). 6. Line up gasket (20) and bolt cap assembly (21), with
assembled power screw shaft (18) and piston (5), to
3. Install and seat new thrust bearing (19) over splined calliper (6) using bolts (2) and washers (3). Tighten bolts
end of power screw shaft (18) with greased side of (2).
thrust bearing (19) against thrust collar of power screw
shaft (18). Note: Care should be taken not to push piston seal (4)
out of seal groove in calliper (6) when assembling cap
Note: Ensure correct installation of thrust bearing (19) assembly (21), with piston (5) and power screw shaft
by verifying that installation was made over the larger (18), to calliper (6).
diameter end of power screw shaft (18), and, that thrust
bearing (19) ID lip is towards splined end of power 7. Install new packing (17), wave spring washer (15)
screw shaft (18). and washer (16) over power screw shaft (18), in the
order shown in Fig. 2.
4. Lubricate threads of power screw shaft (18) with
grease (Lubriplate Aero or equivalent) and screw power 8. Mount actuator (12) on cap assembly (21) with nuts
screw shaft (18) into piston (5). (10), lockwashers (25) and washers (11). Tighten nuts
(10) finger tight only at this stage.
5. Coat outside of piston (5) with grease (Lubriplate
Aero or equivalent) then slide assembled power screw 9. Apply coat of grease (Lubriplate Aero or equivalent)
shaft (18) and piston (5) into cap assembly (21), shaft to mounting spline of slack adjuster (14).
end first.
SM 2428 01-06 3
Parking Brake - Parking Brake and Mounting
Section 170-0010
10. With adjusting screw facing towards actuator (12) 6. Align actuator (9) to slack adjuster (3) and tighten
slide slack adjuster (14) on power screw shaft (18) nuts (10).
aligning slack adjuster (14) arm with clevis (7).
7. Loosen bolt (15) at the control arm of slack adjuster
11. Install snap ring (13) on power screw shaft (18). (3) and control strap (12).
12. Remove nuts (10), lockwashers (25) and washers 8. Position control arm of slack adjuster (3) in fully
(11) securing actuator (12) to cap assembly (21). released position (forcing it in a direction away from
Remove actuator (12) from cap assembly (21) to aid in actuator (9)) by turning adjustment screw (14) on the
installation. slack adjuster (3), until it comes to a positive stop
inside the control strap (12).
1. Attach suitable lifting device and position mounting 11. Remove feeler gauge and apply brake several
plates (1) in mounting bracket and calliper head times. The automatic slack adjuster will adjust the
assembly (2) over brake disc. Secure mounting plates brake pad clearance with each application, which can
(1) to mounting bracket on the frame with bolts (4 & be seen by the rotation of the adjustment screw (14).
16), washers (5) and nuts (6). Tighten nuts (6) to a
torque of 75 Nm (55 lb ft). 12. When the adjustment screw (14) stops rotating, the
specified clearance has been obtained and the brake is
2. Remount actuator (9) on cap assembly (21, Fig. 2) ready for normal operation.
and install washers (11), lockwashers (25, Fig. 2) and
nuts (10). Tighten nuts (10) finger tight only at this 13. Remove wheel blocks and place the steering lock
stage. bar in the 'Stowed' position.
WARNING MAINTENANCE
Do not pressurize actuator until the following
instruction has been carried out. Pressurizing Every 250 hours
the actuator beforehand can result in serious Test park brake for proper operation. Check brake pads
brake damage. and disc for wear. Replace brake pads when lining
thickness is 3.0 mm (0.125 in) or less. Replace disc
3. Turn adjustment screw (14) on the slack adjuster (3) when worn by 3.0 mm (0.125 in) or more.
in a clockwise direction until the brake pads in calliper
head assembly (2) are tight against the brake disc.
Brake Pad Replacement
4. Connect hydraulic line to actuator (9). Place the 1. Remove calliper head assembly as described under
battery master switch in the 'On' position, start the 'Removal'.
engine and pull out parking brake control knob to
extend the actuator. 2. Replace worn brake pad and carrier assemblies.
5. Connect slack adjuster (3) to actuator (9) by 3. Install calliper head assembly and adjust slack
inserting clevis pin (7) through clevis (7, Fig. 2) on adjuster as described in 'Installation'.
actuator (9). Secure clevis pin (7) with cotter pin (8).
4 SM 2428 01-06
Parking Brake - Parking Brake and Mounting
Section 170-0010
SPECIAL TOOLS
There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
tools required. These tools are available from your
dealer.
* * * *
SM 2428 01-06 5
THIS PAGE IS INTENTIONALLY LEFT BLANK
SUSPENSION SYSTEM - Front Suspension
Section 180-0020
SM - 3484
16
17
15
9
11
7 8 8,9,10,11
7
14 12,13,14,15
19 16,17,28
26 13
10
3 18
25 12 19
24 28 26
1
21,22
2 18
25
23
24
5,6 24
30
25 27
5,6 24
23 29
4
30
5,6 20
30
25 20
23
5,6
REMOVAL 13. Remove bolts (23), washer (25) and nuts (24) securing
control links (5) to chassis frame brackets. Both LHS and
RHS of frame.
WARNING 14. Using suitable lifting equipment and jacks, lower axle
To prevent personal injury and property / suspension assembly sufficiently to allow disassembly
damage, be sure wheel blocks, blocking of the remaining components.
materials and lifting equipment are properly
secured and of adequate capacity to do the job 15. Ensure jacks are central under the suspension
safely. frame brackets (1 & 2). Lower jacks until rubber
mounts are free of compression.
1. Position the vehicle in a level work area, ensure the
body is fully lowered, apply the parking brake and 16. Position a suitable trolley under suspension frame,
switch off the engine. Turn steering wheel several carefully lower suspension and axle onto the trolley
times to relieve any pressure in the steering system. and remove from under the vehicle.
5. Support one tyre and rim assembly with suitable 1. Support panhard rod (21) prior to removal.
lifting equipment and remove wheel nuts securing the
rim to the axle. Remove tyre and rim assembly. 2. Remove bolts (4), washers (25) and nuts (24)
securing panhard rod (21) between LHS and RHS
6. Repeat step 5 for the opposite tyre and rim brackets (1 & 2).
assembly.
3. Remove Panhard rod (21) from assembly.
7. Remove sump guards from chassis frame if
necessary. Refer to Section 100-0010 CHASSIS. 4. Remove front suspension mounts (8) from brackets
(1 & 2).
8. Prior to axle removal, support axle using suitable
fixture. 5. Remove pin (13) securing Chains (10) to adjusting
screws (11).
9. Disconnect hydraulic brake line at tee on front axle
assembly. Disconnect differential breather line. Cap 6. Remove pin (12) securing chains (10) to brackets (1
lines and fittings to prevent ingress of dirt. & 2).
10. Support driveline and remove bolts securing 7. Remove adjusting screws (11), chains (10) and
driveline to front axle. Refer to Section 130-0010, bushes (14)
FRONT DRIVELINES.
8. Remove remaining bolts (18), washers (25) and nuts
11. Remove bolts (19) and washers (26) securing (24) securing control links (5) to LHS and RHS
shock absorbers (7) to front frame mounting point. brackets.
12. Remove nut (16) and washer (17), securing rebound 9. Remove control links
mounts (9) to the chassis frame. remove rebound mounts
(9) and washers (15).
2 SM 2391 05-06
Suspension System - Front Suspension
Section 180-0020
SM 2391 05-06 3
Suspension System - Front Suspension
Section 180-0020
15. Remove nut, washer and 1-off rubber bush from the WARNING
bottom of each shock absorber. To prevent personal injury and property
damage, be sure lifting equipment is properly
16. Fit mounting plate (3) over shock absorber. Re-fit secured and of adequate capacity to do the job
nut, washer and rubber bush to each shock absorber. safely.
17. Secure plate (3) (and shock absorbers) to axle 1. Position the vehicle in a level work area, ensure the
bracket using 4-off bolts (19) and washers (26). Torque body is fully lowered, apply the parking brake and
bolts (19) to a value of 169 Nm (125 Ibf ft). switch off the engine. Turn steering wheel several
times to relieve any pressure in the steering system.
18. Remove nut, washer and 1-off rubber bush from top
end of each shock absorber. 2. Following instructions at 'Removal' adjust inner nuts
(16) to give desired compression of rubber mounts (9).
19. Attach shock absorber to front frame mounting
point. Re-fit nut, washer and rubber bush to each shock 3. Apply Loctite Activator 'T' and Loctite 638 to threads
absorber. above inner nuts (16). Tighten down outer nuts (16)
against inner nuts (16), making sure that inner nuts (16)
20. Using suitable lifting equipment, position one tyre do not move.
and rim assembly on a front wheel and secure with
wheel nuts. Tighten locknuts to a torque of 730 Nm 4. Complete installation of front suspension. Refer to
(540 lbf ft). 'Installation'.
4 SM 2391 05-06
Suspension System - Front Suspension
Section 180-0020
* * * *
SM 2391 05-06 5
THIS PAGE IS INTENTIONALLY LEFT BLANK
SUSPENSION SYSTEM - Rear Suspension
Section 180-0040
SM - 3521
12 15 12 14
24,23
'C' 4
26 17
7 5,6
13 29 30
21 20 11
22 4 19
25 30 16 8 'A' 12
30 19
27 DETAIL 'D' 19 19
7
3 'A'
8
29 'A' 9 18
33 2 16
16 32 10
18 'A'
19 7
19 33 5,6 'B'
33 'E'
31 33 8
1 5,6
32
33 31 32
9 'B' 'A'
'A' 33
10 7 'E'
29
'A' 33 9
39 5,6 32 'A'
33 10
1
5,6 16
35
29 19
37 8
51 38
39
DETAIL 'B' 36
3 FORWARD
9
'A' 10
35
37
14 39
12 40
28 36
38
DETAIL 'A' TYPICAL 39
DETAIL 'E' FRAME MTG.
DESCRIPTION
Loads acting on the centre and rear axles are balanced by
Numbers in parentheses refer to Fig. 1 unless centrally pivoting equalizer beams (4) with rubber cushioning
otherwise stated. interleaf mounts (7) between axles and beam ends.
Interleaf mounts (7) are rubber/steel laminated
Each axle is coupled to the chassis by three rubber compression units with chain link ties.
bushed leading or trailing control links (5) which provide
longitudinal restraint. Lateral restraint is by transverse Lubrication of spherical bearings (32) in panhard rods
panhard rods (31). (31) is through remote mounted lube fittings (43, Fig. 2)
SM 2392 01-06 1
Suspension System - Rear Suspension
Section 180-0040
1 SM - 3520
47
BRACKET RH
48 41
43
41 49
42
44
41 31 42 45,46
1
47
42 50
31
51
BRACKET LH
47 TRAILER CHASSIS
LH FRAME RAIL
secured to manifold plate (43). Lubrication of bushings 4. Using suitable blocking equipment, block equalizer
(21) in equalizer beams (4) is through lube fittings (27). beams to prevent movement when raising the trailer
frame.
REMOVAL 5. Whilst the rear road wheels are still on the ground,
Numbers in parentheses refer to Fig. 1 unless loosen the wheel nuts.
otherwise stated.
6. Using suitable lifting equipment, raise the machine
until the rear wheels are off the ground. Support the
vehicle with suitable stands and blocking at the trailer
WARNING frame, articulation pivot area and centre and rear axle
To prevent personal injury and property assemblies.
damage, be sure wheel chocks, blocking
materials and lifting equipment are properly 7. Support one tyre and rim assembly with suitable
secured and of adequate capacity to do the job lifting equipment and remove wheel nuts securing the
safely. rim to the axle. Remove tyre and rim assembly.
1. Position the vehicle in a level work area, raise the 8. Repeat step 7 for the remaining rear tyre and rim
body and install body safety prop to secure body in assemblies.
partially raised position
9. Disconnect hydraulic brake lines from tee at both the
2. Apply the parking brake and switch off the engine. centre axle and rear axle assemblies. Cap lines and
Turn steering wheel several times to relieve any fittings to prevent ingress of dirt.
pressure in the steering system.
10. Remove blocking equipment from equalizer beams
3. Block front road wheels, place the steering lock bar (4).
in the 'Locked' position and the battery master switch in
the 'Off' position. 11. Disconnect grease lines (48,49,50 & 51 Fig. 2) from
elbows (41 & 42, Fig. 2), on both panhard rods (31).
2 SM 2392 01-06
Suspension System - Rear Suspension
Section 180-0040
Cap lines and fittings. If necessary remove elbows (41 Remove mounting bracket (2).
& 42 , Fig. 2) from panhard rods (31).
26. Remove locknuts (10), hardened washers (9) and
12. If necessary, remove p-clips (47) and manifold bolts (8) securing mounting bracket (3) on the centre
bracket (44) from the chassis frame. Refer to Fig. 2. axle. Remove mounting bracket (3).
13. Remove locknuts (30), lockwashers (19) and 27. Remove locknuts (10), hardened washers (9) and
bolts (29) securing interleaf mounts (7) to equalizer bolts (8 & 18) securing mounting bracket (1) on the
beams (4). centre axle. Remove mounting bracket (1).
14. Remove bolts (16) and lockwashers (19) securing 28. Remove bolts (11) and hardened washers (12)
interleaf mounts (7) to brackets (1 & 3) mounted on the securing mounting bracket (34) on the centre axle.
centre and rear axles. Remove interleaf mounts (7).
INSTALLATION
15. Remove bolts (26) and washers (17) securing cover Numbers in parentheses refer to Fig. 1.
(25) to equalizer beam (4). Remove cover (25).
24. Remove locknuts (10), hardened washers (9) and 5. Install bracket (2) on centre axle with holes on
bolts (8 & 18) securing mounting bracket (1) on the rear control link (5) mounting lugs to the front. Apply Loctite
axle. Remove mounting bracket (1). 243 to bolts (11) and secure bracket (2) to centre axle
with bolts (11) and hardened washers (12). Tighten
25. Remove bolts (11) and hardened washers (12) bolts (11) to a torque of 457 Nm (337 lbf ft).
securing mounting bracket (2) on the rear axle.
SM 2392 01-06 3
Suspension System - Rear Suspension
Section 180-0040
6. Install LH bracket (1) on centre axle with control link Locate spacers (51), v-ring seals (39) and panhard rod
(5) mounting brackets to underside and bracket (31) ends in place. Insert pins (35) into bores and
extension to the rear. Secure bracket (1) to centre axle secure pins (35) in place with washers (38),
with bolts (8 & 18), hardened washers (9) and locknuts lockwashers (36) and bolts (37).
(10). Install bolts from the top with hardened washers
and locknuts at the bottom. Tighten bolts (8 & 18) to a Note: Ensure that there is at least 2/3 mounting
torque of 790 Nm (583 lbf ft). surface area contact. Check contact area using a
0.05 mm (0.002 in) feeler gauge.
7. Install RH bracket (3) on centre axle with control link
(5) mounting brackets to underside and pointing 13. Using a suitable solvent, clean equalizer beam (4)
inwards towards the rear. Secure bracket (3) to centre shaft on the frame. Install new 'V' ring seal (13) and
axle with bolts (8), hardened washers (9) and locknuts new wear rings (20) on the shaft with flanges to the
(10). Install bolts from the top with hardened washers inside. Ensure mounting holes on the ends of the shaft
and locknuts at the bottom. Tighten bolts (8) to a are clean.
torque of 790 Nm (583 lbf ft).
14. Using a suitable solvent, clean the bores of
8. Install interleaf mountings (7) on the centre axle. equalizer beams (4). Install new bushings (21) in
Apply Loctite 243 to bolts (16) and secure interleaf equalizer beams (4) aligning holes in bushings with
mounts (7) on the centre axle with bolts (16) and holes in equalizer beams.
lockwashers (19). Tighten bolts (16) to a torque of 169
Nm (125 lbf ft). 15. Using suitable lifting equipment, install equalizer
beam (4) on frame shaft. Apply Loctite 243 to bolts (24)
9. Install control links (5) between rear and centre axle and secure equalizer beam (4) to shaft with bolts (24),
mounting brackets (1 & 3) and frame mounting washers (23) and retaining plate (22). Tighten bolts (24)
brackets and secure with bolts (28), hardened washers to a torque of 169 Nm (125 lbf ft).
(12) and locknuts (14). Install bolts (28) with bolt heads
to the brackets. Tighten bolts (28) to a torque of 531 16. Apply Loctite 243 to bolts (26). Install cover plate
Nm (392 lbf ft). (25) to equalizer beam (4) and secure with bolts (26)
and washers (17). Tighten bolts (26) to a torque of
Note: Ensure that there is at least 2/3 mounting 73 Nm (54 lbf ft).
surface area contact. Check contact area using a
0.05 mm (0.002 in) feeler gauge. 17. Apply Loctite 243 to lube fitting (27) and install in
cover plate (25). Lubricate with grease specified in
10. Install control links (5) between rear and centre axle Section 300-0020, LUBRICATION SYSTEM, until
mounting brackets (2) and frame mounting brackets excess lube is seen.
and secure with bolts (15), hardened washers (12) and
locknuts (14). Tighten bolts (15) to a torque of 531 Nm 18. Repeat steps 15 through 17 to install opposite
(392 lbf ft). equalizer beam (4).
Note: Ensure that there is at least 2/3 mounting 19. Connect interleaf mounts (7) to equalizer beams (4)
surface area contact. Check contact area using a with bolts (29), lockwashers (19) and locknuts (30).
0.05 mm (0.002 in) feeler gauge. Tighten bolts (29) to a torque of 169 Nm (125 lbf ft).
11. Install panhard rod (31) between mounting bracket 20. Remove caps and connect hydraulic brake lines to
(1) on centre axle and LH frame mounting bracket. tees on centre axle and rear axle assemblies.
Locate spacers (51), v-ring seals (39) and panhard rod
(31) ends in place. Insert pins (35) into bores and 21. Using suitable blocking equipment, block equalizer
secure pins (35) in place with washers (38), beams (4) to prevent movement when installing rear
lockwashers (36) and bolts (37). wheels.
Note: Ensure that there is at least 2/3 mounting 22. Secure manifold bracket (43, Fig. 2) to chassis
surface area contact. Check contact area using a frame.
0.05 mm (0.002 in) feeler gauge.
23. Route grease lines (48,49,50 & 51, Fig. 2); securing
12. Install panhard rod (31) between mounting bracket to frame using p-clips (47, Fig. 2). Connect grease
(1) on rear axle and RH frame mounting bracket. lines to their respective elbows (41 & 42, Fig. 2).
4 SM 2392 01-06
Section 180-0040
24. Secure grease fittings (43, Fig. 2) to manifold 27. Remove wheel blocks from front road wheels and
bracket (44, Fig. 2). place the steering lock bar in the 'Stowed' position.
24. Using suitable lifting equipment, position one tyre 28. Bleed all air from hydraulic brake lines. Refer to
and rim assembly on one rear wheel and secure with Section 165-0010, BRAKE PARTS.
wheel nuts.
* * * *
SM 2392 01-06 5
THIS PAGE IS INTENTIONALLY LEFT BLANK
ELECTRICAL SYSTEM - Circuit Diagrams
Section 190-0000
COMPONENT DESIGNATIONS
A4 - 12V Radio/Cassette L5 - Electric Horn S56 - Air Cleaner restrict Press
A5 - Radio/Cassette Speaker L7 - Reverse Camera Monitor Sw
L8 - Body Raise / Lower S57 - Steering Pressure Switch
B7 - Coolant Level Sensor joystick S60 - Difflock Request Switch
B8 - Fuel Level Sender L9 - Transmission Shift Lever S68 - Engine Diagnostic
B13 - Rotational Speed Sensor L10 - Transmission Retarder Lever request switch
B19 - Throttle Position Sensor S69 - Accel idle validation Switch
B21 - Trans Oil Temp Sender M1 - Starter Motor S79 - Heated Mirrors Switch
B32 - Trans Oil Ret Temp Sender M4 - Washer Motor, F S80 - Engin brake 'med' &'high'
B37 - Brake Axle Oil Temp M5 - Wiper Motor, F stages
Sensor (TA40 only) M6 - Wiper Motor, B S82 - Engine brake 'low' stage
B38 - Trans Oil Level Sender M7 - Washer Motor, B S93 -OCDB high Press Switch
M13 - Air Seat Compressor
S100 - Dropbox low ratio select Sw
E3 - Interior Light
E5 - Reverse Light N7 - PWM/Analogue S101 - Dropbox high temp Switch
E11 - Side Marker Light, L convertor module S102 - Dropbox High range
E12 - Taillight, L indicator Sw
E13 - Side Marker Light, R R10 - Rkr Switch 'Locating' LED S103 - Dropbox Low range
E14 - Taillight, R R11 - Rkr Switch 'Function' LED indicator Sw
E15 - High/Low Beam H'lamp, L S104 - Dropbox low oil Press Sw
R12 - 12V Work Socket
E16 - High/Low Beam H'lamp, R S105 - Hood raise / Lower Sw
R13 - 24V Work Socket S106 - Brake pedal Position Sw
E19 - Rear Fog Lamp
E21 - Rotating Beacon Y4 - Emergency/ Park Brk
E23 - Work Light S1 - Battery Master Switch Solenoid
E26 - High Beam H'lamp, L S2 - Starter Keyswitch Y7 - Difflock solenoid (mid axle)
E27 - High Beam H'lamp, R S7 - Emerg/Park Brake Switch Y14 - Retarder Solenoid
E35 - Heated Mirror S9 - Washer Switch, F Y26 - Body Raise Solenoid
S10 - Wiper Switch, F Y27 - Body Lower Solenoid
G1 - Generator/Alternator S11 - Rear Wash/Wipe Switch Y32 - Trans radiator fan
G2 - Battery S13 - Horn Button proportional solenoid
S14 - Hazard w/l Switch Y33 - System hydraulics un-loader
H6 - Direction Indicator; F, L S15 - Direction Ind Switch valve
H7 - Direction Indicator; B, L S18 - Lights Switch Y34 - System Hyd Float Valve
H8 - Direction Indicator; F, R S19 - Dipswitch Y36 - Trans oil cooler fan isolation
H9 - Direction Indicator; B, R S20 - Headlamp Flash Switch solenoid
H10 - Brake Light, L S22 - Body Proximity Switch Y37 - OCDB triple pump motor
H11 - Brake Light, R S29 - Trans Retarder Request Sw solenoid
H29 - Work Socket Illumination S31 - Park Brake w/l Switch Y39 - Engine radiator fan isolation
S37 - Axle difflock position Switch solenoid
K5 - A/C Comp Clutch/Relay S38 - Hydraulic Filter restrict Press Y40 - Engine radiator fan prop.
K21 - Trans Shift / Actuator Clutch Sw solenoid
S41 - Auxilliary Lights Switch Y41 - Low range select solenoid
S48 - Accumulator Press Sw Y42 - High range select solenoid
L3 - Reverse / Back Alarm (Tractor) Y43 - Difflock Solenoid (Dropbox)
L4 - Warning Buzzer S49 - Accumulator Press Sw Y44 - Hood raise/lower actuator
(Trailer)
TERMINAL DESIGNATIONS IN ACCORDANCE WITH DIN 72 552 Wire Colours
B - Black O - Orange
L - LEFT, R - RIGHT, F - FRONT, B - BACK
N - Brown Y - Yellow
DIODE RESISTOR FUSE PLUG U - Blue P - Purple
R - Red W - White
TRAILER G - Green S - Slate
L - Light Green K - Pink
CONNECTION
SM 2439 03-06 1
Electrical System - Circuit Diagrams
Section 190-0000
A Harness interface - Dash Harness and Main Chassis Harness (48 way connector)
B Harness interface - Dash Harness and Main Chassis Harrness (102 way connector)
C Harness interface - Main Chassis Harness and Engine Harness (21 way socket housing on main chassis
section)
D
Harness interface - Main Chassis Harness and Engine Harness (21 way pin housing on main chassis section)
E
Harness interface - Main Chassis Harness and Transmission Interface Harness
F
Harness interface - Main Chassis Harness and Dropbox Harness
G
Harness interface - Main Chassis Harness and Hydraulic Valve Harness
H
Harness interface - Main Chassis Harness and Rear Frame Harness
Harness Auxilliary Components Connection
All stated dash Harness splices are located in the controls area underneath the passenger seat
FUSES
Location Fuse No. Circuit Current Rating
1 Ignition sensed 20A
2 Keyswitch 15A
4 Rear Wash/Wipe 10A
5 Horn Relay Coil, Front Wash/Wipe 10A
Main Fuse Box - 6 Air Seat Compressor 10A
Column A 7 Lights Switch 10A
8 Main Beam/Flash 10A
9 Wiper Park Front and Rear 7.5A
10 Transmission Battery Supply 15A
11 Transmission System Ignition Supply 10A
12 Reverse Alarm/Light 7.5A
13 Hydraulic Electronic Controls 30A
14 Interior Light, Handlamp 5A
15 Direction Indicators/Rocker Switch Search LEDs 5A
16 Emergency/Park Brake 3A
Main Fuse Box - 17 Instrument Panel Ignition Supply 7.5A
Column B 18 Heated Mirrors 15A
19 Ignition Sensed Relay Coils 3A
21 Neutral Start 3A
22 Washers, Front 3A
23 Washers, Rear 3A
24 Horn 10A
25 Ignition Auxilliary Supplies 30A
26 Air Cond/Heater/Ventilation System 15A
27 Reverse Camera 10A
28 Front Working Lights 15A
Main Fuse Box - 29 Rear Working Lights 15A
Column C 30 Rotating Beacon 5A
31 Engine Ignition Supply 10A
32 Engine Battery Supply 30A
33 Body Proximity Switch Supply 10A
34 Dropbox/Difflocks Control System 15A
35 Brake Pedal Switch 5A
36 12V Auxilliary Socket 15A
As FL Hood Raise / Lower Actuator 10A
Lettered FM Instrument Panel / CPU Battery Supply 15A
2 SM 2439 03-06
Electrical System - Circuit Diagrams
Section 190-0000
RELAYS
Location Letter Relay Circuit
Designation
Main Fuse Box C K48 Range Inhibit Relay
Column D D K25 Service Brake Status Relay
SM - 3600
Column A B C D E F G H
12 24 36
FD FH FM A E I M Q
FC FG FL B F J N R
FB FF FK C G K O S
FA FE FJ D H L P T
1 13 25
SM 2439 03-06 3
SM 2439 03-06 4
E D C B A
23 A
F C
R/B TACHOMETER R/B N/Y NO CHARGE
R/B
SIGNAL (NOT USED)
43 B
33 A
R or N R or N
A D
N/Y INDICATOR
(NOT USED)
60 B
N/Y
R or N R or N
F62
15318776
B O R F32
1
1
F61
O F31
R F10
O
S1
F'L'
G2
G2
B B O
JUNCTION
N/K N/K
24VDC
HOOD MOTOR
BOX
O
R K23 RADIO/CASSETTE
B TO DDEC ECM
B TO DDEC ECM
B TO DDEC ECM
B TO DDEC ECM
B TO INSTRUMENT CLUSTER/CPU
R F36
B
R F20
R F'M'
B
B MAIN CHASSIS HARNESS SPLICE
2
F28
BATTERY -VE
109
169 TRANS TCU
TRANS TCU
FRONT WORK
F34
LIGHTS
W
W/B DROPBOX/
F25
DIFFLOCK CONTROLS
W
W TO K32 W W/G W/G
F13
3
3
W
W/L F19
R HYD ELEC W/L K23
48 B 49 B
F33
W
R/O K52
B TO DASH HARNESS
R/O S22 SPLICE
AUX SUPPLIES
B
N
F27
N/W
W
HORN
C D
F24
TRACTOR STANDARD EQUIPMENT
R REVERSE
CAMERA (OPT)
4
4
B
R/U R/U
K1
F18
W
INTERIOR LIGHT
F14
G/S HEATED
MIRRORS (OPT)
10 B
F D
W
W/R
R/P K50
G/P AIR/CON W/G W/G
F35
PARK FNT/WIPER
F9
PARK REAR/WIPER
W
W/R
5
5
U/W
W/L K23 IGNITION
AIR/CON/AUX SUPPLIES MAIN FLASH
K14
W/Y
B DASH HARNESS SPLICE
F19
R/U R/U
F21
W
MAIN BEAM
141
F8
TO TRANS TCU
6
S2
R INSTRUMENT PANEL/CPU
R R
F17
AIR SEAT
W/R
W
F6
0 R 1 2
P/W S7
W/U W/U
F16
W/G S14
30
75
RADIO/CASSETTE
F2
W
R/B K17
W/G TO F4 W/G W/G
15
W
F12
R/B K17
F1
W/G TO F5
W
PAGE 1
IGNITION
8
K23
50
F11
R L9
SM - 3594A
E D C B A
Section 190-0000
Electrical System - Circuit Diagrams
SM 2439 03-06
SM - 3594B
1 2 3 4 5 6 7 8
24 VOLT BUSBAR TO K23 24 VOLT BUSBAR
F5 W F16 W F12
WIPERS
W/U
F15
U/R
R/U
P
W/G
R DASH HARNESS
A
A
W/G
F3 F8 F24 F7
HARNESS SPLICE
R MAIN DASH
2 1 1
B/W
S9/S10/S13 W/G
B/G
B
F9 S15/S19/S20 S18
R/N
0 P U/R
LH (53a)
U B 10
FL/AL 1 2
R
R
L R 15 H 1 R
HORN
1 1
W/G
G/N
G/P
0
10 3 8 6 9
6 5 7 U/R
S14 R
2
0 1
SIGNAL LEFT
SIGNAL LEFT
SIGNAL RIGHT
SIGNAL RIGHT
OFF TURN
ON TURN
ON TURN
HARNESS SPLICE
OFF TURN
1 J 0 R MAIN DASH
WASHER WIPE
8 2 1 3
9 HARNESS SPLICE
B
B
49a 56a 56b 56 15/1 31b 53b 53 J 53c
B DASH
R L9
B/W
W/B
N/B
B/R
B/P
P/Y
B/S
W
W/G
G
3 6 5 8 4 4 2 3 7 6 5
U/W
G
HARNESS SPLICE
U/W
G/N
G/P
G
PANEL CONN D CAV 15 K4 K15
W/G
LG/G
G/U
G/B
DIODE BLOCK
B DASH
MOUNTED TO
6 5 DASH HARNESS
C
C
U/W
U/N
M5
K34
G
G/N
R/N
G/P
G
2 23 B 16 B SPLICES
F22
LOCATED IN
B
3 SPLICE
W/G LOCATED IN MAIN CHASSIS
P
U/N
W/G M6 25 B 24 B 22 B
MAIN CHASSIS HARNESS
G/S
D
D
17 B HARNESS
G/P
G/N
R/N
P
13 B
R/N
G/S
G/P
L5
W/O
W/G
W/S
K/O
R/N
R/N
K47 M4 3 5 4 H 4 H 5 3
2 H 2 H
P
U/W
U/W
U/N
U/N
G/N
G/P
R/N
R/N
E16 E27 E26 E15
L5
Section 190-0000
H8 E13 E11 H6
G/B
R L
E
E
R H P H N H
B
B
B
B
B
1
1 1
B MAIN DASH HARNESS SPLICE
15318776 PAGE 2
TRACTOR STANDARD EQUIPMENT
1 2 3 4 5 6 7 8
5
SM 2439 03-06 6
E D C B A
M13
14
B
A
B B R R R R
15318776
F6
1
1
13
B R/U R/U R/U
E3
F14
P/W INSTRUMENT PANEL CONN D CAV 9
P/W INSTRUMENT PANEL CONN D CAV 18
K50
B MAIN DASH HARNESS SPLICE
2
2
F35
27 B
F H
W F19
R/P
P/W
K25
B MAIN DASH HARNESS SPLICE R/P
S106
W 103 TRANS TCU CAV 3 N 162 TRANS TCU CAV 62
3
3
14 B
HARNESS SPLICE
G/B
G/U
M7
F23
W/G
4
G/U
1
W/G
W/G
S11
1
G/U G/U
3
M6
TRACTOR STANDARD EQUIPMENT
2
4
4
W/S
G/U
W/G
B
W/S
10
0
1
R
F4
F1
F5
5
IGNITION
WIPERS
ENGINE
R12
9 B
B MAIN CHASSIS R R R G2
HARNESS SPLICE
F36
R13
6
6
20 B
B MAIN CHASSIS R R R G2
HARNESS SPLICE
F20
7 B
B/K B/K
Y44
F'L'
2
8 B
B/R B/R
7
N/K N/K
B DASH HARNESS SPLICE
S105
24 VOLT BUSBAR
F28
S41
15
1
1
R
LOCATED IN CAB
8
B U/Y U/Y
HARNESS
0
1
R
SM - 3594C
E D C B A
Section 190-0000
Electrical System - Circuit Diagrams
7 SM 2439 03-06
E D C B A
15318776
1
1
S38
29 B
B MAIN CHASSIS P/K P/K INSTRUMENT PANEL CONN D CAV 26
2
HARNESS SPLICE
2
2
S56
32 B
B MAIN CHASSIS S/K S/K INSTRUMENT PANEL CONN D CAV 3
2
HARNESS SPLICE
3
3
34 B
37 B
1
4
4
HARNESS SPLICE
5
5
CASSETTE
IGNITION
RADIO/
K23
B MAIN DASH
HARNESS SPLICE
4
O O
7
7
5
S S
S
7
Y Y
8
N N
N
A5
A5
L.H
R.H
PAGE 4
8
E D C B A
SM - 3594D
Section 190-0000
Electrical System - Circuit Diagrams
8
Section 190-0000
Electrical System - Circuit Diagrams
SM - 3594E
1 2 3 4 5 6 7 8
AUXILLARY SUPPLIES
W K23 AIRCON/
A
A
11 B
AIR CONDITIONING/HEATER/VENTILLATION UNIT
B
B
B
BLOWER BINARY SW
N/U
7 GROUND T'STAT
P/G
M
G/O
8 INPUT N/S (NOT USED)
P/K
10 + W/G
B 4
3 G C
WATER VALVE ACTUATOR G/P G/P
G/O
1
U/B
O
R
C
G
RESISTOR
C
Y
1 K5
EVAPORATOR UNIT
2
B
M C C
HARNESS SPLICE
L H
B MAIN DASH
B C B C
N/U
HARNESS SPLICE
D
7 GROUND
B MAIN CHASSIS
D
8 INPUT P/G 3 SP A/C ON/OFF
BLOWER SWT SWT
P/K
10 + FRESH/RECIRC DEFROST MODE
SWITCH SWITCH
FRESH/RECIRC ACTUATOR
B C B C
7 GROUND N/U
8 INPUT P/G
P/K
10 + DASH MOUNTED CONTROL PANEL
E
E
SM 2439 03-06
DEFROST ACTUATOR
15318776 HEATING/VENTILATION/AIR CONDITIONING SYSTEM PAGE 5
1 2 3 4 5 6 7 8
SM 2439 03-06
SM - 3594F
1 2 3 4 5 6 7 8
U SPLICE
LOCATED
IN ENGINE
HARNESS R SPLICE R SPLICE
LOCATED LOCATED
Y/B SPLICE
DDEC 5 IN ENGINE IN ENGINE
A
A
LOCATED
ECM HARNESS HARNESS
IN ENGINE
HARNESS
10
Y/R 11
U/Y 13
K 15
R/W 16
24
31
38
U/W 39
O/B 40
U/R 43
U/Y 44
U/W 51
G/S 56
57
58
59
Y/B 60
61
62
63
64
65
66
67
68
B/Y 2
G/B 1
Y/L
G/W
G
U
U
B
B
B
B
R
R
R
R
S
B
B
K C J C K D L C MC E C S D H C L D MD T D R C A C N D H D S C P C
R DASH HARNESS SPLICE
B DASH HARNESS SPLICE
G/Y
R
B DD D E DG D
G/W
U/W
U/W
R/W
G/B
U/Y
O/B
B/Y
U/Y
Y/R
U/R
G/S
Y/L
B G2
B G2
B G2
B G2
AUXILLARY SUPPLIES
G
U
W K23 IGN AIRCON/
B C D C
U
36 A 35 A 45 A 37 A 38 A 27 A 31 A 34 A 46 A 47 A 20 A 41 A 32 A 48 A 43 A 42 A 40 A
R
K
G/W
Y/B
B7
Y/L
A
25 A 24 A
C
B
R
S68
0
WIPERS
K23
Y/B
O/B INST PANEL CONN D CAV 17
1
U
IGN F32
G/B INSTRUMENT PANEL CONN D CAV 30
ENGINE
B/Y INSTRUMENT PANEL CONN D CAV 4
U/W
U/W
G/S
R/W
104 TRANS TCU
U/Y
Y/R
U
44 A 39 A
U
R
Y/B
P D
O
26 A
U
F31
HARNESS SPLICE
D
29 A
S 28 A
B DASH
U/Y CAN_SHIELD DASH HARNESS SPLICE
O F62
U
U CAN_L DASH HARNESS SPLICE
TRANS TCU
TRANS TCU
U/R CAN_H DASH HARNESS SPLICE
B MAIN DASH HARNESS SPLICE
U/W
158
157
U/W
N
R D
W/B
K/S
10
1 2
Section 190-0000
8 6 2 1 R
10
1
U
C C
R 0
E
1 5 6
E
E 0 A B C D E F G H J
U
PANEL DIAGNOSTIC
Y/B
PROGRAMMING CONNECTOR
15318776 DETROIT DIESEL SERIES 60 ENGINE ELECTRONIC CONTROLS PAGE 6
1 2 3 4 5 6 7 8
9
SM 2439 03-06 10
W 103 E D C B A
W 103 K25 W 103 3
15318776
INTEGRAL TO
R
S 104 K32
TRANSMISSION
4
SPLICE LOCATED
110
IN DASH HARNESS
PCS5
B/S 105 K64 5
SPLICES LOCATED
HARNESS
IN DASH
LOCATED
SPLICE
&K
115
1
1
Y 107 7
112
PCS1
90 B
F10
B G2 B 109 9
92 B
R F62 R R 110 10
82 B
1
2 E 89 B
0 111 0 111 0 111 11
16
5 E
K 112 K 112 K 112 K 112 12
B38 W 115
TERMINATION
8 E 32 E
A Y14
B
2
2
RESISTOR
15
U 116 U 116 U 116 16
HARNESS SPLICE
B MAIN DASH
C3PS
36 E 1
70 B 93 B
U 120 U 120 U 120 20
K63
NOT USED
W K23 IGN AIRCON/
94 B
2
AUXILLARY SUPPLIES W 103 NOT USED
3
Y 128 28
TURBINE
A
B
129
B13
74 B
Y 131 Y 131 Y 131 31
ENGINE
A
B
SPEED
TCC
Y 131
INTERFACE
HARNESS
LOCATED
IN TRANS
SPLICE
B13
ALLISON WTEC4 ELECTRONIC CONTROLS
76 B
9
3 E
A
B
PCS4
SPEED
W 134 34
4
4
B13
12 E 14 E
78 B 72 B
4
W W 137
PCS2
W 137 137 37
37 E 29 E
66 B 68 B
5
SS1
SPLICE LOCATED
49
PCS3
Y
10
75 B 77 B
4 E 17 E
18
26 E 20 E
85 B 81 B
B B32
Y 156 6
56
S29
88 B 67 B 69 B
W/B 158
19
N 159 N 159 59
R DASH HARNESS SPLICE
A
B
C
Y 160 Y 160 60
W/B
0
1
R
SPLICE LOCATED
G 158
IN MAIN DASH
158
G
Y
W
HARNESS
HARNESS
&B
R 163 F11 63
R/B F12 RETARDER
O/B INSTRUMENT PANEL CONN D CAV 5 64
7
164
169
RESISITOR
R/B E5,L3 R/B F12 U/G 163 65 MODULE
U 168 CAN_L DASH SPLICE 68
R CAV 8
Y CAV 7
G CAV 6
P CAV 4
O CAV 3
U CAV 2
W CAV 1
R/B REVERSE
91 B
79 B 80 B 87 B 84 B 83 B 71 B
6
E D C B A
Section 190-0000
Electrical System - Circuit Diagrams
11 SM 2439 03-06
E D C B A
15318776
K64
W/B
F34
41 B
A F
R/L R/L R/L P/B
W K23 IGN AIR/CON
1
W/B
B
2
1
Y43
R
9
B
1 0
1 1
R R
R TO MAIN DASH HARNESS SPLICE
10
B DASH
HARNESS
S60
K27 O/B 143 TRANS ECU PIN 43 SPLICE
42 B
2
2
B MAIN CHASSIS
HARNESS SPLICE
W/B
3
3
B F
B B MAIN CHASSIS
HARNESS SPLICE
K/B HYDRAULIC CONTROLS ECU PIN 20
6
K/B
2
B SPLICE LOCATED
IN DROPBOX HARNESS
B
1
1
R
R S14
10
Y42
DROPBOX/DIFFLOCKS CONTROLS
B DASH HARNESS
0
1
R
SPLICE
S100
4
4
51 B
L F
B
5
5
Y41
S102
45 B
F F
6
S103
46 B
H F
47 B
J F
7
S104
50 B
K F
8
56 B
P F
E D C B A
SM - 3594H
Section 190-0000
Electrical System - Circuit Diagrams
SM 2439 03-06 12
E D C B A
30 B
M G
B P/W P/W P/W INSTRUMENT PANEL CONN D CAV 32
15318776
16 A
B G2 B 1
S31
14 A
N/Y N/Y 4
1
1
B MAIN CHASSIS
1
HARNESS SPLICE R F13 R 5
HYDRAULIC CONTROLS
Y39
S48
N 6
HARNESS
IN DASH
LOCATED
SPLICES
ECU
31 B
B P/R P/R P/R INSTRUMENT W 7
G
HYDRAULIC CONTROLS
PANEL CONN D
PROGRAMMING RS232
ECU DIAGNOSTIC/
1
CAV 33
S49
6
PORT
B/U 8
5
2
2
32 B
P G
B37
PANEL CONN D
CAV 22
B/U B 15
1A
33 B
2
R G
1
K/O INSTRUMENT
S57
Y/R Y/R
PANEL CONN D
CAV 14
2 A
R R
B
G/O AIR CON/VENTILATION SYSTEM 18
3
3
12 B
S G
PWM IN (B)
B P/W P/W P/W P/W F16
2
B(U) 19
+24VDC(R)
S7
Y4
GND(U)
Y INSTRUMENT
PANEL CONN D
ELECTRONIC/HYDRAULICS CONTROLS
N7
24
4
4
R
B MAIN CHASSIS P/G S22
HARNESS SPLICE
K52
+5VDC(B)
GND(U)
U CAN_L DASH SPLICE 25
U/R CAN_H DASH SPLICE 26
D GB G
5 A
5
B SPLICES LOCATED IN MAIN VALVE HARNESS
B S 33
2
34
Y33
R
U 35
K INSTRUMENT PANEL CONN 'D' CAV '2' 42
2
1
Y36
13 A
Y/S Y/S 43
B MAIN CHASSIS
HARNESS SPLICE
6
6
A G
3 A
B
2
H G
6 A
Y
R/W
B/W
N/G
B
2
1
Y27
3 2 1 2 1
B
Y
R
B
R
G
C G
4 A
7
L8
J G
7 A
1
Y32
1
Y40
11 A
HARNESS SPLICE
Y37
B
PAGE 9
K G
8 A
B K/B TO Y41 52
2
K/U TO S101 55
Y34
SM - 3594I
E D C B A
Section 190-0000
Electrical System - Circuit Diagrams
SM - 3594J
1 2 3 4 5 6 7 8
G/U DIAGNOSTIC/PROGRAMMING CONNECTOR CAV H
B INSTRUMENT PANEL CONN E CAV 33 R INSTRUMENT PANEL CONN E CAV 35
SM 2439 03-06
B INSTRUMENT PANEL CONN K CAV 34 R INSTRUMENT PANEL CONN K CAV 36
A
A
B B G2
B
28
R R F17
N R R G2
B
F'M' 62
B SPLICE
LOCATED IN
DASH R SPLICE
HARNESS LOCATED IN
DASH
HARNESS
B
U/R CAN_H DASH SPLICE
B
1 10 19 28
2 11 20 29
3 12 21 30
4 13 22 31
C
C
5 14 23 32
6 15 24 33
7 16 25 34
8 17 26 35
9 18 27 36
2 11 20 29
S/K S56 (AIR CLEANER RESTRICTION ICON) G/B DDEC ECM (ENGINE CHECK ICON)
3 12 21 30
Y K52 (BODY UP ICON)
B/N 129 TRANS TCU (CHECK TRANS ICON)
B/Y DDEC ECM (ENGINE STOP ICON) 4 13 22 31
B/Y S49 (TAILER BRAKE PRESSURE ICON)
O/B 164 TRANS TCU (TRANS SUMP TEMPERATURE ICON) P/W S31 (PARK BRAKE ICON)
5 14 23 32
U/W S19 (MAIN BEAM ICON)
K/U S101 (DROPBOX OIL TEMPERATURE ICON) 6 15 24 33 10 11 12
Y/W K51 (RETARDER ENABLE ICON)
7 16 25 34 7 8 9
K/O S102 (DROPBOX HIGH RATIO ICON)
8 17 26 35 4 5 6
O/B DDEC ECM (ENGINE BRAKE ACTIVE ICON)
D
D
12 9 6 3
9 18 27 36 1 2 3
36 27 18 9
11 8 5 2
35 26 17 8
B DASH HARNESS INSTRUMENT PANEL/CPU SPLICE
10 7 4 1
34 25 16 7
G/Y INSTRUMENT PANEL CONN E CAV 7
33 24 15 6
G/R INSTRUMENT PANEL CONN E CAV 26
B DASH HARNESS INSTRUMENT PANEL/CPU SPLICE
32 23 14 5
30 21 12 3
29 20 11 2
28 19 10 1
G/L
E
E
L4
B MAIN CHASSIS
HARNESS SPLICE
K/G S103 (DROPBOX LOW RATIO ICON)
P/W K50 (BRAKE LIGHTS APPLY RETARDER ACTIVE ICON)
P/K S38 (HYDRAULIC FILTER RESTRICTION ICON)
P/W DIODE BLOACK (DIRECTION INDICATORS ICON)
13
14
Section 190-0000
Electrical System - Circuit Diagrams
SM - 3594K
1 2 3 4 5 6 7 8
A
U DIAGNOSTICS/PROGRAMMING CONNECTOR CAV D
U/R DIAGNOSTICS/PROGRAMMING CONNECTOR CAV C
U/Y DIAGNOSTICS/PROGRAMMING CONNECTOR CAV E
U/R HYDRAULICS ELECTRONIC CONTROLLER CAV 26
B
RESISTOR TERMINATION RESISTOR TERMINATION
INTERNAL TO ENGINE INTERNAL TO
HARNESS TRANSMISSION TCU
C
U DDEC ECM CAV 58 U 168 TRANSMISSION TCU CAV 68
U/R (CAN_H)
SPLICE LOCATED
U/R CPU CAV 13
IN DASH HARNESS
U CPU CAV 14
U/Y (CAN_SHIELD)
SPLICE LOCATED
IN DASH HARNESS
U (CAN_L)
SPLICE LOCATED
IN DASH HARNESS
D
D
E
SM 2439 03-06
1 2 3 4 5 6 7 8
A
A
P/G K52
R/O F33
R/B K17
15 B 19 B
36 B 18 B
R/O
P/G
B
B
O/N
R/B
TRAILER CONNECTION
MH B H D H P H N H F H R H J H H H K H
O/N
G/N
R/O
R/N
R/U
P/G
G/P
R/B
B
S37
A
2 A C
U
B
C
C
S22
B
R/B
B
B
B SPLICE
LOCATED IN G/P
REAR FRAME R/U
HARNESS
R/N
R/B SPLICE
D
D
3 2 4 LOCATED IN
R/N & R/U SPLICE
REAR LIGHTS
LOCATED IN ACCESSORY
REAR FRAME 2 4 3
HARNESS HARNESS
G/N
R/N
P/U
R/B
R/B
G/N
R/N
P/U
B
E12 A E14
H7 H10 E5 L3 H11 H9
B
Section 190-0000
B B
B
B
B
B
B E19
3 3
E
E
B
B
1 1
B
B
15318776 TRAILER STANDARD EQUIPMENT PAGE 12
1 2 3 4 5 6 7 8
15
SM 2439 03-06 16
E D C B A
B G/R
1
1
E35
15318776
B B B G/R G/R G/R
S79
TO F27
F18
E35
G/S W
5
G/R
1
1
R
2
2
E35
B TO MAIN DASH HARNESS SPLICE
B G/R
HARNESS
B SPLICE
G/R SPLICE
LOCATED IN
HARNESS
HEATED MIRROR
LOCATED IN
E35
HEATED MIRROR
24 VOLT BUSBAR
S41
F29
3
3
15
5
1
1
1
R
E23
R TO MAIN DASH HARNESS SPLICE
0
1
R
E23
4
4
S41
B
A
1
5
1
L H
R/Y
E19
B
1
1
R
K15
B SPLICE
B REAR FRAME HARNESS SPLICE R TO MAIN DASH HARNESS SPLICE
HARNESS
REAR LIGHT
LOCATED IN
ACCESSORY
0
1
R
5
5
S41
F30
E21
R
F27
W TO F18
L7
K17
7
7
R/B
8
8
PAGE 13
E D C B A
SM - 3594M
Section 190-0000
Electrical System - Circuit Diagrams
SM 2439 03-06
SM - 3594N
1 2 3 4 5 6 7 8
TRAILER
MAIN CHASSIS HARNESS
HARNESS
DASH HARNESS CONNECTORS CONNECTORS
CONNECTORS
A
A
1
20 32
5
48 12 8 40 45 51 57 62 70 82 94 102
102 94 82 70 62 57 51 45 40 32 20 8 36
28 24
20 12 24 28 48 2
20 36
49
55
G/N 4
55
49
3 X J
43
60
H
MAIN LIGHTS W K
60
43
G B
V F A C L
CLUSTER CONNECTORS MIDAXLE DIFFLOCK
48
54
54
48
U M
POSITION SWITCH T E D N
1 9 21 33 41 46 52 58 63 71 83 95 CONNECTION. S R P
95 83 71 63 58 52 46 41 33 21 9 1
P/G G/P 1 2 NO CAVITY
29 13 DIRECTION IDENTIFICATION,
CAB BULKHEAD 37 25 21 1 INDICATORS CAB BULKHEAD 13 29
CONNECTION 1 21 25 37
3
OPERATION NOT POLARITY FRONT FRAME HARNESS
CONNECTOR DIODE BLOCK
CONNECTION SENSITIVE CONNECTION
CAB BULKHEAD OCDB/PANIC STOP
CONNECTOR CAB BULKHEAD PRESSURE SWITCH
1
CONNECTION CONNECTION
X J 2 5
H
W K
G B
20
V F A C L C B A
1
1 8 U M
A B C T E D N 3 4
9 14
S R P 4 1 BODY POSITION
21 40 1
PROXIMITY SWITCH REAR LIGHT CLUSTER/
TRANSMISSION RETARDER CONNECTION REAR ACCESSERIES
B
B
41 60 TRANSMISSION SHIFT RESISTANCE MODULE CONNECTOR CONNECTION
2 2
LEVER CONNECTOR 22 16
1
61 80 ENGINE HARNESS/DROPBOX HARNESS/
HYDRAULIC VALVE HARNESS/TRAILER 37 34 HOOD RAISE/LOWER
HARNESS CONNECTION MIDAXLE DIFFLOCK
TRANSMISSION TCU CONNECTOR SOLENOID ACTUATOR CONNECTION
1 5 TRANSMISSION HARNESS CONNECTION
6 9 4
CONNECTION
37
19
55
36
ELECTRONIC/HYDRAULIC ECU
DIAGNOSTIC/PROGRAMMING
CONNECTOR
3
1
2
1
1 2
TRANSMISSION
HARNESS
1 18
3 2
BODY CONTROL LEVER BODY CONTROL LEVER
ELECTRIC/HYDRAULIC ECU CONNECTOR ENGINE COOLER FAN 2 1
4 1
CONNECTOR ISOLATION SOLENOID/
CONNECTORS
CONNECTOR
TRANSMISSION COOLER FAN
ISOLATION SOLENOID/OCDB MOTOR
SOLENOID/HYDRAULIC FILTER RESTRICTION OCDB TEMPERATURE SENSOR
AIR FILTER RESTRICTION
E D PRESSURE SWITCH CONNECTION PRESSURE SWITCH CONNECTION
C
B
K J H G F CONNECTION
F A
A B C D E A B C 28 36
G
19 27
J
H
ACCELERATOR PEDAL ACCELERATOR PEDAL 10 18
CONNECTOR CONNECTOR 1 9
ENGINE/TRANSMISSION/INSTRUMENT PANEL
DIAGNOSTIC/PROGRAMMING CONNECTOR
INSTRUMENT
9 1
CLUSTER (CONNECTION D)
CONNECTOR
ENGINE HARNESS X
H
J
C
C
W K
G B
18 10 V F A C L
21 22
A B 1 4
U M
CONNECTORS
27 19
T E D N
S R P
36 28 TRANSMISSION
RETARDER SOLENOID 16 22
CONNECTION
34 37
INSTRUMENT
12 3 FRONT FRAME HARNESS
13 14
CLUSTER (CONNECTION K) CONNECTION
CONNECTOR
28 36
10 1 MAIN CHASSIS
1 10 11 15
61 64 X J HARNESS CONNECTION
19 27 H
16 25 26 30 W K
G B
10 18 INSTRUMENT 65 68 V F A C L
12 3 CLUSTER (CONNECTION F)
1 9 31 40 41 45 U M 1 2
CONNECTOR T E D N A B
46 55 56 60 S R P
1 2
10 1
1 2 INSTRUMENT 6
SYSTEM FLOAT/PARK BRAKE/ 1
CLUSTER (CONNECTION E) RETARDER TEMPERATURE
INSTRUMENT PANEL CONNECTOR 3 1 ENGINE ECU COLD START UNLOADER/ SENSOR CONNECTION
INSTRUMENT PANEL FRAME HARNESS TRANSMISSION COOLER PROPORTIONAL/
CPU (CONNECTION C) INSTRUMENT CONNECTION
CPU (CONNECTION A) CLUSTER (CONNECTION B) CONNECTION ENGINE COOLER PROPORTIONAL/
CONNECTOR CONNECTOR CONNECTOR BODY RAISE PROPORTIONAL/
15 13 BODY LOWER PROPORTIONAL
SOLENOID CONNECTION 15 20
B A 6 5 4
A B 3 2 1 CAB MANUFACTURERS HARNESS 1 2
TRANSMISSION
6 5 4 VALVE BLOCK CONNECTION
1 2 A CONNECTOR B A
3 4 3 2 1 COLUMN SWITCH B A
5 6 C CONNECTOR
CONNECTOR 'D' HEATED MIRROR BRAKE PEDAL
D
AIR/CON COMPRESSOR
D
7 8
CONNECTOR CONNECTOR STARTER MOTOR
CONNECTOR COOLANT LEVEL
9 10 CONNECTION HARNESS CONNECTION
2 1 2 1
SENSOR CONNECTION 1 2
5 6 7 8
DASH ROCKER 4 3 4 3
1 2 3 4 3
SWITCHES CONNECTOR 6 5 4 6 5 4 6 5 6 5
3 2 1 3 2 1 8 7 8 7 PARK BRAKE/STEERING A B
COLUMN SWITCH TRACTOR/TRAILER
AIR/CON INTERFACE FRONT WIPER MOTOR CONNECTOR
CONNECTOR RADIO/CASSETTE/CD RADIO/CASSETTE/CD PRESSURE SWITCH
CONNECTOR
UNIT POWER UNIT SPEAKERS CONNECTION OUTPUT SPEED/TURBINE SPEED/
CONNECTOR CONNECTOR ENGINE SPEED SENSOR SENSOR
X J
H CONNECTION
W K
G B
HYDRAULIC
V F A C L
U M 2 1
T E D N 1 2
S R P
Section 190-0000
DROPBOX
E
E
HARNESS CONNECTORS
SM - 3565
SM - 3566
DESCRIPTION 3
The hydraulic electronic control unit (ECU) (Fig. 1) is a
stand alone control which controls the machines
hydraulic systems, including body hoist and
transmission oil cooler fan drive. The IFM ECU
communicates with a variety of input and output
devices. It utilises analog/digital inputs, proportional 2
current outputs and digital outputs.
SM 2443 01-06 1
Electrical System - Hydraulic System ECU
Section 190-0085
SM - 3674
37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Air condition Signal- When the air conditioning has at main control valve spool. Body Raise and Lower
been selected, a signal is sent to the ECU to request Solenoids are rated at 21 W, 0.9 A, 25 ohms.
the Engine Cooling Fan.
Engine Cooling Fan - Engine coolant, air and oil
Body Control Lever Detente - An input signal is sent temp sensors feed back a signal to the ECU when any
from the body lever when the lever has been pushed of the following parameters are seen -
into the detente position, energising a detente solenoid
within the lever to hold it in the forward position. This ˇ Engine Coolant Temp greater than or equal to 89° C
continues until the proximity switch is made, when the (192° F)
ECU de-energises the detent solenoid so that the
lever returns to the neutral position, and the body float ˇ Engine Oil Temp greater than or equal to 109° C
solenoid is energised (see Float Solenoid). (228° F)
SM - 3567
ANALOGUE_IN
Brake Temp PIN 08 0
PIN 27 1
PIN 09 2 DIG OUT
Analog Inputs PIN 28 3
PIN 10 4 PIN 43 Transmission cooling fan stop solenoid
Joystick PIN 29 5
PIN 11 6
PIN 30 7 PIN 04 Engine cooling fan stop solenoid
DIG IN
Tipper prox [n/c] PIN 19 PIN 48 Brake cooling motor solenoid Digital Outputs
Starter Motor Signal PIN 55
Aircon full speed PIN 18
Joystick détente PIN 37 PIN 49 Float solenoid
Digital Inputs PIN 39
PIN 03
PIN 40 PIN 31 Cold start unloader solenoid
PIN 22
PIN 41
PIN 42 PIN 50
PIN 51
FREQ IN
PIN 20 PIN 52
PIN 02
PIN 21
PIN 38 PIN 16
PIN 35
PWM/I OUT
PIN 44
Power Up
VBBo
Proportional Solenoid
GNDo
PIN 45
Power Down
VBBo
Proportional Solenoid
GNDo Current
PIN 46
Transmission Cooling Fan Drive Outputs
VBBo
Proportional Solenoid
GNDo
POWER PIN 47
Engine Cooling Fan
Central Processing Unit/Sensors PIN 01 0VDC VBBo
Proportional Solenoid
Central Processing Unit/Sensors PIN 23 + 24VDC GNDo
Ground Outputs GNDo PIN 15 0VDC PIN 36
Power In Supply Outputs VBBo PIN 05 +24VDC VBBr
Ground Analogues GNDa PIN 12 0VDC GNDo
Supply Outputs via relay VBBr PIN 34 +24VDC PIN 54
VBBr
RS-232 GNDo
PIN 06 RXD PIN 17
PIN 07 TXD VBBr
Communication Port
PIN 33 GND GNDo
PIN 24 TEST PIN 53
VBBr
CAN 2.0B [11] PIN 14 CAN1H GNDo
CAN 2.0B [11] PIN 32 CAN1L
'CAN' Communication Port SAEJ1939 [29] PIN 26 CAN2H
SAEJ1939 [29] PIN 25 CAN2L
Transmission Cooling Fan - Sump oil temp and This in turn outputs a logic signal to the Transcooling
retarder oil temp sensors feed back a signal to the fan stop solenoid to energise it to allow flow to the
ECU when any of the following parameters are seen - cooling function. Depending upon the temperature
condition seen, will dictate the percentage of mA
ˇ Trans Oil Temp greater than or equal to 90°C (194° current sent to the Trans. cooling fan proportional
F) solenoid (Pin46 PWM output). This will cause the fan
to rotate at the desired fan speed.
ˇ Retarder Oil Temp greater than or equal to 90° C
(194° F) Float Solenoid - the body proximity switch sends a
signal via relay K52 to the ECU, which outputs a signal
to energise body float solenoid. This ensures that the
SM 2443 01-06 3
Electrical System - Hydraulic System ECU
Section 190-0085
System Safety
Input/Output Protection - all inputs to the ECU are WARNINGS
designed to withstand the maximum specified supply To prevent personal injury and property
voltage. The outputs are protected against short damage, be sure wheel blocks, blocking
circuit. Additionally, an error on one input/output will materials and lifting equipment are properly
not influence other inputs/outputs. secured and of adequate capacity to do the job
safely.
4 SM 2443 01-06
Section 190-0085
* * * *
SM 2443 01-06 5
THIS PAGE IS INTENTIONALLY LEFT BLANK
ELECTRICAL SYSTEM - Switches and Sensors
Section 190-0270
SM - 3573
HEADER TANK
AIR CLEANER 9 SEC 210-0040
PS1 12
7
17 11
16
22 (RHS) PS3
18 21 4
PS4
20 (RHS)
10 PS2
23 24 14 5
13
RHS BRAKE COOLANT/HYD. TANK
8
RHS 3
RHS 2
STARTER SOLENOID SW.
15
19
MANIFOLD BLOCK
TRANSMISSION LHS - SENSORS (FRONT AXLE)
ENGINE LHS - SENSORS
1 - Hydraulic Filter Restriction Gauge 9 - Air Cleaner Restriction Gauge 17 - Air Temp Sensor
2 - Brake Cooling Oil Pressure Switch 10 - Timing Reference Sensor 18 - Synchronous Ref Sensor
3 - Brake Cooling Oil Temperature Switch 11 - Front Brake Accumulator Pressure W/L 19 - Fuel Pressure Sensor
4 - Parking Brake Pressure Switch 12 - Main Hydraulic Pump Pressure Switch 20 - Oil Temp Sensor (RHS)
5 - Rear Brake Accumulator Pressure W/L 13 - Output Speed Sensor 21 - Oil Pressure Sensor
6 - Fuel Sender 14 - Turbine Speed Sensor 22 - Coolant Temp Sensor (RHS)
7 - Coolant Level Sender 15 - Input Speed Sensor 23 - Barometric Pressure Sensor
8 - Starter Relay 16 - Turbo Boost Press. Sensor 24 - Fuel Temp. Sensor
25 - Proximity Switch
Fig. 1 - Layout View of Switches and Sensors
SM 2368 03-06 1
Electrical System - Switches and Sensors
Section 190-0270
SM - 3394
5 6 7 8 9 10
3 4 11 12
2 13
2 STOP P
1
20 30 15
40 10 20
30 50
20 mph 60
10 40 r / min x100
km/h 5 25
10 70
80
0 0000000 50 L H 0 30
0000
˚C 100 135˚C 165
70
40 120 60 200
150 210 275 320
105 ˚F 250 ˚F 390
140
1 16 17 15 14
2 SM 2368 03-06
Electrical System - Switches and Sensors
Section 190-0270
SM 2368 03-06 3
Electrical System - Switches and Sensors
Section 190-0270
as a bargraph, indicating the amount of fuel left in the Note: The proximity switch prevents the body being
tank. Should the fuel level drop below 25% a warning fully powered down onto the frame. When the proximity
symbol (1, Fig. 3) will be displayed on the VDU switch makes contact, the body control lever detent is
warning screen. de-energised and float solenoid at main hydraulic valve
is energised.
Body
Body Up Proximity Switch (25) - Mounted off the
inside of the trailer left hand frame rail. When the body
is raised off the trailer frame, the switch sends a signal
to the hydraulic ECU. The body symbol on the VDU
warning screen (6, Fig. 3) is displayed when the body
is clear of the proximity switch.
Note: Never move the vehicle until body up warning
symbol on the VDU warning screen (6, Fig.32) goes
out, indicating that the body is fully lowered onto the
trailer frame.
* * * *
4 SM 2368 03-06
FUEL SYSTEM - Fuel System
Section 200-0040
SM - 3485
29
45
TO ENGINE - REAR
30 32
27 44
26 31 36 43
25
24
22,23 39
28 21
42
38
20 40
40
34
6,7
8 19
9,10 18
2
3 11 14
41
1 12
13
38 37
5
4
40
15,16
17
5
35
4
The fuel system consists of the DDEC electronic fuel A Fuel pressure sensor (44) is installed into the side of
system controls, fuel manifolds (integral with the secondary fuel filter (43) and sends an electronic signal
cylinder head), primary fuel filter (42), secondary fuel to the ECM telling it what the engine fuel pressure is at
filter (43), fuel pump, electronic control module (ECM), any given speed.
N3 electronic unit injectors, fuel cooler (41), fuel tank
(1) and the necessary connecting fuel lines. Fuel temperature sensor (45) is installed in a tee on the
top of secondary fuel filter (43) and sends an electrical
There are two spin-on type fuel filters mounted on the signal to the ECM indicating fuel inlet temperature. The
left hand side of the engine. Primary fuel filter (42) is in ECM uses this information to calculate fuel
the fuel flow and acts as a strainer. Integral to the consumption.
Primary fuel filter (42) is the facility to manually prime
the pump via removal of the red cap located centrally Note: Both fuel pressure sensor (44) and fuel
on the filter head. The secondary fuel filter (43) filters temperature sensor (45) are non-serviceable items and
the fuel after having passed through primary fuel filter should be replaced as individual units.
SM 2394 01-06 1
Fuel System - Fuel System
Section 200-0040
The fuel pump is attached to a drive assembly A remote mounted fuel tank breather/filter assembly is
mounted on the rear side of the gear case at the front incorporated into the fuel tank (1), allowing fuel tank (1)
LH side of the engine and transfers fuel from fuel to vent to atmosphere, preventing pressure from
tank (1) to the N3 electronic unit injectors. building up within fuel tank (1) assembly.
2 SM 2394 01-06
Fuel System - Fuel System
Section 200-0040
plug and tighten securely when fuel tank (1) is 7. Fill fuel tank (1) assembly with clean diesel fuel
completely drained. specified in Section 300-0020, LUBRICATION
SYSTEM.
9. Identify and tag fuel lines (30,35 & 36) and, with a
suitable container available to catch leakage, 9. Install filler cap (8) assembly on fuel tank filler neck.
disconnect fuel lines (30,35 & 36). Cap open line ends Tighten filler cap (8) securely and secure in place with
and elbows to prevent entry of dirt. padlock.
10. Remove bolts (4) and washers (5) securing fuel 10. Place the battery master switch in the 'On' position.
tank (1) assembly in the tractor frame. Using a suitable
lifting device, remove fuel tank (1) assembly from the 11. Lower hood assembly and secure front grille
vehicle. assembly to the hood with mounting hardware removed
at removal.
11. If required, remove fuel cooler (16). Refer to
Section 210-0100, HYDRAULIC OIL COOLER. 12. Start the engine and run for a few minutes to
ensure fuel is being supplied to the engine. Check for
12. If required, remove rubber pads from the tractor leaks at fuel lines (30,35 & 36) and tighten if required.
frame. Be sure to remove all rubber and adhesive from
the tractor frame. 13. Remove wheel blocks from all road wheels.
INSTALLATION MAINTENANCE
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.
WARNING WARNING
To prevent personal injury and property To prevent personal injury and property
damage, be sure wheel blocks, blocking damage, be sure wheel blocks and blocking
materials and lifting equipment are properly materials are properly secured and of adequate
secured and of adequate capacity to do the job capacity to do the job safely.
safely.
2. Using suitable lifting equipment, position fuel tank (1) Every 10 Hours/Daily:
assembly in the tractor frame. Make a visual check for fuel leaks at all engine mounted
fuel lines and connections, fuel cooler, and at the fuel tank
3. Secure the front of fuel tank (1) assembly to the suction and return lines. Examine lines for leaks and
tractor frame with bolt (4) and washer (5) as shown in check all fittings, clamps and ties carefully.
Fig. 1. Tighten bolt (4) to a torque of XXX
Make sure that fuel lines are not resting on or touching
4. Secure the rear of fuel tank (1) assembly to the rotating components, heated surfaces including
tractor frame with bolt (4), washer (5) as shown in Fig. 1. exhaust manifolds or sharp edges. If fittings have
Tighten bolt (4) to a torque of XXX loosened or cracked, or if lines have ruptured or worn
through, take corrective action immediately.
5. Remove blanking caps and secure fuel lines (30,35
& 36) to elbows, as identified at removal.
SM 2394 01-06 3
Fuel System - Fuel System
Section 200-0040
Every 500 Hours: sulphur content of 0.5% is recommended for use. Refer
Replace the primary and secondary fuel filters as to Section 300-0020, LUBRICATION SYSTEM.
follows:
2. Fill the replacement filters and coat the gaskets Check for loose, faulty or improper fuel line connectors.
slightly with clean fuel oil as specified in Section Presence of an air leak may be detected
300-0020, LUBRICATION SYSTEM. by following the procedures under 'Checking Fuel Flow'.
Note: Mechanical tightening of fuel filters is not 2. Start and run the engine at maximum rev/min and
recommended, and may result in seal and/or cartridge measure the fuel flow. Nominal fuel return spill with the
damage. Tighten fuel filters by hand only. standard 2.03 mm (0.08 in) restricted fitting is
4.1 litres/min (65 US gal/min).
4. Repeat step 3 to install a new secondary fuel filter.
3. Immerse the end of the fuel return line in the fuel. Air
5. Start the engine and check for leaks. If any leaks bubbles rising to the surface of the fuel will indicate air
are noted, have them corrected. being drawn into the fuel system on the suction side of
the pump. If air is present, tighten all fuel lines
Every 250 Hours: connections between the fuel tank and fuel pump.
Open the drain at the bottom of the fuel tank to drain
off any water and/or sediment. Check the seal in fuel 4. If the fuel flow is insufficient for satisfactory engine
tank filler neck cap and clean filler neck screen and performance then proceed as follows:
cap. Check the condition of all fuel lines and replace if
required. Clean and inspect fins on fuel cooler. a. Replace the primary and secondary fuel filters, as
described under 'Maintenance'. Start the engine and run
Every 1 000 Hours: it at maximum rev/min and recheck the fuel flow. If fuel
Fuel tank breather, replace flow is still unsatisfactory, perform step 'b'.
Diesel Fuel Oil b. Check the fuel lines for restrictions due to pinching,
The sulphur content of diesel fuel oil should be as low kinking or other damage. Be sure the correct restricted
as possible to avoid premature wear of piston rings and fitting is installed at the return port of the fuel tank. If no
liner, excessive deposit formation, and minimise problem is found, substitute another fuel pump that is
sulphur dioxide exhausted into the atmosphere. Limited known to be operating correctly and recheck the fuel flow.
amounts can be tolerated, but the amount of sulphur in When changing the fuel pump, inspect the fuel pump drive
the fuel and engine operating conditions can influence assembly, hubs and coupling. Clean all fuel lines with
corrosion and deposit formation compressed air and be sure all fuel connections are tight.
tendencies. The use of diesel fuel oil with a MAXIMUM
c. Disconnect the fuel lines from the ECM cooling plate
and, using a suitable connector, connect the two fuel
4 SM 2394 01-06
Fuel System - Fuel System
Section 200-0040
lines, bypassing the cooling plate. Run the engine at
maximum rev/min and recheck the fuel flow. If the fuel
flow with the cooling plate bypassed is normal, the
cooling plate should be replaced.
SPECIAL TOOLS
There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
tools required. These tools are available from your
dealer.
* * * *
SM 2394 01-06 5
THIS PAGE IS INTENTIONALLY LEFT BLANK
FUEL SYSTEM - Electronic Foot Pedal
Section 200-0051
SM - 3607
3
2
1 - Pedal Assembly
2 - Bolt
3 - Washer
4 - Idle Validation Switch connection
SM 2395 05-06 1
Fuel System - Electronic Foot Pedal
Section 200-0051
SM - 3608
ECU
TPS
U/Y Signal
V-13 A
Y/R 5 Volt
V-11 B
Y/B Return
V-60 C
U Return
V-29 F
VHC
REMOVAL
Numbers in parentheses refer to Fig. 1. 2. Connect electrical harness (5) and idle validation
switch (4) harness.
WARNING 4. Position floor mat on cab floor and ensure that pedal
To prevent personal injury and property assembly (1) is free to operate.
damage, be sure wheel blocks are properly
secured and of adequate capacity to do the job 5. Place the battery master switch in the 'On' position,
safely. remove wheel blocks and start the engine. Ensure that
pedal assembly (1) operates correctly.
1. Position the vehicle in a level work area, ensure the
body is fully lowered, apply the parking brake and Note: The engine MUST be started with the foot 'OFF'
switch off the engine. Turn steering wheel in both pedal assembly (1).
directions several times to relieve any pressure in the
steering circuit. MAINTENANCE
2. Block all road wheels and place the battery master Numbers in parentheses refer to Fig. 2.
switch in the 'Off' position.
Limited repair of the electronic foot pedal assembly is
3. Disconnect electrical harness (4). by replacement of parts only. Refer to vehicle Parts
Book for spare part numbers.
4. Move cab floor mat back and clear from pedal
assembly (1) and mounting plates. A number of checks can be made to determine correct
voltages are being seen at the pedal, which can help in
5. Remove bolt (2) and washer (3) from pedal assembly diagnosis of problems. These are follows:
(1) and remove pedal from the cab.
Voltages range which should be seen assuming proper
operation:
INSTALLATION
Numbers in parentheses refer to Fig. 1. Input:
Y/R & Y/B = 5.05V - 4.95V
Note: Tighten all fasteners to standard torques listed in
Section 300-0080, STANDARD BOLT AND NUT Idle:
TORQUE SPECIFICATIONS. U/Y & Y/B = 10 - 20% of Input (i.e. 0.5V to 1V)
1. Position pedal assembly (1) in position and secure with Full Throttle:
bolt (2) and washer (3). U/Y & Y/B = 70 - 85% of Input (i.e. 3.5V to 4.25V)
* * * *
2 SM 2395 05-06
COOLING SYSTEM - Cooling System (Series 60 Engine)
Section 210-0000
SM - 3635
12
6 10
14
7
9
1 3
5
13
8 2
1 - Header Tank 5 - Engine Oil Cooler 9 - Coolant Pipe 13 - Filter Inlet Line (not used)
2 - Radiator Assembly 6 - Thermostat Housing 10 - Bypass Line 14 - Filter Outlet Line (not used)
3 - Engine Water Pump 7 - Make-up Line 11 - Radiator Inlet Pipe
4 - Coolant Filter (not used) 8 - Radiator Outlet Pipe 12 - Deaeration Lines
DESCRIPTION
Numbers in parentheses refer to Fig. 1. thermostats located in thermostat housing (7), attached
to the right hand side of the cylinder head, control the
Two combination coolers are utilised in the system. flow of coolant.
Integral to the right hand cooler is the engine radiator ,
on the right hand side and charge-air-cooler on the left The main components of the cooling system are;
hand side. The Left hand combination cooler consists header tank (1), radiator assembly (2), engine water
of a transmission oil cooler, brake coolant oil cooler, pump (3), engine oil cooler (5) and thermostat housing
engine oil cooler and dropbox oil cooler as shown from (6).
left-to-right. Twin cooling fans are installed for cooling Attached to the front of right hand combination cooler
the respective system elements. This system has a is a condenser. Attached to the left hand combination
centrifugal type water pump (3) to circulate coolant cooler are hydraulic oil cooler and fuel cooler.
throughout the system. Two full blocking type
SM 2374 04-06 1
Cooling System - Cooling System (Series 60 Engine)
Section 210-0000
OPERATION SM - 3568
2 SM 2374 04-06
Cooling System - Cooling System (Series 60 Engine)
Section 210-0000
WARNING
WARNING
To prevent possible injury when using
Do not remove the pressure control cap from
compressed air, wear adequate eye protection
the radiator header tank or attempt to drain the
and do not exceed 2.75 bar (40 lbf/in²).
coolant until the engine has cooled. Once the
engine has cooled, use extreme caution when
removing the cap. Always release pressure Every 1 000 Hours
from the system by depressing the pressure
Replace coolant filter. Check and replenish coolant
relief button on the cap. Remove cap slowly as
inhibitor as required.
the sudden release of pressure from a heated
cooling system can result in a loss of coolant
Note: Failure to use and maintain coolant and coolant
and possible personal injury (scalding) from
inhibitor mixture at sufficient concentration levels can
the hot liquid.
result in damage to the cooling system and its related
components. Conversely, over-concentration of coolant
Every 10 Hours (Daily) and/ or inhibitor can result in poor heat transfer, leading
to engine dropout or both. Always maintain
Check coolant level and add if low. Fill the radiator
concentration at recommended levels.
header tank with coolant until coolant reaches the
bottom of the filler neck and holds at that level.
Inspect water pump drain hole to make sure it is open.
Note: Any time a significant amount of coolant is
Note: A small chemical build up or streaking at the
added, the coolant inhibitor MUST be checked. If the
drain hole may occur. This is not an indication of a
concentration is low, engine damage will result.
defective water pump or seal. If coolant does not leak
Conversely, over-inhibiting antifreeze solutions can
from the drain hole under normal operating conditions,
result in silicate dropout. Refer to 'Test Kit Procedures'.
do not replace the water pump.
Check cooling fan for cracks, loose rivets and bent or Every 2 000 Hours
loose blades. Check fan mounting and tighten if
Check coolant level and add if low. Fill the radiator
required. Replace cooling fan if damaged.
header tank with coolant until coolant reaches the
bottom of the filler neck and holds at that level.
Check coolant lines, pipes and components for leaks
and wear.
Note: Any time a significant amount of coolant is
added, the coolant inhibitor MUST be checked. If the
Every 50 Hours concentration is low, engine damage will result.
Conversely, over-inhibiting antifreeze solutions can
Check all drive belts for wear and tension. Refer to
result in silicate dropout. Refer to 'Test Kit Procedures'.
Section 110-0030, ENGINE AND MOUNTING for belt
tension specifications.
SM 2374 04-06 3
Cooling System - Cooling System (Series 60 Engine)
Section 210-0000
2. Refill the cooling system with clean, soft water and a 4. Repeat operation by alternately filling engine with
good radiator cleaning compound. If the engine is clean, soft water and blowing out with air until flushing
warm, fill slowly to prevent the rapid cooling and water runs out clean.
distortion of the metal castings.
3. Start the engine and operate the vehicle for fifteen Back-flushing Radiator
minutes to circulate the solution completely. 1. Disconnect all coolant lines at the engine.
4. Stop the engine and allow to cool. With the engine 2. Clamp flushing gun to lower hose on the radiator and
cool, drain the cooling system completely. fill the radiator with clean, soft water from the gun.
5. Refill the cooling system with clean, soft water and 3. Apply air pressure gradually increasing to a pressure
operate it for fifteen minutes. of 0.7 bar (10 lbf/in²). DO NOT EXCEED THIS
PRESSURE.
6. Stop the engine and allow to cool. With the engine
cool, drain the cooling system completely. 4. Alternatively fill radiator with clean, soft water and
flush with air until water runs out clear.
7. Refill the cooling system with the proper mix of
coolant and water. Refer to instructions under
'Recommended Coolants'. RECOMMENDED COOLANTS
SM 2374 04-06 5
Cooling System - Cooling System (Series 60 Engine)
Section 210-0000
Maintenance dosage of SCA must only be added if For best results make the tests while the coolant is
nitrite concentration is less than 800 parts per million between 10° - 60° C (50° - 140° F). Wait at least 60, but
(PPM). If nitrite concentration is greater than 800 PPM, not longer than, 75 seconds before reading the nitrite
do not add additional SCA. Refer to 'Test Kit level. Promptly replace and tighten container cap after
Procedures'. each use. Discard unused strips if they have turned
light pink or tan.
Test Kit Procedures Note: Failure to properly maintain coolant with SCA
Coolant Test Strips should be used to measure nitrite can result in damage to the cooling system and its
and glycol concentrations (See Special Tools). related components. Conversely, over-concentration of
Cavitation/corrosion protection is indicated on the strip SCA inhibitor can result in poor heat transfer, leading to
by the level of nitrite concentration. Freeze/boil over engine damage. Always maintain concentrations at
protection is determined by glycol concentration. Use recommended levels.
the test strips as follows:
a. Dip the strip into coolant for one second. Remove SPECIAL TOOLS
and shake briskly to eliminate excess fluid. Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of the coolant test strips and general service
b. Immediately compare end pad (% glycol) to the tools required. These strips and tools are available
colour chart. from your dealer.
* * * *
6 SM 2374 04-06
COOLING SYSTEM - Brake Cooling System Schematic
Section 210-0005
SM 2397 04-06 1
Cooling System - Brake Cooling System Schematic
Section 210-0005
Disc Brake Oil Cooler (4) Brake Cooling Oil Relief valve (7)
Refer to Section 210-0050, DISC BRAKE OIL
An internal pressure relief valve is contained within the
COOLER.
manifold blocks mounted on each axle. This valve is
set at 1 bar (14.5 Ibf/ in²) to maintain the brake cooling
The disc brake oil cooler is integral to the left hand
radiator assembly. Mounted on the left hand fender. oil at this pressure.
The fan which supplies air flow to the brake oil cooler is
driven by a hydraulic motor. The fan only turns when
hydraulic motor is supplied with oil from the main 'O' RING FACE SEALS (ORFS)
hydraulic valve, Refer to Section 215-0050 MAIN Where hydraulic lines are fitted with ORFS
HYDRAULIC VALVE ASSEMBLY. Brake cooling oil connections, the following procedure should be carried
enters the top of the cooler and flows through the out during installation. Refer to Fig. 1.
cooler before exiting at the bottom.
a. Ensure 'O' ring/seal is in place and that joining
surfaces are clean. If necessary, retain 'O' ring/seal in
Brake Cooling Oil Filter (6) place with a light coating of grease or vaseline.
The filter, mounted in the brake cooling line between
the motor/triple pump assembly and the front manifold b. Initially, the nuts should be tightened by hand.
block, ensures that the brake cooling oil is filtered. The
filter is fitted with a visual indicator to show when the c. Where a hose is fitted, ensure that it is not twisted
filter is in bypass mode. or kinked when the nuts are tightened so that it is
allowed to adopt a natural position.
Brake Cooling Oil Pressure Switch (8)
A pressure switch is mounted off the front axle brake d. Where a tube is fitted, ensure that the connection is
manifold block. The normally open pressure switch aligned correctly.
closes when brake cooling oil reaches 1.5 bar (22 lbf/
in²) a signal is sent to the VDU which will display the e. Tighten the nut a further 1/4 to 1/2 a turn using the
brake cooling oil pressure warning symbol on the VDU correct size of spanner (wrench).
panel. Refer to Section 190-0270, SWITCHES AND
SENSORS. f. Check that a satisfactory hose or tube routing has
been achieved.
Brake Cooling Oil Temperature Switch/ BRAKE COOLING OIL
Sender (10) The brake cooling system should be kept filled with
The normally closed switch opens when oil temperature brake cooling oil as specified in Section 300-0020,
reaches 50 °C (122 oF) and sends a signal to de- LUBRICATION SYSTEM.
energise the solenoid on the ocdb relief unloader valve,
allowing hydraulic oil flow from the main hydraulic valve Whenever there is a system failure, the brake cooling
assembly to supply the motorside of the motr/triple oil should be drained, the entire system flushed, oil
pump unit. thus drawing cooling oil to the axles. At the filter replaced, oil strainer thoroughly cleaned and clean
same time, a signal is sent to the fan disconnect brake cooling oil added to eliminate all metal particles
solenoid valve to de-enerrgise, thus supplying oil flow or foreign matter.
to the transmission cooling fan Refer to Section 190-
0270, SWITCHES AND SENSORS.
2 SM 2397 04-06
Cooling System - Brake Cooling System Schematic
Section 210-0005
SM - 1335 Multi-gauge
FITTING NUT The multi-gauge is basically four pressure gauges in
TUBE one. Continuous system pressure readings are
indicated on one of three simultaneously reading
gauges through a pressure range of 762 mm (30 in) of
vacuum to 345 bar (5 000 lbf/in2).
SM 2397 04-06 3
FRONT AXLE CENTRE AXLE REAR AXLE
BRAKE PACKS BRAKE PACKS BRAKE PACKS
3 3 3
7 9 7 7
10
4 1
SM - 3617
4 - Disc Brake Oil Cooler
Fig. 1 - Brake Cooling System Schematic
COOLING SYSTEM - Cooling Fan and Motor
Section 210-0010
(185°F).
LHS Radiator:
WARNING
Refer to Fig. 2. To prevent personal injury and property
damage, make sure blocking or lifting
5. Support radiator assembly with suitable lifting equipment is properly secured and of
equipment. Remove fan guard (4) and motor adequate capacity to do the job safely.
carrier frame (3) from radiator assembly.
Erratic Speed Is the motor losing speed Check flow from pump is
erratically? getting to the motor.
* * * *
6
3
SM 2457 05-06 1
Cooling System - Fan Disconnect Valve
Section 210-0044
2 SM 2457 05-06
Cooling System - Fan Disconnect Valve
Section 210-0044
7. Remove bolts and lockwashers securing the fan INSTALLATION
disconnect valve to the fender. Remove fan
Numbers in parentheses refer to Fig. 1.
disconnect valve from the fender.
Note: Tighten all fasteners to standard torques listed
DISASSEMBLY in Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.
Numbers in parentheses refer to Fig. 1.
Note: Tighten all hydraulic lines fitted with ORFS
1. Note location and position of all hydraulic
connections, as described in Section 250-0000,
connectors and adaptors prior to removing them from
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
valve body (3).
where used.
2. Unscrew solenoid cartridge valve (4) from valve
1. Secure fan disconnect valve to hydraulic front
body (3). Disassemble the solenoid as required for
frame of the truck with bolts and lockwashers.
inspection.
2. Remove blanking caps from hydraulic lines and
INSPECTION install lines to the fan disconnect valve as identified
during 'Removal'.
Numbers in parentheses refer to Fig. 1.
3. Re-connect electrical harness connector to solenoid
1. Clean all parts with a suitable solvent and dry with
valve.
compressed air.
4. Fill hydraulic oil tank with hydraulic oil as specified
2. Check port threads and make sure they are not
in Section 300-0020, LUBRICATION SYSTEM. Refer
damaged or stripped.
to Section 230-0040, HYDRAULIC TANK, for hydraulic
oil levels. Install filler cap on hydraulic tank filler neck.
3. Check cartridge valve (2), ensure it is not worn,
nicked, cracked or scored.
5. Place the battery master switch in the 'On' position,
start the engine and bring hydraulic oil to operating
4. Check valve body (3) for damage. Ensure valve
temperature.
body (3) is not worn, nicked, cracked or scored.
6. Check fan disconnect valve and hydraulic line
5. Examine solenoid coil for any defects.
connections for leaks and tighten as required.
Any parts which need to be replaced, should be done
7. Remove all blocking from road wheels and place
so prior to fitting the valve assembly.
steering lock bar in the 'Stowed' position.
SM 2457 05-06 3
THIS PAGE IS INTENTIONALLY LEFT BLANK
COOLING SYSTEM - Disc Brake Oil Cooler
Section 210-0050
SM - 3623
L.H. BRAKE
COOLANT/HYDRAULIC TANK
4
10 2
6
MANIFOLD 7
TRACTOR
11
13 8
22
MOTOR / TRIPLE 5
17 PUMP
9 21
CHECK VALVE
15 10 14
18
COOLER
20
11 1
19
R.H. BRAKE
BRACKET RH FRAME RAIL
DESCRIPTION AND OPERATION inlet hose (4), it is returned to the hydraulic tank (2) via
return hose (5). Cooling oil is drawn from the coolant
Numbers in parentheses refer to Fig. 1. The disc brake tank (2) via the pump and is filtered (7) before being
oil cooler can be identified as item 4 in Section 210- supplied to the manifold block (9) via supply hose (8).
0005, COOLING SYSTEM SCHEMATIC. From the manifold it is distributed to the wheels via
hoses (10 & 11). Return oil is sent to the brake cooler
The disc brake oil cooler (1) is an integral part of the (1) via hoses (14,19 & 20). There is an internal check
LHS combination cooler ,refer to section 210-0040 valve within the manifold block (9) on each axle, should
RADIATOR AND MOUNTING for specific location the pressure in the block reach 1 bar, the check valve
within the radiator assembly. The disc brake oil cooler will relieve the pressure, with flow going back to tank
is a blast air type, air being supplied via the LH cooling via hose (12). The principle is the same for all three
fan. The fan itself is driven by a hydraulic motor. The axle manifold blocks.
motor is supplied by a dedicated brake cooling section
of the motor / triple gear pump, via the OCDB relief Brake cooling oil enters the bottom of the oil cooler (1)
unloader valve. The speed of the fan is dependant on and flows through the oil cooler (1) before exiting at the
the oil flow being supplied to the motor from the relief bottom via hose (21 & 22) where it returns to the
unloader valve. Refer to Section 250-0070, OCDB coolant tank (2). There is one common inlet port and
RELIEF UNLOADER VALVE. outlet port which the return lines tee into to allow the
cooling oil to enter the cooler.
Hydraulic Oil flows from the ocdb relief unloader valve
into the motor section of the triple pump assembly via
SM 2446 05-06 1
Cooling System - Disc Brake Oil Cooler
Section 210-0050
REMOVAL
Numbers in parentheses refer to Fig. 1.
WARNING
To prevent personal injury and property
WARNING damage, make sure blocking or lifting
To prevent personal injury and property equipment is properly secured and of adequate
damage, make sure blocking or lifting capacity to do the job safely.
equipment is properly secured and of adequate
capacity to do the job safely. Generally assembly is the opposite of disassembly. Be
careful not to damage oil cooler (1) during installation.
1. Position the machine on a level floor, apply the
parking brake and switch off the engine. Operate the Note: Ensure there is even clearance, all the way
steering several times to discharge the steering round, between the fan and the radiator assembly.
system. Operate the treadle valve continuously to Refer to section 210-0010 COOLING FAN AND
discharge the braking system. MOTOR, for specific detail.
3. Remove drain plug from inboard face of the brake Note: Tighten all fasteners without special torques
coolant tank. Install a length of hose and drain brake specified, to standard torques listed in
cooling hydraulic oil into a suitable container. Remove Section 300-0080, STANDARD BOLT AND NUT
hose and reinstall drain plug. TORQUE SPECIFICATIONS.
DISASSEMBLY WARNING
Numbers in parentheses refer to Fig. 1. To prevent personal injury and property
damage, make sure blocking or lifting
Note: Tighten all fasteners without special torques equipment is properly secured and of adequate
specified, to standard torques listed in capacity to do the job safely.
Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS. Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 250-0000,
Note: As the brake oil cooler (1) is part of the BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
combination unit, refer to section 210-0040 RADIATOR where used.
AND MOUNTING for disassembly of major elements.
Note: As the brake oil cooler (1) is an integral part of
1. Remove hoses (20 & 21) from the inlet and outlet the LHS combination unit, refer to section 210-0040
port of the brake cooler (1) section of the LHS RADIATOR AND MOUNTING for installation of the
combination cooler. Refer to section 210-0040 radiator package.
RADIATOR AND MOUNTING.
1. Once installed, blanking caps should be removed
2. Any excess fluid contained within the cooler should from hydraulic hoses (20 & 21).
be drained prior to further disassembly.
2. Blaking caps should be removed from the cooler (1)
2. Plug ports and hoses. Ensure hoses are tagged for ports.
ease of installation at the assembly stage.
3. Install hoses (20 & 21) and secure.
ASSEMBLY
Numbers in parentheses refer to Fig. 1.
Note: Prior to start-up, ensure the hydraulic motor is
Note: Tighten all fasteners without special torques primed with clean hydraulic oil as specified in Section
specified, to standard torques listed in 300-0020, LUBRICATION SYSTEM.
Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.
2 SM 2446 05-06
Cooling System - Disc Brake Oil Cooler
Section 210-0050
* * * *
SM 2446 05-06 3
THIS PAGE IS INTENTIONALLY LEFT BLANK
COOLING SYSTEM - Radiator and Mounting
Section 210-0040
SM - 3578
25
23
21
24
5 22 5
4 4
4 4
5 5
5
4
3 1
2
3
4
16 19 5
7
15
16 6
19
7
11 9 26
20 1
8 28
7 29
15
16 19 6
7
5 9 27
4
3 8
10 2
13 3
4
5
18 17
14
18 14
17
18
17
16
19
15 16
12 19
SM 2445 05-06 1
Cooling System - Radiator and Mounting
Section 210-0040
SM - 3579
1
3
WARNING
4 2 To prevent personal injury and property
5 damage, be sure wheel blocks, blocking
4 materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.
4 4
5
4 1. Position the vehicle in a level work area, apply the
6 parking brake and switch off the engine.
4
2. Press hood switch under passenger seat and raise
hood.
4
6 3. Block all road wheels and place the battery master
4
switch in the 'Off' position.
7
Fan plate assemblies fitted to both LH and RH 6. Remove filler cap carefully from header tank. Refer
assemblies improves the cooling fan efficiency, to Section 210-0000, COOLING SYSTEM.
providing a more uniform distribution of air over the
cooler cores integral to each combination cooler 7. Remove plugs and open shut-off valves at the
assembly. bottom of radiator core and transmission oil cooler core
and drain coolant and oil into suitable containers. Close
Recirculation baffles incorporated in the hood assembly shut-off valves when systems are drained and refit
prevent hot air from the engine cooling fan being plugs.
reintroduced into the cooling air circuit.
8. Remove nuts (5) and lockwashers (4) securing brace
rods (1) to the tops of the combination coolers (21 &
REMOVAL 22).
Numbers in parentheses refer to Fig. 1 unless
otherwise specified. 9. Remove nuts (5), lockwashers (4), washers (3) and
flexible mounts (2) securing brace rods (1) to
combination cooler supports. Remove brace rods (1).
WARNING
Do not remove the pressure control cap from 10. Ensure air conditioning lines from condenser
the radiator header tank or attempt to drain the mounted on front of RH combination cooler (22), and
coolant until the engine has cooled. Once the from receiver drier are identified for ease of
engine has cooled, use extreme caution when installation. Disconnect air conditioning lines. Fit
removing the cap. Remove cap slowly as the blanking caps to open lines and ports.
sudden release of pressure from a heated
cooling system can result in a loss of coolant Note: Refer to Section 260-0130, AIR CONDITIONING
and possible personal injury (scalding) from before disturbing the air conditioning circuit.
the hot liquid.
12. Ensure hydraulic lines connected to hydraulic oil
cooler mounted on front of LH combination cooler (21)
are identified for ease of installation and with suitable
containers available to catch leakage, disconnect
2 SM 2445 05-06
Cooling System - Radiator and Mounting
Section 210-0040
hydraulic lines. Fit blanking caps to open lines and SM - 3568
ports. 3
1
4
2
13. Disconnect deaeration line from the radiator (2, Fig. 6
5) and deaeration line in engine. Disconnect make-up 4
line from coolant outlet pipe. Refer to Section 210- 5
4 4
0000, COOLING SYSTEM. Identify lines for ease of 5
4
installation and cap open lines and ports.
7
14. Disconnect all clips and clamps securing air
conditioning lines, hydraulic lines and deaeration lines
to radiator assembly. Move all lines away from radiator 4
assembly to prevent fouling on removal of radiator
assembly. 6
4
19. Slacken clamps (4, Fig. 2) and remove coolant 1. Remove mounting hardware securing shroud (6) to
outlet pipe (7, Fig, 2), hose (5, Fig. 2) and clamps (4, radiator core (2) and charge air cooler core (3).
Fig. 2)) from bottom of radiator assembly and engine
water pump inlet. 2. Remove top plate (10), base plate (9) and gasket (1)
from the assembly. Separate the charge air cooler core
20. Using suitable lifting equipment support RH (3) from the radiator core (2).
combination cooler (22).
LH Combination Cooler
21. Remove bolts (8) and washers (9) securing RH
combination cooler (22) to the frame. Numbers in parentheses refer to Fig. 4, unless
otherwise specified.
22. Remove RH combination cooler (22) from the
vehicle to a clean area for disassembly. Support cooler Note: Take care not to damage transmission oil cooler
standing upright to allow access to front and rear core (2), sump oil cooler core (3), brake oil cooler core
(4) and dropbox oil cooler core (5) during disassembly.
23. Follow the procedure in steps 20 to 22, for removal
of the LH combination cooler (21). 1. Remove mounting hardware securing shroud (6) to
cooler cores (2,3,4 & 5).
2. Remove top plate (10), base plate (9) and gasket (1)
from the assembly. Separate the four individual cooler
core elements from each other.
SM 2445 05-06 3
Cooling System - Radiator and Mounting
Section 210-0040
SM - 3581
2
10
4
6
3
8 5
13
12
1
11
9
4 SM 2445 05-06
Cooling System - Radiator and Mounting
Section 210-0040
SM - 3582
3
10
8
11 5
7
4
12
1
13
9
Note: When installing combination cooler, ensure with base plate and top plate (9 & 10). Use fasteners
clearance around cooling fan tips to plate assembly is removed during the disassembly stage.
of equal dimension all round.
3. Position shroud (6) and secure with fasteners
6. Install air conditioning condenser (5) to combination removed during the disassembly stage.
cooler assembly picking up mounting locations and
hardware as identified at 'Disassembly'. 4. Assemble elements of the fan (11) including
hydraulic motor (12) and secure elements in place to
LH combination Cooler the complete cooler assembly.
SM 2445 05-06 5
Cooling System - Radiator and Mounting
Section 210-0040
13. Remove blanking caps from hydraulic oil cooler
lines and fittings. Connect all hydraulic lines to
WARNING hydraulic oil cooler as identified at removal.
To prevent personal injury and property
damage, be sure lifting equipment is properly 14. Remove blanking caps from air conditioning lines
secured and of adequate capacity to do the job and fittings. Connect air conditioning lines to condenser
safely. and receiver drier. Refer to Section 260-0130, AIR
CONDITIONING for procedure on charging the system.
1. Position brace rods (1) and secure in place at
bottom with nuts (5), washers (3), flexible mounts (2) 15. Secure all lines with clips and clamps as removed
and lockwashers (4). Do not tighten at this stage. during removal. Ensure no lines are chaffing on sharp
edges or resting against areas where heat will be
2. Using suitable lifting equipment, position each cooler evident.
assembly on the frame and secure with bolts (8),
rubber mounts (6) and washers (7). 16. Ensure fittings, lines and pipes are securely
tightened to prevent leaks at initial fill and start up.
3. Secure brace rods (1) to tops of coolers using nuts
(5) and washers (4). Adjust brace rods (1) as 17. If removed, fit header tank to goalpost and secure
necessary at both ends and fully tighten nuts (5). using bolts, nuts and washers removed as
disassembly stage.
4. Install coolant outlet pipe (7, Fig. 2) between
radiator outlet port and engine water pump inlet, and 18. Following installation instructions in Section
secure with hoses (5, Fig. 2) and clamps (4, Fig. 2). 100-0040, HOOD AND MOUNTING, install header tank
and goalpost assembly on the vehicle.
5. Install coolant inlet pipe (3, Fig. 2) between radiator
inlet port and engine thermostat housing, and secure 19. Remove blanking from make-up line (7) and
with hoses (6, Fig. 2) and clamps (4, Fig. 2). connect to header tank (1) and coolant outlet pipe (8).
Secure with clamps. Refer to Section 210-0000,
6. Install air outlet pipe (3, Fig. 3) between engine COOLING SYSTEM.
intake manifold and charge air cooler (1, Fig. 3) and
secure with hoses (5 &6, Fig. 3) and clamps (4, Fig. 3). 20. Remove blanking caps from deaeration lines
(12) and connect to appropriate fittings on header tank
7. Install air inlet pipe (7, Fig. 3) between engine (1), as noted on removal. Refer to Section 210-0000,
turbocharger and charge air cooler (1, Fig. 3) and COOLING SYSTEM.
secure with hoses (5 & 6, Fig. 3) and clamps (4, Fig.
3). 21. Connect overflow line to header tank.
8. Feed electrical harness from engine cooling fan 22. Secure all lines with clips and tie clips as removed
through hole in fan plate assemblies. during removal. Ensure no lines are chaffing on sharp
edges or resting against areas where heat will be
9. Connect engine cooling fan electrical harness to evident.
main electrical harness.
23. Connect electrical harness to coolant level sensor
10. Install horns to front of radiator assembly and at bottom of header tank.
connect electrical harness to horns.
24. Refer to Section 210-0000, COOLING SYSTEM for
11. Install LH and RH fan guards (7, Figs 4 & 5) to correct selection of coolant. Fill the cooling system
radiator assemblies with bolts, washers and nuts through filler in header tank with coolant until coolant
removed during 'Removal'. level stabilizes at the bottom of filler neck.
12. Remove blanking caps from deaeration lines 25. Check all line and pipe connections for leaks prior
(12) and connect deaeration line (12) to connector in to starting the vehicle. Tighten as required.
top of radiator assembly and deaeration line (12) to
connector thermostat housing in engine. Do not clip 26. Switch the battery master switch to the 'On'
lines at this point. Refer to Section 210-0000, position, start up the engine, check for leaks. Tighten
COOLING SYSTEM. lines and fittings and top up coolant level as required.
6 SM 2445 05-06
Cooling System - Radiator and Mounting
Section 210-0040
29. Install filler cap on header tank after the coolant
level has stabilized at the bottom of filler neck. 2. If cooler tubes are badly clogged, circulate an oakite
or alkaline solution through cooler. Solution should be
30. Following installation instructions in Section circulated through cooler, in the reverse direction to
100-0040, HOOD AND MOUNTING, install hood normal flow, for approximately 15 minutes, after
assembly on the vehicle. soaking for 10 minutes. The duration of circulation
depends on how badly clogged the cooler is. Flush
31. Remove wheel blocks from road wheels. thoroughly with clean hot water.
External Cleaning
CLEANING Note: If a build up of dirt is apparent during routine
inspection, the following cleaning procedure should be
Radiator Core Internal Cleaning - Water adopted.
Tubes
If scale deposits are present inside the water tubes of
the radiator core, it is necessary to use a suitable WARNING
scale remover such as 'Powdered Scale Solvent', or To prevent possible injury when using
equivalent. This material is a free-flowing powder, compressed air or steam jet, wear adequate eye
inhibited to prevent attack on the cooling system protection and do not exceed pressure values
materials. stated.
1. Clean transmission oil cooler before sludge hardens. 8. For surfaces with stubborn deposits, it may be
After transmission oil cooler is completely drained, necessary to repeat steps 5 through 7, brushing the
circulate a solution of Agmasol PS40 through the surfaces between stages using a stiff bristle brush.
cooler core to remove sludge.
9. Leave cores to dry before reinstalling the equipment.
SM 2445 05-06 7
Cooling System - Radiator and Mounting
Section 210-0040
MAINTENANCE
Refer to Section 210-0000, COOLING SYSTEM for
recommended preventive maintenance procedures,
service intervals and coolant selection procedures.
SPECIAL TOOLS
There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
tools and adhesives required. These tools and
adhesives are available from your dealer.
8 SM 2445 05-06
COOLING SYSTEM - Transmission Oil Coolers
Section 210-0060
SM - 3598
2
1
SUMP TOP
3
2
SUMP BTM
12
TRANSMISSION VIEW 4 2
FROM ABOVE
11
BTM
8
5
10 9 14 9
13
15 7
19
TOP
6 5 20
16
17
18
15 14
SM 2433 03-06 1
Cooling System - Transmission Oil Coolers
Section 210-0060
2. Block all road wheels and place the battery master INSTALLATION
switch in the 'Off' position.
Numbers in parentheses refer to Fig. 1.
3. Remove inlet line (4) from adaptor (2) in the
Note: Tighten all fasteners to standard torques listed in
transmission oil cooler. Drain oil from inlet line (4) into
Section 300-0080, STANDARD BOLT AND NUT
a suitable container. Plug inlet line and cap port to
TORQUE SPECIFICATIONS.
prevent ingress of dirt.
Note: Tighten all hydraulic lines fitted with ORFS
4. Remove outlet line (3) from adaptor (2). Drain oil
connections, as described in Section 220-0000,
from outlet line (3) into a suitable container. Plug outlet
STEERING SYSTEM SCHEMATIC. Renew all
line and cap port to prevent ingress of dirt.
'O' rings where used.
5. Remove inlet line (7) from adaptor (5) in the retarder
oil cooler. Drain oil from inlet line (7) into a suitable
WARNING
container. Plug inlet line and cap port to prevent
To prevent personal injury and property
ingress of dirt.
damage, be sure wheel blocks and lifting
equipment are properly secured and of
6. Remove outlet line (6) from tee (10). Drain oil from
adequate capacity to do the job safely.
outlet line (6) into a suitabl e container. Plug outlet line
and cap port to prevent ingress of dirt.
1. If the transmission oil cooler or retarder oil cooler
7. If required remove hardware and associated lines
wer eremoved from the complete combination cooler
from combination cooler, Refer to section 210-0040
assembly. They must be reassembled to the cooler
RADIATOR AND MOUNTING, to allow for removal of
prior to connecting cooling lines. Refer to Section 210-
both transmission and retrder cooler portions of the
0040, RADIATOR AND MOUNTING.
combination cooler (20).
2.Install inlet line ( 4) into adaptor (2) on the
CLEANING AND INSPECTION transmission oil cooler.
2 SM 2433 03-06
Section 210-0060
* * * *
SM 2433 03-06 3
THIS PAGE IS INTENTIONALLY LEFT BLANK
COOLING SYSTEM - DropBox Oil Cooler
Section 210-0065
SM - 3525
15
3
8 14
9
TOP
7
5
13
6 2
12
1
OC1
OC2
10 11 8
4
6
7
BTM
SM 2432 03-06 1
Cooling System - DropBox Oil Cooler
Section 210-0065
into a suitable container. Plug inlet line and cap port to
prevent ingress of dirt. WARNING
To prevent personal injury and property
4. Remove outlet line (7) from adaptor (3) and damage, be sure wheel blocks and lifting
connector in dropbox oil cooler (1). Drain oil from outlet equipment are properly secured and of
line (7) into a suitable container. Plug outlet line and adequate capacity to do the job safely.
cap port to prevent ingress of dirt.
1. If removed, reinstall combination cooler and
7. If required remove hardware and associated lines associated lines prior to connecting dropbox (1) cooler
from combination cooler, Refer to section 210-0040 lines. Refer to Section 210-0040, RADIATOR AND
RADIATOR AND MOUNTING, to allow for removal of MOUNTING
the dropbox cooler (1) and its constituent parts.
2. Install inlet line (4) and outlet line (7) in their
CLEANING AND INSPECTION respective ports, as removed at 'Removal'.
1. Inspect fins on dropbox oil cooler carefully, for 3. Place the battery master switch in the 'On' position,
trapped debris and damage. If dropbox oil cooler fins start engine and bring transmission up to operating
show signs of leakage or are excessively damaged, it temperature. Check dropbox oil cooler (1) and lines for
must be replaced as an assembly. leaks. Tighten fittings as required.
2. Check connectors in dropbox oil cooler ports for 4. Remove wheel blocks from all road wheels.
damaged threads. Replace if required.
* * * *
2 SM 2432 03-06
COOLING SYSTEM - Hydraulic Oil Cooler
Section 210-0100
SM - 3634
8
9
7
10
11
12 6
H
S
F1
F2
TANK RETURN
5 4 MANIFOLD
2 3
DESCRIPTION AND OPERATION (1) from the bottom port of the cooler located on the LHS
of the cooler. Oil returns to tank through the hydraulic oil
Numbers in parentheses refer to Fig. 1.
filter.
The air cooled hydraulic oil cooler (1) is mounted to the REMOVAL
bracket (11) on the front face of the left hand radiator
Numbers in parentheses refer to Fig. 1.
assembly, directly below the fuel cooler, Refer to
Section 200-0040 , FUEL LINES for detail.
WARNING
The purpose of the cooler is cooling hydraulic oil
To prevent personal injury and property
circulating through the hydraulic system.
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
Hydraulic oil cooler (1) is connected at tube (8)
secured and of adequate capacity to do the job
between the return ports from the two hydraulic fan
safely.
motorsand the inlet to the hydraulic tank filter
assembly.
1. Position the vehicle in a level work area, ensure the
body is fully lowered, apply the parking brake and
Hydraulic oil enters the hydraulic oil cooler from oil inlet
switch off the engine. Turn steering wheel several
line (7) on the RHS of the cooler at the port located on the
times to relieve any pressure in the steering circuit.
bottom. Oil passes through a series of tubes in the cooler
core, where the oil temperature is reduced by air flow
2. Block all road wheels and place the battery master
through the cooler fins, before exiting hydraulic oil cooler
switch in the 'Off' position.
SM 2459 04-06 1
Cooling System - Hydraulic Oil Cooler
Section 210-0100
3. Remove blanking cap from remote drain line at the INSTALLATION
bottom of the hydraulic tank. Install a length of hose on
Numbers in parentheses refer to Fig. 1.
remote drain fitting, open drain cock and drain hydraulic
oil into a suitable container. Close drain cock, remove
Note: Tighten all fasteners to standard torques
hose and reinstall blanking cap.
specified in Section 300-0080, STANDARD BOLT
AND NUT TORQUE SPECIFICATIONS.
4. Remove mounting hardware securing the front grille
on the hood assembly and remove grille for access to
1. Remove blanking cap from hydraulic oil cooler (1),
hydraulic oil cooler (1).
oil inlet line (7) and oil outlet line (6). Prior to
installation.
5. Press the hood raise switch (located in the cab,
under the passenger seat). Raise the hood to allow for 2. Secure cooler (1) to the bracket (12) using washers
access to the cooler. (5), lockwashers (4) and bolts (3) at both mounting
locations.
6. Remove oil outlet line (6) from hydraulic oil cooler (1)
and drain oil into a suitable container.
3. If removed, fit adaptors (2) to both inlet and outlet
ports of the cooler (1).hte
7. Remove oil inlet line (2) from hydraulic oil cooler (1)
and drain any remaining oil into a suitable container.
5. Position oil inlet (7) and outlet (6) lines lines on the
vehicle following the route taken before removal. Do
8. Remove bolts (3), lockwasher (4) and washers (5)
not clip line in position at this stage.
securing oil cooler (1) to bracket (12).
6. Secrue oil lines to the cooler and the tube (8).
9. Remove oil cooler (1) from the vehicle.
7. Clip oil inlet line (7) and oil outlet line (6) with clips
10. Fit blanking caps to all ports and hose lines which
as noted at removal. Use tie clips where required to
will be fitted at installation.
maintain tidy line routing.
CLEANING AND INSPECTION 8. Fill hydraulic oil tank with hydraulic fluid specified in
Section 300-0020, LUBRICATION SYSTEM. Refer to
1. Inspect fins on hydraulic oil cooler carefully, for
Section 230-0040, HYDRAULIC TANK, for correct fill
trapped debris and damage. If hydraulic oil cooler fins
level. Install filler cap on hydraulic tank.
show signs of leakage or are excessively damaged, it
must be replaced as an assembly.
9. Check all line and pipe connections prior to starting
the vehicle.
2. Check connectors in hydraulic oil cooler ports for
damaged threads. Replace if required.
10. Place the battery master switch in the 'On' position,
start the engine and check for leaks. Tighten lines and
3. After hydraulic oil cooler is completely drained,
fittings as required.
circulate a solution of Agmasol PS40 through the
cooler tubes.
11. Lower hood assembly using the hood switch
located beneath the passenger seat.
4. If cooler tubes are badly clogged, circulate an oakite
or alkaline solution through the hydraulic oil cooler, in
12. secure front grille assembly to the hood with
the reverse direction to normal flow, for approximately
mounting hardware removed at removal. Remove all
15 minutes. The duration of circulation depends on how
wheel blocks.
badly clogged the cooler tubes are. Flush thoroughly
with clean hot water.
SPECIAL TOOLS
There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
tools required. These tools are available from your
dealer.
* * * *
2 SM 2459 04-06
MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050
SM - 2828 closed. As the main pump starts rotating it builds up
residual pressure and the priority valve opens, feeding
the main pump pressure through to the fan drive (22 &
23) & body tipping (27 & 28) valves.
Valves that control all the above functions are Emergency Steering By Pass Valve
integrated into the Main Hydraulic Valve Assembly and Refer to Section 220-0000, STEERING SYSTEM.
are identified in Figs. 2 through 4.
The emergency valve (3) forms part of the emergency
steering system. It is connected to the main output line
System Relief of the wheel driven Emergency Steering Pump
The system relief valve (1) protects the main hydraulic mounted on the transmission.
valve assembly components against pressure spikes.
This system relief valve is pre-set at 260 bar (3770 lbf/
in2 )and is non-adjustable. Brake Charging Function
Refer to Section 250-0000, BRAKE SYSTEM.
Priority Function Brake charge valve (12) and brake pressure reducer
This function automatically ensures that the steering valve (9) are integral valves that form part of the brake
and brake charging circuits are given preference over charging function. Brake charge valve (12) ensures that
the fan and body tipping functions. there is sufficient load sense pressure to the main
pump to allow the charge pressure to be generated.
When the pump is not running, the priority valve (7) is Brake pressure reducer valve (9) maintains a safe
Section 215-0050
MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
PBP TS PB PS4 ACC1 B1 PS3 ACC2 B2 PS2 ACC3 PS5 DF1 DF2 DL
CT24 CT37
CT33
CT10 CT11 TPA
CT27
CT22 PPA
CT23
CT32 CT12
CT9
CT21
T2
CT31
CT41 CT42
CT8 CT13 CT25
CT1 LOWER
CT28 B
PS1
CT35 CT7 CT39
CT14
P1
A
LSM CT43 HOIST
CT15 CT29
CT44
CT3 CT16 CT26
P2G CT5
CT17 CT36
CT20
CT30
P2
CT4 CT34
CT6 CT38
CT2
CT18 CT19
1 - Relief Valve 'CT1' 12 - Brake Charging Valve 'CT12' 22 - Proportional Pressure Control Valve 'CT22' 32 - Directional Control Valve 'CT32'
2 - Relief Valve 'CT2' 13 - Orifice 'CT13' 23 - Proportional Pressure Control Valve 'CT23' 33 - Orifice 'CT33'
3 - Bypass sequence Valve'CT3' 14 - Cold start solenoid Valve 'CT14' 24 - Shuttle Valve 'CT24' 34 - Hoist LS Shuttle Valve 'CT34'
4 - Check Valve 'CT4' 15 - Orifice 'CT15' 25 - Shuttle Valve 'CT25' 35 - Orifice 'CT35'
5 - Check Valve 'CT5' 16 - Shuttle Valve 'CT16' 26 - Shuttle Valve 'CT26' 36 - Hoist LS Valve 'CT36'
6 - Check Valve 'CT6' 17 - Shuttle Valve 'CT17' 27 - Proportional Pressure Control Valve 'CT27' 37 - Relief Valve (Diff Lock) 'CT37'
SM 2442 Rev1 05-06
7 - Priority Valve 'CT7' 18 - Shuttle Valve 'CT18' 28 - Proportional Pressure Control Valve 'CT28' 38 - Auxilliary Check Valve
8 - Check Valve 'CT8' 19 - Shuttle Valve 'CT19' 29 - Float Solenoid 'CT29' 39 - Shuttle Valve 'CT39'
9 - Pressure Reducing Valve 20 - Body Raise LS Relief Valve 'CT20' 30 - Orifice 'CT30' 41 - Body Control spool 'CT41'
10 - Check Valve 'CT10' 21 - Pressure Reducing Valve 'CT21' 31 - Park Brake Solenoid 'CT31' 42 - Check Valve 'CT42'
11 - Check Valve 'CT11' 43 - Relief Valve 'CT43'
SM3538
44 - Check Valve 'CT44'
Fig. 2 Main Hydraulic Valve Assembly Schematic - Based on Engine Shutdown
MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050
operating pressure within the front and rear brake Engine & Transmission Cooler Fan Drives
accumulators.
The engine and transmission cooler fan speeds are
Park/Emergency Brake Function modulated by proportionally controlling the pressure at
the fan motors. Fan speed is a function of the pressure
Refer to Section 250-0000, BRAKE SYSTEM.
at the fan motors.
Park/Emergency brake solenoid (31) is the integral
On a cold start, the cooler fans will not rotate. Fan
valve that controls hydraulic pressure to the park and
drive solenoid valve, mounted on the left and right hand
emergency brake function of the truck.
fender respectively , will remain closed, blocking
actuating pressure to either the engine cooling fan or
Body Control Function transmission cooling fan until any of the following
temperature conditions are met for each system:
Refer to Section 230-0000, BODY SYSTEM
Transmission Conditions
Proportional pressure control valve (27) is the integral
valve that controls the body tipping function. This valve
ˇ Transmission oil temp greater than 80°C.
is operated via the body control lever located in the
ˇ Retarder oil temp greater than 90°C.
operators cab. The body control lever sends an
ˇ Air conditioner 'ON'.
electrical signal to the hydraulic ECU. (Refer to Section
190-0085). The hydraulic ECU processes this signal
Engine Conditions
and delivers an actuating electrical signal to the
proportional pressure control valve (27). The
ˇ Inlet manifold temp greater than 54°C.
proportional pressure control valve (27) converts this
ˇ Engine Coolant temp greater than 89°C.
electrical signal into a pilot pressure, that then is
ˇ Engine Oil temp greater than 108°C.
allowed to stroke the body control spool to the lift
position.
When any of the above conditions are seen, an
electrical signal will be sent via the J1939 datalink to
Proportional pressure control valve (28) is the integral
the hydraulic ECU. Once a signal reflecting any of the
valve that controls the body lower function. This valve
preprogrammed temperature parameters is met. The
is operated via the body control lever located in the
hydraulic ECU wil send a signal to de-energise the
operators cab. The body control lever sends an
appropriate fan drive solenoid valve, allowing actuation
electrical signal to the hydraulic ECU (Refer to Section
pressure to access the fan drive circuit. The fan drive
190-0085). The hydraulic ECU processes this signal
solenoid valves are failsafe. If power or electrical
and delivers an actuating electrical signal to the
connection is lost, the fan drive solenoid valves will de-
proportional pressure control valve (28). The
fault to the open (de-energised) condition.
proportional pressure control valve (28) converts this
electrical signal into a pilot pressure, that then is
Transmission signal
allowed to stroke the body control spool to the lower
position. Subsequent Load sense pressure for raise
The hydraulic ECU (Refer to Section 190-0085) sends
and lower functions is directed back to the pump via
an electrical signal from 'Digital Out' Pin '43' to the fan
hoist 'LS' shuttle valve (34), orifice (30) dampens the
drive solenoid valve. This signal de-energises the fan
laod sense signal.
drive solenoid, opening the transmission cooler fan
drive circuit.
During the lower condition, when the body reaches the
proximity switch on the chassis frame, this energises
The transmission cooler fan speed pressure is
the switch and a signal is sent via relay K52 to the
controlled by the Electro-Hydraulic Proportional Control
float solenoid (29), opening the path to tank. This
Valve (CT22). A varying current input into this valve of
ensures hoist cylinders are vented to tank, allowing
between 0 to 264 mA controls the pressure between 39
body to lower onto chassis under it’s own weight.
bar (490 psi) and 138 bar (1260 psi). This pressure then
acts upon the Shuttle Valve (24) and onto the main
Body relief valve (43) is located on the raise side of the
pump load sense connection via Shuttle Valve (17).
circuit and prevents pressure spikes at maximum
This pressure acts upon the spring chamber of the
extension of the cylinders when the body is raised at
Logic Valve (22) that controls the pressure at the fan.
maximum engine speed. Relief valve (43) is set at 250
bar (3 625 lbf/in2 ).
The hydraulic ECU reads data on the J1939 datalink.
The temperature sensor output is calibrated against The hydraulic ECU reads data on the J1939 datalink.
actual temperature within the hydraulic ECU. The The temperature sensor output is calibrated against
hydraulic ECU converts the temp signal into a varying actual temperature within the hydraulic ECU. The
current output. This varying current output, from 'PWM hydraulic ECU converts the temp signal into a varying
Out' Pin '46', controls Electro-Hydraulic Proportional current output. This varying current output, from 'PWM
Control Valve (22) increasing and decreasing pressure Out' Pin '47', controls Electro-Hydraulic Proportional
at the fan motor. The fan speed increases and de- Control Valve (23) increasing and decreasing pressure
creases proportionally between transmission sump and at the fan motor. The fan speed increases and de-
retarder oil temperatures of 80 to 130°C (176 to 266°F). creases proportionally between Engin oil temperatures
The Fan Drive Solenoid will remain de-energised until of 108 to 114°C (226 to 237°F).
the transmission oil temperature falls below 80°C . At
this point the oil flow to the transmission cooling fan The Fan Drive Solenoid will remain de-energised until
will stop. the engine oil temperature falls below 108°C . At this
point the oil flow to the transmission cooling fan will
Engine signal stop.
The hydraulic ECU (Refer to Section 190-0085) sends Note: the temperatures listed for the engine are
an electrical signal from 'Digital Out' Pin '04' to the fan specific to engine oil temp. being monitored. THe other
drive solenoid valve. This signal de-energises the fan paramaters i.e. intake manifold temp and coolant temp.
drive solenoid, opening the engine cooler fan drive will also cause the engine cooling fan to run at their
circuit. preset temp. conditions.
The engine cooler fan speed pressure is controlled by Refer to troubleshooting charts.
the Electro-Hydraulic Proportional Control Valve
(CT23). A varying current input into this valve of Cold Start Function
between 0 to 264 mA controls the pressure between 39 Cold Start Solenoid (14) is the integral valve that
bar (490 psi) and 138 bar (1260 psi). This pressure then controls the cold start function of the Main hydraulic
acts upon the Shuttle Valve (24) and onto the main valve assembly. Cold start solenoid (14) energises
pump load sense connection via Shuttle Valve (17). when starter motor signal is high, this dumps all load
This pressure acts upon the spring chamber of the sense pressure from the main hydraulic pump,
Logic Valve (23) that controls the pressure at the fan. rendering the pump off-load. This reduces parasitic
SM3539
26
7
14 23
16
Fig. 4 - Main Hydraulic Valve Assembly - Engine & Transmission Cooler Fan Valves/Cold Start Solenoid
Fig. 5 - Main Hydraulic Valve Assembly - Transmission Cooler Fan Valves Continued
Fan unstable over the speed range Fan proportional pressure valves (22 Replace Valve.
when another function is selected. & 23) faulty.
losses during engine cranking procedure. this high signal into digital output signal at 'Pin 31',
There is about a 2 second delay before de-energising energising the cold start solenoid (14). The signal to
cold start solenoid (14) (starter motor signal low). This energise the cold start solenoid (14) will remain on until
function prevents brake charging during engine start a starter motor low signal is received by the hydraulic
up, which is particularly important in cold climates. E.C.U. at 'Pin 55', this will negate the digital output
signal from 'Pin 31'. (Refer to section 190-0085 for full
A starter motor high signal is received by the hydraulic Hydraulic E.C.U. detail.)
ECU at Digital in 'Pin 55'. The hydraulic ECU converts
WARNINGS ASSEMBLY
Accumulators are charged with Nitrogen.
All integral valves must be re-installed into correct
The service pressure in the primary
locations on the main hydraulic valve assembly. All
accumulator is 103 bar (1494 lbf/in²) and in the
integral valves must be torqued to correct value.
Front and Rear Brake accumulators is 55 bar
(798 lbf/in²) at 20° C (68o F). To prevent personal
injury and property damage do not attempt to 1. Re-install O.R.F.S. connectors into correct ports.
remove any valves or fittings until all nitrogen Replace o-rings and seals. Ref. Fig. 6
pressure is completely relieved. SM - 1335
2. Block all road wheels and place battery master FITTING NUT
switch in the 'Off' position. TUBE
SM2919
43
1 - Relief Valve 'CT1'
2 - Relief Valve 'CT2'
3 - Bypass sequence Valve'CT3'
4 - Check Valve 'CT4'
5 - Check Valve 'CT5'
6 - Check Valve 'CT6' 34
7 - Priority Valve 'CT7'
8 - Check Valve 'CT8'
26 7
9 - Pressure Reducing Valve
10 - Check Valve 'CT10' 5
11 - Check Valve 'CT11' 8,35
12 - Brake Charging Valve 'CT12'
40
13 - Orifice 'CT13'
14 - Cold start solenoid Valve 'CT14' 21
15 - Orifice 'CT15' 4
16 - Shuttle Valve 'CT16' 9 22
17 - Shuttle Valve 'CT17'
18 - Shuttle Valve 'CT18' 15,18 14 23
33
19 - Shuttle Valve 'CT19' 16
32 29
20 - Body Raise LS Relief Valve 'CT20'
21 - Pressure Reducing Valve 'CT21' 31
22 - Proportional Pressure Control Valve (Fan Drive)'CT22'
23 - Proportional Pressure Control Valve (Fan Drive) 'CT23'
24 - Shuttle Valve 'CT24'
25 - Shuttle Valve 'CT25'
26 - Shuttle Valve 'CT26'
27 - Proportional Pressure Control Valve (Body Raise) 'CT27'
28 - Proportional Pressure Control Valve (Body Lower) 'CT28' 38 17 20
29 - FLoat Solenoid 'CT29'
30 - Orifice 'CT30'
31 - Park Brake Solenoid 'CT31'
32 - Directional Control Valve 'CT32' 25
33 - Orifice 'CT33' 2
34 - Hoist 'LS' Shuttle Valve 'CT34'
35 - Orifice 'CT35'
36 - Hoist LS Valve 'CT36' 36
37 - Relief Valve (Diff Lock / Centre Axle) 'CT37'
38 - Auxiliary Solenoid 'CT38' 30
39 - Shuttle Valve 'CT39'
41 - Body Control spool 'CT41' 27
42 - Check Valve 'CT42'
43 - Relief Valve 'CT43'
44 - Check Valve 'CT44' (Integral to Body control spool) 1 28
10
3
41
6 19
42
12
13
37
11
39 24
T LS P
3 16
15
17
5
4
6
2 18 19
Steering Orbitrol Valve (A) The steering valve is of a closed centre design,
Refer to Section 220-0090, STEERING VALVE indicating oil is dead headed at the valve until it is
operated.
Mounted off the underside of the cab floor, the steering
SM 2423 04-06 1
STEERING SYSTEM - Steering System Schematic
Section 220-0000
Load Sense (LS) pressure is set 30 bar (435 lbf/in2) The pressure demanded by the steering is fed back to
below steering system pressure, i.e. at maximum the main pump (D) & the priority valve (7) via shuttle
setting LS pressure will be 210 bar (3045 lbf/in2).
2 SM 2423 04-06
STEERING SYSTEM - Steering System Schematic
Section 220-0000
valve (16). The priority valve (7) will close & the main Check valve (5) prevents the emergency steer flow
pump will increase its displacement to make sure there going towards the main pump (D), which may already
is enough flow & pressure available to meet that have failed.
demanded by the steering.
The steering load sense orifice (15) feeds oil from the STEERING PRESSURE SETTING
main pump supply, to boost the load sense pressure
back to the main pump during the steering operation. WARNING
This is to make sure an adequate flow is always Machine has to fully articulate to set steering
available from the main pump (D) to meet that pressure, therefore steering lock bar cannot be
demanded by the steering. This is commonly known as 'Locked'. To prevent personal injury and
a dynamic load sense system. property damage, exercise extreme caution
while working around articulation and
Note: The maximum steer pressure is set by the oscillation pivot area.
pressure cut off (compensator) on the main hydraulic
pump (240 bar (3500 lbf/in2)). Refer to Section 230- The maximum steer pressure is set by the pressure
0050 MAIN HYDRAULIC PUMP. cut off (compensator) on the main pump (240 bar (3500
lbf/in2)). Refer to Section 230-0050, MAIN HYDRAULIC
PUMP.
EMERGENCY STEERING
The emergency steering ground driven pump (C) Steering pressure can be checked at the diagnostic
provides flow to the steering circuit in the event that check point located on the diagnostic plate, located
the main pump (D) can no longer function effectively. direclty outside the cab door on the base of the LH
fender stand point. (refer to Fig. 2). Install pressure
Engine failure, transmission failure or internal failure of gauge capable of reading at least 240 bar (3480 lbf/in2)
the main pump (D) could cause ineffective to correct diagnostic check point (, fig,2).
performance.
Steer truck over relief (against steering stops) to
The emergency steering pump (C) will also assist with observe maximum cut-off pressure of 240 bar (3480
flow from the main pump to articulate the vehicle if the lbf/in2). Adjustment of the main pump should not be
main pump cannot deliver the flow required by the necessary as the units are set by the manufacturer.
steering circuit. This can happen at low engine speed Should the pressure cut-off be incorrect, follow the
when the vehicle is moving and the operator attempts procedure given. Refer to Section 230-0050, MAIN
to articulate the vehicle rapidly. HYDRAULIC PUMP.
SM - 2849
To protect the ground driven emergency steering pump
(3) the maximum pressure at the pump is set by the
relief valve (2) to 240 bar (3480 lbf/in2). 1
2
3
The emergency steering valve (3) is sensing the main 4
5
pump (D) pressure and the load sense pressure at the 6
9 7
spring end of the valve (3). During normal operation the 10 8
differential pressure between the main pump (D) outlet 11
12
and the load sense line will be approximately 20 bar 13
14
(290 lbf/in2) and the emergency steering valve (3) will 15
stroke against its spring dumping the emergency steer
pump (C) flow to tank.
SM 2423 04-06 3
STEERING SYSTEM - Steering System Schematic
Section 220-0000
SM - 3508a-b
(1)
(7)
(5)
(4)
(17)
(2)
4 SM 2423 04-06
STEERING SYSTEM - Steering System Schematic
Section 220-0000
a. Ensure 'O' ring/seal is in place and that the joining b. When the oil in the tank is clear (not cloudy or
surfaces are clean. If necessary, retain 'O' ring/seal in creamy), the system is free of air.
place with a light coating of grease or vaseline.
Note: Slight creep or drift of the steering wheel is
b. Initially, the nuts should be tightened by hand. normal.
c. Where a hose is fitted, ensure that it is not twisted c. Fill hydraulic tank to the recommended level and
or kinked when the nuts are tightened so that it is install the filler cap.
allowed to adopt a natural position.
Hydraulic Oil
d. Where a tube is fitted, ensure that the connection is
aligned correctly. The steering system should be kept filled with
hydraulic oil as listed in Section 300-0020,
e. Tighten the nut a further 1/4 to 1/2 a turn using the LUBRICATION SYSTEM.
correct size spanner (wrench).
MAINTENANCE
f. Check that a satisfactory hose or tube routing has
been achieved. Maintenance instructions, intervals and warnings, in
the individual steering and body hydraulic component
SM - 1335 sections of this manual, should be adhered to at all
times.
FITTING NUT
TUBE
SERVICE TOOLS
It is recommended that the following service tools are
used when carrying out pressure and temperature
checks during maintenance procedures. These tools,
along with other general service tools, are available
from your dealer. Refer to Section 300-0070, SERVICE
SLEEVE TOOLS, for part numbers of these tools.
'O' RING 'O' RING
SM 2423 04-06 5
STEERING SYSTEM - Steering System Schematic
Section 220-0000
simply aim, pull the trigger, and read the temperature. O' Ring Face Seals (ORFS) - Seal Kit
Since there is no need to touch what you are
The steering system utilizes 'O' Ring Face Seal
measuring, temperatures of hard-to-reach or moving
(ORFS) connectors. An ORFS kit, 15271082, is
components can be taken without getting burned or
available. This kit contains a minimum stock
shocked.
requirement of all sizes of ORFS type seal.
Heavy steering due to not enough Fault with main pump or standby Reference main hydraulic
being available at the steering pressure incorrectly set. pump.
valve but differential pressure Faulty Orbitrol steer valve Check Orbitrol steer valve
between the main pump outlet and output
load sense port is 25 bar. Faulty priority valve (CT7) - Stick- Replace valve
ing open. Replace / Clean
Fault in LS orifice (CT15) or (CT18). Replace Valve
Leaking shuttle valve (CT16) Replace Valve
No steering flow available when the Emergency steer valve (CT3) spool Replace Valve
vehicle is still travelling and engine sticking open.
is switched off Emergency steer relief valve (CT2)
- pressure set too low. Check output from ground
Faulty ground driven pump. driven pump - replace if neces-
sary.
With no function operated pressure Emergency steer valve (CT3) spool Replace Valve.
at ground driven pump too high sticking closed.
6 SM 2423 04-06
STEERING SYSTEM - Steering Valve
Section 220-0090
SM - 3381
28
29
27
28
29
27
9
10
26
25
24 4 3 2 1
5
9
8 7 6
10
'T'
'P'
'L'
'R'
11
12
19
15
9
10
13
17 16
18
20 14
22 21
23 'X' - Designates Port Detail
DESCRIPTION (15), sleeve (12), driveshaft (11) and gerotor gear (4)
Numbers in parentheses refer to Fig. 1.
There are five ports on valve housing (8) as follows:
The Steering Valve can be identified as item 'A' in
Section 220-0000, STEERING SYSTEM SCHEMATIC. Port 'P' - Supply from main hydraulic valve
Port 'T' - Return to tank
The steering valve is connected to the steering column Port 'R' - Cylinder supply for right hand turn
and controls hydraulic flow in the steering system. A Port 'L' - Cylinder supply for left hand turn
pressure relief line in the neutral position, between Port 'LS' - Load Sensing to main hydraulic valve
steering cylinder ports 'L' & 'R' and tank return port 'T',
means that the steering valve must only be used with Turning action of the steering wheel is transmitted
a flow amplifier valve. Refer to Section 220-0100, through the steering column to sleeve (8) and
FLOW AMPLIFIER VALVE. driveshaft (11), which is fastened to the sleeve with
centring pin (13). Rotation of driveshaft (11) causes
The steering valve consists of valve housing (8), spool gerotor gear to rotate in gerotor housing (4). When
SM 264 04-06 1
Steering System - Steering Valve
Section 220-0090
gerotor gear rotates, oil in gerotor housing (4) pockets SM - 282
(see Fig. 2) is forced out and flows through spool (15)
POCKETS
and sleeve (12) to the steering cylinder port.
OPERATION
Numbers in parentheses refer to Fig. 1.
When the operator turns the steering wheel a certain GEROTOR HOUSING GEROTOR GEAR
number of degrees for either a left or right hand turn,
Fig. 2 - Gerotor Gear Set
the movement is transmitted through the steering
column to spool (15). After a minimum rotation of 2.5
degrees, the ports in spool (15) start to align with ports SM - 283
Oil from the priority valve flows into valve housing (8)
at port 'P' and is channelled through sleeve (12) and
spool (15) to gerotor housing (4). Porting in gerotor
housing (4) permits oil to flow into pockets formed by
gerotor housing (4) and gerotor gear. As spool (15)
rotates, driveshaft (11) also rotates which, in turn,
rotates gerotor gear to which it is splined. When
gerotor gear rotates it progressively forces oil out of
the pockets (see Fig. 2) of gerotor housing (4). The oil Fig. 3 - Porting of Spool and Sleeve
is channelled through sleeve (12) and spool (15) and
exits valve housing (8) through port 'R' for a right hand REMOVAL
turn, or port 'L' for a left hand turn. Oil then travels
through steering lines to the steering cylinders. Numbers in parentheses refer to Fig. 4.
2 SM 2364 04-06
Steering System - Steering Valve
Section 220-0090
SM - 2827
12 22
20 21
13
14
18
19
12
7
6 9 16
5
10
4 11 17
2 8
1 15
hydraulic oil into a suitable container. Reinstall drain tightens joint (12) onto stub shaft (8).
plug in hydraulic tank remote drain fitting.
7. Support steering valve (1) and remove bolts (7),
4. Pull floor mat back to allow access to bolts (7). locknuts (2) and washers (3 & 6) securing mounting
Raise cab and secure with prop. Refer to Section 260- plate (5) to cab floor. Remove steering valve (1) and
0010, CAB AND MOUNTING. mounting plate (5) to a clean area for disassembly.
Remove nitrile seal (9) and discard rubber mounts (4),
5. Clean outer area of steering valve (1) with a suitable if damaged.
solvent. Ensure all hydraulic lines connected to
steering valve (1) are identified for ease of installation
and with suitable containers available to catch
leakage, disconnect hydraulic lines. Cap all lines and
plug all ports to prevent entry of dirt.
SM 264 04-06 3
Steering System - Steering Valve
Section 220-0090
DISASSEMBLY (19) over end of drive shaft (6) and engage special tool
with splined end of spool (16). Refer to Fig. 6.
Numbers in parentheses refer to Fig. 5, unless
otherwise specified.
8. Hold gerotor gear (19) and prevent drive shaft (6)
from turning. Twist special tool to compress centering
Note: Steering valves fitted with anti-cavitation valves
spring (11) radially CW or CCW, decreasing the coil
must be disassembled and assembled in the vertical
diameter of the centering spring (11) allowing spool
postion to prevent ball valves (24) becoming trapped in
and sleeve assembly to be removed. Refer to Fig. 7.
the wrong cavities within the valve housing (7).
SM - 2019
1. Remove bolts (10, Fig. 4) and washers (11, Fig. 4)
securing mounting plate (5, Fig. 4) to steering valve (1, 11
19
Fig. 4).
SM - 2018
10
19
10 - Pin 19 - Gerotor Gear
11 - Centring Springs
Fig. 7 - Compressing Centering Spring
SM - 2020
Fig. 6 - Gerotor Gear and Splined Drive Engaged
19
4 SM 2364 04-06
Steering System - Steering Valve
Section 220-0090
ASSEMBLY
Numbers in parentheses refer to Fig. 5, unless
otherwise specified.
SM 264 04-06 5
Steering System - Steering Valve
Section 220-0090
Fig. 10 - Removing Ball Valves 10. Release tension on centering spring (11) and
remove special tool and gerotor gear (19).
SM - 2023
PORT FACE 11. Lubricate and install new 'O' ring (22) in groove in
valve housing (7). Refer to Fig. 18.
23
12. Install spacer plate (5) with the 'O' ring groove up, on
valve housing (7). Align bolt holes in spacer plate (5) with
24
tapped holes in valve housing (7). Refer to Fig. 18.
6 SM 2364 04-06
Steering System - Steering Valve
Section 220-0090
SM - 2024 SM - 2027
6 8 11 13
6 8
16
10
6 - Drive Shaft
8 - Sleeve
9 - Ball Check
10 - Pin 9 9 10 16
16 - Spool
9
Fig. 12 - Installing Spool and Ball Checks
SM - 2025
17
6 16
18
6 - Drive Shaft
20
8 - Sleeve
9 - Ball Check 12 14
8 10 10 - Pin
11 - Centring Springs 16 - Spool
12 - Needle Bearing 17 - Seal
6 - Drive Shaft 10 - Pin 13 - Bearing Race 18 - Backup Ring
8 - Sleeve 16 - Spool 14 - 'O' Ring 20 - Retainer
Fig. 13 - Installing Centring Pin and Drive Shaft Fig. 15 - Sectional View of Seals and Bearings
SM - 2026
INSTALLATION
Numbers in parentheses refer to Fig. 4.
SM 264 04-06 7
Steering System - Steering Valve
Section 220-0090
SM - 2028 SM - 2029
Fig. 16 - Compressing Centering Spring Fig. 17 - Installing Spool and Sleeve Assembly
SM - 2030
7
3 4 19 21 5
1
22
2. Install rubber mounts (4) if removed, and secure 7. Fill hydraulic tank with hydraulic oil, as specified in
steering valve (1) and mounting plate (5) to cab floor Section 300-0020, LUBRICATION SYSTEM. Refer to
with bolts (7), washers (3 & 6) and locknuts (2). 'Filling and Bleeding The Steering System'.
3. Install nitrile seal (9) to steering shaft (14). 8. Remove wheel blocks from all road wheels, place
the battery master switch in the 'On' position and start
4. Slide bottom joint (12) of steering shaft (14) over the engine. Operate the steering and check hydraulic
stub shaft (8) and secure by tightening bolt. Slide lines for leaks. Tighten lines and fittings as required.
bellows (13) down over bottom joint (12) and stub
shaft (8).
8 SM 2364 04-06
Steering System - Steering Valve
Section 220-0090
SM - 313
WARNING
Do not operate the vehicle until all air is bled
from the oil.
SM 264 04-06 9
Steering System - Steering Valve
Section 220-0090
* * * *
10 SM 2364 04-06
STEERING SYSTEM - Steering Cylinder
Section 220-0120
SM - 3412
9,10
7 2 8 12
22 6 4 5
22
16 15 15 16
3
23 13 14
11
18 18
21 21
20 20
17 17
19 19
SM 2399 01-06 1
Steering System - Steering Cylinder
Section 220-0120
REMOVAL DISASSEMBLY
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.
WARNINGS WARNING
To prevent personal injury and property To prevent personal injury and property
damage, be sure wheel blocks, blocking damage, be sure lifting equipment is properly
materials and lifting equipment are properly secured and of adequate capacity to do the job
secured and of adequate capacity to do the job safely.
safely.
1. Ensure clean working conditions, remove any port
Hydraulic fluid pressure will remain plugs thus allowing easy entry of air into the cylinder,
within the system after engine shutdown. preventing a vacuum when parts are withdrawn from
Operate the treadle pedal continuously until the cylinder body (7).
pressure has dissipated before carrying out any
work on the hydraulic system or serious injury 2. Remove retaining rings (15) from base end of
could result. cylinder body (7) and piston rod (2) end. Press out
spherical bearings (16).
1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine. Turn steering 3. Using special tool which can be fabricated as shown
wheel several times to relieve any pressure in the in Fig. 2, unscrew end cap (6) until thread is
steering circuit. Operate brake pedal continuously to disengaged from cylinder body (7).
relieve pressure in the braking system.
4. Pull end cap (6) and piston rod (2) out of cylinder
2. Place steering lock bar in the 'Locked' position. body (7) as an assembly.
Block all road wheels and place the battery master
switch in the 'Off' position. 5. Place piston rod (2) on supports which will not
damage the chrome piston rod diameter.
3. Identify, tag and with a suitable container in position
to catch the spillage, disconnect all hydraulic lines on 6. Remove and discard guide ring (10), 'O'-ring (9) and
one steering cylinder. Cap all lines and fittings to wear ring (10) from piston (11).
prevent ingress of dirt.
7. Provide an anti-torsion device through piston rod (2)
4. Support steering cylinder with a suitable lifting eye to allow unscrewing of piston (11). Unscrew piston
device. (11) from piston rod (2).
5. Remove bolt (18), lockwasher (21) and hardened 8. Remove and discard 'O' ring (8) from piston (11).
washer (20) securing pin (17) at base end of the
cylinder. Remove pin (17) securing base end to the 9. Pull end cap (6) assembly off piston rod (2). Remove
front frame. and discard back up ring (5) and 'O' ring (4) from end
cap (6) outer grooves. Remove and discard wiper (23)
6. Remove bolt (18), lockwasher (21) and hardened and rod seal (3) from end cap (6) inner grooves.
washer (20) securing pin (17) at piston rod (2) end of
the cylinder. Remove pin (17) securing piston rod (2) 11. If damaged, remove grease fittings (22) from
end to the articulation and oscillation pivot. cylinder body (7) and piston rod (2).
2 SM 2399 01-06
Steering System - Steering Cylinder
Section 220-0120
INSPECTION 8. Fully grease piston (11) OD and 'O' ring (4) in end
cap (6).
Numbers in parentheses refer to Fig. 1
9. Ensure bore of cylinder body (7) is well lubricated
1. Clean all parts of the cylinder with a suitable solvent
with hydraulic oil. Carefully insert piston rod (2) and end
and dry with clean, lint-free cloths. Clean all grooves
cap (6) assembly into cylinder body (7).
carefully to remove any foreign material.
10. Engage end cap (6) and cylinder body (7), thread
2. Check cylinder body (7), end cap (5) grooves and
screw up fully. Tighten end cap (3) to a torque of 542 -
outer diameter of piston (11) for scratches, cracks or
610 Nm (400 - 450 lbf ft).
other signs of damage. Remove ridges, nicks and
scratches with a fine stone and re-clean. Replace any
11. Replace lube fittings (4) if required.
components which cannot be repaired.
SM 2399 01-06 3
Steering System - Steering Cylinder
Section 220-0120
6. Lubricate pins (17) through grease nipples (22 ) with MAINTENANCE
lubricant, as specified in Section 300-0020,
Inspect steering cylinders regularly for leaks or
LUBRICATION SYSTEM.
damage, repair as required. Lubricate cylinder pins
every 250 hours, as specified in Section 300-0020,
7. Check oil level in hydraulic tank and add oil if low.
LUBRICATION SYSTEM.
Refer to Section 230-0040, HYDRAULIC TANK, for
correct fill level. Refer to Section 300-0020,
LUBRICATION SYSTEM, for the type of oil used. SPECIAL TOOLS
8. Place the steering lock bar in the 'Stowed' position
Refer to Section 300-0070, SERVICE TOOLS, for part
and remove wheel blocks.
numbers of general service tools required. These tools are
available from your dealer.
9. Place the battery master switch in the 'On' position,
start the engine and operate the steering, from lock to
lock several times, to purge air out of the hydraulic
lines. Check hydraulic lines and fittings for leaks.
Tighten lines and fittings as required.
* * * *
4 SM 2399 01-06
BODY SYSTEM - Body System Schematic
Section 230-0000
SM - 3534
ACC3
PS5 DL
1 1
TPA
27
PPA
21
T2
28
8 41 42 LOWER
25
B
43
PS1
35
7
HOIST
P1 29 A
LSM
44
26
17
20 36
30
34
19
LSP T1 TPB
PPB
The body hydraulic system enables the operator to lift The body control lever is mounted on the right hand
and lower the body in a safe manner with an electric side dash panel inside the operators cab. The body
output from the body control lever. control lever is manually operated to control the lift and
lower function of the body assembly.
A brief description of the individual components used in
the body hydraulic system are listed below. Detailed
SM 2441 04-06 1
BODY SYSTEM - Body System Schematic
Section 230-0000
2 SM 2441 04-06
BODY SYSTEM - Body System Schematic
Section 230-0000
SM - 3535
1 - Body Cylinders
17 - Shuttle Valve
20 - Relief Valve
21 - Pressure Reducing Valve 17 LOCATED UNDER 20
25 - Shuttle Valve 20
26 - Shuttle Valve
27 - Proportional Control Valve (Raise)
28 - Proportional Control Valve (Lower)
29 - Float Solenoid
30 - Orifice 25
34 - Shuttle
36 - Hoist Load Sense Valve
41 - Control Spool
42 - Anti Cavitation Valve 36
43 - Relief Valve
44 - Check Valve
30
TANK RETURN
43
42
34 41
26 SUPPLY/RETURN
(LOWER SIDE)
SUPPLY/RETURN
(LIFT SIDE)
21
29
4 SM 2441 04-06
Body System - Body System Schematic
Section 230-0000
SM 2441 04-06 5
BODY SYSTEM - Body System Schematic
Section 230-0000
3. The operators cab has to be raised at this stage so Fig. 6 - Assembly of Typical ORFS Connector
that port 'TPA' on the main hydraulic valve can be
accessed. Refer to Section 260-0010, CAB AND b. Initially, the nuts should be tightened by hand.
MOUNTING.
c. Where a hose is fitted, ensure that it is not twisted
4. Connect a hydraulic gauge, capable of recording a or kinked when the nuts are tightened so that it is
pressure of 0 - 345 bar (0 - 5 000 lbf/in2), into port 'TPA' on allowed to adopt a natural position.
the main hydraulic valve assembly.
d. Where a tube is fitted, ensure that the connection is
5. Place the battery master switch in the 'On' position, aligned correctly.
start the engine and allow all systems to be charged
normally. e. Tighten the nut a further 1/4 to 1/2 a turn using the
correct size spanner (wrench).
6. A hydraulic pressure of 30 bar (435 lbf/in2) should
be observed on the pressure gauge. f. Check that a satisfactory hose or tube routing has
been achieved.
7. Pressure setting can be adjusted by adjusting
pressure reducing valve (21) on the main hydraulic
HYDRAULIC OIL
valve. Adjust pressure reducing valve (21) until 30 bar
(435 lbf/in2) is observed on the pressure gauge. The braking system should be kept filled with hydraulic
oil as specified in Section 300-0020, LUBRICATION
8. Check body system for proper operation. SYSTEM.
9. Shut off the engine and remove the pressure gauge Whenever there is a hydraulic system failure, the oil
from port 'TPA'. should be drained, the entire system flushed, oil filters
replaced, oil screens thoroughly cleaned and clean
10. Operators cab should be lowered into travel hydraulic oil added to eliminate all metal particles or
position. Check hydraulic lines for any leakage. foreign matter.
11. Remove wheel blocks, place the steering lock bar SERVICE TOOLS
in the 'Stowed' position, start the engine and check the
body system for proper operation. It is recommended that the following service tools are
used when carrying out pressure and temperature
checks during maintenance procedures. These tools,
'O' RING FACE SEALS (ORFS) along with other general service tools, are available
Where hydraulic lines are fitted with ORFS from your dealer. Refer to Section 300-0070, SERVICE
connections, the following procedure should be carried TOOLS, for part numbers of these tools.
out during 'Installation'. Refer to Fig. 6.
Multi-Gauge
a. Ensure 'O' ring/seal is in place and that the joining
surfaces are clean. If necessary, retain 'O' ring/seal in The multi-gauge, 15269784, is basically four pressure
place with a light coating of grease or vaseline. gauges in one. Continuous system pressure readings
are indicated on one of three simultaneously reading
6 SM 2441 04-06
Body System - Body System Schematic
Section 230-0000
gauges through a pressure range of 30 in of vacuum to O' Ring Face Seals (ORFS) - Seal Kit
5 000 lbf/in². The braking system utilizes 'O' Ring Face Seal (ORFS)
The following items should be added to the multi-gauge connectors. An ORFS kit, 15271082, is available. This
to enable the gauge to be used on the diagnostic kit contains a minimum stock requirement of all sizes
pressure check points; of ORFS type seal.
15018226 Diagnostic Coupling
00118748 Connector (2 off)
15004085 Hose Assembly (-04 HP, 2130 mm long)
SM 2441 04-06 7
BODY SYSTEM - Body System Schematic
Section 230-0000
Main control spool (41) in the lift Replace lift section of the main
section of the main hydraulic valve hydraulic valve assembly
assembly sticking
Lift function too slow. Proportional control valve ; body raise Check output from body control
solenoid (27 ) current not high enough lever. Refer to Sections190-0085
HYDRAULIC ECU and 230-0081,
BODY CONTROL LEVER
Main control spool (41) not fully Replace lift section of main
selecting. hydraulic valve assembly.
8 SM 2441 04-06
Body System - Body System Schematic
Section 230-0000
Check accumulator settings, pre- Priority valve (7) will give pump
charge and charging cycle times demand to accumulator charge
cycle.
Body will not lower. Supply fuse to hydraulic ECU blown. Check power on light at controller
is illuminated. Replace fuse if
required. Refer to Section190-0000
CIRCUIT DIAGRAMS
Control lever in the cab faulty. Check for output from control lever.
Refer to Sections 190-0085
HYDRAULIC ECU and 230-0081
BODY CONTROL LEVER
Body lowers too slow. Not enough electric current at the Check output from body control
proportional control valve ; body lower lever. Refer to Sections 190-0085
solenoid (28) HYDRAULIC ECU and 230-0081
BODY CONTROL LEVER
Main control spool (41) sticking. Replace lift section of the main
hydraulic valve assembly.
SM 2441 04-06 9
BODY SYSTEM - Body System Schematic
Section 230-0000
Body will not hold Oil by-pass between control spool Replace lift section of main
(41) and valve body hydraulic valve aseembly
Oil by-pass body lift cylinders (1) Repair lift cylinders (1)
Control spool (41) not centering Check that there is zero pilot
pressure at both ends of control
spool (41). Either of proportional
control valves (27/28) could remain
active
Power down available when body is Faulty proximity switch on chassis Check connections. Replace
on the chassis proximity switch. Refer to Section
190-0085 HYDRAULIC ECU, for
check tool
Body fails too slow down when Faulty proximity switch on chassis Check gap between body plate and
reaching the proximity switch on the proximity switch. Max. gap 15mm.
chassis Replace proximity switch
Body fails too go into float and stops Faulty float solenoid valve (29) Check connections. Replace
before it reaches the chassis valve(29). Refer to Section 190-
0085 HYDRAULIC ECU
* * * *
10 SM 2441 04-06
BODY SYSTEM - Main Hydraulic Pump
Section 230-0050
SM - 3543
15 14 26 16 2 16 26 14 15
30
23 6 34 34 7
19
22 27
29
12
11
24 5
9,17,33 39 20 13 8 20 39 19 22
SM - 2845
42
11 & 12
43
40 & 41 45
A - Outlet Port
B - Outlet Kidney Slot 11 & 12 - Drive shaft 43 - Retaining Plate
C - Inlet Port 40 & 41- Control Plate 45 - Cylinder Block
D - Inlet Kidney Slot 42- Piston Group
SM - 603
MAXIMUM SHOE PLATE ANGLE DECREASED SHOE PLATE ANGLE ZERO SHOE PLATE ANGLE
(MAXIMUM DISPLACEMENT) (PARTIAL DISPLACEMENT) (MINIMUM DISPLACEMENT)
VIEW A VIEW B VIEW C
Fig. 3 - Variable Displacement Action
19 SM - 3545
25
5 7
1 - Cap 14 - Spool 8 11 12 13 14
2 - 'O'-ring 15 - Spring
3 - Nut 16 - Spring
4 - Set screw 17 - Spring Seat
5 - Plug 18 - Spool 24
1 2 3 2 4
6 - Plug 19 - Capscrew
7 - 'O'-ring 20 - Plug
8 - Spacer 21 - Plug
9 - 'O'-ring 20
22 - 'O'-ring
10 - Spacer 23 - 'O'-ring 16 18
6 10 15 17 26
9
11 - Spring 24 -
12 - Spring 25 - Plug
23
13 - Spring Seat 26 - Valve Body 22
21
Paying attention to one such piston from either front or Regulated Condition - Refer to Fig. 5. Pump pressure
rear pump rotating groups, then it will move away from is still relatively low but the pressure drop across the
the control plate (40 & 41) for half a rotation (suction main hydraulic valve increases. The cut-off pressure
stroke), and move towards the control plate (40 & 41) spool spring (15 & 16) preload still retains the spool
for the second half of rotation (delivery stroke). The (18) in its extreme left position. However, since the
larger the tilt angle of the swash plate (9 & 10), the pressure drop is increased, the pressure on the left
longer the piston (42) stroke and the higher the pump's hand side of the differential pressure spool (14) (pump
displacement. As the swash plate (9 & 10) tilting angle delivery pressure) overcomes the combination of spring
approaches zero, the piston (42) does not stroke and (11 & 12) preload and pressure in the load sense line in
therefore delivers minimum displacement. (Refer to the right hand side of the differential pressure spool
Fig. 3). (14). Therefore the spool (14) moves to the right,
blocking vent line and causing pressure at large side of
Control Valve piston (14, Fig. 1) to increase, overcoming spring (23)
Numbers in parentheses refer to Figs. 1 & 7. force. This reduces the swash plate (9 & 10) angle and
hence pump displacement.
Control Valve (6) is a pilot operated differential
pressure type spool regulator for load sense control. This will continue until the pump flow across the main
The load sense feedback signal from the main hydraulic valve reduces the pressure drop to the value
hydraulic valve is fed to load sense port (X) on top of determined by the differential spool spring (11 & 12)
the control valve body (26) (see Fig. 7). This feedback preload.
signal acts on the spring chamber end of the spool
(14). Standby Condition - Refer to Fig. 6. When no
hydraulic operations are required, the pump standby
Unregulated Condition - Refer to Fig. 4. Pump condition is reached. The load sense line is vented to
pressure is low and the load sense signal is wide open. tank. Differential pressure spool (14) shifts right due to
The cut-off pressure spool spring (15 & 16) preload pump outlet pressure. This allows oil pressure to pass
shifts the cut-off pressure spool (18) to its extreme left through cut-off pressure spool (18) and reach the large
position. Since the pressure drop across the main side of piston (14, Fig.1 ), overcoming spring (23)
hydraulic valve is low, both sides of the differential force and reducing swash plate (9 & 10) angle to zero.
pressure spool (14) see the same pressure and
therefore the spool (14) remains in the extreme left The pump also has a pressure limiting function, used
position. This condition causes the oil at the control for example when steering cylinder reaches the end of
piston (14, Fig. 1) and rod (15, Fig. 1) to be vented, it's stroke. In this condition the delivery pressure will
causing spring ( 23) force to move piston rod and rise, and the load sense control will try to raise delivery
piston (15 & 14) and swash plate (9 & 10) to maximum pressure above the now 'dead head' pressure. This
pump displacement. causes differential pressure spool (14) to shift to the
extreme right, allowing oil pressure to pass through cut-
SM - 3542
REAR PUMP
20
37 2
12 30
4
10 21 41
16
26 23
14 39
18
3 15
34 28
7
5 27 33
36 22 19 49
32 48
47
46
38
44 45
43 DETAIL OF 39
42
25 ROTATING GROUP
1
35 2 4
25
13 38 37
3
26 14 15
16
31
34
8
29
22 24 6
19
23
11
17
33
30 FRONT PUMP
21
20
39
40
Rear Pump *
*
Note: Discard and replace all 'O' rings and seals
*
removed during disassembly.
SM - 3549
SM - 3434
SM - 3550 SM - 3553
8. Orientate rear housing (7), to allow removal of the 11. Remove 2-off bearing shells (18) and spring (23)
rotating group (39). Remove rotating group as shown a from the housing (7). As shown in Fig. 17.
in Fig. 14.
12. Remove driveshaft (12) with bearing (19) inner race
9. Remove plug (16) and 'o'-ring (26). Pull out control still fitted to the shaft. Refer to Fig. 18
piston (14) using a suitably sized screwdriver. Refer to
Fig. 15.
1
2
SM - 3551 SM - 3554
3
10. Turn swash plate (10) inside of housing along the 13. Pull outer race of bearing (19) out of housing (7)
z-axis. Remove piston rod (15) and swash plate (10) using a suitable bearing puller. Refer to Fig. 19.
from the housing (7) as shown in Fig. 16.
SM - 3552 SM - 3555
4
Fig. 16 - Swash plate / Piston rod removal Fig. 19 - Bearing race removal
SM - 3556 SM - 3558
Front Pump
1. Remove 4-off capscrews (31) securing centre
housing (8) to the front housing (6). Refer to Fig. 21.
SM - 3557
SM - 3434
Fig. 21 - Housing Removal
3. Pull bearing (20) from centre housing (8) using a 5. Orientate front housing (6) horizontally on a bench to
suitable bearing puller, ensure not to damage sealing allow for removal of the rotating group (39). Remove
surfaces. Refer to Fig. 23. rotating group (39) as shown in Fig. 25.
SM - 3435 SM - 3560
6. Remove control piston (14), plug (16),'o'-ring (26) housing (6), using suitable bearing pullers, as shown in
and piston rod (15). Refer to Fig. 26. Fig. 28.
SM - 3436 SM - 3561
7. Remove driveshaft (11), bearing (19) inner race 10. Remove shim (22). Refer to Fig. 29.
should be attached to the driveshaft at this stage.
Refer to Fig. 27.
Control Valve
SM - 3438 Numbers in paretheses refer to Fig. X. unless
otherwise stated.
1. If the control valve (2, Fig 1.) has not already been
removed from the front and rear housings (6 & 7, Fig.
1). Do so, by removing 4-off capscrews (19).
Fig. 27 - Drive shaft & Brg removal 3. Remove 2-off protective caps (1) and 'o'-rings (2).
8. Remove circlip (29) and shaft seal (24). 4. Unscrew nuts (3), remove nuts (3) and 'o'-rings (2).
9. Pull out outer race of tapered bearing (19) out of 5. Unscrew plugs (5 & 6) . This should allow for careful
ASSEMBLY SM - 3586
3. For both front and rear housing (6 & 7), assemble 5. Press in outer races of bearings (20) into centre
respective driveshafts (11 & 12) in correct position. housing (8). Refer to Fig. 32
Ensure bearing outer race is seated fully on the
driveshaft. Refer to Fig. (31). 6. Assemble front and rear pump to centre housing.
Note: Take care not to damage shaft seal (24) during Ensure points marked during disassembly match up.
steps 1 -3.
SM - 3585
SM - 3418
(21) (21)
8. Refer to Fig. 33. For both front and rear housing (6 &
7), measure the dimension between the end face 'A' of
the housing and the front face 'B' of the centre housing
(8).
7
5
Fig. 36 - Assembly
SM - 3427
18. Both front and rear pump housing ( 6 & 7), 20. Assemble centre housing (8) to front pump housing
assemble bearing (20) and adjustment shim (21) to (6), secure using 4-off screws (31). Torque screws (31)
respective driveshafts (11 & 12). Refer to Fig. 40. to a value of 165 Nm (122 Ibf-ft). Refer to Fig. 42.
SM - 3428 SM - 3589
Ensure
marks match
Fig. 40 - Driveshaft Assembly Fig. 42 - Secure Centre & Front Pump Housing
19. Insert splined hub (13) into centre housing (8) bore. 21. Using suitable slings to lift the sub assembled front
Assemble control plates (40 & 41), dowels (30) and 'o'- pump and centre housing elements. Orientate these to
rings (25) to housing. Ensure 'o'-rings are greased prior facilitate assembly into the rear housing unit. Refer to
to being inserted in grooves. Note: maintain correct Fig. 43.
location through dowels. Refer to Fig. 41.
SM - 3590 INSTALLATION
Numbers in parentheses refer to Figs. 1 & 8.
WARNING
To prevent personal injury and property
damage, be sure lifting equipment is properly
secured and of adequate capacity to do the job
safely.
22. Ensure correct position of the control plate ( 41) 3. Remove caps and connect outlet, inlet and load
and 'o'-ring (25) is fitted in the groove. sense lines to pump. Before connecting case drain
line, fill pump casing through drain port with clean
23. Secure front assembly to the rear pump unit with 4- hydraulic oil as used in the hydraulic tank. Connect the
off screws (31). Torque screws (31) to a value of 165 case drain line to pump. Fill hydraulic tank with oil
Nm (122 Ibf-ft). Refer to Fig. 44. specified in Section 300-0020, LUBRICATION
SYSTEM.
SM - 3591
Rear pump
PUMP STARTING PROCEDURE
1. Be sure the pump case drain line is free from
obstructions that restrict the pump case drain flow
back to tank and cause high case drain pressure which
can lead to an early pump failure.
If these pressures are not observed, then pump may 2. Install a pressure gauge capable of at least 240 bar
need to be reset (refer to Troubleshooting). (3 480 lbf/in2) into STR diagnostic checkpoint on the
left hand fender (9, Fig. 45) to measure load sense
pressure setting (Gauge B).
* * * *
The three operating positions of the joystick from front Fig. 1 - Body Control Lever
to rear are as follows:
SM 2418 01-06 1
Body System - Body Control Lever
Section 230-0081
3. Block all road wheels, place the steering lock bar in 9. Place the battery master switch in the 'On' position,
the 'Locked' position and the battery master switch in start the engine and bring hydraulic oil to operating
the 'Off' position. temperature. Operate the body control lever to ensure
correct operation.
4. Disconnect body control lever harness from main
harness. 10. Remove wheel blocks and place the steering lock
bar in the 'Stowed' position.
5. Support body control lever and remove screws
securing body control lever on the right hand dash
panel. TROUBLESHOOTING
A faulty body control lever will cause an input error at
6. Remove body control lever from mounting location. the hydraulic ECU. Refer to Section 190-0085,
HYDRAULIC SYSTEM ECU.
7. Secure new body control lever on the right hand
dash panel with screws.
SPECIAL TOOLS
Note: Ensure harness from body control lever is at the There are no special tools required for procedures
front when lever is installed. outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
8. Reconnect main harness to body control lever tools required. These tools are available from your
harness. dealer.
* * * *
2 SM 2418 01-06
BODY SYSTEM - Body Cylinder
Section 230-0130
SM - 3536
11,22
23
11, 22 20,21
10 9 10 9
8
17 16 19 15 5 14 1 2 7 18 3 13 12 3
26 24
4 25
24 6
25 4
6 27
DESCRIPTION REMOVAL
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.
Cylinder mounting is by pins (26 & 27), spacers (4) and Hydraulic fluid pressure will remain
spherical bearings (10) are secured in place with within the body hoist system after engine
circlips (9). Spherical bearings (10) permit a limited shutdown. Operate the treadle pedal
amount of cylinder misalignment. continuously until the pressure has dissipated
before carrying out any work on the hydraulic
system or serious injury could result.
SM 2402 01-06 1
Body System - Body Cylinder
Section 230-0130
DISASSEMBLY
WARNING Numbers in parentheses refer to Fig. 1.
Exercise extreme caution when lowering
the cylinders from the body. The cylinders will
swing out sharply as they leave their WARNING
mountings. To prevent personal injury and property
damage, be sure lifting equipment is properly
1. Position the vehicle in a level work area, ensure the secured and of adequate capacity to do the job
body is fully lowered, apply the parking brake and safely.
switch off the engine.
1. Ensure clean working conditions, remove any port
2. Press and hold down body hoist bleed down switch plugs thus allowing easy entry of air into cylinder body
and operate the body control joystick continually to (1), preventing a vacuum when parts are withdrawn
relieve pressure in the body hoist system. from cylinder body (1).
3. Block all road wheels, place the steering lock bar in 2. Remove circlips (9) from base end of cylinder body
the 'Locked' position and the battery master switch in (1) and piston rod (2) end. Press out spherical bearings
the 'Off' position. (10).
4. Install a suitable strap around the cylinder and 3. Using suitable tool unscrew end cap (28) until thread
attach to a lifting device. is disengaged from cylinder body (1).
5. Position a suitable container at the base end of one 4. Support piston rod (2) at the rod eye and withdraw
cylinder. Identify and remove the hydraulic lines. Cap piston rod (2) from cylinder body (1). Ensure centre
hydraulic lines and cylinder ports to prevent entry of lines of piston rod (2) and cylinder body (1) remain
dirt. coincidental during removal of piston rod (2).
6. Remove bolt (6), lockwasher (25), washer (24) and 5. Place piston rod (2) on supports which will not
upper pin (26) connecting piston rod (2) end of the damage the piston rod diameter.
cylinder to the body. If due to lack of maintenance the
upper pin can not be removed from the front, there is 6. Remove and discard piston seals (13) and wear
plate on the inside of the body that can be removed to rings (12) from piston (3).
allow access to the rear of the pin to ease removal.
This plate is tack welded in place so a grinder is 7. Remove pin (8) from piston (3).
required to remove it.
8. Provide an anti-torsion device through piston rod (2)
7. Lower cylinder slowly and remove spacers (4). eye to allow unscrewing of piston (3). Using suitable
tool unscrew piston (3) from piston rod (2).
Note: Cylinder will swing out sharply as it leaves its
mounting. 9. Remove bushing (7) from piston rod (2).
8. Remove bolt (6), lockwasher (25), washer (24) and 10. Remove cylinder end cap (28) from piston rod (2).
lower pin (27) connecting base end of the cylinder to Remove and discard bushing (5), rod seal (16), wiper
the frame. ring (17) , 'O' rings (14 & 15) and back up ring (19).
2 SM 2402 01-06
Body System - Body Cylinder
Section 230-0130
ASSEMBLY INSTALLATION
Numbers in parentheses refer to Fig. 1.
Numbers in parentheses refer to Fig. 1.
Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 230-0000, BODY
WARNING
SYSTEM SCHEMATIC. Renew all 'O' rings where used.
To prevent personal injury and property
damage, be sure lifting equipment is properly
secured and of adequate capacity to do the job
WARNING
safely.
To prevent personal injury and property
damage, be sure lifting equipment is properly
1. Press spherical bearing (10) in base end of cylinder
secured and of adequate capacity to do the job
body (1) and piston rod (2) end. Secure spherical
safely.
bearings (10) with circlips (9).
1. Install a suitable strap around the cylinder and
2. Install new bushing (5), '0' -rings (14 & 15), rod seal (16)
position cylinder on unit with base end of cylinder ready
and backup ring (19) into their respective locations on end
for mounting.
cap (28). Load end cap (28) over piston rod (2) thread,
taking care not to damage rod seal (16) on the thread.
2. Install spacers (4) in base end of cylinder and insert
lower pin (27) through mounting bores, spacers (4) and
3. Install new 'O' rings (18) on piston rod (2) and
cylinder. Secure lower pin (27) with washer (24),
replace bushing (7).
lockwasher (25) and bolt (6). Tighten bolt (6) to a torque
of 66 Nm (49 lbf ft).
4. Apply Loctite 243 to first two threads of piston (3).
Using suitable tool screw on piston (3) and tighten to a
3. Install spacers (4) in rod end of cylinder, align
torque of 1 356 Nm (1 000 lbf ft).
spherical bearing (10) with bores in body and install
upper pin (26) through mounting bores, spacers (4) and
5. Ensure bushing (7) is secure to piston (3) end face
cylinder. Secure upper pin (26) with washer (24),
and piston rod (2) face .
lockwasher (25) and bolt (6). Tighten bolt (6) to a torque
of 66 Nm (49 lbf ft).
7. Insert new piston seal (13), wiper (17) and new wear
rings (12) in piston (3).
4. Connect the hydraulic oil lines to the cylinder ports
as tagged during removal.
8. Screw pin (8) into piston (3) torque to a vaule of XX.
5. Lubricate pins at lube fittings (11) with lubricant as
8. Fully grease piston (3) OD and 'O' rings (14 & 15) in
SM 2402 01-06 3
Body System - Body Cylinder
Section 230-0130
specified in Section 300-0020, LUBRICATION SYSTEM. Every 250 hours: Lubricate cylinder pins as described
in Section 300-0020, LUBRICATION SYSTEM. Inspect
6. Check oil level in hydraulic tank and add if low. cylinders for leaks, if leaks are found, replace seals
Refer to Section 230-0040, HYDRAULIC TANK, for with seals contained in the Service Repair Kit, as
correct fill level. Refer to Section 300-0020, specified in the parts book.
LUBRICATION SYSTEM, for the type of oil used.
7. Place the battery master switch in the 'On' position, SPECIAL TOOLS
start the engine, operate the body and check cylinder lines Special tools can be fabricated as shown in Figs. 2 & 3.
for leaks. Tighten lines and fittings as required. Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of general service tools required. These tools are
8. Remove wheel blocks from road wheels. available from your dealer.
MAINTENANCE
4 SM 2402 01-06
BRAKING SYSTEM - Braking System Schematic
Section 250-0000
SM - 3613
TO PARKING
Px BRAKE
FROM
TRANSMISSION
PBP
PB
TS
B1
B2
33
P2
A
TO REAR 10 11
SERVICE BRAKES 32
T2
9
12
E
31
8 13
PS1 14
35
7
P1
15 16
17
19
LSP
D - Main Hydraulic Pump 13 - (CT13) Orifice PS1 - Cold Start Solenoid Valve
E - Brake Treadle Valve 14 - (CT14) Cold Start Solenoid Valve PS2 - Brake Accumulators
15 - (CT15) Orifice PS3 - Primary Accumulator
7 - (CT7) Priority Valve 16 - (CT16) Shuttle Valve PS3 - Pressure Switch
8 - (CT8) Check Valve 17 - (CT17) Shuttle Valve PS4 - Pressure
9 - (CT9) Pres. Reduce Valve 19 - (CT19) Orifice ACC1 - Front Brake Accumulator
10 - (CT10) Check valve 31 - (CT31) Prk Brk Solenoid Valve ACC2 - Rear Brake Accumulator
11 - (CT11) Check Valve 32 - (CT32) Directional Control Valve ACC3 - Primary Accumulator
12 - (CT12) Brake Charging Valve 33 - (CT33) Orifice
There are three accumulators mounted inside the The treadle valve controls the level of hydraulic fluid
battery box located on the front left hand side of the pressure applied to front and rear brakes and the
tractor; one for the front brake system(ACC1) and one maximum pressure available to these circuits.The first
for the rear (ACC2) . The front and rear brake 5° movement of the brake pedal will acutate the brake
accumulators are supplemented by a third (primary) lights on the rear of the vehicle. Continued movement
accumulator (ACC3), also mounted inside the battery will allow pressure to the service brakes. It is operated
box. The primary accumulator supports the service by a foot pedal in the operators cab and, with the
brake system and the body pilot pressure system. All engine running, is automatically applied by the park
three accumulators are of the piston type and are brake solenoid valve (31) on the main hydraulic valve.
precharged with nitrogen to 95 bar (1 380 lbf/in²). It
consists of a charging valve assembly, cylinder
assembly and piston. The charging valve is equipped Valves 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17,
with a locking feature which, when opened, will allow 19, 31, 32 & 33
precharge to be checked or accumulator charged. These valves form part of the brake cuircuit and are an
intregal part of the main hydraulic valve assembly,
SM - 3614 mounted on the left hand side of the tractor frame. Ref.
Section 215-0050, MAIN HYDRAULIC VALVE
ASSEMBLY.
OPERATION
Numbers in parentheses refer to Figs. 1, 2 and 3.
Brake Charging
The valves integral of the main hydraulic valve
assembly automatically maintain the brake
accumulator pressures between a lower and upper
(F) limit.
PS3
SM 2430 04-06 3
Braking System - Braking System Schematic
Section 250-0000
30 bar (435 lbf/in2). When the engine is running, a transmission hydraulic
The accumulators (ACC1 & ACC2) are also pilot pressure acts against the spring at the directional
automatically charged every time the pressure at the control valve (32). The directional control valve (32)
main hydraulic pump rises above the pressure in creates an open circuit between the main hydraulic
accumulator (ACC3). It is therefore possible to achieve valve assembly and port 'Px' on the brake treadle
pressures up to the main hydraulic pump cut off valve. This permits a flow of oil to either energise the
pressure of 240 bar (3 480 lbf/in2) in this accumulator 'Px' port at the treadle valve, or, exhaust the 'Px' port
(ACC3) (eg. when steering over relief). The brake through the main hydraulic valve assembly to tank,
system relief valve (9) will still limit the pressure in dependant on operation of the park brake solenoid
accumulators (ACC1 & ACC2) to 155 bar (2 248 lbf/in2). valve (31). The park brake solenoid valve (31) is
controlled by the park/emergency control switch inside
Orifice (35) would protect all three accumulators the operators cab.
against abnormally high pressure spikes. However,
accumulator (ACC3) can see system pressure if any of When the park/emergency control switch is activated
the main hydraulic functions are held over relief for a (pushed in), the electrical signal between the switch
period of time. and park brake solenoid valve (31) is opened. This
action de-energizes the park brake solenoid valve (31).
Brake Apply Oil flows through park brake solenoid valve (31) and
The minimum pressure required at the brake treadle through the directional control valve (32). The oil
valve is 45.8 bar (665 lbf/in2). travels through the directional control valve and into the
'Px' port in the treadle valve for an emergency brake
The brake treadle valve controls the level of hydraulic application.
pressure applied to front and rear brakes and the
maximum pressure to these circuits. It is operated by Return oil from the parking brake circuit enters the
the foot pedal in the operators cab and in an main hydraulic valve assembly. The oil flows through
emergency with the engine running, is automatically park brake solenoid valve (31) and exits the main
applied by the park brake solenoid valve (31) in the hydraulic valve assembly to the hydraulic tank. With no
main hydraulic valve assembly (Ref. Park/Emergency pressure in the parking brake circuit to hold the parking
Brake Function). brake off, the parking brake is applied.
Mounted on the side of the brake treadle valve is a
potentiometer. This potentiometer links with the brake When the emergency brake switch is deactivated
pedal interface module, mounted on a dashboard (pulled out), the electrical signal between the switch
support, on the underside of the dashboard. The brake and park brake solenoid valve (31) is closed,
pedal interface module converts voltage signals from energizing park brake solenoid valve (31). Oil flows
the potentiometer to activate rear brake lamps. The through park brake solenoid valve (31) and exits the
brake pedal interface module energises K50, brake main hydraulic valve assembly to the parking brake
lamp relay. Relay is located in operator cab fuse box. circuit to release the parking brake.
When the relay is energised an electrical circuit is
complete to energise appropriate lamps and solenoids. Return oil from the 'Px' port on the brake treadle valve
flows through the directional control valve (32) through
The potentiometer works on a 0 to 5 Volt scale. K50 park brake solenoid cartridge (31) and exits the main
relay is activated when the output from the hydraulic valve assembly to the hydraulic tank.
potentiometer is greater than 1 Volt. This allows a 24
Volt signal from the busbar to activate the rear brake When the engine is shutdown, transmission pilot
lamps.The relay is de-activated when the output from pressure at directional control valve (32) is lost,
the potentiometer is less than 1 Volt. causing the directional control valve (32) to move to
the right under the influence of the compressed spring.
The first 5° movement of the brake pedal activates the This movement links the 'Px' port at the brake treadle
rear brake lamps. valve with the hydraulic tank through the main
hydraulic valve assembly. This action results in a
Park/Emergency Brake Function controlled bleed down of the applied service brakes to
The park/emergency brake function is designed to hydraulic tank. This controlled bleed down permits a
electrically operate the park brake and with the engine synchronised service brake release/mechanical park
running automatically actuates the service brakes also brake application.
during this operation.
4 SM 2430 04-06
Braking System - Braking System Schematic
Section 250-0000
When the engine is shutdown, the park brake solenoid
valve (31) is automatically de-energised (fail safe).
Park brake hold off pressure is allowed to return to tank Hydraulic fluid pressure will remain
through the park brake solenoid valve (31), causing within the system after engine shut down.
park brake to apply (spring applied). The vehicle is now Operate the brake treadle pedal continuously
held with park brake only. until the pressure has dissipated before
carrying out any work on the system or serious
CHECKING SYSTEM PRESSURES
injury could result.
Numbers in parentheses refer to Figs. 1, 2 and 9,
unless otherwise stated. 1. Position the vehicle in a level work area, apply the
parking brake, switch off the engine and turn steering
wheel in both directions several times to relieve any
WARNINGS pressure in the steering circuit.
To prevent personal injury and property
damage, be sure wheel blocks and blocking 2. Operate the brake treadle valve continuously to
materials are properly secured and of adequate relieve pressure in the braking system. Block all road
capacity to do the job safely0. wheels, place the steering lock bar in the 'Locked'
position and the battery master switch in the 'Off'
SM - 3518 position.
3. Connect a hydraulic gauge, capable of recording a
pressure of 0 - 345 bar (0 - 5 000 lbf/in²), to park brake
diagnostic pressure point (6, Fig. 7) inside battery box.
A
P2
P
4. Place the battery master switch in the 'On' position,
A2
T T2 start the engine and release park/emergency button
P (pull out), to energise the park brake line. Monitor
P1
system pressure gauge. Pressure setting should be
T T1
A1 155 bar (2 248 lbf/in²).
A
SM 2430 04-06 5
Braking System - Braking System Schematic
Section 250-0000
valve assembly. The operator cab will require to be d. Where a tube is fitted, ensure that the connection is
raised to access brake system relief valve (9). Refer to aligned correctly.
Section 260-0010, CAB AND MOUNTING.
e. Tighten the nut a further 1/4 to 1/2 a turn using the
10. Shut off the engine and remove the pressure gauge correct size spanner (wrench).
from diagnostic check point.
f. Check that a satisfactory hose or tube routing has
been achieved.
SM - 3615
HYDRAULIC OIL
1
2 The braking system should be kept filled with hydraulic
3
4 oil as specified in Section 300-0020, LUBRICATION
5
6 SYSTEM.
9 7
10 8
11
12
Whenever there is a hydraulic system failure, the oil
13 should be drained, the entire system flushed, oil filters
14
15 replaced, oil screens thoroughly cleaned and clean
hydraulic oil added to eliminate all metal particles or
foreign matter.
6 SM 2430 04-06
Braking System - Braking System Schematic
Section 250-0000
The braking system utilizes 'O' Ring Face Seal (ORFS) NUT
FITTING
connectors. An ORFS kit, 15271082, is available. This
kit contains a minimum stock requirement of all sizes TUBE
of ORFS type seal.
SLEEVE
'O' RING 'O' RING
SM 2430 04-06 7
Braking System - Braking System Schematic
Section 250-0000
SM - 3616
9
15 14
33
16
32 13 31
17
7 - Priority Valve
8 - Check Valve
9 - Pressure Reducing Valve
10 - Check valve
11 - Check Valve
12 - Brake Charging Valve
13 - Orifice
14 - Cold Start Solenoid Valve
15 - Orifice
16 - Shuttle Valve
17 - Shuttle Valve
19 - Orifice 10
31 - Park Brake Solenoid Valve
32 - Directional Control Valve
33 - Orifice
19
8 SM 2430 04-06
Section 250-0000
Front and Rear Brake Accumulators Check Valves (10) or (11) leaking Replace Check Valves (10) or (11)
(ACC1 & 2) do not hold their charge
pressure Pre-charge gas pressure in the Check Pre-charge gas pressure in
accumulator not at the correct level the accumulator. Refer to Section
250-0060, ACCUMULATOR
Air or contamination in the Load Lift the body of the truck up and
Sense System, especially when first down several times to purge the
running the truck after new main system.
hydraulic valve is fitted.
Leakage across the Valves (8,12) is Replace each valve one at a time
too high. (in order stated) until the fault is
found.
SM 2430 04-06 9
Braking
Braking System - Braking System System - Braking System Schematic
Schematic
Section 250-0000
Park Brake fails to release. No voltage at Park Brake Solenoid Check park/emergency switch in
Valve (31) when the switch is operators cab.
activated in the cab.
Check wiring between park/
emergency switch and park brake
solenoid (31).
Service brakes fail to come on when Faulty Brake Treadle Valve. Spool not Refer to Section 250-0070,
Parking Brake is selected when the stroking when pressure at port 'Px'. TREADLE VALVE.
engine is running.
No transmission pressure at Port TS Check piping and see instructions
on main hydraulic valve assembly. for the transmission.
Service Brakes come on when Directional Control Valve (32) sticking Replace Valve (32)
Parking Brake is selected and Engine in the selected position.
is not running.
10 SM 2430 04-06
Section 250-0000
* * * *
SM 2430 04-06 11
THIS PAGE IS INTENTIONALLY LEFT BLANK
BRAKING SYSTEM - Brake Coolant / Hydraulic Tank
Section 230-0040
SM - 3599
P11829
26
10 SEC.
190-0270
11
12 21 21
28
28
16 29
14 29
30 36
15 17,18,19,20 35 35
'B' 30
38
14 34
13 9 31
27 15
14
6
15 2,3 31
13
6
13
1
2,3 33
32
39 'A'
5,37
23
25 31
4 24 28
'B'
8
31
5,37 28 BREATHER LINES
22 7 'A'
25
24
DESCRIPTION for the steering, braking, body hoist and fan drive
system. It is mounted off the frame at the rear right
Numbers in parentheses refer to Fig. 1. hand side of the tractor.
The brake coolant / hydraulic tank assembly (1) Integral with brake coolant / hydraulic tank assembly
comprises of both brake cooling oil tank (41) and (1) are cap assemblies (2), suction strainer (4),
hydraulic oil tank (40) in one integral unit. Looking from Hydraulic filter (17)cover plates (6) and drain valves
the LHS of the tractor unit, the brake cooling tank (41) (5). Located on the outboard face of the tank are level
is to the left and the hydraulic tank (40) is to the right. gauges and window nut (8) for checking the fluid levels
The brake coolant tank (41) supplies the brake cooling of both brake cooling oil and hydraulic oil.
circuit. The hydraulic tank (40) is the common reservoir
SM 2447 03-06 1
BRAKING SYSTEM - Brake Coolant / Hydraulic Tank
Section 230-0040
SM - 2864
EMERGENCY
SUPPLY TO
SUPPLY TO MAIN
MAIN HYDRAULIC RETURN
HYDRAULIC
VALVE TO TANK
VALVE
2 SM 2447 03-06
BRAKING SYSTEM - Brake Coolant / Hydraulic Tank
Section 230-0040
e are no signs of damage to the strainer. (7). This tells the operator that there is sufficient oil in
the hydraulic tank to allow the operator to run the
vehicle to heat the oil up to operating temperatures.
Hydraulic Tank 5.Once running the operator should check the oil level
in the sight gauge (7) located above the widnow nut (8)
Every 10 Hours on the hydraulic tank (40). The oil should be within the
'max' and 'min' marked lines. Should more oil be
Check oil level, add if low. Refer to Checking oil level required, remove filler cap (2) from hydraulic tank (40)
paragraph. and fill hydraulic tank (40) with hydraulic oil specified in
Section 300-0020, LUBRICATION SYSTEM.
Hydraulic filter restriction - check, replace element if
required. 6. Install filler cap (2) on hydraulic tank (40) and
tighten.
Every 1000 Hours
Hydraulic tank breather - repalce element. Replacing Hydraulic Oil
Hydraulic oil should be changed every 2 000 hours.
Every 2000 Hours Refer to Section 300-0020, LUBRICATION SYSTEM,
Hydraulic tank - Drain oil and refill. "Refer to replacing for hydraulic oil used in the system.
hydraulic oil"
Note: When replacing the hydraulic oil due to a
OCDB Strainer - Clean strainer and refit, assuming ther hydraulic failure, or at recommended change interval,
e are no signs of damage to the strainer. filter (17) must be replaced and hydraulic tank (40)
cleaned thoroughly using a suitable solvent.
Note: Tighten all fasteners without special torques
specified to standard torques listed in Section
300-0080, STANDARD BOLT AND NUT TORQUE Checking Brake Coolant Tank Oil Level
SPECIFICATIONS. 1. Operate the body hoist and steering systems
several times to bring the oil to correct operating
temperature.
WARNING
To prevent personal injury and property 2. Position the vehicle in a level work area, ensure the
damage, be sure wheel blocks, blocking body is fully lowered, apply the parking brake and
materials and lifting equipment are properly switch off the engine. Turn steering wheel in both
secured and of adequate capacity to do the job directions several times to relieve any pressure in the
safely. steering circuit. Operate treadle valve continuously to
discharge accumulators.
Checking Hydraulic Tank Oil Level 3. Block all road wheels, place the steering lock bar in
1. Operate the body hoist and steering systems the 'Locked' position and the battery master switch in
several times to bring the oil to correct operating the 'Off' position.
temperature.
4. Check oil level and add if low. Oil should be visible
2. Position the vehicle in a level work area, ensure the in the sight gauge (7) integral to the brake coolant tank
body is fully lowered, apply the parking brake and (41). This tells the operator that there is sufficent brake
switch off the engine. Turn steering wheel in both cooling oil in the system.
directions several times to relieve any pressure in the
steering circuit. Operate treadle valve continuously to
discharge accumulators. Replacing Brake Coolant Oil
Brake coolant oil should be changed every 15000
3. Block all road wheels, place the steering lock bar in hours. Refer to Section 300-0020, LUBRICATION
the 'Locked' position and the battery master switch in SYSTEM, for brake coolant oil used in the system.
the 'Off' position.
Replacing Breathers
4. Check oil level and add if low. Oil should be visible Every 1 000 hours of operation, or sooner if the vehicle
in the window nut (8) which is below the sight gauge is being operated in extremely dusty conditions, the
SM 2447 03-06 3
BRAKING SYSTEM - Brake Coolant / Hydraulic Tank
Section 230-0040
hydraulic tank (40) and brake coolant tank (41) plates (6 & 38) and discard gaskets (13).
breathers should be replaced.
11. Secure cover plate (12) and plate (26) to top of tank
Replacing Hydraulic Filter Element with bolts (10) and washers (11).
Every 2 000 hours of operation or when hydraulic filter
restriction warning symbol displays on the instrument 12. Install new gaskets (13) prior to securing cover
panel VDU warning screen, whichever comes first, plates (6 & 38) in place.
clean filter (17) and install new element (18).
13. Secure cover plates (6 & 38) using bolts (14) and
1. Position the vehicle in a level work area, ensure the washers (6 & 15).
body is fully lowered, apply the parking brake and
switch off the engine. Turn steering wheel in both 14. Replace gasket (3) beneath the filler cap (2).
directions several times to relieve any pressure in the
steering circuit. Operate treadle valve continuously to 15. Remove filler cap (2) from hydraulic tank (40) and
discharge accumulators. fill hydraulic tank with hydraulic oil specified in Section
300-0020, LUBRICATION SYSTEM. Install filler cap
2. Block all road wheels, place the steering lock bar in (2) on hydraulic tank (40) and tighten.
the 'Locked' position and the battery master switch in
the 'Off' position. 14. Place the battery master switch in the 'On' position
and the steering lock bar in the 'Stowed' position,
3. Remove drain valve (5) on the bottom of hydraulic remove all wheel blocks, start the engine and operate
tank (1). Install a hose adaptor on drain fitting, open the steering, braking and body hoist systems to
drain cock and drain hydraulic oil into a suitable circulate the oil.
container. Close drain cock, remove hose and reinstall
drain valve (5). 15. Switch off the engine, check for leaks and check
oil level as described under 'Checking Oil Level'.
4. Remove bolts (10) and washers (11) securing cover
plate (26) to and filter cover plate (12) to the top of
hydraulic tank (40). Remove plates (11 & 26) and
gasket (16) from hydraulic tank (40). Discard gasket
(40).
4 SM 2447 03-06
BRAKING SYSTEM - Brake Coolant / Hydraulic Tank
Section 230-0040
3. Ensure all lines connected to tank assembly (1) are Note: Tighten all fasteners without special torques
identified for ease of installation and, with suitable specified to standard torques listed in Section
containers available to catch leakage. Fit blanking 300-0080, STANDARD BOLT AND NUT TORQUE
caps and plugs to all open lines and fittings. SPECIFICATIONS.
4. Place a suitable container beneath the drain port on Note: Tighten all hydraulic lines fitted with ORFS
the hydraulic tank (40). Remove drain valve (5) from connections, as described in Section 230-0000, BODY
hydraulic tank (40) and drain the hydraulic oil into the SYSTEM SCHEMATIC. Renew all 'O' rings where
container. used.
7. Remove three bolts (24) and washers (25) securing 1. Using a suitable lifting device, position tank
the brake coolant / hydraulic tank assembly (1) to the assembly (1) in position on the vehicle, secure with
fender support bracket. bolts (24) and washers (25).
8. Carefully remove tank assembly (1) assembly from 2. Remove any eyebolts that were installed to lift the
the unit to a clean work area for inspection. tank assembly (1).
4. Remove filler cap (2) and fill hydraulic tank (40) with
hydraulic oil specified in Section 300-0020,
LUBRICATION SYSTEM. Install filler cap (2) on
hydraulic tank (40) and tighten.
SM 2447 03-06 5
BRAKING SYSTEM - Brake Coolant / Hydraulic Tank
Section 230-0040
4. Remove filler cap (2) and fill brake coolant tank (41) SPECIAL TOOLS
with hydraulic oil specified in Section 300-0020, There are no special tools required for the procedures
LUBRICATION SYSTEM. Install filler cap (2) on brake outlined in this section. Refer to Section 300-0070,
coolant tank (41) and tighten. SERVICE TOOLS, for part numbers of general service
tools required. These tools are available from your
5. Place the battery master switch in the 'On' position dealer.
and the steering lock bar in the 'Stowed' position,
remove all wheel blocks, start the engine and operate
the steering, braking and body hoist systems to
circulate the oil.
6. Switch off the engine, check for leaks and check oil
levela as described under 'Checking Oil Level'.
6 SM 2447 03-06
BRAKING SYSTEM - Motor/Triple Pump Assembly
Section 250-0045
DESCRIPTION SM - 3523
The motor is supplied with hydraulic oil from the brake Fig. 1 - Motor/Triple Pump
cooling section of the triple gear pump, via the disc
brake oil cooler. The motor and pump elements are
connected by a common shaft, therefore motor TO BRAKE PACKS SM- 3524A
rotation causes pump elements to draw brake cooling FRONT CENTRE REAR
rear axles.
limits the pressure through the motor to 26 bar (377 COOLANT TANK
SM 2422 04-06 1
Braking System - Motor/Triple Pump Assembly
Section 250-0045
SM - 3527
15 22
2
15
5 16 18
17
7
5
4 16
18 20
13 24
11 13 12
9
14
14
19 8
14 21
23
14
3 23
8 6
10
6
14 21
24
14
25
8 6
10
6
24
3
6
10
6
To prevent personal injury and property 4. Remove blanking cap from remote drain line at the
damage, ensure wheel blocks, blocking bottom of the brake coolant tank. Install a length of
materials and lifting equipment are properly hose on remote drain fitting, open drain cock and drain
secured and of adequate capacity to execute brake cooling oil into a suitable container. Close drain
the job safely. cock, remove hose and reinstall blanking cap.
2 SM 2422 04-06
Braking System - Motor/Triple Pump Assembly
Section 250-0045
5. Clean motor/triple pump assembly and surrounding ASSEMBLY
area with a suitable solvent. Identify and tag all
Numbers in parentheses refer to Fig. 1.
hydraulic lines connected to motor/triple pump, to aid
in 'Installation'.
1. From seal kit, replace seals on motor section and
pump elements prior to re-assembly.
6. With suitable containers available to catch leakage,
disconnect hydraulic lines. Fit blanking caps to all
2. Lightly oil parts prior to re-assembly.
open lines.
3. Assemble three pump elements together and locate
7. Remove 4-off bolts (7), washers (8) and nuts (9)
with threaded screws (11). Secure assembly with
securing motor/triple pump to mounting plate (1).
washers (13) and nuts (12). Torque nuts (12) to a
value of 25 Nm (18.4 Ibf ft).
8. If necessary remove brackets (2 & 3) from the
chassis frame, by removal of 4-off bolts (6), washers
4 Install hydraulic connectors and adaptors to correct
(5) and washers (4). This should allow removal of
ports and orientation.
mounting plate (1).
DISASSEMBLY INSTALLATION
Numbers in parentheses refer to Fig. 1.
Numbers in parentheses refer to Fig. 1.
Note: Tighten all fasteners to standard torques listed
1. Place motor/triple pump assembly in a soft-jawed
in Section 300-0080, STANDARD BOLT AND NUT
vice, and clamp on body. Match mark pump sections
TORQUE SPECIFICATIONS.
and motor to aid in assembly.
Note: Tighten all hydraulic lines fitted with ORFS
Note: Do not clamp vice on machined surfaces of the
connections, as described in Section 250-0000,
assembly at any time.
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
where used.
2. Note location of all hydraulic connectors and
adaptors and remove from motor/triple pump.
1. Secure motor/triple pump assembly to brackets
with mounting hardware as removed at 'Removal'.
3. Remove 4-off nuts (12) and washers (13) from
pump end of the assembly.
2. Remove blanking caps from hydraulic lines and
install lines to motor/triple pump as identified during
Note: Do not attempt to pry the motor/triple pump (1)
'Removal'.
assembly apart with a large screwdriver or pry bar.
The machined surfaces of the assembly may be
3. Fill brake coolant tank with oil as specified in
damaged.
Section 300-0020, LUBRICATION SYSTEM. Refer to
Section 250-0025, BRAKE COOLANT TANK, for oil
4. Remove constituent parts of the assembly from
levels. Install filler cap on brake coolant tank filler
pump end, through to the motor end and rear cover
neck.
(4).
4. Fill hydraulic tank with hydraulic oil as specified in
5. Remove and discard seals that are to be replaced
Section 300-0020, LUBRICATION SYSTEM. Refer to
with new seals in kit.
Section 230-0040, HYDRAULIC TANK, for oil levels.
Install filler cap on hydraulic tank filler neck.
INSPECTION
5. Place the battery master switch in the 'On' position,
Numbers in parentheses refer to Fig. 1.
start the engine and bring hydraulic oil to operating
temperature.
1. Clean all parts in a suitable solvent and dry with
compressed air.
6. Check motor/triple pump and hydraulic line
connections for leaks and tighten as required.
2. Check ports threads and make sure they are not
damaged or stripped.
7. Remove all blocking from road wheels and place
steering lock bar in the 'Stowed' position.
SM 2422 04-06 3
Braking System - Motor/Triple Pump Assembly
Section 250-0045
FAULT DIAGNOSIS
CONDITION REASON ACTION
Non rotation of shaft No oil supply. Check pressure at motor section of triple gear pump.
Pressure should be 26 bar (377 psi) at 2 100rpm,
when oil is at operating temperature.
Brake packs overheating No brake cooling oil supply. Check oil level in brake cooling tank.
* * * *
4 SM 2422 04-06
BRAKING SYSTEM - Brake Manifold Valve
Section 250-0050
SM - 3611
7,8
12 9,10
(TS2)
2,3
(B3) (TS1)
16 4
5 (B2)
(C1)
(B1) 13
(A2)
2,3
(PS)
1 (A1)
(Y)
2,3
(C)
(X) (C2)
11 11 (T)
2,3 15
14 6
DESCRIPTION
The brake manifold valve can be identified as item 10 controller, which commands the OCDB relief unloader
in Section 210-0005, BRAKE COOLING SYSTEM valve to de-energise, allowing hydraulic oil to flow from
SCHEMATIC. port 'WB' on the main hydraulic valve assembly, to
supply the motor side of the triple pump/motor unit.
There are three brake manifold blocks within brake The three pumps will then draw brake cooling oil from
cooling circuit. Each is mounted on the respective the brake coolant tank and distribute it to the
axle. The manifold valve distributes hydraulic oil flow front,centre and rear hubs via the 3 manifold valve.
from the ocdb motor/pump to the brake cooling circuit.
Oil from the accumulators passes through the treadle Hydraulic oil from the motor/triple pump enters the
valve is then distributed to front,centre and rear brakes brake manifold valve at port 'A1'. Oil is distributed to
via each manifold block. the hubs via ports 'X' and 'B1'.
Check Valve
OPERATION
Numbers in parentheses refer to Fig. 1,2 & 3. An integral check valve (11) set to relieve at 1bar is
contained within each manifold block. Any excess
At temperatures below 50deg C, Oil from the brake pressure built up will be sent back to the brake coolant
coolant tank is not drawn by the motor/triple pump. tank via this valve.
When the oil in the brake hubs reaches 50deg C.
temperature sender sends a signal to the IFM
SM 2456 04-06 1
Braking System - Brake Manifold Valve
Section 250-0050
SM - 3612
TO
SERVICE PRESS. TO BRAKE
BRAKES SWITCH HUBS
C2 PS1 X Y
FROM B3 CT1
TREADLE
VALVE TANK RELIEF
TS2
BLANKED
TS1
TEMP. SW. / SENDER
D
C1 A1 B1 B2 A2
TO FROM RETURN TO
SERVICE TRIPLE TO BRAKE TANK VIA
BRAKES PUMP HUBS COOLER
Pressure switch 'PS1' is located in the 'PS' port on top The temperature switch monitors brake cooling oil
of the manifold. This monitors brake cooling oil temperature. Two temperature conditions will generate
pressure. Should the brake pressure reach 1.5 bar a response to the system. 50Deg C signalling the
(21.8 lbf/in²) a brake pressure warning symbol will be OCDB relief unloader to allow flow to the triple pump/
displayed on the VDU screen to inform the operator of motor and bringing the engine cooling fan on. The 60
irregular pressure in the system, refer to Fig. 3. deg condition will signal a warning symbol to be
displayed on the VDU screen, refer to Fig. 3
SM - 3613
REMOVAL
Numbers in parentheses refer to Fig. 1.
WARNINGS
Hydraulic fluid pressure will remain within the
system after engine shut down. Operate the
1
2 STOP P treadle valve continuously until the pressure
has dissipated before carrying out any work on
20 30 15
30
40
50
10 20 the braking system or serious injury could
mph
10 20
km/h
60
70
40
5
r / min x100
25 result.
10
80
0 0000000
50 L H 0 30
0000
˚C 100
To prevent personal injury and property
70 135˚C 165
40
105
150 210
˚F 250
120 60
140
275 320
˚F 390
200
damage, be sure wheel blocks are properly
secured and of adequate capacity to do the job
safely.
2 SM 2456 04-06
Braking System - Brake Manifold Valve
Section 250-0050
1. Position the vehicle in a level work area, apply the 4. If removed, install hydraulic line connectors in
parking brake, switch off the engine and turn steering manifold block (1) as noted during disassembly.
wheel in both directions several times to relieve any
pressure in the steering circuit. INSTALLATION
Note: Tighten all fasteners to torques listed in
2. Operate the treadle valve continuously to relieve Section 300-0080, STANDARD BOLT AND NUT
pressure in the braking system. Block all road wheels, TORQUE SPECIFICATIONS.
place the steering lock bar in the 'Locked' position and the
battery master switch in the 'Off' position. Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 250-0000,
3. Remove and tag electrical connections to pressure BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
switch (12). where used.
4. Clean brake manifold valve assembly and 1. Position brake manifold valve assembly onto the
surrounding area with a suitable solvent. Ensure all respective axle, and secure.
hydraulic lines connected to the brake manifold valve
are identified for ease of installation and, with suitable 2. Remove blanking caps from hydraulic lines and
containers available to catch leakage, disconnect connect to brake manifold valve as noted during
hydraulic lines. Fit blanking caps to all open lines. removal.
5. Release and remove mounting hardware securing 3. Connect electrical connection to pressure switch
brake manifold valve to cradle assembly at rear of cab. (13) as noted during removal.
Remove assembly from the vehicle.
4. Check oil level in the hydraulic tank and add oil if
required. Refer to Section 230-0040, HYDRAULIC
DISASSEMBLY TANK for correct fill level, and, Section 300-0020,
Numbers in parentheses refer to Fig. 1. LUBRICATION SYSTEM for oil specification.
Disassembly of the manifold assembly should only be 5. Place the battery master switch in the 'On' position,
carried out if there is the need to replace one of the remove wheel blocks, start the engine and bring
elements. In any case, remove the specific fitting / hydraulic oil to operating temperature.
switch from the respective port and note this for the
assembly stage. 6. Check brake manifold valve and hydraulic line
connections for leaks and tighten as required.
Replace any components which have failed.
7. Shut off engine and make sure a full service brake
1. Clamp manifold block (1) lightly in a soft jawed application is made followed by a parking brake
vice.Do not overtighten jaws. This will allow for removal application.
of any of the elbows (3,8 & 10) or pressure switch (13).
8. Repeat all braking and engine shut down cycles
2. Where any 'o'-rings (2,4,7,9,15 & 16) have been several times and check for appropriate application/
discarded, replace with new at the assembly stage. release cycle several times.
SM 2456 04-06 3
Braking System - Brake Manifold Valve
Section 250-0050
* * * *
4 SM 2456 04-06
BRAKING SYSTEM - Accumulator
Section 250-0060
SM - 3277
19
18
17 20
16
15 21
14
13
12
11
24 25 27 28 10
23 22
26 9
Charge Valve Assembly
7
6
5
4
8
3
2
1
DESCRIPTION assembly (3), end cap (17), cylinder (8) and piston (9).
Charging valve (3) is equipped with a locking feature.
Numbers in parentheses refer to Fig. 1.
Loosening locknut (26) will open the valve so that the
precharge can be checked or the accumulator charged.
The accumulators can be identified as items
ACC1through ACC3 in Section 250-0000, BRAKING OPERATION
SYSTEM SCHEMATIC.
Numbers in parentheses refer to Fig. 1.
There are three accumulators mounted off exhaust
Piston (9) acts as a separator dividing cylinder (8) into
mounting cradle located at the rear of the cab; one for
two sections. The bottom section nearest charging
the front brake system and one for the rear. The front
valve (3) contains the nitrogen precharge. Hydraulic oil
and rear brake accumulators are supplemented by a
from the main hydraulic pump flows through check
third (primary) accumulator. Refer to Fig. 2.
valves in the main hydraulic valve and into the top
section of the accumulators.
The primary accumulator supports the service brake
system and the body pilot pressure system. All three
Accumulator pressure is monitored by pressure
accumulators are of the piston type and are precharged
switches located in the main hydraulic valve, which
with nitrogen. The primary accumulator (1, Fig 2) is
send a signal to illuminate warning lights in the dash
precharged to 103 bar (1494 Ibf/in²). The other two
panel when the pressure drops below 122 bar (1 769
accumulators (2,3 Fig.2) are precharged to 55 bar (798
lbf/in²).
lbf/in²). Each accumulator consists of a charging valve
The warning lights will remain illuminated until the
pressure rises above 135 bar (1 958 lbf/in²).
SM 2431 03-06 1
Braking System - Accumulator
Section 250-0060
SM - 3537
P - Primary Accumulator F
F - Front Brake Accumulator R 4
R - Rear Brake Accumulator 3
5
3
5
1
5
3
6
5
3 7
8
9
1 - U-bolt 6 - Locknut
2 - Accumulator Guard 7 - Washer
3 - Lockwasher 8 - Washer 1 P
4 - Partition Plate 9 - Bracket Cradle
5 - Bolt
2 SM 2431 03-06
Braking System - Accumulator
Section 250-0060
WARNING
Precharge values are different for the Primary
accumulator and front & rear brake
accumulators. Ensure pressures are correct to
the required value for each type!
SM 2431 03-06 3
Braking System - Accumulator
Section 250-0060
Note: Either oil or water pumped nitrogen can be used 8. Check charging valve (3, Fig. 1) for leakage using
to charge the accumulator. Both types are readily soapy water. Reinstall valve cap (24, Fig. 1) and
available from a local compressed gas dealer. tighten finger tight.
7. Rotate 'T' handle of valve chuck (2) anticlockwise 3. Remove accumulator guard (2) a nd partition plate
until it stops, tighten locknut (26, Fig. 1) to 11 Nm (100 (4) if necessary to gain adequate access to remove the
lbf in), loosen the swivel nut and remove gauging head. accumulators; by removal of bolts and washers (5 & 3)
4 SM 2431 03-06
Braking System - Accumulator
Section 250-0060
4. Discharge nitrogen from the accumulators as INSPECTION
described under 'Discharging Nitrogen'.
Numbers in parentheses refer to Fig. 1.
5. Disconnect hydraulic lines from bottom of 1. Wash metal components with a suitable solvent and
accumulators and plug accumulators to prevent oil thoroughly air dry.
spillage. Cap open lines and fittings to prevent entry of
dirt. 2. Inspect piston (9) for cracks or burrs. Replace piston
(9) if excessively scored or worn.
6. Support accumulators with an adequate sling and 3. Use an inspection lamp to check the bore of
lifting device. Remove bolts (19, Fig.1 ), u-bolts (1), accumulator cylinder (8) for scratches or scoring.
locknuts (6), lockwashers (7) and washers (8) securing Minor nicks, scratches or light scoring of the bore can be
accumulators to the bracket (9). Remove accumulators removed by using crocus cloth. Dress the bore until all
and drain oil from top section into a suitable container. apparent imperfections have been removed. Replace
complete accumulator assembly if the inside of cylinder
7. Remove accumulators to a clean area for (8) is excessively scored or worn.
disassembly.
4. Inspect threads in end cap (17) and threads in
DISASSEMBLY cylinder (8) for damage. Replace all parts worn or
damaged beyond repair.
Numbers in parentheses refer to Fig. 1.
ASSEMBLY
WARNINGS
Numbers in parentheses refer to Fig. 1.
Accumulators are charged with Nitrogen.
The service pressure in the primary 1. Lubricate ‘O’ rings (7,11 & 15), Backup rings (6 &
accumulator is 103 bar (1494 lbf/in²) and in the 16), Seal rings (10 & 14) and Washers (11 & 13) and
Front and Rear Brake accumulators is 55 bar inside of cylinder body (8) with hydraulic oil prior to
(798 lbf/in²) at 20° C (68o F). To prevent personal assembly.
injury and property damage do not attempt to
remove any valves or fittings until all nitrogen 2. Install 'O'- ring (15) and Backup ring (16) on the End
pressure is completely relieved. cap (17).
1. Make sure all nitrogen gas has been released before 3. Install End cap (17) on cylinder body (8).
starting to disassemble the accumulator. Refer to
section on 'Discharging Nitrogen'. 4. Install new Seal rings (10 & 14), Washers (11 & 13)
and 'O'-Ring (12) on grooves of Piston (9).
2. Remove charging valve assembly (3) from end cap
(17). 5. Insert Piston (9) into bore of Cylinder body (8) with
the cupped end facing the open end of the cylinder
3. With accumulator lying horizontal, hold accumulator body (8). Taking care not to damage any components
cylinder (8) with a strap wrench. on the threadfs of the Cylinder body (8) on insertion.
Use a hammer and wood block to carefully tap the
4. Install pins in three equally spaced holes in end cap Piston (9) into place until the Piston (9) is 50.8mm (2.0
(17), then use a long bar working against the pins to in) below the beginning of the honed bore. Keep
remove end cap from cylinder (8). Remove and discard pressure against the Piston (9) while tapping into place
Backup ring (6) and 'O' ring (7). to ensure the Piston (9) does not resist movement and
force its way back.
5. Grip cast web of piston (9) with pliers and, while
rotating, pull piston from cylinder (8). Remove and 6. Install 'O'-ring (7) and Backup ring (6) onto the
discard Seal rings (10 & 14), Washers (11 & 13) and Cylinder cap (5) and install the Cylinder cap into the
'O'-Ring (12). bore of the Cylinder body (8). Tighten the Cap so that it
is flush with the end of the Cylinder body (8), within
1.6-2.4mm (0.062 - 0.094in) above or below.
SM 2431 03-06 5
Braking System - Accumulator
Section 250-0060
7. Install the Chargin valve assembly (3). Torque 3. Remove caps installed at removal and install
tighten Locnut (26) clockwise to 11Nm (100 Ibf in) to hydraulic lines securely to the oil inlet ports at the
close the Charging valve (3). Insert Valve core (25) and bottom of the accumulators.
torque to 0.5 Nm ( 5 Ibf in), replace Valve cap (24) and
tighten hand tight. 4. Charge the accumulator with Nitrogen gas as
described under 'Charging the Accumulator' in this
section.
INSTALLATION
Note: Tighten all fasteners without special torques 5. If removed install partition plate (4) with washers (3 )
specified to torques listed in Section 300-0080, and bolts (5).
STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS. 6. Install accumulator guard (2) securely with bolts (5)
Note: Tighten all hydraulic lines fitted with ORFS and washers (3).
connections, as described in Section 250-0000,
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings 7. Check oil level in hydraulic tank and add oil as
where used. required. Refer to Section 230-0040, HYDRAULIC
TANK, for correct fill level and Section 300-0020,
LUBRICATION SYSTEM, for oil specification.
WARNING
To prevent personal injury and property 7. Place the battery master switch in the 'On' position,
damage, be sure lifting equipment is properly start the engine and check for leaks. Tighten lines and
secured and of adequate capacity to do the job fittings as required. Remove wheel blocks.
safely.
MAINTENANCE
Numbers in parentheses refer to Fig. 2. unless Inspect accumulator assembly for leaks. If leaks are
otherwise stated. found, disassemble and replace all 'O' rings and seals.
Inspect hydraulic lines for wear and leaks. Replace/
1. Position accumulators onto their respective tighten lines as required.
mounting brackets (18, Fig. 1) and secure in place
using bolts (19).
SPECIAL TOOLS
2. Attach u-bolts (1) securely with washers (8), Refer to Section 300-0070, SERVICE TOOLS, for part
lockwashers (7) and locknuts (6). numbers of the charging assembly kit and other
general service tools required. These tools are
available from your dealer.
6 SM 2431 03-06
Section 250-0060
WARNING
This vehicle is equipped with precharged nitrogen gas cylinders of more than 2.8 bar (40 lbf/in2).
Special permits may be required when transporting the vehicle or cylinders by any method while
cylinders are charged. For shipment, contact the appropriate agency in the country involved. Consult
your dealer for further permit information.
* * * *
SM 2431 03-06 7
THIS PAGE IS INTENTIONALLY LEFT BLANK
BRAKING SYSTEM - Treadle Valve
Section 250-0070
SM - 3517
50 39
13
49 14
48
46 29
47 38 28 16
27 15 10
45
44 12
37
26 11 12
42 43 36
35 25
24 51,52
34 22 9
33 23 12
41 11
32 20
12 8
40
31 22 19
9 12
6
20 21 5
30 7 4
3
19
18
2
17 12
1
SM 2427 04-06 1
Braking System - Treadle Valve
Section 250-0070
SM - 2875 SM - 2876
9 9
PP PP
SUPPLY SUPPLY
FROM FROM
P1 P1
TO FRONT A1 MAIN HYDRAULIC FROM FRONT A1 MAIN HYDRAULIC
BRAKES VALVE, PORT ACC1 BRAKES VALVE, PORT ACC1
T1 T1
SUPPLY SUPPLY
FROM FROM
P2 P2
TO REAR A2 MAIN HYDRAULIC FROM REAR A2 MAIN HYDRAULIC
BRAKES VALVE, PORT ACC2 BRAKES VALVE, PORT ACC2
T2 T2
Fig. 2 - Normal Service Brake Application Fig. 3 - Normal Service Brake Release
2 SM 2427 04-06
Braking System - Treadle Valve
Section 250-0070
SM - 2877 SM - 2878
9 9
SUPPLY
FROM TO TANK VIA
PP PP MAIN HYDRAULIC
MAIN HYDRAULIC
VALVE, PORT PBP VALVE, PORT PBP
SUPPLY
SUPPLY FROM
P1 P1
TO FRONT A1 FROM FROM FRONT A1 MAIN HYDRAULIC
BRAKES MAIN HYDRAULIC BRAKES VALVE, PORT ACC1
T1 VALVE, PORT ACC1 T1
SUPPLY SUPPLY
FROM FROM
P2 P2
TO REAR A2 MAIN HYDRAULIC FROM REAR A2 MAIN HYDRAULIC
BRAKES VALVE, PORT ACC2 BRAKES VALVE, PORT ACC2
T2 T2
Note: Check all hydraulic lines and fittings to ensure Hydraulic oil pressure will remain
leakage is not coming from there. within the system after engine shut down.
Operate the treadle pedal continuously until the
2. Failure of the pedal to return to full upright position. pressure has dissipated before carrying out any
work on the braking system or serious injury
3. Treadle valve holds pressure when in the neutral could result.
position.
1. Position the vehicle in a level work area, apply the
4. Varying output pressure with the pedal fully parking brake, switch off the engine and turn steering
depressed. wheel in both directions several times to relieve any
pressure in the steering circuit.
5. Output pressure does not remain constant between
circuits. 2. Operate the treadle valve continuously to relieve
pressure in the braking system. Block all road wheels
and place battery master switch in the 'Off' position.
SM - 3518
50
49
48 A
P2
P
P2 T
A2 T2
44
P1
P
T2
T T1
47 A1
41
A
39
P1
Px
40 Px
T1
34
33
30
38
36 37
35
32
46
29
31
28
27
21 23
26
25
24
18 17
P1 - Pressure from main hydraulic valve, port ACC2 A2 - Pressure to front brakes
P2 - Pressure from main hydraulic valve, port ACC1 T1 - Tank return, rear brakes
A1 - Pressure to rear brakes T2 - Tank return, front brakes
oil into a suitable container. Close drain cock, remove catch leakage, disconnect hydraulic lines. Fit blanking
hose and reinstall blanking cap. caps to all open lines and treadle valve ports.
5. If necessary remove engine air intake tube to gain 7. Disconnect electrical connection from the brake
access to treadle valve on front of cab. Alternatively, pedal potentiometer.
tilt the cab to gain access. Refer to Section 260-0010,
CAB AND MOUNTING. 8. Separate pedal (1) from base (10) by removing one
'e'-ring (12) from each pin (9 & 11) and sliding pin (11)
6. Clean treadle valve assembly and surrounding area from clevis (15) and pin (9) from base (10).
with a suitable solvent. Ensure all hydraulic lines
connected to the treadle valve are identified for ease of 9. Remove boot (4) and spring (5) from base (10).
installation and, with suitable containers available to
4 SM 2427 04-06
Braking System - Treadle Valve
Section 250-0070
10. Inspect pin (2) and push rod (3), make sure push 12. Separate housing halves (38 & 44) by removing
rod is in good working order and moving freely. cap screws (46) and washers (45). Remove 'o'-rings (39
& 41) from housing halves.
11. Inspect pins (9 & 11), clevis (15) and cam (16) to
make sure clevis and cam are in good working order 13. Carefully remove spools (40 & 47) from housing
and moving freely. halves (38 & 44). Note: Be careful not to damage
spools or housing bores.
12. Any further disassembly is unneccessary unless
there is damage to the assembly.
WARNINGS
13. Separate valve assembly from base (10) by Do not intermix spools and housings. Spools
removing cap screws (7) and washers (8). and housings are matched sets.
DISASSEMBLY ASSEMBLY
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.
1. Remove blanking caps from treadle valve ports and Lubricate all new rubber components with clean
drain all oil from valve body ports by rotating the valve hydraulic oil used in the braking system. Refer to
over a suitable container. Section 300-0020, LUBRICATION SYSTEM.
2. Remove treadle valve from mounting plate and 1. Clean all parts thoroughly before assembly.
secure the valve assembly upright in a table vice.
2. Install new 'o'-rings (39 & 41) in proper pockets on
3. Remove circlips to allow cam assembly to be housings (38 & 44).
disassembled.
3. Lubricate spool (40) with hydraulic oil used in the
4. Remove boot (17) from push rod (18), then remove braking system. Carefully slide into bottom end of
push rod (18) and spring (21) from pilot housing (23) valve housing half (38) bore. Ensure correct orientation
bore. of spool.
5. Separate pilot housing (23) and valve housing half
(44) by removing screws (37). Remove 'O' ring (17) Note: Spool must slide frelly into bore. If either part is
from valve housing (38). damaged, a new spool/ housing assembly may be
required.
6. Remove piston (26) from pilot housing (23). Piston
must be removed trhough bottom end of housing. 4. Reassemble valve housing halves (38 & 44) using
Note: Be careful not to scratch or mar housing bore. A cap screws (46) and washers (45). Use loctite 242 on
wooden dowel will help in this procedure. cap screws and torque to a value of 29.8 - 33.9 Nm (22
- 25 Ibf ft).
7. Remove 'O' rings (25 & 27) and back-up rings (24 &
28) from piston (26), being careful not to damage 'O' Note: Make sure valve housing halves line up correctly
ring and back-up ring grooves. and that 'o'-rings (39 & 41) remain in their pockets
during assembly.
8. Remove piston (29), springs (30, 31 & 32) and
shim(s) (33) from valve housing bore. Note: Be aware 5. Install new 'o'-ring (49) on plug (50) and install in
of the number of shim(s) being removed from housing. valve housing half (44). Tighten securely.
9.Carefully remove cup (35) and seal (36) from valve 6. Lubricate spool (47) with hydraulic oil used in the
housing half (44) bore. Note: Be careful not to scratch braking system. Carefully slide into valve housing half
or mar housing bore. (44) bore. Ensure correct orientation of spool.
10. Remove end plug (50) and spring (48) from valve Note: Spool must slide frelly into bore. If either part is
housing half (44). Remove 'o'-ring (49) from end plug. damaged, a new spool/ housing assembly may be
required.
11. Remove plug (42) from valve housing half (44).
Remove 'o'-ring (43) from plug. 7. Install new 'o'ring (49) on end plug (50).
SM 2427 04-06 5
Braking System - Treadle Valve
Section 250-0070
2. Connect electrical connection to the brake pedal
8. Install new spring (48) and end plug (50) into valve potentiometer.
half housing (44). Torque to a value of 47.5 - 54.2 Nm
(35-40 Ibf ft). 3. Remove blanking caps and connect hydraulic lines
to the treadle valve assembly as noted at 'Removal'.
9. Carefully install new seal (36) and new cup (35) into
valve housing half (38) bore. 4. If previously removed install engine air intake tube,
or if applicable, lower the cab. Refer to Section 260-
Note: Direction and order of cup and seal. Be careful 0010, CAB AND MOUNTING.
not to scratch or mar bore.
5. Fill hydraulic tank with oil specified in Section
10. Assemble springs (30, 31 & 32), shim(s) (33) and 300-0020, LUBRICATION SYSTEM.
retainer assembly (34) in piston (29).
6. Place the battery master switch in the 'On' position,
11. Carefully install piston (29) assembly into valve start the engine and bring hydraulic oil to operating
housing half (38) bore. temperature.
12. Install new 'o'-rings (25 & 27) and new back-up 7. Apply the brakes and check for oil leaks. Tighten
rings (24 & 28) on piston (26). line connections and fittings as necessary.
Note: Ensure correct order of 'o'-rings & back-up rings. Note: When performing Step 8, make sure that parking
brake applies and releases appropriately.
13. Install piston (26) into pilot housing (23) through the
bore of the bottom end. Be sure to install piston as far 8. Check brake operations by actuating pedal and park/
as it will go into pilot housing bore. emergency control. Ensure that the pedal assembly is
14. Install new 'o'-ring (37) on valve housing half (38). free to operate.
15. Carefully attach pilot housing (23) to valve housing 9. Shut off engine and check hydraulic tank oil level.
half (38) using cap screws (22). Torque cap screws to Replenish as necessary.
a value of 27.1 - 33.9 Nm (20 -25 Ibf ft).
16. Install spring (21) and push rod (18) into pilot CHECKING SYSTEM PRESSURES
housing (23) bore.
17. Install new boot (17) on push rod (18) and over pilot WARNINGS
housing (23). To prevent personal injury and property
damage, be sure wheel blocks and blocking
18. When reinstalling pdeal actuated valve, use hex materials are properly secured and of adequate
cap screws (7), Torque cap screws to a value of 24.4 - capacity to do the job safely.
29.8 Nm (18 - 22 Ibf ft).
6 SM 2427 04-06
Braking System - Treadle Valve
Section 250-0070
place the steering lock bar in the 'Locked' position and MAINTENANCE
the battery master switch in the 'Off' position.
General
3. Connect a hydraulic gauge, capable of recording a Check all hydraulic brake lines and fittings at treadle
pressure of 0 - 345 bar (0 - 5 000 lbf/in²), to front brake valve for leaks and damage. Tighten/replace as
diagnostic pressure point (FR BRK) located on the left required.
hand fender directly outside the cab door.
4. Place the battery master switch in the 'On' position, Every 1 000 Hours
start the engine and apply park/emergency brake (push Check front and rear brake pressures at remote
button in), to apply service brakes. Monitor system diagnostic test points. If the pressures are outwith the
pressure gauge. Brake actuating pressure for the front specified pressure range, refer to Troubleshooting table
brake circuit is 48 +/- 2.4 bar (700 +/- 35 lbf/in²). for treadle valve and Section 250-0000, BRAKING
SYSTEM SCHEMATIC.
Note: When brakes are released, a residual pressure of
0.5 bar (7 lbf/in²) should remain.
SPECIAL TOOLS
5. Repeat steps 1 through 4 at rear brake diagnostic There are no special tools required for the procedures
pressure point (RR BRK) located outside the cab door. outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
Note: Actuating pressure for the front and rear brake tools and adhesives required. These tools and
circuits is 48 +/- 2.4 bar (700 +/- 35 lbf/in²), however, adhesives are available from your dealer.
system pressure is 240 bar (3 480 lbf/in²) and can be
checked at the steering diagnostic pressure point
(STR) located on the left hand fender directly outside
the cab door . System pressure is checked against
steering pressure as this is the highest pressure
requirement in the hydraulic circuit. Refer to Section
230-0050, MAIN HYDRAULIC PUMP.
6. If the pressures to the brake circuits have been
determined as high or low, refer to Troubleshooting
table for treadle valve and Section 250-0000,
BRAKING SYSTEM SCHEMATIC.
SM 2427 04-06 7
Braking System - Treadle Valve
Section 250-0070
8 SM 2427 04-06
Braking System - Treadle Valve
Section 250-0070
Brakes will not release Brakes not properly adjusted Adjust brakes. Refer to Section 165-0010,
completely BRAKE PARTS
Inoperative brakes Check brakes. Refer to Section 165-0010,
BRAKE PARTS
Pedal angle out of adjustment Check for proper pedal angle
Air in system Bleed air from system. Refer to Section
165-0010, BRAKE PARTS
Inoperative treadle valve. Replace treadle valve
Piston (29) sticking, spring
(32) broken
Back pressure on return line Remove restriction
excessive
No brakes No oil in hydraulic system Add oil to tank
Broken/damaged hydraulic line Replace broken/damaged line
Brakes not properly adjusted Adjust brakes. Refer to Section 165-0010,
BRAKE PARTS
No accumulator Check accumulator pre-charge pressure.
pre-charge pressure Refer to Section 250-0060,
ACCUMULATOR
No pump pressure Check pump operation
Worn brakes Replace brake pads and discs
Inoperative treadle valve. Replace treadle valve
Piston (29) binding, broken
spring (32)
Pedal kickback when brakes Air in system Bleed air from system. Refer to Section
are applied 165-0010, BRAKE PARTS
* * * *
SM 2427 04-06 9
THIS PAGE IS INTENTIONALLY LEFT BLANK
Braking System - OCDB Relief Unloader Valve
Section 250-0075
SM - 3609
6 6
1
2
8
7
11 12
10 5
4 3 13 14
6 6
DESCRIPTION SM - 3516
TO MOTOR /
The OCDB relief unloader valve can be identified as TRIPLE PUMP
item 2 in Section 210-0005, BRAKE COOLING
SYSTEM SCHEMATIC. Numbers in parentheses refer RETURN FROM
MOTOR /
to Fig. 1. TRIPLE PUMP
SM 2426 04-06 1
Braking System - OCDB Relief Unloader Valve
Section 250-0075
valve(A) being energised. (d) Re-start engine and allow pressures to rise with
engine at low idle, until all warning lights are
FUNCTIONAL CHECK extinguished.
Numbers in parentheses refer to Fig. 1. (e) Turn setting screw clockwise (CW) until correct
pressure is observed on gauge.
The relief unloader valve, although adjustable, should
be preset to 26 bar (377 lbf/in²). Refer to following (g) Re-tighten lock nut.
procedure for valve pressure check and adjustment.
REMOVAL
WARNING Numbers in parentheses refer to Fig. 1.
Hydraulic fluid pressure will remain within the
system after engine shut down. Operate the
treadle valve continuously until the pressure WARNING
has dissipated before carrying out any work on To prevent personal injury and property
the braking system or serious injury could damage, ensure wheel blocks, blocking
result. materials and lifting equipment are properly
secured and of adequate capacity to execute
WARNING the job safely.
To prevent personal injury and property
damage, be sure wheel blocks are properly 1. Position the vehicle in a level work area, apply the
secured and of adequate capacity to do the job parking brake and switch off the engine. Operate
safely. treadle valve continuously to relieve pressure in the
braking system.
1. Attach appropriate pressure gauge to the diagnostic
check point on the brake manifold valve (Port P1). 2. Block all road wheels and place the battery master
switch in the 'Off' position. Place the steering lock bar
2. Start truck and allow pressures to increase with in the 'Locked' position.
engine at low idle, until all warning lights are
extinguished. 3. Remove blanking cap from remote drain line at the
bottom of the hydraulic tank. Install a length of hose on
3. Take note of the gauge reading; this is the pressure remote drain fitting, open drain cock and drain
setting of the relief unloader valve. Valve should be set hydraulic oil into a suitable container. Close drain
at 26 bar (377 lbf/in²). cock, remove hose and reinstall blanking cap.
4. If pressure setting is too low after following steps 1 4. Clean priority unloader valve body (1) and
through 3: surrounding area with a suitable solvent. Identify and
(a) Ensure engine is operating at low idle. tag all hydraulic lines connected to the priority
unloader valve, to aid in 'Installation'.
(b) Loosen lock nut on unloader relief valve (2).
(c) Turn setting screw on unloader relief valve (2) 5. With suitable containers available to catch leakage,
clockwise (CW) until correct pressure is observed on disconnect hydraulic lines. Fit blanking caps to all
gauge. open lines.
(d) Re-tighten lock nut.
6. Remove bolts and lockwashers securing the priority
Note: Always adjust hydraulic pressure on the unloader valve to the hydraulic cradle. Remove priority
increase. unloader valve.
2 SM 2426 04-06
Braking System - OCDB Relief Unloader Valve
Section 250-0075
contaminant is allowed to enter the internal galleries. 2. Remove blanking caps from hydraulic lines and
1. Note location and position of all hydraulic install lines to the priority unloader valve as identified
connectors and adaptors prior to removing them from during removal.
valve body (1).
3. Fill hydraulic oil tank with hydraulic oil as specified
2. Remove unloader relief valve. Check for wear, in Section 300-0020, LUBRICATION SYSTEM. Refer
scoring or contamination. to Section 230-0040, HYDRAULIC TANK, for hydraulic
oil levels. Install filler cap on hydraulic tank filler neck.
3. Remove relief valve (2). Check for wear, scoring or
contamination. 4. Place the battery master switch in the 'On' position,
start the engine and bring hydraulic oil to operating
4. If necessary, remove solenoid valve assembly. temperature.
Check for wear, scoring or contamination.
5. Check priority unloader valve and hydraulic line
5. If necessary, remove flow regulator (3). Check for connections for leaks and tighten as required.
wear, scoring or contamination.
6. Remove all blocking from road wheels and place
6. Ensure all o-rings are checked and replaced when steering lock bar in the stowed position.
re-assembly is carried out. Check parts book for
relevant kit information.
FAULT DIAGNOSIS
Refer to following fault diagnosis chart. As stated
ASSEMBLY previously, it is not recommended that any of the
Numbers in parentheses refer to Fig. 1. cartridge assemblies are disassembled for
maintenance purposes. Ensure that valve assembly is
1. Replace all 'O' rings on hydraulic connectors and cleaned off prior to removal of any components and
adaptors. that no contaminant is allowed to enter the internal
galleries.
2. Replace all seals on unloader relief valve body (1),
relief valve (2), solenoid coil/spool (4 &5) and flow If investigation shows that the cartridge assemblies
regulator (3) valve prior to assembly. are in good clean condition and fit for use, the seals
should be replaced prior to re-assembly. Damage to
3. Install hydraulic connectors (15) and adaptors to the cartridge assemblies or valve body would
correct ports and orientation. Torque each to 35Nm necessitate a new priority unloader valve assembly.
(25.8 Ibf-ft)
4. Fit relief valve (2), flow regulator (3) and solenoid SPECIAL TOOLS
valve assembly to valve body (1) at correct ports. There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
INSTALLATION tools required. These tools are available from your
Numbers in parentheses refer to Fig. 1. dealer.
SM 2426 04-06 3
Braking System - OCDB Relief Unloader Valve
Section 250-0075
Circuit does not load or Unloader relief valve sticking. Replace priority unloader valve assembly.
unload.
Worn or damaged unloader Replace priority unloader valve assembly.
relief valve.
* * * *
4 SM 2426 04-06
OPERATORS COMPARTMENT - Cab and Mounting
Section 260-0010
SM - 3571
11 20,21
12
13
19
14,18 13
12
11
20,21
15
3, 35, 36, 37
16
17
CAB -
R.H.S.
23, 24
LH 25, 26 RH
31
R H - HINGED LH
32 22
34
38 1 6
33 4
5 40
27
41
29
5 28
2 39
10
LH
29
39 39
39
30 9 7 8
RH 30
SM 2388 01-06 1
Operators Compartment - Cab and Mounting
Section 260-0010
SM - 2882
11
9
8 CAB BRACKET
10 5
13
3 9 12
6
BRACKET IN 11
1 BATTERY BOX
FRAME BRACKET
12 13
16
2
15
14
2 SM 2388 01-06
Operators Compartment - Cab and Mounting
Section 260-0010
4. Disconnect the electrical cables in the following Disconnect earth strap at rear right hand cab support
order to prevent damage to the electrical components: (40).
a. Battery earth cable. 11. Lower cab safety prop (7) and place in the stowed
b. Battery supply cable. position, then using lifting equipment, slowly lower cab
c. Alternator earth cables. until horizontal.
d. Alternator supply cables.
e. Electrical harnesses at cab bulkhead. 12. Remove spring pins (5) to allow right hand pins (2)
to be driven out using a suitable driver.
9. Attach suitable slings to the cab lifting points and 5. Install and connect steering valve hoses as noted on
raise lifting equipment to take up the slack. Disconnect removal. Connect earth strap at rear right hand cab
cab raise cylinder (7, Fig. 2) from cab floor by removing support.
bolt (11, Fig. 2), washer (12, Fig. 2) and nut (13, Fig.
2). 6. Connect and secure any other harnesses and hoses
that were previously removed.
10. Tag and disconnect any other harnesses and
hoses that may be affected by cab removal. 7. Place cab safety prop (7) in the stowed position.
SM 2388 01-06 3
Operators Compartment - Cab and Mounting
Section 260-0010
Using hand pump (1, Fig. 2) to control lowering of cab, SM - 3572
gently lower cab until cab brackets align with cab
supports (40). Install pins (1) and secure with bushes
(4) and bolts (6).
4 SM 2388 01-06
Operators Compartment - Cab and Mounting
Section 260-0010
10. Lock off hand valve on hand pump (1). Remove 1. Support mirror arm bracket (11) and remove locknuts
lever (6) from pump (1) and place in the stowed (17), hardened washers (15) and springs (16) securing
position. mirror arm assembly to mounting brackets.
WARNINGS
To prevent damage, always ensure hood is MIRROR ARMS
raised before tilting or lowering the cab.
Installation
Never work near or under an unblocked Numbers in parentheses refer to Fig. 1.
or unsupported cab. Always use the cab safety
prop. Note: Tighten all fasteners without special torques
specified to standard torques listed in
1. Remove pin assembly (8, Fig. 1) from bracket at Section 300-0080, STANDARD BOLT AND NUT
front left hand cab leg. Place cab safety prop (1, Fig. 3) TORQUE SPECIFICATIONS.
in stowed position by locating pin assembly (8, Fig. 1)
in bracket under cab.
WARNING
2. Slowly open hand valve on hand pump (1) to allow To prevent personal injury and property
cab to gently lower. Rate of descent is controlled by damage, be sure blocking materials and lifting
the hand valve on pump (1). equipment are properly secured and of
adequate capacity to do the job safely.
3. Lower cab until holes in cab brackets line up with
holes in cab supports (2, Fig. 3). Hold cylinder (7) in 1. Coat ball bearings (14) with grease (18) and locate in
this position by locking hand valve on hand pump (1). mounting brackets.
4. Install pins (1, Fig. 1) through cab brackets and cab 2. Locate mirror arm bracket (11) to mounting brackets
supports (2, Fig. 3). Secure pins in position with bush and install hardened washers (15), springs (16) and
(4, Fig. 1) and bolts (6, Fig. 1). locknuts (17) as shown in Fig. 1.
5. Lower the hood and place the battery master switch 3. Set mirror bracket spring (16) pressure as follows;
in the 'On' position before closing the battery box. a. rotate mirror arm (11) until ball bearings (14) are
out of their detent.
6. Ensure parking brake is applied and remove wheel b. tighten locknut (17) until spring (16) is almost
blocks from all road wheels. completely compressed (typical two places).
c. swing arm until it seats in detent.
d. check the other two detent positions
MIRROR ARMS
4. Repeat steps 1, 2 and 3 for other mirror arm bracket
Removal (11).
Numbers in parentheses refer to Fig. 1.
REPLACING GLASS
WARNING Note: When replacing broken glass, it is the user’s
To prevent personal injury and property responsibility to ensure that the replacement glass
damage, be sure blocking materials and lifting meets the required specifications. Replacement glass
equipment are properly secured and of can be purchased from your dealer.
adequate capacity to do the job safely.
The rear glass, left and right hand side glasses and
front windscreen are held in place by a bonding
adhesive.
SM 2388 01-06 5
Operators Compartment - Cab and Mounting
Section 260-0010
To replace a glass assembly, proceed as follows: 8. Ensuring the glass is adequately supported, allow
the sealing adhesive to set properly.
Note: Ensure the glass is supported adequately before
starting to cut the adhesive seal. 9. Clean off any excess adhesive using a suitable
solvent.
1. Using a pointed tool, pierce a hole in the adhesive
seal, it is advisable to start at the top edge of the
glass. Unscrew one handle of the special tool and feed Water Leaks
the wire through the opening. Pierce a second hole in Test for leaks by directing a stream of water along the
the adhesive on the side directly opposite the first. adhesive seal, while an assistant marks the spot of
leakage inside the cab. Care should be taken to note
2. From inside the cab pull the wire through and feed it whether the leak is between adhesive and glass. Then
back out through the second hole. apply a sealing compound from the outside. Start from
a point near the leak and continue applying the sealer
3. Re-fit the handle on the special tool. Pull both until well beyond the suspected point of entry.
handles outwards until wire is taut.
This should stop the leak immediately, but since some
4. Manoeuvre the special tool around the edge of the sealing compounds should be allowed to set before
glass, keeping the wire taut, to cut the adhesive seal. getting wet, wait a few minutes before testing.
Ensure the glass is supported adequately before
completing the cut.
MAINTENANCE
5. Clean the remains of the adhesive from the edge of
the panel opening using a suitable solvent.
General
Ensure that hand pump hydraulic tank (2, Fig. 2) is
6. Coat the edge of the replacement glass with primer filled with clean hydraulic oil as specified in Section
and apply adhesive around the lip of the window 300-0020, LUBRICATION SYSTEM. Capacity is 0.75
aperture, as per the manufacturers recommendations. litre (0.2 US gallon).
* * * *
6 SM 2388 01-06
OPERATORS COMPARTMENT - Driver Seat and Mounting
Section 260-0090
SM - 2884
DESCRIPTION pan (10). Seat pan (10) is attached to a cab seat base
by means of a suspension assembly (14). The air seat
Numbers in parentheses refer to Fig. 1.
only reacts when the driver sits on the seat. When
WARNING unoccupied, the seat sinks to the lowest position to
allow easier access.
By Law, seat belts must be provided. Always
wear seat belts when travelling in the vehicle.
A retractable seat belt (4) is secured to the seat
assembly using nuts and spacers. A push button
The seat assembly consists of a seat cushion (3) and
allows quick release of seat belt (4).
backrest cushion (2) mounted to backrest (8) and seat
SM 2400 11-05 1
Operator's Compartment - Driver Seat and Mounting
Section 260-0090
SM - 2885 the seat position in now engaged properly.
34 - Bolt (x4)
35 - Washer (x4)
36 - Lock Washer (x4)
6 3. Pull up horizontal adjustment handle (2) and move
37 - Nut (x4) seat forwards or backwards, release handle when
required position is achieved.
OPERATION REMOVAL
To achieve the most comfortable driving position, Numbers in parentheses refer to Fig. 2.
adjust the seat as follows;
WARNINGS
1. Sit in seat. To prevent personal injury and property
damage, be sure wheel chocks, blocking
2. Pull up and release height and weight adjustment (1) materials and lifting equipment are properly
handle - this will reset the seat to the predetermined secured and of adequate capacity to do the job
height setting - 'bounce' lightly until a 'click' is heard, safely.
2 SM 2400 11-05
Operator's Compartment - Driver Seat and Mounting
Section 260-0090
1. Position the vehicle in a level work area, apply the Horizontal Shock Absorber
parking brake and switch off the engine.
Numbers in parentheses refer to Fig. 3.
2. Block all road wheels and place the battery master
Note: Remove seat assembly as described in
switch in the 'Off' position.
'Disassembly'
3. Disconnect harness connector at the rear of the
1. Remove pop-out buttons (1) and remove access
seat.
cover (2) to allow access to suspension assembly.
4. Push down height and weight adjustment (1) handle
2. Unclip hooked end of shock absorber (4) from
to release the air from the seat air suspension system.
horizontal spring assembly.
5. Remove bolts (34), washers (35), lock washers (36)
3. Remove circlip (3) and lever out shock absorber (4)
and nuts (37) securing complete seat assembly to the
from rocker shaft and slide off of mounting pin.
cab seat base. Remove seat assembly from vehicle
using suitable lifting equipment.
4. Remove spacer (5) from mounting pin.
SM 2400 11-05 3
Operator's Compartment - Driver Seat and Mounting
Section 260-0090
Note: Inscription must face upwards when assembling 3. Remove pressurised airline (5) from compressor (6).
shock absorber (7).
4. Identify and tag and disconnect electrical plug
SM - 2488 connections (7 & 8). Unfasten cable tie on the rocker.
SM - 2489 SM - 2490
Fig. 5 - Exploded View of Compressor and Mounting Fig. 6- Exploded View of Level Controller and Mounting
Note: Remove seat assembly as described in Note: Remove seat assembly as described in
'Disassembly' 'Disassembly'
1. Remove pop-out buttons (1) and remove access 1. Remove pop-out buttons (1) and remove access
cover (2) to allow access to suspension assembly. cover (2) to allow access to suspension assembly.
2. Remove pop-out buttons (3) and push down 2. Remove pop-out buttons (3) and push down
suspension skirt (4) to allow further access to suspension skirt (4) to allow further access to
suspension assembly. suspension assembly.
4 SM 2400 11-05
Operator's Compartment - Driver Seat and Mounting
Section 260-0090
3. Pull suspension assembly up to its highest position slide seat assembly rearwards. Hold captive nuts using
and block securely. a suitable spanner and install front allen screws.
Tighten allen screws to a torque of 25 Nm (18 lbf ft).
4. Unhook bowden wires (5 & 6) from level controller (7).
3. Install seat cushion (3) to seat frame (1) and secure
5. Identify and tag and disconnect electrical plug using screws.
connections (8 & 9).
4. Install backrest cushion (2) to seat frame (1) and
6. Identify and tag and disconnect pressurised airlines secure using screws.
(10) from air suspension unit (11). Unfasten cable tie on
the rocker. 5. Refit headrest (5) to seat frame (1).
7. Remove screw (12), push out pin (13) and release 6. Position lap belt (4) to seat assembly and secure
roll up belt (17). using nuts and spacers as removed at 'Disassembly'.
Tighten nuts to a torque of 50 Nm (36 lbf ft). Refit
8. Remove nuts (14) and manoeuvre level controller (7) covers (6 & 7).
until studs are free from mounting holes.
10. Remove level controller (7) from suspension base. Note: Tighten all fasteners without special torques
specified to torques listed in Section 300-0080,
11. Reassembly is done in the reverse order. STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
Note: Tighten nuts (14) to a torque of 25 Nm (18 lbf ft).
WARNINGS
INSPECTION To prevent personal injury and property
Numbers in parentheses refer to Fig. 1. damage, be sure wheel chocks, blocking
materials and lifting equipment are properly
1. Inspect air lines, shock absorbers (15 & 26), secured and of adequate capacity to do the job
compressor (21), level controller (28) and air spring safely.
(30) for leaks and damage and replace if required.
2. Check all brackets and frame for cracks and/or 1. Using suitable lifting equipment, position seat
damage. Repair or replace as necessary. assembly on the cab seat base and secure using bolts
(34), washers (35), nuts (37) and lock washers (36).
3. Check springs for fatigue or damage and replace as
required. 2. Reconnect harness at the rear of the seat.
Note: Tighten all fasteners without special torques 4. Remove wheel chocks from road wheels.
specified to torques listed in Section 300-0080,
STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
SM 2400 11-05 5
Operator's Compartment - Driver Seat and Mounting
Section 260-0090
MAINTENANCE
Numbers in parentheses refer to Fig. 1.
* * * *
6 SM 2400 11-05
OPERATORS COMPARTMENT - Air Conditioning
Section 260-0130
SM - 2430
1 3 IN
D
S OUT
4
5
2 SM 2460 04-06
Operators Compartment - Air Conditioning
Section 260-0130
SM 2460 04-06 3
Operators Compartment - Air Conditioning
Section 260-0130
SM - 3636
21 5
9
19
CAB 3
FIREWALL 6 9
20 18
16
24
7
17
8
10
8
23
14 18
21
7
23
15
11
12 7
4
14
7 22
4 SM 2460 04-06
Operators Compartment - Air Conditioning
Section 260-0130
SM - 3637
24
4
23
7 20
10 22
2
12
17
13 21
11
65 15
16 25
18
9
14 26
19
27 1
28,30
31,32
2 3
1 28,30
31,33
28,29,30,31
7. If removed, install receiver/drier (12) to mounting Note: If fan guard and compressor drive belt were
bracket (11) and secure with clamps. removed, proceed with steps 12 & 13.
8. Remove caps from end of refrigerant hoses (1 & 2) 12. Install new drive belt onto engine pulley and fit to
and ports on receiver/drier (12) and connect hoses to groove on compressor (10).
ports as tagged at removal.
13. Adjust tension of compressor drive belt with nut on
9. If removed, install condenser (23) to radiator adjuster bolt until there is approximately an inward
assembly and secure. deflection of 10 mm (0.4 in) at the centre of drive belt
(3). Fully tighten all mounting hardware.
10. Remove caps and connect refrigerant hoses
(1 & 8) to condenser (23) ports as tagged at removal. 14. Remove caps from end of refrigerant hoses (3 & 4)
and ports on compressor (10) and connect hoses to
11. Fit compressor (10) to engine and secure with bolts ports as tagged at removal.
(16) and washers (17). Do not fully tighten at this
stage. 15. Connect electrical connection to compressor (10)
clutch.
SM 2460 04-06 5
Operators Compartment - Air Conditioning
Section 260-0130
16. Secure all lines with clips and clamps as removed 2. If the system has a heater in the same location as
during removal. Ensure no lines are chaffing on sharp the air conditioning evaporator core, heater valves
edges or resting against areas where heat will be should be closed.
evident.
3. To check the refrigerant level, run the engine at
17. Charge the air conditioning system as described 1 200 rev/min with fans on high speed and thermostat
under 'Charging Procedure'. fully open for a minimum of five minutes. If the clutch
is engaged in this situation, there should be very few
18. Switch the battery master switch to the 'On' bubbles visible in the receiver-drier sight glass.
position, start up the engine and check for correct
operation of the air conditioning system. Note: Unit can operate with some bubbles visible, but
not milky looking.
19. Lower hood and remove wheel blocks from all road
wheels. 4. Ensure all hoses and hose clamps are free from
contact with sharp metal, moving parts or near to
manifolds.
MAINTENANCE
5. Inspect condensation drain lines for debris, sharp
bends or breaks.
WARNINGS
Always wear goggles or glasses to protect your 6. Inspect the clutch wire from the thermostat for bare
eyes when working around R-134a. R-134a boils spots.
at sea level temperatures of -29.8° C (-21.6° F),
which means that direct contact with your skin 7. Inspect bolts and nuts on the compressor and
will produce frostbite. Exercise extreme care mounting bracket for proper tightness.
when handling R-134a. If R-134a contacts your
skin, wash immediately with plenty of warm 8. Check for any air blockages within the system.
water. Remove any contaminated clothing with Clean recirculation filter periodically, by shaking off
caution as it may adhere to the skin. If blistering dust or by washing in soapy water.
or continued irritation occurs obtain immediate
medical attention. 9. If the refrigerant system is broken into following gas
loss due to mechanical damage or there is any other
If you get the slightest trace of R-134a in reason to suspect foreign material ingress, then the
your eye, flood the eye immediately with cool receiver/drier should be replaced.
water; then treat with mineral oil or clear
petroleum jelly followed by boric acid rinse. 10. Every 4 000 hours, drain, flush and refill the
Report to a hospital or doctor as soon as compressor with refrigerant oil specified in Section
possible. 300-0020, LUBRICATION SYSTEM. Also see
'Refrigerant Oil'.
The chemicals of R-134a when burned
produce gases that will damage the respiratory
system if inhaled. NEVER SMOKE in an area
where R-134a is used or stored. Use hot water or
an approved heated charge cylinder as a heat
source if required to force R-134a into the
system. If using water, do not exceed 52° C
(125° F). Never use direct flame or electric
heaters in direct contact with the R-134a
container. High temperatures may result in
raising the pressure to a dangerous level.
6 SM 2460 04-06
Operators Compartment - Air Conditioning
Section 260-0130
4. Never attempt to correct belt slippage by using a Condenser add 1 fl oz (28.4 ml)
belt dressing. The dressing may cause softening and Drier add 1 fl oz (28.4 ml)
deterioration. Evaporator add 3 fl oz (85.2 ml)
Compressor add 4.4 fl oz (125 ml)
5. If belt slips, even when properly tensioned, check for
overload, worn sheave grooves or oil or grease on the The oil should be added to the oil filling port of the
belts. compressor before the evacuation procedure is started
or by using an oil injector when the system is being
6. Never pry a drive belt or force it into the sheave charged, observing the following good practises:
groove. Loosen the drive belt tightener prior to
installation. a. Only pour the amount required from the container
straight into a CLEAN measuring jug and
7. A belt that has operated while rolled over in the immediately pour the oil into the compressor.
sheave groove may be damaged - replace it. b. Re-cap container tightly as soon as the required
amount has been taken (never leave an oil container
8. Store belts in a cool, dry place. If stored on a open).
machine, relieve all belt tension by loosening the c. Do not mix different oils.
drive belt tightener.
Only new oil should be used, because oil that has
9. Never attempt to check or adjust belts while they are been exposed to the air will have absorbed water
running. (hygroscopic).
SM 2460 04-06 7
Operators Compartment - Air Conditioning
Section 260-0130
System Leak Testing system is empty before connecting the vacuum so that
refrigerant does not enter the pump.
Recommended Equipment Required:
Electronic Leak Detector
5. Tighten down (turn clockwise) both high and low side
valves on the gauge manifold to the closed position.
Switch off the engine and check all connections
Remove protective caps from the service ports on the
throughout the system for leaks. A large leak point will
compressor.
have an oily or greasy appearance. The refrigerant
carries compressor oil with it and deposits it around the
6. Connect both service hoses from the two fittings (2
leak area. Check all such points for loose connections
& 3) in the bottom of the manifold to the two service
and tighten.
ports on the compressor. High side (red) to compressor
discharge valve, low side (blue) to compressor suction
Using a suitable leak detector, search for leaks around
valve.
all joints, connections, seals and control devices. If a
leak is located, purge the system of refrigerant and
7. Switch vacuum pump on, open vacuum pressure
repair. Fully evacuate and charge the system to make
valve (1) until less than 6 mb is reached on vacuum
it operational.
gauge (A). The vacuum gauge (A) should remain at
this value when vacuum pressure valve (1) is closed
DISCHARGING THE SYSTEM to indicate that there are no leaks.
Note: Refer to all WARNINGS listed under
8. Open the low side hand valve on the manifold and
'Maintenance' prior to discharging the system.
vacuum pressure valve (1) and watch that the
gauges start to register that a vacuum is being drawn.
Recommended Equipment Required:
If the gauges do not register the vacuum thena
Portable High Vacuum Charging Station
blockage is present. Open the high side and pump
Suitable Canister
down until a vacuum of 10 mb is achieved.
or Standard Service Manifold (Refer to Fig. 4)
To eliminate system contaminants from an air
9. After 10 - 15 minutes close vacuum pressure valve
conditioning system requires discharging the entire
(1) and allow the system to settle, vacuum gauge (A)
system. This means removing all of the refrigerant
should not alter. If the vacuum is held, no leaks or
and cleansing all contamination (air and moisture) from
refrigerant contaminated oil is present. If not, open the
the system components. If any of the major system
vacuum pressure valve (1) and continue pumping,
components are to be repaired or replaced, the system
checking at regular intervals. If there is a leak, check
must also be completely discharged.
all fittings and tighten if necessary.
WARNING 10. Tighten down (turn clockwise) both high and low
The vehicle must not be running during this side valves on the gauge manifold to the closed
procedure. Be sure to have adequate ventilation position, remove the service hose (yellow) from the
during this operation. Do not discharge vacuum connection (6) on vacuum pump and switch
refrigerant near an open flame. the pump 'Off'.
Numbers and letters in parentheses refer to Fig. 4. 11. Connect the service hose (yellow) to the R-134a
cylinder. Open the cylinder valve and then purge air
1. Position the vehicle in a level work area, apply the from the hose at the manifold connection.
parking brake and switch off the engine.
12. Open the low side hand valve on the manifold
2. Block all road wheels and place the battery master slowly, until low pressure gauge (B) is at bottle
switch in the 'Off' position. pressure. Watch the high side manifold gauge (C) rise
to ensure that no blockage is present. Close the
3. Pull on handle to release hood catch and raise the manifold valve and cylinder, then disconnect the hose
hood. from the cylinder.
4. Connect the service hose (yellow) to the centre 13. Connect the service hose (yellow) to the Nitrogen
access port on the manifold gauge and to the vacuum cylinder. Open the neck valve on the cylinder and set
connection (6) on vacuum pump. Ensure that the the regulator pressure such that it is higher than the
8 SM 2460 04-06
Operators Compartment - Air Conditioning
Section 260-0130
system pressure then purge the hose. Open the low 9. Run vacuum pump for approximately 30 minutes.
side hand valve on the manifold, as the pressure rises Ideal gauge readings should be 29.92 inches of
open the high side hand valve on the manifold and mercury. The pressure will vary with altitude; it will be
allow a system pressure of 10 bar (150 psig) to be approximately 0.03 bar (0.5 lbf/in²) less for each 305 m
reached. Close all the valves. Using a suitable (1 000 ft) of elevation.
electronic leak detector, check all joints in the air
conditioning system for leaks. Tighten any loose 10. Before disconnecting power supply from vacuum
joints and re-test if necessary. pump, close both high and low side gauges. Remove
yellow hose from vacuum pump and connect to
14. Vent the refrigerant mix to atmosphere by R-134a source.
removing the service hose (yellow) from the Nitrogen
cylinder and opening the low side hand valve on the 11. Open R-134a source. Loosen, but do not remove,
manifold. Re-evacuate the system to below 6 mb yellow supply hose at manifold on gauges to remove all
(steps 7 to 10). air in the yellow supply hose, replacing the air with R-
134a. This is done in a few seconds. Tighten yellow
15. Lower hood assembly and remove wheel blocks. supply hose.
Recommended Equipment Required: Note: Never charge with liquid R-134a. Charge on the
Portable High Vacuum Charging Station low pressure side only.
Electronic Leak Detector
or Standard Service Manifold (Refer to Fig. 4)
Final Charging Of The System
For New Or Completely Empty System 1. Start the engine and run at engine idle speed.
Note: The charging procedure must be done in ambient
temperatures above 15.5° C (60° F) with the R-134a 2. Turn the air conditioning system on with the
canister temperature equal to the outside ambient thermostat set on maximum cooling and fan on high
temperature. speed.
1. Shut off engine and block all road wheels. 3. At this point a visual inspection must be made of
the sight glass on top of the receiver-drier. Allow
2. Pull on handle to release hood catch and raise the charging to continue until 1.1 kg (2.43 lbs) of refrigerant
hood. has been added. The charging process can be speeded
up by running the engine at a fast idle.
3. Remove protective caps from 'quick coupler' valves
on rear of compressor. 4. The sight glass on top of the receiver/drier will be
substantially free of bubbles.
4. Connect low pressure gauge hose (blue hose and
gauge) to suction side or low side fitting on Note: It is normal for bubbles to increase during clutch
compressor. The suction side can be identified by the cycling or system start-up.
size of the hose connected to the fitting. This will be
the largest diameter hose of the system. 5. With the system completely charged, shut off the
engine. Close the valve on the R-134a canister and
5. Connect the high pressure gauge hose (red hose and remove the yellow supply hose. Remove both the low
gauge) to discharge or high side fitting on compressor. pressure (blue) hose and high pressure (red) hose from
6. Connect yellow supply hose to suction port on the filling ports on the compressor.
vacuum pump.
Note: Some R-134a will escape as the hoses are being
7. Open both sides of gauges, low and high, completely. removed.
8. Start vacuum pump to evacuate the complete air The system is completely charged when;
conditioning system.
SM 2460 04-06 9
Operators Compartment - Air Conditioning
Section 260-0130
a. the suction pressure on the gauge is approx. 4. Check the cab fresh air inlet filter for blockage.
20 - 30 psig at 25° C ambient.
b. the correct weight of refrigerant has been added i.e. 5. Check that, with the ignition switch on (engine not
1.1 kg (2.43 lbs). running), the blower operates over whole speed range
c. the correct sub-cooling can be measured at the
condenser, approx. 5 - 7° C. 6. Check that, with the ignition switch on (engine not
running), the blower and air conditioning switched on,
6. Replace protective caps on hoses and valve fittings. the compressor clutch engages.
2. Check the condenser and engine radiator are not SPECIAL TOOLS
blocked by debris. Clean with compressed air or water Refer to Section 300-0070, SERVICE TOOLS, for part
if necessary. numbers of special tools referenced in this section and
general service tools and sealants required. These
3. Check that the condenser fins are not flattened or tools and sealants are available from your dealer.
damaged, the fins must allow air to pass freely.
SM - 2424
B C D
2 3 4
SUC DIS R
ACCESS E
F
PORT R
I
G
E
A R
A
N
T
VACUUM PUMP
6
1 5
Gauges: Valves:
A - Vacuum Gauge 1 - Vacuum Pressure
B - Low Pressure Gauge 2 - Suction Line
C - High Pressure Gauge 3 - Discharge Line
D - Charging Cylinder 4 - Refrigerant Gas
Pressure Gauge 5 - Refrigerant Liquid
Port:
6 - Vacuum Connection
10 SM 2460 04-06
Operators Compartment - Air Conditioning
Section 260-0130
SM 2460 04-06 11
Operators Compartment - Air Conditioning
Section 260-0130
2. Vibration/Noise in Compressor
area
3. Noise - Evaporator
12 SM 2460 04-06
Operators Compartment - Air Conditioning
Section 260-0130
5. Electrical Trouble
Blower motor or condenser fan Defective circuit breaker or bad Replace. Clean and tighten
motor inoperable wiring connections connections
SM 2460 04-06 13
Operators Compartment - Air Conditioning
Section 260-0130
* * * *
14 SM 2460 04-06
BODY - Body and Mounting
Section 270-0010
SM - 3522
14
1 37 7
1 4
15
16 3
6 1
5
26
27
25 11
13
18 20 21
12
24 32
23 9
28 34
29 30 31
33 10
36 17
19
22 29 2
35
38
DESCRIPTION OPERATION
The standard body is an all welded construction with all A body control joystick, mounted on the right hand
wear plates fabricated from high hardness dash panel, actuates the body control valve by means
(min. 360 BHN) 10 150 bar (145 000 lbf/in²) yield of electrical signals to the solenoid valves, which in
strength material. Angled lower body sides reduce turn operate the body hoist cylinders. The four
body impacts when loading and a tailshute angle of operating positions of the joystick from front to rear are
25° provides good load retention when travelling as follows:
without a tailgate. Refer to Section 000-0000,
GENERAL INFORMATION for body capacities. 'FLOAT' - The joystick should be moved to this
position while the body is lowering by gravity and
The body is pivoted at the rear of the trailer frame and should remain in this position until the body must be
is operated by two single stage, double acting body operated again. The control joystick should always be
cylinders which are cushioned at both ends of the kept in 'FLOAT' while the machine is in motion.
stroke to reduce impact shocks. The body cylinders
raise the body to a tipping angle of 65° in 'LOWER' - Pushing the joystick forward and holding it
16 seconds and powerdown the body in 12 seconds. in this position provides hydraulic force to power-down
the body. It is needed when the body cannot be started
SM 2429 03-06 1
Body - Body and Mounting
Section 270-0010
downward from the fully raised position by gravity. 2. Block all road wheels and place the battery master
When the body starts lowering by gravity, the joystick switch the 'Off' position.
can be released and internal valve springs will move
the joystick to the 'HOLD' position. 3. Remove upper pins securing the body cylinders to
body (1) and secure body cylinders clear of the body.
'HOLD' - Moving the joystick to this position while the Refer to Section 230-0130, BODY CYLINDER.
body is being raised or lowered traps the oil in the
body hoists to stop and hold the body at any desired 4. Using suitable lifting equipment, sling body (1)
height. The joystick will remain in the 'HOLD' position assembly at the four lifting points and take an initial
when released. strain.
WARNINGS WARNING
To prevent personal injury and property To prevent personal injury and property
damage, be sure wheel chocks and lifting damage, be sure wheel chocks and lifting
equipment are properly secured and of equipment are properly secured and of
adequate capacity to do the job safely. adequate capacity to do the job safely.
Exercise extreme caution when lowering 1. If removed, install bushing (2) to pin mounting
the cylinders from the body. The cylinders will bores.
swing out sharply as they leave their
mountings. 2. Using suitable lifting equipment, sling body (1)
assembly and position over the trailer frame.
1. Position the vehicle in a level work area, ensure the
body is fully lowered, apply the parking brake and Note: Approximate weight of body (1) assembly is
switch off the engine. Turn steering wheel several 5 400 kg (11 905 lb).
times to relieve any pressure in the steering circuit.
3. Align body hinge pin (3) bores in body (1) with bores in
2 SM 2429 03-06
Body - Body and Mounting
Section 270-0010
the trailer frame. Install body hinge pins (3) and shims (4) of the load, resulting in uneven load distribution along
and secure with bolts (5) and washers (6). the chassis.
4. Secure body cylinders to body (1) assembly with 1. Raise body (1) clear of the trailer frame and lay body
pins and mounting hardware removed during removal. pads (10) (metal face down) roughly in position on the
Refer to Section 230-0130, BODY CYLINDER. frame.
5. Lubricate body hinge pins (3) and body cylinder pins 2. Lower body (1) onto body pads (10).
with lubricant specified in Section 300-0020,
LUBRICATION SYSTEM. Lubricate slowly until 3. Centralise body (1) to the frame and place shims
excess lube is seen. (11 & 12) under the front two body pads (10) until all
other pads are clear of body (1).
6. If removed, install body pads (10) and body guide
plates (15) on body (1) as described under 'Body 4. Slide shims (11 & 12) under the other body pads
Shimming Procedure'. (10) until they just make contact with body (1).
7. Remove lifting equipment from body (1) and wheel 5. Raise body (1) and install body pads (4) and shim
chocks from all road wheels. packs (11 & 12) to their relative brackets on body (1)
securing with bolts (8), washers (9) and locknuts (13).
8. Start the engine and check for correct operation of
body (1) assembly. 6. Lower body (1) and check shimming.
* * * *
SM 2429 03-06 3
THIS PAGE IS INTENTIONALLY LEFT BLANK
MISCELLANEOUS - Lubrication System
Section 300-0020
When working on or around exhaust components, Small circles on the following illustration represent
remember that the components may be hot and can points at which lubrication and/or servicing must take
cause burns to unprotected skin. place, at the intervals indicated on the left hand side of
the lubrication and service chart.
Always deflate the tyre before trying to remove any
embedded objects or removing the tyre and rim The numbered circles on the illustration contain
assembly from the vehicle. reference numbers which correspond to the reference
numbers in the 'Ref. Points' column of the lubrication
Always use a self-attaching chuck with a long airline, and service chart.
and stand to one side while inflating the tyre. Refer to
Section 160-0050, WHEEL RIM AND TYRE.
SM - 3526
24 35 28 27 13 11 9 12 21 16 18 22 19 25 22 16 20 10 16 23
1 33 32 5 4 3 7 15 2 12 21 14 34 22 26 22 17 10 20 8 23
2 Transmission Mtg. Bolts Check Torque. (Torque Seal). 2 921 Nm (680 Ibf ft).
1 Turbocharger Mtg. Nuts Check Torque. (Torque Seal). 2 921 Nm (680 Ibf ft).
24 Cooling System Check concentrate, add booster. - Ethylene 67 Litres (18 US Gal.)
Glycol
4000 35 Air Conditioning Compressor Drain flush and refill 1 PAG Oil 0.125 Litres.
1 Thermostats and Seals Replace.
6000 2 Transmission Drain oil and refill. 1 TranSynd / 61 Litres (16 US Gal.)
TES 295*
* - When determining whether a fluid is TES 295 approved or not look and/ or ask for one of two things - The
Allison TES 295 approval number or the Allison approved logo . TES 295 approved fluids are listed on the
following page. If uncertain if a fluid is approved, consult Allison Transmission for confirmation.
Note: Use 'Lubrication and Service Chart' in conjunction with 'Notes on Lubrication and Service Chart' and
'Miscellaneous Servicing' contained on the following pages.
LZ - Lubrizol 6178 Hydraulic Tank - Check oil level and add oil if low.
PAG Oil - Polyalklene Glycol (PAG) Compressor Brake Coolant Tank (TA40 only) - Check oil level
Lubricating Oil - Low Viscosity (ISO46). and add if low.
RECOMMENDED LUBRICANTS
COMPONENT LUBRICANT *CAPACITY SPECIFICATIONS API CODE SAE GRADE
Engine Engine Oil with 1.00% 32 litre CH-4 15W-40
(Including Filters) sulphated ash limit is (9.8 US gal)
recommended. Sulphated ash
must not exceed 1.85% limit
Transmission 61 litre See Trans.
(Including Filters) TranSynd / TES 295 (16.1 US gal) TranSynd / TES 295 - TES 295
(dry fill) Oil Table.
Hydraulic System Hydraulic Transmission Oil 330 litre Textran TDH Prem. See Hydraulic Oil Table
(Including Lines) (87 US gal) (See Note 2)
* - When determining whether a fluid is TES 295 approved or not look and/ or ask for one of two things - The
Allison TES 295 approval number or the Allison approved logo . TES 295 approved fluids are listed on the
following page. If uncertain if a fluid is approved, consult Allison Transmission for confirmation.
API
SAE CODE MIL-SPEC
1 - - MIL-H-5606A
2 DEXRON Auto Trans. Fluid
3 10W CC/CD MIL-L-2104 B/C
4 20W/20 CC/CD MIL-L-2104 B/C
5 30 CC/CD MIL-L-2104 B/C
SM - 639
ENGINE OIL
ENGINE OIL
(See Note 4)
Note - Consult your lubricant supplier for correct viscosity of lubricant when ambient temperatures are
consistently above or below those listed.
* * * *
MISCELLANEOUS - Service Tools
Section 300-0070
INTRODUCTION Hood
Contained in this section are recommended service For manual wind of the linear actuator a 6mm Ball End
tools and equipment required for maintenance, overhaul Allen key with extension is necessary to gain sufficient
and troubleshooting. In certain instances, both Metric access.
and Imperial equivalents of the same tools are listed.
Series 60 Engine
Note: The Company reserves the right to make General
changes in the design or construction of tools and
equipment without obligation to incorporate such See 'Fabricated tools' detail at end of this section for
changes in tools and equipment previously sold. details of engine support brackets.
SM 2437 03-06 1
Miscellaneous - Service Tools
Section 300-0070
2 SM 2437 03-06
Miscellaneous - Service Tools
Section 300-0070
Cab
15271016 - Glass Removal Tool
15271017 - Bonding Kit (Quick Dry)
SM 2437 03-06 3
Miscellaneous - Service Tools
Section 300-0070
140 SM - 3529
85 43 90
25
" "
50 10 100 Ø 20 4 POS'N
332 245
210 12
75
¾"unc
10 100 50
190
(mm)
Fig. 1 - Engine Support Bracket LHS (Section 110-0030, ENGINE AND MOUNTING)
140 SM - 3530
ENGINE SUPPORT BRACKET (RHS)
10
25
"
43 90
"
5
" "
100 Ø 20
4 POS'N VIEW ON 'A'
"
377 280
50 "
155 70
10 80
'A'
12
5
5 ¾"unc
60
12
225 (mm)
Fig. 2 - Engine Support Bracket RHS (Section 110-0030, ENGINE AND MOUNTING)
4 SM 2437 03-06
MISCELLANEOUS - Standard Bolt and Nut Torque Specifications
Section 300-0080
SM 1238 2-98 1
Miscellaneous - Standard Bolt and Nut Torque Specifications
Section 300-0080
Note: Where materials other than GM Standards are used, refer to the conversion table below.
Types of Steel Rockwell Hardness Range Applicable Torque Values SAE Bolt Head Symbols
2 SM 1238 2-98
Miscellaneous - Standard Bolt and Nut Torque Specifications
Section 300-0080
SM 1238 2-98 3
Miscellaneous - Standard Bolt and Nut Torque Specifications
Section 300-0080
Lockscrews Locknuts
SAE Grade 5 & 8
and ASTM A-574 SAE Grade 5 SAE Grade 8
Size Nm lbf in Nm lbf in Nm lbf in
0.25 - 20 0.3 3 0.4 3.5 0.5 4.5
0.25 - 28 0.3 3 0.4 3.5 0.5 4.5
0.31 - 18 0.6 5 0.6 5.5 0.9 7.5
0.31 - 24 0.6 5 0.6 5.5 0.9 7.5
0.38 - 16 1.0 9 1.0 8.5 1.3 11.5
0.38 - 24 1.0 9 1.0 8.5 1.3 11.5
0.44 - 14 1.4 12 1.4 12 1.8 16
0.44 - 20 1.4 12 1.4 12 1.8 16
0.50 - 13 1.8 16 1.7 15 2.3 20
0.50 - 20 1.8 16 1.7 15 2.3 20
0.56 - 12 2.5 22 2.4 21 3.2 28
0.56 - 18 2.5 22 2.4 21 3.2 28
0.62 - 11 3.4 30 3.1 27 4.1 36
0.62 - 18 3.4 30 3.1 27 4.1 36
0.75 - 10 5.1 45 4.6 41 6.1 54
0.75 - 16 5.1 45 4.6 41 6.1 54
0.88 - 9 7.3 65 7.0 62 9.3 82
0.88 - 14 7.3 65 7.0 62 9.3 82
1.00 - 8 9.6 85 9.5 84 12.7 112
1.00 - 12 9.6 85 9.5 84 12.7 112
1.00 - 14 - - 9.5 84 12.7 112
* * * *
4 SM 1238 2-98
MISCELLANEOUS - Unit Storage
Section 300-0090
5. RUST PREVENTION - Remove all evidence of rust 8. TRANSMISSION - Consult the relevant
from the machine and repaint. In addition, cover all Transmission Maintenance Manual for storage data
exposed machine surfaces with a good rust involving periods longer than 30 days.
preventive.
9. ENGINE - Consult the relevant Engine Maintenance
6. SUPPLY TANKS - Fill fuel and hydraulic tanks to Manual for storage data involving periods longer than
prevent moisture condensation within the tanks. 30 days.
7. TYRES - Inflate all tyres to correct pressure. During 10. VENTS AND BREATHERS - Remove all vents
storage, check inflation pressure approximately once and breathers and plug openings with pipe plugs. If it
every two weeks. is not possible to do this, seal vents and breathers with
waterproof tape.
SM 1239 2-98 1
Miscellaneous - Unit Storage
Section 300-0090
EXTENDED STORAGE - Over Six Months 2. BATTERIES - Install batteries and check for a full
When a machine is to be stored for a period over SIX charge. Charge batteries as required.
MONTHS, the following procedure must be followed:
3. TYRES - Inflate tyres to the proper pressures. Refer
Note: These steps are in addition to those given to Section 140-0040, WHEEL RIM AND TYRE, of this
previously under 'Extended Storage - Under Six manual.
Months'.
4. FUEL AND HYDRAULIC TANKS - Drain off
1. LUBRICATION - Completely lubricate the machine condensation and fill tanks to proper level, remove
according to the instructions contained in Section breather covers and install air breathers. Be sure
300-0020, LUBRICATION SYSTEM of this manual. breathers are clean before installation.
2. WHEEL BEARING - Remove, clean, inspect and 5. VENTS AND BREATHERS - Remove seals and
repack all wheel bearings. plugs from all breather openings, then install all
breathers and vents.
Note: The above steps must be repeated for every Six
Month period the machine is in storage. 6. ENGINES - Consult the relevant Engine
Maintenance Manual for instructions on removing an
engine from storage.
REMOVAL FROM EXTENDED STORAGE
7. PAINT - Check machine for rust. Remove all rust
General spots and repaint rusted areas.
1. LUBRICATION - Completely lubricate the machine
according to the instructions in Section 300-0020, 8. TRANSMISSION - Consult the relevant
LUBRICATION SYSTEM of this manual. Transmission Maintenance Manual for instructions on
removing from storage.
* * * *
2 SM 1239 2-98