Ta40 842 Ocdb ZF 06 2005 PDF

CUSTOMER SUPPORT DEPARTMENT
TEREX EQUIPMENT LIMITED

MOTHERWELL, SCOTLAND ML1 5RY
REF. NO. SM842
SM 2145 Rev 5 06-05
TA40 OCDB-ZF
Articulated Dumptruck
Maintenance Manual
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TABLE
OF CONTENTS
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Part No. 15501184
TEREX SERVICE DEPARTMENT
PURPOSE:
To advise potentially hazardous condition.
DETAIL:
It has been brought to our attention that 'Viton' material used in manufacture of oil seals and 'O' rings, produces a
highly corrosive acid (Hydrofluoric) when subjected to temperatures above 315 C.
The resulting contamination can have extreme consequences on human tissue since it is almost impossible to
remove after contact.
We therefore recommend the following procedure when it is necessary to inspect any equipment that has been
subjected to a high temperature i.e. fire.
a. Visually inspect for any gaskets or seals which have suffered from heat; they will appear black and sticky.
b. If this is affirmed - Do Not Touch
c. Make enquiries to ascertain the material composition. Any Fluoro-elastomer (Viton, Fluorel or Tecmoflon)
should be considered dangerous but natural rubber and nitrile are non-hazardous.
d. If Fluoro-elastomer seals have been used, then the affected area MUST be decontaminated before
undertaking further work.
e. Disposable Heavy Duty Gloves (Neoprene) MUST be worn and the affected area decontaminated by washing
thoroughly with Limewater (Calcium Hydroxide solution).
f. Any cloths, residue and gloves used MUST be safely discarded after use.
Note: Burning of the discarded items is NOT RECOMMENDED, except in an approved incineration process
where the gaseous products are treated by alkaline scrubbing.
Service
Information
Alert
DATE: April 1994 B168
MODEL: General
SUBJECT: VITON 'O' RINGS AND SEALS (FLUORO-ELASTOMERS) - SAFETY HAZARDS
TEREX Equipment Limited, Motherwell, Scotland ML1 5RY Tel. (0698) 732121 Tlx. 77141 Fax. (0698) 734046
TEREX Division, Tulsa, Oklahoma, 74107 USA Tel. (918) 446-5581 Fax. (918) 446-9752
The information contained within this
Alert must not be made available to
third parties not authorised to receive it.
THIS PAGE IS INTENTIONALLY LEFT BLANK
SM 222 Rev 1 9-93
Proper service and repair is important to the safe, reliable operation of all motor vehicles. The service
procedures recommended and described in this publication, are effective methods for performing service
operations. Some of these service operations require the use of tools specially designed for the purpose.
The special tools should be used when, and as recommended.
It is important to note that this publication contains various WARNINGS and NOTES which should be
carefully read in order to minimize the risk of personal injury to personnel, or the possibility that improper
service methods will be followed which may damage the vehicle or render it unsafe. It is also important to
understand these WARNINGS and NOTES are not exhaustive. It is not possible to know, evaluate and
advise the service trade of ALL conceivable ways in which service might be carried out, or, of the possible
hazardous consequences of each way. Consequently, no such broad evaluation has been undertaken.
Accordingly, anyone who uses a service procedure, or tool, which is not recommended, must first satisfy
themselves thoroughly that neither their safety, nor vehicle safety, will be jeopardized by the service
method he/she selects.
Two types of heading are used in this manual to attract your attention.
1. WARNING - This symbol is used when an operating procedure, practice, etc., which, if not correctly
followed could result in personal injury or loss of life. Look for this symbol to point out important safety
precautions. It means - ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
2. Note - This is used when an operating procedure, practice, etc., which, if not strictly observed, could result in
damage to or destruction of equipment.
IMPORTANT SAFETY NOTICE
WARNING
Never use parts which are altered, modified, or weakened in operation. This can seriously jeopardize
the integrity of the machine and could result in property damage or serious personal injury.
THIS PAGE IS INTENTIONALLY LEFT BLANK
SM 2355 Rev 5 06-05
1
TABLE OF CONTENTS
Section No. Description SM No.
000 GENERAL INFORMATION
0000 Technical Data - TA40 2255 Rev 3
0010 Welding Procedure 2172
100 CHASSIS
0010 Frames 1372 Rev 1
0020 Articulation and Oscillation Pivot 2273
0040 Hood and Mounting 2120
110 ENGINE
0030 Engine and Mounting 2121 Rev 1
0050 Air Cleaner 2122 Rev 1
120 TRANSMISSION
0010 Transmission and Mounting 2124 Rev 3
130 DRIVELINES
0010 Front Drivelines 1378 Rev 2
0020 Rear Drivelines 1379 Rev 2
140 FRONT AXLE GROUP
0020 Axle Group (Hub) (Refer to Section 160-0030) -
0040 Wheel Rim and Tyre (Refer to Section 160-0050) -
0060 Differential Drive Head (Refer to Section 160-0020) -
150 CENTRE AXLE
0020 Differential Drive Head 2249
160 REAR AXLE GROUP
0020 Differential Drive Head 2248
0030 Axle Group (Hub) 2256
0050 Wheel Rim and Tyre 2247 Rev 1
165 BRAKE ASSEMBLY
0015 Oil Cooled Disc Brakes 2257 Rev 1
170 PARKING BRAKE
0010 Parking Brake and Mounting 2253
0030 Actuator 2166 Rev 1
180 SUSPENSION SYSTEM
0020 Front Suspension 2119
0040 Rear Suspension From A8421011 to A8421065 1384 Rev 2
0040 Rear Suspension From A8421066 2340
190 ELECTRICAL SYSTEM
0000 Circuit Diagrams (DDEC IV, 6WG 310 transmission) 2258
0270 Switches and Sensors 2259
200 FUEL SYSTEM
0040 Fuel System 1398 Rev 2
0051 Electronic Foot Pedal 1399
SM 2355 Rev 5 06-05
2
* * * *
TABLE OF CONTENTS
Section No. Description SM No.
210 COOLING SYSTEM
0000 Cooling System (Series 60 Engine) 2260
0005 Cooling System Schematic 2261
0010 Cooling Fan and Motor 2116
0040 Radiator and Mounting 2118 rev 1
0045 Low Temperature Unloader Valve 2152
0050 Disc Brake Oil Cooler 2153
0060 Transmission Oil Cooler 1922 Rev 2
0100 Hydraulic Oil Cooler 1403 Rev 1
220 STEERING SYSTEM
0000 Steering System Schematic 1390 Rev 2
0090 Steering Valve 1391
0100 Flow Amplifier Valve 1392 Rev 3
0120 Steering Cylinder 1393 Rev 1
0140 Emergency Valve 1395 Rev 1
230 BODY SYSTEM
0000 Body System Schematic 1407 Rev 2
0040 Hydraulic Tank 1913 Rev 2
0050 Main Hydraulic Pump 1394 Rev 1
0060 Body Control Valve 1410 Rev 2
0081 Body Control Joystick 1411 Rev 2
0121 Pilot Supply Valve 1448 Rev 1
0130 Body Cylinder 1409 Rev 1
250 BRAKING SYSTEM
0000 Braking System Schematic 2155 Rev 2
0025 Brake Coolant Tank 2270
0040 Triple Pump 2271
0045 Motor/Triple Pump Assembly 2272
0050 Brake Manifold Valve 2158
0060 Accumulator 2160
0065 Two Speed Control Valve 2159
0070 Treadle Valve 2165 Rev 2
0075 Priority Unloader Valve 2161
0090 Directional Control Valve 2254
0120 Relief Valve 2163
260 OPERATORS COMPARTMENT
0010 Cab and Mounting 1404 Rev 2
0090 Driver Seat and Mounting 1981
0130 Air Conditioning 1405 Rev 2
270 BODY
0010 Body and Mounting 1406 Rev 2
300 MISCELLANEOUS
0020 Lubrication System 2129 Rev 4
0070 Service Tools 2277 Rev 1
0080 Standard Bolt and Nut Torque Specifications 1238
0090 Unit Storage 1239
1
Section 000-0000
SM 2255 Rev 3 03-05
SM - 3303
GENERAL INFORMATION - Technical Data
ENGINE
Make/Model .................................... Detroit Diesel Series 60
Type .............. Four cycle diesel, turbocharged with air-to-air
charge cooling, water cooled. Electronic management.
Gross power at 2 200 rev/min ...... 332 kW (445 hp, 451 PS)
Net power at 2 200 rev/min .......... 291 kW (390 hp, 395 PS)
Note: Net power is after deductions for alternator. Engine
emission meets Tier II USA EPA/CARB MOH 40 CFR 89
and EU NRMM (non-road mobile machinery) directive.
Maximum Torque.............................. 2 000 Nm (1 475 lbf ft)
at 1 350 rev/min
Number of cylinders/configuration ............ 6 cylinder, in line
Bore and Stroke .................... 130 x 160 mm (5.12 x 6.30 in)
Total Displacement ................................. 12.7 litres (774 in)
Air cleaner .................................... Dry type, double element
Starting ..................................................................... Electric
Maximum Speed (No load) ............................ 2 325 rev/min
Maximum Speed (Full load) ........................... 2 200 rev/min
Idle Speed ......................................................... 700 rev/min
Maximum Operating Slope........................ 30 (57% Grade)
TRANSMISSION
Make/Model ..................................... ZF 6WG 310 Automatic
with manual override. The transmission consists of a
torque converter close-coupled to a 6 speed gearbox with
integral output transfer gearing. Automatic shifting
throughout the range, with kickdown feature. Lockup in
all forward gears. A torque-proportioning output
differential transmits drive permanently to front and rear
axles. This differential may be locked by the driver for
use in difficult traction conditions. Integral hydraulic
retarder.
Pressures:
Main ....................................... 16 + 2 bar (232 + 30 lbf/in)
Lockup (Wk) ........................ 14
+
/- 1 bar (190
+
/- 15 lbf/in)
Converter 'IN' ........... 7.6 bar (110 lbf/in) at 2 300 rev/min
Converter 'OUT' .......... 4.8 bar (70 lbf/in) at 2 300 rev/min
Converter Relief Valve ....................... 8.5 bar (123 lbf/in)
Retarder ................................................... 6 bar (87 lbf/in)
Temperatures:
Normal ................................... 80 - 110 C (176 - 230 F)
Maximum .................................................. 120 C (248 F)
Stall Speed ............................................. 1 835 50 rev/min
Fig. 1 - Machine Dimensions
Dimensions in mm (ft-in)
3 020
(9-11)
3 220
( 10-7 )
45 Vehicle Clearance
Turning Diameter
19.5m (64ft)
3 430
(11-3)
3 720
(12-2)
560
(1-10)
3 450
(11-4)
3 670
(12-0)
2 540
(8-4)
1 600
(5-3)
3 000
(9-10)
10 650
(34-11)
28
6 500
(21-4)
5 700 (18-8)
65
2 240
(7-4)
675
(2-3)
3 100
(10-2)
25
1 540
(5-0)
1 970
(6-6)
5 370 (17-7)
Max
Body
Depth
1 450
(4-9)
2 640
(8-8)
1 810
(5-11)
525
(1-9)
General Information - Technical Data
Section 000-0000
SM 2255 Rev 3 03-05
2
BRAKES
Full hydraulic braking system with enclosed, forced oil-
cooled multiple discs on each wheel. Independent circuits
for front and rear brake systems. Warning lights and
audible alarm indicate low brake system pressure. Brake
system conforms to ISO 3450, SAE J1473.
Actuating Pressure ................ 48 2.4 bar (700 35 lbf/in)
Pump Type ................................................ Triple stage gear
Capacity at 2 200 rev/min ... 1.98 litre/s (31.4 US gal/min)
combined
Braking surface (tractor) ....... 590240 mm
2
(914.9 in
2
)/brake
Braking surface (trailer) ........ 590240 mm
2
(914.9 in
2
)/brake
Parking: Spring-applied, hydraulic-released disc on
rear driveline.
Emergency: Automatic application of driveline brake
should pressure fall in main brake hydraulic
system. Service brakes may also be applied
using the parking-emergency brake control.
Retardation: Hydraulic retarder integral with transmission.
WHEELS AND TYRES
Wheels ...... Five-piece Earthmover rims with 23 Stud Fixing
Size:
Standard ....................... 25 x 25.00 in for 29.5 R25** tyres
Tyres:
Standard ............................................... 29.5 R25** Radial
Inflation Pressures (Bridgestone):
Front Rear
29.5 R25** 3.5 bar (51 lbf/in) 4.25 bar (62 lbf/in)
Inflation Pressures (Continental):
Front Rear
Inflation Pressures (Michelin):
Front Rear
Note: Tyre pressures should be regarded as nominal only.
It is recommended that for tyres both listed and unlisted, the
user should consult the tyre manufacturer and evaluate all
job conditions in order to make the proper selection.
HYDRAULIC SYSTEM
Steering and Body Hoist
Ratios:
Torque Converter .................................................... 1.84:1
Transmission .................................... Refer to table below.
Forward
Gear 1 2 3 4 5 6
km/h 6.2 9.5 14.9 23.2 34.0 51.7
mile/h 3.8 5.9 9.2 14.4 21.1 32.1
Reverse
Gear 1 2 3
km/h 6.2 14.9 34
mile/h 3.8 9.2 21.1
Note: During reversing operations it is recommended to
reduce engine speed, use only 1st or 2nd gear and never
exceed 10 km/h (6.2 mile/h).
AXLES
Three axles in permanent all-wheel drive with differential
coupling between each axle to prevent driveline wind-up.
Heavy duty axles with fully-floating axle shafts and outboard
planetary gearing.
Automatic limited slip differentials in each axle. Leading
rear axle incorporates a through-drive differential to transmit
drive to the rearmost axle. Locking of this differential is
actuated simultaneously with the transmission output
differential lock.
Ratios:
Differential ............................................................... 3.70:1
Planetary ................................................................. 6.35:1
Total Reduction ..................................................... 23.51:1
SUSPENSION
Front: Axle located by a leading A-frame permitting both
vertical movement and oscillation. Rubber cone
suspension medium with heavy duty hydraulic dampers.
Axle Vertical Travel .................................. 105 mm (4.2 in)
Rear: Each axle is coupled to the frame by three rubber-
bushed links with lateral restraint by a transverse link.
Pivoting inter-axle balance beams equalise load on each
rear axle. Suspension movement is cushioned by rubber/
metal laminated compression units between each axle
and underside of balance beam ends. Pivot points on rear
suspension linkages are rubber-bushed and
maintenance-free.
Axle Vertical Travel ............................ 115 mm ( 4.5 in)
Axle Oscillation ............................................................ 9
The steering and body hydraulic systems are supplied
with oil from a common tank by the main hydraulic gear
pump. Pump is driven from power takeoff on transmission.
The components are protected by advanced full flow
filtration to 5 micron particle size on the return line.
Pump capacity (at 2258 rpm) ..................... 7.03 litre/s
(111 US gal/min)
3
Section 000-0000
SM 2255 Rev 3 03-05
General Information - Technical Data
Steering
Hydrostatic power steering by two double-acting,
cushioned steering cylinders. Actuating pressure for
steering operation is supplied by the main hydraulic gear
pump.
Emergency steering pressure is provided by a ground
driven pump mounted on the transmission. An indicator
lamp signals should the emergency system activate.
Conforms to SAE J53.
System pressure ................................. 206 bar (3000 lbf/in)
Steering Angle (left and right) ......................................... 45
Lock to Lock Turns, steering wheel .................................... 4
Clearance Turning Diameter (SAE) ................ 19.5 m (64 ft)
Body
Two single-stage, double-acting hoist cylinders, cushioned
at both ends of stroke. Electro servo assisted hoist control.
Actuating pressure for body hoist is supplied by the main
hydraulic gear pump.
System pressure ................................. 172 bar (2500 lbf/in)
Control Valve .......................... Pilot Operated, Open Centre
Body Raise Time (loaded) ......................................... 16 sec
Body Lower Time (power down) ................................ 12 sec
ELECTRICAL SYSTEM
Type ............................................. 24 volt, Negative Ground.
Battery ......... Two, 12 Volt, 175 Ah each, Maintenance Free
Accessories ............................................................... 24 Volt
Alternator .................................................................. 70 Amp
BODY
All welded construction, fabricated from high hardness
(min. 360 BHN) 1 000 MPa (145 000 lbf/in) yield strength
steel. 25 tail chute angle provides good load retention
without tailgate.
Plate Thicknesses:
Floor and Tailchute................................... 15.0 mm (0.59 in)
Sides ......................................................... 12.0 mm (0.47 in)
Front .......................................................... 10.0 mm (0.39 in)
Volume:
Struck (SAE) ............................................ 17.0 m (22.2 yd)
Heaped 2:1 (SAE) ................................... 22.0 m (28.8 yd)
* * * *
VEHICLE WEIGHTS
Standard Vehicle kg lb
Net Distribution
Front Axle 15 275 33 675
Centre Axle 7 750 17 085
Rear Axle 7 705 16 985
Net Weight 30 730 67 745
Payload 36 500 80 470
Gross Distribution
Front Axle 20 170 44 465
Centre Axle 23 530 51 875
Rear Axle 23 530 51 875
Gross Weight 67 230 148 215
Bare Chassis 24 670 54 390
Body 5 400 11 905
Body Hoists (pair) 660 1 455
SERVICE CAPACITIES
Fuel tank .......................................... 463 litres (122 US gal)
Hydraulic System
(Steering, Braking & Body) ................ 209 litres (55 US gal)
Brake Cooling System.................... 175 litres (46.2 US gal)
Cooling System ................................ 80 litres (21.1 US gal)
Engine Crankcase (with filters) .......... 37 litres (9.8 US gal)
Transmission (with filters) ................. 56 litres (14.8 US gal)
Differentials......................................... 31 litres (8.2 US gal)
Planetaries ........................................... 9 litres (2.4 US gal)
Driveshaft Bearings ........................... 1.5 litres (0.4 US gal)
Air Conditioning Compressor .... 0.125 litres (0.033 US gal)
Ground Pressures
At 15% sinkage of unloaded radius and specified weights
29,5 R25 Net Loaded
Front 102 kPa (14.8 psi) 135 kPa (19.6 psi)
Rear 52 kPa (7.5 psi) 158 kPa (22.9 psi)
Section 000-0010
SM 2172 10-02 1
Welding
WARNINGS
Before any welding is done on a machine
equipped with any electronic systems,
disconnect the following (if applicable) in this
order: Battery earth cable, battery supply
cable, alternator earth cables, alternator supply
cables and electrical connections at the engine
ECM, transmission ECU, body control lever,
hydraulics ECU and cab bulkhead to avoid
damage to electrical components. Turn off
battery master switch to isolate the batteries
before disconnecting any components.
After welding connect all of the above in the
reverse order.
Before any welding is done ensure all paint has
been removed from the area to be welded.
Failure to do so may result in hazardous fumes
being given off from the paint.
Note: Always fasten the welding machines ground
cable to the piece/frame being welded if possible.
Electric arc welding is recommended for all welded
frame repairs. Since the nature and extent of damage
to the frame cannot be predetermined, no definite
repair procedure can be established. As a general rule
however, if parts are twisted, bent or pulled apart, or a
frame is bent or out of alignment, no welding should be
done until the parts are straightened or realigned.
Successfully welded repairs will depend to a great
extent upon the use of the proper equipment, materials
and the ability of the welder. The Customer Support
Department can be consulted regarding the feasibility
of welding repairs.
WARNING
Welding and flame cutting cadmium plated
metals produce odourless fumes which are
toxic. Recommended industrial hygiene
practice for protection of the welding operator
from the cadmium fumes and metallic oxides
requires enclosure ventilation specifically
designed for the welding process. A
respiratory protective device such as the
M.S.A. 'Gasfoe' respirator with G.M.A. cartridge
will provide protection against cadmium,
fumes and metallic oxides. The 'Gasfoe'
respirator has been approved by the U.S.
Bureau of Mines: Approval number 23B-10,
and is designed to protect against gases,
vapours, and/or metal fumes.
Note: The current from the welding rod always follows
the path of least resistance. If, for example, the ground
clamp is attached to the rear frame when welding is
performed on the front frame, the current must pass a
frame connection to return to the welding machine.
Since the pivot coupling offers the least resistance but
not a sound electrical connection, small electric arcs
may be set up across the moving parts which may
cause welding blotches on their wearing surfaces and
increase the wear rate of these components.
General Welding Procedure
The following general procedure should be used for
the repair of defects outwith the vicinity of alloy steel
castings.
1. Completely ARC-AIR gouge or grind out the crack
until sound metal is reached. If ARC-AIR method is
employed, pre-heat area to 100 C (212 F), measure
3 - 4" either side of repair prior to gouging. On
completion of gouging grind to remove thin carbon
layer.
2. Apply dye-penetrant check to ensure crack has
been completely removed.
GENERAL INFORMATION - Welding Procedure
General Information - Welding Procedure
Section 000-0010
SM 2172 10-02 2
3. Pre-heat area to 100 C (212 F), measured 3 - 4"
either side of repair. Avoid local overheating.
4. Weld completely using E-7016 electrodes. Care
must be taken to ensure electrodes are protected from
moisture pick-ups at all times.
5. Allow repair weld to cool slowly.
6. Grind and blend repair to original contour. Paint
heat damaged areas.
The following general procedure should be used for
the repair of defects in alloy steel castings and in the
welds joining steel castings.
1. Completely ARC-AIR gouge or grind out the crack
until sound metal is reached. If ARC-AIR method is
employed, pre-heat area to 200 C (392 F), measure
3 - 4" either side of repair prior to gouging. On
completion of gouging grind to remove thin carbon
layer.
2. Apply dye-penetrant check to ensure crack has
been completely removed.
3. Pre-heat area to 200 C (392 F), measured 3 - 4"
either side of repair. Avoid local overheating.
4. Weld completely using E-7016 electrodes. Care
must be taken to ensure electrodes are protected from
moisture pick-ups at all times.
5. On completion of welding, post-heat repair area to
400 C (752 F), measure 3 - 4" either side of repair.
6. If welding has to be interrupted for any reason, e.g.
overnight, post-heat immediately as in Step 5.
* * * *
Section 100-0010
1 SM 1372 Rev 1 2-00
SM - 1859
CHASSIS - Frames
DESCRIPTION
The front and rear frames are all-welded high grade
steel fabrications, with rectangular box section beams
forming the main side and cross-members. These
heavy duty structures are designed to withstand the
severe loadings incurred when operating over rough
terrain.
The front frame houses engine, transmission,
hydraulic and fuel tanks and carries the cab, front
suspension and front drive axle. The rear frame
carries the body, body cylinders, rear suspension
system and the rear drive axles.
Inter-frame oscillation is provided by a robust
cylindrical coupling, carried on large nylon bushes.
Steering is by frame articulation to 45 degrees either
side by two widely spaced vertical pivot pins in taper
roller bearings.
Note: For details on the articulation and oscillation
pivot and procedures for separating the front and rear
frames, refer to Section 100-0020, ARTICULATION
AND OSCILLATION PIVOT.
MAINTENANCE
Note: This section covers maintenance of the front
and rear frames only.
Inspection
Inspect the frames and attached parts at intervals not
exceeding 250 hours for cracked or broken welds and
bending of the frame. Any defects found should be
repaired before they progress into major failures.
Fig. 1 - General Arrangement of Frame Assemblies
2 SM 1372 Rev 1 2-00
Chassis - Frames
Section 100-0010
Straightening
If the frame is not too badly sprung or twisted,
hydraulic straightening and aligning equipment can be
used to straighten the frame without dismantling the
machine. However, if the frame is severely damaged,
it will be necessary to disassemble the machine in
order to repair or replace the frame assembly.
All straightening operations should be performed
without application of heat if possible. If heat must be
applied, do not heat the metal beyond a dull cherry red
colour, as it will result in serious weakening of the
frame by decreasing the tensile strength of the steel.
When it is necessary to apply heat, apply it uniformly
over the area to be straightened until the metal
reaches a uniform colour. Protect the heated surface
from drafts to prevent sudden cooling of the metal. If
the frame or frame parts cannot be straightened they
must be replaced.
Welding
WARNINGS
equipped with the DDEC system, disconnect
wiring harnesses at the ECM, connections at
body hydraulics joystick, all battery
connections at both positive and negative
terminals and ground cable to alternator to
avoid damage to electrical components. Turn
battery master switch to the 'Off' position
Remove battery ground cable first, and
reconnect last, to avoid damaging electrical
components.
Before any welding is done ensure all paint
has been removed from the area to be welded.
Failure to do so may result in hazardous fumes
being given off from the paint.
Note: Prior to welding, switch off/disconnect the
following in the order given. Failure to do so may
seriously damage the machines electrical
components.
a - Turn keyswitch off
b - Turn battery master switch off
c - Battery earth cables
d - Battery supply cables
e - Alternator earth cables
f - Alternator supply cables
g - Body hydraulics joystick
h - Transmission (Est-37) connector
i - ECM interface harness connector (30 pin RHS)
j - ECM power harness connector (5 pin RHS)
k - ECM sensor harness connector (30 pin LHS)
l - ECM engine to transmission datalink connector
(6 pin RHS)
After welding, connect all of the above in the reverse
order.
Note: Always fasten the welding machines ground
cable to the piece/frame being welded if possible.
Electric arc welding is recommended for all welded
frame repairs. Since the nature and extent of damage
to the frame cannot be predetermined, no definite
repair procedure can be established. As a general rule
however, if parts are twisted, bent or pulled apart, or a
frame is bent or out of alignment, no welding should be
done until the parts are straightened or realigned.
Successfully welded repairs will depend to a great
extent upon the use of the proper equipment, materials
and the ability of the welder. The Service Department
can be consulted regarding the feasibility of welding
repairs.
Reinforcement
Frame reinforcement can be made with channel, angle
or flat structural stock. Whenever possible, the
reinforcement should extend well beyond the bent,
broken or cracked area. The reinforcement stock
thickness should not exceed that of the frame stock
and the material should be of the same tensile
strength.
Painting
To keep rust and corrosion to a minimum, periodic
painting of abrasions and other exposed metal areas
on the frames is highly recommended.
If painting of a frame is required, thoroughly clean the
areas to be painted. Apply a primer coat of synthetic
red oxide and then a finish coat of synthetic enamel.
* * * *
Section 100-0020
SM 2273 03-04
1
DESCRIPTION AND OPERATION
The articulation and oscillation pivot allows the front
and rear frames to rotate horizontally (articulation) and
tilt laterally (oscillation) with respect to each other. It is
also the main load bearing coupling between the two
frames. The pivot assembly houses the driveshaft
connecting the drive between the front and rear frames.
Articulation bearings, oscillation bushes, pivot
driveshaft bearing and associated parts can be
removed, inspected and replaced or renewed by
following the procedures outlined in this section.
Fig. 1 - Articulation and Oscillation Pivot
SM - 3109
CHASSIS - Articulation and Oscillation Pivot
1 - Pivot Assembly
2 - Nylon Bush
3 - Loctite 648
4 - Loc Quick Primer
5 - Gasket
6 - Cover Plate
7 - Bolt
8 - Bearing Assy - Cup
9 - Bearing Assy - Cone
10 - 'V' Ring Seal
11 - Thrust Nut
12 - Locking Plate
13 - Antiseize Comp
14 - Driveshaft
15 - Seal
55 - Lube Fitting
56 - Elbow
57 - Adaptor
58 - Connector
59 - Elbow
60 - Pipe Assembly
61 - Washer
62 - Bolt
63 - Thrust collar-Rear
64 - Shim
65 - Shim
66 - Shim
67 - Shim
68 - Shim
41 - Washer
42 - Nut
43 - Lower Pin
44 - Hardened Washer
45 - Washer
46 - Bolt
47 - Bolt
48 - Bolt
49 - Loctite 243
50 - Thrustcollar-Front
51 - 'O' Ring
52 - Hose Assembly
53 - Hose Assembly
54 - Connector
27 - Lube Fitting
28 - Plug
29 - 'O' Ring
30 - Bearing Assembly
31 - Retaining Ring
32 - Seal Housing
33 - Seal Housing
34 - Seal Housing
35 - Seal Housing
36 - Seal
37 - Seal
38 - Shim
39 - Spacer
40 - Upper Pin
16 - Lockplate
17 - Front Yoke
18 - Brake Yoke
19 - Bolt
20 - Washer
21 - Lockwasher
22 - Bolt
23 - Extreme Pressure
Lithium No.2 Grease
24 - SAE 80W-90 EP
Gear Oil
25 - Plug
26 - Extreme Pressure
Multipurpose Grease
42
41
45,46,49
32
30
23
38
33
36,49 40 28
39
36,49
45,47,49
1
43
44,48,49
37,49
35
38
30,23
34
45,46,49 45,47,49
37,49
10,26
25
51
17
19
50
16
29
14 24
15
8,9
31
26,56
52,55
26,53
54,55
56
2,3,4 2,3,4
10,26
11
60
13
57,58,59
18
16
51
19
64-68
63
29
31
8,9
15
21,22
12
25
5,6
7
20
25
27
55
56
56
52
56
53
54
DETAIL A
19
17
14 8,9
16
50
51 29
49,61,62
Section 100-0020
Chassis - Articulation and Oscillation Pivot
SM 2273 03-04
2
THRU-DRIVE DRIVESHAFT
Numbers in parentheses refer to Fig. 1, unless
otherwise specified.
Note: The following procedures assume that only
thru-drive components require repair.
Note: Tighten all fasteners without special torques
specified to torques listed in Section 300-0080,
STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
WARNINGS
To prevent personal injury and property
damage, be sure wheel blocks are properly
secured and of adequate capacity to do the job
safely.
When necessary to drive out or drive on
components during disassembly/assembly, be
sure to use a soft drift to prevent property
damage and personal injury.
Removal and Disassembly
1. Position the vehicle on a level work area and apply
parking brake.
2. Raise body and install body safety prop to secure
body in partially raised position.
3. Shut down engine and block all wheels securely.
4. Identify the relationship of the driveline caps to the
transmission yoke and front yoke (17). Remove
capscrews and remove driveline from vehicle.
Note: Take extra care when handling drivelines as
any deformity on a rotating mass creates vibration
and excessive wear during any operation.
5. Remove wheel blocks, start engine and steer
vehicle into a full left-hand lock. Shut down engine
and block all wheels securely.
6. Remove Lockplate (16) , 2 0ff Front bolts (19) &
Front thrust collar (50).
7. Remove and discard 'O' rings (29 & 51) from Thrust
collar (50).
8. Place a suitable container under the front of the
pivot and pull front yoke (17) from driveshaft (14).
9. Disconnect mounting hardware securing protective
guard (if fitted), from beneath the parking brake disc, to
the rear frame.
10. Release the parking brake by turning the hex-head
on the parking brake actuator fully anticlockwise.
WARNING
Tensioned spring on adjuster.
11. Remove mounting hardware securing parking
brake assembly to mounting bracket on frame, then
secure parking brake assembly clear of brake disc.
12. Identify the relationship of the driveline caps to
brake yoke (18). Remove capscrews, disconnect
driveline and secure clear of brake yoke.
13. Withdraw driveshaft assembly (14) from housing
by pulling rearwards on parking brake disc/brake
yoke assembly (18). If necessary, tap front end of
driveshaft (14) to ease removal, take care to avoid
damaging threads. Place driveshaft (14) assembly on
work bench for further disassembly.
14. Prise out and discard seal (15) from front of the
housing.
15. Lift out front bearing assembly cup (8) from front
of the housing.
16. If bearing replacement is required, use a suitable
puller to remove front and rear bearing assembly
cups (8) from the housing.
Note: If either bearing assembly cup or cone (8 or 9)
need replacing, they must be replaced as a set.
17. If retaining rings (31) need replacing, use a
suitable drift or puller to remove them from the housing.
18.Temporarily install front yoke (17) fully onto front of
driveshaft (14) and suitably restrain to resist rotation.
19. Remove mounting hardware securing parking
brake disc to brake yoke (18) and remove brake disc.
20. Remove Lockplate (16) , 2 off Rear bolts (19) ,
Rear Thrust collar (63) & Brake yoke (18) from
driveshaft (14). Identify front and rear ends of
driveshaft (14).
21. Remove and discard 'O' rings (29 & 51) from Rear
Thrust collar (63).
Section 100-0020
SM 2273 03-04
3
6. Refer to Fig. 2, Maintain end face of cone approximately
55mm from end of spline face.
7. Insert driveshaft (14) into truck end of pivot casing
until bearing assembly cone (9) seats firmly in the
bearing asembly cup (8).
8. Apply loctite (3) to new seal (15) and fit over the
driveshaft (14) with seal 'Lip' to bearing side.Press seal
home using a mandrel.
9. Apply grease to splines of Front yoke (17) and slide
onto the drive shaft (14).
10. Fit new 'O'-rings ( 29 & 51) to Front thrust collar
(50) and fit collar over stub end of driveshaft (14) (align
mating holes). Fit 2 off front bolts (19).
11. Tighten Front bolts (19) ; alternately 1/4 - 1/2 turns,
drawing driveshaft (14) hard against the inner face of
Front thrust collar (50). Shaft will be visible through
inspection hole on the collar.
12. Lock Front yoke (17) from rotation by a suitable
method / bar acting on the ground. Torque front bolts
(19) to 54Nm/39 Ibf ft.
13. Using special mandrel (15270104) home locking
plate (16) onto Bolts (19). Remove the clamping bar.
14. Slide Rear bearing asembly cone (9) onto rear end
of drive shaft (14) until it seats in bearing assembly
cup (8).
15. Position clamping bar assembly and screw central
bolt hard against bolts (19) of front thrust collar (50),
enabling body end bearing to be fully seated home.
16. Using mandrel and heavy hammer, drive Rear
bearing assembly cone, fully into cup. Now remove
clamp bar assembly from front end.
22. Remove and discard seal (15) from driveshaft (14).
23. If bearing replacement is required, use a suitable
puller or drift to remove rear bearing assembly cone (9)
from driveshaft (14).
Inspection
1. Clean all parts with a suitable solvent and let dry.
DO NOT spin bearings with compressed air. Place
bearings on a clean surface, cover with a lint free
cloth and allow to dry.
2. Check bearing assemblies cups and cones (8 & 9)
for wear or damage. Renew as necessary.
Note: If either bearing assembly cup or cone (8 or 9)
need replacing, they must be replaced as a set.
3. Inspect splines of driveshaft (14) and yokes
(17 & 18) for nicks, burrs or excessive wear. Replace
if wear is excessive or splines are nicked. Burrs may
be removed with a fine file or medium India stone.
4. Check yokes (17 & 18) for damage in region
polished by oil seal lip; even slight damage in this
area can cause leakage. Very slight marks may be
polished out with fine emery cloth but it is essential
that polishing marks are parallel to the seal lip.
5. Replace all seals and 'O' rings with new parts.
Assembly and Installation
1. If removed, use a suitable driver and install retaining
rings (31) into housing, ensuring that they butt hard
against abutment shoulders.
2. Using a suitable driver, install front bearing cup (8)
into tractor end of pivot casing. Ensure it is firmly
seated & that a 0.05mm (0.002") feeler gauge cannot
be inserted between cup and mating face.
3. Check rear bearing cup (8) is firmly seated in the
body end of the pivot casing, again ensuring 0.05mm
(0.002") feeler gauge cannot be inserted between cup
and mating face.
4. Lightly oil both bearing assembly cones (9) with SAE
80W - 90 E. P. gear oil (24).
5. Support driveshaft (14) in a suitable fixture & tap one
Bearing assembly cone (9) onto driveshaft (14) using a
tubular mandrel.
9
14
55mm
SM - 3143
Fig. 2 - Pre assembly of bearing
Section 100-0020
SM 2273 03-04
4
22. The actual free air space 'E' to be shimmed
between end of drive shaft (14) and compression face
of Thrust collar (63) equals:
E='D' - 'C'.
23. Now add 0.6mm (0.024") to dimension 'E' to allow
for oversize shims. This value is dimension 'F'
(End float will be determined by subtraction).
24. Remove Rear bolts (19) and Rear thrust collar (63)
from pivot body end and chap drive shaft (14) to free
bearing.
25. Calculate the nominal combination of minimum
number if shims (64) to achieve the size nearest to
dimension 'F'. Record the appropriate part numbers and
total nominal thickness value.
26. Select the shims (64) and measure the total actual
thickness of the combination. Record this value.
27. Place the shim pack (64) in the rear thrust collar
(63) , lock off the Brake yoke (18) from rotation by
suitable method / bar on ground. Torque bolts (19) to
full torque.
28. Remove the clamp and spin the yoke (18) to
ensure driveshaft (14) free rotation.
29. Take a magnetic clock gauge located on the flange
of pivot casing, needle acting on rear thrust collar (63)
17. Take remaining seal (15), apply loctite (3) and fit
over drive shaft with seal 'Lip' to bearing side. Press
seal home using a mandrel.
18. Apply grease to splines of brake yoke (18) and
slide onto drive shaft (14). Ensure milled slots of
driving flanges are aligned with those of brake yoke.
Note : For Measurment letters- refer to fig. 3, unless
otherwise stated.
19. Before fitting of Rear Thrust collar (63) record
Measurements as stated:
i) Measure total width 'A' of Rear thrust collar (63)
ii) Using Depth micrometer, measure inner bore depth
'B' of collar (63) and record value.
iii) Subtract 'B' from 'A' to determine recess dimension
'C'.
20. Fit Rear thrust collar (63) without 'O'-rings onto
Drive shaft (14) and tighten Rear bolts (19) to a nominal
torque of 15Nm/11Ibf ft.
Note : a gap should be visible between end of shaft
and inner face of collar.
21. Using a Depth micrometer, measure distance 'D'
from collar (63) outer face to end face of drive shaft
(14) via the hole in the collar and record the value.
'E' ('D' - 'C')
'D'
'A'
'B'
'C'
SHAFT
SHIM AREA
DEPTH
MICROMETER
Fig. 3 - Measurements / various
Sm 3144
Section 100-0020
SM 2273 03-04
5
43. Remove plug (25) from underside of oscillation hub
to drain the cavity between the oscillation hub and
pivot assembly (1) of any oil that entered while filling
the driveshaft bearing housing.
44. Install plug (25) into filler/level hole on pivot
assembly (1). Install gasket (5) and cover plate (6) on
side of oscillation hub, secure with bolts (7) and
washers (20).
45. Install plug (25) into cavity drain port on underside
of oscillation hub.
46. Install parking brake disc protective guard (if fitted)
and secure with bolts, washers and nuts. Tighten nuts
to a torque of 73 Nm (54 lbf ft).
47. Start engine, raise body, lower body safety prop
and lower body.
48. Remove wheel blocks.
ARTICULATION COMPONENTS
Note: The following procedures assume that only
components associated with articulation require repair.
Note: It is essential that the grease used for articulation
components is Extreme Pressure Lithium Complex No. 2
(23), as specified in Section 300-0020, LUBRICATION
SYSTEM.
SPECIFICATIONS.
WARNINGS
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
safely.
end face. Check Brake yoke (18) float movement.
30. Take reading obtained and subtract a figure
sufficient to give an end float in the range 0.05mm -
0.15mm (0.002" - 0.006"), reduce shim pack (64)
accordingly.
31. Remove Rear thrust collar (63) and shims (64) and
re-assemble with the apporpriate shims. Ensure 'O'-
rings (29 & 51) are now fitted.
32. Lock Brake yoke (18) flange as before ,applying
alternate 1/4 -1/2 turns on bolts (19). Torque to 54 Nm
(39 Ibf ft).
33. Remove the locking bar and confirm that the
driveshaft (14) end float is in the range 0.05mm -
0.15mm (0.002" - 0.006") by moving the brake yoke
(18) for and aft against the clock gauge.
34. Adjust and refit the shim pack (63) as necessary.
35. Float set correctly; Drive home locking plate (16)
using a mandrel (15270104) . Re-check the end float.
36. Install parking brake disc on brake yoke (18) and
secure with bolts and washers. Tighten bolts to a
torque of 73 Nm (54 lbf ft).
37. Install parking brake assembly to mounting
brackets and secure with bolts, washers and nuts.
Refer to Section 170-0010, PARKING BRAKE AND
MOUNTING.
38. Apply parking brake by turning the hex-head on the
parking brake actuator fully clockwise.
39. Apply Loctite 638 to the threads of capscrews used
to mount driveline to brake yoke (18). Align match
marks and install driveline. Tighten capscrews to a
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).
41. Remove bolts (7), washers (20), gasket (5) and
cover plate (6) from side of oscillation hub to gain
access to filler/level hole plug (25) on pivot assembly
(1). Remove filler/level plug (25).
42. Add SAE 80W - 90 E. P. gear oil (24) through filler/
level hole in pivot assembly (1) until the oil is level with
the bottom of filler/level hole.
Section 100-0020
SM 2273 03-04
6
Disconnecting Front and Rear Frames
Note: The front and rear frames can be separated
sufficiently to permit disassembly/assembly of the
articulation components without disconnecting
hydraulic lines or electrical wiring.
parking brake.
capscrews and remove driveline from vehicle.
5. Support tractor frame at front and rear with suitably
placed stands or timbers so the frame will remain level
during and after pin removal.
6. Remove bolts, washers and pins securing steering
cylinders to pivot. Secure steering cylinders clear of
pivot.
7. Release the parking brake by turning the hex-head
on the parking brake actuator fully anticlockwise.
WARNING
8. Attach suitable lifting equipment to pivot/rear frame
assembly. Lifting equipment must prevent pivot from
oscillating after separation, and, be capable of pulling
pivot/rear frame assembly clear of front frame. Raise
lifting equipment to support pivot/rear frame assembly.
9. Remove bolt (62), washer (61), large nut (42) and
washer (41) securing upper pin (40).
10. Remove upper pin (40). If necessary tap upper pin
(40) to ease removal taking care to avoid damaging the
threads.
Note: It may be necessary to relieve binding between
the pin and pin bores by raising or lowering the pivot/
rear frame assembly.
11. Remove bolt (48) and hardened washer (44)
securing lower pin (43).
12. Remove lower pin (43). If necessary tap lower pin
pin.
Note: Only separate the frames sufficiently to permit
removal of the articulation bearings or damage to
hydraulic and electrical connections could result.
13. Remove blocks from rear wheels and use lifting
equipment to pull pivot/rear frame assembly clear of
the front frame. After moving, block pivot/rear frame
assembly and block the wheels.
14. Remove spacer (39) noting orientation to ensure
correct installation.
Disassembly
1. Identify seal housings (32, 33, 34 & 35) to ensure
correct location on assembly/installation.
Note: Seal housings (32, 33, 34 & 35) are not
interchangeable.
2. Remove bolts (46 & 47), washers (45), seal housings
(32, 33, 34 & 35) and upper and lower shims (38).
3. Prise out and discard seals (36 & 37) from the
housings.
4. Remove and tag all bearing assemblies (30) with
spacers to ensure correct assembly/installation.
Note: Bearing assemblies (30) and spacers are a
matched set, never interchange cups, cones or
spacers between sets.
Inspection
1. Clean all parts with a suitable solvent and let dry.
DO NOT spin bearings with compressed air. Place
bearings on a clean surface, cover with a lint free cloth
Fig. 4 - Determining Shim Thickness
SM - 008
Section 100-0020
SM 2273 03-04
7
and allow to dry.
2. Check bearing assemblies (30) and spacers, and
pins (40 & 43) for wear or damage. Renew as
necessary.
Note: Bearing assemblies (30) and spacers must be
renewed as a matched set.
3. Replace all seals with new parts.
Assembly
1. Apply Loctite 243 (49) sparingly to bore of seal
housings (32, 33, 34 & 35).
2. Using a suitable driver, install seals (36 & 37) into
seal housings (32, 33, 34 & 35) ensuring that the metal
ring on inside of the seals are not disturbed, and, that
they are located towards the inside of seal housing.
3. Apply Loctite 243 (49) to threads of outer seal
housing bolts (46).
4. Place outer seal housings (32 & 34) in position
ensuring that grease relief hole in seal housings are
directly opposite bearing grease port on pivot. Secure
with bolts (46) and washers (45). Tighten bolts (46) to a
Note: Bearing assemblies (30) and spacers are a
matched set, never interchange cups, cones or
spacers between sets.
5. Using Extreme Pressure Lithium Complex No. 2
grease (23), pack bearing assemblies (30), including
end faces, and install bearings.
6. Place inner seal housings (33 & 35) temporarily in
position and secure with bolts (47) and washers (45).
Tighten bolts (47) to a torque of 16 Nm (12 lbf ft).
7. Using feeler gauges, as shown in Fig. 4, measure
the dimension between the inner pivot faces and seal
housings (33 & 35). Measure at 3 positions equally
spaced around seal housings and determine average
dimension, this is the size of shims (38) required.
8. Remove bolts (47), washers (45) and inner seal
housings (33 & 35).
9. Install shims (38) as calculated at Step 7, reinstall
inner seal housings (33 & 35) and secure with bolts
(47) and washers (45). Tighten bolts (47) to a torque of
94 Nm (68 lbf ft).
Connecting Front and Rear Frames
1. Install spacer (39) in upper outer seal housing (32),
as noted on removal.
2. Smear bearing and pin bores with Extreme Pressure
Lithium Complex No. 2 grease (23).
oscillating and be capable of pulling pivot/rear frame
assembly to align pivot bearing bores and front frame
pin bores. Raise lifting equipment to support pivot/rear
frame assembly.
4. Remove blocks from rear wheels and blocking from
pivot/rear frame assembly. Using lifting equipment, pull
pivot/rear frame assembly to align pivot bearing bores
and front frame pin bores. Block wheels and block
pivot/rear frame assembly to remain level and
stationary.
5. Freeze upper and lower pins (40 & 43) to ease
installation.
6. Smear lower pin (43) with Extreme Pressure Lithium
Complex No. 2 grease (23) and install through front
frame and bearing bores.
the pin and pin bores by raising or lowering pivot/rear
frame assembly.
7. Apply Loctite 243 (49) to threads of bolt (48) and
secure lower pin (43) with bolt (48) and hardened
washer (44). Tighten bolt (48) to a torque of 73 Nm
(54 lbf ft).
8. Smear upper pin (40) with Extreme Pressure Lithium
9. Apply Loctite 243 (49) to threads of bolt (62). Secure
upper pin (40) with bolt (62), washer (61), large nut (42)
and washer (41). Tighten nut (42) to a torque of 1 425
Nm (1 050 lbf ft).
Final Assembly
2. Remove lifting equipment from pivot/rear frame
assembly.
3. Remove stands or timbers from front frame.
Section 100-0020
SM 2273 03-04
8
to mount driveline between transmission yoke and front
5. Align steering cylinder bores and mounting pin bores
on pivot, install pins and secure with bolts and
washers. Tighten bolts to a torque of 73 Nm (54 lbf ft).
6. Remove plugs (28) from articulation bearing, grease
ports and replace with lube fittings (27).
Note: Lube fittings (27) are stored on pad on side of
pivot assembly (1).
7. Fill bearing housings with Extreme Pressure Lithium
Complex No. 2 grease (23), through lube fittings (27),
until excess grease starts to escape from seal
housings (32 & 34).
8. Remove lube fittings (27) and reinstall plugs (28).
Store lube fittings (27) on pad on side of pivot
assembly (1).
9. Start engine, raise body, lower body safety prop and
lower body.
OSCILLATION COMPONENTS
Numbers in parentheses refer to Fig. 1.
Note: The following procedure assumes that only
components associated with oscillation require repair.
Note: It is necessary to disconnect the front and rear
frames at the articulation point to service the
oscillation components.
Note: It is essential that the grease used for
oscillation components is Extreme Pressure
Multipurpose Grease (26), as specified in Section 300-
0020, LUBRICATION SYSTEM.
SPECIFICATIONS.
WARNINGS
To prevent personal injury and property damage,
be sure wheel blocks, blocking materials and
SM - 038
Fig. 5 - Preventing Pivot Assembly From Oscillating
lifting equipment are properly secured and of
adequate capacity to do the job safely.
Hydraulic fluid pressure will remain
within the braking system after engine shut
down. Operate the treadle pedal continuously
until the pressure has dissipated before
carrying out any work on the braking system
or serious injury could result.
Disconnecting Front and Rear Frames
parking brake.
4. Depress and release brake pedal continuously to
relieve the pressure in the braking system.
5. Carefully loosen brake lines at base of both
accumulators to check that the pressure has
released. Re-tighten brake lines.
6. Tag all hydraulic lines and electrical wiring between
front and rear frames to ensure correct assembly/
installation. Disconnect all hydraulic lines and plug
openings to prevent ingress of dirt. Disconnect
electrical wiring and any other attachments which could
be damaged on separation of front and rear frames.
Section 100-0020
SM 2273 03-04
9
capscrews and remove driveline from the vehicle.
8. Support tractor frame at front and rear with suitably
placed stands or timbers to keep the frame level during
and after pin removal.
9. Remove bolts, washers and pins securing steering
cylinders to pivot. Secure steering cylinders clear of
pivot.
10. Release the parking brake by turning the hex-
head on the parking brake actuator fully anticlockwise.
WARNING
oscillating after separation, and, be capable of pulling
pivot/rear assembly clear of front frame. Raise lifting
equipment to support pivot/rear frame assembly.
12. Remove bolt, washer, large nut (42) and washer
(41) securing upper pin (40).
13. Remove upper pin (40). If necessary tap upper pin
(40) to ease removal taking care to avoid damaging
the threads.
the pin and pin bores by raising or lowering the pivot/
rear frame assembly.
14. Remove bolt (48) and hardened washer (44)
securing lower pin (43).
15. Remove lower pin (43). If necessary tap lower pin
pin.
16. Remove blocks from rear wheels and use lifting
equipment to pull pivot/rear frame assembly clear of
the front frame. After moving, block pivot/rear frame
assembly and block the wheels.
17. Remove spacer (39) noting orientation to ensure
correct installation. Cover articulation bearings to
prevent ingress of dirt.
Disassembly
1. Remove protective guard (if fitted) from beneath
parking brake disc by removing mounting hardware
securing guard to the rear frame. Refer to
Section 170-0010, PARKING BRAKE AND
MOUNTING.
2. Remove mounting hardware securing parking brake
assembly to mounting bracket on frame. Remove and
secure parking brake assembly clear of brake disc.
3. Identify the relationship of the driveline caps to
brake yoke (18). Remove capscrews, disconnect
driveline and secure clear of brake yoke (18).
4. Remove mounting hardware securing parking brake
disc to brake yoke (18) and remove brake disc.
5. Place a suitable container under rear brake yoke (18)
to catch oil released when pulling brake yoke (18) from
driveshaft (14).
6. Remove Rear bolts (19), Lockplate (16) & Rear
thrust collar (63). Pull brake yoke (18) from driveshaft
(14) .
7. Remove adaptor (57), connector (58), elbow (59)
and pipe assembly (60) from oscillation hub.
8. Remove bolts (22) and washers (21) securing
locking plate (12). Remove locking plate (12).
9. Restrain pivot assembly (1) to prevent it oscillating,
by placing a heavy bar between the steering cylinder
mountings. Lock the bar in position using suitable
trestles or stands. See Fig. 5.
10. Using a suitable tool, remove thrust nut (11). If
wear area of thrust nut (11) is damaged, replace thrust
nut (11).
11. Insert an M20 eyebolt into tapped pad provided on
top of pivot assembly (1) and attach suitable lifting
equipment.
12. Remove pivot restraining bar.
13. Using lifting equipment, carefully pull pivot
assembly (1) clear of oscillation hub. Place pivot
assembly (1) in a suitable work area for further
disassembly.
14. Note position of front 'V' ring (10) to aid in
'Installation'. Remove and discard 'V' ring (10).
15. Inspect nylon oscillation bushes (2) as described in
'Inspection'. If bushes are to be renewed, proceed with
step 16.
16. Remove nylon oscillation bushes (2) with hammer
and chisel.
Section 100-0020
SM 2273 03-04
10
Note: The suggested method is to make an axial cut
along the bush then to lever the bush in order to
collapse it upon itself.
Inspection
1. Clean nylon oscillation bushes with a suitable
solvent and allow to dry.
2. Inspect nylon oscillation bushes for wear, scoring,
erosion and 'out of round'. Pay particular attention to
the thrust faces of the bushes which should also be
inspected for cracking/splitting. Renew if required.
3. Replace all seals with new parts.
Assembly
SPECIFICATIONS.
WARNING
safely.
1. Wipe bush housing clean using a suitable solvent
and allow to dry.
2. Apply Loctite 648 (3) and Loc Quick Primer (4) and
align new bushes (2) to housing with grease holes
aligned vertically and identification 'PAINT DOT' at Top
Dead Centre. Refer to Fig. 6. Drift bushes (2) into
housing using hammer with soft packing for protection.
3. Install plug (25) in filler/level hole on pivot assembly
(1). Install gasket (5) and cover plate (6) on side of
oscillation hub and secure with bolts (7) and washers
(20).
4. Install plug (25) in cavity drain port on underside of
oscillation hub.
5. Install plugs (28) into oscillation bearing grease
ports.
6. Lightly coat 'V' ring (10) and machined surfaces of
pivot with Extreme Pressure Multipurpose Grease (26)
and, install 'V' ring (10), with lip towards rear, on front of
oscillation hub.
7. Using suitable lifting equipment, and taking care to
prevent damaging bushes (2) or pivot threads, install
pivot assembly (1) into rear frame.
8. Lightly coat 'V' ring (10) and machined surfaces of
pivot with Extreme Pressure Multipurpose Grease (26)
and, install 'V' ring (10), with lip towards front, on rear of
oscillation hub.
9 . a) Restrain pivot assembly (1) to prevent it
oscillating, by placing a heavy bar between the steering
cylinder mountings. Lock the bar in position using
suitable trestles or stands. See Fig. 5.
b) Secure a suitable tool to pivot thrust nut (11) and
tighten thrust nut (11) until there is no end float/
clearance at thrust face of either bush. Slacken thrust
nut (11) until pin of the locking plate (12) can be
inserted in the first available hole in the thrust nut (11).
c) Secure locking plate (12) with bolts (22) and
lockwashers (21). Torque tighten bolts (22) to 94 Nm
(69 lbf ft).
10. Install adaptor (57), connector (58), elbow (59) and
pipe assembly (60) to oscillation hub.
11. Install brake yoke (18) on driveshaft (14) until it
butts against bearing assembly cup and cone (8 & 9).
12. Install parking brake disc on brake yoke (18) and
secure with bolts, washers and nuts. Tighten bolts to a
13. Install rear of driveshaft (14).
14. install Brake yoke (18) , Rear thrust collar (63)
ensuring 'O'-rings (29& 51) are in place , shim pack (64)
and bolts (19).
Fig. 6 - Installing Oscillation Bushes
SM - 011
PAINT DOT
Section 100-0020
SM 2273 03-04
11
15. Lock off Brake yoke flange as before (18) with
suitable clamping method. Torque bolts (19) to 73 Nm
(Ibf ft)
16. Take a magnetic clock gauge located on the flange
of pivot casing , needle acting on Rear thrust collar (63)
end face. Check Brake yoke (18) float movement.
Ensure still within range 0.05mm - 0.15mm (0.002" -
0.006").
17. If float is incorrect, alter arrangement of shim pack
(64) to bring within size.
18. Using special mandrel (15270104) home locking
plate (16) onto bolts (19). Remove clamping bar.
Connecting Front and Rear Frames
1. Install spacer (39) in upper bearing assembly (30) as
noted on removal.
2. Smear bearing assembly (30) and pin bores with
Extreme Pressure Lithium Complex No. 2 grease (23).
oscillating and be capable of pulling pivot/rear frame
assembly to align pivot bearing bores and front frame
pin bores. Raise lifting equipment to support pivot/rear
frame assembly.
4. Remove blocks from rear wheels and blocking from
pivot/rear frame assembly. Using lifting equipment, pull
pivot/rear frame assembly to align pivot bearing bores
and front frame pin bores. Block wheels and block
pivot/rear frame assembly to remain level and
stationary.
5. Freeze upper and lower pins (40 & 43) to ease
installation.
the pin and pin bores by raising or lowering pivot/rear
frame assembly.
6. Smear lower pin (43) with Extreme Pressure Lithium
lower pin (43) with bolt (48) and hardened washer (44).
Tighten bolt (48) to a torque of 73 Nm
(54 lbf ft).
8. Smear upper pin (40) with Extreme Pressure Lithium
upper pin (40) with bolt (62), washer (61), washer (41)
and large nut (42). Tighten nut (42) to a torque of 1 425
Nm (1 050 lbf ft).
Final Assembly
1. Install parking brake assembly to mounting
brackets and secure with bolts, washers and nuts.
MOUNTING.
WARNING
3. Remove lifting equipment from pivot/rear frame
assembly.
4. Remove stands or timbers from front frame.
5. Apply Loctite 270 to threads of capscrews used to
mount driveline between transmission yoke and front
6. Align match marks and reconnect driveline to brake
yoke (18). Tighten capscrews to a torque of
153 Nm (113 lbf ft).
Note: Take extra care when handling drivelines as
chips, dents, burrs or deformity on any rotating mass
creates vibration and excessive wear during any
operation.
7. Align steering cylinder bores and mounting pin bores
on pivot. Install pins and secure with bolts and washers.
Tighten bolts to a torque of 73 Nm (54 lbf ft).
8. Connect hydraulic lines and electrical wiring as
noted on disassembly.
access to filler/level plug (25) on pivot assembly (1).
Remove filler/level plug (25).
Section 100-0020
SM 2273 03-04
12
12. Install plug (25) in filler/level hole on pivot
washers (20).
13. Install plug (25) in cavity drain port on underside of
oscillation hub.
14. Remove plugs (28) from articulation bearing grease
pivot assembly (1).
15. Fill bearing housings with Extreme Pressure
Lithium Complex No. 2 grease (23) through lube fittings
(27) until excess grease starts to escape from seal
housings (32 & 34).
Store grease fittings (27) on pad on side of pivot
assembly (1).
17. Add Extreme Pressure Multipurpose grease (26) to
oscillation bushing lube fittings (55) on top of oscillation
hub. Lube until excess grease in seen.
and secure with bolts, washers and nuts. Tighten nuts
19. Start engine to charge hydraulic systems, raise
body, lower body safety prop and lower the body.
20. Bleed the braking system as described in Section
165-0010, BRAKE PARTS.
MAINTENANCE
Every 250 hours, oscillation bushes must be
lubricated. Add Extreme Pressure Multipurpose grease
(26) to oscillation bushing lube fittings (55) on top of
oscillation hub. Lube until excess grease in seen.
WARNING
safely.
Every 250 hours, check the end float/clearance at the
thrust face of the oscillation bushes. Any clearance
found must be removed by adjustment of the thrust
nut, as described in step 9 of 'Assembly' procedure.
Note: A practical method of establishing the effective
adjustment of the thrust nut is to use movement of the
machines body in the raised position. Move the body
from fully raised to almost fully raised while watching
the effect of this action on the frame and pivot
arrangement. Any slackness between the thrust nut
and thrust faces will be clearly visible movement of the
frame.
Every 1 000 hours (6 months), follow the procedure
given below to check the oil level in the driveshaft
bearing housing, and, lubricate the articulation and
oscillation bearings.
Note: It is essential that the grease used for
articulation components is Extreme Pressure Lithium
Complex No. 2 grease (23), as specified in Section
300-0020, LUBRICATION SYSTEM.
parking brake.
4. Remove protective guard (if fitted) from beneath
parking brake disc by removing nuts, washers and
bolts securing guard to rear frame.
access to filler/level plug (25) on pivot assembly (1).
Remove filler/level plug (25).
Section 100-0020
SM 2273 03-04
13
8. Install plug (25) into filler/level hole on pivot
washers (20).
9. Install plug (25) into cavity drain port on underside of
oscillation hub.
10. Remove plugs (28) from articulation bearing grease
pivot assembly (1).
11. Fill bearing housings with Extreme Pressure
Lithium Complex No. 2 grease (23) through lube fittings
(27) until excess grease starts to escape from seal
housings (32 & 34).
Store grease fittings (27) on pad on side of pivot
assembly (1).
13. Add Extreme Pressure Multipurpose grease (26) to
oscillation bushing lube fittings (55) on top of oscillation
hub. Lube until excess grease in seen.
and secure with bolts, washers and nuts. Torque
tighten nuts to 73 Nm (54 lbf ft).
15. Start engine, raise body, lower body safety prop
and lower body.
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.
Section 100-0020
SM 2273 03-04
14
* * * *
SPECIAL TORQUE SPECIFICATIONS
TORQUE
FIG. No. ITEM No. ITEM NAME Nm lbf ft
1 19 Nut (to seat bearing only) 250 180
1 22 Bolt 94 69
1 42 Nut 1 425 1 050
1 46 & 47 Bolt 94 68
1 48 Bolt 73 54
- - Parking Brake Disc Bolts 73 54
- - Parking Brake Brkt Mounting Nuts 680 490
- - Driveline Mounting Capscrews 153 113
- - Protective Guard Mounting Nuts 73 54
- - Steering Cylinder Pin Bolts 73 54
Section 100-0040
SM 2120 2-02
1
HOOD
Removal
WARNING
damage, be sure blocking materials and lifting
equipment are properly secured and of
1. Position the machine on a level surface, apply the
parking brake and switch off the engine.
2. Block all road wheels and place the battery master
switch in the 'Off' position.
3. Remove bolts (30) and lockwashers (31) securing
grille (29) to grille subframe (7). Secure grille (29) clear
of hood (1).
4. Pull cable assembly (22), handle inside cab, to
release hood catch and lift up hood (1). Secure hood
(1) in raised position using suitable lifting equipment.
5. Carefully remove bolts (34), hardened washers (35),
tubes (36 & 37), washers (38), lockwashers (39) and
nuts (40).
SM - 2675
Fig 1 - Hood and Mounting
25 - Bolt
26 - Bolt
27 - Washer
28 - Locknut
29 - Grille
30 - Bolt
31 - Lockwasher
32 - Gas Strut
33 - Hood Strap
34 - Bolt
36 - Tube
13 - Washer
14 - Hoodcatch Kit
15 - Bolt
16 - Locknut
17 - Bolt
18 - Washer
20 - Hood Stop
21 - Spring
22 - Cable Assembly
23 - Plate
24 - Goalpost Assembly
1 - Hood
2 - Handle - LH
3 - Bolt
4 - Washer
5 - Bolt
6 - Washer
7 - Grille Subframe
8 - Hinge Assembly
9 - Plate
10 - Bolt
11 - Locknut
12 - Washer
37 - Tube
38 - Washer
39 - Lockwasher
40 - Locknut
41 - Hood Blanking Piece
42 - Bolt
43 - Washer
45 - Locknut
46 - Hood Safety Bar
47 - Bolt
48 - Locknut
14
1
4
42
41
43
44
45
3
2
24
23
22
25
12
13
13
12
11
34
35
48
46
32
37
37
36
36
47
2
5
6
15
20
21
16
17
19
18
16
38
39
40
33
35
34
FRAME
HOOD
10
9
9
8
8
26
27
28
7
29
30
31
CHASSIS - Hood and Mounting
Chassis - Hood and Mounting
Section 100-0040
SM 2120 2-02 2
GOALPOST ASSEMBLY
Removal
WARNING
1. Position the machine on a level surface, apply the
switch in the off position.
3. Pull cable assembly (22), handle inside cab, to
release hood catch and lift up hood (1).
4. Remove mounting hardware securing washer bottle
to mounting bracket on the left hand side of goalpost
assembly (24). Secure washer bottle clear of goalpost
assembly (24).
5. With a suitable container available to catch leakage,
remove drain plug from radiator header tank and drain
coolant. Apply Loctite 225 to drain plug and reinstall in
header tank.
6. Ensure all cooling lines connected to header tank
are identified for ease of installation and with suitable
containers available to catch leakage, disconnect
cooling lines. Fit blanking caps to all open lines.
7. Note routing of all hoses and harnesses attached to
goalpost assembly (24) and disconnect.
8. Disconnect ball joint from cam assembly in
hoodcatch kit (14) and secure cable assembly (22)
clear of lock mechanism.
9. Check to make certain that all necessary line and
cable disconnections have been made, before lifting
goalpost assembly (24).
10. Attach suitable lifting equipment to goalpost
assembly (24). Remove bolts (25), washers (12),
washers (13) and locknuts (11) securing goalpost
assembly (24) to its mounting. Lift goalpost assembly
(24) from the machine.
6. Remove hood straps (33) and gas struts (32) from
hood.
7. Remove bolts (26), washers (27) and nuts (28)
securing hinges (8) to frame and lift hood (1) assembly
from the machine.
8. If required, remove bolts (3) and washers (4)
securing grille subframe (7) to hood (1). Secure grille
subframe (7) clear of hood.
9. If required, remove mounting hardware (5 & 6)
securing handle (2) to hood (1). Secure handle (2)
clear of hood (1).
Installation
Note: Tighten all fasteners to torques listed in
Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.
WARNING
1. If removed, secure handle (2) to hood (1) using
mounting hardware (5 & 6) as removed at 'Removal'.
2. If removed, secure grille subframe (7) to hood (1)
with bolts (3) and washers (4).
3. Using suitable lifting equipment, lift and position
hood (1) on the machine and align holes in hinges (8)
with mounting holes on frame. Secure hood (1) using
bolts (26), washers (27) and locknuts (28).
4. Carefully install hood straps (33) and gas struts (32)
using mounting hardware (34 - 40) as removed at
'Removal'.
5. Remove lifting equipment and lower hood (1) to
match with goalpost assembly (24).
6. Install grille (29) to hood (1) and secure using bolts
(30) and lockwashers (31).
Section 100-0040
SM 2120 2-02
3
11. If required, remove locknuts (16), bolts (15), hood
stops (20) and springs (21) from goalpost assembly
(24).
12. If required, remove mounting hardware securing
hood blanking piece (41) to right hand fender. Remove
hood blanking piece (41) from the machine.
Installation
WARNING
1. If removed, secure hood blanking piece (41) to right
hand fender with mounting hardware as removed at
'Removal'.
2. If removed, secure hood stops (20) and springs (21)
to goalpost assembly (24) with bolts (15) and locknuts
(16).
3. Using suitable lifting equipment, lift and position
goalpost assembly (24) on the machine. Secure
goalpost assembly (24) to its mounting with bolts (25),
washers (12), washers (13) and locknuts (11).
4. Remove lifting equipment.
5. Connect ball joint to cam assembly in hoodcatch kit
(14) and secure cable assembly (22) using clips
removed during 'Removal'.
6. Install washer bottle to mounting bracket on the left
hand side of goalpost assembly (24) and secure using
mounting hardware as removed during 'Removal'.
7. Remove blanking caps from all cooling lines and
connect cooling lines to radiator header tank as tagged
at 'Removal'.
8. Secure all hoses and harnesses to goalpost
assembly (24) following routing as noted at 'Removal'.
9. Fill radiator header tank with coolant as specified in
Section 210-0000, COOLING SYSTEM.
10. Lubricate hood catch mechanism. Use grease as
specified in Section 300-0020, LUBRICATION
SYSTEM.
11. Lower hood assembly and check for correct
alignment between hood (1) and goalpost assembly
(24) and for operation of hood catch mechanism.
MAINTENANCE
Periodically check bolts (26), washers (27) and
locknuts (28) and tighten when necessary.
Periodically check condition of lock mechanism and
adjust and lubricate when necessary.
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.
Chassis - Hood and Mounting
* * * *
Section 110-0030
SM 2121 Rev 1 11-03
1
ENGINE - Engine and Mounting
SM - 2676
DESCRIPTION
For engine make, model and specification, refer to
Section 000-0000, GENERAL INFORMATION. For
engine servicing and repair data refer to the engine
manufacturers service manual.
The engine is mounted to the tractor frame at three
points by a mounting bracket at the front of engine (1)
and two rear mounts (18 & 19). Rubber isolation
mounts (28) through engine mounts provide sufficient
flexibility to absorb varying engine vibration and
torsional loads.
There are two full-flow oil filters (2) mounted on the
right hand side of engine (1) in a downward position.
The filters are of the throw away, spin-on type. Oil
supplied by the engine oil pump passes through oil
filters (2) before reaching the various moving parts of
engine (1). The oil is forced by pump pressure through
a passage in the filter adaptor and into the elements.
Impurities are filtered out as the oil passes through the
elements and out through another passage in the filter
adaptor.
Engine coolant filter (3) and conditioner is a compact
bypass type unit with a replaceable spin-on type
element mounted on the gear case cover at the front
right hand side of engine (1). Refer to Section
Fig. 1 - Engine and Mounting
1 - Engine
2 - Oil Filter
3 - Coolant Filter
4 - Primary Fuel Filter
5 - Secondary Fuel Filter
6 - Dipstick
7 - Engine Coupling
8 - Snubbing Washer
9 - Washer
10 - Nut
11 - Bolt
12 - Bolt
13 - Bolt
14 - 'V' Belt
15 - Bolt
16 - Plate
17 - Screw Assembly
18 - Rear LH Mount
19 - Rear RH Mount
20 - Link
21 - Bolt
22 - Bushing
23 - Connector
24 - Link
25 - Washer
26 - Bolt
27 - Lockwasher
28 - Isolation Mount
29 - Bolt
30 - Step
31 - Lockwasher
32 - Bolt
33 - Washer
34 - Nut
35 - Pin
36 - Bolt
37 - Washer
38 - Bolt
39 - Washer
40 - Locknut
41 - Locknut
42 - Clip
43 - Alternator
26
27
40 39 38
24
34 35
20
37
36
41
29
8
28
9
10
21
25
18 LH
19 RH
15
2
7
23
22
ON ENGINE LHS
8
13
28
8
10
3
4 5
14
16
33
12
31 32
30
42
1
9
31
32
6
17
43
Section 110-0030
Engine - Engine and Mounting
SM 2121 Rev 1 11-03
2
210-0000, COOLING SYSTEM.
There are two spin-on type fuel filters mounted on the
left hand side of engine (1). Primary fuel filter (4) is in
the fuel flow and acts as a strainer and secondary fuel
filter (5) filters the fuel after having passed through
primary fuel filter (4). The word 'Primary' or 'Secondary
is cast into the top of the respective adaptor to prevent
mismatching.
DETROIT DIESEL ELECTRONIC
CONTROL (DDEC)
Description
Refer to Fig. 2.
WARNING
equipped with the DDEC system, disconnect
the following in this order:
Battery earth cable, battery supply cable,
alternator earth cables, alternator supply
cables, body hydraulics joystick, transmission
(Est-37) connector, ECM interface harness
connector (30 pin RHS), ECM sensor harness
connector (30 pin LHS) and ECM engine to
transmission datalink connector (6 pin RHS).
Turn off battery master switch before
disconnecting any components.
After welding connect all of the above in the
reverse order.
The engine is equipped with DDEC which controls the
timing and amount of fuel injection by the electronic
unit injectors (EUI). The system also monitors
several engine functions using electrical sensors
which send electrical signals to the electronic control
module (ECM). The ECM then computes the
incoming data and determines the correct fuel output
and timing for optimum power, fuel economy and
emissions.
The DDEC system also takes action to prevent
damage to the engine and, provides the serviceman
with diagnostic capabilities so that problems can be
corrected quickly and easily.
1. Electronic Control Module (ECM) - Receives
electronic inputs from the driver as well as from
mounted sensors that provide information
electronically, such as oil pressure and temperature
and intake manifold pressure. This information is used
to control both the quantity of fuel injected and injection
timing.
2. Programmable Read Only Memory (PROM) -
Located in the ECM and encoded with the operating
software. Additional information is programmed into
the EEPROM. This information controls the
horsepower rating, torque curve, maximum engine
speed and engine protection devices. The ECM
processes this information and sends electronic
signals to the Electronic Unit Injectors (EUI) where the
precise amount of fuel is injected into the engine.
3. Electronic Unit Injectors (EUI) - The EUI is a
lightweight, compact unit that injects diesel fuel directly
into the combustion chamber. The amount of fuel
injected and the beginning of injection timing is
determined by the ECM. The ECM sends a command
pulse which activates the injector solenoid.
The EUI performs four functions:
a - Creates the high fuel pressure required for efficient
injection.
b - Meters and injects the exact amount of fuel
required to handle the load.
c - Atomizes the fuel for mixing with the air in the
combustion chamber.
d - Permits continuous fuel flow for component cooling.
Electronic unit injectors are self compensating and
virtually eliminate engine tune-ups.
Note: Never apply 12 V directly to terminals on the
injector or engine sensors as they will burn out. Before
removing injectors, the fuel passages must be blown
out to prevent fuel flow from entering the cylinder
head.
4. Batteries - Two 12 volt maintenance free batteries
supply the machine with electrical power to operate all
electrical components.
5. Electronic Foot Pedal - The electronic foot pedal
provides an electrical signal to the engine's fuel control
system in proportion to the degree of pedal actuation.
Note: The DDEC controlled engine will override the
electronic foot pedal position until the engine is warmed
up to the correct operating temperature. The engine
MUST be started with foot 'OFF' the electronic foot
pedal.
6. Check Engine Light - When the 'Check Engine' light
comes on, the computer has detected a fault in the
Section 110-0030
SM 2121 Rev 1 11-03
3
engine. The fault should be diagnosed and corrected at
the earliest opportunity.
7. Stop Engine Light - When the 'Stop Engine' light
comes on, the computer has detected a major
malfunction in the engine that requires immediate
attention. It is the operators responsibility to shut down
the engine to avoid serious damage.
8. Diagnostic Request/Stop Engine Override
Switch - Operates as a diagnostic request switch
when:
a - the engine is not running and ignition is 'On'.
b - the engine is idling and not in an engine protection
condition.
Pressing and releasing the switch will flash out the
engine codes. Pressing the switch a second time will
stop the engine codes flashing.
Note: Inactive codes are displayed on Check Engine
Light and active codes are displayed on Stop Engine
Light. Code 25 means no codes present.
Operates as a Stop Engine Override Switch when the
engine is in a rampdown protection mode for any of the
following:
Low Coolant Level
High Coolant Temperature
Low Oil Pressure
High Oil Temperature
9. Diagnostic Test Point - Plug in connector for
diagnostic data reader (DDR).
Operation
The machine is equipped with the DDEC engine
protection system, which records the stop engine
malfunction in ECM (1). The stop engine and check
engine lights illuminate when the engine protection
system is initiated. The engine will immediately reduce
to 70% of the available torque. Rampdown then
commences over a 30 second period and reduces the
engine to 40% of the available torque.
SM - 1840
Fig. 2 - DDEC Components
1 - Electronic Control Module (ECM)
2 - Programmable Read Only Memory (PROM)
3 - Electronic Unit Injectors (EUI)
4 - Batteries
5 - Electronic Foot Pedal
6 - Check Engine Light
7 - Stop Engine Light
8 - Diagnostic Request/Stop
Engine Override Switch
9 - Diagnostic Test Point
8
6
7
5
3
1,2
4
P
1 2
STOP
9
Section 110-0030
SM 2121 Rev 1 11-03
4
To allow for the possibility of the engine protection
system being activated while the machine is operating
in a critical situation, a stop engine override switch (8)
is provided. If the switch is pressed and released
during rampdown, the 30 second timer will reset,
restoring torque to the level immediately following
illumination of stop engine (7) and check engine (6)
lights. The switch must be pressed and released again
to obtain a subsequent override.
Note: The operator must continue to reset the
automatic engine protection system by pressing and
releasing stop engine override switch (8) at intervals of
approximately 15 to 20 seconds.
Note: ECM (1) will record the number of times the
override is activated after the fault occurs. Available
Torque is the actual torque available from the engine
when the fault occurred based on the actual rev/min
when the fault occurred.
The engine should not be restarted after it has been
shut down after activation of the engine protection
system unless the problem has been diagnosed and
corrected.
Conditions that will cause the Stop Engine Light to
come on are; Low Coolant Level, High Coolant
Temperature, Low Oil Pressure and High Oil
Temperature.
Whenever check engine light (6) or stop engine light
(7) comes on, the DDEC computer will determine
where the problem is and will store this information in
its memory. If the malfunction is intermittent, the lights
will come on and go off as the computer senses the
changing engine condition.
A special diagnostic data reader (DDR) is available that
can be plugged into the engine computer memory to
extract information related to the cause of the problem.
Once the malfunction has been corrected, the DDEC
system will return the engine to normal operation. The
DDR can now distinguish between active codes and
those stored in the historic code memory. The
malfunction code recorded in ECM (1) memory will
remain until it is erased by a technician.
WARNINGS
The operator of a DDEC-equipped vehicle must
not attempt to use or read a DDR of any kind
while the vehicle is operating. Doing so can
result in loss of control, which may cause
vehicle damage and may result in personal
injury.
When engine or electronics system
diagnosis is required on a DDEC-equipped
vehicle, this must be done by a person other
than the operator. The operator must maintain
control of the moving vehicle while the
assistant performs the diagnosis.
When the engine is not running and the ignition is on,
or, the engine is idling and not in an engine protection
condition, engine faults can be diagnosed by the
operator. Pressing and releasing diagnostic request
switch (8) will cause check engine light (6) or stop
engine light (7) to flash a code number indicating the
fault, e.g. flash twice - pause - flash five times - pause
indicates a code 25. Code 25 indicates all systems are
operating correctly. Pressing the switch a second time
will stop the engine codes flashing. Refer to 'DDEC III
& IV Diagnostic Codes' table for other code
descriptions.
Note: Only one light will be flashing at any one time.
When code flashing is initiated, the active codes (or
code 25) will be flashed on stop engine light (7), then
the inactive codes (or code 25) will be flashed on
check engine light (6). When all of the inactive codes
have been flashed, the process of flashing the codes
will repeat until the conditions for code flashing are no
longer satisfied.
Section 110-0030
SM 2121 Rev 1 11-03
5
DDECIII & IV DIAGNOSTIC CODES
DDEC Code #
(Flashed) PID SID FMI DDEC Description
- 240 - 2 Fram checksum incorrect
- 251 - 10 Clock module abnormal rate
- 251 - 13 Clock module fault/failure
- - 253 13 Incompatible calibration version
- - 254 0 External failed RAM
- - 254 1 Internal failed RAM
- - 254 6 Entered boot via switches
11 187 - 4 VSG sensor voltage low
11 187 - 7 VSG switch system not responding
12 187 - 3 VSG sensor high
13 111 - 4 Coolant level sensor input voltage low
13 111 - 6 Add coolant level sensor input voltage low
14 52 - 3 Intercooler coolant temperature sensor input voltage high
14 110 - 3 Coolant temperature sensor input voltage high
14 175 - 3 Oil temperature sensor input voltage high
15 52 - 4 Intercooler coolant temperature sensor input voltage low
15 110 - 4 Coolant temperature sensor input voltage low
15 175 - 4 Oil temperature sensor input voltage low
16 111 - 3 Coolant level sensor input voltage high
16 111 - 5 Add coolant level sensor input voltage high
17 72 - 3 Throttle plate position sensor input voltage high
17 51 - 3 Throttle position sensor input voltage high
18 72 - 4 Bypass position sensor input voltage low
18 51 - 4 Throttle plate position sensor input voltage low
21 91 - 3 TPS input voltage high
22 91 - 4 TPS input voltage low
23 174 - 3 Fuel temperature sensor input voltage high
23 - 65 3 Oxygen content circuit input voltage high
24 174 - 4 Fuel temperature sensor input voltage low
24 - 65 4 Oxygen content circuit input voltage low
25 - - - Reserved for 'No Codes'
26 - 25 1 Auxiliary shutdown #1 active
26 - 61 11 Auxiliary shutdown #2 active
27 171 - 3 Ambient air temperature sensor input voltage high
(Release 2.00 or later only)
27 172 - 3 Air temperature sensor input voltage high
27 105 - 3 Intake manifold temperature sensor input voltage high
28 171 - 4 Ambient air temperature circuit failed low (Release 2.00
or later only)
28 172 - 4 Air temperature sensor input voltage low
28 105 - 4 Intake manifold temperature sensor input voltage low
31 - 51 3 Aux. output #3 open circuit (high side) - S3
31 - 51 4 Aux. output #3 short to ground (high side) - S3
31 - 51 7 Aux. output #3 mechanical system fail - S3
31 - 52 3 Aux. output #4 open circuit (high side) - T3
31 - 52 4 Aux. output #4 short to ground (high side) - T3
31 - 52 7 Aux. output #4 mechanical system fail - T3
32 - 238 4 SEL open circuit
32 - 238 3 SEL short to battery (+)
32 - 239 3 CEL short to battery (+)
32 - 239 4 CEL open circuit
Section 110-0030
SM 2121 Rev 1 11-03
6
DDEC III & IV DIAGNOSTIC CODES
DDEC Code #
33 102 - 3 Turbo boost pressure sensor input voltage high
34 102 - 4 Turbo boost pressure sensor input voltage low
35 100 - 3 Oil pressure sensor input voltage high
35 19 - 3 High range oil pressure sensor input voltage high
36 100 - 4 Oil pressure sensor input voltage low
36 19 - 4 High range oil pressure sensor input voltage low
37 94 - 3 Fuel pressure sensor input voltage high
37 18 - 3 High range fuel pressure sensor input voltage high
37 95 - 3 Fuel restriction sensor input voltage high
38 94 4 Fuel pressure sensor input voltage low
38 18 - 4 High range fuel pressure sensor input voltage low
38 95 - 4 Fuel restriction sensor input voltage low
41 - 21 0 Too many SRS (missing TRS)
42 - 21 1 Too few SRS (missing SRS)
43 111 - 1 Coolant level low
44 52 - 0 Intercooler coolant temperature high
44 110 - 0 Coolant temperature high
44 172 - 0 Air inlet temperature high
44 175 - 0 Oil temperature high
44 105 - 0 Intake manifold temperature high
45 100 - 1 Oil pressure low
45 19 - 1 High range oil pressure low
46 168 - 1 ECM battery voltage low
46 - 232 1 Sensor supply voltage low
47 94 - 0 Fuel pressure high
47 102 - 0 Turbo boost pressure high
47 106 - 0 Air inlet pressure high
47 164 - 0 Injection control pressure high
47 18 - 0 High range fuel pressure high
48 18 - 1 High range fuel pressure low
48 94 - 1 Fuel pressure low
48 106 - 1 Air inlet pressure low
48 164 - 1 Injection control pressure low
52 - 254 12 A/D conversion fail
53 - 253 2 Non-voilatile checksum incorrect
53 - 253 12 EEPROM write error
53 - 253 13 Out of calibration
54 84 - 12 Vehicle speed sensor fault
55 - 231 12 J1939 data link fault
55 - 248 8 Proprietary datad link fault (Master)
55 - 248 9 Proprietary datad link fault (Receiver)
58 92 - 0 Torque overload
61 - xxx 0 Injector xxx response time long
62 - 26 3 Aux. output #1 short to battery (+) - F3
62 - 26 4 Aux. output #1 open circuit - F3
62 - 40 3 Aux. output #2 short to battery (+) - A2
62 - 40 4 Aux. output #2 open circuit - A2
62 - 53 3 Aux. output #5 short to battery (+) - W3
62 - 53 4 Aux. output #5 open circuit - W3
Section 110-0030
SM 2121 Rev 1 11-03
7
DDEC Code #
62 - 54 3 Aux. output #6 short to battery (+) - X3
62 - 54 4 Aux. output #6 open circuit - X3
62 - 55 3 Aux. output #7 short to battery (+) - Y3
62 - 55 4 Aux. output #7 open circuit - Y3
62 - 56 3 Aux. output #8 short to battery (+) - A1
62 - 56 4 Aux. output #8 open circuit - A1
62 - 26 7 Aux. output #1 mechanical system not responding
properly - F3
properly - A2
properly - W3
properly - X3
properly - Y3
properly - A1
63 - 57 3 PWM #1 short to battery (+)
63 - 57 4 PWM #1 open circuit
63 - 57 0 PWM #1 above normal range
63 - 57 1 PWM #1 below normal range
64 103 - 8 Turbo speed sensor input failure
64 103 - 0 Turbo overspeed
65 51 - 0 Throttle plate position above normal range
65 51 - 1 Throttle plate position below normal range
65 51 - 2 Throttle plate position erratic
65 51 - 7 Throttle plate not responding
65 107 - 3 Air filter restriction sensor voltage high
65 107 - 4 Air filter restriction sensor voltage low
66 - 76 0 Engine knock level above normal range
66 - 76 3 Engine knock level sensor input voltage high
66 - 76 4 Engine knock level sensor input voltage low
66 - 76 7 Engine knock level sensor not responding
66 - 99 3 Oil filter restriction sensor voltage high
66 - 99 4 Oil filter restriction sensor voltage low
67 109 - 3 Coolant pressure sensor input voltage high
67 109 - 4 Coolant pressure sensor input voltage low
67 106 - 3 Air inlet pressure sensor input voltage high
67 106 - 4 Air inlet pressure sensor input voltage low
Section 110-0030
SM 2121 Rev 1 11-03
8
DDEC Code #
67 20 - 3 High range coolant pressure sensor input voltage high
67 20 - 4 High range coolant pressure sensor input voltage low
68 - 230 6 TPS idle validation circuit fault (short to ground)
68 - 230 5 TPS idle validation circuit fault (open circuit)
71 - xxx 1 Injector xxx response time short
72 84 - 0 Vehicle overspeed
72 84 - 11 Vehicle overspeed (absolute)
72 - 65 0 Oxygen content too high
72 - 65 1 Oxygen content too low
73 - 151 14 ESS transmission stuck in gear
73 - 226 11 Transmission neutral switch failure (ESS Transmission)
73 - 227 2 Aux. analog input data erratic, intermittent, or incorrect
(ESS transmission)
73 - 227 3 Aux. analog input #1 voltage high (ESS transmission)
73 - 77 0 Gas valve position above normal range
73 - 77 1 Gas valve position below normal range
73 - 77 3 Gas valve position input voltage high
73 - 77 4 Gas valve position input voltage low
73 - 77 7 Gas metering valve not responding
73 107 - 0 Air filter restriction high
74 99 - 0 Oil filter restriction high
74 70 - 4 Optimized idle safety loop short to ground
75 168 - 0 ECM battery voltage high
75 - 232 0 Sensor supply voltage high
76 121 - 0 Engine overspeed with engine brake
81 - 20 3 Timing actuator (dual fuel) input voltage high
81 98 - 3 Oil level sensor input voltage high
81 101 - 3 Crankcase pressure sensor input voltage high
81 164 - 3 Injection control pressure circuit voltage high
81 173 - 3 Exhaust temperature sensor input voltage high
82 - 20 4 Timing actuator (dual fuel) input voltage low
82 98 - 4 Oil level sensor input voltage low
82 101 - 4 Crankcase pressure sensor input voltage low
82 164 - 4 Injection control pressure circuit voltage low
82 173 - 4 Exhaust temperature sensor input voltage low
83 98 - 0 Oil level high
83 101 - 0 Crankcase pressure high
83 173 - 0 Exhaust temperature high
83 173 - 4 Exhaust temperature sensor input voltage low
83 73 - 0 Pump pressure high
84 98 - 1 Oil level low
84 101 - 1 Crankcase pressure low
85 190 - 0 Engine overspeed
86 73 - 3 Pump pressure sensor input voltage high
86 108 - 3 Barometric pressure sensor input voltage high
87 73 - 4 Pump pressure sensor input voltage low
87 108 - 4 Barometric pressure sensor input voltage low
88 109 - 1 Coolant pressure low
88 20 - 1 High range coolant pressure low
89 95 - 0 Fuel restriction high
89 111 - 12 Maintenance alert coolant level fault
Section 110-0030
SM 2121 Rev 1 11-03
9
REMOVAL
Note: Tag all cables, harnesses, lines and pipes
disconnected during removal to aid in installation.
WARNINGS
safely.
High electrical current can cause sparks
and personal injury from burns. Turn battery
master switch to the 'Off' position before
removing any components. Remove battery
ground cable first, and reconnect last, to avoid
damaging electrical components.
1. Position the vehicle in a level work area, ensure the
body is fully lowered, apply the parking brake and
switch off the engine. Turn steering wheel several
times to relieve any pressure in the steering circuit.
3. Disconnect battery cables from terminal posts
(earth cable first).
4. Pull on handle to release hood catch and lift up hood.
5. Remove mounting hardware securing air cleaner
assembly to right hand fender. Slacken mounting clamp
at air cleaner intake pipe and draw air cleaner, complete
with rubber hose, away from intake pipe. Cover open ends
to prevent entry of dirt.
6. With a suitable container in position, open shut-off
valve on the radiator assembly and drain the coolant.
7. Remove hood and goalpost from the vehicle. Refer
to Section 100-0040, HOOD AND MOUNTING.
Note: Radiator header tank will be removed as part of
the goalpost assembly.
8. Support engine sump guard with suitable blocking
and remove mounting hardware securing sump guard to
the frame. Remove sump guard from the frame.
9. Support guard plate under the engine at the front of
the frame with suitable blocking and remove mounting
hardware securing guard plate to the frame. Remove
guard plate from the frame.
10. Place a suitable container under the engine drain
port, remove drain plug and drain the oil. After
draining, reinstall drain plug in engine sump and
tighten securely.
WARNING
Before disconnecting any air conditioner lines,
refer to Section 260-0130, AIR CONDITIONING.
Refrigerant will rapidly freeze all objects with
which it comes into contact. It can cause
serious and permanent damage to the eyes
and skin.
11. Evacuate air conditioning system and disconnect
air conditioner lines at the engine compressor. Refer to
Section 260-0130, AIR CONDITIONING.
12. Remove the radiator assembly from the vehicle.
Refer to Section 210-0040, RADIATOR AND
MOUNTING.
13. With a suitable container in position, remove drain
cock on the transmission oil cooler flanges and drain
the coolant. Remove coolant pipes from the engine
water pump and engine oil cooler. Refer to Section
210-0060, TRANSMISSION OIL COOLER.
14. Remove charge air cooler pipes from engine
turbocharger and engine inlet manifold.
15. Disconnect exhaust piping from the engine
turbocharger.
16. Disconnect air cleaner intake pipe from engine
turbocharger and remove from the engine.
17. Identify heater lines for ease of installation and with a
suitable container in position, disconnect heater lines
from the engine. Cap open line ends and fittings.
18. Identify fuel lines for ease of installation and with a
suitable container in position, disconnect fuel lines
from the engine. Cap open line ends and fittings.
19. Identify all electrical harnesses and cables for ease
of installation and disconnect from the engine.
20. Disconnect clips securing items to the engine that
cannot be removed with the engine.
21. Disconnect driveline from the engine coupling and
secure clear of the engine. Refer to Section
Section 110-0030
SM 2121 Rev 1 11-03
10
130-0010, FRONT DRIVELINES.
22. Attach suitable lifting equipment to the lifting
brackets on the engine and raise lifting equipment to
take up the slack.
23. Remove locknuts (10), washers (9), snubbing
washers (8), bolts (13) and bolts (29) securing engine
(1) to the frame through front mounting bracket and rear
mounting brackets (18 & 19).
electrical disconnections have been made before lifting
engine (1).
25. Carefully lift engine (1) clear of the frame, remove
to a suitable work area and mount securely on a work
stand.
DISASSEMBLY
1. Identify rear mounts (18 & 19) to aid in assembly then
remove bolts (21) and washers (25) securing rear mounts
to engine (1). Remove mounts (18 & 19).
2. If required, remove rubber isolation mounts (28) from
rear mounts (18 & 19) and front mounting bracket on
engine (1).
3. Loosen air conditioner compressor drive belt and
remove compressor from engine (1). Refer to Section
260-0130, AIR CONDITIONING.
4. Loosen alternator mounting bolt (38) to allow slack in
'V' belts (14). Remove 'V' belts (14).
Note: Adjuster screw and link assembly (17, 20, 24, 34
& 35) will have been released when removing radiator
assembly from the vehicle.
5. Remove bolt (26) and lockwasher (27) securing
screw and link assembly (17, 20, 24, 34 & 35) to
alternator (43). Support alternator (43) and remove
locknut (40), washer (39) and bolt (38). Remove
alternator (43) from engine (1).
6. Remove bolts (15) securing engine coupling (7) at
rear of engine (1) then remove engine coupling.
7. Remove mounting hardware supporting dipstick
assembly (6) to engine (1). Remove dipstick assembly
(6) from engine (1).
8. If required, remove bolts (32), lockwashers (31), clip
(42) and step (30) from engine (1).
9. Remove and discard filters (2, 3, 4 & 5) from engine
(1), as described in 'Maintenance'. Cover engine inlet
ports to prevent entry of dirt.
10. Refer to 'Engine Manufacturers Service Manual' if
engine service or repair is required.
INSPECTION
1. Inspect rubber isolation mounts (28) for damage and
replace if required.
2. Check rear mounts (18 & 19), front mounting bracket
on engine (1) and mounting brackets on the front frame
for cracks and/or damage. Repair or replace as
necessary.
3. Inspect engine coupling (7) for damage and repair or
replace as required.
ASSEMBLY
specified to standard torques listed in Section
300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
1. Remove covers from engine filter ports and install
new filters (2, 3, 4 & 5) on engine (1), as described in
'Maintenance'.
2. If removed, secure step (30) and clip (42) to engine
(1) with bolts (32) and lockwashers (31).
3. Install dipstick assembly (6) on engine (1) and
secure with mounting hardware as removed at
'Disassembly'.
4. Install engine coupling (7) to rear of engine (1) and
secure with bolts (15).
5. Position alternator (43) on engine mounting bracket
and align the holes in the alternator mounting flanges
with the tube in the bracket. Secure alternator (43) in
position with bolt (38), washer (39) and locknut (40).
Tighten bolt (38) finger tight at this stage.
6. Install adjuster screw and link assembly (17, 20, 24, 34
& 35) to alternator (43) and secure with bolt (26) and
lockwasher (27). Tighten bolt (26) finger tight at this
Section 110-0030
SM 2121 Rev 1 11-03
11
stage.
Note: Replace all belts in a set when one is broken or
replaced.
7. Install 'V' belts (14) in the grooves of alternator (43)
and accessory drive pulley.
Note: Alternator belt tension adjustment is made after
installation of engine (1) and the radiator assembly.
8. Install air conditioner compressor and drive belt to
engine (1). Refer to Section 260-0130, AIR
CONDITIONING.
Note: Position rubber isolation mounts (28) to their
mounts as shown in Fig. 1.
9. If removed, install rubber isolation mounts (28) to
front mounting bracket on engine (1).
10. If removed, install rubber isolation mounts (28) in
rear mounts (18 & 19). Secure rear mounts (18 & 19) to
engine (1) with bolts (21) and lockwashers (25) as
identified at disassembly. Tighten bolts (21) to a torque
of 150 Nm (110 lbf ft).
INSTALLATION
SPECIFICATIONS.
WARNING
damage, be sure lifting device is properly
safely.
1. Attach suitable lifting equipment to engine (1) lifting
brackets and carefully position engine (1) assembly in
the tractor frame.
2. Secure engine (1) assembly to frame mounting brackets
with bolts (13 & 29), snubbing washers (8) washers (9) and
locknuts (10) as shown in Fig. 1. Tighten locknuts (10) to
a torque of 264 Nm (195 lbf ft).
3. Connect driveline to the engine coupling and secure
bracket to engine crossmember. Refer to Section
130-0010, FRONT DRIVELINES.
4. Install transmission oil cooler pipes to the engine
water pump and engine oil cooler. Refer to Section 210-
0060, TRANSMISSION OIL COOLER.
5. Install radiator assembly on the vehicle. Refer to
Section 210-0040, RADIATOR AND MOUNTING.
Note: When installing radiator support bracket to engine
(1), locate bolt (36) through link (20) then secure with
snubbing washer (37) and locknut (41). Tighten locknut
(41) to a torque of 165 Nm (122 lbf ft).
6. Adjust 'V' belts (14) by loosening locknut (34) and
turning screw assembly (17) clockwise until the correct
tension is obtained (refer to 'Drive Belt Adjustments').
When correct tension is obtained tighten locknut (34).
7. Tighten bolt (38) securing alternator (43) to engine
mounting bracket and bolt (26) securing link (24)
assembly to alternator (43) to a torque of 81 - 95 Nm
(60 - 70 lbf ft).
8. Install air cooler pipes from engine turbocharger and
engine inlet manifold to charge air cooler mounted on
the radiator assembly. Refer to Section 210-0040,
RADIATOR AND MOUNTING.
9. Install air cleaner intake pipe and exhaust piping to
engine turbocharger.
10. Remove caps from heater lines and fittings and
connect heater lines to engine (1) as identified at
removal.
11. Remove caps from fuel lines and fittings and
connect fuel lines to engine (1) as identified at removal.
12. Connect all electrical harnesses and cables to
engine (1) (with the exception of battery connections)
as identified at removal.
13. Connect air conditioner lines at the compressor as
identified at removal. On completion of engine
installation the air conditioning system will require to
be charged. Refer to Section 260-0130, AIR
CONDITIONING.
14. Install the goalpost and radiator header tank
assembly on the vehicle. Refer to Section 100-0040,
HOOD AND MOUNTING.
15. Ensure all cooling lines to radiator assembly,
engine (1) and radiator header tank are correctly
connected. Refer to Section 210-0040, RADIATOR
AND MOUNTING.
Section 110-0030
SM 2121 Rev 1 11-03
12
MAINTENANCE
Note: Carry out the following maintenance procedures
in conjunction with additional procedures listed in
Section 300-0020, LUBRICATION SYSTEM.
Every 10 Hours (Daily)
Engine (1): Visually check engine for damage, loose or
frayed belts and listen for any unusual noises. Check
the turbocharger for leaks.
Engine (1) Oil Level: Check engine oil level and add
oil if low. To allow checking before starting as well as
immediately after shutting down the engine, the
dipstick is provided with two types of marks:
1. Dot Marks - Before starting up after a major shut
down period the oil level should be up to the top dot
mark (cold level).
2. Dash Marks - Upon shutting down the engine at low
idling (wait 1 to 2 minutes) the oil level should be up to,
but not over, the top dash mark (hot level).
Every 250 Hours
Engine (1): Drain engine oil and refill. Refer to Section
300-0020, LUBRICATION SYSTEM for oil
specification.
Engine Water Pump: Inspect water pump drain hole
and clean if required.
Engine Oil Filters (2): Replace oil filters as follows:
1. Using filter wrench, remove and discard both oil
filters (2) from engine (1). Inspect the sealing surface
of the filter to ensure that the seal ring stayed with the
filter. If not, remove it from the filter adaptor.
2. Clean the filter adaptor with a clean, lint free cloth.
3. Lightly coat new oil filter (2) seal with clean engine
oil as specified in Section 300-0020, LUBRICATION
SYSTEM.
4. Start a new oil filter (2) on the filter adaptor and
tighten it by hand until the seal touches the adaptor
filter head. Tighten an additional 2/3 of a turn after
contact.
Note: Mechanical tightening of oil filters (2) is not
16. Remove covers from air cleaner intake pipe and
rubber hose on the air cleaner inlet then slide air
cleaner assembly towards the hood locating the rubber
hose to the inlet pipe.
17. Secure air cleaner assembly to the right hand
fender and rubber hose to the inlet pipe with mounting
hardware removed during removal.
18. Connect battery positive connections to battery
terminals. Connect battery earth connections to battery
terminals.
19. Ensure all lines, harnesses and cables are secured
with clips and clamps as removed during removal.
Ensure no lines are chaffing on sharp edges or resting
against areas where heat will be evident.
20. Ensure shut-off valve at the bottom of the radiator
assembly, drain plugs in transmission oil cooler flanges
and drain cocks on engine (1) water jacket are securely
closed. Ensure shut off cocks at coolant filter (3) are
open to allow flow through the filter.
21. Fill the cooling system with coolant. Refer to
Section 210-0000, COOLING SYSTEM.
22. Fill the engine with lubricant through oil filler to the top
mark on dipstick (6). Refer to Section 300-0020,
LUBRICATION SYSTEM for oil specification.
23. Check all line and pipe connections for leaks prior
to starting the vehicle. Tighten as required.
24. Switch the battery master switch to the 'On'
position, start up the engine and check for leaks.
Tighten lines, pipes and fittings and top up all systems
as required.
25. Install hood assembly on the vehicle. Refer to
Section 100-0040, HOOD AND MOUNTING.
Note: Check that gap between hood and cowl is correct
(12 mm (0.5 in) maximum).
26. Using suitable lifting equipment position front guard
plate under the engine and secure to the frame with
mounting hardware removed during removal.
27. Using suitable lifting equipment position engine
sump guard under the engine and secure to the frame
with mounting hardware removed during removal.
28. Remove wheel blocks from all road wheels.
Section 110-0030
SM 2121 Rev 1 11-03
13
excessive loss of coolant.
1. Close shut off valves at coolant filter (3) inlet and
outlet lines and, using filter wrench, remove and
discard coolant filter (3) from engine (1).
2. Clean the filter adaptor with a clean, lint free cloth.
3. Lightly coat new coolant filter (3) seal with clean
engine oil as specified in Section 300-0020,
LUBRICATION SYSTEM.
4. Start coolant filter (3) on the filter adaptor and tighten
it by hand until the seal touches the adaptor filter head.
Tighten an additional 2/3 of a turn after contact.
Note: Mechanical tightening of coolant filter (3) is not
necessary and will distort or crack the adaptor.
Tighten coolant filter by hand only.
5. Open shut off valves at coolant filter (3) inlet and
outlet lines.
6. Start the engine and check for leaks. If any leaks are
noted, have them corrected. Add coolant as required.
Refer to Section 210-0000, COOLING SYSTEM.
Drive Belt Adjustments
Every 50 Hours: Check all drive belt tensions and
adjust if required. If vehicle is equipped with air
conditioning, compressor belts should be checked and
adjusted as described in Section 260-0130, AIR
CONDITIONING.
Every 2 000 Hours: Replace all drive belts.
Note: Replace all belts in a set when one is worn.
Single belts of similar size should not be used as a
substitute for a matched belt set as premature belt
wear can result due to belt length variation. All belts in
a matched belt set are within 0.81 mm (0.032 in) of
their specified centre distances.
Using belt tension gauge, adjust the belt tension to the
following values:
Alternator - 'V' Belt
Belt Tension 'New' - 556 N (125 lbf)
Belt Tension 'Used' - 445 N (100 lbf)
Note: A belt is considered 'Used' if it has been in
service for 10 minutes or longer. If the used belt
tension is less than the minimum value, tighten the belt
necessary and will distort or crack the adaptor. Tighten
oil filters by hand only.
5. Repeat steps 3 and 4 for second oil filter (2).
6. Start and run the engine for a short period and check
for oil leaks. If any leaks are noted, have them
corrected.
7. After the engine has been stopped long enough
(approximately 20 minutes) for the oil from various
parts of engine (1) to drain back to the crankcase,
check oil level and add oil to bring it to the proper
level on the dipstick. Refer to Section 300-0020,
Fuel Filters (4 & 5): Replace primary fuel filter (4) and
secondary fuel filter (5) as follows:
Note: There is a fuel system shut off valve on the
discharge side of secondary fuel filter (5). Closing this
valve will prevent loss of fuel prime at time of filter
replacement.
1. Close shut off valve at secondary fuel filter (5) and,
using filter wrench, remove and discard both fuel filters
(4 & 5) from engine (1).
2. Fill the replacement filters and coat the gaskets
slightly with clean fuel oil as specified in Section
3. Start new primary fuel filter (4) on the filter adaptor
and tighten it by hand until the gasket contacts the
adaptor fully with no side movement of the filter
evident. Tighten an additional 1/2 of a turn.
Note: Mechanical tightening of fuel filters (4 & 5) is not
recommended, and may result in seal and/or cartridge
damage. Tighten fuel filters by hand only.
4. Repeat step 3 for secondary fuel filter (5).
5. Start the engine and check for leaks. If any leaks
are noted, have them corrected.
Every 500 Hours
Coolant Filter (3): Check condition of coolant inhibitor
as described in Section 210-0000, COOLING
SYSTEM. Replace coolant filter (3) as follows:
Note: There is a shut off valve at the coolant inlet and
outlet lines of coolant filter (3). Closing these valves
will enable coolant filter (3) to be replaced without an
Section 110-0030
SM 2121 Rev 1 11-03
14
* * * *
to the maximum value.
Belts should be neither too tight nor too loose. Belts
that are too tight impose excess loads on the alternator
bearings, shortening both belt and bearing life. A loose
belt will slip and may cause damage to accessory
components.
TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 10 Locknut 264 195
1 21 Bolt 150 110
1 26 Bolt 81 - 95 60 - 70
1 38 Bolt 81 - 95 60 - 70
1 41 Locknut 165 122
SPECIAL TOOLS
numbers of service tools which should be used in
conjunction with procedures outlined in the engine
manufacturers service manual, and, general service
tools required. These tools are available from your
dealer.
SM 2122 Rev 1 4-02
1
Section 110-0050
The dual dry element air cleaner is remote mounted on
the fender of the vehicle. The air cleaner prolongs
engine life by removing grit and dust from the air as it
enters the engine. Grit and dust, combined with engine
oil, forms a highly abrasive compound which can
destroy the engine in a comparatively short time.
ENGINE - Air Cleaner
SM - 1262
1 - Restriction Indicator Fitting
2 - Body
3 - Latches
4 - Access Cover
5 - Gaskets
6 - Wing Nut
7 - Nut
8 - Cotter Pin
9 - Secondary (Safety) Filter Element
10 - Primary Filter Element
11 - Gasket
12 - Clamp
13 - Gasket
14 - Tube Section
15 - Funnel Shaped Tubes
16 - Clamp
17 - Dust Cup
18 - Vacuator Valve
19 - Centre Tubes
A - Air Inlet
B - Air Outlet
Fig. 1 - Cutaway View of Typical Air Cleaner
A rubber vacuator valve (18) attached to the dust cup
(17) in a downward position ejects grit, dust, and water
while the engine is running. The vacuator valve
minimizes the need for daily servicing. Even though
the valve is normally under a slight vacuum when the
engine is running, pulsing of the vacuum opens and
closes the rubber valve, expelling dust and water as
they collect. The valve also unloads when the engine is
stopped, by opening and releasing any accumulated
dust or water.
2
SM 2122 Rev 1 4-02
Engine - Air Cleaner
Section 110-0050
Dust laden air enters pre-cleaner tube section (14)
through air inlet opening (A). As the air enters this
portion of the cleaner, it passes through the vanes in
funnel shaped outer tubes (15). These vanes give the
air a whirling motion and as the air rotates down the
tubes, centrifugal force throws the heavier dust
particles to the outside of the tubes and through the
bottom of the funnel shaped tubes to dust cup (17).
The partially cleaned air is then drawn through centre
tubes (19) and flows through primary filter element (10)
and secondary (safety) filter element (9) where any
remaining dust particles are removed. As the filtered air
leaves the cleaner through air outlet (B), it is drawn
through a ducting pipe which is securely clamped
between the air cleaner and the engine air intake.
AIR CLEANER
Removal
1. Position the vehicle in a level work area, apply the
parking brake, switch off the engine and turn the
steering wheel in both directions several times to
relieve pressure in the steering system.
2. Block all road wheels, place the steering lock bar in
the 'Locked' position and the battery master switch in
the 'Off' position.
3. Pull on handle to release hood catch and lift up the
hood.
SM - 2677
Fig. 2 - Exploded View of Typical Air Cleaner Mounting
15 - Bolt
16 - Lockwasher
17 - Bolt
18 - Lockwasher
19 - Washer
20 - Clamp
21 - Plate
TO TURBO
12
11
9
10
22
24
23
19
20
21
14
6
17
18
15
16 8
7 10
2
2
4
4
3
3
5
5
13
1
25
26
27
28
8 - Clamp
9 - Elbow
10 - Clamp
11 - Insert
12 - Clamp
13 - Bracket
14 - Bracket
1 - Bracket
2 - Bolt
3 - Lockwasher
4 - Washer
5 - Nut
6 - Tube
7 - Hose
22 - Bolt
23 - Nut
24 - Clamp
25 - Air Restriction Gauge
26 - Clamp
27 - Clamp
28 - Cap
SM 2122 Rev 1 4-02
3
Section 110-0050
Fig. 3 - Exploded View of Typical Air Cleaner
SM - 1263
1 - Access Cover
2 - Gasket
3 - Wing Nut
4 - Gasket
5 - Primary Filter Element
6 - Nut
7 - Cotter Pin
8 - Secondary (Safety) Filter Element
9 - Latches
10 - Body
11 - Clamp
12 - Gasket
13 - Tube Section
14 - Clamp
15 - Dust Cup
16 - Vacuator Valve
17 - Inlet Cap
4. Slacken clamps (8 & 10) and slide hose (7) clear of
the air cleaner assembly.
5. Using suitable lifting equipment, support the air
cleaner assembly and remove bolts (2), washers (4),
lockwashers (3) and nuts (5). Remove air cleaner
assembly from brackets (1 & 13).
6. Blank off air cleaner outlet and hose (7) end with
tape or cardboard to prevent entry of dirt.
7. If required, remove bolts (2), washers (4),
lockwashers (3) and nuts (5) securing brackets (1 & 13)
to the right hand fender. Remove brackets (1 & 13).
Disassembly
1. Remove air cleaner access cover assembly by
undoing securing latches (9). Empty dust collected in
access cover (1) and wipe clean.
4
SM 2122 Rev 1 4-02
Section 110-0050
2. Unscrew wing nut (3), remove gasket (4) and
carefully withdraw primary filter element (5). Inspect
gaskets (2 & 4). Replace if damaged.
3. Do not disturb secondary (safety) filter element (8).
Replace access cover (1) temporarily.
4. The primary filter element (5) should be replaced
after a maximum of six cleanings, or annually
whichever comes first. Should the primary filter
element (5) require cleaning one of the methods
mentioned in the Cleaning Primary Filter Element
section should be used.
Assembly/Installation
Note: Tighten all fasteners to standard torques listed in
Assembly and installation of the air cleaner assembly
is the reverse of disassembly and removal. Always
check air cleaner threads are clean and undamaged.
Reset air restriction gauge (16).
Following installation, but before starting the engine,
the following system checks should be carried out:
a. Check air cleaner to engine tube (6) for defects and
that clamps (8, 10 & 12) are securely tightened to
ensure that there are no leaks in the system. Replace
any worn or damaged parts.
b. Check that air cleaner mounting brackets (1 & 13)
are secure and that air cleaner is mounted securely.
MAINTENANCE
WARNING
Always shut down engine before servicing air
cleaner.
1. Check the air restriction gauge (Fig. 4) daily. This
gauge is mounted on the air cleaner outlet pipe and
shows when the system air flow is being restricted, by
a yellow band that gradually rises in the gauge window
as air restriction increases. The yellow band is locked
when maximum allowable restriction is reached.
2. When the yellow band locks at the top of the gauge
window the primary filter element should be serviced.
The air restriction gauge should be reset by pushing
the button on the gauge, holding it for several seconds
and then releasing it. While this device indicates the
need for servicing, it does not give as precise a
measurement as a water manometer or vacuum gauge
connected to the tapping point on the air cleaner outlet
or engine manifold.
3. The vacuator valve (16, Fig. 3) eliminates the need
for frequent servicing. To function, the vacuator valve
lip must point down and be kept free of debris. The
valve should be closed except when the engine is
idling slowly or stopped. If the vacuator valve is lost or
damaged, replace it to maintain normal element service
life.
CLEANING TUBE SECTION
The tube section (13) of the air cleaner should be
thoroughly cleaned twice a year. Inspect lower end of
tubes each time dust (15) cup is removed.
Note: Do not apply heat in any form to the air cleaner
plastic tube section.
1. Loosen clamp (14) and remove dust cup (15) and
gasket (12).
Note: Filter elements should always be installed when
cleaning tubes as described in Step 2. This prevents
dirt from entering the clean air chamber.
2. Tubes with a light dust buildup can be cleaned with
compressed air or a stiff fibre brush without removing
from machine. (Do not use a wire brush.)
3. If tubes require washing, remove air inlet cap (17),
any attaching parts securing tube section (13) to
machine and remove clamp (11), tube section (13) and
gasket (12) from body (10).
Fig. 4 - Air Restriction Gauge
SM - 058
SM 2122 Rev 1 4-02
5
Section 110-0050
4. Submerge tube section in the manufacturers
recommended solution, or equivalent, and warm water,
not to exceed 66 C (150 F). Soak for 30 minutes and
agitate for 5 minutes. Rinse clean with clean water and
allow body to dry.
Note: If plugging is severe, use a solution of 50%
Oakite 202 and 50% water, or equivalent, and follow
Step 4.
5. Inspect gaskets (12) and replace if damaged.
6. Position gasket (12) on body (10) and secure tube
section (13) to body with clamp (11). Secure tube
section (13) to machine.
7. Position gasket (12) on tube section (13) and secure
dust cup (15) to tube section with clamp (14).
8. Position air inlet cap (17) on tube section (13) and
secure with clamp.
Cleaning Primary Filter Element
Although a paper primary filter element (5) is used, it is
possible to remove excess dirt by tapping element.
The number of times one element can be reused
depends on the type of dirt on it and the care exercised
in cleaning. Element damage will be indicated by areas
of concentrated dust on the clean side of the element.
If in doubt - always fit a new element.
1. Release latches on cover assembly (1) and remove
cover assembly from air cleaner body (10).
2. Remove primary element (5) from air cleaner body
(10) and clean/replace. It is advised to replace the
element rather than attempt to clean thoroughly.
3. Install primary element (5) in air cleaner body (10).
4. Install cover assembly (1) on air cleaner body (10)
and secure with latches.
Secondary (Safety) Filter Element
The secondary (safety) filter element (8) is installed in
the air cleaner body (10) and inside of the primary filter
element (5). This secondary (safety) element increases
the reliability of the air cleaners protection of the
engine from airborne dirt. It protects the engine from
dirt admitted by a damaged primary filter element (5),
or dirt that might be dropped into the air cleaner body
(10) while changing the primary filter element (5). Since
the secondary (safety) filter element (8) is protected
from contamination by the primary filter element (5) it
needs no periodic cleaning but should be replaced
when it affects the total air flow restriction of the air
cleaner, or on at least every third primary filter element
service.
Note: Do not clean secondary (safety) filter element -
replace with a new element.
Secondary (Safety) Filter Element
Removal
1. Remove secondary (safety) filter element (8) by
removing cotter pin (7) and then loosen nut (6).
Remove nut (6) and gasket (4), then lift out element.
2. Wipe clean inside of air cleaner body (10) using a
damp cloth. Check all body gaskets are properly
secured and in good condition. Also check cleaner
body (10) for cracks or other structural damage.
Replace damaged parts immediately.
3. Check all new or properly serviced components for
damage prior to installing in the cleaner body. Always
check new filter element part numbers against air
cleaner information label.
RECOMMENDATIONS
1. Under no condition should the unit be operated
without both filter elements.
2. Carbon, soot and oil fumes will quickly hamper the
operation of the paper filter element. Keep air cleaner
inlet as far away as possible from sources of theses
products, such as a parked vehicle with engine
running. Also, make sure that the engine exhaust
system does not leak, to prevent fouling the element
with soot .
3. Keep new or cleaned filter elements on hand for
replacement to prevent unnecessary vehicle downtime.
* * * *
Section 120-0010
1
SM 2124 Rev 3 8-03
DESCRIPTION
For transmission make, model and specification, refer
to Section 000-0000, GENERAL INFORMATION. For
transmission servicing and repair data refer to
transmission manufacturers service manual.
The transmission is supported by front bracket
assembly (1), LH bracket (7) and RH bracket (13)
which are bolted to the transmission and attached to
front frame mounting brackets through isolation
mounts (2 & 8). Isolation mounts (2 & 8) provide
sufficient flexibility to absorb varying transmission
vibration and torsional loads.
The transmission assembly consists of a torque
converter close-coupled to a 6 speed gearbox with
integral output transfer gearing. Automatic shifting in
gear ranges 1 to 6, with kickdown feature. Lockup in all
forward gears. A wear-resistant hydrodynamic retarder
is integral of the transmission.
Two engine dependent power takeoffs at the rear of the
transmission provide the drive for the braking system
brake pump and the main hydraulic pump which
supplies the steering and body hoist systems. A
ground driven emergency steering pump is attached at
the lower rear left hand side of the transmission.
Mounted off front bracket assembly (1) is the retarder
solenoid, pressure reducing valve and centre axle
differential lock solenoid (TA40 only). The transmission
differential lock solenoid is located on the front frame
adjacent to the right hand steering cylinder.
TRANSMISSION - Transmission and Mounting
SM - 1842
1
2
3
4
5
6
9
12
11
6
7 LH
13 RH
8
3
10
14
5
23
24
15
25
30
29
13
25
26,27
28
22
17
16
19
18
20
21
23 - Screw
24 - Gasket
25 - Dipstick
26 - Clamp
27 - Bolt
28 - Locknut
29 - Latch Assembly
30 - Padlock & Key
15 - Dipstick Tube
16 - Bracket
17 - Clamp
18 - Bolt
19 - Washer
20 - Locknut
21 - Bolt
22 - Lockwasher
8 - Isolation Mount
9 - Lockwasher
10 - Bolt
11 - Lockwasher
12 - Bolt
13 - RH Bracket
1 - Front Bracket Assembly
2 - Isolation Mount
3 - Snubbing Washer
4 - Washer
5 - Locknut
6 - Bolt
7 - LH Bracket
Fig. 1 - Exploded View of Transmission and Mounting
Section 120-0010
Transmission - Transmission and Mounting
SM 2124 Rev 3 8-03
2
SM - 1843
SWITCHES AND SENSORS
Transmission Oil Temperature
Oil temperature sender (9) sends a signal to indicate
transmission oil temperature on the transmission oil
temperature gauge. The gauge should read in the
green zone during normal operation and may read in
the yellow zone during retarder operation. If the
needle remains in the red zone for extended periods,
the machine should be brought to a stop,
transmission shifted to neutral and engine speed
increased to 1 200 - 1 500 rev/min. Under this
condition, oil temperature should drop to normal
values in about 2 - 3 minutes. If oil temperature does
not drop, the cause should be investigated.
The transmission oil temperature is monitored by
temperature sensors in the main control valve, which
sends a signal to illuminate the transmission STOP
warning light. The light will illuminate to indicate any
of the following conditions:
High retarder temperature
High transmission sump temperature
Engine overspeed
If the light illuminates during normal operation, a fault
code will also register on the display unit (See EST-37
Trouble Shooting tables). Bring the machine to a stop
and investigate the cause.
4
1
K2 KR KV K4 K3
K1
Y
9
11
10
2
4
5
6
3
VIEWED FROM THE REAR
DETAIL Y
8
7
Fig. 2 - Location of Transmission Switches, Sensors and Solenoids
1 - Retarder Oil Temperature Sensor
2 - Main Control Valve
3 - Difflock Warning Light Switch
4 - Lockup Solenoid
5 - Engine Speed Sensor
6 - Output Speed Sensor
7 - Central Gear Train Sensor
8 - Turbine Speed Sensor
9 - Oil Temperature Sender (Gauge)
10 - Breather
11 - Emergency Steering Low Pressure Switch
KV, KR, K1 to K4 - Supply ports to
Multi-disc Clutches
Section 120-0010
3
SM 2124 Rev 3 8-03
Lockup Clutch (Wk)
The transmission lockup clutch is automatically
engaged. Engine speed is picked up by turbine speed
sensor (8) which sends a signal to energise lockup
solenoid (3, Fig. 3) when turbine speed reaches a
predetermined level. Energising lockup solenoid
(3, Fig. 3) will move lockup valve (4, Fig. 3) across,
allowing oil to flow through the valve to engage
lockup.
Gear Selection
The transmission can be engaged and disengaged
under load by means of hydraulically controlled multi-
disc clutches. All gears run in antifriction bearings
and are constantly meshed. The gears, bearings and
clutches are lubricated with cooled oil.
The transmission is equipped with six multi-disc
clutches. These clutches are controlled via the six
proportional valves (6, Fig. 3). Each proportional
valve (6, Fig. 3) is composed of a pressure regulator
(Y1 to Y6, Fig.3), follow-on slide (5, Fig. 3) and
vibration damper (7, Fig. 3).
The control pressure of 9 bar for the actuation of the
follow-on slides (5, Fig. 3) is created by the pressure
reduction valve (2, Fig. 3). The pressure oil (16+2
bar) is directed via the follow-on slide (5, Fig. 3) to
the respective clutch.
Due to the direct proportional control with separate
pressure modulation for each clutch, the pressures to
the clutches, which are taking place in the gear
change, are controlled. In this way, a hydraulic
SM - 1826
Y1 to Y6 - Pressure Regulators
1 - Main Pressure Valve 16+2 bar
2 - Pressure Reduction Valve 9 bar
3 - Lockup Solenoid
4 - Lockup Reduction & Shift Valve
5 - Follow-on Slide
6 - Proportional Valve (P1 to P6)
7 - Vibration Damper
8 - Harness Connection
Fig. 3 - Sectional View of Typical Control Unit with Lockup Clutch (Wk)
VALVE BLOCK
COVER
8
HOUSING
2
1
5
6
7
4
3
BREATHER
SYSTEM PRESSURE FROM
CONTROL UNIT
Y3
Y2
Y1
Y4
Y5
Y6
Section 120-0010
SM 2124 Rev 3 8-03
4
intersection of the clutches to be engaged and
disengaged becomes possible. This creates fast
shiftings without traction force interruption.
Speedometer Sensor
Speedometer sensor, within the ECU, sends a signal to
the speedometer, via the speedometer frequency
divider, to indicate travel speed in kilometres per
hour and miles per hour.
Differential Locks
Note: The transmission differential lock requires
hydraulic pressure to hold it 'Off', whereas, the centre
axle differential lock requires pressure to hold it 'On'.
When the engine is started, hydraulic pressure is
applied to the transmission differential lock to ensure
the differential lock is released. On activation of the
differential lock switch, the transmission differential
lock solenoid is energised and hydraulic pressure is
released at the transmission differential lock and
applied at the centre axle differential lock (TA40 only).
In this condition, the differential locks are engaged.
Note: The differential locks can be preselected when the
machine is moving however, they will only engage on the
move when the vehicle speed is below 5 km/hr.
Note: Before driving in soft or slippery conditions, stop
and engage the differential locks. Spinning wheels can
result in damage to the transmission and axle
differentials.
Note: Disengage differential locks when driving on firm
ground.
Retarder Control
The hydro dynamic retarder is arranged between the
engine and torque converter so that a good braking
effect is obtained in all speeds. The retarder is a
wear resistant hydrodynamic brake with speed
dependent action.
Retarder solenoid is energised on application of the
retarder switch, located either on the right hand dash
panel or within the treadle valve, provided that the
lockup clutch is engaged and the transmission 'Stop'
warning light is OUT. Energising retarder solenoid will
shift retarder solenoid valve and allow oil to flow
through the valve to engage the retarder.
Pressing the retarder switch OFF will de-energise
retarder solenoid and retarder solenoid valve will shift
back to disengage the retarder.
S
e
c
t
i
o
n

1
2
0
-
0
0
1
0 5
S
M

2
1
2
4

R
e
v

3

8
-
0
3
WK RETARDER
INPUT
OUTPUT OUTPUT
DIFFERENTIAL ENGAGEMENT AND DISENGAGEMENT
DIFFERENTIAL LOCK
PUMP
1st POWER TAKE-OFF
2nd POWER TAKE-OFF
31
14
6
39
CONVERTER
KV K1
KR K2
K4 K3
D
E
F
J H
K
G
C
B
A
56
60
55
66
67 65
51
57
53
58
52
63
S
M

-

1
8
2
4
SCHEDULE OF MEASURING POINTS
Measurements to be carried out with oil at normal operating
temperature of 80 C and operating at full speed.
MEASURING POINTS FOR PRESSURE OIL AND TEMPERATURE:
51 = Before the Convertor - Opening Pressure 8.5 bar
52 = Behind the Convertor - Opening Pressure 5 bar
53 = Clutch forward 16+2 bar KV
55 = Clutch reverse 16+2 bar KR
56 = Clutch 16+2 bar K1
63 = Temperature 100 C behind the retarder (short time 150 C)
65 = System pressure 16+2
66 = Temperature 100 C behind the converter (short time 120 C)
67 = WK-Control pressure 131 bar
PRESS REG. UNDER VOLTAGE
SPEED Y1 Y2 Y3 Y4 Y5 Y6
F1
F2
F3
F4
F5
F6
R1
R2
R3
N
CLUTCH KR K4 K1 K3 KV K2
POS. VALVE F E D C B A
POINTS 55 60 56 58 53 57
INDUCTIVE TRANSMITTERS AND SPEED SENSORS
6 = Inductive Transmitter n Turbine
14 = Inductive Transmitter n Engine
31 = Speed Sensor n Output and Speedometer
39 = Inductive Transmitter n Central Gear Train
Fig. 4 - Typical Schedule of Measuring Points and Gear Pattern
T
r
a
n
s
m
i
s
s
i
o
n

-

T
r
a
n
s
m
i
s
s
i
o
n

a
n
d

M
o
u
n
t
i
n
g
S
e
c
t
i
o
n

1
2
0
-
0
0
1
0
T
r
a
n
s
m
i
s
s
i
o
n

-

T
r
a
n
s
m
i
s
s
i
o
n

a
n
d

M
o
u
n
t
i
n
g
S
M

2
1
2
4

R
e
v

3

8
-
0
3
6
P1
KR
B
D
Y1
NFS
F 55
P2
K4
B
D
Y2
NFS
E 60
P3
K1
B
D
Y3
NFS
D 56
P4
K3
B
D
Y4
NFS
HDV
C 58
K 65
P5
KV
B
D
Y5
NFS
TEMP
RV-9
B 53
P6
K2
B
D
Y6
NFS
A 57
32
16 15
63
34 33
WGV
WK
WSV
WK-M
WK-V
RT-V
RT
H
51
66 52
28
29
CONVERTER
BYPASS VALVE
NOT SCOPE OF SUPPLY ZF
PRESSURE REDUCTION VALVE
5.5 bar
TO THE RETARDER VALVE
5.5 bar
HYDRAULIC PRESSURE
WT (SCOPE OF SUPPLY CUSTOMER)
WITH RETARDER
FILLING POSITON
ZF-FINE FILTER
IN THE CABIN
OIL SUMP
LUBRICATION
WITHOUT RETARDER
TRANSMISSION PUMP
COARSE FILTER
67
LEGEND:
= MAIN PRESSURE
= CONTROLLED MAIN PRESSURE
= PILOT PRESSURE
= CONVERTER INLET PRESSURE
= CONVERTER EXIT PRESSURE
= LUBRICATION
= RETURN TO SUMP
S
M

-

2
5
7
0
No. Denomination of the Position Port
15 To the heat exchanger
16 From the heat exchanger
28 To the ZF-filter
29 From the ZF-filter
32 Behind the Convertor to heat exchanger
33 Before the Convertor to heat exchanger
34 From heat exchanger to lubrication into Transmission
51 Before the Convertor - Opening Pressure 8.5 bar H
52 Behind the Convertor - Opening Pressure 5 bar
53 Clutch forward 16+2 bar KV B
55 Clutch reverse 16+2 bar KR F
56 Clutch 16+2 bar K1 D
57 Clutch 16+2 bar K2 A
58 Clutch 16+2 bar K3 C
60 Clutch 16+2 bar K4 E
63 Temp. 100 C behind the retarder (short time 150 C)
65 System pressure 16+2 K
66 Temp. 100 C behind the converter (short time 120 C)
67 WK-Control pressure 131 bar
Fig. 5 - Oil Circulation Diagram for Typical Transmission with Lockup Clutch and Retarder
Section 120-0010
7
SM 2124 Rev 3 8-03
OPERATION
EST-37 Automatic Shift Control
The EST-37 transmission is equipped with an
electronic control unit (ECU) which continually
monitors the transmission and shift system electrical
components and warns the operator when a problem
develops. It also takes action to prevent damage to
the transmission, and provides the serviceman with
diagnostic capabilities so that problems can be
corrected quickly and easily.
When a fault occurs, a two digit error code will be
displayed on the LCD display on the dash panel. The
error code is also recorded in the transmission ECU,
and can be accessed by the serviceman by plugging
in a data reader to extract information relating to the
fault. The error code recorded in the ECU memory
will remain until it is erased by a technician.
If a major fault is detected, it is the operators
responsibility to shut down the machine as soon as it
is safe to do so. The machine should not be restarted
until the fault has been diagnosed and corrected.
Refer to 'EST-37 Trouble Shooting' table for a list of
fault codes and checks.
The EST-37 transmission control has been designed
to provide the driver with maximum operational
flexibility by allowing the choice of automatic or
manual gear selection to optimize vehicle
performance under all operating conditions.
The transmission provides six forward gears, three
reverse gears and a neutral position. The gear
positions are indicated on the LCD display located on
the dash panel. The transmission will only operate in
the gear selected by the operator in the manual
range, or, when the lever is in the automatic range,
shifts will occur automatically between 1st and 6th
gear, depending on operating requirements. The
reverse gears 1st through 3rd are manual mode only.
WARNING
equipped with an EST-37 shift system,
disconnect battery earth cable, battery supply
cable, alternator earth cables, alternator supply
positive cables, body hydraulics joystick and
electrical connections at the ECU to avoid
damage to electrical components. Turn off
battery master switch to isolate the batteries
VTS-3 Shift Controller - Operation: The shift
controller has 3 positions the lever can rest in,
Forward, Neutral and Reverse. Within each of these
positions, the gear can be changed by pushing the
lever to the right (+) to upshift or to the left (-) to
downshift. In the Neutral position, this can be used to
preselect the starting gear (the default being 2nd
gear).
The shift controller has a 'Function' button on the top
of the lever which is used to switch between
automatic and manual modes. Press the function
button from 'NEUTRAL' and move the lever forward to
select automatic mode, when driving normal
upshifting and downshifting will occur. If required, a
gear can be held in manual mode by pressing the
function button once, to resume full automatic mode
the function button should be pressed again. Manual
gears can also be selected by pushing the lever to
the left for lower gears or to the right for higher gears,
again by pressing the function button once automatic
mode will be resumed.
Note: The transmission will only allow gearshifting
when the predetermined values have been reached.
Note: There is no shift inhibitor in the gear shift
control, therefore, no resistance would be felt while
moving through the gear ranges.
The gear lever housing sends a signal to the
electronic control unit, which in turn will only allow
the engine to be started when the gear lever is in the
'NEUTRAL' position. The gear shift lever must always
be placed in 'NEUTRAL' and the parking brake
applied when starting the engine, or whenever the
machine is left unattended.
When shifting from 'NEUTRAL' to start from a
standstill, or to reverse direction, decelerate the
engine to idle speed before selecting the proper gear.
When 'REVERSE' is selected, the 'Reverse Alarm'
sounds and the 'Reverse Light' illuminates to warn
personnel to the rear of the machine that reverse
gear has been selected.
During reversing operations it is recommended to
reduce engine speed, use only 1st or 2nd gear and
never exceed 10 km/h (6.2 mile/h).
Section 120-0010
SM 2124 Rev 3 8-03
8
The electronic control system distinguishes between
the throttle position (or load ranges) depending on the
governor position (injection pump). On a light throttle
opening, the transmission will give earlier upshifts
and later downshifts than when operating at full
throttle.
A kickdown facility (See Fig. 6), which can be used
when automatic mode is selected, allows for the
possibility of selecting a lower gear by pressing down
fully on the throttle pedal and holding. This can be
used to provide a downshift on demand provided that
the vehicle speed is within the range allowable. That
is, the vehicle is not travelling at a speed that would
result in the engine overspeeding in the lower gear.
When driving with kickdown, the transmission will
give earlier downshifts and later upshifts. To
disengage the transmission kickdown, release the
throttle pedal and allow it to return to a light throttle
position.
When operating in automatic range with the display
indicating that the transmission has downshifted to
2nd gear, there are two options for providing a further
downshift as conditions indicate.
1. 1st gear can be manually selected by pushing the
shift lever to the left.
2. Kickdown can be selected from 2nd automatic,
when the transmission will downshift to 1st gear,
depending upon vehicle speed.
When the kickdown is released the transmission will
upshift to 2nd automatic, provided that the forward
speed has increased sufficiently to allow this to
happen, and that the shift lever is in the automatic
mode.
A dashboard display is provided which indicates gear
selected and driving direction as follows (See Fig. 7):
Manual Mode - When driving with shift selector in
manual range, the bars only are shown in position 1,
and, driving direction and gear selected are indicated
in positions 2 and 3.
Automatic Mode - When driving with shift selector in
automatic range, a full display of bars and arrows are
shown in position 1, and, driving direction and gear
selected are indicated in positions 2 and 3.
Under certain conditions the transmission may start
to 'hunt' between gears when in automatic mode. The
transmission changes up and down between two
gears at short intervals because there is not
sufficient power to sustain driving in the higher gear,
but is sufficient for upshifting from the lower gear. By
using the shift display, it can be established which
gears are involved and in these circumstances the
lower gear should be selected using the shift control
lever. Automatic mode should be reselected at the
earliest opportunity.
During machine operation, watch for wide deviations
from normal readings on the transmission oil
temperature gauge. If the gauge shows the oil
temperature rising above the green zone during
normal operation, or above the yellow zone during
retarder operation, the machine must be stopped and
inspected for external oil leakage. If no leaks are
found, shift to 'NEUTRAL' and operate the engine at
1 200 - 1 500 rev/min. If the transmission oil
temperature does not decrease into the green zone
within 2 or 3 minutes, the cause of the overheating
should be corrected before the machine is operated
further.
Fig. 6 - Accelerator Load Ranges and Kickdown Position
SM - 1828
Fig. 7 - Dashboard Display
SM - 2335
1 - Bars show gear ranges and full display (as
shown) indicates driving in automatic mode.
2 - Display shows actual driving direction.
3 - Display shows actual gear in use.
IDLE
FULL LOAD/
THROTTLE
KICK/HOLD
DOWN
S
T
O
P
1 2 3
Section 120-0010
9
SM 2124 Rev 3 8-03
Note: In cold weather, the transmission oil should be
warmed up by running the engine at idle speed with
the gear selector in neutral, since the system will not
operate satisfactorily if the oil is too cold.
When temporarily stopped, such as for yielding the
right-of-way to a loaded machine, the transmission
can be left in gear and the machine held stationary
with the service brakes.
When stopped for a more extended period with the
engine left running, shift to 'NEUTRAL' to avoid
unnecessary heat buildup, and apply the parking
brake.
WARNINGS
Always select the correct drive direction and
gear before releasing the parking brake.
Never allow the machine to coast with the
transmission in 'NEUTRAL'.
WARNINGS
When running down a gradient the engine
speed should not be allowed to drop below
1 200 rev/min, at which point, lockup would
disengage preventing retarder operation.
In the event of a loss of electric power to the
gear shift control, the transmission will
automatically shift to 'NEUTRAL'. If this
occurs, stop the machine using the service
brakes and apply the parking brake. Do not
operate until the fault has been repaired.
Always select 'NEUTRAL' and apply the
parking brake before leaving the operators
seat.
The retarder will automatically disengage when
the oil temperature reaches 150 C (302 F),
irrespective of engine speed.
Display during operation
Symbol Meaning Remarks
1F, 1R Actual gear and direction. Left digit shows
2F, 2R actual gear, right digit shows actual
3F, 3R direction
4F
5F
6F
LF, LR limp home gear
F or R, no gear Clutch Cutoff
F or R flashing only 6WG:
direction F or R selected while turbine
speed is too high, CAUTION gear will
engage if turbine speed drops
NN not neutral, waiting for neutral after go engage a gear, first move shift
power up or a severe fault selector to neutral position and again
to F or R position
** oil temperature too low, no gear available warm up engine / transmission
*N oil temperature low, only one gear available warm up engine / transmission
1 bar (special symbol) manual mode 1. gear
2 bars manual mode 2. gear
4 bars and 2 arrows automatic mode
bars flashing 6 WG: converter lockup clutch open difference of engine and turbine speed
above a certain limit and lockup clutch
not activated
spanner at least one fault active select neutral to get fault code displayed
fault code see faultcode list
Section 120-0010
SM 2124 Rev 3 8-03
10
The AEB-Starter is a tool to start the AEB (automatic filling parameter adjustment) of ergopower transmissions
with ease. Connect AEB-Starter to plug X25 located below dash adjacent to TCU.
Display during operation - Continued
WS warning sump temperature changes between actual gear/direction
while driving, in neutral only displayed
if no fault is detected (spanner)
WR warning retarder temperature changes between actual gear/direction
WT warning torque converter temperature changes between actual gear/direction
WE warning high engine speed changes between actual gear/direction
PN direction F or R selected while parking transmission in neutral until parking
brake engaged brake is released CAUTION: vehicle
starts to move after release of parking
brake
F or R flashing direction F or R selected while turbine
speed is to high, CAUTION gear will
engage if turbine speed drops
EE flashing no communication with display checked wiring from TCU to display
Display during AEB-Mode
PL AEB - Starter is plugged at the diagnostic
plug
ST AEB-Starter-button is pressed
K1..K4,KV,KR calibrating clutch K1..K4,KV,KR
_ and Kx wait for start, initialization of clutch Kx,
x: 1, 2, 3, 4, V, R
and Kx fast fill time determination of clutch Kx
= and Kx compensating pressure determination of
clutch Kx
OK calibration for all clutches finished Transmission stays in neutral, you
have to restart the TCU (ignition off/on)
after removing AEB-Starter
STOP AEB cancelled (activation stopped) Transmission stays in neutral, you
STOP and Kx AEB stopped, clutch Kx cant be calibrated Transmission stays in neutral, you
Spanner and Kx Kx couldnt be calibrated, AEB finished Transmission stays in neutral, you
E engine speed too low, -> raise engine
speed
E engine speed too high, -> lower engine
speed
T transmission oil temperature too low,
-> heat up transmission
Section 120-0010
11
SM 2124 Rev 3 8-03
Display during AEB-Mode - Continued
T transmission oil temperature too high
-> cool down transmission
FT transmission temperature not in defined Transmission stays in neutral, you
range during calibration have to restart the TCU (ignition off/on)
FB operating mode not NORMAL or Transmission stays in neutral, you
transmission temperature sensor defective have to restart the TCU (ignition off/on)
or storing of Calibrated values to
EEPROM-has failed.
FO Outputspeed_not_zero Transmission stays in neutral, you
FN Shift lever not in Neutral position Transmission stays in neutral, you
FP Parkbrake_not_applied Transmission stays in neutral, you
STOP AEB - Starter was used incorrect or is Transmission stays in neutral, you
defective have to restart the TCU (ignition off/on)
TABLE OF FAULT CODES
Fault MEANING OF CODE TCU reaction Checks Remarks
Code possible reason for fault detection
(hex)
11 LOGICAL ERROR AT GEAR RANGE SIGNAL TCU shifts transmission to check cables from TCU to Failure cannot be
TCU detected a wrong signal combination for the neutral shift lever detected in systems
gear range OP-Mode: transmission check signal combinations with DW2/DW3 shift
cable from shift lever to TCU is broken shutdown of shift lever positions for lever
cable is defective and is contacted to battery voltage gear range
or vehicle ground
shift lever is defective
12 LOGICAL ERROR AT DIRECTIONSELECT SIGNAL TCU shifts transmission to check cables from TCU to
TCU detected a wrong signal combination for the neutral shift lever
direction OP-Mode: transmission check signal combinations
cable from shift lever to TCU is broken shutdown of shift lever positions
cable is defective and is contacted to battery voltage F-N-R
or vehicle ground
13 LOGICAL ERROR AT ENGINE DERATING DEVICE after selecting neutral, check engine derating This fault is reset
TCU detected no reaction of engine while TCU changes to device after power up of
derating device active TCU
15 LOGICAL ERROR AT DIRECTION SELECT SIGNAL 2 TCU shifts transmission check cables from TCU Fault is taken back if
SHIFT LEVER to neutral if selector to shift lever 2 TCU detects a valid
TCU detected a wrong signal combination for the active check signal neutral signal for the
direction OP-Mode: transmission combinations of shift lever direction at the shift
cable from shift lever 2 to TCU is broken shutdown if selector positions F-N-R lever
cable is defective and is contacted to battery active
voltage or vehicle ground
16 LOGICAL ERRORAT AXLE CONNECTION OP-Mode: normal check cables from TCU
feedback axle connection measured by TCU to feedback axle
and output signal axle connection don't fit connection switch
axle can't be connected/disconnected due to check signals of the
mechanical problem feedback axle connection
one of the cables from feedback axle connection -
switch to TCU is broken
Section 120-0010
SM 2124 Rev 3 8-03
12
(hex)
17 S.C. TO GROUND AT customer specific check cables from TCU See figure 8
TCU detected a wrong voltage at the output pin, to device
that looks like a s.c. to vehicle ground check connectors from
cable is defective and is contacted to vehicle TCU to device
ground check the resistance of
device has an internal defect device
connector pin is contacted to vehicle ground
18 S.C. TO BATTERY VOLTAGE AT ADM4 no reaction check cables from TCU See figure 8
TCU detected a wrong voltage at the output pin, to relay
that looks like a s.c. to battery voltage check connectors from
cable is defective and is contacted to battery TCU to relay
voltage check the resistance of
relay has an internal defect relay
connector pin is contacted to battery voltage
19 O.C. AT ADM4 no reaction check cable from TCU See figure 8
TCU detected a wrong voltage at the output pin, to relay
that looks like a o.c. for this output pin check connectors from
cable is defective and has no connection to TCU relay to TCU
relay has an internal defect check resistance of
connector has no connection to TCU relay
25 S.C. TO BATTERY VOLTAGE OR O.C. AT TRANSMISSION SUMP no reaction, check cable from TCU to
TEMPERATURE SENSOR INPUT TCU uses default temp. sensor
the measured voltage is too high: OP-Mode: normal check connectors
cable is defective and is contacted to battery voltage check temperature sensor
cable has no connection to TCU
temperature sensor has an internal defect
connector pin is contacted to battery voltage or is
broken
26 S.C. TO GROUND AT TRANSMISSION SUMP TEMPERATURE SENSOR no reaction, check cable from TCU to
INPUT TCU uses default temp. sensor
the measured voltage is too low: OP-Mode: normal check connectors
cable is defective and is contacted to vehicle ground check temperature sensor
27 S.C. TO BATTERY VOLTAGE OR O.C. AT RETARDER no reaction, check cable from TCU to
TEMPERATURE SENSOR INPUT TCU uses default temp. sensor
the measured voltage is too high: OP-Mode: normal check connectors
cable is defective and is contacted to battery voltage check temperature sensor
connector pin is contacted to battery voltage or is
broken
28 S.C. TO GROUND AT RETARDER TEMPERATURE SENSOR INPUT no reaction, check cable from TCU to
the measured voltage is too low: TCU uses default temp. sensor
cable is defective and is contacted to vehicle ground OP-Mode: normal check connectors
temperature sensor has an internal defect check temperature sensor
31 S.C. TO BATTERY VOLTAGE OR O.C. AT ENGINE SPEED INPUT OP-Mode: substitute clutch check cable from TCU to
TCU measures a voltage higher than 7.00 V at speed control sensor
input pin check connectors
cable is defective and is contacted to battery voltage check speed sensor
speed sensor has an internal defect
connector pin is contacted to battery voltage or has
no contact
Section 120-0010
13
SM 2124 Rev 3 8-03
(hex)
32 S.C. TO GROUND AT ENGINE SPEED INPUT OP-Mode: substitute clutch check cable from TCU to
TCU measures a voltage less than 0.45V at speed input control sensor
pin check connectors
cable/connector is defective and is contacted to check speed sensor
vehicle ground
33 LOGICAL ERROR AT ENGINE SPEED INPUT OP-Mode: substitute clutch check cable from TCU to This fault is reset after
TCU measures a engine speed over a threshold and the control sensor power up to TCU
next moment the measured speed is zero check connectors
cable / connector is defective and has bad contact check speed sensor
speed sensor has an internal defect check sensor gap
sensor gap has the wrong size
34 S.C. TO BATTERY VOLTAGE OR O.C. AT TURBINE SPEED INPUT OP-Mode: substitute clutch check cable from TCU to
input pin if a failure is existing at check connectors
cable is defective and is contacted to battery voltage output speed, check speed sensor
cable has no connection to TCU TCU shifts to neutral
speed sensor has an internal defect OP-Mode: limp home
no contact
35 S.C. TO GROUND AT TURBINE SPEED INPUT OP-Mode: substitute clutch check cable from TCU to
TCU measures a voltage less than 0.45V at speed control sensor
input pin if a failure is existing at check connectors
cable / connector is defective and is contacted to output speed, check speed sensor
vehicle ground TCU shifts to neutral
speed sensor has an internal defect OP-Mode: limp home
36 LOGICAL ERROR AT TURBINE SPEED INPUT OP-Mode: substitute clutch check cable from TCU to This fault is reset after
TCU measures a turbine speed over a threshold and control sensor power up of TCU
at the next moment the measured speed is zero if a failure is existing at check connectors
cable / connector is defective and has bad contact output speed, check speed sensor
speed sensor has an internal defect TCU shifts to neutral check sensor gap
sensor gap has the wrong size OP-Mode: limp home
37 S.C. TO BATTERY VOLTAGE OR O.C. AT INTERNAL SPEED INPUT OP-Mode: substitute clutch check cable from TCU to
input pin check connectors
cable is defective and is contacted to battery voltage check speed sensor
no contact
38 S.C. TO GROUND AT INTERNAL SPEED INPUT OP-Mode: substitute clutch check cable from TCU to
TCU measures a voltage less than 0.45V at speed input control sensor
pin check connectors
cable / connector is defective and is contacted to check speed sensor
vehicle ground
39 LOGICAL ERROR AT INTERNAL SPEEDINPUT OP-Mode: substitute clutch check cable from TCU to This fault is reset after
TCU measures a internal speed over a threshold and at control sensor power up of TCU
the next moment the measured speed is zero check connectors
cable / connector is defective and has bad contact check speed sensor
speed sensor has an internal defect check sensor gap
sensor gap has the wrong size
Section 120-0010
SM 2124 Rev 3 8-03
14
(hex)
3A S.C. TO BATTERY VOLTAGE OR O.C. AT OUTPUT SPEED INPUT special mode for gear check cable from TCU to
TCU measures a voltage higher than 12.5 V at speed selection sensor
input pin OP-Mode: substitute clutch check connectors
cable is defective and is contacted to battery voltage control check speed sensor
cable has no connection to TCU if a failure is existing at
speed sensor has an internal defect turbine speed,
connector pin is contacted to battery voltage or has TCU shifts to neutral
no contact OP-Mode: limp home
3B S.C. TO GROUND AT OUTPUT SPEED INPUT special mode for gear check cable from TCU to
TCU measures a voltage less than 1.00V at speed input selection sensor
pin OP-Mode: substitute clutch check connectors
cable / connector is defective and is contacted to control check speed sensor
vehicle ground if a failure is existing at
turbine speed,
TCU shifts to neutral
OP-Mode: limp home
3C LOGICAL ERROR AT OUTPUT SPEEDINPUT special mode for gear check cable from TCU to This fault is reset after
TCU measures a output speed over a threshold and at selection sensor power up of TCU
the next moment the measured speed is zero OP-Mode: substitute clutch check connectors
cable / connector is defective and has bad contact control check speed sensor
speed sensor has an internal defect if a failure is existing at check sensor gap
sensor gap has the wrong size turbine speed,
TCU shifts to neutral
OP-Mode: limp home
3E OUTPUT SPEED ZERODOESNT FIT TO OTHER SPEED SIGNALS special mode for gear check sensor signal of This fault is reset after
if transmission is not neutral and the shifting has selection output speed sensor power up of TCU
finished, OP-Mode: substitute clutch check sensor gap of output
TCU measures outputspeed zero and turbine speed or control speed sensor
internal speed not equal to zero. if a failure is existing at check cable from TCU to
speed sensor has an internal defect turbine speed, sensor
sensor gap has the wrong size TCU shifts to neutral
OP-Mode: limp home
56 ENGINE CONF TIMEOUT OP-Mode: substitute clutch check engine controller
Timeout of CAN-message ENGINE CONF from engine control check wire of CAN-Bus
controller check cable to engine
interference on CAN-Bus controller
CAN wire/connector is broken
CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
57 EEC1 TIMEOUT OP-Mode: substitute clutch check EEC controller
Timeout of CAN-message EEC1 from EEC controller control check wire of CAN-Bus
interference on CAN-Bus check cable to EEC
CAN wire/connector is broken controller
58 EEC3 TIMEOUT OP-Mode: substitute clutch check EEC controller
Timeout of CAN-message EEC3 from EEC controller control check wire of CAN-Bus
interference on CAN-Bus check cable to EEC
CAN wire/connector is broken controller
65 ENGINGE TORQUE SIGNAL OP-Mode: substitute clutch check engine controller
CAN signal for engine torque is defective control check wire of CAN-Bus
engine controller is defective check cable to engine
66 KICKDOWNSIGNAL no reaction check engine controller
CAN signal for kickdown is defective check wire of CAN-Bus
Section 120-0010
15
SM 2124 Rev 3 8-03
(hex)
69 REFERENCE ENGINE TORQUE SIGNAL OP-Mode: substitute clutch check engine controller
CAN signal for reference of engine torque is defective control check wire of CAN-Bus
6A ACTUAL ENGINE TORQUE SIGNAL OP-Mode: substitute clutch check engine controller
CAN signal for actual engine torque is defective control check wire of CAN-Bus
6B NOMFRICTIONTORQUE SIGNAL OP-Mode: substitute clutch check engine controller
CAN signal for nominal friction torque is defective control check wire of CAN-Bus
6E EEC2 TIMEOUT no reaction check EEC controller
Timeout of CAN-message EEC2 from EEC controller TCU uses default signal check wire of CAN-Bus
interference on CAN-Bus accelerator pedal in idle check cable to EEC
CAN wire/connector is broken position controller
CAN wire/connector is defective and has contact to OP-Mode: normal
6F ACCELERATOR LOWIDLE SWITCHSIGNAL no reaction check EEC controller if this signal is not
CAN signal for manual downshift is defective TCU uses default signal check wire of CAN-Bus transmitted via CAN,
EEC controller is defective accelerator pedal in idle check cable to EEC TCU uses default
interference on CAN-Bus position controller signal
OP-Mode: normal
71 S.C. TO BATTERY VOLTAGE AT CLUTCH K1 TCU shifts to neutral check cable from TCU to
1)
see figure 8
the measured resistance value of the valve is out of OP-Mode: limp home gearbox
limit, the voltage at K1 valve is too high. if failure at another check connectors from
cable / connector is defective and has contact to clutch is pending TCU to gearbox
battery voltage TCU shifts to neutral check regulator resistance
1)
cable / connector is defective and has contact to OP-Mode: TCU shutdown check internal wire
another regulator output of the TCU harness of the gearbox
regulator has an internal defect
72 S.C. TO GROUND AT CLUTCH K1 TCU shifts to neutral check cable from TCU to
1)
see figure 8
limit, the voltage at K1 valve is too low. if failure at another check connectors from
cable / connector is defective and has contact to clutch is pending gearbox to TCU
vehicle ground TCU shifts to neutral check regulator resistance
1)
regulator has an internal defect OP-Mode: TCU shutdown check internal wire
harness of the gearbox
73 O.C. AT CLUTCH K1 TCU shifts to neutral check cable from TCU to
1)
see figure 8
limit. if failure at another check connectors from
cable / connector is defective and has no contact to clutch is pending gearbox to TCU
TCU TCU shifts to neutral check regulator resistance
1)
1)
see figure 8
1)
Section 120-0010
SM 2124 Rev 3 8-03
16
(hex)
1)
see figure 8
1)
1)
see figure 8
1)
1)
see figure 8
1)
1)
see figure 8
1)
1)
see figure 8
1)
1)
see figure 8
1)
1)
see figure 8
1)
1)
see figure 8
1)
Section 120-0010
17
SM 2124 Rev 3 8-03
(hex)
84 S.C. TO BATTERY VOLTAGE AT CLUTCH KV TCU shifts to neutral check cable from TCU to
1)
see figure 8
limit, the voltage at KV valve is too high. if failure at another check connectors from
1)
85 S.C. TO GROUND AT CLUTCH KV TCU shifts to neutral check cable from TCU to
1)
see figure 8
limit, the voltage at KV valve is too low. if failure at another check connectors from
1)
86 O.C. AT CLUTCH KV TCU shifts to neutral check cable from TCU to
1)
see figure 8
1)
87 S.C. TO BATTERY VOLTAGE AT CLUTCH KR TCU shifts to neutral check cable from TCU to
1)
see figure 8
limit, the voltage at KR valve is too high. if failure at another check connectors from
1)
88 S.C. TO GROUND AT CLUTCH KR TCU shifts to neutral check cable from TCU to
1)
see figure 8
limit, the voltage at KR valve is too low. if failure at another check connectors from
1)
89 O.C. AT CLUTCH KR TCU shifts to neutral check cable from TCU to
1)
see figure 8
1)
91 S.C. TO GROUND AT RELAY REVERSE WARNING ALARM backup alarm will be on check cable from TCU to
1)
see figure 8
TCU detected a wrong voltage at the output pin, that until TCU power down backup alarm device
looks like a s.c. to vehicle ground even if fault vanishes check connectors from
cable is defective and is contacted to vehicle ground (loose connection) backup alarm device to
backup alarm device has an internal defect OP-Mode: normal TCU
connector pin is contacted to vehicle ground check resistance
1)
of
backup alarm device
92 S.C. TO BATTERY VOLTAGE AT RELAY REVERSE WARNINGALARM no reaction check cable from TCU to
1)
see figure 8
TCU detected a wrong voltage at the output pin, that OP-Mode: normal backup alarm device
looks like a s.c. to battery voltage check connectors from
cable is defective and is contacted to battery voltage backup alarm device to
backup alarm device has an internal defect TCU
connector pin is contacted to battery voltage check resistance
1)
of
backup alarm device
Section 120-0010
SM 2124 Rev 3 8-03
18
(hex)
93 O.C. AT RELAY REVERSE WARNING ALARM no reaction check cable from TCU to
1)
see figure 8
TCU detected a wrong voltage at the output pin, that OP-Mode: normal backup alarm device
looks like a o.c. for this output pin check connectors from
cable is defective and has no connection to TCU backup alarm device to
backup alarm device has an internal defect TCU
connector has no connection to TCU check resistance
1)
of
backup alarm device
9A S.C. TO GROUND AT CONVERTER LOCK UP CLUTCH no reaction check cable from TCU to
1)
see figure 8
TCU detected a wrong voltage at the output pin, that OP-Mode: normal converter clutch solenoid
looks like a s.c. to vehicle ground check connectors from
cable is defective and is contacted to vehicle ground converter clutch solenoid
converter clutch solenoid has an internal defect to TCU
connector pin is contacted to vehicle ground check resistance
1)
of
converter clutch solenoid
9B O.C. AT CONVERTER LOCK UP CLUTCH converter clutch always check cable from TCU to
1)
see figure 8
TCU detected a wrong voltage at the output pin, that open, retarder not converter clutch solenoid
looks like a o.c. for this output pin available check connectors from
cable is defective and has no connection to TCU OP-Mode: normal converter clutch solenoid
connector has no connection to TCU check resistance
1)
of
9C S.C. TO BATTERY VOLTAGE AT CONVERTER LOCK UP CLUTCH no reaction check cable from TCU to
1)
see figure 8
TCU detected a wrong voltage at the output pin, that OP-Mode: normal converter clutch solenoid
cable is defective and is contacted to battery voltage converter clutch solenoid
connector pin is contacted to battery voltage check resistance
1)
of
9D S.C. TO GROUND AT RETARDER no reaction check cable from TCU to
1)
see figure 8
TCU detected a wrong voltage at the output pin, that OP-Mode: normal retarder solenoid
cable is defective and is contacted to vehicle ground retarder solenoid to TCU
retarder solenoid has an internal defect check resistance
1)
of
connector pin is contacted to vehicle ground retarder solenoid
9E O.C. AT RETARDER no reaction check cable from TCU to
1)
see figure 8
cable is defective and has no connection to TCU retarder solenoid to TCU
1)
of
connector has no connection to TCU retarder solenoid
9F S.C. TO BATTERY VOLTAGE AT RETARDER SOLENOID no reaction check cable from TCU to
1)
see figure 8
cable is defective and is contacted to battery voltage retarder solenoid to TCU
1)
of
connector pin is contacted to battery voltage retarder solenoid
A1 S.C. TO GROUND AT DIFFLOCK SOLENOID no reaction check cable from TCU to
1)
see figure 8
TCU detected a wrong voltage at the output pin, that OP-Mode: normal difflock solenoid
cable is defective and is contacted to vehicle ground difflock solenoid to TCU
difflock solenoid has an internal defect check resistance
1)
of
connector pin is contacted to vehicle ground difflock solenoid
A2 S.C. TO BATTERY VOLTAGE AT DIFFLOCK SOLENOID no reaction check cable from TCU to
1)
see figure 8
cable is defective and is contacted to battery voltage difflock solenoid to TCU
1)
of
connector pin is contacted to battery voltage difflock solenoid
A3 O.C. AT DIFFLOCK SOLENOID no reaction check cable from TCU to
1)
see figure 8
cable is defective and has no connection to TCU difflock solenoid to TCU
1)
of
connector has no connection to TCU difflock solenoid
Section 120-0010
19
SM 2124 Rev 3 8-03
(hex)
A4 S.C. TO GROUND AT WARNING SIGNAL OUTPUT no reaction check cable from TCU to
1)
see figure 8
TCU detected a wrong voltage at the output pin, that OP-Mode: normal warning device
cable is defective and is contacted to vehicle ground warning device to TCU
warning device has an internal defect check resistance
1)
of
connector pin is contacted to vehicle ground warning device
A5 O.C. AT WARNING SIGNAL OUTPUT no reaction check cable from TCU to
1)
see figure 8
cable is defective and has no connection to TCU warning device to TCU
1)
of
connector has no connection to TCU warning device
A6 S.C. TO BATTERY VOLTAGE AT WARNINGSIGNAL OUTPUT no reaction check cable from TCU to
1)
see figure 8
cable is defective and is contacted to battery voltage warning device to TCU
1)
of
connector pin is contacted to battery voltage warning device
B1 SLIPPAGE AT CLUTCH K1 TCU shifts to neutral check pressure at clutch K1
TCU calculates a differential speed at closed clutch K1. OP-Mode: limp home check main press. in system
If this calculated value is out of range, TCU interprets if failure at another check sensor gap at internal
this as slipping clutch. clutch is pending speed sensor
low pressure at clutch K1 TCU shifts to neutral check sensor gap at output
low main pressure OP-Mode: TCU shutdown speed sensor
wrong signal at internal speed sensor check signal at internal
wrong signal at output speed sensor speed sensor
wrong size of the sensor gap check signal at output
clutch is defective speed sensor
replace clutch
replace clutch
replace clutch
low pressure at clutch K4 TCU shifts to neutral check sensor gap at turbine
wrong signal at turbine speed sensor speed sensor
wrong size of the sensor gap check signal at turbine
replace clutch
Section 120-0010
SM 2124 Rev 3 8-03
20
(hex)
B5 SLIPPAGE AT CLUTCH KV TCU shifts to neutral check pressure at clutch KV
TCU calculates a differential speed at closed clutch KV. OP-Mode: limp home check main press. in system
low pressure at clutch KV TCU shifts to neutral check sensor gap at turbine
replace clutch
B6 SLIPPAGE AT CLUTCH KR TCU shifts to neutral check pressure at clutch KR
TCU calculates a differential speed at closed clutch KR. OP-Mode: limp home check main press. in system
low pressure at clutch KR TCU shifts to neutral check sensor gap at turbine
replace clutch
B7 OVERTEMP SUMP no reaction cool down machine
TCU measured a temperature in the oil sump that is OP-Mode: normal check oil level
over the allowed threshold. check temperature sensor
B8 OVERTEMP RETARDER TCU disables retarder cool down machine
TCU measured a temperature in the retarder oil that is OP-Mode: normal check oil level
over the allowed threshold. check temperature sensor
B9 OVERSPEEDENGINE retarder applies - not used
OP-Mode: normal
BA DIFFERENTIAL PRESSURE OIL FILTER no reaction check oil filter
TCU measured a voltage at differential pressure switch OP-Mode: normal check wiring from TCU to
out of the allowed range. differential pressure switch
oil filter is polluted check differential pressure
cable/connector is broken or cable/connector is switch (measure resistance)
contacted to battery voltage or vehicle ground
differential pressure switch is defective
BB SLIPPAGE AT CONVERTER LOCKUP CLUTCH check pressure at
TCU calculates a differential speed at closed converter converter lockup clutch
lockup clutch. If this calculated value is out of range, check main pressure in the
TCU interprets this as slipping clutch. system
low pressure at converter lockup clutch check sensor gap at engine
low main pressure speed sensor
wrong signal at engine speed sensor check sensor gap at turbine
wrong size of the sensor gap check signal at engine
check signal at turbine
speed sensor
replace clutch
BD S.C. TO GROUNDAT ENGINE BRAKE SOLENOID no reaction check cable from TCU to
1)
see figure 8
TCU detected a wrong voltage at the output pin, that OP-mode: normal engine brake solenoid
cable is defective and is contacted to vehicle ground engine brake solenoid
engine brake solenoid has an internal defect to TCU
connector pin is contacted to vehicle ground check the resistance
1)
of
engine brake solenoid
Section 120-0010
21
SM 2124 Rev 3 8-03
(hex)
BE S.C. TO BATTERY VOLTAGE AT ENGINE BRAKE no reaction check cable from TCU to
1)
see figure 8
cable is defective and is contacted to battery voltage engine brake solenoid
connector pin is contacted to battery voltage check the resistance
1)
of
BF O.C. AT ENGINE BRAKE no reaction check cable from TCU to
1)
see figure 8
cable is defective and has no connection to TCU engine brake solenoid
connector has no connection to TCU check the resistance
1)
of
C3 OVERTEMP TORQUE CONVERTOROUTPUT no reaction cool down machine
TCU measured an oil temperature at the OP-mode: normal check oil level
converter output that is over the allowed threshold check temperature
sensor
CA ENGINE_RETARDERCONFIG_TIMEOUT OP-mode: substitute check EEC controller
Timeout of CAN message clutch control check wire of CAN-Bus
ENGINE_RETARDER CONFIG from EEC check cable to EEC
controller controller
inteference on CAN-Bus
CAN wire/connector is defective and has contact
to vehicle ground or battery voltage
CB ERC1 TIMEOUT OP-mode: substitute check EEC controller
Timeout of CAN-message ERC1 from EEC clutch control check wire of CAN-Bus
controller check cable to EEC
inteference on CAN-Bus controller
CAN wire/connector is defective and has contact
to vehicle ground or battery voltage
D1 S.C. TO BATTERY VOLTAGE AT POWER SUPPLY FOR SENSORS see fault codes no. 21 check cables and fault codes no. 21
TCU measures more than 6V at the pin AU1 to no. 2C connectors to sensors, to no. 2C may be
(5V sensor supply) which are supplied a reaction of this
from AU1 fault
check power supply at
pin AU1 (should be
approx. 5V)
D2 S.C. TO GROUND AT POWER SUPPLY FOR SENSORS see fault codes no. 21 check cables and fault codes no. 21
TCU measures less than 4V at the pin AU1 to no. 2C connectors to sensors, to no. 2C may be
(5V sensor supply) which are supplied a reaction of this
from AU1 fault
check power supply at
pin AU1 (should be
approx. 5V)
D3 LOWPOWER AT BATTERY shift to neutral check power supply
measured voltage at power supply is lower OP-Mode: TCU shutdown battery
than 18 V check cables from
batteries to TCU
check connectors from
batteries to TCU
D4 HIGHPOWER AT BATTERY shift to neutral check power supply
measured voltage at power supply is higher OP-Mode: TCU shutdown battery
than 32.5 V check cables from
batteries to TCU
check connectors from
batteries to TCU
Section 120-0010
SM 2124 Rev 3 8-03
22
(hex)
D5 ERROR AT SWITCH 1 FOR VALVE POWER SUPPLY VPS1 shift to neutral check fuse
TCU switched on VPS1 and measured VPS1 is off or OP-Mode: TCU shutdown check cables from
TCU switched off VPS1 and measured VPS1 is still on gearbox to TCU
cable or connectors are defect and are contacted to check connectors from
battery voltage gearbox to TCU
cable or connectors are defect and are contacted to replace TCU
vehicle ground
permanent power supply KL30 missing
TCU has an internal defect
D6 ERROR AT SWITCH 2 FOR VALVE POWER SUPPLY VPS2 shift to neutral check fuse
TCU switched on VPS2 and measured VPS2 is off or OP-Mode: TCU shutdown check cables from
TCU switched off VPS2 and measured VPS2 is still on gearbox to TCU
cable or connectors are defect and are contacted to check connectors from
battery voltage gearbox to TCU
cable or connectors are defect and are contacted to replace TCU
vehicle ground
permanent power supply KL30 missing
TCU has an internal defect
E3 S.C. TO BATTERY VOLTAGE AT DISPLAY OUTPUT no reaction check cable from TCU
TCU sends data to the display and measures always a OP-Mode: normal to the display
high voltage level on the connector. check connectors at
cable or connectors are defect and are contacted to the display
battery voltage change display
display has an internal defect
E4 S.C. TO GROUND AT DISPLAY OUTPUT no reaction check cable from TCU
TCU sends data to the display and measures always a OP-Mode: normal to the display
high voltage level on the connector. check connectors at
cable or connectors are defect and are contacted to the display
vehicle ground change display
display has an internal defect
F1 GENERAL EEPROM FAULT no reaction replace TCU often shown
TCU cannot read non volatile memory OP-Mode: normal together with fault
TCU is defective code F2
F3 APPLICATIONERROR transmission stay neutral replace TCU fault occurs only if
something of this application is wrong OP-Mode: TCU shutdown a test engineer did
something wrong in
the application of
the vehicle
F5 CLUTCHFAILURE transmission stay neutral check clutch TCU shows also the
AEB was not able to adjust clutch filling parameters OP-Mode: TCU shutdown affected clutch on
One of the AEB-Values is out of limit the Display
F6 CLUTCH ADJUSTMENT DATA LOST TCU shifts to neutral execute AEB
TCU was not able to read correct clutch adjustment OP-Mode: limp home
parameters
interference during saving data on non volatile
memory
TCU is brand new or from another vehicle
Section 120-0010
23
SM 2124 Rev 3 8-03
Retarder
The retarder is engaged when the bottom of the switch is
pressed and provided that the transmission 'Stop' warning
light is OUT and the transmission is in 'lockup'. To
disengage retarder, press the top of the switch. On TA40
machines, the retarder switch is incorporated in the brake
pedal. The first 7 of pedal travel engages the retarder,
provided that the transmission 'Stop' warning light is OUT
and the transmission is in 'lockup'. Further depression of
pedal applies service brakes. To disengage retarder,
release brake pedal. A warning light illuminates on the
dash to indicate when retarder is applied.
The retarder is used to apply a continuous braking force
to hold the truck to a safe steady speed when descending
grades, to reduce the need for service brake applications,
thus reducing service brake wear and preventing
overheating. The retarder may be used anytime to slow
down. If additional braking is required apply the service
brakes. The retarder is not meant for bringing the vehicle
to a halt, or for sudden deceleration - the service brakes
should be employed for this purpose.
Before the vehicle starts down the grade, release
accelerator, slow the vehicle with the service brakes,
select the required gear, and apply the retarder. For
maximum retardation, oil circulation and cooling, the
vehicle downgrade speed (retarder applied) in the gear
selected should be high enough to keep the engine
operating at governed speed. Generally the gear used to
ascend a grade is also correct for its descent. If the rate
of descent is too slow, the transmission should be
upshifted to the next highest gear. If the rate of descent
is too fast, the service brakes should be applied and the
transmission shifted into a lower gear which will allow a
safe descent and efficient retarder operation.
Frequent use of the retarder will result in higher transmission
oil temperatures. Therefore, the oil temperature gauge
should be checked frequently. During normal operation
the gauge should read in the green zone. However, during
retarder operation the gauge can read in the yellow zone.
Provided the vehicle is not in an overspeed condition, the
transmission 'Stop' warning light will illuminate when the
1
1 2
2
R
G
TCU
U
Bat
Gnd
P (power supply)
C (chassis)
Actuator / Sensor
8.1 Actuator:
8.2 Cable:
open circuit: R
12
R
1G
R
2G

short cut to ground: R
12
R; R
1G
0, R
2G
R or R
1G
R, R
2G
0 (for s.c. to ground, G is connected to
vehicle ground)
short cut to battery: R
12
R; R
1G
0, R
2G
R or R
1G
R, R
2G
0 (for s.c. to battery, G is connected to
battery voltage)
open circuit: R
12
R
1P
R
1C
R
2P
R
2C

short cut to ground: R
12
0; R
1C
R
2C
0, R
1P
R
2P

short cut to battery: R
12
0, R
1C
R
2C
, R
1P
R
2P
0
Fig. 8 - Measuring Resistance at Actuator/Sensors and Cable
Section 120-0010
SM 2124 Rev 3 8-03
24
3. Disconnect the following cables and connectors in
the order given, to prevent serious damage to the
vehicles electrical components.
a - Battery earth cables
b - Battery supply cables
c - Alternator earth cables
d - Alternator supply cables
e - Body hydraulics joystick
f - Transmission (Est-37) connector
g - ECM interface harness connector (30 pin RHS)
h - ECM power harness connector (5 pin RHS)
i - ECM sensor harness connector (30 pin LHS)
j - ECM engine to transmission datalink connector
(6 pin RHS)
4. Carefully loosen brake pipes at base of both
accumulators to check that brake pressure has been
discharged. Tighten brake pipes.
5. Remove blanking cap from remote drain line at the
bottom of the hydraulic tank. Install a length of hose
on remote drain fitting, open drain cock and drain
hydraulic oil into a suitable container. Close drain
cock, remove hose and reinstall blanking cap.
6. Disconnect transmission harness at the cab floor
and earth strap between rear LH side of the
transmission and the frame.
7. Remove cab from the machine. Refer to Section
260-0010, CAB AND MOUNTING.
8. Disconnect all drivelines connected to the
transmission and secure clear of the transmission.
Refer to Section 130-0010, DRIVELINES.
9. Remove both exhaust tubes above transmission.
10. Disconnect all electrical harnesses and
connections not previously disconnected on removal of
the cab assembly.
11. Identify and tag all hydraulic lines at the main
hydraulic, brake and emergency steering pumps.
Disconnect hydraulic lines and cap lines and ports to
prevent entry of dirt.
Note: The transmission can be removed from the
vehicle without removing any of the pumps.
transmission oil temperature reaches 140 C (284 F). The
retarder will automatically disengage when the oil
temperature reaches 150 C (302 F) irrespective of
engine speed. The speed must be reduced by using the
service brakes so that the oil is cooled down. Reduce
downgrade travel speed to avoid the oil overheating and
possible damage to the transmission.
If the vehicle is approaching an overspeed condition,
the transmission performs an upshift at an engine
speed of 2 500 rev/min to the next highest gear to
decrease the engine speed, whether in manual or
automatic mode. If 6th gear is already selected, the
retarder is automatically engaged at 2600 rev/min to
decrease the engine speed irrespective of the
accelerator position. The retarder is disengaged at
2450 rev/min. A fault code will be displayed and
recorded by the TCU. If the oil temperature reaches
150 C (302 F) the retarder is disengaged and a fault
code will be displayed and recorded by the TCU.
REMOVAL
Note: Tag all lines, cables and linkages disconnected
during removal to aid in installation.
WARNINGS
be sure wheel blocks, blocking materials and
lifting equipment are properly secured and of
Hydraulic oil pressure will remain within
the braking system after engine shutdown.
Operate the treadle valve continuously until
the pressure has dissipated before removing
any brake lines or serious injury could result.
High electrical current can cause sparks
and personal injury from burns. Turn battery
master switch to the 'Off' position before
disconnecting any components.
body is fully lowered, apply the parking brake and switch
off the engine. Operate steering right and left several
times to relieve any pressure in the steering system.
2. Operate the treadle valve continuously to discharge the
brake accumulators, block all road wheels, place the
steering lock bar in the 'Locked' position and the battery
master switch in the 'Off' position.
Section 120-0010
25
SM 2124 Rev 3 8-03
12. Identify, tag and disconnect hydraulic lines at
transmission differential lock cylinder. Cap lines and
ports to prevent entry of dirt.
13. Identify, tag and disconnect transmission oil cooler
lines from the transmission retarder valve. Cap lines
and ports to prevent entry of dirt.
14. Identify and tag oil filter hose assemblies (2, 3 &
26, Fig. 9) to aid installation. Disconnect hose
assemblies (2, 3 & 26, Fig. 9) and cap open ends and
adaptor (1, Fig. 9) and elbows (4, 11 & 27, Fig. 9) to
15. Identify and tag diagnostic hose assemblies (6, 7 &
8, Fig. 9) to aid in installation. Disconnect hose
assemblies (6, 7 & 8, Fig. 9) and cap open ends and
elbow (5, Fig. 9) and adaptors (10 & 26, Fig. 9) to
16. Identify, tag and disconnect all remaining lines and
fixtures necessary to allow removal of the transmission
from the vehicle.
17. Attach suitable lifting equipment to the lifting points
on transmission and raise lifting equipment to take up
the slack.
18. Remove locknut (5), hardened washer (14), bolt (6)
and snubbing washer (3) securing LH bracket (7) to
frame mounts.
19. Remove locknut (5), hardened washer (14), bolt (6)
and snubbing washer (3) securing RH bracket (13) to
frame mounts.
20. Remove locknuts (5), washers (4), snubbing
washers (3) and bolts (6) securing front bracket
assembly (1) to frame mounts.
1 - Adaptor
2 - Hose Assembly
3 - Hose Assembly
4 - Elbow
5 - Elbow
6 - Hose Assembly
7 - Hose Assembly
8 - Hose Assembly
9 - Dust Cap
10 - Adaptor
11 - Elbow
12 - Adaptor
13 - Adaptor
14 - Diagnostic Nipple
15 - Oil Filter Head
16 - Filter Cartridge
17 - Tee
18 - Adaptor
19 - Hose Assembly
20 - Elbow
21 - Adaptor
22 - Hose Assembly
23 - Adaptor
24 - Elbow
25 - Adaptor
26 - Hose Assembly
27 - Elbow
Fig. 9 - Transmission Oil Lines
SM - 2682
C
B
A
6
7 12
1
9
9
14
14
5
12
10
24
19
13
23
25
17
11
20 21
22
8
4
15,16
1
10
4
TO SOL VALVE
PORT T
RETARDER
VALVE
2
3
27
26
18
Section 120-0010
SM 2124 Rev 3 8-03
26
cable disconnections have been made before lifting the
transmission.
22. Carefully raise the transmission ensuring that no
lines, cables or components foul during removal.
When the transmission is clear of the frame
assembly, move to a suitable work area and mount
securely on a work stand.
23. Remove front isolation mounts (2) from frame
mounts and replace if required.
DISASSEMBLY
1. Remove mounting hardware securing retarder
solenoid, differential lock solenoid and pressure
reducing valve to front bracket assembly (1).
Remove items from front bracket assembly (1).
2. Remove bolts (12), lockwashers (11) and front
bracket assembly (1) from the transmission.
3. Remove bolts (10), lockwashers (9) and LH
bracket (7) from the transmission. Remove isolation
mount (8) from LH bracket (7) and replace if required.
4. Remove bolts (10), lockwashers (9) and RH bracket
(13) from the transmission. Remove isolation mount (8)
from RH bracket (13) and replace if required.
5. Remove mounting hardware securing main
hydraulic pump to the transmission power takeoff.
Refer to Section 230-0050, MAIN HYDRAULIC
PUMP.
6. Remove mounting hardware securing brake pump
to the transmission power takeoff. Refer to Section
250-0040, BRAKE PUMP.
7. If required, identify and tag electrical connections
to engine speed sensor, output speed sensor, central
gear train sensor and turbine speed sensor (5, 6, 7 &
8, Fig. 2) and remove sensors from the transmission.
8. If required, identify and tag electrical connections
to oil temperature sender (gauge) (9, Fig. 2) and
retarder oil temperature sender (1, Fig. 2) and
remove from the top of the transmission.
9. Remove locknut (20), bolt (21), lockwasher (22)
and clamp (17) securing dipstick tube (15) assembly to
bracket (16). Remove screws (23), dipstick tube (15)
assembly and gasket (24) from the transmission.
10. Refer to transmission manufacturers service
manual if transmission service or repair is required.
INSPECTION
1. Check front bracket assembly (1), LH bracket (7),
RH bracket (13) and frame mounting brackets for
cracks and damage. Repair or replace as required.
2. Check general condition of transmission assembly
for wear and damage. Check for worn or damaged
driveline flanges and excessive wear on mounting
holes.
3. Check condition of all electrical harnesses and
connections and repair/replace as required. Check
condition of all hydraulic lines on the transmission
and replace if damaged.
ASSEMBLY
specified to standard torques listed in Section 300-
0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
1. Install new gasket (24) on dipstick tube (15)
assembly and secure assembly to the transmission
with screws (23). Secure dipstick tube (15) to
bracket (16) with bolt (21), lockwasher (22), clamp
(17) and locknut (20).
2. If removed, install oil temperature sender (gauge)
(9, Fig. 2) and retarder oil temperature sender (9, Fig.
2) in top of the transmission. Tighten electrical
connection securely.
3. If removed, install engine speed sensor, output
speed sensor, central gear train sensor and turbine
speed sensor (5, 6, 7 & 8, Fig. 2) in the transmission
as shown in Fig. 2. Tighten electrical connections
securely.
4. Install main hydraulic pump to the transmission
power takeoff and secure using mounting hardware
removed at Disassembly. Refer to Section 230-0050,
MAIN HYDRAULIC PUMP.
Section 120-0010
27
SM 2124 Rev 3 8-03
5. Install brake pump to the transmission power takeoff
and secure using mounting hardware removed at
Disassembly. Refer to Section 250-0040, BRAKE
PUMP.
6. Secure LH bracket (7) and RH bracket (13) to the
transmission with bolts (10) and lockwashers (9).
7. Secure front bracket assembly (1) to the
transmission with bolts (12) and lockwashers (11).
8. Secure retarder solenoid, differential lock solenoid
and pressure reducing valve to front bracket
assembly (1) with mounting hardware removed during
disassembly.
INSTALLATION
SPECIFICATIONS.
Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 250-0000,
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
where used.
WARNING
safely.
Note: Isolation mounts (2 & 8) are colour coded to
aid in installation. Front isolation mounts (2) are
green and white whereas rear isolation mounts (8)
are blue and white.
1. Lubricate front isolation mounts (2) with water or a
suitable rubber lubricant and install in front frame
mounts, with spigots to the underside of the mounts.
2. Lubricate rear isolation mounts (8) with water or a
suitable rubber lubricant and install in brackets
(7 & 13), with spigots to the underside of the brackets.
3. Attach suitable lifting equipment to transmission
lifting points and carefully position the transmission
assembly in the frame. Take care to avoid snagging
any lines, harnesses or components attached to the
transmission.
4. Secure rear mounting brackets (7 & 13) to frame
mounts with bolts (6), snubbing washers (3), hardened
washers (14) and locknuts (5), as shown in Fig. 1.
5. Secure front bracket assembly (1) to frame
mounts with bolts (6), snubbing washers (3), washers
(4) and locknuts (5), as shown in Fig. 1. Tighten bolts
6. Remove lifting equipment from lifting points on
transmission.
7. Remove blanking cap from hose assembly
(8, Fig. 9) and adaptor (26, Fig. 9) and connect hose
assembly to the adaptor.
(7, Fig. 9) and adaptor (10, Fig. 9) and connect hose
assembly to the adaptor.
(6, Fig. 9) and elbow (5, Fig. 9) and connect hose
assembly to the elbow.
10. Remove blanking caps from hose assemblies
(2, 3 & 26, Fig. 9), elbows (4, 11 & 27, Fig. 9) and adaptor
(1, Fig. 9) and connect hose assemblies to the elbow and
adaptors.
11. Remove blanking caps from transmission oil cooler
lines and retarder ports and connect oil cooler lines.
Refer to Section 210-0060, TRANSMISSION OIL
COOLER.
12. Remove blanking caps and connect lines to
retarder solenoid, differential lock solenoid and
pressure reducing valve mounted on front bracket
assembly (1), as identified at removal.
13. Remove blanking caps and connect hydraulic
lines to the main hydraulic, brake and steering
pumps, as identified at removal.
14. Connect all electrical cables, harnesses and
connections to the transmission, as identified at
removal.
15. Install both exhaust tubes above transmission.
16. Connect all drivelines to the transmission and
secure with mounting hardware removed during
removal. Refer to Section 130-0010, DRIVELINES.
Section 120-0010
SM 2124 Rev 3 8-03
28
17. Prior to installing the cab, ensure that all connections
to the transmission, other than cab connections, are
connected securely and properly clipped.
18. Install the cab assembly on the front frame. Refer
to Section 260-0010, CAB AND MOUNTING.
19. Connect transmission harness at the cab floor
and earth strap between LH side of the transmission
and the frame.
20. Connect main frame harness and electrical
connections at front left hand of the cab. Secure
cover plate with mounting hardware removed during
removal.
21. Fill hydraulic tank with hydraulic oil specified in
Section 300-0020, LUBRICATION SYSTEM. Refer to
Section 230-0040, HYDRAULIC TANK for fill level
and procedure.
22. Fill transmission with engine oil specified in
Section 300-0020, LUBRICATION SYSTEM. Check
the oil level as described under 'Oil Level Check'.
23. Connect the following cables and connectors in
the order given to prevent serious damage to the
engines electrical components.
a - ECM engine to transmission datalink connector
(6 pin RHS)
b - ECM sensor harness connector (30 pin LHS)
c - ECM power harness connector (5 pin RHS)
d - ECM interface harness connector (30 pin RHS)
e - Transmission (Est-37) connector
f - Body hydraulics joystick
g - Alternator supply cables
h - Alternator earth cables
i - Battery supply cables
j - Battery earth cables
24. Turn the battery master switch to the 'On'
position, start the engine and make an operational
check of all lines and electrical connections
disconnected during removal. Check for leaks and
tighten lines and fittings as required. Allow
transmission to warm up and recheck all connections
for leaks.
25. Ensure parking brake is applied, disconnect
steering lock bar and secure in the 'Stowed' position.
Remove wheel blocks from all road wheels.
26. Check for correct operation of the transmission,
shift selector and warning lights.
MAINTENANCE
Periodic Inspections
For easier inspection, the transmission should be kept
clean. Make periodic checks for loose mounting bolts
and leaking air and oil lines. Check the condition of
electrical harnesses and connections regularly.
Transmission breather (10, Fig. 2) should be checked
on a regular basis, and as frequently as necessary,
depending on operating conditions. A badly corroded
or plugged breather restricts proper breathing and
causes a buildup of condensation and subsequent oil
deterioration.
Oil Level Check
WARNING
When checking the oil level, be sure that the
parking brake is applied and all road wheels are
securely blocked.
Check the transmission oil level and add oil if low,
every 10 hours/daily. Use only oil specified in
Because the transmission oil cools, lubricates and
transmits hydraulic power it is important that the proper
oil level be maintained at all times. If the oil level is too
low, the converter and clutches will not receive an
adequate supply of oil. If the oil level is too high, the oil
will aerate and the transmission will overheat. It is
absolutely necessary that the oil put into the
transmission is clean.
Cold Oil Level Check - Engine Off
This check is made only to determine if the transmission
contains sufficient oil for safe starting. Oil level should
show at least 6" (152 mm) above the hot oil maximum
(MAX 80 C) mark on the dipstick. Add oil if low.
Cold Oil Level Check - Engine Running
This cold check is valid only when transmission oil
temperature is below 40 C (104 F).
1. Position the vehicle on a level work area, apply the
parking brake and block all road wheels securely.
2. With parking brake applied, gear selector in neutral
and engine idling, check the oil level on dipstick. Oil
level should be up to the 'COLD MIN' mark on the
dipstick. Add oil if low.
Section 120-0010
29
SM 2124 Rev 3 8-03
Hot Oil Level Check - Engine Running
This hot check is valid for normal operating oil
temperature of 80 C (176 F).
1. Position the vehicle on a level work area, apply the
parking brake and block all road wheels securely.
2. With the transmission in neutral and the engine
running, allow the machine to idle until normal operating
temperature of 80 C (176 F) is achieved.
3. With parking brake applied, foot on service brake,
engine idling and transmission operating at normal
temperature, select each gear position in turn. Allow
the transmission to remain in each gear for 5 - 10
seconds.
4. Return gear selector to neutral and, with the engine
idling, check the oil level on dipstick. Oil level should
be between the 'MAX 80 C' upper mark and the 'MIN
80 C' lower mark on the dipstick. Add oil if low.
Oil and Filter Change
After the first 500 hours of operating a new or rebuilt
transmission, the transmission oil and filter cartridges
(16, Fig. 9) should be changed. Internal filter and finger
magnet at the lower front left hand of the sump should
be removed and cleaned.
The transmission oil and filter cartridges should be
changed every 1 000 hours, or sooner, depending on
operating conditions. Clean oil filter head (15, Fig. 9)
when changing filter cartridges (16, Fig. 9). Also, the oil
must be changed whenever there are traces of dirt or
evidence of high temperature indicated by discoloration
or strong odour.
The internal filter and finger magnet at the lower front
left hand of the sump should be removed and cleaned
with mineral spirits at each oil and filter change. Metal
particles in the oil (except for the minute particles
normally trapped in the oil filters) indicate damage has
occurred in the transmission. When these particles are
found in the filters, the cause must be established and
rectified immediately to prevent damage to the
transmission.
At each oil change, examine the used oil for evidence
of dirt or water. A normal amount of condensation will
emulsify in the oil during transmission operation.
However, if there is evidence of water or engine coolant
in the oil, the cause must be established and rectified
immediately to prevent damage to the transmission.
AEB Starter
The AEB Starter is an electronic tool used to calibrate
the transmission to ensure optimum shift comfort. It is
recommended to run the AEB Starter after the first 500
hours of transmission operation. The AEB Starter
should also be run if shift quality deteriorates, or
whenever the transmission, electronic control unit
(ECU) or shift lever are replaced. The procedure for
running the AEB Starter is detailed in the table on the
following page. Refer to table on page 10 for typical
codes displayed during AEB mode.
Note: Connect the AEB Starter to plug X25 located
below the right hand dash panel, adjacent to the ECU.
TROUBLESHOOTING
otherwise specified. Refer to Fig. 11 for plug
identification.
Transmission Sensor Checks
The engine (5), turbine (8), central gear train (7) and
output (6) speed sensors can be checked by
measuring their resistance at plug X8 (located below
the dash panel).
1. Engine speed sensor (5). Check across pins 1 & 2.
Resistance should be 945 - 1 155 ohms at a
2. Turbine speed sensor (8). Check across pins 3 & 4.
Resistance should be 945 - 1 155 ohms at a
3. Central gear train speed sensor (7). Check across
pins 5 & 6. Resistance should be 945 - 1 155 ohms at
a temperature of 20 C (68 F).
4. Output speed sensor (6). Check across pins 21 &
22. Resistance should be 5 mega ohms.
The installation of the speed sensors can also be
checked by measuring the gap between the sensor and
the gear tooth:
SM - 2797
Fig. 10 - Transmission Dipstick Markings
COLD FILL LEVEL
MINIMUM -
ENGINE OFF
HOT
LEVEL
BAND -
ENGINE
RUNNING
COLD FILL
LEVEL
MINIMUM -
ENGINE
RUNNING
MAX
152mm (6") Min
MIN
Section 120-0010
SM 2124 Rev 3 8-03
30
Engine speed sensor (5) and turbine speed sensor (8) -
gap should be 0.5 - 0.8 mm.
Central gear train speed sensor (7) - gap should be 0.3
+
/- 0.1 mm.
Output speed sensor (6) - gap should be 1.0 - 1.5 mm.
Lock-Up Solenoid
The solenoid can be checked at plug X9, pins 7 & 8
(located below the dash panel).
Resistance: 60 - 80 ohms
Current: 0.25 - 0.35 A
Voltage: 24 V
Pressure can also be checked (see Fig. 4).
Temperature Sensors
The sump temperature sensor, located in the main
control valve (2) can be checked at plug X8, pins 14 &
15. Resistance should be 1 000 - 1 500 ohms.
The retarder oil temperature sensor (1) can be checked
at plug X9, pins 15 & 16. Resistance should be 800 - 1
500 ohms.
Shift Controller
To troubleshoot the shift controller, continuity checks
can be easily done by removing plug X2, selecting
position and measuring across following pins:
Neutral - Pins 2 & 5
Forward - Pins 2 & 4
Reverse - Pins 2 & 6
Up - Pins 2 & 7
Down - Pins 2 & 8
Button - Pins 2 & 10
Transmission To Engine CAN-Bus
The communication link between the transmission and
the engine can be electrically checked by measuring
resistance and voltage. Refer to tables below.
Solenoid Coil Ratings
The following data should be referenced when
checking solenoids:
1. Diff-lock solenoid(s). Solenoid(s) can be checked at
plug X9, pins 11 & 12.
Resistance: 41 ohms
Current: 0.6 A
Measuring CAN-Bus Resistance At Plug X4 (Ignition OFF)
Measurement between Specified Value (ohms) Actual Value (ohms) Possible Cause
CAN H (X4 pin 1) 60 0 Short circuit from CAN H to CAN L
and 60 120 Connection to one end of
CAN L (X4 pin 2) resistor is damaged or cut off
60 Infinity End resistors damaged or cut off
Measuring CAN-Bus Voltage At Plug X4 (Ignition ON)
Measurement between Specified Value (Volts) Actual Value (volts) Possible Cause
CAN H (X4 pin 1) 24 Short circuit from CAN H to battery
and 2.4 - 2.9 0 Short circuit from CAN H to ground
Ground 0 - 2.3 Intermittent short circuit from
3.0 - 24 CAN H to another component
CAN L (X4 pin 2) 24 Short circuit from CAN L to battery
and 2.2 - 2.7 0 Short circuit from CAN L to ground
Ground 0 - 2.1 Intermittent short circuit from
2.8 - 24 CAN L to another component
Section 120-0010
31
SM 2124 Rev 3 8-03
TORQUE
1 6, Front Mounts Bolt 920 678
1 6, Rear Mounts Bolt 920 678
ACTION DISPLAY MESSAGE REMARK
1 warm up transmission normal operating messages
2 turn off ignition nothing
3 plug in AEB - Starter
4 move shift lever to N position
engage parkbrake
5 start engine PL TCU must recognise PL for at
least 2 seconds before you
can press the button
6 set engine speed to idle PL if start conditions are OK
7 press button of the AEB-Starter ST if start conditions are OK The button must not be
released before TCU has
started the AEB or quit with
an error code (see display
table)
8 hold button until AEB has started K1 (Information about the AEB TCU has started the AEB,
state) and goes on adjusting K1, K2,
, KR. (Button may be
released)
9 wait until AEB has finished OK (AEB has been successful)
10 turn off ignition and unplug nothing
AEB-Starter
AEB Starter Procedure
2. Retarder solenoid (on bracket at front of
transmission). The solenoid can be checked at plug
X9, pins 9 & 10.
Resistance: 30 ohms
Current: 0.8 A
Differential Pressure Switch
When oil is at operating temperature, the switch can
be checked at plug X9, pins 17 & 18. With the harness
connected to the switch, resistance should be 500
ohms.
Pressure Checks
Refer to Fig. 4 for measurement points and pressures.
The system pressure, convertor pressure and retarder
pressure can be measured at the diagnostic test points
located at the rear of the tractor frame. If other
pressures are to be measured, then diagnostic
connectors on main control valve (2) should be moved
to required point, so pressure can be read from
diagnostic test point.
SERVICE TOOLS
number of AEB Starter and other service tools which
should be used in conjunction with procedures outlined
in the transmission manufacturers service manual,
and, general service tools required. These tools are
available from your dealer.
Section 120-0010
SM 2124 Rev 3 8-03
32
* * * *
Fig. 11 - Plug Identification
SM - 3088
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
23
1
2 4 6 8 1012141618
1 3 5 7 9 11131517
2 4 6 8 1012141618
1 3 5 7 9 11131517
2022
1921
2 4
1 3
12
11
10
9
8
7
6
5
4
3
2
1
1 3 5 7 9 111315171921
2 4 6 8 10121416182022
3
2
1
6
5
4
POLE PATTERN
W1 - X1
POLE PATTERN
W1 - X2
PLUG HOUSING
AMPMATE-N-LOCK
12 POLE SOCKET
POLE PATTERN
W1 - X8
22 POLE AMP
JUNIOR POWER TIME
SOCKET
POLE PATTERN
W1 - X7, W2 - X1
22 POLE AMP
JUNIOR POWER TIME
PIN
POLE PATTERN
W1 - X4
4 POLE AMP
JUNIOR POWER TIME
PIN
POLE PATTERN
W1 - X9
18 POLE AMP
JUNIOR POWER TIME
SOCKET
POLE PATTERN
W1 - X25
LOCATING HOUSING
AMPMATE-N-LOCK
6 POLE PIN
AMP
68 POLE
SOCKET
Section 130-0010
1 SM 1378 Rev 2 8-03
DRIVELINES - Front Drivelines
SM - 2303
DESCRIPTION
The function of the driveline is to transmit rotating
power from one point to another in a smooth and
continuous action while allowing a degree of
movement or misalignment of the components it
connects.
The drivelines must operate through constantly
changing relative angles between the components
they are mounted to and must also be capable of
changing length while transmitting torque.
A typical driveline consists of universal joints which
allow some misalignment and permit the driveline to
pivot in any direction, and, a light rigid hollow slip
yoke and splined shaft assembly forming a slip joint.
The slip joint accommodates length variations
generated during operation, preventing tension or
compression loads from causing serious damage to
the components.
Note: Extra care should be taken when handling the
drivelines since chips, dents, burrs or deformity on
any rotating mass creates vibration and excessive
wear during any operation.
There are three driveline assemblies installed
between various components in the tractor frame as
follows:
Driveline assembly (1) is connected between the
engine drive and transmission input drive.
Driveline assembly (2) is connected between the front
axle drive flange and transmission final drive.
Driveline assembly (3) connects the rear final drive of
the transmission to the articulation and oscillation
pivot.
6 - Capscrew
7 - Screw
8 - Screw
9 - Screw
10 - Bracket
11 - Bolt
12 - Washer
13 - Bracket
14 - Locknut
1 - Driveline Assembly
4 - Capscrew
5 - Capscrew
Fig. 1 - Front Drivelines and Mounting
4 1 4
ENGINE
FRONT AXLE
TRANSMISSION
A
DETAIL A
13
11
12
14
5 5 2 6 6 3
10
TO
TRAILER
7
8
9
Section 130-0010
Drivelines - Front Drivelines
SM 1378 Rev 2 8-03 2
REMOVAL
Note: Extra care should be taken when handling
drivelines since carelessness can result in premature
failure of the components. Chips, dents, burrs, or any
other deformity of universal joints will prevent accurate
mating. This will cause misalignment which is
accompanied by vibration and excessive wear.
WARNINGS
damage, be sure wheel chocks, blocking
safely.
To prevent serious injury or death, DO
NOT go under the vehicle when the engine is
running. Rotating shafts can be dangerous.
You can snag clothes, skin, hair, hands, etc..
parking brake and switch off the engine. Depress the
brake pedal continuously to relieve any pressure in the
braking circuit. Turn the steering wheel several times to
relieve any pressure in the steering circuit.
3. Remove mounting hardware securing insulation
quilts under the fenders to allow access to driveline
assembly (1). Remove insulation quilts.
Note: Access to driveline assembly (1) can be
obtained from underneath the vehicle.
4. Remove mounting hardware securing guard bracket
(13) over driveline assembly (1) and at the
transmission. Remove guard bracket (13).
5. Match mark universal joints and their mating
surfaces to ensure correct mating alignment when
installing driveline assembly (1).
6. Support driveline (1) with suitable lifting equipment
and remove capscrews (4) securing universal joints
to their mating components and remove driveline
assembly (1). If necessary tap driveline assembly (1)
from its mating components with a soft faced hammer.
Note: Access to driveline assemblies (2 & 3) can be
installing driveline assemblies (2 & 3).
DISASSEMBLY
Universal Joint
1. Place the yoke end of driveline assembly (1) in a
soft jawed vice, clamping on the tube of shaft.
Note: Do not distort the tube with excessive grip.
2. Remove screws (7) and universal joint from driveline
assembly (1).
3. Place the shaft end of driveline assembly (1) in a
soft jawed vice.
assembly (1).
5. Repeat steps 1 to 4 for drivelines (2 & 3).
INSPECTION
1. Clean all metal parts in a suitable solvent, and dry
all parts with compressed air.
2. Inspect splines of shaft and yoke for nicks, burrs
and excessive wear. Replace if wear is excessive or
splines are nicked. Burrs may be removed with a fine
file or medium India stone.
3. Check the surfaces of the components that universal
joints mate against for parallelism. Refer to Fig. 2.
4. Check condition of mounting capscrews and replace
if required.
Section 130-0010
3 SM 1378 Rev 2 8-03
WARNINGS
safely.
1. Position driveline assembly (3) on the vehicle as
shown in Fig. 1 and align match marks on universal
joints with those on their mating surfaces.
2. Apply Loctite 648 to the threads of capscrews (6).
Secure universal joints to their mating surfaces with
capscrews (6). Tighten capscrews (6) to a torque of
154 Nm (113 lbf ft).
154 Nm (113 lbf ft).
154 Nm (113 lbf ft).
7. Secure guard bracket (13) evenly over driveline
assembly (1) and onto bracket at transmission with
8. Secure insulation quilts under fenders and on to
mounting brackets with hardware removed during
removal.
9. Ensure the parking brake is applied and remove
wheel chocks from all road wheels.
ASSEMBLY
Universal Joint
2. Install universal joint to yoke end of driveline
assembly (1) and secure with screws (7).
soft jawed vice.
4. Install universal joint to shaft end of driveline
5. Repeat steps 1 to 4 for drivelines (2 & 3).
INSTALLATION
SPECIFICATIONS.
SM - 088
Fig. 2 - Checking Parallelism
REMOVE ALL
BURRS AND
PAINT FROM
THESE SURFACES
STRAIGHT EDGE
MAXIMUM PERMISSIBLE
GAP IS 0.2 mm (0.008 in)
APPLY PRESSURE
HERE BY HAND
Section 130-0010
SM 1378 Rev 2 8-03 4
MAINTENANCE
Universal Joints
Every 500 Hours: Check the universal joints for wear
and replace if required.
Every 2 000 Hours: Check drivelines for leaks and
damage, and replace if required.
Periodic Inspection
Use a small pry bar to check the companion flange
yokes for looseness. If loose, drop one end of the
driveline and twist the yoke to check the backlash
between the splines and yokes. Replace any yoke that
does not fit snugly.
With the pry bar, check the universal joints for play. If
loose, replace the universal joints. Check the splines
at the slip joint and replace the yoke if excessively
worn.
SPECIAL TOOLS
* * * *
TORQUE
1 4 Capscrew 154 113
DRIVELINE DIAGNOSIS CHART
CONDITION REASON REMEDY
Vibration or noise Driveline bent or out of balance Clean driveline in a suitable solvent. Inspect for
contact with adjacent parts. If driveline is
distorted or sprung, replace. If driveline does not
run smoothly, and vibration is felt, remove
driveline and dynamically balance the assembly.
Driveline loose at yoke/flange Check driveline mounting capscrews for
tightness. If loose, replace capscrews and
torque tighten to the proper specification.
Excessive wear of Poor yoke/flange alignment Check yoke/flange for alignment, run-out and
universal joints and/or run-out balance. Repair or replace as required.
Driveline imbalance Check to see if balance weights are missing or if
driveline is distorted. If driveline is distorted,
replace; if weights are missing, check balance of
driveline dynamically and rebalance.
Section 130-0020
SM 1379 Rev 2 8-03
1
DRIVELINES - Rear Drivelines
SM - 2944
DESCRIPTION
The function of the driveline is to transmit rotating
power from one point to another in a smooth and
continuous action while allowing a degree of
movement or misalignment of the components it
connects.
The drivelines must operate through constantly
changing relative angles between the components
they are mounted to and must also be capable of
changing length while transmitting torque.
A typical driveline consists of universal joints which
allow some misalignment and permit the driveline to
pivot in any direction, and, a light rigid hollow slip yoke
and splined shaft assembly forming a slip joint.
The slip joint accommodates length variations
generated during operation, preventing tension or
compression loads from causing serious damage to
the components.
Note: Extra care should be taken when handling the
drivelines since chips, dents, burrs or deformity on any
rotating mass creates vibration and excessive wear
during any operation.
There are two driveline assemblies connecting the
centre and rear axles to the drive supplied from the
transmission, through the pivot drive arrangement, as
follows:
Driveline assembly (1) is connected between the
articulation and oscillation pivot and the centre axle.
Driveline assembly (4) is connected between the centre
axle and the rear axle.
REMOVAL
WARNINGS
safely.
Fig. 1 - Rear Drivelines and Mounting
5 - Capscrew
6 - Screw
3 - Screw
2 - Capscrew
CENTRE AXLE REAR AXLE
2 1
2
5 6 4 3
3 5 6
Section 130-0020
Drivelines - Rear Drivelines
SM 1379 Rev 2 8-03
2
running. Rotating shafts can be dangerous. You
can snag clothes, skin, hair, hands, etc..
Disconnecting or removing any of the
rear drivelines will make the parking brake
ineffective.
parking brake and switch off the engine. Depress the
brake pedal continuously to relieve any pressure in the
braking circuit. Turn the steering wheel several times to
Note: Access to driveline assemblies (1 & 4) can be
4. Remove capscrews (2) securing universal joints to
their mating components and remove driveline
6. Remove capscrews (5) securing universal joints to
their mating components and remove driveline
DISASSEMBLY
Universal Joint
assembly (1).
soft jawed vice.
assembly (1).
5. Repeat steps 1 to 4 for driveline (4).
INSPECTION
1. Clean all metal parts in a suitable solvent, and dry
all parts with compressed air.
2. Inspect splines of shaft and yoke for nicks, burrs
and excessive wear. Replace if wear is excessive or
splines are nicked. Burrs may be removed with a fine
file or medium India stone.
3. Check the surfaces of the components that universal
joints mate against for parallelism. Refer to Fig. 2.
4. Check condition of mounting capscrews and replace
if required.
ASSEMBLY
Universal Joint
2. Install universal joint to yoke end of driveline
soft jawed vice.
4. Install universal joint to shaft end of driveline
5. Repeat steps 1 to 4 for driveline (4).
INSTALLATION
SPECIFICATIONS.
Section 130-0020
SM 1379 Rev 2 8-03
3
WARNINGS
safely.
Disconnecting or removing any of the
rear drivelines will make the parking brake
ineffective.
154 Nm (113 lbf ft).
154 Nm (113 lbf ft).
5. Ensure the parking brake is applied and remove
wheel blocks from all road wheels.
MAINTENANCE
Universal Joints
Every 500 Hours: Check the universal joints for wear
and replace if required.
Every 2 000 Hours: Check drivelines for leaks and
damage, and replace if required.
Periodic Inspection
Use a small pry bar to check the companion flange
yokes for looseness. If loose, drop one end of the
driveline and twist the yoke to check the backlash
between the splines and yokes. Replace any yoke that
does not fit snugly.
With the pry bar, check the universal joints for play. If
loose, replace the universal joints. Check the splines at
the slip joint and replace the yoke if excessively worn.
SPECIAL TOOLS
SM - 088
Fig. 2 - Checking Parallelism
REMOVE ALL
BURRS AND
PAINT FROM
THESE SURFACES
STRAIGHT EDGE
MAXIMUM PERMISSIBLE
GAP IS 0.2 mm (0.008 in)
APPLY PRESSURE
HERE BY HAND
Section 130-0020
SM 1379 Rev 2 8-03
4
DRIVELINE DIAGNOSIS CHART
Vibration or noise Driveline bent or out of balance Clean driveline in a suitable solvent. Inspect for
contact with adjacent parts. If driveline is
distorted or sprung, replace. If driveline does not
run smoothly, and vibration is felt, remove
driveline and dynamically balance the assembly.
Driveline loose at yoke/flange Check driveline mounting capscrews for
tightness. If loose, replace capscrews and
torque tighten to the proper specification.
Excessive wear of Poor yoke/flange alignment Check yoke/flange for alignment, run-out and
universal joints and/or run-out balance. Repair or replace as required.
Driveline imbalance Check to see if balance weights are missing or if
driveline is distorted. If driveline is distorted,
replace; if weights are missing, check balance of
driveline dynamically and rebalance.
* * * *
TORQUE
Section 150-0020
SM 2249 9-03
1
DESCRIPTION
The differential assembly is mounted to the axle
housing. It comprises of two differentials; one for the
normal cross-axle drive function; the other for the thru-
drive.
The differential is a spiral bevel ring gear type with an
automatically limited slip element (See Fig. 2).
The thru-drive differential is lockable by the operator.
Note: Never engage or disengage the Differential
Lock when moving or when the wheels are spinning.
REMOVAL AND INSTALLATION
WARNING
safely.
1. Position the vehicle in a level work area, raise the
body and install the body safety prop to secure the
body in the partially raised position.
2. Apply the parking brake and switch off the engine.
the 'Off' position.
4. Drain the gear oil out of the axle housing and both
planetaries into a suitable container.
5. Remove the planetary assemblies and axle shafts
from the axle housing. Note from which side the long
CENTRE AXLE - Differential Drive Head
and short axle shafts are removed. Refer to
Section 160-0030, AXLE GROUP (HUB).
6. Identify the relationship of the front and rear
driveline flanges and differential flanges with punch
marks.
7. Disconnect the drivelines from the differential
flanges. The drivelines can be removed if it is
convenient to do so.
8. Support the weight of differential housings (2 & 31)
and layshaft housing (3) with suitable lifting equipment.
Remove bolts securing differential housing (2) to axle
casing and carefully remove differential assembly clear
of axle casing.
INSTALLATION
Installation is the reversal of the 'Removal' procedure.
Note: Use sealing compound (Loctite 574) between the
axle housing and differential housing mounting faces.
Tighten bolts securing differential assembly to axle
casing to 375 Nm (277 lbf ft). Tighten nuts to 280 Nm
(207 lbf ft).
Section 300-0080, AXLE BOLT AND NUT TORQUE
SPECIFICATIONS.
Fill the layshaft housing (3) and the differential housing
(31) with 1.5 litres (0.4 US gallon) of gear oil of the type
SYSTEM, through the differential filler/level hole. Fill
the axle casing with gear oil of the type specified in
Section 300-0020, LUBRICATION SYSTEM, through
the differential filler/level hole until the oil is level with
the bottom of the filler/level hole. Fill the planetary
assemblies up to the 'Oil Level Check Line'. Check oil
levels after a few minutes to ensure level remains
constant.
SM 2249 9-03
2
Centre Axle - Differential Drive Head
Section 150-0020
SM - 3022
Fig. 1 - Exploded View Of Centre Differential
Section 150-0020
SM 2249 9-03
3
SM - 3023
Fig. 2 - Exploded View of Limited Slip Cross-axle Differential
1 - Adjusting Nut
2 - Differential Housing
3 - Layshaft Housing
4 - Plug
5 - 'O' Ring
6 - Plug
7 - 'O' Ring
8 - Plate
9 - Pin
10 - Bushing
11 - Capscrew
12 - Bearing
13 - Bush Spacer
14 - Adjusting Ring
15 - Bearing
16 - Shim
17 - Bearing
18 - Bearing
19 - Adjusting Nut
20 - Slotted Pin
21 - Washer
22 - Slotted Nut
23 - Bearing
24 - Bearing
25 - Adjusting Ring
26 - Spacer Ring
27 - Slotted Nut
28 - Bolt
29 - Bolt
30 - Slotted Pin
32 - Slotted Pin
33 - Plug
34 - 'O' Ring
35 - Plug
36 - 'O' Ring
37 - Differential Case Half
38 - Thrust Washer
39 - Pin
40 - Quill Shaft
41 - Side Gear
42 - Pinion Gear
43 - Thrust Washer
44 - Spider
45 - Flange
46 - Ring Gear
48 - Externally Splined Disc
49 - Internally Splined Disc
50 - Thrust Ring
51 - Side Gear
52 - Thrust Washer
53 - Pinion Gear
54 - Thrust Washer
55 - Differential Axle
56 - Bolt
57 - Housing Cover
58 - Capscrew
59 - Bearing
60 - Shim
61 - Shaft Seal
62 - Flange
63 - Bolt
64 - Bolt
65 - Bolt
66 - Washer
67 - Slotted Nut
68 - Sliding Dog
69 - Shifter Fork Assembly
70 - Thrust Block
71 - Shifter Fork Lock Pin
72 - Bolt
73 - Seal
74 - Piston
75 - 'U' Ring
76 - Spring
77 - Centering Ring
78 - Cylinder
79 - Bolt
80 - Filter Element
81 - Adjusting Bolt
82 - Nut
83 - Disc
84 - Contact Pin
85 - Seal Ring
86 - Contact Switch
87 - Drive Shaft Flange
88 - Flange
89 - Shaft Seal
90 - Bearing
91 - Shim
92 - Retaining Ring
93 - Bolt
94 - Drive Flange
95 - Dust Cap
96 - Pinion Gear
97 - Spur Gear
98 - Spur Gear
99 - Shim
LEGEND FOR FIGS. 1 & 2.
A
B
SM 2249 9-03
4
Section 150-0020
DISASSEMBLY
Numbers in parentheses refer to Figs. 1 & 2.
WARNING
safely.
Note: The following removal procedure assumes the
complete axle assembly was removed from the
vehicle.
1. Ensure oil is drained from planetaries, axle casing,
differential housings (2 & 31) and layshaft housing (3).
2. Remove bolts (93) securing flange (88) to axle
casing. Using special tools (15271101 Back-up Tool
and 15500905 Extractor) remove drive shaft flange (87)
as shown in Fig. 3.
3. Remove retaining ring (92) and shim (91) from drive
shaft flange (87). Press off flange (88) and bearing (90)
from drive shaft flange (87).
4. Press shaft seal (89) out of flange (88).
5. Remove both planetary assemblies and axle shafts
by following the procedure in Section 160-0030, AXLE
GROUP (HUB). Using suitable lifting equipment,
support differential assembly. If not done already,
remove nuts and bolts and remove the differential
assembly from the axle casing as shown in Fig. 4.
6. Loosen ring gear bolts (56) as shown in Fig. 5.
SM - 3024
Fig. 3 - Removing Drive Shaft Flange
Fig. 4 - Removing Differential Assembly
SM - 3025
SM - 2951
Fig. 5 - Removing Ring Gear Bolts
SM - 2952
Fig. 6 - Removing Adjusting Nuts
7. Remove slotted pins (20) before loosening adjusting
nuts (1 & 19) as shown in Fig. 6.
Section 150-0020
SM 2249 9-03
5
SM - 2953
8. Using special tool (15269899 220V Hot Air Blower or
15269900 110V Hot Air Blower) heat the area around
the threaded holes and loosen bolts securing bearing
caps. Remove bearing caps.
Fig. 7 - Removing Bearing Caps
SM - 858
Fig. 8 - Removing Differential
SM - 2954
Fig. 9 - Removing Bearing Inner Rings
SM - 2955
Fig. 10 - Differential Components
9. Lift the differential assembly out of differential
housing (2) with the special tool (15269929 Lifting
Pliers) as shown in Fig. 8.
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.
11. Remove capscrews (58) and separate housing (47)
from cover (57). Remove single components as shown
in Fig. 10.
SM 2249 9-03
6
Section 150-0020
12. Using suitable lifting equipment, remove bolts (28 &
29) and separate layshaft housing (3) and differential
housing (31) from differential housing (2) as shown in
Fig. 11.
SM - 3026
SM - 3028
Fig. 11 - Separating Differential
SM - 3027
Fig. 12 - Loosening Nut
Fig. 13 - Separating Housing
13. Using special tool (15269899 220V Hot Air Blower
or 15269900 110V Hot Air Blower) heat the slotted nut
(67) to around 120
o
C before loosening using special
tools (15500890 Socket and 15270120 Clamping Yoke)
as shown in Fig. 12. Do not remove nut (67) at this
point.
14. Remove bolts (65) and using suitable lifting
equipment, separate the inter-axle differential with
flanges (45 & 62) from housing (31) as shown in Fig.
13.
SM - 3029
Fig. 14 - Pressing Differential
15. Remove slotted nut (67), washer (66) and drive
flange (94). Press the inter-axle differential out of
flanges (45 & 62) as shown in Fig. 14.
Section 150-0020
SM 2249 9-03
7
18. Remove capscrews (11) and separate inter-axle
differential as shown in Fig. 16.
SM - 3031
Fig. 16 - Inter-axle Differential
SM - 3032
SM - 3030
Fig. 15 - Removing Bearing
Fig. 17 - Removing Cylinder
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.
19. Loosen bolts (79) evenly and separate cylinder (78)
from the housing (31) as shown in Fig. 17.
SM - 1111
Fig. 18 - Removing Contact Switch
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
8
Section 150-0020
23. Using special tool (15500907 Fixture) lock quill
shaft (40) as shown in Fig. 20.
or 15269900 110V Hot Air Blower) heat slotted nut (27)
to around 120
o
C before removing using special tool
(15500908 Socket). Remove fixture installed in Step
23.
SM - 1116
SM - 3033
Fig. 19 - Removing Shifter Fork And Piston
Fig. 20 - Locking Shaft
SM - 3034
SM - 3035
Fig. 22 - Pressing Bearing Inner Race
Fig. 21 - Pressing Shaft
21. Remove shifter fork assembly (69) and piston (74)
assembly as shown in Fig. 19.
22. Remove adjusting bolt (81) and nut (82) from
housing (31).
25. Press out quill shaft (40) using special tool
(15269946 Puller Set) as shown in Fig. 21.
26. Remove adjusting ring (25) from shaft (40). Support
shaft (40) on sliding dog (68) and press off bearing (24)
inner race as shown in Fig. 22.
Section 150-0020
SM 2249 9-03
9
SM - 3036
Fig. 24 - Separating Housings
SM - 3037
Fig. 25 - Removing Slotted Nut
Fig. 26 - Pressing Out Pinion Gear
27. Remove bearing (23) inner race and spacer ring
(26) from housing (3) as shown in Fig 23.
28. Remove bolts (64) securing differential housing (31)
to layshaft housing (3) and separate housings using
suitable lifting equipment as shown in Fig. 24. Remove
spur gear (97).
to around 120
o
C before removing using special tool
(15500891 Socket). Block spur gear (98) with wooden
block, as shown in Fig. 25.
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 - 2965
SM - 2962
Fig. 23 - Removing Bearing Inner Race
SM 2249 9-03
10
Section 150-0020
Fig. 27 - Removing Bearing From Pinion Gear
SM - 2966
SM - 2967
Fig. 28 - Pressing Out Bushing
31. Pull off the bearing (15) inner race from the pinion
gear (96) using special tools (15500892 Gripping Insert
and 15272560 Bearing Puller).
32. Remove bush spacer (13) and adjusting ring (14)
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
The importance of careful and thorough inspection
cannot be overstressed. Thorough inspection and
necessary replacement of parts now may eliminate
costly and avoidable trouble later.
1. Clean all parts in petroleum base solvent.
2. Immediately after cleaning, dry all parts, except
bearings, with compressed air, or with a soft, clean lint
free wiping cloth. Compressed air has a corrosive
effect on bearings, therefore, they must be wiped dry
with a cloth.
3. Coat cleaned, dried parts immediately with light oil to
prevent corrosion. If parts are not to be assembled
immediately, treat them with a good rust preventive
and wrap them with treated paper or other suitable
material designed to prevent corrosion.
4. Before installing the differential assembly to the
machine, clean the inside and outside of the axle
housing to remove any foreign material.
5. Inspect all gears, pinions, and splines for cracked or
broken teeth, excessive wear, and pitted or scored
surfaces. Repair or replace as necessary. Fig. 30 - Pressing Bearing Outer Race in Housing
SM - 2969
Fig. 29 - Pressing Bearing Outer Race in Housing
SM - 2968
Section 150-0020
SM 2249 9-03
11
SM - 2971
Fig. 32 - Installing Bushing
Fig. 33 - Measuring Dimension 'A'
SM - 2973
Fig. 34 - Assembling The Measuring Shaft
SM - 2972
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.
6. Check for pitted, scored or worn thrust surfaces of
differential case halves.
ASSEMBLY
Numbers in parentheses refer to Figs. 1 & 2 unless
specified otherwise.
specified to torques listed in Section 300-0080, AXLE
BOLT AND NUT TORQUE SPECIFICATIONS.
Note: During assembly and installation, make sure that
mated, punch marked, or otherwise identified parts are
returned to their original positions, if still serviceable.
WARNING
safely.
1. Press bearing (12) outer race into housing (3) bore
as shown in Fig. 29.
3. Insert spur gear (98) into housing (3) bore, ensuring
that inner diameter (85 mm) is facing down, as shown
in Fig. 31.
4. Press the bushing (10) into housing (3) bore and
ensure it is firmly home, as shown in Fig. 32.
5. At this stage in the assembly procedure the
thickness of shim (16) must be determined to ensure
correct contact pattern between pinion gear (96) and
ring gear (46). As shown in Fig. 33, measure
Dimension 'A' from the mounting face of housing (3) to
the locating face of the bearing (15) outer ring, using
special tools (15270113 Gauge Blocks, 15269948
Straight Edge and 15270114 Digital Depth Gauge).
Fig. 31 - Installing Spur Gear
SM - 2970
SM 2249 9-03
12
Section 150-0020
SM - 2974
Fig. 35 - Measuring Dimension 'B'
SM - 868
Fig. 36 - Measuring Bearing Thickness
SM - 2975
Fig. 37 - Dimension On Pinion Face
Fig. 38 - Installing Spacing Washer
SM - 2976
Eg. Dimension 'A' = 29.70 mm
6. As shown in Fig. 34, use special tools (15500893
Shims, 15500894 Shims and 15269934 Measuring
Shaft) and place shims into the bores of differential
housing (2) and assemble the measuring shaft.
7. Measure Dimension 'B' from mounting face of
housing (2) to Measuring Shaft (see Fig. 35).
Eg. Dimension 'B' = 196.75 mm
Example:
Dimension 'A' 29.70 mm
+ Dimension 'B' 196.75 mm
- Dimension 'C' (
1
/
2
diameter of Measuring
Shaft) 15.00 mm
= Dimension 'X' 241.45 mm
8. Measure thickness of bearing (15) as shown in Fig.
36 using special tools (15270113 Gauge Blocks and
15270114 Digital Depth Gauge). Record as Dimension
'D'.
Eg. Dimension 'D' = 42.70 mm
9. The arrow in Fig. 37 is pointing to a dimension
stamped on the face of pinion gear (96). Record as
Dimension 'E'.
Eg. Dimension 'E' = 198 - 0.1 = 197.90 mm
Example:
Dimension 'D' 42.70 mm
+ Dimension 'E' 197.90 mm
= Dimension 'Y' 240.60 mm
10. Calculate shim (16) thickness by subtracting
Dimension 'Y' from Dimension 'X'.
Example:
Dimension 'X' 241.45 mm
- Dimension 'Y' 240.60 mm
= Required thickness 0.85 mm
Install shim (16) of required thickness into the bushing
(10) as shown in Fig. 38.
Section 150-0020
SM 2249 9-03
13
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.
SM - 2979
Fig. 42 - Installing Spacer Bush and Adjusting Ring
12. Heat inner race of bearing (15) to approximately 90
C (190 F) and press it on to the shaft of pinion gear
(96). Be sure it is firmly seated against the shaft
shoulder as shown in Fig. 40.
WARNING
13. Install assembled pinion gear (96) in layshaft
housing (3) using special tool (15269946 Puller Set) as
shown in Fig. 41. Do not remove special tool at this
point.
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).
Fig. 39 - Installing Bearing Outer Race
SM - 2977
Fig. 40 - Installing Bearing Inner Race
SM - 873
Fig. 41 - Installing Pinion Gear
SM - 2978
SM 2249 9-03
14
Section 150-0020
Fig. 43 - Installing Bearing
Fig. 44 - Tightening Slotted Nut
Fig. 45 - Checking Rolling Resistance
SM - 2980
SM - 2981
SM - 2982
SM - 2983
(96) until it is firmly home as shown in Fig. 43.
WARNING
After bearing (12) inner race has cooled, remove special
tool installed in Step 13.
16. Coat threads of slotted nut (22) with Loctite 649.
Locate washer (21) and install slotted nut (22). Using
special tool (15500891 Socket) tighten slotted nut (22)
Note: When tightening nut (22), rotate the pinion gear (96)
in both directions several times.
17. Check the rolling resistance of the pinion bearing
as shown in Fig. 45 by using special tool (15500895
Torque Spanner). If the rolling resistance is outwith
range (3.5 - 4.0 Nm), adjusting ring (14) thickness must
be changed.
Record this torque as T
pinion
e.g. 3.5 Nm.
18. Install spur gear (97) in housing (3) as shown in
Fig. 46.
Section 150-0020
SM 2249 9-03
15
SM - 3039
SM - 3040
Fig. 48 - Installing Differential Housing
SM - 3038
Fig. 49 - Tightening Bolts
Fig. 50 - Installing Sliding Dog
19. Install bearing (24) outer race into bore of
differential housing (31) as shown in Fig. 47.
20. Apply Loctite 574 to mounting face of layshaft
housing (3). Using suitable lifting equipment, install the
differential housing (31) to layshaft housing (3) as
shown in Fig. 48.
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).
22. Install sliding dog (68) on quill shaft (40) with the
gearing showing downwards as shown in Fig. 50.
SM - 3041
SM 2249 9-03
16
Section 150-0020
23. Press bearing (24) inner race onto quill shaft (40)
until it is firmly home as shown in Fig. 51.
SM - 3042
SM - 3043
Fig. 52 - Installing Shaft
24. Install adjusting ring (25) in housing (31) before
installing sub assembled quill shaft (40) as shown in
Fig. 52.
SM - 3033
Fig. 53 - Locking Shaft
SM - 2985
Fig. 54 - Installing Spacer
25. Using special tool (15500907 Fixture) lock quill
shaft (40) as shown in Fig. 53.
26. The spacer ring (26) is used to obtain the rolling
resistance of the shaft (40) bearing. Rolling resistance
resistance (T
Ho
) 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.
Section 150-0020
SM 2249 9-03
17
C (190 F) and press it on to the shaft (40) until it is
firmly home as shown in Fig. 55.
WARNING
28. Allow bearing (23) to cool, then coat threads of
slotted nut (27) with Loctite 649. Assemble slotted nut
(27) on shaft (40) and tighten using special tool
(15500908 Socket). Torque slotted nut (27) to 1200 Nm
(885 lbf ft) as shown in Fig. 56.
Note: When tightening nut (27), rotate the shaft (40) in
both directions several times.
SM - 2986
SM - 3044
SM - 2997
SM - 3045
Fig. 58 - Installing Fork Assembly
29. Remove special tool (15500908 Fixture) installed at
Step 25. As shown in Fig. 57, check total rolling
resistance of pinion gear (96) and shaft (40) by using
special tool (15500895 Torque Spanner). Record this
torque as T
tot
e.g. 4.5 Nm.
Example:
T
tot
e.g. 4.5 Nm
T
pinion
e.g. - 3.5 Nm
Results in T
Ho
= 1.0 Nm
As specified in Step 26, rolling resistance (T
Ho
) of shaft
(40) should be 0.5 - 2.0 Nm. If outwith this range,
spacer ring (26) thickness must be changed.
30. Attach thrust blocks (70) to shifter fork assembly
(69) and install in differential housing (31) as shown in
Fig. 58. Thrust blocks (70) fit into sliding dog (68)
groove.
Note: Shifter fork assembly is not symmetrical, 'X'
denotes short side.
X
SM 2249 9-03
18
Section 150-0020
31. Place 'U' section ring (75) on piston (74) with
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).
SM - 3047
SM - 3046
Fig. 59 - Installing Piston
Fig. 60 - Installing Lock Pins
SM - 3048
Fig. 61 - Installing Cylinder
SM - 3049
Fig. 62 - Installing Thrust Washer
32. Place new seals (73) on shifter fork lock pins (71).
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).
33. Apply Loctite 574 to mounting face of cylinder (78)
and secure to differential housing (31) using bolts (79).
Ensure port is at top, as shown in Fig. 61. Tighten
bolts to 23 Nm (17 lbf ft).
34. Sub-assemble inter-axle differential by installing
thrust washer (38) in differential case half (37), with
lubrication groove facing up. Secure thrust washer with
pins (39).
Note: Ensure pins do not protrude above contact face
of thrust washer.
Section 150-0020
SM 2249 9-03
19
35. Install side gear (41) in differential case half (37).
36. Sub-assemble differential spider (44), pinion gears
(42) and thrust washers (43), ensuring thrust washers
are correctly fitted. Install sub-assembly as shown in
Fig. 63.
SM - 3051
SM - 3050
Fig. 63 - Installing Spider Assembly
Fig. 64 - Assembling Differential
SM - 3052
SM - 3053
37. Install differential case half (37) and fasten with
capscrews (11). Tighten capscrews to 115 Nm (85 lbf
ft).
Note: Use part number stamped on differential cage
halves (37) to ensure correct alignment, as shown in
Fig. 64.
38. Install the pre-assembled inter-axle differential in
differential housing (31).
To meet required differential end float (0.18 - 0.23 mm)
shim (99) dimension should be calculated. Initially
measure Dimension 'A' from the housing (31) mounting
face to inter-axle differential locating face as shown in
Fig. 65.
Measure at several points and determine average
dimension.
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
Place calculated shim (99) into the flange (45).
ZF-No.:
SM 2249 9-03
20
Section 150-0020
SM - 3055
SM - 3054
Fig. 68 - Installing Flange to Differential
SM - 3056
Fig. 69 - Installing Flange
SM - 3057
Fig. 70 - Measuring Dimension 'X'
40. Press bearing (59) into flange (45) until firmly
home.
41. Install both bearing (59) inner rings. Place pre-
assembled flange (45) on inter-axle differential and
press until firmly home as shown in Fig. 68.
or 15269900 110V Hot Air Blower) heat housing (31)
bore and coat mounting face with sealing compound
Loctite 574.
Note: Carry out following steps (43 - 46) promptly
before sealing compound hardens.
43. Install flange (62) on housing (31) as shown in Fig.
69. Use guide screws if necessary.
44. To remove bearing (59) backlash, initially measure
Dimension 'X' from the bearing (59) face to the flange
(62) mounting face as shown in Fig. 70.
Eg. Dimension 'X' = 10.40 mm
Section 150-0020
SM 2249 9-03
21
SM - 3059
SM - 3058
Fig. 71 - Measuring Dimension 'Y'
Fig. 72 - Installing Shaft Seal
SM - 3060
Fig. 73 - Installing Drive Flange
SM - 3061
Fig. 74 - Compressing Diff-lock Cylinder
45. Remove flange (62) and measure Dimension 'Y'
from mounting face to bearing contact face as shown
in Fig. 71.
Eg. Dimension 'Y' = 11.10 mm
Example:
Dimension 'Y' 11.10 mm
Dimension 'X' - 10.40 mm
Shim (60) Dimension = 0.70 mm
Place calculated shim (60) into the flange (62).
46. Again coat mounting face with sealing compound
Loctite 574. Assemble flange (62) complete with shim
(60) on housing (31) and secure with bolts (65). Tighten
47. Using special tool (15500896 Driver) install shaft
seal (61) as shown in Fig. 72.
Note: If seal outer diameter is rubber coated, coat with
spirit. If seal outer diameter is metallic, coat with
Loctite 574.
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).
Note: Coat threads of slotted nut (67) with Loctite 649.
50. Set inter-axle differential lock by installing special
tool (15500910 Compressed Air Connection) and
pressurising piston with compressed air (maximum 10
bar (145 lbf/in
2
)) as shown in Fig. 74. Ensure differential
lock is engaged by turning the drive flange (94).
51. Coat threads of adjusting bolt (81) with sealing
compound Loctite 574 and hand tighten until bolt
contacts piston (74). Tighten adjusting bolt (81) a
further 1/3 of a turn, and lock with nut (82).
SM 2249 9-03
22
Section 150-0020
SM - 3063
SM - 3062
Fig. 75 - Installing Indicator
Fig. 76 - Checking Contact Switch
SM - 3064
Fig. 77 - Installing Filter
SM - 3065
Fig. 78 - Installing Pre-assembled Layshaft Housing
52. Install contact pin (84), seal ring (85) and contact
switch (86). Connect special tool (15500911 Indicator)
53. Pressurise piston with compressed air (maximum
10 bar (145 lbf/in
2
)) as shown in Fig. 76. Ensure
differential lock is engaged by turning the drive flange
(94). The warning lamp on the Indicator should
illuminate when the sliding dog (68) is fully engaged.
54. Install disc (83) and filter element (80) in bore
arrowed in Fig. 77. Cover port until final installation of
hose.
55. Coat mounting face of differential housing (2) with
sealing compound Loctite 574. Using suitable lifting
equipment, install pre-assembled layshaft housing on
the differential housing (2). Install new bolts (28 & 29)
and slotted pins (30) in correct locations (arrowed in
Fig. 78). Tighten bolts to 155 Nm (114 lbf ft).
Section 150-0020
SM 2249 9-03
23
56. Heat ring gear (46) and install it on the differential
housing (47) until it is firmly home as shown in Fig. 79.
WARNING
gloves when handling ring gear.
57. Prior to assembly, coat components with gear oil
as specified in Section 300-0020, LUBRICATION
SYSTEM. Place both thrust washers (52 & 54) in the
housing (47), installing steel thrust washer (52) first as
shown in Fig. 80.
58. Install disc set A (Fig. 2) in housing (47), beginning
with externally splined disc (48) as shown in Fig. 81.
59. Install thrust ring (50) as shown in Fig. 82.
Fig. 79 - Installing Ring Gear
SM - 3074
Fig. 80 - Installing Thrust Washers
SM - 2999
Fig. 81 - Installing Disc Set A
SM - 3000
Fig. 82 - Installing Thrust Ring
SM - 3001
SM 2249 9-03
24
Section 150-0020
Fig. 83 - Installing Side Gear
SM - 3002
Fig. 84 - Installing Differential Pinion Gears
SM - 3003
SM - 3004
SM - 3005
60. Install side gear (51) as shown in Fig. 83. Ensure
both internally splined discs (49) of set A are located
on side gear (51).
61. Sub-assemble pinion gears (53) and differential
axles (55). Install sub-assembly as shown in Fig. 84.
62. Install second side gear (51) as shown in Fig. 85.
63. Install second thrust ring (50) as shown in Fig. 86.
Section 150-0020
SM 2249 9-03
25
Fig. 87 - Installing Disc Set B
SM - 3006
Fig. 88 - Measuring Differential Housing Clearance
SM - 3007
Fig. 89 - Measuring Housing Cover
SM - 3008
SM - 3009
64. Install disc set B (Fig. 2) beginning with internally
splined disc (49) as shown in Fig. 87.
65. The clearance between the assembled differential
housing and the cover (57) should be 0.2 - 0.6 mm.
Press outer externally splined disc (48) evenly on and
measure Dimension 'A' from the mounting face of
housing (47) to the outer disc (48) as shown on Fig. 88,
using special tool (15270114 Digital Depth Gauge).
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.
67. With reference to Steps 65 - 66, calculate
clearance as shown in the example below.
Example:
Results in clearance 0.30 mm
If clearance falls outwith specification (0.2 - 0.6 mm),
then thicker or thinner outer externally splined discs
(48) should be installed.
Note: If necessary to change the outer externally
SM 2249 9-03
26
Section 150-0020
splined discs (48) to obtain correct clearance, these
should be changed so that the overall thickness of disc
sets A and B (Fig. 2) are identical.
Note: If installing new discs, the lower clearance
should be aimed for.
68. Place both thrust washers (52 & 54) in the cover
(57), installing steel thrust washer (52) first as shown in
Fig. 90.
69. Secure cover (57) to housing (47) with two
capscrews (58). Torque capscrews to 46 Nm (34 lbf ft).
70. Heat bearings (17 & 18) inner races and install on
assembled differential, as shown in Fig. 91.
WARNING
71. Using suitable lifting equipment, position the
assembled differential in the differential housing (2) and
install bearings (17 & 18) outer rings, as shown in Fig.
92.
SM - 3010
Fig. 92 - Installing Differential
SM - 3011
Fig. 93 - Installing Bearing Caps
SM - 3012 72. Install adjusting nuts (1 & 19) and locate bearing
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).
Note: Bearing adjusting nuts (1 & 19) have two basic
functions: preloading the bearings and positioning ring
gear (46) to obtain the correct backlash between it and
pinion gear (96).
73. Install new bolts (56) in differential assembly and
torque bolts to 390 Nm (288 lbf ft) as shown in Fig. 94.
Fig. 94 - Tightening Differential Bolts
SM - 3013
55
Section 150-0020
SM 2249 9-03
27
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.
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.
Fig. 95 - Measuring Backlash
SM - 3014
Fig. 96 - Measuring Bracket Dimension
SM - 3015
Fig. 97 - Checking Contact Pattern
SM - 891
Fig. 98 - Installing Slotted Pin
SM - 3016
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.
Compare the contact pattern obtained with the Gear
tooth patterns for the Gleason Gear Tooth system
shown on the following pages.
77. Fasten adjusting nuts (1 & 19) with slotted pins (20)
SM 2249 9-03
28
Section 150-0020
Fig. 99 - Installing Studs
SM - 3017
SM - 3018
78. Install studs in positions shown by arrows in Fig.
99. Apply Loctite 262 to studs and torque to 55 Nm (40
lbf ft).
79. Apply Loctite 574 to axle casing mounting face.
Using suitable lifting equipment, install differential
assembly in axle casing and secure using new bolts
and nuts. Torque bolts to 375 Nm (277 lbf ft) and nuts
to 280 Nm (206 lbf ft).
SM - 3066
SM - 3067
80. Install shaft seal (89) into flange (88) using special
tool (15500912 Driver) as shown in Fig. 101.
Note: If seal outer diameter is rubber coated, coat with
spirit. If seal outer diameter is metallic, coat with
Loctite 574.
81. Install flange (88) on drive flange shaft (87). Heat
bearing (90) to approximately 90 C (190 F) and press
it on to the drive flange shaft (87) and locate it on the
collar as shown in Fig. 102.
WARNING
Install shim (91) and retaining ring (92) to secure
bearing on shaft.
Section 150-0020
SM 2249 9-03
29
Fig. 103 - Tightening Bolts
SM - 3068
or 15269900 110V Hot Air Blower) heat axle housing
bore and coat mounting face with sealing compound
Loctite 574.
83. Install pre-assembled flange shaft (87) and secure
with bolts (93). Tighten bolts to 23 Nm (17 lbf ft) as
shown in Fig. 103.
Install axle shafts as noted on removal. Refer to
SM 2249 9-03
30
Section 150-0020
Fig. 105 - Drive Side (Convex)
Fig. 104 - Coast Side (Concave)
SM - 893
SM - 894
SM - 895
GLEASON GEAR TOOTH SYSTEM
Ideal tooth-contact patterns are shown in Figs. 104 & 105
indicating the pinion distance is correct.
If the patterns obtained are the same as that shown in
Figs. 106 & 107 then decrease the pinion distance.
Refer to Fig. 108.
Figs. 109 & 110 then increase the pinion distance.
Refer to Fig. 111.
MAINTENANCE
Proper lubrication of the differential assembly is
essential if the differentials 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.
SPECIAL TOOLS
The special tools referenced in this section are
available from your dealer. Refer to Section 300-0070,
tools and sealants required.
Section 150-0020
SM 2249 9-03
31
Fig. 108 - Pinion Distance Must Be Decreased
SM - 896
SM - 897
SM - 898
SM - 899
SM - 900
Fig. 111 - Pinion Distance Must Be Increased
SM 2249 9-03
32
Section 150-0020
DIFFERENTIAL DIAGNOSIS
Noises and vibrations originating in the tyres,
transmission, planetaries and drivelines are easily
transmitted and may be erroneously attributed to the
differential. Therefore, all possible sources of noise
should be investigated before the differential is taken
apart.
Whenever noises such as a grating or rattle are heard
coming from the differential, stop the unit immediately.
One tooth from a gear can cause damage to all gears
and bearings. When the differential is definitely at fault,
remove the axle shafts and disconnect the driveline
before moving the vehicle.
WARNING
safely.
WARNING
Removing the axle shafts or drivelines will
make the parking brake ineffective.
DIAGNOSIS CHART
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
TORQUE
FIG. NO. ITEM NO. PART NAME Nm lbf ft
1 22 Slotted Nut 1 200 885
1 64 Bolt 155 114
1 27 Slotted Nut 1 200 885
1 72 Bolt 45 33
1 79 Bolt 23 17
1 65 Bolt 155 114
1 67 Slotted Nut 1 000 738
1 28/29 Bolt 155 114
1 58 Capscrew 46 34
- - Bearing Cap Bolt 390 288
1 56 Bolt 390 288
- - Stud 55 40
- - Axle Casing Bolts 375 277
- - Axle Casing Nuts 280 206
1 93 Bolts 23 17
Section 150-0020
SM 2249 9-03
33
* * * *
DIAGNOSIS CHART (CONTINUED)
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
1
Section 160-0020
SM 2248 8-03
DESCRIPTION
Numbers and letters in parentheses refer to Fig. 1.
Fig. 1 illustrates both a standard pinion gear and
spider differential (A) and a limited slip type (B).
Basically the differential consists of pinion gear (3) and
ring gear (5). The differential is a spiral bevel ring gear
type with an automatically operating limited slip
element (B).
The differential is mounted to the axle housing. The
1 - Bearing Adjuster
2 - Housing
3 - Pinion Gear (Drive)
4 - Drive Flange
5 - Ring Gear
6 - Spider (Pinion) Gear
7 - Side Gear
8 - Differential Case Assembly
SM - 849
Fig. 1 - Sectional View of Typical Differential
REAR AXLE GROUP - Differential Drive Head
driveline yoke attaches directly to differential
flange (4) which is splined to the shaft of pinion gear (3).
Limited Slip Assembly
The limited slip assembly consists of housing (1), thrust
washers (2 & 11), externally splined discs (3), internally
splined discs (4), thrust ring (5), side gears (6), pinion
gears (7), differential axle (8) and cover (9).
2
Rear Axle Group - Differential Drive Head
Section 160-0020
SM 2248 8-03
SM - 2949
Fig. 2 - Exploded View of Limited Slip Assembly
1 - Cover
2 - Thrust Washers (Steel)
3 - Externally Splined Discs
4 - Internally Splined Discs
5 - Thrust Ring
6 - Side Gears
7 - Pinion Gears
8 - Differential Axle
9 - Housing
10 - Bolts
11 - Thrust Washers (Brass)
12 - Capscrews
OPERATION
Pinion gear (3, Fig. 1) is mated with ring gear (5, Fig. 1)
which is bolted to differential case assembly (8, Fig. 1).
When both drive wheels are free to turn under equal
resistance loads, ring gear (5, Fig. 1) and four small
pinion (spider) gears (6, Fig. 1) act as one rigid unit,
transmitting torque to both splined side gears (6). Side
gears (6), being splined to the axle shafts, then drive
each rear wheel with the same amount of torque at
identical rates of speed. In this instance, pinion gears (7)
do not rotate on their axis, therefore, side gears (6)
rotate at the same rev/min as ring gear (5, Fig. 1).
When resistance on one drive wheel exceeds the
resistance on the other, or when the vehicle makes a
turn creating the same effect, one gear continues to
revolve but pinion gears (7) cease to act rigidly with it.
Pinion gears (7) now rotate on their own axis,
permitting one drive wheel to rotate at a different
speed from the other. Since the ratio of the pinion and
side gear assembly is approximately 2 to 1, the result
is that as one drive wheel slows down, the speed of
the other proportionately increases. This prohibits the
application of a torsional load to either axle, which is
greater than that existing during normal operation.
Thus pinion gears (7) serve a dual purpose:
1. They allow a differential in speed between the two
drive wheels, permitting maximum manoeuvrability.
2. They prohibit the application of all torque to one axle
shaft.
7
8
7
6
5
4
3
4
3
11
2
9
6
5
4
3
4
3
11
2
1
10
A
B
12
3
Section 160-0020
SM 2248 8-03
REMOVAL
WARNING
safely.
1. Before attempting to remove the road wheels, drive
the vehicle onto a level, solid concrete floor, preferably
after a short run to warm the oil.
Note: If the rear differential is being removed, raise the
body and prop it up with the body prop.
the 'Off' position.
4. Drain the gear oil out of the axle housing and both
planetaries into a suitable container.
5. Remove the planetary assemblies and axle shafts
from the axle housing. Note from which side the long
and short axle shafts are removed. Refer to Section
160-0030, AXLE GROUP (HUB).
6. Identify the relationship of the driveline flange and
differential pinion flange with punch marks.
7. Disconnect the driveline from the differential drive
flange. The driveline can be removed if it is convenient
to do so.
8. Index mark differential housing (1) and the axle
housing to ensure that differential housing (1) is
installed in the same position.
9. Loosen and remove nuts and bolts from the
differential and axle housings. Thread in three puller
bolts to break the seal between the differential and axle
housings and to partially pull the differential assembly
out of the axle housing.
10. Using suitable lifting equipment, support the weight
of the differential assembly.
Note: When removing the rear differential, weld a loop
to the bottom side of the body above the differential
and attach the lifting device.
11. Pull out the differential assembly until it clears the
axle housing, then carefully lower it to the floor. Slide
the differential assembly out from beneath the vehicle.
INSTALLATION
Installation is the reversal of the 'Removal' procedure.
Note: Use sealing compound (Loctite 574) between the
axle housing and differential housing mounting faces.
Tighten bolts securing differential assembly to axle
housing to 375 Nm (277 lbf ft). Tighten nuts to 280 Nm
(207 lbf ft).
Note: Tighten all fasteners without specified torques to
standard torques listed in Section 300-0080,
SPECIFICATIONS.
Fill the layshaft housing (3) with 1.5 litres (0.4 US
gallon) of gear oil of the type specified in Section 300-
0020, LUBRICATION SYSTEM, through the differential
filler/level hole. Fill the axle casing with gear oil of the
type specified in Section 300-0020, LUBRICATION
SYSTEM, through the differential filler/level hole until
the oil is level with the bottom of the filler/level hole. Fill
the planetary assemblies up to the 'Oil Level Check
Line'. Check oil levels after a few minutes to ensure
level remains constant.
4
Section 160-0020
SM 2248 8-03
SM - 2950
Fig. 3 - Exploded View of Rear Differential
31 - Pin
32 - Spacer
33 - Bearing
34 - Shim Support
35 - Retainer
36 - Spur Gear
37 - Bushing
38 - Slotted Pin
39 - Bolt
40 - Bolt
41 - Bolt
42 - Plate
43 - Pin
44 - Bearing
16 - Bearing
17 - Pinion Gear
18 - Ring Gear
19 - Bolt
20 - Pin
21 - Slotted Nut
22 - Washer
23 - Bearing
24 - Adjusting Ring
25 - Spacer Bush
26 - Layshaft Housing
27 - Plug
28 - 'O' Ring
29 - Plug
30 - 'O' Ring
2 - Slotted Nut
3 - Washer
4 - Drive Flange
5 - Seal Holder
6 - Dust Shield
7 - Shaft Seal
8 - Bearing
9 - Spacer
10 - Adjusting Nut
11 - Quill Shaft
12 - Bearing
13 - Spur Gear
14 - Cover
15 - Spacing Washer
2
3
4
6
7
39
5
11
8
9
13
19
14
20
21
22
23
24
25
26
27
28
29,30
31
36
37
32
33
34
35
15
16
17
18
38
10
12
1
42
43
40,41
44
10
5
Section 160-0020
SM 2248 8-03
DISASSEMBLY
WARNING
safely.
Note: The following removal procedure assumes the
complete axle assembly was removed from the
vehicle.
1. Ensure oil is drained from both axle casing and
layshaft housing as shown in Fig. 4.
2. Remove both planetary assemblies and axle shafts
by following the procedure in Section 160-0030, AXLE
GROUP (HUB). Using suitable lifting equipment,
support differential assembly. Remove nuts and bolts
and remove the differential assembly from the axle
casing as shown in Fig. 5.
SM - 3020
SM - 3021
SM - 2951 3. Loosen ring gear (18) bolts as shown in Fig. 6.
Fig. 5 - Removing Differential Assembly
Fig. 6 - Removing Ring Gear Bolts
Fig. 4 - Removing Drain Plugs
4. Remove slotted pins (38) before loosening adjusting
nuts (10) as shown in Fig. 7.
Fig. 7 - Removing Adjusting Nuts
SM - 2952
6
Section 160-0020
SM 2248 8-03
5. Using special tool (15269899 220V Hot Air Blower or
15269900 110V Hot Air Blower) heat the area around
the threaded holes and loosen bolts securing bearing
caps. Remove bearing caps.
Fig. 8 - Removing Bearing Caps
SM - 858
SM - 2955
Fig. 11 - Differential Components
6. Lift the differential assembly out of differential
housing (1) with the special tool (15269929 Lifting
Pliers) as shown in Fig. 9.
7. Remove both bearings (12 & 44) inner rings using
special tools (15272560 Puller, 15500887 Gripping
Insert, 15500888 Gripping Insert and 15500889
Reducer) as shown in Fig. 10.
8. Remove capscrews (12, Fig. 2) and separate
housing (9, Fig. 2) from cover (1, Fig. 2). Remove
single components as shown in Fig. 11.
SM - 2953
Fig. 9 - Removing Differential
SM - 2954
Fig. 10 - Removing Bearing Inner Rings
7
Section 160-0020
SM 2248 8-03
9. Remove bolts (40 & 41) securing layshaft housing
(26) to differential housing (1). Separate the housings
using suitable lifting equipment, and secure layshaft
housing to a suitable fixture.
Fig. 12 - Separating Layshaft Housing
SM - 2956
SM - 2957
SM - 2958
SM - 2959
Fig. 15 - Removing Retainer
or 15269900 110V Hot Air Blower) heat the slotted nut
(2) to around 120
o
C before loosening using special tool
(15500890 Socket) as shown in Fig. 13. Remove
slotted nut (2), washer (3) and drive flange (4).
11. Remove bolts (39) and seal holder (5) from cover
12. Remove retainer (35) and shim support (34) from
layshaft housing (26) as shown in Fig. 15.
Fig. 14 - Removing Seal Holder
8
Section 160-0020
SM 2248 8-03
Fig. 17 - Pressing Inner Race of Bearing
SM - 2960
SM - 2961
13. As shown in Fig. 16 use special tool (15269946
Puller Set) to press quill shaft (11) out of the bearing.
14. Remove spacer (9) and press the bearing (8) inner
race from the shaft (11).
Fig. 16 - Pressing Out Shaft
15. Remove bearing (33) inner race and spacer (32)
from housing (26).
Fig. 18 - Removing Inner Race of Bearing
SM - 2962
16. Remove bolts (19) and separate cover (14) from
layshaft housing (26) as shown in Fig. 19. Remove
spur gear (13) at this time.
Fig. 19 - Separating Cover From Housing
SM - 2963
9
Section 160-0020
SM 2248 8-03
Fig. 23 - Pressing Out Components
before removing using special tool (15500891 Socket)
Fig. 22 - Removing Bearing From Pinion Gear
SM - 2966
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 - 2964
Fig. 21 - Pressing Out Pinion Gear
SM - 2965
18. With the special tool (15269946 Puller Set) shown
in Fig. 21, press the pinion gear (17) out of the bearing
(23).
19. Pull off the bearing (16) inner race from the pinion
gear (17) using special tools (15500892 Gripping Insert
and 15272560 Bearing Puller).
10
Section 160-0020
SM 2248 8-03
Fig. 27 - Installing Bushing
SM - 2969
SM - 2970
SM - 2971
INSPECTION
1. Clean all parts with a suitable solvent. Dry all parts,
except bearings, with compressed air or with soft,
clean lint free cloths. DO NOT spin bearings with
compressed air. Place bearings on a clean surface,
cover with lint free cloths and allow to dry.
2. Coat cleaned, dried parts immediately with light oil to
prevent corrosion. If parts are not to be assembled
immediately, treat them with a good quality rust
preventive and wrap them with treated paper or suitable
material designed to prevent corrosion.
3. Before installing the differential assembly into the
axle housing, clean the inside and outside of the axle
housing to remove any debris or dirt.
4. Inspect all gears, pinions and splines for cracked or
broken teeth, excessive wear, and pitted or scored
surfaces. Repair or replace as necessary.
Note: If either ring gear or pinion gear is defective, both
gears must be replaced, because they are serviced
only as a matched set.
5. Check for pitted, scored or worn thrust surfaces of
differential case halves.
6. During assembly and installation, make sure that
mated, punch marked or otherwise identified parts are
returned to their original positions, if still serviceable.
ASSEMBLY
specified to standard torques listed in
Section 300-0080, AXLE BOLT AND NUT TORQUE
SPECIFICATIONS.
WARNING
safely.
SM - 2968
11
Section 160-0020
SM 2248 8-03
3. Insert spur gear (36) into housing (26) bore, ensuring
that inner diameter (85 mm) is facing down, as shown
in Fig. 26.
4. Press the bushing (37) into housing (26) bore and
ensure it is firmly home, as shown in Fig. 27.
5. At this stage in the assembly procedure the
thickness of spacing washer (15) must be determined
to ensure correct contact pattern between pinion gear
(17) and ring gear (18). As shown in Fig. 28, measure
Dimension 'A' from the mounting face of housing (26) to
the locating face of the bearing (16) outer ring, using
special tools (15270113 Gauge Blocks, 15269948
Straight Edge and 15270114 Digital Depth Gauge).
6. As shown in Fig. 29, use special tools (15500893
Shims, 15500894 Shims and 15269934 Measuring
Shaft) and place shims into the bores of differential
housing (1) and assemble the measuring shaft.
7. Measure Dimension 'B' from mounting face of
housing (1) to Measuring Shaft (see Fig. 30).
Example:
+ Dimension 'B' 196.75 mm
- Dimension 'C' (
1
/
2
diameter of Measuring
Shaft) 15.00 mm
= Dimension 'X' 241.45 mm
SM - 2972
SM - 2973
Fig. 29 - Assembling The Measuring Shaft
SM - 2974
8. Measure thickness of bearing (16) as shown in Fig.
31 using special tools (15270113 Gauge Blocks and
15270114 Digital Depth Gauge). Record as Dimension
'D'.
Eg. Dimension 'D' = 42.70 mm
Fig. 31 - Measuring Bearing Thickness
SM - 868
12
Section 160-0020
SM 2248 8-03
9. The arrow in Fig. 32 is pointing to a dimension
stamped on the face of pinion gear (17). Record as
Dimension 'E'.
Eg. Dimension 'E' = 198 - 0.1 = 197.90 mm
Example:
Dimension 'D' 42.70 mm
+ Dimension 'E' 197.90 mm
= Dimension 'Y' 240.60 mm
Fig. 32 - Dimension On Pinion Face
Fig. 33 - Installing Spacing Washer
SM - 2975
SM - 2976
SM - 2977
SM - 873
10. Calculate spacing washer (15) thickness by
subtracting Dimension 'Y' from Dimension 'X'.
Example:
Dimension 'X' 241.45 mm
- Dimension 'Y' 240.60 mm
= Required thickness 0.85 mm
Install spacing washer (15) of required thickness into
the bushing (37) as shown in Fig. 33.
11. Freeze bearing (16) outer race and install in
bushing (37), ensuring it is firmly home.
WARNING
(17). Be sure it is firmly seated against the shaft
shoulder as shown in Fig. 35.
WARNING
13
Section 160-0020
SM 2248 8-03
13. Install assembled pinion gear (17) in layshaft
housing (26) using special tool (15269946 Puller Set)
as shown in Fig. 36. Do not remove special tool at this
point.
Fig. 36 - Installing Pinion Gear
Fig. 37 - Installing Spacer Bush and Adjusting Ring
SM - 2978
SM - 2979
SM - 2980
SM - 2981
(17) until it is firmly home as shown in Fig. 38.
WARNING
After bearing (23) inner race has cooled, remove special
tool installed in Step 13.
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)
Note: When tightening nut (21), rotate the pinion gear (17)
in both directions several times.
14. The adjusting ring (24) is used to obtain the rolling
resistance of the pinion bearing. Rolling resistance
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).
14
Section 160-0020
SM 2248 8-03
17. Check the rolling resistance of the pinion bearing
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.
Record this torque as T
pinion
e.g. 3.5 Nm.
SM - 2983
SM - 2984
SM - 2985
SM - 2982
18. Install spur gear (13) in housing (26) as shown in
Fig. 41.
19. Install quill shaft (11) into housing (26) using
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)
with the collar facing down as shown in Fig. 43.
Fig. 42 - Installing Quill Shaft
15
Section 160-0020
SM 2248 8-03
WARNING
Fig. 45 - Installing Shim Support and Retainer
Fig. 46 - Pressing Shaft
Fig. 47 - Pressing Bearing Outer Race
SM - 2986
SM - 2987
SM - 2988
SM - 2989
22. Install shim support (34) and snap in the retainer
23. Remove special tool (15269946 Puller Set) installed
in Step 19, and install it to the retainer (35) end of shaft
(11). Press the shaft (11) until the shim support (34) is
located on retainer (35).
Do not remove special tool at this point.
24. Press bearing (8) outer race into cover (14) until firmly
home, as shown in Fig. 47.
16
Section 160-0020
SM 2248 8-03
L
O
C
T
IT
E
25. Apply Loctite 574 to mounting face of housing (26)
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).
26. The spacer (9) is used to obtain the rolling
resistance of the shaft (11) bearing. Rolling resistance
resistance (T
An
) is calculated once shaft (11) is
secured in housing (26) (Step 32). As shown in Fig. 49,
install spacer (9) on shaft (11).
WARNING
Once the bearing (8) has cooled, remove special tool
(15269946 Puller Set) installed in Step 23.
28. Apply Loctite 574 to mounting face of cover (14).
Place the seal holder (5) on cover (14) and secure
using new bolts (39). Torque bolts (39) to 155 Nm (114
lbf ft) as shown on Fig. 51.
Fig. 48 - Applying Loctite 574
Fig. 51 - Tightening Seal Holder Bolts
SM - 2991
SM - 2992
SM - 2993
SM - 2990
17
Section 160-0020
SM 2248 8-03
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.
30. Press dust shield (6) over drive flange (4) as shown
in Fig. 53.
Fig. 53 - Installing Dust Shield
SM - 2995
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.
Note: When tightening nut (2), rotate the shaft (11) in
both directions several times.
SM - 2997 32. As shown in Fig. 55, check total rolling resistance
of pinion gear (17) and shaft (11) using by using special
tool (15500895 Torque Spanner). Record this torque as
T
tot
e.g. 5.5 Nm.
Example:
T
tot
e.g. 5.5 Nm
T
pinion
e.g. - 3.5 Nm
Results in T
An
= 2.0 Nm
As specified in Step 26, rolling resistance (T
An
) of shaft
(11) should be 1.5 - 3.0 Nm. If outwith this range,
spacer (9) thickness must be changed.
18
Section 160-0020
SM 2248 8-03
Fig. 56 - Installing Pre-assembled Layshaft Housing
SM - 2998
Fig. 57 - Installing Ring Gear
SM - 3074
SM - 2999
Fig. 59 - Installing Disc Set A
SM - 3000
33. Coat mounting face of differential housing (1) with
Loctite 574. Using suitable lifting equipment, install the
pre-assembled layshaft housing to the differential
housing (1).
34. As shown in Fig. 56, secure the pre-assembled
layshaft housing to the differential housing (1) with pins
(refer to arrows) and new bolts (40 & 41). Torque bolts
(40 & 41) to 155 Nm (114 lbf ft).
35. Heat ring gear (18) and install it on the differential
housing (9, Fig. 2) until it is firmly home as shown in
Fig. 57.
WARNING
gloves when handling ring gear.
36. Prior to assembly, coat components with gear oil
as specified in Section 300-0020, LUBRICATION
SYSTEM. Place both thrust washers (2 & 11, Fig. 2) in
the housing (9, Fig. 2), installing steel thrust washer (2,
Fig. 2) first as shown in Fig. 58.
37. Install disc set A (Fig. 2) in housing (9, Fig. 2),
beginning with externally splined disc (3, Fig. 2) as
shown in Fig. 59.
19
Section 160-0020
SM 2248 8-03
38. Install thrust ring (5, Fig. 2) as shown in Fig. 60.
SM - 3001
SM - 3002
Fig. 62 - Installing Differential Pinion Gears
SM - 3003
SM - 3004
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).
40. Sub-assemble pinion gears (7, Fig. 2) and
differential axles (8, Fig. 2). Install sub-assembly as
shown in Fig. 62.
41. Install second side gear (6, Fig. 2) as shown in Fig.
63.
20
Section 160-0020
SM 2248 8-03
42. Install second thrust ring (5, Fig. 2) as shown in
Fig. 64.
SM - 3005
Fig. 65 - Installing Disc Set B
SM - 3006
Fig. 66 - Measuring Differential Housing Clearance
SM - 3007
Fig. 67 - Measuring Housing Cover
SM - 3008
43. Install disc set B (Fig. 2) beginning with internally
splined disc (4, Fig. 2) as shown in Fig. 65.
44. The clearance between the assembled differential
housing and the cover (1, Fig. 2) should be 0.2 - 0.6
mm. Press outer externally splined disc (3, Fig. 2)
evenly on and measure Dimension 'A' from the
mounting face of housing (9, Fig. 2) to the outer disc
(3, Fig. 2) as shown on Fig. 66, using special tool
(15270114 Digital Depth Gauge).
45. Measure Dimension 'B' from the contact face to the
mounting face of housing cover (1, Fig. 2) using
special tool (15270114 Digital Depth Gauge) as shown
in Fig. 67.
21
Section 160-0020
SM 2248 8-03
46. With reference to Steps 44 - 45, calculate
clearance as shown in the example below.
Example:
Results in clearance 0.30 mm
If clearance falls outwith specification (0.2 - 0.6 mm),
then thicker or thinner outer externally splined discs (3,
Fig. 2) should be installed.
Note: If necessary to change the outer externally
splined discs (3, Fig. 2) to obtain correct clearance,
these should be changed so that the overall thickness
of disc sets A and B (Fig. 2) are identical.
Note: If installing new discs, the lower clearance
should be aimed for.
47. Place both thrust washers (2 & 11, Fig. 2) in the
cover (1, Fig. 2), installing steel thrust washer (2, Fig.
2) first as shown in Fig. 68.
48. Secure cover (1, Fig. 2) to housing (9, Fig. 2) with
two capscrews (12, Fig. 2). Torque capscrews to 46
Nm (34 lbf ft).
49. Heat bearings (12 & 44) inner races and install on
assembled differential, as shown in Fig. 69.
WARNING
50. Using suitable lifting equipment, position the
assembled differential in the differential housing (1) and
install bearings (12 & 44) outer rings, as shown in Fig.
70.
SM - 3009
SM - 3010
SM - 3011
Fig. 71 - Installing Bearing Caps
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
Note: Bearing adjusting nuts (10) have two basic
functions: preloading the bearings and positioning ring
gear (18) to obtain the correct backlash between it and
pinion gear (17).
55
22
Section 160-0020
SM 2248 8-03
52. Install new bolts (10, Fig. 2) in differential assembly
and torque bolts to 390 Nm (288 lbf ft) as shown in Fig.
72.
Fig. 72 - Tightening Differential Bolts
SM - 3013
Fig. 73 - Measuring Backlash
SM - 3014
Fig. 74 - Measuring Bracket Dimension
SM - 3015
Fig. 75 - Checking Contact Pattern
SM - 891
53. Check the backlash between ring gear (18) and
pinion gear (17). 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. 73. Establish the backlash by
alternately setting both adjusting nuts (10). Rock the
ring gear back and forth being careful not to move the
pinion gear. Backlash should be 0.27 - 0.33 mm.
54. Determine the bearing (12 & 44) rolling resistance
and bracket dimension by further tightening of both
adjusting nuts (10). The bearing rolling resistance
should be 3 - 4 Nm (2.2 - 2.9 lbf ft). Measure bracket
dimension as shown in Fig. 74 using 15500899
Micrometer. Dimension should be 358
-0.1
mm.
55. To check the tooth pattern of ring gear (18), 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. 75.
Compare the contact pattern obtained with the Gear
tooth patterns for the Gleason Gear Tooth system
shown on the following pages.
23
Section 160-0020
SM 2248 8-03
Fig. 76 - Installing Slotted Pin
SM - 3016
Fig. 77 - Installing Studs
SM - 3017
SM - 3018
56. Fasten adjusting nuts (10) with slotted pins (38) as
shown in Fig. 76.
57. Install studs in positions shown by arrows in Fig.
77. Apply Loctite 262 to studs.
58. Apply Loctite 574 to axle casing mounting face.
Using suitable lifting equipment, install differential
assembly in axle casing and secure using new bolts
and nuts. Torque bolts to 375 Nm (277 lbf ft) and nuts
to 280 Nm (206 lbf ft).
Install axle shafts as noted on removal. Refer to
24
Section 160-0020
SM 2248 8-03
Fig. 83 - Pinion Distance must be Decreased Fig. 80 - Drive Side (Convex)
SM - 893
SM - 894
SM - 895
SM - 896
SM - 897
GLEASON GEAR TOOTH SYSTEM
Ideal tooth-contact pattern shown in Figs. 79 and 80
indicating the pinion distance is correct.
Figs. 81 and 82 then decrease the pinion distance (Fig.
83). Refer to Steps 5 - 10.
Figs. 84 and 85 then increase the pinion distance
(Fig. 86). Refer to Steps 5 - 10.
25
Section 160-0020
SM 2248 8-03
SM - 898
SM - 899
SM - 900
Fig. 86 - Pinion Distance must be Increased
26
Section 160-0020
SM 2248 8-03
DIAGNOSIS CHART
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
MAINTENANCE
Proper lubrication of the differential assembly is
essential if the differentials 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.
SPECIAL TOOLS
The special tools referenced in this section are
available from your dealer. Refer to Section 300-0070,
tools and sealants required.
DIFFERENTIAL DIAGNOSIS
Noises and vibrations originating in the tyres,
transmission, planetaries and drivelines are easily
transmitted and may be erroneously attributed to the
differential. Therefore, all possible sources of noise
should be investigated before the differential is taken
apart.
Whenever noises such as a grating or rattle are heard
coming from the differential, stop the unit immediately.
One tooth from a gear can cause damage to all gears
and bearings. When the differential is definitely at fault,
remove the axle shafts and disconnect the driveline
before moving the vehicle.
WARNINGS
safely.
Removing the axle shafts or drivelines
will make the parking brake ineffective.
27
Section 160-0020
SM 2248 8-03
* * * *
TORQUE
FIG. NO. ITEM NO. PART NAME Nm lbf ft
2 12 Capscrew 46 34
2 10 Bolt 390 288
3 2 Slotted Nut 750 553
3 19 Bolt 155 114
3 21 Slotted Nut 1 200 885
3 39 Bolt 155 114
3 40, 41 Bolt 155 114
- - Bearing Cap Bolts 390 288
- - Axle Casing Bolts 375 277
- - Axle Casing Nuts 280 206
1
SM 2256 11-03
Section 160-0030
REAR AXLE GROUP - Axle Group (Hub)
OPERATION
Power from the differential is transmitted through a
fully floating axle shaft connected to sun gear shaft (14)
by driver (15). As sun gear shaft (14) rotates in a
clockwise direction, the four planet gears (20) meshed
with sun gear shaft (14) rotate anticlockwise. Ring gear
(10) is splined to hub carrier (1) and does not rotate but
causes planet gears (20), which are meshed with ring
gear (10), to move around it in a clockwise direction.
As planet carrier (16) is bolted to wheel hub (8) the
wheel then rotates in a clockwise direction.
Fig. 1 - Exploded View of Planetary and Wheel
20 - Planet Gear Assy
21 - Retainer Ring
22 - Thrust Washer
23 - Bolt
24 - Capscrew
25 - Wheel Nut
26 - Plug
27 - Lockwasher
28 - Slotted Nut
11 - Snap Ring
12 - Locking Plate
13 - Lock Screw
14 - Sun Gear Shaft
15 - Driver
16 - Planet Carrier
17 - 'O' Ring
18 - Plug Screw
19 - 'O' Ring
1 - Hub Carrier
2 - Shim
3 - Shaft Seal
4 - Ring
5 - Roller Bearing
6 - Bolt
7 - Roller Bearing
8 - Hub
9 - Ring Gear Carrier
10 - Ring Gear
SM - 3097
28
Rear Axle Group - Axle Group (Hub)
Section 160-0030
2
SM 2256 11-03
REMOVAL AND DISASSEMBLY
Note: On dismantling, clean all parts in paraffin or
other suitable cleaning agent and place on a clean
work surface.
WARNINGS
safely.
damage, the procedure for removing tyre and
rim assembly described in Section 160-0050,
WHEEL, RIM AND TYRE, must be strictly
followed.
When necessary to drive out components
during disassembly, be sure to use a soft drift
to prevent property damage and personal
injury.
1. Before attempting to remove the road wheels, drive
the vehicle onto a level, solid concrete floor,
preferably after a short run to warm the oil.
3. Block the appropriate road wheels, place the
steering lock bar in the 'Locked' position and the
battery master switch in the 'Off' position.
4. Whilst road wheels are still on the ground, loosen
wheel nuts (25).
5. Jack up the axle and support with suitably placed
stands or timbers.
6. Support tyre and rim assembly with a suitable sling
and lifting device. Remove wheel nuts (25) and remove
tyre and rim assembly from the machine. Remove
opposite road wheel in the same way. Refer to Section
160-0050, WHEEL, RIM AND TYRE.
7. Place suitable containers under the differential and
both hubs (8). Remove differential drain plug and drain
oil from the differential.
8. Rotate hubs (8) until plug screws (26) are at their
lowest points. Remove plug screws (26) and 'O' rings
and drain oil from hubs. Remove capscrew (24).
Fig. 2 - Jacking Planet Carrier Out Of Hub
Fig. 3 - Removing Planet Carrier Assembly
SM - 1026
SM - 1027
9. Remove drain plugs and drain cooling oil from brake
packs into a clean container. Refit drain plugs.
10. Index mark planet carrier (16) and hub (8) to aid in
installation.
11. Remove bolts (23) then prise planet carrier (16)
from hub (8) and place on the floor with planet gears
(20) facing upwards. If necessary, use jacking bolts in
tapped holes provided, as shown in Fig. 2.
12. Remove bearing (5) inner race from hub carrier (1).
13. Lift out sun gear shaft (14) from planet carrier (16)
assembly. Remove retainer rings (21) and pull planet
gear assemblies (20) from planet carrier (16) using
special tool (15271107, Puller). Remove thrust washer
(22).
14. Remove driver (15) from axle shaft. Pull axle shaft
from axle housing. Note: Left and right axle shafts are
different lengths.
15. Remove two lock screws (13) and locking plate (12)
from ring gear (10). Remove slotted nut (28) from hub
carrier (1) with the special tools (15500882, Socket and
15500883 Centering Bracket) as shown in Fig. 4.
3
SM 2256 11-03
Section 160-0030
Remove shims (2) from hub carrier (1).
16. Using suitable lifting equipment, remove ring gear
(10), squeeze out the snap ring (11) and separate ring
gear carrier (9) from the ring gear (10).
17. Using suitable lifting equipment, separate hub (8)
assembly from brake pack.
18. Remove shaft seal (3), ring (4), roller bearing (7)
and bearing (5) outer race from hub (8) as shown in Fig.
5.
19. If necessary, drive or press wheel bolts (6) from
hub (8).
20. For further disassembly of brake packs refer to
Section 165-0015, OIL COOLED DISC BRAKES.
INSPECTION
Thoroughly clean all parts with a suitable solvent and
dry with compressed air. Inspect all parts for damage
or excessive wear and replace where necessary.
Inspect thrust washer (22) to make sure it is free of
burrs and is absolutely flat. Replace all 'O' rings.
ASSEMBLY AND INSTALLATION
300-0080, AXLE BOLT AND NUT TORQUE
SPECIFICATIONS.
WARNING
damage, be sure lifting equipment is properly
safely.
1. Install brake pack on axle as described in Section
165-0015, OIL COOLED DISC BRAKES.
2. If removed, install new wheel bolts (6) on hub (8)
using the special tools (15500884, Wheel Bolt Puller
and 15269895, Insert) shown in Fig. 6.
3. Install roller bearing (7) outer race in inner bore of
hub (8) using special tools (15500885, Driver and
15269898, Handle). Turn the hub over and similarly
install bearing (5) outer race into the hub (8) bore.
SM - 1029
SM - 1028
Fig. 5 - Removing Bearing Outer Race
Fig. 6 - Installing Wheel Bolts
SM - 1030
SM - 1032
Section 160-0030
4
SM 2256 11-03
4. Place the roller bearing (7) inner race into outer race
in hub (8).
5. Grease sealing lip of shaft seal (3) and install shaft
seal (3) in hub (8) bore using special tool (15275464,
Driver). Install shaft seal (3) on hub carrier (1) using
special tool (15500886, Press Ring).
6. With a suitable lifting device, pick up hub (8)
assembly, then, being careful to prevent damaging
the lip of shaft seal (3), slide hub (8) assembly onto
hub carrier (1). Be sure hub (8) assembly is firmly
seated against the shoulder of hub carrier (1).
7. Install bearing (5) inner race on the splined end of
hub carrier (1) as shown in Fig. 7. Be sure the inner
race is firmly seated.
8. Assemble ring gear (10) to ring gear carrier (9) and
fasten using snap ring (11).
9. Slide ring gear (10) assembly over the splines of hub
carrier (1). Be sure it is pushed all the way in.
10. Install special tool (15500900 Adjusting Nut) on hub
carrier (1) threads and, using special tools (15500882
Socket and 15500883 Centering Bracket) tighten
Adjusting Nut until the rolling resistance (T) is 20 - 30
Nm (15 - 22 lbf ft). See Fig. 8.
Note: During tightening the wheel hub must be
spinning.
11. Check the rolling resistance of hub (8) by wrapping a
length of string around hub (8) and pulling with a suitable
scale as shown in Fig. 9. The rolling resistance (T) should
be 20 - 30 Nm (15 - 22 lbf ft). This corresponds to a pull
of 90 - 135 N.
Formula to calculate F.
F = T/R
Where:
F = Pull (N)
T = Rolling resistance (Nm)
R = Radius of hub (m)
12. Determine thickness of shim (2) (dimension 'S') as
shown in Fig. 10. Measure dimension 'A' from the front
face of Adjusting Nut to the face of the hub carrier (1).
Remove 15500900 Adjusting Nut. Measure dimension
'B' as the thickness of 15500900 Adjusting Nut.
Example:
Dimension 'A' = 17.60 mm (0.69 in)
Dimension 'B' = 16.00 mm (0.63 in)
Fig. 10 - Calculating Shim Thickness
Fig. 9 - Checking Hub Rolling Resistance
Fig. 11 - Installing Planet gear Assemblies
F
SM - 1035
SM - 1033
SM - 1034
SM - 3098
Adjusting Nut
B "S"
A
12
8
5
5
1
5
SM 2256 11-03
Section 160-0030
Dimension 'S' = 1.60 mm (0.06 in)
13. Install shim (2) of thickness calculated in Step 12,
and slotted nut (28) on hub carrier (1) threads and,
using special tools (15500882, Socket and 15500883,
Centering Bracket) shown in Fig. 8, tighten slotted nut
(28) to a torque of 2 000 Nm (1 475 lbf ft). If required,
increase the torque until the slotted nut (28) can be
locked with plate (12).
Note: During tightening the wheel hub must be
spinning.
14. Recheck the rolling resistance. If rolling resistance
is not reached, select a thinner shim (2). If rolling
resistance is exceeded, select a thicker shim (2).
15. Install locking plate (12) and secure with lock
screws (13). Tighten lock screws to 86 Nm (63 lbf ft).
Note: Use new lock screws (13) only.
16. Carefully slide axle shaft through the bore of hub
carrier (1) until the axle shaft splines into the
differential side gears. Slide driver (15) onto axle shaft.
17. Heat planet gear assemblies (20) and press onto
the pins of planet carrier (16) as shown in Fig. 11.
Secure planet gears by installing retainer rings (21).
18. Before positioning sun gear shaft (14) it is
necessary at this stage to determine the end play of
sun gear shaft (14) before installing the planetary
assembly into the hub. The required end play should
be 0.3 - 0.6 mm (0.012 - 0.024 in) and can be achieved
by installing different thicknesses of thrust washer
(22).
Determine end play of sun gear shaft (14) as follows:
a. Position the assembled planet carrier (16) as shown
in Fig. 12. Place a straight edge along top of planetary
gears and measure the dimensions to carrier mounting
face (dimension 'X') and thrust washer (22) (dimension
'Y'). Note the difference and record this as dimension
'A'.
Example:
Dimension 'X' = 100.00 mm (3.937 in)
Dimension 'Y' = 85.40 mm (3.362 in)
b. Slide sun gear shaft (14) fully into driver (15). Place
a straight edge across the mounting surface of hub (8)
and measure the distance from the mounting surface
SM - 2947
Fig. 13 - Calculating Shim Thickness
Adjusting Nut
B "S"
A
14
10
8
7
1
SM - 2830
X
Y
A
PLANET CARRIER
SM - 2831
B
SUN GEAR SHAFT
HUB
Section 160-0030
6
SM 2256 11-03
27. Refit road wheels, securing with wheel nuts (25).
Remove stands or timber supports and lower the
machine to the ground. Fully tighten wheel nuts to a
torque of 730 Nm (540 lbf ft). Remove blocks from the
wheels.
Note: Wheel nuts should be checked and tightened if
necessary, after the first 10 hours of operation. Check
torque every 50 hours (weekly) thereafter.
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.
SPECIAL TOOLS
The special tools referenced throughout this section
are available from your dealer. Refer to Section
300-0070, SERVICE TOOLS, for part numbers of
general service tools and sealants required.
AXLE DIAGNOSIS
Noises originating in the tyres, transmission, brakes or
drivelines might be attributed by mistake to the axle
components, therefore, all possible sources of noise
should be investigated before deciding the axle is at
fault.
WARNING
safely.
True axle noises may be located by lifting or jacking
the machine up until all tyres are clear of the floor or
ground. Securely block the machine in this position.
Run power train at moderate speed. Be certain all tyres
are off the ground to prevent damage to the differential
and make sure that there is no brake drag.
of hub (8) to the end of sun gear shaft (14) as shown in
Fig. 14. Record this as dimension 'B'.
Example:
Example:
Difference (End play) = 0.30 mm (0.012 in)
Once correct endplay is achieved, fix thrust washer
(22) with grease in the planet carrier (16).
19. Remove sun gear shaft (14) from driver (15) and
position in planet carrier (16) in mesh with planet gear
assemblies (20).
20. Place greased 'O' ring (19) into the annular groove
in the planet carrier (16).
21. Coat the face of planet carrier (16) with Loctite 574
sealing compound. Line up index marks and install
planet carrier (16) assembly into hub (8) and secure
with bolts (23). Tighten bolts (23) to a torque of 280 Nm
(206 lbf ft).
22. Place a new 'O' ring (17) on plug screw (18) and
thread assembled plug screw into the outer face of
planetary carrier (16). Tighten plug screw (18) to a
23. Place a new 'O' ring on plug screw (26) and thread
assembled plug screw into the outer face of planetary
carrier (16). Tighten plug screw (26). Coat capscrew
(24) with Loctite 574 then install adjacent to plug screw
(26). Tighten capscrew (24).
24. Install differential drain plug. Add gear oil of the
type specified in Section 300-0020, LUBRICATION
SYSTEM, through the differential filler/level hole until
the oil is level with the bottom of the filler/level hole.
25. Fill the planetary assemblies up to the 'Oil Level
Check Line' with gear oil of the type specified in
26. Fill the brake coolant tank with oil as specified in
Section 300-0020, LUBRICATION SYSTEM. Fill until
oil is halfway up sight glass. Install filler cap on brake
coolant tank filler neck. Once engine has been started,
oil level will drop as brake packs are filled. Top up oil
as necessary.
7
SM 2256 11-03
Section 160-0030
* * * *
AXLE DIAGNOSIS CHART
Noises Insufficient or incorrect lubricant Check level. Fill with proper type and grade of
lubricant.
Wheel bearings scored or rough Replace wheel bearings
Gear teeth in planetary chipped Replace gear
Loss of lubricant Lubricant foams excessively Drain and fill with proper type and grade of
lubricant
Worn or broken oil seal Replace oil seal
Loose nuts or bolts Tighten nuts or bolts
Gain of lubricant Incorrect lubricant Drain and fill with proper type and grade of
lubricant
Planetaries running hot Bearings seized Replace bearings
TORQUE
1 25 Wheel Nut 730 540
1 13 Lock Screw 86 63
1 23 Bolt 280 206
1 18 Plug Screw 40 30
1 28 Slotted Nut 2 000 1 475
SM 2247 Rev 1 03-05
Section 160-0050
1
REAR AXLE GROUP - Wheel Rim and Tyre
7 - Cap
8 - Driver
9 - Wheel Nut
4 - Lock Ring
5 - Wheel Rim
6 - Valve Assembly
Fig. 1 - Cutaway View of Wheel Rim
The wheel assembly is designed to allow the tyre and
rim assembly to be replaced with a pre-assembled tyre
and rim. The tyre and rim may be removed from the
machine as an assembly and transported to a more
suitable location for removing the tyre from the rim.
Procedures for removing tyre and rim assembly from
machine, dismounting tyre from rim and the use of
hand and special tools, are described in this section.
The rim assembly consists of the following
components which are illustrated in Fig. 1: wheel rim,
inner and outer flange, 'O' ring, bead seat band, driver
and lock ring.
When dismounting a tyre and rim assembly from the
machine, special equipment and careful handling are
required because of the size and weight of the tyres.
One of the following pieces of hoisting equipment
should be used to lift the tyre and rim: chain block and
tackle, overhead crane, fork lift truck, boom truck, or
tripod tyre changing tool.
PREPARATION FOR SERVICING
WARNING
Before performing any service on the tyres or
rim components, to prevent personal injury
and property damage, completely deflate the
tyre by removing the valve cap and core. Insert
a thin wire through valve to be sure valve is
not plugged. Even a flat tyre, in some cases,
will retain sufficient air pressure to blow off a
rim component with enough force to cause
bodily injury or death.
SM - 1176
1 - Flanges
2 - 'O' Ring
3 - Bead Seat Band
Rear Axle Group - Wheel Rim and Tyre
2
Section 160-0050
SM 2247 Rev 1 03-05
REMOVING TYRE AND RIM ASSEMBLY
FROM MACHINE
Note: If tyre and rim assembly is to be replaced pre-
assembled, it is not necessary to remove the tyre from
the rim. It may be removed as an assembly.
WARNING
safely.
parking brake and shutdown the engine. Turn the
relieve pressure in the steering system.
2. Block all road wheels, except the one to be raised,
and place the battery master switch in the 'Off'
position.
3. Break wheel nuts (9) loose with tyre still on the
ground, but do not remove from wheel studs.
4. Jack up the axle to the height required to allow
removal of the tyre and rim assembly.
5. Place safety blocks under the axle.
6. Support tyre and rim assembly with a suitable sling
and attach a suitable lifting device.
7. Remove wheel nuts (9) securing wheel rim (5).
8. With lifting device, remove tyre and rim assembly
from wheel and lift clear of machine.
DISMOUNTING TYRE FROM RIM
Note: The following instructions apply to use of hand
tools. For procedures and tooling required to dismount
the tyre from the rim using hydraulic tools, contact the
relevant tyre manufacturer.
SM - 1039
Fig. 2 - Typical Rim Assembly
4 - Lock Ring
5 - Wheel Rim
6 - Inner Flange
1 - Outer Flange
2 - Driver
3 - Bead Seat Band
SM - 205
SM - 206
Fig. 3 - Pry Bar
Fig. 4 - Breaking Typical Tyre Bead
SM 2247 Rev 1 03-05
Section 160-0050
3
WARNING
When lifting tyre from rim, be sure the
equipment is of sufficient capacity and
properly secured to do the job safely.
1. Remove valve cap and valve core and leave valve
open to prevent trapping of air in tyre. Tape valve
threads for protection.
2. Remove driver (2) from bead seat band (3) and
wheel rim (5).
3. Break outer tyre bead loose with pry bar shown in
Fig. 3.
4. Insert flat hooked end of pry bar into breaking slots
between bead seat band (3) and outer flange (1) (See
Fig. 4). A pipe over the straight end of the pry bar will
increase leverage.
5. Twist bar toward tyre to break bead.
6. A second bar may be inserted in space between
bead seat band (3) and outer flange (1). Twist second
bar to maintain space gained by the first bar.
7. Move the first bar around the rim, twisting and
following with the second bar, until the outer tyre bead
is loose.
8. Pry bead seat band (3) away from lock ring (4) by
placing hooked end of pry bar in groove of wheel rim
(5), between ends of lock ring (4), and prying up with
bar. Using two bars, as in Step 7, work completely
around wheel rim (5).
9. Pry lock ring (4) out in same manner by starting at
prying notch in rim assembly and work all the way
around rim with two pry bars.
10. Remove and discard 'O' ring (2, Fig. 1).
11. Remove lock ring (4), pry out and remove bead
seat band (3).
12. Breaking slots are provided inside the rims. The
inner bead may be broken as described in Steps 4
through 8. If tyre and rim assembly are on the
machine, the following procedure may be used for
breaking the inner bead.
13. Place jack between inner flange (6) and machine
frame. Extend jack until tyre bead is broken. Continue
around rim until tyre bead is broken at all points.
14. Using suitable lifting equipment, remove tyre from
rim. This completes the removal of the tubeless tyre.
15. If necessary, remove inner flange (6).
Note: If tyre rim is on machine, and no tyre lifting
equipment is available, 'walk' tyre off rim as follows:
Force bottom of tyre outward as far as possible; lower
jack enough to allow weight of tyre to rest on ground;
force top of tyre out as far as possible; raise jack to
original height and repeat the above until tyre is off rim.
INSPECTION
Tyre
Check the interior surface of the tyre to determine its
condition. Inspect for cuts or fabric breaks that have
penetrated the tyre body. The casing should be
inspected closely for any sharp , pointed object that
may have penetrated the tyre body but is invisible from
the outside. All dust, dirt, water or other foreign matter
should be cleaned from the inside of tyre.
Rim Assembly
Overloading, improper tyre inflation, rough terrain, high
speed, accidents, dirt accumulation, and corrosion all
tend to reduce the service life of rims and rim
components. It is recommended that rims be
inspected, as below, not less often than at every tyre
change and that, as the warranty limit approaches,
consideration be given to periodic replacement.
The rim and its components are designed with built-in
safety factors, to prevent the components from flying
off with killing force during inflation. Check components
for cracks, bends, distortion, or other damage. If
damage is found, the component must be replaced.
WARNING
Never mix components of one manufacturer's
rims with those of another. Using the rim base
of one manufacturer with the lock ring of
another or vice versa is dangerous. The lock
ring of one may not fully engage with the lock
ring groove of the other. Always consult the
rim manufacturer for proper matching and
assembly instructions. Also, use and servicing
of damaged, worn out, or improperly
assembled rim assemblies is a very dangerous
practice. Failure to comply with the above
warnings could result in explosions from tyre
pressure causing serious personal injury and
property damage.
4
Section 160-0050
SM 2247 Rev 1 03-05
SM - 207
soft hammer to rotate lug. Use bar for installing lock
ring, as illustrated in Fig. 5.
8. Force bead seat band (3) past 'O' ring groove in
wheel rim (5) by prying, or with lift truck forks. Use
blocking between the forks and tyre to prevent
damage. Insert a new 'O' ring (2, Fig. 1) in groove of
the rim behind lock ring (4). Lubricate area of front
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
excessive amount of lubricant.
9. Install driver (2). Make sure all rim components are
correctly assembled.
10. Lift the tyre upwards to effect a seal between bead
seat band (3) and 'O' ring (2, Fig. 1). In some cases
the tyre will automatically spring out, making this step
unnecessary.
11. Refer to 'Tyre Inflation' in this section for the proper
procedure for inflating the tyre.
MOUNTING TYRE AND RIM ASSEMBLY
ON MACHINE
WARNING
When jacking, lifting, or blocking the machine,
be sure the equipment is of sufficient capacity
to do the job safely.
1. Support tyre and rim assembly with a chain, or rope
sling. Attach sling to overhead lifting device. Slide
assembly on to wheel of machine, with lock ring (4)
and bead seat band (3) facing outward.
Clean all rust and dirt from the rim parts and wheel
and apply a coat of good grade primer paint. Allow the
paint to dry thoroughly before remounting tyre.
The rim parts used with tubeless tyres form an
important part of the air chamber. Therefore, they
should be carefully checked for distortion or mutilation
that would prevent an effective air seal when the tyre
and rim are reassembled.
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.
Note: Handle 'O' rings carefully, as damage will
prevent an airtight seal for tyre inflation.
MOUNTING TYRE ON RIM
For mounting a tyre with rim on or off machine, the
procedure is basically the same.
WARNING
When lifting tyre onto rim, be sure the
equipment is of sufficient capacity and
properly secured to do the job safely.
1. For off-machine installation, lay rim on blocks or
mounting stand with 'O' ring groove up. Rim should be
off floor enough to allow tyre to rest on rim and not on
floor. Blocks are not to extend more than 13 mm
(0.50 in) beyond rim base.
2. If removed, install inner flange (6) over wheel rim (5).
3. Lubricate tyre beads and 'O' ring, with a thin solution
of vegetable base soap and water.
4. Using suitable lifting equipment, lower tyre onto rim.
Seat tyre firmly against inner flange (6).
5. Install outer flange (1) on rim (5).
6. Align lock ring driver notch in bead seat band (3)
with notch in wheel rim (5) and install bead seat band
on rim.
7. Install lock ring (4) in groove of wheel rim (5) so that
lock ring lug engages both notches. Notches and lock
ring lug must line up correctly. If necessary, use only a
Fig. 5 - Installing Typical Lock Ring
2 - Drive Lug 1 - Lock Ring
SM 2247 Rev 1 03-05
Section 160-0050
5
C.
Be sure to thoroughly flush and blow off all
flammable solvents used for cleaning the air
compressor inlet screen before using the
compressor for tyre inflation, or any other
purpose.
D.
Do not charge batteries, either in or out of a
machine, near the air inlet of a compressor
used for inflating tyres. Charging batteries
produces highly explosive hydrogen gas
which can be readily drawn into a nearby
compressor inlet and pumped into the tyre.
E.
Never exceed the specified concentration of
alcohol when adjusting the alcohol vaporizer,
or adding alcohol to the auxiliary air tank, used
on machine air systems to prevent freezing or
moisture condensate in below-freezing
temperatures. Excessive alcohol, added to the
machines air tanks in this manner can produce
flammable vapours that will be pumped into a
tyre when this air supply is used for tyre
inflation if the tyre inflation kit is not equipped
with a moisture filter. Alcohol added to
machine air systems in recommended
concentration to prevent condensate freezing
are below hazardous levels for tyre inflation.
F.
Another source of hazardous flammable
vapours in tyres is the tyre bead lubricant.
Always use bead lubricants that do not
introduce flammable vapours into the tyre.
Inflation
Note: Always use tyre inflation equipment with an air
filter that removes moisture from the air supply, when
available, to prevent moisture corrosion of internal rim
parts.
1. Inflate tyre to 1 bar (15 lbf/in) initially to seat
components and tap lock ring lightly to ensure correct
seating. Visually check that all components are in
place, then continue inflation observing all safety
precautions. (See Step 2).
2. If the tyre is off the machine, place it in a safety
cage after initially inflating to 1 bar (15 lbf/in) to seat
components. See Fig. 6.
2. Install wheel nuts (9) on wheel studs. Gradually
tighten nuts opposite each other until all nuts are snug.
Torque tighten wheel nuts (9) to 730 Nm
(540 lbf ft). Torque tighten wheel nuts (9) again, after
10 hours of machine operation.
TYRE INFLATION
WARNING
damage, the tyre and rim assembly should be
placed in a safety cage before inflating. If no
safety cage is available or tyre is on the
machine, the tyre and rim assembly should be
wrapped with safety chains or with lash cables
before inflating.
Even with these precautions remember that
air-blast is a potential hazard. Tyre inflation
should be carried out away from busy working
areas.
WARNING
To avoid personal injury and property damage,
never stand or sit in front of a mounted tyre
during tyre inflation. Use a clip-on air chuck
with a long hose and stand to one side while
the tyre is being inflated.
WARNING
damage, always prevent flammable vapours
that could produce tyre explosions, from being
pumped into tyres during inflation, by
observing the following precautions:
A.
Use an air compressor and reservoir located
inside a heated building, when available, so
that alcohol, methanol, or other flammable
antifreeze liquids are not needed in the air
tanks to prevent moisture freezing in the tank
and lines in subfreezing outside temperatures.
B.
Make sure that paints, lacquers, paint thinners,
or similar materials that produce volatile,
flammable vapours are not used or stored near
the air intake of the compressor that supplies
the air for inflating tyres. The compressor
should be isolated from all such sources of
flammable vapours.
6
Section 160-0050
SM 2247 Rev 1 03-05
3. Inflate tyres to 5.2 bar (75 lbf/in) to seat beads and
seal the 'O' ring, then adjust to the recommended
inflation pressure.
4. For recommended operating air pressure, refer to
the 'Tyre Inflation Pressures Table'.
NITROGEN TYRE INFLATION
Note: All Warnings and procedures under 'Tyre
Inflation' will apply, except for differences covered by
this passage.
In certain environments it is recommended that tyres
be inflated with dry nitrogen gas, and that the resulting
oxygen content of the inflation does not exceed 5%.
All machines whose tyres are factory inflated with dry
nitrogen gas will be identified by a decal on the body
or frame.
Nitrogen gas improves tyre pressure retention,
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
tyre explosion because it is an inert gas and will not
support combustion inside the tyre.
The same tyre inflation pressure used for air inflation
should be used for nitrogen inflation. Tyre valves
formerly used with air inflation are entirely satisfactory
for use with nitrogen gas.
Nitrogen Tyre Inflation Kit
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.
Nitrogen gas cylinders used to inflate
tyres are generally charged to approximately
152 bar (2 200 lbf/in
2
). A tyre blowout and/or
rim failure could occur if inflation equipment is
not properly used. Proper nitrogen charging
equipment and personnel training for its use is
a must to avoid over inflation.
SM - 208
Fig. 6 - Typical Safety Cage
SM - 1040
Fig. 7 - Nitrogen Tyre Inflation Kit
1. A nitrogen tyre inflation kit is available from your
dealer and consists of the following. Refer to Fig. 7.
a. Pressure regulator, 0 - 13 bar (0 - 200 lbf/in
2
), with
two dual pressure gauges.
SM 2247 Rev 1 03-05
Section 160-0050
7
b. Safety relief valve, 8.6 bar (125 lbf/in), that will
assure an upper limit to the pressure available for tyre
inflation.
c. A 15.2 m (50 ft) length of flexible hose with
interconnecting fittings. On the tyre end of the hose is
a large bore quick connect/disconnect clip-on chuck.
2. The pressure regulator is connected to a nitrogen
compressed gas cylinder available from local suppliers.
3. The usual procedure for using this type of
equipment is as follows:
a. Connect nitrogen tyre inflation kit to nitrogen
compressed gas supply. DO NOT connect clip-on
chuck to the tyre valve at this time.
b. Open valve on nitrogen supply.
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
pressure is not more than 1.4 bar (20 lbf/in) higher
than the desired tyre inflation pressure.
d. Connect clip-on chuck to the tyre valve. The tyre will
now inflate. Tyre pressure can be monitored by
observing the gauge at the pressure regulator. STAY
AWAY FROM THE TYRE.
e. When desired inflation pressure has been achieved,
back off the regulator or close the valve on the
compressed gas cylinder.
f. Remove the clip-on chuck and adjust the tyre
pressure with the tyre gauge in the usual manner.
Re-inflation of a Mounted Tyre
To re-inflate a tyre with dry nitrogen gas which is now
inflated with air, proceed as follows:
1. Exhaust the tyre until only air at atmospheric
pressure remains in the tyre.
2. Re-inflate the tyre using only dry nitrogen gas to
4.15 bar (60 lbf/in) gauge as a minimum, or to bead-
seating pressure as a maximum.
3. Adjust to the service inflation pressure required:
a. If the required service inflation pressure is LESS
than 4.1 bar (60 lbf/in), remove the clip-on chuck and
adjust the pressure with the tyre gauge in the usual
manner.
b. If the required service inflation pressure is greater
than 4.1 bar (60 lbf/in), further inflate, with dry
nitrogen gas only, to the pressure level required. Then
remove the clip-on chuck and adjust the pressure with
the tyre gauge in the usual manner.
New Tyre Mounts and Remounts
To newly mount or remount a tyre to its rim, use only
dry nitrogen gas; this includes the pressure required to
seat the beads. After seating the tyre beads, remove
the clip-on chuck and adjust the pressure with the tyre
gauge in the usual manner.
Note: Although a little more nitrogen gas is used to seat
beads than that used for re-inflation of a mounted tyre,
refer to 'Re-inflation of a Mounted Tyre', its cost is
generally negligible in comparison to the time and labour
saving and, longer tyre life achievable with the reduced
oxygen content which results.
TYRE EXPLOSION HAZARD
WARNINGS
Whenever a machines tyre(s) is (are) exposed
to excessive heat such as a machine fire or
extremely hot brakes the hazard of a
subsequent violent tyre explosion must be
recognized. All persons must avoid
approaching the machine so as not to be
physically endangered in the event of an
explosion of the tyre and rim parts. The
machine should be moved to a remote area,
but only when this can be done with complete
safety to the operator operating or towing the
machine. All other persons should stay clear of
the machine. The fire or overheated brakes,
wheel, etc. should be extinguished or cooled
from a safe distance. Do not attempt to
extinguish the fire or cool the machine by use
of hand-held fire extinguishers.
If it is absolutely necessary to approach a
machine with a suspect tyre, approach only
from the front or the back. Stay at least 15 m
(50 ft) from the tread area. Keep observers out
of the area and at least 460 m (1 500 ft) from
the tyre sidewall. Refer to Fig. 8. The tyre(s)
should be allowed at least eight (8) hours
cooling time after the machine is shut down or
the fire extinguished before approaching
closer.
8
Section 160-0050
SM 2247 Rev 1 03-05
SM - 1041
Fig. 8 - APPROACH AREA.
Do Not Approach Tyre in Shaded Area
AT LEAST
460 m (1 500 lbf
ft)
AT LEAST
15 m (50 ft)
WARNINGS
There is always a possibility of a tyre explosion
whenever the smell of burning rubber or
excessively hot brakes is detected. The danger
is also present when a fire on the machine
reaches the tyre and wheel area. Under such
conditions, all personnel must avoid
approaching the machine in a manner that
could result in injury should an explosion
actually occur. Move the machine to a remote
area only if it can be done without endangering
the operator or other personnel in the area.
DO NOT WELD ON OR HEAT RIM
COMPONENTS. For several years the company
and tyre and rim manufacturers have warned
users never to weld rim components with the
tyre mounted on the rim. The gases that build
up inside the tyre during arc welding or
heating on rim components can ignite,
resulting in one of these explosive-like failures
of the tyre and rim. This warning also applies
to nitrogen inflated tyres. Ignition will not
occur in the nitrogen atmosphere, but the
pressure buildup from the heat of welding may
be sufficient to cause a blowout severe enough
to injure or kill. It is recommended to scrap the
part if heat is necessary to repair any rim
component.
TYRE AND WHEEL RIM MAINTENANCE
Tyre Repairs
Prompt repair of tyre injuries will prevent small injuries
from enlarging and causing tyre failure. Use the best
tyre facilities available. If good repair facilities are not
available, have the nearest dealer make the necessary
repairs.
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
sufficient depth or shape to hold pebbles or dirt. The
angle of the skive should be no more than sufficient to
expel all foreign material and should extend no deeper
than the breaker. The skive should go to the bottom of
the hole. Tyres with shallow cuts, if treated promptly,
may be allowed to continue in service. If the cut
extends deeper into the tyre carcass, the tyre should
be removed for repair.
The tyre must be removed from the rim to repair larger
punctures or cuts. Irregular shaped punctures or cuts
less than 13 mm (0.50 in) in size can be repaired with a
plug and hot patch. Insert a repair plug into the hole to
keep out moisture and to back up the hot patch. Trim the
plug off flush with the inside of the casing, buff, and apply
the hot patch according to the instructions supplied with
the hot patch equipment.
Punctures 13 mm (0.50 in) or larger, large cuts, or
bruise breaks require sectional or reinforced
vulcanized repair. Cover the repair patch with a layer
of cushion gum after application to the tubeless tyre to
ensure an airtight repair. Any cords of the inside ply
that are exposed in buffing and are not covered with
repair patch must be coated with cushion gum to
prevent air leakage into the carcass plies on tubeless
tyres.
Recapping and Retreading
There are two general methods employed in restoring
the tread surface of off-the-highway tyres: recapping
and retreading.
A recapped tyre has a new tread cured right over the
old tread surface.
A retreaded tyre has the old tread removed entirely
and a new tread cured directly onto the body of the
tyre. A tyre can be recapped or retreaded if the cord
body is free of cuts, bruises and separation, and is
thoroughly sound, including previous repairs.
SM 2247 Rev 1 03-05
Section 160-0050
9
TYRE CARE
To obtain maximum service from off-highway tyres, the
following common-sense precautions should be
followed.
Maintain Correct Inflation
The most common cause of tyre damage is improper
inflation. Both over-inflation and under-inflation are
detrimental to tyre life. Tyre pressure should be
checked daily, preferably before the machine is placed
in operation. Refer to 'Tyre Inflation Table'.
The valve cores should be checked for leaks. Keep in
mind that valve cores are delicate mechanisms that
wear out in service; therefore, they should be replaced
with new ones when they become worn. Each tyre
should be equipped with a valve cap to prevent dirt
from damaging the valve core and causing air leakage.
Maintain Good Haul Roads
Because haul roads are considered temporary roads
they are frequently neglected. The better the haul
road, the longer the tyre and machine life of off-
highway machines.
Although it takes time and effort to maintain good haul
roads, the delay and cost of tyres and machine
breakdowns caused by poor haul roads is many times
greater.
Inspect Tyres Regularly
A systematic plan for tyre inspection will more than
pay for itself in lowered tyre costs per hour of
operation. All tyres should be checked regularly for
cuts, bruises, ply material breaks, excessive or
uneven wear, embedded foreign matter, and any other
damage which can be repaired. A considerable
increase in tyre service can be realized if tyre injuries
are repaired before they have progressed to the
irreparable stage.
The rim mounting nuts should also be checked
periodically and tightened to the torque specified.
Prevent Overloading
Off-highway machines are designed to carry a
maximum allowable payload. Excessive loading will
overstress both the machine and tyres and shorten the
life of both.
Prevent Contact with Oil
Prevent tyre contact with petroleum products. Rubber
that is exposed to oil, gasoline, or grease becomes
soft and spongy and deteriorates rapidly. Always avoid
driving machine through a puddle of gasoline, fuel oil,
lubricating oil, or grease. Never let a tyre stand in an
oil or grease spot overnight.
Store Tyres Properly
The best of care given to tyres in service by operators
and maintenance personnel can be completely
nullified by careless storage. Time is not the only
contributing factor to the deterioration of rubber
products. Therefore, tyres that are to be stored must
be protected from light, heat, oils, dirt, moisture, and
ozone. Stored tyres should be carefully covered with a
tarpaulin or some other suitable material, such as
opaque plastic sheets, to prevent contact with the
contaminants listed above.
Proper Handling of Tyres and Wheel Rim
Parts
Tyres should be stored vertically. Horizontal stacking
may compress the tyre walls, making inflation difficult. If
tyres are stored in racks, the lower supporting members
should provide as broad a surface as possible to the tyre
tread to avoid a concentration of load.
The beads of tubeless tyres must be protected from
damage or a faulty air seal will result. Do not use hooks,
cables, or chains in contact with the tyre beads when
lifting these tyres. If forklift trucks are used for handling,
they should be equipped with broad, well-rounded arms
to distribute the load and prevent damage to the tyre
bead. When handling tyres with the fork truck do not
scrape the fork across the bead.
Tubeless tyre rims perform an important function as part
of the assembly air seal. Proper care, therefore, must be
taken not to distort or mutilate the rim parts because they
must mate properly to form part of the basic air chamber.
Since the rim base and bead seat band are mating
surfaces, distortion may prevent easy assembly as well
as possibly resulting in no seal.
Never drop, tumble, or roll rim parts.
If rim parts are stored outdoors, they should be given a
protective coat of a good commercial primer.
Similar parts should be stacked neatly to prevent distortion.
10
Section 160-0050
SM 2247 Rev 1 03-05
Babbit or lead hammers, not sledge hammers, should
be used in assembling rim parts.
'O' rings are seals and should be carefully stored in a
cool, dry place where they will not be injured or
damaged.
Valve cores should also be stored in a cool, dry and
clean place.
MAINTENANCE
Check tyre pressures daily, preferably before the
machine is placed in operation. Refer to 'Tyre Inflation
Pressures Table'.
Every 50 hours of operation (weekly), torque tighten
wheel rim nuts to 730 Nm (540 lbf ft).
Check tyres regularly and replace or repair if required.
SERVICE TOOLS
Refer to Section 300-0070, SERVICE TOOLS for part
numbers of the nitrogen tyre inflation kit shown in
Fig. 7 and general service tools required.
TORQUE
1 9 Wheel Nut 730 540
TYRE INFLATION PRESSURES (BRIDGESTONE)
FRONT CENTRE AND REAR
MODEL TYRE SIZE bar lbf/in
2
bar lbf/in
2
TA35 26.5 R 25** 3.75 54 4.75 69
TYRE INFLATION PRESSURES (MICHELIN)
FRONT CENTRE AND REAR
MODEL TYRE SIZE bar lbf/in
2
bar lbf/in
2
TA30 26.5 R 25** 3.25 57 4 58
SM 2247 Rev 1 03-05
Section 160-0050
11
TUBELESS TYRE LEAK DIAGNOSIS TABLE499
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.
Mount tyre using a lubricant such as Murphy's Tyre and Tube
Mounting Compound, or equivalent, on tyre beads and rim bead
seat area.
* * * *
Section 165-0015
1 SM 2257 Rev 1 11-04
Hydraulic fluid will remain within the
braking system after engine shutdown. Operate
the treadle valve continuously until the
pressure has dissipated before carrying out any
work on the braking system or serious injury
could result.
Use extreme caution to prevent personal
injury when removing wheels. The exact
procedure must be followed as described in
Section 160-0050, WHEEL, RIM AND TYRE.
2. Turn the steering wheel in both directions several
Operate the treadle valve continuously to relieve any
pressure in the braking system. Block all road wheels.
3. Remove drain plug and drain cooling oil from brake
packs into a clean container. Reinstall plugs.
4. Drain oil from hubs and differentials. Refer to
Section 160-0030, AXLE GROUP (HUB) and Section
160-0020, DIFFERENTIAL DRIVE HEAD.
5. Refer to Section 160-0030, AXLE GROUP (HUB) for
disassembly instructions.
6. Attach suitable lifting equipment to brake assembly
and support weight. Loosen and remove bolts securing
brake assembly and hub carrier to axle stub.
7. With brake assembly supported, remove brake
assembly from axle stub.
8. Place brake assembly on a clean work surface for
disassembly.
9. Remove and discard all 'O' rings and oil seals from
brake assembly.
The service brakes are of the enclosed, forced oil-
cooled multiple disc type. The service brakes are
actuated by hydraulic oil as specified in Section 300-
0020, LUBRICATION SYSTEM. DO NOT use BRAKE
FLUID (J 1703). Multiple discs within the brake
assemblies are cooled by brake cooling oil as specified
in Section 300-0020, LUBRICATION SYSTEM.
The brake assembly is bolted to the stub axle and
houses a sandwich of friction discs splined to a hub
rotor. There are four friction discs (20) in each brake
assembly.
When the treadle valve is actuated, hydraulic oil enters
the brake assembly and forces the brake piston (14)
against the rotating friction discs (20) which react with
stationary reaction discs (21). The reaction discs (21)
are retained by scalloped tangs at the outside
diameter, which in turn transfers the reaction torque to
the rigid outside housing (1), slowing or stopping wheel
rotation.
In an emergency situation, application of the park/
emergency valve will actuate the service brakes and
the parking brake to bring the machine to a halt. In this
condition, a restriction in the 'Px' line from the brake
manifold valve will slow oil flow from the parking brake
allowing the service brakes to actuate momentarily
ahead of the parking brake.
When the treadle valve or park/emergency brake is
released, hydraulic pressure against piston (14) is
relieved and cup springs (24) force the piston (14) to
return to its original position, thus, relieving the
pressure against the brake disc pack.
REMOVAL
WARNINGS
secured and of sufficient capacity to do the job
safely.
BRAKE ASSEMBLY - Oil Cooled Disc Brakes
Section 165-0015
Brake Assembly - Oil Cooled Disc Brakes
2
SM 2257 Rev 1 11-04
Fig. 1 - Brake Pack Explosion
1 - Brake Housing
2 - 'O' Ring
3 - Sealing Holder
4 - 'O' Ring
5 - Seal Slide Ring
6 - Screw Neck
7 - 'O' Ring
8 - Vent Valve
9 - Plug
10 - 'O' Ring
INSTALLATION
1. Refer to Fig 33. Using suitable lifting equipment,
offer Anchor plate (3), brake assembly (5)and hub
carrier (1) up to axle stub (8) and secure with washers
(7) and bolts (6); applying adhesive 15500690 to bolts
(6) and torquing to a value of 460 Nm (339 Ibf ft).
2. Refer to Section 160-0030, AXLE GROUP (HUB) for
assembly instructions.
3. Fill hubs and differentials with oil. Refer to Section
160-0030, AXLE GROUP (HUB) and Section 160-0020,
DIFFERENTIAL DRIVE HEAD.
4. Refill brake coolant tank with oil as described in
Section 250-0025, BRAKE COOLANT TANK.
11 - Anchor Plate
12 - 'O' Ring
13 - Screw
14 - Brake Piston
15 - 'U' Ring
16 - Support Ring
17 - 'U' Ring
18 - Support Ring
19 - Guide Ring
20 - Friction Disc
21 - Reaction Disc
22 - Pin
23 - Gripping Ring
24 - Cup Spring
25 - Shim Support
26 - Snap Ring
27 - Snap Ring
28 - Slot Pin
SM - 3099
WARNINGS
secured and of sufficient capacity to do the job
safely.
Section 165-0015
3 SM 2257 Rev 1 11-04
DISASSEMBLY
Numbers in Parentheses refer to Fig. 1 , unless
otherwise stated. For removal of AXLE HUB refer to
section 160-0030.
1. Loosen the hex headed screws (13) and separate
the sealing holder (3) from the brake housing (1). As
shown in Fig 2. Install adjusting screws 15501167, to
maintain remaining assembly together.
2. Lever the slide ring seal (5) out of the sealing holder
(3) and then remove the 'O'-ring (4) from the holder (3).
Shown in Fig 3.
3.Remove the 'disc set' (20 & 21) from the brake
housing (1).Now carefully remove the brake housing (1)
from the Anchor plate (11) by means of a lifting tackle
15501170 and Eyebolts 15270115 . Shown in Fig 4.
4. Drive back the slotted pins (28) to be flush and
unsnap the snap ring (27) from the Brake piston (14).
shown Fig 5.
13 3
1
20,21
1
11
SM - 3145 Fig. 2 -Sealing Holder removal
SM -3112 Fig. 3 - 'O'-ring removal
SM - 3113 Fig. 4 - 'Disc set / Brake Housing removal'
SM - 3114 Fig. 5 Snap Ring removal
3
3
5
4
STEP 1
STEP 2
27
28
14
Section 165-0015
4
SM 2257 Rev 1 11-04
5. Press out the support shims (25) by means of
automatic adjusting from the Brake piston (14).Shown
Fig 6.
6.Tap out the slotted pins (28) from the Shim support
(25) shown in Fig 7.
7. Using the tools - Clamping pliers 15501175 and
Assembly fixture 15501174. Remove the snap rings
(26). Preload the cup springs (24) to ease removal.
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).
9. By means of compressed air, press the piston out of
the brake housing (1).
10. Remove the guide ring (19), U-rings (15 & 17) and
support rings (16 & 18) from the annular grooves of the
brake housing (1).
ASSEMBLY
otherwise stated.
1. Apply sealing compound to the mounting face of
the axle stub and install adjusting screws 15501167.
Shown in Fig. 8
2. Refer to Fig 9. Taking Eyebolts 15270115, mount
the Anchor plate (11) to the axle. Now apply sealing
compound to the face of the plate.
3. Refer to Fig. 10. Locate the screw connection hub
carrier/ brake anchor & anchor plate (1,3,8 , fig 33)by
means of hex screws with washers provissionally unitl
contact is obtained ( do not tighten).
SM - 3115 fig. 6 - Support Shim Removal
SM - 3116 fig. 7 - Support Shim breakdown
SM - 3118 Fig. 8 Sealing / adjusting screws
SM - 3119 Fig. 9 Fitting Anchor Plate
SM - 3120 Fig. 10 Screw Connection
Section 165-0015
5 SM 2257 Rev 1 11-04
* * * *
4. Refer to Fig. 11, FLUSH MOUNT SLOTTED PINS
(28)- install slots of pins in direction of force and by
180 Deg turned to each other.
5. Ensure adhesive 15500690 has been applied to bolts
(6, Fig. 33) prior to tightening. Now tighten bolt (6, Fig.
33 ) connections to 460 Nm (339 lb ft ).
Note : It is now necessary to adjust the rolling moment
of the wheel bearing, prior to final fit of the brake pack
assembly.
6. Press the wheel bolts into the output shaft until
contact, using wheel bolt puller 15500884 and inserts
15269895.
7. Refer Fig.12, Press both bearing outer rings into the
hub until contact is made using a suitable Driver and
Handle 15269898.
8. Fig.13.,Using a suitable lifting aid, mount the bearing
inner ring (1) onto the hub carrier (2).
9. Fig. 13, Heat the inner diameter of the bearing inner
ring to approximately 120Deg Celsius using Hot air
blower 15269899. At which point mount the ring (1) and
bearing (2) onto the hub carrier (3) until seated home.
10. Refer to Fig 14. Insert the ring gear carrier (1) into
the ring gear (2) and fasten it by means of the retaining
ring (3).
11. Refer to fig. 15, Insert the ring gear sub assembly
(fig 14) . Now screw on the slotted nut (34, fig. 33) and
tighten nut to 2000 Nm Max, using Socket 15500882
and Centering bracket 15500883.
SM - 3120 Fig. 11 Slotted Pins
SM - 3120 Fig. 12 Wheel bolts & Bearing Mounting
SM - 31203 Fig. 13 Mounting to Hub.
3
2
1
SM - 3123 Fig. 14 - Ring Gear Sub-assembly.
STEP 1
STEP 2
SM - 3125, 3126 Fig. 15 - Securing Nut.
Section 165-0015
6
SM 2257 Rev 1 11-04
Rotate Hub in a clockwise directions several times to
ensure free rotation.
12. Refer to fig. 16, Check the rolling moment by
means of a spring balance 15501169. As follows:
Rolling moment 'Torque' must be within range :-
T= 20 Nm (max) - 14.5 Nm (min)
(Hub dia. 444mm therefor r = 0.222m.)
Tensile force Fmax = T / r = 20 / 0.222 = 90N
Tensile force Fmin = T / r = 14.5 / 0.222 = 65N
Note: If the rolling moment is not achieved, it has to
be corrected by means of the Shim (35, fig. 33). i.e.
Moment to low, then a thinner ring must be installed.
Conversley if the moment is too high, then a thicker
ring must be installed.
If bearings are being used which have already been
run, it is acceptable to reduce the max and min rolling
moment range by 50%. i.e. within the range of :-
32N - 45 N
13. Now loosen the nut (34, fig. 33) and remove the
hub (16, fig. 33) from the hub carrier (1, fig. 33) using
Socket- 15500882 & Centering bracket- 15500883.
THE BRAKE DISC SSEMBLY CAN NOW BE
INSTALLED.
Numbers in parentheses refer to Fig 1. unless stated
otherwise.
1. Clean the annular grooves of the brake housing (1)
with spirit.
2. Refer to Fig (17). Install the support rings (16) , U-
rings (15 & 17) and guide rings(19) as shown.
Secure the guide ring with Loctite (type No 415) at its
extremities.
3. Refer to fig. 17, Insert the piston (14) into the Brake
housing, ensuring adequate levels of oil have been
applied to sliding /contact surfaces of the constiuent
parts.
4. Refer to fig. 18, Mount the piston by means of
tooling fixture, comprising of Sliding Pads 15501171,
Two armed puller 15501172 and Support shim
15501173.
SM - 3127 Fig. 16 - Checking Rolling Moment
SM - 3128 Fig. 17 - Brake Housing Assembly.
14
1 9
19
16
15
17
18
SM - 3130 Fig. 18 - Piston Mounting / tooling
Section 165-0015
7 SM 2257 Rev 1 11-04
5. Refer to fig. 19, Insert the pins (28) into the
assembly fixture 15501174, until contact.
6. Refer to fig. 20, Press gripping rings (23) onto the
pins until contact on the Assembly fixture 15501174.
7. Refer to fig. 21 & 22 , Exact installation dimension
'X' is obtained when using the specified assembly
fixture, the value of which should be in the range 8.2 -
8.5mm. Observe the installation position , install
gripping rings with the orifice offset by 180Deg to each
other.
8. Refer to fig. 22, Mount cup spring (24) onto the pin.
9. Take the preassembled pins and insert into the
support shim (25) and secure in place by means of
snap rings (26), using Clamping pliers 15501175,
shown in fig. 23.
10. Insert the preassembled support shim into position
and fasten by means of Snap ring(27) as shown
in Fig. 24
SM - 3130 Fig. 19 - Pin fitment
23
SM - 3132 Fig. 20 - Gripping ring fitment
SM - 3133 Fig. 21 - Pin installation setup
25
24
22
23
26
22
23
24
25
26
X
SM - 3134 Fig. 22 - Pin installation Detail
SM - 3135 Fig. 23 - Locking pins to support shim
SM - 3136 Fig. 24 - Retaining Support Shim in Piston
27
Section 165-0015
8
SM 2257 Rev 1 11-04
11. Drive 6 off , slot pins (28) into bore holes of
support shim (25) - thus locking snap ring(27) as shown
in fig. 25.
Note: Apply grease to pins on extremities.
Snap ring opening must be located between 2
Slotted pins.
Always use new pins.
12. Refer to fig. 26, 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
shown in fig. 26
Note: Plug tightening Torque 60Nm max
14. Using Eye bolts 15270115, locate the brake carrier
onto the Anchor plate (11) and fasten 3 Hex screws at
equal intervals to the brake housing. As shown in fig.
27.
15. Take Adjusting screws 15501167 and locate on
Hub carrier (1, fig. 33). Using Spline mandrel 15501176,
install Reaction & Friction Discs (20,21) alternately ,
starting with a Reaction disc, as shown in fig. 28.
Note: Oil Disc to ZF list of Lubricants TE-ML 05
16. There may be the requirement for a new lined
(inner ) disc to keep the clearance within the specified
tolerance range: -
Max clearance for new lines discs: 1.3 +0.3 / -0 mm
SM - 3137 Fig. 25 - Brake Housing sub assembly
SM - 3138 Fig. 26 - 'O'-Ring fitting
SM - 3139 Fig. 27 - Fit Brake Housing to Axle hub
SM - 3139 Fig. 28 - Install Frction / Reaction discs.
1 22 25 28
14 27 X
INSTALLTION DIMENSION 'X' OF SLOTTED PINS SHOULD BE
IN THE RANGE OF 4mm - 4.5mm max. LOCATED AS SHOWN :-
Section 165-0015
9 SM 2257 Rev 1 11-04
Max. Clearance (Worn ) : 4.1 mm
To determine the clearance, procede as follows;
Refer to Fig. 30,
Determination of clearance for lined disc:
X......................................= 28.00mm
Y...................................= 26.60mm
Clearance -1.40mm.
If required , correct the clearance with an adequate
outer disc.
17. Grease 'O'-ring (4) and insert into the annular
groove of the sealing holder (3).
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 performace / inegrity of the
sealing elements.
WARNINGS
Seal slide ring has a sharp edge so safety gloves
must be worn to prvent injury to user.
20. Mount sealing holder (3) on to the brake housing (1)
until contact is obtained and fasten with hex screws
(13) to 390Nm max, as shown in Fig. 30,
21. Install valve vent plug (8), new 'O'-ring (7) and
screw neck (6). Now install a suitable adaptor and
pressurize the piston with air to approximately 4 bar to
fasten the disc set. As shown in Fig. 31
22. Remove the Mandrel 15501176 for aligning the Disc
set (20 & 21). As shown in Fig. 3,
X
Y
1
14
11
21
20
3
SM - 3141 Fig. 29 - Lined Disc Clearance details.
13
3
SM - 3169 Fig. 30- Mounting Sealing holder / mandrel.
SM - 3170 Fig. 31- Pressurizing Disc set
SM - 3171 Fig. 32- Removing Mandrel
Section 165-0015
10
SM 2257 Rev 1 11-04
MAINTENANCE
WARNING
safely.
1
10
11
12
13
14
15
16
24
25 26
27
23 28
29 30
22
20
21
31
32
33
34
35
19
18
17
9
7
6
8
2
3
4
5
1 - Hub Carrier
2 - Drive shaft
3 - Anchor Plate
4 - 'O'-Ring
5 - Brake Assembly
6 - Bolt
7 - Washer
8 - Axle Housing
9 - Shaft Seal
10 - Ring
11 - Roller Bearing
12 - Bolt
13 - Lockwasher
14 - Wheel nut
15 - Roller Bearing
16 - Hub
17 - Snap ring
18 - Ring Gear Carrier
19 - Ring Gear
20 - Locking Plate
21 - lock Screw
22 - 'O'-Ring
23 - Planet Carrier
24 - Bolt
25 - 'O'-Ring
26 - Plug Screw
27 - Plug
28 - Capscrew
29 - Planet Gear Assy
30 - Retainer Ring
31 - Thrust Washer
32 - Sun Gear Shaft
33 - Drive
34 - Slotted Nut
35 - Shim
Fig. 33- Brake Assembly / Axle Stub installation
Oil Change Period
Note: For recommended oils, refer to Section
Drain (preferably after a short run to warm the oil) oil
from brake coolant tank every 1 000 hours. Refer to
Section 250-0025, BRAKE COOLANT TANK. Remove
drain plugs and drain brake cooling oil from each brake
SM - 3172
Section 165-0015
11 SM 2257 Rev 1 11-04
assembly every 1 500 hours of operating. Change oil
filter every 1 500 hours. Refill brake coolant tank as
described in Section 250-0025, BRAKE COOLANT
TANK.
* * * *
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.
Section 170-0010
1 SM 2253 10-03
SM - 2648
WARNINGS
Use only hydraulic oils meeting specifications
outlined in Section 300-0020, LUBRICATION
SYSTEM. Do Not use Brake Fluid (J1703). Use
of improper fluids is destructive to rubber
components of brakes resulting in loss of
braking and possible catastrophic failure.
Exercise extreme caution while working
on the braking system. Braking system actuating
pressure is 138 6.9 bar (2 000 100 lbf/in).
The parking brake consists of a sliding calliper acting
on a brake disc on a rear drive line. The parking brake
is of 'Inverted Design' i.e. requiring pressure to hold the
parking brake off.
Operation is by a spring applied/hydraulically released
actuator (9). Actuator (9) is connected through slack
adjuster (3) to the power screw shaft (19, Fig. 2) that is
screwed into piston (6, Fig. 2) in calliper head
assembly (2). Calliper head assembly (2) slides on
anchor plate guides in bracket assembly (1) bolted to
the frame. Slack adjuster (3) automatically maintains
brake clearance after each application through the
control strap (12). Control strap (12) connects the slack
adjuster (3) to the cap assembly (13).
A push control on the dash panel activates the solenoid
on the brake manifold valve, controlling oil pressure
from the rear brake circuit accumulator to actuator (9).
Application of the push control releases oil from
actuator (9) allowing internal springs in the actuator to
apply the parking brake. Pulling out the push control
directs oil pressure from the rear brake circuit
accumulator to actuator (9), compressing internal
springs, to release the parking brake.
Note: The parking brake is automatically applied when
Fig. 1 - Parking Brake Mounting
1 - Bracket Assembly
2 - Calliper Head Assembly
3 - Slack Adjuster
4 - Bolt
5 - Washer
6 - Nut
7 - Clevis Pin
8 - Cotter Pin
9 - Actuator
10 - Nut
11 - Washer
12 - Control strap
13 - Cap assembly
14 - Slack adjuster screw
15 - Bolt
9
11 10 7,8 6
2
12
15
1
3
4
14
13
5
PARKING BRAKE - Parking Brake and Mounting
Parking Brake - Parking Brake and Mounting
Section 170-0010
2 SM 2253 10-03
the ignition is switched off.
REMOVAL
WARNINGS
safely.
carrying out any work on the braking system or
serious injury could result.
1. Position the vehicle on a level surface, apply the
parking brake, block all road wheels and place the
steering lock bar in the 'Locked' position.
2. Raise the body and install body safety prop to
secure in partially raised position.
3. Pull out push control to release the parking brake.
4. Release spring tension on slack adjuster clevis pin
(7) by unscrewing tensioning bolt on slack adjuster (3)
until clevis pin (7) feels loose. Remove cotter pin (8)
and clevis pin (7) from actuator (9).
5. Switch off the engine and place the battery master
6. Disconnect and plug hydraulic line from actuator (9).
Cap actuator (9) to prevent ingress of dirt.
7. Remove nuts (10) and washers (11) securing
actuator (9) to cap assembly (13). Remove actuator (9)
from cap assembly (13).
8. Support calliper head assembly (2) and remove bolts
(4), washers (5) and nuts (6) securing bracket
assembly (1) to mounting bracket on the frame.
9. Remove bracket assembly (1) and calliper head
assembly (2) from the vehicle.
10. Slide calliper head assembly (2) from bracket
assembly (1) and set aside for disassembly.
Note: Service of actuator (9) is covered in Section
170-0030, ACTUATOR.
DISASSEMBLY
1. Remove calliper head assembly as described under
removal.
2. Remove snap ring (14) from power screw shaft (19).
3. Slide slack adjuster (15) from power screw shaft (19).
4. Remove and discard washer (16), wave spring
washer (17) and packing (18) from power screw
shaft (19).
5. Remove bolts (2) and washers (3) securing cap
assembly (22) to calliper (7).
6. Remove as a unit, power screw shaft (19),
piston (6) and cap assembly (20 through 23) from
calliper (7).
7. Slide power screw shaft (19) and piston (6) from cap
assembly (22).
8. Unscrew piston (6) from power screw shaft (19).
9. Remove and discard thrust bearing (20) from power
screw shaft (19) and gasket (21) from cap
assembly (22).
10. Remove and discard piston seal (5) from calliper (7).
INSPECTION
1. Thoroughly clean all parts. Inspect journal bearing
(23) in cap assembly (22) for wear. Journal bearing (23)
ID should not exceed 38.35 mm (1.51 in). Replace if
necessary.
2. Replace cap assembly (22) if excessively worn.
3. Inspect all brake parts for cracks, excessive wear or
scoring. Replace brake parts as required.
ASSEMBLY
1. Install new piston seal (5) into seal groove in calliper
(7).
Section 170-0010
3 SM 2253 10-03
SM - 1851
2. Apply grease (Lubriplate Aero or equivalent) to flat
face of new thrust bearing (20).
3. Install and seat new thrust bearing (20) over splined
end of power screw shaft (19) with greased side of
thrust bearing (20) against thrust collar of power screw
shaft (19).
Note: Ensure correct installation of thrust bearing (20)
by verifying that installation was made over the larger
diameter end of power screw shaft (19), and, that thrust
bearing (20) ID lip is towards splined end of power
screw shaft (19).
4. Lubricate threads of power screw shaft (19) with
grease (Lubriplate Aero or equivalent) and screw power
screw shaft (19) into piston (6).
5. Coat outside of piston (6) with grease (Lubriplate
Aero or equivalent) then slide assembled power screw
shaft (19) and piston (6) into cap assembly (22), shaft
end first.
6. Line up gasket (21) and bolt cap assembly (22), with
assembled power screw shaft (19) and piston (6), to
calliper (7) using bolts (2) and washers (3). Tighten bolts
(2) to a torque of 170 - 183 Nm (125 - 135 lbf ft).
Note: Care should be taken not to push piston seal (5)
out of seal groove in calliper (7) when assembling cap
assembly (22), with piston (6) and power screw shaft
(19), to calliper (7).
7. Install new packing (18), wave spring washer (17)
and washer (16) over power screw shaft (19), in the
order shown in Fig. 2.
8. Mount actuator (13) on cap assembly (22) with nuts
(11) and washers (12). Tighten nuts (11) finger tight
only at this stage.
9. Apply coat of grease (Lubriplate Aero or equivalent)
Fig. 2 - Exploded View of Parking Brake Assembly
1 - Brake Pad
2 - Bolt
3 - Washer
4 - Piston Seal
5 - Piston
6 - Calliper
7 - Clevis
8 - Clevis Pin
9 - Cotter Pin
10 - Nut
11 - Washer
12 - Actuator
13 - Snap Ring
14 - Slack Adjuster
15 - Wave Spring Washer
16 - Washer
17 - Packing
18 - Power Screw Shaft
19 - Thrust Bearing
20 - Gasket
21 - Cap Assembly
22 - Journal Bearing
23 - Plug
24 - Pressure Relief Fitting
6
1
4
5
24
23
18
19
20
21
3
2
22
17
15
16
14
13
8
7
9
12
11
10
Section 170-0010
4 SM 2253 10-03
to mounting spline of slack adjuster (15).
10. With adjusting screw facing towards actuator (13)
slide slack adjuster (15) on power screw shaft (19)
aligning slack adjuster (15) arm with clevis (10).
11. Install snap ring (14) on power screw shaft (19).
12. Remove nuts (11) and washers (12) securing
actuator (13) to cap assembly (22). Remove actuator
(13) from cap assembly (22) to aid in installation.
INSTALLATION
WARNING
safely.
1. Assemble bracket assembly (1, Fig. 3) and torque
plate side A (2, Fig. 3) and secure with bolts (4, Fig. 3),
hardened washers (6, Fig. 3) and nuts (7, Fig. 3).
2. Install park brake assembly (8, Fig. 3) and push park
brake assembly (8, Fig. 3) hard against torque plate
side A (2, Fig. 3). Slide torque plate side B (3, Fig. 3)
into the slots of park brake assembly (8, Fig. 3).
3. Secure torque plate side B (3, Fig. 3) by installing
bolts (4, Fig. 3), clamp plate (5, Fig. 3), hardened
washers (6, Fig. 3) and nuts (7, Fig. 3).
4. Install a feeler gauge of 0.635 mm (0.025") between
park brake assembly (8, Fig. 3) and torque plate side B
(3, Fig. 3) to obtain clearance as shown in Fig. 3.
5. Tighten all four bolts to 680 Nm (490 lbf ft) and
recheck clearance is within tolerance 0.51 - 0.76 mm
(0.020 - 0.030").
6. Attach suitable lifting device and position bracket
assembly (1) and calliper head assembly (2) over brake
disc. Secure bracket assembly (1) to mounting bracket
on the frame with bolts (4), washers (5) and nuts (6).
Tighten nuts (6) to a torque of 745 Nm (550 lbf ft).
SM - 3070
Fig. 3 - Assembling Parking Brake Mounting
2 - Torque Plate Side A
3 - Torque Plate Side B
4 - Bolt
5 - Clamp Plate
6 - Hardened Washer
7 - Nut
8 - Park Brake Assembly
7
6
5
3
4
8
4
2
6
7
1
Section 170-0010
5 SM 2253 10-03
* * * *
7. Remount actuator (9) on cap assembly (22, Fig. 2)
and install washers (11) and nuts (10). Tighten nuts
(10) finger tight only at this stage.
WARNING
Do not pressurize actuator until the following
instruction has been carried out. Pressurizing
the actuator beforehand can result in serious
brake damage.
8. Turn adjustment screw (14) on the slack adjuster (3)
in a clockwise direction until the brake pads in calliper
head assembly (2) are tight against the brake disc.
9. Connect hydraulic line to actuator (9). Place the
battery master switch in the 'On' position, start the
engine and pull out parking brake control knob to
extend the actuator.
10. Connect slack adjuster (3) to actuator (9) by
inserting clevis pin (7) through clevis (10, Fig. 2) on
actuator (9). Secure clevis pin (7) with cotter pin (8).
11. Align actuator (9) to slack adjuster (3) and torque
nuts (10) to 115 - 136 Nm (85 - 100 lbf ft).
12. Loosen bolt (15) at the control arm of slack adjuster
(3) and control strap (12).
13. Position control arm of slack adjuster (3) in fully
released position (forcing it in a direction away from
actuator (9)) by turning adjustment screw (14) on the
slack adjuster (3), until it comes to a positive stop
inside the control strap (12).
14. Tighten bolt (15) at the control arm of slack
adjuster (3) and control strap (12).
Note: Failure to position the slack adjuster against the
internal stop may result in brake drag.
15. Use 1.5mm feeler gauge between brake pads in
calliper head assembly (2) and brake disc. Turn the
adjustment screw (14) on the slack adjuster (3) until
the 1.5 mm total clearance is obtained.
16. Remove feeler gauge and apply brake several
times. The automatic slack adjuster will adjust the
brake pad clearance with each application, which can
be seen by the rotation of the adjustment screw (14).
17. When the adjustment screw (14) stops rotating, the
specified clearance of 0.7 - 1.0 mm has been obtained
and the brake is ready for normal operation.
18. Remove wheel blocks and place the steering lock
bar in the 'Stowed' position.
MAINTENANCE
Every 250 hours
Check wear on brake pads and disc. Replace brake
pads when lining thickness is 3.0 mm (0.125 in) or
less.
Brake Pad Replacement
1. Remove calliper head assembly as described under
removal.
2. Replace worn brake pad and carrier assemblies.
3. Install calliper head assembly and adjust slack
adjuster as described in installation.
SPECIAL TOOLS
dealer.
TORQUE
1 6 Nut 745 550
1 10 Nut 115 - 136 85 - 100
2 2 Bolt 170 - 183 125 - 135
3 4 Bolt 680 490
Section 170-0030
SM 2166 Rev 1 10-03 1
PARKING BRAKE - Actuator
WARNING
Use only hydraulic oils meeting specifications
outlined in Section 300-0020, LUBRICATION
SYSTEM. Do Not use Brake Fluid (J 1703). Use
of improper fluids is destructive to rubber
components of brakes resulting in loss of
braking and possible catastrophic failure.
The actuator is a spring on/fluid off type which
operates the parking brake. It is connected, through a
slack adjuster to the power screw shaft, screwed into a
piston in the brake calliper head assembly.
A push control on the dash panel, in the operators
compartment, activates the solenoid on the brake
manifold valve, controlling oil pressure from the rear
brake circuit accumulator to the actuator. Application of
the push control releases oil from the actuator allowing
internal springs in the actuator to apply the parking
brake. Pulling out the push control directs oil pressure
from the front brake circuit accumulator to the actuator,
compressing internal springs, to release the parking
brake.
REMOVAL
WARNINGS
safely.
carrying out any work on the braking system or
1. Position the vehicle on a level surface, raise the
body and install safety prop to secure body in the
partially raised position.
2. Block all road wheels and place the steering lock bar
in the 'Locked' position.
3. Pull out push control to release the parking brake.
Fig. 1 - Actuator Mounting
SM - 2648
9
11 10 7,8 6
2
12
15
1
3
4
14
13
5
2 - Calliper Head Assembly
3 - Slack Adjuster
4 - Bolt
5 - Washer
6 - Nut
7 - Clevis Pin
8 - Cotter Pin
9 - Actuator
10 - Nut
11 - Washer
12 - Control strap
13 - Cap assembly
14 - Slack adjuster screw
15 - Bolt
Section 170-0030
Parking Brake - Actuator
SM 2166 Rev 1 10-03 2
4. Release spring tension on clevis pin (7) by
unscrewing tensioning bolt on slack adjuster (3) until
clevis pin (7) feels loose. Remove cotter pin (8) and
clevis pin (7) from actuator (9).
Note: On engine shutdown the parking brake will
automatically apply. Ensure there is sufficient
clearance for actuator rod travel.
5. Switch off the engine and place the battery master
6. Disconnect and plug hydraulic line from actuator (9).
Cap actuator (9) and hydraulic line to prevent entry of
dirt.
7. Remove nuts (10) and washers (11) securing actuator
(9) to cap assembly (13). Remove actuator (9) from cap
assembly (13) and set aside for disassembly.
REPLACEMENT OF SEALING RINGS
Note: Before and during assembly and disassembly of
the brake actuator precautions should be taken to
avoid damaging plunger (12) assembly.
Disassembly
1. Turn bolt (34) until it is approximately 25 mm (1 in)
out of cap (31).
2. Remove bolts (30) from the periphery of actuator
housing (1).
3. Press cap (31) approximately 10 mm (0.4 in) into
actuator housing (1). If necessary use a rubber
hammer.
4. Remove retaining ring (39) from the boss of actuator
housing (1).
5. Press plunger (12) fully in. Cap (31) with springs (37
& 38) will be pressed out of actuator housing (1).
WARNING
Springs (37 & 38) have been assembled under
pressure. Bolts (24 & 34) should not be turned
in this situation.
6. Turn joining nipple (21) and remove from actuator
housing (1). Remove and discard U-sit ring (19) and
grommet (20).
7. Remove four bolts (6) and lockwashers (5) from the
front cap.
8. Remove the hydraulic unit, with plungers (12 & 23)
and base (22), from actuator housing (1).
9. Press plungers (12 & 23) out of base (22).
10. Remove and discard wiper (13), U-cups (15 & 28)
and 'O' ring (16) from hydraulic unit.
11. Carefully press plunger (12) assembly out of
plunger (23). Remove and discard 'O' ring (17) from
plunger (23).
Note: Remove 'O' rings carefully from 'O' ring grooves
in order to avoid damaging the grooves.
Assembly
1. Install new 'O' ring (17) in plunger (23) and carefully
press plunger (12) assembly into plunger (23).
2. Install new wiper (13), U-cups (15 & 28) and 'O' ring
(16) in/on hydraulic unit, as shown in Fig. 2.
Note: U-cups (15 & 28) close, but only in one direction.
These should be assembled with the groove side in the
correct direction, as shown in Fig. 2.
3. Lightly grease plunger assembly (12 & 23) and
install in base (22). Install 'O' ring gland (14) in base (22).
4. Install the hydraulic unit with Tectyl 280 rust preventive
or equivalent, against the front cap in actuator housing (1).
Secure hydraulic unit to the front cap with four bolts (6) and
lockwashers (5). Tighten bolts (6) to a torque of 25 Nm (18
lbf ft).
5. Grease new grommet (20) and install in actuator
housing (1).
6. Install new U-sit ring (19) on joining nipple (21).
Smear the threads of joining nipple (21) with
Loctite 270 and install through grommet (20). Tighten
joining nipple (21) to a torque of 95 Nm (70 lbf ft).
7. Install rear cap (31) assembly, complete with springs
(37 & 38), in actuator housing (1).
8. Press rear cap (31) assembly approximately
10 mm (0.4 in) under the rim of actuator housing (1).
9. Smear groove in actuator housing (1) and retaining
ring (7) with Tectyl 280 or equivalent, and install
retaining ring (7) in the groove.
Section 170-0030
SM 2166 Rev 1 10-03 3
SM - 1853
(12) assembly.
Disassembly
1. Remove bolts (30) from the periphery of actuator
housing (1).
2. Remove bolts (35) from rear cap (31).
3. Press release bolt (34) complete with nut (32) in and
remove plate (36).
4. Place the complete actuator under a press with the
flat plunger side (front side) face down.
10. Screw release bolt (34) fully in, so that springs
(37 & 38) press rear cap (31) against retaining ring (7).
Check if retaining ring (7) is flush in the groove.
11. Apply Loctite 221 on bolts (30) and install bolts in
actuator housing (1). Tighten bolts (30) to a torque of 3
Nm (26 lbf in). The actuator is now ready for use.
REPLACEMENT OF SPRINGS
Note: Before and during assembly or disassembly
precautions should be taken to avoid damaging plunger
Fig. 2 - Sectional View of Parking Brake Actuator
Upper Section No Oil Pressure Applied - Lower Section Oil Pressure Applied
29 - Ball
30 - Bolt
31 - Cap
32 - Nut
33 - 'O' Ring
34 - Bolt
35 - Bolt
36 - Plate
37 - Spring
38 - Spring
19 - U-Sit Ring
20 - Grommet
21 - Joining Nipple
22 - Base
23 - Plunger
24 - Bolt
25 - Bearing
26 - Retaining Ring
27 - Washer
28 - U-Cup
10 - Tube
11 - Ball
12 - Plunger
13 - Wiper
14 - Gland
15 - U-Cup
16 - 'O' Ring
17 - 'O' Ring
18 - Retaining Ring
1 - Actuator Housing
2 - Lockwasher
3 - Nut
4 - Bolt
5 - Lockwasher
6 - Bolt
7 - Retaining Ring
8 - Rod-End
9 - Seeger Circlip
Section 170-0030
SM 2166 Rev 1 10-03 4
WARNING
Springs (37 & 38) have been assembled under
pressure, therefore pressing should be carried
out with the utmost precaution.
5. Press rear cap (31) in approximately 10 mm (0.4 in) by
using a solid plate of approximately 130 mm (5 in)
diameter.
6. Remove retaining ring (7) from groove in actuator
housing (1).
7. Release the pressure slowly allowing rear cap (31) to
be pushed completely out of actuator housing (1) until
springs (37 & 38) are totally released.
8. Remove rear cap (31) and take out springs (37 & 38).
Assembly
1. Place new springs (37 & 38) in actuator housing (1).
2. Place rear cap (31) on springs (37 & 38).
3. By using a press and a solid plate of approximately
130 mm (5 in) diameter, press rear cap (31)
approximately 10 mm (0.4 in) under the top rim of
actuator housing (1).
4. Smear groove in actuator housing (1) and retaining
ring (7) with Tectyl 280 or equivalent. Fit retaining ring
(7) in groove in actuator housing (1).
5. Release the pressure on rear cap (31) very slowly.
6. Check if retaining ring is correctly in the groove.
7. By using an M8 threaded rod, with a minimum length
of 130 mm (5 in) and pushing this through bolt
holes in rear cap (31), nut (32) can be pulled into place.
8. Install plate (36) with Tectyl 280 or equivalent,
around bolt (35) hole and inside rim of actuator housing
(1).
9. Install bolts (35) with lockwashers (5) and tighten
bolts (35) to a torque of 25 Nm (18 lbf ft).
10. Apply Loctite 221 on bolts (30) and install bolts in
actuator housing (1). Tighten bolts (30) to a torque of 3
Nm (26 lbf in). The actuator is now ready for use.
INSTALLATION
WARNING
safely.
1. Remount actuator (9) on cap assembly (13) and
install washers (11) and nuts (10). Tighten nuts (10)
finger tight only at this stage.
WARNING
Do not pressurize actuator until the following
instruction has been carried out. Pressurizing
the actuator beforehand can result in serious
brake damage.
2. Turn adjustment screw (14) on the slack adjuster (3)
in a clockwise direction until the brake pads in calliper
head assembly (2) are tight against the brake disc.
3. Connect hydraulic line to actuator (9). Place the
battery master switch in the 'On' position, start the
engine and pull out parking brake control knob to
extend the actuator.
4. Connect slack adjuster (3) to actuator (9) by
inserting clevis pin (7) through clevis on actuator (9).
Secure clevis pin (7) with cotter pin (8).
5. Align actuator (9) to slack adjuster (3) and torque
nuts (10) to 115 - 136 Nm (85 - 100 lb ft).
6. Loosen bolt (15) at the control arm of slack adjuster
7. Position control arm of slack adjuster (3) in fully
released position (forcing it in a direction away from
actuator (9)) by turning adjustment screw (14) on the
slack adjuster (3), until it comes to a positive stop
inside the control strap (12).
8. Tighten bolt (15) at the control arm of slack adjuster
Note: Failure to position the slack adjuster against the
internal stop may result in brake drag.
9. Use 1.5mm feeler gauge between brake pads in
calliper head assembly (2) and brake disc. Turn the
Section 170-0030
SM 2166 Rev 1 10-03 5
* * * *
adjustment screw (14) on the slack adjuster (3) until
the 1.5 mm total clearance is obtained.
10. Remove feeler gauge and apply brake several
times. The automatic slack adjuster will adjust the
brake pad clearance with each application, which can
be seen by the rotation of the adjustment screw (14).
11. When the adjustment screw (14) stops rotating, the
specified clearance of 0.7 - 1.0 mm has been obtained
and the brake is ready for normal operation.
SPECIAL TOOLS
TORQUE
1 10 Nut 115 - 136 85 - 100
2 6 & 35 Bolt 25 18
2 21 Joining Nipple 95 70
2 30 Bolt 3 -
Section 180-0020
SM 2119 2-02
1
SUSPENSION SYSTEM - Front Suspension
SM - 2674
1 - Suspension Frame
2 - Snubbing Washer
3 - Shock Absorber
4 - Link
5 - Rubber Mount
6 - Rubber Mount
7 - Rubber Mount
8 - Bolt
9 - Chain
10 - Pin Assembly
21 - Locknut
22 - Locknut
23 - Locknut
26 - Washer
27 - Washer
28 - Chain & Shackle
29 - Bolt
30 - Lockwasher
11 - Panhard Rod
12 - Bearing
13 - Bush
14 - Bolt
15 - Bolt
16 - Bolt
17 - Bolt
18 - Bolt
19 - Nut
20 - Bolt
31 - Nut
32 - Plate
33 - Suspension Bush
34 - Washer
35 - Guard
36 - Lockwasher
37 - Bolt
38 - Shackle
39 - Bolt
40 - Locknut
Fig. 1 - Exploded View of Front Suspension
DESCRIPTION
The front axle assembly is mounted on the leading
arms of suspension frame (1). The complete unit is
pivoted at the rear through a spherilastic type bearing
(12) connecting the rear of suspension frame (1) to
the tractor frame, forward of the lower articulation
pivot point. Side thrust is taken up by panhard rod
(11) connected at one end on the underside of the
chassis and the other end to the suspension frame
(1). A link (4) is provided as a tie bar connected to
the upper part of the suspension assembly.
Suspension is provided by two heavy duty rubber
suspension mounts (5) mounted on top of suspension
frame (1) and connected to the tractor frame. In
addition, there are two smaller heavy duty rubber
suspension mounts (6) mounted between the axle
beam and chassis beam. Apart from rubber mounts
1
3
3
12
3
4
5
32
5
6
6
10
33
11
13
21
25
25
17
25
18
25
35
17
25
15
14
16
18
25
37
21
23
22
24
40
39
26
28
29
29
30
30
31
31
25
36
20
34
2,7,8,9
19,27,33
38,39,40
7
8
9
38
19
27
2
Section 180-0020
Suspension System - Front Suspension
SM 2119 2-02 2
(5 & 6) there are four heavy duty double acting shock
absorbers (3) (two off each side) to smooth out the
ride. Two chain and shackle assemblies (28) and
rubber rebound mounts (7) provide extra retention on
rebound.
REMOVAL
WARNING
safely.
1. Position the vehicle in a level work area, ensure
the body is fully lowered, apply the parking brake and
2. Block rear road wheels, place the steering lock bar
in the 'Locked' position and place the battery master
3. Whilst the front road wheels are still on the ground,
loosen the wheel nuts.
4. Using suitable lifting equipment, raise the machine
until both front tyres are off the ground. Support the
vehicle with suitable stands and blocking at the
tractor frame and articulation pivot area.
5. Support one tyre and rim assembly with suitable
lifting equipment and remove wheel nuts securing the
rim to the axle. Remove tyre and rim assembly.
6. Repeat step 5 for the opposite tyre and rim
assembly.
7. Support guard (35) and remove bolts (20 & 37),
washer (34) and lockwasher (36) securing guard (35) to
suspension frame (1). Remove guard (35).
8. Disconnect hydraulic brake line at tee on front axle
assembly. Disconnect differential breather line. Cap
lines and fittings to prevent ingress of dirt.
9. Remove nuts (31), lockwashers (30) and bolts (29)
securing chain and shackle assemblies (28) to
suspension frame (1) and tractor frame assembly.
10. Support driveline and remove bolts securing
driveline to front axle. Refer to Section 130-0010,
FRONT DRIVELINES.
11. Remove thread cap and mounting hardware securing
shock absorbers (3) to suspension frame (1).
12. Support rebound mounts (7) and remove nuts (19),
washers (27) and shackles (38) securing rebound
mounts (7) to suspension frame (1). Remove bolts (39)
and locknuts (40) securing chains (9) to bolts (8).
13. Remove rebound mounts (7), bolts (8) and
snubbing washers (2) from suspension frame (1).
14. Support panhard rod (11) and remove locknuts (23),
hardened washers (24) and bolts (16) securing panhard
rod (11) assembly to suspension frame (1).
15. Support link (4) and remove locknuts (22), washers
(26) and bolts (14) securing link (4) to suspension
frame (1).
16. Position two jacks under the leading arms of
suspension frame (1) and remove bolts (18) and
hardened washers (25) securing rubber mounts
(5 & 6) to the tractor frame. Lower jacks until rubber
mounts are free of compression.
17. Position a suitable trolley under suspension frame
(1) and, using suitable equipment, support the rear
end of suspension frame (1).
18. Remove locknuts (21), hardened washers (25),
bolts (15) and bushes (13) securing bearing (12) to the
tractor frame.
19. Carefully lower suspension frame (1) assembly
onto the trolley and remove from under the vehicle.
20. Remove cap from shock absorber (3) mounting
nuts and remove nuts and washers securing shock
absorbers (3) to the tractor frame assembly. Remove
shock absorbers (3).
21. Support panhard rod (11) assembly and remove
locknuts (23), hardened washers (24) and bolts (16).
Remove panhard rod (11) assembly from the tractor
frame assembly.
Section 180-0020
SM 2119 2-02
3
DISASSEMBLY
WARNING
safely.
1. Remove locknuts (21), hardened washers (25) and
bolts (17) securing front axle assembly on
suspension frame (1). Using suitable lifting
equipment, remove front axle assembly from
suspension frame (1).
2. Remove bolts (18) and washers (25) securing pin
assemblies (10) and suspension mounts (6) to
3. Remove suspension mounts (5) and locator plate
(32) assemblies from suspension frame (1).
4. If required, press spherilastic bearing (12) from
ASSEMBLY
SPECIFICATIONS.
WARNING
safely.
1. Using suitable lifting equipment, position front axle
assembly on suspension frame (1) and secure with bolts
(17), hardened washers (25) and locknuts (21). Tighten
locknuts (21) to a torque of 869 Nm (627 lbf ft).
2. If bearing (12) was removed during disassembly,
install a new spherilastic bearing as follows:
a. Enter spherilastic bearing (12) into bore in
suspension frame (1), ensure flats on shaft are
perpendicular to the main suspension plate.
b. Mark a slot on bearing (12) and face of suspension
frame (1) adjacent to slot on bearing and remove
bearing (12). Apply Loctite to bearing surface.
c. Using press tool and power press (See Special
Tools), install bearing (12) in suspension frame (1),
ensuring that bearing (12) does not twist during
pressing operation.
d. Re-check angle of shaft with level gauge.
3. Install suspension mounts (5) and plate (32) assemblies
on locating bosses on suspension frame (1).
4. Install suspension mounts (6) and pin assemblies
(10) to axle mounts and secure using bolts (18) and
washers (25).
INSTALLATION
WARNING
safely.
1. Position suspension frame (1) assembly and trolley
under the front frame with bearing (12) to the rear.
2. Using suitable lifting equipment, lift suspension
frame (1) assembly and locate bearing (12) to its
mounting bracket. Install bushes (13) through bearing
(12) and secure with bolts (15), hardened washers
(25) and locknuts (21). Tighten locknuts (21) to a
3. Apply a small bead of Hylosil Sealant around the
top edge of rubber mounts (5 & 6). Mount two
hydraulic jacks (See Special Tools) between outside
shock absorber mountings.
4. Align holes in rubber mounts (5) and locator plate
(32) assemblies with mounting pins on suspension
frame (1). Install rubber mounts (6) and pin assemblies
(10) and secure with bolts (18) and hardened washers
(25). Using a hydraulic pump to operate hydraulic
jacks, compress rubber mounts.
5. Connect chain and shackle assemblies (28) between
suspension frame (1) and tractor frame and secure with
bolts (29), lockwashers (30) and locknuts (31).
Section 180-0020
SM 2119 2-02 4
6. Install link (4) to mounting on tractor frame and
secure with bolts (14), hardened washers (26) and
locknuts (22). Tighten bolts (14) to a torque of
1136 Nm (820 lbf ft).
7. While rubber mounts are still compressed, install
panhard rod (11) to mounting on tractor frame and
suspension frame (1) and secure with bolts (16),
hardened washers (24) and locknuts (23). Tighten bolts
8. Release pressure from hydraulic jacks and remove
from shock absorber mountings.
9. Install shock absorbers (3) to the tractor frame and
secure with locknuts and washers. Tighten upper
locknuts to a torque of 103 Nm (74 lbf ft).
10. Align bottom of shock absorbers (3) with
mounting brackets on suspension frame (1) and
secure with washers and locknuts. Tighten lower
locknuts to a torque of 215 Nm (155 lbf ft). Install
thread caps.
11. Remove caps and connect hydraulic brake line to
tee on front axle assembly. Connect differential
breather line.
12. Remove trolley from underneath tractor frame.
13. Position rebound mounts (7) on upper surface of
mounting plate on chassis. Install shackles (38),
chains (9) and sealant to bolts (8).
14. Insert bolts (8) through suspension bushes (33) and
rebound mounts (7). Secure chains (9) to bolts (8) with
bolts (39) and nuts (40).
15. Position snubbing washers (2), washers (27) and
nuts (19). Adjust nuts (19) until all parts are seated.
Note: No compression on mounts (7) and no slack in
assembly.
16. After parts are seated, compress rebound mount
(7) to suit working conditions. See 'Adjustments'.
17. Position guard (35) on suspension frame (1), using
suitable lifting equipment and secure with bolts (37 &
38), washer (34) and lockwasher (36).
18. Using suitable lifting equipment, position one tyre
and rim assembly on a front wheel and secure with
wheel nuts. Tighten locknuts to a torque of 540 Nm
(400 lbf ft).
19. Using suitable lifting equipment, position opposite
tyre and rim assembly on the opposite front wheel and
secure with wheel nuts.
20. Using suitable lifting equipment, raise tractor frame
sufficiently to remove stands and blocking from the
tractor frame and articulation pivot. Lower vehicle to the
ground and remove lifting equipment. Tighten all wheel
nuts to a torque of 540 Nm (400 lbf ft).
21. Remove wheel blocks from rear road wheels and
place the steering lock bar in the 'Stowed' position.
22. Bleed all air from hydraulic brake lines. Refer to
Section 165-0010, BRAKE PARTS.
ADJUSTMENTS
WARNING
safely.
To improve ride comfort, the front suspension can be
adjusted to suit working conditions, by altering the
height of the rubber rebound mounts (7). The rebound
mounts (7) are factory set at a height of 185 mm. For a
harder ride, the rubber mounts (7) should be
compressed to 140 - 185 mm. For a softer ride, the
rubber mounts (7) should be set to 185 - 200 mm.
2. Following instructions at 'Removal' adjust inner nuts
(19) to give desired compression of rubber mounts (7).
3. Apply Loctite Activator 'T' and Loctite 638 to threads
above inner nuts (19). Tighten down outer nuts (19)
against inner nuts (19), making sure that inner nuts (19)
do not move.
4. Complete installation of front suspension. Refer to
'Installation'.
Section 180-0020
SM 2119 2-02
5
* * * *
TORQUE
1 14 Bolt 1136 820
1 16 Bolt 535 386
1 21 Locknut 869 627
1 3 Shock Absorber Nut (Upper) 103 74
1 3 Shock Absorber Nut (Lower) 215 155
- - Wheel Nut 540 400
SPECIAL TOOLS
numbers of hydraulic jack, power press, press tool and
general service tools and sealants required. These
tools and sealants are available from your dealer.
Section 180-0040
1 SM 1384 Rev 2 9-03
SUSPENSION SYSTEM - Rear Suspension
SM - 3071
DESCRIPTION
Each axle is coupled to the chassis by three rubber
bushed leading or trailing control links (5) which
provide longitudinal restraint. Lateral restraint is by
transverse control links (31).
Loads acting on the centre and rear axles are balanced by
centrally pivoting equalizer beams (4) with rubber cushioning
interleaf mounts (7) between axles and beam ends.
Interleaf mounts (7) are rubber/steel laminated
compression units with chain link ties.
The rear suspension system is effectively
maintenance free due to the use of rubber bushings (6
& 32) being used in control links (5 & 31). Lubrication
Fig. 1 - Exploded View of Rear Suspension
28 - Bolt
29 - Bolt
30 - Locknut
31 - Control Link
32 - Bushing
33 - 'V' Ring Seal
19 - Lockwasher
20 - Wear Ring
21 - Bushing
22 - Retaining Plate
23 - Washer
24 - Bolt
25 - Cover Plate
26 - Bolt
27 - Lube Fitting
10 - Locknut
11 - Bolt
13 - Bolt
14 - Locknut
15 - Bolt
16 - Bolt
17 - Washer
18 - Bolt
1 - Bracket
2 - Bracket
3 - Bracket
4 - Equalizer Beam
5 - Control Link
6 - Bushing
7 - Interleaf Mount
8 - Bolt
9 - Hardened Washer
of bushings (21) in equalizer beams (4) is through lube
fittings (27).
REMOVAL
WARNING
safely.
body and install body safety prop to secure body in
26
17
24,23
27
25
22
21
4
30
19
7
8
16
19
1
9
10
14
12
13
14
12
28
29
18
31,32
5,6
5,6
5,6
5,6
29
8
3
9
10
30
19
19
16
29
20
33
11
12
2
5,6
5,6
30
19
7
8
3
9
10
2
11
12
18
16
19
7
8
9
10
29
1
31,32
16
19
7
14
12
12
13
12 15 12 14
4
30
19
DETAIL 'C'
'C'
'C'
'D'
DETAIL 'D'
'A'
'A'
'A'
'A'
'A'
'A'
'A'
'A'
'A'
'A'
'A'
DETAIL 'A' TYPICAL
DETAIL 'B'
'B'
'B'
'B'
'E'
'E'
DETAIL 'E'
Section 180-0040
Suspension System - Rear Suspension
SM 1384 Rev 2 9-03 2
partially raised position
Turn steering wheel several times to relieve any
pressure in the steering system.
3. Block front road wheels, place the steering lock bar
in the 'Locked' position and the battery master switch
in the 'Off' position.
4. Using suitable blocking equipment, block equalizer
beams to prevent movement when raising the trailer
frame.
5. Whilst the rear road wheels are still on the ground,
until the rear wheels are off the ground. Support the
vehicle with suitable stands and blocking at the trailer
frame, articulation pivot area and centre and rear axle
assemblies.
8. Repeat step 7 for the remaining rear tyre and rim
assemblies.
9. Disconnect hydraulic brake lines from tee at both
the centre axle and rear axle assemblies. Cap lines
and fittings to prevent ingress of dirt.
10. Remove blocking equipment from equalizer beams
(4).
11. Remove locknuts (30), lockwashers (19) and
bolts (29) securing interleaf mounts (7) to equalizer
beams (4).
interleaf mounts (7) to brackets (1 & 3) mounted on
the centre and rear axles. Remove interleaf mounts (7).
13. Remove bolts (26) and washers (17) securing cover
(25) to equalizer beam (4). Remove cover (25).
retaining plate (22) to shaft on frame. Remove
retaining plate (22).
15. Using suitable lifting equipment, support equalizer
beam (4) and withdraw from shaft on frame. If
required remove bushing (21) from equalizer beam (4).
16. Remove wear ring (20) and 'V' ring seal (33) from
shaft on frame.
17. Repeat steps 13 through 16 to remove the opposite
equalizer beam (4).
bolts (15 & 28) securing control links (5) between the
rear and centre axle brackets (1, 2 & 3) and frame
mounting brackets. Remove control links (5).
bolts (13 & 28) securing control link (31) between
mounting bracket (1) on the centre axle and LH frame
mounting bracket. Remove control link (31).
bolts (13 & 28) securing control link (31) between
mounting bracket (1) on the rear axle and RH frame
mounting bracket. Remove control link (31).
bolts (8) securing mounting bracket (3) on the rear
axle. Remove mounting bracket (3).
bolts (8 & 18) securing mounting bracket (1) on the
rear axle. Remove mounting bracket (1).
23. Remove bolts (11) and hardened washers (12)
securing mounting bracket (2) on the rear axle.
Remove mounting bracket (2).
bolts (8) securing mounting bracket (3) on the centre
centre axle. Remove mounting bracket (1).
securing mounting bracket (2) on the centre axle.
INSTALLATION
WARNING
Section 180-0040
3 SM 1384 Rev 2 9-03
1. Install bracket (2) on rear axle with holes on control
link (5) mounting lugs to the rear. Apply Loctite 243 to
bolts (11) and secure bracket (2) to rear axle with bolts
(11) and hardened washers (12). Tighten bolts (11) to
2. Install RH bracket (1) on rear axle with control link
(5) mounting brackets to underside and bracket
extension to the front. Secure bracket (1) to rear axle
with bolts (8 & 18), hardened washers (9) and locknuts
(10). Install bolts from the top with hardened washers
and locknuts at the bottom. Tighten bolts
(8 & 18) to a torque of 790 Nm (583 lbf ft).
3. Install LH bracket (3) on rear axle with control link (5)
mounting brackets to underside and pointing inwards
towards the rear. Secure bracket (3) to rear axle with
bolts (8), hardened washers (9) and locknuts (10).
Install bolts from the top with hardened washers and
locknuts at the bottom. Tighten bolts (8) to a torque of
790 Nm (583 lbf ft).
4. Install interleaf mountings (7) on the rear axle. Apply
Loctite 243 to bolts (16) and secure interleaf mounts (7)
on the rear axle with bolts (16) and lockwashers (19).
5. Install bracket (2) on centre axle with holes on
control link (5) mounting lugs to the front. Apply Loctite
243 to bolts (11) and secure bracket (2) to centre axle
with bolts (11) and hardened washers (12). Tighten
6. Install LH bracket (1) on centre axle with control link
extension to the rear. Secure bracket (1) to centre axle
and locknuts at the bottom. Tighten bolts (8 & 18) to a
7. Install RH bracket (3) on centre axle with control link
(5) mounting brackets to underside and pointing
inwards towards the rear. Secure bracket (3) to centre
axle with bolts (8), hardened washers (9) and locknuts
and locknuts at the bottom. Tighten bolts (8) to a
8. Install interleaf mountings (7) on the centre axle.
Apply Loctite 243 to bolts (16) and secure interleaf
mounts (7) on the centre axle with bolts (16) and
lockwashers (19). Tighten bolts (16) to a torque of 169
Nm (125 lbf ft).
9. Install control links (5) between rear and centre axle
mounting brackets (1 & 3) and frame mounting
brackets and secure with bolts (28), hardened washers
(12) and locknuts (14). Install bolts (28) with bolt heads
to the brackets. Tighten bolts (28) to a torque of 531
Nm (392 lbf ft).
Note: Ensure that there is at least 2/3 mounting
surface area contact. Check contact area using a
0.05 mm (0.002 in) feeler gauge.
10. Install control links (5) between rear and centre
axle mounting brackets (2) and frame mounting
brackets and secure with bolts (15), hardened
washers (12) and locknuts (14). Tighten bolts (15) to a
11. Install control link (31) between mounting bracket
(1) on centre axle and LH frame mounting bracket and
secure with bolts (13 & 28), hardened washers (12)
and locknuts (14). Tighten bolts (13 & 28) to a torque
of 531 Nm (392 lbf ft).
12. Install control link (31) between mounting bracket
(1) on rear axle and RH frame mounting bracket and
secure with bolts (13 & 28), hardened washers (12)
and locknuts (14). Tighten bolts (13 & 28) to a torque
of 531 Nm (392 lbf ft).
13. Using a suitable solvent, clean equalizer beam (4)
shaft on the frame. Install new 'V' ring seal (33) and
new wear rings (20) on the shaft with flanges to the
inside. Ensure mounting holes on the ends of the shaft
are clean.
14. Using a suitable solvent, clean the bores of
equalizer beams (4). Install new bushings (21) in
equalizer beams (4) aligning holes in bushings with
holes in equalizer beams.
15. Using suitable lifting equipment, install equalizer
beam (4) on frame shaft. Apply Loctite 243 to bolts
(24) and secure equalizer beam (4) to shaft with bolts
(24), washers (23) and retaining plate (22). Tighten
Section 180-0040
SM 1384 Rev 2 9-03 4
16. Apply Loctite 243 to bolts (26). Install cover plate
(25) to equalizer beam (4) and secure with bolts (26)
and washers (17). Tighten bolts (26) to a torque of
73 Nm (54 lbf ft).
17. Apply Loctite 243 to lube fitting (27) and install in
cover plate (25). Lubricate with grease specified in
Section 300-0020, LUBRICATION SYSTEM, until
excess lube is seen.
18. Repeat steps 15 through 17 to install opposite
equalizer beam (4).
19. Connect interleaf mounts (7) to equalizer beams (4)
with bolts (29), lockwashers (19) and locknuts (30).
20. Remove caps and connect hydraulic brake lines to
tees on centre axle and rear axle assemblies.
beams (4) to prevent movement when installing rear
wheels.
and rim assembly on one rear wheel and secure with
wheel nuts.
23. Repeat step 22 for remaining rear wheels.
24. Using suitable lifting equipment, raise trailer frame
axles, articulation pivot and trailer frame. Lower vehicle
to the ground and remove lifting equipment. Tighten all
wheel nuts to torque specified in Section 160-0050,
WHEEL RIM AND TYRE.
25. Remove wheel blocks from front road wheels and
MAINTENANCE
Every 250 Hours: Lubricate equalizer beam bushings
(21) through lube fittings (27) with grease specified in
SPECIAL TOOLS
* * * *
TORQUE
1 8 & 18 Bolt 790 583
1 11 Bolt 457 337
1 15 & 28 Bolt 531 392
1 16, 24 & 29 Bolt 169 125
1 26 Bolt 73 54
Section 180-0040
1 SM 2340 09-04
26
17
24,23
27
25
22
21
4
30
19
7
8
16
19
1
9
10
14
12
28
29
33
33
32
33
32
33
33
32
33
33
32
18
5,6
5,6
5,6
31
31
5,6
29
8
3
9
10
30
19
19
16
29
20
13
11
12
34
5,6
5,6
30
19
7
8
3
9
10
2
11
12
18
16
19
7
8
9
10 33
29
35
39
37
36
38
51
39
1
16
19
7
12 15 12 14
4
30
19
DETAIL 'C'
'C'
'C'
'D'
DETAIL 'D'
'A'
'A'
'A'
'A'
'A'
'A'
'A'
'A'
'A'
'A'
'A'
DETAIL 'A' TYPICAL
DETAIL 'B'
DETAIL 'E' FRAME MTG.
'B'
'B'
'E'
'E'
FORWARD
39
39
51
35
37
38
36
50
43
49
45
44
27,40
40
48
47
46
40
27,42,41
SUSPENSION SYSTEM - Rear Suspension
SM - 3295
DESCRIPTION
Each axle is coupled to the chassis by three rubber
bushed leading or trailing control links (5) which
provide longitudinal restraint. Lateral restraint is by
transverse panhard rods (31).
Loads acting on the centre and rear axles are balanced by
centrally pivoting equalizer beams (4) with rubber cushioning
Fig. 1 - Exploded View of Rear Suspension
32 - Spherical Bearing
33 - Retainer
35 - Pin
36 - Lockwasher
37 - Bolt
38 - Washer
39 - V-Ring Seal
40 - elbow
41 - Nipple
22 - Retaining Plate
23 - Washer
24 - Bolt
25 - Cover Plate
26 - Bolt
27 - Lube Fitting
28 - Bolt
29 - Bolt
30 - Locknut
31 - Panhard Rod
13 - V-Ring Seal
14 - Locknut
15 - Bolt
16 - Bolt
17 - Washer
18 - Bolt
19 - Lockwasher
20 - Wear Ring
21 - Bushing
1 - Bracket assembly
4 - Equalizer Beam
5 - Control Link
6 - Bushing
7 - Interleaf Mount
8 - Bolt
9 - Hardened Washer
10 - Locknut
11 - Bolt
interleaf mounts (7) between axles and beam ends.
Interleaf mounts (7) are rubber/steel laminated
compression units with chain link ties.
Lubrication of spherical bearings (32) in panhard rods
(31) is through lube fittings (27). Lubrication of
bushings (21) in equalizer beams (4) is through lube
fittings (27).
42 - Elbow
43 - Lockwasher
44 - Bolt
45 - Washer
46 - Manifold Bracket
47 - Grease Line
48 - Grease Line
49 - P-Clip
50 - Bolt
51 - Spacer
Section 180-0040
SM 2340 09-04 2
REMOVAL
WARNING
safely.
body and install body safety prop to secure body in
partially raised position
Turn steering wheel several times to relieve any
pressure in the steering system.
3. Block front road wheels, place the steering lock bar
beams to prevent movement when raising the trailer
frame.
5. Whilst the rear road wheels are still on the ground,
until the rear wheels are off the ground. Support the
vehicle with suitable stands and blocking at the trailer
frame, articulation pivot area and centre and rear axle
assemblies.
8. Repeat step 7 for the remaining rear tyre and rim
assemblies.
9. Disconnect hydraulic brake lines from tee at both
the centre axle and rear axle assemblies. Cap lines
and fittings to prevent ingress of dirt.
10. Remove blocking equipment from equalizer beams
(4).
11. Disconnect grease lines (47 & 48) from elbows
(40), on both panhard rods (31). Cap lines and fittings.
If necessary remove elbows (40) from panhard rods
(31).
manifold brackets (46) to equaliser beams (4). Remove
manifold brackets (46).
13. Remove locknuts (30), lockwashers (19) and
bolts (29) securing interleaf mounts (7) to equalizer
beams (4).
interleaf mounts (7) to brackets (1 & 3) mounted on the
centre and rear axles. Remove interleaf mounts (7).
(25) to equalizer beam (4). Remove cover (25).
retaining plate (22) to shaft on frame. Remove
retaining plate (22).
17. Using suitable lifting equipment, support equalizer
beam (4) and withdraw from shaft on frame. If
required remove bushing (21) from equalizer beam (4).
18. Remove wear ring (20) and 'V' ring seal (13) from
shaft on frame.
19. Repeat steps 13 through 16 to remove the opposite
equalizer beam (4).
bolts (15 & 28) securing control links (5) between the
rear and centre axle brackets (1, 2 , 3 & 34) and frame
mounting brackets. Remove control links (5).
21. Refer to detail 'B' & 'E'. Remove bolts (37),
lockwashers (36) and washers (38) securing pins (35)
through mounting brackets (1) on both centre axle/ LH
frame mounting bracket and the rear axle / RH frame
mounting brackets.
22. Remove both panhard rods (31), v-ring seals (39)
and spacers (51). If necessary remove retainers (33)
and spherical bearings (32) from panhard rods (21).
bolts (8) securing mounting bracket (3) on the rear axle.
rear axle. Remove mounting bracket (1).
securing mounting bracket (2) on the rear axle.
Section 180-0040
3 SM 2340 09-04
bolts (8) securing mounting bracket (3) on the centre
centre axle. Remove mounting bracket (1).
securing mounting bracket (34) on the centre axle.
INSTALLATION
WARNING
1. Install bracket (2) on rear axle with holes on control
link (5) mounting lugs to the rear. Apply Loctite 243 to
bolts (11) and secure bracket (2) to rear axle with bolts
(11) and hardened washers (12). Tighten bolts (11) to
2. Install RH bracket (1) on rear axle with control link
extension to the front. Secure bracket (1) to rear axle
and locknuts at the bottom. Tighten bolts
(8 & 18) to a torque of 790 Nm (583 lbf ft).
3. Install LH bracket (3) on rear axle with control link (5)
mounting brackets to underside and pointing inwards
towards the rear. Secure bracket (3) to rear axle with
bolts (8), hardened washers (9) and locknuts (10).
Install bolts from the top with hardened washers and
locknuts at the bottom. Tighten bolts (8) to a torque of
790 Nm (583 lbf ft).
4. Install interleaf mountings (7) on the rear axle. Apply
Loctite 243 to bolts (16) and secure interleaf mounts (7)
on the rear axle with bolts (16) and lockwashers (19).
5. Install bracket (2) on centre axle with holes on
control link (5) mounting lugs to the front. Apply Loctite
243 to bolts (11) and secure bracket (2) to centre axle
with bolts (11) and hardened washers (12). Tighten
6. Install LH bracket (1) on centre axle with control link
extension to the rear. Secure bracket (1) to centre axle
and locknuts at the bottom. Tighten bolts (8 & 18) to a
7. Install RH bracket (3) on centre axle with control link
(5) mounting brackets to underside and pointing
inwards towards the rear. Secure bracket (3) to centre
axle with bolts (8), hardened washers (9) and locknuts
and locknuts at the bottom. Tighten bolts (8) to a
8. Install interleaf mountings (7) on the centre axle.
Apply Loctite 243 to bolts (16) and secure interleaf
mounts (7) on the centre axle with bolts (16) and
lockwashers (19). Tighten bolts (16) to a torque of 169
Nm (125 lbf ft).
9. Install control links (5) between rear and centre axle
mounting brackets (1 & 3) and frame mounting
brackets and secure with bolts (28), hardened washers
(12) and locknuts (14). Install bolts (28) with bolt heads
to the brackets. Tighten bolts (28) to a torque of 531
Nm (392 lbf ft).
10. Install control links (5) between rear and centre
axle mounting brackets (2) and frame mounting
brackets and secure with bolts (15), hardened
washers (12) and locknuts (14). Tighten bolts (15) to a
11. Install panhard rod (31) between mounting bracket
(1) on centre axle and LH frame mounting bracket.
Locate spacers (51), v-ring seals (39) and panhard rod
(31) ends in place. Insert pins (35) into bores and
secure pins (35) in place with washers (38),
lockwashers (36) and bolts (37).
12. Install panhard rod (31) between mounting bracket
(1) on rear axle and RH frame mounting bracket.
Locate spacers (51), v-ring seals (39) and panhard rod
(31) ends in place. Insert pins (35) into bores and
Section 180-0040
SM 2340 09-04 4
secure pins (35) in place with washers (38),
lockwashers (36) and bolts (37).
13. Using a suitable solvent, clean equalizer beam (4)
shaft on the frame. Install new 'V' ring seal (13) and
new wear rings (20) on the shaft with flanges to the
inside. Ensure mounting holes on the ends of the shaft
are clean.
14. Using a suitable solvent, clean the bores of
equalizer beams (4). Install new bushings (21) in
equalizer beams (4) aligning holes in bushings with
holes in equalizer beams.
15. Using suitable lifting equipment, install equalizer
beam (4) on frame shaft. Apply Loctite 243 to bolts
(24) and secure equalizer beam (4) to shaft with bolts
(24), washers (23) and retaining plate (22). Tighten
16. Apply Loctite 243 to bolts (26). Install cover plate
(25) to equalizer beam (4) and secure with bolts (26)
and washers (17). Tighten bolts (26) to a torque of
73 Nm (54 lbf ft).
17. Apply Loctite 243 to lube fitting (27) and install in
cover plate (25). Lubricate with grease specified in
18. Repeat steps 15 through 17 to install opposite
equalizer beam (4).
19. Connect interleaf mounts (7) to equalizer beams (4)
with bolts (29), lockwashers (19) and locknuts (30).
20. Remove caps and connect hydraulic brake lines to
tees on centre axle and rear axle assemblies.
beams (4) to prevent movement when installing rear
wheels.
22. Secure manifold brackets (46) to equaliser beams
(4), using bolts (44) and washers (45). Fit elbows (40 &
41) to panhard rods (31) and nipples (42).
23. Route grease lines (47 & 48); securing to manifold
brackets (46), using clips (49), lockwashers (43) and
bolts (50). Connect grease lines (47 & 48) to their
respective elbows (40 & 42).
and rim assembly on one rear wheel and secure with
wheel nuts.
25. Repeat step 24 for remaining rear wheels.
26. Using suitable lifting equipment, raise trailer frame
axles, articulation pivot and trailer frame. Lower vehicle
to the ground and remove lifting equipment. Tighten all
wheel nuts to torque specified in Section 160-0050,
WHEEL RIM AND TYRE.
27. Remove wheel blocks from front road wheels and
MAINTENANCE
Every 250 Hours: Lubricate equalizer beam bushings
(21) through lube fittings (27) with grease specified in
SPECIAL TOOLS
Section 180-0040
5 SM 2340 09-04
* * * *
TORQUE
1 8 & 18 Bolt 790 583
1 11 Bolt 457 337
1 15 & 28 Bolt 531 392
1 16, 24 & 29 Bolt 169 125
1 26 Bolt 73 54
Section 190-0000
1 SM 2258 11-03
ELECTRICAL SYSTEM - Circuit Diagrams (DDEC IV, 6WG 310)
COMPONENT DESIGNATIONS
A4 - Radio/cassette
A5 - Radio/cassette speaker
B2 - Coolant temperature sender
B7 - Coolant Level sender
B8 - Fuel Level sender
B13 - Rot'nl speed sensor
B15 - Air temperature sender
B19 - Throttle position sender
B20 - Engine oil temp sender
B21 - Trans oil temp sender
B22 - Engine oil press sender
B24 - Turbo boost sender
B25 - Fuel pressure sender
B26 - Fuel temperature sender
B27 - Synchro reference sender
B28 - Timing reference sender
B32 - Trans oil retard temp sender
B33 - Air cond temp sender
B37 - Brake cooling oil temp sender
E3 - Interior light
E5 - Reverse light
E7 - Inst panel lights
E11 - Side marker light, L
E12 - Taillight, L
E13 - Side marker light, R
E14 - Taillight, R
E15 - High/low beam headlamp, L
E16 - High/low beam headlamp, R
E19 - Rear fog lamp (Option)
E21 - Rotating Beacon (Option)
E23 - Work light (Option)
E26 - High beam headlamp, L
E27 - High beam headlamp, R
E35 - Heated mirror
G1 - Generator
G2 - Battery
H2 - Warning light
H5 - Dir indicator w/l
H6 - Dir indicator, F, L
H7 - Dir indicator, B, L
H8 - Dir indicator, F, R
H9 - Dir indicator, B, R
H10 - Brake light, L
H11 - Brake light, R
H12 - High beam w/l
H23 - Engine check w/l
H24 - Engine stop w/l
H27 - Trans stop w/l
K1 - Starter relay
K4 - Dir ind flasher unit
K5 - Air cond compressor clutch
K14 - Start interlock relay
K15 - Headlamp relay
K17 - Reverse alarm/lights relay
K21 - Trans shift clutch
K22 - Lock-up clutch
K23 - Ignition relay
K32 - Retarder apply relay
K33 - Radiator fan relay
K34 - Horn relay
K35 - Body up relay
K36 - Body float relay
K37 - Body hyd system relay 12V
K40 - Low temp unloader valve
K43 - Radio/cassette relay
K45 - Brake pump compensator
K57 - Sound power relay No. 1
K58 - Sound power relay No. 2
L3 - Reverse alarm
L4 - Buzzer
L5 - Electric horn
M1 - Starter motor
M3 - Heater blower motor
M4 - Washer motor, F
M5 - Wiper motor, F
M6 - Wiper motor, B
M7 - Washer motor, B
M10 - Cab fan motor
M13 - Air seat compressor
N3 - Voltage convertor 12V
N4 - Frequency divider
P1 - Speedometer/odometer
P2 - Tachometer/hourmeter
P4 - Fuel level gauge
P8 - Trans oil temp gauge
P16 - Brake axle temp gauge
R7 - Cigar Lighter
Section 190-0000
Electrical System - Circuit Diagrams (DDEC IV, 6WG 310)
SM 2258 11-03 2
COMPONENT DESIGNATIONS
TERMINAL DESIGNATIONS IN ACCORDANCE
WITH DIN 72 552
L - LEFT R - RIGHT F - FRONT B - BACK
FUSE RESISTOR PLUG DIODE
Wire colours
B - Black
N - Brown
U - Blue
R - Red
G - Green
L - Light green
TRAILER
CONNECTION
S1 - Battery master switch
S2 - Starter keyswitch
S4 - W/L test switch
S7 - Emergency/park brake sw
S9 - Washer switch, F
S10 - Wiper switch, F
S11 - Rear wash/wipe switch
S13 - Horn button
S14 - Hazard w/l switch
S15 - Direction ind switch
S16 - Stoplight switch
S18 - Lights switch
S19 - Dipswitch
S20 - Headlamp flash switch
S22 - Body-up switch
S29 - Retarder request switch
S31 - Park brake w/l switch
S37 - Axle difflock switch
S40 - Gear shift selector
S41 - Auxillary lights switch
S43 - Air cond pressure sw
S48 - Accumulator press sw, F
S49 - Accumulator press sw, B
S50 - Brake cooling oil temp switch
S57 - Steering press switch
S60 - Difflock request switch
S67 - Lock-up press switch
S68 - Diagnostic request & engine
override switch
S71 - Air cond rheostat switch
S74 - Kickdown switch
S77 - Trans difflock switch
S79 - Heated mirror switch
S80 - Engine compression brake
deacceleration mode switch
S81 - Retarder/engine compression
brake selection switch
S82 - Eng comp brake on/off switch
S90 - Trans filter restriction switch
S92 - Retarder apply press switch
S93 - Brake cooling oil press switch
S94 - Brake oil cooler temp switch
X1 - Handlamp socket
Y3 - Retarder valve
Y4 - Brake diverter valve
Y7 - Difflock valve transmission
Y7 - Difflock valve middle axle
Y20 - Fuel injector
Y26 - Body raise solenoid
Y27 - Body lower solenoid
Y29 - Engine comp brake solenoid
O - Orange
Y - Yellow
P - Purple
W - White
S - Slate
K - Pink
Section 190-0000
3 SM 2258 11-03
DDEC IV COMPONENT
AND CABLE DESIGNATIONS
STANDARD (DDEC) CABLES
109 - Timing reference sender ground
110 - Timing reference sender supply
111 - Sync reference sender supply
112 - Sync reference sender ground
115 - ECM supply to coolant level sender
120 - Oil temperature sender supply
132 - Air temperature sender supply
133 - Coolant temperature sender supply
150 - ECM to master switch ground
151 - ECM to master switch ground
240 - 24 Volt battery post to ECM via 15A fuse
241 - 24 Volt battery post to ECM via 15A fuse
416 - Engine sender supplys (5VDC)
417 - Throttle position sender signal
419 - Check engine light ground to ECM
432 - Turbo boost sender signal
439 - Ignition sensed supplys
440 - 24 Volt battery post to ignition relay
452 - Engine sender returns
472 - Fuel temperature sender supply
509 - Stop engine light ground to ECM
528 - Diagnostic/stop engine override switch
530 - Oil pressure sender signal
NOTES:
1. DDEC IV WIRE NUMBERS ARE IN ( ).
2. WIRES MARKED * ARE SUPPLIED WITH
ENGINE.
3. SOME DDEC III & IV HARNESSES ARE
SHIELDED FROM ELECTRO MAGNETIC
INDUCTION WHERE THEY RUN CLOSE TO
OTHER VEHICLE SYSTEMS.
531 - Digital input transmission lockup
561 - Engine compression brake low solenoid
562 - Engine compression brake medium solenoids
583 - Digital input engine compression brake low
611 - Injector 1 power drive
619 - Injectors 1, 2, 3 returns
620 - Injectors 4, 5, 6 returns
900 - Data link diagnostics supply
901 - Data links diagnostics return
905 - Fuel pressure sender signal
911 - PWM radiator fan ground
916 - Throttle sender supply (5VDC)
925 - CAN H / J1939 (+) control link data
926 - CAN L / J1939 (-) control link data
927 - CAN SHLD / J1939 shield
952 - Throttle return
953 - Master switch grounds
979 - Digital input engine compression brake
medium
DIODE
INDICATOR LIGHT RESISTOR
FUSE
CABLES TWISTED
30 TURNS / metre
SCREENED
CABLES
TERMINAL DESIGNATIONS IN ACCORDANCE
WITH DIN 72 552
L - LEFT R - RIGHT F - FRONT B - BACK
TRAILER
CONNECTION
ELECTRICAL SYSTEM - Circuit Diagrams (DDEC IV, 6WG 310)
Section 190-0000
SM 2258 11-03 4
FUSES
Location Fuse No. Circuit Current Rating
1 Ignition Sensed Relay Contacts (Heater) 30A
2 Keyswitch 15A
3 Cab Fan Ventilator Blower 15A
4 Rear Wash/Wipe 10A
5 Horn Relay Coil, Front Wash/Wipe 10A
Fuse Box - 6 Air Seat Compressor 10A
Column A 7 Lights Switch 10A
8 Main Beam 10A
9 Wiper Park Front and Rear 7.5A
10 Hazards 7.5A
11 Transmission System Ignition Supply 7.5A
12 Reverse System 7.5A
13 Brake Lights 5A
14 Interior Light, Handlamp 5A
15 Direction Indicators, Rocker Switch Lights 5A
16 Alarm Brake/Steering System 3A
17 Warning Lights 3A
Fuse Box - 18 Spare -
Column B 19 Gauges/Ignition Sensed Relay Coils 3A
20 Radiator Fan 3A
21 Neutral Start 3A
22 Washers, Front 3A
23 Washers, Rear 3A
24 Horn 10A
25 Ignition Sensed Relay Contacts (Air Conditioning) 30A
26 Air Conditioning Compressor 15A
27 Spare -
28 Ignition Auxilary Supply Option 10A
29 Work Lights 15A
Fuse Box - 30 Rotating Beacon 5A
Column C 31 Cab Fan 3A
32 Transmission System Battery Supply 7.5A
33 Body Hydraulic System 5A
34 Alternator Drive Signal 3A
35 Heated Mirrors 15A
36 Cigar Lighter 10A
Radio Harness 38 Radio/Cassette Supply (Glass Fuse) 7A
39 Radio/Cassette Supply (Glass Fuse) 1A
40 DDEC IV ECM Ignition Sensed Supply 5A
Battery Box 41 DDEC IV ECM Battery Supply 15A
42 DDEC IV ECM Battery Supply 15A
Bus Bar 47 Sound Power Legislation Relay No. 1 Supply 3A
Section 190-0000
5 SM 2258 11-03
SM - 3103
RELAYS
Location Relay Circuit
K23 Ignition Sensed Relay - Optional
Fuse Box - K23 Ignition Sensed Relay
Column D K34 Horn Relay
K15 Headlamp Relay
K57 Sound Power Relay No. 1
K17 Reverse Alarm/Lights Relay
Fuse Box - K14 Start Interlock Relay
Column E K5 Air Conditioning Compressor Clutch
K35 Body Up Relay
K58 Sound Power Relay No. 2
K4 Direction Indicator Flasher Unit
Fuse Box - K33 Radiator Fan Relay
Column F K23 Engine Ignition
K36 Body Float Relay
K32 Retarder Apply Relay
Fuse Box - K32 Retarder Apply Relay
Column G K37 Body Hydraulics System Relay (12V)
K43 Radio/Cassette Relay
K23
K23
K34
K15
K17
K14
K5
K35
K4
K33
K23
K36
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
F25
F26
F27
F28
F29
F30
F31
F32
F33
F34
F35
F36
K32
K32
K37
K43
K57 K58
Column A B C D E F G
Section 190-0000
SM 2258 11-03 6
S
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Section 190-0000
7 SM 2258 11-03
S
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Section 190-0000
SM 2258 11-03 8
S
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Section 190-0000
9 SM 2258 11-03
S
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Section 190-0000
SM 2258 11-03 10
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Section 190-0000
11 SM 2258 11-03
S
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Section 190-0000
SM 2258 11-03 12
S
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3
1
8
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CLICK HERE FOR
HORIZONTAL
DRAWING
Section 190-0000
13 SM 2258 11-03
S
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Section 190-0000
SM 2258 11-03 14
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Section 190-0000
15 SM 2258 11-03
S
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Section 190-0000
SM 2258 11-03 16
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Section 190-0000
17 SM 2258 11-03
S
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Section 190-0000
SM 2258 11-03 18
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* * * *
Section 190-0270
SM 2259 11-03
1
ELECTRICAL SYSTEM - Switches and Sensors
SM - 3100
DESCRIPTION
This section describes the location and function of
various switches and sensors fitted to the vehicle to
monitor all major components and systems. Gauges
and warning lights located in the centre dash panel,
relay this information to the operator.
Note: Always make sure all gauges, warning lights
and controls are working properly before operating the
vehicle.
Engine
The DDEC engine management system monitors the
engine at all times and sends a signal to the engine
check light (2, Fig. 2) and engine stop light (1, Fig. 2)
on the dash panel to alert the operator of a fault in the
engine circuit. Refer to Section 110-0030, ENGINE
AND MOUNTING.
Engine Coolant Level Sender (1) - Located in the
radiator header tank, the sender sends a signal to
engine stop light (1, Fig. 2) indicating that engine
coolant level is low.
1 - Coolant Level Sender
2 - Stop Light Pressure Switch
3 - Rear Brake Pressure Switch
4 - Front Brake Pressure Switch
5 - Parking Brake Pressure Switch
6 - Oil Temperature Sender
7 - Kickdown Switch
8 - Emergency Steering Pressure Switch
9 - Body Up Proximity Switch
10 - Air Cleaner Restriction Indicator
11 - Brake Cooling Oil Pressure Switch
12 - Brake Cooling Oil Temp. Switch/Sender
13 - Retarder Proximity Switch
14 - Retarder Pressure Switch
15 - Brake Oil Cooler Temp. Switch
Fig. 1 - Switches and Sensors
20
15
10
7
25
IN
PUMP
TS2
TS1
1
2
10 7
8
9
5
HEADER TANK
TREADLE VALVE
BRAKE MANIFOLD VALVE
THROTTLE PEDAL
MAIN
HYDRAULIC
PUMP
L.H. FRAME RAIL
ON AIR CLEANER
FRONT AXLE
MANIFOLD BLOCK
13
3
4
ACCUMULATORS
14
TRANSMISSION
12
15 11
6
Section 190-0270
Electrical System - Switches and Sensors
2
SM 2259 11-03
Tachometer/Hourmeter (9, Fig. 2) - Driven from the
alternator, the tachometer indicates the number of
engine crankshaft revolutions per minute (rev/min).
The needle shows the variations in engine operating
speed. Never accelerate the engine to speeds
indicated by the red zone on the dial face. A digital
hourmeter is incorporated in the tachometer to record
total hours of engine operation.
Tachometer Calibration
1. Determine the impulse setting required. Reference
tachometer calibration table.
1 - Engine Stop W/L
2 - Engine Check W/L
3 - Front Brake Accumulator W/L
4 - Not Used On This Machine
5 - Brake Cooling Oil W/L
6 - Body Up W/L
7 - Rear Brake Accumulator W/L
15 - Retarder Apply Ind/L
16 - Not Used On This Machine
17 - Emergency Steering W/L
18 - Alternator Charging W/L
19 - Direction Indicator Ind/L
20 - Brake Cooling Oil Temperature Gauge
21 - Transmission Oil Temperature Gauge
8 - Parking Brake Ind/L
9 - Tachometer/Hourmeter
10 - Fuel Gauge
11 - Speedometer/Odometer
12 - Transmission Stop W/L
13 - Differential Lock Ind/L
14 - Headlight Main Beam Ind/L
Fig. 2 - Layout View of Instruments and Indicator/Warning Lights
SM - 3101
2. Using a suitable screwdriver, depress and hold
calibration button at the rear of the tachometer and
turn the ignition keyswitch to position '1'. Release
button when PULSE is displayed.
3. After a few seconds, the digits will flash in
sequence. Depress the button until the desired
number is displayed the release the button for a few
seconds until the next digit flashes.
4. Repeat step 3 to obtain the desired impulses/
revolution. The tachometer is now calibrated.
Transmission
Refer to Section 120-0010, TRANSMISSION AND
MOUNTING, for detailed information on switches and
sensors fitted to the transmission.
Speedometer/Odometer (11, Fig. 2) - Driven by a
signal from the transmission ECU, the speedometer
indicates vehicle travel speed in kilometres per hour
Tachometer Calibration Table -
All units with standard tyres
Unit Engine Pulses/revolution
TA25 Cummins QSC 17.40
TA27 Cummins QSL 17.40
TA30 Cummins QSM 16.68
TA35 DD Series 60 18.66
TA40 DD Series 60 18.66
0
5
10
15
20
25
RPM x100
30
0
10
30 20
40
km/h
50
MPH
20
20
20
20
OIL TEMP
TRANS
50 0
150
120
140
OIL TEMP
BRAKE P
1 2
STOP
STOP
1 1
21
9
20
11
10
16
17
18
19
12
13
14
15
5
6
7
8
1
2
3
4
Section 190-0270
SM 2259 11-03
3
Braking System
Stop Light Pressure Switch (2) - The normally open
(NO) pressure switch is located at a tee in 'B2' port of the
treadle valve. As brake apply pressure increases to
2.7 bar (39 lbf/in
2
) and above, the circuit closes and sends
a signal to illuminate the brake lights at the rear of the
vehicle. As pressure drops below 2.7 bar (39 lbf/in
2
) the
circuit opens and brake lights go out.
Rear Brake Pressure Switch (3) - The normally
closed (NC) pressure switch, located below the rear
brake accumulator, senses pressure in the rear brake
circuit. The pressure switch sends a signal to
illuminate 'Red' trailer brakes overstroke warning light
(7, Fig. 2) when pressure drops below 115 bar
(1 668 lbf/in). An audible buzzer also sounds.
Front Brake Pressure Switch (4) - The normally
closed (NC) pressure switch, located below the front
brake accumulator, senses pressure in the front brake
circuit. The pressure switch sends a signal to
illuminate 'Red' tractor brakes overstroke warning light
(3, Fig. 2) when pressure drops below 115 bar
(1 668 lbf/in). An audible buzzer also sounds.
Parking Brake Pressure Switch (5) - The normally
closed (NC) pressure switch, located in the brake
manifold valve, senses pressure in the parking brake
(Pk) line. The pressure switch opens at a pressure of
4.9 bar (71 lbf/in) and sends a signal to illuminate
'Green' parking brake indicator light (8, Fig. 2) when
the parking brake is applied.
Brake Cooling Oil Pressure Switch (11) - The
normally open (NO) switch, fitted to port PS of the
manifold block on the front axle, senses brake cooling
oil pressure. The switch sends a signal to illuminate
'Red' brake cooling oil high pressure warning light (5,
Fig. 2) when oil pressure reaches 1.5 bar (22 lbf/in).
Brake Cooling Oil Temperature Switch/Sender (12)
- The normally closed (NC) switch, fitted to port TS1 of
the manifold block on the front axle, senses oil
temperature in the brake cooling lines. The switch
sends a signal to de-energise the solenoid on the
motor/triple pump assembly when oil temperature
reaches 50 C, causing an increase in motor speed.
Refer to Section 250-0045, MOTOR/TRIPLE PUMP
ASSEMBLY.
The switch also acts as a sender unit by sending a
signal to indicate brake cooling oil temperature on the
brake cooling oil temperature gauge (20, Fig. 2) in the
cab.
(km/h) and miles per hour (mph). A digital odometer is
incorporated in the speedometer to record the
distance travelled by the vehicle at any given time.
Speedometer Calibration
1. Determine the impulse setting required. Reference
speedometer calibration table.
2. Depress and hold calibration button at the front of
the speedometer and turn the ignition keyswitch to
position '1'. Release button when PULSE is displayed.
3. After a few seconds, the digits will flash in
sequence. Depress the button until the desired
number is displayed the release the button for a few
seconds until the next digit flashes.
4. Repeat step 3 to obtain the desired impulses/
revolution. The speedometer is now calibrated.
Retarder Proximity Switch (13) - Incorporated in the
treadle valve. The first 7 of pedal travel will request
the transmission retarder. The retarder will engage,
provided that the transmission 'Stop' warning light (12,
Fig. 2) is out and the transmission is in lockup. Further
depression of pedal will apply the service brakes. To
disengage the retarder, release the treadle valve.
Retarder Pressure Switch (14) - The normally open
(NO) pressure switch, located on top of the
transmission, senses pressure in the transmission
retarder line. As retarder pressure increases to
0.3 bar (4.4 lbf/in
2
) and above, the circuit closes and
sends a signal to illuminate the retarder apply indicator
light (15, Fig. 2).
Oil Temperature Sender (6) - Sends a signal to
indicate transmission oil temperature on the
transmission oil temperature gauge (21, Fig. 2) in the
cab.
Kickdown Switch (7) - Refer to Section 120-0010,
TRANSMISSION AND MOUNTING, for detailed
operation of the kickdown switch.
Speedometer Calibration Table -
All units with standard tyres
Unit Transmission Pulses
TA25 6 WG 210 333650
TA27 6 WG 260 232100
TA30 6 WG 310 232100
TA35 6 WG 310 231900
TA40 6 WG 310 217130
Section 190-0270
4
SM 2259 11-03
Brake Oil Cooler Temperature Switch (15) - The
normally closed (NC) switch, fitted to port TS2 of the
manifold block on the front axle, senses oil
temperature in the brake cooling lines. The switch
sends a signal to the control valve to direct oil flow
through the disc brake oil cooler fan motor, causing
fan to rotate, when brake cooling oil temperature
reaches 60 C. Refer to Section 250-0065, CONTROL
VALVE.
Steering
Emergency Steering Pressure Switch (8) - The
normally closed (NC) pressure switch is located in a
block at the rear outlet port of the main hydraulic
pump. The pressure switch sends a signal to
illuminate 'Red' emergency steering warning light
(17, Fig. 2) when pressure drops to 4.8 bar (70 lbf/in
2
)
or lower.
* * * *
Air Cleaner
Air Cleaner Restriction Indicator (10) - Mounted on
the air cleaner outlet pipe, the indicator indicates the
degree of air cleaner element restriction as the yellow
band rises in the gauge window. The filter element
should be replaced if the yellow band locks in place
when the engine is shut down. Reset the gauge by
pressing the button on the gauge with the engine
running.
Body
Body Up Proximity Switch (9) - Mounted on the
inside of the trailer left hand frame rail. When the body
is raised off the trailer frame, the switch sends a signal
to illuminate the 'Amber' body up warning light
(6, Fig. 2).
Note: Never move the vehicle until body up warning
light (6, Fig. 2) goes out, indicating that the body is
fully lowered onto the trailer frame.
Note: The proximity switch prevents the body being
fully powered down onto the chassis. At a
predetermined height, the switch automatically
defaults the body control valve to the detented
'FLOAT' condition.
Section 200-0040
SM 1398 Rev 2 2-04 1
FUEL SYSTEM - Fuel System
SM - 1895
DESCRIPTION
The fuel system consists of the DDEC electronic fuel
system controls, fuel manifolds (integral with the
cylinder head), primary fuel filter (3), secondary fuel
filter (9), fuel pump (5), electronic control module
(ECM) cooling plate (7), electronic unit injectors (15)
fuel cooler (16), fuel tank (1) and the necessary
connecting fuel lines.
There are two spin-on type fuel filters mounted on the
left hand side of the engine. Primary fuel filter (3) is in
the fuel flow and acts as a strainer and secondary fuel
filter (9) filters the fuel after having passed through
primary fuel filter (3). The word 'Primary' or 'Secondary
is cast into the top of the respective adaptor.
Fuel pressure sensor (10) is installed into the side of
secondary fuel filter (9) and sends an electronic signal
to the ECM telling it what the engine fuel pressure is at
any given speed.
Fuel temperature sensor (11) is installed in a tee on the
top of secondary fuel filter (9) and sends an electrical
signal to the ECM indicating fuel inlet temperature. The
ECM uses this information to calculate fuel
consumption.
Note: Both fuel pressure sensor (10) and fuel
temperature sensor (9) are non-serviceable items and
should be replaced as individual units. No adjustment
is required.
Fig. 1 - Fuel Lines and Components
1 - Fuel Tank
2 - Fuel Supply Line
3 - Primary Filter
4 - Fuel Line
5 - Fuel Pump
6 - Fuel Line
7 - ECM Cooling Plate
22 - Fuel Return Line
23 - Restricted Fitting
24 - Filler Cap
25 - Bolt
26 - Washer
27 - Spring
28 - Locknut
29 - Strainer
15 - Electronic Unit Injector (EUI)
16 - Fuel Cooler
17 - Mounting Bracket
18 - Mounting Bracket
19 - Bolt
20 - Padlock
21 - Key
8 - Fuel Line
9 - Secondary Filter
10 - Fuel Pressure Sensor
11 - Fuel Temperature Sensor
12 - Shut Off Cock
13 - Fuel Line
14 - Fuel Line
Section 200-0040
Fuel System - Fuel System
SM 1398 Rev 2 2-04 2
When installing fuel lines, it is recommended that
connections be tightened only sufficiently to prevent
leakage of fuel; thus flared ends of the fuel lines will
not become twisted or fractured because of excessive
tightening.
A fuel tank breather/filter assembly is incorporated into
the fuel filler cap (24), allowing fuel tank (1) to vent to
atmosphere, preventing pressure from building up
within fuel tank (1) assembly.
OPERATION
Fuel is drawn from fuel tank (1) through primary fuel
filter (3) and enters fuel pump (5). Leaving fuel pump
(5) under pressure, the fuel flows through ECM cooling
plate (7), through secondary fuel filter (9) to the engine
cylinder head. The fuel flows to electronic unit injectors
(15) in the cylinder head through passages integral with
the cylinder head. Surplus fuel exits at the rear of the
cylinder head just above the inlet, flows through fuel
cooler (16) and back to fuel tank (1). Restricted fitting
(23) at rear of engine maintains fuel pressure in the
system.
REMOVAL
WARNING
safely.
parking brake and switch off the engine. Operate
steering right and left several times to relieve pressure
in the steering system.
3. If required, remove mounting hardware securing the
front grille on the hood assembly and remove grille for
access to the fuel cooler (16).
4. Pull on handle to release hood catch mechanism
and raise hood.
5. Remove padlock (20) and remove filler cap (24) from
fuel tank (1).
Fuel pump (5) is attached to a drive assembly mounted
on the rear side of the gear case at the front LH side of
the engine and transfers fuel from fuel
tank (1) to the electronic unit injectors (15).
The electronic unit injector (15) is a lightweight,
compact unit that injects diesel fuel directly into the
combustion chamber. The amount of fuel injected and
the beginning of injection timing is determined by the
ECM. The ECM sends a command pulse which
activates the injector solenoid.
The EUI performs four functions:
a - Creates the high fuel pressure required for efficient
injection.
b - Meters and injects the exact amount of fuel required
to handle the load.
c - Atomizes the fuel for mixing with the air in the
combustion chamber.
d - Permits continuous fuel flow for component cooling.
Electronic unit injectors are self compensating and
virtually eliminate engine tune-ups.
Note: Never apply 12 V directly to terminals on the
injector as it will burn out. Before removing injectors,
the fuel passages must be blown out to prevent fuel
flow from entering the cylinder head.
ECM cooling plate (7) is mounted in front of the ECM
on the LH side of the engine and absorbs heat
generated by the ECM. Fuel from fuel pump (5) outlet
line (6) flows through ECM cooling plate (7) to absorb
this heat.
Fuel cooler (16) is mounted on the front of the radiator
and cools fuel returning to fuel tank (1).
Flexible fuel lines (2, 4, 6, 8, 13, 14 & 22) are used to
facilitate connection of lines leading to and from fuel
tank (1), and to minimize the effects of any vibration in
the installation. A 2.03 mm (0.08 in) restricted orifice is
incorporated in the fuel return fitting (23) at rear of
engine to maintain fuel pressure in the system. The
restricted orifice is designed to provide the proper fuel
system pressure under all conditions.
Note: Do not alter or substitute another size of orifice
since this may alter engine performance and
emissions.
Note: Do not use restricted fittings anywhere else in
the fuel system and do not substitute a standard fitting
for the restricted fitting.
Section 200-0040
SM 1398 Rev 2 2-04 3
4. Secure the rear of fuel tank (1) assembly to the
tractor frame with bolts (25), washers (26), springs (27),
washers (26) and locknuts (28), as shown in Fig. 1.
Tighten locknuts (28) until spring compresses to a
length of 31.75 mm (1.25 in).
5. Remove blanking caps and secure fuel lines (2, 14 &
22) to elbows, as identified at removal.
6. If removed, install fuel cooler (16). Refer to Section
210-0100, HYDRAULIC OIL COOLER.
7. Install fuel strainer (29) in fuel tank (1).
8. Fill fuel tank (1) assembly with clean diesel fuel
SYSTEM.
9. Install filler cap (24) assembly on fuel tank filler
neck. Tighten filler cap (24) securely and secure in
place with padlock (20).
10. Lower hood assembly and secure front grille
assembly to the hood with mounting hardware removed
at removal.
11. Place the battery master switch in the 'On' position,
start the engine and run for a few minutes to ensure
fuel is being supplied to the engine. Check for leaks at
fuel lines (2, 14 & 22) and tighten if required.
MAINTENANCE
WARNING
damage, be sure wheel blocks and blocking
materials are properly secured and of adequate
capacity to do the job safely.
WARNING
To prevent personal injury or even death,
welding of the fuel tank is strictly prohibited at
all times, due to the hazardous flammable
liquids and vapours present inside the tank,
even when empty.
6. Remove fuel strainer (29) from fuel tank (1) and
clean with clean diesel fuel.
7. With a suitable container in position, remove
drain plug from bowl in the underside of fuel tank (1)
and drain fuel from fuel tank (1). Reinstall drain
plug and tighten securely when fuel tank (1) is
completely drained.
8. Identify and tag fuel lines (2, 14 & 22) and, with a
suitable container available to catch leakage,
disconnect fuel lines (2, 14 & 22). Cap open line ends
and elbows to prevent entry of dirt.
9. Remove locknuts (28), bolts (25), washers (26) and
springs (27) securing fuel tank (1) assembly in the
tractor frame. Using a suitable lifting device, remove
fuel tank (1) assembly from the vehicle.
10. If required, remove fuel cooler (16). Refer to
Section 210-0100, HYDRAULIC OIL COOLER.
11. If required, remove rubber pads from the tractor
frame. Be sure to remove all rubber and adhesive from
the tractor frame.
INSTALLATION
WARNING
safely.
Note: Tighten all fasteners to standard torques
specified in Section 300-0080, STANDARD BOLT AND
NUT TORQUE SPECIFICATIONS.
1. If removed, apply a suitable adhesive to new rubber
pads and position on the tractor frame.
2. Using suitable lifting equipment, position fuel tank (1)
assembly in the tractor frame.
3. Secure the front of fuel tank (1) assembly to the
tractor frame with bolt (25), washer (26), spring (27),
washer (26) and locknut (28), as shown in Fig. 1.
Tighten locknut (28) until spring compresses to a
length of 31.75 mm (1.25 in).
Section 200-0040
SM 1398 Rev 2 2-04 4
General
Refill fuel tank (1) at the end of each day's operation to
prevent condensation from contaminating the fuel.
When filling fuel tank (1), check that there is no buildup
of dirt and sludge at fuel strainer (29) and filler cap (24).
Remove and clean fuel strainer and filler cap
as required.
Every 10 Hours/Daily:
Make a visual check for fuel leaks at all engine mounted
fuel lines and connections, fuel cooler, and at the fuel tank
suction and return lines. Examine lines for leaks and
check all fittings, clamps and ties carefully.
Make sure that fuel lines are not resting on or touching
rotating components, heated surfaces including
exhaust manifolds or sharp edges. If fittings have
loosened or cracked, or if lines have ruptured or worn
through, take corrective action immediately.
Every 250 Hours:
Replace the primary and secondary fuel filters as
follows:
Note: There is a fuel system shut off cock on the
discharge side of the secondary fuel filter. Closing this
valve will prevent loss of fuel prime at time of filter
replacement.
1. Close shut off valve at secondary fuel filter and,
using a strap type filter wrench, remove and discard
both the primary and secondary fuel filters from the
engine.
2. Fill the replacement filters and coat the gaskets
slightly with clean fuel oil as specified in Section
3. Start new primary fuel filter on the filter adaptor and
tighten it by hand until the gasket contacts the adaptor
fully with no side movement of the filter evident.
Tighten an additional 1/2 of a turn.
Note: Mechanical tightening of fuel filters is not
recommended, and may result in seal and/or cartridge
damage. Tighten fuel filters by hand only.
4. Repeat step 3 to install a new secondary fuel filter.
5. Start the engine and check for leaks. If any leaks
are noted, have them corrected.
Every 250 Hours:
Open the drain at the bottom of the fuel tank to drain
off any water and/or sediment. Check the seal in fuel
tank filler neck cap and clean filler neck screen and
cap. Check the condition of all fuel lines and replace if
required. Clean and inspect fins on fuel cooler.
Every 1 000 Hours:
Remove filler cap (24) from filler neck. With the handle
in the up and rotated position, remove the two screws
securing the filter assembly to the cap. Discard 'O'-
rings. Clean top of filler cap (24) and valve cavity.
Install new filter assembly to filler cap (24) using new
screws and 'O'-rings (supplied with new filter). Tighten
screws to 10 - 13 in lbs.
Diesel Fuel Oil
The sulphur content of diesel fuel oil should be as low
as possible to avoid premature wear of piston rings and
liner, excessive deposit formation, and minimise
sulphur dioxide exhausted into the atmosphere. Limited
amounts can be tolerated, but the amount of sulphur in
the fuel and engine operating conditions can influence
corrosion and deposit formation
tendencies. The use of diesel fuel oil with a MAXIMUM
sulphur content of 0.5% is recommended for use. Refer
to Section 300-0020, LUBRICATION SYSTEM.
TROUBLESHOOTING
Locating Air Leaks in Fuel Lines
Air drawn into the fuel system may result in uneven
running of the engine, black or white smoking and
stalling when idling, or a loss of power. Poor operation
is particularly noticeable at lower engine speeds. If air
is found in the fuel, the source will normally be between
the fuel tank and the fuel pump.
Check for loose, faulty or improper fuel line connectors.
Presence of an air leak may be detected
by following the procedures under 'Checking Fuel Flow'.
Checking Fuel Flow
1. Disconnect the fuel return line from the fitting at the
fuel tank and hold the open end in a suitable container.
2. Start and run the engine at maximum rev/min and
measure the fuel flow. Nominal fuel return spill with the
Section 200-0040
SM 1398 Rev 2 2-04 5
standard 2.03 mm (0.08 in) restricted fitting is
4.1 litres/min (65 US gal/min).
3. Immerse the end of the fuel return line in the fuel. Air
bubbles rising to the surface of the fuel will indicate air
being drawn into the fuel system on the suction side of
the pump. If air is present, tighten all fuel lines
connections between the fuel tank and fuel pump.
4. If the fuel flow is insufficient for satisfactory engine
performance then proceed as follows:
a. Replace the primary and secondary fuel filters, as
described under 'Maintenance'. Start the engine and run
it at maximum rev/min and recheck the fuel flow. If fuel
flow is still unsatisfactory, perform step 'b'.
b. Check the fuel lines for restrictions due to pinching,
kinking or other damage. Be sure the correct restricted
fitting is installed at the return port of the fuel tank. If no
problem is found, substitute another fuel pump that is
known to be operating correctly and recheck the fuel flow.
When changing the fuel pump, inspect the fuel pump drive
assembly, hubs and coupling. Clean all fuel lines with
compressed air and be sure all fuel connections are tight.
c. Disconnect the fuel lines from the ECM cooling plate
and, using a suitable connector, connect the two fuel
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
dealer.
* * * *
Section 200-0051
SM 1399 5-98 1
FUEL SYSTEM - Electronic Foot Pedal
SM - 1478
DESCRIPTION
The electronic foot pedal assembly provides an
electrical signal to the engine's fuel control system in
proportion to the degree of pedal actuation. Maximum
and minimum stops are built into the pedal assembly
during manufacture. The pedal assembly comes
preset and therefore no adjustment is necessary.
Note: The DDEC controlled engine will override the
pedal position until the engine is warmed up to the
correct operating temperature. The engine MUST be
started with foot 'OFF' pedal assembly (1).
Kickdown switch (17), which can be used when
automatic range is selected, allows for the possibility
of selecting a lower gear by pressing down fully on
pedal assembly (1) and holding. This can be used to
provide a downshift on demand provided that the
vehicle speed is within the range allowable. That is,
the vehicle is not travelling at a speed that would result
in the engine overspeeding in the lower gear. To
disengage the transmission kickdown, allow pedal
assembly (1) to return to the full load or part load
position. Refer to Section 120-0010, TRANSMISSION
AND MOUNTING
Fig. 1 - Electronic Foot Pedal and Kickdown Assembly
1 - Pedal Assembly
2 - Spring
3 - Pin
4 - 'E' Clip
5 - Spring
6 - Pin
7 - Bearing
8 - Pedal Stop
9 - Plate
10 - Pivot Block
11 - Bellows
12 - Rod End
13 - Spring
14 - Lever Stop
15 - Lever
16 - Sensor
17 - Kickdown Switch
18 - Harness
19 - Grommet
20 - Bolt
21 - Nut
22 - Lockwasher
18
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
19
20
21,22
Section 200-0051
Fuel System - Electronic Foot Pedal
SM 1399 5-98 2
REMOVAL
WARNING
safely.
switch off the engine. Turn steering wheel in both
directions several times to relieve any pressure in the
steering circuit.
3. Disconnect electrical harness (18) and kickdown
switch (17) harness.
4. Move cab floor mat back and clear from pedal
assembly (1) and mounting plates.
5. Remove mounting hardware securing plate (9) and
pedal assembly (1) to cab floor plate. Remove plate (9)
and pedal assembly (1).
6. Remove bolts (20), nuts (21) and lockwashers (22)
securing pedal assembly (1) to plate (9). Remove
pedal assembly (1) from plate (9).
INSTALLATION
Note: Tighten all fasteners to standard torques listed
in Section 300-0080, STANDARD BOLT AND NUT
1. Position pedal assembly (1) on plate (9) and secure
with bolts (20), lockwashers (22) and nuts (21).
2. Secure plate (9) and pedal assembly (1) to the cab
floor plate with mounting hardware removed during
removal.
3. Connect electrical harness (18) and kickdown
switch (17) harness.
4. Position floor mat on cab floor and ensure that pedal
assembly (1) is free to operate.
remove wheel blocks and start the engine. Ensure that
pedal assembly (1) operates correctly.
Note: The engine MUST be started with the foot 'OFF'
pedal assembly (1).
MAINTENANCE
Limited repair of the electronic foot pedal assembly is
by replacement of parts only. Refer to vehicle Parts
Book for part numbers of overhaul kits.
* * * *
Section 210-0000
SM 2260 11-03
1
COOLING SYSTEM - Cooling System (Series 60 Engine)
SM - 2664
DESCRIPTION
A radiator and fan cooling system is used on Series 60
engines installed in these vehicles. This system has a
centrifugal type water pump (3) to circulate coolant
throughout the system. Two full blocking type
thermostats located in thermostat housing (7), attached
to the right hand side of the cylinder head, control the
flow of coolant.
Fig. 1 - Cooling Lines and Flow
1 - Header Tank
2 - Radiator Assembly
3 - Engine Water Pump
4 - Coolant Filter (not used)
5 - Transmission Oil Cooler
6 - Engine Oil Cooler
7 - Thermostat Housing
8 - Make-up Line
9 - Radiator Outlet Pipe
10 - Coolant Pipe
11 - Coolant Pipe
12 - Bypass Line
13 - Radiator Inlet Pipe
14 - Deaeration Lines
15 - Filter Inlet Line (not used)
16 - Filter Outlet Line (not used)
The main components of the cooling system are;
header tank (1), radiator assembly (2), engine water
pump (3), transmission oil cooler (5), engine oil cooler
(6) and thermostat housing (7).
Attached to the front of radiator assembly (2) are an
air-to-air charge cooler, a fuel cooler and a hydraulic oil
cooler.
1
14
7
12
13
2
8
9
15
4
16
3
11
5
10
6
Section 210-0000
Cooling System - Cooling System (Series 60 Engine)
SM 2260 11-03
2
OPERATION
Upon starting a cold engine or when the coolant is
below operating temperature, the coolant is restricted
at thermostat housing (7) and bypass line (12) provides
water circulation within the engine during the warm-up
period.
Note: Engine coolant thermostats start to open at
88 C (190 F) and are fully open at 96 C (205 F).
Engine water pump (3) draws coolant from the radiator
through radiator outlet pipe (9). Engine water pump (3)
then pumps coolant through coolant pipe (10) into
transmission oil cooler (5). Coolant flows through
transmission oil cooler (5), drawing heat from the
transmission oil cooler, and then flows through coolant
pipe (11) and into engine oil cooler (6). The coolant
then flows through the engine block and passes up
through the cylinder head to thermostat housing (7).
Aerated coolant is drawn off to header tank (1) from
thermostat housing (7) through deaeration line (14).
Excess coolant at header tank (1) is discharged
through an overflow line from the filler neck.
When the coolant reaches operating temperature, the
thermostats open allowing coolant to flow into the
radiator through radiator inlet pipe (13). The coolant
passes through a series of tubes in radiator assembly
(2) core, where the coolant temperature is lowered by
the air stream created by the revolving fan, and into the
radiator outlet pipe (9) to be re-circulated back through
the system.
Aerated coolant is drawn off to header tank (1) from the
radiator, radiator inlet pipe (13) and thermostat housing
(7) through deaeration lines (14). Excess coolant at
header tank (1) is discharged through an overflow line
from the filler neck.
The use of antifreeze is mandatory with the cooling
system. The lack of coolant flow through the radiator
with the thermostats closed allows the coolant in
radiator assembly (2) to freeze under low ambient
temperature conditions.
SM - 1221
Air-To-Air Charge Cooling
In the air system used on the Series 60 engines,
outside air drawn into the engine through the air
cleaner, passes through the air filter element and is
pulled into the turbocharger where it is compressed. It
then exits the turbocharger through outlet pipe (4) and
enters air-to-air charge cooler (2), mounted on the front
of radiator assembly (1), through inlet pipe (3). The hot
air travels through a series of tubes in
air-to-air charge cooler (2) core, where the air
temperature is lowered from approximately 149 C
(300 F) to below 38 C (100 F). From here the air
flows through outlet pipe (5) and into the engine intake
manifold through inlet pipe (6). From the engine intake
manifold the air travels into the cylinders where it
mixes with atomized fuel from the injectors. This cooler
air aids combustion, thereby increasing fuel economy.
Fig. 2 - Air-to-Air Charge Cooler Lines and Flow
2 - Air-to-Air Charge Cooler
3 - Inlet Pipe
4 - Outlet Pipe
5 - Outlet Pipe
6 - Inlet Pipe
Section 210-0000
SM 2260 11-03
3
Note: It may be necessary to clean radiator and
air-to-air charge cooler fins more frequently if the
vehicle is being operated in extremely dusty or dirty
areas.
WARNING
To prevent possible injury when using
compressed air, wear adequate eye protection
and do not exceed 2.75 bar (40 lbf/in).
Every 500 Hours
Inspect water pump drain hole to make sure it is open.
Note: A small chemical build up or streaking at the
drain hole may occur. This is not an indication of a
defective water pump or seal. If coolant does not leak
from the drain hole under normal operating conditions,
do not replace the water pump.
Every 2 000 Hours
Replace all drive belts. Refer to Section 110-0030,
ENGINE AND MOUNTING.
Note: Replace all belts in a set when one is worn.
Single belts of similar size should not be used as a
substitute for a matched belt set. Premature belt wear
can result because of belt length variation.
Every 7 500 Hours
Check the coolant concentration using Terex Pro-Cool
Test Strips (see Special Tools). Add Terex Pro-Cool
Booster if necessary.
DRAINING AND FLUSHING
WARNING
Do not remove the pressure control cap from
the radiator header tank or attempt to drain the
coolant until the engine has cooled. Once the
engine has cooled, use extreme caution when
removing the cap. Always release pressure
from the system by depressing the pressure
relief button on the cap. Remove cap slowly as
the sudden release of pressure from a heated
cooling system can result in a loss of coolant
and possible personal injury (scalding) from
the hot liquid.
1. With the engine cool, drain the coolant from the
PREVENTIVE MAINTENANCE
To ensure the continued efficient functioning of the
cooling system, certain checks and operations should
be performed at regular intervals.
WARNING
removing the cap. Always release pressure
from the system by depressing the pressure
relief button on the cap. Remove cap slowly as
the sudden release of pressure from a heated
the hot liquid.
Every 10 Hours (Daily)
Check coolant level and add if low. Fill the radiator
header tank with coolant until coolant reaches the
bottom of the filler neck and holds at that level.
Note: Any time a significant amount of coolant is
added, the coolant inhibitor MUST be checked. If the
concentration is low, engine damage will result.
Conversely, over-inhibiting antifreeze solutions can
result in silicate dropout. Refer to 'Test Kit Procedures'.
Check cooling fan for cracks, loose rivets and bent or
loose blades. Check fan mounting and tighten if
required. Replace cooling fan if damaged.
Check coolant lines, pipes and components for leaks
and wear.
Every 50 Hours
Check all drive belts for wear and tension. Refer to
Section 110-0030, ENGINE AND MOUNTING for belt
tension specifications.
Every 250 Hours
Inspect the radiator and air-to-air charge cooler fins
and, if necessary, clean with a quality grease solvent
such as mineral spirits and dry with compressed air.
Note: Fuel oil, kerosene or gasoline should not be used
to clean fins.
Section 210-0000
SM 2260 11-03
4
engine and radiator assembly.
2. Refill the cooling system with clean, soft water and a
good radiator cleaning compound. If the engine is
warm, fill slowly to prevent the rapid cooling and
distortion of the metal castings.
3. Start the engine and operate the vehicle for fifteen
minutes to circulate the solution completely.
4. Stop the engine and allow to cool. With the engine
cool, drain the cooling system completely.
5. Refill the cooling system with clean, soft water and
operate it for fifteen minutes.
6. Stop the engine and allow to cool. With the engine
cool, drain the cooling system completely.
7. Refill the cooling system with the proper mix of
coolant and water. Refer to instructions under
'Recommended Coolants'.
8. Entrapped air must be purged after filling the cooling
system. To do this, allow the engine to warm up with
the pressure cap on the remote header tank removed.
With the transmission in neutral, increase engine speed
above 1 000 rev/min and add coolant as required. Vent
the cock on the water return line at the water-jacketed
turbocharger until a steady stream of water (no air) is
seen. Close the cock.
9. Install the pressure cap on the remote header tank
after the coolant level has stabilized at the bottom of
the header tank filler neck.
Note: If the engine overheats and the coolant level is
satisfactory, the cooling system may require cleaning
with a descaling solvent and back-flushing.
Back-flushing Engine Jacket
Whenever the engine water jacket is rust clogged,
pressure back-flushing should be used after the
draining of the cleaning compound. Be certain to
remove both thermostats from thermostat housing
before beginning back-flushing operation.
1. Remove both thermostats from thermostat housing
and clamp flushing gun to front neck of the water
manifold.
2. Temporarily block engine water pump inlet opening
and fill engine jacket with clean, soft water.
3. Unblock water pump inlet opening and blow water
from the engine jacket with air from flushing gun
clamped to neck of water manifold. Use full air
pressure.
4. Repeat operation by alternately filling engine with
clean, soft water and blowing out with air until flushing
water runs out clean.
Back-flushing Radiator
1. Disconnect all coolant lines at the engine.
2. Clamp flushing gun to lower hose on the radiator and
fill the radiator with clean, soft water from the gun.
3. Apply air pressure gradually increasing to a pressure
of 0.7 bar (10 lbf/in). DO NOT EXCEED THIS
PRESSURE.
4. Alternatively fill radiator with clean, soft water and
flush with air until water runs out clear.
RECOMMENDED COOLANTS
WARNING
Hazardous substance. To prevent personal
injury, wear appropriate personal protective
equipment when there is a risk of contact or
inhalation of fumes. Always work in a well
ventilated area.
WARNING
If substance gets into your eyes, immediately
flush eyes gently with water for at least 15
minutes. Seek immediate medical attention.
If substance contacts skin, immediately flush
with water for at least 15 minutes. Remove
contaminated clothing. Wash affected area with
soap and water and seek immediate medical
attention.
If substance is swallowed or inhaled, seek
immediate medical attention.
Heavy duty diesel engines installed in these vehicles
require a heavy duty coolant for optimum performance.
Terex Pro-Cool extended life antifreeze coolant is an
ethylene glycol based formulation specifically designed
to meet Detroit Diesel and other heavy duty diesel
engines requirements.
Terex Pro-Cool extended life antifreeze coolant meets
Section 210-0000
SM 2260 11-03
5
the performance of ASTM D4985 specification for
heavy duty engines.
The following table provides mixing information. Clean
tap water or demineralized water is recommended for
dilution. A 40% to 70% concentration range is
suggested for optimum corrosion protection, however a
Terex Pro-Cool solution is recommended and is used
as a factory fill. Concentrations over 70% are not
recommended because of poor heat transfer capability,
adverse freeze protection and possible silicate dropout.
Concentrations below 30% offer little freeze, boil over
or corrosion protection.
Note: TEREX Pro-Cool obtained from recognised Terex
Distributors is 50/50 pre-mixed. No dilution with water
is required.
Test Kit Procedures
Coolant Test Strips should be used to measure nitrite
and glycol concentrations (See Special Tools).
Cavitation/corrosion protection is indicated on the strip
by the level of nitrite concentration. Freeze/boil over
protection is determined by glycol concentration. Use
the test strips as follows:
a. Collect coolant sample from the radiator draincock,
sample not to be taken from header tank. Coolant must
be between 10 - 60C (50 - 140F) when checking.
b. Remove one strip from packet, DO NOT TOUCH the
pads on the end of the strip. DISCARD STRIP IF
NITRITE TEST PAD HAS TURNED BROWN.
c. Dip strip in coolant sample for one second remove,
and shake strip briskly to remove excess liquid.
d. 45 seconds after dipping strip compare and record
results in the following order :
1. Compare FREEZEPOINT (end pad) to colour chart
on reverse side of the card and record result
2. Next compare MOLYBDATE (middle pad) to colour
chart on reverse side of the card and record result.
3. Finally compare NITRITE test to colour chart on
reverse side of the card and record result.
e. All three readings must be completed no later than
75 SECONDS after dipping strip. It is okay to estimate
a value a between colour blocks, but if uncertain about
the colour match, pick the LOWER numbered block
(e.g if nitrite colour is not F, use column E).
f. Determine where the MOLYBDATE level intersects
the NITRITE level on the chart. For best results follow
test times carefully. Use a stopwatch or clock with a
sweep second hand. Comparing the test strips to the
colour chart too soon or too late may result in incorrect
readings and improper treatment and could result in
liner pitting and engine damage.
Antifreeze
If Terex Pro-Cool is not used, an equivalent ethylene
glycol base antifreeze coolant (low silicate formulation)
that meets or exceeds the standard of either the GM
6038-M formulation (GM 1899-M performance) or
ASTM D 4985 requirements must be used.
WARNING
Do not mix Terex Pro-Cool extended life
antifreeze coolant with other ethylene glycol
based coolants, as the long life characteristics
of Terex Pro-Cool may be diminished.
If another ethylene glycol based coolant is to be used:
1. Drain and flush Terex Pro-Cool from the cooling
system.
2. Install a new precharge coolant filter at cooling
system fill and whenever the coolant is changed.
Replace the precharge filter with a maintenance filter
after 250 hours then every 500 hours thereafter. Refer
to the vehicle Parts Book for coolant filter part
numbers.
3. Fill cooling system with ethylene glycol based
antifreeze coolant.
A 50% antifreeze/water solution is preferred.
Concentrations over 70% are not recommended
because of poor heat transfer capability, adverse
freeze protection and possible silicate dropout.
Terex Pro-Cool Extended Life Antifreeze/Coolant
Freeze/Boil Protection
% Coolant Freezing Point,C/F Boiling Point,C/F
33 -17 / 0 123 / 256
40 -24 / -12 126 / 260
50 -36 / -34 128 / 265
70 -67 / -90 135 / 277
Section 210-0000
SM 2260 11-03
6
Note: Selection of the correct coolant filter element is
vital when precharging the cooling system and at
maintenance intervals. A fully formulated cooling
system must not have SCA's added at initial fill.
The concentration of SCA will gradually deplete during
normal engine operation and should be checked after
every filter change. Additional SCA must be added to
the coolant when it becomes depleted below the level
specified in the table on the following page.
Maintenance dosage of SCA must only be added if
nitrite concentration is less than 800 parts per million
(PPM). If nitrite concentration is greater than 800 PPM,
do not add additional SCA. Refer to 'Test Kit
Procedures'.
Concentrations below 30% offer little freeze, boil over
or corrosion protection. Refer to graph in Fig. 3.
Antifreeze solution should be used year-round to
provide freeze and boil over protection as well as a
stable environment for seals and hoses. In extremely
hot environments, clean, soft, properly inhibited water
may be used if Detroit Diesel Maintenance Product
supplemental corrosion inhibitors are also added in the
right concentration. If water is used, supplemental
coolant additive levels should be increased from 3% to
6% by volume.
Only non-chromate inhibitors should be used with
coolant solutions. Chromate coolant inhibitors are not
compatible with ethylene glycol antifreeze (low silicate
formulation) and if these compounds are combined a
green sludge will be produced. This sludge will deposit
on cooling system passages and reduce heat transfer
from the engine to coolant.
Methyl alcohol-based antifreeze is not recommended
for use because of its effect on the nonmetallic
components of the cooling system and its low boiling
point. Methoxy propanol-based antifreeze is also not
recommended for use because it is not compatible
with fluoroelastomer seals found in the cooling system.
Soluble oil additives are not approved for use in the
cooling system. A small amount of oil adversely
affects heat transfer; 1.25% concentration increases
the fire deck temperature 6% and 2.5% concentration
increases fire deck temperature 15%.
Supplemental Coolant Additives (SCA)
SCA's provide protection for the cooling system
components. The coolant must have the proper
concentration of SCA's. Detroit Diesel Maintenance
products are recommended for use in all Detroit Diesel
Engines.
The proper application of SCA will provide:
a - pH control to prevent corrosion.
b - Water-softening to deter formation of mineral
deposits.
c - Cavitation protection to reduce the effects of
cavitation.
Install a new precharge coolant filter at initial cooling
system fill and whenever the coolant is changed.
Replace the precharge filter with a maintenance filter
after 250 hours then every 500 hours thereafter. Refer
to the vehicle Parts Book for coolant filter part
numbers.
SM - 1209
Fig. 3 - Coolant Freezing and Boiling Temperatures versus
Inhibited Ethylene Glycol (IEG) Concentration (Sea Level)
Section 210-0000
SM 2260 11-03
7
Test Kit Procedures
Coolant Test Strips should be used to measure nitrite
and glycol concentrations (See Special Tools).
Cavitation/corrosion protection is indicated on the strip
by the level of nitrite concentration. Freeze/boil over
protection is determined by glycol concentration. Use
the test strips as follows:
a. Dip the strip into coolant for one second. Remove
and shake briskly to eliminate excess fluid.
b. Immediately compare end pad (% glycol) to the
colour chart.
c. Sixty seconds (one minute) after dipping, compare
the nitrite pad.
For best results make the tests while the coolant is
between 10 - 60 C (50 - 140 F). Wait at least 60,
but not longer than, 75 seconds before reading the
nitrite level. Promptly replace and tighten container cap
after each use. Discard unused strips if they have
turned light pink or tan.
Note: Failure to properly maintain coolant with SCA
can result in damage to the cooling system and its
related components. Conversely, over-concentration of
SCA inhibitor can result in poor heat transfer, leading
to engine damage. Always maintain concentrations at
recommended levels.
SPECIAL TOOLS
numbers of the coolant test strips and general service
tools required. These strips and tools are available
from your dealer.
SCA Concentration Limitations
Table650
MINIMUM
PPM
MAXIMUM
PPM
Boron (B)
Nitrite (NO2)
Nitrates (NO3)
Silicon (Si)
Phosphorous (P)
pH
1 000
800
1 000
50
0
8.5
1 500
2 400
2 000
250
500
10.5
* * * *
COOLING SYSTEM DIAGNOSIS CHART
TABLE651
Engine coolant temperature too
high
Low coolant level Fill cooling system to correct fill level
Check for leaks and repair
Faulty radiator pressure cap Check pressure cap, replace if required
Air in cooling system Purge air from cooling system
Front of radiator obstructed preventing
free flow of air
Remove obstruction and clean radiator
fins
Fan drive belts broken or slipping Adjust or replace fan belts
Thermostats not opening Replace thermostats
Restricted cooling system passages Flush cooling system
Faulty engine water pump Repair or replace water pump
Engine coolant temperature too
low
Thermostats remain open or open at
too low a temperature
Replace thermostats
Leakage around thermostat seals Replace thermostat seals
Extremely cold weather Cover radiator or install radiator shutters
Section 210-0005
SM 2261 11-03
1
COOLING SYSTEM - Brake Cooling System Schematic
DESCRIPTION
Numbers in parentheses refer to Figs. 2 through 5.
The braking system on the machine uses brake cooling
oil to cool the brake packs. This cooling oil is separate
from the hydraulic oil used in the main hydraulic
systems.
A brief description of the individual components used in
the brake cooling system are listed below. Detailed
service and operating instructions can be found in the
relevant component sections of this manual.
Service Brakes
Refer to Section 165-0015, BRAKE ASSY - OCDB.
FLUID (J 1703). Multiple discs within the brake packs
are cooled by brake cooling oil as specified in Section
The brake assembly is bolted to the stub axle and
houses a sandwich of friction discs splined to a hub
rotor. There are four friction discs in each brake
assembly.
the brake assembly and forces the brake piston
against the rotating friction discs which react with
stationary reaction discs. The reaction discs are
retained by scalloped tangs at the outside diameter,
which in turn transfers the reaction torque to the rigid
outside housing, slowing or stopping wheel rotation.
When the treadle valve or park/emergency brake is
released, hydraulic pressure against piston is relieved
and cup springs force the piston to return to its original
position, thus, relieving the pressure against the brake
disc pack.
Triple Pump (1)
Refer to Section 250-0040, TRIPLE PUMP.
The triple pump is mounted off the transmission power
takeoff. It is a triple gear type pump, which supplies
various circuits:
a) front section (closest to driveshaft) supplies brake
actuation circuit and engine cooling circuit.
b) middle section combines with front section to
supply engine cooling circuit.
c) rear section supplies the brake cooling circuit.
The triple pump is assembled for left hand (anticlockwise)
rotation, as viewed from the driveshaft end.
Note: Never drive a pump in the wrong direction of
rotation, as pump seizure may result.
Brake Coolant Tank (2)
Refer to Section 250-0025, BRAKE COOLANT TANK.
The brake coolant tank is the reservoir for the brake
cooling oil. It is mounted off the left hand frame rail in
front of the fender and is secured in three places.
Integral with brake coolant tank assembly are oil level
sight gauge, strainer and access covers. Located on
top of the tank is filler cap, breather and walkway plate.
Heatshields are fitted to front and side of tank.
Low Temperature Unloader Valve (3)
Refer to Section 210-0045, LOW TEMPERATURE
UNLOADER VALVE.
The low temperature unloader valve is located on the
hydraulic cradle, below the hydraulic diverter tube.
The low temperature unloader valve receives hydraulic
supply from the engine cooling section (mid section) of
the triple gear pump (1). An integral two way solenoid
cartridge controls flow to the hydraulically driven engine
cooling fan. The pressure relief valve controls circuit
pressure to a preset 205 bar (2970 lbf/in).
Pressure Relief Valve (4)
Refer to Section 250-0120, PRESSURE RELIEF
VALVE.
Mounted on the disc brake oil cooler casing on the right
hand fender, the pressure relief valve limits the
maximum pressure in the brake cooling circuit. The
pressure relief valve is installed between the triple gear
pump (1) and the control valve (5).
Section 210-0005
Cooling System - Brake Cooling System Schematic
SM 2261 11-03
2
Brake Cooling Oil Pressure Switch (9)
A pressure switch is mounted off the front axle brake
manifold block. The normally open pressure switch
closes when brake cooling oil reaches 1.5 bar (22 lbf/
in) and illuminates warning light in cab. Refer to
Section 190-0270, SWITCHES AND SENSORS.
Brake Oil Cooler Temperature Switch (10)
The normally closed switch opens when brake cooling
oil temperature reaches 60 C (140
o
F). The switch
sends a signal to the control valve (5) to direct oil flow
through the disc brake oil cooler (6) fan motor, causing
fan to rotate. Refer to Section 190-0270, SWITCHES
AND SENSORS.
Brake Cooling Oil Relief valve (11)
An internal pressure relief valve is contained within the
manifold blocks mounted on each axle. This valve is
set at 1 bar (14.5 Ibf/ in) to maintain the brake cooling
oil at this pressure.
Brake Cooling Oil Temperature Switch/
Sender (12)
The normally closed switch opens when oil temperature
reaches 50 C (122
o
F) and sends a signal to de-
energise the solenoid on the motor/triple pump
assembly (7), causing an increase in motor speed.
Refer to Section 190-0270, SWITCHES AND
SENSORS.
The switch also acts as a sender unit by sending a
signal to indicate brake cooling oil temperature on the
gauge in the cab.
CHECKING SYSTEM PRESSURE
WARNINGS
1. Ensure that hydraulic oil has reached operating
temperature, position the vehicle in a level work area
and apply the parking brake. Block all road wheels.
2. Connect a hydraulic gauge, capable of recording a
pressure of 0 - 345 bar (0 - 5 000 lbf/in), to diagnostic
check point at brake cooling section of triple pump.
Control Valve (5)
Refer to Section 250-0065, CONTROL VALVE.
Mounted on the disc brake oil cooler casing on the right
hand fender, the control valve controls the fan speed of
the disc brake oil cooler. The control valve is supplied
by the rear section of the triple gear pump (1), via
pressure relief valve (4).
Disc Brake Oil Cooler (6)
Refer to Section 210-0050, DISC BRAKE OIL
COOLER.
The disc brake oil cooler is mounted on the right hand
fender adjacent to the main hydraulic tank. The fan
within the brake oil cooler is driven by a hydraulic
motor. The fan only turns when hydraulic motor is
supplied with oil from the control valve (5).
Brake cooling oil enters the top of the cooler and flows
through the cooler before exiting at the bottom. There
are three inlet ports and three outlet ports, one for each
axle.
Motor/Triple Pump Assembly (7)
Refer to Section 250-0045, MOTOR/TRIPLE PUMP
ASSEMBLY.
Mounted on the left hand frame rail, adjacent to the
brake coolant tank, the motor/triple pump assembly
consists of three pump elements coupled to a single
direction hydraulic motor. A solenoid controls motor by
restricting flow through the motor until the brake cooling
oil reaches 50
o
C (122
o
F).
The motor is supplied with hydraulic oil from the rear
section of the triple gear pump (1), via the disc brake
oil cooler (6). The motor and pump elements are
connected by a common shaft, therefore motor rotation
causes pump elements to draw brake cooling oil from
brake coolant tank (2). Brake cooling oil is then
pumped to brake packs.
Brake Cooling Oil Filter (8)
The filter, mounted in the brake cooling line between
the motor/triple pump assembly and the front manifold
block, ensures that the brake cooling oil is filtered. The
filter is fitted with a visual indicator to show when the
filter is in bypass mode.
Section 210-0005
SM 2261 11-03
3
3. Increase the engine speed to 2 200 rpm and note the
reading on the gauge. Pressure should be 110 bar
(1600 lbf/in).
4. If pressure is low, triple pump should be checked.
5. Shut off the engine and remove the pressure gauge
from triple pump. Remove wheel blocks.
'O' RING FACE SEALS (ORFS)
Where hydraulic lines are fitted with ORFS
connections, the following procedure should be carried
out during installation. Refer to Fig. 1.
a. Ensure 'O' ring/seal is in place and that joining
surfaces are clean. If necessary, retain 'O' ring/seal in
place with a light coating of grease or vaseline.
b. Initially, the nuts should be tightened by hand.
c. Where a hose is fitted, ensure that it is not twisted
or kinked when the nuts are tightened so that it is
allowed to adopt a natural position.
d. Where a tube is fitted, ensure that the connection is
aligned correctly.
Cooling System - Brake Cooling System Schematic
SM - 1335
Fig. 1 - Assembly of Typical ORFS Connector
'O' RING 'O' RING
SLEEVE
TUBE
FITTING
NUT
e. Tighten the nut a further 1/4 to 1/2 a turn using the
correct size of spanner (wrench).
f. Check that a satisfactory hose or tube routing has
been achieved.
BRAKE COOLING OIL
The brake cooling system should be kept filled with
brake cooling oil as specified in Section 300-0020,
LUBRICATION SYSTEM.
Whenever there is a system failure, the brake cooling
oil should be drained, the entire system flushed, oil
filter replaced, oil strainer thoroughly cleaned and clean
brake cooling oil added to eliminate all metal particles
or foreign matter.
SERVICE TOOLS
It is recommended that the following tools are used
when carrying out pressure or temperature checks
during maintenance procedures. These tools, along
with other general service tools, are available from
your dealer. Refer to Section 300-0070, SERVICE
TOOLS, for part numbers of these tools.
Multi-gauge
The multi-gauge is basically four pressure gauges in
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/in
2
).
Non-contact Infrared Thermometer
The infrared thermometer can be used to spot heat
problems early in electrical, mechanical and hydraulic
systems. Hand held and easy to use, you simply aim,
pull the trigger, and read the temperature. Since there
is no need to touch what you are measuring,
temperatures of hard-to-reach or moving components
can be taken without getting burned or shocked.
S
e
c
t
i
o
n

2
1
0
-
0
0
0
5
C
o
o
l
i
n
g

S
y
s
t
e
m

-

B
r
a
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e

C
o
o
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s
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c
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m
a
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S
M

2
2
6
1

1
1
-
0
3
4
Fig. 2 - Brake Cooling System Schematic - Engine Running,Brakes Charging,
Low Temperature Unloader Valve Energised
S
M
-
3
1
0
4
A
COMPONENTS
1 - Triple Pump
2 - Brake Coolant Tank
3 - Low Temperature Unloader Valve
4 - Pressure Relief Valve
5 - Control Valve
6 - Disc Brake Oil Cooler
7 - Motor/Triple Pump Assembly
8 - Brake Cooling Oil Filter
9 - Pressure Switch
10 - Temperature Switch
11- Pressure Relief valve
12 - Temperature Switch/Sender
PRESSURE TEST POINTS
A - Brake Cooling System Pressure
COLOUR CODES
Red - Pressurized Oil
Blue - Exhaust or Return Oil
Green - Intake Oil
Orange - Pilot Pressure
Yellow - Static Oil
Intermittent Red/Blue - Brake Cooling Oil
2
REAR AXLE
BRAKE PACKS
CENTRE AXLE
BRAKE PACKS
FRONT AXLE
BRAKE PACKS
HYDRAULIC TANK
1
TO BRAKE
MANIFOLD VALVE
ENGINE
COOLING
FAN
2
3
4
5
6
7
8
PRIORITY
UNLOADER VALVE
A
9
10
12
2 2
11 11 11
S
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o
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2
1
0
-
0
0
0
5
S
M

2
2
6
1

1
1
-
0
3
5
S
M
-
3
1
0
4
B
C
o
o
l
i
n
g

S
y
s
t
e
m

-

B
r
a
k
e

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m

S
c
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a
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i
c
Fig. 3 - Brake Cooling System Schematic - Engine Running,Brakes Charged,
Low Temperature Unloader Valve De-Energised
COMPONENTS
1 - Triple Pump
5 - Control Valve
9 - Pressure Switch
11 - Pressure Relief valve
COLOUR CODES
Green - Intake Oil
Yellow - Static Oil
2
REAR AXLE
BRAKE PACKS
CENTRE AXLE
BRAKE PACKS
FRONT AXLE
BRAKE PACKS
HYDRAULIC TANK
1
TO BRAKE
MANIFOLD VALVE
ENGINE
COOLING
FAN
2
3
4
5
6
7
8
PRIORITY
UNLOADER VALVE
A
9
10
12
2 2
11
11 11
S
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2
1
0
-
0
0
0
5
C
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a
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a
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2
2
6
1

1
1
-
0
3
6
S
M

-

3
1
0
4
C
Fig. 4 - Brake Cooling System Schematic - Engine Running,Control Valve
De-Energised
COMPONENTS
1 - Triple Pump
5 - Control Valve
9 - Pressure Switch
COLOUR CODES
Green - Intake Oil
Yellow - Static Oil
2
REAR AXLE
BRAKE PACKS
CENTRE AXLE
BRAKE PACKS
FRONT AXLE
BRAKE PACKS
HYDRAULIC TANK
1
TO BRAKE
MANIFOLD VALVE
ENGINE
COOLING
FAN
2
3
4
5
6
7
8
PRIORITY
UNLOADER VALVE
A
9
10
12
2 2
11 11 11
S
e
c
t
i
o
n

2
1
0
-
0
0
0
5
S
M

2
2
6
1

1
1
-
0
3
7
*

*

*

*
S
M

-

3
1
0
4
D
Fig. 5 - Brake Cooling System Schematic - Engine Running, Motor/Triple
Pump Solenoid De-Energised
COMPONENTS
1 - Triple Pump
5 - Control Valve
9 - Pressure Switch
COLOUR CODES
Green - Intake Oil
Yellow - Static Oil
C
o
o
l
i
n
g

S
y
s
t
e
m

-

B
r
a
k
e

C
o
o
l
i
n
g

S
y
s
t
e
m

S
c
h
e
m
a
t
i
c
2
REAR AXLE
BRAKE PACKS
CENTRE AXLE
BRAKE PACKS
FRONT AXLE
BRAKE PACKS
HYDRAULIC TANK
1
TO BRAKE
MANIFOLD VALVE
ENGINE
COOLING
FAN
2
3
4
5
6
7
8
PRIORITY
UNLOADER VALVE
A
9
10
12
2 2
11
11 11
Section 210-0010
1 SM 2116 1-02
COOLING SYSTEM - Cooling Fan and Motor
SM - 2662
1 - Radiator
2 - Fan
3 - Fan Motor
4 - Fan Hub Adaptor
Fig. 1 - Exploded View Of Hydraulic Fan Drive
Note: The rate of fan speed change and maximum
fan speed is preset to the cooling needs of the engine.
The hydraulic fan drive system uses an electrical
signal from the engine electronic control module
(ECM) to provide the appropriate fan speed
necessary to satisfy any cooling demand. The fan (2)
is driven by a single vane type hydraulic motor (3),
which is supplied by a dedicated engine cooling
section of the triple gear pump. The fan motor (3) can
also be supplied by the brake section of the triple gear
pump when accumulators are charged. Refer to
Section 250-0040, TRIPLE PUMP, and Section 250-
0000, BRAKING SYSTEM SCHEMATIC.
After the accumulators are charged, oil from the brake
section of the triple pump will be forced to the fan
motor (3), causing the fan (2) to rotate. At pre-
determined conditions, an electrical signal closes the
low temperature unloader valve. The oil from the
engine cooling section of the triple pump is then
directed to the fan motor (3), increasing oil flow
through fan motor (3). Hence fan speed is increased
until the fan (2) is fully engaged. Refer to Section 210-
0045, LOW TEMPERATURE UNLOADER VALVE.
When electrical signal reopens the low temperature
unloader valve, oil from engine cooling section of
1
9
10
11
7
8
5
4
2
3
6
9 - Split Pin
10 - Slotted Nut
11 - Washer
5 - Motor Carrier Frame
6 - Fan Guard
7 - Bolt
8 - Lockwasher
Section 210-0010
SM 2116 1-02 2
triple pump is returned to tank, reducing oil flow
through fan motor (3) therefore decreasing fan speed.
The hydraulic fan drive system has a failsafe feature,
ie. if the electrical signal to the low temperature
unloader valve fails, the valve will close causing
maximum oil flow through fan motor (3), driving fan (2)
at maximum speed.
REMOVAL
WARNING
damage, make sure blocking or lifting
equipment is properly secured and of
1. Position the machine on a level floor. Switch off the
engine and operate the steering several times to
discharge the steering system.
3. Remove mounting hardware securing hood
assembly to the machine and, using suitable lifting
equipment, remove hood assembly as described in
Section 100-0040, HOOD.
4. Remove radiator assembly from machine as
described in Section 210-0040, RADIATOR AND
MOUNTING.
5. Support radiator assembly with suitable lifting
equipment. Remove fan guard (6) and motor carrier
frame (5) from radiator assembly.
6. Remove two bolts, nuts and washers securing fan
(2) and motor (3) assembly to the motor carrier frame
(5). Remove fan (2) and motor (3) assembly from
motor carrier frame (5).
7. Remove six bolts (7) and lockwashers (8) securing
fan (2) to fan hub adaptor (4) on motor (3). Remove
fan (2) from fan hub adaptor (4).
8. Remove split pin (9), slotted nut (10) and washer
(11) from motor (3) shaft. Remove fan hub adaptor (4)
from motor (3).
MOTOR OVERHAUL
Internal parts of the motor are lubricated by the
operating fluid itself; therefore, preventive
maintenance is limited to keeping the fluid in the
system clean. Dirt should not be allowed to
accumulate on the motor or around the shaft seal.
Check frequently that all fittings and bolts are tight.
DISASSEMBLY
1. Drain all fluid from the motor, and clean the
external surface. Prepare a clean, lint free surface on
which to place the internal parts for inspection and
repair.
2. Remove the four housing screws (20) and carefully
remove the end cap (1).
3. By using two 10-24 UNC-2B screws, remove the
cartridge assembly (2-6) from the housing (9), giving it
small oscillations around its axis. Be careful the
cartridge assembly (2-6) does not explode: the rotor
(2) and the cam ring (6) must be removed from the
housing (9) at the same time.
4. With the same screws, remove the pressure plate
(7).
Note: The cartridge assembly (2-6) and the pressure
plate (7) may come out together if they are stuck by
oil.
ASSEMBLY
specified, to standard torques listed in
WARNING
1. Use clean hydraulic fluid to lubricate all the internal
parts, including seals.
2. Install seal (16) on the pressure plate (7) spigot.
Install seal (8) in the housing (9).
3. By using two 10-24 UNC-2B screws, install the
pressure plate (7) inside the housing (9) and make
sure it is completely inserted and seated on its two
seals.
Section 210-0010
3 SM 2116 1-02
4. Install the two dowel pins (17) and two 10-24 UNC-
2B screws on the cam ring (6). By using the screws,
insert the cartridge assembly (2 - 6) into the housing
(9), dowel pins (17) facing the corresponding hole on
the pressure plate (7).
5. Be sure the cartridge assembly (2 - 6) is well
seated on the pressure plate (7) by pushing with
fingers on the vanes (5) and the cam ring (6) - they
should not be lower than the cam ring surface.
6. Install seal (18) on the end cap (1) spigot. Insert the
end cap (1) in the housing (9), the locating hole facing
the dowel pin (17) on the cam ring (6). As the cap (1)
is well inserted, less than 1 mm (0.04 in) between cap
(1) and housing (9), rotate the end cap (1) to the
specified porting combination.
7. Insert the four screws (20) and tighten to 100 Nm
(74 lbf ft).
8. Check that it is possible to rotate the shaft (12), and
fill the motor with oil before connecting the pipes.
INSTALLATION
WARNING
1. Install fan hub adaptor (4) to motor (3) and secure
using split pin (9), slotted nut (10) and washer (11).
2. Attach fan (2) to fan hub adaptor (4) using six bolts
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20
SM - 2661
Fig. 2 - Sectional View Of Hydraulic Motor
1 - End Cap
2 - Rotor
3 - Spring
4 - Pin
5 - Vane
6 - Cam Ring
7 - Pressure Plate
8 - Seal
9 - Housing
10 - Bearing
11 - Key
12 - Shaft
13 - Retaining Ring
14 - Retaining Ring
15 - Seal
16 - Seal
17 - Dowel Pin
18 - Seal
19 - Bearing
20 - Screw
Section 210-0010
SM 2116 1-02 4
(7) and lockwashers (8). Torque tighten bolts (7) to
54 - 61 Nm (40 - 45 lbf ft).
3. Install fan (2) and motor (3) assembly to motor
carrier frame (5) and secure using bolts, nuts and
washers.
4. Using suitable lifting equipment, position motor
carrier assembly on the radiator assembly and
secure using bolts, nuts and washers.
Note: Ensure there is even clearance, all the way
round, between fan (2) and the fan shroud.
5. Install fan guard (6) to the radiator assembly and
secure with mounting hardware, as removed at
'Removal'.
6. Using suitable lifting equipment, install radiator
assembly to the machine as described in Section
210-0040, RADIATOR AND MOUNTING.
7. Position the hood assembly on the machine using
a suitable lifting device. Secure hood assembly on
the machine with mounting hardware, as described in
Section 100-0040, HOOD.
8. Start the engine and check for correct operation of
the fan (2). Refer to 'Testing' procedure contained in
this section.
TESTING
Failsafe Check
Note: This test is carried out with the machine static
and secured at rest. Hood should be raised and
secured.
1. Start the engine and increase engine speed to
2 200 rev/min.
2. Maintain engine speed at 2 200 rev/min and
disconnect harness from the low temperature
unloader valve. Fan should automatically engage to
full flow speed.
MAINTENANCE
Motor Cartridge Replacement
1. Disassemble the motor without removing the
pressure plate (7).
2. Replace the cartridge assembly (2-6).
3. Reassemble the motor.
Note: To change the cam ring (6) only, or to
reassemble an exploded cartridge assembly (2-6), it
is necessary to compress the springs (3) under the
vanes (5).
Motor End Cap Replacement
1. Disassemble the motor without removing the plate
(7) or cartridge assembly (2-6).
2. Lubricate the needle bearing (19) of the new end
cap (1).
3. Reassemble the motor.
Motor Shaft Replacement
1. Disassemble the motor.
2. Place the housing on a clean surface, shaft up.
Remove the retaining ring (13) and extract the shaft
(12) from the housing (9), by pulling it straight out to
avoid damaging shaft seal (15).
3. Inspect the seal (15). If lips are damaged, replace
seal (15).
4. Grease the seal (15) and the shaft (12) seal area.
5. Insert the shaft (12) into the housing (9), and install
the retaining ring (13).
Motor Shaft Seal Replacement
1. Disassemble the motor.
2. Remove the shaft (12).
3. Place the housing (9) under a press, spigot up.
Using a seal driver, extract the shaft seal (15) from
the housing (9).
4. Grease the new seal (15) and install it on the seal
driver.
5. Install the housing (9) under the press, large
opening upward, and insert the shaft seal (15).
6. Reinstall the shaft (12), and reassemble the motor.
Section 210-0010
5 SM 2116 1-02
* * * *
TORQUE
1 7 Bolt 54 - 61 40 - 45
2 20 Screw 100 74
Every 10 Hours/Daily
Check the fan and motor for debris or damage. Clean
or replace as required.
Note: The fan is a non-serviceable component.
However, the following instructions must be strictly
adhered to:
1. DO NOT clean around fan drive with steam or high
pressure jet.
2. DO NOT add any fluids or lubricants to the drive.
3. DO NOT restrict fan rotation during engine
operation for ANY reason.
4. DO NOT operate a machine with a damaged fan
assembly. Replace a damaged fan as soon as the
fault is noted.
5. DO NOT disassemble ANY fan assembly or
associated parts that are still within the warranty
coverage period.
6. IMMEDIATELY investigate and correct ANY
operator complaint involving drive or cooling system
performance.
SPECIAL TOOLS
SERVICE TOOLS, for part numbers of general
service tools required. These tools are available from
your dealer.
Section 210-0040
SM 2118 Rev 1 11-04 1
Cooling System - Radiator and Mounting
5
4
3
1
2
23
51
23
23
23
24
24
24
23
23
24
25
26
21
20
19
22
18
17
51
16
29
30
41
42
40
27
28
31
32
33
31
34
35
36
43
42
37
38
38
39
23
23
44
45
15
14
13
6
8
9
7
46
47
50
50
47
48
48
47
46
49
27 - Elbow
28 - Deaeration Line
29 - Elbow
31 - Elbow
33 - Connector
34 - Connector
35 - Filler Cap
36 - Header Tank
37 - Nut
38 - Washer
39 - Bolt
40 - Firemaster Hose
41 - Make-up Line
42 - Clamp
43 - Overflow Line
44 - Connector
45 - Bushing
46 - Nut
47 - Locwasher
48 - washer
49 - Rubber Mount
50 - Nut
51 - Brace Rod
1 - Top Baffle
2 - LH Baffle
3 - RH Baffle
4 - Bottom Baffle
5 - Support Bracket
6 - Rubber Mounting
7 - Bolt
8 - Snubbing Washer
9 - Locknut
10 - Bolt
11 - Washer
12 - Locknut
13 - Bolt
14 - Washer
15 - Locknut
16 - Bushing
17 - Connector
18 - Elbow
19 - Connector
20 - Shut-Off Valve
21 - Plug
22 - Drain Hose
23 - Clamp
24 - Hose
25 - Coolant Inlet Pipe
26 - Coolant Outlet Pipe
Fig. 1 - Exploded View of Radiator Mounting and Hoses
DESCRIPTION
Radiator assembly is mounted in front of the engine
cooling fan at the front end of the vehicle. It is fed from
header tank (36) located in front of the operators
compartment and mounted to the goalpost
arrangement.
Mounted to the front of radiator assembly are an air-to-
air charge cooler assembly, fuel cooler assembly and a
hydraulic oil cooler assembly. Refer to Section 210-
0000, COOLING SYSTEM.
Fan plate assembly (7, Fig. 2) improves the engine
cooling fan efficiency, provides a more uniform distribution
of air over radiator core (1, Fig. 2) and helps restrict
recirculation of air within the engine compartment.
Recirculation baffle plates (1, 2, 3 & 4) around radiator
assembly prevent hot air from the engine cooling fan
being reintroduced into the cooling air circuit.
REMOVAL
Numbers in parentheses refer to Fig. 1 & 4, unless
SM - 3334
Section 210-0040
SM 2118 Rev 1 11-04 2
5
18
2
4
7
15
16
17
14
13
8
9
11
12
21
20
19
1
6
2
3
10
SM - 3335
12 - Fan Drive Motor
13 - Washer
14 - Slotted Nut
15 - Split Pin
16 - Bolt
1 - Radiator Core
2 - Joint
3 - LH Tank
4 - RH Tank
5 - Top Column
6 - Bottom Column
7 - Fan Plate Assy
8 - Fan
9 - Motor Carrier Frame
10 - Fan Guard Assy
11 - Fan Hub Adaptor
Fig. 2 - Exploded View of Radiator Assembly
WARNING
removing the cap. Remove cap slowly as the
sudden release of pressure from a heated
the hot liquid.
WARNING
safely.
parking brake and switch off the engine. Turn steering
wheel several times to relieve any pressure in the
steering circuit.
3. Remove hood assembly from the vehicle. Refer to
Section 100-0040, HOOD AND MOUNTING.
4. Remove filler cap (35) carefully from header tank
(36).
5. Remove plug (21) and open shut-off valve (20) at the
bottom of radiator assembly and drain coolant into a
suitable container. Close shut-off valve (20) when
coolant is completely drained and refit plug (21).
17 - Lockwasher
18 - Charge Cooler Assy
19 - Bolt
20 - Lockwasher
21 - Washer
Section 210-0040
SM 2118 Rev 1 11-04 3
RADIATOR
CHASSIS FRAME
50
50
47
47
51
46
47
48
49
48
47
46
SM - 1216
6. Remove locknuts (46), lockwashers (47), washers (48)
and rubber mountings (49) securing brace rods (51) to
assembly.
7. Remove locknuts (50) and lockwashers (47) securing
brace rods to the radiator assembly. Remove brace rods
(51).
8. Ensure fuel lines connected to fuel cooler mounted
at front of radiator assembly are identified for ease of
installation and with suitable containers available to
catch leakage, disconnect fuel lines. Fit blanking caps
to open lines and ports.
9. Ensure hydraulic lines connected to hydraulic oil
cooler mounted at front of radiator assembly are
identified for ease of installation and with suitable
hydraulic lines. Fit blanking caps to open lines and
ports.
10. Ensure hydraulic lines connected to fan drive motor
(12, Fig. 2) mounted at rear of radiator assembly are
identified for ease of installation and with suitable
hydraulic lines. Fit blanking caps to open lines and
ports.
11. Disconnect deaeration line (30) from elbow (29) in
radiator assembly and deaeration line (28) from elbow
(27) in coolant inlet pipe (25). Identify lines for ease of
installation and cap open lines and elbows.
12. Disconnect all clips and clamps securing fuel
cooler lines, hydraulic lines and deaeration lines
attached to radiator assembly and coolant inlet pipe
(25). Move all lines away from radiator assembly to
prevent fouling on removal of radiator assembly.
13. Slacken clamps (23) and remove coolant inlet pipe
(25), hoses (24) and clamps (23) from radiator
assembly and engine thermostat housing.
14. Slacken clamps (23) and remove coolant outlet
pipe (26), hoses (24) and clamps (23) from bottom of
radiator assembly and engine water pump inlet.
15. Slacken clamps (5, Fig. 3) securing cooler hoses
(6, Fig. 3) to air inlet pipe (4, Fig. 3) and remove air
inlet pipe from charge cooler assembly (2, Fig. 3) and
16. Slacken clamps (5, Fig. 3) securing hose (6, Fig. 3)
and elbow (7, Fig. 3) to air outlet pipe (3, Fig. 3) and
remove air outlet pipe from charge cooler assembly (2,
Fig. 3) and engine inlet manifold.
17. Install two eye bolts in lifting bosses on top of
radiator assembly. Using suitable lifting equipment
support radiator assembly.
18. Remove bolts (7), snubbing washers (8) and
locknuts (9) securing radiator assembly to mounting
brackets at the front of the frame.
19. Remove radiator assembly from the vehicle to a
clean area for disassembly. Support radiator standing
upright to allow access to front and rear of radiator.
Fig. 3 - Air-To-Air Charge Cooler Piping
2 - Charge Cooler Assembly
3 - Air Outlet Pipe
4 - Air Inlet Pipe
5 - Clamp
6 - Hose
7 - Elbow
Fig. 4 - Radiator Support Detail
Section 210-0040
SM 2118 Rev 1 11-04 4
6. Remove bolts and washers securing top baffle (1,
Fig. 1) to radiator assembly. Remove top baffle (1, Fig.
1) from radiator assembly.
7. Remove bolts and washers securing LH baffle (2,
Fig. 1) and RH baffle (3, Fig. 1) to radiator assembly.
Remove baffles (2 & 3, Fig. 1) from radiator assembly.
Note: Take care not to damage radiator core, charge
cooler (18) core, fuel cooler core and hydraulic oil cooler
core during disassembly.
8. Remove mounting hardware securing fuel cooler and
hydraulic oil cooler to radiator assembly. Note which
radiator bolts are used for mounting coolers to aid in
assembly. Remove coolers from radiator assembly.
9. Remove bolts, washers and spacers securing
charge cooler (18) to mounting brackets. Remove
charge cooler (18) from radiator assembly.
10. Identify mounting brackets for ease of assembling
and remove bolts, washers and mounting brackets
from side tanks (3 & 4).
11. Remove bolts, washers, lockwashers and nuts
securing top column (5) to LH tank (3) and RH tank (4).
Remove top column (5).
12. Remove bolts, washers, lockwashers and nuts
securing bottom column (6) to LH tank (3) and RH tank
(4). Remove bottom column (6).
13. Remove bolts, washers and nuts securing LH tank
(3) to radiator core (1). If required, remove drain hose
and fittings (16 - 22, Fig. 1) and elbow (29, Fig. 1) from
LH tank (3). Remove LH tank (3) assembly and discard
joint (2).
14. Remove bolts, washers and nuts securing RH tank
(4) to radiator core (1). Remove RH tank (4) assembly
and discard joint (2).
15. If damaged, remove rubber mountings (6, Fig. 1)
from mounting brackets on side tanks (3 & 4) and
discard.
INSPECTION
1. Steam clean all parts thoroughly with a suitable
solvent.
2. Examine radiator core (1), charge cooler (18) core,
fuel cooler core and hydraulic oil cooler core carefully
20. If required, remove bolts (13), washers (14) and
locknuts (15) securing bottom baffle (4) on the vehicle.
Note: If Header Tank (36) requires to be removed,
follow steps 21 through 26.
21. With suitable container in position, remove lower
drain plug from header tank (36) to ensure coolant has
been drained from header tank (36). When all coolant
has been drained, apply Loctite 225 to drain plug and
reinstall in header tank (36).
22. Disconnect overflow line (43) from header tank (36).
23. Ensure deaeration lines (28, 30 & 32) connected to
header tank (36) are identified for ease of installation
and disconnect deaeration lines. Fit blanking caps to
open lines and fittings.
24. Slacken clamp (42) and disconnect make-up line
(41) from header tank (36). Blank off open line end.
25. Following removal instructions in Section
100-0040, HOOD AND MOUNTING, remove goalpost
and header tank (36) as an assembly from the vehicle.
26. Remove bolts (39), nuts (37) and washers (38)
securing header tank (36) to goalpost. Remove header
tank (36) from goalpost.
DISASSEMBLY
1. Remove bolts and washers securing fan guard (10)
to radiator assembly. Remove fan guard (10) from
radiator assembly.
2. Remove bolts (19) and washers (20,21) securing
motor carrier frame (9) to radiator assembly. Remove
motor carrier frame (9) from radiator assembly.
3. Following removal instructions in Section
210-0010, COOLING FAN AND MOTOR, remove fan
drive motor (12) from motor carrier frame (9).
4. Remove bolts and washers securing fan plate
assembly (7) to radiator assembly. Remove fan plate
assembly (7) from radiator assembly.
5. Lay radiator assembly down flat on wooden blocks
with baffle plates (1, 2 & 3, Fig. 1) facing up.
Section 210-0040
SM 2118 Rev 1 11-04 5
11. Install top baffle (1, Fig. 1) to top front of the
radiator assembly and secure with bolts and washers.
12. Position side baffles (2 & 3, Fig. 1) to radiator
assembly and secure with bolts and washers.
13. Fit drain hose and fittings (17 - 22, Fig. 1) to
bushing (16, Fig. 1) in LH tank (3).
14. Position fan plate assembly (7) to radiator
assembly and secure to supports and columns (5 & 6)
using bolts and washers.
15. Fit fan drive motor (12) to motor carrier frame (9).
Refer to Section 210-0010, COOLING FAN AND
MOTOR.
16. Install motor carrier frame (9) to radiator assembly
and secure with bolts (19), lockwashers (20) and
washers (21).
Note: Ensure clearance around cooling fan tips to plate
assembly is of equal dimension all round.
17. Position fan guard (10) to radiator assembly and
secure using bolts and washers.
INSTALLATION
Numbers in parentheses refer to Fig. 1 & 4, unless
SPECIFICATIONS.
WARNING
safely.
1. If removed, secure bottom baffle (4) to the vehicle
with bolts (13), washers (14) and locknuts (15).
2. Using suitable lifting equipment, position radiator
assembly to mounting brackets on the frame and
secure with bolts (7), snubbing washers (8) and locknuts
(9). Tighten bolts (7) to a torque of 165 Nm (122 lbf ft).
3. Install air inlet pipe (4, Fig. 3) between engine
turbocharger and charge cooler assembly (2, Fig. 3)
and secure with hoses (6, Fig. 3) and clamps (5, Fig. 3).
4. Install air outlet pipe (3, Fig. 3) between engine inlet
manifold and charge cooler assembly (2, Fig. 3) and
for possible damage. Repair any damage discovered if
equipped to do so, or, have repairs made at a reputable
radiator repair shop.
3. Clean radiator LH tank (3) and RH tank (4) of all
traces of corrosion, scale and old joint material.
ASSEMBLY
TORQUE SPECIFICATION.
1. If removed, apply Loctite 225 to threads of bushing
(16, Fig. 1) and install in LH tank (3).
2. Fit new joint (2) on radiator LH tank (3) and secure
LH tank (3) to radiator core (1) and supports with bolts,
washers and nuts.
3. Fit new joint (2) on radiator RH tank (4) and secure
RH tank (4) to radiator core (1) and supports with bolts,
washers and nuts.
Note: Tighten LH tank (3) and RH tank (4) to radiator
core (1) from the centre out to ensure an evenly spread
load.
4. If removed, apply Loctite 225 to threads of elbow
(29, Fig. 1) and install in LH tank (3) noting orientation
of elbow as identified at disassembly.
5. If removed, install new rubber mountings (6, Fig. 1)
in mounting brackets on side tanks (3 & 4).
6. Position top column (5) to radiator assembly and
secure to side tanks (3 & 4) with bolts, washers,
lockwashers and nuts.
7. Position bottom column (6) to radiator assembly and
secure to side tanks (3 & 4) with bolts, washers,
lockwashers and nuts.
8. Secure mounting brackets to side tanks (3 & 4), as
identified at disassembly, with bolts and washers.
9. Position charge cooler (18) to mounting brackets and
secure with bolts, washers and spacers.
10. Install fuel cooler and hydraulic oil cooler to radiator
assembly picking up mounting locations and hardware
as identified at disassembly.
Section 210-0040
SM 2118 Rev 1 11-04 6
secure with hoses (6, Fig. 3), elbow (7, Fig. 3) and
clamps (5, Fig. 3).
5. Install coolant outlet pipe (26) between engine water
pump inlet and bottom port on radiator assembly and
secure with hoses (24) and clamps (23).
6. Install coolant inlet pipe (25) between engine
thermostat housing and top port on radiator assembly
and secure with hoses (24) and clamps (23).
7. If removed, apply Loctite 225 to threads of elbow
(27) and install in coolant inlet pipe.
8. Remove blanking caps from deaeration lines
(28 & 30) and connect deaeration line (28) to elbow (27)
in coolant inlet pipe (25) and deaeration line (30) to
elbow (29) in top of radiator assembly. Do not clip lines
at this point.
9. Remove blanking caps from fuel cooler lines and
fittings, hydraulic oil cooler lines and fittings, and fan
drive motor (12, Fig. 2) lines and fittings. Connect all
fuel lines to fuel cooler, hydraulic lines to hydraulic oil
cooler and hydraulic lines to fan drive motor (12, Fig. 2)
as identified at removal.
10. Secure all lines with clips and clamps as removed
during removal. Ensure no lines are chaffing on sharp
edges or resting against areas where heat will be
evident.
11. Fit 1-off nuts (50) and lockwashers (47) to each
rod (51) and run up full length of thread. Locate rod end
through holes on radiator support arms. Take remaining
nuts (50) and lockwashers (47) and thread onto rod
(51), securing brace rods to radiator brackets.
12. Fit 1-off nuts (46), lockwashers (47),washers (48) and
rubber mounts (49) to both rods (51), run up full length of
the thread. Locate rod ends trhough frame support brackets.
Fit remaining nuts (46), lockwashers (47) washers (48)
and rubber mounts (49) to end of rods (51) and tighten in
accordance with standard torques listed in Section
SPECIFICATIONS.
13. Ensure fittings, lines and pipes are securely
tightened to prevent leaks at initial fill and start up.
Note: If Header Tank (36) was removed and has not
yet been installed, proceed from step 14, however, if
header tank (36) was not removed or has been
reinstalled, proceed from step 20.
14. Fit header tank (36) to goalpost and secure using
bolts (39), nuts (37) and washers (38).
15. Following installation instructions in Section
100-0040, HOOD AND MOUNTING, install header tank
(36) and goalpost assembly on the vehicle.
16. Remove blanking from make-up line (41) and
connect to header tank (36). Secure with clamp (42).
17. Remove blanking caps from deaeration lines
(28, 30 & 32) and connect to appropriate fittings on
header tank (36), as noted on removal.
18. Connect overflow line (43) to header tank (36).
19. Secure all lines with clips and tie clips as removed
evident.
Note: If make-up line (41) had been removed
completely, ensure that firemaster hose (40) is
correctly fitted and is properly clamped away from the
20. Refer to Section 210-0000, COOLING SYSTEM for
correct selection of coolant. Fill the cooling system
through filler in header tank (36) with coolant until coolant
level stabilizes at the bottom of filler neck.
21. Check all line and pipe connections for leaks prior
to starting the vehicle. Tighten as required.
Tighten lines and fittings and top up coolant level as
required.
23. Entrapped air must be purged after filling the
cooling system. To do this, allow the engine to warm
up with filler cap (35) still removed. With the
transmission in neutral, increase engine speed above
1000 rev/min and add coolant as required. Vent the
cock on the water return line at the water-jacketed
turbocharger until a steady stream of water (no air) is
seen. Close the cock.
24. Install filler cap (35) on header tank (36) after the
coolant level has stabilized at the bottom of filler neck.
25. Following installation instructions in Section
100-0040, HOOD AND MOUNTING, install hood
assembly on the vehicle.
Note: Check that gap between hood and cowl is correct
12 mm (0.5 in) maximum).
Section 210-0040
SM 2118 Rev 1 11-04 7
26. Remove wheel blocks from road wheels.
CLEANING
Internal Cleaning - Water Tubes
If scale deposits are present inside the water tubes of
the radiator, it is necessary to use a suitable scale
remover such as 'Powdered Scale Solvent', or
equivalent. This material is a free-flowing powder,
inhibited to prevent attack on the cooling system
materials.
WARNING
Take care to avoid contact of skin or eyes with
the solvent. If contact is made it should be
washed off immediately with clean water and
medical advice should be taken.
For general cleaning use it is recommended to use a
concentration of 50 - 100 kg/m of water at a
temperature of up to 60 C. Rapid circulation or
agitation with compressed air will reduce the time for
cleaning.
Note: If scale deposits within the radiator are
exceptionally heavy, concentrations up to 200 kg/m
may be used.
The most convenient method of use is to prepare a
concentrated solution by mixing the powder in hot
water in a tank and then adding the concentrated
solution to water contained in the radiator.
Note: The solvent must always be added carefully to
water, not water to solvent.
External Cleaning
Note: If a build up of dirt is apparent during routine
inspection, the following cleaning procedure should be
adopted.
WARNING
To prevent possible injury when using
compressed air or steam jet, wear adequate eye
protection and do not exceed pressure values
stated.
1. Direct a steam jet at 100 - 300 kN/m, or
compressed air at 500 - 700 kN/m on to the faces of
the radiator core.
2. Liberally brush a liquid detergent on to those
surfaces which were not satisfactorily cleaned at
step 1. Leave to soak for at least 1 hour.
3. Apply a high pressure steam jet at 100 - 300 kN/m, or
compressed air at 500 - 700 kN/m on to the treated
surfaces, forcing the fouling material out from the radiator
core.
4. Leave radiator core to dry before reinstalling the
cooling equipment.
Note: In the case of grossly fouled surfaces which are
not cleaned adequately in steps 1 through 4, the
following procedure may be used.
5. Ensure that the radiator core is dry.
6. Liberally brush on to both sides of the radiator core
an emulsifying cleaner such as 'Gunk', or equivalent,
and leave to soak for at least 1 hour.
7. Apply a high pressure steam jet at 100 -300 kN/m,
or compressed air at 500 - 700 kN/m on to the treated
surfaces, from several different angles, forcing the
fouling material out from the radiator core.
8. For surfaces with stubborn deposits, it may be
necessary to repeat steps 5 through 7, brushing the
surfaces between stages using a stiff bristle brush.
9. Leave radiator core to dry before reinstalling the
cooling equipment.
MAINTENANCE
Refer to Section 210-0000, COOLING SYSTEM for
recommended preventive maintenance procedures,
service intervals and coolant selection procedures.
SPECIAL TOOLS
* * * *
TORQUE
1 7 Bolt 165 122
Section 210-0045
1 SM 2152 6-02
DESCRIPTION
The low temperature unloader valve can be identified
as item 3 in Section 210-0005, COOLING SYSTEM
SCHEMATIC. Numbers in parentheses refer to Fig. 1.
Located on the hydraulic cradle, below the hydraulic
diverter tube, the low temperature unloader valve houses
the following:
(1) two way solenoid operated cartridge valve with open
and closed positions
(2) relief valve cartridge assembly
(3) check valve cartridge assembly.
The low temperature unloader valve receives hydraulic
supply from the engine cooling section (mid section) of
the triple gear pump. An integral two way solenoid
cartridge (1) controls flow to the hydraulically driven
engine cooling fan. The pressure relief valve (2)
controls circuit pressure to a preset 205 bar (2970 lbf/
in).
OPERATION
The low temperature unloader valve forms part of the
engine cooling fan circuit. The integral solenoid valve
(1) controls the two speed engine cooling fan motor
and the relief valve (2) maintains a safe working circuit
pressure of 205 bar (2970 lbf/in).
The low temperature unloader valve has two ports, an
inlet port (P) and an outlet port (T). The inlet port (P) is
protected by the relief valve (2) which, although
adjustable, should be preset to 205 bar (2970 lbf/in).
The relief valve has a separate internal pilot
connection which, when vented to the outlet port (T),
allows the relief valve to pass flow at a very low
pressure from the inlet port (P) to the outlet port (T).
Refer to Fig. 2. The solenoid valve (1) provides a
means to opening this pilot connection to the outlet
port (T). This connection is made when the solenoid
valve is energised. The solenoid valve is energised on
ignition contact, when a 24V signal is supplied to the
solenoid valve from the engine ECU. With the solenoid
valve energised no pressure can be raised at the inlet
port (P). A minimum flow will circulate the engine
cooling fan motor allowing it to rotate. This minimum
flow is supplemented by the relief flow via the priority
unloader valve. Refer to Section 250-0075, PRIORITY
UNLOADER VALVE.
Refer to Fig. 3. The solenoid valve (1) is de-energised
when the voltage from the engine ECU drops to 0V.
The voltage signal is cut to 0 volts when the engine
E.C.U. senses any one of the following 4 pre-
programmed parameters:
SM - 2742
Fig. 1 - Low Temperature Unloader Valve
SM - 2744
Fig. 2 - Low Temperature Unloader Valve -
Solenoid Energised
SM - 2743
Fig. 3 - Low Temperature Unloader Valve -
Solenoid De-energised
1 - Solenoid Valve
2 - Relief Valve
3 - Check Valve
FROM
TRIPLE
GEAR
PUMP
TO
TANK
FROM
TRIPLE
GEAR
PUMP
TO
TANK
COOLING SYSTEM - Low Temperature Unloader Valve
2
1
3
T P
T P
Section 210-0045
Cooling System - Low Temperature Unloader Valve
SM 2152 6-02 2
1. Engine coolant temperature reaches 96C (205F).
2. Engine oil temperature reaches 110C (230F).
3. Air intake temperature reaches 66C (151F).
4. Transmission retarder requested.
When the solenoid valve is de-energised, the flow is
blocked in the pilot line, allowing the relief valve to
operate at its preset 205 bar (2970 lbf/in), therefore
allowing pressure to be raised at the inlet port (P). This
increase in hydraulic pressure forces more oil through
the engine cooling fan motor, thus increasing the fan
speed.
As soon as the cooling requirement is satisfied, engine
ECU energises the solenoid valve by applying 24V
(refer to Fig. 2). This will result in only minimum flow
being supplied to engine cooling fan motor, therefore
slowing engine cooling fan.
The low temperature unloader valve also has a
integral check valve, that allows oil to pass from the
outlet port (T) to the inlet port (P). This will happen
when the pressure at the output port (T) is higher than
the pressure at the inlet port (P).
FUNCTIONAL CHECK
Checking the proper operational function of the low
temperature unloader valve can be simply executed by
removing the electrical harness connection, while
operating the engine at full throttle. An increase in
engine cooling fan speed should be observed.
However, it is advisable to check the pressure setting
of the valve if proper operational function is
questionable. Refer to following procedure for valve
pressure check.
WARNINGS
damage, ensure wheel blocks and steering
locking bar is installed prior to executing
functional checks.
within the system after engine shut down.
Operate the treadle pedal continuously until
the pressure has dissipated before carrying
out any work on the hydraulic system or
Follow directly from the checking procedure for the
Priority Unloader Valve. Refer to Section 250-0075,
PRIORITY UNLOADER VALVE.
1. Fit pressure gauge to the diagnostic check point on
the brake manifold valve (port P1).
2. Remove electrical harness connection to solenoid
valve (1). This will render the solenoid valve de-
energised.
3. Increase engine rpm to full throttle (2200 rpm).
4. Take note of the gauge reading. This is the pressure
setting of the low temperature unloader valve, which
should be 205 bar (2970 psi).
5. If pressure setting is too low after following steps 1
through 4:
(a) Ensure engine is operating at full throttle (2200
rpm).
(b) Loosen lock nut on relief valve (2).
(c) Turn setting screw on relief valve (2) clockwise until
correct pressure is observed on gauge.
(d) Re-tighten lock nut.
Note: Always adjust hydraulic pressure on the
increase.
6. If pressure setting is too high after following steps 1
through 4:
(a) Reduce engine rpm to low idle (700 rpm).
(b) Depress foot brake pedal continuously to relieve
pressure in the braking system.
(c) Loosen lock nut on relief valve (2).
(d) Turn setting screw on relief valve (2) counter
clockwise 2 to 3 full turns.
(e) Return engine rpm to full throttle (2200 rpm).
(f) Adjust setting screw on relief valve (2) clockwise
until correct pressure is observed on gauge.
(g) Re-tighten lock nut.
7. Re-connect electrical harness connection to
solenoid valve (1) on completion.
FAULT DIAGNOSIS
There are 4 possible points of failure:
1. The solenoid (1) coil, although continuously rated
they may fail after long periods of service. This failure
is protected by the fail-safe design of the valve. If the
Section 210-0045
3 SM 2152 6-02
solenoid fails to energise, hydraulic pressure will be
allowed to rise at the inlet port (P). This will default the
engine cooling fan to run constant at the higher speed
setting, thus safeguarding the engine against high
operating temperatures.
Solenoid Coil Rating: 22 Watt continuous.
2. The solenoid cartridge valve (1) to which the
solenoid is attached. Failure is only likely to occur due
to contamination in the system. The valve (1) is a low
leakage device and any contamination may cause
either damage to the components or cause
components to stick in position. Failure may be more
difficult to detect due to the different modes of failure.
Damage to the components will allow a progressively
increasing leakage, eventually resulting in some flow
not being shut off when the solenoid is selected.
Sticking components could hold the system at either a
low engine cooling fan speed or a high fan speed
depending on what position the cartridge valve (1) is
stuck.
3. The relief valve (2). Contamination is the only likely
cause of failure, causing damage to the relief valve (2)
seat. Failure will be difficult to detect as the result of
contamination damage is likely to be loss of flow
across the relief valve (2) seat at pressure. This loss
of flow is difficult to detect until it becomes very
excessive. For example when the solenoid valve (1) is
energised, the relief valve (2) may not act due to the
contamination, allowing pressure to be raised at the
inlet port (P). This would default the engine cooling fan
to the higher speed setting, even although preset
parameters have not been attained.
4. The check valve (3). Contamination is the only likely
cause of failure, causing damage to the non-return
valve seat. Failure will be difficult to detect as the
result of contamination damage is likely to be loss of
flow across the check valve (3) seat at pressure. This
loss of flow is difficult to detect until it becomes very
excessive.
REMOVAL
WARNING
damage, ensure wheel blocks, blocking
secured and of adequate capacity to execute
the job safely.
treadle valve continuously to relieve pressure in the
braking system.
switch in the 'Off' position. Place steering lock bar in
the 'Locked' position.
bottom of the hydraulic tank. Install a length of hose on
remote drain fitting, open drain cock and drain
4. Clean low temperature unloader valve and
surrounding area with a suitable solvent. Identify and
tag all hydraulic lines connected to the low
temperature unloader valve, to aid in 'Installation'.
5. With suitable containers available to catch leakage,
disconnect hydraulic lines. Fit blanking caps to all
open lines.
6. Remove electrical harness connector from solenoid
valve (1).
7. Remove bolts and lockwashers securing the low
temperature unloader valve to the hydraulic cradle.
Remove low temperature unloader valve from the
cradle.
DISASSEMBLY
1. Note location and position of all hydraulic
connectors and adaptors prior to removing them from
valve body.
2. Remove knurled nut from end of the centre shaft of
the solenoid. Slide off solenoid coil.
3. Unscrew solenoid cartridge valve (1) from valve
body. Extract cartridge valve (1).
4. Remove relief valve (2) from valve body.
5. Remove check valve (3) from valve body.
INSPECTION
1. Clean all parts with a suitable solvent and dry with
compressed air.
Section 210-0045
SM 2152 6-02 4
2. Check port threads and make sure they are not
damaged or stripped.
3. Check solenoid valve (1) seat and control spool.
Ensure they are not worn, nicked, cracked or scored.
4. Check relief valve (2) for damage. Ensure relief
valve (2) seat is not worn, nicked, cracked or scored.
5. Examine check valve assembly (3) for any wear or
scoring.
It is not recommended that cartridge assemblies are
disassembled for maintenance purposes. Ensure that
valve assembly is cleaned prior to removal of any
components and that no contaminant is allowed to
enter the internal galleries.
ASSEMBLY
1. Replace all seals on cartridge assemblies housed in
low temperature unloader valve prior to re-assembly.
2. Install check valve cartridge (3) into low temperature
unloader valve body and tighten assembly to 85 Nm
(63 lbf ft).
3. Install relief valve cartridge (2) into low temperature
unloader valve body and tighten assembly to 75 Nm
(55 lbf ft).
4. Install solenoid cartridge valve (1) into low
temperature unloader valve body and tighten
assembly to 30 Nm (22 lbf ft).
5. Install hydraulic connectors and adaptors to correct
ports and orientation.
INSTALLATION
where used.
1. Secure low temperature unloader valve to hydraulic
cradle with bolts and lockwashers.
2. Remove blanking caps from hydraulic lines and
install lines to the low temperature unloader valve as
identified during 'Removal'.
3. Re-connect electrical harness connector to solenoid
valve (1).
4. Fill hydraulic oil tank with hydraulic oil as specified
in Section 300-0020, LUBRICATION SYSTEM. Refer
to Section 230-0040, HYDRAULIC TANK, for hydraulic
oil levels. Install filler cap on hydraulic tank filler neck.
start the engine and bring hydraulic oil to operating
temperature.
6. Check low temperature unloader valve and
hydraulic line connections for leaks and tighten as
required.
7. Remove all blocking from road wheels and place
steering lock bar in the 'Stowed' position.
SPECIAL TOOLS
dealer.
* * * *
Section 210-0050
1 SM 2153 7-02
2
3
4
4
5
5
6
7
8
9
10
11
12
13
12
14
1
15
SM - 2746
1 - Bolt
2 - Front Cover
3 - Oil Cooler
4 - Adaptor
5 - Anti-Vibration Mounting
Fig. 1 - Exploded View Of Disc Brake Oil Cooler
Numbers in parentheses refer to Fig. 1. The disc brake
oil cooler can be identified as item 6 in Section 210-
0005, COOLING SYSTEM SCHEMATIC.
The disc brake oil cooler is a blast air type, mounted
on the right hand fender adjacent to the main hydraulic
tank. The fan (7) within the brake oil cooler is driven by
a hydraulic motor (10). The motor (10) is supplied by a
dedicated brake cooling section of the triple gear pump,
via two speed control valve. The speed of the fan (7) is
dependant on the oil flow being supplied to the motor
(10) from the two speed control valve. Refer to Section
250-0065, TWO SPEED CONTROL VALVE.
Brake cooling oil enters the top of the oil cooler (3) and
flows through the oil cooler (3) before exiting at the
bottom. There are three inlet ports and three outlet
ports, one for each axle.
REMOVAL
WARNING
equipment is properly secured and of adequate
1. Position the machine on a level floor, apply the
parking brake and switch off the engine. Operate the
steering several times to discharge the steering
system. Operate the treadle valve continuously to
discharge the braking system.
switch in the off position. Place steering lock bar in the
locked position.
11 - Bolt
12 - Washer
13 - Isolation Mount
14 - Locknut
15 - Bolt
6 - Casing
7 - Fan
8 - Fan Plate Assembly
9 - Rear Guard Assembly
10 - Hydraulic Motor
COOLING SYSTEM - Disc Brake Oil Cooler
Section 210-0050
Cooling System - Disc Brake Oil Cooler
SM 2153 7-02 2
remote drain fitting, open drain cock and drain hydraulic
oil into a suitable container. Close drain cock, remove
hose and reinstall blanking cap.
bottom of the brake coolant tank. Install a length of
hose on remote drain fitting, open drain cock and drain
brake cooling oil into a suitable container. Close drain
5. Remove bolts (15) securing rear guard assembly (9)
to casing (6). Remove rear guard assembly (9).
6. Clean disc brake oil cooler and surrounding area with
a suitable solvent. Ensure all hydraulic lines connected
to hydraulic motor (10) are identified for ease of
installation and, with suitable containers available to
catch leakage, disconnect hydraulic lines. Fit blanking
caps to all open lines.
7. Ensure all brake cooling lines connected to oil cooler
(3) are identified for ease of installation and, with
suitable containers available to catch leakage,
disconnect brake cooling lines. Fit blanking caps to all
open lines.
8. Identify and tag all hydraulic lines connected to two
speed control valve and relief valve mounted to casing
(6), to aid in 'Installation'. With suitable containers
available to catch leakage, disconnect hydraulic lines.
Fit blanking caps to all open lines.
9. Remove bolts (1) securing front cover (2) to casing
(6). Remove front cover (2).
10. Remove bolts (11), washers (12), isolation mounts
(13) and nuts (14) securing disc brake oil cooler to
fender.
11. Using suitable lifting equipment, remove brake oil
cooler from the vehicle to a clean area for
disassembly.
DISASSEMBLY
1. Remove bolts and washers securing two speed
control valve to casing (6). Remove two speed control
valve.
2. Remove bolts and washers securing relief valve to
bracket on casing (6). Remove relief valve.
3. Remove bolts and washers securing fan plate
assembly (8) to casing (6). Carefully remove fan plate
assembly (8), complete with fan (7) and hydraulic
motor (10) from casing (6).
4. Carefully remove fan (7) from hydraulic motor (10)
shaft.
5. Remove nuts securing hydraulic motor (10) to fan
plate assembly (8). Remove the hydraulic motor (10).
6. Loosen and remove nuts securing oil cooler (3) in
casing (6). Carefully remove oil cooler (3) from casing
(6).
MOTOR OVERHAUL
Internal parts of the hydraulic motor (10) are lubricated
by the operating fluid itself; therefore, preventive
maintenance is limited to keeping the fluid in the
system clean. Dirt should not be allowed to accumulate
on the motor or around the shaft seal. Check frequently
that all fittings and bolts are tight.
ASSEMBLY
WARNING
Generally assembly is the opposite of disassembly. Be
careful not to damage oil cooler (3) when installing in
casing (6).
Note: Ensure there is even clearance, all the way
round, between fan (7) and fan plate assembly (8).
INSTALLATION
Section 210-0050
3 SM 2153 7-02
WARNING
where used.
1. Using suitable lifting equipment, position brake oil
cooler on vehicle and secure using bolts (11), washers
(12), isolation mounts (13) and nuts (14).
2. Install front cover (2) to the casing (6) and secure
with bolts (1).
install lines to two speed control valve and relief valve
as identified during 'Removal'.
4. Remove blanking caps from brake cooling lines and
attach lines to oil cooler (3) as identified during
'Removal'.
install lines to hydraulic motor (10) as identified during
'Removal'.
Note: Prior to start-up, ensure the hydraulic motor (10)
is primed with clean hydraulic oil as specified in
6. Install rear cover (9) to the casing (6) and secure
with bolts (15).
8. Fill brake coolant tank with oil as specified in
Section 300-0020, LUBRICATION SYSTEM. Fill until
oil is halfway up sight glass. Install filler cap on brake
coolant tank filler neck.
and start the engine. Top up oil levels in hydraulic tank
and brake coolant tank as required. Bring hydraulic oil
to operating temperature.
10. Check valves, motor (10) and hydraulic line
connections for leaks and tighten as required.
steering lock bar in the stowed position.
MAINTENANCE
Every 10 Hours/Daily
Check the fan and motor for debris or damage. Clean
or replace as required. Check oil cooler fins for debris
and clean as required.
Note: The fan is a non-serviceable component.
However, the following instructions must be strictly
adhered to:
1. DO NOT clean around fan drive with steam or high
pressure jet.
2. DO NOT add any fluids or lubricants to the drive.
3. DO NOT restrict fan rotation during engine operation
for ANY reason.
4. DO NOT operate a machine with a damaged fan
assembly. Replace a damaged fan as soon as the fault
is noted.
5. DO NOT disassemble motor assembly or associated
parts that are still within the warranty coverage period.
6. IMMEDIATELY investigate and correct ANY
operator complaint involving drive or brake cooling
system performance.
SPECIAL TOOLS
dealer.
Cooling System - Disc Brake Oil Cooler
* * * *
Section 210-0060
SM 1922 Rev 2 11-04
1
5,6
5,6
4
6
6
2
2,6
3
9,10
9,10
7
11 11
6
12
8
17
18
19
20
13,15
14,15
1
16
COOLING SYSTEM - Transmission Oil Cooler
SM - 3336
The transmission oil cooler is mounted on the inside
of the right hand tractor frame rail and is connected in
the water cooling and transmission oil circuits,
between the radiator and transmission. The purpose
of the transmission oil cooler is to maintain the
transmission oil within its required operating
temperature range.
Coolant is pumped from the engine water pump
through water inlet pipe (3) and into oil cooler
assembly (1). Coolant circulates through cooler tubes
in oil cooler assembly (1) cooling transmission oil
around the tubes and then flows through water outlet
pipe (4) and into the engine oil cooler.
Transmission oil to be cooled enters oil cooler
assembly (1) through oil inlet line (7), circulates
around the cooler tubes within oil cooler assembly
(1), and exits through oil outlet line (8) to return to the
transmission.
Note: To obtain the maximum cooling effect, oil flow
must always flow in the opposite direction to coolant
flow through the transmission oil cooler assembly.
REMOVAL
WARNING
safely.
Fig. 1 - Transmission Oil Cooler Lines
11 - Adaptor
12 - Plate
13 - Elbow
14 - Elbow
15 - 'O'-Ring
6 - Clamp
7 - Oil Inlet Line
8 - Oil Outlet Line
9 - Bolt
10 - Lockwasher
1 - Oil Cooler Assembly
2 - Hose
3 - Water Inlet Pipe
4 - Water Outlet Pipe
5 - Hose
16 - Temp. switch
17 - Clamp
18 - Spacer
19 - Split Bushing
20 - Bolt
Section 210-0060
Cooling System - Transmission Oil Cooler
SM 1922 Rev 2 11-04
2
SM - 2432
parking brake and switch off the engine. Turn
steering wheel several times to relieve any pressure
in the steering circuit.
3. Pull on handle (inside cab) to release hood catch
and raise hood.
4. Open drain cock at the bottom of the radiator
assembly and drain coolant into a suitable container.
Close drain cock when coolant is completely drained.
5. Support engine sump guard with suitable blocking and
remove mounting hardware securing rear of sump guard
to the frame. Drop rear end of sump guard to allow access
to remove oil cooler assembly (1).
6. Remove plug (6, Fig. 2) from oil cooler (1) and
drain coolant into a suitable container. Reinstall plug
(6, Fig. 2) when coolant is completely drained.
7. Remove oil inlet line (7) from adaptor (11) in oil
cooler assembly (1). Drain any remaining oil in oil
inlet line (7) into a suitable container. If required,
remove adaptor (11) from oil cooler assembly (1).
8. Fit blanking cap to oil inlet line (7) and oil cooler
assembly (1) port to prevent ingress of dirt.
9. Remove oil outlet line (8) from adaptor (11) in oil
cooler assembly (1). Drain any remaining oil in oil
outlet line (8) into a suitable container. If required,
remove adaptor (11) from oil cooler assembly (1).
10. Fit blanking cap to oil outlet line (8) and oil cooler
assembly (1) port to prevent ingress of dirt.
4 - 'O' Ring
5 - Bolt
6 - Plug
1 - Heat Exchanger
2 - Water Inlet Flange
3 - Water Outlet Flange
Fig. 2 - Exploded View of Transmission Oil Cooler
5
3
4
1
3
6
4
2
5
Section 210-0060
SM 1922 Rev 2 11-04
3
1. Clean transmission oil cooler before sludge hardens.
After transmission oil cooler is completely drained,
circulate a solution of Agmasol PS40 through the
cooler core (1) to remove sludge.
2. If cooler tubes are badly clogged, circulate an oakite
or alkaline solution through cooler (1). Solution should
be circulated through cooler (1), in the reverse direction
to normal flow, for approximately 15 minutes, after
soaking for 10 minutes. The duration of circulation
depends on how badly clogged the cooler is. Flush
thoroughly with clean hot water.
Cleaning Water Side
1. Match mark cooler flanges (2 & 3) and heat
exchanger (1) to aid in 'Assembly'.
2. Remove bolts (5) securing water inlet flange (2)
and 'O' ring (4) to heat exchanger (1). Remove water
inlet flange (2) from heat exchanger (1) and discard
'O' ring (4).
3. Remove bolts (5) securing water outlet flange (3)
and 'O' ring (4) to heat exchanger (1). Remove water
outlet flange (3) from heat exchanger (1) and discard 'O'
ring (4).
4. Make up a solution composed of 1/3 muriatic acid
and 2/3 water. To each 9.5 litres (2.5 gal) of solution,
add 227 g (0.5 lb) of oxalic acid.
5. Immerse heat exchanger (1) in the cleaning solution.
Cleaning action is noticeable by bubbling and foaming.
The process must be carefully observed and when
bubbling stops, usually between 30 - 60 sec., remove
heat exchanger (1) from cleaning solution and flush
thoroughly with clean, hot water. After cleaning, dip heat
exchanger (1) in light oil.
Note: Severely fouled cooler tubes can be cleaned by
use of a rotary brush if normal cleaning is not sufficient.
ASSEMBLY
1. Install new 'O' ring (4) to water inlet flange (2) and
align flange to heat exchanger (1), as match marked at
'Disassembly'.
2. Secure water inlet flange (2) to heat exchanger (1)
11. Loosen clamps (6) securing hoses (2) to water inlet
pipe (3) and water outlet pipe (4). Slide hoses (2) along
pipes to break connection at cooler flanges.
12. Support oil cooler assembly (1) with suitable lifting
equipment and remove bolts (9) and lockwashers (10)
securing oil cooler assembly (1) to its mounting.
Remove oil cooler assembly (1) from the vehicle.
13. If required, remove nuts, clamps (6) and plate (12)
securing water inlet pipe (3) and water outlet pipe (4)
together.
14. If required, loosen clamps (6) securing elbows (5)
to engine water pump inlet and engine oil cooler inlet
and remove water inlet pipe (3) and water outlet pipe
(4) from the vehicle.
15. If oil inlet line (7) and oil outlet line (8) are to be
replaced proceed as follows.
16. Remove bolts (20) and one half of clamp (17).
Remove split bushings (19) from lines (7 & 8).
17. Disconnect lines (7 & 8) from elbows (13 & 14) and
remove from the vehicle.
18. If required, remove elbows (13 & 14) and 'O' rings
(15) from transmission inlet and outlet ports. Remove
and discard 'O' rings (15).
CLEANING AND DISASSEMBLY
In the event of a major mechanical failure, the
transmission oil cooler assembly should be cleaned
thoroughly or replaced. Do not attempt to clean cooler
cores after a transmission failure where metal
particles from worn or broken parts are released into
the oil. Replace the cooler cores.
In many areas, raw water is extremely corrosive or
scale forming and should be treated to prevent
damage to the transmission oil cooler. A properly
maintained cooling system will significantly reduce
cleaning intervals. Refer to Section 210-0000,
COOLING SYSTEM for service intervals and coolant
selection procedures.
Cleaning Oil Side
In the event of a major mechanical failure, the
transmission oil cooler assembly should be cleaned
thoroughly or replaced.
Section 210-0060
SM 1922 Rev 2 11-04
4
with bolts (5). Tighten bolts (5) alternately to give an
even seal around cooler flange area.
3. Install new 'O' ring (4) to water outlet flange (3) and
align flange to heat exchanger (1), as match marked
at 'Disassembly'.
4. Secure water outlet flange (3) to heat exchanger
(1) with bolts (5). Tighten bolts (5) alternately to give
an even seal around cooler flange area.
INSTALLATION
WARNING
safely.
1. Using suitable lifting equipment, position oil cooler
assembly (1) to frame rail and secure with bolts (9)
and lockwashers (10).
2. Fit elbow (5) onto water inlet pipe (3) and fit inlet
pipe to engine water pump inlet. Fit hose (2) on
opposite end of water inlet pipe (3) and connect to
water inlet flange (2, Fig. 2). Secure hose (2) and
elbow (5) in position with clamps (6).
3. Fit elbow (5) onto water outlet pipe (4) and fit outlet
pipe to engine oil cooler inlet. Fit hose (2) on opposite
end of water outlet pipe (4) and connect to water
outlet flange (3, Fig. 2). Secure hose (2) and elbow
(5) in position with clamps (6).
4. Clip water inlet pipe (3) and water outlet pipe (4)
together with clamps (6), plate (12) and nuts.
5. Install new 'O' rings (15) in elbows (13 & 14) and
secure elbows to transmission inlet and outlet ports.
6. Remove blanking caps from oil inlet and outlet lines
(7 & 8) and connect oil outlet line (8) and oil inlet line
(7) to elbows (13 & 14) (inlet line (7) to the top port). Do
not tighten oil inlet and outlet lines at this point.
7. Remove blanking caps from oil cooler assembly (1).
If removed, install adaptors (11) in oil cooler assembly
(1).
8. Install oil inlet line (7) to adaptor (11) in oil cooler
assembly (1). Do not tighten securely at this point.
9. Install oil outlet line (8) to adaptor (11) in oil cooler
assembly (1). Do not tighten securely at this point.
10. Fit split bushings (19) on oil inlet line (7) and outlet
line (8). Fit split bushings (19) with lines in fixed half of
clamp (17) and secure with remaining half of clamp
(17), spacers (18) and bolts (20).
11. Ensure transmission oil lines are following a neat
and tidy run and secure both ends of each line to their
respective fittings.
12. Fill transmission with lubricant as specified in
Section 120-0010, TRANSMISSION AND
MOUNTING, for oil level check.
13. Remove filler cap on radiator header tank and fill
radiator with coolant as specified in Section 300-0020,
LUBRICATION SYSTEM. Refer to Section 210-0000,
COOLING SYSTEM, for filling procedure and level
check.
14. Check all line and pipe connections for noticeable
leaks prior to starting the vehicle.
Tighten lines and fittings and top up systems as
required.
16. Using suitable lifting equipment, raise engine
sump guard and secure with mounting hardware
removed during removal.
17. Lower hood assembly and remove wheel blocks.
SPECIAL TOOLS
dealer.
Section 210-0060
SM 1922 Rev 2 11-04
5
* * * *
Section 210-0100
SM 1403 Rev 1 10-03 1
COOLING SYSTEM - Hydraulic Oil Cooler
SM - 1882
before exiting hydraulic oil cooler (4) from the bottom port
of the cooler. Oil returns to diverter tube (31) through oil
outlet line (7) and returns to tank through the hydraulic oil
filter.
Note: The fitting closest to the port on the body control
valve is the supply to the cooler with the other fitting
being the return.
REMOVAL
WARNING
safely.
The air cooled hydraulic oil cooler (4) is mounted on
the front of the radiator assembly with the purpose of
cooling hydraulic oil circulating through the hydraulic
system.
Hydraulic oil cooler (4) is connected at diverter tube
(31) between the return port on the body control valve
and the inlet to the hydraulic tank filter assembly.
Note: When hydraulic oil cooler (4) is fitted, the return
port used is the port on the body control valve
normally fitted with a blanking plate. Refer to Section
230-0060, BODY CONTROL VALVE.
Hydraulic oil enters the top port on hydraulic oil cooler (4)
through oil inlet line (8) from diverter tube (31). Oil passes
through a series of tubes in the cooler core, where the oil
temperature is reduced by air flow through the cooler fins,
Fig. 1 - Exploded View of Hydraulic Oil Cooler, Lines and Mounting
19 - Bolt
20 - Fuel Cooler
21 - Fuel Cooler Bracket
22 - Fuel Cooler Bracket
23 - Fleximount
24 - Bolt
25 - Bolt
26 - Washer
27 - Locknut
10 - Washer
11 - Bolt
12 - Lockwasher
13 - Clip
14 - Nut
15 - Plate
16 - Lockwasher
17 - Bolt
18 - Bolt
1 - Bracket
2 - Elbow
3 - Bracket
4 - Hydraulic Oil Cooler
5 - Bracket
6 - Fleximount
7 - Oil Outlet Line
8 - Oil Inlet Line
9 - Bracket
28 - Hydraulic Line
29 - Bolt
30 - Washer
31 - Diverter Tube
32 - Bolt
33 - Lockwasher
34 - Split Flange
35 - 'O' Ring
HYDRAULIC
CONTROL
VALVE
8
28
7
1
22
8
20
31
2
21
23
12
17
5
15
6
15
7
2
16
10
10
19
12
18
4
3
16
10
6
15
15
10
18
12
19
13
14
9
12
11
12
B
B
B
B
A
A
A
A
A
A
A
A
A
A
A
A
25
26
27
B
24
26
27
A
30
29
35
34
33
32
Section 210-0100
Cooling System - Hydraulic Oil Cooler
SM 1403 Rev 1 10-03 2
4. Remove mounting hardware securing the front grille
on the hood assembly and remove grille for access to
hydraulic oil cooler (4).
5. Pull on handle to release hood catch mechanism
and raise hood.
6. Remove oil outlet line (7) from hydraulic oil cooler
(1) and drain oil into a suitable container.
7. Remove oil inlet line (8) from hydraulic oil cooler (1)
and drain any remaining oil into a suitable container.
8. Remove bolts (18), lockwasher (12) and plate (15)
securing oil cooler (4) to brackets (1 & 5).
bracket (5) to bracket (1) and remove bracket (5).
10. Remove bolts (29) and lockwasher (30) securing
bracket (1) to fuel cooler bracket (22) and the radiator
assembly and remove bracket (3).
11. Remove bolts (29), lockwasher (30) securing
bracket (3) fuel cooler bracket (21) and the radiator
assembly and remove bracket (3).
12. If required remove bolt (24) washer (26) and
locknut (27) securing fleximount (23) to fuel cooler (20)
and brackets (21) and (22).
13. Disconnect oil inlet & outlet line (7 & 8) and filter
line (28) from diverter tube. Blank off open ends and
plug ports to prevent ingress of dirt.
14. If required remove bolts (32), lockwasher (33) and
split flanges (34) securing diverter tube (31). Remove
diverter tube (31), discard 'O' ring (35) and blank off
open end.
15. Remove bolt (11), lockwasher (12), nuts (14) and
clips (13) securing lines (7 & 8).
16. If oil inlet & outlet lines (7 & 8) require to be
replaced, note location of all clips (13) and remove
lines from the vehicle.
CLEANING AND INSPECTION
1. Inspect fins on hydraulic oil cooler carefully, for
trapped debris and damage. If hydraulic oil cooler fins
show signs of leakage or are excessively damaged, it
must be replaced as an assembly.
2. Check connectors in hydraulic oil cooler ports for
damaged threads. Replace if required.
3. After hydraulic oil cooler is completely drained,
circulate a solution of Agmasol PS40 through the
cooler tubes.
4. If cooler tubes are badly clogged, circulate an oakite
or alkaline solution through the hydraulic oil cooler, in
the reverse direction to normal flow, for approximately
15 minutes. The duration of circulation depends on how
badly clogged the cooler tubes are. Flush thoroughly
with clean hot water.
INSTALLATION
specified in Section 300-0080, STANDARD BOLT
AND NUT TORQUE SPECIFICATIONS.
1. Remove blanking cap from body control valve and
diverter tube (31).
2. Install new O ring (35) in split flange end of
diverter tube (31) and connect to body control valve
with split flanges (34), bolts (32) and lockwasher (33).
Do not tighten bolts (32) securely at this point.
Section 210-0100
SM 1403 Rev 1 10-03 3
Cooling System - Hydraulic Oil Cooler
* * * *
3. Connect hydraulic filter line (28) to diverter tube
(31). Remove blanking caps from hydraulic lines and
connect hydraulic filter line (28) to diverter tube.
4. Tighten bolts (32), lockwasher (33) at split flange
fitting on diverter tube (31) after correct line
installation has been obtained.
5. If oil inlet line (8) and oil outlet line (7) were
removed, position lines on the vehicle following the
route taken before removal. Do not clip line in position
at this stage.
6. Connect lines (8) & (7) to fittings on diverter tube
(31) (outlet line (7) to inside fitting on tube). Tighten
line fittings at diverter tube.
7. Secure bracket (3) to fuel cooler bracket (21) with
bolt (29), lockwasher (30).
8. Secure bracket (1) to fuel cooler bracket (22) and
radiator assembly with bolts (29), lockwasher (30).
9. Reinstall fuel cooler (20) securing fleximount (23)
with bolts (24), washer (26) and locknut (27).
10. Install bracket (5) to bracket (1) with bolts (17),
lockwasher (12).
11. Fit fleximount (6) to hydraulic oil cooler (4). Secure
with bolts (19), washer (10) and locknut (16).
12. Locate plate (15) either side of fleximount (6) and
secure to brackets (5) & (3) with bolt (18), lockwasher
(12).
13. Connect oil inlet line (8) to elbow (2) in top of
hydraulic oil cooler (4) and oil outlet line to elbow (2)
in bottom port.
14. Remove bottom bolt (18) and lockwasher (12) from
bracket (5) and secure oil outlet line (7) to bracket (5)
with clips (13), bolt (18) and lockwasher (12).
15. Clip oil inlet line (8) and oil outlet line (7) with clips
(13) as noted at removal. Use tie clips where required
to maintain tidy line routing.
16. Fill hydraulic oil tank with hydraulic fluid specified
to Section 230-0040, HYDRAULIC TANK, for correct
fill level. Install filler cap on hydraulic tank.
17. Check all line and pipe connections prior to starting
the vehicle.
start the engine and check for leaks. Tighten lines and
fittings as required.
19. Lower hood assembly and secure front grille
assembly to the hood with mounting hardware
removed at removal. Remove all wheel blocks.
SPECIAL TOOLS
dealer.
Section 220-0000
SM 1390 Rev 2 2-02 1
STEERING SYSTEM - Steering System Schematic
DESCRIPTION
The operation of the steering system is hydrostatic.
That is to say, there is no mechanical connection
between the steering column and the steered wheels.
Instead there are hydraulic pipes and lines between
the steering components and the steering cylinders.
Actuating pressure for steering operation is supplied
by main hydraulic pump (2).
When the steering wheel is turned, steering valve (7)
meters an oil volume proportional to the amount of
turn. This volume of oil flows through flow amplifier
valve (5) and is led to the appropriate side of
cushioned steering cylinders (8). Steering valve (7)
returns automatically to its neutral position when
turning is completed.
Emergency steering pressure is provided by a wheel
driven emergency steering pump (3) on the transmission.
A warning light (on the right hand bank of warning lights
in the cab) illuminates to warn of a fault in the steering
system supply pressure. If the light illuminates, stop the
vehicle and investigate the cause.
Note: The steering system warning light illuminates
when the ignition is turned on and should go out when
the engine starts.
A brief description of the individual components used
in the steering system are listed below. Detailed
Hydraulic Tank (1)
Refer to Section 230-0040, HYDRAULIC TANK.
The hydraulic tank is the common reservoir for the
steering, braking and body hoist systems. It is
mounted off the frame and fender bracket at the rear
right hand side of the tractor.
Integral with the hydraulic tank assembly are the
hydraulic oil filter, oil strainer and oil level sight gauge.
Located on top of the tank assembly is the filler cap
and breather.
Main Hydraulic Pump (2)
Refer to Section 230-0050, MAIN HYDRAULIC PUMP.
Mounted off the transmission power takeoff, the main
hydraulic pump supplies hydraulic oil for operating
the steering and body hoist systems. Hydraulic oil is
drawn from the hydraulic tank (1) and pumped
through the dual manifold check valve (6) to the flow
amplifier valve (5). A priority spool within the flow
amplifier valve (5) directs oil supply from the main
hydraulic pump to the steering valve.
The maximum oil delivery rate of the pump is fixed by
the width of its respective gear set and the speed at
which the driveshaft is turned.
The pump operates in the one direction only (it is
assembled for right hand (clockwise) rotation, as
viewed from the driveshaft end).
travel as pump seizure may result.
Emergency Valve (4)
Refer to Section 220-0140, EMERGENCY VALVE.
Located on the inside of the front left hand side frame
rail, the emergency valve forms part of the emergency
steering system. It is connected to the main output line
of the wheel driven Emergency Steering Pump (3)
mounted on the transmission.
Dual Manifold Check Valve (6)
rail, the dual manifold check valve is supplied by the
main hydraulic pump (2). A pilot line to the emergency
valve (4) holds off the emergency valve (4) when the
main hydraulic pump (2) is operating. The dual manifold
check valve distributes oil from the main hydraulic
pump (2) to the flow amplifier valve (5) under normal
operating conditions. If the main hydraulic pump (2)
fails, the emergency valve (4) directs oil to the flow
amplifier valve (5) via the dual manifold check valve.
Flow Amplifier Valve (5)
Refer to Section 220-0100, FLOW AMPLIFIER VALVE.
The flow amplifier valve amplifies the oil flow from the
steering valve to the steering cylinders by eight. It is
mounted on the cradle assembly at the rear of the
cab and consists of the following:
Counter pressure & anti-cavitation valve maintains a
back pressure of 5 bar (73 lbf/in) to give improved
suction during steering and prevent cavitation in the
steering cylinder circuit.
S
e
c
t
i
o
n

2
2
0
-
0
0
0
0
S
t
e
e
r
i
n
g

S
y
s
t
e
m

-

S
t
e
e
r
i
n
g

S
y
s
t
e
m

S
c
h
e
m
a
t
i
c
S
M

1
3
9
0

R
e
v

2

2
-
0
2
2
Fig. 1 - Steering System Schematic - Neutral Position
CONDITION BASED ON
ENGINE SHUTDOWN
1 - Hydraulic Tank
2 - Main Hydraulic Pump
3 - Emergency Steering Pump
4 - Emergency Valve
5 - Flow Amplifier Valve
6 - Check Valve
7 - Steering Valve
8 - Steering Cylinders
PRESSURE TEST POINT
A - Steering System Pressure
S
M
-
2
6
8
6
6
4
3
1
2
R L
7
P T LS
CR CL
8 8
R
5
EF P PP HP LS HT T L
A
LEFT HAND
CYLINDER
RIGHT HAND
CYLINDER
BODY
HOIST
SYSTEM
Section 220-0000
SM 1390 Rev 2 2-02 3
SM - 1335
'O' RING 'O' RING
SLEEVE
TUBE
FITTING
NUT
bearings permit a limited amount of cylinder misalignment
when travelling over rough terrain.
Pressure Test Point
A diagnostic pressure test point, located in the
manifold at the rear left hand side of the tractor frame,
provides a quick and easy method of checking steering
system pressure. The pressure is taken from a tee at
port 'PP' of the flow amplifier valve. System pressure is
206 bar (3 000 lbf/in
2
).
connections, the following procedure should be carried
out during installation. Refer to Fig. 2.
Steering System - Steering System Schematic
System relief valve is set to control maximum working
pressure in the steering system to 206 bar (3 000 lbf/in).
Priority spool directs oil supply from the pump when
engine is running, to steering valve port 'P' and through
the 'EF' passage to the body control valve.
Shock & anti-cavitation valves limit shock pressures in
the steering cylinders to 241 bar (3 500 lbf/in). The
shock valves sense cylinder shock pressure when
there is no steering taking place. Shock pressure is
absorbed in the cylinder circuit and is not transmitted
to the steering valve. The anti-cavitation part of the
valve prevents cavitation in the cylinder circuit.
Amplifier spool controls the amount of oil flowing into
the directional spool 'HP' passage.
Directional spool when moved in either direction
against the return springs, sends oil pressure to the
steering cylinders for right or left turns.
Various orifices, orifice drillings and check valves are
located within the valve assembly.
Steering Valve (7)
Refer to Section 220-0190, STEERING VALVE.
The steering valve is connected to the steering
column and controls hydraulic flow in the steering
system. A pressure relief line in the neutral position,
between steering cylinder ports 'L' & 'R' and tank
return port 'T', means that the steering valve must
only be used with flow amplifier valve (5).
Steering Cylinders (8)
Refer to Section 220-0120, STEERING CYLINDER.
There are two single stage, double acting, cushioned
steering cylinders on the vehicle. The cylinder base
end is connected to the front frame and piston rod
end is connected to the rear frame. Single stage,
double acting means that the piston rod can have oil
applied to either side, extending or retracting the
piston rod.
The cushioning effect is obtained by a tapered spear
at the base end of the cylinder body entering a cavity
in the piston rod through a cushioning sleeve. This
gradually slows the piston which in turn helps to control
destructive shock effects when the piston bottoms.
Cylinder mounting is by pins through spherical bearings
in the cylinder base and piston rod ends. The spherical
aligned correctly.
been achieved.
FILLING AND BLEEDING THE STEERING
SYSTEM
1. Fill hydraulic tank to maximum level. Be ready to
add oil when the engine is started. Do not let oil drop
Section 220-0000
SM 1390 Rev 2 2-02 4
Hydraulic Oil
The steering system should be kept filled with
hydraulic oil as specified in Section 300-0020,
LUBRICATION SYSTEM.
SERVICE TOOLS
with other general service tools, are available from your
dealer. Refer to Section 300-0070, SERVICE TOOLS,
for part numbers of these tools.
Multi-gauge
2
).
below the pump suction line to prevent air entering the
system.
2. Remove wheel blocks from all road wheels, start the
engine and let it idle. Add oil to the hydraulic tank as
required. When the hydraulic tank is filled to the
maximum level and oil is clear proceed as follows:
a. Turn the steering wheel from lock to lock to bleed
the air in the steering cylinders and lines.
Note: Immediately upon valve spool actuation oil must
be added to the hydraulic tank to replenish the oil
moving into the circuit.
WARNING
Do not operate the vehicle until all air is bled
from the oil.
b. When the oil in the hydraulic tank is clear (not
cloudy or creamy) the system is free of air.
Note: Slight creep or drift of the steering wheel is
normal.
c. Fill hydraulic tank to the recommended level and
install the filler cap.
Section 220-0000
SM 1390 Rev 2 2-02 5
AMPLIFIER VALVE DIAGNOSIS
TABLE627
Too few steering wheel turns from
stop to stop
Dirty, leaky or missing check
valve
Clean or renew check valve
Steering over-reacting Amplifier spool stuck in open position Disassemble and check amplifier
spool movement
Too many steering wheel turns from
stop to stop
Steering too slow
Amplifier spool stuck in closed
position
Disassemble and check amplifier
spool movement
Prolonged hard point when beginning
to turn the steering wheel
Amplification is delayed and sets in
suddenly
Dirty orifice in directional spool Clean or replace orifice
Dirty orifice in amplifier spool Clean or replace orifice
Dirty orifice in valve housing Clean or replace orifice
Dirty orifice in 'LS' port Clean or replace orifice
Blocked up throttle check valve in 'PP'
port
Clean or replace throttle check valve
Steering wheel can be turned rapidly Setting of shock & anti-cavitation
valve set too low
Untighten the counter nut and adjust
the valve setting screw with an allen
key. Tighten the counter nut to
secure.
Leaking or hanging shock &
anti-cavitation valve
Disassemble shock & anti-cavitation
valve and renew, if necessary
No end stop feeling Missing end stop in directional
spool
Mount end stop
Steering has insufficient force to turn
the wheels at standstill
System relief valve adjusted too low Remove plug and adjust pressure
setting with an allen key
Steering unit spool and sleeve
installed in wrong manner to each
other. No 'LS' signal can be built up.
Disassemble steering unit and turn
the spool and sleeve to the right
position
Steering unit spool and sleeve worn Change steering unit
No function at all Oil flows direct from pump to tank in
the steering unit
Manual steering ball is missing
Short hard point when beginning to
turn the steering wheel
Air in the 'LS' and 'PP' lines Bleed 'LS' and 'PP' lines
Clogged orifice in 'LS' port and/or
clogged check valve in 'PP' port
Clean the orifice and/or check valve
Section 220-0000
SM 1390 Rev 2 2-02 6
STEERING VALVE DIAGNOSIS
TABLE626
Steering wheel does not centre Binding in steering linkage to valve Align as required
Worn gear wheel Replace parts
Broken neutral position springs Replace neutral position springs,
drain and flush system
Burrs on sleeve or spool Disassemble and repair or replace
parts
Apparent inability to steer when
wheel is turned slowly
Dirt in system Drain and flush system. Refill with
clean oil.
Slow steering Excessive wear in sleeve and spool Replace sleeve and spool
Excessive wear in gear wheel Replace gear wheel
Hard steering See 'Slow Steering'
Opposite steering Lines hooked up incorrectly Reconnect correctly
Wrong orientation between gear
wheel and gear rim
Realign per instructions
Steering wheel rocking back and forth See 'Opposite Steering'
Steering wheel continues to turn Input linkage binding Align as required
Burr on sleeve or spool Disassemble and repair or replace
clean oil.
No steering action Sleeve and spool locked together Disassemble and repair or replace
* * * *
Section 220-0090
SM 1391 5-98 1
STEERING SYSTEM - Steering Valve
SM - 534
1 - Seal Ring
2 - Valve Housing
3 - Check Valve Ball
4 - Bushing
5 - 'O' Ring
6 - Kin Ring
8 - Ring
9 - Spool
10 - Cross Pin
11 - Sleeve
12 - Neutral Position Spring
13 - Driveshaft
14 - Spacer
15 - 'O' Ring
16 - Distributor Plate
17 - Gear Wheel
18 - Gear Rim
19 - 'O' Ring
20 - End Cover
21 - Washer
22 - Roll Pin
23 - Bolt
24 - Bolt
Fig. 1 - Sectional View of Steering Valve
DESCRIPTION
Numbers in parentheses refer to Fig. 1. Letters in
parentheses refer to Fig. 3.
The Steering Valve can be identified as item 7 in Section
220-0000, STEERING SYSTEM SCHEMATIC.
The steering valve is connected to the steering column
and controls hydraulic flow in the steering system. A
pressure relief line in the neutral position, between
steering cylinder ports 'L' & 'R' and tank return port 'T',
means that the steering valve must only be used with
a flow amplifier valve. Refer to Section 220-0100,
FLOW AMPLIFIER VALVE.
The steering valve consists of valve housing (2),
bearing assembly (7), spool (9), sleeve (11), driveshaft
(13), gear wheel (17) and gear rim (18).
OPERATION
Refer to Fig. 3 for port identification.
There are five ports on the steering valve:
Port 'P' - Inlet from flow amplifier valve
Port 'T' - Return to tank
Port 'L' - Supply to LH steering circuit
Port 'R' - Supply to RH steering circuit
Port 'LS' - Load sensing line to flow amplifier valve
For operation of the steering valve refer to Section
220-0100, FLOW AMPLIFIER VALVE.
Section 220-0090
Steering System - Steering Valve
SM 1391 5-98 2
SM - 1849
REMOVAL
WARNING
safely.
wheel in both directions several times to relieve any
pressure in the steering circuit.
2. Block all road wheels and place battery master
4. Pull floor mat back and remove mounting hardware
securing access cover to the floor plate.
5. Clean outer area of steering valve (1) with a suitable
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. Fit blanking caps
to all open lines.
6. Slide bellows (2) over steering column (3) to allow
access and loosen bolt (5), washer (16) and nut (17)
which tightens coupling (12) onto steering column (3).
7. Support steering valve (1) and remove mounting
bolts (5) and washers (6) securing steering valve (1) to
steering column (3) and bracket (4). Remove steering
valve (1) to a clean area for disassembly.
8. If required, remove bolts (7), washers (8 & 10),
locknuts (11), rubber mounts (9) and bracket (4) from the
floor plate. Discard rubber mounts (9), if damaged.
14
18
19
2
12
13
22
20
21
11
3
15
9
10
8
1
7
5
6
16
17
4
Fig. 2 - Exploded View of Steering Valve Mounting
1 - Steering Valve
2 - Bellows
3 - Steering Column
4 - Bracket
5 - Bolt
6 - Washer
7 - Bolt
8 - Washer
9 - Rubber Mount
10 - Washer
11 - Locknut
12 - Coupling
13 - Flex Coupling
14 - Steering Shaft
15 - Bolt
16 - Washer
17 - Nut
18 - Bracket
20 - Bolt
21 - Lockwasher
22 - Nitrile Seal
Section 220-0090
SM 1391 5-98 3
SM - 536
Fig. 3 - Exploded View of Steering Valve Assembly
19 - 'O' Ring
20 - End Cover
21 - Washer
22 - Roll Pin
23 - Bolt
24 - Bolt
13 - Driveshaft
14 - Spacer
15 - 'O' Ring
16 - Distributor Plate
17 - Gear Wheel
18 - Gear Rim
8 - Ring
9 - Spool
10 - Cross Pin
11 - Sleeve
12 - Neutral Position Spring
1 - Seal Ring
2 - Valve Housing
3 - Check Valve Ball
4 - Bushing
5 - 'O' Ring
6 - Kin Ring
DISASSEMBLY
1. Place steering valve assembly in a soft jawed vice,
end cover (20) up.
2. Remove bolts (23 & 24) and washers (21) securing
end cover (20) to valve housing (2). Remove end
cover (20) from valve housing (2). Remove roll pin (22)
from bolt (23).
3. Remove gear rim (18), gear wheel (17) and spacer
(14) from valve housing (2). Remove and discard
'O' rings (19) from gear rim (18).
4. Remove driveshaft (13) from valve housing (2).
5. Remove distributor plate (16) from valve housing (2).
6. Unscrew and remove bushing (4) from valve
housing (2). Remove and discard 'O' ring (15) from
valve housing (2).
7. Remove valve housing (2) assembly from the vice
and shake out check valve ball (3).
8. Take care to keep cross pin (10) in sleeve (11) and
spool (9) horizontal. Cross pin (10) can be seen
through the open end of spool (9). Press spool (9)
inwards and remove with sleeve (11), ring (8) and
bearing assembly (7).
Note: The outer (thin) bearing race can sometimes
'stick' in valve housing (2). Ensure that bearing race
has been removed from valve housing (2).
9. Using bolt (23) and roll pin (22), press cross pin (10)
Section 220-0090
SM 1391 5-98 4
from sleeve (11) and spool (9).
10. Carefully remove spool (9) from sleeve (11) and
press neutral position springs (12) from spool (9).
11. Remove and discard seal ring (1), 'O' ring (5) and
kin ring (6) from valve housing (2).
INSPECTION
1. Clean all parts in a suitable solvent and dry with
clean, lint free cloths.
2. Check all parts for wear or damage and replace if
necessary.
ASSEMBLY
SPECIFICATIONS.
Note: Before assembly, lubricate all parts with
LUBRICATION SYSTEM.
1. Install the two flat neutral position springs (12) in
their slot in spool (9). Install the curved neutral position
springs (12) between the flat ones and press into
place.
2. Line up neutral position spring (12) set.
3. Guide spool (9) into sleeve (11).
Note: When assembling spool (9) and sleeve (11) only
one of two possible ways of positioning neutral
position springs (12) slot is correct. There are three
slots in spool (9) and three holes in sleeve (11) in the
end opposite to neutral position springs (12) slot.
Place the slots and holes opposite each other so that
parts of the holes in sleeve (11) are visible through the
slots in spool (9).
4. Press neutral position springs (12) together and
push into place in sleeve (11). Line up neutral position
springs (12) and centre them.
5. Install ring (8) down over sleeve (11). Ensure ring (8)
rotates free of neutral position springs (12).
6. Install cross pin (10) into spool (9) and sleeve (11)
assembly.
SM - 537
7. Install bearing assembly (7) on spool (9) as shown
in Fig. 4.
8. Turn valve housing (2) until spool (9) and sleeve
(11) bore is horizontal. Using assembly tool shown in
Fig. 7, guide the outer part into valve housing (2) bore.
9. Install new kin ring (6) and 'O' ring (5) on assembly
tool guide. Install the guide in inner part of assembly
tool.
10. Hold the outer part of the assembly tool in the
bottom of valve housing (2) and guide the inner part of
the tool until it bottoms.
11. Press and turn 'O' ring (5) and kin ring (6) into
position in valve housing (2).
12. Draw the inner and outer parts of the assembly
tool out of valve housing (2) bore, leaving the guide
from the inner part in the bore.
13. With a light turning movement guide spool (9) and
sleeve (11) assembly into valve housing (2).
Note: Install spool (9) and sleeve (11) assembly with
cross pin (10) in the horizontal position.
14. Spool (9) and sleeve (11) assembly will push
assembly tool guide out of valve housing (2) when
installed. 'O' ring (5) and kin ring (6) are now installed
in position.
Fig. 4 - Installation of Bearing Assembly
1 - Outer Bearing Race
2 - Needle Bearing
3 - Inner Bearing Race
4 - Spool
5 - Sleeve
Section 220-0090
SM 1391 5-98 5
SM - 538
22. Install new 'O' rings (19) in gear rim (18). Install
gear wheel (17) and gear rim (18) on driveshaft (13).
Note: Install gear wheel (17) on driveshaft (13) so that
a tooth base in gear wheel (17) is positioned in relation
to the shaft slot, as shown in Fig. 6. Turn gear rim (18)
to line up the seven through holes to valve housing (2).
23. Install spacer (14) in gear wheel (17).
24. Install end cover (20) in position on valve housing
(2). Remove mounting fork tool from assembly.
25. Install roll pin (22) in bolt (23) and install bolt (23)
with washer (21) in bushing (4) hole.
26. Secure end cover (20) with remaining washers
(21) and bolts (24). Tighten bolts (23 & 24) to a torque
of 30 Nm (22 lbf ft).
27. Turn valve housing (2) in vice and install seal ring
(1) in valve housing.
28. Plug valve housing (2) ports to prevent ingress of
dirt prior to installation.
INSTALLATION
SPECIFICATIONS.
STEERING SYSTEM SCHEMATIC. Renew all
'O' rings where used.
WARNING
1. If removed, secure rubber mounts (9) and bracket
(4) to cab floor plate with bolts (7) washers (8 & 10)
and locknuts (11). Tighten bolts (7) to a torque of
30 Nm (22 lbf ft).
2. Install steering valve (1) through bracket (4) and
secure to steering column (3) and bracket (4) with
bolts (5) and washers (6).
SM - 539
Fig. 5 - Positioning Driveshaft (13) With Mounting Fork
15. Secure valve housing (2) in a soft jawed vice, end
cover (20) up.
16. Install check valve ball (3) into the hole, as shown
in Fig. 3.
17. Screw threaded bushing (4) lightly into check valve
ball (3) hole. The top of bushing (4) must lie just below
the surface of valve housing (2).
18. Install new 'O' ring (15) in valve housing (2).
19. Install distributor plate (16) on valve housing (2),
ensuring channel holes match the holes in valve
housing (2).
20. Insert driveshaft (13) in spool (9) bore ensuring
that the slot is parallel with cross pin (10).
21. Place driveshaft (13), as shown in Fig. 5, so that it is
held in position with the mounting fork (shown in Fig. 8).
Fig. 6 - Relationship of Shaft To Gear
Section 220-0090
SM 1391 5-98 6
Note: Slight creep or drift of the steering wheel is
normal.
c. Fill hydraulic tank to the recommended level and
install the filler cap.
Hydraulic Oil
The steering system should be kept filled with
LUBRICATION SYSTEM.
SPECIAL TOOLS
Special tools required for assembly of the steering
valve, are shown in Figs. 7 & 8. Refer to Section
these tools and general service tools required. These
tools are available from your dealer.
3. Tighten bolt (5), washer (16), nut (17) and coupling
(12) onto steering column (3). Slide bellows (2) down
over steering column (3) and tuck lower lip under cab
floor plate.
4. Connect all hydraulic lines to steering valve (1) as
tagged at removal.
5. Fill hydraulic tank with hydraulic oil, as specified in
'Filling and Bleeding The Steering System'.
6. Remove wheel blocks from all road wheels, place
the battery master switch in the 'On' position, start the
engine and operate the steering system. Check
hydraulic lines and steering valve (1) for leaks. Tighten
lines and fittings as required.
7. Secure access cover to cab floor plate with
mounting hardware and install floor mat in position.
FILLING AND BLEEDING THE STEERING
SYSTEM
1. Fill hydraulic tank to maximum level. Be ready to
add oil when the engine is started. Do not let oil drop
below the pump suction line to prevent air entering the
system.
2. Remove wheel blocks from all road wheels, start up
engine and let it idle. Add oil to the hydraulic tank as
required. When the hydraulic tank is filled to the
maximum level and oil is clear proceed as follows:
a. Turn the steering wheel from lock to lock to bleed
the air in the steering cylinders and lines.
Note: Immediately upon valve spool actuation oil must
be added to the hydraulic tank to replenish the oil
moving into the circuit.
WARNING
from the oil.
b. When oil in the hydraulic tank is clear (not cloudy or
creamy) the system is free of air.
SM - 540
Fig. 7 - 'O' Ring and Kin Ring Assembly Tool
SM - 541
Fig. 8 - Driveshaft Mounting Fork
Section 220-0090
SM 1391 5-98 7
STEERING VALVE DIAGNOSIS
TABLE626
Steering wheel does not centre Binding in steering linkage to valve Align as required
Worn gear wheel Replace parts
Burrs on sleeve or spool Disassemble and repair or replace
parts
Apparent inability to steer when
wheel is turned slowly
clean oil.
Slow steering Excessive wear in sleeve and spool Replace sleeve and spool
Excessive wear in gear wheel Replace gear wheel
Hard steering See 'Slow Steering'
Opposite steering Lines hooked up incorrectly Reconnect correctly
Wrong orientation between gear
wheel and gear rim
Realign per instructions
Steering wheel rocking back and forth See 'Opposite Steering'
Steering wheel continues to turn Input linkage binding Align as required
Burr on sleeve or spool Disassemble and repair or replace
clean oil.
No steering action Sleeve and spool locked together Disassemble and repair or replace
TABLE077
FIG. NO. ITEM NO. ITEM NAME
TORQUE
Nm lbf ft
1 & 3 23 & 24 Bolt 30 22
2 7 Bolt 30 22
* * * *
Section 220-0100
1 SM 1392 Rev 3 10-03
STEERING SYSTEM - Flow Amplifier Valve
The flow amplifier valve amplifies the oil flow from the
steering valve to the steering cylinders by eight. It is
mounted at the rear of the cab and consists of the
following:
Counter pressure & anti-cavitation valve (2)
DESCRIPTION
Numbers in parentheses refer to Figs. 1 & 6. Letters
in parentheses refer to Figs. 1 & 2.
The Flow Amplifier Valve can be identified as item 5 in
Section 220-0000, STEERING SYSTEM SCHEMATIC.
SM - 528
1 - System Relief Valve
2 - Counter Pressure & Anti-cavitation Valve
3 - Orifice
4 - Orifice
5 - Shock & Anti-cavitation Valve
L - Steering Valve Left Turn Oil
R - Steering Valve Right Turn Oil
LS - Load Sensing Pressure
EF - Excess Flow
HP - Pump Supply
PP - Pilot Pressure
HT - Return To Tank
CL - Left Turn Cylinder Oil Supply
CR - Right Turn Cylinder Oil Supply
11 - Throttle Check Valve
12 - Orifice
13 - Cover
14 - Cover
6 - Directional Spool
7 - Priority Spool
8 - Amplifier Spool
9 - Check Valve
10 - Orifice
Fig. 1 - Sectional View of Flow Amplifier Valve
Section 220-0100
2
Steering System - Flow Amplifier Valve
SM 1392 Rev 3 10-03
SM - 529
A - Counter Pressure and Anti-cavitation Valve
B - System Relief Valve
C - Priority Spool
D - Shock and Anti-cavitation Valve
E - Amplifier Spool
F - Directional Spool
LS - Load Sensing Pressure
EF - Excess Flow
HP - Pump Supply
PP - Pilot Pressure
P - Pump Supply To Steering valve
HT - Return To Tank
T - Steering valve Tank Return
R - Steering valve Right Turn Oil
CL - Left Turn Cylinder Oil Supply
CR - Right Turn Cylinder Oil Supply
L - Steering valve Left Turn Oil
shock pressures in the steering cylinders to 241 bar
(3 500 lbf/in). The shock valves sense cylinder
shock pressure when there is no steering taking
place. Shock pressure is absorbed in the cylinder
circuit and is not transmitted to the steering valve.
The anti-cavitation part of the valve prevents
cavitation in the cylinder circuit.
Amplifier spool (8) (Port 'E') controls the amount of oil
flowing into directional spool (6) 'HP' passage.
Directional spool (6) (Port 'F') when moved in either
direction against the return springs, sends oil pressure
to the steering cylinders for right or left turns.
maintains a back pressure of 5 bar (73 lbf/in) to give
improved suction during steering and prevent
cavitation in the steering cylinder circuit.
System relief valve (1) (Port 'B') is set to control
maximum working pressure in the steering system to
206 bar (3 000 lbf/in).
Priority spool (7) (Port 'C') directs oil supply from the
pump when engine is running, to steering valve port
'P', through the 'EF' passage to the body control
valve.
Shock & anti-cavitation valves (5) (Port 'D') limit
Fig. 2 - Flow Amplifier Valve Port Identification
HP
EF
LS
B PP A
P
HT
T
R
CL
CR
L
C
D
E
F
Section 220-0100
3 SM 1392 Rev 3 10-03
R L
7
P T LS
CR CL
8 8
R
5
A
TANK SUPPLY FROM
MAIN HYDRAULIC
PUMP
LEFT HAND
CYLINDER
RIGHT HAND
CYLINDER
OPERATION
Neutral Position
Numbers in parentheses refer to Figs. 1 & 6. Refer to
Fig. 3 for hydraulic schematic of the flow amplifier
valve and steering valve operating in the neutral position.
Oil flows out of the hydraulic tank, through the main
hydraulic pump, through check valves and enters the
flow amplifier valve at port 'HP'. Oil flows through
priority spool (7) and dead heads at amplifier spool (8).
At the same time, oil flows through priority spool (7),
exits from port 'P' and flows into the steering valve at
port 'P'. This pressure is dead headed at the steering
valve and, as the pressure builds up, pilot pressure is
tapped off of line 'P' and flows through port 'PP' to the
left hand end of priority spool (7).
This pressure moves priority spool (7) to the right,
thus opening the main supply 'HP' line to the 'EF'
passage. Oil exits from port 'EF' to the inlet port 'P'
on the body control valve. At the same time, a
restricted pressure in line 'P' maintains the pilot
pressure on the left hand end of priority spool (7).
SM - 3105A
Fig. 3 - Hydraulic Schematic - Neutral Position
Orifice (3) meters oil in the left hand end of amplifier
spool (8). During right or left hand turns this oil will
balance amplifier spool (8).
Orifice (4) meters working pressure in the load
sensing line 'LS' during normal steering operation and
dead heads at system relief valve (1).
Check valve (9) is located in the right hand end of
amplifier spool (8).
Orifices (10) are threaded into the ends of directional
spool (6). Their purpose is to control the movement
of directional spool (6) which controls the oil flow to
the steering cylinders.
Throttle check valve (11) is located in pilot pressure
port 'PP'.
Orifice (12) is threaded in the cross passage above
amplifier spool (8) and meters oil in the right hand
end of amplifier spool return spring area.
Orifice drillings are located in covers (13 & 14) at
either end of directional spool (6).
7 - Steering Valve
Section 220-0100
4
SM 1392 Rev 3 10-03
R L
7
P T LS
CR CL
8 8
R
5
A
TANK SUPPLY FROM
MAIN HYDRAULIC
PUMP
LEFT HAND
CYLINDER
RIGHT HAND
CYLINDER
SM - 3105B
In this condition, the body control valve has priority
over the steering valve. If oil is not required to operate
the body hoist cylinders, the oil flows through the body
control valve and back to tank.
Right Hand Turn
Fig. 4 for hydraulic schematic of the flow amplifier valve
and steering valve operating in the right turn position.
On turning the steering wheel for a right turn
application, oil flows from the steering valve 'LS' port to
the flow amplifier valve 'LS' port. The oil flows through
the load sensing orifice and into the spring cavity of
priority spool (7) moving the spool to the left. This
movement allows oil to flow out of port 'P' in the flow
amplifier valve and into port 'P' in the steering valve.
Oil leaves the steering valve through port 'R' and into
the left hand end of directional spool (6). This pressure
moves directional spool (6) to the right allowing a pilot
pressure to act on the right hand end of amplifier spool
(8). Pilot pressure overcomes spring pressure on the
left hand end of amplifier spool (8) moving amplifier
spool (8) to the left. This movement allows the main oil
flow from priority spool (7) and pilot flow through
directional spool (6) to merge at directional spool (6)
and flow through port 'CR' to the steering cylinders.
Return oil from the opposite ends of the steering
cylinders flows into port 'CL' and through directional
spool (6). Oil then flows through counter pressure &
anti-cavitation valve (2) and back to tank.
In this condition remaining oil supplied from the main
hydraulic pump, is available for the body hydraulics or
is returned to tank.
Left Hand Turn
Fig. 5 for hydraulic schematic of the flow amplifier valve
and steering valve operating in the left turn position.
On turning the steering wheel for a left turn application, oil
flows from the steering valve 'LS' port to the flow amplifier
valve 'LS' port. The oil flows through the load sensing
orifice and into the spring cavity of priority spool (7)
moving the spool to the left. This movement allows oil to
flow out of port 'P', in the flow amplifier valve, and into port
'P' in the steering valve.
Oil leaves the steering valve through port 'L' and into
Fig. 4 - Hydraulic Schematic - Right Turn
7 - Steering Valve
Section 220-0100
5 SM 1392 Rev 3 10-03
R L
7
P T LS
CR CL
8 8
R
5
A
TANK SUPPLY FROM
MAIN HYDRAULIC
PUMP
LEFT HAND
CYLINDER
RIGHT HAND
CYLINDER
SM - 3105C
Fig. 5 - Hydraulic Schematic - Left Turn
REMOVAL
WARNING
safely.
parking brake and switch off the engine. Turn
bottom of the hydraulic tank. Install a length of hose
on remote drain fitting, open drain cock and drain
4. Disconnect mounting hardware securing hydraulic
guard to the unit and remove hydraulic guard.
the right hand end of directional spool (6). This
pressure moves directional spool (6) to the left allowing
a pilot pressure to act on the right hand end of amplifier
spool (8). Pilot pressure overcomes spring pressure on
the left hand end of amplifier spool (8) moving amplifier
spool (8) to the left. This movement allows the main oil
flow from priority spool (7) and pilot flow through
directional spool (6) to merge at directional spool (6)
and flow through port 'CL' to the steering cylinders.
Return oil from the opposite ends of the steering
cylinders flows into port 'CR' and through directional
spool (6). Oil then flows through counter pressure &
anti-cavitation valve (2) and back to tank.
In this condition, remaining oil supplied from the main
hydraulic pump, is available for the body hydraulics or
is returned to tank.
7 - Steering Valve
Section 220-0100
6
SM 1392 Rev 3 10-03
6. Remove spring stop (27), springs (28 & 29) and
spring guide (30) from directional spool (6).
7. Remove spring (26) from amplifier spool (8).
8. Remove plate (22) and discard 'O' rings (19, 20 & 25).
9. Remove directional spool (6), priority spool (7) and
amplifier spool (8) assemblies from housing (36).
Note: Directional spool (6), priority spool (7),
amplifier spool (8) and check valve (9), are not sold
separately and are supplied as part of an assembly
with housing (36). Further disassembly of the spools
is therefore not required.
Shock & Anti-cavitation Valves (5)
1. Prise shock & anti-cavitation valves (5) from
housing (36) with a screwdriver. Take care not to
damage valves or housing.
Note: Shock & anti-cavitation valve (5) is available
only as an assembly.
Orifices (4 & 12) and Throttle Check
Valve (11)
1. Unscrew orifice (4) from 'LS' port in housing (36).
2. Unscrew throttle check valve (11) from 'PP' port in
housing (36).
3. Unscrew orifice (12) from cover (14) face in
housing (36).
INSPECTION
Clean and examine all parts for wear and damage. If
directional spool (6), priority spool (7), amplifier spool
(8) or housing (36) are damaged beyond repair,
replace as a unit.
Replace all 'O' rings and seals.
ASSEMBLY
Note: Before assembly, lubricate all parts with
LUBRICATION SYSTEM.
5. Clean outer area of the flow amplifier valve with a
suitable solvent. Ensure all hydraulic lines connected
to the flow amplifier valve are identified for ease of
catch leakage, disconnect hydraulic lines. Fit
blanking caps to all open lines and fittings.
6. Disconnect mounting hardware securing flow
amplifier valve to the vehicle. Remove flow amplifier
valve to a clean area for disassembly.
DISASSEMBLY
System Relief Valve (1)
1. Unscrew plug (31) and remove from housing (36).
Discard 'O' ring seal (32).
2. Unscrew system relief valve (1) and remove from
housing (36). Remove and discard 'O' ring seal (33)
from housing (36).
3. If required, hold system relief valve (1) body with
pipe pliers and unscrew adjusting screw from the body.
Counter Pressure & Anti-cavitation
Valve (2)
1. Unscrew plug (34) and remove from housing (36).
Discard 'O' ring (35).
2. Remove counter pressure & anti-cavitation valve (2)
from housing (36) by removing, small spring, steel ball,
piston housing and large spring, in that order.
Spools (6, 7 & 8)
1. Remove screws (15 & 17) and lockwashers
(16 & 18) securing cover (13) to housing (36).
Remove cover (13) from housing (36).
2. Remove spring stop (27), springs (28 & 29) and
spring guide (30) from directional spool (6).
3. Remove spring stop (23) and spring (24) from
priority spool (7).
4. Remove plate (21) and discard 'O' rings (19 & 20).
5. Remove screws (15 & 17) and lockwashers (16 & 18)
securing cover (14) to housing (36). Remove cover
(14) from housing (36).
Section 220-0100
7 SM 1392 Rev 3 10-03
SM - 533
Fig. 6 - Exploded View Of Flow Amplifier Valve
1 - System Relief Valve
2 - Counter Pressure & Anti-cavitation Valve
3 - Orifice
4 - Orifice
5 - Shock & Anti-cavitation Valve
6 - Directional Spool
7 - Priority Spool
8 - Amplifier Spool
9 - Check Valve
28 - Spring
29 - Spring
30 - Spring Guide
31 - Plug
32 - 'O' Ring Seal
33 - 'O' Ring Seal
34 - Plug
35 - 'O' Ring
36 - Housing
10 - Orifice
11 - Throttle Check Valve
12 - Orifice
13 - Cover
14 - Cover
15 - Screw
16 - Lockwasher
17 - Screw
18 - Lockwasher
19 - 'O' Ring
20 - 'O' Ring
21 - Plate
22 - Plate
23 - Spring Stop
24 - Spring
25 - 'O' Ring
26 - Spring
27 - Spring Stop
1. Install orifice (12) in cover (14) face of housing (36) and
tighten to a torque of 5 1 Nm (45 10 lbf in).
2. Install throttle check valve (11) in 'PP' port of
housing (36) and tighten to a torque of 10 3 Nm
(90 25 lbf in).
3. Install orifice (4) in 'LS' port of housing (36) and
4. Install shock & anti-cavitation valves (5) in port 'D'
of housing (36). Secure shock & anti-cavitation
valves (5) by hand.
5. If removed, install orifice (10) in each end of
directional spool (6) and tighten to a torque of 5 1 Nm
(45 10 lbf in).
6. Install directional spool (6), priority spool (7) and
amplifier spool (8) assemblies, in their respective
ports of housing (36).
7. Install spring (26) on amplifier spool (8) at cover
(14) end of housing (36).
8. Install spring guide (30), springs (28 & 29) and
spring stop (27), in that order, on directional spool
(6), at cover (14) end of housing (36).
9. Install new 'O' rings (19, 20 & 25) on plate (22) and
Section 220-0100
8
SM 1392 Rev 3 10-03
position in place on cover (14) end of housing (36).
10. Secure cover (14) on housing (36) with
lockwashers (16 & 18) and screws (15 & 17). Tighten
screws (15) to a torque of 80 10 Nm (710 90 lbf in)
and screws (17) to 25 5 Nm (220 45 lbf in).
11. Install spring (24) and spring stop (23) on priority
spool (7) at cover (13) end of housing (36).
12. Install spring guide (30), springs (28 & 29) and
spring stop (27), in that order, on directional spool
(6), at cover (13) end of housing (36).
13. Install new 'O' rings (19 & 20) on plate (21) and
position in place on cover (13) end of housing (36).
14. Secure cover (13) on housing (36) with
lockwashers (16 & 18) and screws (15 & 17). Tighten
screws (15) to a torque of 80 10 Nm (710 90 lbf in)
and screws (17) to 25 5 Nm (220 45 lbf in).
15. Install counter pressure & anti-cavitation valve
(2) in port 'A' of housing (36) as follows:
a. Smear large spring with vaseline and install in
piston housing. Install piston housing assembly in
housing (36).
b. Insert steel ball in piston housing.
c. Insert new 'O' ring (35) on plug (34) and insert
small spring in plug (34).
d. Install plug (34) assembly in housing (36) and
16. If removed, install adjusting screw in system
relief valve (1) body, as removed at disassembly.
17. Install new 'O' ring seal (32) in port 'B' of housing (36).
18. Screw system relief valve (1) into port 'B' in
housing (36). Tighten system relief valve (1) to a
torque of 30 3 Nm (265 25 lbf in).
19. Install new 'O' ring seal (32) on plug (31) and
secure in housing (36). Tighten plug (31) to a torque
of 60 5 Nm (530 45 lbf in).
INSTALLATION
SPECIFICATIONS.
WARNING
1. Install flow amplifier valve on the vehicle and
secure with mounting hardware removed during
removal.
2. Connect hydraulic lines and tubes to flow amplifier
valve, as tagged at removal.
in Section 300-0020, LUBRICATION SYSTEM. Install
filler cap on hydraulic tank.
4. Place the battery master switch in the 'On'
position, remove all wheel blocks, start the engine
and operate steering and body systems. Check
hydraulic lines and tubes for leaks. Tighten as
required.
5. Check hydraulic tank oil level and replenish as
required.
RELIEF VALVE - PRESSURE CHECK
1. Attach a 276 bar (4 000 lbf/in) pressure gauge to
remote steering pressure check point at the rear left
hand side of the tractor frame.
2. With the engine and hydraulic oil at operating
temperature, continuously steer into the LH stop at full
throttle. The pressure should rise to 206 bar (3 000 lbf/
in) and remain stable. Repeat this test 10 - 12 times.
3. Repeat the above test, continuously steering into
the RH stop.
4. If required, adjust relief valve pressure as follows:
a. Remove plug (31) from housing (36).
b. Screw adjusting screw with an allen key,
clockwise to increase the pressure reading, or
anticlockwise to reduce the pressure reading.
Section 220-0100
9 SM 1392 Rev 3 10-03
SPECIAL TOOLS
There are no special tools required for the procedures
dealer.
c. Install plug (31) in housing (36) and tighten to a
torque of 60 5 Nm (530 45 lbf in).
5. Repeat steps 2 and 3 to ensure pressure reading
remains constant.
AMPLIFIER VALVE DIAGNOSIS
TABLE076
Too few steering wheel turns from
stop to stop
Dirty, leaky or missing check
valve (9)
Clean or renew check valve (9)
Steering over-reacting Amplifier spool (8) stuck in open
position
spool (8) movement
Too many steering wheel turns from
stop to stop
Steering too slow
Amplifier spool (8) stuck in closed
position
spool (8) movement
Prolonged hard point when beginning
to turn the steering wheel
Amplification is delayed and sets in
suddenly
Dirty orifice (10) in directional
spool (6)
Clean or replace orifice (10)
Dirty orifice (3) in amplifier spool (8) Clean or replace orifice (3)
Dirty orifice (12) in valve housing Clean or replace orifice (12)
Dirty orifice (4) in 'LS' port Clean or replace orifice (4)
Blocked up throttle check valve (11)
in 'PP' port
Clean or replace throttle check valve
(11)
Steering wheel can be turned rapidly Setting of shock & anti-cavitation
valve (5) set too low
Untighten the counter nut and adjust
the valve setting screw with an allen
key. Tighten the counter nut to
secure.
Leaking or hanging shock &
anti-cavitation valve (5)
Disassemble shock & anti-cavitation
valve (5) and renew, if necessary
No end stop feeling Missing end stop in directional
spool (6)
Mount end stop
Steering has insufficient force to turn
the wheels at standstill
System relief valve (1) adjusted too
low
Remove plug and adjust pressure
setting with an allen key
Steering unit spool and sleeve
installed in wrong manner to each
other. No 'LS' signal can be built up.
Disassemble steering unit and turn
the spool and sleeve to the right
position
Steering unit spool and sleeve worn Change steering unit
No function at all Oil flows direct from pump to tank in
the steering unit
Manual steering ball is missing
Short hard point when beginning to
turn the steering wheel
Air in the 'LS' and 'PP' lines Bleed 'LS' and 'PP' lines
Clogged orifice in 'LS' port and/or
clogged check valve in 'PP' port
Clean the orifice and/or check valve
Section 220-0100
10
SM 1392 Rev 3 10-03
* * * *
TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf in
1 & 6 1 System Relief Valve 30 3 265 25
1 & 6 4 Orifice 10 3 90 25
1 & 6 10 Orifice 5 1 45 10
1 & 6 11 Throttle Check Valve 10 3 90 25
1 & 6 12 Orifice 5 1 45 10
1 & 6 15 Screw 80 10 710 90
1 & 6 17 Screw 25 5 220 45
1 & 6 31 Plug 60 5 530 45
1 & 6 34 Plug 25 3 220 25
SM 1393 Rev 1 2-00 1
Section 220-0120
SM - 406
STEERING SYSTEM - Steering Cylinder
8 - Rod Seal
9 - Wiper
10 - Bearing Ring
11 - Grub Screw
12 - Piston Seal
13 - 'O' Ring
14 - Backup Ring
15 - Cushion Sleeve
16 - Lube Fitting
17 - Pin
18 - Pin
19 - Spacer
20 - Seal (if fitted)
21 - Seal (if fitted)
22 - Bolt
24 - Locknut
25 - Washer
Fig. 1 - Sectional View Of Steering Cylinder and Mounting
DESCRIPTION
The steering cylinders can be identified as item 8 in
There are two single stage, double acting, cushioned
steering cylinders on the vehicle. The cylinder base
end is connected to the front frame and piston rod (2)
end is connected to the rear frame. Single stage,
double acting means that piston rod (2) can have oil
applied to either side, extending or retracting the
piston rod.
The cushioning effect is obtained by a tapered spear
at the base end of cylinder body (1) entering a cavity
in piston rod (2) through cushioning sleeve (15). This
gradually slows piston (3) which in turn helps to control
destructive shock effects when piston (3) bottoms.
Cylinder mounting is by pins (17 & 18), spacers (19),
seals (20 & 21, if fitted) and spherical bearings (5)
secured with circlips (6). Spherical bearings (5) permit
a limited amount of cylinder misalignment when
travelling over rough terrain.
Note: Refer to Section 220-0100, FLOW AMPLIFIER
VALVE for steering operation.
REMOVAL
WARNING
safely.
1 - Cylinder Body
2 - Piston Rod
3 - Piston
4 - End Cap
6 - Circlip
7 - 'O' Ring
Steering
Lock Bar
SM 1393 Rev 1 2-00 2
Steering System - Steering Cylinder
Section 220-0120
3. Support steering cylinder with blocks or suitable
lifting device.
4. Position a suitable oil container at line ends of one
cylinder. Ensure all hydraulic lines connected to the
steering cylinder assembly are identified for ease of
installation and disconnect hydraulic lines. Fit blanking
caps to all open lines and fittings to prevent ingress of
dirt.
5. Remove locknut (24), washer (25), hardened
washer (23) and bolt (22) securing pin (18) at piston
rod (2) end of cylinder assembly. Remove pin (18),
spacers (19) and seals (20 & 21, if fitted) from piston
rod (2) end of cylinder assembly.
6. Remove locknut (24), washer (25), hardened
washer (23) and bolt (22) securing pin (17) at base
end of cylinder assembly. Remove pin (17), spacers
(19) and seals (20 & 21, if fitted) from base end of
cylinder assembly.
7. Remove cylinder assembly to a clean area for
disassembly. Drain oil from cylinder assembly into a
suitable container.
8. Repeat steps 2 through 6 for opposite cylinder.
DISASSEMBLY
WARNING
safely.
1. Ensure clean working conditions, remove any port
plugs thus allowing easy entry of air into the cylinder,
preventing a vacuum when parts are withdrawn from
cylinder body (1).
2. Remove circlips (6) from base end of cylinder body
(1) and piston rod (2) end. Press out spherical
bearings (5).
3. Using special tool which can be fabricated as
shown in Fig. 2, unscrew end cap (4) until thread is
disengaged from cylinder body (1).
4. Support piston rod (2) at the rod eye and withdraw
from cylinder body (1). Ensure centre lines of piston
rod (2) and cylinder body (1) remain on the same axis
during removal of piston rod (2).
5. Place piston rod (2) on supports which will not
damage the piston rod diameter.
6. Remove and discard piston seal (12) and bearing
rings (10) from piston (3).
7. Remove grub screw (11) from bearing ring (10)
groove in piston (3).
8. Provide an anti-torsion device through piston rod (2)
eye to allow unscrewing of piston (3). Using special
tool which can be fabricated as shown in
Fig. 3, unscrew piston (3) from piston rod (2).
9. Remove and discard 'O' ring (13) and backup ring
(14) from piston (3).
10. Remove cushion sleeve (15) from piston rod (2).
11. Remove end cap (4) assembly from piston rod (2).
Remove and discard rod seal (8), wiper (9) and 'O'
ring (7) from end cap (4).
INSPECTION
Numbers in parentheses refer to Fig. 1
1. Clean all parts of the cylinder with a suitable solvent
and dry with clean, lint-free cloths. Clean all grooves
carefully to remove any foreign material.
2. Check cylinder body (1) and outer diameter of
piston (3) for scratches, cracks or other signs of
damage. Remove ridges, nicks and scratches with a
fine stone and re-clean. Replace any components
which cannot be repaired.
3. Inspect piston rod (2) for distortion, cracks or other
defects. Replace piston rod (2) if defective area is
irreparable.
4. Check spherical bearings (5) and cushion sleeve (15)
for wear and replace if necessary.
5. Replace all seals, 'O' rings and wipers.
SM 1393 Rev 1 2-00 3
Section 220-0120
ASSEMBLY
WARNING
safely.
1. Press spherical bearings (5) in base end of cylinder
body (1) and piston rod (2) end. Secure spherical
bearings (5) with circlips (6).
2. Install new rod seal (8), wiper (9) and 'O' ring (7), in
end cap (4). Install end cap (4) assembly over piston
rod (2) thread taking care not to damage rod seal (8)
on the thread.
3. Install cushion sleeve (15) in piston rod (2) end.
4. Install new 'O' ring (13) and backup ring (14) in
piston (3).
5. Apply Loctite 242 to the first two threads of piston rod
(2) and, using special tool which can be fabricated as
shown in Fig. 3, screw piston (3) on piston rod (2). Tighten
piston (3) to a torque of 1 356 Nm (1 000 lbf ft).
6. Insert grub screw (11) through bearing ring (10)
groove in piston (3) and into groove machined in
piston rod (2). Tighten grub screw (11) to a torque of
49 Nm (36 lbf ft). Ensure the extreme of grub screw
(11) is below the level of bearing ring (10) groove.
7. Insert new piston seal (12) and new bearing rings
(10) on piston (3).
8. Fully grease piston (3) OD and 'O' ring (7) in end
cap (4).
9. Sling piston rod (2) in a manner to allow careful
leading of assembled piston rod (2) into cylinder body
(1). Take care not to damage piston seal (12) on
cylinder body (1) threads.
10. After piston (3) is installed in cylinder body (1),
push piston rod (2) into cylinder body (1) maintaining
centre lines of piston rod (2) and cylinder body (1)
along the same axis.
11. Before piston rod (2) is fully home, and with slings
still taking some of piston rod (2) weight, engage end
cap (4) thread and screw home.
12. Push piston rod (2) to the mid-stroke position and,
using special tool which can be fabricated as shown in
Fig. 2, tighten end cap (4) to a torque of 542 Nm
(400 lbf ft).
INSTALLATION
SPECIFICATIONS.
WARNING
1. Install a suitable strap, or other lifting device, around
one cylinder assembly and position cylinder assembly
on the vehicle, with base end of cylinder ready for
mounting.
2. Install spacers (19) and seals (20 & 21) on base
end of cylinder and insert pin (17). Secure pin (17) with
bolt (22), hardened washer (23), washer (25) and
locknut (24).
3. Install spacers (19) and seals (20 & 21) on rod end
of cylinder and insert pin (18). Secure pin (18) with
bolt (22), hardened washer (23), washer (25) and
locknut (24).
5. Connect the hydraulic oil lines to the cylinder ports
as tagged during removal.
6. Lubricate pins at lube fittings (16) with lubricant specified
7. Check oil level in hydraulic tank and add oil as
required. Refer to Section 230-0040, HYDRAULIC
TANK, for correct fill level and Section 300-0020,
LUBRICATION SYSTEM, for oil specification.
SM 1393 Rev 1 2-00 4
Section 220-0120
and operate the steering from lock to lock several
times to purge air from the steering lines. Check
steering lines and fittings for leaks and tighten as
required.
MAINTENANCE
Visually inspect steering cylinders and mounting
regularly for leaks and damage. Repair/replace as
required. Lubricate cylinder pins every 50 hours
through lube fittings (16, Fig. 1) with lubricant specified
SPECIAL TOOLS
Special tools for removal and installation of the piston
and end cap can be fabricated as shown in Figs. 2 & 3.
numbers of general service tools and adhesives required.
These tools and adhesives are available from your
dealer.
SM - 407
Dimensions in mm
(inches) Fig. 2 - End Cap Torque Tool
SM - 408
EN3B
DOM TUBE
S
Q
U
A
R
E
Dimensions in mm (inches)
SILVER STEEL
OUTER SHELL TO BE SECURED
TO INNER BODY WITH 2BA CAPSCREWS
Fig. 3 - Piston Torque Tool
DRILL AND REAM THROUGH
AND FIT 12 (0.472)
HARDENED DOWEL
TORQUE PINS 2 PLACES
SECURE ALUMINIUM
COLLAR WITH (3) M8
CAP SCREWS
SM 1393 Rev 1 2-00 5
Section 220-0120
TABLE074
TORQUE
Nm lbf ft
1 3 Piston 1 356 1 000
1 4 End Cap 542 400
1 11 Grub Screw 49 36
* * * *
Section 220-0140
SM 1395 Rev 1 2-00 1
STEERING SYSTEM - Emergency Valve
SM - 542
DESCRIPTION
The Emergency Valve can be identified as item 4 in
rail, the emergency valve forms part of the emergency
steering system. It is connected to the main output line
of the wheel driven emergency steering pump on the
transmission.
OPERATION
Normal Steering
Refer to Fig. 2 for hydraulic schematic of emergency
valve during normal steering operation.
During normal operation, pilot pressure from the main
hydraulic pump acts on spool (3), pushing the spool to
the right. The emergency steering pump draws oil from
the hydraulic tank and pumps it to port 'B' of the
emergency valve. The oil is directed through the
emergency valve, exits at port 'C' and returns to the
hydraulic tank.
SM - 543
Fig. 2 - Emergency Valve - Normal Steering Operation
4 - Emergency Valve
6 - Check Valve
1 - Hydraulic Tank
3 - Emergency Pump
FLOW
AMPLIFIER
INLET
STEERING
PUMP
Fig. 1 - Sectional View of Emergency Valve
1 - Retainer
2 - Cage
3 - Spool
4 - Spring Ring
5 - Spring
6 - Spring
7 - 'O' Ring
8 - 'O' Ring
9 - 'O' Ring
10 - 'O' Ring
11 - 'O' Ring
12 - Backup Washer
13 - Backup Washer
14 - Backup Washer
15 - Backup Washer
16 - Sealing Washer
17 - 'O' Ring
Section 220-0140
Steering System - Emergency Valve
SM 1395 Rev 1 2-00 2
Emergency Steering
Refer to Fig. 3 for hydraulic schematic of emergency
valve during emergency steering.
In the event of loss of pressure from the steering pump,
springs (5 & 6) return spool (3) to the left. The emergency
steering pump draws oil from the hydraulic tank and
pumps it to port 'B' of the emergency valve. The oil is
directed through the emergency valve and exits at port 'A'
to supply the steering system.
A pressure switch, installed in the block at the top port
on the main hydraulic pump, sends a signal to
illuminate the steering pressure warning light to indicate
a fault in the steering system supply pressure.
REMOVAL
WARNING
be sure wheel blocks are properly secured and of
3. Clean outer area of the emergency valve with a
to the emergency valve are identified for ease of
caps to all open lines.
4. Remove mounting hardware securing emergency
valve assembly and remove emergency valve
assembly.
INSTALLATION
SM - 544
4 - Emergency Valve
6 - Check Valve
1 - Hydraulic Tank
3 - Emergency Pump
Fig. 3 - Emergency Valve - Emergency Steering Operation
FLOW
AMPLIFIER
INLET
1. Install emergency valve assembly to the cradle
assembly at the rear of the cab and secure with
2. Remove blanking caps and connect hydraulic lines
to the emergency valve as tagged at removal.
remove all wheel blocks and start the engine. Check all
lines and fittings for leaks and tighten as required.
MAINTENANCE
The emergency valve is a non-serviceable item except
in the instance of damage being caused to the seals.
Should a fault be diagnosed the cartridge assembly
can be unscrewed from the housing for inspection.
Check for sticking spool or faulty seals.
Refer to the vehicle's parts book for part numbers of
the cartridge kit and seal kit for the emergency valve.
* * * *
STEERING
PUMP
Section 230-0000
SM 1407 Rev 2 11-01 1
BODY SYSTEM - Body System Schematic
DESCRIPTION
Oil supply to the body hoist system is by common
components to both the body and steering systems.
Refer to Section 220-0000, STEERING SYSTEM
SCHEMATIC.
Hydraulic oil is drawn from the hydraulic tank (1) by
the main hydraulic pump and pumped to the flow
amplifier valve via double check valve. A priority spool
within the flow amplifier valve directs oil supply from
the main hydraulic pump to the steering valve, and,
through the 'EF' port to body control valve (2).
A brief description of the individual components shown
in the body hoist system schematic are listed below.
Detailed service and operating instructions can be
found in the relevant component sections of this
manual.
Hydraulic Tank (1)
hydraulic oil filter, oil strainer and oil level sight gauge.
Located on top of the tank assembly is the filler cap
and breather.
Body Control Valve (2)
Refer to Section 230-0060, BODY CONTROL VALVE.
The single spool body control valve is mounted to the
cradle assembly at the rear of the cab. The control
valve consists of a relief valve assembly and a four
position control spool.
The four positions of the control spool are 'Raise',
'Hold', 'Lower' (Power Down) and 'Float'. The 'Float'
position is detented and the control spool should be
kept in this position at all times, except when Raising
or Lowering the body.
A relief valve assembly at the pressure inlet, opens
and allows oil to flow through hydraulic oil cooler (4)
and back to hydraulic tank (1) when pressure in the
hydraulic system exceeds 172 bar (2 500 lbf/in).
Movement of the control spool is controlled by
electrical signals from the body control joystick in the
operators compartment. Refer to Section 230-0081,
BODY CONTROL JOYSTICK.
Body Cylinders (3)
Refer to Section 230-0130, BODY CYLINDER.
There are two single stage, double acting body hoist
cylinders, cushioned at both ends of the stroke, on the
vehicle. The cylinder base end is connected to the
trailer frame and piston rod eye end is connected at
the body. Single stage double acting means that the
piston rod can have oil applied to either end, extending
or retracting the piston rod.
The cushioning effect when the cylinder is being
extended is obtained by a tapered spear on the piston
rod passing through a cushioned sleeve. This
gradually slows the piston which in turn helps to
control destructive shock effects when the piston
reaches the full extent of its travel.
retracted is obtained by a tapered spear at the base
end of the cylinder body entering a cavity in the piston
rod through a cushioning ring. This gradually slows the
piston which in turn helps to control destructive shock
effects when the piston bottoms.
Cylinder mounting is by pins, spacers and spherical
bearings secured in place by circlips. Spherical
bearings permit a limited amount of cylinder
misalignment.
Pilot Supply Valve (5)
Refer to Section 230-0121, PILOT SUPPLY VALVE.
Mounted to the cradle assembly at the rear of the cab,
the pilot supply valve is a direct acting pressure
reducing valve which steps down the supply pressure
to 30 bar (435 lbf/in). Intregal of the pilot supply valve
is a relief valve which opens at 45 bar (652 lbf/in).
Section 230-0000
Body System - Body System Schematic
SM 1407 Rev 2 11-01 2
Pressure Test Points
There are two pressure check points within the body
hoist system. Pressure readings at these points should
be as follows:
Test Point A - Located in the manifold at the rear left
hand side of the tractor frame. The pressure is taken
off the outlet tube from port 'EF' in the flow amplifier
valve.
System Relief Pressure - 172 bar (2 500 lbf/in)
Test Point B - Located in tee piece at port 'U' of pilot
supply valve (5).
Pilot Valve Pressure - 30 bar (435 lbf/in)
aligned correctly.
been achieved.
MAINTENANCE
Maintenance instructions, intervals and warnings
contained in the individual component sections of this
manual should be strictly adhered to.
Hydraulic Oil
The hydraulic tank should be kept filled with hydraulic
fluid as specified in Section 300-0020, LUBRICATION
SYSTEM. Refer to Section 230-0040, HYDRAULIC
TANK for correct fill level and procedure.
SERVICE TOOLS
Multi-gauge
gauges through a pressure range of 762 mm (30 in)
of vacuum to 345 bar (5 000 lbf/in
2
).
problems early in electrical, mechanical and
hydraulic systems. Hand held and easy to use, you
simply aim, pull the trigger, and read the temperature.
Since there is no need to touch what you are
measuring, temperatures of hard-to-reach or moving
components can be taken without getting burned or
shocked.
SM - 1335
'O' RING 'O' RING
SLEEVE
TUBE
FITTING
NUT
Body Control Valve - Pilot Pressures
Position Port 'P1' Port 'P2'
Raise 30 bar 0 bar
Hold 0 bar 0 bar
Float 0 bar 30 bar
Lower 0 bar 13.5 bar
connections, the following procedure should be
carried out during installation. Refer to Fig. 1.
surfaces are clean. If necessary, retain 'O' ring/seal
in place with a light coating of grease or vaseline.
Section 230-0000
SM 1407 Rev 2 11-01 3
Body System - Body System Schematic
BODY SYSTEM DIAGNOSIS
Body raise time too slow, Worn pump. Pump output should Repair or replace pump.
should be 16 sec, loaded. be as specified in Section 000-0000,
Hydraulic oil pressure too GENERAL INFORMATION.
Pump cavitation Check oil level in hydraulic tank. Refer to
Section 230-0040, HYDRAULIC TANK.
Check for suction leak at pump inlet port.
Check for obstruction in hydraulic lines.
Check anti-cavitation plug on suction line
for tightness
Dirt or foreign particles lodged Replace relief valve assembly. Refer to
between relief valve control Section 230-0060, BODY CONTROL
poppet and seat VALVE.
Relief valve worn Check relief valve setting, as described in
Section 230-0060, BODY CONTROL
VALVE. Replace relief valve assembly if
worn.
Control valve spool not stroking Check spool travel, as described in Section
completely 230-0060, BODY CONTROL VALVE.
Body cylinder binding or Repair or replace body cylinder.
obstruction in oil passage
Incorrect pilot pressure from the Check pilot pressure. Replace valve if
pilot control valve necessary (non-servicable item).
Body lower time too slow, Return oil from body cylinders is Check hydraulic lines for restrictions.
should be 12 sec in 'Power being restricted in hydraulic lines
Down' or body control valve
Incorrect pilot pressure from the Check pilot pressure. Replace valve if
pilot control valve necessary (non-servicable item).
Body will not hold Oil bypassing between control Replace body control valve assembly.
spool and control valve body
Control spool not centred Repair body control valve.
Oil bypassing body cylinder seals Repair body cylinders.
Body will not raise or lower Pump failure Repair or replace pump.
Relief valve pressure too low Check and adjust relief valve setting, as
described in Section 230-0060, BODY
CONTROL VALVE.
Electrical failure at joystick or body Check and replace joystick and/or control
control valve solenoids solenoids.
low, should be 172 bar
(2 500 lbf/in).
Check control valve spool for correct 'Float'
position. Refer to Section 230-0060, BODY
CONTROL VALVE.
Check pump driveshaft.
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COMPONENTS
1 - Hydraulic Tank
2 - Body Control Valve
3 - Body Cylinders
5 - Pilot Supply Valve
COLOUR CODES
Green - Intake Oil
Yellow - Static Oil
3 3
4
1
A
B
5
2
FROM
BRAKING
SYSTEM
FROM EF PORT
IN FLOW AMPLIFIER
VALVE
P2 T2 U2
P1
P1
T1
T1
U1
T2
P2
L T R
P
30
45
bar
bar
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COMPONENTS
1 - Hydraulic Tank
3 - Body Cylinders
COLOUR CODES
Green - Intake Oil
Yellow - Static Oil
3 3
4
1
A
B
5
2
FROM
BRAKING
SYSTEM
FROM EF PORT
IN FLOW AMPLIFIER
VALVE
P2 T2 U2
P1
P1
T1
T1
U1
T2
P2
L T R
P
30
45
bar
bar
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4
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2

1
1
-
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1
6
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-

1
8
4
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COMPONENTS
1 - Hydraulic Tank
3 - Body Cylinders
COLOUR CODES
Green - Intake Oil
Yellow - Static Oil
3 3
4
1
A
B
5
2
FROM
BRAKING
SYSTEM
FROM EF PORT
IN FLOW AMPLIFIER
VALVE
P2 T2 U2
P1
P1
T1
T1
U1
T2
P2
L T R
P
30
45
bar
bar
S
e
c
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2
3
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-
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COMPONENTS
1 - Hydraulic Tank
3 - Body Cylinders
COLOUR CODES
Green - Intake Oil
Yellow - Static Oil
3 3
4
1
A
B
5
2
FROM
BRAKING
SYSTEM
FROM EF PORT
IN FLOW AMPLIFIER
VALVE
P2 T2 U2
P1
P1
T1
T1
U1
T2
P2
L T R
P
30
45
bar
bar
Section 230-0040
SM 1913 Rev 2 10-03
1
BODY SYSTEM - Hydraulic Tank
SM - 2413
DESCRIPTION
The hydraulic tank can be identified as item 1 in
Section 230-0000, BODY SYSTEM SCHEMATIC.
The hydraulic tank (1) is the common reservoir for the
mounted off the frame and fender bracket (23) on
springs (16), at three points, at the rear right hand
side of the tractor.
Integral with hydraulic tank (1) assembly are filter
assembly (13), oil level sight gauge (11), strainer
(12) and access covers (4 & 10). Located on top of
the tank is filler cap (2), breather (8) and filter visual
indicator (29).
Fig. 1 - Exploded View of Hydraulic Tank and Mounting
1 - Hydraulic Tank
2 - Filler Cap
3 - Gasket
4 - Access Cover
5 - Bolt
6 - Lockwasher
7 - Gasket
8 - Breather
9 - Nipple
28 - Elbow - 90
29 - Visual Indicator
30 - Washer
31 - Valve Assembly
32 - Element
*33 - Padlock
*34 - Key
* - Not Shown
10 - Access Cover
11 - Sight Gauge
12 - Strainer
13 - Filter Assembly
14 - Bolt
15 - Washer
16 - Spring
17 - Washer
18 - Locknut
19 - Bolt
20 - Washer
21 - Bolt
22 - Lockwasher
23 - Fender Bracket
24 - Cover Plate
25 - Wing Nut
26 - Rod
27 - Adaptor
8
7
4
9
5
6
12
14
15
16
17
18
23
22
21
31
30
1
2,3
24
29
28
27
5
6
10
7
25
26
13,32
19
11
20
16
17
18
Section 230-0040
Body System - Hydraulic Tank
SM 1913 Rev 2 10-03
2
SM - 1847
OPERATION
otherwise specified. Refer to Fig. 2 for hydraulic
schematic of hydraulic tank.
Oil from hydraulic tank (1) is filtered through strainer
(12) before it is pumped through the respective
hydraulic systems.
The brake control oil is drawn from hydraulic tank (1)
by brake pump (4, Fig. 2) and pumped to the brake
manifold valve to supply the braking system. Refer to
Section 250-0050, BRAKE MANIFOLD VALVE.
The steering and body hoist oil is drawn from hydraulic
tank (1) by main hydraulic pump (2, Fig. 2) and
pumped to the flow amplifier valve to supply the
steering and body hoist systems. Refer to Section
220-0100, FLOW AMPLIFIER VALVE.
Emergency steering oil is drawn from hydraulic tank
(1) by emergency pump (3, Fig. 2) and is pumped to
the emergency valve. Should a failure occur at the
main hydraulic pump the emergency pump will supply
the steering system with oil to enable the vehicle to be
brought to a safe halt.
Return oil from the hydraulic systems flows through
hydraulic oil cooler (5, Fig. 2) and filter assembly
(13 & 32) before entering the tank storage area. The
filter assembly has a bypass valve which allows oil to
bypass element (32) when it is cold or when the filter
element is plugged. The bypass valve starts to open
at a pressure differential of 1.5 bar (22 lbf/in
2
) and is
fully open at 3.5 bar (50 lbf/in
2
). Visual indicator (29)
shows red when element (32) requires to be changed.
MAINTENANCE
SPECIFICATIONS.
Fig. 2 - Hydraulic Schematic of Hydraulic Tank
1 - Hydraulic Tank
2 - Main Hydraulic Pump 3 - Emergency Pump 4 - Brake Pump 5 - Hydraulic Oil Cooler
SUPPLY TO
BRAKE MANIFOLD
VALVE
SUPPLY TO
EMERGENCY
VALVE
RETURN
TO TANK
SUPPLY TO FLOW
AMPLIFIER VALVE
1
5
3
2
4
Section 230-0040
SM 1913 Rev 2 10-03
3
WARNING
safely.
Checking Oil Level
1. Operate the body hoist and steering systems
several times to bring the oil to correct operating
temperature.
steering circuit. Operate treadle valve continuously to
discharge braking accumulators.
the 'Off' position.
4. Check oil level and add if low. Sight gauge (11)
should show half full. If oil is required, remove
padlock (33) and filler cap (2) from hydraulic tank (1)
and fill hydraulic tank with hydraulic oil specified in
Section 300-0020, LUBRICATION SYSTEM. Install
filler cap (2) on hydraulic tank (1) and secure with
padlock (33).
Replacing Hydraulic Oil
Hydraulic oil should be changed every 2 000 hours.
Refer to Section 300-0020, LUBRICATION SYSTEM,
for hydraulic oil used in the system.
Note: When replacing the hydraulic oil due to a
hydraulic failure, or at recommended change interval,
element (32) must be replaced and hydraulic tank (1),
and strainer (12) cleaned thoroughly using a suitable
solvent.
Replacing Filter Element
After first 100 hours of operation or when visual
indicator (29) shows red, whichever comes first, clean
filter assembly (13) and install new element (32).
Every 1 000 hours of operation or when visual indicator
(29) shows red, whichever comes first, clean filter
assembly (13) and install new element (32).
directions several times to relieve any pressure in
the steering circuit. Operate treadle valve
continuously to discharge braking accumulators.
the 'Off' position.
plate (24) and access cover (10) to top of hydraulic
tank (1). Remove access cover (10) and gasket (7)
from hydraulic tank (1). Discard gasket (7).
4. Unscrew wing nuts (25) and remove filter
assembly (13) from hydraulic tank (1).
5. Remove and discard element (32) from filter
assembly (13).
6. Install new element (32) in filter assembly (13).
7. Install filter assembly (13) over rods (26) and
secure in place with wing nuts (25).
8. Secure cover plate (24), access cover (10) and
new gasket (7) on hydraulic tank (1) with bolts (5)
and lockwashers (6).
9. Remove padlock (33) and filler cap (2) from
hydraulic tank (1) and fill hydraulic tank with hydraulic
oil specified in Section 300-0020, LUBRICATION
SYSTEM. Install filler cap (2) on hydraulic tank (1) and
secure with padlock (33).
Cleaning/Replacing Strainer
Note: Strainer (12) should be cleaned every time
hydraulic tank (1) is drained for any reason. Refer to
'Replacing Hydraulic Oil' for change interval.
steering circuit. Operate treadle valve continuously to
discharge braking accumulators.
the 'Off' position.
Section 230-0040
SM 1913 Rev 2 10-03
4
TANK ASSEMBLY
Removal
WARNING
safely.
1. Position the vehicle in a level work area, ensure
the body is fully lowered, apply the parking brake and
directions several times to relieve any pressure in
the steering circuit. Operate treadle valve
continuously to discharge braking accumulators.
2. Block all road wheels, place the steering lock bar
3. Remove blanking cap from remote drain assembly
(31) on the bottom of hydraulic tank (1). Install a
length of hose on remote drain fitting, open drain
cock and drain hydraulic oil into a suitable container.
Close drain cock, remove hose and reinstall blanking
cap on remote drain assembly (31).
4. Ensure all hydraulic lines connected to hydraulic
tank (1) are identified for ease of installation and, with
disconnect hydraulic lines. Fit blanking caps and
plugs to all open lines and fittings.
5. Install a suitable lifting device on lifting eyes of
hydraulic tank (1) and remove locknuts (18), washers
(15, 17 & 20), springs (16) and bolts (14 & 19)
securing hydraulic tank (1) to fender bracket (23) and
frame.
6. Carefully remove hydraulic tank (1) assembly from
the unit to a clean work area for disassembly.
(31) on the bottom of hydraulic tank (1). Install a
length of hose on remote drain fitting, open drain
cock and drain hydraulic oil into a suitable container.
4. Remove bolts (5), lockwashers (6), access cover
(4) and gasket (7) from top of hydraulic tank (1).
Discard gasket (7).
5. Unscrew and remove strainer (12) from the inside
of hydraulic tank (1).
WARNING
Splashing liquid. Wear a suitable face shield
when using compressed air to dry hydraulic
tank and components.
6. Clean out the inside of hydraulic tank (1) and
strainer (12) with a suitable solvent and dry with
compressed air.
7. Inspect strainer (12) for damage and replace if
required.
8. Install strainer (12) in hydraulic tank (1) and secure.
9. Place new gasket (7) and access cover (4) on
hydraulic tank (1) and secure with bolts (5) and
lockwashers (6).
hydraulic tank (1) and fill hydraulic tank with hydraulic
oil specified in Section 300-0020, LUBRICATION
SYSTEM. Install filler cap (2) on hydraulic tank (1) and
secure with padlock (33).
11. Place the battery master switch in the 'On' position
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.
12. Switch off the engine, check for leaks and check
oil level as described under 'Checking Oil Level'.
Section 230-0040
SM 1913 Rev 2 10-03
5
Disassembly
1. Remove internal components from hydraulic tank (1)
as described under 'Maintenance'.
hydraulic tank (1).
3. Remove breather (8), nipple (9) and sight gauge
(11) from hydraulic tank (1).
Inspection
WARNING
1. Clean hydraulic tank (1) and components with a
suitable solvent and dry with compressed air.
2. Inspect hydraulic tank (1) for weld cracks and
security of internal pipes and weld fitments.
3. Inspect breather (8), strainer (12) and filter
assembly (13) for damage. Replace if required.
Assembly
1. Renew all seals and gaskets and install all internal
components in hydraulic tank (1), as previously
described under 'Maintenance'.
2. Install breather (8), nipple (9) and sight gauge (11)
on hydraulic tank (1).
Installation
SPECIFICATIONS.
BODY SYSTEM SCHEMATIC. Renew all 'O' rings
where used.
WARNING
safely.
1. Using a suitable lifting device, position hydraulic
tank (1) in position on the vehicle and secure with
bolts (14 & 19), washers (15, 17 & 20), springs (16)
and locknuts (18). Tighten locknuts (18) until springs
(16) are compressed to a length of 30 mm (1.18 in).
2. Install new 'O' rings and install all hydraulic lines
and fittings to hydraulic tank (1), as tagged at
removal.
3. Fill hydraulic tank (1) with hydraulic oil specified in
filler cap (2) on hydraulic tank (1) and secure with
padlock (33).
remove all wheel blocks, start the engine and operate
the steering, braking and body hoist systems to
circulate the oil.
5. Switch off the engine, check for leaks and check oil
level as described under 'Checking Oil Level'.
SPECIAL TOOLS
dealer.
* * * *
Section 230-0050
SM 1394 Rev1 12-04
1
1
10
7
14
12
11
13
8
9
9
8
21
4
5
18
19 20
6
7
2
15
3
17
16
3
20
17
18
19
8.5 mm
APPLY GREASE
SEALANT POSITION
11
1
0

m
m

A
P
P
.
4 mm
BODY SYSTEM - Main Hydraulic Pump
SM - 3366
OPERATION
Numbers in parentheses refer to Fig. 1. Refer to
Fig. 2 for typical pump operation.
DESCRIPTION
Mounted off the transmission power takeoff (PTO), the
hydraulic pump supplies oil to the body control valve to
operate the body hoist system. The hydraulic pump is
a rotary gear pump mounted to the transmission
housing and driven by the transmission gear train.
The major pump components are; body (1), front cover
(2), mounting flange (3), driveshaft and gear (11),
driven gear (12), wear plates (13 & 14), wear plate
seals (8) and bearings (7).
There are two ports on the hydraulic pump:
Port 'A' - Suction side from hydraulic oil tank
Port 'B' - Pressure supply to body control valve
SM - 1864
Fig. 2 - Typical Gear Pump Operation
Fig. 1 - Exploded View of Hydraulic Pump
7 - Bearing
8 - Wear Plate Seal
9 - Backup Seal
10 - Ring Seal
11 - Driveshaft and Gear
12 - Driven Gear
13 - Wear Plate
14 - Wear Plate
15 - Capscrew
16 - Capscrew
17 - Multistep Push Clip
18 - Seal
19 - Location Sleeve
20 - Seal
21 - Seal
1 - Body Housing
2 - Front Cover
3 - Mounting Flange
4 - Bolt
5 - Washer
6 - 'O'-Ring
INLET OUTLET
DRIVE GEAR
DRIVEN GEAR
DRIVE
DRIVEN
Body System - Main Hydraulic Pump
Section 230-0050
SM 1394 Rev1 12-04
2
DISASSEMBLY
Numbers in parentheses refer to Figs. 1.
1. Place pump assembly in a soft-jawed vice, and
clamp on body (1) casing. Match mark port body (1),
front cover (2) and mounting flange (3) to aid in
assembly.
Note: Do not clamp vice on machined surfaces of the
pump at any time.
2. Remove capscrews (16) securing mounting flange
(3) and front cover (2) together.
3. Tap mounting flange (3) with a soft hammer and
remove it from front cover (2).
Note: Do not attempt to pry the pump units apart with
a large screwdriver or pry bar. The machined surfaces
of the mounting flange (3) or front cover (2) may be
damaged.
4. Remove and discard shaft seals (18 & 20).
5. Remove capscrews (15) securing front cover (2)
and body housing (1) together.
6. Tap front cover (2) with a soft hammer and remove
from body housing (1).
Note: Do not attempt to pry the pump units apart with
a large screwdriver or pry bar. The machined surfaces
of the body housing (1) or front cover (2) may be
damaged.
7. Remove and discard ring seal (10) from body
housing (1).
8. Remove wear plate (13), wear plate seal (8) and
backup seal (9) from shaft front cover (2). Note the
position of wear plate seal (8) in wear plate (13)
groove, for proper assembly.
9. Remove driveshaft gear (11) and driven gear (12)
from body housing (1).
10. Remove wear plate (14) and wear plate seal (8)
from body housing (1). Note the position of wear plate
seal (8) in wear plate (14) groove, for proper
assembly.
11. Using a suitable puller, remove bearings (7) from
shaft front cover (2), only if they are being replaced.
As driveshaft and gear (11) rotates, driven gear (12)
rotates in the opposite direction. Pockets between the
drive and driven gear teeth carry oil from inlet port 'A',
around gear housing (2) ID, to outlet port 'B'. As the
gear teeth re-mesh, oil is forced out of outlet port 'B' to
the body control valve. Refer to Section 230-0060,
BODY CONTROL VALVE.
The maximum oil delivery of the hydraulic pump is
fixed by the width of its respective gear set and the
speed at which driveshaft and gear (11) rotates.
REMOVAL
WARNING
safely.
3. Remove hydraulic tank remote drain plug and drain
hydraulic oil into a suitable container. Reinstall drain
plug in hydraulic tank remote drain fitting.
4. Clean pump housing and disconnect inlet line and
outlet line from pump assembly. Drain oil in hydraulic
lines into a suitable container. Cap hydraulic lines and
plug pump ports to prevent ingress of dirt.
5. Support pump assembly with suitable lifting
equipment. Remove bolts (4) and lockwashers (5)
securing pump assembly to the transmission. Remove
pump assembly from the transmission and discard 'O'-
Ring (6).
6. Wash outside of the pump assembly thoroughly,
with a suitable solvent, and move to a clean work area
for disassembly.
Section 230-0050
SM 1394 Rev1 12-04
3
ASSEMBLY
1. If removed, install bearings (7) in front cover (2) and
body housing (1) using an arbor press. Lightly oil
bearing (7) outside diameter with mineral oil prior to
insertion.
Note: Assemble bearings (7) in body housing (1)
bores with the bushing split line positioned at
3 o'clock. The lubrication groove will be positioned at 1
o'clock.
Note: Assemble bearings (7) in the front cover (2)
bores with the bushing split line positioned at
9 o'clock. The lubrication groove will be positioned at
11 o'clock, as shown in Fig. 3.
INSPECTION
Numbers in parentheses refer to Figs. 1.
compressed air.
2. Check driveshaft and gear (11) and driven gear (12)
carefully for wear. Remove burrs or light score marks
from gear faces and teeth with an India stone. Heavy
scoring, grooving or burring of gear teeth OD requires
gear replacement. Nicked, grooved or fretted gear
tooth mating surfaces also requires gear replacement.
Any wear of gear hubs in excess of 0.025 mm (0.001
in), or detectable by touch, requires gear replacement.
Note: Since both driveshaft and gear (11) and driven
gear (12) of a set are matched, they must be replaced
as a set if one is worn or damaged.
3. If gears are replaced, bearings (7) must be replaced
at the same time. Bearings (7) should fit into their
bores with a heavy press fit.
4. Check the centre of wear plates (13 & 14) at the
point of meshing of driveshaft and gear (11) and driven
gear (12). Erosion indicates contaminated oil. Pitting
indicates cavitation or aeration of the oil supply.
Discoloured wear plates are a sign of the pump over
heating.
Wear plate (13 & 14) side wear permits oil to bypass
gears and allows internal oil slippage and reduced
pump efficiency. Check wear plate (13 & 14) wear
against the size of new wear plates. Replace wear
plates (13 & 14) if worn in excess of 0.05 mm
(0.002 in).
5. Deburr all machined surfaces of port end body
housing (1), front cover (2) and mounting flange (3)
with a medium grit India stone. Replace gear housing
(2) if wear on machined surfaces exceeds 0.127 mm
(0.005 in).
6. Replace all wear plate seals (8), backup seals (9),
ring seal (10) and lip seals (18 & 19).
7. Clean parts in a suitable solvent and dry with
compressed air after deburring surfaces.
Fig. 3 - Bearing Lubrication Groove Position
SM - 1865
7
7
OUTLET
(SMALL PORT)
INLET
(LARGE PORT)
INLET
(LARGE PORT)
OUTLET
(SMALL PORT)
LUBRICATION
GROOVE TYP.
BEARING SPLIT LINE
INSTALL BEARING IN
POSITION SHOWN
WITHIN 5 TYP.
VIEW SHOWING FRONT COVER
ITEM 2 ONLY
VIEW SHOWING
BODY HOUSING
ITEM 1 ONLY
Section 230-0050
SM 1394 Rev1 12-04
4
Note: Ensure bearings (7) are pressed to insertion
depth indicated in Fig. 4.
2. Install new lip seals (20) and location sleeve (19) to
front cover (2), as shown in Fig. 1.
3. Apply a thin film of grease on new wear plate seal
(8) and backup seal (9) and install in wear plate (14),
as shown in Fig. 5.
4. Install wear plate (14) into body housing (1) bore,
with wear plate seal (8) facing down.
Note: The relief groove in wear plate (14) should face
the outlet side of the pump.
5. Lightly oil gear faces, gear flanks and journals with
mineral oil prior to assembly.
6. Slide driven gear (12) and drive shaft (11) into its
bearing in body housing (1).
Note: When installing the original gear sets, align as
match marked at disassembly.
7. Apply a thin film of grease on second wear plate
seal (8) and backup seal (9) and install in second wear
plate (13), as shown in Fig. 5.
8. Install wear plate (13) assembly on gear shaft end
(11) and body housing (1) bore, with wear plate seal
(8), and backup seal (9) facing up.
Note: The relief groove in wear plate (13) should face
the outlet side of the pump.
9. Fit ring seal (10) to body housing (1) machined face.
Ring seal (10) to be fitted dry.
10. Coat special sleeve tool, which can be fabricated
as shown in Fig. 8, with grease and install driveshaft
and gear (11) in the sleeve tool, as shown in Fig. 6.
11. Position assembled front cover (2) over gear shaft
ends (11 & 12). Tap front cover (2) with a soft hammer
until it rests against wear plate (14) in body housing
(1), as shown in Fig. 7. Take care not to damage ring
seal (10) and seal (20).
Note: Make sure index marks on front cover (2) and body
housing (1) match up, as marked at disassembly.
12. Remove sleeve tool from drive of driveshaft and gear
(11) and cover the gear set with hydraulic oil specified in
13. Secure body housing (1) and front cover (2)
together with four capscrews (15). Tighten capscrews
(15) alternately to ensure correct alignment of parts.
Rotate driveshaft (11) to check for internal binding of
parts. If no binding is evident, tighten capscrews (15)
alternately to a torque of
772 Nm (569 lbf ft).
14. Apply a continuous beading (1 - 1.5 mm dia.) of
sealant to flange mounting (3) face, approximately
10 mm from locating sleeve (19) before installing
mounting flange (3). Tap mounting flange (3) with soft
hammer until it rests against front cover (2).
15. Secure mounting flange (3) to front cover (2)
together with three capscrews (16). Tighten
capscrews (16) alternately to ensure correct alignment
of parts. Rotate driveshaft (11) to check for internal
binding of parts. If no binding is evident, tighten
capscrews (16) alternately to a torque of
162 Nm (119 lbf ft).
Fig. 4 - Bearing Insertion Depth
SM - 1866
SM - 1867
Fig. 5 - Wearplate Seal Fitting
BEARING
(ITEM 7)
BODY HOUSING
(ITEM 1)
1.50/1.75 mm
OUTLET INLET
Z
Z
WEARPLATE
SEAL
(ITEM 8)
WEARPLATE
SEAL
(ITEM 8)
WEARPLATE
SEAL
(ITEM 8)
BACKUP
SEAL
(ITEM 9)
BACKUP
SEAL
(ITEM 9)
BACKUP
SEAL
(ITEM 9)
45 CHAMFER
WEARPLATE
(ITEMS 13 & 14)
ALTERNATIVE CUT
SEAL AND BACKUP SEAL
SECTION Z - Z
Section 230-0050
SM 1394 Rev1 12-04
5
3. Remove cap from the inlet line and install a new
'O' ring in the split flange fitting. Secure inlet line to
inlet port 'A' on the pump with bolts and lockwashers,
as removed during removal.
4. Before connecting the outlet line to outlet port 'B' on the
pump, fill the pump with hydraulic oil as specified in
5. Remove cap from the outlet line and install a new
'O' ring in the split flange fitting. Secure outlet line to
outlet port 'B' on the pump with bolts and lockwashers,
as removed during removal.
Note: It is very important that the pump cavity is filled
with hydraulic oil. This will ensure proper lubrication of
the internal parts of the pump when it is initially
operated.
in Section 300-0020, LUBRICATION SYSTEM. Install
filler cap on hydraulic tank filler neck.
START-UP PROCEDURE
Before starting the engine and running the pump,
back-off the system relief valve on the body control
valve, until the adjusting screw spring tension is
relieved. Refer to Section 230-0060, BODY
CONTROL VALVE, for details. This avoids the
possibility of immediate damage to the pump if the
relief valve pressure setting had been increased,
beyond the recommended operating pressure, before
removal of the pump. Loosen the bolts at flange fitting
on outlet line at port 'B' on the pump to allow
entrapped air to bleed out at initial start-up.
Note: Always install steering lock bar when working in
the articulation area.
Place the battery master switch in the 'On' position and
the steering lock bar in the 'Locked' position. Start the
engine and run the pump at idle for two or three
minutes and with no pressure. When oil runs out of
pump outlet port 'B' in a steady stream, tighten outlet
line flange fittings. During the break-in period, the
pump should run free and not develop an excessive
amount of heat. If the pump becomes hot to touch, it is
binding and might seize. In this instance the pump will
have to be rebuilt with extra care to prevent binding.
If the pump is running properly, engine speed and
hydraulic system pressures can gradually be
increased to normal operating values. Adjust the
system relief valve to the proper setting as described
INSTALLATION
WARNING
safely.
1. Coat pump driveshaft with molybdenum disulphide
grease and install gasket (20) on mounting face of the
pump assembly.
2. Support pump assembly with suitable lifting
equipment and position on the transmission housing.
Secure pump assembly to transmission housing with
bolts (4) and lockwashers (5), as removed during
removal.
Fig. 7 - Installing Front Cover
Fig. 6 - Installing Driveshaft and Gear in Body Housing
SM - 1868
SM - 1869
Section 230-0050
SM 1394 Rev1 12-04
6
SM - 647
Fig. 8 - Special Sleeve Tool Dimensions
SPECIAL SLEEVE TOOL DIMENSIONS TABLE190
DIMENSION mm in
A 85.7 3.375
B 114.3 4.50
C Radius 14.3 0.56
D Diameter
34.9758 + 0.000
- 0.0508
1.377 + 0.000
- 0.002
E Diameter
31.75 + 0.050
- 0.000
1.250 + 0.002
- 0.000
F Chamfer 1.6 x 60 0.063 x 60
6 mm (0.25 in)
Drill Thru Hole
* * * *
TORQUE
1 15 Capscrew 772 569
1 16 Capscrew 162 119
in Section 230-0060, BODY CONTROL VALVE.
Note: Always use accurate pressure gauges when
adjusting the relief valve.
Check pump mounting and hydraulic line connections
for leaks. Tighten lines and fittings as required.
Remove wheel blocks from all road wheels.
LUBRICATION
All pump parts are lubricated by the hydraulic oil. The
oil, therefore, must be kept clean to minimize pump
wear. Whenever there is a hydraulic system failure,
the hydraulic oil should be drained and replaced. Refer
oil change procedures.
for recommended periodic oil change periods and oil
specifications.
SPECIAL TOOL
The special sleeve tool for installing the driveshaft and
gear in the pump can be fabricated from steel bar as
shown in Fig. 8. Refer to Section 300-0070, SERVICE
TOOLS, for part numbers of general service tools
required. These tools are available from your dealer.
Section 230-0060
SM 1410 Rev 2 2-02 1
BODY SYSTEM - Body Control Valve
SM - 1879
1 - Control Spool
2 - Retainer
3 - 'O' Ring
4 - Spool Cap
5 - 'O' Ring
6 - Spring Retainer
7 - Spring
8 - Washer
9 - Shoulder Screw
10 - End Cap
11 - Seal Retainer
12 - Capscrew
13 - Pressure Reducing Valve
14 - Capscrew
15 - Shim (if fitted)
32 - Spring
33 - Poppet
34 - Cap
35 - Ring
36 - 'O' Ring
37 - Relief Valve
38 - 'O' Ring
39 - 'O' Ring
40 - Cap
41 - Valve Housing
42 - Plug
43 - Seal
44 - Bolt
45 - Capscrew
46 - End Plate
47 - 'O' Ring
16 - Shim (if fitted)
17 - End Cap
18 - Seal
19 - Plug
20 - Mounting Block
21 - 'O' Ring
22 - Capscrew
23 - Capscrew
24 - Lockwasher
25 - Blanking Plate
26 - 'O' Ring
27 - Cover Plate
28 - 'O' Ring
29 - Locknut
30 - Adjusting Screw
31 - 'O' Ring
DESCRIPTION
The single spool body control valve, which is fitted with
electro hydraulic operation, is mounted off the cradle
assembly at the rear of the cab. The main components
of the control valve assembly are a four position
control spool (1), relief valve (37), check valve
assembly and valve housing (41).
The position of the control spool is controlled by the
body control joystick by means of electrical signals to
the pressure reducing valves (13). Refer to
Section 230-0060, BODY CONTROL JOYSTICK. The
body control joystick has a pre-feel ramp which
controls the current to the pressure reducing valve
Fig. 1 - Exploded View of Body Control Valve
45
46
47
20
13,14
12
10
9
8 6
15
16
23
24
25
26
7
6
4
3
2
3
5
29 30
31
32
33
34
35
36
24
23
28
27
43
42
37
38
39
36
40
41
1
5
3
11
44
3
22
20
17
21
13,14
18
19
A
B
C
D
E
F
Section 230-0060
Body System - Body Control Valve
SM 1410 Rev 2 2-02 2
Oil from the pump enters port 'E', flows around relief
valve (37) assembly, into the right hand side of control
spool (1), unseats check valve plunger, flows out of
port 'D' and into the base end of the cylinders.
Oil returning from the rod end of the cylinders enters
control valve housing at port 'C', flows into and out of
control spool (1) and into the tank return passage. Oil
exits from port 'A' to the hydraulic oil tank.
When the body control joystick is released, spring (7)
returns control spool (1) to the 'Hold' position.
Lower Position (Power Down)
The 'Lower' or 'Power Down' position is only used to
start lowering the body. Once the body has started to
come down, the control joystick should be placed into
the detented 'Float' position.
Oil from the pump enters valve housing (41) at port 'E',
flows around relief valve (37) assembly, into the left
hand side of control spool (1), exits from port 'C' and
flows into the rod end of the cylinders.
Oil from the base end of the cylinders enters control
valve housing (41) at port 'D'. The returning oil unseats
check valve plunger and flows into the tank return
passage. Oil exits from port 'A' to the hydraulic oil tank.
Float Position
Moving the body control joystick to the 'Float' position,
moves control spool (1) to a position within the valve
housing (41) which allows the body to lower by it's own
weight.
In the 'Float' position, because of the design of control
spool (1), the body cylinder rod and base end ports
are connected together at the control valve.
Oil from the pump enters valve housing (41) at port 'E',
flows around relief valve (37) assembly, past control
spool (1), and, if the oil is not required by the cylinders,
exits from port 'A' to the hydraulic oil tank.
Relief Valve
Relief valve (37) assembly, in valve housing (41), is
set to relieve oil pressure in excess of 172 bar
such that the pressure into the end cap moves the
spool to the 'Power Down' position. Further selection
of the joystick, beyond the ramp position, allows full
current to reach the pressure reducing valve such that
full pilot pressure is seen in the end cap. Full selection
then occurs and the 'Float' position is achieved.
The four positions of the control spool are 'Raise',
'Hold', 'Lower' (Power Down) and 'Float'. The 'Float'
position is detented and control spool (1) should be
kept in this position at all times, except when Raising
or Lowering the body.
Control valve housing (41) has six ports as follows:
Port 'A' - Tank Return Port.
Port 'B' - Capped with blanking plate (25).
Ports 'C' & 'D' - Body Cylinder Ports.
Port 'E' - Pump Inlet Port. Also connected to hydraulic
system diagnostic test point at rear of tractor
frame.
Port 'F' - Cover (27) tapped to provide a diagostic test
port.
Relief valve (37) assembly at the pressure inlet opens
and allows oil to flow back to the hydraulic tank when
pressure in the hydraulic system exceeds 172 bar
(2 500 lbf/in).
Pilot pressures can be checked at ports 'P1' and 'P2'
which are located in mounting blocks (20). Refer to
Section 230-0000, BODY SYSTEM SCHEMATIC for
table of Body Control Valve pressure checks.
OPERATION
Hold Position
When control spool (1) is in the 'Hold' position, oil from
the pump enters port 'E', flows around relief valve (37)
assembly and control spool (1), and out of port 'A' to
the hydraulic tank. Cylinder ports 'C' and 'D' are
blocked by control spool (1) and oil is trapped between
the control valve and the cylinders. In this position the
body can be in any partially raised position.
Raise Position
Pushing the body control joystick into the 'Raise'
position and holding it there, moves control spool (1)
position within the valve housing (41).
Section 230-0060
SM 1410 Rev 2 2-02 3
(2 500 lbf/in).
Should oil at the inlet side of the valve exceed
172 bar (2 500 lbf/in), pilot poppet (33) will be forced
off its seat. Oil will flow through an internal passage
and exit from port 'A' to the hydraulic oil tank. When
pressure is relieved, tension of spring (32) will force
pilot poppet (33) to re-seat.
REMOVAL
WARNING
safely.
in the steering system. Operate the treadle valve
continuously to relieve pressure in the braking system.
4. Clean body control valve housing (41) and
tag all hydraulic and servo control lines connected to
body control valve, to aid in 'Installation'.
5. With suitable containers available to catch spillage,
disconnect hydraulic and servo control lines from
control valve. Drain the oil from the lines into the
container and discard all 'O' rings. Cap hydraulic lines
and control valve ports to prevent ingress of dirt.
6. Support body control valve with a suitable lifting
device and remove mounting hardware securing body
control valve to the cradle assembly. Remove body
control valve to a clean area for disassembly.
DISASSEMBLY
WARNING
Spring loaded parts. Use care when removing
end cap, retainers and plugs to prevent sudden
release of spring tension behind these parts.
Personal injury or property damage could
result if care is not taken.
Note: Clean entire control valve assembly with a
suitable solvent and dry thoroughly prior to
disassembly.
Valve Body
1. If required, remove bolts (23), lockwashers (24),
blanking plate (25) and 'O' ring (26) from port 'B' in
valve housing (41). Discard 'O' ring (26).
2. If required, remove bolts (23), lockwashers (24),
cover plate (27) and 'O' ring (28) from port 'F' in valve
housing (41). Discard 'O' ring (28). If required, remove
plug (42) and seal (43) from cover plate (27).
Control Spool
1. Clean the entire body control valve assembly with a
suitable solvent and dry thoroughly. Remove caps
from valve housing (41) ports.
2. If required, clamp body control valve assembly in a
soft jawed vice. Take care to avoid damaging valve
housing (41) machined surfaces.
3. Remove capscrews (14) securing pressure
reducing valve (13) from mounting block (20).
Withdraw pressure reducing valve (13) from mounting
block (20).
4. Remove capscrews (22) securing mounting block
(20) to end cap (10). Remove mounting block (20) and
discard 'O' ring (21).
5. If required, remove plug (19) from mounting block
(20) and discard 'O' ring (18).
6. Repeat steps 3 to 5 for opposite end of valve
housing (41), end cap (17).
Section 230-0060
SM 1410 Rev 2 2-02 4
7. Remove capscrews (12) securing end cap (10)
assembly to valve housing (41). Remove end cap (10).
If required, remove bolts (45) and end plate (46) from
end cap (10). Remove and discard 'O' ring (47).
8. Carefully withdraw spool and spring pack assembly
from valve housing (41). Remove and discard 'O' rings
(3 & 5).
Note: 'O' rings (3 & 5) can be replaced without
disassembly of the spring mechanism.
9. If necessary, the centring mechanism can be
removed from the spool assembly. Remove shoulder
screw (9) to release washer (8), spring seats (6),
spring (7) and shims (15 & 16).
Relief Valve
1. Clean the entire body control valve assembly with a
suitable solvent and dry thoroughly. Remove caps
from valve housing (41) ports.
2. If desired, clamp body control valve assembly in a
soft jawed vice. Take care to avoid damaging valve
housing (41) machined surfaces.
3. Release locking nut (29) and slacken adjusting
screw (30) until loose.
4. Remove cap (34) from valve housing (41) and
5. Withdraw spring (32) and poppet (33) from valve
housing (41) bore.
6. Remove plug (40) from the opposite end of valve
housing (41) and discard 'O' ring (36).
7. Push out relief valve (37) assembly from bore in
valve housing (41). Discard 'O' rings (38 & 39).
INSPECTION
1. Clean all parts thoroughly and examine for wear
and/or damage.
2. Inspect valve housing (41) bores and control spool
(1) for grooves, deep scratches or excessive wear.
Note: If condition of valve housing (41) bores or
control spool (1) indicates that they require to be
replaced, the body control valve should be replaced as
an assembly.
3. If either poppet (33) or relief valve (37) are damaged,
BOTH parts should be replaced by new parts.
Note: Do not lap or grind poppet (33) to relief valve
(37) assembly.
ASSEMBLY
Note: Lightly lubricate all components with hydraulic
oil. Refer to Section 300-0020, LUBRICATION
SYSTEM, for recommended oil specifications.
Valve Body
1. If removed, install new 'O' ring (26) on port 'B' of
valve housing (41). Install blanking plate (25) and
secure using bolts (23) and lockwashers (24).
3. If removed, install new 'O' ring (28) on port 'F' of
valve housing (41). Install cover plate (27) and secure
using bolts (23) and lockwashers (24). If removed,
install plug (42) and new seal (43) to cover plate (27).
Control Spool
1. If required, reassemble spring seats (6), shims
(15 & 16), spring (7) and washer (8) and secure
assembly to spool cap (4) using shoulder screw (9).
Note: Apply 3 drops of Loctite 243 to the spool cap (4)
threads prior to reassembly.
2. Replace 'O' rings (3 & 5) on spool and spring pack
assembly.
3. Refit spool and spring pack assembly to valve
housing (41).
4. Install end cap (10) to valve housing (41) and
secure using capscrews (12). Tighten capscrews (12)
5. If removed, fit new 'O' ring (47) and install end plate
(46) on end cap (10) using capscrews (45). Tighten
capscrews (45) to a torque of 30 Nm (22 lbf ft).
6. If required, install new 'O' ring (18) on plug (19) and
refit to mounting block (20).
7. Install new 'O' rings (21) and secure mounting blocks
Section 230-0060
SM 1410 Rev 2 2-02 5
(20) to end caps (10 & 17) using capscrews (22).
8. Install pressure reducing valves (13) to mounting
blocks (20) and secure using capscrews (14). Tighten
capscrews (14) to a torque of 2 Nm (1.5 lbf ft).
Relief Valve
1. Install new 'O' rings (38 & 39) on relief valve (37)
assembly. Install relief valve (37) assembly into relief
valve bore in valve housing (41).
Note: Push relief valve (37) assembly fully in until the
snap ring on the outer sleeve locates in the recess in
the relief valve bore.
2. Install a new 'O' ring (36) on plug (40) and install
plug (40) in valve housing (41). Tighten plug (40) to a
3. Install poppet spring (32) and poppet (33) in cap
(34). Install a new 'O' ring (36) on cap (34).
4. Install cap (34) assembly, adjusting screw (30) and
locking nut (29) in valve housing (41) bore. Tighten
cap (34) to a torque of 150 Nm (110 lbf ft).
5. Leave adjusting screw loose prior to pressure
setting. Refer to 'Adjustments' for correct pressure
setting.
INSTALLATION
WARNING
safely.
1. Using a suitable lifting device, position body control
valve in place on the machine. Secure body control
valve to the cradle assembly with mounting hardware
as removed at 'Removal'.
2. Reconnect all servo control lines to body control
valve, as tagged at 'Removal'.
3. Install new 'O' rings in split flange line fittings and
install all hydraulic lines to body control valve, as
tagged at 'Removal'.
Note: Be sure to use new 'O' rings with the split flange
fittings.
5. Adjust the system relief valve according to the
instructions in 'Adjustments'.
ADJUSTMENTS
Relief Valve Adjustment
This type of relief valve is very sensitive to adjustment.
Relief valve setting and adjustment can be carried out
as follows:
Note: If adjustment only is to be carried out, the
procedure for blocking the machine as described in
'Removal, must be strictly adhered to.
WARNING
safely.
pressure of 0 - 207 bar (0 - 3 000 lbf/in), to remote
diagnostic pressure point.
2. Start engine and raise body completely.
3. Check reading on pressure gauge. Slacken locking
nut (29) and turn adjusting screw (30) until a pressure
reading of 172 bar (2 500 lbf/in) is recorded on the
pressure gauge.
Note: Turning adjusting screw (30) 'IN' will increase
relief valve pressure, turning adjusting screw (30) 'OUT'
will reduce relief valve pressure.
4. Secure locking nut (29) in place and operate body.
Re-check relief valve pressure and adjust if required.
Section 230-0060
SM 1410 Rev 2 2-02 6
5. Check body control valve assembly and hydraulic
lines for leaks. Tighten as required.
MAINTENANCE
Relief valve pressure should be checked on a regular
basis to ensure correct operating pressures are being
maintained. Limited repair of the control valve is with
replacement of parts only.
* * * *
BODY CONTROL VALVE DIAGNOSIS
CONDITION REASON CHECK AND/OR REMEDY
Valve leaks at 'O' rings Defective 'O' ring Partially pull out control spool and replace the
defective 'O' ring.
Control spool does not Faulty return spring Replace return spring.
Corrosion or contamination Disassemble control spool assembly, clean parts and
replace any worn parts.
System does not build up Defective relief valve Check relief valve pressure. Adjust as required.
pressure
Load drops with control Excessive clearance Replace control valve assembly.
spool in 'Hold' position between control spool and
bore
return to 'Hold' position
SERVICE TOOLS
service tools and adhesives. These tools and
Section 230-0081
SM 1411 Rev 2 04-02
1
BODY SYSTEM - Body Control Joystick
Fig. 1 - Body Control Joystick Installation
1 - Body Control
Joystick
SM - 2718 DESCRIPTION
The body control joystick is mounted on the right hand
side dash panel, between the transmission shift
controller and the document location.
OPERATION
The body control joystick controls the hydraulic control
valve operation, by means of electrical signals to the
pressure reducing valves, which in turn operates the
body hoist cylinders. The four operating positions of
the joystick from front to rear are as follows:
'FLOAT' - The joystick should be moved to this
position while the body is lowering by gravity and
should remain in this position until the body must be
operated again. The control joystick should always be
kept in 'FLOAT' while the machine is in motion.
'LOWER' - Pushing the joystick forward and holding it
in this position provides hydraulic force to power-down
the body. It is needed when the body cannot be
started downward from the fully raised position by
gravity. When the body starts lowering by gravity, the
joystick can be released and internal valve springs will
move the joystick to the 'HOLD' position.
'HOLD' - Moving the joystick to this position while the
body is being raised or lowered traps the oil in the
body hoists to stop and hold the body at any desired
height. The joystick will remain in the 'HOLD' position
when released.
'RAISE' - Pushing the joystick back and holding it in
this position directs oil to extend the body hoists and
raise the body. When released, the joystick will be
spring-returned to the 'HOLD' position.
Note: The body control lever must remain in the
'FLOAT' position until it is necessary to operate the
body again. Failure to comply to this could result in
overheating the hydraulic oil and failure of the
hydraulic system components.
Note: A proximity sensor prevents the body being fully
powered down onto the chassis. At a predetermined
height, the sensor automatically defaults the body
control valve to the detented 'FLOAT' condition.
Note: If an electrical failure occurs, 12V relay (K37 -
engine signal) ensures the body control valve
automatically defaults to the 'HOLD' condition. The
cause of the electrical fault must be investigated and
corrected. Refer to Section 190-0000, CIRCUIT
DIAGRAMS.
WARNING
Always disconnect body control joystick before
welding on the machine.
MAINTENANCE
The body control joystick is a non-serviceable item and
should be replaced completely, if damaged, as follows:
WARNINGS
safely.
switch off the engine. Operate the steering right and
left several times to relieve pressure in the steering
system.
2 - Screw
3 - Harness
2
1
3
Section 230-0081
Body System - Body Control Joystick
2
SM 1411 Rev 2 04-02
the 'Off' position.
3. Disconnect harness (3) from connector port on the
bottom of body control joystick (1).
4. Support body control joystick (1) and remove screws
(2) securing body control joystick (1) to mounting
bracket on the underside of the right hand dash panel.
5. Remove body control joystick (1) from mounting
location.
6. Secure new body control joystick (1) to mounting
bracket on the underside of the right hand dash panel
with screws (2).
Note: Ensure identifying mark on the body control joystick
casing is orientated towards the rear of the cab.
7. Reconnect harness (3) to connector port on the
bottom of the body control joystick (1).
temperature. Operate the body control joystick (1) to
ensure correct operation.
SPECIAL TOOLS
dealer.
* * * *
Section 230-0121
SM 1448 Rev 1 1-02
1
BODY SYSTEM - Pilot Supply Valve
Fig. 1 - Exploded View of Pilot Valve
1 - Valve Body
2 - Spring Cover
3 - 'O' Ring
4 - Control Spring
5 - Spring Guide
6 - Control Spool
SM - 1870
DESCRIPTION
The pilot supply valve can be identified as item 5 in the
layout drawing in Section 230-0000, BODY SYSTEM
SCHEMATIC.
Mounted off the cradle assembly at the rear of the cab,
the pilot supply valve is located in the hydraulic servo
control lines. See Fig. 2 for schematic symbol.
The pilot supply valve is a direct acting pressure
reducing valve which steps down the supply pressure
of 185 bar (2 682 lbf/in) to 30 bar (435 lbf/in). Intregal
of the pilot supply valve is a relief valve which opens at
45 bar (652 lbf/in).
7 - Plug
8 - 'O' Ring
9 - Seat
10 - 'O' Ring
11 - Spacer
12 - Pilot
13 - Spring
14 - 'O' Ring
15 - Plug
16 - Plug
17 - 'O' Ring
18 - Adaptor
19 - Plug
20 - Plug
21 - 'O' Ring
22 - Reducer
23 - Adaptor
Fig. 2 - Pilot Supply Valve Schematic Symbol
SM - 1871
24 - Elbow
25 - Tee Piece
26 - Elbow
27 - Bolt
28 - Lockwasher
2
3
4
5
6
15
14
13 12
1
16
17
18
19
19 19
11
10
9
8
7
23
26
24
25
23
23
24
21
22
20
28
27
19
CRADLE
ASSEMBLY
TO BRAKING
SYSTEM
TO BODY
CONTROL
VALVE
TO BODY
CONTROL
VALVE
FROM BRAKING
SYSTEM
P2 P1
T2 T1
U1 U2
45 bar (652 lbf/in)
30 bar (435 lbf/in)
Section 230-0121
Body System - Pilot Supply Valve
2 SM 1448 Rev 1 1-02
REMOVAL
WARNING
safely.
in the steering system. Operate treadle valve
continuously to relieve pressure in the braking system.
4. Clean pilot valve (1) and surrounding area with a
suitable solvent. Identify and tag all hydraulic lines
connected to pilot valve (1), to aid in 'Installation'.
5. Clean pilot valve (1) and surrounding area with a
to pilot valve (1) are identified for ease of installation
and, with suitable containers available to catch
leakage, disconnect hydraulic lines. Fit blanking caps
to all open lines.
6. Remove bolts (27) and lockwashers (28) securing pilot
valve (1) to cradle assembly. Remove pilot valve (1).
DISASSEMBLY
1. Note location of elbows (24), Tee piece (25) and
adaptors (23) and remove from valve body (1) and
reducer (22).
2. Remove reducer (22) and 'O' ring (21) from valve
body (1). Discard 'O' ring (21).
3. Remove plug (7) and 'O' ring (8) from valve body (1).
Remove valve seat (9), 'O' ring (10) and spacer (11)
from valve body (1). Discard 'O' rings (8 & 10).
4. Remove adaptor (18) and 'O' ring (17) from valve
body (1). Discard 'O' ring (17). If necessary remove
plug (19) from adaptor (18).
5. Remove spring guide (15) and 'O' ring (14) from
valve body (1). Discard 'O' ring (14).
6. Withdraw spring (13) and pilot (12) from valve body (1).
7. Remove spring cover (2) and 'O' ring (3) from valve
body (1). Discard 'O' ring (3).
8. Withdraw control spring (4), spring guide (5) and
control spool (6) from valve body (1).
INSPECTION
compressed air.
2. Check ports threads and make sure they are not
3. Check valve seat (9), pilot (12), control spool (6) and
spring guide (5). Ensure they are not worn, nicked,
cracked or scored.
Section 230-0121
SM 1448 Rev 1 1-02
3
* * * *
ASSEMBLY
1. Install new 'O' ring (3) to spring cover (2). Install
control spool (6), spring guide (5) and control spring (4)
into its bore in valve body (1).
2. Install pilot (12) and spring (13) into its bore in valve
body (1). Install new 'O' ring (14) to spring guide (15)
and install in valve body (1).
3. Install new 'O' ring (8) to plug (7). Install spacer (11),
new 'O' ring (10) and valve seat (9) into its bore in valve
body (1). Install plug (7) in valve body (1).
4. Install new 'O' ring (17) to adaptor (18). Install
adaptor (18) in valve body (1). If removed, install plug
(19) in adaptor (18).
5. Install new 'O' ring (21) to reducer (22). Install
reducer (22) in valve body (1).
6. Install elbows (24), Tee piece (25) and adaptors (23)
in valve body (1) and reducer (22).
INSTALLATION
where used.
1. Secure pilot valve (1) to cradle assembly with bolts
install lines to pilot valve (1) as identified during
removal.
temperature.
5. Check pilot valve (1) and hydraulic line connections
for leaks and tighten as required.
SPECIAL TOOLS
dealer.
Body System - Pilot Supply Valve
Section 230-0130
SM 1409 Rev 1 9-05 1
21 23 7 6 29 10 18 8 3 2 9 4 5 1 11 17 14 13 15 14 16 19 20 12 22 23
24
28
27
26
22 21
25
28
27
26
PIN MTG. - LOWER
PIN MTG. - UPPER
SM - 3337
BODY SYSTEM - Body Cylinder
DESCRIPTION
There are two single stage, double acting body hoist
cylinders, cushioned at both ends of the stroke, on the
vehicle. The cylinder base end is connected to the
trailer frame and piston rod (2) eye end is connected
at the body. Single stage double acting means that
piston rod (2) can have oil applied to either end,
extending or retracting the piston rod.
extended is obtained by tapered spear (11) on piston
rod (2) passing through cushion sleeve (4). This
gradually slows piston (12) which in turn helps to
control destructive shock effects when piston (12)
reaches the full extent of its travel.
retracted is obtained by a tapered spear at the base
end of cylinder body (1) entering a cavity in piston rod
(2) through cushion ring (19). This gradually slows
piston (12) which in turn helps to control destructive
shock effects when piston (12) bottoms.
Cylinder mounting is by pins (24 & 25), spacers (26)
and spherical bearings (21) secured in place by
circlips (22). Spherical bearings (21) permit a limited
amount of cylinder misalignment.
REMOVAL
WARNING
safely.
Fig. 1 - Sectional View Of Body Cylinder and Mounting
9 - 'O' Ring
10 - Lock Ring
11 - Cushion Spear
12 - Piston
13 - Piston Seal
14 - Bearing Ring
15 - Grub Screw
16 - Grub Screw
17 - 'O' Ring
18 - Backup Ring
19 - Cushion Ring
20 - Circlip
22 - Circlip
23 - Lube Fitting
24 - Lower Pin
25 - Upper Pin
26 - Spacer
27 - Washer
28 - Bolt
29 - Nylon Ring
1 - Cylinder Body
2 - Piston Rod
3 - End Cap
4 - Cushion Sleeve
5 - Circlip
6 - Rod Seal
7 - Wiper
8 - 'O' Ring
Body System - Body Cylinder
Section 230-0130
2
SM 1409 Rev 1 9-05
(1) and piston rod (2) end. Press out spherical
bearings (21).
3. Remove lock ring (10) from end cap (3).
4. Using special tool which can be fabricated as shown
in Fig. 2, unscrew end cap (3) until thread is
disengaged from cylinder body (1).
Note: Approximate weight of piston rod (2) is 318 kg
(700 lb), therefore, correct slinging is important along
the length of the rod to prevent subsequent damage.
5. Support piston rod (2) at the rod eye and withdraw
piston rod (2) from cylinder body (1). Ensure centre
lines of piston rod (2) and cylinder body (1) remain
coincidental during removal of piston rod (2).
6. Place piston rod (2) on supports which will not
damage the piston rod diameter.
7. Remove and discard piston seals (13) and bearing
rings (14) from piston (12).
8. Remove grub screws (15 & 16) from bearing ring
(14) groove in piston (12).
9. Provide an anti-torsion device through piston rod (2)
eye to allow unscrewing of piston (12). Using special
tool which can be fabricated as shown in Fig. 3,
unscrew piston (12) from piston rod (2).
10. Remove cushion spear (11) and 'O' rings (17) from
piston rod (2). Discard 'O' rings (17).
11. Remove cylinder end cap (3) from piston rod (2).
Remove and discard cushion sleeve (4), circlip (5),
rod seal (6), nylon ring (29), wiper (7), backup ring (18)
and 'O' rings (8 & 9).
INSPECTION
1. Clean all parts of the cylinder with a suitable solvent
and dry with clean, lint-free cloths. Clean all grooves
carefully to remove any foreign material.
2. Check cylinder body (1) and outer diameter of
piston (12) for scratches, cracks or other defects.
Remove ridges, nicks and scratches with a fine stone
and re-clean. Replace any components which cannot
be repaired.
3. Inspect piston rod (2) for distortion, cracks or other
defects. Replace piston rod (2) if defective area is
irreparable.
steering circuit.
3. Position a suitable oil container at line ends of the
cylinder. Ensure hydraulic lines connected to the body
cylinder assembly are identified for ease of installation
and disconnect hydraulic lines. Fit blanking caps to all
open lines and fittings to prevent entry of dirt.
4. Install a suitable strap around one body cylinder
assembly and attach to a suitable lifting device.
Remove bolt (28), washer (27) and upper pin (25)
connecting piston rod (2) eye end to the body. If due to
lack of maintenance the upper pin can not be removed
from the front, there is plate on the inside of the body
that can be removed to allow access to the rear of the
pin to ease removal. This plate is tack welded in place
so a grinder is required to remove it.
WARNING
Exercise extreme caution when lowering the
cylinder from the body, as the cylinder will
swing out sharply as it leaves its mounting.
5. Lower cylinder slowly and remove spacers (26).
6. Remove bolt (28), washer (27) and lower pin (24)
connecting base end of body cylinder to the frame.
7. Remove spacers (26) and remove cylinder to a
clean area for disassembly.
DISASSEMBLY
WARNING
safely.
1. Ensure clean working conditions, remove any port
plugs thus allowing easy entry of air into cylinder body
(1), preventing a vacuum when parts are withdrawn
from cylinder body (1).
2. Remove circlips (22) from base end of cylinder body
Section 230-0130
SM 1409 Rev 1 9-05 3
4. Check spherical bearing (21) for wear and replace if
necessary.
ASSEMBLY
WARNING
safely.
1. Press spherical bearing (21) in base end of cylinder
body (1) and piston rod (2) end. Secure spherical
bearings (21) with circlips (22).
Note: Install circlip (22) to base end of cylinder
ensuring that it is facing down when the cylinder is
mounted to the unit.
2. Install new cushion ring (4), circlip (5), rod seal (6),
nylon ring (29), 'O' rings (8 & 9) and backup ring (18)
in end cap (3).
3. Apply Loctite 242 to the first two threads on end cap
(3). Load end cap (3) over piston rod (2) thread taking
care not to damage rod seal (6) on the thread.
4. Install new 'O' rings (17) on piston rod (2) and
replace cushion spear (11).
5. Using special tool which can be fabricated as shown
in Fig. 3, screw on piston (12) and tighten to a torque
of 1 356 Nm (1 000 lbf ft).
6. Insert piston grub screw (16) through bearing ring
(14) groove in piston (12) and into groove machined in
piston rod (2). Tighten grub screw (16) to a torque of
49 Nm (36 lbf ft).
7. Lock grub screw (16) in place with grub screw (15)
and tighten grub screw (15) to a torque of 49 Nm
(36 lbf ft). Ensure the extreme of grub screw (15) is
below the level of bearing ring (14) groove.
8. Ensure cushion ring (19) and circlip (20) are secure
in piston (12).
9. Insert new piston seal (13) and new bearing rings
(14) in piston (12).
10. Fully grease piston (12) OD and 'O' rings (8 & 9) in
end cap (3).
Note: Approximate weight of piston rod (2) is 318 kg
(700 lb), therefore, correct slinging is important along
the length of the rod to prevent subsequent damage.
11. Sling assembled piston rod (2) in a manner to allow
careful leading of the assembled piston rod into
cylinder body (1). Take care not to damage piston seal
(13) on cylinder body threads.
12. After piston (12) is inserted in cylinder body (1),
push the piston rod assembly into cylinder body (1)
maintaining coincidental centre lines of piston rod and
cylinder body.
13. Before piston rod (2) is fully home and, with slings
still taking some of piston rod (2) weight, engage end
cap (3) thread and screw home.
14. Push piston rod (2) to the fully retracted position
and torque tighten end cap (3) to 237 Nm (175 lbf ft).
15. Re-drill end cap (3) for lock ring (10) (3 x 12 mm
(0.125 x 0.50 in) deep) if necessary. Insert lock ring
(10) in end cap (3).
INSTALLATION
connections, as described in Section 230-0000, BODY
SYSTEM SCHEMATIC. Renew all 'O' rings where
used.
WARNING
safely.
1. Install a suitable strap around the cylinder and
position cylinder on unit with base end of cylinder
(circlip (22) facing down) ready for mounting.
2. Install spacers (26) in base end of cylinder, align
spherical bearing (21) with bores in frame mounting
and install lower pin (24) through mounting bores,
spacers (26) and spherical bearing (21). Secure lower
pin (24) to the frame with washer (27) and bolt (28).
Tighten bolt (28) to a torque of 66 Nm (49 lbf ft).
3. Install spacers (26) in piston rod (2) eye end of
cylinder, align spherical bearing (21) with bores in
body and install upper pin (25) through mounting
bores, spacers (26) and spherical bearing (21). Secure
Section 230-0130
4
SM 1409 Rev 1 9-05
MAINTENANCE
Visually inspect body cylinders, lines and mounting
regularly for leaks and damage. Repair/replace as
required. Lubricate cylinder pins every 50 hours through
lube fittings (23, Fig. 1) with lubricant specified in Section
SPECIAL TOOLS
Special tools required for removal and installation of
the piston and end cap can be fabricated as shown in
Figs. 2 & 3. Refer to Section 300-0070, SERVICE
TOOLS, for part numbers of general service tools and
adhesives required. These tools and adhesives are
upper pin (25) to the body with washer (27) and bolt
(28). Tighten bolt (28) to a torque of 66 Nm (49 lbf ft).
connect the lines to the cylinder ports as tagged during
removal.
5. Lubricate pins at lube fittings (23) with lubricant as
SYSTEM.
6. Repeat steps 1 through 5 for installation of the
opposite cylinder.
start the engine and operate the body. Check lines and
fittings for leaks and tighten as required.
SM - 409
Fig. 2 - End Cap Torque Tool
Dimensions in mm (in)
FIT (2) B & T BUSH
12 (0.472) ID - 18 (0.708) OD
AND (2) DOWELS 12 (0.472) ID.
DRIVE FIT DOWEL IN BUSH.
SECURE ALUMINIUM
COLLAR WITH 3 M8
CAP SCREWS
19 (0.75)
SQUARE
DRILL 13 (0.51)
x 25 (0.984)
DEEP
Section 230-0130
SM 1409 Rev 1 9-05 5
SM - 410
Fig. 3 - Piston Torque Tool
SILVER STEEL
EN3B
MILD STEEL
2
5
.
4

(
1
.
0
)
S
Q
U
A
R
E
TABLE070
TORQUE
Nm lbf ft
1 3 End Cap 237 175
1 12 Piston 1 356 1 000
1 15 & 16 Grub Screw 49 36
1 28 Bolt 66 49
* * * *
Section 250-0000
SM 2155 Rev 2 06-05
1
BRAKING SYSTEM - Braking System Schematic
DESCRIPTION
The hydraulic braking system is of closed centre
design wherein constant pressure is stored in
accumulators and is regulated as required to retard or
stop the machine.
A brief description of the individual components used
in the braking system are listed below. Detailed
Service Brakes
Refer to Section 165-0015, BRAKE ASSY - OCDB.
FLUID (J 1703). Multiple discs within the brake packs
are cooled by brake cooling oil as specified in Section
The brake pack is bolted to the stub axle and houses a
sandwich of friction discs splined to a hub rotor. There
are six friction discs in each of the front axle brake
packs, four in the centre and rear axle brake packs.
the brake pack and forces the piston against the
rotating friction discs which react with stationary stator
plates. The stator plates are retained by scalloped
tangs at the outside diameter, which in turn transfers
the reaction torque to the rigid outside housing, slowing
or stopping wheel rotation.
Parking Brake
MOUNTING.
The parking brake consists of a sliding calliper acting
on a brake disc on a rear driveline and is of 'Inverted
Design' i.e. requiring pressure to hold it off.
Operation is by a spring applied/hydraulically released
actuator. The actuator is connected through a slack
adjuster to the power screw shaft that is screwed into the
piston in the calliper head assembly. The calliper head
assembly slides on anchor plate guides in a bracket
assembly bolted to the trailer frame.
A push control on the right hand dash panel activates
the solenoid on the brake manifold valve controlling oil
pressure from the front brake circuit accumulator to the
actuator. Application of the push control releases oil
from the actuator allowing internal springs in the
actuator to apply the parking brake. Pulling out the
push control directs oil pressure from the front brake
circuit accumulator to the actuator, compressing
internal springs, to release the parking brake.
Hydraulic Tank
steering, body hoist and brake actuation systems. It is
hydraulic oil filter, oil strainer and oil level sight
gauge. Located on the top of the tank assembly is the
filler cap and breather.
Triple Pump (1)
The triple pump is mounted off the transmission power
takeoff. It is a triple gear type pump, which supplies
various circuits:
a) front section (closest to driveshaft) supplies brake
actuation circuit and engine cooling circuit.
b) middle section combines with front section to
supply engine cooling circuit.
c) rear section supplies the brake cooling circuit.
The triple pump is assembled for left hand (anticlockwise)
Section 250-0000
Braking System - Braking System Schematic
SM 2155 Rev 2 06-05
2
Accumulator pressure is monitored by pressure
switches (4) in the brake lines.
Treadle Valve (6)
Refer to Section 250-0070, TREADLE VALVE.
The treadle valve controls the level of hydraulic fluid
pressure applied to front and rear brakes and the
maximum pressure available to these circuits. It is
operated by a foot pedal in the operators cab and, with
the engine running, is automatically applied by the
solenoid on the brake manifold valve.
The first 7
o
of pedal travel will activate the transmission
retarder. Further depression of pedal will apply service
brakes.
Stop Light Pressure Switch (7)
A pressure switch located at a tee in the 'B2' line
energizes (illuminates) the vehicle's stop lights on
application of the treadle valve.
Directional Control Valve (8)
Refer to Section 250-0090, DIRECTIONAL CONTROL
VALVE.
The directional control valve is mounted off the cradle
assembly at the rear of the cab alongside brake
manifold valve (2). It is located in the 'Px' hydraulic
circuit between brake manifold valve (2) and treadle
valve (6). The 'Px' circuit hydraulically actuates treadle
valve (6) when the park/emergency control switch is
activated. It also controls automatic service brake,
applied pressure bleed down, with engine shutdown.
Brake Accumulator (9)
The small brake accumulator, located between the
brake manifold valve (2) and the pilot supply valve, is
pre-charged to 30 bar (435 lbf/in).
Priority Unloader Valve (10)
Refer to Section 250-0075, PRIORITY UNLOADER
VALVE.
the priority unloader valve distributes hydraulic oil flow
from the front section of the triple pump to the brake
manifold valve as it's first priority. Once the maximum
pressure is achieved in the brake circuit, the valve then
switches to supplement flow to the engine cooling fan
motor.
Brake Manifold Valve (2)
Refer to Section 250-0050, BRAKE MANIFOLD
VALVE.
The brake manifold valve is mounted off the cradle
assembly at the rear of the cab alongside the
directional control valve. It distributes hydraulic oil flow
from the priority unloader valve, to the treadle valve,
front and rear brake circuit accumulators and parking
brake at the rear wheels. It also provides appropriate
returns to tank for the hydraulic oil.
Parking Brake Pressure Switch (3)
Located in the brake manifold valve body it senses
pressure in the parking brake (Px) line. The pressure
switch closes at a pressure of 4.9 bar (71 lbf/in) and
sends a signal to illuminate the parking brake indicator
light when the parking brake is applied.
Brake Circuit Pressure Switches (4)
Front brake circuit pressure switch is located in a tee
piece below the front brake accumulator. The rear
brake circuit pressure switch is also located in a tee
piece below the rear brake accumulator. The pressure
switches sense pressure in the front and rear brake
circuits and send a signal to warning lights on the dash
(a buzzer also sounds) when the pressure drops below
115 bar (1 668 lbf/in).
Brake Accumulators (5)
Refer to Section 250-0060, ACCUMULATOR.
There are two brake accumulators mounted on the
cradle assembly at the rear of the cab; one for the
front brake system and the other for the rear. The
accumulator is of the piston type and is precharged
with nitrogen to 55 bar (800 lbf/in). It consists of a
charging valve assembly, cylinder assembly and
piston. The charging valve is equipped with a locking
feature which, when opened, will allow precharge to be
checked or accumulator charged.
The piston acts as a separator dividing the cylinder
assembly into two sections. The section nearest the
charging valve contains the nitrogen precharge.
Hydraulic oil from the priority unloader valve flows
through accumulator check valves in the brake
manifold valve and into the other section of the
accumulators.
Section 250-0000
SM 2155 Rev 2 06-05
3
braking system for proper operation.
Pressure Test Points
Two diagnostic pressure test points, located in the
manifold at the rear left hand side of the tractor frame,
provide a quick and easy method of checking front and
rear brake system pressure. The pressure is taken
from the 'B1' (front) and 'B2' (rear) brake circuits.
CHECKING SYSTEM PRESSURE
WARNINGS
Operate the treadle pedal continuously until the
could result.
parking brake, switch off the engine and turn steering
2. Operate the treadle valve continuously to relieve
pressure in the braking system. Block all road wheels,
place the steering lock bar in the 'Locked' position and the
3. Remove mounting hardware securing cover plate to
cradle assembly at the rear of the cab. Remove cover
plate to gain access to brake manifold valve.
pressure of 0 - 345 bar (0 - 5 000 lbf/in), to remote
diagnostic pressure point on brake manifold valve.
start the engine and monitor system pressure gauge.
Priority unloader valve pressure setting should be 170
bar (2 465 lbf/in).
6. Pressure setting can be adjusted as described by
Section 250-0075, PRIORITY UNLOADER VALVE.
Note: Actuating pressure for the front and rear brake
circuits is 48 2.4 bar (700 35 lbf/in) and can be
checked at remote diagnostic test points. Refer to
'Pressure Test Points'.
7. Shut off the engine and remove the pressure gauge
from brake manifold valve.
8. Secure cover plate to the cab wall with mounting
hardware.
9. Remove wheel blocks, place the steering lock bar in
the 'Stowed' position, start the engine and check the
connections, the following procedure should be
carried out during installation. Refer to Fig. 1.
aligned correctly.
been achieved.
BLEEDING THE BRAKING SYSTEM
1. Fill hydraulic tank with oil specified in Section
300-0020, LUBRICATION SYSTEM. Fill brake coolant
tank with oil specified in Section 300-0020,
LUBRICATION SYSTEM. Switch on engine and
operate systems until correct operating pressures are
recorded.
SM - 1335
'O' RING 'O' RING
SLEEVE
TUBE
FITTING
NUT
Section 250-0000
SM 2155 Rev 2 06-05
4
2. Check oil level in both tanks and add oil if low. Oil
should be halfway up sight gauge on both tanks.
WARNING
3. Ensure gear shift selector is in neutral, block all
road wheels, secure shipping bar in position and
release the park/emergency brake.
4. Install a clear length of tubing over bleed nipple on
one of the brake packs. Position the opposite end of
the tubing into a suitable container.
5. Crack open bleed nipple and operate treadle valve
gently to bleed air in the brake lines.
6. When the oil from the brake pack is clear (not cloudy
or creamy) close bleed nipple and remove length of
tubing.
WARNING
from the braking system.
7. Perform steps 4 through 6 for the remaining five
brake packs until the brake system is clear of air.
8. Check hydraulic oil level and add oil if low. Fill
hydraulic tank with oil specified in Section 300-0020,
LUBRICATION SYSTEM. Oil should show halfway up
sight gauge on the hydraulic tank.
9. Check brake cooling oil level and add if low. Fill
brake coolant tank with oil specified in Section 300-
0020, LUBRICATION SYSTEM. Oil should show
halfway up sight gauge on brake coolant tank.
HYDRAULIC OIL
The braking system should be kept filled with hydraulic
oil as specified in Section 300-0020, LUBRICATION
SYSTEM.
Whenever there is a hydraulic system failure, the oil
should be drained, the entire system flushed, oil filters
replaced, oil screens thoroughly cleaned and clean
hydraulic oil added to eliminate all metal particles or
foreign matter.
SERVICE TOOLS
Multi-gauge
2
).
Section 250-0000
SM 2155 Rev 2 06-05
5
BRAKING SYSTEM DIAGNOSIS
Inadequate braking Low System Pressure Check oil level
Check oil condition
Check for leakage
Check system pressure and adjust as
required
Treadle valve delivery pressure below Check front and rear brake circuits
normal Check treadle valve operation
Check for leakage (modular assembly)
Brake surfaces inefficient Check friction disc wear
Check brake packs for leakage
Replace seals or components as required
Brakes do not release Defective treadle valve Repair or replace defective components
Check adjustments (pedal return)
Loose or broken wire in brake manifold Repair circuit as required
valve circuit
Faulty solenoid Replace defective component
Faulty park/emergency switch Repair or replace as required
Restriction in tank return line Clear restriction
Seal bypass condition - parking brake Replace seals or component as required
assembly
Parking brake does Faulty park/emergency switch Repair or replace as required
Faulty park brake assembly Replace seals or component as required
Blocked orificed check valve in brake Clean or replace orificed check valve
manifold valve
Faulty brake manifold valve Check brake manifold valve operation.
Repair or replace valve as required
Emergency brakes do Faulty park/emergency switch Repair or replace as required
No transmission pilot pressure at Check transmission pressure
directional control valve Check for restriction in pilot line
Faulty directional control valve Check spool operation. Repair or replace
valve as required
Oil leakage - service brakes Check and repair
Faulty park brake assembly Replace seals or component as required
Faulty brake manifold valve Check brake manifold valve operation.
Repair or replace valve as required.
Faulty priority unloader valve Check priority unloader valve operation.
Refer to Section 250-0075, PRIORITY
UNLOADER VALVE.
not apply
not apply
S
e
c
t
i
o
n

2
5
0
-
0
0
0
0
B
r
a
k
i
n
g

S
y
s
t
e
m

-

B
r
a
k
i
n
g

S
y
s
t
e
m

S
c
h
e
m
a
t
i
c
S
M

2
1
5
5

R
e
v

2

0
6
-
0
5
6
Fig. 2 - Braking System Schematic - Engine Shutdown
S
M
-
2
7
6
5
A
COMPONENTS
1 - Triple Pump
2 - Brake Manifold Valve
4 - Brake Circuit Pressure Switches
5 - Brake Accumulators
6 - Treadle Valve
8 - Directional Control Valve
9 - Brake Accumulator
10 - Priority Unloader Valve
A - Front Brake System Pressure
B - Rear Brake System Pressure
C - Brake System Pressure
COLOUR CODES
Green - Intake Oil
Yellow - Static Oil
8
T P
a
b
B
PX
P1
T1
P2
B1
B2
T2
A
C
B
5 5
P A
3
6
7
4
2
B P
Y
A
C
C
1
TO PILOT SUPPLY
VALVE PORT 'P1'
(BODY SYSTEM)
A
C
C
2
P2
P1 T
PS2
PS1
A
PS3
REAR AXLE
SERVICE BRAKES
PARKING BRAKE
CENTRE AXLE
SERVICE BRAKES
FRONT AXLE
SERVICE BRAKES
HYDRAULIC TANK
TO ENGINE
COOLING CIRCUIT
TO BRAKE
COOLING CIRCUIT
TO ENGINE
COOLING CIRCUIT
10
REF. COOLING
SYSTEM
1
9
4
S
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c
t
i
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n

2
5
0
-
0
0
0
0
S
M

2
1
5
5

R
e
v

2

0
6
-
0
5
7Fig. 3 - Braking System Schematic - Engine Running, Brakes Off
S
M
-
2
7
6
5
B
COMPONENTS
1 - Triple Pump
B
r
a
k
i
n
g

S
y
s
t
e
m

-

B
r
a
k
i
n
g

S
y
s
t
e
m

S
c
h
e
m
a
t
i
c
6 - Treadle Valve
COLOUR CODES
Green - Intake Oil
Yellow - Static Oil
8
T P
a
b
B
PX
P1
T1
P2
B1
B2
T2
A
C
B
5 5
P A
3
6
7
4
2
B P
Y
A
C
C
1
TO PILOT SUPPLY
VALVE PORT 'P1'
(BODY SYSTEM)
A
C
C
2
P2
P1 T
PS2
PS1
A
PS3
REAR AXLE
SERVICE BRAKES
PARKING BRAKE
CENTRE AXLE
SERVICE BRAKES
FRONT AXLE
SERVICE BRAKES
HYDRAULIC TANK
TO ENGINE
COOLING CIRCUIT
TO BRAKE
COOLING CIRCUIT
TO ENGINE
COOLING CIRCUIT
10
REF. COOLING
SYSTEM
1
9
4
S
e
c
t
i
o
n

2
5
0
-
0
0
0
0
B
r
a
k
i
n
g

S
y
s
t
e
m

-

B
r
a
k
i
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g

S
y
s
t
e
m

S
c
h
e
m
a
t
i
c
S
M

2
1
5
5

R
e
v

2

0
6
-
0
5
8
Fig. 4 - Braking System Schematic - Service Brakes Apply
S
M

-

2
7
6
5
C
COMPONENTS
1 - Triple Pump
6 - Treadle Valve
COLOUR CODES
Green - Intake Oil
Yellow - Static Oil
8
T P
a
b
B
PX
P1
T1
P2
B1
B2
T2
A
C
B
5 5
P A
3
6
7
4
2
B P
Y
A
C
C
1
TO PILOT SUPPLY
VALVE PORT 'P1'
(BODY SYSTEM)
A
C
C
2
P2
P1 T
PS2
PS1
A
PS3
REAR AXLE
SERVICE BRAKES
PARKING BRAKE
CENTRE AXLE
SERVICE BRAKES
FRONT AXLE
SERVICE BRAKES
HYDRAULIC TANK
TO ENGINE
COOLING CIRCUIT
TO BRAKE
COOLING CIRCUIT
TO ENGINE
COOLING CIRCUIT
10
REF. COOLING
SYSTEM
1
9
4
S
e
c
t
i
o
n

2
5
0
-
0
0
0
0
S
M

2
1
5
5

R
e
v

2

0
6
-
0
5
9Fig. 5 - Braking System Schematic - Park/Emergency Brake Apply
S
M

-

2
7
6
5
D
B
r
a
k
i
n
g

S
y
s
t
e
m

-

B
r
a
k
i
n
g

S
y
s
t
e
m

S
c
h
e
m
a
t
i
c
COMPONENTS
1 - Triple Pump
6 - Treadle Valve
COLOUR CODES
Green - Intake Oil
Yellow - Static Oil
8
T P
a
b
B
PX
P1
T1
P2
B1
B2
T2
A
C
B
5 5
P A
3
6
7
4
2
B P
Y
A
C
C
1
TO PILOT SUPPLY
VALVE PORT 'P1'
(BODY SYSTEM)
A
C
C
2
P2
P1 T
PS2
PS1
A
PS3
REAR AXLE
SERVICE BRAKES
PARKING BRAKE
CENTRE AXLE
SERVICE BRAKES
FRONT AXLE
SERVICE BRAKES
HYDRAULIC TANK
TO ENGINE
COOLING CIRCUIT
TO BRAKE
COOLING CIRCUIT
TO ENGINE
COOLING CIRCUIT
10
REF. COOLING
SYSTEM
1
9
4
*

*

*

*
Section 250-0025
SM 2270 1-04
1
BRAKING SYSTEM - Brake Coolant Tank
SM - 3106
DESCRIPTION
The brake coolant tank can be identified as item 2 in
Section 210-0005, COOLING SYSTEM SCHEMATIC.
The brake coolant tank (1) is the reservoir for the brake
cooling oil. It is mounted off the left hand frame rail in
front of the fender and is secured in three places.
Integral with brake coolant tank (1) assembly are oil
level sight gauge (6), strainer (34), manifold blocks (30)
and access covers (5 & 15). Located on top of the tank
is filler cap (2), breather (10) and walkway plate (17).
Heatshields (18 & 19) are fitted to front and side of
tank.
OPERATION
otherwise specified. Refer to Fig. 2 for hydraulic
schematic of brake coolant tank.
Oil from brake coolant tank (1) is filtered through
Fig. 1 - Exploded View of Brake Coolant Tank and Mounting
2 - Latch
3 - Cap Assembly
4 - Gasket
5 - Cover
6 - Sight Gauge
7 - Bolt
8 - Lockwasher
9 - Nipple
31 - Bolt
32 - Washer
33 - Lockwasher
34 - Strainer
35 - Bush
36 - Connector
37 - Hose Assembly
38 - Bracket
10 - Breather
11 - Seal
12 - Drain Valve
15 - Cover Plate Assy
16 - Gasket
17 - Walkway Plate
18 - Heatshield
19 - Heatshield
20 - Screw
21 - Bolt
22 - Washer
23 - Lockwasher
24 - Bolt
25 - Washer
26 - Lockwasher
27 - Nut
30 - Manifold Block
24
25
25
26
27
31
32
33
2,3
30
18
22
23
21
22
23
21
7 8
7
8
34
4
5
16
15
17
10
9
20
1
19
6
11 12
A
A
DETAIL A
35
36
37
38
36
Section 250-0025
Braking System - Brake Coolant Tank
SM 2270 1-04
2
SM - 3107
strainer (34) before it is pumped through the brake
cooling circuit.
The brake cooling oil is drawn from brake coolant tank
(1) by motor/triple pump (3, Fig. 2) and pumped to each
brake pack. Refer to Section 250-0045, MOTOR/
TRIPLE PUMP ASSEMBLY. Oil being supplied to front
brake packs passes through filter (6, Fig. 2). The filter
has a visual indicator to show when the filter is in
bypass mode.
Return oil from the brake packs flows through disc
brake oil cooler (4, Fig. 2) and manifold blocks (30)
before entering the tank storage area.
MAINTENANCE
SPECIFICATIONS.
WARNING
safely.
Checking Oil Level
1. Start up the machine and bring the oil to correct
operating temperature.
switch off the engine.
3. Check oil level and add if low. Sight gauge (6)
should show half full. If oil is required remove padlock,
open latch (2) and remove filler cap (3) from brake
coolant tank (1) and fill brake coolant tank with oil
SYSTEM. Install filler cap (3) on brake coolant tank (1)
and secure with latch (2) and padlock.
Fig. 2 - Hydraulic Schematic of Brake Coolant Tank
2 - Strainer
3 - Motor/Triple Pump
5 - Manifold Block
6 - Filter
4 3
FROM CONTROL
VALVE
TO HYDRAULIC
TANK
TO HYDRAULIC
TANK
TO BRAKE PACKS
REAR CENTRE FRONT
FROM BRAKE PACKS
REAR CENTRE FRONT
1
2
5
FROM CONTROL
VALVE
6
Section 250-0025
SM 2270 1-04
3
Replacing Brake Cooling Oil
Brake cooling oil should be changed every 1 500 hours.
for oil used in the system.
Note: When replacing the brake cooling oil due to a
hydraulic failure, or at recommended change interval,
filter (6, Fig. 2) must be replaced, and brake coolant
tank (1) and strainer (34) cleaned thoroughly using a
suitable solvent. Breather (10) should also be replaced.
Note: When draining brake cooling oil, all six brake
assemblies should also be drained. Refer to Section
165-0015, OIL COOLED DISC BRAKES.
Replacing Breather
Every 1 000 hours of operation, replace breather (10).
the 'Off' position.
3. Unscrew breather (10) and discard. Install new
breather (10).
Cleaning Strainer
Note: Strainer (34) should be cleaned every time brake
coolant tank (1) is drained for any reason. Refer to
'Replacing Brake Cooling Oil' for change interval.
the 'Off' position.
(12) on the bottom of brake coolant tank (1). Install a
length of hose on remote drain fitting, open drain cock
and drain brake cooling oil into a suitable container.
4. Remove bolts (21) and washers (22 & 23) securing
heatshield (18) to front of brake coolant tank (1).
Remove heatshield (18) from tank.
5. Remove bolts (7), lockwashers (8), access cover (5)
and gasket (4) from front of brake coolant tank (1).
Discard gasket (4).
6. Unscrew and remove strainer (34) from the inside of
brake coolant tank (1).
WARNING
7. Clean out the inside of brake coolant tank (1) and
strainer (34) with a suitable solvent and dry with
compressed air.
8. Inspect strainer (34) for damage and replace if
required.
9. Install strainer (34) in brake coolant tank (1) and
secure.
10. Place new gasket (4) and access cover (5) on
brake coolant tank (1) and secure with bolts (7) and
lockwashers (8).
11. Install heatshield (18) and secure using bolts (21)
and washers (22 & 23).
12. Remove padlock, open latch (2) and remove filler
cap (3) from brake coolant tank (1). Fill brake coolant
tank with oil specified in Section 300-0020,
LUBRICATION SYSTEM. Install filler cap (3) on brake
coolant tank (1) and secure with latch (2) and padlock.
remove all wheel blocks and start the engine.
Note: The oil level will drop during initial start up due to
brake assemblies and lines being charged.
14. Switch off the engine, check for leaks and check
oil level as described under 'Checking Oil Level'.
TANK ASSEMBLY
Removal
Section 250-0025
SM 2270 1-04
4
manifold blocks (30) to brake coolant tank (1). Remove
manifold blocks (30).
Inspection
WARNING
1. Clean brake coolant tank (1) and components with a
suitable solvent and dry with compressed air.
2. Inspect brake coolant tank (1) for weld cracks and
security of internal pipes and weld fitments.
3. Inspect breather (10) and strainer (34) for damage.
Replace if required.
Assembly
1. Renew all seals and gaskets and install all internal
components in brake coolant tank (1), as previously
described under 'Maintenance'.
2. Fit filler cap (3), latch (2) and padlock.
3. Install breather (10), nipple (9) connectors (36), bush
(35) and hose (37) in tank.
4. Fit sight gauge (6) to brake coolant tank (1).
5. Install heatshields (18 & 19) and secure using bolts
(21) and washers (22 & 23).
6. Using new 'O' rings, install manifold blocks (30) on
tank, using fasteners removed at 'Disassembly'.
Installation
SPECIFICATIONS.
WARNING
safely.
the 'Off' position.
(12) on the bottom of brake coolant tank (1). Install a
length of hose on remote drain fitting, open drain cock
and drain oil into a suitable container. Close drain cock,
remove hose and reinstall blanking cap on remote drain
assembly (12).
4. Ensure all cooling lines connected to brake coolant
tank (1) are identified for ease of installation and, with
disconnect cooling lines. Fit blanking caps and plugs to
all open lines and fittings.
5. Remove screws (20) and walkway (17) from top of
tank. Install lifting eyes in brake coolant tank (1) and
attach a suitable lifting device. Remove nuts (27),
washers (25 & 26) and bolts (24) securing brake
coolant tank (1) to frame.
6. Carefully remove brake coolant tank (1) assembly
from the unit to a clean work area for disassembly.
Disassembly
1. Remove internal components from brake coolant tank
(1) as described under 'Maintenance'.
2. Remove padlock, latch (2) and filler cap (3) from
brake coolant tank (1).
3. Remove breather (10), nipple (9), connectors (36),
bush (35) and hose (37).
4. Remove sight gauge (6) from brake coolant tank (1).
heatshields (18 & 19) to brake coolant tank (1).
Remove heatshields (18 & 19).
Section 250-0025
SM 2270 1-04
5
SYSTEM SCHEMATIC. Renew all 'O' rings where
used.
WARNING
safely.
1. Using a suitable lifting device, locate brake coolant
tank (1) in position on the vehicle and secure with bolts
(24), washers (25 & 26) and nuts (27).
2. Install new 'O' rings and install all cooling lines and
fittings to brake coolant tank (1), as tagged at removal.
3. Fill brake coolant tank (1) with oil specified in
filler cap (3) on brake coolant tank (1) and secure with
padlock.
* * * *
remove all wheel blocks, start the engine and bring the
oil to correct operating temperature.
5. Switch off the engine, check for leaks and check oil
level as described under 'Checking Oil Level'.
SPECIAL TOOLS
dealer.
Section 250-0040
SM 2271 1-04
1
BRAKING SYSTEM - Triple Pump
SM - 2763
driving the motors for the disc brake oil cooler and
the motor/triple pump. Oil is supplied via control
valve. Refer to Section 250-0065, CONTROL
VALVE.
The three separate sections of the triple gear pump are
connected together as one assembly. The front section
consists of driveshaft & gear (10), driven gear (11) and
front pump housing (12). Middle and rear pumps (15)
are coupled to front pump by connecting shaft (13).
OPERATION
Numbers in parentheses refer to Fig. 1. Refer to Fig. 2
for the operation of a typical gear type hydraulic pump.
Refer to Fig. 3 for hydraulic schematic of the triple
pump operation.
As the drive gear rotates, the driven gear rotates in the
DESCRIPTION
Numbers in parentheses refer to Fig. 1. The triple pump
can be identified as item 1 in Section 210-0005,
COOLING SYSTEM SCHEMATIC.
The triple gear pump, mounted off the transmission
power takeoff, provides the following:
a) front section (closest to driveshaft) supplies the
brake circuit as a priority, before augmenting
engine cooling circuit via priority unloader valve.
Refer to Section 250-0075, PRIORITY UNLOADER
VALVE.
b) middle section combines with residual flow from
front section to drive engine cooling fan motor. Low
temperature unloader valve controls flow to fan
motor. Refer to Section 210-0045, LOW
TEMPERATURE UNLOADER VALVE.
c) rear section supplies the brake cooling circuit,
Fig. 1 - Exploded View of Triple Pump
7 - Bolt
8 - Bolt
9 - Front Cover
10 - Driveshaft & Gear
11 - Driven Gear
12 - Front Pump Housing
13 - Connecting Shaft
14 - 'O' Ring
15 - Rear Pumps
16 - Bolt
1 - Mounting Flange
2 - Seal
3 - Front Seals
4 - Rear Seals
5 - Bolt
6 - Washer
2
3
4
6
5
14
15
1
7
8
9
10
11
12
13
16
Braking System - Triple Pump
Section 250-0040
SM 2271 1-04
2
SM - 2764 SM - 338
DRIVE GEAR
OUTLET INLET
DRIVEN GEAR
Fig. 2 - Typical Pump Operation Fig. 3 - Hydraulic Schematic of Triple Pump Operation
4. Clean pump housing and tag and disconnect inlet
and outlet lines from the pump. Drain oil in lines into a
suitable container. Cap lines and pump ports to prevent
ingress of dirt.
5. With suitable blocking or lifting equipment, support
pump before loosening mounting bolts (5). Remove
bolts (5) and washers (6) and lift pump clear. Move
pump to a suitable work area for 'Disassembly'.
DISASSEMBLY
1. Place pump in a soft-jawed vice, driveshaft (10)
down. Match mark all pump sections to aid assembly.
Note: Do not clamp vice on pump machined surfaces
at any time.
2. Note location of all hydraulic connectors and
adaptors and remove from triple pump.
3. Remove bolts (16) and washers securing front pump
housing (12) to rear pumps (15).
opposite direction. The pockets between the gear teeth
carry oil from the inlet port around the gear housing ID
to the pump outlet port. As the gear teeth re-mesh,
this oil is forced out of the outlet port of the gear
housing. The maximum oil delivery rate of each section
of the triple pump is fixed by the width of its respective
gear set and the speed at which driveshaft (10) is
turned.
Maximum delivery of front section = 59 litres/min.
Maximum delivery of middle section = 42 litres/min.
Maximum delivery of rear section = 18 litres/min.
The triple pump draws oil from the hydraulic tank, then
pumps the oil to supply the various circuits. The triple
pump is assembled for left hand (anticlockwise)
REMOVAL
WARNINGS
Hydraulic fluid pressure will remain within the
system after engine shut down. Operate the
treadle valve continuously until the pressure
has dissipated before carrying out any work on
the braking system or serious injury could
result.
secured and of adequate capacity to execute the
job safely.
HYDRAULIC TANK
TO ENGINE
COOLING CIRCUIT
TO BRAKE
CIRCUIT
TO BRAKE
COOLING CIRCUIT
Section 250-0040
SM 2271 1-04
3
4. Tap front pump housing (12) with a soft hammer if
required to separate from rear pumps (15). If front
pump housing (12) must be pried off, use care to avoid
damaging machined surfaces.
5. Separate mounting flange (1) from front cover (9) by
removing bolts (7). If it must be pried loose, use care
to prevent damage to machined surfaces.
6. Remove bolts (8) securing front cover (9) to front
pump housing (12) and carefully separate. If sections
must be pried apart, use care to prevent damage to
machined surfaces.
7. Remove front and rear seals (3 & 4) to allow
driveshaft and gear (10) and driven gear (11) to be
removed. Discard seal (2) from front cover (9).
8. Remove 'O' ring (14) and connecting shaft (13) from
rear pumps (15).
9. Separate rear pumps (15) by removing nuts at rear
of triple pump and prise apart, using care to prevent
damage to machined surfaces.
ASSEMBLY
SPECIFICATIONS.
1. Replace seals in rear pumps (15) and assemble. Fit
nuts at rear and tighten.
2. Install new 'O' ring (14) and connecting shaft (13) to
rear pumps.
3. Fit new rear seals (4) to front pump housing (12).
Carefully install driveshaft and gear (10) and driven
gear (11) into front pump housing (12).
4. Fit new front seals (3) to front pump housing (12)
before fitting front cover (9) to front pump housing (12)
with bolts (8). Torque bolts to 162 Nm (119 lbf ft).
5. Fit new seal (2) to front cover (9).
6. Assemble mounting flange (1) to front cover (9)
using bolts (7). Torque bolts (7) to 46 Nm (34 lbf ft).
7. Assemble front pump housing (12) to rear pumps
(15) and secure with bolts (16). Torque bolts to 40 Nm
(29 lbf ft).
INSTALLATION
SYSTEM SCHEMATIC. Renew all 'O' rings where used.
WARNING
equipment is of adequate capacity and properly
secured to do the job safely.
1. With suitable lifting equipment position triple pump
on transmission power takeoff. Secure with bolts (5)
and washers (6). Torque bolts (5) to 73 Nm (54 lbf ft).
2. Fill all pump ports with clean hydraulic oil and
connect lines to pump, as tagged during 'Removal.
3. Fill hydraulic tank with hydraulic oil as specified in
Section 230-0040, HYDRAULIC TANK, for oil levels.
Install filler cap on hydraulic tank filler neck.
start the engine and allow the machine to idle for at
least two minutes. During this break-in period, the
pump should run free and not develop excessive heat.
If the pump becomes hot to touch, it is binding and
might seize. The pump will then have to be removed
and inspected. If the pump runs properly, speed and
pressure can be increased to normal operating values.
5. Check pump mounting and hydraulic line connections
for leaks and tighten as required.
steering bar in the 'Stowed' position.
LUBRICATION
All pump parts are lubricated by the hydraulic oil. The
oil, therefore, must be kept clean to minimize pump
wear. Whenever there is a hydraulic system failure, the
oil should be drained, the entire system flushed, filter
replaced, oil screens thoroughly cleaned and fresh
hydraulic oil installed to eliminate all metal particles or
Section 250-0040
SM 2271 1-04
4
foreign matter.
FAILURE MODES
It is not recommended giving the triple gear pump a
major overhaul, however replacement seal kits are
available. Typical failure modes of triple pump are
illustrated in table below.
SPECIAL TOOLS
dealer.
PART TYPE OF WEAR WEAR CAUSES MATING COMPONENT
DEFECT
Shaft seal Lip wear external leakage. - External contamination Grooving of driveshaft.
- High oil temperature
- Overspeeding
- High inlet pressure
Wearplates Scoring/burning of faces - Oil contamination Scoring or abrasive wear
adjacent to gear - low - Cavitation of gear side faces.
volumetric efficiency. - Starting pump dry
- Running pump in reverse
Wearplate back-up Extrusion/melting of back-up - - Over pressurisation This type of failure is likely
seal low volumetric efficiency. - High oil temperature to be accompanied by
- Cavitation severe damage to wearplates
gears and bearing.
Wearplate seal Extrusion/seal failure - low - Over pressurisation Damage to wearplate and
volumetric efficiency. - Excessive pressure cycle backup seal may also occur
- Running pump in reverse with this type of fault.
Bearings Smooth even wear with a - Long service life Gear journals are likely to
tendancy for bearing surface - Working for high show even polishing with
to change colour from grey to percentage of duty cycle light scoring due to
bronze, indicating that the close to peak pressure contamination passing
PTFE overlay is wearing rating intermittently through the
through - the bearing is coming - High oil temperature bearings. Replace pump
to end of its useful life. - Low oil viscosity section.
Bearings Total bearing failure with - Oil contamination Usually results in severe
heavy scoring, overheating - Over pressurisation damage to all the major
and possible bearing meltdown. - High oil temperature pump components. Pump is
- Oil starvation almost certainly beyond
- Low viscosity or grade economic repair.
- Inferior oil quality
- Cavitation
- Running pump in reverse
* * * *
Section 250-0045
1
SM 2272 3-04
DESCRIPTION
Numbers in parentheses refer to Fig. 1. The motor/
triple pump (1) can be identified as item 7 in Section
210-0005, COOLING SYSTEM SCHEMATIC.
Mounted off brackets on the left hand frame rail,
adjacent to the brake coolant tank, the motor/triple
pump assembly consists of three pump elements
coupled to a single direction hydraulic motor. The
hydraulic motor within the assembly is protected by a
relief valve (2).
OPERATION
Refer to Fig. 2. The motor is supplied with hydraulic oil
from the brake 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 rotation causes pump elements to draw brake
cooling oil from brake coolant tank. Cooling oil is then
pumped to brake packs via manifold blocks on front,
centre and rear axles.
Note: A filter is fitted between motor/triple pump and
front axle brake packs.
A solenoid controls the output of the motor/triple pump
by controlling the flow of hydraulic oil to the motor.
Refer to Fig. 2. When brake cooling oil is below 50
o
C
(122
o
F) solenoid is energised, which directs a
proportion of hydraulic oil to tank rather than through
the motor, causing a reduced motor speed hence
reduced pump output.
Refer to Fig. 3. When brake cooling oil reaches 50
o
C
(122
o
F) solenoid is de-energised, thereby directing all
of the hydraulic oil through the motor, increasing motor
speed therefore increasing pump output.
A sealing arrangement within the assembly prevents
cross contamination of hydraulic oil from triple gear
pump with brake cooling oil from brake coolant tank.
The relief valve (2) limits the pressure through the
motor to 100 bar (1450 lbf/in
2
).
Note: Direction of rotation is clockwise as viewed from
shaft end, and is indicated by an arrow.
BRAKING SYSTEM - Motor/Triple Pump Assembly
SM - 2761
1 - Motor/Triple Pump
2 - Relief Valve
3 - Bolt
4 - Washer
5 - Nut
6 - Rubber Plate
7 - Bolt
8 - Lockwasher
9 - Washer
10 - Rubber Plate
Fig. 1 - Motor/Triple Pump
SM- 3108
Fig. 2 - Motor/Triple Pump- Solenoid energised.
1
10
3
4
5
6
7
8
9
2
SM- 3148
Fig. 3 - Motor/Triple Pump- Solenoid de-energised.
3
TO HYDRAULIC
TANK
TO BRAKE PACKS
REAR CENTRE FRONT
2
6
FROM BRAKE
COOLANTTANK
FROM DISC BRAKE
OIL COOLER
3
TO HYDRAULIC
TANK
TO BRAKE PACKS
REAR CENTRE FRONT
2
6
FROM BRAKE
COOLANTTANK
FROM DISC BRAKE
OIL COOLER
Section 250-0045
Braking System - Motor/Triple Pump Assembly
SM 2272 3-04
2
REMOVAL
WARNINGS
result.
the job safely.
bottom of the brake coolant tank. Install a length of
hose on remote drain fitting, open drain cock and drain
brake cooling oil into a suitable container. Close drain
5. Clean motor/triple pump (1) assembly and
tag all hydraulic lines connected to motor/triple pump
(1), to aid in 'Installation'.
open lines.
7. Remove bolt (7), washers (8 & 9) and rubber plate
(6) securing motor/triple pump (1) to bracket.
8. Remove nuts (5), washers (4), bolts (3) and rubber
plate (10) securing motor/triple pump (1) to bracket.
DISASSEMBLY
1. Place motor/triple pump (1) assembly in a soft-
jawed vice, and clamp on body. Match mark pump
sections and motor to aid in assembly.
Note: Do not clamp vice on machined surfaces of the
assembly at any time.
adaptors and remove from motor/triple pump (1).
3. Unscrew and remove relief valve (2) from motor/
triple pump (1) body.
4. Remove hexagon socket bolts and washers from
motor/triple pump (1) to separate motor section from
pump elements. Tap motor section with a soft hammer
if required.
Note: Do not attempt to pry the motor/triple pump (1)
assembly apart with a large screwdriver or pry bar.
The machined surfaces of the assembly may be
damaged.
5. Remove bolts from motor section if further
disassembly is required.
6. Remove nylock nuts to allow pump elements to be
separated.
Note: Do not attempt to pry the pump elements apart
with a large screwdriver or pry bar. The machined
surfaces may be damaged.
7. Remove and discard seals that are to be replaced
with new seals in kit.
INSPECTION
compressed air.
3. Check relief valve cartridge (2) for damage. Ensure
valve seat is not worn, scored or cracked.
It is not recommended that the valve cartridge (2) is
assembly is cleaned prior to removal of any
Section 250-0045
3
SM 2272 3-04
ASSEMBLY
1. From seal kit, replace seals on motor section and
pump elements prior to re-assembly.
2. Lightly oil parts prior to re-assembly.
3. Assemble three pump elements together and
secure with threaded rods and nylock nuts.
4. If disassembled, assemble motor section and
secure with bolts.
5. Install motor section to pump elements and secure
with hexagon socket bolts and washers.
6. Refit relief valve (2) to motor/triple pump (1) body.
INSTALLATION
where used.
1. Secure motor/triple pump (1) assembly to brackets
with mounting hardware as removed at 'Removal'.
install lines to motor/triple pump as identified during
'Removal'.
3. Fill brake coolant tank with oil as specified in
Section 250-0025, BRAKE COOLANT TANK, for oil
levels. Install filler cap on brake coolant tank filler
neck.
4. Fill hydraulic tank with hydraulic oil as specified in
Section 230-0040, HYDRAULIC TANK, for oil levels.
Install filler cap on hydraulic tank filler neck.
temperature.
6. Check motor/triple pump (1) and hydraulic line
FAULT DIAGNOSIS
Numbers in parenthesis refer to Fig. 1.
Refer to following fault diagnosis chart. As stated
previously, it is not recommended that the relief valve
(2) cartridge assembly is disassembled for
maintenance purposes. Ensure that motor/triple pump
(1) is cleaned off prior to removal of any components
and that no contaminant is allowed to enter the
internal galleries.
If investigation shows that the relief valve (2) is in
good clean condition and fit for use, the seals should
be replaced prior to re-assembly. Any damage to the
motor section or any of the pump elements would
necessitate a new motor/triple pump (1) assembly.
SPECIAL TOOLS
service tools required. These tools are available from
your dealer.
Section 250-0045
SM 2272 3-04
4
FAULT DIAGNOSIS
CONDITION REASON ACTION
Non rotation of shaft No oil supply. Check pressure at rear section of triple gear pump.
Pressure should be 110 bar (1600 psi) at 2200 rpm,
when oil is at operating temperature.
Internal relief valve (2) sticking. Clean/replace relief valve.
Relief valve faulty. Check - refer to Section 250-0120, RELIEF VALVE.
Brake packs overheating No brake cooling oil supply. Check oil level in brake cooling tank.
Pump elements damaged. Replace motor/triple pump.
* * * *
Section 250-0050
SM 2158 7-02
1
BRAKING SYSTEM - Brake Manifold Valve
SM - 2749
DESCRIPTION
The brake manifold valve can be identified as item 2 in
Section 250-0000, BRAKING SYSTEM SCHEMATIC.
the brake manifold valve distributes hydraulic oil flow
from the priority unloader valve to the treadle valve,
front and rear brake circuit accumulators, priority
unloader accumulator and parking brake at the rear
wheels. The valve also provides appropriate returns to
tank for the hydraulic oil.
OPERATION
Numbers in parentheses refer to Fig. 1. Refer to Figs. 2
and 3 for hydraulic schematics.
Hydraulic oil from the priority unloader valve enters the
brake manifold valve at port 'P'. Oil pressure moves
check balls (9) from their seats (10) and allows oil to
flow through ports 'ACC1' and 'ACC2' to the brake
accumulators.
Pressurised oil exits the brake manifold valve through
port 'PY' and flows to port 'P1' on the treadle valve,
and, through port 'P2' on the brake manifold valve to
port 'P2' on the treadle valve.
Solenoid Cartridge - De-energized
When the emergency brake switch is activated (pushed
in), the electrical signal between the switch and
solenoid coil (3) is opened, de-energizing solenoid
cartridge (2). Oil flows through solenoid cartridge (2)
and exits the brake manifold valve through port 'A' to
the directional control valve. The oil travels through the
directional control valve and into the 'Px' port in the
treadle valve for an emergency brake application.
Fig. 1 - Exploded View of Brake Manifold Valve
1 - Valve Body
2 - Solenoid Cartridge
3 - Solenoid Coil
4 - Locknut
5 - Plug
6 - Retainer
7 - 'O' Ring
8 - Spring
9 - Check Ball
10 - Seat
11 - 'O' Ring
12 - 'O' Ring
13 - Backup Rings
14 - 'O' Ring
15 - Backup Rings
16 - 'O' Ring
17 - Backup Rings
18 - 'O' Ring
19 - Plug
20 - Park Brake Pressure Switch
7
6
8
9
10
1
4
3
2
5,18
19
20
16
14
12
17
15
13
11
PY
P
PS1
PS2
A
B
P2
PS3
P1
P
ACC1
ACC2
T
Section 250-0050
Braking System - Brake Manifold Valve
2
SM 2158 7-02
T
P
A
3
2
B
P1
PY
ACC1
ACC2
PS1 PS2
PS3 P2
P
Return oil from the parking brake circuit enters the
brake manifold valve at port 'B'. The oil flows through
solenoid cartridge (2) and exits the brake manifold
valve at port 'T' to the hydraulic tank. With no pressure
in the parking brake circuit to hold the parking brake
off, the parking brake is applied.
Solenoid Cartridge - Energized
When the emergency brake switch is deactivated
(pulled out), the electrical signal between the switch
and solenoid coil (3) is closed, energizing solenoid
cartridge (2). Oil flows through solenoid cartridge (2)
and exits the brake manifold valve at port 'B' to the
parking brake circuit to release the parking brakes.
Return oil from the 'Px' port on the treadle valve flows
through the directional control valve and into the brake
manifold valve at port 'A'. The oil travels through
solenoid cartridge (2) and exits the brake manifold
valve at port 'T' to the hydraulic tank.
Pressure Switches
Accumulator pressure switches fitted to bottom of
brake accumulators send a signal to illuminate warning
lights in the dash panel when the pressure drops below
115 bar (1 668 lbf/in).
Parking brake pressure switch (20) sends a signal to
illuminate the parking brake light in the dash panel
SM - 2750
when the pressure in the parking brake circuit drops
below 4.9 bar (71 lbf/in).
REMOVAL
WARNINGS
result.
safely.
pressure in the braking system. Block all road wheels,
place the steering lock bar in the 'Locked' position and the
Fig. 2 - Emergency Brake Switch Activated - Solenoid Cartridge De-energized
TO DIRECTIONAL
CONTROL VALVE
FROM PARKING BRAKE
TO PORT 'P1' TREADLE VALVE
TO BRAKE ACCUMULATOR
TO DIAGNOSTIC
PRESSURE CHECK POINT
FROM PRIORITY UNLOADER
VALVE/TO PILOT SUPPLY VALVE
(BODY HOIST SYSTEM)
TO PORT 'P2'
TREADLE VALVE
Section 250-0050
SM 2158 7-02
3
T
P
A
3
2
B
P1
PY
ACC1
ACC2
PS1 PS2
PS3 P2
P
SM - 2751
3. Remove and tag electrical connections to solenoid
coil (3) and pressure switch (20).
4. Clean brake manifold valve assembly and
surrounding area with a suitable solvent. Ensure all
hydraulic lines connected to the brake manifold valve
are identified for ease of installation and, with suitable
hydraulic lines. Fit blanking caps to all open lines.
5. Release and remove mounting hardware securing
brake manifold valve to cradle assembly at rear of cab.
Remove assembly from the vehicle.
DISASSEMBLY
1. Clamp valve body (1) lightly in a soft jawed vice,
retainers (6) face up. Do not overtighten jaws. Remove
retainers (6) from valve body (1) and discard 'O' rings
(7).
2. Remove plug (5) from valve body (1) and discard 'O'
ring (18).
3. Carefully remove valve body (1) assembly from the
vice and remove springs (8) and check balls (9) from
valve body (1).
4. If required, clamp valve body (1) lightly in soft jawed
vice and remove check ball seats (10).
5. Rotate valve body (1) in vice until solenoid coil (3) is
facing up. Lightly clamp valve body (1) in vice and
remove locknut (4) and solenoid coil (3) from solenoid
cartridge (2).
6. Remove solenoid cartridge (2) assembly from valve
body (1) and discard 'O' rings (11, 12, 14 & 16) and
backup rings (13, 15 & 17).
7. Mark valve body (1) port identification on pressure
switch (20) and remove from valve body (1).
8. Remove plugs (19) from valve body (1) and discard
'O' rings.
9. If required, note orientation and remove hydraulic
line connectors from ports in valve body (1).
ASSEMBLY
1. Install new 'O' rings (11, 12, 14 & 16) and backup
Fig. 3 - Emergency Brake Switch Deactivated - Solenoid Cartridge Energized
TO PARKING BRAKE
FROM DIRECTIONAL
CONTROL VALVE
TO PORT 'P1' TREADLE VALVE
TO PORT 'P2'
TREADLE VALVE
TO DIAGNOSTIC
PRESSURE CHECK POINT
FROM PRIORITY UNLOADER
VALVE/TO PILOT SUPPLY VALVE
(BODY HOIST SYSTEM)
Section 250-0050
4
SM 2158 7-02
rings (13, 15 & 17) on solenoid cartridge (2) as shown
in Fig. 1.
2. Install solenoid cartridge (2) assembly in valve body
(1) and tighten securely. Install solenoid coil (3) on
solenoid cartridge (2) and secure with locknut (4).
3. Rotate valve body (1) in vice until retainer (6) face is
up. Install new 'O' ring (18) on plug (5) and install plug
(5) assembly in valve body (1).
4. If removed, apply Loctite 603 to threads of seats
(10) and install seats (10) in valve body (1). Tighten
seats (10) to a torque of 20 Nm (15 lbf ft). See Fig. 4.
5. Install one check ball (9) on seat (10) and spring (8)
on check ball (9). Install new 'O' ring (7) on retainer (6)
and carefully place retainer (6) assembly over spring
(8) in valve body (1). Tighten retainer (6) securely in
valve body (1). See Fig. 4.
6. Repeat step 5 for second check ball, spring and
retainer assembly.
7. Install pressure switch (20) in valve body (1) as
noted during disassembly.
8. Install new 'O' rings on plugs (19). Fit plugs (19) to
valve body (1).
9. If removed, install hydraulic line connectors in valve
body (1) as noted during disassembly.
INSTALLATION
where used.
1. Position brake manifold valve assembly to the
cradle assembly, at the rear of the cab and secure
with mounting hardware.
SM - 1508
connect to brake manifold valve as noted during
removal.
3. Connect electrical connections to solenoid coil (3)
and pressure switch (20) as noted during removal.
4. Check oil level in the hydraulic tank and add oil if
TANK for correct fill level, and, Section 300-0020,
remove wheel blocks, start the engine and bring
hydraulic oil to operating temperature.
6. Check brake manifold valve and hydraulic line
7. Shut off engine and make sure a full service brake
application is made followed by a parking brake
application.
8. Repeat all braking and engine shut down cycles
several times and check for appropriate application/
release cycle several times.
9. Check all connections again for leaks and tighten as
required.
Fig. 4 - Section Through Check Ball Assembly
6 - Retainer
7 - 'O' Ring
8 - Spring
9 - Check Ball
10 - Seat
6
8
7
9
10
Section 250-0050
SM 2158 7-02
5
10. Place steering lock bar in the 'Stowed' position.
MAINTENANCE
Inspect the brake manifold valve regularly for any signs
of leakage or damage and repair/replace as required.
Note: Limited repair of the brake manifold valve is by
TORQUE
1 10 Seat 20 15
* * * *
replacement of parts only.
SPECIAL TOOLS
tools and adhesives required. These tools, and
Section 250-0060
SM 2160 7-02
1
BRAKING SYSTEM - Accumulator
SM - 277
DESCRIPTION
The brake accumulators can be identified as items 5
and the pressure switches as items 4 in Section
250-0000, BRAKING SYSTEM SCHEMATIC.
There are two brake accumulators mounted at the rear
of the cab; the left hand accumulator supplies
pressure for the front brake circuit, and the right hand
accumulator supplies pressure for the rear brake circuit
and the parking brake circuit. The accumulator is of the
piston type and is precharged with nitrogen to 55 bar
(800 lbf/in). It consists of charging valve (1), end cap
(10), cylinder (12) and piston (5). Charging valve (1) is
equipped with a locking feature. Loosening locknut (1D)
will open the valve so that the precharge can be
checked or the accumulator charged.
OPERATION
Piston (5) acts as a separator dividing cylinder (12)
into two sections. The section nearest charging valve
(1) contains the nitrogen precharge. Hydraulic oil from
the brake section of the triple gear pump flows through
accumulator check valves in the brake manifold valve
and into the other section of the accumulators.
Accumulator pressure is monitored by pressure
switches fitted to bottom of accumulators, which send
a signal to illuminate warning lights in the dash panel
when the pressure drops below 115 bar (1 668 lbf/in).
TESTING
WARNINGS
safely.
Accumulators are charged with Nitrogen.
The service pressure is 55 bar (800 lbf/in) at
21 C (70
o
F). To prevent personal injury and
property damage do not attempt to remove any
valves or fittings until all nitrogen pressure is
completely relieved.
Fig. 1 - Exploded View of Accumulator
9 - 'O' Ring
10 - End Cap
11 - Pad
12 - Cylinder
5 - Piston
6 - Backup Rings
7 - 'V' Section Ring
8 - Wear Rings
1 - Charging Valve
1A - Cap
1B - Core
1C - 'O' Ring
1D - Locknut
1E - Body
1F - 'O' Ring
2 - Screw
3 - Lockwasher
4 - Protector
Section 250-0060
Braking System - Accumulator
SM 2160 7-02
2
WARNING
Operate the treadle pedal continuously until the
could result.
Testing Charging Valve For Leakage
1. Remove screws (2), lockwashers (3), protector (4)
and pads (11) from accumulator.
2. Remove cap (1A) from charging valve (1) and
loosen locknut (1D). Coat open end of charging valve
(1) with soapy water. Bubbles indicate leaky valve
core (1B).
3. Attempt to reseat the valve core by depressing and
releasing it quickly once or twice. Recheck for
leakage. If leakage continues, discharge the
accumulator as described under 'Discharging Nitrogen'
in this section.
4. Replace valve core (1B). Tighten locknut (1D) to
11 Nm (100 lbf in) and replace valve cap (1A) finger
tight.
Testing Precharge Pressure
Note: The nitrogen pressure in an accumulator is
directly affected by changes in nitrogen temperature.
The cylinder pressure will increase or decrease
proportionally with temperature changes. An
accumulator pressure reading can vary about 4.3 bar
(62 lbf/in) with 22 C (72 F) temperature change.
Such temperature changes could easily occur
between noon and midnight of the same day. Refer to
the table at the end of this section for nitrogen
pressures at ambient temperatures of other than
21 C (70 F).
To test accumulator precharge pressure or to charge
the accumulator, a charging assembly kit can be used.
Refer to Fig. 2.
SM - 1273
pressure in the braking system. Block all road wheels
and place battery master switch in the 'Off' position.
3. Check accumulator mountings to be sure the
accumulator is held tightly in position.
4. Remove cap (1A, Fig. 1) from accumulator charging
valve (1, Fig. 1). Attach charging line (1) to charging
valve by rotating 'T' handle of valve chuck (2)
anticlockwise until it stops then screw the swivel nut
down on the valve. Loosen locknut (1D, Fig. 1) by
turning anticlockwise one to two turns.
5. Turn 'T' handle clockwise until charging valve core
is depressed. Be sure bleeder valve (10) is tight and
does not leak, and valves (4 & 6) are closed.
6. To read accumulator precharge pressure, slowly
open cylinder valve (4). Pressure gauge (5) will
register precharge pressure, it should be 55 bar
(800 lbf/in) at 21 C (70 F) ambient temperature.
Refer to the table at the end of this section for nitrogen
pressures at ambient temperatures of other than 21 C
(70 F).
1 - Line
2 - Valve Chuck
3 - Valve Extension
4 - Cylinder Valve
5 - Pressure Gauge
6 - Tank Valve
7 - Gland Fitting
8 - Gland Nut
9 - Cylinder Adaptor
10 - Bleeder Valve
Fig. 2 - Charging Assembly Kit
Section 250-0060
SM 2160 7-02
3
7. Close cylinder valve (4) and open bleeder valve (10)
to dissipate gauge pressure. Close bleeder valve (10)
after pressure is relieved. If the accumulator needs
charged, leave line (1) and valve chuck (2) attached to
charging valve (1, Fig. 1)). Charge the accumulator as
described under 'Charging The Accumulator'.
8. If precharge pressure is correct, rotate 'T' handle
anticlockwise until it stops. Tighten locknut (1D, Fig. 1)
on charging valve (1, Fig. 1) to 11 Nm (100 lbf in).
Loosen the swivel nut and remove gauging head.
9. Install cap (1A, Fig. 1) on charging valve (1, Fig. 1)
and tighten finger tight.
10. Remove wheel blocks and place the battery
master switch in the 'On' position.
CHARGING THE ACCUMULATOR
Note: Either oil or water pumped nitrogen can be used
to charge the accumulator. Both types are readily
available from a local compressed gas dealer.
WARNINGS
Do not use Oxygen or any gas other than
Nitrogen to charge an accumulator. Oxygen
under pressure coming into contact with oil or
grease will cause a violent explosion. Always
double check to make sure you are using
Nitrogen to prevent personal injury and
property damage.
A high pressure nitrogen pressure
regulator must be used with the charging
assembly kit. Failure to use pressure regulator
could cause property damage, personal injury
or death.
1. Attach line (1) and the swivel nut to charging valve
(1, Fig. 1) as described in steps 1 through 4 under the
heading 'Testing Precharge Pressure'. Be sure valves
(4 & 6) are closed.
2. Attach gauging head to nitrogen bottle by screwing
down on gland nut (8).
3. Open tank valve (6) slowly; pressure shown on
pressure gauge (5) is tank pressure.
4. Open cylinder valve (4) slowly and charge
accumulator to 55 bar (800 lbf/in
2
) at 21 C (70 F)
ambient temperature, closing valve occasionally. Refer
to the table at the end of this section for nitrogen
pressures at ambient temperatures of other than 21 C
(70 F).
5. To check accumulator charge, close tank valve (6),
relieve pressure between tank and pressure gauge (5)
by opening bleeder valve (10) momentarily. This will
allow gauge needle to settle, thus giving correct
pressure reading of accumulator charge.
6. When the correct pressure for the ambient
temperature has been reached, close valves (4 & 6)
tightly. Bleed pressure off pressure gauge (5) by
opening bleeder valve (10). Close bleeder valve when
all pressure is bled off from the gauge and unscrew
gland nut (8) from the nitrogen bottle.
7. Rotate 'T' handle of valve chuck (2) anticlockwise
until it stops, tighten locknut (1D, Fig. 1) to 11 Nm (100
lbf in), loosen the swivel nut and remove gauging
head.
8. Check charging valve (1, Fig. 1) for leakage using
soapy water. Reinstall valve cap (1A, Fig. 1) and
tighten finger tight.
DISCHARGING NITROGEN
Make sure charging valve (1) is closed internally by
turning locknut (1D) clockwise. Remove cap (1A) and
core (1B) from charging valve (1). Slowly turn locknut
(1D) anticlockwise to open charging valve (1).
Do not remove charging valve (1) until all the gas has
been completely evacuated.
WARNING
Do not try to discharge the accumulator by
depressing charging valve core (1B).
Section 250-0060
SM 2160 7-02
4
SM - 278 REMOVAL
WARNINGS
safely.
Accumulators are charged with Nitrogen.
The service pressure is 55 bar (800 lbf/in) at
21 C (70
o
3. Remove screws (2, Fig. 1), lockwashers (3, Fig. 1)
and protector (4, Fig. 1).
4. Discharge nitrogen from the accumulators as
described under 'Discharging Nitrogen'.
5. Disconnect hydraulic lines from underside of
accumulators and drain oil into a suitable container.
Cap open lines and fittings to prevent entry of dirt.
6. Support accumulators with an adequate sling and
lifting device. Remove bolts (1 & 2), washers (3) and
clamps (4). Remove accumulators to a clean area for
disassembly.
DISASSEMBLY
WARNING
Accumulators are charged with Nitrogen. The
service pressure is 55 bar (800 lbf/in) at 21 C
(70
o
1. Make sure all nitrogen gas has been released
before starting to disassemble the accumulator. Refer
to section on 'Discharging Nitrogen'.
2. Remove charging valve (1) from end cap (10).
3. With accumulator lying horizontal, hold accumulator
cylinder (12) with a strap wrench.
4. Install pins in three equally spaced holes in end cap
(10), then use a long bar working against the pins to
remove end cap from cylinder (12). Remove and
5. Grip cast web of piston (5) with pliers and, while
rotating, pull piston from cylinder (12). Remove and
discard wear rings (8), backup rings (6) and 'V' section
ring (7).
INSPECTION
1. Wash metal components with a suitable solvent and
thoroughly air dry.
2. Inspect piston (5) for cracks or burrs. Replace
piston (5) if excessively scored or worn.
Fig. 3 - Accumulator Installation
1 - Bolt
2 - Bolt
3 - Washer
4 - Clamp
5 - Accumulator
Section 250-0060
SM 2160 7-02
5
3. Use an inspection lamp to check the bore of
accumulator cylinder (12) for scratches or scoring. Minor
nicks, scratches or light scoring of the bore can be
removed by using crocus cloth. Dress the bore until all
apparent imperfections have been removed. Replace
complete accumulator assembly if the inside of cylinder
(12) is excessively scored or worn.
4. Inspect threads in end cap (10) and threads in
cylinder (12) for damage. Replace all parts worn or
damaged beyond repair.
ASSEMBLY
1. Lubricate O ring (9), wear rings (8), backup rings
(6), 'V' section ring (7) and inside of cylinder (12) with
hydraulic oil prior to assembly.
2. Install new 'V' section ring (7), backup rings (6) and
wear rings (8) on piston (5).
3. Insert piston (5) into cylinder (12) with cupped end
facing the open end of the cylinder. Do not let
'V' section ring (7) drag on cylinder threads. Use a
hammer and wood block to tap piston into place until
all of piston is 50 mm (2.0 in) below beginning of
honed bore. Keep pressure against piston while
tapping 'V' section ring (7) through the bore chamfer,
otherwise piston will bounce back, damaging the
'V' section ring.
4. Install new 'O' ring (9) on end cap (10) and install
end cap (10) in cylinder (12). Tighten cap so that it is
flush with the end of cylinder (12) within 1.59 - 2.38 mm
(0.0625 - 0.0938 in) above or below.
5. Install charging valve (1). Tighten locknut (1D)
clockwise to 11 Nm (100 lbf in) to close charging
valve, insert valve core (1B), replace valve cap (1A)
and tighten finger tight.
6. Test accumulator hydraulically for leakage or failure
at 255 - 276 bar (3 700 - 4 000 lbf/in). Discharge after
testing.
INSTALLATION
SPECIFICATIONS.
where used.
WARNING
safely.
1. Position accumulators on mounting bracket with the
oil inlet ports downward.
2. Attach clamps (4) securely with washers (3) and
bolts (1 & 2).
3. Remove caps installed at removal and install
hydraulic lines securely to the oil inlet port at the
bottom of the accumulators.
4. Charge the accumulator with Nitrogen gas as
described under 'Charging the Accumulator' in this
section.
start the engine and check for leaks. Tighten lines and
fittings as required. Remove wheel blocks.
MAINTENANCE
Inspect accumulator assembly for leaks. If leaks are
found, disassemble and replace all 'O' rings and seals.
Inspect hydraulic lines for wear and leaks. Replace/
tighten lines as required.
SPECIAL TOOLS
numbers of the charging assembly kit and other
general service tools required. These tools are
Section 250-0060
SM 2160 7-02
6
TABLE017
TORQUE
Nm lbf ft lbf in
1 1D Locknut 11 - 100
AMBIENT TEMPERATURE - NITROGEN PRE-CHARGE PRESSURE
TABLE051
AMBIENT TEMPERATURE NITROGEN PRE-CHARGE PRESSURE
C F bar lbf/in
-18 0 47.7 692
-12 10 48.8 708
-7 20 49.8 723
-1 30 50.9 738
5 40 52 754
10 50 53 769
16 60 54.1 785
21 70 55 800
27 80 56.2 815
32 90 57.3 831
38 100 58.3 846
43 110 59.4 862
49 120 60.5 877
54 130 61.5 892
WARNING
This vehicle is equipped with precharged nitrogen gas cylinders of more than 2.8 bar (40 lbf/in
2
).
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.
* * * *
Section 250-0065
1
SM 2159 7-02
DESCRIPTION
Numbers in parentheses refer to Fig. 1. The two speed
control valve can be identified as item 5 in Section
210-0005, COOLING SYSTEM SCHEMATIC.
Mounted on the disc brake oil cooler casing on the
right hand fender, the two speed control valve
regulates the fan speed of the disc brake oil cooler.
The two speed control valve houses two valves: two
way solenoid operated cartridge (1) and flow regulator
cartridge (2).
The two speed control valve is supplied by a dedicated
brake cooling section (rear section) of the triple gear
pump, via pressure relief valve. The solenoid cartridge
(1) controls flow to the hydraulically driven disc brake
oil cooler fan motor. The flow regulator cartridge (2)
controls the flow rate through the solenoid to a preset
supply of 10 litres/min.
OPERATION
The two speed control valve has 2 ports, an inlet port
and an outlet port. The inlet port is connected to the
outlet port via the flow regulator cartridge (2) and the
two way solenoid cartridge valve (1).
Refer to Fig. 2. The two speed control valve forms part
of the disc brake oil cooler fan speed control system.
With the solenoid cartridge (1) de-energised, the
majority of the available hydraulic oil will be allowed to
flow through the two speed control valve at a rate of 10
litres/min. The remainder of the available hydraulic oil
will be forced to circulate the disc brake oil cooler fan
motor, thus rotating the fan.
Refer to Fig. 3. The normally open temperature switch
on the front axle manifold valve closes when disc
brake cooling oil temperature reaches 60C (140F),
energising the solenoid cartridge (1). When the
solenoid cartridge (1) is energised, hydraulic oil is
prevented from flowing through the valve and is forced
through the disc brake oil cooler fan motor, thus
increasing the fan speed.
FUNCTIONAL CHECK
To check proper operational function of the two speed
control valve, refer to following procedure.
BRAKING SYSTEM - Two Speed Control Valve
SM - 2752
1 - Solenoid Cartridge
2 - Flow Regulator Cartridge
3 - Valve Body
4 - Washer
5 - Lockwasher
6 - Bolt
Fig. 1 - Two Speed Control Valve
SM - 2753
Fig. 2 - Two Speed Control Valve -
Solenoid De-energised
SM - 2754
Fig. 3 - Two Speed Control Valve -
Solenoid Energised
FROM TRIPLE
GEAR PUMP
TO DISC BRAKE
OIL COOLER
FROM DISC BRAKE
OIL COOLER
TO MOTOR/
TRIPLE PUMP
FROM TRIPLE
GEAR PUMP
TO DISC BRAKE
OIL COOLER
FROM DISC BRAKE
OIL COOLER
TO MOTOR/
TRIPLE PUMP
1
6
4
5
2
3
Section 250-0065
Braking System - Two Speed Control Valve
SM 2159 7-02
2
WARNING
damage, ensure wheel blocks and steering
locking bar is installed prior to executing
functional checks.
2. Disconnect electrical harness from temperature
switch at front axle manifold block (switch nearest
manifold block). Refer to Section 190-0270,
SWITCHES AND SENSORS.
3. Start engine and allow to idle.
4. Bridge connection on the temperature switch
harness. This will energise the solenoid cartridge (1) in
the two speed control valve.
5. Observe increase in disc brake oil cooler fan speed.
6. If fan speed does not increase, investigate fault on
two speed control valve solenoid cartridge (1) and
associated wiring.
FAULT DIAGNOSIS
Numbers in parentheses refer to Fig. 1. There are 4
possible points of failure:
1. Temperature switch failure. The disc brake oil
cooler temperature switch, mounted on the front axle
manifold block, should close when disc brake cooling
oil temperature rises above 60C (140F). Failure to
close will result in the solenoid cartridge (1) remaining
de-energised and the disc brake oil cooler fan will
remain at the slower speed setting. (Refer to
Functional Checks). Failure to energise the solenoid
cartridge (1) will result in higher disc brake cooling oil
temperatures.
2. The solenoid coil, although continuously rated they
may fail after long periods of service. Failure will be
evident as the higher speed operation of the disc
brake oil cooler fan will not be possible. (See
temperature switch failure above).
Solenoid Coil Rating: 14 W.
3. The cartridge valve (1) to which the solenoid is
attached. Failure is only likely to occur due to
contamination in the system. The valve is a low
leakage device and any contamination may cause
either damage to the components or cause
components to stick in position. Failure may be more
difficult to detect due to the different modes of failure.
Damage to the components will allow a progressively
increasing leakage, eventually resulting in some flow
not being shut off when the solenoid is energised.
Sticking components could hold the system at either a
low fan motor speed or a high fan motor speed,
depending on where the assembly has stuck.
4. Flow regulator cartridge (2). Contamination is the
only likely cause of failure, causing damage to the
relief valve seat. Failure will be difficult to detect as the
result of contamination damage is likely to be a
variation in the flow across the valve when the
solenoid is de-energised. This change of flow is
difficult to detect until it becomes very excessive.
Erratic disc brake oil cooler fan speed may be evident.
REMOVAL
WARNING
the job safely.
braking system.
3. Remove guard from rear of disc brake oil cooler.
COOLER.
5. Clean two speed control valve and surrounding area
with a suitable solvent. Identify and tag all hydraulic
lines connected to two speed control valve, to aid in
'Installation'.
Section 250-0065
3
SM 2159 7-02
open lines.
7. Remove electrical harness connector from solenoid
(1).
8. Remove bolts (6) and washers (4 & 5) securing two
speed control valve to disc brake oil cooler casing.
Remove two speed control valve from casing.
DISASSEMBLY
adaptors and remove from valve body (3).
2. Remove knurled nut from end of the centre shaft of
the solenoid. Slide off solenoid coil.
3. Unscrew solenoid cartridge valve (1) from valve
body (3). Extract cartridge valve (1).
4. Remove flow regulator cartridge (2) from valve body
(3).
INSPECTION
compressed air.
3. Check solenoid cartridge valve (1) seat and control
spool. Ensure they are not worn, nicked, cracked or
scored.
4. Check flow regulator cartridge (2) for damage.
Ensure valve seat is not worn, scored or cracked.
It is not recommended that any of the cartridge
assemblies are disassembled for maintenance
purposes. Ensure that valve assembly is cleaned prior
to removal of any components and that no
contaminant is allowed to enter the internal galleries.
ASSEMBLY
1. Replace all seals on solenoid cartridge (1) and flow
regulator cartridge (2) valves prior to re-assembly.
2. Install flow regulator cartridge (2) into valve body (3)
and torque to 75 Nm (55 lbf ft).
3. Install solenoid cartridge (1) into valve body (3) and
torque to 30 Nm (22 lbf ft).
4. Install solenoid over cartridge valve (1) centre shaft
and re-tighten knurled nut.
INSTALLATION
where used.
1. Secure two speed control valve to disc brake oil
cooler casing with bolts (6), washers (4) and
lockwashers (5).
install lines to the two speed control valve as identified
during 'Removal'.
3. Reconnect electrical harness connector to solenoid
(1).
temperature.
6. Check two speed control valve and hydraulic line
Section 250-0065
SM 2159 7-02
4
SPECIAL TOOLS
dealer.
* * * *
Section 250-0070
SM 2165 Rev 2 12-04
1
BRAKING SYSTEM - Treadle Valve
SM - 2766
Fig. 1 - Sectional View of Treadle Valve Assembly
15 - 'O' Ring
16 - Regulator Spool - Upper
17 - Spring Seat
18 - Regulator Spring
19 - Return Spring - Piston
20 - Glyde Ring Assembly
21 - 'O' Ring
22 - Backup Ring
23 - 'O' Ring
24 - Polypak Seal
25 - Backup Ring
26 - 'O' Ring
27 - Backup Ring
28 - Proximity Switch
1 - Pedal Assembly
2 - Pivot Pin
3 - Actuator Base
4 - Adjusting Screw
5 - Boot
6 - Piston Guide
7 - Piston
8 - Valve Body - Pilot
9 - Valve Body - Upper
10 - Capscrew
11 - Valve Body - Lower
12 - Plug
13 - Return Spring - Spool
14 - Regulator Spool - Lower
1
2
3
4
5
6
7
8
9
10
11
12
14
13
15
16
17
18
19
20
21
22,23
24,25
26,27
28
Section 250-0070
Braking System - Treadle Valve
SM 2165 Rev 2 12-04
2
DESCRIPTION
Note: The treadle valve can be identified as item 6 in
Section 250-0000, BRAKING SYSTEM SCHEMATIC.
The tandem circuit modulating treadle valve is a
closed centre controller which controls the level of
hydraulic oil pressure applied to the front and rear
brakes and the maximum pressure available to these
circuits. It is operated by a foot pedal in the operators
cab and with the engine running, is automatically
applied by the brake manifold valve. Refer to
Section 250-0050, BRAKE MANIFOLD VALVE.
The tandem circuit modulating treadle valve consists
of an upper and lower spool, the lower spool being of a
smaller diameter. As the foot pedal is depressed the
upper spool is pushed down and the lower spool is
pilot applied by the pressure in the brake circuit of the
upper spool.
In the normal position, brake pedal assembly (1) and
upper and lower regulator spools (16 & 14) are in the
up position. In this condition the notched area near the
top of regulator spools (16 & 14) is exposed to the
tank cavity in valve body (9 & 10), the lower portion of
the notched area is exposed to the regulated pressure
outlet ports of the valve. This effects a direct link
between the tank port 'T' and the regulated outlet ports
'B1' and 'B2'. While upper and lower regulator spools
(16 & 14) are in this position the brakes are released.
A proximity switch (28), which requests the
transmission retarder, is fitted to the treadle valve. The
first 7
o
of pedal travel will activate the proximity switch
(28) and request the transmission retarder. A warning
light on the dash will also be illuminated by pressure
switch fitted at transmission. The normally open switch
closes at 2.7 bar (39 lbf/in). Further depression of the
treadle valve then applies the brakes. Refer to Section
120-0010, TRANSMISSION AND MOUNTING.
A pressure switch located at a tee in the 'B2' line
energizes (illuminates) the vehicles stop lights on
application of the treadle valve.
OPERATION
Normal Service Brake Application
Refer to Fig. 2. When the operator depresses pedal
assembly (1), piston (7) is moved down and pushes
on regulator spring (18) which in turn, pushes upper
regulator spool (16) down and pilot pressure pushes
lower regulator spool (14) down. As regulator spools
(16 & 14) move down, the metering notches move out
of the tank cavity and close outlet ports 'B1' and 'B2'
off to tank port 'T'. Regulator spools (16 & 14) continue
to move downward until the lower edge of the
SM - 2767 SM - 2768
Fig. 3 - Normal Service Brake Release Fig. 2 - Normal Service Brake Application
PX
P1
T1
P2
B1
B2
T2
6
7
TO FRONT
BRAKES
TO REAR
BRAKES
SUPPLY
FROM
BRAKE
MANIFOLD
SUPPLY
FROM
BRAKE
MANIFOLD
PX
P1
T1
P2
B1
B2
T2
6
7
FROM FRONT
BRAKES
FROM
REAR
BRAKES
SUPPLY
FROM
BRAKE
MANIFOLD
SUPPLY
FROM
BRAKE
MANIFOLD
Section 250-0070
SM 2165 Rev 2 12-04
3
metering notches become exposed to the inlet
pressure ports. This movement opens inlet ports 'P1'
and 'P2' to outlet ports 'B1' and 'B2' respectively.
As hydraulic pressure builds in the brake, oil flows
through the small orifice in the side of regulator spools
(16 & 14) and into the cavities below the spools. As
pressure rises in the brake it also rises in the cavities
below the spools forcing regulator spools (16 & 14)
upwards closing outlet ports 'B1' and 'B2'. Regulator
spools (16 & 14) are now balanced between the brake
pressure and the pressure of regulator spring (18)
generated by the operators force on pedal (1)
assembly. Regulator spools (16 & 14) have closed off
the inlet ports, outlet ports and the tank port and will
remain in this position as long as pedal (1) assembly is
not moved. If the operator further depresses pedal (1)
assembly, regulator spools (16 & 14) will move down
and build more pressure in the brake until it balances
the pedal force.
Normal Service Brake Release
Refer to Fig. 3. When the operator releases pedal (1)
assembly, regulator spools (16 & 14) will become
unbalanced and move upwards, opening outlet ports
'B1' and 'B2' to tank. At this point, oil in the 'B1' and
'B2' lines is released to tank through tank port 'T',
releasing the brakes.
Emergency Stop Brake Application/
Release
Refer to Fig. 4. Pressing/pushing of the emergency
control knob results in the de-energization of the brake
manifold valve solenoid. This allows full pressure to
enter the 'Px' port in the treadle valve simulating a full
and immediate depression of pedal (1) assembly, i.e.
pushing regulator spools (16 & 14) downwards and
thereby applying maximum braking action.
Refer to Fig. 5. Releasing the emergency control knob
will energize the brake manifold valve solenoid,
allowing the pressure in the 'Px' line to fall via the
return to tank port opened within the directional control
valve. Outlet ports 'B1' and 'B2' are opened to tank port
'T' allowing oil in the 'B1' and 'B2' lines to return to tank,
releasing the brakes.
REBUILD CRITERIA
Inspect the valve regularly for any signs of leakage or
damage. Check the actuator for excessive cam rock
and replace components if necessary.
The controller should be rebuilt if one or more of the
following conditions exist:
1. Any sign of external leakage.
Note: Check all hydraulic lines and fittings to ensure
SM - 2770 SM - 2769
Fig. 4 - Park/Emergency Brake Application Fig. 5 - Park/Emergency Brake Release
PX
P1
T1
P2
B1
B2
T2
6
7
TO FRONT
BRAKES
TO REAR
BRAKES
SUPPLY
FROM
BRAKE
MANIFOLD
SUPPLY
FROM
DIRECTIONAL
CONTROL
VALVE
SUPPLY
FROM
BRAKE
MANIFOLD
PX
P1
T1
P2
B1
B2
T2
6
7
FROM FRONT
BRAKES
FROM
REAR
BRAKES
SUPPLY
FROM
BRAKE
MANIFOLD
SUPPLY
FROM
BRAKE
MANIFOLD
TO TANK VIA
DIRECTIONAL
CONTROL
VALVE
Section 250-0070
SM 2165 Rev 2 12-04
4
leakage is not coming from there.
2. Failure of the pedal to return to full upright position.
3. Treadle valve holds pressure when in the neutral
position.
4. Varying output pressure with the pedal fully
depressed.
5. Output pressure tolerance for upper circuit should be
within +/- 2.4 bar (+/- 35 lbf/in).
6. Output pressure tolerance for lower circuit should be
within +/- 2.4 bar (+/- 35 lbf/in).
REMOVAL
WARNINGS
safely.
Hydraulic oil pressure will remain
out any work on the braking system or serious
injury could result.
1. Position the vehicle in a level work place, raise the
body and secure in place with the body prop. Apply
the parking brake, switch off the engine and turn
3. Pull on handle to release hood catch and lift up
hood.
5. Move cab floor mat back and remove bolts and
lockwashers securing service access plate to cab
floor.
6. Clean treadle valve assembly and surrounding area
with a suitable solvent. Ensure all hydraulic lines
connected to the treadle valve are identified for ease of
caps to all open lines and treadle valve ports.
7. Tag and disconnect electrical connections from the
proximity switch and stop light pressure switch.
8. Tag and disconnect electrical connections from the
kick-down switch and accelerator pedal assembly.
9. Remove service access panel and attached valve
assemblies to a clean area for 'Disassembly'.
10. Release and remove mounting hardware securing
the treadle valve to the service access plate. Remove
treadle valve assembly to a clean area for further
'Disassembly'.
DISASSEMBLY
1. Remove blanking caps from treadle valve ports and
drain all oil from valve body ports by rotating the valve
over a suitable container.
2. Secure the valve assembly upright in a table vice.
3. Remove pedal (1) from actuator cam by loosening
two capscrews at the pedal heel. Note that capscrews
need not be removed.
4. Loosen but do not remove nuts from 'U' bolts
securing actuator pivot pin (2).
5. Loosen nut securing proximity switch (28) to
actuator base and remove.
6. Remove pivot pin (2) from actuator base (3) with a
punch and hammer. Remove actuator cam assembly
and inspect for any abnormal wear or cracks. Set
aside for assembly.
7. Remove boot (5) from pilot valve body (8).
8. Remove capscrews securing actuator base (3) to
pilot valve body (8). Remove actuator base (3) from
pilot valve body (8).
9. Remove adjusting screw (4) from pilot valve body (8).
10. Remove valve assembly from the vice.
Section 250-0070
SM 2165 Rev 2 12-04
5
11. With valve assembly horizontal, remove capscrews
and separate pilot valve body (8) from upper valve
body (9). Remove capscrews (10) and separate lower
valve body (11) from upper valve body (9).
12. With the pilot valve body (8) upright on the work
bench, hold with one hand and push the actuator
piston (7) down with the other hand until piston guide
(6) pops loose.
13. Turn pilot valve body (8) on its side on the work
bench and remove piston guide (6) and actuator piston
(7) from pilot valve body (8).
14. Remove glyde ring assembly (20) from actuator
piston (7).
15. Remove 'O' rings (21, 23 & 26), backup rings (22,
25 & 27) and Polypak seal (24) from piston guide (6)
and discard.
16. Turn upper valve body (9) on its side on the work
bench and remove piston return spring (19), regulator
spring (18), spring seat (17) and upper regulator spool
(16) from upper valve body (9).
17. Turn lower valve body (11) on its side on the work
bench and remove lower regulator spool (14) and
spool return spring (13) from lower valve body (11).
Remove and discard 'O' ring (15) from counterbore in
lower valve body (11).
18. Secure lower valve body (11) upright in a table vice
and remove plug (12) and 'O' ring from lower valve body
(11). Discard 'O' ring. Remove lower valve body (11)
from the vice.
INSPECTION
1. Clean all parts with a suitable cleaning solvent.
2. Inspect actuator piston (7) and piston guide (6) for
damage and wear. If axial grooves are seen or if any
wear is evident, replace actuator piston (7) and piston
guide (6) as a matched set.
3. Lightly lubricate regulator spools (14 & 16). Place
upper and lower regulator spools (14 & 16) into
corresponding regulator bore in valve body and push
the spool lightly through the bore. Each regulator spool
must be able to move freely and smoothly the entire
length of the regulator bore. If it cannot, regulator
spool and valve must be replaced as a matched set.
Note: Never replace just the spool or valve. They must
be replaced as a matched set.
4. Inspect each spring carefully for cracks or breaks.
Any spring with a crack or break must be replaced.
Also, if the treadle valve was not reaching proper
regulated pressure, replace all regulator springs.
5. Inspect threaded inserts in actuator cam, actuator
base (3) and pedal assembly (1). If any of the threads
are damaged, the inserts must be replaced.
6. Clean pilot valve body (8) thoroughly to remove all
residual adhesive or particles of boot (5). Using a knife
or suitable scraper, thoroughly clean the sides of pilot
body (8) by scraping the lip where the pilot body
contacts the boot (5).
SUB-ASSEMBLY
Note: All metal parts should be thoroughly cleaned
with a suitable solvent, dried, and lubricated with a
light weight oil before assembly. This valve is built to
extremely close manufacturing tolerances. Great care
should be taken to keep components protected from
contamination prior to and during assembly.
Threaded Inserts
1. Position actuator base (3) upside down on the work
bench and support directly under each of the four floor
mounting holes. Install threaded inserts into actuator
base (3) by tapping lightly with a small hammer until
insert flanges become flush with actuator base (3). Be
sure actuator base (3) is supported to prevent
breaking. Thoroughly clean actuator base (3)
assembly and set aside.
2. Position actuator cam upside down on the work
bench and support it at the centre hole. Insert
threaded insert by tapping lightly with a small hammer
until its flange becomes flush with actuator cam
surface. Be sure actuator cam is supported to prevent
breaking. Thoroughly clean actuator cam assembly
and set aside.
3. Position pedal (1) upside down on the work bench
and support it directly above the two holes near its
centre. Install threaded inserts by tapping lightly with a
small hammer until their flanges becomes flush with
pedal (1) surface. Be sure pedal (1) is supported to
prevent breaking.
4. Install oval point screws into inserts and screw down
Section 250-0070
SM 2165 Rev 2 12-04
6
until 12.7 mm (0.5 in) of screws protrude below insert
flanges. Make sure that both screws are adjusted to
the same dimension.
5. If removed, install capscrews into pedal (1) and
install washers and nuts onto capscrews. Screw nuts
on flush with the ends of capscrews and set the
assembly aside.
Piston Guide
1. Install Polypak seal (24) and backup ring (25) into
seal groove of piston guide (6). See Fig. 6.
Note: Be sure Polypak seal (24) is installed so that the
internal 'O' ring will be facing the bottom of the valve
when the actuator piston (7) is installed into the upper
valve body (9).
2. Install 'O' ring (21) into seal groove above threads
on piston guide (6).
3. Apply a thin film of oil to Polypak seal (24) and outer
'O' ring seal of piston guide (6).
4. Install backup rings (22 & 27) and 'O' rings (23 &
26) into seal grooves of piston guide (6). See Fig. 6.
Actuator Piston
Note: Glyde ring (20) assembly consists of an 'O' ring
and a split glyde ring.
1. Install 'O' ring into the 'O' ring groove located at the
large diameter end of actuator piston (7).
2. Install split glyde ring over the 'O' ring. Twist and
squeeze the split glyde ring into a small circle before
installing to ensure a tight fit over the 'O' ring.
ASSEMBLY
1. Hold upper valve body (9) horizontally. Lightly
lubricate upper regulator spool (16) and insert into
regulator bore of upper valve body (9).
Note: Slide spool (16) back and forth in the regulator
bore to ensure spool will slide smoothly and freely.
Note: Remove upper regulator spool (16) from bore
and set aside for future assembly.
2. Hold upper valve body (9) upright and install spring
seat (17), regulator spring (18) and piston return
spring (19) into upper valve body (9).
3. Install actuator piston (7) assembly into piston guide
(6), hold upper valve body (9) assembly upright and
screw actuator piston (7) and piston guide (6)
assembly into upper valve body (9). Tighten piston
guide (6) assembly using a suitable spanner.
4. Secure pilot valve body (8) to upper valve body (9)
with capscrews. Tighten capscrews evenly to a torque
of 16 - 17 Nm (140 - 150 lbf in).
5. Lightly lubricate upper regulator spool (16) and
install into regulator bore of upper valve body (9)
assembly. The spherical end of regulator spool (16)
should be at the towards the top of valve body (9)
assembly.
Note: Set aside upper valve body (9) assembly for
future assembly.
6. Hold lower valve body (11) horizontally. Lightly
lubricate lower regulator spool (14) and insert into
regulator bore of lower valve body (11).
Note: Slide spool (14) back and forth in the regulator
bore to ensure spool will slide smoothly and freely.
7. Insert spool return spring (13) into regulator spool
(14).
Fig. 6 - Piston Guide Seal Installation
SM - 2406
25
27
26
24
23
22
22 - Backup Ring
23 - 'O' Ring
24 - Polypak Seal
25 - Backup Ring
26 - 'O' Ring
27 - Backup Ring
Section 250-0070
SM 2165 Rev 2 12-04
7
8. Install new 'O' ring on plug (12) and install into the
counter bore on the bottom of lower valve body (11).
Tighten plug (12) to a torque of 17 - 20 Nm
(150 - 180 lbf in).
9. Lightly lubricate 'O' ring (15) and install into the
counter bore in the top end of lower valve body (11).
10. Assemble lower valve body (11) to upper valve
body (9) assembly, with correct port orientation as
shown in Fig. 1, and secure with capscrews (10).
Tighten capscrews (10) evenly to a torque of
16 - 17 Nm (140 - 150 lbf in).
11. Coat threads of adjusting screw (4) with a thin film
of Loctite Primer T 747. Allow primer to cure (minimum
of one minute), then screw adjusting screw (4) into
actuator piston (7) all the way down until they bottom
on the threads.
Note: It is extremely important to bottom-out
adjustment screw (4) to prevent over pressurization
during initial adjustment procedure. Excessive
regulated output pressure could cause premature
failure of regulator springs.
TESTING AND ADJUSTMENTS
Note: A hydraulic test fixture with capabilities similar to
the one shown in Fig. 7 is required.
1. Position the valve in the test fixture to allow plunger
to be activated by hand using a lever. See Fig. 8.
2. Attach pilot input supply pressure to the 'Px' port of
valve body.
3. Attach main supply input pressure to 'P1' and 'P2'
ports of valve body.
4. Attach tank return lines to 'T1' and 'T2' ports of valve
body.
5. Attach output ports 'B1' and 'B2' to test lines. Check
that all ports are used.
6. Set supply line pressure to 170 3.5 bar
(2 465 50 lbf/in).
7. Set pilot supply pressure to 170 3.5 bar
(2 465 50 lbf/in).
8. Return line pressure during this test is not to exceed
0.34 bar (5 lbf/in).
9. Test valve with 10W hydraulic oil at 50 6 C
(120 10 F).
Setting Manual and Pilot Pressure
1. Install actuator base (3) and secure to valve using
capscrews, washers and nuts. Torque tighten
capscrews to 20 - 21 Nm (180 - 190 lbf in). Install pivot
pin (2) in actuator base (3) by itself without installing
pedal assembly (1).
2. By taking a screw driver or pry bar and placing it
under pivot pin (2) and on top of adjusting screw (4),
you will be able to actuate the piston. See Fig. 8.
3. Gradually apply pressure to check for leaks. Make
sure adjusting screw (4) is screwed all the way down
on the threads.
4. Adjust adjusting screw (4) up (anticlockwise) in
small increments until the output pressure is
48.3 2.4 bar (700 35 lbf/in) at port 'B1' with
adjusting screw (4) contacting actuator base (46) (fully
actuated). See Fig. 8. Fine adjustment will require only
turning the screw in 1/8 turn increments.
5. Cycle valve 50 times using pilot apply.
6. Actuate valve as quickly as possible. The output
pressure must reach 48.3 2.4 bar (700 35 lbf/in)
within 1.0 seconds. Measurement of time begins the
moment force is applied to move the piston.
7. With the input pressure supplied, check internal
(tank) leakage of the valve at zero output pressure and
full manual apply pressure. At zero output pressure,
the valve must not pass more than 50 cc/min, through
each tank port. At full regulated pressure, the valve
must not pass more than 75 cc/min, through each tank
port. If leakage is greater than specified, rebuild of the
valve will be required.
8. Recheck regulated output pressures after cycling. If
they have changed, readjust.
9. Apply Loctite 290 to the threads of the adjusting
screw (4). Leave valve for a minimum of two minutes
to allow Loctite to cure.
Note: Use a syringe to apply Loctite to threads of
screw. Do not allow Loctite to spill over onto outer
diameter of piston. If Loctite is allowed to set up
between piston and piston guide it can result in a stuck
valve.
Section 250-0070
SM 2165 Rev 2 12-04
8
1. Depress pedal assembly (1) as quickly as possible.
The output pressure on the circuits must reach
48.3 2.4 bar (700 35 lbf/in) at port 'B1' and port 'B2'
within 1 second. Measurement of time begins the
moment force is applied to move pedal (1).
2. Set the deadband by placing a 0.64 mm (0.025 in)
shim between the actuator base and the pedal return
stop. See Fig. 9.
4. Turn adjustment screw (4) down (clockwise) until it
is touching actuator cam.
5. Continue turning adjustment screw (4) clockwise
until you start to see a pressure reading on the
pressure gauge then back-off adjustment screw (4)
1/8 turn (anticlockwise).
6. Lock adjustment screw (4) with jam nut and remove
the shim stock. Apply a few drops of Loctite 290 to
adjustment screw (4) and nut.
Pedal Angle Adjustment
1. Loosen nuts at the rear of actuator cam. Do not
loosen nuts on 'U' bolts.
2. Adjust pedal assembly (1) angle by turning screws
located in the top face or ribbed side of pedal
assembly (1). Clockwise will raise the angle and
anticlockwise will lower the angle.
3. Adjust the two screws evenly. When the desired
pedal angle is achieved, apply Loctite 243 on screws.
4. While holding the pedal down, retighten the rear
capscrews and nuts.
INSTALLATION
where used.
1. Position treadle valve assembly on service access
panel and secure with mounting hardware.
2. Secure service access panel to cab floor using bolts
and lockwashers as removed at 'Removal'.
3. Remove blanking caps and connect hydraulic lines
FINAL ASSEMBLY
1. Remove pivot pin (2) from actuator base (3).
2. Install boot (5) over lip of pilot valve body (8) and
over head of adjusting bolt (4). Apply a light coating of
Loctite Activator 710 between head of adjusting bolt (4)
and boot (5). Apply Loctite 410 adhesive to boot (5)
and head of adjusting bolt (4).
3. Insert pivot pin (2) through the hole in actuator base
(3), through the holes in 'U' bolts, and through the pivot
pin hole in the other side of actuator base (3). As pivot
pin (2) is being inserted, install pedal return springs.
4. Centre pivot pin (2) and secure with nuts and
washers on 'U' bolts. Tighten nuts to a torque of
16 - 17 Nm (140 - 150 lbf in).
5. Install pedal assembly (1) on actuator cam and
secure with capscrews, washers and nuts.
6. Install deadband adjustment screw. Thread the
screw into actuator cam until the screw contacts the
flanged adjusting screw (4).
PROXIMITY SWITCH INSTALLATION AND
ADJUSTMENT
1. Install proximity switch (28) into the actuator base
(3) until switch is flush to 0.125" (3.18mm) above the
boss on the actuator base (3).
2. Lock the proximity switch into this position with the
lower jam nut.
3. Install adjusting screw and jam nut into the pedal.
4. Thread the adjusting screw into the pedal until the
switch activates. Thread screw into the pedal 1/4 to 1/2
turn more.
5. Slowly apply pedal and note the pressure at which
the switch 'trips'. Readjust the switch to trip at 2.5 lbf/
in (0.17 bar). Threading the set screw 'in' will raise the
'trip' point; backing the set screw 'out' will lower the 'trip'
point. Secure the set screw with the jam nut once the
proper setting is achieved.
ADDITIONAL TESTING AND ADJUSTMENT
Section 250-0070
SM 2165 Rev 2 12-04
9
Fig. 7 - Typical Test Fixture
SM - 2771
SM - 1238
Fig. 8 - Actuator Piston Actuation
to the treadle valve assembly as noted at 'Removal'.
4. Connect electrical connections to the stop light
pressure switch as noted at 'Removal'.
5. Connect electrical connections to the kick-down
switch and accelerator pedal assembly as noted at
'Removal'.
6. Fill hydraulic tank with oil specified in Section
temperature.
8. Apply the brakes and check for oil leaks. Tighten
line connections and fittings as necessary.
Note: When performing Step 9, make sure that parking
brake applies and releases appropriately.
9. Check brake operations by actuating pedal and park
FULLY ACTUATED
NORMAL POSITION
SCREWDRIVER
OR PRY BAR
T1
P1
B1
PX
T2
P2
B2
G3
G1
G2
M P
D1
P1
P2
PX
PILOT
RETURN
RETURN
SUPPLY
SUPPLY
SIMULATED
BRAKE
VOLUME
FRONT BRAKE
PRESSURE
REAR BRAKE
PRESSURE
170 3.5 bar
(2 465 50lbf/in)
Section 250-0070
SM 2165 Rev 2 12-04
10
9. Slacken adjusting screw (4) in valve body.
10. Install pivot pin (2) in actuator base (3) and by
taking a screw driver or pry bar and placing it under
pivot pin (2) and on top of adjusting screw (4), you will
be able to actuate each circuit individually.
11. Start engine to ensure full hydraulic pressure.
12. Test front 'B1' and rear 'B2' brake circuit actuating
pressures at remote diagnostic test points (at the rear
LH side of the tractor frame) and adjust if necessary.
Pressures should be 48.3 2.4 bar (700 35 lbf/in).
Note: Turning adjustment screw (4) up (anticlockwise)
will increase the pressure while turning it down
(clockwise) will decrease the pressure. Fine
adjustment will require only turning the collar in 1/8
turn increments.
14. When pressure is set correctly, apply Loctite 290
to the threads of adjustment screw (4). Leave valve for
a minimum of two minutes to allow Loctite to cure.
Note: Use a syringe to apply Loctite to threads of
screw. Do not allow Loctite to spill over onto outer
diameter of piston. If Loctite is allowed to set up
between piston and piston guide it can result in a stuck
valve.
15. Shut down the engine.
16. Remove pivot pin (2) from actuator base (3).
emergency control.
10. Shut off engine and check hydraulic tank oil level.
Replenish as necessary.
11. Position floor mat on cab floor and ensure that the
pedal assembly is free to operate.
SERVICE
Brake Actuating Pressure
Note: Test front 'B1' and rear 'B2' brake circuit
actuating pressures at remote diagnostic test points (at
the rear LH side of the tractor frame) and adjust if
necessary.
1. Connect a hydraulic gauge capable of recording a
pressure of 0 - 207 bar (0 - 3 000 lbf/in) to remote
diagnostic pressure point for front 'B1' brake pressure.
2. Start engine and bring hydraulic oil temperature to
operating temperature.
3. Actuate treadle valve fully and check reading on
pressure gauge. Pressure reading should be
48.3 2.4 bar (700 35 lbf/in).
4. Repeat steps 1 through 3 at remote diagnostic
pressure point for rear 'B2' brake pressure.
Note: Actuating pressure for the front and rear brake
circuits is 48.3 2.4 bar (700 35 lbf/in), however,
system pressure is 170 bar (2 465 lbf/in) and can only
be checked at the pressure check point in the manifold
valve. Refer to Section 250-0050, BRAKE MANIFOLD
VALVE.
Note: If the pressures to the brake circuits have been
determined as low or high, the pressures can be raised
or lowered by an in service (in situ) adjustment.
5. Remove pedal assembly (1) from actuator cam by
loosening two capscrews at the pedal heel. Note that
capscrews need not be removed.
6. Loosen but do not remove nuts from 'U' bolts
securing actuator pivot pin (2).
7. Remove pivot pin (2) from actuator base (3) with a
punch and hammer. Remove actuator cam assembly.
8. Remove boot (5) from valve body.
SM - 1239
Fig. 9 - Deadband Adjustment
Actuator Base
Return Stop
Shim Stock
0.64 mm
(0.025 in)
Section 250-0070
SM 2165 Rev 2 12-04
11
17. Install boot (5) over lip of valve body and over head
of adjusting bolt (4). Apply a light coating of Loctite
Activator 710 between head of adjusting bolt (4) and
boot (5). Apply Loctite 410 adhesive to boot (5)and
head of adjusting bolt (4).
18. Insert pivot pin (2) through the hole in actuator
base (3), through the holes in 'U' bolts, and through the
pivot pin hole in the other side of actuator base (3). As
pivot pin (2) is being inserted, install pedal return
springs.
19. Centre pivot pin (2) and secure with nuts and
washers on 'U' bolts. Tighten nuts to a torque of
16 - 17 Nm (140 - 150 lbf in).
20. Install pedal assembly (1) on actuator cam and
secure with capscrews, washers and nuts.
Brake Signal Pressure Switch
Attach a continuity tester to black and brown wires on
signal pressure switch located at a tee in the 'B2' line.
The circuit should be open.
Note: As brake pressure increases to 2.7 bar (39 lbf/
in) the circuit should close.
MAINTENANCE
General
Check all hydraulic brake lines and fittings at treadle
valve for leaks and damage. Tighten/replace as
required.
Every 1 000 Hours
Check front and rear brake pressures at remote
diagnostic test points. If the pressures are outwith the
specified pressure range, inspect the valve and take
relevant action (adjust pressures, strip down and
repair valve or replace valve).
SPECIAL TOOLS
* * * *
TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf in
1 10 Capscrew 16 - 17 140 - 150
1 12 Plug 17 - 20 150 - 180
Section 250-0075
1 SM 2161 7-02
TO BRAKE
MANIFOLD VALVE
TO ENGINE
COOLING FAN
MOTOR
FROM TRIPLE
GEAR PUMP
3
1
2
DESCRIPTION
The priority unloader valve can be identified as item 10
in Section 250-0000, BRAKING SYSTEM
SCHEMATIC. Numbers in parentheses refer to Fig. 1.
Located on the right hand side of the hydraulic cradle,
the priority unloader valve comprises of an aluminium
body (3) with an integral check valve (2) and unloader
relief valve (1).
The priority unloader valve receives hydraulic supply
from the brake section of the triple gear pump. The
priority unloader valve controls pressure to the treadle
valve and the brake accumulators, via the brake
manifold valve. Refer to Section 250-0050, BRAKE
MANIFOLD VALVE.
OPERATION
Refer to Fig. 2. The priority unloader valve forms part
of the brake actuation circuit. Main hydraulic supply
pressure is delivered by the brake section (front
section) of the triple gear pump. The priority unloader
valve maintains pressure within the brake circuit to
170 bar (2465 lbf/in). This is achieved by internally
sensing the pressure within the brake circuit. When
the system pressure is below the defined setting of
170 bar (2465 lbf/in), the unloader relief valve (1)
connects the supply pressure to the brake manifold
valve by unseating the check valve (2), allowing the
brake accumulators to charge. When the brake circuit
pressure is attained, the unloader relief valve (1)
diverts supply pressure to engine cooling circuit to
supplement the engine cooling fan motor. The check
valve (2) is now closed, isolating the brake circuit.
FUNCTIONAL CHECK
The priority unloader valve, although adjustable,
should be preset to 170 bar (2465 lbf/in). Refer to
following procedure for valve pressure check and
adjustment.
WARNING
result.
WARNING
safely.
1. Attach appropriate pressure gauge to the diagnostic
check point on the brake manifold valve (Port P1).
BRAKING SYSTEM - Priority Unloader Valve
SM - 2755
Fig. 1 - Priority Unloader Valve
1 - Unloader Relief Valve
2 - Check Valve
3 - Valve Body
SM - 2756
Fig. 2 - Priority Unloader Valve Schematic
Section 250-0075
Braking System - Priority Unloader Valve
SM 2161 7-02 2
2. Start truck and allow pressures to increase with
engine at low idle, until all warning lights are
extinguished.
3. Take note of the gauge reading; this is the pressure
setting of the priority unloader valve. Valve should be
set at 170 bar (2465 lbf/in).
4. If pressure setting is too low after following steps 1
through 3:
(a) Ensure engine is operating at low idle.
(b) Loosen lock nut on unloader relief valve (1).
(c) Turn setting screw on unloader relief valve (1)
clockwise (CW) until correct pressure is observed on
gauge.
(d) Re-tighten lock nut.
Note: Always adjust hydraulic pressure on the
increase.
5. If pressure setting is too high after following steps 1
through 3:
(a) Stop engine and operate treadle valve continuously
to dissipate pressure in brake accumulators.
(b) Loosen lock nut on unloader relief valve (1).
(c) Turn setting screw on unloader relief valve (1)
counter clockwise (CCW) 2 to 3 full turns.
(d) Re-start engine and allow pressures to rise with
engine at low idle, until all warning lights are
extinguished.
(e) Turn setting screw clockwise (CW) until correct
pressure is observed on gauge.
(g) Re-tighten lock nut.
REMOVAL
WARNING
the job safely.
braking system.
switch in the 'Off' position. Place the steering lock bar
in the 'Locked' position.
4. Clean priority unloader valve body (3) and
tag all hydraulic lines connected to the priority
unloader valve, to aid in 'Installation'.
open lines.
6. Remove bolts and lockwashers securing the priority
unloader valve to the hydraulic cradle. Remove priority
unloader valve.
DISASSEMBLY
It is not recommended that any of the cartridge
assemblies are disassembled for maintenance
purposes. Ensure that valve assembly is cleaned off
prior to removal of any components and that no
contaminant is allowed to enter the internal galleries.
1. Note location and position of all hydraulic
connectors and adaptors prior to removing them from
valve body (3).
2. Remove unloader relief valve (1). Check for wear,
scoring or contamination.
3. Remove check valve (2). Check for wear, scoring or
contamination.
ASSEMBLY
1. Replace all 'O' rings on hydraulic connectors and
adaptors.
2. Replace all seals on unloader relief valve (1) and
check valve (2) prior to assembly.
3. Locate unloader relief valve (1) in valve body (3)
and tighten to 95 Nm (70 lbf ft).
4. Locate check valve (2) in valve body (3) and tighten
to 95 Nm (70 lbf ft).
Section 250-0075
3 SM 2161 7-02
PRIORITY UNLOADER VALVE FAULT DIAGNOSIS
Rapid switching of High leakage in brake circuit. Check brake circuit for leakage.
unloader relief valve.
Internal leakage to priority Replace priority unloader valve assembly.
unloader valve.
Check valve leaking or not Replace priority unloader valve assembly.
seating properly.
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.
Braking System - Priority Unloader Valve
INSTALLATION
where used.
1. Secure priority unloader valve to hydraulic cradle
with bolts and lockwashers.
install lines to the priority unloader valve as identified
during removal.
temperature.
5. Check priority unloader valve and hydraulic line
FAULT DIAGNOSIS
previously, it is not recommended that any of the
cartridge assemblies are disassembled for
maintenance purposes. Ensure that valve assembly is
cleaned off prior to removal of any components and
that no contaminant is allowed to enter the internal
galleries.
If investigation shows that the cartridge assemblies
are in good clean condition and fit for use, the seals
should be replaced prior to re-assembly. Damage to
the cartridge assemblies or valve body would
necessitate a new priority unloader valve assembly.
SPECIAL TOOLS
dealer.
* * * *
Section 250-0090
SM 2254 11-03
1
BRAKING SYSTEM - Directional Control Valve
DESCRIPTION
The directional control valve can be identified as
item 8 in Section 250-0000, BRAKING SYSTEM
SCHEMATIC.
The directional control valve is mounted on the cradle
assembly at the rear of the cab alongside the brake
manifold valve. It is located in the 'Px' hydraulic
circuit between the brake manifold valve and the
treadle valve. The 'Px' circuit hydraulically actuates
the treadle valve when the park/emergency control
switch is activated. It also controls automatic service
brake applied pressure bleed down, with engine
shutdown.
The directional control valve assembly comprises of
a sub plate and valve body assembly. Hydraulic
connections to the directional control valve assembly
Fig. 1 - Directional Control Valve
are made as follows:
Valve Body Assembly
Port 'a' - Transmission pilot pressure
Port 'b' - Case drain to tank
Sub Plate
Port 'A' - Plugged
Port 'B' - To 'Px' port at treadle valve
Port 'P' - Supply line from brake manifold valve
Port 'T' - Tank return
OPERATION
Numbers in parentheses refer to Fig. 1. Figs. 2 and 3
are shown with brake manifold valve de-energized.
Refer to Fig. 2. Engine shutdown, park/emergency
control switch applied, results in a loss of transmission
pilot pressure at port 'a'. The resultant spool (3)
5 - Spring End Cap
6 - Slide Washer
7 - Spring
8 - Spacer
1 - Valve Body Unit
2 - End Cover
3 - Spool
4 - Spring End Cap
P
B
T
a
b
b a
A
7 4 9 8 1 5 7 10
6
3 11 12 11
2
3
6
13
9 - Allen Bolt
10 - Allen Bolt
11 - 'O' Ring
12 - 'O' Ring
13 - Sub Plate
SM - 2309
Section 250-0090
Braking System - Directional Control Valve
SM 2254 11-03
2
SM - 2311 SM - 2310
movement under the influence of compressed spring
(7) links port 'B' to port 'T' permitting a controlled bleed
down of the applied service brakes to tank at port 'T'.
This controlled bleed down permits a synchronised
service brake release/mechanical park brake
application. Refer to Section 250-0000, BRAKING
SYSTEM SCHEMATIC.
Note: With engine shutdown, brake manifold valve
pressure is dead headed at ports 'P' and 'A'.
Refer to Fig. 3. When the engine is running,
transmission hydraulic pilot pressure enters the
directional control valve through port 'a'. Spool (3) is
pushed by this pressure and compresses spring (7) on
port 'b' side of directional control valve. This movement
internally links port 'P' to 'B' in sub plate (13).
With transmission pilot pressure operating at port 'a',
the directional control valve (energised) has an open
circuit between the brake manifold valve and port 'Px'
in the treadle valve. This permits a flow of oil to either
energise the 'Px' port at the treadle valve, or, exhaust
the 'Px' port through the manifold block to tank,
dependant on operation of the brake manifold valve.
The brake manifold valve is controlled by the park/
emergency control switch.
Port 'b' is connected as a drain to tank to prevent
excess oil forming a hydraulic lock within the
directional control valve. This could result in erratic
park brake operation.
REMOVAL
WARNINGS
materials are properly secured and of
out any work on the braking system or serious
injury could result.
3. Remove mounting hardware securing cover plate
to cradle assembly at the rear of the cab. Remove
cover plate to gain access to directional control
valve.
4. Ensure all hydraulic lines connected to the
directional control valve are identified for ease of
catch leakage, disconnect hydraulic lines. Fit
blanking caps to all open lines and fittings.
Fig. 3 - Directional Control Valve - Energised Fig. 2 - Directional Control Valve - De-energised
8
T
P
a
b
B A
TO 'Px' PORT
TREADLE VALVE
FROM BRAKE
MANIFOLD VALVE
8
T
P
a
b
B A
TO 'Px' PORT
TREADLE VALVE
FROM BRAKE
MANIFOLD VALVE
Section 250-0090
SM 2254 11-03
3
2. Make sure all control valves to supply lines are closed.
3. Turn on hydraulic power supplies and make sure
hydraulic oil is at normal operating temperature.
4. Open control valve for port 'P' supply and adjust to
give a supply reading of 185 bar (2 682 lbf/in). Reading
on pressure gauge at port 'B' should be zero.
Note: The directional control valve starts to de-energise
(close) when transmission pilot pressure falls below
7 bar (100 lbf/in) and is fully de-energised (closed)
when transmission pilot pressure falls to 5.5 bar
(80 lbf/in).
5. Open control valve for port 'a' supply and slowly
increase this supply pressure from 0 - 21 bar
(0 - 300 lbf/in) thus energising (opening) directional
control valve. Pressure reading at port 'B' should now
read 185 7 bar (2 682 100 lbf/in). Reading on
pressure gauge at port 'B' should begin to fall when
supply pressure at port 'a' drops to 7 bar (100 lbf/in).
This rate of fall should reach a maximum rate when
supply pressure at port 'a' drops to 5.5 bar (80 lbf/in) or
below. With supply pressure at port 'a' at 5.5 bar (80
lbf/in) or less, pressure on gauge at port 'B' should
quickly drop to almost zero, by exhausting to tank via
port 'T'.
6. Slowly energise (open) control valve for port 'a'
supply. Pressure reading at port 'B' should start to
rise when pressure at port 'a' reaches 5.5 bar
(80 lbf/in). Rate of pressure increase at port 'B',
should reach a maximum level, when supply
pressure at port 'a' reaches 7 bar (100 lbf/in) or
above.
7. Close all control valves and turn off hydraulic
supply pressures. Bleed off hydraulic supply lines
and remove directional control valve from test bed for
installation.
INSTALLATION
where used.
1. Position directional control valve assembly on the
vehicle and secure with mounting hardware removed
at removal.
5. Release and remove mounting hardware and remove
directional control valve from the vehicle. Move
directional control valve to a clean area for
disassembly.
DISASSEMBLY/ASSEMBLY
Note: With the exception of replacing 'O' rings (11 & 12),
the directional control valve is a non serviceable item
and should be replaced as a complete assembly. The
'O' rings can be replaced as follows:
1. Note orientation of valve body (1) to sub plate (13)
to facilitate assembly.
2. Clamp sub plate (13) lightly in a soft jawed vice and
remove allen bolts (9) and spacers (8).
3. Separate valve body (1) from sub plate (13) and
discard 'O' rings (12).
4. Install new 'O' rings (12) in valve body (1) and fit
valve body (1) to sub plate (13) as noted prior to
disassembly. Install spacers (8) in valve body (1)
and secure valve body (1) to sub plate (13) with allen
bolts (9).
5. Remove allen bolts (10) and end covers (2) from
valve body (1) and discard 'O' rings (11).
6. Install new 'O' rings (11) in end covers (2) and
secure to valve body (1) with allen bolts (10).
BENCH TEST
Letters in parentheses refer to Fig. 1.
1. Install directional control valve on a test bench and
connect as follows:
a. Install hydraulic supply capable of 0 - 159 bar
(0 - 2 300 lbf/in) to port 'P'.
b. Install hydraulic supply capable of 0 - 21 bar
(0 - 300 lbf/in) to port 'a'.
c. Install a suitable return line to port 'T'.
d. Install a pressure gauge suitable for 0 - 207 bar
(0 - 3 000 lbf/in) to port 'D'.
Section 250-0090
SM 2254 11-03
4
8. Repeat all braking and engine shut down cycles
several times and check for appropriate application/
release cycle several times. Check for appropriate
warning light indications.
9. Check all connections again for leaks and tighten
as required. Check hydraulic oil tank level and
replenish as required.
MAINTENANCE
Inspect directional control valve assembly for leaks.
If leaks are found, replace seals with seal kit listed in
the vehicle parts book. Inspect hydraulic lines for
wear and leaks. Replace/tighten lines as required.
SPECIAL TOOLS
There are no special tools required for the
procedures outlined in this section. Refer to Section
general service tools required. These tools are
fittings and connect to directional control valve as
recorded at removal.
3. Secure cover plate to the cradle assembly with
mounting hardware removed at removal.
and bring hydraulic fluid to operating temperature.
6. Apply all brakes in sequence. Check directional
control valve for leaks and tighten connections as
required.
7. Shut off engine and make sure a full service brake
application is made followed by a parking brake
application.
* * * *
Section 250-0120
1 SM 2163 7-02
BRAKING SYSTEM - Pressure Relief Valve
DESCRIPTION
Numbers in parentheses refer to Fig. 1. The pressure
relief valve can be identified as item 4 in Section 210-
0005, COOLING SYSTEM SCHEMATIC.
Mounted on the disc brake oil cooler casing on the
right hand fender, the pressure relief valve houses a
direct acting relief valve cartridge (2).
The pressure relief valve is installed between the triple
gear pump and the two speed control valve. Pressure
relief valve limits the maximum pressure in the disc
brake cooling circuit.
OPERATION
The pressure relief valve houses a direct acting
pressure relief cartridge (2), set at 200 bar (2900 lbf/
in). The relief cartridge (2) controls pressure supplied
to brake cooling circuit by triple gear pump, bypassing
excess pressure back to the main hydraulic tank.
REMOVAL
WARNINGS
result.
the job safely.
3. Remove guard from rear of disc brake oil cooler.
COOLER.
5. Clean pressure relief valve and surrounding area
with a suitable solvent. Identify and tag all hydraulic
lines connected to pressure relief valve, to aid in
'Installation'.
open lines.
pressure relief valve to disc brake oil cooler casing.
Remove pressure relief valve from casing.
DISASSEMBLY
adaptors and remove from valve body (1).
2. Remove relief valve cartridge (2) from valve body
(1).
INSPECTION
compressed air.
SM - 2759
Fig. 1 - Pressure Relief Valve
1 - Valve Body
2 - Relief Valve Cartridge
3 - Washer
4 - Lockwasher
5 - Bolt
1
5
3
4
2
Section 250-0120
SM 2163 7-02 2
3. Check relief valve cartridge (2) for damage. Ensure
valve seat is not worn, scored or cracked.
It is not recommended that the cartridge assembly is
valve assembly is cleaned prior to removal of any
ASSEMBLY
1. Replace seals on relief valve cartridge (2).
2. Install relief valve cartridge (2) into valve body (1)
and torque to 59 Nm (44 lbf ft).
ports and orientations.
INSTALLATION
where used.
1. Secure pressure relief valve to disc brake oil cooler
casing with bolts (5), washers (3) and lockwashers (4).
install lines to the pressure relief valve as identified
during removal.
temperature.
5. Check pressure relief valve and hydraulic line
FAULT DIAGNOSIS
previously, it is not recommended that the cartridge
assembly is disassembled for maintenance purposes.
Ensure that valve assembly is cleaned off prior to
removal of any components and that no contaminant
is allowed to enter the internal galleries.
If investigation shows that the cartridge assembly is in
good clean condition and fit for use, the seals should
be replaced prior to re-assembly. Damage to the
cartridge assembly or valve body would necessitate a
new pressure relief valve assembly.
SPECIAL TOOLS
dealer.
Braking System - Pressure Relief Valve
FAULT DIAGNOSIS
Cannot raise pressure. No oil supply. Check triple gear pump. Check hydraulic oil level.
Relief valve sticking. Clean relief valve.
Relief valve spring broken Replace relief valve cartridge.
Circuit pressure too high. Relief valve sticking. Clean relief valve.
Overheating. Relief valve worn. Replace relief valve cartridge.
* * * *
1
Section 260-0010
SM 1404 Rev 2 12-04
Fig. 1 - Cab and Mounting
DESCRIPTION
The cab is fully insulated and mounted on rubber
isolation mounts (2) to damp structure-borne noise and
vibration. It conforms with ISO/SAE, ROPS (Roll Over
Protective Structure) and FOPS (Falling Object
Protective Structure) requirements as standard.
ROPS - ISO 3471, SAE J1040 APR 88
FOPS - ISO 3449, SAE J231
WARNING
The protection offered by the roll over and
falling object protective structure may be
impaired if it has been subjected to any
modification or damage.
Cab assembly (1) is spacious and offers outstanding
visibility through large areas of tinted safety glass.
Access to cab assembly (1) is from the left hand side
with open tread steps, platform and handrail.
The cab interior, trimmed with noise-absorbent
material, is extensively thermally insulated and a
heater/filter/pressurizer and demisting unit keeps
internal air fresh and dust free. Sliding windows provide
additional ventilation. A side mounted air conditioner is
also fitted. Refer to Section 260-0130, AIR
CONDITIONING.
Note: Access from the cab, in the case of an emergency,
can be gained by breaking any of the windows using the
hammer provided (mounted on the right hand cab pillar).
SM - 3368
CAB - Cab and Mounting
6 - Bolt
7 - Hardened Washer
8 - Rear Window Guard
9 - Spill Guard
10 - Support
11 - Bolt
12 - Lockwasher
13 - Locknut
14 - Bolt
15 - Lockwasher
1 - Cab Assembly
2 - Isolation Mount
3 - Washer
4 - Locknut
5 - Bolt
16 - Firewall Barrier Mat
17 - Spill guard
18 - Spring
19 - Strap
4
7
2
3
5
1
16
6
3
2
4
15
14
8
11
12
13
9
10
FRONT MOUNTING
REAR MOUNTING
17
19
18
SM 1404 Rev 2 12-04
Cab - Cab and Mounting
Section 260-0010
2
REMOVAL
WARNING
safely.
Note: Tag all lines, cables and linkages disconnected
during removal to aid in installation.
2. Operate the treadle valve continuously to discharge
the brake accumulators, block all road wheels, place
the steering lock bar in the 'Locked' position and the
and lift up hood assembly.
4. Disconnect the following cables and connectors in
the order given, to prevent serious damage to the
vehicles electrical components.
a - Battery earth cables
b - Battery supply cables
c - Alternator earth cables
d - Alternator supply cables
e - Body hydraulics joystick
f - Transmission (Est-37) connector
g - ECM interface harness connector (30 pin RHS)
h - ECM power harness connector (5 pin RHS)
i - ECM sensor harness connector (30 pin LHS)
j - ECM engine to transmission datalink connector
(6 pin RHS)
5. Carefully loosen brake pipes at base of both
accumulators to check that brake pressure has been
discharged. Tighten brake pipes.
7. Remove mounting hardware and cover plate from
front left hand of cab assembly (1). Tag and disconnect
electrical harnesses and connections.
8. Tag and disconnect the harnesses and hoses at the
underside of the manifold on the right-hand side of the
cab. Disconnect cab earth strap at rear left hand cab
leg.
WARNING
Before disconnecting any air conditioner lines,
refer to Section 260-0130, AIR CONDITIONING.
Refrigerant will rapidly freeze all objects with
which it comes into contact. It can cause
serious and permanent damage to the eyes and
skin.
9. Evacuate air conditioning system and disconnect air
conditioner lines. Refer to Section 260-0130, AIR
CONDITIONING. Fit blanking caps to all open lines
and fittings.
10. Ensure heater lines are identified for ease of
installation and with suitable containers available to
catch leakage, disconnect heater lines. Fit blanking
caps to open line ends and fittings.
11. Loosen the steering coupling attaching the upper
column to the lower column. Remove mounting
hardware securing the steering valve mounting plate to
the cab floor and lower the assembly from the cab.
12. Remove mounting hardware securing the treadle
valve and accelerator pedal mounting plate to the cab
floor and lower the assembly from the cab.
13. With a suitable container in position, drain the
cooling system. Refer to Section 210-0000, COOLING
SYSTEM.
14. Remove mounting hardware and cover plate from
cradle assembly at rear left hand side of the cab.
15. Ensure brake lines and steering lines are identified
for ease of installation and with suitable containers
available to catch leakage, disconnect lines. Fit
blanking caps to all open lines and ports.
16. Unhook hoses from elastic supports at underside of
spill guard (9) and secure hoses away from guard so as
not to foul when lifting the cab.
17. Attach suitable lifting equipment to support spill
guard (9) and remove bolts (11), lockwashers (12) and
locknuts (13) securing spill guard (9) and supports (10)
to window guard (8). Taking care to prevent damage to
3
Section 260-0010
SM 1404 Rev 2 12-04
exhaust stack, carefully lift spill guard (9) from unit.
18. Disconnect ball joint and clips securing hood
release cable to goalpost and lock mechanism.
19. Remove mounting hardware securing air cleaner
assembly to right hand fender. Slacken mounting
clamp at air cleaner intake pipe and draw air cleaner,
complete with rubber hose, away from intake pipe and
cowl. Cover open ends to prevent entry of dirt.
20. Attach suitable lifting equipment to the cab lifting
points and raise lifting equipment to take up the slack.
21. Remove locknuts (4), washers (3), hardened
washers (7) and bolts (5 & 6) securing the cab
assembly (1) to isolation mounts (2) and cab mounting
brackets on the tractor frame.
22. Check to make certain that all necessary
disconnections have been made, before lifting cab
assembly (1). Taking care to prevent damaging the
insulating material, lift cab assembly (1) from the frame
and place on suitable stands.
INSTALLATION
SPECIFICATIONS.
WARNING
1. Inspect isolation mounts (2) for damage and replace
if necessary. If installing rubber mounts, lubricate them
with water or a suitable rubber lubricant and install
them from above into the cab mounting brackets on
frame. Use a driver of the same diameter as the
internal metal sleeve in the mount to drive the mounts
fully home.
2. Attach suitable lifting equipment to the cab lifting
points and raise and position cab on frame.
3. Secure front of cab assembly (1) to cab mounts with
bolts (5), washers (3), hardened washers (7) and
locknuts (4), as shown in Fig. 1. Tighten locknuts (4) to
4. Secure rear of cab assembly (1) to cab mounts
with bolts (6), washers (3) and locknuts (4), as shown
in Fig. 1. Tighten locknuts (4) to a torque of 380 Nm
(280 lbf ft).
5. Slide cowl assembly into position and secure using
6. Position air cleaner assembly on right hand fender,
reconnect intake pipe and tighten mounting clamp.
Secure air cleaner to fender using mounting hardware
removed during removal.
7. Reconnect ball joint to lock mechanism and secure
hood release cable to goalpost using material removed
during removal.
8. Attach suitable lifting equipment to spill guard (9)
and taking care to prevent damage to exhaust stack,
position onto mounting brackets on window guard (8) at
rear of cab. Secure using bolts (11), lockwashers (12),
locknuts (13) and supports (10).
9. Secure hoses to underside of spill guard (9) using
elastic supports.
10. Connect brake lines and steering lines as identified
at removal.
11. Install treadle valve and accelerator pedal mounting
plate assembly and secure to cab floor with mounting
hardware removed during removal.
12. Install steering valve assembly and secure to cab
floor with mounting hardware removed during removal.
Secure the steering coupling to the lower steering
column with mounting hardware removed during
removal.
13. Connect the heater hoses to the cab as identified
at removal.
14. Connect air conditioning lines and charge air
conditioning system. Refer to Section 260-0130, AIR
CONDITIONING.
15. Connect the harnesses and hoses at the underside
of the manifold on the right-hand side of the cab as
noted on removal. Connect earth strap at rear left hand
cab leg.
16. Connect electrical harnesses at cab bulkhead.
SM 1404 Rev 2 12-04
Section 260-0010
4
4. Manouver the special tool around the edge of the
glass, keeping the wire taut, to cut the adhesive seal.
Ensure the glass is supported adequately before
completing the cut.
5. If fitted, loosen mounting blocks to allow the glass to
be removed from window aperture. Remove the
mounting blocks if necessary.
6. Clean the remains of the adhesive from the edge of
the panel opening using a suitable solvent.
7. If removed, re-fit window mounting blocks, do not
tighten.
8. Coat the edge of the replacement glass with primer
and apply adhesive around the lip of the window
aperture, as per the manufacturers recommendations.
9. Position glass onto panel opening, pressing firmly so
that adhesive bonds sufficiently to allow the glass to
be moved or straightened up as required.
10. Ensuring the glass is adequately supported, allow
the sealing adhesive to set properly.
11. Clean off any excess adhesive using a suitable
solvent.
12. If necessary, tighten window mounting blocks.
Water Leaks
Test for leaks by directing a stream of water along the
adhesive seal, while an assistant marks the spot of
leakage inside the cab. Care should be taken to note
whether the leak is between adhesive and glass. Then
apply a sealing compound from the outside. Start from
a point near the leak and continue applying the sealer
until well beyond the suspected point of entry.
This should stop the leak immediately, but since some
sealing compounds should be allowed to set before
getting wet, wait a few minutes before testing.
17. Fill the cooling system with coolant specified in
18. Connect electrical connections and cables in
reverse order to removal, with battery earth cable last.
start the engine and check for leaks. Tighten fittings if
necessary. Allow engine to warm up and recheck all
connections for leaks. Ensure electrical systems and
gear shift are functioning properly.
20. Ensure parking brake is applied and remove wheel
blocks from all road wheels.
REPLACING GLASS
Note: When replacing broken glass, it is the users
responsibility to ensure that the replacement glass
meets the required specifications. Replacement glass
can be purchased from your dealer.
The rear glass, left and right hand side glasses and
front windscreen are held in place by a bonding
adhesive. The rear glass and right hand side glass also
have two mounting blocks to support the glass.
To replace a glass assembly, proceed as follows:
Note: Ensure the glass is supported adequately before
starting to cut the adhesive seal.
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 the wire
through the opening. Pierce a second hole in the adhesive
on the side directly opposite the first.
2. From inside the cab pull the wire through and feed it
back out through the second hole.
3. Re-fit the handle on the special tool. Pull both
handles outwards until wire is taut.
5
Section 260-0010
SM 1404 Rev 2 12-04
* * * *
TORQUE
1 4 Locknut 380 280
SERVICE TOOLS
numbers of the glass removal tool, adhesive bonding
kit and other general service tools required. These tools
are available from your dealer.
1
Section 260-0090
SM 1981 4-00
OPERATORS COMPARTMENT - Driver Seat and Mounting
SM - 2486
DESCRIPTION
WARNING
By Law, seat belts must be provided. Always
wear seat belts when travelling in the vehicle.
Fig. 1 - Exploded View of Driver Seat
1 - Seat Frame
2 - Backrest Cushion
3 - Seat Cushion
4 - Screw
5 - Screw
6 - Backrest
7 - Cover
8 - Cover
9 - Lap Belt
10 - Nut
11 - Spacer
12 - Bushing
13 - Plug
14 - Slide Adjuster Rail
15 - Shock Absorber - Horizontal
16 - Locking Lever
17 - Bowden Cable
18 - Adjuster Control Unit
19 - Handle
20 - Horizontal Isolator Unit
21 - Compressor
22 - Connecting Cable
23 - Air Hose
24 - Lever
25 - Bowden Cable
26 - Shock Absorber - Vertical
27 - Cover
28 - Level Controller
29 - Swing Arm
The driver seat is secured to the cab wall with bolts
(35) and washers (36). The seat assembly consists of
a seat cushion (3) and backrest cushion (2) mounted to
seat frame (1). Seat frame (1) is attached to seat base
(34) by means of a suspension assembly. The air seat
only reacts when the driver sits on the seat. When
unoccupied, the seat sinks to the lowest position to
allow easier access.
30 - Air Spring
31 - Pop-out Button
32 - Suspension Skirt
33 - Allen Screw
34 - Seat Base
35 - Bolt
36 - Washer
37 - Bolt
38 - Washer
39 - Lockwasher
40 - Nut
Operator's Compartment - Driver Seat and Mounting
Section 260-0090
SM 1981 4-00 2
8. Set fore/aft isolator (C) position to suit driving
conditions, (forward position - unlocked, rearmost
position - locked).
9. Engage seat belt (D).
REMOVAL
WARNINGS
secured and of adequate capacity to do the
job safely.
3. Disconnect harness connector at the rear of
the seat.
4. Push down height and weight adjustment (A) handle
to release the air from the seat air suspension system.
6. Using suitable lifting equipment, support seat and
remove bolts (35) and washers (36) securing complete
seat assembly to the cab wall. Remove seat assembly
from vehicle.
DISASSEMBLY
Note: The disassembly and assembly procedures will
cover only basic subassemblies due to the multitude of
parts. If a subassembly must be disassembled, use
the exploded view in Fig. 1 for reference.
1. Remove bolts (37), washers (39), lockwashers (39)
and nuts (40) securing seat base (34) to seat
assembly. Remove seat base (34) from seat
assembly.
2. Remove covers (7 & 8) from seat assembly.
Remove nuts and spacers securing lap belt (9) to seat
assembly. Remove lap belt (9).
3. Pull up and remove backrest (6) from seat frame (1).
A retractable lap belt (9) is secured to the seat
assembly using nuts and spacers. A push button
allows quick release of lap belt (9).
The following is the list of controls to adjust the seat:
A. Height and weight adjustment.
B. Horizontal adjustment (sliderails).
C. Fore/aft isolator (forward position - unlocked,
rearmost position - locked).
D. Seat belt.
E. Backrest angle adjustment.
F. Backrest height adjustment.
G. Damper adjustment (4 positions; forward position -
hardest setting, rearmost position - softest setting).
WARNING
Do not attempt to adjust the seat or seat belt
while the machine is moving. Loss of control
may result. Stop the machine; apply the brakes;
then adjust.
OPERATION
To achieve the most comfortable driving position,
adjust the seat as follows;
1. Sit in seat.
2. Pull up and release height and weight adjustment (A)
handle - this will reset the seat to the predetermined
height setting - 'bounce' lightly until a 'click' is heard,
the seat position in now engaged properly.
3. Pull up horizontal adjustment handle (B) and move
seat forwards or backwards, release handle when
required position is achieved.
4. Pull up (or push down) height and weight adjustment
(A) handle and hold until the require height position is
achieved, release handle - 'bounce' lightly until a 'click'
is heard, the seat position in now engaged properly.
5. Pull up handle (E) and adjust backrest to the required
angle, release handle when required position is
achieved.
6. Pull up (or push down) backrest (F) to the required
height.
7. Set damper adjustment (G) position to suit driving
conditions, (4 positions; forward position - hardest
setting, rearmost position - softest setting).
3
Section 260-0090
SM 1981 4-00
4. Remove screws (5) securing backrest cushion (2) to
seat frame (1). Remove backrest cushion (2).
5. Remove screws (4) securing seat cushion (3) to seat
frame (1). Remove seat cushion (3).
6. Pull up horizontal adjustment (B) lever and slide seat
assembly rearwards. Hold captive nuts using a suitable
spanner and remove front allen screws (33).
assembly forwards. Hold captive nuts using a suitable
spanner and remove rear allen screws (33).
8. Remove seat assembly from suspension base.
Horizontal Shock Absorber
Note: Remove seat assembly as described in
'Disassembly'
1. Remove pop-out buttons (1) and remove access
cover (2) to allow access to suspension assembly.
2. Unclip hooked end of shock absorber (4) from
horizontal spring assembly.
3. Remove circlip (3) and lever out shock absorber (4)
from rocker shaft and slide off of mounting pin.
4. Remove spacer (5) from mounting pin.
5. Reassembly is done in the reverse order.
Vertical Shock Absorber
'Disassembly'
2. Unhook Bowden wire (5) and damper adjuster (6)
assembly from the top of shock absorber (7).
3. Remove circlips (3) and lever out shock absorber (7)
from mounting pins (4).
4. Remove spacers (8) from lower mounting pin (4).
Note: Inscription must face upwards when assembling
shock absorber (7).
Fig. 2 - Exploded View of Horizontal Shock Absorber
Compressor
'Disassembly'
2. Remove pop-out buttons (3) and push down
suspension skirt (4) to allow further access to
suspension assembly.
3. Remove pressurised airline (5) from compressor (6).
Fig. 3 - Exploded View of Vertical Shock Absorber
SM - 2488
SM - 2487
Section 260-0090
SM 1981 4-00 4
4. Identify and tag and disconnect electrical plug
connections (7 & 8). Unfasten cable tie on the rocker.
5. Pull suspension assembly up to its highest position
and block securely.
6. Unscrew lower nut (9) and remove micro
encapsulated cylinder screw (10) and retaining clamp
(11).
7. Remove compressor (6) and felt mat (12) from
suspension base.
Note: Replace micro encapsulated cylinder screw (10).
Note: Centralise compressor (6) and felt mat (12)
between rocker arms.
3. Pull suspension assembly up to its highest position
and block securely.
4. Unhook bowden wires (5 & 6) from level controller (7).
5. Identify and tag and disconnect electrical plug
connections (8 & 9).
6. Identify and tag and disconnect pressurised airlines
(10) from air suspension unit (11). Unfasten cable tie on
the rocker.
7. Remove screw (12), push out pin (13) and release
roll up belt (17).
8. Remove nuts (14) and manoeuvre level controller (7)
until studs are free from mounting holes.
9. Remove screws (15) and remove bowden wire (16)
retainer from level controller (7).
10. Remove level controller (7) from suspension base.
Note: Tighten nuts (14) to a torque of 25 Nm (18 lbf ft).
Fig. 4 - Exploded View of Compressor and Mounting
Level Controller
'Disassembly'
2. Remove pop-out buttons (3) and push down
suspension skirt (4) to allow further access to
suspension assembly.
Fig. 5 - Exploded View of Level Controller and Mounting
SM - 2490
SM - 2489
5
Section 260-0090
SM 1981 4-00
INSPECTION
1. Inspect air lines, shock absorbers (15 & 26),
compressor (21), level controller (28) and air spring (30)
for leaks and damage and replace if required.
2. Check all brackets and frame for cracks and/or
damage. Repair or replace as necessary.
3. Check springs for fatigue or damage and replace as
required.
ASSEMBLY
SPECIFICATIONS.
1. Position seat assembly onto suspension base. Hold
captive nuts using a suitable spanner and install rear
allen screws (33). Tighten allen screws (33) to a torque
of 25 Nm (18 lbf ft).
assembly rearwards. Hold captive nuts using a suitable
spanner and install front allen screws (33). Tighten
allen screws (33) to a torque of 25 Nm
(18 lbf ft).
3. Install seat cushion (3) to seat frame (1) and secure
using screws (4).
4. Install backrest cushion (2) to seat frame (1) and
secure using screws (5).
5. Refit backrest (6) to seat frame (1).
6. Position lap belt (9) to seat assembly and secure
using nuts (10) and spacers (11) as removed at
'Disassembly'. Tighten nuts (10) to a torque of 50 Nm
(36 lbf ft). Refit covers (7 & 8).
7. Position seat assembly onto seat base (34) and
secure using bolts (37), washers (38), lockwashers (39)
and nuts (40).
INSTALLATION
SPECIFICATIONS.
WARNINGS
safely.
1. Using suitable lifting equipment, position seat
assembly on the cab wall and secure with bolts (35)
and washers (36).
2. Reconnect harness at the rear of the seat.
3. Place battery master switch in the 'On' position, start
the engine and charge the air system. Check seat for
proper operation, refer to 'Operation'.
4. Remove wheel chocks from road wheels.
MAINTENANCE
The care of the upholstery on seat cushion (3) and
backrest cushion (2) is a relatively simple, but
important matter. Accumulation of dirt on the surface
eventually turns into a hard gritty substance which cuts
into the surface of the upholstery.
To clean seat cushion (3) and backrest cushion (2),
use warm water and a mild soap, such as Castile.
Work up thin soap suds on a piece of soft cloth and rub
the upholstery briskly. Remove the suds with a damp
cloth, using no soap, and finish by wiping the
upholstery dry with a soft, dry cloth.
Lap belt (9) assembly should be inspected by the user
on a regular basis. Replace lap belt (9) immediately if
hardware is worn or damage, straps are nicked or
frayed, buckle is not functioning correctly, loose
stitching is found, or if the strap material has lost
strength due to the effects of ultraviolet rays.
Note: Regardless of appearance, lap belt (9) must be
removed and replaced at least once every three years.
Section 260-0090
SM 1981 4-00 6
TORQUE
1 10 Nut 50 36
1 33 Allen Screw 25 18
5 14 Nut 25 18
* * * *
Section 260-0130
SM 1405 Rev 2 11-04 1
DESCRIPTION
Temperature Control Switch
A thermostat switch senses the temperature of the
evaporator and engages or disengages the
compressor clutch. The control for this switch is
located in the cab.
Compressor
The compressor is designed to compress vapour and
can be damaged by non-compressibles such as dirt,
moisture, liquid refrigerant (R-134a), etc. The
compressor draws vaporized R-134a from the
evaporator (which maintains the low pressure
necessary for proper evaporation) and compresses
the vapour to a high pressure, which is necessary for
condensation. The high pressure vapour then moves
into the condenser where heat can be radiated to
change the R-134a back to liquid.
Note: R-134a designates the type of refrigerant used
in heavy duty vehicle air conditioning systems.
Compressor Drive Clutch
The R-134a compressor systems use an electronically
actuated clutch to engage and disengage drive to the
compressor. The 'V' belt pulley is mounted on a bearing
and is free to rotate without turning the compressor
crankshaft any time electrical power is disconnected.
The compressor is not operating when the pulley is
freewheeling. The field coil is energized by supplying
electrical current to the exposed wire. The other end of
the coil winding is grounded to the compressor and
equipment frame. Energizing the coil creates a magnetic
force that locks the driven disk to the pulley and drives the
compressor.
Condenser
The purpose of the condenser is to radiate enough
heat energy from the compressed high pressure
vaporized R-134a so that the R-134a changes from
vapour to liquid. During normal operation all the high
pressure section of the system will be warm or hot, but
large quantities of heat should be radiating from the
condenser. Nothing should be permitted to stop or
Fig. 1 - Typical Air Conditioning Flow Diagram
SM - 2430
1 - Compressor
2 - Condenser
3 - Receiver Drier
4 - Expansion Valve
5 - Evaporator
OPERATORS COMPARTMENT - Air Conditioning
2
3
4
5
1
S
D
IN
OUT
Section 260-0130
Operators Compartment - Air Conditioning
SM 1405 Rev 2 11-04 2
slow down this radiation of heat. Cooling fins are
located on the condenser tubes and fans are used to
circulate cool air around the condenser tubes. Keep all
leaves, paper, dirt, etc. clear from the condenser and
condenser filter. The cooling fins should be straight to
permit free flow of air. The condenser is sometimes
located ahead of the engine radiator and blockage of
air flow through the radiator also affects the
condenser. Bent fan blades, slipping fan drive,
inoperable condenser fan motors, or any other fault
that lessens the amount of cool air circulated through
the condenser, should be corrected. The oil, dirt, or
antifreeze will act as an insulator that will inhibit the
radiation of heat.
Since the purpose of the condenser is to radiate heat
energy, anything that prevents or inhibits this action
may affect cooling, but the temperature and pressure
of the R-134a raise and lower together. Heat energy
that has not been radiated will remain in the R-134a
and the result will be pressure that is too high. The
condenser, hoses, connections and seals can be
damaged by the high pressure. Pressure sensing
safety switches may be activated by the high pressure
caused by the condenser not radiating enough heat.
Receiver Drier
The high pressure liquid R-134a moves from the
condenser to the receiver drier, where the R-134a is
stored and filtered. Moisture is the major enemy of the air
conditioning system and the desiccant inside the receiver
drier will absorb only a small amount. The container of
desiccant inside the receiver drier may break open and
contaminate the system if any attempt is made to dry the
desiccant, or, if more moisture is inside the system than
the desiccant can absorb.
Every effort should be made to remove all moisture from
the system and install a new receiver drier if its condition
is questionable. Installation of a new receiver drier is
recommended each time any part of the R-134a system
is open to the atmosphere. Bubbles are observed in the
sight glass on top of the receiver drier during the
charging procedure.
A filter screen is located in the receiver drier to stop
solid contaminates from leaving the unit. Blockage of
the filter will result in a drop in pressure that will be
indicated by a drop in temperature. Connections of
the new receiver drier should be securely capped
before installation to prevent the entrance of moisture
(air) while in storage.
Thermostatic Expansion Valve
An expansion valve is installed in the system to lower
the pressure before the R-134a enters the evaporator.
The reduction in pressure is done by passing the
R-134a through a small hole (orifice). The size of the
orifice must be controlled to compensate for changes
in pressure and temperature. The temperature of
R-134a leaving the evaporator is sensed by a
thermostatic sensor that moves the valve seat via a
diaphragm and actuating pin.
Evaporator - Heat/Cool
The evaporator is the low pressure, low temperature
component where liquid R-134a absorbs heat from
surrounding air. The expansion valve bleeds high
pressure R-134a into the low pressure evaporator.
The R-134a expands rapidly in the evaporator and its
temperature is quickly reduced. The R-134a absorbs
heat from the air when the blower fan circulates air
over the evaporator coil fins. The exchange of heat
from the air to the R-134a depends upon the
difference in temperature. During high heat load, such
as usually encountered when the system is first turned
on, the temperature difference is great and the R-134a
will absorb heat quickly. The blower fan can be set at
its highest setting to circulate large quantities of warm
air around the evaporator. After the cab has cooled,
the fan speed should be reduced so that the already
cool air will have a longer time to yield heat to the
R-134a as it passes the evaporator coils. The heater
circuits utilize engine coolant at approximately 82 C
(180 F).
High Pressure and Low Pressure Switches
The pressure switches are electric switches that
monitor air conditioner operation. The high pressure
and low pressure switches are activated at preset
pressures and engage and disengage the compressor
clutch.
Section 260-0130
SM 1405 Rev 2 11-04 3
REMOVAL
otherwise stated.
WARNINGS
Always wear goggles or glasses to protect
your eyes when working around R-134a.
R-134a boils at sea level temperatures of
-29.8 C (-21.6 F), which means that direct
contact with your skin will produce frostbite.
Exercise extreme care when handling R-134a. If
R-134a contacts your skin, wash immediately
with plenty of warm water. Remove any
contaminated clothing with caution as it may
adhere to the skin. If blistering or continued
irritation occurs obtain immediate medical
attention.
If you get the slightest trace of R-134a in
your eye, flood the eye immediately with cool
water; then treat with mineral oil or clear
petroleum jelly followed by boric acid rinse.
Report to a hospital or doctor as soon as
possible.
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.
safely.
and raise the hood.
4. Discharge the air conditioning system as described
under 'Discharging The System'.
5. Remove screws (2) and lockwashers (3) securing
cover on air conditioner (1) outer box to gain access to
refrigerent hosing.
6. When satisfied that the system is completely
discharged, tag refrigerant hoses (5 & 6) to aid in
installation and carefully disconnect hoses from air
conditioner (1). Cap air conditioner (1) fittings and
refrigerant hoses (5 & 6) to prevent foreign matter
from entering the system.
7. Remove bolts (45, Fig. 3) and lockwashers
(46, Fig. 3) securing front cover and filter assemblies
on air conditioner (1) outer box.
8. Disconnect harness (4, Fig. 3) and unhook control
cable (47, Fig. 3) from water valve (48, Fig. 3).
9. Remove bolts (40, Fig. 3), lockwashers (41, Fig. 3)
and washers (42, Fig. 3) securing air conditioner (1)
outer box to cab assembly and withdraw box.
10. Tag refrigerant hoses (5 & 9) to aid in installation
and carefully disconnect hoses from receiver/drier
(16). Cap receiver/drier (16) fittings and refrigerant
hoses (5 & 9) to prevent foreign matter from entering
the system.
11. Support receiver/drier (16) and remove nuts
securing receiver/drier (16) to mounting bracket (17). If
necessary, remove bolts (13), lockwashers (14) and
mounting bracket (17) from engine block.
12. Tag refrigerant hoses (7, 8, 9 & 10) to aid in
installation and carefully disconnect hoses at radiator
cowl and condenser (11). Cap condenser (11) fittings
and refrigerant hoses to prevent ingress of foreign
matter.
13. If required, support air conditioner condenser (11)
and remove bolts (13), lockwashers (14) and washers
(15) securing condenser (11) to radiator assembly.
Remove condenser (11) from vehicle.
14. Tag refrigerant hoses (6 & 7) to aid in installation
and carefully disconnect hoses from compressor (12).
Cap compressor (12) fittings and refrigerant hoses
(6 & 7) to prevent foreign matter from entering the
system.
15. Disconnect electrical connection from compressor
(12) clutch.
Section 260-0130
SM 1405 Rev 2 11-04 4
SM - 1862B
1 - Air Conditioner
2 - Screw
3 - Lockwasher
5 - Refrigerant Hose
11 - Condenser
12 - Compressor
13 - Bolt
14 - Lockwasher
15 - Washer
16 - Receiver/Drier
17 - Bracket
18 - 'V' Belt
19 - Bracket
20 - Adjuster Bracket
23 - Washer
24 - Adjuster Rod
25 - Adjuster Block
26 - Nut
27 - Lockwasher
28 - Bolt
29 - Bolt
30 - Spacer
31 - Bolt
32 - Spacer
33 - Locknut
34 - Bolt
35 - Bolt
36 - Washer
37 - Bolt
Fig. 2 - Air Conditioner Lines and Mounting
13
11
14
15
8
9
10
16
17
5
14
13
2
3
1
7
6
28
26
25
27
26
24
31
12
33
33
33
36
35
27
26
23
34
21
22
19
33
36
37
31
18
33
32
29
30
31
20
AIR CONDITIONER
OUTER BOX
Section 260-0130
SM 1405 Rev 2 11-04 5
SM - 1862A
4 - Harness
38 - Harness
39 - Harness
40 - Bolt
41 - Lockwasher
42 - Washer
43 - Cover
44 - Blower Unit
45 - Bolt
46 - Lockwasher
47 - Control Cable
48 - Water Valve
Fig. 3 - Air Conditioner Lines and Mounting
42
41
40
MOUNTING
A-A
A
A
44
43
39
38
48
4
47
47
46
45
DETAIL INSIDE CAB
EXPLODED VIEW ON FRONT
OF AIR CONDITIONER BOX
Section 260-0130
SM 1405 Rev 2 11-04 6
16. Slacken nuts (26) and lockwasher (27) on adjuster
rod (24) to release tension on 'V' belt (18).
17. Slacken locknut (33) on bolt (34). 'V' belt (18)
should now be free to slide off of groove in compressor
(12).
18. Slacken nut (26) on bolt (28). Remove locknut (33)
and spacer and slide adjuster block (25) clear of
compressor (12). Remove bolt (28), lockwasher (27),
nut (26) and adjuster rod assembly (24) from
mounting bracket (19).
19. Support compressor (12) and remove bolt (34),
washer (23) and locknut (33) securing compressor
(12) to bracket (19). Remove compressor (12) from
the vehicle.
Note: If 'V' belt (18) does not require replacement do
not remove from engine fan pulley. If 'V' belt (18)
requires replacement, proceed with steps 20 and 21.
20. If required, remove mounting hardware securing
fan guard assembly to radiator shroud assembly.
Refer to SECTION 210-0040, RADIATOR AND
MOUNTING.
21. Release tension on Poly 'V' fan belt and remove
from fan pulley. Remove compressor 'V' belt (18) from
the rear groove of the fan pulley. Refer to Section
110-0030, ENGINE AND MOUNTING.
22. If required, remove bolts (35 & 37), locknuts (33),
washers (36) and bracket (19) from engine timing case.
23. If required, disconnect all clamps and clips
securing refrigerant hoses and harnesses to the
vehicle. Remove hoses and harnesses from the
vehicle.
24. If necessary to gain access to blower unit (44, Fig. 3),
disconnect harnesses (38 & 39, Fig. 3) and air ducting
tubes from air conditioning unit (located in the right hand
side of the cab). Remove bolts (40, Fig. 3), lockwashers
(41, Fig. 3), washers (42, Fig. 3) and slide cover
(43, Fig. 3) from air conditioning unit.
INSTALLATION
otherwise stated.
specified in Section 300-0080, STANDARD BOLT
AND NUT TORQUE SPECIFICATIONS.
WARNING
safely.
1. If removed, slide air conditioner cover (43, Fig. 3)
into position inside the cab and connect harnesses
(38 & 39, Fig. 3) and air ducting tubes. Secure cover
(43, Fig. 3) with bolts (40, Fig. 3) and lockwashers
(41, Fig. 3).
2. If removed, position air conditioner (1) outer box
assembly over aperture on right hand side of cab.
Secure outer box assembly with bolts (40, Fig. 3),
lockwashers (41, Fig. 3) and washers (42, Fig. 3).
3. Connect harness (4, Fig. 3) and attach control cable
(47, Fig. 3) to water valve (48, Fig. 3).
4. Position front cover and filter assemblies on air
conditioner (1) outer box and secure using bolts
(45, Fig. 3) and lockwashers (46, Fig. 3).
5. Remove caps from end of refrigerant hoses (5 & 6)
and ports on air conditioner (1) and connect hoses to
ports as tagged at removal.
6. Route refrigerant hoses (5 & 6) behind the engine
and along the LH side of the engine securing with
clamps removed during removal.
7. If removed, install receiver/drier (16) to mounting
bracket (17) and secure with nuts as removed at
removal. Secure assembly to engine block with bolts
and ports on receiver/drier (16) and connect hoses to
9. If removed, install condenser unit (11) to radiator
assembly and secure with bolts (13), washers (15) and
lockwashers (14).
10. Remove caps and connect refridgerant hoses
(7, 8, 9 & 10) to radiator cowl and condenser unit (11)
11. If removed, install mounting bracket (19) to engine
timing case and secure using bolts (35 & 37), washers
(36) and locknuts (33) as shown in Fig. 2.
Section 260-0130
SM 1405 Rev 2 11-04 7
MAINTENANCE
WARNING
Always wear goggles or glasses to protect your
eyes when working around R-134a. R-134a boils
at sea level temperatures of -29.8 C (-21.6 F),
which means that direct contact with your skin
will produce frostbite. Exercise extreme care
when handling R-134a.If R-134a contacts your
skin, wash immediately with plenty of warm
water. Remove any contaminated clothing with
caution as it may adhere to the skin. If
blistering or continued irritation occurs obtain
immediate medical attnetion.
WARNINGS
If you get the slightest trace of R-134a in
your eye, flood the eye immediately with cool
water; then treat with mineral oil or clear
petroleum jelly followed by boric acid rinse.
Report to a hospital or doctor as soon as
possible.
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.
1. Periodically clean the condenser coil of debris and
dirt using water or air pressure. A partially blocked
condenser coil can reduce the life of the compressor
belt and/or clutch.
2. If the system has a heater in the same location as
the air conditioning evaporator core, heater valves
should be closed.
3. To check the refrigerant level, run the engine at
1 200 rev/min with fans on high speed and thermostat
fully open for a minimum of five minutes. If the clutch is
engaged in this situation, there should be very few
bubbles visible in the receiver-drier sight glass.
Note: Unit can operate with some bubbles visible, but
not milky looking.
12. Fit compressor (12) to mounting bracket (19) and
secure with bolt (34), washer (23) and locknut (33). Do
not fully tighten at this stage.
Note: If fan guard, Poly 'V' fan belt and compressor
'V' belt (18) were removed, proceed with steps 11 & 12.
13. Install new 'V' belt (18) onto rear groove on engine fan
pulley and fit to rear groove on compressor (12).
14. Refit Poly 'V' fan belt and adjust tension. Refer to
Section 110-0030, ENGINE AND MOUNTING. Refit fan
guard and secure with mounting hardware as removed
during removal. Refer to Section 210-0040, RADIATOR
AND MOUNTING.
15. Install spacer (30) on adjuster block (25). Locate
adjuster block (25) through centre hole in adjuster
bracket (20) and secure in place with locknut (33).
16. Support compressor (12) and position eyelet of
adjuster rod (24) adjacent to lug on bracket (19) and
secure with bolt (28), lockwasher (27) and nut (26).
17. Adjust tension of compressor 'V' belt with nuts (26)
on adjuster rod (24) until there is approximately an
inward deflection of 10 mm (0.4 in) at the centre of 'V'
belt (18). Fully tighten all mounting hardware.
and ports on compressor (12) and connect hoses to
19. Connect electrical connection to compressor (12)
clutch.
20. Secure all lines with clips and clamps as removed
evident.
21. Charge the air conditioning system as described
under 'Charging Procedure'.
position, start up the engine and check for correct
operation of the air conditioning system.
24. Secure cover to air conditioner (1) outer box using
screws (2) and lockwashers (3). Lower hood assembly
and remove wheel chocks.
Section 260-0130
SM 1405 Rev 2 11-04 8
7. A belt that has operated while rolled over in the
sheave groove may be damaged - replace it.
8. Store belts in a cool, dry place. If stored on a
machine, relieve all belt tension by loosening the
'V' belt tightener.
9. Never attempt to check or adjust belts while they
are running.
Refrigerant Oil
WARNINGS
To prevent personal injury always wear rubber
gloves when handling refrigerant oils.
Too much refrigerant oil will dampen the
cooling effect and too little refrigerant oil may
lead to compressor failure. If in doubt flush
the system.
Oil is required to lubricate the compressor. The oil
mixes with the refrigerant and is carried around the
system. The compressor is supplied with an oil
charge. However, additional oil is required, the
amount depending on the length of refrigerant hose
being used. The quantity added should be calculated
using the following equation:
Amount of oil to add in fl oz. =
(0.47 x total length of hoses in m) - 2.15
If any component is replaced the following amount of
oil should be added to the system;
Condenser add 1 fl oz (28.4 ml)
Drier add 1 fl oz (28.4 ml)
Evaporator add 3 fl oz (85.2 ml)
Compressor add 4.4 fl oz (125 ml)
The oil should be added to the oil filling port of the
compressor before the evacuation procedure is
started or by using an oil injector when the system is
being charged, observing the following good
practises:
a. Only pour the amount required from the container
straight into a CLEAN measuring jug and
immediately pour the oil into the compressor.
b. Re-cap container tightly as soon as the required
amount has been taken (never leave an oil container
open).
c. Do not mix different oils.
4. Ensure all hoses and hose clamps are free from
contact with sharp metal, moving parts or near to
manifolds.
5. Inspect condensation drain lines for debris, sharp
bends or breaks.
6. Inspect the clutch wire from the thermostat for bare
spots.
7. Inspect bolts and nuts on the compressor and
mounting bracket for proper tightness.
8. Inspect and clean outside and inside cab air filters
periodically, depending on dust conditions. Replace the
outside filter when it becomes saturated to the point it
won't come clean.
Maintenance of 'V' belt Drives
1. Listen for 'ticking' sound - they mean interference
with the belts. Visually inspect for bent or damaged
belt guards.
2. Replace all belts in a mismatched set at one time to
ensure even load distribution.
3. Periodically check tension and keep belts tight.
- The ideal tension is the lowest tension at which the
belt will not slip under peak load conditions.
- Check belt tension frequently during the first 24 - 48
hours of run-in operation.
- Initial belt tension should be 445 N (100 lbf)
dropping to 334 N (75 lbf) after the first 48 hours.
- There should be a freeplay of 10 mm in the 'V' belt.
- Do not over tension belts.
- Keep belts free from foreign material that may
cause slippage.
- Inspect the V-drive periodically. Re-tension belts if
they are slipping.
- Maintain sheave alignment with a strong straight
edge tool while tensioning belts.
4. Never attempt to correct belt slippage by using a
belt dressing. The dressing may cause softening and
deterioration.
5. If belt slips, even when properly tensioned, check
for overload, worn sheave grooves or oil or grease on
the belts.
6. Never pry a 'V' belt or force it into the sheave
groove. Loosen the 'V' belt tightener prior to
installation.
Section 260-0130
SM 1405 Rev 2 11-04 9
Only new oil should be used, because oil that has been
exposed to the air will have absorbed water
(hygroscopic).
Use only refrigerant oil as specified in Section
System Leak Testing
Recommended Equipment Required:
Electronic Leak Detector
Switch off the engine and check all connections
throughout the system for leaks. A large leak point
will have an oily or greasy appearance. The
refrigerant carries compressor oil with it and deposits
it around the leak area. Check all such points for
loose connections and tighten.
Using a suitable leak detector, search for leaks
around all joints, connections, seals and control
devices. If a leak is located, purge the system of
refrigerant and repair. Fully evacuate and charge the
system to make it operational.
DISCHARGING THE SYSTEM
Note: Refer to all WARNINGS listed under
'Maintenance' prior to discharging the system.
Portable High Vacuum Charging Station
Suitable Canister
or Standard Service Manifold (Refer to Fig. 4)
To eliminate system contaminants from an air
conditioning system requires discharging the entire
system. This means removing all of the refrigerant and
cleansing all contamination (air and moisture) from the
system components. If any of the major system
components are to be repaired or replaced, the
system must also be completely discharged.
WARNING
The vehicle must not be running during this
procedure. Be sure to have adequate
ventilation during this operation. Do not
discharge refrigerant near an open flame.
wheel several times to relieve pressure in the steering
circuit.
3. Pull on handle to release hood catch and raise the
hood.
4. Connect the service hose (yellow) to the centre
access port on the manifold gauge and to the vacuum
connection (6) on vacuum pump. Ensure that the
system is empty before connecting the vacuum so
that refrigerant does not enter the pump.
5. Tighten down (turn clockwise) both high and low
side valves on the gauge manifold to the closed
position. Remove protective caps from the service
ports on the compressor.
6. Connect both service hoses from the two fittings (2
& 3) in the bottom of the manifold to the two service
ports on the compressor. High side (red) to compressor
discharge valve, low side (blue) to compressor suction
valve.
7. Switch vacuum pump on, open vacuum pressure
valve (1) until less than 6 mb is reached on vacuum
Gauges:
A - Vacuum Gauge
B - Low Pressure Gauge
C - High Pressure Gauge
D - Charging Cylinder
Pressure Gauge
Valves:
1 - Vacuum Pressure
2 - Suction Line
3 - Discharge Line
4 - Refrigerant Gas
5 - Refrigerant Liquid
Port:
6 - Vacuum
Connection
Fig. 4 - Standard Service Manifold
B C D
A
VACUUM PUMP
SUC DIS
ACCESS
PORT
2 3
4
5
6
1
R
E
F
R
I
G
E
R
A
N
T
SM - 2424
Section 260-0130
SM 1405 Rev 2 11-04 10
gauge (A). The vacuum gauge (A) should remain at this
value when vacuum pressure valve (1) is closed to
indicate that there are no leaks.
8. Open the low side hand valve on the manifold and
vacuum pressure valve (1) and watch that the
gauges start to register that a vacuum is being
drawn. If the gauges do not register the vacuum then
a blockage is present. Open the high side and pump
down until a vacuum of 10 mb is achieved.
9. After 10 - 15 minutes close vacuum pressure valve
(1) and allow the system to settle, vacuum gauge (A)
should not alter. If the vacuum is held, no leaks or
refrigerant contaminated oil is present. If not, open
the vacuum pressure valve (1) and continue
pumping, checking at regular intervals. If there is a
leak, check all fittings and tighten if necessary.
10. Tighten down (turn clockwise) both high and low
side valves on the gauge manifold to the closed
position, remove the service hose (yellow) from the
vacuum connection (6) on vacuum pump and switch
the pump 'Off'.
11. Connect the service hose (yellow) to the R-134a
cylinder. Open the cylinder valve and then purge air
from the hose at the manifold connection.
12. Open the low side hand valve on the manifold
slowly, until low pressure gauge (B) is at bottle
pressure. Watch the high side manifold gauge (C)
rise to ensure that no blockage is present. Close the
manifold valve and cylinder, then disconnect the hose
from the cylinder.
13. Connect the service hose (yellow) to the Nitrogen
cylinder. Open the neck valve on the cylinder and set
the regulator pressure such that it is higher than the
system pressure then purge the hose. Open the low
side hand valve on the manifold, as the pressure
rises open the high side hand valve on the manifold
and allow a system pressure of 10 bar (150 psig) to
be reached. Close all the valves. Using a suitable
electronic leak detector, check all joints in the air
conditioning system for leaks. Tighten any loose
joints and re-test if necessary.
14. Vent the refrigerant mix to atmosphere by
removing the service hose (yellow) from the Nitrogen
cylinder and opening the low side hand valve on the
manifold. Re-evacuate the system to below 6 mb
(steps 7 to 10).
CHARGING THE SYSTEM
Note: Refer to all WARNINGS listed under
'Maintenance' prior to charging the system.
Portable High Vacuum Charging Station
Electronic Leak Detector
or Standard Service Manifold (Refer to Fig. 4)
For New Or Completely Empty System
Note: The charging procedure must be done in
ambient temperatures above 15.5 C (60 F) with the
R-134a canister temperature equal to the outside
ambient temperature.
1. Shut off engine and block all road wheels.
2. Pull on handle to release hood catch and raise the
hood.
3. Remove protective caps from 'quick coupler'
valves on rear of compressor.
4. Connect low pressure gauge hose (blue hose and
gauge) to suction side or low side fitting on
compressor. The suction side can be identified by the
size of the hose connected to the fitting. This will be
the largest diameter hose of the system.
5. Connect the high pressure gauge hose (red hose
and gauge) to discharge or high side fitting on
compressor.
6. Connect yellow supply hose to suction port on
vacuum pump.
7. Open both sides of gauges, low and high, completely.
8. Start vacuum pump to evacuate the complete air
conditioning system.
9. Run vacuum pump for approximately 30 minutes.
Ideal gauge readings should be 29.92 inches of
mercury. The pressure will vary with altitude; it will be
approximately 0.03 bar (0.5 lbf/in) less for each 305 m
(1 000 ft) of elevation.
10. Before disconnecting power supply from vacuum
pump, close both high and low side gauges. Remove
yellow hose from vacuum pump and connect to
R-134a source.
Section 260-0130
SM 1405 Rev 2 11-04 11
11. Open R-134a source. Loosen, but do not remove,
yellow supply hose at manifold on gauges to remove all
air in the yellow supply hose, replacing the air with R-
134a. This is done in a few seconds. Tighten yellow
supply hose.
12. Open low side of R-134a gauges slowly. When
gauge reads zero open both sides completely.
Vacuum in the system will draw R-134a gas into the
system. Hold until both gauge readings equalize.
Note: Never charge with liquid R-134a. Charge on
the low pressure side only.
Final Charging Of The System
1. Start the engine and run at engine idle speed.
2. Turn the air conditioning system on with the
thermostat set on maximum cooling and fan on high
speed.
3. At this point a visual inspection must be made of
the sight glass on top of the receiver-drier. As
charging continues, the sight glass will appear milky
coloured as the bubbles in the system circulate. As
the system continues the charging process, the
regularity of the bubbles in the sight glass will
gradually diminish. When no bubbles are seen in the
sight glass, close the low pressure valve (blue side)
completely.
4. Increase the engine idle speed while observing the
sight glass. If many bubbles are seen resulting from
the increased engine speed, open the low pressure
side valve. Allow the system to continue the charging
procedure until the sight glass is clear. If the sight
glass remains clear, with the increased engine
speed, do not add any more R-134a.
Note: Occasionally bubbles are noticed during clutch
cycling or system start-up. This is a normal condition.
5. With the system completely charged, shut off the
engine. Close the valve on the R-134a canister and
remove the yellow supply hose. Remove both the low
pressure (blue) hose and high pressure (red) hose
from the filling ports on the compressor.
Note: Some R-134a will escape as the hoses are
being removed.
The system is completely charged when;
a. the sight glass is free from bubbles.
b. the suction pressure on the gauge is approx.
20 - 30 psig at 25 C ambient.
c. the correct weight of refrigerant has been added
(3.75 lbs.)
d. the correct superheat can be measured at the
evaporator, approx. 3 - 6 C.
e. the correct sub-cooling can be measured at the
condenser, approx. 5 - 7 C.
6. Replace protective caps on hoses and valve
fittings.
SPECIAL TOOLS
Refer to Section 300-0070, SERVICE TOOLS, for
part numbers of special tools referenced in this
section and general service tools and sealants
required. These tools and sealants are available from
your dealer.
Section 260-0130
SM 1405 Rev 2 11-04 12
AIR CONDITIONING DIAGNOSIS
TABLE158
CONDITION PROBLEM REMEDY
1. Belt Trouble
Slipping
Excessive wear
Loose
Overcharge
Air in system
Pulley not aligned
Belt too tight
Bad idler bearing
Belt wrong width
Adjust belt to 12 mm (0.5 in)
depression
Correct the charge
Evacuate and re-charge
Align Pulley
Adjust or replace
Replace idler bearing
Replace with correct belt
2. Vibration/Noise in Compressor
area
Vibration/noise
Vibration
Noise with clutch engaged
Noise with clutch engaged or
disengaged
Noise
Chatter/Knock
Stuck compressor or clutch
Overcharge
Air in system
Compressor mounting or belts loose
Drive pulley loose
Belt tension incorrect
Faulty compressor
Faulty clutch bearing
Clutch loose
Clutch rubbing field coil
Faulty belt
Compressor oil level low
Valve plate broken
Replace
Correct the charge
Evacuate system and re-charge
Tighten
Tighten
Correct tension
Replace compressor
Replace bearing
Tighten
Align clutch
Replace belt
Add oil
Repair or replace
Section 260-0130
SM 1405 Rev 2 11-04 13
AIR CONDITIONING DIAGNOSIS (CONT.)
3. Noise - Evaporator
Rubbing/scraping Fan blade or blower Repair or replace
Hissing Low charge/leak Correct charge/repair leak
Chatter/knocking Expansion valve Replace
Noisy case Loose brackets/screws Tighten
Motor squeal Dry bearings Replace
4. Air Conditiong Inadequate
After Short Period of Operation
Cooling quits Loss of refrigerant Charge system/check for leaks
Moisture in system Replace drier
Thermostat Replace thermostat
Clutch Check pull-in of clutch or replace
Cooling intermittent Moisture in system Replace drier
5. Electrical Trouble
Blower motor or condenser fan Defective circuit breaker or bad Replace. Clean and tighten
motor inoperable wiring connections connections
Tight motor bearing Repair or replace motor
Switch open or shorted Repair or replace switch
Slow running blower Shaft binding Replace motor - worn bearings
Wheel misaligned Replace
Bad blower switch Replace blower
Insufficient current Install larger alternator
Clutch inoperable Defective circuit breaker Replace
Loose connection Clean and tighten connection
Broken wire - ground Repair wire
Shorted or open field Replace field
Section 260-0130
SM 1405 Rev 2 11-04 14
* * * *
AIR CONDITIONING DIAGNOSIS (CONT.)
6. Air Conditiong System
Trouble - Gauges must be
connected
High head pressure Overcharge of refrigerant Purge system as necessary
Air in system Evacuate and re-charge
Condenser clogged Clean condenser
Low head pressure Undercharge of refrigerant Complete charge
Bad compressor valve plate or Repair or replace
gasket
Restriction in drier Replace drier
Low suction pressure Restriction in lines Clean lines
Restriction in expansion valve Replace expansion valve and drier
Improper expansion valve in charge Replace expansion valve
Refrigerant leak Inspect lines and fittings. Tighten,
repair or replace
Section 270-0010
SM 1406 Rev 2 12-04 1
1
1
9
8
14
15
23
24
25
26
27
28
29
30
31
32
22
21
20
16
17
18
19
5
7
3
2
4
33
35
34
10
1
13
12
11
9
8
6
BODY - Body and Mounting
SM - 3371
1 - Body
2 - Bushing
3 - Body Hinge Pin
4 - Shim
5 - Bolt
6 - Washer
7 - Grease Fitting
8 - Bolt
9 - Washer
10 - Body Pad
11 - Shim
12 - Shim
13 - Locknut
14 - Spacer
15 - Plate
16 - Plate
17 - Bracket
18 - Plate
19 - Proximity Switch
20 - Bolt
21 - Washer
22 - Locknut
23 - Bolt
24 - Washer
25 - Cover Plate
26 - Body Prop
27 - Washer
28 - Locknut
29 - Bolt
30 - Nut
31 - Bolt
32 - Pin Assembly
33 - Chain
34 - Pin Spring
35 - Pin Assembly.
Fig. 1 - Body and Mounting
DESCRIPTION
The standard body is an all welded construction with all
wear plates fabricated from high hardness
(min. 360 BHN) 10 150 bar (145 000 lbf/in) yield
strength material. Angled lower body sides reduce
body impacts when loading and a tailshute angle of
25 provides good load retention when travelling
without a tailgate. Refer to Section 000-0000,
GENERAL INFORMATION for body capacities.
The body is pivoted at the rear of the trailer frame and
is operated by two single stage, double acting body
cylinders which are cushioned at both ends of the
stroke to reduce impact shocks. The body cylinders
raise the body to a tipping angle of 65 in
16 seconds and powerdown the body in 12 seconds.
OPERATION
A body control joystick, mounted on the right hand
dash panel, actuates the body control valve by means
of electrical signals to the solenoid valves, which in
turn operate the body hoist cylinders. The four
operating positions of the joystick from front to rear are
as follows:
'FLOAT' - The joystick should be moved to this
position while the body is lowering by gravity and
should remain in this position until the body must be
operated again. The control joystick should always be
kept in 'FLOAT' while the machine is in motion.
'LOWER' - Pushing the joystick forward and holding it
in this position provides hydraulic force to power-down
the body. It is needed when the body cannot be started
Section 270-0010
Body - Body and Mounting
SM 1406 Rev 2 12-04
2
switch the 'Off' position.
3. Remove upper pins securing the body cylinders to
body (1) and secure body cylinders clear of the body.
4. Using suitable lifting equipment, sling body (1)
assembly at the four lifting points and take an initial
strain.
Note: Approximate weight of body (1) assembly is
5 400 kg (11 905 lb).
5. Remove bolts (5) and washers (6) securing body
hinge pins (3) through body (1) and pin mounting
bores.
6. Remove body hinge pins (3) and shims (4) from
body (1) and remove body (1) assembly from the
vehicle. If necessary, remove bushing (2) from pin
mounting bores.
Note: Do not remove body pads (10) and shims (11 &
12) unless body pads are being replaced.
7. If required, remove locknuts (13), washers (9) and
bolts (8) securing body pads (10) and shims (11 & 12)
to body (1) assembly. Remove and discard body pads
(10) and shims (11 & 12).
INSTALLATION
WARNING
damage, be sure wheel chocks and lifting
1. If removed, install bushing (2) to pin mounting
bores.
2. Using suitable lifting equipment, sling body (1)
assembly and position over the trailer frame.
Note: Approximate weight of body (1) assembly is
5 400 kg (11 905 lb).
3. Align body hinge pin (3) bores in body (1) with bores in
downward from the fully raised position by gravity.
When the body starts lowering by gravity, the joystick
can be released and internal valve springs will move
the joystick to the 'HOLD' position.
'HOLD' - Moving the joystick to this position while the
body is being raised or lowered traps the oil in the
body hoists to stop and hold the body at any desired
height. The joystick will remain in the 'HOLD' position
when released.
'RAISE' - Pushing the joystick back and holding it in
this position directs oil to extend the body hoists and
raise the body. When released, the joystick will be
spring-returned to the 'HOLD' position.
Note: The body control lever must remain in the
'FLOAT' position until it is necessary to operate the
body again. Failure to comply to this could result in
overheating the hydraulic oil and failure of the
hydraulic system components.
Note: A proximity sensor (19) prevents the body (1)
being fully powered down onto the chassis. At a
predetermined height, the sensor automatically
defaults the body control valve to the detented
'FLOAT' condition.
Note: If the body-up warning light goes out while the
body is being raised, the 'POWER DOWN' operation
will not be available and the body control valve will
automatically default to the detented 'FLOAT'
condition. The cause of the electrical fault must be
investigated and corrected.
REMOVAL
WARNINGS
damage, be sure wheel chocks and lifting
Exercise extreme caution when lowering
the cylinders from the body. The cylinders will
swing out sharply as they leave their
mountings.
Section 270-0010
SM 1406 Rev 2 12-04 3
the trailer frame. Install body hinge pins (3) and shims (4)
and secure with bolts (5) and washers (6).
4. Secure body cylinders to body (1) assembly with
pins and mounting hardware removed during removal.
5. Lubricate body hinge pins (3) and body cylinder pins
with lubricant specified in Section 300-0020,
LUBRICATION SYSTEM. Lubricate slowly until
6. If removed, install body pads (10) and body guide
plates (15) on body (1) as described under 'Body
Shimming Procedure'.
7. Remove lifting equipment from body (1) and wheel
chocks from all road wheels.
8. Start the engine and check for correct operation of
body (1) assembly.
BODY SHIMMING PROCEDURE
Note: When it becomes necessary, body pads (10)
should be replaced as a set to maintain load
distribution along the chassis. Existing body pads will
have taken a compression 'set' and a new pad
shimmed to match existing pads will not carry its share
of the load, resulting in uneven load distribution along
the chassis.
1. Raise body (1) clear of the trailer frame and lay body
pads (10) (metal face down) roughly in position on the
frame.
2. Lower body (1) onto body pads (10).
3. Centralise body (1) to the frame and place shims
(11 & 12) under the front two body pads (10) until all
other pads are clear of body (1).
4. Slide shims (11 & 12) under the other body pads
(10) until they just make contact with body (1).
5. Raise body (1) and install body pads (4) and shim
packs (11 & 12) to their relative brackets on body (1)
securing with bolts (8), washers (9) and locknuts (13).
6. Lower body (1) and check shimming.
7. Install body guide plates (15) with spacers (14) to
mounting brackets on body (1) setting gap between
plate (15) and the frame at 5 - 10 mm (0.2 - 0.4 in).
Secure plate (15) and spacers (14) to mounting
brackets with bolts (8) and washers (9).
MAINTENANCE
Every 50 Hours: Lubricate body hinge pins and body
cylinder pins with lubricant specified in Section
300-0020, LUBRICATION SYSTEM. Lubricate slowly
until excess lube is seen.
Body - Body and Mounting
* * * *
Section 300-0020
SM 2129 Rev 4 06-05 1
MISCELLANEOUS - Lubrication System
LUBRICATION AND SERVICE
WARNING
These vehicles are equipped with engine and
transmission oil pans which permit operation at
maximum gradeability as designated in the
'Performance Data' section of the relevant Sales
Specification Sheet.
Lubrication is an essential part of preventive
maintenance. It is important that the instructions
regarding lubricant specifications, and the frequency of
their application, be followed to prolong the useful life
of the vehicle. Periodic lubrication of moving parts
reduces to a minimum the possibility of mechanical
failures.
All change periods are recommendations based on average
operating conditions. Lubricants showing evidence of
excessive heat, oxidation or dirt should be changed more
frequently to prevent these conditions.
Lubricant change and service periods must be
established on the basis of individual job conditions
utilizing oil sampling and recommendations from
lubricant suppliers.
Thoroughly clean all fittings, caps, plugs etc., to
prevent dirt from entering any system while carrying
out servicing procedures. Lubricants must be at normal
operating temperature when draining.
Note: Do not operate any system unless oil level is
within the recommended operating levels as indicated
on oil level dipstick, sight gauge or level plug.
Small circles on the following illustration represent
points at which lubrication and/or servicing must take
place, at the intervals indicated on the left hand side of
the lubrication and service chart.
The numbered circles on the illustration contain
reference numbers which correspond to the reference
numbers in the 'Ref. Points' column of the lubrication
and service chart.
SAFETY PRECAUTIONS
Do not allow unauthorized personnel to service or
maintain this vehicle. Study the Operators Handbook
and Maintenance Manual before starting, operating or
servicing this vehicle. Always follow procedures and
safety precautions detailed throughout this manual.
Always attach a DO NOT OPERATE or similar warning
sign to the ignition switch or a prominent control before
cleaning, lubricating or servicing the vehicle.
Never allow anyone to work on the vehicle while it is
moving. Make sure there is no one on the vehicle
before working on it.
Do not work under or near an unblocked or unsupported
body. Always use the body prop. The body prop must only
be used when the body is empty.
Always install the steering lock bar before making
adjustments or servicing the vehicle with the engine
running.
Do not work under or near any unblocked or
unsupported linkage, part or vehicle.
Always relieve pressure before servicing any
pressurized system. Follow the procedures and safety
precautions detailed in the relevant Maintenance
Manual section.
When changing oil in the engine, transmission and
hydraulic system, or removing hydraulic lines,
remember that the oil may be hot and can cause burns
to unprotected skin.
When working on or around exhaust components,
remember that the components may be hot and can
cause burns to unprotected skin.
Always deflate the tyre before trying to remove any
embedded objects or removing the tyre and rim
assembly from the vehicle.
Always use a self-attaching chuck with a long airline,
and stand to one side while inflating the tyre. Refer to
Section 160-0050, WHEEL RIM AND TYRE.
Miscellaneous - Lubrication System
Section 300-0020
SM 2129 Rev 4 06-05
2
18 8 25 17 35 34 9 15
26
37 36 7 23 21 14 33 16 32 27 20
22
21 2 21
19
14 20
19
19
20 14
14
19
14
13
13
12
12
22 28 11 10 24
22 3 21
22
21 10 11 29 31 30 21 21 20
19 22 5 4
1 6
38
21 22
19
11 39
39
40
SM - 3461
Lubrication and Servicing Points
LUBRICATION AND SERVICE CHART
Interval Ref. No. of Service
Hours Points Identification Service Instructions Points Lubricant Quantities
1 Engine Check oil level. Add if low. 1 EO As required
2 Transmission Check oil level. Add if low. 1 EO As required. See Note 3
3 Hydraulic Tank Check oil level. Add if low. 1 HO As required
38 Brake Coolant Tank (TA40 only) Check oil level. Add if low 1 HTO As required
4 Hydraulic Oil Filter Indicator Check. Replace element if required. 1
6 Radiator Top Tank Check coolant level. Add if low. 1
8 Fuel Tank Check fuel level. Add if low. 1 As required
10 - Fuel Lines Check for leaks.
- Turbocharger Check for leaks.
- Hydraulic Systems Check for proper operation.
9 Air Filter Restriction Gauge Check. Replace element if required. 1
- Air Cleaner Vacuator Valve Check for proper operation. 1
- Tyres Check condition and pressure. 6 Refer to Page 3
- Transmission Oil Gauge Check temperature readings.
- General Check for debris, leaks and damage.
28 Oscillation Bushes Lube. 2 EP, NLGI See Note 1
12 Suspension Beam Lube. 6 EP, NLGI See Note 1
and Panhard Bushings
13 Body Hinge Pins Lube. 2 EP, NLGI See Note 1
14 Wheel Rim Nuts (TA40) Check torque. 138 540 Nm (400 lb ft)
14 Wheel Rim Nuts (TA35) Check torque. 138 730 Nm (540 lb ft)
50 15 Cab Ventilation Filter Inspect and clean if required.
18 Drive Belts Check tension. Adjust if required. See Engine Manual
- Battery Electrolyte Check level. Add if low. 2 As Required.
150 - Engine Air Cleaner Check. Clean inlet screen. 1 - -
1 Engine Drain oil and refill. 1 EO See Page 13
7 Radiator Clean and inspect radiator fins. 1 See Note 6
8 Fuel Tank Drain water and sediment from tank. 1 - -
10 Steering Cylinder Pins Lube. 4 EP, NLGI See Note 1
250 11 Body Cylinder Pins Lube. 4 EP, NLGI See Note 1
17 Engine Oil Filters Replace. 3 EO See Page 13
- Transmission Breather Clean if required. 1 - -
19 Wheel Planetaries Check oil level. Add if low. 6 EPL As required
Section 300-0020
SM 2129 Rev 4 06-05 3
Note: Use 'Lubrication and Service Chart' in conjunction with 'Notes on Lubrication and Service Chart' and
'Miscellaneous Servicing' contained on the following pages.
LUBRICATION AND SERVICE CHART (Continued)
Interval Ref. No. of Service
Hours Points Identification Service Instructions Points Lubricant Quantities
20 Differentials Check oil level. Add if low. 3 EPL & LZ As required
23 Primary Fuel Filter Replace. 1
24 Secondary Fuel Filter Replace. 1
250 28 Oscillation Pivot Check end float. Adjust if required. 2
30 Parking Brake Slack Adjuster Lube 1
31 Parking Brake Pads Check wear. Replace/adjust if required. 2
- Service Brake Pads (TA35) Check wear. Replace if required 12
36 Fuel Cooler Clean and inspect cooler fins. 1 See Note 6
37 Charge Air Cooler Clean and inspect cooler fins. 1 See Note 6
25 Coolant Filter Replace 1
- Coolant Inhibitor Check inhibitor concentration.
26 Water Pump Inspect drain hole. Clean if required 1
500 - Engine Mounting Bolts Check torque. 4 265 Nm (195 lb ft)
- Transmission Mounting Bolts Check torque. 4 Front 300 Nm (220 lb ft)
Rear 265 Nm (195 lb ft)
- Engine Crankcase Pressure Check and record.
750 5 Hydraulic Oil Filter Clean housing and replace element. 1
- Engine Air Cleaner Replace element
- Alternator Check terminals and wiring.
2 Transmission Drain oil and refill. 1 EO See Page 13
8 Fuel Tank Replace cap filter/cartridge. 1
15 Cab Ventilation Filter Replace. 1
19 Wheel Planetaries (TA35) Drain oil and refill. 6 EPL See Page 13
20 Differentials (TA35) Drain oil and refill. 3 EPL & LZ See Note 4
27 Articulation Bearing Lube. 2 EMS19057 See Note 2
1 000 29 Driveshaft Bearings Check oil level. Add if low. 1 EPL To fill plug. See Note 5
32 Transmission Oil Filters Replace. 2
33 Transmission Internal Oil Filter Clean. 1
38 Brake Coolant Tank (TA40 only) Drain oil and refill.Change filter/breather 1 HTO See Page 14
38 Brake Coolant Tank Breather Replace 1 TA40 Only
- Exhaust System Check for leaks. Repair if damaged.
- Crankcase Breather Clean. 1
- Door Hinges Lube. 2 EP, NLGI See Note 1
- Service Brakes (TA40) Check wear indicator pins 6
1 Engine Steam clean 1
7 Radiator and Cooling System Drain, flush and refill. Coolant See Page 13
2000 21/22 Drivelines (Low Maintenance) Check for leaks and damage. - - See Page 12
27 Articulation Pivot Nut Check torque 1 1 425 Nm (1 050 lb ft)
36 Fuel Cooler Strip, clean and inspect 1
37 Charge Air Cooler Strip, clean and inspect 1
18 Drive Belts Replace all belts.
40 OCDB Filter Replace.
2 250 3 Hydraulic Tank Drain oil and refill. 1 HO See Page 13
- Suction Screens and Strainers Clean. 2
4 000 - Thermostats and Seals Replace.
6 000 34 Engine Oil Cooler Strip, clean and inspect. 1
35 Transmission Oil Cooler Strip, clean and inspect. 1
Section 300-0020
SM 2129 Rev 4 06-05
4
MISCELLANEOUS SERVICING
WHEN REQUIRED
Seat Belts - Inspect for damage and replace if
required.
Note: Replace seat belts at least once every three
years, regardless of appearance.
Windscreen Wipers and Washers - Inspect wiper
blades and replace if damaged. Top up washer
reservoir.
Wheel Rim Nuts (Dana Axles) - After first 10 hours
of operation re-torque nuts to 540 Nm (400 lbf ft).
Check torque every 50 hours (weekly) thereafter.
Wheel Rim Nuts (ZF Axles) - After first 10 hours of
operation re-torque nuts to 730 Nm (540 lbf ft).
Check torque every 50 hours (weekly) thereafter.
EVERY 10 HOURS OF OPERATION (DAILY)
Walk Around Inspection - Inspect the vehicle as
described in Section 4 of the Operator's Handbook.
Engine - Visually check engine for damage, loose or
frayed belts and listen for any unusual noises.
Engine Air Cleaner - Change air cleaner element
only when the yellow band of the air restriction
gauge locks up in the orange. Service vacuator
valve daily. Inspect and remove any obstructions
from the vacuator valve lips which should be open
and pliable with the engine stopped.
Note: Service air cleaners more often when
operating under extremely dusty conditions.
Engine Crankcase - Check oil level and add if low.
To allow checking before starting as well as
immediately after shutting down the engine, the oil
dipstick is provided with two types of marks:
1. Dot Marks - Before starting up after a major shut
down period the oil level should be up to the top dot
mark (Cold level).
2. Dash Marks - Upon shutting down the engine at
low idling (wait 1 to 2 minutes) the oil level should be
up to, but not over, the top dash mark (Hot level).
Transmission - Check oil level and add oil if low.
Refer to Section 120-0010, TRANSMISSION AND
MOUNTING, for correct oil level check procedure.
Hydraulic Tank - Check oil level and add oil if low.
With the engine off and body down the oil should be
visible in the bottom of the top sight gauge.
Notes on 'Lubrication and Service Chart'
Note - Capacities given are approximate - work to
dipstick, sight gauges or level plugs.
Note 1 - Lubricate slowly until excess lube is seen.
Note 2 - Remove plugs and fit lube fittings. Lubricate
slowly until excess lube is seen. Remove
fittings and refit plugs.
Note 3 - Check with the engine idling and the
transmission at its normal operating
temperature.
Note 4 - When refilling centre axle ensure that 3rd
differential unit is primed with 1 litre (1.75 UK
pints) of oil before filling drive head.
Note 5 - Remove plug from port on underside of
oscillation hub. Plug is removed to drain the
cavity of any oil that enters the cavity when
filling. Remove grommet and level plug on
side of oscillation hub. Add oil if required.
Refit all plugs.
Note 6 - Clean radiator, condenser and cooler fins
more often when operating under extremely
dusty conditions.
EO - Engine Oil. Refer to 'Recommended
Lubricants'.
* - Refer to chart under 'Recommended
Lubricants'.
HO - Hydraulic Oil. Refer to 'Recommended
Lubricants'.
EPL - Extreme Pressure Lubricant specification
MIL-L-2105 D.
EP, NLGI - Extreme Pressure, Lithium No. 2
Grease (which may, or may not,
contain Molybdenum).
*EP, NLGI - Extreme Pressure, Lithium No. 2
Grease (without Molybdenum).
EMS19057 - Extreme Pressure, Lithium Complex
Grease. Refer to 'Recommended
Lubricants'.
HTO - Hydraulic Transmission Oil. Refer to
'Recommended Lubricants'.
LZ - Lubrizol 6178
PAG Oil - Polyalklene Glycol (PAG) Compressor
Lubricating Oil - Low Viscosity (ISO46).
Section 300-0020
SM 2129 Rev 4 06-05 5
necessary. Test for proper function.
Note: This service interval applies to normal driving.
Check the pins more frequently under more severe
conditions. In the fully worn plate condition the indicator
pin is flush with the bottom of the counterbore.
Parking Brake - Check pads and discs for wear and
replace where necessary. Test for proper function.
Check the pads more frequently under more severe
conditions. Thickness of pad friction material should
never be allowed to wear below 3 mm (0.12 in).
Oil Can Points - Oil working parts with engine oil.
EVERY 1 000 HOURS OF OPERATION (6 MONTHS)
Transmission - Drain oil, replace remote mounted
filters, clean internal filter and finger magnet. Refill
transmission.
Hydraulic Oil Filter - Clean filter housing and install
new element when indicated, or after 1 000 hours of
operation, whichever comes first.
Brake Coolant Tank (TA40 only) - Drain oil, replace
filter and breather. Refill brake coolant tank.
Axles (ZF) - Drain lubricant and refill to level plug.
Note: When refilling centre axle ensure that 3rd
differential unit is primed with 1 litre (1.75 UK pints)
of oil before filling drive head.
Parking Brake - Check pads and disc for wear.
Adjust or replace if required. Test for proper function.
Thickness of pad friction material should never be
allowed to wear below 3 mm (0.12 in).
Articulation Vertical Bearings - IMPORTANT -
Use only grease which conforms to EMS19057
specification. Remove plugs and fit lube fittings.
Lubricate slowly until excess lube is seen. Remove
lube fittings and refit plugs.
Driveshaft Bearings - Remove plug from port on
underside of oscillation hub. Plug is removed to drain
the cavity of any oil that enters the cavity when filling.
Remove grommet and level plug on side of oscillation
hub. Add oil if required. Refit all plugs.
Grease Points - Grease door hinges.
EVERY 2 000 HOURS
Drivelines - Visually check Low Maintenance
drivelines for leaking or damaged seals.
Brake Coolant Tank (TA40 only) - Check oil level
and add if low.
Radiator - Check coolant level and add if low. Fill the
radiator header tank with coolant until coolant
reaches the bottom of the filler neck and holds at
that level.
Note: Any time a significant amount of coolant is
added, the coolant inhibitor MUST be checked. If the
concentration is low, engine damage will result.
Conversely, over-inhibiting antifreeze solutions can
result in silicate dropout. Refer to Section
210-0000, COOLING SYSTEM.
AFTER FIRST 100 HOURS OF OPERATING NEW OR
REBUILT COMPONENTS
Transmission - Drain oil, replace remote mounted
filters, clean internal filter and finger magnet. Refill
transmission.
Differentials - Drain lubricant and refill to level plug.
Planetaries - Drain lubricant and refill to level plug.
Hydraulic Oil Filter - Clean filter housing and install
new element at 100 hours of operation, or when
indicated, whichever comes first.
Note: A 6 micron filter is used to flush the system.
This is replaced with a 12 micron filter for normal
use. See vehicle Parts Book for filter part numbers.
Brake Cooling Oil Filter (TA40 only) - Clean filter
within brake coolant tank after 100 hours of
operation.
EVERY 250 HOURS OF OPERATION
General Inspection - Check entire vehicle for leaks,
loose bolts and nuts or damaged parts. Examine the
vehicle, particularly the chassis, for cracks or broken
welds. Repair where necessary.
Service Brakes (TA35) - Check pads and discs for
wear and replace where necessary. Test for proper
function.
Check the pads more frequently under more severe
conditions. Thickness of pad friction material should
never be allowed to wear below 3 mm (0.12 in).
Service Brakes (TA40) - Check indicator wear pins
for signs of wear and replace friction plates where
Section 300-0020
SM 2129 Rev 4 06-05
6
Note: Low Maintenance drivelines can be identified
by having plugs fitted to the spiders, not grease
nipples.
Note: When service is required, remove plug and fit
grease nipple. Grease spider and refit plug when
finished. Use Type K lubricating grease in
accordance to DIN 51825-KP2-K-40.
Axles (Dana) - Drain lubricant and refill to level
plugs.
Hydraulic Oil Tank - Drain oil, remove and clean
suction screens and strainers. Reinstall suction
screens and strainers and refill hydraulic oil tank.
ENGINES AND TRANSMISSIONS
All information contained in the 'Lubrication and Service
Chart' was extracted from the relevant manufacturers
Operators Manual and was correct at time of publication.
User should ensure that information contained in this
chart, regarding Engines and Transmissions, reflects the
information shown in the relevant manufacturers
Operators Manuals supplied with the vehicle.
Maintenance procedures should be carried out in
conjunction with any additional procedures contained in
the relevant manufacturers 'Operation and Maintenance
Manual', at the intervals specified.
RECOMMENDED LUBRICANTS
COMPONENT LUBRICANT *CAPACITY SPECIFICATIONS API CODE SAE GRADE
Engine Engine Oil with 1.00% 37 litre MIL-L-2104 F CG-4 15W-40
(Including Filters) sulphated ash limit is (9.8 US gal) or CF-4
recommended. Sulphated ash
must not exceed 1.85% limit
Transmission Engine Oil with 1.85% 56 litre MIL-L-2104 C/D/E CD, CE, CF, See Trans.
(Including Filters) max. sulphated ash limit (14.8 US gal) MIL-L-46152 C/D/E SF & SG Oil Table.
(dry fill) (See Note 1)
Transmission Engine Oil with 1.85% 28 litre MIL-L-2104 C/D/E CD, CE, CF, See Trans.
(Including Filters) max. sulphated ash limit (7.4 US gal) MIL-L-46152 C/D/E SF & SG Oil Table.
(wet fill) (See Note 1)
Hydraulic System Hydraulic Transmission Oil 209 litre See Hydraulic Oil Table
(Including Lines) (55 US gal) (See Note 2)
Cooling System Anti-freeze, Ethylene 80 litre
Glycol (21.1 US gal)
Differential - Dana Extreme Pressure 37.5 litre each MIL-L-2105 D GL-5 80W-90 LS
(Front) Gear Lubricant (9.9 US gal) (See Note 3)
Differential - Dana Extreme Pressure 38 litre MIL-L-2105 D GL-5 80W-90 LS
(Centre) Gear Lubricant (10 US gal) (See Note 3)
Differential - Dana Extreme Pressure 31.5 litre MIL-L-2105 D GL-5 80W-90 LS
(Rear) Gear Lubricant (8.3 US gal) (See Note 3)
Planetaries - Dana Extreme Pressure 8.5 litre each MIL-L-2105 D GL-5 80W-90 LS
Gear Lubricant (2.2 US gal) (See Note 3)
Differentials - ZF Extreme Pressure 31 litre each MIL-L-2105 D GL-5 80W-90 LS
(Front,Centre,Rear) Gear Lubricant (8.2 US gal) (See Note 3)
Planetaries - ZF Extreme Pressure 9 litre each MIL-L-2105 D GL-5 80W-90 LS
Gear Lubricant (2.4 US gal) (See Note 3)
Fuel Tank Diesel Fuel Oil with 463 litre DIN EN590
max. sulphur 0.5% (122 US gal)
Grease Nipples** Extreme Pressure No.2
Lithium Grease Consistency
Driveshaft through Extreme Pressure 1.50 litre MIL-L-2105 D GL-5 80W-90
Bearings Gear Lubricant (0.40 US gal)
Articulation Extreme Pressure EMS 19057
Bearings Lithium Complex
Air Conditioning Polyalklene Glycol (PAG) 0.125 litre ISO46
Compressor Compressor Lubricating Oil - (0.033 US gal) SP 10
Low Viscosity
Brake Cooling Hydraulic Transmission Oil 199 litre MIL-L-2104 E CF,CD,SF
System (TA40 only) (52.6 US gal) MIL-L-46152 B/C
Section 300-0020
SM 2129 Rev 4 06-05 7
LUBRICANT GRADE SELECTION GUIDE AT AMBIENT (START-UP) TEMPERATURE
SM - 637
* - Capacities given are approximate, work to dipstick,
sight gauges or level plugs.
** - Refer to the 'Lubrication and Service Chart' for the
different applications. DO NOT use on the Articulation
bearings.
Note 1 - Operation below the minimum temperatures
listed for the oil used without proper pre-heat or
warm-up results in greatly reduced transmission life.
Proper warm-up requires 20 minutes minimum
operation in neutral (with engine at part throttle) before
operating the transmission in gear.
HYDRAULIC OIL
TRANSMISSION OIL
(See Note 4)
Note - Consult your lubricant supplier for correct viscosity of lubricant when ambient temperatures are
consistently above or below those listed.
* * * *
SM - 639
Note 2 - Hydraulic Transmission Oil meeting
Specification EMS19058 is also suitable for use in the
hydraulic system.
Note 3 - Axles have limited slip differentials. If use of a
standard SAE 90 oil results in very loud noise and
jerking of the wheels when driving slowly round sharp
corners, an EP oil with limited slip additives should be
used.
Note 4 - Automatic Transmission Fluids (ATF) may
only be used when the ambient temperature is less
than - 10C (14F). Should the temperature increase,
it is necessary to switch to engine oil.
ENGINE OIL
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
Section 300-0070
SM 2277 Rev 1 11-04
1
MISCELLANEOUS - Service Tools
INTRODUCTION
Contained in this section are recommended service
tools and equipment required for maintenance, overhaul
and troubleshooting. In certain instances, both Metric
and Imperial equivalents of the same tools are listed.
Note: The Company reserves the right to make
changes in the design or construction of tools and
equipment without obligation to incorporate such
changes in tools and equipment previously sold.
Note: A tool may be of one piece construction or
consist of a number of parts.
General
*15269784 - Multi-Gauge - Pressure range of 30 in of
vacuum to 5 000 lbf/in
15269785 - Non-contact Infrared Thermometer
15268968 - Strap Type Filter Wrench
15268969 - Socket Type Filter Wrench
15268970 - Universal Belt Tension Gauge
15270180 - Belt Tension Gauge - Poly 'V' Belt
15269858 - Digital Tachometer
15269859 - Multimeter
15269813 - Water Manometer
15269802 - Dial Indicator Gauge - Metric
15269803 - Dial Indicator Gauge - Imperial
15269804 - Magnetic Base for Dial Indicator Gauge
15269805 - Micrometer - 0 to 25 mm
15269806 - Micrometer - 0 to 1 in
15269809 - Internal Micrometer - 50 to 210 mm
15269810 - Internal Micrometer - 2 to 8 in
15269860 - 92 Piece Heavy Equipment Tool Kit
15269861 - Torque Wrench - 3/8 in drive,
20 - 100 Nm (15 - 80 lbf ft) range
60 - 330 Nm (45 - 250 lbf ft) range
4 - 20 Nm (40 - 180 lbf in) range
300 - 1 000 Nm (200 - 750 lbf ft) range
700 - 1 500 Nm (500 - 1 000 lbf ft) range
15269866 - Torque Multiplier - 1/2 in to 1 in drive,
25:1 Ratio, 3 000 Nm (2 200 lbf ft) range
* - The following items should be added to the
multi-gauge to enable the gauge to be used on
diagnostic test points:
15018226 - Diagnostic Coupling
00118748 - Connector (2 off)
15004085 - Hose Assembly (-4 HP, 84 in long)
Series 60 Engine
DDEC IV Electronic Diagnostic
15275098 - Detroit Diesel Multi Kit, consisting of PRO-
LINK Diagnostic Data Reader and cables,
Detroit Diesel 6 pin Adaptor Cable and
Multi-Cartridge.
15273793 - Detroit Diesel Diagnostic Link (Diskette)
15273794 - Detroit Diesel Diagnostic Link (CD)
15269239 - High Impedance Digital Multimeter Kit
15270271 - Diagnostic Jumper Wire Kit
15273795 - DDEC Repair Kit
15270310 - Detroit Diesel 6 pin Adaptor Cable
15269038 - Portable Printer for use with DDR,
complete with 110 V AC Adaptor
15269039 - Portable Printer for use with DDR,
complete with 220 V AC Adaptor
15269040 - Printer Paper for use in above
printers - 5 rolls
15275096 - DDEC III/IV Card
15273084 - Multi-Cartridge
15268971 - PRO-LINK Diagnostic Data Reader and
cables
The following tools are recommended for Engine
Maintenance Procedures. These tools should be used
in conjunction with procedures outlined in the Series 60
Engine service manual.
Cylinder Block
15270266 - Cup Plug Driver Set
15270305 - Handle
15270303 - Cylinder Block Pressure Test Kit
15270255 - Cylinder Liner Installation Tool
15270275 - Cylinder Liner Removal Tool
15270289 - Dowel Installation Tool
15270286 - Dowel Remover/Installer (No. 6 Main
Bearing Saddle)
15270260 - Engine Cylinder Block and Stand Adaptor
Plates
15270253 - Eye Bolts - Block Lifting
15270273 - Guide Studs - Bull Gear/Flywheel Housing
15270272 - Guide Studs - Cylinder Head
15270290 - Guide Studs - Flywheel/Crankshaft Pulley
15270285 - Guide Studs - Gear Case/Exhaust
Manifold
15270274 - Guide Studs - Oil Cooler Housing
15270287 - Main Bearing Remover/Installer
Cylinder Head
15270293 - Cup Plug Installer - Rocker Shaft
15270261 - Cylinder Head - Engine Stand Adaptor
15270262 - Cylinder Head Lifter Bracket
15270279 - Cylinder Head Pressure Test Kit
15270282 - Socket - Rocker Arm Shaft Stud
15270259 - Pilot; Valve Seat Grinder (Hall-Toledo)
Section 300-0070
Miscellaneous - Service Tools
2
SM 2277 Rev 1 11-04
15270295 - Valve Button Retainer Expander
15270248 - Valve Guide Installer
15270250 - Valve Guide Remover
15270251 - Valve Seat Insert Installer (Exhaust)
15270247 - Valve Seat Insert Installer (Intake)
15270240 - Valve Seat Remover (Exhaust)
15270241 - Valve Seat Insert Remover (Intake)
15270252 - Valve Spring Compressor (head installed)
15270257 - Valve Stem Seal Installer
15270296 - Head Bolt Resurface
15270304 - Injector Timing Tool
15270302 - Rocker Arms and Shaft Assembly
Crankshaft
15270281 - Crankshaft Protector
15270291 - Engine Barring Tool
15270267 - Front/Rear Oil Seal Expander
15270268 - Front/Rear Oil Seal Installer (std. OS and
wear sleeve)
15270309 - Front/Rear Oil Seal Remover
Piston, Piston Rings and Connecting Rod
15270239 - Piston Ring Pliers
15270278 - Connecting Rod Guides
15270288 - Piston/Connecting Rod Holding Fixture
15270276 - Piston, Fire Ring Groove Gauge
(2.5 mm ring)
15270297 - Piston, Fire Ring Groove Gauge
(3.5 mm ring)
15270256 - Piston Ring Compressor
15270294 - Cylinder Kit Lifter
Gear Train
15270284 - Accessory Drive Service Set
15270277 - Camshaft Gear Pilot
15270265 - Camshaft Gear Torque Holding Tool
15270254 - Camshaft/Idler Gear Lash Adjusting Tool
15270263 - Crankshaft Gear/Remover/Installer
15270264 - Gear Case Alignment Plug
15270269 - Water Pump Lash and Impeller Slip
Tester
15270298 - Accessory Drive Gear Lash Tool
15270300 - Water Pump Gear Lash Tool
Fuel System
15270271 - Diagnostic Jumper Wire
15268969 - Fuel Filter Wrench
15270283 - Fuel Pump Gear Installer
15270237 - Fuel Pump Holding Fixture
15270299 - Fuel Pump Service Kit
15269235 - Group I Terminal Removal Tool
15269234 - Group I Terminal Crimping Tool
15270245 - Group II Terminal Removal
15270258 - Group II Terminal Crimping Tool
15269237 - Group III Terminal Removal Tool
15270270 - Group III Terminal Crimping Tool
15269238 - PROM removal Tool
15270307 - Brass Wire Buffing Wheel (Injector
spray nozzle)
15270235 - Oil Seal Installer Handle
15270236 - Oil Seal Installer Adaptor
15270238 - Oil Seal Remover
15270249 - Injector Tube Installation/Removal Tool
Air Intake System
15270243 - Turbocharger Inlet Shield
15270301 - Turbocharger Gauge Arm Tool
15270306 - Dial Indicator Set
Lube System
15270274 - Oil Cooler Housing Guide Studs
15270246 - Band Type Oil Filter Wrench
Cooling System
15270242 - Radiator and Cooling System Pressure
Tester
15270280 - Water Pump Service Tool Kit
15270269 - Water Pump Lash and Impeller Slip
Tester
15270300 - Water Pump Gear Lash Tool
15270308 - Thermostat Seal Installation Tool
15270305 - Handle
15270292 - Fan Hub/Air Compressor Drive Service Kit
Transmission
The following tools are recommended for Transmission
Maintenance Procedures. These tools should be used
in conjunction with procedures outlined in the
transmission manufacturers service manual.
15270087 - Straight Pin
15270195 - Ring
15270196 - Threaded Insert
15270092 - Puller
15270093 - Puller
15270098 - Driver
15270197 - Driver
15270198 - Driver
15270199 - Driver
15270200 - Driver
15270201 - Driver
15270104 - Driver
15270202 - Driver
15270203 - Driver
15270204 - Driver
15270112 - Measuring Pin
15270115 - Set of Eye Bolts
15270205 - Back-off Screws - M10
15270119 - Adjusting Screws - M10
Section 300-0070
SM 2277 Rev 1 11-04
3
15269089 - Oil Seal Bumper Tool
15269090 - Hub Spanner
15272390 - Hub Seal Tool
15500012 - Large Face Seal Insertion Tool
15500013 - Small Face Seal Insertion Tool
15500014 - Plate Centralising Tool
15500015 - Ring Gear Alignment Tool
15500016 - Hub Guide Sleeve
15500439 - Setting Gauge
15271107 - Puller
15269895 - Insert
15269898 - Handle
15275464 - Driver
15269899 - 220V Hot Air Blower
15269900 - 110V Hot Air Blower
15269929 - Lifting Pliers
15269946 - Puller Set
15272560 - Bearing Puller
15270113 - Gauge Blocks
15270132 - Resetting Device
15269948 - Straight Edge
15270114 - Digital Depth Gauge
15269934 - Measuring Shaft
15270120 - Clamping Yoke
15271101 - Back-Up Tool
15270121 - Handle
15500882 - Socket
15500883 - Centering Bracket
15500884 - Wheel Bolt Puller
15500885 - Driver
15500886 - Press Ring
15500887 - Gripping Insert
15500889 - Reducer
15500890 - Socket
15500891 - Socket
15500893 - Shim
15500894 - Shim
15500895 - Torque Spanner
15500896 - Driver
15500897 - Magnetic Stand
15500898 - Dial Indicator
15500899 - Micrometer
15500900 - Adjusting Nut
15500905 - Extractor
15500906 - Puller
15500907 - Fixture
15500908 - Socket
15500909 - Driver
15500910 - Connector Air Compressor
15500911 - Indicator
15500912 - Driver
15501167 - Adjusting Screws
15501168 - Lifting Strap
15501169 - Spring Balance
15270210 - Adjusting Screws - M12 x 1.5
15269899 - Hot Air Blower 220 V
15269900 - Hot Air Blower 110 V
15270211 - Backup Tool
15270120 - Clamping Yoke
15269942 - Handle
15270212 - Hoist
15270213 - Pulling Hook
15270214 - Ring Nut
15270215 - Hoist
15270216 - Internal Puller
15270217 - Backup Tool
15270218 - Mounting Rail
15270127 - Guide Plate
15270131 - Pry Bar
15270219 - Adjusting Spanner
15270220 - Hook Spanner
15270222 - Insert for Torque Spanner
15270223 - Extension
15270224 - Extension
15270227 - Pressing Sleeve
15270228 - Pressing Ring
15270229 - Pressure Piece
15270230 - Backup Ring
15270231 - Test Cover
15270139 - Striker
15270233 - Internal Snap Ring Pliers
15270145 - External Snap Ring Pliers
15270234 - Two Leg Puller
15270149 - Two Leg Puller
15270150 - Three Leg Puller
15270151 - PR-78A Tester
15270311 - Harness
15270153 - Foil
15270725 - PR-68 Tester
15269943 - Spanner
15272559 - Ring Clamp
15272560 - Bearing Puller
15272561 - Bearing Remover
15273664 - AEB Starter
Articulation and Oscillation Pivot
15269101 - Thrust Nut Tool
15270104 - Driver
Axles and Differentials
15269088 - Helical Gear Tool
Section 300-0070
4
SM 2277 Rev 1 11-04
15501170 - Lifting Tackle
15501171 - Sliding Pads
15501172 - Two Armed Puller
15501173 - Support Shim
15501174 - Assembly Fixture
15501175 - Clamping Pliers
15501176 - Spline Mandrel
15501177 - Mounting Tool
15501178 - Lifting Chain
Front Suspension
15269095 - Hydraulic Jack
15269096 - Power Press
15269097 - Press Tool
Steering Valve
15270173 - 'O' Ring and Kin Ring Assembly Tool
15270174 - Driveshaft Mounting Fork
Nitrogen Charging
09359489 - Charging Assembly
Cooling and Air Conditioning
15270181 - Coolant Test Strips
15500709 - Pro Cool Test Strips
15269816 - Refractometer - C Scale
15269817 - Refractometer - F Scale
15269844 - Portable High Vacuum Charging
Station - R-134a Gas
15269845 - Halogen Leak Tester
SM - 407
Dimensions in mm
(inches) Fig. 1 - End Cap Torque Tool (Section 220-0120, STEERING CYLINDER)
DRILL AND REAM THROUGH
AND FIT 12 (0.472)
HARDENED DOWEL
TORQUE PINS 2 PLACES
SECURE ALUMINIUM
COLLAR WITH (3) M8
CAP SCREWS
Cab
15271016 - Glass Removal Tool
15271017 - Bonding Kit (Quick Dry)
Adhesives and Sealants
15269103 - Loctite 221
09362529 - Loctite 225
09029849 - Loctite 243
15500690 - Loctite 262
09244598 - Loctite 270
09985300 - Loctite 271
15269104 - Loctite 275
15269245 - Loctite 277
15233715 - Loctite Prism 406
15269111 - Loctite Prism 410
15269105 - Loctite 515
09007209 - Loctite 574 (50 ml)
09379518 - Loctite 574 (160 ml)
15269106 - Loctite 577 (Superflex)
15270244 - Loctite 592 - Pipe Sealer with Teflon
15023696 - Loctite 635
09371048 - Loctite 638
15269107 - Loctite 641
15269108 - Loctite Superclean Safety Solvent 706
15229541 - Loctite Activator 'N'
09243825 - Loctite Activator 'T'
09175039 - General Adhesive
15269114 - Tectyl 280 Wax Based Rust Preventive
09380475 - Hylosil RTV Silicone Compound
15303808 - Silicon Grease (Dielectric)
Fabricated Tools
The service tools shown in Figs. 1 through 4 can be
fabricated as shown.
Section 300-0070
SM 2277 Rev 1 11-04
5
SM - 408
EN3B
DOM TUBE
S
Q
U
A
R
E
Dimensions in mm (inches)
SILVER STEEL
Fig. 2 - Piston Torque Tool (Section 220-0120, STEERING CYLINDER)
SM - 409
Fig. 3 - End Cap Torque Tool (Section 230-0130, BODY CYLINDER)
FIT (2) B & T BUSH
12 (0.472) ID - 18 (0.708) OD
AND (2) DOWELS 12 (0.472)
ID.
DRIVE FIT DOWEL IN BUSH.
SECURE ALUMINIUM
COLLAR WITH 3 M8
CAP SCREWS
19 (0.75)
SQUARE
DRILL 13
(0.51)
x 25 (0.984)
DEEP
Section 300-0070
6
SM 2277 Rev 1 11-04
* * * *
SM - 410
Fig. 4 - Piston Torque Tool (Section 230-0130, BODY CYLINDER)
SILVER STEEL
EN3B
MILD STEEL
2
5
.
4

(
1
.
0
)
S
Q
U
A
R
E
Section 300-0080
1 SM 1238 2-98
WARNING
Some fasteners are important attaching parts
which could affect the performance of vital
components and systems, and/or, could result
in major repair expense. Fasteners should be
replaced with parts of the same part number,
or with equivalent parts, if replacement
becomes necessary. Do not use replacement
parts of lesser quality or substitute design. The
torque values shown in the following tables
should be used in all cases, unless otherwise
specified elsewhere in this manual, in order to
avoid possible personal injury or property
damage.
The following torque specification tables are based on
GM Standard Materials for bolts, nuts, studs and self-
locking fasteners based on SAE bolt steel
classifications, or, prevailing torque specifications for
self-locking fasteners.
To prevent the threaded bolts and nuts used on this
equipment from being overstressed during assembly,
MISCELLANEOUS - Standard Bolt and Nut Torque Specifications
and to establish a uniform value to which these
fasteners can be safely tightened, the following torque
tables have been compiled.
The torque values listed in the tables have been
established over a period of years and cover all
conditions of assembly. The maximum torque values
for standard bolts and nuts are based on 75% of the
specified minimum proof strength of the bolt steel in
order to provide a safety factor to compensate for the
variation in the accuracy of torque wrenches, skill of
the assembler, and variance in fractional conditions.
All torque values are for lubricated threads. The
term 'lubricated' includes the application of thread
lubricants, cadmium plating or the use of hardened
washers.
To provide a quick method for determining the GM
material classification of a particular standard bolt or
nut, compare the bolt head markings to those in the
appropriate tables, then locate the maximum torque
value for that bolt size in the column under that
marking.
RECOMMENDED MAXIMUM TORQUES (IMPERIAL) 10%
TABLE144
Size
SAE Symbol
GM 260-M Steel
(SAE GR 2)
SAE Symbol
GM 280-M Steel
(SAE GR 5)
SAE Symbol
GM 290-M Steel
(SAE GR 7)
SAE Symbol
GM 300-M Steel
(SAE GR 8)
12 Point Cap
Screws
Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft
0.25 - 20
0.25 - 28
0.31 - 18
0.31 - 24
0.38 - 16
0.38 - 24
0.44 - 14
0.44 - 20
0.50 - 13
0.50 - 20
0.56 - 12
0.56 - 18
0.62 - 11
0.62 - 18
0.75 - 10
0.75 - 16
0.88 - 9
0.88 - 14
1.00 - 8
1.00 - 12
1.00 - 14
5
7
11
12
20
23
33
37
50
56
75
81
102
115
176
203
169
190
258
285
285
4
5
8
9
15
17
24
27
37
41
55
60
75
85
130
150
125
140
190
210
210
8
10
18
19
31
34
47
54
75
88
108
122
149
169
271
298
434
488
651
719
732
6
7
13
14
23
25
35
40
55
65
80
90
110
125
200
220
320
360
480
530
540
11
12
22
24
38
43
59
68
94
106
136
149
190
210
332
366
536
590
800
881
902
8
9
16
18
28
32
43
50
69
78
100
110
140
155
245
270
395
435
590
650
665
12
14
24
27
43
49
68
79
106
122
156
176
217
244
380
420
610
678
915
1 003
1 030
9
10
18
20
32
36
50
58
78
90
115
130
160
180
280
310
450
500
675
740
760
14
15
27
30
49
56
75
87
119
134
171
191
237
270
420
472
679
751
1 021
1 119
1 148
10
11
20
22
36
41
55
64
88
99
126
141
175
199
310
348
501
554
753
825
847
Section 300-0080
Miscellaneous - Standard Bolt and Nut Torque Specifications
SM 1238 2-98 2
RECOMMENDED MAXIMUM TORQUES (IMPERIAL) 10%
TABLE145
Size
SAE Symbol
GM 260-M Steel
(SAE GR 2)
SAE Symbol
GM 280-M Steel
(SAE GR 5)
SAE Symbol
GM 290-M Steel
(SAE GR 7)
SAE Symbol
GM 300-M Steel
(SAE GR 8)
12 Point Cap
Screws
Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft
1.12 - 7
1.12 - 12
1.25 - 7
1.25 - 12
1.38 - 6
1.38 - 12
1.50 - 6
1.50 - 8
1.50 - 12
1.75 - 5
1.75 - 12
1.88 - 8
1.88 - 12
2.00 - 4.5
2.00 - 8
2.00 - 12
2.25 - 4.5
2.25 - 8
2.25 - 12
2.50 - 12
366
407
515
569
664
759
881
936
990
-
-
-
-
-
-
-
-
-
-
-
270
300
380
420
490
560
650
690
730
-
-
-
-
-
-
-
-
-
-
-
800
902
1 132
1 254
1 478
1 688
1 966
2 088
2 217
-
-
-
-
-
-
-
-
-
-
-
590
665
835
925
1 090
1 245
1 450
1 540
1 635
-
-
-
-
-
-
-
-
-
-
-
1 132
1 274
1 600
1 776
2 095
2 393
2 786
2 962
3 145
4 393
5 091
6 006
6 304
6 623
7 342
7 687
9 701
10 629
11 050
15 280
835
940
1 180
1 310
1 545
1 765
2 055
2 185
2 320
3 240
3 755
4 430
4 650
4 885
5 415
5 670
7 155
7 840
8 150
11 270
1 302
1 451
1 830
2 034
2 400
2 739
3 186
3 390
3 593
5 016
5 830
6 874
7 213
7 565
8 406
8 786
11 090
12 148
12 636
17 463
960
1 075
1 350
1 500
1 770
2 020
2 350
2 500
2 650
3 700
4 300
5 070
5 320
5 580
6 200
6 480
8 180
8 960
9 320
12 880
1 447
1 624
2 043
2 267
2 676
3 056
3 556
3 781
4 010
5 604
6 497
7 664
8 048
8 448
9 367
9 811
12 377
13 566
14 102
19 500
1 067
1 198
1 507
1 672
1 974
2 254
2 623
2 789
2 958
4 133
4 792
5 653
5 936
6 231
6 909
7 236
9 129
10 006
10 401
14 383
Types of Steel Rockwell Hardness Range Applicable Torque Values SAE Bolt Head Symbols
Plain Low Carbon
(eg. SAE 1018 or 1020) Rockwell "B" 85-100 GM 260-M
Plain Medium Carbon
(eg. SAE 1035, 1038 & 1045) Rockwell "C" 19-30 GM 280-M
Medium Carbon Alloy
Medium Carbon Alloy
Note: Where materials other than GM Standards are used, refer to the conversion table below.
Section 300-0080
3 SM 1238 2-98
RECOMMENDED MAXIMUM TORQUES (METRIC) 10%
TABLE146
Size
Class 8.8 Class 9.8 Class 10.9 Class 12.9
Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft
M 1.6 - 0.35
M 1.6 - 0.20
M 2.0 - 0.40
M 2.0 - 0.25
M 2.0 - 0.45
M 2.5 - 0.35
M 3.0 - 0.50
M 3.0 - 0.35
M 3.5 - 0.60
M 4.0 - 0.70
M 4.0 - 0.35
M 5.0 - 0.80
M 5.0 - 0.50
M 6.0 - 1.00
M 6.3 - 1.00
M 6.0 - 0.75
M 8.0 - 1.25
M 8.0 - 1.00
M 10.0 - 1.50
M 10.0 - 1.25
M 12.0 - 1.75
M 12.0 - 1.25
M 14.0 - 2.00
M 14.0 - 1.50
M 16.0 - 2.00
M 16.0 - 1.50
M 18.0 - 2.50
M 18.0 - 1.50
M 20.0 - 2.50
M 20.0 - 1.50
M 22.0 - 2.50
M 22.0 - 1.50
M 24.0 - 3.00
M 24.0 - 2.00
M 27.0 - 3.00
M 27.0 - 2.00
M 30.0 - 3.00
M 30.0 - 2.00
M 30.0 - 1.50
M 36.0 - 4.00
M 36.0 - 3.00
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
169
181
234
263
330
367
451
495
571
623
837
903
1 135
1 258
1 300
1 985
2 102
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
122
130
169
190
239
265
325
357
412
450
605
652
820
908
939
1 433
1 517
0.20
0.25
0.25
0.45
0.25
1
1
1
2
3
3
5
6
9
10
10
21
23
42
45
74
81
118
128
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
0.15
0.20
0.20
0.30
0.20
0.75
0.75
0.75
1.5
2
2
4
4
6
8
7
15
17
31
32
53
58
85
92
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
13
12
27
29
54
57
94
103
151
163
234
250
323
363
457
507
623
684
790
861
1 158
1 250
1 570
1 740
1 799
2 745
2 907
-
-
-
-
-
-
-
-
-
-
-
-
-
-
10
9
20
21
39
41
68
74
109
118
169
180
234
262
330
366
450
494
570
622
836
902
1 134
1 256
1 299
1 982
2 099
0.20
0.40
0.45
0.45
0.45
1
2
2
3
4
5
8
9
13
16
14
32
34
63
67
110
121
176
190
274
292
378
425
531
593
728
800
923
1 007
1 354
1 461
1 835
2 034
2 102
3 208
3 398
0.15
0.30
0.30
0.30
0.30
0.75
1.5
1.5
2
3
3
6
6
10
11
10
23
25
46
48
80
87
127
137
197
211
273
307
386
423
526
577
667
727
977
1 055
1 325
1 468
1 516
2 317
2 453
Section 300-0080
SM 1238 2-98 4
SELF-LOCKING FASTENERS
Self-locking fasteners develop a measured gripping
action or torque and provide a renewed locking action
after being removed and reinstalled to their original
mating part. The self-locking fasteners used on this
equipment meet specifications necessary to allow the
fasteners to be reused up to five times. Whenever a
self-locking fastener is removed, the head of the
fastener should be deeply scribed or otherwise
marked to record the number of times the fastener has
been used. Do not use a self-locking fastener more
than five times.
The following table shows the minimum torque
specifications allowed to remove self-locking fasteners
after the initial break-away torque has been achieved.
Any self locking fastener that can be removed with
less than the prevailing torque value shown in the
table should be discarded, even if the fastener has not
yet been reused five times.
MINIMUM PREVAILING TORQUE - REMOVAL
TABLE537
Size
Lockscrews Locknuts
SAE Grade 5 & 8
and ASTM A-574 SAE Grade 5 SAE Grade 8
Nm lbf in Nm lbf in Nm lbf in
0.25 - 20
0.25 - 28
0.31 - 18
0.31 - 24
0.38 - 16
0.38 - 24
0.44 - 14
0.44 - 20
0.50 - 13
0.50 - 20
0.56 - 12
0.56 - 18
0.62 - 11
0.62 - 18
0.75 - 10
0.75 - 16
0.88 - 9
0.88 - 14
1.00 - 8
1.00 - 12
1.00 - 14
0.3
0.3
0.6
0.6
1.0
1.0
1.4
1.4
1.8
1.8
2.5
2.5
3.4
3.4
5.1
5.1
7.3
7.3
9.6
9.6
-
3
3
5
5
9
9
12
12
16
16
22
22
30
30
45
45
65
65
85
85
-
0.4
0.4
0.6
0.6
1.0
1.0
1.4
1.4
1.7
1.7
2.4
2.4
3.1
3.1
4.6
4.6
7.0
7.0
9.5
9.5
9.5
3.5
3.5
5.5
5.5
8.5
8.5
12
12
15
15
21
21
27
27
41
41
62
62
84
84
84
0.5
0.5
0.9
0.9
1.3
1.3
1.8
1.8
2.3
2.3
3.2
3.2
4.1
4.1
6.1
6.1
9.3
9.3
12.7
12.7
12.7
4.5
4.5
7.5
7.5
11.5
11.5
16
16
20
20
28
28
36
36
54
54
82
82
112
112
112
* * * *
1
Section 300-0090
SM 1239 2-98
GENERAL
The storage of machines for short periods of time or
during the off-season is an important item if major
damage to components is to be avoided. Failure to
take the necessary steps to protect the various
assemblies while the machine is being stored can
result in an expensive overhaul job and delay in
returning the machine to work.
TEMPORARY STORAGE
When storing a machine for a period of 30 days or less,
the following precautions must be taken:
1. INSPECTION AND REPAIR - Thoroughly inspect and
test the machine and make any necessary repairs or
adjustments which may be necessary to prepare the
machine for service. This will enable you to put the
machine back into use immediately at the end of the
storage period.
2. LUBRICATION - Lubricate the machine completely
according to the instructions given in Section
300-0020, LUBRICATION SYSTEM of this manual.
3. PARKING - After thoroughly cleaning the entire
machine, park it on a hard, dry, level surface that is
free from grease and oil. The oil and grease would
cause tyre deterioration. Apply the parking brake.
4. BATTERIES - Where moderate temperatures are
expected, the batteries may be left in the machine. Up to 30
days, the batteries may require a boost at the end of the
storage period. Preferably place the batteries in the shop
where they can be inspected, brought up to full charge and
placed on a trickle charge to keep them at full charge. In
very cold or hot climates, store the batteries where they will
be protected from temperature extremes.
5. RUST PREVENTION - Remove all evidence of rust
from the machine and repaint. In addition, cover all
exposed machine surfaces with a good rust preventive.
6. SUPPLY TANKS - Fill fuel and hydraulic tanks to
prevent moisture condensation within the tanks.
7. TYRES - Inflate all tyres to correct pressure. During
storage, check inflation pressure approximately once
every two weeks.
8. ENGINE - Consult the relevant Engine Maintenance
Manual for complete information on storing the engine
for periods shorter than 30 days.
9. TRANSMISSION - Fill transmission sumps to the
proper level.
EXTENDED STORAGE - Under Six
Months
When storing a machine for periods of longer than 30
days, but under six months, the following procedure
must be followed:
1. INSPECTION AND REPAIR - Same as Step 1 given
under 'Temporary Storage'.
2. LUBRICATION - Same as Step 2 given under
'Temporary Storage'.
3. PARKING - Same as Step 3 given under 'Temporary
Storage'. Machines should be blocked up so the tyres
are off the ground or floor.
4. BATTERIES - Remove batteries from the machine
and store them in a suitable place where they can be
inspected and charged at least every 30 days or placed
on a trickle charger.
5. RUST PREVENTION - Same as Step 5 given under
6. SUPPLY TANKS - Same as Step 6 given under
7. TYRES - With the machine on blocks, as called for
in Step 3, deflate the tyres to 0.7 bar (10 lbf/in)
pressure. Remove all traces of grease and oil and
protect the tyres from direct sunlight and water with a
suitable cover.
8. TRANSMISSION - Consult the relevant
Transmission Maintenance Manual for storage data
involving periods longer than 30 days.
9. ENGINE - Consult the relevant Engine Maintenance
Manual for storage data involving periods longer than
30 days.
10. VENTS AND BREATHERS - Remove all vents and
breathers and plug openings with pipe plugs. If it is not
possible to do this, seal vents and breathers with
waterproof tape.
MISCELLANEOUS - Unit Storage
Section 300-0090
Miscellaneous - Unit Storage
SM 1239 2-98 2
EXTENDED STORAGE - Over Six Months
When a machine is to be stored for a period over SIX
MONTHS, the following procedure must be followed:
Note: These steps are in addition to those given
previously under 'Extended Storage - Under Six
Months'.
1. LUBRICATION - Completely lubricate the machine
according to the instructions contained in Section
300-0020, LUBRICATION SYSTEM of this manual.
2. WHEEL BEARING - Remove, clean, inspect and
repack all wheel bearings.
Note: The above steps must be repeated for every Six
Month period the machine is in storage.
REMOVAL FROM EXTENDED STORAGE
General
1. LUBRICATION - Completely lubricate the machine
according to the instructions in Section 300-0020,
LUBRICATION SYSTEM of this manual.
2. BATTERIES - Install batteries and check for a full
charge. Charge batteries as required.
3. TYRES - Inflate tyres to the proper pressures. Refer
to Section 140-0040, WHEEL RIM AND TYRE, of this
manual.
4. FUEL AND HYDRAULIC TANKS - Drain off
condensation and fill tanks to proper level, remove
breather covers and install air breathers. Be sure
breathers are clean before installation.
5. VENTS AND BREATHERS - Remove seals and
plugs from all breather openings, then install all
breathers and vents.
6. ENGINES - Consult the relevant Engine
Maintenance Manual for instructions on removing an
engine from storage.
7. PAINT - Check machine for rust. Remove all rust
spots and repaint rusted areas.
8. TRANSMISSION - Consult the relevant
Transmission Maintenance Manual for instructions on
removing from storage.
* * * *

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CUSTOMER SUPPORT DEPARTMENT

TEREX EQUIPMENT LIMITED

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