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TR60 Tier3
MAINTENANCE MANUAL
Issued by;
Customer Support Department
Terex Equipment Limited
Newhouse Industrial Estate
Motherwell, ML1 5RY
Scotland
http//:constructionsupport.terex.com
www.terex.com
MAINTENANCE MANUAL
SM882
Re-order Part Number
15503447
15503447
S M882
TEREX Equipment Limited Maintenance Manual - Introduction
For further information on the subject matter detailed within this Maintenance Manual,
please refer to Terex Equipment Limited Operator Handbooks and Product Parts
Books.
The illustrations, technical information, data and descriptive text in this manual, to the
best of our knowledge, were correct at the time of print. The right to change
specifications, equipment and maintenance instructions at any time without notice, is
reserved as part of the Terex Equipment Limited policy of continuous development
and improvement of the product.
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.
Hazard Classification
A multi-tier hazard classification system is used to communicate potential personal injury hazards. The following
signal words used with the safety alert symbol indicate a specific level of severity of the potential hazard. Signal
words used without the safety alert symbol relate to property damage and protection only. All are used as
attention getting devices throughout this manual as well as on deals and labels fixed to the machinery to assist in
potential hazard recognition and prevention.
CAUTION used without the safety alert symbol indicates a potentially hazardous
CAUTION
situation which, if not avoided, may result in property damage.
WARNING
Never use parts which are altered, modified, or weakened in operation. This can seriously jeopardise
the integrity of the machine and could result in property damage or serious personal injury.
SM 2495 03-07
TABLE OF CONTENTS
Section No. Description SM No.
100 CHASSIS
0010 Chassis, Hood and Fenders 1904 Rev 1
110 ENGINE
0030 Engine and Mounting 2503 Rev 1
0050 Air Cleaner 1572 Rev 1
0130 Power Takeoff 1573 Rev 2
0150 Fuel Pre-Filter 2470
120 TRANSMISSION
0010 Transmission and Mounting 1905 Rev 1
0070 Commercial Electronic Control 2 (CEC2) 2128 Rev 4
0090 Power Takeoff 1178
0100 Transmission Oil Filter 1576
130 DRIVELINE
0010 Front Driveline - Pre June 1998 Production 1180
0010 Front Driveline - From June 1998 Production 1577
0020 Rear Driveline - Pre June 1998 Production 1181
0020 Rear Driveline - From June 1998 Production 1578
300 MISCELLANEOUS
0020 Lubrication System 2506 Rev 4
0070 Service Tools 2507
0080 Standard Bolt and Nut Torque Specifications 1238 Rev 1
0090 Unit Storage 2629
* * * *
SM - 3250
4 470
Max 1 425 (14-8)
Body (4-8)
Depth 4 270
(14-0)
3 950
(12-11)
950 600
(3-1) (2-0)
1 380 Vehicle Clearance Diameter (SAE) 21 m (68-10)
(4-6) 8 050
2 900 (9-6) (26-5)
4 450 (14-7)
ENGINE TRANSMISSION
Make/Model .................................... Cummins QSK19-C700 Make/Model .............................................. Allison M6610AR
Type ................... 4 Cycle, Turbocharged/Low Temperature Automatic electronic control with soft shift feature.
Aftercooled. Electronic Management Remote mounted in the frame. Integral TC 682 torque
Gross Power 1500 through 2000 rev/min ................ 522 kW converter and planetary gearing. Six speeds forward, two
(700 hp, 710 PS) reverse. Automatic converter lockup action in all speed
Net Power 1500 through 2000 rev/min ................... 462 kW ranges. With body up, gear range is limited to 1st forward
(620 hp, 628 PS) only. Downshift inhibitor. Integral hydraulic retarder.
Ratios: Retardation
Differential ................................................................... 3.73:1 Modulated lever control of rear disc pack. 510 kW (685 hp)
Planetary ..................................................................... 5.80:1 continuous.
Total Reduction ......................................................... 21.63:1 Retarder Actuation Pressure ......... up to 33 bar (480 lbf/in)
Emergency
SUSPENSION
Push button solenoid control applies service and parking
Front: King pin strut type independent front wheel brakes. Automatically applies when engine is switched off.
suspension by self-contained, variable rate, nitrogen/oil Parking brake applies should system pressure fall below a
cylinders. predetermined level.
Rear: Variable rate nitrogen/oil cylinders with A-frame Brakes conform to ISO 3450, SAE J1473 OCT 90.
linkage and lateral stabilizer bar.
Plate Thicknesses: Note: Noise Level Exposure to the operator and bystander
Floor ......................................................... 19 mm (0.75 in) personnel may be higher depending upon proximity to
Side .......................................................... 10 mm (0.39 in) buildings, rock piles, machinery etc. The actual job site
Front, lower ............................................... 10 mm (0.39 in) Noise Level Exposure must be measured and applicable
regulations complied with in respect to Employee Hearing
ROPS Cabguard SAE J1040 Feb 86. ISO 3471 Protection.
Volumes:
Struck (SAE) ............................................... 26 m (34 yd) Vehicle Weights (Mass)
Heaped 2:1 (SAE) ...................................... 35 m (46 yd) kg lb
Chassis, with hoists 30600 67460
SERVICE CAPACITIES
Engine Crankcase and Filters .................. 55 l (17.5 US gal) Body, standard 10650 23480
Transmission and Filters .......................... 85 l (22.5 US gal) Net Weight 41250 90940
Cooling System ...................................... 136 l (44.7 US gal) PAYLOAD, maximum 54430 120000
Fuel Tank ................................................ 606 l (160 US gal) Maximum Gross Weight* 95680 210940
Steering Hydraulic Tank .............................. 61 l (16 US gal)
Steering System .......................................... 72 l (19 US gal) FOR UNIT EQUIPPED WITH OPTIONAL HARD ROCK
Body and Brake Cooling Tank .................. 216 l (57 US gal) BODY:
Body and Brake Cooling System .............. 258 l (68 US gal) Chassis, with hoists 30600 67460
Planetaries (Total) .................................... 43 l (11.4 US gal) Body, with wear plates 13200 29100
Differential ................................................ 52 l (13.7 US gal)
Net Weight 43800 96560
Front Ride Strut (Each) ............................... 14 l (3.7 US gal)
Rear Ride Strut (Each) ............................... 17 l (4.5 US gal) PAYLOAD, maximum 51880 114380
Power Takeoff .................................................. 2 l (1 US gal) Maximum Gross Weight* 95680 210940
Air Conditioning Compressor ..... 0.135 litres (0.036 US gal) * Maximum permissible gross vehicle weight with options,
attachments, full tank and payload.
WEIGHT DISTRIBUTION Front Axle Rear Axle
Empty % 48 52
Loaded % 34 66
* * * *
Welding
WARNING
Welding and flame cutting cadmium plated
WARNINGS metals produce odourless fumes which are
Before any welding is done on a machine toxic. Recommended industrial hygiene
equipped with any electronic systems, practice for protection of the welding operator
disconnect the following (if applicable) in this from the cadmium fumes and metallic oxides
order: Battery earth cable, battery supply requires enclosure ventilation specifically
cable, alternator earth cables, alternator supply designed for the welding process. A
cables and electrical connections at the engine respiratory protective device such as the
ECM, transmission ECU, body control lever, M.S.A. 'Gasfoe' respirator with G.M.A. cartridge
hydraulics ECU and cab bulkhead to avoid will provide protection against cadmium,
damage to electrical components. Turn off fumes and metallic oxides. The 'Gasfoe'
battery master switch to isolate the batteries respirator has been approved by the U.S.
before disconnecting any components. Bureau of Mines: Approval number 23B-10,
After welding connect all of the above in the and is designed to protect against gases,
reverse order. vapours, and/or metal fumes.
SM 2172 10-02 1
General Information - Welding Procedure
Section 000-0010
3. Pre-heat area to 100 C (212 F), measured 3 - 4" 3 - 4" either side of repair prior to gouging. On
either side of repair. Avoid local overheating. completion of gouging grind to remove thin carbon
layer.
4. Weld completely using E-7016 electrodes. Care
must be taken to ensure electrodes are protected from 2. Apply dye-penetrant check to ensure crack has
moisture pick-ups at all times. been completely removed.
5. Allow repair weld to cool slowly. 3. Pre-heat area to 200 C (392 F), measured 3 - 4"
either side of repair. Avoid local overheating.
6. Grind and blend repair to original contour. Paint
heat damaged areas. 4. Weld completely using E-7016 electrodes. Care
must be taken to ensure electrodes are protected from
moisture pick-ups at all times.
The following general procedure should be used for
the repair of defects in alloy steel castings and in the 5. On completion of welding, post-heat repair area to
welds joining steel castings. 400 C (752 F), measure 3 - 4" either side of repair.
1. Completely ARC-AIR gouge or grind out the crack 6. If welding has to be interrupted for any reason, e.g.
until sound metal is reached. If ARC-AIR method is overnight, post-heat immediately as in Step 5.
employed, pre-heat area to 200 C (392 F), measure
* * * *
2 SM 2172 10-02
CHASSIS - Chassis, Hood and Fenders
Section 100-0010
SM - 2395
2
11
15
16
12
14
17
13
9
10
4 13
8
7 16
6 5 12
3 8 14
7 17
6 11
13 - Locknut
1 - Frame Assembly 5 - Bolt 9 - Bolt 14 - Spring Disc
2 - Bushing 6 - Nut 10 - Transmission Guard 15 - Washer
3 - Engine Guard 7 - Lockwasher 11 - Bolt 16 - Spacer
4 - Channel 8 - Washer 12 - Hardened Washer 17 - Washer
Fig. 1 - Exploded View of Chassis and Guards
MAINTENANCE SM - 2396
8
Inspection
7
Inspect the frame and attached parts at intervals not 6
exceeding 250 hours for cracked or broken welds and
bending/twisting of the frame. Any defects found 1
should be repaired before they progress into major
failures. Contact your dealer for recommended weld
and repair instructions.
Welding 5 4
Note: It is important that the electrical connections are 3
disconnected in the following order to prevent damage 2
to the electrical components: 5 4
3
a. Disconnect battery equalizer ground cables.
b. Disconnect battery cables from terminal posts
(ground cable first).
1 - Hood Assembly 5 - Nut
c. Disconnect battery equalizer positive cables.
2 - Plate 6 - Baffle
d. Disconnect electrical connections at the ECU. 3 - Bolt 7 - Baffle
4 - Hardened Washer 8 - Beading
After welding, reconnect all of the above in the reverse
Fig. 2 - Exploded View of Hood and Mounting
order.
Successfully welded repairs will depend to a great To keep rust and corrosion to a minimum, periodic
extent upon the use of the proper equipment, materials painting of abrasions and other exposed metal areas
on the frame is highly recommended.
SM - 3251
22 22
10
18
32 10 17
10 41
42 19 34
18
28 39
A 33
23 30 18
19
34 37 38
35 41
40
37 34
17 36
19 34
22 18 35
10
28
18 19 4
31 17
19 19
3 13 29
18
5 22
26 19
25 10
24 8
7 9
12
11
2
27 21
25 17
24 19
22
18 1
10
15 6
16
14
18 19 17
43,46,57 DETAIL A
56
20
44
57 A
43
45
56
48
44
51 57
50 43
47 49
55
54
53
52
43 - Nut
1 - LH Fender Assembly 15 - Locknut 29 - Mudguard 44 - Plate
2 - LH Platform Assembly 16 - Hardened Washer 30 - Mudguard 45 - Mirror Arm Assembly
3 - RH Fender Assembly 17 - Bolt 31 - Bolt 46 - Bar
4 - RH Platform Assembly 18 - Locknut 32 - Bolt 47 - Rod Assembly
5 - Crossmember 19 - Hardened Washer 33 - Fender Extension RH 48 - Bracket Assembly
6 - Support 20 - Mirror 34 - Washer 49 - Bolt
7 - Support 21 - LH Handrail 35 - Nut 50 - Lockwasher
8 - Bolt 22 - Bolt 36 - Bolt 51 - Washer
9 - Lockwire 23 - Mirror Wide Angle 37 - Washer 52 - Nut
10 - Hardened Washer 24 - Nut 38 - Nut 53 - Lockwasher
11 - Bolt 25 - Washer 39 - Plate Bent 54 - Washer
12 - Washer 26 - Bolt 40 - Plate bent 55 - Bolt
13 - Engine Access Cover 27 - Bolt 41 - Bolt 56 - 'U' Bolt
14 - Bolt 28 - Bolt 42 - RH Handrail 57 - Hardened Washer
SM - 1960
1413
14
6
4 10
12
12
1413 4
14 11
14
6
10
12
12
11
3 3
4
14
4
1
11
12
12
2
10
11
12
12
10
5
9
7
7 9
8 5 7
8 7
7 - Washer 11 - Bolt
1 - LH Step Assembly 4 - 'U' Bolt & Nut 8 - Bolt 12 - Hardened Washer
2 - RH Step Assembly 5 - Step 9 - Locknut 13 - Nut
3 - Plate 6 - Bolt 10 - Nut 14 - Hardened Washer
SM - 3252
2
1 9
4
3
11 7
11
6
7
11
10
5
9 7
11
11 12
15
14
11
11
12 13
* * * *
SM - 3741
54 55 56
50 51 52 53 57 58
62
61 60 59
69
68
67
66
65 46 47
7 42 42 42
RHS 45 43
45
64 45
37
34
35 38
63 8
40
33 36
38
37
1 28 29
9 30
31 32
4 44
17
2
15
LOCATED ON 25
LH FRAME RAIL
41
26 18 39
6 40
5 16 48
13 11,12 14
10 41
15 16 49
21 22
27 24 40 39
19 23 20
DESCRIPTION
Numbers in parentheses refer to Fig. 1. The engine is mounted to the frame at three points by
a mounting bracket (10) at the front of engine (1) and a
For engine make, model and specification, refer to left-hand and a right-hand rear mounts (11,12). Rubber
Section 000-0000, GENERAL INFORMATION. For isolation mounts (13,14) through engine mounts provide
engine servicing and repair data refer to the engine sufficient flexibility to absorb varying engine vibration
manufacturers service manual. and torsional loads.
SM - 1791
3 STOP
9
7
10 11
1,2
5
11. Diagnostic Search Switch - When the engine is in Whenever the 'Stop' light (6), 'Warning' light (7) or 'Fluid'
diagnostic mode this switch is used to search through light (8) come on, the Electronic Fuel System computer
a list of fault codes, i.e.. pressing the top of the switch will determine where the problem is and will store this
momentarily will advance to the next active fault code, information in its memory. If the malfunction is
pressing the bottom of the will go back to the previous intermittent, the lights will come on and go off as the
code. computer senses the changing engine condition.
A special diagnostic data reader (INSITE) is available
On machines which have a Low Idle Adjustment that can be plugged into the engine computer memory
feature, this switch can also be used to increase or via the onboard diagnostic test point (9). The reader is
decrease (in increments of 25 RPM), the idle or used to extract information related to the cause of the
intermediate speed of the engine. problem. Once the malfunction has been corrected, the
Electronic Fuel System will return the engine to normal
operation. The data reader can now distinguish
Operation between active codes and those stored in the historic
Numbers in parentheses refer to Fig. 2. code memory (inactive codes). Inactive codes can only
be viewed using the data reader. The fault code
The machine is equipped with the Quantum engine recorded in the ECM memory will remain until it is
protection system which records fault codes in the erased by a technician.
ECM (1), when the engine malfunctions and when an
out-of-range condition is found.
WARNINGS
When the 'Stop' light (6) on the dash panel illuminates, The operator of a Quantum-equipped vehicle
the computer has detected a major malfunction in the must not attempt to use or read a data reader of
engine that requires immediate attention. It is the any kind while the vehicle is operating. Doing
operators responsibility to shut down the engine to so can result in loss of control, which may
avoid serious damage. cause vehicle damage and may result in
personal injury.
When an out-of-range conditions is found, the 'Fluid'
light (8) illuminates and the engine protection system is The operator can check for active faults by turning the
initiated. The 'Fluid' light will start to flash if the out-of- ignition key switch to the 'OFF' position, switching the
range condition continues to get worse. The operator diagnostic switch 'ON' and then turning the ignition key
MUST shut down the engine to avoid serious damage. switch to position '1'.
The engine should not be restarted after it has been If no active fault codes are recorded, all three ('Stop',
shut down after activation of the engine protection 'Warning' & 'Fluid') lights will come on and stay on. If
system unless the problem has been diagnosed and active codes are recorded, all three lights will come on
corrected. momentarily. The yellow ('Warning') and red ('Stop')
lights will begin to flash the code of the recorded fault.
The fault codes flash in the following sequence: the
yellow light flashes once, then there is a pause where
both lights are off. Then the numbers of the recorded
1845 Water in Fuel Injector Sensor Circuit - Component High Voltage or Maint
shorted high
1846 Water in Fuel Injector Sensor Circuit - Component Low Voltage or Maint
shorted low
1852 Water in Fuel Indicator - Data Valid but only slightly above Amber
operating range (moderately severe)
1891 Engine Oil Change Interval Amber
1911 Injector Metering Rail 1 Pressure - Data Valid but above normal Amber
operating range (most severe level)
2185 Sensor Supply 4 Circuit - Component High Voltage or shorted high Maint
2186 Sensor Supply 4 Circuit - Component Low Voltage or shorted low Maint
2215 Fuel Pump Delivery Pressure - Data Valid but only slightly below Amber
operating range (moderately severe)
2261 Fuel Pump Delivery Pressure - Data Valid but above operating range Maint
(least severe level)
2262 Fuel Pump Delivery Pressure - Data Valid but below operating range Maint
(least severe level)
2265 Electric Lift Pump for Engine Fuel Supply Circuit - Component High Voltage or Amber
shorted high
2266 Electric Lift Pump for Engine Fuel Supply Circuit - Component Low Voltage or Amber
shorted low
2311 Electronic Fuel Injection Control Valve Circuit Amber
2321 Engine Crankshaft Speed/Position - Data Erratic, Intermittant or Incorrect -
2322 Engine Camshaft Speed/Position Sensor - Data Erratic, Intermittant or Incorrect -
4. Remove mounting hardware securing the hood on 15. Identify all electrical harnesses and cables
the vehicle. Remove hood assembly from the vehicle. attached to engine (1) for ease of installation and
disconnect from engine (1).
5. Disconnect electrical connections from the radiator
guard and remove mounting hardware securing the 16. Disconnect driveline from engine coupling and
radiator guard on the vehicle. Remove radiator guard secure clear of engine (1). Refer to Section 130-0010,
from the vehicle. FRONT DRIVELINE.
Note: The hydraulic lines can be left attached to the 6. Remove bolts (65 & 69) and lockwashers (66)
tandem pump. securing alternator guard (64) to engine (1). Remove
alternator guard (64).
18. Attach suitable lifting equipment to the lifting 8. Remove bolt (50) and lockwasher (51) securing
brackets on engine (1) assembly and raise lifting screw and link assembly (52 thru 56) to alternator (62).
equipment to take up the slack. Support alternator (62) and remove locknut (59),
lockwasher (60) and bolt (61). Remove alternator (62)
19. Remove locknuts (27) and bolts (25) securing from engine (1).
engine (1) assembly to front mounting (10). Remove
locknuts (20), washers (22), snubbing washers (16) and 9. If necessary, damper (28) can be removed from the
bolts (18) securing rear mounting brackets (11,12) to flywheel after the power takeoff assembly is removed.
the frame. Refer to Section 110-0130, POWER TAKEOFF.
20. Check to make certain that all necessary line and 10. With power takeoff assembly removed, remove
electrical disconnections have been made before lifting bolts (30) and washers (29). Remove damper (28) from
engine (1). engine (1). If necessary, remove bolts (32) from flange
coupling (31). Remove flange coupling (31) from
21. Carefully lift engine (1) assembly clear of the frame damper (28).
and move to a clean work area. Securely mount engine
(1) assembly to a work stand. 11. If required, remove bolt (61), washers (59) and
locknut (58) securing filler assembly (62) to bracket
DISASSEMBLY (60). Loosen bottom clamp (41) and remove filler hose
(40) and filler assembly (62) from engine (1).
Numbers in parentheses refer to Fig. 1.
12. Remove and discard filters (2, 5, 6 & 7 ) from
1. If required, remove bolts (23) and lockwashers (24) engine (1), as described in 'Maintenance'. Cover engine
securing rear mounts (5) to engine (1). Remove rear inlet ports to prevent entry of dirt.
mounts (11,12).
13. Refer to 'Engine Manufacturers Service Manual' if
2. If required, remove rubber isolation mounts (14) from engine service or repair is required.
rear mounts (11,12).
4. Loosen the fan hub mounting bolts and turn the 1. Inspect rubber isolation mounts (13,14) for damage
adjusting rod anticlockwise enough to allow slack in
poly 'V' belts. Remove poly 'V' belts.
ASSEMBLY 10. Position fan to fan pulley on engine (1) and secure with
bolts (34) and lockwashers (35). Tighten the bolts in a star
Numbers in parentheses refer to Fig. 1.
shaped pattern to a torque of 34 Nm (25 lbf ft).
Note: Tighten all fasteners without special torques
11. If removed, install rubber isolation mounts (13) to
specified to standard torques listed in Section
front mounting bracket (10).
300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
12. Secure rear mounts (11,12) to engine (1) with bolts
(23) and lockwashers (24) as identified at disassembly.
1. Remove covers from engine filter ports and install
Tighten bolts (23) to a torque of 150 Nm (110 lbf ft). If
new filters (2, 5, 6 & 7) on engine (1), as described in
removed, install rubber isolation mounts (14) in rear
'Maintenance'.
mounts (11,12).
2. If removed, secure filler hose and filler assembly to
engine (1) with bottom clamp. Secure filler assembly to INSTALLATION
bracket using bolt , washers and locknut.
Numbers in parentheses refer to Fig. 1.
3. Install damper (28) to rear of engine (1) and secure
Note: Tighten all fasteners without special torques
with bolts (20) and washers (29). Install flange
specified to standard torques listed in Section
coupling (31) to damper (28) and secure with bolts (32).
300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
4. Position alternator (62) on engine mounting bracket
and align the holes in the alternator mounting flanges
with the tube in the bracket. Secure alternator (62) in WARNING
position with bolt (61), lockwasher (60) and locknut (59). To prevent personal injury and property
Tighten bolt (61) finger tight at this stage. damage, be sure lifting device is properly
secured and of adequate capacity to do the job
5. Install adjuster screw and link assembly (52 thru 56) safely.
to alternator (62) and secure with bolt (50) and
lockwasher (51). Tighten bolt (50) finger tight at this 1. Attach suitable lifting equipment to engine (1) lifting
stage. brackets and carefully position engine (1) assembly in
the frame.
Note: Replace all belts in a set when one is broken or
replaced. 2. Secure engine (1) assembly to rear mounts on the
frame with bolts (18), snubbing washers (16) washers
6. Install 'V' belts in the grooves of alternator (56) and (22) and locknuts (20). Secure engine (1) assembly to
accessory drive pulley. front mounting bracket (10) with bolts (25), hardened
washers (31) and locknuts (14).
Note: Alternator belt tension adjustment is made after
installation of engine (1) and the radiator assembly. 3. Connect driveline to the engine coupling. Refer to
Section 130-0010, FRONT DRIVELINES.
7. If equipped with air conditioning, install air
conditioner compressor and drive belt to engine (1). 4. Install tandem pump on power takeoff assembly and
Refer to Section 260-0130, AIR CONDITIONING. secure with mounting hardware. Refer to Section
230-0050, TANDEM PUMP.
13. If the vehicle is equipped with air conditioning, Engine (1) Oil Level: Check engine oil level and add oil
connect the lines at the compressor as identified at if low. To allow checking before starting as well as
removal. On completion of engine installation the air immediately after shutting down the engine, the dipstick
conditioning system will require to be charged. Refer to is provided with two types of marks:
Section 260-0130, AIR CONDITIONING.
1. Dot Marks - Before starting up after a major shut
14. Using suitable lifting equipment, install radiator down period the oil level should be up to the top dot
guard assembly to the frame. Secure with the required mark (cold level).
mounting hardware and connect electrical connections
as identified at removal. 2. Dash Marks - Upon shutting down the engine at low
idling (wait 1 to 2 minutes) the oil level should be up to,
15. Using suitable lifting equipment, install hood but not over, the top dash mark (hot level).
assembly into position on the vehicle. Secure hood
assembly with mounting hardware removed at removal. Fuek Pre-filter (2) - Drain water and sediment Section
210-0150
16. Connect battery positive connections to battery
terminal posts. Connect battery earth connections to
battery terminal posts. Every 250 Hours
Engine (1): Drain engine oil and refill. Refer to Section
17. Ensure all lines, harnesses and cables are secured 300-0020, LUBRICATION SYSTEM for oil specification.
with clips and clamps as removed during removal.
Ensure no lines are chaffing on sharp edges or resting Engine Water Pump: Inspect water pump drain hole
and clean if required.
Fuel Pre-filter (2): Replace the fuel pre-filter as 2. Fill the replacement filters and coat the gaskets
follows: slightly with clean fuel oil as specified in Section
300-0020, LUBRICATION SYSTEM.
1. Turn off the engine. Loosen the vent cap to
break the air lock in the filter. 3. Start a new fuel filter on the filter adaptor and tighten
it by hand until the gasket contacts the adaptor fully
2. open the drain valve and drain the fuel with no side movement of the filter evident. Tighten an
level below the collar, then close the drain valve. additional 1/2 of a turn.
3. Using the Collar/Vent Cap Wrench , remove the Note: Mechanical tightening of fuel filters is not
clear cover from thefuel processor by removing the recommended, and may result in seal and/or cartridge
collar. Discard theo-ring from the base of the cover. (A damage. Tighten fuel filters by hand only.
new o-ring sealis supplied with the new filter.) Remove
the filter element (3) from the pre-filter by pulling 4. Repeat step 3 for second fuel filter.
upward and twisting slightly. Be sure the sealing
grommet is removed from the center stud. 5. Start the engine and check for leaks. If any leaks
are noted, have them corrected.
4. Install the new filter element (supplied with
a Sealing Grommet already inserted into the
element) on the processor center stud by pushing
Note: There is a shut off valve at the coolant inlet and Note: Replace all belts in a set when one is worn.
outlet lines of coolant filter (38). Closing these valves Single belts of similar size should not be used as a
will enable coolant filter (38) to be replaced without an substitute for a matched belt set as premature belt
excessive loss of coolant. wear can result due to belt length variation. All belts in
a matched belt set are within 0.81 mm (0.032 in) of
1. Close shut off valves at coolant filter (7) inlet and their specified centre distances.
outlet lines and, using filter wrench, remove and
discard coolant filter (7) from engine (1). Using belt tension gauge, adjust the belt tension to the
following values:
2. Clean the filter adaptor with a clean, lint free cloth.
Fan - Poly 'V' Belt
3. Lightly coat new coolant filter (38) seal with clean Belt Tension 'New' - 3 340 N (750 lbf)
engine oil as specified in Section 300-0020, Belt Tension 'Used' - 2 450 - 3 340 N (550 - 750 lbf)
LUBRICATION SYSTEM.
Alternator - 'V' Belt
4. Start coolant filter (7) on the filter adaptor and tighten Belt Tension 'New' - 556 N (125 lbf)
it by hand until the seal touches the adaptor filter head. Belt Tension 'Used' - 445 N (100 lbf)
Tighten an additional 2/3 of a turn after contact.
Note: A belt is considered 'Used' if it has been in
Note: Mechanical tightening of coolant filter (7) is not service for 10 minutes or longer. If the used belt
necessary and will distort or crack the adaptor. Tighten tension is less than the minimum value, tighten the belt
oil filters by hand only. to the maximum value.
5. Open shut off valves at coolant filter (7) inlet and Belts should be neither too tight nor too loose. Belts
outlet lines. that are too tight impose excess loads on the
crankshaft, fan and alternator bearings, shortening both
6. Start the engine and check for leaks. If any leaks belt and bearing life. Excessively overtightened belts
* * * *
are noted, have them corrected. Add coolant as can result in crankshaft breakage. A loose belt will slip
required. Refer to Section 210-0000, COOLING and may cause damage to accessory components.
SYSTEM.
SPECIAL TOOLS
Drive Belt Adjustments Refer to Section 300-0070, SERVICE TOOLS, for part
Every 50 Hours: Check all drive belt tensions and numbers of tools referenced in this section, general
adjust if required. If vehicle is equipped with air service tools required, and service tools which should
conditioning, compressor belts should be checked and be used in conjunction with procedures outlined in the
engine manufacturers service manual. These tools are
SPECIAL TORQUE SPECIFICATIONS available from your dealer.
TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 7 Bolt 150 110
1 22 Bolt 34 25
1 50 Bolt 81 - 95 60 - 70
1 61 Bolt 81 - 95 60 - 70
- - Fan Hub Mounting Bolts 101 - 126 75 - 93
SM - 1532
DESCRIPTION SM - 3254
An electrical air restriction gauge (14, Fig. 3) indicates While the indicator light indicates the need for
when air restriction levels reach the maximum servicing, it does not give as precise a measurement
allowable limit. When air restriction levels are reached, as a water manometer or vacuum gauge. Refer to
SM - 1701
P9546
15
14
7 22
17
18
19
17
22 16
4
6
4
10
13
8 20
3
1
5
10
12
2 10
21
11
5 3
10
10
1 - Bolt 17 - Adaptor
2 - Hardened Washer 7 - Cap Assembly 12 - Tube Assembly 18 - Nylon Tube
3 - Hardened Washer 8 - Hump Hose 13 - Bracket Assembly 19 - Nipple
4 - Bolt 9 - Clamp 14 - Air Restriction Gauge 20 - Tube
5 - Locknut 10 - Clamp 15 - Protective Cap 21 - Hump Hose
6 - Mounting Band 11 - Elbow 16 - Tee 22 - Elbow
Fig. 3 - Exploded View of Air Cleaner Mounting
'Measuring Air Restriction'. over service. When restriction readings finally indicate
a change, remove primary element (2) carefully and
Safety element (3) is installed in each air cleaner clean/replace as required. Refer to 'Primary Element'.
assembly inside of primary element (2). This element
increases the reliability of the air cleaners protection Never attempt to clean safety element (3). Change
of the engine from airborne dirt. It protects the engine safety element (3) after every third primary element (2)
from dirt admitted by a damaged primary element (2), service.
or dirt that might be dropped into the air cleaner
assembly while servicing primary element (2). Make sure vacuator valve (6) is not damaged or
plugged and that the joint with cover assembly (4) is
not broken. If vacuator valve (6) is lost or damaged,
MAINTENANCE replace it to maintain pre-cleaner efficiency and normal
Numbers in parentheses refer to Fig. 1, unless filter element service life.
otherwise specified.
Check condition of clamps (9 & 10, Fig. 3), hump
hoses (8 & 21, Fig. 3), elbow (11, Fig. 3), tube
WARNING assembly (12, Fig. 3) and tube (20, Fig. 3). Tighten/
Always shutdown the engine before servicing replace as necessary.
air cleaner.
The air cleaner elements should be serviced only Air Cleaner Assembly
when the maximum allowable restriction has been Numbers in parentheses refer to Fig. 1, unless
reached, as indicated by air cleaner restriction otherwise specified.
indicator light. The elements should not be serviced on
the basis of visual observation as this would lead to Note: Air cleaner body (1) should be thoroughly
2. Remove primary element (2) and safety element (3) 4. If the major contaminant on primary element (2) is
from air cleaner body (1). light dust, direct a jet of compressed air, not exceeding
6.9 bar (100 lbf/in2), against the pleats of the element.
3. Slacken clamps (9, Fig. 3) and disconnect hump The air jet should be directed in the opposite direction
hose (8, Fig. 3) from air cleaner body (1). of normal operating air flow. Move the air jet up and
down the pleats, holding the air nozzle 25 mm (1.0 in)
4. Remove locknuts (5, Fig. 3), hardened washers away from the pleats, to prevent rupturing the element
(3, Fig. 3) and bolts (4, Fig. 3) securing the air cleaner with either the nozzle or air jet.
assembly to the platform.
5. In cases where the dust cake on primary element
5. Remove the air cleaner assembly from the platform (2) contains oil or carbon, air will not clean effectively.
for cleaning. Using manufacturers recommended solution and
warm water, not exceeding 48 C (120 F), soak
6. Open clamps (6) and remove from air cleaner primary element (2) for fifteen minutes. Element
body (1). Open clamp on cap assembly (7) and should be gently agitated to assist cleaning process.
remove cap assembly from air cleaner body (1).
Note: It is possible to modify an old agitator type
7. Blank off air cleaner body (1) outlets with tape or washing machine for primary element (2) cleaning. Do
cardboard. Reach inside body with a compressed air not soak or agitate primary element (2) in the solution
nozzle or brush and remove dust from the body. for more than fifteen minutes. Prolonged exposure
softens vertical seams in the element.
8. Remove all loose dust from air cleaner body (1) and
remove tape or cardboard from body outlets. 6. Rinse washed element thoroughly with a low
pressure stream of water, not exceeding 0.7 bar
Note: Assembly and installation of the air cleaner (10 lbf/in2), opposite from the normal air flow, until
assembly is the reverse of disassembly and removal. rinse water runs clear.
4. Install cover assembly (4) on air cleaner body (1) c. With the manometer held vertically and the engine
and secure with latches (5). drawing maximum air, the difference in height of the
water columns in the two legs is measured as the air
cleaner restriction.
Recommendations
Numbers in parentheses refer to Fig. 3. d. If the restriction exceeds the levels indicated,
engine performance will be affected. Primary filter
1. Under no condition should the vehicle be operated element should be cleaned or replaced.
without both filter elements in each air cleaner
assembly. Vacuum Gauge
a. Remove protective cap (15) and disconnect
2. It is very important that hump hoses (8 & 21), tube harness at air restriction gauge (14). Remove air
assembly (12), tube (20) and elbow (11) from the air restriction gauge (14) from tee (16).
cleaner assembly to the engine be airtight or the
purpose of the air cleaner will be completely defeated. b. Connect the hose from the vacuum gauge to
All clamps (9 & 10) should be checked frequently and tee (16) and, with the engine drawing maximum air,
tightened to prevent leaks. take a note of the reading on the gauge.
3. Keep new or cleaned filter elements on hand for c. If the restriction exceeds the levels indicated, engine
replacement to prevent unnecessary downtime of the performance will be affected. Primary filter element
vehicle. should be cleaned or replaced.
* * * *
17
The function of the power takeoff (PTO), as the name
implies, is to provide the means of mounting and
driving an auxiliary component. The tandem pump for 11 11
the body hoist system and disc brake cooling system
is mounted to PTO cover (26) and its input shaft is
meshed with the internal splines in the hub of driven
5
gear (12). Refer to Section 230-0050, TANDEM 15 10
PUMP.
SM - 3255
26
2 30
18
4 3
6
17
12 11
1 6 16
13 9 19
11 6 22
27
2
10 17
15
14 8 7
10
21
28
5 29 20
25,23
6 24
15 - Driveshaft 23 - Bolt
1 - Flywheel Cover Case 8 - Lockwasher 16 - Locknut 24 - Lockwasher
2 - Dowel Pin 9 - Oil Seal 17 - Snap Ring 25 - Bolt
3 - Bolt 10 - Bearing 18 - Gasket 26 - PTO Cover
4 - Lockwasher 11 - Bearing 19 - Hardened Washer 27 - Spacer
5 - Oil Seal 12 - Driven Gear 20 - Breather 28 - Coupling
6 - Plug 13 - Plug 21 - Breather Cap 29 - Adaptor
7 - Bolt 14 - Drive Gear 22 - Yoke 30 - Plug
Fig. 2 - Exploded View of Power Takeoff Assembly
2. Remove bolts (3 & 7) and lockwashers (4 & 8) from 8. If necessary, note locations and remove dowel pins
PTO cover (26). Pull PTO cover (26) and gasket (18) (2) from flywheel cover case (1) and breather
from flywheel cover case (1). Discard gasket (18). assembly (20, 21, 28 & 29) from PTO cover (26).
4. Remove snap rings (17) from pump and driveshaft 1. Wash all parts thoroughly in a suitable solvent and
bores. Drive bearings (10 & 11) from PTO cover (26) dry all but bearings (10 & 11) with compressed air.
with a sleeve or soft steel drift. Drive on the outer Dry bearings (10 & 11) with a clean lint free cloth.
race of bearings (10 & 11) taking care not to damage
the bearings. 2. Check the condition of splines and teeth on gears
(12 & 14), driveshaft (15) and yoke (22) for burrs or
5. Slide drive gear (14) from driveshaft (15) and pull signs of wear.
driven gear (12) from flywheel cover case (1).
3. Lubricate bearings (10 & 11) with oil and check
6. Pull driveshaft (15) from flywheel cover case (1). operation by spinning bearings by hand. DO NOT spin
Pry oil seal (5) from flywheel cover case (1). bearings with compressed air. Inspect bearing bores
for out of roundness. Replace bearings, if required.
7. Pull bearings (10 & 11) from flywheel cover case
(1) with a suitable bearing puller. 4. Inspect flywheel cover case (1) and PTO cover
(26) for cracks. If either flywheel cover case (1) or
* * * *
SM 3740
1
1- Collar
2 2- Vent Cap
3 3- Vent Seal
4- Cover
5- Filter Spring
6- Filter Element
4
7- O-Ring Pack
8- Filter Mounting Spud
9- Industrial Pro
10 - Bottom Seal
5 11 - Bottom Plate
14 15 12- Bowl Assembly Seal
13- Bowl Assembly
14- Primer pump Bracket
15- Primer Pump
16 16- Primer Pump Bypass Valve
6
17- Primer Pump Vibration Isolators
17 18- SAE 3/4" Plug with M14 Diagnostic Port and
O-Ring Seal
19- Check Valve Service Kit
7
8 20- Check Valve Body
23
21- SAE 1 3/4" Plug with O Ring
21 22- Water in Fuel Sensor
18
23- Mounting bracket
18 24- Coller / Vent Cap Wrench
19
20
9
22
10
11
12
13 24
DESCRIPTION Maintenance
Numbers in parentheses refer to Fig. 1, unless Numbers in parentheses refer to Fig. 1, unless
otherwise specified. otherwise specified.
There is a fuel pre-filter mounted on the left hand frame Weekly Drain water.
rail between the OCDB filter and the OCDB cooler. The
fuel pre-filter gives a more consistent and reliable Every Filter Change / 250 hours Change the o-rings
operation of the fuel system giving in turn a more and grommet
reliable and durable engine by removing dirt particles
from the fuel system Every 12 Months Check all electrical connections for
corrosion. Check all fuel fittings for leaks.
Dirt particles in the fuel forms an abrasive compound Extreme winter or salt corrosion environments may
which can have serious impact on the fuel pump and require lubrication of the top collar threads with
injectors. Abnormal wear in the fuel injectors can affect Loctite 76747 antiseize every 180 days.
the engine ability to start and drive and may also affect
engine emissions. Abnormal wear in the fuel pump can
lead to more costly overhauls and replacement of WARNING
parts. Always shutdown the engine before servicing
fuel pre-filter.
SM - 3744
5 3
2
6 7
ENGINE LHS
FUEL RETURN MANIFOLD BLK.
PORT
13
12
10
11
9
Draining Contaminants
1. Turn off the engine and open the filter vent.
SERVICE TOOLS
Refer to Section 300-0070, SERVICE TOOLS for part
numbers of service tools referenced in this section and
general service tools required. These tools are
available from your dealer.
SM - 2400
20 21 24
32
23 33
22 34
37 35,36
3
49
20 4
47 21 53
46 19
48
44 29
28
13
14
27 2 53
26 30 5
31
25
6
15 10 7
11
12
47
46
45
52 48 44
51
50
1 12
16 42
9 11 10 43
39
41 8
38 15 17 40
18
40 - Drain Cock
1 - Transmission 14 - Gasket 27 - Padlock 41 - Adaptor
2 - Trunnion 15 - Clamp 28 - Bolt 42 - Adaptor
3 - Bolt 16 - Filler Hose 29 - Cover Plate 43 - Snubbing Washer
4 - Washer 17 - Filler Tube 30 - Level Gauge 44 - P-clip
5 - Locknut 18 - Elbow 31 - Ring 45 - Bracket
6 - Bolt 19 - Connector 32 - Bolt 46 - Lockwasher
7 - Hardened Washer 20 - Nut 33 - Strip 47 - Nut
8 - Nut 21 - Sleeve 34 - Retainer 48 - Bolt
9 - Mounting Bracket 22 - Nylon Tube 35 - Shim 49 - P-clip
10 - Bolt 23 - Elbow 36 - Shim 50 - Bolt
11 - Lockwasher 24 - Breather 37 - Input Yoke 51 - Hardened Washer
12 - Isolation Mount 25 - Adaptor 38 - Nut 52 - Nut
13 - Filler Cap 26 - Key 39 - Output Yoke 53 - Isolation Mount
5. Using suitable lifting equipment, support 19. Slacken nut (20) and move nut (20) and nylon tube
transmission guard and remove mounting hardware (22) assembly free from connector (19) in the top of
securing the guard to the frame. Remove transmission transmission (1).
guard.
20. Detach clamps (15) and remove filler hose (16)
6. Disconnect driveline from input yoke (37) at the from filler tube (17) and adaptor (25).
front of transmission (1). Refer to Section 130-0010,
FRONT DRIVELINE. 21. Install suitable lifting eyes into the holes provided
at the top of transmission (1) housing and secure a
7. Disconnect driveline from output yoke (39) at the suitable lifting device to the eyes. Take up slack in the
rear of transmission (1). Refer to Section 130-0020, chain or cable.
REAR DRIVELINE.
22. Remove locknuts (5), bolts (3) and washers (4)
8. Place a suitable container under drain cock (40), securing trunnion (2) to the frame.
loosen drain cock and drain oil from transmission (1).
After draining, tighten drain cock (40) securely. 23. Remove bolts (6), hardened washers (7), snubbing
washers (43) and nuts (8) securing mounting brackets
9. Disconnect the transmission retarder linkage at (9) to frame.
transmission (1).
24. Check to make certain that all hydraulic lines and
10. Place a suitable container under the steering tank electrical connections fitted to transmission (1) have
drain plug, remove drain plug and drain the oil from the been disconnected before moving transmission (1).
steering tank. After draining, reinstall drain plug.
25. Carefully manoeuvre transmission (1) out of the
11. Disconnect steering lines from the steering pump frame mounting and lower onto a suitable dolly or pallet.
and remove mounting hardware securing steering
lines to transmission (1). Cap all open line ends and 26. Move transmission (1) assembly to a suitable work
steering pump fittings to prevent entry of dirt. area or onto a work stand for further disassembly, if
necessary.
12. Disconnect transmission oil cooler lines and oil
filter lines from transmission (1). Cap all open lines
and fittings to prevent entry of dirt. DISASSEMBLY
Numbers in parentheses refer to Fig. 1.
13. Disconnect hydraulic line from lockup drop out
valve at the front right hand side of transmission (1). Note: Refer to the transmission manufacturers
Service Manual if transmission service or repair is
14. Disconnect all remaining hydraulic lines attached required.
to transmission (1). Cap all open lines and fittings to
prevent entry of dirt. 1. Remove bolts (32), strip (33), retainer (34) and
shims (35 & 36) securing input yoke (37) on
15. Disconnect all electrical connections and cables transmission (1). Pull input yoke (37) from
attached to transmission (1). transmission (1).
16. Remove mounting hardware securing accumulator 2. Pull trunnion (2) assembly from transmission (1)
valve mounting bracket to the front left hand side of and remove ring (31) from trunnion (2), if required. If
necessary, remove isolation mounts (53) from
7. Secure accumulator valve mounting bracket to the Note: It is important that the electrical connections are
front left hand side of transmission (1) assembly with made in the order listed in step 21 to prevent damage
mounting hardware removed during removal. to the electrical components.
8. Secure kick-over valve mounting bracket to top of 21. Connect electrical connections at the ECU.
transmission (1) assembly with mounting hardware Connect battery equalizer positive connection.
removed during removal. Connect battery cables to battery terminal posts
(ground cable last). Connect battery equalizer ground
9. Secure body hoist lines mounting brackets to the connection.
top of transmission (1) assembly with mounting
hardware removed during removal. 22. Start the engine and make an operational check
while the engine is running of all lines and connections
10. Connect all electrical connections and cables to disconnected during removal of transmission (1).
transmission (1) as tagged at removal. Check for leaks and tighten lines and fittings as
required.
11. Connect transmission oil cooler lines to
transmission (1) and oil filter lines to transmission oil 23. Ensure parking brake is applied, remove the body
filter as tagged at removal. prop pins and lower the body. Refer to Section
270-0010, BODY AND MOUNTING. Remove wheel
12. Connect steering pump hydraulic lines as tagged chocks from all road wheels.
at removal and secure lines to transmission (1) with
mounting hardware removed during removal.
MAINTENANCE
13. Connect hydraulic line from lockup drop out valve
to front right hand side of transmission (1). Periodic Inspections
For easier inspection, the transmission should be kept
14. Connect any remaining hydraulic lines which were clean. Make periodic checks for loose bolts and
removed during removal. Ensure all hydraulic lines are leaking oil lines. Check the condition of electrical
securely tightened. harnesses and connections regularly.
15. Connect transmission retarder linkage at The transmission breather should be checked
transmission (1). regularly and as frequently as necessary, depending
on the operating conditions of the vehicle. A badly
16. Install rear driveline to output yoke (39) at the rear corroded or plugged breather restricts proper
of transmission (1) and secure with mounting breathing and causes a buildup of condensation and
hardware removed during removal. Refer to Section subsequent oil deterioration.
130-0020, REAR DRIVELINE.
Converter Drive Housing
17. Install front driveline to input yoke (37) at the front
of transmission (1) and secure with mounting
hardware removed during removal. Refer to Section Note: The following detail should be
130-0010, FRONT DRIVELINE. applied to transmissions prior to serial number
S/N 3110100359.
18. Using suitable lifting equipment, support
transmission guard and secure guard to the frame with Should any repair / overhaul or component
mounting hardware removed during removal. replacement be necessary on the converter drive
housing assembly and relevant components i.e. input
19. Fill transmission (1) assembly with oil specified in yoke/flange, converter drive housing or hub. Please
Section 300-0020, LUBRICATION SYSTEM, and check refer to transmission manufacturers Service
the oil level as described under 'Oil Level Check'. Information Letter "SIL: 35-TR-94, Rev.A" ensure
correct parts and transmission manufacturers service
20. Fill steering tank with oil specified in Section detail is adhered to.
300-0020, LUBRICATION SYSTEM, and check the oil
WARNING
When checking the oil level, be sure that the
parking brake is applied and all road wheels
are securely blocked.
RED LINE
Check the transmission oil level and add oil if low,
every 10 hours/daily. Use only oil of the type specified NO RED
in Section 300-0020, LUBRICATION SYSTEM. LINE VISIBLE
(OVERFILL)
Because the transmission oil cools, lubricates and
transmits hydraulic power it is important that the proper
SAFE
oil level be maintained at all times. If the oil level is too FULL MARK
OPERATIONAL
(CENTRE)
low, the converter and clutches will not receive an LEVEL AREA
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 NO OIL VISIBLE
transmission be clean. (UNDERFILL)
Electronic Troubleshooting
Refer to Section 120-0070, CEC SHIFT SYSTEM for SPECIAL TOOLS
general electrical troubleshooting. For more detailed There are no special tools required for the procedures
electrical troubleshooting refer to the Allison outlined in this section. Refer to Section 300-0070,
Transmission Commercial Electronic Control (CEC) SERVICE TOOLS for part numbers of service tools
Troubleshooting Manual SA2712A. which should be used in conjunction with procedures
outlined in the transmission manufacturers service
Mechanical Troubleshooting manual, and general service tools required. These
It is recommended to follow the procedures laid down tools are available from your dealer.
for mechanical troubleshooting, as outlined in the
* * * *
SM 1905 Rev1 01-06 11
Transmission - C.E.C. 2
Section 120-0070
SM2657
10 11
3 9
CONNECTOR TO
TERMINATION
RESISTOR
EARTH
2
SHIFT
4 E.C.U. SELECTOR
TRANS. HARNESS
12 5
INTERFACE MODULE
GHJ
KLM
7
DIAGNOSTIC
8 REF. CONSOLE HARNESS CONNECTOR
VEHICLE
CONNECTION
(V)
CEC2 COMPONENTS
K
C
UE
A
BL
L
B
10 7
1
7
2
3
4
8
5
6
9 A C B
1. Check Trans. Relay 7. Converter Drive Relay
2. Neutral Start Relay 8. On Board Weighing Relay
3. Reverse Relay 9. Rear View Camera Relay
4. Body Up Relay 10. Ignition Signal Fuse
5. Delta P Relay A. Manual/Automatic Key
6. Lock Up Off Relay B. Power/Economy Key
C. Manual Mode Light
Fig. 5- Interface Box
1. Timer Relay 6. Transmission Battery Power
2. Battery Fuse (15 A) Fuse (15 A) Gear Shift Selector - The shift selector is a remote
3. Engine ECM Battery Power 7. Ignition Sense Relay mounted lever type (Fig. 6). The gear shift selector is
Fuse (5 A) 8. Engine ECM Ignition Sense connected to the ECU by a wiring harness. The shift
4. Transmission Ignition Sense Relay lever has 6 forward ranges and 2 reverse ranges, as
Fuse (5A) 9. Transmission ECU Ignition
5. Transmission Battery Power Sense Relay well as a neutral position. The shift selector has a
Fuse (15 A)Fuse single digit LED display, that during normal operation
will display the gear selected (Not gear attained).
Fig. 3 - Power Module Diagnostic information can be displayed on the single
digit LED display by pressing the diagnostic display
SM2679
button. There is a hold override button that must be
pressed when shifting between R, N and D. The hold
override button is released when desired selector
position is reached. The selector lever can move freely
between D and the number ranges without pressing the
L. E. D.
hold override button.
Release delay
On-off pulse
On-pulse
Off-pulse SET DIAL TO 'Release delay' WARNING
Do not allow the vehicle to coast in Neutral. This
0.6 - 6 sec
6 - 60 sec practice can result in severe transmission damage.
0.6 - 6 min
6 - 60 min SET DIAL TO '6 - 60 sec'
4
5
3
6
The transmission upshifts and downshifts
SET DIAL TO '3'
LOCK IN POSITION 2 automatically between first range and the highest range
USING ARALDITE OR
SIMILAR
1 selected on the range selector in direct response to
throttle position and transmission output speed.
MODE LIGHT
1
MODE BUTTON MODE
2
3
TURBINE SPEED SENSOR
4
DISPLAY
5
D
N
DIAGNOSTIC R1
BUTTON R2
When drive 'D' is selected, the transmission right-of-way to a loaded vehicle, the transmission can
automatically upshifts and downshifts through all six be left in the selected range and the vehicle held
forward ranges as required by loads and travel speeds. stationary with the service brakes.
Selecting a lower range (4th, 3rd etc.) limits the highest
range to which the transmission will automatically upshift. However, when stopped for a more extended period
with the engine left running, shift the transmission to
If a lower range is selected while moving forward, the neutral to avoid unnecessary heat buildup and apply
transmission automatically downshifts sequential to the parking brake.
the selected lower range at maximum controlled engine
speeds. Downshifts will not occur until vehicle is
slowed by use of the service brakes and/or retarder. WARNING
Always select Neutral and apply the parking brake
When shifting from neutral to start from a standstill, before leaving the operators seat.
or to reverse direction, decelerate the engine to idle
speed. To move forward, select drive 'D' and
accelerate the engine to the vehicle load and speed Speed Sensors - 3 off speed sensors (Fig. 7); Input,
requirements. The transmission will automatically Turbine and Output Speed, provide information to the
upshift from 1st through 6th ranges as travel speed ECU. The input speed signal is generated by the gear
increases. teeth on the top PTO gear. The turbine speed signal is
generated by the serrations on the tone wheel. The
With the throttle fully depressed, and the mode output speed sensor signal is generated by a toothed
selection switch in the Power position, the member attached to the output shaft. The speed ratios
transmission upshifts to the next higher range when between the various speed sensors allow the ECU to
the engine attains maximum rated speed, since determine if the transmission is in the selected range.
maximum power train output is needed under this Hydraulic problems are detected by comparing the
condition. speed sensor information for the current range to that
At lower throttle settings where minimum power train ranges speed sensor information programmed in the
performance is required, the transmission will upshift ECU memory.
to the next higher range at less than maximum
rated engine speed. Mode Selection Switch - Gives the option to select
between transmission Power and Economy shift
Upgrades or soft spots might slow travel speed, even schedules. The transmission must be in Neutral before
at full throttle, requiring transmission downshifts to the switch will function.
maintain maximum powertrain performance. When this
occurs, the transmission downshifts automatically. The transmission torque converter is equipped with a
lockup clutch which, when engaged by the ECU, locks
Shift the transmission to the next lowest range if the converter pump and turbine together as a single
transmission 'Hunting' or 'Shift Cycling' occurs. unit and allows power to be transmitted mechanically
from the engine directly to the transmission gearing on
When temporarily stopped, such as for yielding the a 1:1 ratio. When the lockup clutch is disengaged, the
The Economy mode is designed for applications Check Trans Warning Light (Fig. 8) - Illuminates to
involving lighter loads and level duty cycles or where alert of a minor fault in the transmission control system
fuel economy is more important than performance. or abnormal transmission temperature. The light will
come 'On' when the ignition key switch is turned to
In the Economy mode, the ECU controls operation of position '1' to provide a bulb and system check and
the lockup clutch with a timed, preprogrammed should go 'Off' a few seconds after the engine is
schedule where in second through sixth gears the started and the transmission oil pressure rises.
lockup clutch is disengaged only long enough to allow The check trans warning light will come 'On' during
the torque converters fluid coupling to absorb shift operation, if the ECU has detected a minor fault in an
shock. Otherwise, the lockup clutch is engaged and no electrical component or abnormal transmission oil
torque multiplication takes place in second through temperature. If transmission oil temperature is too high,
sixth gears. stop the vehicle, select neutral 'N', and increase engine
speed to allow a greater flow of oil to the cooler until oil
Manual Mode Switch - The manual mode facility is temperature drops to normal operating range. In most
designed as a Service Technician facility to allow stall cases, a minor fault triggering the check trans warning
checks and clutch pressure checks to be implemented light will not prevent normal operation from continuing
by Service Personnel, and permit movement of the but, depending on the nature of the problem, the ECU
vehicle, if necessary, to a repair area. With the manual could take action to protect the transmission from damage,
mode switch in the 'On' position, the body up interlock such as preventing operating in high gear ranges. If the
and hoist interlock pressure switch mechanisms are check trans light comes 'On', have the problem
disengaged! This allows unauthorised selection of diagnosed and corrected at the earliest opportunity.
reverse or any forward gear with the body raised,
constituting a safety hazard. Operators must not use Converter Mode Light - Illuminates when the
the manual mode facility when working the vehicle! It is transmission is in torque converter drive. It goes 'Off'
recommended that the mode selection key is removed when Lockup is engaged. In order to avoid
from the unit and retained in a safe place until required unnecessary waste of fuel, if traffic or other road
by Service personnel. conditions permit, the operator should modify throttle
position, or gear held, to achieve a steady road speed
Note: The manual mode can only be used if the mode with the torque converter lockup engaged (light 'Off').
selection switch is in the Power position and the The Lockup relay in the interface box (Fig. 5) is also
transmission is in neutral. activated by the 20 bar (290 psi) pressure switch on
the foot brake pedal. When this switch is activated the
Manual Mode Warning Light - This light is located on converter in light will be illuminated due to the
the front face of the CEC2 interface box. The Manual transmission dropping out of converter lock up,
Mode Warning Light illuminates to alert the operator avoiding engine stall. (Ref. Fig. 24)
when the transmission has been switched to operate in
LOCKUP CONNECTOR
ALL MODELS
TRIM BOOST CONNECTOR (K Solenoid and sump
(Solenoid J) temperature sensor)
5610, 6610
C.E.C.2 FUNCTIONS
1. Check Transmission - Relay within the Interface
Box triggers the Transmission Check Light on the dash
panel, when the transmission ECU senses a fault.
Fig. 11 - Hold in Range (Body Mag-Pick Up Switch)
2. Neutral Start - Neutral start relay inside the interface
box will not close unless the Transmission Shift 4. Bed Hoist Interlock (Reverse Hoist Interlock) - The
Selector is in the neutral position, thus preventing the ECU shifts the transmission to neutral (N) if the body is
engine ignition circuit being energised. raised when the transmission is in a selected reverse
gear (R). To over-ride this function, stop the truck, shift
ELECTRICAL DIAGRAMS
Transmission ECU Power Diagrams
Transmission ECU Power via the power module mounted on the trucks battery
box (Ref. Fig. 15 and 17). Inside the power module
Refer to Fig. 14
there are 3 relays, 1 timer relay and 5 power fuses.
With the ignition key (S2) in the off position - The
Battery Disconnect Relay (K2), Ignition Run Relay
After the ignition run relay (K23) has been energised,
(K23), Neutral Start Relay and Starter Relay (K1) are all
24 Volts is permitted to access the Power Module.
de-energised.
Inside the power module the three relays (A, B and C)
are energized allowing 24 Volt power to access the
Turning the ignition key (S2) to position 'R' energises
transmission and engine ECUs via the 5 power fuses.
the battery disconnect relay (K2). This allows 24 Volts
The timer relay (Fig. 18) allows the transmission and
to access the bus-bar from the batteries (G2). 24 Volts
engine ECUs to remain powered for at least 30
power is also on stand-by at the alternator (G1) and
seconds after the ignition key has been switched off
starter relay (K1).
(position '0'). This allows all operating data to be
downloaded into the ECU memory.
Turning the ignition key (S2) to position '1' energises
ignition run relay (K23). By energising ignition run relay
The truck will not be able to start up unless the
(K23), 24 Volts power from the bus-bar is directed to
transmission gear shift selector is in the neutral (N)
the power module (Ref. Fig. 18), via engine ECU fuse
position. An electrical signal via wire number 123 (Ref.
(F3) and transmission ECU fuse (F7).
Fig. 14), from the transmission ECU will energise the
neutral start relay, Only if the gear shift selector is in
Both the transmission and engine ECUs are powered
10 7
A C B
1. Check Trans. Relay 7. Converter Drive Relay
2. Neutral Start Relay 8. On Board Weighing Relay
3. Reverse Relay 9. Rear View Camera Relay
4. Body Up Relay 10. Ignition Signal Fuse
5. Delta P Relay A. Manual/Automatic Key
6. Lock Up Off Relay B. Power/Economy Key
C. Manual Mode Light
SM3870
2. Neutral Start - The Neutral Start Circuit prevents the
engine being started unless the shift selector is in the
neutral (N) position. Neutral start relay (2) inside the
1 interface box (Ref. Fig. 16) will not close unless the
Transmission Shift Selector is in the neutral position,
7
2 this signal is received via the ECU vehicle connector
3
4 (V), pin 6, wire 123.
8
5
6 SM3256
9 5 1
6 2
4 3
1. Timer Relay 6. Transmission Battery Power
2. Battery Fuse (15 A) Fuse (15 A)
3. Engine ECM Battery Power 7. Ignition Sense Relay (A)
Fuse (5 A) 8. Engine ECM Ignition Sense
4. Transmission Ignition Sense Relay (B) 1. Transmission Check Light 4. Converter Mode Light
Fuse (5A) 9. Transmission ECU Ignition 2. Delta P Filter Restriction 5. Transmission Oil Temperature
5. Transmission Battery Power Sense Relay (C) 3. Transmission Overspeed 6. Retarder Apply Light
Fuse (15 A)Fuse Fig. 19 - Warning Lights
Release delay
On-off pulse
4. Bed Hoist Interlock (Reverse Hoist Interlock) - The
On-pulse
Off-pulse SET DIAL TO 'Release delay'
ECU shifts the transmission to neutral (N) if the body is
raised when the transmission is in a selected reverse
0.6 - 6 sec
6 - 60 sec gear (R). To over-ride this function, stop the truck, shift
0.6 - 6 min
6 - 60 min SET DIAL TO '6 - 60 sec' gear shift selector to neutral, than back to reverse. The
4
5 ECU receives a signal from pressure switch (S51)
3
6
located on the raise circuit on the body control valve
SET DIAL TO '3'
LOCK IN POSITION 2 (Fig. 23). This signal request the interlock function via
USING ARALDITE OR
SIMILAR
1 wire 177 to the ECU vehicle connector (V), pin 14.
SM2932
1
8. Reverse Relay Signal - The signal to the reverse 12. Power/Economy Key - The power/economy key,
alarm is made by energising reverse relay (3), inside mounted on the interface box, is defined as (S53) -
the interface box (Ref. Fig. 16). When a reverse gear Ref. Fig. 21. The signal to switch between power and
has been selected, the signal from ECU vehicle economy mode is received at ECU shifter connector
connector (V) pin 4, wire 113, energises the reverse (S), pin 28, wire 126. For power/economy mode
relay (3), completing the reverse alarm circuit. functions, please refer to CEC-2 COMPONENTS,
Descriptions and Operation.
9. Engine Overspeed Lamp - Overspeed lamp will
illuminate, (Ref. Fig. 19), when a speed greater that SOLENOID WIRING HARNESS
2350 RPM is sensed. The speed sense signal
originates from the ECU vehicle connector (V), pin 22, For all transmission solenoid locations please refer to
wire 112. Fig. 9. All transmission solenoid inputs/outputs are
LOCKUP BODY
2 A + K
20 B -
27 C + TEMP
D - SENSOR
1
25 A
10 B TPS
9 C
14 A
30 B SS - ENGINE 3
15 A
31 B SS - TURBINE 2
16 A
32 B SS - OUTPUT
SM2937
Y
A
R
G
inputs and out puts for transmission functions. The 3
VEHICLE
connections are; CONNECTION
(V)
K
UE
A
BL
L
B
Refer to Fig. 30, 31 & 32 for generic connector pin Fig.29 - ECU
identifications.
WARNING
Before any welding is done on a machine equipped with an C.E.C. 2 system, disconnect the following
in this order: Battery earth cable, battery supply cable, alternator earth cables, alternator supply cables
and electrical connections at the engine ECM, transmission ECU and cab bulkhead to avoid damage to
1
electrical components. Turn off ignition key switch to isolate the batteries before disconnecting any
components. After welding connect all of the above in the reverse order.
GRAY
16
32
17
No. COLOUR WIRE# DESCRIPTION
1 R 136-V1 Main Power to ECU
3 O 132-V3 Converter Drive Warning Light
4 W 113-V4 Reverse Alarm
6 N 123-V6 Neutral Start
14 N 177-V14 Reverse Hoist Interlock
16 R 136-V16 Battery Power
17 B 143-V17 ECU Earth
22 N 112-V22 Overspeed Warning Light
26 K 146-V26 Engine Run Signal
27 W 154-V27 Lock Up Off Signal
28 O 178-V28 Retarder Apply
29 O 137-V29 Park Brake Interlock
30 G 117-V30 Delta P Switch
31 Y 161-V31 Isolated Return
32 B 143-V32 ECU Earth
Fig.30 - ECU Vehicle Connector (V)
BLACK
16
32
17
No. COLOUR WIRE# DESCRIPTION
1 W 142-S1 Diagnostic connector (High)
3 K 124-S3 Shift Selector Power
4 Y 146-S4 Ignition Sense (Diagnostic Connector)
5 O 170-S5 PSS, Data Bit 1
6 G 171-S6 PSS, Data Bit 2
7 U 172-S7 PSS, Data Bit 4
8 Y 173-S8 PSS, Data Bit 8
9 N 174-S9 PSS, Parity
10 G 175-S10 PSS Mode Input
11 Y 119-S11 ECU To Manual Mode Switch
12 G 182-S12 CAN Controller Shield (J1939)
13 R 183-S13 CAN Controller, High (+) (J1939)
14 U 180-S14 PSS Display
16 R 136-S16 Battery Power
17 U 151-S17 Diagnostic Connector (Low)
27 U 163-S27 Range Inhibit Signal
28 Y 126-S28 Secondary Mode Switch
29 B 184-S29 CAN Controller, Low (-) (J1939)
30 N 157-S30 Speedometer Drive
31 G 115-S31 Check Transmission
32 B 143-S32 Battery Return
BLUE
16
32
17
No. COLOUR WIRE# DESCRIPTION
1 O 102-T1 Solenoid Power, Solenoids F, G & I
2 N 121-T2 Solenoid Power, Solenoid K
3 G 107-T3 Solenoid Power, Solenoid J or H
4 W 120-T4 F Solenoid, Low
5 G 103-T5 B Solenoid, Low
6 N 129-T6 E Solenoid, Low
7 W 104-T7 A Solenoid, Low
8 G 111-T8 I Solenoid, Low
9 K 124-T9 TPS Power
10 U 156-T10 TPS Input
13 Y 195-T13 Transmission Identification
14 N 141-T14 Engine Speed Sensor, High
15 O 149-T15 Turbine Speed Sensor, High
16 Y 139-T16 Output Speed Sensor, High
17 Y 130-T17 Solenoid Power, Solenoids A & B
19 Y 116-T19 Solenoid Power, Solenoids E, D & C
20 O 128-T20 K Solenoid, Low
21 U 131-T21 G Solenoid, Low
22 W 110-T22 J or H Solenoid, Low
23 W 127-T23 D Solenoid, Low
24 U 101-T24 C Solenoid, Low
25 G 135-T25 Analog Return
27 N 147-T27 Sump Temperature Sensor Input
30 O 150-T30 Engine Speed Sensor, Low
31 U 140-T31 Turbine Speed Sensor, Low
32 G 148-T32 Output Speed Sensor, Low
5. Display starts with the code position, which will be (F) Event Counter - Determines how many times
d1, d2 etc. This is followed by the two digit main the code has occurred without being cleared from
code, then the two digit sub-code. the memory.
Clearing Codes
1. For Active Codes - Press and hold the mode button
for 3 to 5 seconds.
Abbreviations; DNS - Do Not Shift, Transmission will not respond to the shift selector when the transmission check light is illuminated.
SOL OFF - All Solenoids Off.
GPO - General Purpose Output, Output signal from ECU to control vehicle components to allow special operating mode.
Abbreviations; DNS - Do Not Shift, Transmission will not respond to the shift selector when the transmission check light is illuminated.
SOL OFF - All Solenoids Off.
GPO - General Purpose Output, Output signal from ECU to control vehicle components to allow special operating mode.
Abbreviations; DNS - Do Not Shift, Transmission will not respond to the shift selector when the transmission check light is illuminated.
SOL OFF - All Solenoids Off.
GPO - General Purpose Output, Output signal from ECU to control vehicle components to allow special operating mode.
Temperature Resistance
-40C (-40F) 200 ohms
20C (68F) 300 ohms
110C (230F) 400 ohms
SPECIAL TOOLS
The Special Tools listed in the following tables are
required for servicing the CEC 2 Shift System and are
available from your dealer.
SPECIAL TOOLS
TOOL NUMBER TOOL NAME
15275098 Diagnostic Data Reader (DDR) Multikit (Includes Reader, Cartridge, Cables)
15275180 CEC 2 Diagnostic Card
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 printer - 5 Rolls
15270344 No Flash Electro Contact Cleaner
SPECIAL TOOLS
The following list of tools are required to service CEC 2
wiring harnesses.
SPECIAL TOOLS
TOOL NUMBER TOOL NAME
15275719 Sealed Splice (14-16 AWG)
15275720 Sealed Splice (18-22 AWG)
15275721 Crimper - Deutsch Connector, Transmission Harness Bulkhead, J1939 Connector
15269234 Crimper (Alternate) - Delphi Packard (DDL connector)
15275722 Crimper (Alternate) - Throttle Position Sensor
15275723 Wire Stripper
15275724 Remover - Delphi Packard (DDL Connector), Sump Temperature Sensor
15275725 Remover - Throttle Position Sensor
15275726 Remover - Deutsch Connector
15275727 Crimper - Throttle Position Sensor, Delphi Packard (DDL Connector)
15275728 Crimper - Speed Sensors, Throttle Position Sensor,
15275729 Crimper - Repair of broken cable using appropriate Sealed Splice
15275730 Remover - Deutsch Connector (Optional DDL)
15269241 Crimper (Alternate) - Throttle Position Sensor
15275731 Remover - ECU Connectors, Shift Selector Connection
15275732 Connector Repair Kit - Transmission Harness Bulkhead Connector
15275733 Guide Pin - Transmission Harness Bulkhead Connector
15275734 Insertion Tool - Transmission Harness Bulkhead Connector
15275735 Terminal Remover - Transmission Harness Bulkhead Connector
15275736 Crimper - ECU Connectors, Shift Selector Connection
GLOSSARY
Detailed below is a glossary of abbreviation used
withing the C.E.C. 2 descriptions.
Abbreviation Termination Point
AGND Analog Return (Ground)
ASOL Solenoid A - Main Valve Body Cover
BSOL Solenoid B - Main Valve Body Cover
CSOL Solenoid C - Main Valve Body Cover
DDRD Diagnostic Data Reader - Deutsch
DDRP Diagnostic Data Reader - Packard
DSOL Solenoid D - Main Valve Body Cover
ECU-S Electronic Control Unit - Selector (S) Connector
ECU-T Electronic Control Unit - Transmission (T) Connector
ECU-V Electronic Control Unit - Vehicle (V) Connector
ESOL Solenoid E - Main Valve Body Cover
FSOL Solenoid F - Main Valve Body Cover
GSOL Solenoid G - Main Valve Body Cover
H/JSOL Solenoid H/J - Trim Boost or 1-2 Cover
ISOL Solenoid I - Solenoid I - 1-2 Cover
J1939 J1939 Data-link From ECU Selector (S) Harness
KSOL Solenoid K - Lockup Cover
LOW Low or 1-2 Cover
LU Lockup Cover
MNVB Main Valve Body Cover
NE Input (Engine) Speed Sensor
NO Output Speed Sensor
NT Turbine Speed Sensor
PSS Primary Shift Selector
RNGTRM Chassis Ground Ring Terminal
SCI Serial Communication Interface
TB Trim Boost Cover
TEMP Sump Temperature Sensor - Lockup cover
TPS Throttle Position Sensor
VIM Vehicle Interface Module
VIW Vehicle Interface Wiring
* * * *
SM - 1386
DESCRIPTION REMOVAL
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.
SM 1178 2-98 1
Transmission - Power Takeoff
Section 120-0090
parking brake and switch off the engine. suitable puller tool into the internally splined output
shaft (4) and pull output shaft, together with bearing
2. Turn steering wheel in both directions several times (14) from driven gear (5).
to relieve pressure in the steering circuit. Block all road
wheels. 6. Remove snap rings (1 & 3) and bearing (14) from
output shaft (4) if necessary.
3. Match mark the steering pump housing and power
takeoff housing (12) to facilitate assembly. Remove 7. Remove driven gear (5) and bearing (2) from
steering pump from power takeoff housing (12) housing (12). Remove bearing (2) from driven gear (5).
following procedures outlined in Section 220-0050,
STEERING PUMP.
INSPECTION
4. Disconnect hose assembly (22) from adaptor (21) Numbers in parentheses refer to Fig. 1.
and cap hose assembly and adaptor to prevent entry
of dirt. 1. Clean all parts, except bearings (2, 9 & 14), in a
suitable solvent and dry with compressed air.
5. Attach suitable lifting equipment to the power takeoff
assembly and remove bolts (18) and lockwashers 2. Clean bearings (2, 9 & 14) in volatile mineral spirits,
(19). Lift the power takeoff assembly and shims (15, and wipe dry with clean, lint-free cloth. Lubricate with
16 & 17) from the torque converter housing. Keep light oil, and spin by hand to check for wear and
shims (15, 16 & 17) with power takeoff housing (12) to roughness. Replace with new bearings if excessively
assure correct installation. Cover torque converter worn, or if operation is rough or noisy.
housing to prevent entry of dirt.
3. Check the condition of splines and teeth on all gears
Note: Identify or mark the number and thickness of and shafts for burrs or signs of excessive wear.
shims (15, 16 & 17) removed. This procedure is
necessary so as not to alter the backlash of the gears 4. Pinion shaft (8) and output shaft (4) should not be
during assembly. rough, worn, cracked or damaged. If either shaft is
distorted, it should be replaced.
Note: The gasket used at the steering pump mounting
face should be discarded and replaced at installation. 5. Check all threaded parts and tapped holes for
stripped or battered condition.
1. Remove the 'stake' mark from set screw (11), then 7. Gear teeth should not be worn, cracked or broken.
remove set screw (11).
8. Any small nicks, scratches or burrs should be
2. Place housing (12) on the bed of an arbor press smoothed up with a fine stone or crocus cloth, and
with the steering pump mounting flange facing part cleaned in solvent and dried with lint-free cloth.
downward. Remove pipe plug (13) and press pinion
shaft (8) out of housing (12).
ASSEMBLY
Note: If an arbor press is unavailable, the pinion shaft Numbers in parentheses refer to Fig. 1. Refer to
can be driven out of the housing using a soft drift and Fig. 2 for location of parts within housing (12).
hammer.
1. With housing (12) in position with steering pump
3. Remove and discard 'O' ring (7) from pinion shaft (8). mounting face up, press bearing (2) into bearing bore
in housing (12).
4. With housing (12) positioned mounting flange face up,
lift out pinion gear (10) and bearings (9) as an assembly. Note: Be sure bearing is seated by tapping outer race
Remove bearings (9) from pinion gear (10). with a soft drift and hammer.
5. Remove snap ring (1) from housing (12). Insert a 2. Install snap ring (3) onto output shaft (4).
2 SM 1178 2-98
Transmission - Power Takeoff
Section 120-0090
INSTALLATION
Numbers in parentheses refer to Fig. 1.
WARNING
To prevent personal injury and property
damage, be sure wheel chocks and lifting
equipment are properly secured and of
adequate capacity to do the job safely.
4. Press bearing (14) onto opposite end of output shaft 4. Hold or block either the power takeoff drive gear, or
(4) and install snap ring (1). Be sure bearing (14) is the converter charging pump driven gear, whichever is
seated against output shaft (4) shoulder, with shielded the case, so that it cannot revolve.
side of bearing facing toward snap ring (1) (facing out).
5. Set the dial indicator to a zero reading then, with a
5. Rotate driven gear (5) and check for any visible screwdriver, turn pinion gear (10) back and forth as far
signs of drag. as possible. The maximum allowable backlash is from
0.381 - 0.635 mm (0.015 - 0.025 in).
6. Press bearings (9) into bearing bores of pinion gear
(10). Be sure bearings are seated against shoulder in 6. If the dial indicator reading is less than 0.381 mm
pinion gear. (0.015 in) additional shims (15, 16 & 17) will have to be
installed. A greater reading than 0.635 mm
7. Position pinion gear (10) and bearings (9) assembly (0.025 in) means that some shims (15,16 & 17) will
in housing (12). Install a new 'O' ring (7) on pinion have to be removed.
shaft (8). Insert pinion shaft (8) through pinion gear
(10) and bearings (9), lining up set screw hole in pinion 7. After the correct backlash is obtained, remove the
shaft (8) with set screw hole in housing (12). block preventing the gear from revolving. Install pipe
plug (6) in housing (12) and secure the power takeoff
SM 1178 2-98 3
Transmission - Power Takeoff
Section 120-0090
assembly in position with bolts (18) and tighten lines and fittings as required.
lockwashers (19).
11. Ensure parking brake is applied and remove wheel
8. Remove blanking caps from adaptor (21) and hose chocks from all road wheels.
assembly (22) and install hose assembly (22).
* * * *
4 SM 1178 2-98
TRANSMISSION - Transmission Oil Filter
Section 120-0100
SM - 1385
SM 1576 12-98 1
Transmission - Transmission Oil Filter
Section 120-0100
REMOVAL INSTALLATION
Numbers in parentheses refer to Fig. 1, unless Numbers in parentheses refer to Fig. 1, unless
otherwise specified. otherwise specified.
2 SM 1576 12-98
Transmission - Transmission Oil Filter
Section 120-0100
5. Remove and discard 'O' ring (3) from filter head (1).
6. Clean housing (5) with clean fuel oil and dry with a
clean lint free cloth. Lubricate new 'O' ring (3) and
install on filter head (1).
1 - Filter Head 7. Install new element (2) on filter head (1), making
2 - Element sure plastic insert in element centre contacts spiral
3 - 'O' Ring snap ring on filter head (1).
4 - Pressure Switch
5 - Housing
8. Install housing (5) over element (2) and secure
Fig. 2 - Exploded View of Transmission Oil Filter tightly with locking collar.
* * * *
SM 1576 12-98 3
DRIVELINE - Front Driveline
Section 130-0010
SM - 084
TRANSMISSION
ENGINE
1 - Bolt
2 - Locking Strap
3 - Bearing Assembly
4 - Driveline
Fig. 1 - Exploded View of Driveline Installation
DESCRIPTION REMOVAL
The function of the driveline is to transmit rotating Numbers in parentheses refer to Fig. 1.
power from one point to another in a smooth and
continuous action while allowing a degree of
movement or misalignment of the components it WARNINGS
connects. To prevent personal injury and property
damage, be sure wheel blocks, blocking
The drivelines must operate through constantly materials and lifting equipment are properly
changing relative angles between the components secured and of adequate capacity to do the job
they are mounted to and must also be capable of safely.
changing length while transmitting torque.
Rotating shafts can be dangerous. You
A typical driveline consists of universal joints which can snag clothes, skin, hair, hands, etc. This
allow some misalignment and permit the driveline to can cause serious injury or death. Do not go
pivot in any direction, and, a light rigid hollow slip yoke under a vehicle when the engine is running.
and splined shaft assembly forming a slip joint.
Note: Extra care should be taken when handling
The slip joint accommodates length variations drivelines since carelessness can result in premature
generated during operation, preventing tension or failure of the components. Chips, dents, burrs, or any
compression loads from causing serious damage to other deformity of flanges will prevent accurate mating
the components. with the crosses and bearings. This will cause
misalignment, which is accompanied by vibration and
Note: Extra care should be taken when handling the excessive wear.
driveline since chips, dents, burrs or deformity on any
rotating mass creates vibration and excessive wear 1. Position the vehicle in a level work area, apply the
during any operation. parking brake and switch off the engine.
SM 1180 2-98 1
Driveline - Front Driveline
Section 130-0010
SM - 085
1 - Bolt
2 - Bearing Assembly 7 - Washer
3 - Cross Assembly 8 - Cork Washer
4 - Grease Fitting 9 - Yoke
5 - Shaft 10 - Grease Fitting
6 - Retainer 11 - Locking Strap
5. Using a soft faced hammer, tap bearing assembly 3. Remove cork washer (8), washer (7) and retainer
(3) lightly clockwise, then anticlockwise. Pry up each (6) from shaft (5). Discard cork washer (8).
end of bearing assembly (3) alternately until it is free
from the flange yoke. Remove opposite bearing
assembly (3) in the same manner. Universal Joint
1. Place the shaft (5) end of the driveline in a soft
6. Disconnect driveline (4) from flange yoke. jawed vice. Bend down tabs of locking strap (11) and
remove bolts (1) and locking strap.
7. Repeat Steps 4 through 6 to disconnect opposite
end of driveline (4). 2. Using a soft faced hammer, lightly tap bearing
assembly (2) in a clockwise rotation, then counter-
8. Remove driveline (4) assembly from vehicle. clockwise. Pry up each end of bearing assembly
alternately until it is free from the yoke. Turn assembly
over and remove opposite bearing assembly in the
same manner.
2 SM 1180 2-98
Driveline - Front Driveline
Section 130-0010
3. Insert bearing assembly (2) into yoke lug hole. Note: Make sure driveline is assembled with
Press bearing assembly into place with an arbor press alignment arrows and grease fittings properly aligned.
or tap in place with a plastic hammer. Replace locking
strap (11) and bolts (1). 1. Using suitable lifting equipment, raise driveline (4)
into position on the vehicle.
4. Turn yoke assembly over and replace opposite
bearing assembly (2) as described in Step 3. Tighten 2. Install bearing assembly (3) in flange yoke over the
bolts (1) on both ends of yoke to a torque of 45 Nm end of the cross and secure with locking strap (2) and
(33 lbf ft), and bend tabs on locking straps (11) up bolts (1). Tighten bolts (1) to a torque of 45 Nm
against flat sides of bolts to prevent bolts loosening. (33 lbf ft), and bend tabs of locking strap (2) up against
flat sides of bolts to prevent bolts loosening.
5. If joint appears to bind, tap bearing assembly (2)
lightly to relieve any pressure on cross assembly (3). 3. Repeat Step 2 on opposite side of flange yoke.
6. Repeat Steps 1 through 5 for opposite end of driveline. 4. Repeat Steps 2 and 3 at opposite end of driveline.
SM 1180 2-98 3
Driveline - Front Driveline
Section 130-0010
MAINTENANCE Using a small pry bar, check the crosses for play. If
loose, replace the cross and bearings. Check splines
Lubrication at slip joint and replace yoke, if excessively worn.
Lubricate driveline with either a hand-operated or a
pressure grease gun. Refer to Section 300-0020, Note: In the event of a failed or worn bearing, a new
LUBRICATION SYSTEM, for recommended lubricant cross with a new set of bearings must be installed.
and service intervals.
SPECIAL TOOLS
Periodic Inspection There are no special tools required for procedures
Use a small pry bar to check companion flange yokes outlined in this section. Refer to Section 300-0070,
for looseness. If loose, drop one end of the driveline SERVICE TOOLS, for part numbers of general service
and twist the yoke to check backlash between splines tools required. These tools are available from your
and yokes. Replace any yoke that does not fit snugly. dealer.
* * * *
4 SM 1180 2-98
DRIVELINE - Front Driveline
Section 130-0010
SM - 1982
ENGINE 2
2
1
TRANSMISSION
3
3
4 4
1 - Driveline Assembly
2 - Universal joint
3 - Capscrew
4 - Capscrew
DESCRIPTION REMOVAL
The function of the driveline is to transmit rotating Numbers in parentheses refer to Fig. 1.
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. WARNINGS
To prevent personal injury and property
The drivelines must operate through constantly damage, be sure wheel blocks, blocking
changing relative angles between the components they materials and lifting equipment are properly
are mounted to and must also be capable of changing secured and of adequate capacity to do the job
length while transmitting torque. safely.
A typical driveline consists of universal joints which Rotating shafts can be dangerous. You
allow some misalignment and permit the driveline to can snag clothes, skin, hair, hands, etc. This
pivot in any direction, and, a light rigid hollow slip yoke can cause serious injury or death. Do not go
and splined shaft assembly forming a slip joint. under a vehicle when the engine is running.
The slip joint accommodates length variations Note: Extra care should be taken when handling
generated during operation, preventing tension or drivelines since carelessness can result in premature
compression loads from causing serious damage to the failure of the components. Chips, dents, burrs, or any
components. other deformity of universal joints will prevent accurate
mating. This will cause misalignment, which is
Note: Extra care should be taken when handling the accompanied by vibration and excessive wear.
driveline since chips, dents, burrs or deformity on any
rotating mass creates vibration and excessive wear 1. Position the vehicle in a level work area, apply the
during any operation. parking brake and switch off the engine.
SM 1577 12-98 1
Driveline - Front Driveline
Section 130-0010
2. Turn steering wheel in both directions several times SM - 088
to relieve pressure in the steering circuit. Block all road
wheels. APPLY PRESSURE MAXIMUM PERMISSIBLE
HERE BY HAND GAP IS 0.2 mm (0.008 in)
3. Match mark universal joints (2) and their mating
surfaces to ensure correct mating alignment when
installing driveline assembly (1). STRAIGHTEDGE
DISASSEMBLY
Numbers in parentheses refer to Fig. 1. Fig. 2 - Checking Parallelism
Universal Joint
1. Place the yoke end of driveline assembly (1) in a ASSEMBLY
soft jawed vice, clamping on the tube of shaft. Numbers in parentheses refer to Fig. 1.
Note: Do not distort the tube within excessive grip. Universal Joint
1. Place the yoke end of driveline assembly (1) in a
2. Remove capscrews (3) and universal joints (2) from soft jawed vice, clamping on the tube of shaft.
driveline assembly (1).
Note: Do not distort the tube within excessive grip.
3. Place the shaft end of driveline assembly (1) in a
soft jawed vice. 2. Install universal joints (2) to yoke end of driveline
assembly (1) and secure with capscrews (3). Tighten
4. Remove capscrews (3) and universal joint (2) from capscrews (3) to a torque of 128 - 142 Nm
driveline assembly (1). (95 - 105 lbf ft).
3. Check the surfaces of the components that Note: Tighten all fasteners without special torques
universal joints mate against for parallelism. Refer to specified to standard torques listed in Section
Fig 2. 300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
4. Check the condition of mounting capscrews and
replace if required. Note: Extra care should be taken when handling
drivelines since carelessness can result in premature
failure of the components. Chips, dents, burrs, or any
2 SM 1577 12-98
Driveline - Front Driveline
Section 130-0010
WARNINGS
To prevent personnel injury and property Periodic Inspection
damage, be sure wheel blocks, blocking Use a small pry bar to check companion flange yokes
materials and lifting equipment are properly for looseness. If loose, drop one end of the driveline
secured and of adequate capacity to do the job and twist the yoke to check backlash between splines
safely. and yokes. Replace any yoke that does not fit snugly.
To prevent serious injury or death, DO Using a small pry bar, check the universal joints for
NOT go under vehicle when the engine is play. If loose, replace the universal joints. Check
running. Rotating shafts can be dangerous. You splines at slip joint and replace universal joints, if
can snag clothes, skin, hair, hands, etc. excessively worn.
1. Using suitable lifting equipment, position driveline Note: In the event of a failed or worn bearing, a new
assembly (1) on the vehicle and align match marks on universal joint with a new set of bearings must be
universal joints (2) with those on its mating surfaces. installed.
MAINTENANCE
SM 1577 12-98 3
Driveline - Front Driveline
Section 130-0010
* * * *
4 SM 1577 12-98
DRIVELINE - Rear Driveline
Section 130-0020
SM - 1534
2 2
2
3 1 3
DESCRIPTION REMOVAL
The function of the driveline is to transmit rotating Numbers in parentheses refer to Fig. 1.
power from one point to another in a smooth and
continuous action while allowing a degree of
movement or misalignment of the components it WARNINGS
connects. To prevent personal injury and property
damage, be sure wheel blocks, blocking
The drivelines must operate through constantly materials and lifting equipment are properly
changing relative angles between the components secured and of adequate capacity to do the job
they are mounted to and must also be capable of safely.
changing length while transmitting torque.
Rotating shafts can be dangerous. You
A typical driveline consists of universal joints which can snag clothes, skin, hair, hands, etc. This
allow some misalignment and permit the driveline to can cause serious injury or death. Do not go
pivot in any direction, and, a light rigid hollow slip under a vehicle when the engine is running.
yoke and splined shaft assembly forming a slip joint.
Note: Extra care should be taken when handling
The slip joint accommodates length variations drivelines since carelessness can result in premature
generated during operation, preventing tension or failure of the components. Chips, dents, burrs, or any
compression loads from causing serious damage to other deformity of flanges will prevent accurate
the components. mating with the crosses and bearings. This will cause
misalignment, which is accompanied by vibration and
Note: Extra care should be taken when handling the excessive wear.
driveline since chips, dents, burrs or deformity on
any rotating mass creates vibration and excessive 1. Position the vehicle in a level work area, apply the
wear during any operation. parking brake and switch off the engine.
SM 1181 2-98 1
Driveline - Rear Driveline
Section 130-0020
4. Remove bolts and nuts (4) securing flange yoke 1. Using suitable lifting equipment, raise driveline (1)
(2) to transmission flange and differential flange. assembly into position on the vehicle.
5. Remove driveline (1) assembly from the vehicle. 2. Connect flange yoke (2) to transmission flange
with bolts and nuts (4). Tighten bolts (4) to a torque
of 290 - 300 Nm (215 - 220 lbf ft).
INSTALLATION
Numbers in parentheses refer to Fig. 1. 3. Connect flange yoke (2) to differential flange with
bolts and nuts (4). Tighten bolts (4) to a torque of
Note: Extra care should be taken when handling 290 - 300 Nm (215 - 220 lbf ft).
drivelines since carelessness can result in premature
failure of the components. Chips, dents, burrs, or any
other deformity of flanges will prevent accurate MAINTENANCE
mating with the crosses and bearings. This will cause Lubricate driveline with either a hand-operated or a
misalignment, which is accompanied by vibration and pressure grease gun. Refer to Section 300-0020,
excessive wear. LUBRICATION SYSTEM, for recommended lubricant
and service intervals.
WARNING
To prevent personal injury and property SPECIAL TOOLS
damage, be sure wheel blocks, blocking There are no special tools required for procedures
materials and lifting equipment are properly outlined in this section. Refer to Section 300-0070,
secured and of adequate capacity to do the job SERVICE TOOLS, for part numbers of general
safely. service tools required. These tools are available from
your dealer.
2 SM 1181 2-98
Driveline - Rear Driveline
Section 130-0020
* * * *
SM 1181 2-98 3
DRIVELINE - Rear Driveline
Section 130-0020
SM - 1983
TRANSMISSION
2
1 4
DIFFERENTIAL
4
2
1 - Driveline Assembly
2 - Universal joint
3 - Capscrew
4 - Capscrew
DESCRIPTION REMOVAL
The function of the driveline is to transmit rotating Numbers in parentheses refer to Fig. 1.
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. WARNINGS
To prevent personal injury and property
The drivelines must operate through constantly damage, be sure wheel blocks, blocking
changing relative angles between the components they materials and lifting equipment are properly
are mounted to and must also be capable of changing secured and of adequate capacity to do the job
length while transmitting torque. safely.
A typical driveline consists of universal joints which Rotating shafts can be dangerous. You
allow some misalignment and permit the driveline to can snag clothes, skin, hair, hands, etc. This
pivot in any direction, and, a light rigid hollow slip yoke can cause serious injury or death. Do not go
and splined shaft assembly forming a slip joint. under a vehicle when the engine is running.
The slip joint accommodates length variations Note: Extra care should be taken when handling
generated during operation, preventing tension or drivelines since carelessness can result in premature
compression loads from causing serious damage to the failure of the components. Chips, dents, burrs, or any
components. other deformity of universal joints will prevent accurate
mating. This will cause misalignment, which is
Note: Extra care should be taken when handling the accompanied by vibration and excessive wear.
driveline since chips, dents, burrs or deformity on any
rotating mass creates vibration and excessive wear 1. Position the vehicle in a level work area, apply the
during any operation. parking brake and switch off the engine.
SM 1578 12-98 1
Driveline - Rear Driveline
Section 130-0020
2. Turn steering wheel in both directions several times SM - 088
to relieve pressure in the steering circuit. Block all road
wheels. APPLY PRESSURE MAXIMUM PERMISSIBLE
HERE BY HAND GAP IS 0.2 mm (0.008 in)
3. Match mark universal joints (2) and their mating
surfaces to ensure correct mating alignment when
installing driveline assembly (1). STRAIGHTEDGE
DISASSEMBLY
Numbers in parentheses refer to Fig. 1. Fig. 2 - Checking Parallelism
Universal Joint
1. Place the yoke end of driveline assembly (1) in a ASSEMBLY
soft jawed vice, clamping on the tube of shaft. Numbers in parentheses refer to Fig. 1.
Note: Do not distort the tube within excessive grip. Universal Joint
1. Place the yoke end of driveline assembly (1) in a
2. Remove capscrews (3) and universal joints (2) from soft jawed vice, clamping on the tube of shaft.
driveline assembly (1).
Note: Do not distort the tube within excessive grip.
3. Place the shaft end of driveline assembly (1) in a
soft jawed vice. 2. Install universal joints (2) to yoke end of driveline
assembly (1) and secure with capscrews (3). Tighten
4. Remove capscrews (3) and universal joint (2) from capscrews (3) to a torque of 312 - 325 Nm
driveline assembly (1). (230 - 240 lbf ft).
3. Check the surfaces of the components that Note: Tighten all fasteners without special torques
universal joints mate against for parallelism. Refer to specified to standard torques listed in Section
Fig 2. 300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
4. Check the condition of mounting capscrews and
replace if required. Note: Extra care should be taken when handling
drivelines since carelessness can result in premature
failure of the components. Chips, dents, burrs, or any
2 SM 1578 12-98
Driveline - Rear Driveline
Section 130-0020
WARNINGS
To prevent personnel injury and property Periodic Inspection
damage, be sure wheel blocks, blocking Use a small pry bar to check companion flange yokes
materials and lifting equipment are properly for looseness. If loose, drop one end of the driveline
secured and of adequate capacity to do the job and twist the yoke to check backlash between splines
safely. and yokes. Replace any yoke that does not fit snugly.
To prevent serious injury or death, DO Using a small pry bar, check the universal joints for
NOT go under vehicle when the engine is play. If loose, replace the universal joints. Check
running. Rotating shafts can be dangerous. You splines at slip joint and replace universal joints, if
can snag clothes, skin, hair, hands, etc. excessively worn.
1. Using suitable lifting equipment, position driveline Note: In the event of a failed or worn bearing, a new
assembly (1) on the vehicle and align match marks on universal joint with a new set of bearings must be
universal joints (2) with those on its mating surfaces. installed.
MAINTENANCE
SM 1578 12-98 3
Driveline - Rear Driveline
Section 130-0020
* * * *
4 SM 1578 12-98
FRONT AXLE - Wheel, Rim and Tyre
Section 140-0040
SM - 228
DESCRIPTION
The wheel is mounted on the axle spindle with two WARNING
tapered roller bearings mounted in the hub. The brake Tyre explosion hazard. Gases that build up
disc is bolted to the wheel. The tyre rim consisting of a inside an air inflated tyre mounted on a rim
base assembly, bead seat band and flanges is during welding and/or heating of rim
mounted on the wheel with clamps and nuts. components can ignite, causing an explosion
of the tyre and rim components. This warning
The wheel itself is a large cylindrical casting with the also applies to Nitrogen gas inflated tyres.
bearing bores and other finished surfaces machined Ignition will not occur in a Nitrogen gas
after the wheel is cast. atmosphere; but the pressure build up from
the applied heat may be sufficient to cause a
The rim assembly consists of a rim base, inner and blowout severe enough to injure or kill. Never
outer flanges, bead seat band, 'O' ring and lock ring. weld or otherwise apply heat on rim
components with the tyre mounted on the rim,
The wheel rim assembly is designed to be replaced whether the tyre is inflated or deflated, to
with a pre-assembled tyre and rim. prevent injury or property damage from the
potential tyre explosion! Also, do not attempt
to repair rims or rim components by welding or
PREPARATION FOR SERVICING heating, even if the tyre is not mounted on the
rim. It is recommended to scrap questionable
rim parts unless specific permission and repair
WARNING procedures are obtained in writing either from
Before loosening rim clamps or performing the company or the rim manufacturer.
any service on the tyre or rim components, to
prevent personal injury and property damage,
completely deflate tyre by removing the valve REMOVING TYRE AND RIM ASSEMBLY
cap and core. Insert a thin wire through the Numbers in parentheses refer to Fig. 1.
valve to be sure the valve is not plugged. Even
a flat tyre, in some cases, will retain sufficient If the tyre and rim assembly is to be replaced with a
air pressure to blow off a rim component with pre-assembled tyre and rim assembly, it is not
enough force to cause injury or death.
SM 1579 12-98 1
Front Axle - Wheel, Rim and Tyre
Section 140-0040
necessary to remove the tyre from the rim on the SM - 204
machine. The tyre and rim may be removed from the
machine as an assembly, and transported to a more
desirable location for removing the tyre from the rim.
WARNING
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of sufficient capacity to do the job
safely.
WARNING
When lifting tyre from rim, be sure the
equipment is of sufficient capacity and
properly secured to do the job safely.
2 SM 1579 12-98
Front Axle - Wheel, Rim and Tyre
Section 140-0040
SM 1579 12-98 3
Front Axle - Wheel, Rim and Tyre
Section 140-0040
WARNING
When lifting tyre onto rim, be sure the
equipment is of sufficient capacity and
properly secured to do the job safely.
7. Install lock ring (3) in groove of rim (4). Use pry bar 2. Install clamps (1) and start wheel nuts (2) on wheel
for this operation, as illustrated in Fig. 5. studs (3). Gradually tighten wheel nuts opposite each
other, until all nuts are snug, torque tighten wheel nuts
8. Force bead seat band (2) past 'O' ring groove in rim (2) to 690 Nm (510 lbf ft).
(4) by prying, or with lift truck forks. Use blocking Re-tighten nuts after a few hours operation.
between the forks and tyre to prevent tyre damage.
Lubricate area of rim adjacent to 'O' ring groove with a Note: Wheel rim fastener torque should be checked
thin solution of soap and water or another approved regularly, particularly on new machines or newly-
lubricant which is not harmful to rubber. Avoid using an installed wheels, to maintain the required wheel rim-
excessive amount of lubricant. Insert a new 'O' ring (7, clamp load. A newly installed wheel or a new machine
Fig. 1) in the groove of the rim behind the lock ring. should be checked at 30 day intervals until rim
fasteners show no significant torque loss from the
9. Lift tyre upwards to effect a seal between bead seat previous check. After that, a 90 day torque check
band (2) and 'O' ring (7, Fig. 1). In some cases the tyre interval should be adequate.
4 SM 1579 12-98
Front Axle - Wheel, Rim and Tyre
Section 140-0040
SM - 229
BRAKE CALLIPER
SEC 165-0020
1 - Lockwire
2 - Bolt
3 - Plate
4 - Shim Pack
5 - Outer Bearing Cone
6 - Outer Bearing Cup
7 - Wheel
8 - Spindle
9 - Inner Bearing Cone
10 - Inner Bearing Cup
11 - Washer
12 - Snap Ring
13 - Seal
14 - Bushing
15 - Bolt
16 - Lockwasher
17 - Brake Disc
18 - Bolt
19 - Lockwasher
20 - Cover
21 - Gasket
WHEEL 1. Block the front and rear of all wheels, except the
one to be raised. Jack up or lift machine so its weight
Removal and Disassembly is no longer on that wheel.
Numbers in parentheses refer to Fig. 6.
2. Deflate tyre completely, and remove the tyre and
rim assembly from the wheel. Follow instructions
WARNINGS under 'Removing Tyre and Rim Assembly'.
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly WARNING
secured and of sufficient capacity to do the job To prevent possible personal injury, relieve the
safely. pressure in the braking system. The exact
procedure must be followed as described in
To prevent personal injury and property Section 250-0000, BRAKING SYSTEM
damage, completely deflate tyre by removing SCHEMATIC.
the valve cap and core. Insert a thin wire
through valve to be sure valve is not plugged. 3. Relieve the pressure in the braking system. Refer to
Even a flat tyre, in some cases, will retain Section 250-0000, BRAKING SYSTEM SCHEMATIC.
sufficient air pressure to blow off a rim Disconnect brake hydraulic line at brake calliper.
component with enough force to cause injury
or death.
SM 1579 12-98 5
Front Axle - Wheel, Rim and Tyre
Section 140-0040
BEARING ADJUSTMENT
INITIAL SEATING GAUGING BOLT SHIM PACK FINAL BOLT
BOLT TORQUE TORQUE THICKNESS TORQUE
No. of Nm lbf ft No. of Nm lbf ft mm in All Nm lbf ft
Bolts Bolts Bolts
6 54 40 2 54 40 Ave. Gap Ave. Gap 6 224 165
+ 0.025 + 0.001
6 SM 1579 12-98
Front Axle - Wheel, Rim and Tyre
Section 140-0040
hot enough. Slide heated bushing (14) on spindle (8) only two bolts (2) located 180o apart, adjacent to the
and tap lightly with a hammer to seat it. gauging holes in plate (3). Tighten bolts (2) evenly in
equal increments to 'Gauging Bolt Torque', as
Note: Do not apply flame directly to bushing. Place specified in 'Bearing Adjustment Table', while rotating
bushing on steel plate and apply flame to centre of and bumping wheel (7) assembly.
plate, to evenly distribute heat.
11. Determine gap between plate (3) and end of
2. If removed, install bearing cups (6 & 10) in their spindle (8) at both gauging holes. To determine gap,
respective wheel (7) bearing bores with care to avoid use a depth micrometer in both gauging holes to
damaging their raceways. Installation by press fit at measure distance from outer face of plate (3) to end of
ambient temperature is best. Note that the cups must spindle (8). Using a micrometer, measure thickness of
seat fully against the shoulders of the cup bores in the plate (3). Subtract plate thickness reading from depth
wheel hub to assure retention of bearing adjustment. If gauge readings.
carbon dioxide, or dry ice, freezing of the cup is used,
remember to permit the cup and hub to warm to 12. Average the two readings, obtained at Step 11, in
ambient temperature after insertion and then to tap increments of 0.025 mm (0.001 in) and round off to the
them with a soft steel drift and hammer to seat. next higher 0.025 mm (0.001 in). This is the average
gap. The required shim pack (4) thickness is equal to
3. Lubricate the bearings with lubricant specified in the average gap plus the tabulated constant as shown
Section 300-0020, LUBRICATION SYSTEM. Do not in the 'Bearing Adjustment Table'.
pack bearings solidly with lubricant, as too much is
harmful. Fill wheel cavity not less than one-third to not 13. Install the required shim pack (4), plate (3) and
more than one-half full with lubricant. bolts (2) on the end of spindle (8). Tighten bolts (2)
evenly in equal increments to 'Final Bolt Torque', as
4. If removed, install brake disc (17) on wheel (7) and specified in 'Bearing Adjustment Table', while rotating
secure with bolts (15) and lockwashers (16). Tighten and bumping the wheel (7) assembly. Secure bolts (2)
bolts (15) to a torque of 420 Nm (310 lbf ft). with lockwire (1).
5. Install inner cone (9), washer (11), snap ring (12) 14. Install gasket (21) and cover (20) and secure to
and seal (13) in wheel end facing spindle. Seal lip wheel (7) with bolts (18) and lockwashers (19).
must be facing out.
15. Install brake calliper, connect brake hydraulic line
6. With suitable lifting equipment slide wheel (7) and bleed braking system. Refer to Section
assembly onto spindle (8). 165-0020, BRAKE PARTS.
7. Install outer bearing cone (5) on spindle (8) and seat 16. Install tyre and rim assembly as described under
in outer bearing cup (6). 'Mounting Tyre and Rim Assembly on Machine'.
10. Reassemble plate (3) without shims (4) and using Even with these precautions remember
that air-blast is a potential hazard. Tyre
inflation should be carried out away from busy
working areas.
SM 1579 12-98 7
Front Axle - Wheel, Rim and Tyre
Section 140-0040
SM - 208
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
To prevent personal injury and property
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 temperatures.
B. Fig. 7 - Typical Safety Cage
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 WARNING - Continued
the air for inflating tyres. The compressor recommended concentration to prevent
should be isolated from all such sources of condensate freezing are below hazardous
flammable vapours. levels for tyre inflation.
C. F.
Be sure to thoroughly flush and blow off all Another source of hazardous flammable
flammable solvents used for cleaning the air vapours in tyres is the tyre bead lubricant.
compressor inlet screen before using the Always use bead lubricants that do not
compressor for tyre inflation, or any other introduce flammable vapours into the tyre.
purpose.
D.
Do not charge batteries, either in or out of a Inflation
machine, near the air inlet of a compressor Note: Always use tyre inflation equipment with an air
used for inflating tyres. Charging batteries filter that removes moisture from the air supply, when
produces highly explosive hydrogen gas which available, to prevent moisture corrosion of internal rim
can be readily drawn into a nearby compressor parts.
inlet and pumped into the tyre.
E. 1. If the tyre is off the machine, it should be placed in a
Never exceed the specified concentration of safety cage before inflating. See Fig. 7.
alcohol when adjusting the alcohol vaporiser,
or adding alcohol to the auxiliary air tank, used 2. Inflate all tyres with ratings of 16-ply and above to
on machine air systems to prevent freezing or 5.2 bar (75 lbf/in) to seat beads and seal 'O' ring, then
moisture condensate in below-freezing adjust to the recommended pressure.
temperatures. Excessive alcohol, added to the
machines air tanks in this manner can produce 3. For recommended operating air pressure, refer to
flammable vapours that will be pumped into a the chart under the heading, 'Tyre Inflation Pressures'.
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
8 SM 1579 12-98
Front Axle - Wheel, Rim and Tyre
Section 140-0040
SM 1579 12-98 9
Front Axle - Wheel, Rim and Tyre
Section 140-0040
observing the gauge at the pressure regulator. STAY TYRE EXPLOSION HAZARD
AWAY FROM THE TYRE.
10 SM 1579 12-98
Front Axle - Wheel, Rim and Tyre
Section 140-0040
SM - 218
AT LEAST 15 m (50 ft) AT LEAST 460 m
(1 500 ft)
without removing the tyre from the rim. Use tyre repair
WARNING plugs and follow the directions given by the
There is always a possibility of a tyre manufacturer.
explosion whenever the smell of burning
rubber or excessively hot brakes is detected. The tyre must be removed from the rim to repair larger
The danger is also present when a fire on the punctures or cuts. Irregular shaped punctures or cuts
machine reaches the tyre and wheel area. less than 13 mm (0.5 in) in size can be repaired with a
Under such conditions, all personnel must plug and hot patch. Insert a repair plug into the hole to
avoid approaching the machine in a manner keep out moisture and to back up the hot patch. Trim
that could result in injury should an explosion the plug off flush with the inside of the casing, buff,
actually occur. Move the machine to a remote and apply the hot patch according to the instructions
area only if it can be done without endangering supplied with the hot-patch equipment.
the operator or other personnel in the area.
Punctures 13 mm (0.5 in) or larger, large cuts, or
bruise breaks require sectional or reinforced
TYRE MAINTENANCE vulcanized repair. Cover the repair patch with a layer
of cushion gum after application to the tubeless tyre to
Tyre Repairs ensure an airtight repair. Any cords of the inside ply
Prompt repair of tyre injuries will prevent small injuries that are exposed in bugging and are not covered with
from enlarging and causing tyre failure. Use the best repair patch must be coated with cushion gum to
tyre facilities available. If good repair facilities are not prevent air leakage into the carcass plies on tubeless
available, have the nearest dealer make the necessary tyres.
repairs.
SM 1579 12-98 11
Front Axle - Wheel, Rim and Tyre
Section 140-0040
Maintain Good Haul Roads Proper Handling of Tubeless Tyres and Rims
Because haul roads are considered temporary roads, Tubeless tyres should be stored vertically. Horizontal
they are frequently neglected. The better the haul stacking may compress the tyre walls making inflation
road, the longer the tyre and machine life of off-the- difficult. If tyres are stored in racks, the lower
highway equipment. supporting members should provide as broad a
surface as possible to the tyre tread to avoid a
Although it takes time and effort to maintain good haul concentration of load.
roads, delay and cost of tyre and machine breakdowns
caused by poor haul roads is many times greater. 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
Inspect Tyres Regularly when lifting these tyres. If forklift trucks are used for
A systematic plan for tyre inspection will more than handling they should be equipped with broad, well
pay for itself in lowered tyre costs per hour of rounded arms to distribute the load and prevent
operation. All tyres should be checked regularly for damage to the tyre bead. When handling tyres with the
cuts, bruises, fabric breaks, excessive or uneven fork truck do not scrape the fork across the bead.
wear, embedded foreign matter, and any other
damage which can be repaired. A considerable Tubeless tyre rims perform an important function as
increase in tyre service can be realized if tyre injuries part of the assembly air seal. Proper care therefore
are repaired before they have progressed to the must be taken not to distort or mutilate the rim parts
irreparable stage. The rim mounting nuts should be because they must mate properly to form part of the
checked periodically and tightened to the basic air chamber. Since the rim base, bead seat
recommended torque. bands, and flanges are endless, distortion may
prevent easy assembly as well as possibly resulting in
no seal.
Prevent Overloading
Off-the-highway machines are designed to carry a Never drop, tumble, or roll rim parts.
maximum allowable payload. Excessive loading will
overstress both the machine and tyres and shorten the If rim parts are stored outdoors they should be given a
life of both. protective coat of a good commercial primer.
12 SM 1579 12-98
Front Axle - Wheel, Rim and Tyre
Section 140-0040
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.
SM 1579 12-98 13
Front Axle - Wheel, Rim and Tyre
Section 140-0040
* * * *
14 SM 1579 12-98
REAR AXLE - Differential
Section 160-0020
SM - 1984
SM 1580 12-98 1
Rear Axle - Differential
Section 160-0020
REMOVAL 10. Remove the self locking nuts which secure the
Numbers in parentheses refer to Fig. 1. differential housing to the axle banjo housing. Each
time a nut is removed, deeply scribe one of the flats
on the nut. The nuts should not be reused more than
WARNINGS five times.
To prevent personal injury and property
damage, be sure wheel chocks, blocking 11. Turn the four thread protectors in to break the
materials and lifting equipment are properly seal between the differential assembly and banjo
secured and of adequate capacity to do the job housing. If this does not move the differential
safely. assembly out enough, either remove the thread
protectors and insert longer bolts in the four holes, or
A come-a-long or chain fall with a use a suitable bar to pry the differential assembly
minimum capacity of one ton is required for away from the banjo housing and studs. If a bar is
removal and installation of a differential used, caution should be exercised to prevent
assembly. damaging the mounting surfaces.
1. Position the vehicle in a level work area, raise the 12. Pull the differential assembly away from the banjo
body and install the body prop pins. Refer to Section until it clears the studs of the axle banjo housing,
270-0010, BODY AND MOUNTING. then carefully lower the differential assembly.
2. Apply the parking brake and switch off the engine. 13. Move differential assembly to a clean work area
for disassembly.
3. Turn the steering wheel in both directions several
times to relieve pressure in the steering system.
Block all road wheels. DISASSEMBLY
Numbers in parentheses refer to Fig. 1.
4. With suitable containers in position, drain the
lubricant from the differential banjo housing and
wheel planetary assemblies. WARNING
To prevent personal injury and property
5. Remove the driving flange cover from each wheel damage, be sure lifting equipment is properly
and pull the axle shaft and sun pinion gear assembly secured and of adequate capacity to do the job
of each driving wheel at least 150 mm (6 in) out of safely.
the wheel housing to disengage the inner axle shaft
splines from the splines of side gears (34). Refer to
Section 160-0030, AXLE GROUP. Ring Gear Group
1. Remove lockwire (1) from bolts (2). Secure a C'
6. Identify the relationship of pinion yoke (5) flange clamp over ring gear (29) to prevent it from turning.
with that of the driveline companion flange using Loosen, do not remove, bolts (2).
punch marks. Remove rear driveline connecting
differential and transmission. Refer to Section 2. Cut and remove lockwire (1), then loosen, but do
130-0020, REAR DRIVELINE. not remove bolts (21) securing bearing caps (22) to
carrier housing (19).
7. Remove set screw (4) from differential housing
and replace it with a lifting eye. Note: Make identifying punch marks on both the
bearing caps (22) and carrier housing (19), so that
8. Install chain fall or come-a-long to the loop placed the bearing caps can be returned to their original
on the body just behind the hoist brackets. Attach the position in assembly.
other end of the lifting device to eye previously
installed in the differential assembly. 3. Scribe an identifying line on bearing adjusters (25)
and carrier housing (19) bores which these adjusters
9. Support the weight of the differential assembly with screw into. If the differential assembly is
the lifting device. disassembled for inspection purposes only, this line
will be of assistance when readjusting the preload on
the side bearing cups (26) and cones (27). If the
2 SM 1580 12-98
Rear Axle - Differential
Section 160-0020
differential is disassembled and parts replaced, do SM - 094
not rely on this line for determining the preload on the
side bearings.
8. Remove side bearing cups (26) and cones (27), Fig. 2 - Removing Differential Assembly from Housing
using a bearing puller. Wire the bearing races
together for mating in assembly, and tag them for 15. Remove one thrust washer (32) and side gear
mating to plain case (38) and flanged case (28), from (34), then lift spider (35) and spider pinion gears (36)
which they were removed. out of flanged case (28).
Note: In conjunction with the bearing puller, use a 16. Separate the four spider pinion gears (36) from
round steel disc, approximately 95 mm (3.75 in) spider (35) and bearings (37). Do not remove spider
diameter and 10 mm (0.38 in) thick. This will serve pinion gears (36) or bearings (37) unless worn or
as a centre for the puller screw to push against. damaged.
Puller arms must not exert a force on the bearing
roller separator cage. 17. Remove remaining side gear (34) and thrust
washer (32) from flanged case (28).
9. Position the differential assembly vertically on a
bench so that a portion of ring gear (29) can be 18. Turn flanged case (28) and ring gear (29)
clamped securely in a soft-jawed vice. assembly over on a suitable block of wood.
10. Loosen bolts (39) holding plain case (38) and Note: Make sure that identifying marks are stamped
flanged case (28) together. on the side of ring gear (29) and flanged case (28) for
assembly purposes.
11. Loosen bolts (31) and nuts (30) which hold ring
gear (29) to flanged case (28). Remove all but two 19. Remove remaining bolts (31) and nuts (30), then
opposite nuts (30) and bolts (31). separate flanged case (28) from ring gear (29) by
tapping the edge of the ring gear with a soft-faced
12. Remove six of the bolts (39) which hold plain hammer as shown in Fig. 3.
case (38) and flanged case (28) together.
SM - 095
SM 1580 12-98 3
Rear Axle - Differential
Section 160-0020
20. Remove dowel pins (33) from plain case (38) and SM - 096
flanged case (28) only if they are damaged and have
to be replaced.
3. Remove and discard 'O' ring (7) from groove in Fig. 4 - Driving Out Retainer Assembly
yoke (5).
SM - 097
4. Remove set screws (8) and screw in two 1/2"-13
UNC bolts in the tapped holes of retainer (9) flange,
using these bolts as pullers to remove retainer (9)
assembly.
6. Using a soft-jawed vice with the jaws opened Fig. 5 - Removing End Bearing
slightly wider than retainer (9) bore, place retainer (9)
on top of the bars, with the flange facing downward.
Tap out cup (13) and oil seal (12) with a soft-faced 9. Remove cones (14) from pinion gear (15) shaft
hammer. Be careful not to damage the inside machined using a suitable bearing puller.
surface of retainer (9) when removing cup (13).
10. Tap cup (17) and shims (18) from carrier
Note: If the bearing races are still serviceable, wire housing (19).
the cups and corresponding cones together for
mating in assembly. Bearing assembly (13 & 14) is
replaceable as an assembly only. If any component INSPECTION
is defective, the complete assembly must be Numbers in parentheses refer to Fig. 1.
replaced.
The importance of careful and thorough inspection
7. Remove pinion assembly (14, 15 & 16) from cannot be over stressed. Thorough inspection and
carrier housing (19). necessary replacement of parts now, may eliminate
costly and avoidable trouble later.
8. Using a bearing puller similar to that shown in
Fig. 5, remove cone (16) from pinion gear (15) shaft. 1. Clean all parts in a suitable solvent.
4 SM 1580 12-98
Rear Axle - Differential
Section 160-0020
2. Immediately after cleaning, dry all parts, except 10. Inspect carrier housing (19), ring gear (29), plain
bearings, with compressed air, or lint-free cloth. case (38) and retainer (9) for bore damage, cracks
Bearings are better left to air dry, then inspected and and wear. Replace as necessary.
oiled thoroughly with gear lubricant for protection
from corrosion. 11. Check the amount of run-out on the machined
surfaces of retainer (9). The outer machined surface
3. With the parts cleaned, coat parts immediately on the hub of the bearing cage must be concentric
with light oil to prevent corrosion. If parts are not to with the bearing cup bore within 0.05 mm (0.002 in)
be assembled immediately, treat them with a good total indicator reading (T.I.R.).
rust preventative and wrap them with treated paper or
other suitable material designed to prevent corrosion. 12. The outer machined surface (OD) on retainer (9)
must be concentric within 0.05 mm (0.002 in) T.I.R.
4. Replace all gaskets, 'O' rings and seals with new with the surface into which oil seal (12) fits.
parts.
13. The threads and bores of bearing caps (22) and
5. Before installing the differential assembly to the carrier housing (19) must be concentric within
banjo, clean the inside and outside of the banjo 0.127 mm (0.005 in) T.I.R. and must be square with
housing to remove any foreign material. the pinion bore within 0.08 mm (0.003 in) when
checked at points 254 mm (10 in) from the centre line
6. Oil seal (12) rides on a special sleeve (6), which is on of the pinion bore.
yoke (5) to provide a smooth contact surface. If the
sleeve is rough or worn, pull it from the yoke and install Note: Bearing caps (22) and carrier housing (19) can
a new one. Heat the new sleeve to 177 - 205o C only be replaced as an assembly.
(350 - 400 F) in oil to expand it for installation. If oil
heating equipment is not available, heat the bushing 14. The machined mating surfaces of plain case (38)
evenly to 205o C (400o F). This takes about 1 minute using and flanged case (28) must be square with the axis of
a torch with a heating tip. Use a Tempilstik or other the cases within 0.08 mm (0.003 in) T.I.R.. The
temperature gauge to make sure sleeve (6) is hot mating diameters of the cases must also be
enough. Slide heated sleeve on the yoke and tap lightly concentric within 0.08 mm (0.003 in) T.I.R..
with a hammer to seat it.
SM 1580 12-98 5
Rear Axle - Differential
Section 160-0020
special tool as an aid in determining the required SM - 098
thickness of shims (18).
GAUGING DISTANCE
c. Measure the gap between retainer (9) and carrier 6. Install measured shim pack (11) as calculated in
housing (19) adjacent to the two installed bolts and Step 2d on retainer (9) and install the assembly on
record the average measurement as Dimension 'C'. carrier housing (19). Align slot in retainer (9) with the
lubrication holes in shims (11) and carrier housing
d. The correct thickness of shim pack (11) is: (19) and install retainer assembly in carrier housing.
6 SM 1580 12-98
Rear Axle - Differential
Section 160-0020
SM - 100 Spider and Component Parts Assembly
1. Press thrust washer dowel pins (33) into holes in
plain case (38) and flanged case (28), if removed.
SM 1580 12-98 7
Rear Axle - Differential
Section 160-0020
gear toward the pinion gear. Bearing adjuster (25), SM - 102
located on the opposite side of pinion gear (15) than
the ring gear, pushes the ring gear away from the
pinion gear. The ring gear assembly must be installed
onto carrier housing (19) so that cups (26) and cones RING GEAR RUNOUT
(27) are properly pre-loaded; correct backlash exists READING TAKEN AS
between ring gear (29) and pinion gear (15), and SHOWN, AND MUST
NOT EXCEED 0.08 mm
satisfactory tooth pattern is established between ring (0.003 in).
gear and pinion gear.
2. Install a dial indicator to check the back side of Fig. 11 - Checking Ring Gear Backlash
ring gear (29) for true running. Rotate the assembly
with an easy motion and note the back face runout.
The runout is not to exceed 0.08 mm (0.003 in) with point, it can be accomplished without changing the
the dial indicator position as shown in Fig. 10. bearing preload by backing off one adjuster a certain
number of notches and tightening up the opposite
3. Using a micrometer, take a measurement adjuster an equal number of notches.
diagonally across bearing cap (22) lock pads and
record it for reference later. 8. When a satisfactory backlash tolerance has been
established, check the gear tooth pattern as
4. Install bearing adjusters (25) in their respective described under the heading 'Adjustments'.
bearing caps (22).
9. If gear tooth pattern is not correct, some correction
5. Place a dial indicator in the position shown in can be made by systematically loosening and
Fig. 11, to check ring gear backlash. Tighten bearing tightening the bearing adjusters (25), as previously
adjuster (25) on the ring gear side until the backlash described, but in every instance re-check the
between ring gear (29) and pinion gear (15) reads backlash tolerance. If a favourable gear tooth pattern
0.000 on the dial indicator. cannot be established within the backlash tolerance,
it will be necessary to alter, add or remove, shims
6. Tighten the opposite bearing adjuster (25) until (18) between bearing cup (17) and carrier housing
another measurement across bearing cap (22) lock (19) and alter shims (11) by the same amount.
pads indicates a 0.05 - 0.13 mm (0.002 - 0.005 in)
expansion when compared to the measurement 10. When altering these shims as described in 'Pinion
recorded in Step 3. Cage Group', disregard all procedures given for
comparing the micrometer (measured) dimension and
7. At this point the backlash tolerance between ring etched dimension on pinion gear (15) tail shaft end.
gear (29) and pinion gear (15) should be 0.30 - 0.46 mm
(0.012 - 0.018 in) on gear sets with a 3.73:1 gear 11. The procedures for keeping differential side
ratio. If this tolerance has not been obtained at this bearing preload, backlash and favourable gear tooth
8 SM 1580 12-98
Rear Axle - Differential
Section 160-0020
pattern within specifications is strictly a 'try, check, 3. Gear tooth patterns can be interpreted by referring
and try again' method. to Figs. 12 through 17.
12. After a satisfactory preload, backlash and gear a. If a contact pattern similar to that shown in
tooth pattern is obtained, make certain that the Fig. 12 is obtained, the adjustment is correct.
retainer bolts (10) are tightened to a torque of 156
Nm (115 lbf ft). Again check backlash tolerance and b. If the contact area is on the inner side of the ring
gear tooth pattern. gear teeth, see Fig. 13, move ring gear away from
pinion by turning bearing adjusters equal amounts
13. Tighten bearing cap bolts (21) to a torque of until the proper bearing pattern is obtained.
644 Nm (475 lbf ft) and tie with lockwire (1). The
lockwire passes over the top of bearing cap (22) and c. If the contact area is on the outer part of the ring
through the heads of the respective bolts. The same gear teeth, see Fig. 14, move ring gear toward
procedure is to be followed for both bearing caps. pinion by turning bearing adjuster.
14. A final measurement across bearing cap (22) pilot d. If the contact area is along the root of the ring
pads must indicate a 0.05 mm (0.002 in) to 0.13 mm gear teeth, see Fig. 15, move the pinion out by
(0.005 in) expansion, after ten ring gear revolutions adding shims.
under a light load, when compared to the original
measurement recorded in Step 3. This ensures that e. If the contact area is along the top edge of the
the side bearings have the proper preload. ring gear teeth, see Fig. 16, move the pinion in by
removing shims.
15. Install adjuster locks (24) and secure with bolts (23).
Tighten bolts (23) to a torque of 33 Nm (24 lbf ft) and SM - 105
ADJUSTMENTS
When adjusting a noisy differential that has been in
service for some time, more harm than good can
result. Changes in adjustment will frequently
concentrate the bearing area on a small portion of the
teeth which often results in failure. Therefore, it is
advisable to know exactly what the end result will be
before adjustments are made in an old differential.
SM 1580 12-98 9
Rear Axle - Differential
Section 160-0020
SM - 107 SM - 109
Fig. 14 - Excessive Backlash Fig. 16 - Pinion Out Too Far - Remove Shims
SM - 108 SM - 110
MOVE GEAR IN THIS DIRECTION
FOR CORRECTION IN FIG. 13
Fig. 15 - Pinion In Too Far - Add Shims Fig. 17 - Correct Movement for Adjustment
2. If the body is not already raised, raise body and 5. Position the differential assembly under the truck
install body prop pins. Refer to Section 270-0010, in front of the banjo housing.
BODY AND MOUNTING.
6. Install chain fall or come-a-long to the loop on the
10 SM 1580 12-98
Rear Axle - Differential
Section 160-0020
8. Secure the differential assembly to the banjo with The differential should be checked and periodically
the self locking nuts removed at removal. Tighten the drained and filled to the bottom of the fill-level hole, or
nuts evenly in increments of 90 Nm (66 lbf ft) to a to no more than 13 mm (0.5 in) below the fill level,
final torque of 380 Nm (280 lbf ft). with new lubricant as recommended. Refer to
Section 300-0020, LUBRICATION SYSTEM. When
9. Replace the rear driveline, aligning marks made the lubricant is drained, remove any chips of steel
during disassembly. Refer to Section 130-0020, particles that may be attached to the magnetic drain
REAR DRIVELINE. plug located in the bottom of the banjo housing.
10. Install the axle shafts, then replace and secure After draining and refilling an axle, the planetary
the driving flange cover to the wheels. Refer to gearing should be checked after 10 hours of operation.
Section 160-0030, AXLE GROUP.
1. Check the level in planetaries at oil level plug. If
11. Fill the drive axle, planetary reservoirs and the oil level is low, add oil. This check point is a
differential with the proper grade and quantity of minimum check point only. If the oil level is above the
lubricant specified in Section 300-0020, check point, do not drain off oil.
LUBRICATION SYSTEM.
2. Add oil if needed. The oil level is correct when oil
flows from the lube level check plug in the banjo.
MAINTENANCE These checks should be made every 10 hours until
oil level in the differential is maintained.
Periodic Inspection
Inspect regularly the flange yoke mounting bolts,
pinion shaft nut, pinion cage and seal retainer bolts, SPECIAL TOOLS
and differential stud nuts for tightness. Tighten the The spider bearing spreader tool can be fabricated as
stud nuts and flange bolts weekly until they 'set' or shown in Fig. 19. Refer to Section 300-0070,
show that they no longer need tightening. Keep the SERVICE TOOLS for part numbers of measuring
nuts tight to reduce the possibility of differential or tools referenced in this section and general service
driveline failure due to excessive vibration or wear. tools and adhesives required. These tools and
adhesives are available from your dealer.
SM 1580 12-98 11
Rear Axle - Differential
Section 160-0020
SM - 112
in mm
1/8 3.2
ONE-4340 STL. OR EQUIV.-HDN.-GRIND
1/4 6.4
3/8 9.5
7/16 11.1
1/2 12.7
5/8 15.9
3/4 19.1
29/32 23.0
1 25.4
1 1/8 28.6
ACME THD.
1 1/4 31.8
1 3/8 34.9
1 1/2 38.1
APPROX ONE-4340
STL.-HDN.-GRIND 1 7/8 47.6
2 50.8
2 1/32 51.6
2 1/8 54.0
2 15/32 62.7
2 3/4 69.9
4 3/4 120.7
4 7/8 123.8
5 1/2 139.7
5 3/4 146.0
5 31/32 151.6
6 7/8 174.6
7 1/2 190.5
9 1/2 241.3
12 SM 1580 12-98
Rear Axle - Differential
Section 160-0020
DIAGNOSIS CHART
CONDITION REASON REMEDY
Vibration. Broken gear teeth. Replace damaged gear.
Excessive runout 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 and pinion gear adjustment tight. Adjust.
Noise on coast. Bearing damaged. Replace bearings.
Loose ring and pinion gear adjustment. Adjust gears.
Excessive pinion gear end play. Adjust.
Noise on turns. Worn spider gears or side gears. Replace gears.
Worn or damaged spider bushings. Replace bushings.
Loss of lubricant. Oil seals worn. Replace seal.
Loose nuts. Tighten nuts to correct torque.
Cracked housing. Repair or replace housing.
* * * *
SM 1580 12-98 13
REAR AXLE - Axle Group
Section 160-0030
SM - 235
* Shown in Fig. 2.
PLANETARY
Description and Operation Axle shaft (26) is driven by the differential and turns
Numbers in parentheses refer to Fig. 1. sun gear (9) to which it is splined. Sun gear (9)
meshes with and rotates planetary pinions (8). Since
The planetary gearing is a single stage planetary gear ring gear (22) is splined to the wheel spindle it cannot
assembly. This assembly contains sun gear (9), turn and forces the planetary carrier (14) to rotate.
planetary carrier (14) with planet pinions (8) and ring This results in planetary carrier (14) being the output to
gear (22), to provide gear ratio to the drive wheels. the drive wheels.
SM 1184 2-98 1
Rear Axle - Axle Group
Section 160-0030
SM - 236
Planetary Gearing - Towing 1. Position the vehicle in a level work area with
Numbers in parentheses refer to Fig. 1. magnetic plug (18) at its lowest point. Apply the
parking brake and switch off the engine.
2 SM 1184 2-98
Rear Axle - Axle Group
Section 160-0030
holes. A hoist should be used, as shown in Fig. 3, to Note: If ring gear carrier (1) is replaced, the wheel
support the assembly during removal. Remove studs bearing adjustment must be checked and corrected
(21) if damaged. as required, as described in Section 160-0050,
WHEEL, RIM AND TYRE.
7. Remove and discard 'O' ring (13) and place
planetary assembly on a clean work surface with gear 1. Insert snap rings (11) in planet pinion (8) grooves.
side up. Oil bearing sets (10) and insert spacers (7) and
bearings (10) in planet pinions (8).
8. Remove nuts (24), bolts (4) and washers (6) from
planet pinion (8) assemblies. Slide planet pinion (8) 2. Install new 'O' rings (5) in planetary carrier (14).
assemblies from planetary carrier (14). Slide assembled planet pinions into their respective
positions in planetary carrier (14).
9. Separate pinion bearing (10) sets and spacers (7)
from planet pinions (8) and remove snap rings (11) 3. Insert planet pins (12) through planet pinion (8)
from internal grooves of planet pinion (8). assemblies into planetary carrier (14) bores. Install
washers (6) on bolts (4) and insert bolts (4) through
10. Remove and discard 'O' rings (5) from planetary planetary carrier (14) and planet pinions (8). Install
carrier (14). nuts (24) on bolts (4) and tighten securely. Check
planet pinions (8) for free rotation.
INSPECTION
Numbers in parentheses refer to Fig. 2. WARNING
To prevent personal injury and property
1. Clean all parts thoroughly in suitable solvent and dry damage, be sure lifting equipment is of
with moisture-free compressed air or a clean, lint-free adequate capacity and properly secured to do
cloth. Allow bearings to air dry and dip in clean the job safely.
planetary lubricant.
4. Install new 'O' ring (13) in its groove in planetary
2. Inspect all parts for damage. Repair or replace as carrier (14). Place the planetary assembly in position
necessary. on the wheel. Mesh planet pinions (8) with ring gear
(22) and push the planetary assembly into place.
3. Inspect all pinions, gears and splines for excessive Install studs (21), if removed, and install nuts (20).
wear, cracked or broken teeth and pitted or scored
surfaces. If replacing planet pinions or sun gear, be 5. If sun gear (9) was removed during 'Disassembly',
sure the new pinions or gear have the same number of slide sun gear (9) over splines of axle shaft (26) and
teeth as the old ones so torque multiplication will install snap ring (27). Install ring (2) on axle shaft (26)
remain the same. and insert axle shaft assembly into the spindle and
SM 1184 2-98 3
Rear Axle - Axle Group
Section 160-0030
banjo housing, pushing the axle shaft part way into the SM - 238
differential side gear. Mesh sun gear (9) with planet
pinions (8).
6. Push axle shaft (26) and sun gear (9) inward as far
as they will go. With a steel rule and straight edge,
measure from cover mounting surface on planetary
carrier (14) to the end of axle shaft (26). Note as
dimension 'A'. See Fig. 4.
Note: If the end play is too small, the axle shaft is not
pushed completely into the differential side gear. If the
end play is greater than the allowable maximum, either
the axle shaft end or the driving flange thrust cover, or
both are excessively worn. To correct this, replace
cover (16) first. If the end play is still too great, a new
axle shaft must be installed.
REAR AXLE
WARNINGS
Description and Operation Heavy machine. Make sure lifting device or
Numbers in parentheses refer to Fig. 6. jack has proper lifting capacity and is
adequately secured to do the job safely.
The rear axle assembly consists of banjo (1) assembly Personal injury and damage may result if
and A-frame (39). The banjo provides the housing for machine falls or jack or lifting device
the differential and axle shafts which drive the wheels, collapses.
and spindles (2) to which the wheels are mounted. The
banjo also connects the rear wheels to the chassis To prevent possible personal injury,
through A-frame (39), link (16), and the rear ride relieve the pressure in the braking system. The
cylinders. exact procedure must be followed as
described in Section 250-0000, BRAKING
The rear axle is centrally mounted on the rear frame SYSTEM SCHEMATIC.
crossmember with a tapered pin (12) and component
parts, which allows the axle to oscillate as the truck 1. Position the vehicle in a level work area, apply the
moves over uneven terrain. parking brake and switch off the engine.
4 SM 1184 2-98
Rear Axle - Axle Group
Section 160-0030
SM - 1380
30 - Hardened Washer
31 - Bolt
32 - Pin
17 - Spacer 33 - Bolt
18 - Snap Ring 34 - Hardened Washer
19 - Bearing 35 - Hardened Washer
20 - Lube Fitting 36 - Locknut
8 - Retainer 21 - Lube Fitting 37 - Axle Shaft
9 - Washer 22 - Coupling 38 - Snap Ring
1 - Banjo 10 - Split Cup 23 - Elbow 39 - A-Frame
2 - Spindle 11 - Spacer 24 - Nut 40 - Nipple
3 - Stud 12 - Tapered Pin 25 - Bolt 41 - Bushing
4 - Bearing Ring 13 - Bearing 26 - Bolt 42 - Connector
5 - Hardened Spacer 14 - Lube Line 27 - Magnetic Plug 43 - Breather Line
6 - Oscillation Stop 15 - Breather 28 - Plug 44 - Elbow
7 - Tapped Retainer 16 - Link 29 - Bolt 45 - Spacer
2. Turn the steering wheel in both directions several deteriorate the rubber.
times to relieve pressure in the steering system. Operate
the treadle valve continuously to relieve pressure in the 4. Jack up or lift the vehicle so its weight is no longer
braking system. Block all road wheels. resting on the tyres of the axle assembly. Securely
block the vehicle in this position.
3. Disconnect brake, cooling, breather and lubrication
lines. Drain all the lubricant from the axle, brake assemblies 5. Remove four bolts from the driveline flange and
and planetary assemblies into suitable containers. Refer swing-driveline away from the differential. Punch mark
to Section 160-0020, DIFFERENTIAL, and, Section both flanges to facilitate installation. Refer to
165-0030, BRAKE PARTS. Cap all open lines and fittings Section 130-0020, REAR DRIVELINE.
to prevent entry of dirt.
6. If necessary remove the tyre and rim assemblies as
Note: Avoid spilling lubricant on tyres, as it will described in Section 160-0050, WHEEL, RIM AND TYRE.
SM 1184 2-98 5
Rear Axle - Axle Group
Section 160-0030
7. Position a hydraulic jack under the axle at the 6. Remove lube line (14), elbow (23) and lube fitting
differential housing, being sure jack is of suitable (21) from link (16).
capacity and proportions to lift and balance the axle
assembly. Place wheeled dollies at both ends of the 7. Remove breather line (43) and elbow (44) from
axle for wheels to rest on when the axle is lowered. banjo (1).
Raise axle just enough to take weight off centre
tapered pin (12). 8. If differential is to be removed, remove nuts (36),
hardened spacers (5) and hardened washers (35).
8. Remove lower ends of rear ride cylinders. Refer to Using suitable lifting equipment, remove differential
Section 180-0050, RIDE CYLINDER. assembly from banjo (1). Refer to Section 160-0020,
DIFFERENTIAL.
9. Remove bolt (33), hardened washer (34) and pin
(32) which mount link (16) to the chassis. Remove 9. If required, remove magnetic plug (27) and plug (28)
spacers (17). from banjo (1).
10. Remove nut (24), washers (9) and bolt (25) 10. If required, remove snap rings (38) and axle shafts
attaching A-frame (39) to the chassis. Remove split (37) from spindles (2).
cups (10) from tapered pin (12).
11. Drive tapered pin (12) out of the chassis using a Inspection
soft drift. As tapered pin (12) moves out, remove 1. Clean all metal parts in a suitable solvent, using a
spacers (11). Lower the axle assembly onto the brush to clean bearings. Dry all parts on a clean
wheeled dollies and roll out from beneath the vehicle. surface and allow bearings to dry naturally. Make sure
parts are free from dirt.
3. Remove bolts (29) and hardened washers (30) Note: Tighten all fasteners without special torques
securing oscillation stop (6) to banjo (1). Remove specified to standard torques listed in Section
oscillation stop (6) and spacer (45). 300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
4. Remove bolt (33), hardened washer (34) and pin
(32) which mount link (16) to banjo (1). Remove Note: If heating of banjo (1) is required to assemble
spacers (17). spindles (2) and banjo (1), banjo interference areas
must cool to 66 C (150 F) maximum before welding.
5. Remove link (16) from banjo (1) brackets. Remove For welding spindles (2) to banjo (1) preheat spindles
snap rings (18) and bearings (19) from link (16). and banjo to 150 C (300 F) minimum in weld area
and maintain during welding.
6 SM 1184 2-98
Rear Axle - Axle Group
Section 160-0030
WARNING WARNING
To prevent personal injury and property To prevent personal injury and property
damage, be sure lifting equipment is of damage, be sure lifting equipment is of
adequate capacity and properly secured to do adequate capacity and properly secured to do
the job safely. the job safely.
1. If axle shafts (37) have been removed from spindles 1. After banjo (1) and its components are
(2) install axle shafts in the spindles and secure with reassembled, roll the assembly under the vehicle and
snap rings (38). align under the chassis.
2. If removed, install magnetic plug (27) and plug (28) 2. Using a hydraulic jack of suitable capacity and
in banjo (1). proportions to lift and balance the axle assembly, raise
the axle assembly into position in the chassis. Insert
3. If differential was removed, position differential in spacers (11) and, using a soft drift, drive in tapered pin
banjo (1) and secure with nuts (36), hardened (12).
spacers (5) and hardened washers (35). Refer to
Section 160-0020, DIFFERENTIAL. 3. Install split cups (10) and washers (9) on tapered
pin (12) and secure with bolt (25) and nut (24).
4. Install elbow (44) in banjo (1) and connect breather
line (43) to elbow (44). Note: Since tapered pin (12) relies on bolt (25)
clamping to spread out and seat split cups (10) against
5. Install lube fitting (21) and elbow (23) in link (16) the pin for retention at initial assembly, the pin tends to
and connect lube line (14) to elbow (23). loosen up after the vehicle is in operation. Positive
seating is required and accomplished by re-tightening
6. Install bearings (19) in link (16) and secure with bolts (25) after the first few hours of operation, and
snap rings (18). Position link (16) assembly in banjo thereafter, until bolts (25) retain their torque.
(1) brackets and install spacers (17). Secure link (16)
to banjo (1) with pin (32), hardened washer (34) and 4. Align link (16) assembly and spacers (17) with the
bolt (33). chassis and install pin (32). Secure pin (32) to the
chassis with hardened washer (34) and bolt (33).
7. Position spacer (45) and oscillation stop (6) on
banjo (1) and secure with bolts (29) and hardened 5. Install rear ride cylinders to the chassis and axle
washers (30). assembly as outlined in Section 180-0050, RIDE
CYLINDER.
8. Install bearing (13) in A-frame (39). Fit retainer (8)
and tapped retainer (7) to A-frame (39) and secure 6. With the axle group securely fastened to the rear
with bolts (26). If removed, install lube fitting (20) in ride cylinders and the two sections of the chassis at
A-frame (39). link (16) and A-frame (39), release and remove the
hydraulic jack.
9. Position A-frame (39) assembly to banjo (1) and
secure with bolts (31). Tighten bolts (31) to a torque of 7. Align the punch marks, as marked during removal,
2 034 Nm (1 500 lbf ft). on the driveline and differential flanges, and secure
with four bolts. Refer to Section 130-0020, REAR
DRIVELINE.
Installation
Numbers in parentheses refer to Fig. 6. 8. If removed, replace tyre and rim assemblies as
outlined in Section 160-0050, WHEEL, RIM AND
Note: Tighten all fasteners to standard torques listed TYRE.
in Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS. 9. Remove blanking caps and reconnect all brake,
cooling, breather and lubrication lines. Refer to Section
Note: Tighten all hydraulic lines fitted with ORFS 160-0020, DIFFERENTIAL, and, Section
connections, as described in Section 230-0000, BODY 165-0030, BRAKE PARTS.
SYSTEM SCHEMATIC. Renew all 'O' rings where
used.
SM 1184 2-98 7
Rear Axle - Axle Group
Section 160-0030
10. Fill banjo, planetaries and disc brake assemblies AXLE DIAGNOSIS
with lubricant specified in Section 300-0020, Noises originating in the tyres, transmission or
LUBRICATION SYSTEM. driveline might be attributed by mistake to the axle.
Therefore, all possible sources of noise should be
11. Lubricate the rear axle assembly through lube investigated before deciding the axle is at fault.
fittings (20 & 21) with lubricant specified in
Section 300-0020, LUBRICATION SYSTEM. True axle noises may be located by lifting or jacking
the truck until all driving wheels are clear of the floor or
12. Bleed the braking system as described in ground. Securely block the truck in this position. Run
Section 165-0030, BRAKE PARTS. power train at moderate speed. Be certain all tyres are
off the ground and, to prevent damage to the
differential, see that neither rear brake drags.
MAINTENANCE
Proper lubrication of the axle group is essential if axles
are to deliver the service intended. Refer to Section SPECIAL TOOLS
300-0020, LUBRICATION SYSTEM for lubrication There are no special tools required for procedures
intervals and lubricant specifications. outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
tools and sealants required. These tools and sealants
are available from your dealer.
AXLE DIAGNOSIS
CONDITION REASON REMEDY
Noise Insufficient or incorrect lubricant Check level; fill with proper type and
grade lubricant
Wheel bearings scored or rough Replace bearings
Gear teeth in planetary chipped Replace gear
Loss of lubricant Lubricant level too high Drain and fill to proper level
Lubricant foams excessively Drain and fill with correct type and
grade lubricant
Worn or broken oil seal Replace oil seal
Restricted breather vent Clean vents
Loose nuts or bolts Tighten nuts or bolts
Gain of lubricant Restricted differential housing vent Clean vent
Planetaries running hot Insufficient or incorrect lubricant Check level; fill with proper type and
grade of lubricant
Pinion bearings seized Replace bearings
* * * *
8 SM 1184 2-98
REAR AXLE - Wheel, Rim and Tyre
Section 160-0050
SM - 203
DESCRIPTION
Each drive wheel is mounted on its spindle with two WARNING
tapered roller bearings. All the weight of the truck Tyre explosion hazard. Gases that build up
resting on the drive axle is supported by the wheels inside an air inflated tyre mounted on a rim
and bearings; none of the weight is supported by, or during welding and/or heating of rim
transmitted through, the axle shafts. This type of components can ignite, causing an explosion
construction is known as 'Full Floating'. of the tyre and rim components. This warning
also applies to Nitrogen gas inflated tyres.
The wheel itself is a large cylindrical casting with the Ignition will not occur in a Nitrogen gas
bearing bores and other finished surfaces machined atmosphere; but the pressure build up from
after the wheel is cast. the applied heat may be sufficient to cause a
blowout severe enough to injure or kill. Never
The dual rim assembly consists of two rim bases, weld or otherwise apply heat on rim
inner and outer flanges, bead seat bands, 'O' rings components with the tyre mounted on the rim,
and lock rings. whether the tyre is inflated or deflated, to
prevent injury or property damage from the
The tyre and rim assembly is designed to be replaced potential tyre explosion! Also, do not attempt
with a pre-assembled tyre and rim. to repair rims or rim components by welding
or heating, even if the tyre is not mounted on
the rim. It is recommended to scrap questionable
PREPARATION FOR SERVICING rim parts unless specific permission and
repair procedures are obtained in writing
either from the company or the rim manufacturer.
WARNING
Before loosening rim clamps or performing
any service on the tyres or rim components, to REMOVING TYRE AND RIM ASSEMBLY
prevent personal injury and property damage, Numbers in parentheses refer to Fig. 1.
completely deflate BOTH TYRES of dual
assembly by removing the valve caps and If the tyre and rim assembly is to be replaced with a
cores. Insert a thin wire through valves to be pre-assembled tyre and rim assembly, it is not
sure valves are not plugged. Even a flat tyre, necessary to remove the tyre from the rim on the
in some cases, will retain sufficient air truck. The tyre and rim may be removed from the
pressure to blow off a rim component with truck as an assembly, and transported to a more
enough force to cause bodily injury or death. desirable location for removing the tyre from the rim.
SM 1582 12-98 1
Rear Axle - Wheel, Rim and Tyre
Section 160-0050
SM - 204
WARNING
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of sufficient capacity to do the
job safely.
2 SM 1582 12-98
Rear Axle - Wheel, Rim and Tyre
Section 160-0050
SM 1582 12-98 3
Rear Axle - Wheel, Rim and Tyre
Section 160-0050
distorted, battered, and rusted parts which may have SM - 207
resulted from abusive practices outlined above.
Replace any damaged parts with new parts.
WARNING
Fig. 5 - Installing Typical Lock Ring
When lifting tyre onto rim, be sure the
equipment is of sufficient capacity and
properly secured to do the job safely. thin solution of soap and water or another approved
lubricant which is not harmful to rubber. Avoid using
1. If tubeless tyre valve assembly was removed from an excessive amount of lubricant. Insert new 'O' ring
rim, install this assembly in the rim valve hole and (6, Fig. 1) in groove of the rim behind lock ring.
tighten securely.
9. Lift the tyre upwards to effect a seal between bead
2. Tyre installations are performed in basically the seat band (2) and 'O' ring (6, Fig. 1). In some cases
same manner whether the rim (4) is on or off the the tyre will automatically spring out, making this
truck. For off-truck installations, lay the rim on blocks step unnecessary.
or a mounting stand with 'O' ring groove up. The rim
should be just off the floor enough so the tyre rests on
the rim and does not touch the floor. Blocks should
MOUNTING TYRE AND RIM ASSEMBLY
not extend more than 13 mm (0.5 in) beyond the rim ON WHEEL
base, so they wont interfere with inner flange (5). Numbers in parentheses refer to Fig. 1.
4 SM 1582 12-98
Rear Axle - Wheel, Rim and Tyre
Section 160-0050
SM - 202
SM 1582 12-98 5
Rear Axle - Wheel, Rim and Tyre
Section 160-0050
2. Turn the steering wheel in both directions several with light oil to facilitate assembly.
times to relieve pressure in the steering system.
Block all road wheels, except the ones to be raised. 2. Using a suitable solvent, clean bearings and wipe
dry with a lint free cloth. Lubricate lightly with light oil
3. Release parking brake. and spin by hand, to check for wear and roughness.
Replace with new bearings if excessively worn, or if
operation is rough or noisy.
WARNING
To prevent personal injury and property 3. Inspect all machined surfaces of all parts for
damage, completely deflate BOTH TYRES of scoring, pitting, corrosion and burring. Resurface or
dual assembly by removing the valve caps and replace with new parts as necessary.
cores. Insert a thin wire through valves to be
sure valves are not plugged. Even a flat tyre, 4. Inspect all threaded components, and repair or
in some cases, will retain sufficient air replace as necessary.
pressure to blow off a rim component with
enough force to cause bodily injury or death.
Assembly and Installation
4. Deflate both tyres completely, and remove the tyre Numbers in parentheses refer to Fig. 6.
and rim assembly from the wheel. Follow instructions
under 'Removing Tyre and Rim Assembly'.
WARNING
5. Drain differential and planetary gear lubricant and To prevent personal injury and property
remove planetary gear assembly from the wheel. damage, be sure wheel blocks, blocking
Refer to Section 160-0030, AXLE GROUP. materials and lifting equipment are properly
secured and of sufficient capacity to do the
6. Remove lockwire (1), bolts (2), plate (3) and shim job safely.
pack (4) from spindle (11). Retain shim pack (4).
1. Install bearing cups (8 & 9) in their respective
7. Pull ring gear (5) from end of spindle (11). wheel (6) bearing bores with care to avoid damaging
their raceways. Installation by press fit at ambient
8. With suitable lifting equipment, pull wheel (6) off of temperature is best. Note that cups must seat fully
spindle (11), being careful that outer bearing cone (7) against shoulders of cup bores in the wheel hub to
does not fall. assure retention of bearing adjustment. If carbon
dioxide, or dry ice, freezing of the cup is used,
9. Remove and discard 'O' ring (14) from wheel remember to permit the cup and hub to warm to
driver (13). ambient temperature after insertion and then to tap
them with a soft steel drift and hammer to seat.
Note: The wheel driver (13) portion of the disc brake
assembly is bolted to inner face of wheel (6), when 2. If removed, install spacer (12), onto spindle (11).
the wheel is removed, the attached disc brake wheel
driver (13) will also be removed. Refer to Section 3. Lubricate inner bearing cone (10) with lubricant
165-0030, BRAKE PARTS, if necessary to remove specified in Section 300-0020, LUBRICATION
wheel driver. SYSTEM. Install inner bearing cone (10) onto spindle
(11), hard against spacer (12).
Note: Bearing cups and cones must always be
replaced as a matched set, never separately. 4. If removed, install wheel driver (13) on wheel (6).
Refer to Section 165-0030 BRAKE PARTS.
10. Remove inner bearing cone (10) from spindle (11).
5. Install new 'O' ring (14) on wheel driver (13). Refer
11. If required, remove bearing cups (8 & 9) from wheel. to Section 165-0030, BRAKE PARTS.
6 SM 1582 12-98
Rear Axle - Wheel, Rim and Tyre
Section 160-0050
7. Lubricate outer bearing cone (7) with lubricant 15. Install planetary gear assembly and fill planetary
specified in Section 300-0020, LUBRICATION and differential assemblies with lubricant specified in
SYSTEM. Install outer bearing cone (7) on spindle Section 300-0020, LUBRICATION SYSTEM. Install
(11) and seat in outer bearing cup (8). tyre and rim assembly as described under 'Mounting
Tyre and Rim Assembly on Machine'.
8. Install ring gear (5) on end of spindle (11).
Note: Ensure all dirt, grease and oil is completely TYRE INFLATION
removed from plate (3), shim pack (4) and end of
spindle (11) to allow accurate setting of the bearing
pre-load. WARNING
To prevent personal injury and property
9. Install plate (3), without shim pack (4) on end of damage, the tyre and rim assembly should be
spindle (11), and secure with eight bolts (2). Tighten placed in a safety cage before inflating. If no
bolts (2) evenly in equal increments to 'Gauging Bolt safety cage is available or tyre is on the
Torque', as specified in 'Bearing Adjustment Table', machine, the tyre and rim assembly should be
while rotating and bumping wheel (6) assembly. wrapped with safety chains or with lash cables
before inflating.
10. Remove bolts (2) and tap the wheel (6) assembly
to free bearings. Even with these precautions remember that
air-blast is a potential hazard. Tyre inflation
11. Reassemble plate (3) without shim pack (4) and should be carried out away from busy working
using only two bolts (2) located 180 apart, adjacent areas.
to gauging holes in plate (3). Tighten bolts (2) evenly
in equal increments to 'Gauging Bolt Torque' (ref.
'Bearing Adjustment Table'), while rotating and WARNING
bumping wheel (6) assembly. To avoid personal injury and property damage,
never stand or sit in front of a mounted tyre
12. Determine gap between plate (3) and end of during tyre inflation. Use a clip-on air chuck
spindle (11) at both gauging holes. To determine gap, with a long hose and stand to one side while
use a depth micrometer in both gauging holes to the tyre is being inflated.
measure distance from outer face of plate (3) to end
of spindle (11). Using a micrometer, measure
thickness of plate (3). Subtract plate thickness WARNING
reading from depth gauge readings. To prevent personal injury and property
damage, always prevent flammable vapours
13. Average the two readings, obtained at Step 12, in that could produce tyre explosions, from
increments of 0.03 mm (0.001 in) and round off to the being pumped into tyres during inflation, by
next higher 0.03 mm (0.001 in). This is the average observing the following precautions:
gap. The required shim pack (4) thickness is equal to
the average gap plus 0.18 mm (0.007 in). A.
Use an air compressor and reservoir located
14. Install required shim pack (4), plate (3) and bolts inside a heated building, when available, so
(2) on end of spindle (11). Tighten bolts (2) evenly in that alcohol, methanol, or other flammable
equal increments to 'Final Bolt Torque' (ref. 'Bearing antifreeze liquids are not needed in the air
Adjustment Table'), while rotating and bumping wheel tanks to prevent moisture freezing in the tank
(6) assembly. Secure bolts (2) with lockwire (1). and lines in subfreezing temperatures.
SM 1582 12-98 7
Rear Axle - Wheel, Rim and Tyre
Section 160-0050
SM - 208
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.
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 Fig. 7 - Typical Safety Cage
produces highly explosive hydrogen gas
which can be readily drawn into a nearby
SM - 1040
compressor inlet and pumped into the tyre.
E.
Never exceed the specified concentration of
alcohol when adjusting the alcohol vaporiser,
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.
1. If the tyre is off the truck, it should be placed in a 3. For recommended operating air pressure, refer to the
safety cage before inflating. See Fig. 7. chart under the heading, 'Tyre Inflation Pressures'.
8 SM 1582 12-98
Rear Axle - Wheel, Rim and Tyre
Section 160-0050
NITROGEN TYRE INFLATION b. Safety relief valve, 8.6 bar (125 lbf/in), that will
Note: All Warnings and procedures under 'Tyre assure an upper limit to the pressure available for
Inflation' will apply, except for differences covered by tyre inflation.
this passage.
c. A 15.2 m (50 ft) length of flexible hose with
In certain environments it is recommended that tyres interconnecting fittings. On the tyre end of the hose is
be inflated with dry nitrogen gas, and that the a large bore quick connect/disconnect clip-on chuck.
resulting oxygen content of the inflation does not
exceed 5%. All machines whose tyres are factory 2. The pressure regulator is connected to a nitrogen
inflated with dry nitrogen gas will be identified by a compressed gas cylinder available from local suppliers.
decal on the body or frame.
3. The usual procedure for using this type of
Nitrogen gas improves tyre pressure retention, equipment is as follows:
increases tyre life by reducing carcass oxidation
from within, minimizes rim rust and has no a. Connect nitrogen tyre inflation kit to nitrogen
detrimental effects on the tyre. It also reduces the compressed gas supply. DO NOT connect clip-on
potential of a tyre explosion because it is an inert gas chuck to the tyre valve at this time.
and will not support combustion inside the tyre.
b. Open valve on nitrogen supply.
The same tyre inflation pressure used for air inflation
should be used for nitrogen inflation. Tyre valves c. With flexible hose and clip-on chuck connected to
formerly used with air inflation are entirely nitrogen tyre inflation kit assembly but not connected
satisfactory for use with nitrogen gas. 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.
Nitrogen Tyre Inflation Kit
d. Connect clip-on chuck to the tyre valve. The tyre
will now inflate. Tyre pressure can be monitored by
WARNINGS observing the gauge at the pressure regulator. STAY
DO NOT USE charging assembly, Part No. AWAY FROM THE TYRE.
9359489, for tyre inflation because this
assembly does not include a pressure e. When desired inflation pressure has been
regulator, safety relief valve, and adequate achieved, back off the regulator or close the valve on
pressure gauging which is mandatory for tyre the compressed gas cylinder.
inflation purposes. Tyre volume is as much as
90 times greater than the average accumulator f. Remove the clip-on chuck and adjust the tyre
volume and hence it takes very much longer to pressure with the tyre gauge in the usual manner.
inflate a tyre - up to 40 minutes or more for
very large tyres.
Re-inflation of a Mounted Tyre
Nitrogen gas cylinders used to inflate To re-inflate a tyre with dry nitrogen gas which is now
tyres are generally charged to approximately inflated with air, proceed as follows:
152 bar (2 200 lbf/in2). A tyre blowout and/or
rim failure could occur if inflation equipment 1. Exhaust the tyre until only air at atmospheric
is not properly used. Proper nitrogen charging pressure remains in the tyre.
equipment and personnel training for its use
is a must to avoid over inflation. 2. Re-inflate the tyre using only dry nitrogen gas to
4.15 bar (60 lbf/in) gauge as a minimum, or to bead-
1. A nitrogen tyre inflation kit is available from your seating pressure as a maximum.
dealer and consists of the following. Refer to Fig. 8.
3. Adjust to the service inflation pressure required:
a. Pressure regulator, 0 - 13 bar (0 - 200 lbf/in2), with
two dual pressure gauges. a. If the required service inflation pressure is LESS
than 4.1 bar (60 lbf/in), remove the clip-on chuck
SM 1582 12-98 9
Rear Axle - Wheel, Rim and Tyre
Section 160-0050
and adjust the pressure with the tyre gauge in the SM - 214
usual manner.
10 SM 1582 12-98
Rear Axle - Wheel, Rim and Tyre
Section 160-0050
SM - 218
SM 1582 12-98 11
Rear Axle - Wheel, Rim and Tyre
Section 160-0050
TYRE MAINTENANCE A retreaded tyre has the old tread removed entirely
and a new tread cured directly onto the body of the
Tyre Repairs tyre. A tyre can be recapped or retreaded if the cord
Prompt repair of tyre injuries will prevent small body is free of cuts, bruises and separation, and is
injuries from enlarging and causing tyre failure. Use thoroughly sound, including previous repairs.
the best tyre facilities available. If good repair
facilities are not available, have the nearest dealer
make the necessary repairs. TYRE CARE
To obtain maximum service from off-the-highway
Minor cuts, snags, or punctures should be repaired tyres, a few common-sense precautions should be
upon discovery. Skive with a sharp pointed knife followed.
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 Maintain Correct Inflation
to expel all foreign material and should extend no The most common cause of tyre damage is improper
deeper than the breaker. The skive should go to the inflation. Both over-inflation and under-inflation are
bottom of the hole. Tyres with shallow cuts, if treated detrimental to tyre life. Tyre pressure should be
promptly, may be allowed to continue in service. If checked daily, preferably before the machine is
the cut extends deeper into the tyre carcass, the tyre placed in operation. Refer to 'Tyre Inflation
should be removed for repair. Pressures' for tyre pressure.
Ordinary tubeless tyre punctures can be repaired The valve cores should be checked for leaks. Keep in
without removing the tyre from the rim. Use tyre mind that valve cores are delicate mechanisms that
repair plugs and follow the directions given by the wear out in service; therefore, they should be
manufacturer. replaced when they become worn. Each tyre should
be equipped with a valve cap to prevent dirt from
The tyre must be removed from the rim to repair damaging the valve core and causing air leakage.
larger punctures or cuts. Irregular shaped punctures
or cuts less than 13 mm (0.5 in) in size can be
repaired with a plug and hot patch. Insert a repair Maintain Good Haul Roads
plug into the hole to keep out moisture and to back up Because haul roads are considered temporary roads,
the hot patch. Trim the plug off flush with the inside of they are frequently neglected. The better the haul
the casing, buff, and apply the hot patch according to road, the longer the tyre and truck life of off-the-
the instructions supplied with the hot-patch highway equipment.
equipment.
Although it takes time and effort to maintain good
Punctures 13 mm (0.5 in) or larger, large cuts, or haul
bruise breaks require sectional or reinforced roads, the delay and cost of tyre and truck
vulcanized repair. Cover the repair patch with a layer breakdowns caused by poor haul roads is many
of cushion gum after application to the tubeless tyre times greater.
to ensure an airtight repair. Any cords of the inside
ply that are exposed in bugging and are not covered
with repair patch must be coated with cushion gum to
Inspect Tyres Regularly
prevent air leakage into the carcass plies on tubeless A systematic plan for tyre inspection will more than
tyres. pay for itself in lowered tyre costs per hour of
operation. All tyres should be checked regularly for
cuts, bruises, fabric breaks, excessive or uneven
Recapping and Retreading wear, embedded foreign matter, and any other
There are two general methods employed in restoring damage which can be repaired. A considerable
the tread surface of off-the-highway tyres: recapping, increase in tyre service can be realized if tyre
and retreading. injuries are repaired before they have progressed to
the irreparable stage. The rim mounting nuts should
A recapped tyre has a new tread cured right over the be checked periodically and tightened to the
old tread surface. recommended torque.
12 SM 1582 12-98
Rear Axle - Wheel, Rim and Tyre
Section 160-0050
SM 1582 12-98 13
Rear Axle - Wheel, Rim and Tyre
Section 160-0050
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.
TYRE INFLATION PRESSURES road maintenance and length, maximum and workday
E3 tyres may be so roaded up to 48 km/h (30 mile/h), average speed, job t-km/h (ton-mile/h) required and
maximum, with a 30 minute cooling stop after each tyre t-km/h (ton-mile/h) capacity, etc., may require an
80 km (50 miles) or 2 hours sustained operation - increase in inflation pressure. It is recommended that
whichever occurs first - and a 60 minute cooling stop for tyres both listed and unlisted the user consult the
after each aggregate of 4 hours of operation. tyre manufacturer and evaluate all job conditions in
order to make the proper selection.
E4 tyres may be so roaded up to 32 km/h (20 mile/h),
maximum, with a 30 minute cooling stop after each
32 km (20 miles) or 1 hour of sustained operation - TYRE INFLATION PRESSURES
whichever occurs first - and a 60 minute cooling stop
after each aggregate of 4 hours of operation. PRESSURE
BRIDGESTONE TYRE bar lbf/in
The inflation pressures listed should be regarded as
nominal only. Specific job conditions, terrain, haul 24.00 R 35** Radial 5.7 83
* * * *
14 SM 1582 12-98
BRAKE PARTS - Front Axle
Section 165-0020
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.
SM 1186 2-98 1
Brake Parts - Front Axle
Section 165-0020
SM - 043
BRAKE PAD REMOVAL AND 2. Turn the steering wheel in both directions several
INSTALLATION times to relieve pressure in the steering system.
Numbers in parentheses refer to Fig. 2. Block all road wheels. Remove tyre and rim, as
described in Section 140-0040, WHEEL, RIM AND
Note: Tighten all fasteners without special torques TYRE.
specified, to torques listed in Section 300-0080,
STANDARD BOLT AND NUT TORQUE 3. Loosen two bolts (2) securing large torque pins (3)
SPECIFICATION. at the end of the brake head. It is not necessary to
loosen or remove the two smaller torque pins (6) at
opposite end.
WARNINGS
To prevent personal injury and property 4. Move the two unlocked torque pins (3) away from
damage, be sure blocking or lifting equipment the brake disc.
is of sufficient capacity and properly secured
to do the job safely. 5. Attach a bleeder line and open bleeder valve (1).
Use a screwdriver or pry bar inserted between the
Use extreme caution to prevent personal brake disc and brake pads to press pistons (11) back
injury when removing wheel. The exact into torque plate (15) piston bores, as far as possible.
procedure must be adhered to as described in Close bleeder valve.
Section 140-0040, WHEEL, RIM AND TYRE.
6. Rotate brake pads (4 & 5) out of the opened end of
To prevent personal injury, keep hands the brake.
and fingers etc. clear of the area between the
brake disc and the brake head pistons. 7. Install new brake pads (4 & 5) by placing friction
material next to the brake disc and rotating into
1. Position the vehicle in a level work area, apply the position in the brake head.
parking brake and shutdown the engine.
2 SM 1186 2-98
Brake Parts - Front Axle
Section 165-0020
8. Push the two unlocked pins (3) toward the brake disc. BRAKE REMOVAL AND DISASSEMBLY
Numbers in parentheses refer to Fig. 2, unless
9. Thread the two loosened bolts (2) in until bolts seat otherwise specified.
in grooves of pins (3). This can be checked by limited
axial movement of pins as the bolts are being seated.
Tighten bolts (2) to a torque of 30 - 38 Nm (22 - 28 lbf ft). WARNINGS
To prevent personal injury and property
Note: Make sure torque pins (3 & 6) do not touch the damage, be sure blocking or lifting equipment
brake disc. If they do, loosen bolts (2) and adjust is of sufficient capacity and properly secured
pins to clear disc by 1.5 to 3.0 mm (0.060 to 0.120 to do the job safely.
in). Check to make sure that bolts (2) fully engage in
pins and retighten bolts. Use extreme caution to prevent personal
injury when removing wheel. The exact
10. Depress the brake pedal until brake pads (4 & 5) procedure must be adhered to as described in
contact the brake disc. Section 140-0040, WHEEL, RIM AND TYRE.
SM 1186 2-98 3
Brake Parts - Front Axle
Section 165-0020
8. Inspect brake pads (4 & 5) per Step 1 in the to press pistons the remainder of the way into piston
'General Inspection Procedure'. bores. Snap open end of boot (12) into groove of
piston.
9. Clean torque plate (15) making sure no solvent
remains in the oil passages or grooves. Inspect dust 6. Install seals (10) and piston plugs (9) into open
boot and seal grooves, and, land areas between end of piston bores of torque plate (15).
grooves for damage or cracks. Minor nicks and
scratches may be blended with crocus cloth. Replace 7. Attach cover plate (8) to torque plate with bolts (7)
torque plate (15) if corrosion is excessive or dust and washers (16). Tighten bolts (7) to a torque of
boot and seal grooves are damaged, prohibiting 380 Nm (280 lbf ft).
proper rebuild of brake head.
8. When installing torque pins (3 & 6) and bolts (2)
10. Inspect pistons (11) for minor scratches and make sure the groove in the pin is directly under the
nicks and blend with crocus cloth. If piston is badly bolt so that bolt (2) can perform its locking and
nicked or scratched or if the chrome plate is worn off, retaining function.
replace piston.
Note: Lubricate torque pins (3 & 6) with a corrosion
11. Torque pins (3 & 6) which are deeply grooved resistant lubricant prior to installation, to facilitate
should be replaced. next pin removal.
1. Lubricate packings (13), seals (10) and pistons Note: Tighten all fasteners without special torques
(11) with petroleum base lubricating oil or vaseline. specified to torques listed in Section 300-0080,
STANDARD BOLT AND NUT TORQUE
SPECIFICATION.
WARNING
Do not use brake fluid (SAE J1703).
WARNINGS
2. Install backup rings (14), packings (13) and boots To prevent personal injury and property
(12) into torque plate (15) piston bores. Lubricate per damage, be sure blocking or lifting equipment
Step 1. is of sufficient capacity and properly secured
to do the job safely.
3. Install pistons (11) in torque plate (15) as follows:
Position lubricated piston (11) into dust boot (12) and Use extreme caution to prevent personal
piston bore, holding piston at a slight angle. Insert injury when installing wheel. The exact
forefinger between piston and dust boot and rotate procedure must be adhered to as described in
forefinger around piston OD, lifting dust boot ID over Section 140-0040, WHEEL, RIM AND TYRE.
OD of piston. Make sure OD lip of dust boot remains
in the groove in the piston bore. 1. Install washers (5) on bolts (4).
4. After piston (11) is through dust boot (12), centre 2. Position brake head over brake disc on brake
piston by feel over packing (13). Apply, by hand, a mounting plate, aligning holes. Install assembled
turning thrusting pressure, working piston into and bolts (4) and washers (5) through mounting plate and
through packing. into torque plate. Tighten bolts (4) to a torque of 610
Nm (450 lbf ft).
5. When assured pistons (11) are through packings
(13), pressure other than hand pressure may be used Note: Ensure torque pins (3 & 6, Fig. 2) do not touch
4 SM 1186 2-98
Brake Parts - Front Axle
Section 165-0020
the brake disc. If they do, loosen bolts (2) and adjust brake treadle. Remove bleeder line.
pins to clear disc by 1.5 - 3.0 mm (0.060 - 0.120 in).
Check to make sure that bolts (2, Fig. 2) fully engage Note: This system is equipped with accumulators
in pins and tighten bolts to a torque of 30 - 38 Nm which maintain pressure in the system even after
(22 - 28 lbf ft). engine shutdown. However, If the system pressure is
zero, it will be necessary to start the engine to
3. Remove plugs from brake head and hydraulic inlet charge the system prior to bleeding. Always
line and attach hydraulic inlet line at brake head. shutdown the engine before starting bleeding
procedure.
4. Bleed the braking system as described under the
heading 'Bleeding' in this section. 4. Repeat Steps 1 through 3 at each brake head
assembly.
5. Install tyre and rim. Refer to Section 140-0040,
WHEEL, RIM AND TYRE.
MAINTENANCE
Every 10 Hours of Operation (Daily)
BLEEDING Inspect brake assembly to ensure that all bolts are
Numbers in parentheses refer to Fig. 2. tight and there are no leaks. Inspect for boot
deterioration.
In order to obtain satisfactory braking, the system
should be bled as follows to eliminate any air in the Check oil level in the steering and brake control tank
hydraulic brake lines: and add oil if low. Refer to Section 220-0040,
STEERING AND BRAKE CONTROL TANK, for
1. Check oil level in the steering and brake control correct fill level and Section 300-0020,
tank and add oil if low. Refer to Section 220-0040, LUBRICATION SYSTEM, for oil specification.
STEERING AND BRAKE CONTROL TANK, for
correct fill level and Section 300-0020, Every 250 Hours of Operation
LUBRICATION SYSTEM, for oil specification. Check the brake pads and discs for wear and adjust
or replace where necessary. Test for proper function.
2. Securely connect a bleeder line to bleeder valve (1),
and place loose end of line in clean container. Note: This service interval applies to normal driving.
Check the pads more frequently under more severe
conditions. Thickness of pad friction material should
WARNING never be allowed to wear below 3 mm (0.12 in).
Loosen bleed nipples carefully. The braking
system operates at high pressure.
SPECIAL TOOLS
3. Depress brake treadle valve and gradually open Refer to Section 300-0070, SERVICE TOOLS, for
bleeder valve (1). Bleeder valve should remain open part numbers of the non-contact infrared thermometer
until oil exhausting from the bleeder valve is free and general service tools required. These tools are
from air bubbles. Close bleeder valve and release the available from your dealer.
* * * *
SM 1186 2-98 5
BRAKE PARTS - Rear Axle
Section 165-0030
DESCRIPTION AND OPERATION plates (30). The rotating discs are compressed
Numbers in parentheses refer to Figs. 1 and 2. between the splined plates and are held stationary,
thus keeping the wheels from rotating. As long as
Service Brakes there is no hydraulic pressure at port 'F', Fig. 2,
Note: The service brakes are of 'Upright Design', i.e. parking brake will be applied. When hydraulic oil
requiring pressure to hold the brakes on. pressure is applied at port 'F', Fig. 2, parking brake
will be released.
The rear service brakes are hydraulically actuated to
slow or stop drive wheel rotation. When the service
brake treadle in the operators' compartment is REMOVAL
depressed, or when the retarder control lever on the Numbers in parentheses refer to Figs. 1 and 2.
centre console is actuated, with the retarder selection
switch at the disc brake position, hydraulic pressure
is transmitted to port 'D', Fig. 2, on the disc brake WARNINGS
assembly. Hydraulic pressure entering port 'D', Fig. To prevent personal injury and property
2, forces service piston (31) against the brake disc damage, be sure wheel blocks, blocking
pack consisting of damper assemblies (28), rotating materials and lifting equipment are properly
friction discs (29) and splined plates (30). secured and of sufficient capacity to do the
job safely.
The rotating friction discs, which are driven by the
wheel, through wheel drivers (5) and disc drivers Hydraulic fluid will remain within the
(27), are compressed between splined plates (30). braking system after engine shutdown.
This slows down and stops rotation of the driving Operate the treadle valve continuously until
wheels. The force applied against the disc pack is the pressure has dissipated before carrying
directly proportional to the degree of which the out any work on the braking system or serious
service brake treadle is depressed. injury could result.
When the service brake treadle or retarder control Use extreme caution to prevent personal
lever is released, hydraulic pressure against service injury when removing wheels. The exact
piston (31) is relieved, brake return springs (36) procedure must be followed as described in
tension against heads of retaining pins (35) forces Section 160-0050, WHEEL, RIM AND TYRE.
the pins to return service piston (31) to its original
position, thus, relieving the pressure against the Note: Before removing and disassembling disc brake
brake disc pack. assemblies, measure and record the amount of wear
of the brake disc and damper plates. Refer to 'Disc
Assembly Wear Measurement Procedure', under
Parking Brakes 'Inspection' in this section, for the measurement
Note: The parking brake is of 'Inverted Design', i.e. procedure and the maximum allowable wear limits.
requiring pressure to hold the brakes off.
1. Position the vehicle in a level work area, apply the
The parking brakes are controlled by the park/ parking brake and switch off the engine.
emergency brake control mounted on the instrument
panel. The parking brakes are applied by spring 2. Turn the steering wheel in both directions several
tension and released by hydraulic pressure. With the times to relieve any pressure in the steering circuit.
control pulled 'OUT', hydraulic oil enters port 'F', Fig. Operate the treadle valve continuously to relieve any
2, flows through a channel in disc housing (25) into a pressure in the braking system. Block all road
passage behind parking piston (23). Hydraulic oil wheels.
pressure forces parking piston (23) against the
tension of springs (20 & 21), keeping pressure off of 3. Remove plug (49) and drain cooling oil from disc
the damper assemblies (28), thereby keeping brake assembly into a clean container. Reinstall plug.
pressure off the disc pack. With the control pushed
'IN', hydraulic pressure at port 'F', Fig. 2, is released, 4. Open bottom bleeder valve (54) and drain brake
pressure against parking piston (23) is released. hydraulic oil into a clean container. Close bleeder
Spring (20 & 21) tension forces the parking piston valve.
against damper assembly (28) and disc pack
consisting of rotating friction discs (29) and splined
SM 1583 12-98 1
Brake Parts - Rear Axle
Section 165-0030
SM - 1295
SPINDLE
BEARING
SECTION E-E
2 SM 1583 12-98
Brake Parts - Rear Axle
Section 165-0030
SM - 114
PORT B
PORT D PORT F
PORT D
SECTION C-C
PORT F
PORT C
Note: To minimize loss of brake hydraulic oil when 5. Tag and disconnect brake cooling lines from ports
the brake tubes are removed from the brake 'B' and 'C' on piston housing assembly (41). See
assemblies, remove the air breather from the steering Fig. 2. Plug lines and ports to prevent ingress of dirt
and brake control tank and connect a vacuum pump and hold oil in lines and tank.
to the breather port. Evacuate the air in the tank to a
vacuum of 0.5 - 0.7 bar (15 - 20 inches of mercury). 6. Tag and disconnect service brake tube from port 'D'
SM 1583 12-98 3
Brake Parts - Rear Axle
Section 165-0030
SM - 1297
4 SM 1583 12-98
Brake Parts - Rear Axle
Section 165-0030
on piston housing assembly (41). See Fig. 2. Plug a clean flat surface with spring housing (14) side up.
tube and port to keep out dirt and hold oil in tube.
17. Repeat Steps 3 through 16 to remove the opposite
7. Tag and disconnect parking brake tube from port 'F' disc brake assembly.
on piston housing assembly (41). See Fig. 2. Plug
tube and port to keep out dirt and hold oil in tube.
DISASSEMBLY
8. Remove wheel assembly from the truck as Numbers in parentheses refer to Fig. 3.
described in Section 160-0050, WHEEL, RIM AND
TYRE.
WARNING
9. Lay wheel down with wheel driver (5) up. To prevent personal injury and property
damage, ensure lifting equipment is of
10. Remove and discard 'O' ring (8) from outer sufficient capacity and properly secured to do
diameter of wheel driver (5). the job safely.
11. Remove bolts (7) and hardened washers (6) 1. Remove lockwire (56) from bolts (9). Remove bolts
securing wheel driver (5) to wheel. Using a suitable (9) and hardened washers (55) securing seal housing
lifting device, lift wheel driver from wheel. (10) to disc driver (27) and remove seal housing.
12. Remove and discard 'O' ring (4) from spindle. 2. Remove and discard 'O' ring (4) from outer
diameter of disc driver (27).
13. Remove and discard bolts (57) securing inner seal
housing (1). Remove seal housing from spindle. 3. Remove face seal (11) from disc driver (27) and
Remove and discard 'O' ring (2) from seal housing. discard toric rings of face seal. Retain metallic
elements unless scratched or damaged.
14. Remove face seal (3) from spindle and discard
toric rings of face seal. Retain metallic seal elements 4. Using a suitable lifting device attached to disc driver
and set aside for 'Inspection'. (27), carefully lift disc driver from disc brake assembly.
15. Remove one bolt (12) and hardened washer (13) from 5. Using a suitable lifting device, turn disc brake
spring housing (14) and one bolt (43) and hardened assembly over, with piston housing assembly (41) up.
washer (42) from piston housing assembly (41), remove
both bolts from as close to 12:00 oclock position as 6. Remove and discard 'O' ring (53) from piston
possible. Install a lifting eye in each bolt hole. housing assembly (41).
16. Attach a suitable lifting device to disc brake 7. If necessary, remove bleeder valves (50 & 54) from
assembly (at lifting eyes installed in Step 15) and take piston housing assembly (41).
up slack. Remove nut (52) and hardened washer (51).
Using lifting device, carefully remove disc brake 8. If necessary, remove plug (49) and 'O' ring (48)
assembly from spindle. Place disc brake assembly on
SM 1583 12-98 5
Brake Parts - Rear Axle
Section 165-0030
from piston housing assembly (41). Discard 'O' ring. SM - 116
18. Remove and discard 'D' section seals (38 & 39)
Fig. 7 - Removing/Installing 'D' Section Seal
from piston housing assembly (41). See Fig. 7.
6 SM 1583 12-98
Brake Parts - Rear Axle
Section 165-0030
SM - 120
WARNING
Return springs (36) are under compression.
To prevent personal injury and property
damage, use care when removing bolts (33)
and retaining plates (34).
WARNING
Spring housing (14) is under pressure from
spring (20 & 21) compression. To prevent
personal injury and property damage, use care
when removing socket head screws (15) and
hardened washers (16).
SM 1583 12-98 7
Brake Parts - Rear Axle
Section 165-0030
at a time. Using a suitable lifting device, lift spring SM - 125
housing (14) from disc housing (25). Refer to Fig. 12.
27. Remove springs (20 & 21) from parking piston (23).
See Fig. 12.
29. Remove and discard seal (22) from parking Fig. 14 - Removing/Installing Parking Piston
piston (23). See Fig. 15. Remove spacer ring (58)
from parking piston (23).
SM - 128
SM - 124
Fig. 15 - Removing/Installing Parking Piston Seal
SM - 129
Fig. 12 - Removing/Installing Spring Housing Fig. 16 - Removing/Installing Typical Disc Housing Seal
8 SM 1583 12-98
Brake Parts - Rear Axle
Section 165-0030
SM - 130
CORRECT
INSTALLATION
OF 'D' RING
2. Depress service brake treadle or, with retarder Splined Plate Thickness
selection mode switch in the disc brake position, New Plate ... 2.413 0.064 mm (0.095 0.0025 in)
place retarder control lever in the applied position. Worn Plate - Minimum
This will pressurize the service brake piston cavity. Permissible Size ...................... 2.29 mm (0.090 in)
3. Carefully remove pipe plug (1) from piston housing (6). Damper Plate Thickness
New Damper
4. Insert a depth micrometer into the pipe plug hole Plate ................. 6.9 0.051 mm (0.270 0.020 in)
and measure distance from end of retainer pin (2) to Compression 'Set' after use ..... 5.84 mm (0.230 in)
SM 1583 12-98 9
Brake Parts - Rear Axle
Section 165-0030
3. After cleaning and drying, coat all parts with light oil
to prevent corrosion.
Note: When using metallic rings which have satisfied 11. Check all disc (29) and plate (30) contact
inspection requirements, a slight 'overlap' condition, surfaces for nicks, pits or corrosion. Check teeth of
related to the original orientation of the seal faces, discs and plates for wear and damage.
could occur and cause initial light leakage which will
stop when the assembly has been 'run in'. 12. Check finished surfaces of all other parts for
scored or worn surfaces. Repair or replace as necessary.
5. Before installing the disc brake assembly, clean all
exterior surfaces to remove any foreign material.
ASSEMBLY
6. Inspect all splines for cracked or broken teeth, Numbers in parentheses refer to Fig. 3.
excessive wear and pitted or scored surfaces. Repair
or replace as necessary. Note: Tighten all fasteners without special torques
specified to standard torques listed in Section
7. Check for pitted, scored or worn mating surfaces of 300-0080, STANDARD BOLT AND NUT TORQUE
housings. SPECIFICATIONS.
8. Check all threaded holes and threaded parts for dirt Note: All 'O' rings, seals and all contacting surfaces
or damaged threads. Repair or replace as necessary. must be clean and lubricated at assembly.
10 SM 1583 12-98
Brake Parts - Rear Axle
Section 165-0030
SM - 132
10. Install springs (20 & 21) in bores in parking piston
(23). See Fig. 12.
Fig. 20 - Disc Driver Installed in Typical Disc Housing 13. Install five socket head screws (15) and hardened
washers (16) in holes under protruding ears on spring
housing (14). Tighten socket head screws (15)
alternately, one turn at a time, to draw spring housing
WARNING (14), against the tension of springs (20 & 21), down
To prevent personal injury and property to disc housing (25). Tighten socket head screws
damage, make sure lifting equipment is of (15) to a torque of 260 - 280 Nm (190 - 210 lbf ft).
adequate capacity and properly secured to do
the job safely. 14. Install bolts (12) and hardened washers (13) in
remaining holes in spring housing (14) and disc
1. With a suitable lifting device, place disc housing housing (25). Tighten bolts (12) to a torque of
(25) on a clean level surface, with spring housing (14) 260 - 280 Nm (190 - 210 lbf ft). See Fig. 11.
end up.
15. With a suitable lifting device, turn disc housing
2. If removed, install dowels (18) in disc housing (25). (25) over and place on a clean flat surface, spring
housing (14) side down. See Fig. 19.
3. Stretch new seal (24) slightly. Lubricate seal groove
in disc housing (25) and seal (24) with 'Wynns S.T.P.' 16. If removed, install dowels (26) in disc housing (25).
to aid seal installation. Install seal (24). See Fig. 16.
17. With a suitable lifting device attached to disc
4. Lubricate spacer ring (59) with 'Wynns S.T.P' and driver (27), position disc driver inside disc housing
install in disc housing (25) as shown in Fig. 17. (25), with large splined end up. See Fig. 20. Block up
disc driver with 50 mm x 100 mm (2 in x 4 in) blocks.
5. If removed, install dowels (19) in parking piston (23).
18. Install damper assembly (28) in disc housing
6. Lubricate new seal (22) and groove in outer (25), aligning teeth of damper with splines in disc
diameter of parking piston (23) with 'Wynns S.T.P.'. housing. See Fig. 10. Ensure cork side of damper
Install seal (22). See Fig. 15. faces downward toward parking piston (23).
7. Lubricate spacer ring (58) with 'Wynns S.T.P' and Note: Prior to installing friction discs (29), apply a
SM 1583 12-98 11
Brake Parts - Rear Axle
Section 165-0030
coating of oil, of the type used in the system, to the SM - 133
discs.
12 SM 1583 12-98
Brake Parts - Rear Axle
Section 165-0030
SM - 137 SM - 138
Fig. 24 - Installing Piston Housing on Disc Housing Fig. 25 - Tightening Piston Housing to Disc Housing
SM - 140
DISC BRAKE
ASSY PORT F
3/8 NPT
PORTABLE ADAPTOR
HAND POWERED
3/8 NPT
OIL PUMP
CONNECTOR
7.6 litre
(2 US gal)
3/8 NPT 9.5 mm (0.375 in) MEDIUM
CAPACITY
CONNECTORS PRESSURE HOSES
1 830 mm (6.0 ft) LONG
Fig. 26 - Typical Pressure Test Setup for Service and Parking Brakes
33. Install new 'O' ring (37) on piston housing hardened washers (44), in holes under protruding
assembly (41) as shown in Fig. 23. ears on piston housing assembly (41). Tighten socket
head screws (45) alternately, one turn at a time, to
34. With a suitable lifting device, turn piston housing draw piston housing assembly down snug on disc
assembly (41) over, with service piston (31) down. housing (25). Tighten socket head screws (45) to a
torque of 260 - 280 Nm (190 - 210 lbf ft).
35. If removed, install bleeder valves (50 & 54) in
piston housing assembly (41). 39. Install bolts (43) and hardened washers (42) in
piston housing assembly (41). Tighten bolts (43) to a
36. If plug (49) was removed, install new 'O' ring (48) torque of 260 - 280 Nm (190 - 210 lbf ft). See Fig. 25.
on plug and install plug in piston housing assembly (41).
Note: Be careful that disc driver (27) does not slide
37. Using a suitable lifting device attached to piston out of disc housing (25) when turning disc brake
housing assembly (41), position piston housing assembly over.
assembly (41) on disc housing (25), making sure
dowel pin holes in housing are aligned with dowels 40. Refer to Fig. 26 for typical pressure test setup.
(26) on disc housing. Gradually lower piston housing Position brake assembly vertically with bleeder
onto disc housing. See Fig. 24. valves (50 & 54, Fig. 2) at the 12:00 oclock position.
Connect a portable hand pump filled with clean brake
38. Install five socket head screws (45), with hydraulic oil to Port 'D', Fig. 2, and pressurize service
SM 1583 12-98 13
Brake Parts - Rear Axle
Section 165-0030
brake piston cavity to 52 bar (750 lbf/in2). See Fig. 27. SM - 139
INSTALLATION
Numbers in parentheses refer to Figs. 1 and 2.
WARNING
To prevent personal injury and property
Fig. 28 - Pressurizing Parking Brake Assembly
damage, ensure lifting equipment is of
adequate capacity and properly secured to do
the job safely. spindle flange, making sure 'O' ring (53) remains in
counterbore on piston housing assembly.
1. Install new 'O' ring (53) in counterbore on mounting
face of piston housing assembly (41). 4. Install nuts (52) and hardened washers (51) on
studs (46). Tighten nuts (52) to a torque of
2. Remove one bolt (12) and hardened washer (13) 1 166 - 1 193 Nm (860 - 880 lbf ft). Remove lifting
from spring housing (14) and one bolt (43) and device and lifting eyes and reinstall bolts (12 & 43)
hardened washer (42) from piston housing assembly and hardened washers (13 & 42) and tighten bolts to
(41), both bolts from as close to 12:00 oclock position specified torque.
as possible. Install a lifting eye in each bolt hole.
Note: Prior to installing face seal (11), clean face seal
3. With a suitable lifting device attached to the disc (11) and toric rings in '1.1.1. Trichlorethane' liquid.
brake assembly, at the lifting eyes installed in Step 2,
position disc brake assembly on spindle. When Note: Seal installation kit (ref. Special Tools)
installing right-hand brake assembly, 'INLET' port comprises of seal sleeve, seal driver and a spring.
should be at the top. When installing left-hand brake
assembly, 'INLET' port should be at the bottom. Insert 5. Insert seal sleeve tool (Fig. 29) in spring housing (14)
studs (46) of disc brake assembly through holes in until it is in as far as it can go.
14 SM 1583 12-98
Brake Parts - Rear Axle
Section 165-0030
SM - 450 SM - 451
SM - 452
DISC
DRIVER
SEAL METALLIC
ELEMENT
TORIC
RING
SEAL
SPRING
DRIVER
SEAL PARKING
SLEEVE PISTON
SPRING
HOUSING
6. Insert seal installation kit spring on one half of face and into spring housing (14).
seal (11) and install toric ring on face seal. The
spring prevents the toric ring from riding up the ramp 8. Press home face seal (11) with seal driver (Fig. 30)
on face seal (11) hence leading to easier installation. until inside face of seal driver is flush with outside face
of seal sleeve. See Fig. 31.
7. Install one half of face seal (11) with 'O' ring and
toric ring fitted, toric ring end first, inside seal sleeve 9. Remove seal driver from spring housing (14) and
SM 1583 12-98 15
Brake Parts - Rear Axle
Section 165-0030
slowly remove seal sleeve. When seal driver and seal SM - 148
sleeve are removed, withdraw the spring from face
seal (11). Apply a thin film of oil to metal contacting
surface of face seal (11).
10. Install toric ring in other half of face seal and install
in seal housing (10), toric ring side down. Refer to Figs.
32 & 33. Install seal installation tool (Fig. 34 'B') over face
seal and press face seal into housing. See Fig. 35.
Remove seal installation tool.
11. Coat 'O' ring (4) with grease and install in groove
of disc driver (27). Apply a thin film of oil to metal Fig. 32 - Seal Housing (10)
contacting surface of face seal (11). Install seal
housing (10), with half seal installed, over disc driver
SM - 149
(27). Secure seal housing to disc driver with bolts (9)
and hardened washers (55). Secure bolts (9) with
lockwire (56).
12. Install one half of new face seal (3), toric ring side
inward, over spindle. Using seal installation tool (Fig.
34 'A'), press seal into disc driver (27) by tapping tool Fig. 33 - Half of Seal (11) Installed in Seal Housing
with a soft hammer. Remove seal installation tool.
SM - 150
13. Install other half of new face seal (3), toric ring
side inward, into inner seal housing (1). Using seal
installation tool (Fig. 34 'A'), press seal into seal
housing. Remove seal installation tool.
14. Coat 'O' ring (2) with grease and install in groove
on seal housing (1). Install seal housing (1), with face
seal (3) installed, and secure with new bolts (57).
WARNING
Use extreme caution to prevent personal injury
when installing wheels. The exact procedure
must be followed, as described in Section
160-0050, WHEEL, RIM AND TYRE.
16 SM 1583 12-98
Brake Parts - Rear Axle
Section 165-0030
SM - 1486
2 1
4,5
6,7 11 12
1 2
13
8,9,10 TO MAIN AIRLINE
14,15
18,19
16,17
inserting wheel driver (5) on disc driver (27), not to seals are properly seated, to prevent oil leaks.
damage 'O' ring (8) and to align wheel driver splines
with splines on disc driver. Note: Be sure to uncap and install only one hydraulic
line at a time to prevent loss of oil from brake
19. Fill service brake pack with 11 litres (3 US gal) of hydraulic oil tank. The vacuum pump, installed during
clean hydraulic oil, of the same type used in the brake removal, cannot retain oil in tank if more than one line
cooling circuit. Pressurize the brake assembly with 2 bar is uncapped at a time.
(30 lbf/in2) air pressure through Port 'B' (Inlet), Fig. 2, with
the opposite Port 'C' (Outlet), Fig. 2, plugged. 20. Remove plugs and install service brake hydraulic
tube in port 'D', Fig. 2, as tagged at removal.
Note: Refer to Fig. 36 for typical brake pressure test
setup. Blanking plates for ports 'B' and 'C' may be 21. Remove plugs, and install parking brake hydraulic
fabricated as shown in Figs. 39 and 40. tube in port 'F', Fig. 2, as tagged at removal.
While rotating the wheel, observe for air pressure loss 22. Remove plugs and install cooling lines in ports 'B'
on the air supply hose gauge. Less than 0.14 bar and 'C', Fig. 2, as tagged at removal.
(2 lbf/in2) air pressure loss in 15 minutes is
satisfactory. If the air pressure loss is greater than 23. Remove vacuum pump from brake hydraulic oil
0.14 bar (2 lbf/in2) in 15 minutes, rotate the wheel tank, installed during removal and reinstall air
additionally to reseat all seals and pressurise the breather, in tank.
brake assembly to 2 bar (30 lbf/in2). If the brake
assembly again leaks more than 0.14 bar (2 lbf/in2) air 24. Fill steering and brake control tank with hydraulic
pressure in 15 minutes, loosen the wheel retainer oil specified in Section 300-0020, LUBRICATION
bolts, rotate the wheel to reseat the seals, and tighten SYSTEM. Refer to SECTION 220-0040, STEERING
the bolts. Repeat the air pressure test to be sure the AND BRAKE CONTROL TANK, for correct fill level.
SM 1583 12-98 17
Brake Parts - Rear Axle
Section 165-0030
Note: If brake discs, service and/or parking pistons,
piston housing, or the complete brake assembly have WARNING
been replaced, a new brake-disc-stack-height Loosen bleeder valves carefully. The braking
measurement should be taken as described under system operates at high pressure.
'Disc Assembly Wear Measurement Procedure',
under 'Inspection' in this section. This dimension 5. Depress service brake pedal and gradually open
should then be stamped on the machined surface of bleeder valve (54). Bleeder valve should remain open
pipe plug (47, Fig. 1) hole location for future until oil coming from bleeder valve is free of air
reference. bubbles. Close bleeder valve and release brake
pedal.
BLEEDING
Note: Recharge the system when necessary by
Numbers in parentheses refer to Fig. 1. repeating Step 2.
18 SM 1583 12-98
IN
0.50
0.62
0.47
0.06
0.03
0.38
0.26
0.25
0.22
0.19
0.18
0.12
0.177
0.139
0.130
SM 1583 12-98
9.6
6.6
6.3
5.6
4.8
4.6
3.0
4.5
3.5
3.3
MM
12.7
15.7
11.9
1.52
0.76
IN
3.00
2.56
2.50
2.00
0.81
6.00
5.50
4.00
1.68
1.12
1.00
0.75
0.72
20.00
SPRING COMPRESSOR TOOL
MM
508
152
140
101
76.2
65.0
63.5
50.8
42.7
28.4
25.4
20.5
19.0
18.2
100 SQ.
STOCK
ITEM #1 - HANDLE
.250 DIA.
HOLE THRU.
KNURL
DIA. HOLE
ITEM #5 - 'T' HANDLE
(WELDMENT)
19
Section 165-0030
Brake Parts - Rear Axle
Brake Parts - Rear Axle
Section 165-0030
SM - 126
0.56 - 3 HOLES
in mm
EQUALLY SPACED
0.12 3.0
0.50 12.7
0.56 14.22
0.62 15.7
1.00 25.4
1.62 41.1
2.00 50.8
2.50 63.5
MATERIAL: 3.25 82.5
PLAIN CARBON STEEL 3.31 84.0
9.38 238
15.88 403
26.25 668
SM - 1487 SM - 1488
117 16 108 16
77.8 4.45 77.8 4.45
+- 0.13 +- 0.13
14 R51.6 R51.6
7.1 14 7.1
+- 0.13 +- 0.13
66.7 +- 0.25
66.7 +- 0.25
28.4
42.9
57
42.9
42.9
R0.50
/0.76 R0.50
in NPT R15 /0.76
R0.13/0.25 R15 R0.13/0.25
Fig. 39 - Fabrication of Blanking Plate for Port 'B' Fig. 40 - Fabrication of Blanking Plate for Port 'C'
* * * *
20 SM 1583 12-98
SUSPENSION SYSTEM - Front Ride Cylinder
Section 180-0030
SM - 1985
1 - End Cap
*2 - Valve Assembly
*3 - Check Valve
*4 - Plug
5 - 'O' Ring
6 - Backup Ring
7 - Inner Tube
8 - Bolt
9 - Piston
10 - Wear Ring
11 - 'O' Ring
12 - Backup Ring
13 - Seal Retainer
14 - Seal
15 - 'O' Ring
16 - Bolt
17 - Lube Fitting
18 - Tube
19 - Wear Ring
20 - Seal
21 - Wiper
22 - Piston Rod
23 - Ball
24 - Relief Fitting
25 - Locknut
* 26 - Shear Key
* 27 - Hardened Washer
* 28 - Bolt
29 - Disc
30 - Hardened Washer
31 - Bolt
32 - Hardened Washer
* Shown on Fig. 4.
DESCRIPTION AND OPERATION Oil and compressed nitrogen fill the inside of tube
Numbers in parentheses refer to Figs. 1 & 4. (18). When the wheel hits a road bump, piston rod
(22) is forced into tube (18). Inward movement of
The front ride cylinder suspends the front wheel and piston rod (22) compresses the nitrogen within tube
spindle from the chassis and absorbs road shock as (18) thereby slowing piston rod travel speed. As
the wheel travels over rough and uneven surfaces. piston rod (22) moves inward in tube (18), oil
REMOVAL
Numbers in parentheses refer to Fig. 2.
WARNINGS
Pressurized cylinders. Release pressure as
described under 'Relieving Cylinder Pressure'
before removing valves or fittings. Accidental 1 - Front Ride Cylinder
release of pressure will result in personal 2 - Washer
injury and property damage. 3 - Bolt
4 - Shear Key
To prevent personal injury and property Fig. 2 - Exploded View of Front Ride Cylinder Mounting
damage, be sure blocking or lifting equipment
is of sufficient capacity and properly secured SM - 191
to do the job safely.
FRAME FRONT
1. Position the vehicle in a level work area, apply the RIDE CYLINDER
parking brake and switch off the engine.
7. Remove cotter pins and castle nuts attaching tie 9. Remove bolts (3) and washers (2) attaching front
rod and steering cylinder to steering arm. Secure ride cylinder (1) to the frame.
both tie rod and steering cylinder away from the work
area. Refer to Section 220-0120, STEERING 10. Carefully remove the front ride cylinder, spindle
CYLINDER AND LINKAGE. and wheel assembly to a suitable work area for
further disassembly.
8. Position lift truck forks under front ride cylinder
and block up ride cylinder, spindle and wheel 11. Follow procedures in Steps 4 through 10 above if
assembly as shown in Fig. 3. the other front ride cylinder is to be removed.
SM - 2004
2 25
3,4 8
5 10
32
1
19
20
9
16 15
21 6
26
23
22 27
24 28 7
17 11
18
12
27
28
13
29
14
30
31
6. Remove bolts (8) and hardened washers (32) 2. Inspect tube (18), piston rod (22) and piston (9) for
securing piston (9) to top of piston rod (22). scores, scuffing or small ridges in the walls. Use a
fine stone to smooth out any defective areas. If
7. Install a lifting eye in the top of piston rod (22) and damage is too extensive, replace with a new part.
attach to an adequate lifting device. Slide piston rod
(22) and piston (9) as an assembly out from top of 3. Inspect all cylinder assembly components for
tube (18). signs of unusual distortion or excessive wear.
Replace defective components.
Note: When removing piston rod (22), seal retainer
(13) and inner tube (7) should come out as an 4. Inspect plug (4), check valve (3), valve assembly
assembly. If they do not come out intact after (2) and lube fitting (17). Check their seating positions
removing piston rod (22), remove inner tube (7) and in end cap (1) and tube (18). If threads in any of
seal retainer (13) individually from tube (18). these parts are damaged, restore the threads.
Replace defective parts if necessary.
8. Slide piston (9) up piston rod (22) and remove
ball (23). 5. Inspect wear ring (19) for excessive wear or
damage. Replace if damaged.
Note: Take care not to misplace ball (23).
9. Remove piston (9) and remove wear ring (10) from ASSEMBLY
piston. Numbers in parentheses refer to Figs. 1 & 4.
PLUG 1. Install new backup ring (12), seal (14) and 'O' ring
(11) to seal retainer (13). Press seal retainer (13)
assembly down into tube (18) until retainer bottoms
Fig. 5 - Spindle Annular Groove for Separating Tapers
at lower end of tube. Insert inner tube (7) into tube
(18). Refer to Fig. 6.
SM - 1374
SM - 195
(22) into outer tube (18) is illustrated in Fig. 7.
2. Install wear ring (10) to piston (9) and install piston d) Remove jack, threaded rod stock, nuts, and
assembly to piston rod (22). Slide piston (9) washers. Remove any wood debris left from the wood
assembly up piston rod (22) enough to install ball block.
(23) in piston rod.
e) Move piston rod (22) and piston (9) assembly to
3. Apply Loctite 277 to threads of bolts (8) and full extended position and tighten bolts (8) to a torque
secure piston (9) assembly to piston rod (22) with of 105 Nm (78 lbf ft). This will help to centre parts
bolts (8) and hardened washers (32). Do not tighten and eliminate binding.
bolts (8) at this time.
7. Install new 'O' rings (5 & 15) and backup ring (6) to
4. Install wear ring (19) in tube (18). Install with wear end cap (1). Secure end cap (1) to the top of tube
ring joint in line with lube fitting (17). (18) with bolts (16) and locknuts (25). Tighten
locknuts (25) evenly to a torque of 105 Nm (78 lbf ft).
5. Install seal (20) and wiper (21) in tube (18).
8. Insert tapered end of piston rod (22) into the
6. Insert piston rod (22), piston (9) and wear ring (10) spindle and secure disc (29) to bottom of piston rod
as an assembly, through the top of tube (18). Make (22) with bolts (31) and hardened washers (30).
sure check ball (23) is correctly positioned in piston Tighten bolts (31) to a torque of 280 Nm (205 lbf ft).
rod (22).
Note: A periodic inspection should be made to ensure
Note: A convenient method for pressing piston rod proper torque is maintained on bolts (31).
WARNING
WARNING To prevent personal injury and property
To prevent personal injury and property damage, be sure blocking or lifting equipment
damage, be sure blocking or lifting equipment is of sufficient capacity and properly secured
is of sufficient capacity and properly secured to do the job safely.
to do the job safely.
1. Use lift truck forks with blocking placed as shown Relieving Cylinder Pressure
in Fig. 3 to position front ride cylinder to frame Numbers in parentheses refer to Fig. 8.
mounting surface.
3. Remove equipment used to position front ride 1. Support the frame near the ride cylinder with
cylinder to frame mounting surface. blocking and/or a hydraulic jack with adequate
capacity.
4. Attach steering cylinder and tie rod to steering arm
with castle nuts and cotter pins. Tighten tie rod nut to 2. Remove the cap from nitrogen charging valve (4)
a torque of 1 150 - 1 290 Nm (850 - 950 lbf ft) and at the top of the cylinder. Turn the hex nut on the
steering cylinder nut to a torque of 1 560 - 1 630 Nm valve 1/4 to 1/2 turn counter-clockwise and depress
(1 150 - 1 200 lbf ft). the valve core. If no gas escapes, continue to turn
the hex nut in 1/4 turn increments until the nitrogen
Note: If necessary, refer to Section 220-0120, releases as the valve core is depressed.
STEERING CYLINDER AND LINKAGE, for procedure
in Step 4 above. 3. Remove blocking or release pressure on the
hydraulic jack and allow the vehicles weight to fully
5. Connect brake hydraulic line to brake calliper and retract the ride cylinder rod.
bleed braking system. Refer to Section 165-0020,
BRAKE PARTS.
WARNING
6. Install front tyre and rim assembly as described in Pressurised cylinders. Keep valve core
Section 140-0040, WHEEL, RIM AND TYRE. depressed until all gas is bled from cylinder.
Failure to release all pressure may result in
7. If the opposite ride cylinder was removed, follow personal injury or property damage.
steps 1 through 6 to install the cylinder.
4. Depress nitrogen charging valve (4) core again to
8. Charge ride cylinders as described in 'Charging be sure all pressure has been relieved.
Instructions', in this section.
Note: Nitrogen leaving the cylinder will often carry oil
with it. This results from foaming of the oil in the
cylinder. The foaming takes place as nitrogen which
was dissolved in the oil at high pressure expands at
atmospheric pressure. The oil lost in this operation
must be replaced in the charging operation. The
SM - 2005
GUIDE ONLY:
DIMENSION 'A'
RIDE POSITION
TRUCK EMPTY
mm in
165 - 171 6.5 - 6.75
Note: To ensure that both ride cylinders will be A high pressure nitrogen pressure
equally charged to the required height specifications regulator must be used with the charging
and equal pressures, both cylinders should be assembly. Failure to use a pressure regulator
charged simultaneously. could cause property damage, personal injury,
or death.
Also when front ride cylinders are being charged,
both rear ride cylinders should be extended equally. 1. Remove pipe plug (2) from check valve (3). Attach
This can be accomplished by placing equal thickness hose from a pressure pump filled with hydraulic oil
blocks between axle and frame at the bump stops. It specified in Section 300-0020, LUBRICATION SYSTEM,
may be necessary to raise frame slightly to install to check valve (3). Remove charging valve (4).
spacers. Be sure to remove spacers when charging
is complete. Note: Approximately 14 bar (200 lbf/in2) pressure is
required to open the check valve allowing oil to flow
Note: The pressure of a confined gas varies directly through the fitting into the cylinder. If a pump is not
with its temperature. Hence, extreme changes in ride available to overcome this check valve cracking
cylinder ambient temperature will change its nitrogen pressure:
charge volume and, consequently, its operating
height. It might be necessary, therefore, to add or a) Modify a spare check valve assembly by removing
remove nitrogen to maintain proper cylinder height as the internal valve and spring or,
To charge both cylinders simultaneously with nitrogen, valve (6, Fig. 9). Open the valve on the nitrogen bottle
a tee piece, coupling, two hoses (1, Fig. 9), valve slowly and note the reading on pressure gauge
chuck (2, Fig. 9) and valve extension (3, Fig. 9) can (5, Fig. 9). The available pressure in the nitrogen
be added to the charging assembly (See Fig. 9). bottle must be over 31 bar (450 lbf/in2).
Assembly of this kit is described under 'Special Tools'.
7. Close tank valve (6, Fig. 9) and open cylinder valve
4. Attach the charging assembly kit to the nitrogen (4, Fig. 9). Charge both cylinders to correct pressure
bottle by turning down on gland nut (8, Fig. 9). as shown in table on page 9, by opening tank valve (6,
Fig. 9) slowly and closing it occasionally. To check
5. Install valve chucks (2, Fig. 9) to nitrogen charging pressures in the cylinders, close tank valve (6, Fig. 9)
valve (4) as follows: and note the reading on pressure gauge (5, Fig. 9).
a. Rotate 'T' handle of valve chucks (12) anticlockwise Note: If both cylinders do not extend evenly, check
until they stop. rear ride cylinders. Both rear ride cylinders should be
extended equally (both can be fully collapsed). Also
b. Screw the swivel nuts down on nitrogen charging check that the truck is on a flat, level surface and
valves (4) until they seat. empty.
c. Turn small hex on nitrogen charging valves (4) two Note: The cylinder should be charged to the correct
to three turns anticlockwise to unseat the valves pressure and MUST NOT be over charged above the
internally. recommended height. Overcharging can cause the
cylinders to over extend, thus damaging the piston
d. Rotate 'T' handles clockwise until they seat, retaining bolts.
opening check valves (valve cores) in nitrogen
charging valves (4). Note: The cylinder height shown in fig. 8 is a guide
only. Cylinders should be charged according to the
6. To check the amount of pressure in the nitrogen pressure specified in the table and NOT solely on the
tank, close cylinder valve (4, Fig. 9) and open tank basis of monitoring cylinder height.
9. With cylinder valve (4, Fig. 9) open and tank valve Refer to Section 300-0070, SERVICE TOOLS, for
(6, Fig. 9) closed, bleed pressure gauge (5, Fig. 9) part numbers of the charging assembly shown in
and hoses (1, Fig. 9) through bleeder valve (10, Fig. 9). Fig. 9, additional parts required for simultaneous
Loosen the swivel nuts and remove valve chucks (2, charging of both ride cylinders, general service tools
Fig. 9) and hoses (1, Fig. 9) from nitrogen charging and adhesives required. These parts, tools and
valves (4). adhesives are available from your dealer.
Note: On new or rebuilt cylinders, the seals and To simultaneously charge the ride cylinders, the
wipers may grip the piston rods tighter and make it charging assembly can be modified as follows:
difficult to obtain the correct height shown in Fig. 8. If
this happens, the cylinders should be charged as a. Disconnect hose (1) assembly from cylinder valve
accurately as possible, the vehicle operated for (4) and install a tee piece in cylinder valve (4).
several days, and then the cylinder checked.
b. Connect hose (1) assembly to one branch of the
10. Check nitrogen charging valves (4) for leakage tee piece and secure.
with soapy water. If either core is leaking, depress it
quickly once or twice to reseat the core. If leakage c. To make the second hose assembly, connect both
persists, replace core. Tighten charging valve lock additional hoses together with a coupling. Install a
nut and replace valve cap. Tighten valve cap so that valve extension in a chuck valve and install the
it cannot be removed by hand. chuck valve assembly on the hose assembly.
WARNING
This vehicle is equipped with precharged nitrogen gas cylinders of more than 2.8 bar (40 lbf/in2).
Special permits may be required when transporting the vehicle or cylinders by any method while
cylinders are charged. For shipment, contact the appropriate agency in the country involved.
Consult your dealer for further permit information.
* * * *
SM - 1369
PASSAGE 'A'
SM - 1370
1 - Ride Cylinder
2 - Bolt 5 - Pin Assembly 8 - Lube Fitting
3 - Lockwasher 6 - Spacer 9 - Bolt
4 - Washer 7 - Pin Assembly 10 - Boot Assembly
3. Place a 35 mm (1.38 in) spacer between the frame assembly (5) out of ride cylinder (1) and bracket eyes.
and oscillation stop on both sides. Remove spacers (6).
4. Relieve nitrogen pressure from BOTH rear ride 7. Remove bolt (2), lockwasher (3) and washer (4)
cylinders. Refer to 'Relieving Cylinder Pressure', in this securing pin assembly (7) through upper end of ride
section. cylinder (1) and frame mounting. Drive pin assembly
(7) out of frame and upper ride cylinder (1) eyes and
5. Attach a suitable lifting device or 'come-along' to remove spacers (6).
ride cylinder (1). If a 'come-along' is used, place a bar
or heavy pipe through both body prop pin holes in the 8. Lower ride cylinder (1) assembly and move to a
frame. Attach the 'come-along' to the bar or pipe. clean work area for disassembly.
Place a suitable strap or chain around ride cylinder (1)
and take up the slack. 9. If required, repeat Steps 5 through 8 to remove
second ride cylinder (1).
Note: Lower end of ride cylinder (1) must be
disconnected before upper end.
DISASSEMBLY
6. Remove bolt (2), lockwasher (3) and washer (4) Numbers in parentheses refer to Fig. 3.
securing pin assembly (5) through lower end of ride
cylinder (1) and rear axle housing brackets. Drive pin 1. Remove clamp (30), bolts (27) and plate (29)
SM - 1378
4. Carefully remove tube (19) from piston rod (1) 7. Place piston rod (1) assembly securely into position
assembly. in a press bed with piston rod eye down. Press piston
rod (1) out of seal retainer (12).
5. Remove bolts (18) and washers (5) from piston (17)
end of piston rod (1) assembly. 8. Remove and discard 'O' ring (15) and backup ring
(14) from seal retainer (12) outer groove.
9. Remove and discard seal (11) and wiper (9) from ASSEMBLY
seal retainer (12) inner grooves. Numbers in parentheses refer to Fig. 3.
10. Remove check valve (6) and plug (7) assembly Note: Apply a light coating of clean hydraulic oil to all
from piston rod (1). If required, remove plug (7) from components to facilitate assembly procedure. Make
check valve (6). certain that all work is carried out in a clean area so no
dirt or other contaminants can get into the oil.
11. Remove charging valve assembly (22) from piston
rod (1). Do not disassemble charging valve assembly 1. If removed, install snap ring (21) into tube (19) eye.
(22) unless required. Use a hand press to position spherical bushing (20)
against snap ring (21) in eye of tube (19). Retain
12. Remove lube fitting (10) from piston rod (1) and spherical bushing with remaining snap ring (21). Use
lube fitting (4) from tube (19). similar procedure to install spherical bushing (2) and
snap rings (3) in piston rod (1) eye end.
13. Spherical bushings (2 & 20) can be removed by
removing retainer snap rings (3 & 21) and pressing 2. Install new seal (11) and wiper (9) into inner groove
spherical bushings out of piston rod (1) and tube (19) of seal retainer (12). See Fig. 4.
eyes.
3. Install new backup ring (14) and 'O' ring (15) into
outer groove of seal retainer (12). See Fig. 4.
INSPECTION
Numbers in parentheses refer to Fig. 3. 4. Install seal retainer (12) on piston rod (1). Be careful
not to damage wiper (9).
1. Wash all parts thoroughly in a suitable solvent. Dry
all parts with compressed air. Check all inner and 5. Place ball (8) into its seat in piston rod (1). Install
outer grooves in seal retainer (12) for cleanliness. wear ring (16) on piston (17) and press piston
assembly into position on end of piston rod (1). Secure
2. Inspect tube (19), piston rod (1) and piston (17) for piston (17) assembly to piston rod (1) with bolts (18)
scores, scuffing or small ridges in the walls. Use a fine and washers (5). Tighten bolts (18) evenly to a torque
stone to smooth out any defective areas. If damage is of 95 - 117 Nm (70 - 86 lbf ft).
too extensive, replace with a new part.
SM - 1373
Note: Lower end of ride cylinder (1) must be attached 3. Remove cap from nitrogen charging valve (2) at top
first. of ride cylinder. Turn hex nut on charging valve
1/4 to 1/2 turn anticlockwise and depress the valve
2. Apply an anti-seize lubricant to pin assembly (5). core. If no gas escapes, continue to turn hex nut in
1/4 turn increments until nitrogen releases as the
3. Install spacers (6) in place as pin assembly (5) is charging valve core is depressed.
driven through banjo housing bracket and lower ride
cylinder (1) mounting eyes. Secure pin assembly (5) in 4. Repeat step 3 for second ride cylinder.
position to housing bracket with washer (4),
lockwasher (3) and bolt (2). 5. Remove blocking or release pressure on the
hydraulic jack and allow the vehicles weight to retract
4. Install upper end of ride cylinder (1) to frame by ride cylinder rods.
installing spacers (6) in place as pin assembly (7) is
being driven through frame and upper ride cylinder (1) Note: Ride cylinders will not be fully retracted due to the
eyes. Secure pin assembly (7) to frame with washer spacers between the oscillation stops and frame rail.
(4), lockwasher (3) and bolt (2).
SM - 160
FRAME
1 - Lube Fitting
2 - Nitrogen Charging Valve
3 - Plug SPACER
4 - Check Valve 35 mm (1.38 in)
5 - Check Valve TOP OF SEAL
RETAINER
GUIDE ONLY:
DIMENSION 'A'
RIDE POSITION
TRUCK EMPTY
mm in
505 19.88
BANJO
ASSY
WARNING WARNINGS
Pressurized cylinders. Keep valve core Pressurized cylinders. Release pressure as
depressed until all gas is bled from cylinder. described under 'Relieving Cylinder Pressure',
Failure to release all pressure may result in before removing valves or fittings. Accidental
personal injury or property damage. release of pressure will result in personal
injury and property damage.
6. Depress nitrogen charging valve (2) core again to
ensure all pressure has been relieved. A high pressure nitrogen pressure
regulator must be used with the charging
assembly. Failure to use a pressure regulator
Charging Instructions could cause property damage, personal injury,
Numbers in parentheses refer to Fig. 6, unless or death.
otherwise specified.
1. Remove pipe plug (3) from check valve (5). Loosen
Note: To ensure that both ride cylinders will be equally check valve (4) slowly until groove in check valve
charged to the required height specifications and equal thread is exposed. This opens a bleed path from the
pressures, both cylinders should be charged inside of the cylinder to the atmosphere. Attach hose
simultaneously as shown in Fig. 6. from a pressure pump filled with hydraulic oil specified
in Section 300-0020, LUBRICATION SYSTEM, to
Note: The pressure of a confined gas varies directly check valve (5).
with its temperature. Hence, extreme changes in ride
cylinder ambient temperature will change its nitrogen Note: Approximately 14 bar (200 lbf/in2) pressure is
charge volume and, consequently, its operating height. required to open the check valve allowing oil to flow
It might be necessary, therefore, to add or remove through the fitting into the cylinder.
nitrogen to maintain proper cylinder height as ambient
temperature changes. Note: To readjust oil level, the truck must remain
stationary for at least 10 hours to avoid, and release,
SM - 1372
1 - Lube Fitting
2 - Nitrogen Charging Valve
3 - Pipe Plug
4 - Check Valve (upper)
5 - Check Valve (lower)
6 - Ride Cylinder
7 - Hose
8 - Tee Piece
9 - Pressure Gauge
10 - Charging Assembly
11 - Nitrogen Bottle
12 - Valve Chuck
13 - Pressure Regulator
Fig. 6 - Charging Two Ride Cylinders Simultaneously
Note: If both cylinders do not extend evenly, check Fig. 7 - Charging Assembly
front ride struts. Both front struts should be extended
equally (both can be fully collapsed). Also check that
machine is on a flat, level surface and empty. 9. With cylinder valve (4, Fig. 7) open and tank valve
(6, Fig. 7) closed, bleed pressure gauge (9) and
Note: The cylinders should be charged to the pressure hoses (7) through bleeder valve (10, Fig. 7). Loosen
shown and MUST NOT be overcharged. Overcharging the swivel nuts and remove valve chucks (12) and
can cause the cylinders to over extend, thus damaging hoses (7) from nitrogen charging valves (2).
the piston retaining bolts.
Note: On new or rebuilt cylinders, the seals and
Note: Cylinderheights shown in the Fig. 5 are intended wipers may grip the piston rods tighter and make it
to be a guide only. Cylinders should be charged difficult to obtain the correct height shown in Fig. 5. If
according to thecorrect pressure and NOT solely on this happens, the cylinders should be charged as
the basis of monitoring height. accurately as possible, the vehicle operated for
several days, and then the cylinder re-checked.
Note: As the frame rises during charging operations,
follow the frame up with suitable blocking and/or a 10. Check nitrogen charging valves (2) for leakage
hydraulic jack. with soapy water. If either core is leaking, depress it
quickly once or twice to reseat the core. If leakage
8. When correct pressure has been reached, close the persists, replace core. Tighten charging valve lock nut
valve on nitrogen bottle (11) and tank valve (6, Fig. 7) and replace valve cap. Tighten valve cap so that it
securely. Turn small hex on nitrogen charging valves cannot be removed by hand.
(2) clockwise to close valves internally. Rotate 'T'
handles of valve chucks (12) anticlockwise until they 11. Remove spacers from oscillation stops.
stop.
12. After charging cylinders to the correct ride height
CYLINDER CHARGING PRESSURE the vehicle, with rated load, should have a 35 mm
bar lbf/in (1.38 in) gap or more, between the oscillation stops
with the truck on a level surface. If there is less than
Standard Body 8.3 120 30 mm (1.25 in) between stops, check for machine
Rock Body 9 130 overload. If the machine is not being overloaded, the
WARNING
This vehicle is equipped with precharged nitrogen gas cylinders of more than 2.8 bar (40 lbf/in2).
Special permits may be required when transporting the vehicle or cylinders by any method while
cylinders are charged. For shipment, contact the appropriate agency in the country involved. Consult
your dealer for further permit information.
* * * *
Fuses, Relays and Warning Lights In addition, fuse F60, (Transmission ECM Ignition
Fuses, relays and warning lights which were not Power [10 A] is located in the Vehicle Interface Module
described under 'Component Designations' on the (VIM).
previous page, are identified in the following tables.
WARNING LIGHTS - Located in Dash Panel
FUSES - Located in Fuse Box A Front Brake Accumulator Pressure
B Rear Brake Accumulator Pressure
Current
C Low Steering Accumulator Pressure
Column Fuse No. Circuit Rating
D Low Steering and Brake Tank Oil Level
1 Spare - E Parking Brake
2 Spare - F Main Beam
3 ECM/Power Module 5A G Direction Indicators
4 Spare - H Body-up
5 Spare -
J Alternator Charging
A 6 Spare -
K Engine Oil Pressure
7 Transmission 10 A
L Engine Coolant Temperature
8 Stop Lights 5A
M Engine Stop
9 Sound power body-up 3A
N Engine Coolant Level
10 Panel Warning Lights 5A
P Engine Check
11 Instruments 5A
Q Air Filter Restriction
12 Body Proximity Switch 5A
R Engine Maintenance
13 Wiper/Washer/Horn 10 A S Transmission Oil Temperature
14 Wiper Park 10 A T Transmission Check
15 Horn 10 A U Brake Oil Temperature
16 Spare - V Steering Filter Restriction
17 Blower/Air Cond. 25 A W Retarder On
18 Auto Lube 5A X Transmission Oil Filter Restriction
B 19 Lights 10 A Y Converter Drive
20 Main Beam 10 A Z Overspeed
21 Direction Indicators 5A
22 Hazard Warning Lights 5A
23 Radio 15 A-
24 Headlamp Flash 10 A
25 Spare -
26 Front Brakes Press Red'n 5A
27 Lockup Drop-out Solenoid 5A
28 Retarder Control/Lights 5A
29 Reverse Relay 5A
C 30 Spare -
31 Electric Window 10 A
32 Worklamp/Cab Light 5A
33 Cigarette Lighter 10 A
34 Heated Mirrors 15 A
35 Air Suspension Seat 15 A
36 Reverse camera* 5A Relays - Located in Fuse Box
FUSES - Located in Power Module
Ignition
X Flasher
Current
Fuse No. Circuit Rating
Radio X X Sound Power
40 Control Circuits 15 A Body Raise
41 Engine ECM Power 1 10 A
Horn X
42 Transmission ECM Ignition 10 A
43 Transmission ECM Power 15 A Main
Dipped
44 Transmission ECM Power 15 A Beam Beam Sound Power
1st /Rev Gear
* * * *
SM - 3367
19 18 17
HEADER TANK 14
2 16 15
1 3 RETARDER
5 VALVE CHASSIS -
LH CAB LEG
13
ENGINE BODY
TRANSMISSION 12
22
11
10
7
6
HYD CONTROL
VALVE
4
8
1 - Engine Water Temperature Sender/Sw. 8 - Steering Oil Temperature Switch 15 - Rear Brake Accumulator Press Sw.
2 - Engine Oil Pressure Sender/Switch 9 - Steering Filter Restriction Pressure Sw. 16 - Front Brake Accumulator Press Sw.
3 - Transmission Oil Pressure Sender/Sw. 10 - Disc Brake Hydraulic Temp Switch 17 - Retarder Pressure Switch
4 - Disc Brake Hydraulic Temp Switch 11 - Fuel Level Sender 18 - Stop Light Pressure Switch
5 - Transmission Oil Temp. Sender/Sw. 12 - Body Up Proximity Switch 19 - Lockup Drop Out Pressure Switch
6 - Hoist Interlock Pressure Switch 13 - Steering Pressure Switch 20 - Engine Water Level Probe
7 - Hydraulic Oil Level Probe 14 - Parking Brake Pressure Switch 21 - Engine Water Level Probe
22 - Air filter Restriction Switch.
DESCRIPTION Engine
Numbers in parentheses refer to Fig. 1, unless The Quantum electronic engine management system
otherwise specified. monitors the engine at all times and sends a signal to
the engine stop light (6, Fig. 3), engine warning light (7,
This section describes the location and function of the Fig. 3) and engine protection light (8, Fig. 3) to alert the
various switches and sensors fitted to the vehicle to operator of a fault in the engine circuit. Refer to Section
monitor all major components and systems. Gauges 110-0030, ENGINE AND MOUNTING.
and indicator/warning lights mounted on the dash panel
relay this information to the operator. Engine Oil Pressure Sender/Switch (2) - Combined
sender and switch unit, located in the lube oil filter
Note: Always make sure all gauges, indicator/warning housing at the rear left hand side of the engine.
lights and controls are working properly before
operating the vehicle. The pressure switch sends a signal to illuminate engine
oil pressure warning light (5, Fig. 3) to indicate when
the engine oil pressure drops below the safe operating
pressure.
SM - 3258
1 2
15 P
20 30
10 RPM x100 20 20
20 MPH 20
10 40
5 25
2 6 km/h 20
0 30 0 50
STOP
ENG TRANS
OIL PRESS OIL PRESS
4
1 7
120
140
ENG TRANS
WATER TEMP 50 150
OIL TEMP
3 5
1 - Tachometer/Hourmeter Gauge
2 - Engine Oil Pressure Gauge 4 - Fuel Gauge 6 - Transmission Oil Pressure Gauge
3 - Engine Water Temperature Gauge 5 - Transmission Oil Temperature Gauge 7 - Speedometer/Odometer Gauge
The pressure sender sends a signal to the Engine Oil Tachometer/Hourmeter (1, Fig. 2) - Driven from the
Pressure Gauge (4, Fig.2). The gauge should read in engine ECM, the tachometer indicates the engine
the lower end of the green zone at normal operating speed in revolutions per minute (rev/min). Never
speeds and may fall to the lower end of the yellow accelerate the engine to speeds indicated by the red
zone at engine idle. Stop the engine if the gauge does zone on the dial face. A digital hourmeter is
not rise above the red zone until the fault is corrected. incorporated in the tachometer to record total hours of
engine operation.
Engine Water Temperature Sender/Switch (1) -
Combined sender and switch unit, located in the Tachometer Calibration Table -
thermostat housing.
All units with standard tyres or *optional 21*35 tyres
The temperature switch sends a signal to illuminate
engine water temperature warning light (2, Fig. 3) when Unit Engine Pulses/revolution
engine water temperature rises above the safe TR35 Cummins M11 12.00
operating temperature. TR45 Cummins QSK 12.00
TR45* Cummins QSK 12.00
The temperature sender sends a signal to the Engine TR60 Cummins QSK 12.00
Water Temperature Gauge (3, Fig. 2). The gauge TR70 DD Series 2000 12.00
should read in the green zone after the engine has TR100 Cummins KTA 15.72
warmed. If the gauge reads in the red zone, stop the (Standard 70 A Altr)
engine until the fault is corrected. TR100 Cummins KTA 18.34
(100 A, 14 Pole Altr)
Engine Water Level Probe (21) - Located in the TR100 Cummins KTA 20.96
bottom of the coolant system header tank. Sends a (100 A, 16 Pole Altr)
signal to illuminate engine water level warning light TR100 DD Series 2000 12.00
(3, Fig. 3) when engine water level falls below the safe
operating level.
SM - 3259
9 10 11 12
1 2
1 21
13 14 15 16
2 5 17 22
STOP
6 18
3 23
7 19
4 24
8 20
Tachometer Calibration red zone for short periods under heavy loading. When
1. Determine the impulse setting required. Reference the load decreases, the needle should return to the
tachometer calibration table. green zone and may fall momentarily into the lower red
zone. If the needle remains in either of the extreme
2. Using a suitable screwdriver, depress and hold zones for extended periods, stop the vehicle until the
calibration button at the rear of the tachometer and turn fault is corrected.
the ignition keyswitch to position '1'. Release Converter Drive - Transmission ECU sends a signal to
button when PULSE is displayed. illuminate transmission in-converter indicator light (20,
Fig. 3) to indicate when the transmission is in torque
converter drive. The light goes out when transmission
3. After a few seconds, the digits will flash in
lockup is engaged.
sequence. Depress the button until the desired number
is displayed the release the button for a few seconds
Transmission Oil Filter Pressure Switch - Located in
until the next digit flashes.
the transmission oil filter head. Sends a signal to
transmission oil filter restriction indicator light (23, Fig. 3)
4. Repeat step 3 to obtain the desired impulses/
to indicate that the filter is restricted and that the
revolution. The tachometer is now calibrated.
element requires to be changed. Refer to
Transmission Section 120-0100, TRANSMISSION OIL FILTER.
Transmission Oil Pressure Sender (3) - Located at
Transmission Oil Temperature Sender/Switch (5) -
the top of the converter housing, the pressure sender
Combined sender and switch unit, located at the outlet
sends a signal to the Transmission Oil Pressure Gauge
port for the transmission oil cooler.
(6, Fig.2) to indicate clutch application pressure. The
reading will vary during shifts and with varying speeds
The temperature switch sends a signal to illuminate
and loads. The needle should remain in the green zone
transmission oil temperature warning light (17, Fig. 3)
during normal operation but might rise into the upper
when the transmission oil temperature rises above the
safe operating temperature.
The temperature sender sends a signal to the (magnetic pick-up) is installed in the rear cover of the
Transmission Oil Temperature Gauge (5, Fig. 2) to transmission. The magnetic end of the sensor is
indicate converter-out oil temperature. The gauge positioned adjacent to the gear located on the
should read in the green zone during normal operation. transmission output shaft. Rotation of the output shaft
Watch for wide deviations from normal readings on the causes the gear teeth to pass through the magnetic
gauge during vehicle operation. If the gauge, on field at the end of the sensor. The passing of each gear
vehicles which do not have a transmission retarder tooth generates an electrical pulse which is directed to
fitted, shows oil temperature consistently rising above the ECU. The ECU recognises this signal as output
the green zone (43 - 135 C; 100 - 275 F) under normal speed. Refer to Section 120-0070, CEC SHIFT
operating conditions; check for external causes. If SYSTEM.
none are evident shift to Neutral 'N' and operate the
engine at 1 200 - 1 500 rev/min. If the transmission oil CEC Lockup Drop Out Pressure Switch (19) - The
temperature does not decrease into the green zone normally open (NO) pressure switch is located in the
within 2 or 3 minutes, the cause of overheating should front plate of the treadle valve in the 'B2' circuit. As
be corrected before the vehicle is operated further. brake pressure increases to 20 bar (290 lbf/in) and
above, the circuit should close and send a signal to the
Watch the gauge when operating on upgrades. If the oil lockup drop out solenoid, which in turn drops the
temperature goes into the red zone (135 - 176 C; transmission out of lockup. As pressure drops below
275 - 350 F), select the range which will limit upshifts 20 bar (290 lbf/in) the circuit should open and lockup
to the highest range in which the transmission will can be engaged. This will prevent the drive between
operate within the normal temperature range. If the engine and transmission from locking up and
upshifting must be consistently limited to ranges lower subsequently stalling the engine.
than normal for the loads and the grades encountered
to prevent overheating the transmission oil, the causes
should be determined and corrected.
Braking and Retardation
Front Brake Accumulator Pressure Switch (16) - The
During transmission retarder operation (optional) oil normally closed (NC) pressure switch, located in port
temperature can enter the yellow 'Retarder On' zone but 'PS1' of the brake manifold valve, senses the pressure
should not enter the red zone. Do not allow the in the front brake accumulator. The pressure switch
temperature to stay at or near the top of the yellow sends a signal to illuminate front brake accumulator
zone for more than three minutes. Reduce downgrade pressure warning light (9, Fig. 3) when pressure drops
travel speed to avoid the oil overheating and possible below 131 bar (1 900 lbf/in). An audible alarm also
damage to the transmission. sounds.
Speedometer/Odometer (7, Fig. 2) - Driven by a Rear Brake Accumulator Pressure Switch (15) - The
signal from the CEC, the speedometer indicates normally closed (NC) pressure switch, located in port
vehicle travel speed in kilometres per hour (km/h) and 'PS2' of the brake manifold valve, senses the pressure
miles per hour (mph). A digital odometer is incorporated in the rear brake accumulator. The pressure switch
in the speedometer to record the distance travelled by sends a signal to illuminate rear brake accumulator
the vehicle at any given time.For speedometer pressure warning light (10, Fig. 3) when pressure drops
calibration details, refer to Section 120-0070, below 131 bar (1 900 lbf/in). An audible alarm also
Transmission - C.E.C.2. sounds.
Transmission Oil Temperature Sensor - The Parking Brake Pressure Switch (14) - The normally
temperature sensor (thermistor) is mounted in the closed (NC) pressure switch, located in port 'PS3' of
lockup control valve body cover at the front left hand the brake manifold valve, senses pressure in the
side of the transmission. The transmission oil parking brake line. The pressure switch sends a signal
temperature is continuously monitored by the ECU. to illuminate parking brake indicator light (13, Fig. 3)
The ECU will only permit operation in a range best when pressure drops below 65 bar (940 lbf/in).
suited for the temperature condition and the 'Check
Transmission' light will illuminate. Refer to Section Stop Light Pressure Switch (18) - The normally open
120-0070, CEC SHIFT SYSTEM. (NO) pressure switch is located in the front plate of the
treadle valve in the 'B1' circuit. As brake pressure
Output Speed Sensor - The output speed sensor increases to 2.7 bar (39 lbf/in) and above, the circuit
should close and send a signal to illuminate the brake
lights. As pressure drops below 2.7 bar (39 lbf/in) the transmission to the range that will maintain an engine
circuit should open and brake lights go out. speed as high as possible, without exceeding the
maximum recommendation, to increase oil circulation
Retarder Pressure Switch (17) - The normally open and cooling. If trouble persists, stop the vehicle and
(NO) pressure switch is located in the retarder control have the fault corrected.
valve body. As retarder pressure increases to 2.7 bar
(39 lbf/in) and above, the circuit should close and send Body Up Proximity Switch (12) - Mounted off a
a signal to illuminate retarder indicator light bracket on the platform to the rear right hand side of
(19, Fig. 3), and the retarder light at the rear of the the cab. When the body is raised off the chassis, the
vehicle. As pressure drops below 2.7 bar (39 lbf/in) the proximity switch opens and completes the electrical
circuit should open and the retarder lights should go circuit to the ECU. The ECU then prevents the
out. transmission from shifting above 1st gear until the
body is fully lowered and the switch closes. Body-up
Steering warning light (16, Fig. 3) illuminates to indicate when
Steering Pressure Switch (13) - The normally closed the body is not resting on the chassis. Refer to Section
(NC) pressure switch is located in a tee at accumulator 120-0070, CEC SHIFT SYSTEM.
valve mounted off the left hand side of the
transmission. Sends a signal to illuminate low steering Note: Never move the vehicle until body-up warning
pressure warning light (11, Fig. 3) when steering light (16, Fig. 3) goes out.
pressure drops to 83 bar (1 200 lbf/in) or lower. An
audible alarm also sounds.
Hoist Interlock Pressure Switch - Located in a tee
Steering Filter Restriction Pressure Switch (9) - The installed in body hoist control valve. The hoist interlock
normally open (NO) oil pressure switch is located is a safety feature to prevent the vehicle from backing
beside steering oil temperature switch (8) in the up while the body is being raised. If the pressure
manifold block at the return port of the steering and switch is opened by the body control joystick being
brake control tank. The oil pressure switch will close moved to the raise position, current is interrupted and
and illuminate steering filter restriction indicator light the ECU will shift the transmission to neutral. To obtain
(22, Fig. 3) when the restriction pressure exceeds reverse gear whilst the body is held in the raise
2.7 bar (39 lbf/in2), indicating a filter change is required. position, move the transmission shift lever to neutral,
then re-select reverse gear. This interlock will not
Steering Oil Temperature Switch (8) - The normally prohibit shifts to a forward range while the body is
open (NO) oil temperature switch closes when a being raised. Refer to Section 120-0070, CEC SHIFT
temperature of 50 C (122 F) is reached. The oil SYSTEM.
temperature switch is connected in series with steering
pressure switch (9), therefore, steering filter restriction
indicator light (22, Fig. 3) will not illuminate until the oil Fuel Tank
reaches normal operating temperature. Fuel Level Sender (11) - Located in the rear of the fuel
Low Oil Level Switch (7) - Located in the steering and tank, the fuel level sender sends a signal to the fuel
brake control tank, with electrical connection at the rear level gauge to indicate the amount of fuel left in the
of the tank. Sends a signal to illuminate steering and fuel tank.
braking tank low oil level warning light (12, Fig. 3) when
the oil level in the tank falls below the safe operating
level. An audible alarm also sounds. Refer to Section Air Cleaner
220-0040 STEERING AND BRAKE CONTROL TANK. Air Cleaner Restriction Gauge - Located in the air
cleaner outlet pipe (22, Fig. 1), the gauge sends a
Body and Disc Brake Cooling signal to illuminate air cleaner restriction indicator light
Disc Brake Hydraulic Temperature Switch (4 & 10) - (4, Fig. 3) to indicate that the air cleaner is restricted
Located in the disc brake oil return tube to indicate if and that the element requires to be cleaned/changed.
the disc brake cooling oil is overheating. The oil
temperature switch sends a signal to illuminate
discbrake hydraulic temperature warning light (16, Fig.
3) when a temperature of 121 C (250 F) is reached. If
the light illuminates, reduce speed and shift
* * * *
SM 2316 Rev 2 10-07 5
Electrical System - Switches and Sensors
Section 190-0270
SM - 1702
16 CHASSIS
22
5
19
29
6
28
8 7
27 23
3
20
2
18
25
24
17,21 10
12
19
15
14
1 11
13
26
4
DESCRIPTION Integral with fuel tank (1) are fuel strainer (23) and fuel
Numbers in parentheses refer to Fig. 1. level sender (27). Fuel strainer (23) helps prevent
foreign particles from entering fuel tank (1) when fuel
Note: Refer to Section 300-0020, LUBRICATION tank (1) is being filled. Fuel level sender (27), located
SYSTEM, for fuel tank capacity and fuel in the rear of fuel tank (1), sends a signal to the fuel
specifications. level gauge in the dash panel to indicate the amount of
fuel left in the fuel tank.
Fuel tank (1) is mounted off mounting brackets (17 & 21)
secured to the right hand frame rail and is secured to
mounting brackets (17 & 21) by heavy duty straps (18).
SM 1587 12-98 1
Fuel System - Fuel Tank and Mounting
Section 200-0010
REMOVAL DISASSEMBLY
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.
1. Position the vehicle in a level work area, raise the 3. Remove screws (12) securing level gauge (9 &11) to
body and install the body safety pins. Refer to fuel tank (1) and remove level gauge (9 & 11). Check
Section 270-0010, BODY AND MOUNTING. condition of gasket (10) on level gauge (9 & 11) and
replace if required.
2. Apply the parking brake and switch off the engine.
4. Remove bolts (26), lockwashers (13), cover plate
3. Turn the steering wheel in both directions several (14) and 'O' ring (15) from fuel tank (1). Discard
times to relieve any pressure in the steering system. 'O' ring (15).
Block all road wheels.
5. Remove filler cap (5) from fuel tank (1). Discard 1. Remove all dirt particles from fuel strainer (23) and
gaskets (6 & 7) from filler cap (5) if damaged. clean fuel strainer (23) with clean diesel fuel.
6. Remove cover (29) from fuel level sender (27) and 2. Cover plate (14) port in fuel tank (1) can be used as
disconnect electrical connections at fuel level an opening to remove dirt and sludge from the bottom
sender (27). of fuel tank (1) with a clean dry cloth. Remove drain
plug (4) and flush fuel tank (1) with clean diesel fuel to
7. With a suitable container in position, remove drain remove any remaining dirt particles. Reinstall drain plug
plug (4) and drain fuel from fuel tank (1). Reinstall (4) and tighten securely.
drain plug (4) when fuel tank (1) is completely
drained.
ASSEMBLY
8. Identify and tag fuel lines connected to fuel tank Numbers in parentheses refer to Fig. 1.
(1) and, with a suitable container available to catch
leakage, disconnect fuel lines from fuel tank (1). Cap 1. Install new 'O' ring (15) in groove of fuel tank (1)
open line ends to prevent entry of dirt. boss and secure cover plate (14) to fuel tank (1) boss
with lockwashers (13) and bolts (26).
9. Using a suitable lifting device, support fuel tank (1)
and take up any slack. Remove nuts (19) securing 2. Ensure rubber sealing ring is located on fuel level
heavy duty straps (18) to lower end of mounting sender (27) and position fuel level sender (27) in fuel
brackets (17 & 21). tank (1). Secure fuel level sender (27) to fuel tank (1)
with screws (28).
10. Swing heavy duty straps (18) clear of fuel tank (1) and
remove fuel tank (1) from mounting brackets (17 & 21). 3. Ensure gasket (10) is located on level gauge (9 & 11)
and position level gauge (9 & 11) in fuel tank (1). Secure
11. If required, remove nuts (19) securing heavy duty level gauge (9 & 11) to fuel tank (1) with screws (12).
straps (18) to top end of mounting brackets (17 & 21)
and remove heavy duty straps (18). 4. Install fuel strainer (23) in fuel tank (1). If removed
install new gaskets (6 & 7) in filler cap (5) and install
12. If required, remove nuts (16), lockwashers (22), filler cap assembly loosely to prevent entry of dirt.
bolts (20) and mounting brackets (17 & 21) from the
chassis mounting brackets. 5. Ensure that plugs (2 & 3) and drain plug (4) are
securely tightened in fuel tank (1).
2 SM 1587 12-98
Fuel System - Fuel Tank and Mounting
Section 200-0010
7. Secure filler cap (5) on the filler neck with latch (8)
and padlock (24).
MAINTENANCE clean fuel strainer (23) and filler cap (5) as required.
Numbers in parentheses refer to Fig. 1. From time to time make a visual check on the
electrical connections at fuel level sender (27).
Prior to starting the vehicle check the fuel level. Fuel
tank (1) should be filled at the end of each shift to The condition of fuel tank (1) mounting should be
prevent condensation from gathering in the tank. checked carefully. Check heavy duty straps (18) and
Ensure vent hole in filler cap (5) is clear to prevent a mounting brackets (17 & 21) for any sign of wear or
vacuum from building up in fuel tank (1). Check damage and repair or replace as required. Check that
condition of all fuel lines. nuts (16 & 19) and bolts (20) are securely tightened
and that no wear on mounting holes is evident. Tighten
When filling fuel tank (1) check that there is no buildup nuts (16 & 19) and bolts (20) as required.
of dirt and sludge at fuel strainer (23). Remove and
* * * *
4 SM 1587 12-98
FUEL SYSTEM - Fuel Lines
Section 200-0040
SM - 3744
5 3
2
6 7
ENGINE LHS
FUEL RETURN MANIFOLD BLK.
PORT
13
12
10
11
9
DESCRIPTION
Numbers in parentheses refer to Fig. 1. secondary fuel filter and sends an electronic signal to
the ECM telling it what the engine fuel pressure is at
The fuel system consists of the QUANTUM electronic any given speed.
fuel system controls, fuel manifolds (integral with the
cylinder head), fuel pre-filter (14), primary fuel filter, Fuel temperature sensor is installed into the top of
secondary fuel filter, fuel pump, electronic control secondary fuel filter and sends an electrical signal to
module (ECM) cooling plate, electronic fuel injectors the ECM indicating fuel inlet temperature. The ECM
fuel cooler, fuel tank (1) and the necessary connecting uses this information to calculate fuel consumption.
fuel lines.
Note: Both fuel pressure sensor and fuel temperature
There is a fuel pre-filter mounted on the left hand frame sensor are non-serviceable items and should be
rail. The pre-filter is located in the fuel line and replaced as individual units. No adjustment is required.
removes dust particles for the fuel before reaching the
injectors. Fuel pump is attached to a drive assembly mounted on
the rear side of the gear case at the front LH side of
There are two spin-on type fuel filters mounted on the the engine and transfers fuel from fuel tank (1) to the
left hand side of the engine. Primary fuel filter acts as electronic fuel injectors.
a strainer and secondary fuel filter filters the fuel after
having passed through primary fuel filter. The electronic fuel injector is a lightweight, compact
unit that injects diesel fuel directly into the combustion
Fuel pressure sensor is installed into the side of chamber. The amount of fuel injected and the
SM 2504 03-07 1
Fuel System - Fuel Lines
Section 200-0040
beginning of injection timing is determined by the ECM. secondary fuel filters and enters fuel pump. Leaving
The ECM sends a command pulse which activates the fuel pump under pressure, the fuel flows through ECM
injector solenoid. cooling plate to the engine cylinder head. The fuel
flows to electronic fuel injectors in the cylinder head
The injector performs four functions: through passages integral with the cylinder head.
Surplus fuel exits at the rear of the cylinder head just
a - Creates the high fuel pressure required for efficient above the inlet, flows through fuel cooler and back to
injection. fuel tank (1).
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 MAINTENANCE
combustion chamber. Every 10 Hours/Daily:
d - Permits continuous fuel flow for component cooling. Make a visual check for fuel leaks at all engine
mounted fuel lines and connections, fuel cooler, and at
Electronic fuel injectors are self compensating and the fuel tank suction and return lines. Examine lines
virtually eliminate engine tune-ups. for leaks and check all fittings, clamps and ties carefully.
Note: Never apply 12 V directly to terminals on the Make sure that fuel lines are not resting on or touching
injector as it will burn out. Before removing injectors, rotating components, heated surfaces including
the fuel passages must be blown out to prevent fuel exhaust manifolds or sharp edges. If fittings have
flow from entering the cylinder head. loosened or cracked, or if lines have ruptured or worn
through, take corrective action immediately.
ECM cooling plate is mounted in front of the ECM on
the LH side of the engine and absorbs heat generated Refill the fuel tank at the end of each day's operation to
by the ECM. Fuel from fuel pump outlet line flows prevent condensation from contaminating the fuel.
through ECM cooling plate to absorb this heat.
Every 250 Hours:
Fuel cooler is mounted on the front RH side of the Replace the primary and secondary fuel filters as
radiator and cools fuel returning to fuel tank (1). follows:
Flexible fuel lines are used to facilitate connection of Note: There is a fuel system shut off cock (Fig 2. ) on
lines leading to and from fuel tank (1), and to minimize the discharge side of the secondary fuel filter. Closing
the effects of any vibration in the installation. A check this valve will prevent loss of fuel prime at time of filter
valve is incorporated in the fuel supply line to maintain replacement.
fuel pressure in the system. The restricting check
SM - 3232
valve is designed to provide the proper fuel system
pressure under all conditions.
2 SM 2504 03-07
Fuel System - Fuel Lines
Section 200-0040
300-0020, LUBRICATION SYSTEM. Open the drain at the bottom of the fuel tank to drain
off any water and/or sediment. Check the seal in fuel
3. Start new primary fuel filter on the filter adaptor and tank filler neck cap and clean filler neck screen and
tighten it by hand until the gasket contacts the adaptor cap. Check the condition of all fuel lines and replace if
fully with no side movement of the filter evident. required. Clean and inspect fins on fuel cooler.
Tighten an additional 1/2 of a turn.
2. open the drain valve and drain the fuel level below
Locating Air Leaks in Fuel Lines
the collar, then close the drain valve. Air drawn into the fuel system may result in uneven
running of the engine, black or white smoking and
3. Using the Collar/Vent Cap Wrench, remove the clear stalling when idling, or a loss of power. Poor operation
cover from the fuel processor by removing the collar. is particularly noticeable at lower engine speeds. If air
Discard the o-ring from the base of the cover. (A new is found in the fuel, the source will normally be between
o-ring seal is supplied with the new filter.) Remove the the fuel tank and the fuel pump.
filter element from the pre-filter unit by pulling upward
and twisting slightly. Be sure the sealing grommet is Check for loose, faulty or improper fuel line connectors.
removed from the center stud. Presence of an air leak may be detected
by following the procedures under 'Checking Fuel Flow'.
4. Install the new filter element (supplied with
a Sealing Grommet already inserted into the
Checking Fuel Flow
element) on the processor center stud by pushing 1. Disconnect the fuel return line from the fitting at the
down and twisting slightly. After checking to make fuel tank and hold the open end in a suitable container.
sure the new o-ring seal (supplied with the filter) at
the base of the cover is in place, install the cover 2. Start and run the engine at maximum rev/min and
and collar. Hand tighten the collar until seated. Do measure the fuel flow. Nominal fuel return spill with the
not use tools to tighten. check valve is 4.1 litres/min (65 US gal/min).
5. Remove the vent cap from the top of the clear cover 3. Immerse the end of the fuel return line in the fuel. Air
by turning the vent cap counterclockwise. bubbles rising to the surface of the fuel will indicate air
Fill the clear cover with enough clean fuel to cover being drawn into the fuel system on the suction side of
the bottom half of the filter element. Make sure the the pump. If air is present, tighten all fuel lines
vent cap. Reinstall the vent cap and tighten by connections between the fuel tank and fuel pump.
hand only.
4. If the fuel flow is insufficient for satisfactory engine
6. Start the engine. When the lubrication system performance then proceed as follows:
reaches its normal operating pressure, increase engine
RPM for one minute. a. Replace the primary and secondary fuel filters, as
Every 500 Hours: described under 'Maintenance'. Start the engine and run
* * * *
SM 2504 03-07 3
Fuel System - Fuel Lines
Section 200-0040
it at maximum rev/min and recheck the fuel flow. If fuel
flow is still unsatisfactory, perform step 'b'.
SPECIAL TOOLS
There are special tools required for procedures outlined
in this section. Refer to Section 300-0070, SERVICE
TOOLS, for part numbers of general service tools
required. These tools are available from your dealer.
4 SM 2504 03-07
FUEL SYSTEM - Electronic Foot Pedal
Section 200-0051
SM - 3233
28
26
27
29
25
3
24 23 4
22 16
21
15 20
19
5
6
7
12 17,18
10
14 13 17
26,27
9
18
8 10 ENGINE
REF.
8,9
31
FLOORPLATE
DESCRIPTION REMOVAL
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.
Note: The electronically controlled engine will override 1. Position the vehicle in a level work area, ensure
the electronic foot pedal position until the engine is the body is fully lowered, apply the parking brake and
warmed up to the correct operating temperature. The switch off the engine.
engine MUST be started with foot 'OFF' pedal
assembly (1).
4. Move cab floor mat back and clear from pedal 3. Connect electrical harness (31) to the mating
assembly (1) and mounting plates. engine and transmission harnesses.
5. Remove mounting bolts (8) and lockwashers (9) 4. Position floor mat on cab floor and ensure that pedal
securing plate assembly (10) and pedal assembly (1) assembly (1) is free to operate.
to cab floor plate. Remove plate assembly (10) and
pedal assembly (1). 5. Remove wheel blocks and start the engine. Ensure
that pedal assembly (1) operates correctly.
6. Remove bolts (17) and lockwashers (18) securing
pedal assembly (1) to plate assembly (10). Remove Note: The engine MUST be started with the foot 'OFF'
pedal assembly (1) from plate assembly (10). pedal assembly (1).
INSTALLATION MAINTENANCE
Numbers in parentheses refer to Fig. 1. Limited repair of the electronic foot pedal assembly is
by replacement of parts only. Refer to vehicle Parts
Note: Tighten all fasteners to standard torques listed Book for part numbers of overhaul kits.
in Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.
* * * *
SM - 1759
2
15 16
1
16
14
13
5
3
11
7
17 6
9 10
18
12
DESCRIPTION OPERATION
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.
A radiator and fan cooling system is used on the Upon starting a cold engine or when the coolant is
engines installed in these machines. This system has below operating temperature, the coolant is restricted
a centrifugal type water pump (5) to circulate coolant at thermostat housing (8) and bypass line (13)
throughout the system. Two full blocking thermostats provides water circulation within the engine during the
located in thermostat housing (8) control the flow of warm-up period.
coolant throughout the system.
Note: Engine coolant thermostats start to open at
The main components of the cooling system are; 80 2 C (175 3 F) and are fully open at 90 + 6 C
header tank (1), radiator (2), engine water pump (5), (195 + 12 F).
DCA4 coolant filter (6), disc brake oil cooler (3),
transmission oil cooler (4), engine oil cooler (7) and Engine water pump (5) draws coolant from the radiator
thermostat housing (8). bottom tank through coolant pipe (9) and also from
SM 1305 2-98 1
Cooling System - Cooling System
Section 210-0000
2 SM 1305 2-98
Cooling System - Cooling System
Section 210-0000
Replace DCA4 coolant filter if required. When testing The draining and flushing of the cooling system should
the DCA4 concentration, depending on the level of be performed as follows:
DCA4 , the coolant filter may not require to be
changed. Refer to instructions under 'Coolant
Recommendations' in this section. WARNING
Do not remove the pressure control cap from
Note: Under concentration of the DCA4 coolant the radiator header tank or attempt to drain the
additive can result in liner pitting and system coolant until the engine has cooled. Once the
corrosion. Over concentration can result in water engine has cooled, use extreme caution when
pump seal leakage. Always maintain DCA4 removing the cap. Always release pressure
concentration at recommended levels. from the system by depressing the pressure
relief button on the cap. Remove cap slowly as
the sudden release of pressure from a heated
Every 250 hours: cooling system can result in a loss of coolant
Lubricate the fan idler pivot arm with grease as and possible personal injury (scalding) from
specified in Section 300-0020, LUBRICATION the hot liquid.
SYSTEM. Lubricate the pivot arm until grease
appears from under the cap. 1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine. Turn the
steering wheel in both directions several times to
Every 1 500 hours: relieve pressure in the steering system.
Lubricate the fan idler hub with grease as specified in
Section 300-0020, LUBRICATION SYSTEM. Remove 2. Drain the coolant from the engine and radiator into a
vent plug from fan hub grease cavity and apply suitable container.
grease through grease fitting until grease comes out
of the vent hole. 3. Refill 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
Every 6 000 hours: distortion of the metal castings.
Drain and flush the cooling system as described under
the heading 'Draining and Flushing' in this section. Fill 4. Start the engine and operate the truck for fifteen
the cooling system with the correct mixture of (15) minutes to circulate the solution thoroughly.
antifreeze, water and DCA4 liquid as described under
'Coolant Recommendations' in this section. 5. Drain the cooling system completely.
Inspect the fan hub for wobble and grease leakage. 6. Refill cooling system with clean, soft water and
Replace with a new or rebuilt unit as necessary. operate the truck for fifteen (15) minutes. Drain the
cooling system completely to remove all cleaner
Inspect the fan idler pulley assembly. Rebuild or residue from the system.
replace the idler pulley as necessary.
7. Refill cooling system with proper mix of antifreeze
Inspect the engine water pump for coolant or oil and water and install new precharge filter and correct
leakage at the water pump weep hole. concentration of DCA4 liquid. Refer to instructions
under 'Coolant Recommendations'.
Note: A minor chemical buildup or streaking at the
water pump weep hole is normal. Do not repair or Note: If engine overheats and fan belt tension and
replace the water pump unless an actual leak is water level are satisfactory, the entire cooling system
confirmed. may require cleaning with a descaling solvent and
back flushing.
SM 1305 2-98 3
Cooling System - Cooling System
Section 210-0000
4. Alternatively fill radiator with clean, soft water and d. Thoroughly blend all components.
flush with air until water runs out clear.
4 SM 1305 2-98
Cooling System - Cooling System
Section 210-0000
Note: Following the correct order for mixing the heavy a. Compare Freeze Point (end pad) to colour chart
duty coolant will prevent additive dropout during the and record the result.
mixing process.
b. Next, compare Sodium Molybdate (middle pad) to
Note: The cooling system must be clean before colour chart and record the result.
adding DCA4 liquid.
c. Finally, compare Sodium Nitrate test to colour
Note: Do not use soluble oils in the cooling system. chart and record the result.
The use of soluble oils will lead to cylinder lining
pitting, corrode brass and copper, damage heat 5. All three readings must be completed no later than
transfer surfaces and damage seals and hoses. 75 seconds after dipping the strip.
a. When excessive coolant loss occurs. 7. Determine where the Sodium Molybdate level
intersects the Sodium Nitrite level on the chart. The
b. After every 250 hours of operation amount of SCA units per litre in the cooling system is
given where the Sodium Molybdate row intersects the
c. If the concentration is known to be above the high Sodium Nitrite column.
limit of 0.8 units per litre. Test at each subsequent oil
change until the concentration decreases below the Note: For best results follow test times carefully. Use
high limit. a stopwatch or clock with a sweep second hand.
Comparing the test strip to the colour chart too soon
Note: Do not use the test kit to omit or extend the before, or too late after, the required test time will
service intervals unless the concentration is above result in incorrect readings and improper treatment,
0.8 units per litre. and could result in liner pitting and engine damage.
The test strip container is marked with an expiration 8. All readings should be recorded on the truck
date and the plastic container must be securely maintenance record for future reference.
tightened to protect the moisture sensitive strips.
Discard the strips if there is any doubt about the test
strip quality. Treatment Instructions
If the concentration is:
Test Instructions Above 0.8 units per litre - Do not replace the DCA4
1. Collect coolant sample from the radiator or petcock. filter or add liquid DCA4 until the concentration drops
DO NOT collect from the coolant recovery or overflow below 0.8 units per litre. The concentration must be
system. Coolant must be between 10 C and 55 C tested at every subsequent 250 hour service interval
when tested. until the concentration decreases below 0.8 units per
litre.
2. Remove one strip from bottle and replace cap
immediately. DO NOT touch the pads on the end of Between 0.3 and 0.8 units per litre - Add the normal
the strip. amount of DCA4 liquid as specified in the 'Service
Chart'. Replace the DCA4 coolant filter.
Note: Discard kit if unused strips have turned brown.
Below 0.3 units per litre - Add both the normal
3. Dip strip in coolant sample for one second, remove, amount of DCA4 liquid specified in the 'Service Chart'
and shake strip briskly to remove excess liquid. and the amount specified in the 'Precharge Chart'.
Replace the DCA4 coolant filter.
4. 45 seconds after dipping strip compare and record
results in the following order:
SM 1305 2-98 5
Cooling System - Cooling System
Section 210-0000
* * * *
6 SM 1305 2-98
COOLING SYSTEM - Radiator, Header Tank and Mounting
Section 210-0040
4 SM - 3261
42 19
5
4 20
21 25
4 22
35 23
5
6
3 22
7
37
6
5
4
1 34
27 26 36
30 2
29
27
31
33
18
22 36
13
33
32
8
10
11 24
14
12 10 16 17 A
28 POSITION A
26
16 39
12 17
10 9 16 38
38
40
41
15
DESCRIPTION REMOVAL
Numbers in parentheses refer to Fig. 1, unless Numbers in parentheses refer to Fig. 1, unless
otherwise specified. otherwise specified.
SM 2317 06-04 1
Cooling System - Radiator, Header Tank and Mounting
Section 210-0040
28
23
33 26 14
25 24
21 6 30
22
8 29
18 35
2
32 5
5
A
3
31
11 TO ENGINE
A THERMOSTAT
13
HOUSING
5
8
3
15
12 3
10
1 9
7 4 10
36
16 10
5 30
17
15 27
10
37
20
34 38
19
18 9 RADIATOR
ASSEMBLY
1 - Header Tank 11 - Window Nut 20 - Bolt 29 - Bracket
2 - Bolt 12 - Coolant Pipe 21 - Filler Cap 30 - Nut
3 - Elbow 13 - Deaeration Line 22 - Filler Neck 31 - Grommet
4 - Bolt 14 - Deaeration Line 23 - Bolt 32 - Heat Shield
5 - Hardened Washer 15 - Plug 24 - Clamp 33 - Mounting Bracket
6 - Overflow Tubing 16 - Clamp 25 - P-Clip 34 - Lockwasher
7 - P-Clip 17 - Float Level Switch 26 - P-Clip 35 - Bolt
8 - Bolt 18 - Gasket 27 - P-Clip 36 - Plug
9 - Hose 19 - Adaptor Plate 28 - Bolt 37 - Bracket
10 - Band Clamp 38 - Bolt
Fig. 2 - Radiator Header Tank Mounting and Lines
1. Position the vehicle in a level work area, apply the 6. With a suitable container in position, open drain cock
parking brake and switch off the engine. (15) at the bottom of radiator assembly (42) and drain
the cooling system. Close drain cock (15) securely
2. Turn the steering wheel in both directions several when coolant is completely drained.
times to relieve pressure in the steering system. Block
all road wheels. 7. Remove locknuts (26), washers (27) and bolts (31)
securing screens (18, 28 & 32) to ring (2). Remove
3. Remove mounting hardware securing the hood screens (18, 28 & 32) from the vehicle. Remove stems
assembly to the vehicle and, using suitable lifting (29) and rings (30) from screens (18, 28 & 32) if
equipment, remove the hood assembly. Refer to required.
Section 100-0010, CHASSIS, HOOD AND FENDERS.
8. Slacken band clamps (2, Fig. 3) and pull silicone
4. Disconnect electrical connections to lights on the hoses (1 & 3, Fig. 3) away from radiator top tank
radiator guard and remove mounting hardware securing connections.
2 SM 2317 06-04
Cooling System - Radiator, Header Tank and Mounting
Section 210-0040
SM - 3262
RADIATOR
2 ASSY. SEC. 210-0010
2
1
3
POSITION A
8
9
2 6
2 8
5
10
6 6
A 11
5
6
12
4
ENGINE 7
THERMOSTAT
HOUSING
9. Slacken band clamps (6, Fig. 3) and slide hose 14. Attach suitable lifting equipment to radiator
(5, Fig. 3) back over coolant tube (4, Fig. 3) and away assembly (42) and remove nuts (14), washers (24) and
from radiator bottom tank connection. bolts (13) securing radiator assembly (42) on flexible
mounting (8). Remove radiator assembly (42).
10. Identify and disconnect deaeration line (13, Fig. 2)
from elbow (3, Fig. 2) in radiator top tank. 15. If necessary, remove nuts (11), lockwashers (10)
and bolts (33) securing flexible mountings (8) to
11. Ensure all coolant pipes and lines have been chassis mounting brackets.
disconnected from radiator assembly (42).
12. Remove nuts (4) and lockwashers (5) securing Header Tank
support rods (3) to radiator side columns. Numbers in parentheses refer to Fig. 2.
13. If necessary, remove nuts (4), lockwashers (5), 1. Slacken band clamps (10) and slide hose (9) over
washers (6) and flexible mountings (7) from bottom end coolant pipe (12) and off of header tank (1) connection.
of each support rod (3). Loosen inside nuts (4),
lockwashers (5) and washers (6) securing support rods 2. Disconnect deaeration lines (13 & 14) from elbows
(3) to chassis brackets. Remove both support rods (3) (3) in header tank (1).
from radiator side columns and chassis brackets.
3. Disconnect overflow tubing (6) from filler neck (22).
SM 2317 06-04 3
Cooling System - Radiator, Header Tank and Mounting
Section 210-0040
SM - 3263
13
14
9-17-19-20 25-27-28-29 1
12
25
27
28
21-22-23-24
29
11
17 15
20 6
26
5
4
3
3 10
7-8-19-20
5 16
18
6
25-27-28-29
23-24-25
2
9-17-19-20
22 - Lockwasher
1 - Top Tank 8 - Plate 15 - Joule Tube 23 - Locknut
2 - Bottom Tank 9 - Screw 16 - Spacer 24 - Nut
3 - Side Column - LH 10 - Tube Stay Strip 17 - Lockwasher 25 - Screw
4 - Side Column - RH 11 - Gasket 18 - Screw 26 - Screw
5 - Crossbrace Rod 12 - Tube Plate 19 - Nut 27 - Lockwasher
6 - Stiffener 13 - Brass Ferrule 20 - Washer 28 - Nut
7 - U Bolt 14 - Rubber Ferrule 21 - Washer 29 - Screw
4. Disconnect electrical connection from float level 2. If required, remove bolts (20, Fig. 1), washers (21,
switch (17). Fig. 1) and lockwashers (36, Fig. 1) securing plate
assembly (19, Fig. 1), bracket assemblies (23 & 35
5 Remove bolts (2) and washers (5) securing header Fig. 1) and cover plates (25, Fig. 1) to radiator
tank (1) to mounting bracket (33). Remove bolts (4) and assembly (34, Fig. 1). Now remove all plates, bracket
hardened washers (5) securing header tank (1) to the assemblies and rubber seals (22, Fig. 1) from the
platform. radiator assembly (34, Fig. 1).
6. Attach suitable lifting equipment to header tank (1) Note: Joule tube (15) type radiators are designed in
and remove header tank assembly from the platform. such a way that individual tubes can be replaced
without the need to replace the entire radiator core.
DISASSEMBLY/ASSEMBLY Note: It may be necessary to remove several
Numbers in parentheses refer to Fig. 4, unless undamaged joule tubes (15) in order to gain access to
otherwise specified. the damaged tube.
1. Remove bolts (12, Fig. 1), lockwashers (10, Fig. 1), Note: The top and bottom ends of joule tube (15) are
washers (16, Fig. 1) and rubber washers (17, Fig. 1) distinguished by the top end of the tube having a long
securing shroud (1, Fig. 1) and ring (2, Fig. 1) length of tube bare of grilling and the bottom end being
assembly to radiator assembly (35, Fig. 1). fitted with a locating washer.
4 SM 2317 06-04
Cooling System - Radiator, Header Tank and Mounting
Section 210-0040
3. Removal of joule tube (15) and rubber ferrules (14) is Header Tank
as follows:
Numbers in parentheses refer to Fig. 2.
a. Insert a lever under the locating washer of joule
1. Remove bolts (23) securing filler neck (22) assembly
tube (15) and exert pressure to push the tube into top
to header tank (1). Remove filler neck (22) assembly
tank (1).
and discard gasket (18).
b. Carefully pull joule tube (15) clear of bottom tank
2. Remove bolts (20) securing adaptor plate (19) and
(2) and pull out from top tank (1).
float level switch (17) assembly to header tank (1).
Remove adaptor plate (19), gasket (18) and float level
c. Remove and discard rubber ferrules (14) from tube
switch (17) from header tank (1). Discard gasket (18).
plates (12).
3. If required, remove lock nut from float level
4. Replacement of joule tube (15) and rubber ferrules
switch (17) and remove float level switch from adaptor
(14) is as follows:
plate (19).
a. Lightly coat outside diameter of new rubber
4. Remove window nut (11) from header tank (1).
ferrules (14) and tube holes in tube plates (12) with
petroleum jelly.
5. Assembly of header tank (1) is the reverse of
disassembly. Be sure to use new gaskets (18) when
b. Press rubber ferrules (14) by hand into the tube
assembling filler neck (22) assembly and adaptor plate
holes in the tube plates (12), taking care that the
(19) assembly to header tank (1).
flange of each rubber ferrule (14) fits flush on the
respective tube plate (12) face. It may be necessary
to lightly tap the top of rubber ferrule (14) flange with INSTALLATION
a hammer to ensure a flush fit.
Numbers in parentheses refer to Fig. 1, unless
otherwise specified.
c. Lightly coat the bore of rubber ferrules (14) and
each end of joule tube (15) with petroleum jelly.
Note: Tighten all fasteners to standard torques listed in
Section 300-0080, STANDARD BOLT AND NUT
d. Enter the top (longer) end of joule tube (15) into TORQUE SPECIFICATIONS.
rubber ferrule (14) in tube plate (12) and press upward
until the short end of the tube is clear of rubber
1. If removed, position flexible mountings (8) on
ferrule (14) flange in bottom tube plate (12).
chassis mounting brackets and secure with bolts (33),
lockwashers (10) and nuts (11).
e. Carefully enter the bottom of joule tube (15) into
rubber ferrule (14) in bottom tube plate (12) taking
2. Using suitable lifting equipment, position radiator
care that the tube does not damage rubber ferrule
assembly (42) on flexible mountings (8) and secure
(14) by scoring. Press down firmly until the locating
with bolts (13), washers (24) and nuts (14).
washer rests on the flange of rubber ferrule (14).
3. Install nut (4), lockwasher (5), washer (6) and one
5. If removed, install rubber seals (22, Fig. 1), plate
half of flexible mounting (7) on the bottom end of each
assembly (19, Fig. 1), bracket assemblies (23, Fig. 1)
support rod (3). Install support rods (3) in chassis
and cover plates (25, Fig.1) to front of the radiator
support brackets and secure with opposite half of
assembly (42, Fig. 1). Secure all items with bolts (20 &
flexible mountings (7), washers (6), lockwashers (5)
33, Fig. 1), washers (21, Fig. 1) and lockwashers (36,
and nuts (4).
Fig.1).
Note: Before securing support rods (3) to mounting
6. Secure shroud (1, Fig. 1) and ring (2, Fig. 1)
brackets on radiator side columns, align the radiator
assembly to radiator assembly (34, Fig. 1) with rubber
core assembly to be parallel with the leading end of the
washers (17, Fig. 1), washers (16, Fig. 1), lockwashers
cooling fan. Adjust fan ring (2) to obtain adequate fan
(10, Fig. 1) and bolts (12, Fig. 1).
tip clearance.
SM 2317 06-04 5
Cooling System - Radiator, Header Tank and Mounting
Section 210-0040
4. Install nuts (4) and lockwashers (5) on top end of 6. Connect electrical connection to float level switch (17).
support rods (3) and secure support rods (3) to
mounting brackets on radiator side columns with
lockwashers (5) and nuts (4). Initial Fill and Start-up
Numbers in parentheses refer to Fig. 2, unless
5. Connect deaeration line (13, Fig. 2) to elbow (3, Fig. 2) otherwise specified.
and adaptor (24, Fig. 2) and tighten securely.
1. Refer to Section 210-0000, COOLING SYSTEM for
6. Slide coolant tubes (1 & 3, Fig. 3) over radiator top correct selection of heavy duty coolant.
tank connections. Secure coolant tubes (1 & 3, Fig. 3)
to radiator top tank connections with band clamps 2. Ensure drain cock (15, Fig. 1) is securely closed
(2, Fig. 3). and fill the cooling system through filler neck (22)
on header tank (1). Fill with coolant until coolant
7. Slide hose (5, Fig. 3) over radiator bottom tank reaches the bottom of filler neck (22) and holds at that
connection. Secure hose (5, Fig. 3) to coolant tube level.
(4, Fig. 3) and radiator bottom tank connection with
band clamps (6, Fig. 3). 3. Check all line and pipe connections for leaks prior to
starting the vehicle. Tighten as required.
8. If removed, install stems (29) and rings (30) in
screens (18, 28 & 32). Install screens (18, 28 & 32) on 4. Start the engine and check for leaks. Tighten lines
ring (2) and secure with bolts (31), washers (27) and and fittings and top up coolant level as required.
locknuts (26). Window nut (11) should show full at all times. Fit filler
cap (21).
9. Using suitable lifting equipment, position radiator
guard assembly on the front of the chassis and secure 5. Using suitable lifting equipment, position hood
with mounting hardware removed during removal. Refer assembly on the vehicle and secure with mounting
to Section 100-0010, CHASSIS, HOOD AND hardware removed during removal. Refer to
FENDERS. Section 100-0010, CHASSIS, HOOD AND FENDERS.
10. Connect all electrical connections to lights in 6. Remove all wheel blocks.
radiator guard assembly.
Header Tank
Numbers in parentheses refer to Fig. 2, unless Internal Cleaning - Water Tubes
otherwise specified. If scale deposits are present inside the water tubes of
the radiator, it is necessary to use a suitable scale
1. Using suitable lifting equipment, position header tank remover such as 'Powdered Scale Solvent', or
(1) on the platform and secure with bolts (4) and equivalent. This material is a free-flowing powder,
hardened washers (5). inhibited to prevent attack on the cooling system
materials.
2. Secure header tank (1) to mounting bracket (33) with
bolts (2) and washers (5).
WARNING
3. Slide hose (9) over bottom connection on header Take care to avoid contact of skin or eyes with
tank (1) and secure to header tank (1) and coolant pipe the solvent. If contact is made it should be
(12) with band clamps (10). washed off immediately with clean water and
medical advice should be taken.
4. Connect deaeration lines (13 & 14) to elbows (3) and
tighten lines securely.
6 SM 2317 06-04
Cooling System - Radiator, Header Tank and Mounting
Section 210-0040
For general cleaning use it is recommended to use a 4. Leave radiator core assembly to dry before
concentration of 50 - 100 kg/m of water at a reinstalling the cooling equipment.
temperature of up to 60 C. Rapid circulation or
agitation with compressed air will reduce the time for Note: In the case of grossly fouled surfaces which are
cleaning. not cleaned adequately in steps 1 through 4, the
following procedure may be used.
Note: If scale deposits within the radiator are
exceptionally heavy, concentrations up to 200 kg/m 5. Ensure that the radiator core assembly is dry.
may be used.
6. Liberally brush on to both sides of the radiator core
The most convenient method of use is to prepare a assembly an emulsifying cleaner such as 'Gunk', or
concentrated solution by mixing the powder in hot equivalent, and leave to soak for at least 1 hour.
water in a tank and then adding the concentrated
solution to water contained in the radiator. 7. Apply a high pressure steam jet at 100 -300 kN/m,
or compressed air at 500 - 700 kN/m on to the treated
Note: The solvent must always be added carefully to surfaces, from several different angles, forcing the
water, not water to solvent. fouling material out from the radiator core assembly.
WARNING
To prevent possible injury when using SPECIAL TOOLS
compressed air or steam jet, wear adequate eye There are no special tools required for procedures
protection and do not exceed pressure values outlined in this section. Refer to Section 300-0070,
stated. SERVICE TOOLS, for part numbers of general service
tools required. These tools are available from your
1. Direct a steam jet at 100 - 300 kN/m, or dealer.
compressed air at 500 - 700 kN/m on to the faces of
the radiator core assembly.
* * * *
SM 2317 06-04 7
COOLING SYSTEM - Disc Brake Oil Cooler
Section 210-0050
SM - 1987
12 13
11
B 2
11
C D
18
17
8
15 7
16 6
8
1
4 3 7 5
DESCRIPTION AND OPERATION Coolant is pumped from the engine water pump to
Numbers and letters in parentheses refer to Fig. 1. port 'A', circulates through cooler tubes in heat
exchanger (2), and exits from port 'D' to the
The disc brake oil cooler is connected in the cooling transmission oil cooler.
system between the engine water pump outlet and
transmission oil cooler. Refer to Section 210-0000, Disc brake cooling oil enters through port 'C' from the
COOLING SYSTEM. The disc brake oil cooler is disc brake oil filter, circulates around cooler tubes in
connected in the hydraulic system between disc heat exchanger (2) and exits at port 'B' to the disc
brake filters and disc brake assemblies, and is used brakes.
to cool disc brake cooling oil.
Note: Oil flow must always flow in the opposite
The disc brake oil cooler consists mainly of heat direction to coolant flow through the disc brake oil
exchanger (2) and two cooler flanges (3), and is cooler.
mounted at the engine front crossmember.
SM 1589 12-98 1
Cooling System - Disc Brake Oil Cooler
Section 210-0050
2 SM 1589 12-98
Cooling System - Disc Brake Oil Cooler
Section 210-0050
Note: Severely fouled cooler tubes can be cleaned 2. Install coolant tubes (18) on connections at ports
by use of a rotary brush if normal cleaning is not 'A' and 'D' and secure with clamps (17).
sufficient.
3. Install new 'O' ring (12) on oil line (14) and secure
oil line (14) to port 'B' with split flanges (11), bolts
ASSEMBLY (10) and lockwashers (13).
Numbers in parentheses refer to Fig. 1.
4. Install new 'O' ring (12) on oil line (9) and secure
Note: Tighten all fasteners without special torques oil line (9) to port 'C' with split flanges (11), bolts (10)
specified to standard torques listed in Section and lockwashers (13).
300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS. 5. Fill the body and disc brake cooling tank with
hydraulic oil specified in Section 300-0020,
1. Install new gaskets (4) to cooler flanges (3) and LUBRICATION SYSTEM. Refer to Section 230-0040,
align cooler flanges (3) to heat exchanger (2) as match BODY AND DISC BRAKE COOLING TANK for
marked at disassembly. Secure with bolts correct fill level. Install filler cap.
(5 & 6) and washers (7) tightening alternately to give
an even seal around cooler flange area. 6. Ensure all drain cocks on the cooling system are
securely locked and fill cooling system with coolant
2. Install drain plugs (8) in underside of heat specified in Section 210-0000, COOLING SYSTEM.
exchanger (2).
7. Using suitable lifting equipment, install engine pan
guard on the truck. Secure engine pan guard to the
INSTALLATION truck with bolts, lockwashers, washers and nuts.
Numbers and letters in parentheses refer to Fig. 1.
8. Start the engine and check for leaks. Tighten lines
Note: Tighten all fasteners without special torques and fittings as required.
specified to standard torques listed in Section
300-0080, STANDARD BOLT AND NUT TORQUE 9. Remove wheel blocks from all road wheels.
SPECIFICATIONS.
SPECIAL TOOLS
There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general
service tools required. These tools are available from
your dealer.
* * * *
SM 1589 12-98 3
COOLING SYSTEM - Transmission Oil Cooler
Section 210-0060
SM - 3264
1
27
25 26 17
29 28
30
TO ENGINE
WATER MANIFOLD
13
8 10 8
16
7 B 7
C 15
31 9 2 9
4 31 16
D
A 5
18 4 6
19
22 24
20
24
21
14
11
FROM DISC
BRAKE OIL COOLER
22
23
24
12
1 - Transmission Oil Cooler 10 - Oil Inlet Line 17 - Coolant Outlet Tube 24 - Locknut
2 - Heat Exchanger 11 - Saddle 18 - Clamp 25 - Spring Clamp
3 - Cooler Flange 12 - Clamp 19 - Sleeve 26 - Sleeve
4 - Gasket 13 - Oil Outlet Line 20 - Clamp 27 - Bolt
5 - Cooler Flange 14 - Yoke 21 - Coolant Inlet Tube 28 - Washer
6 - Plug 15 - Sleeve 22 - Bolt 29 - Tube
7 - Bolt 16 - Clamp 23 - Lockwasher 30 - Gasket
8 - Lockwasher 31 - 'O'-Ring
9 - Split Flange
Fig. 1 - Exploded View of Transmission Oil Cooler
DESCRIPTION AND OPERATION convertor outlet port, circulates around cooler tubes in
Numbers and letters in parentheses refer to Fig. 1. heat exchanger (2), and exits at port 'B' to the
transmission convertor inlet port.
The transmission oil cooler is connected between the
radiator and transmission to maintain transmission oil Note: Oil flow must always flow in the opposite
within its required operating temperature range. Refer to direction to coolant flow through transmission oil
Section 210-0000, COOLING SYSTEM. cooler.
Coolant enters port 'A' from the disc brake oil cooler, Transmission oil temperature switch, located on the left
circulates through cooler tubes in heat exchanger (2), hand side of the transmission, sends a signal to illuminate
and exits at port 'D' to the engine water manifold. the transmission oil temperature warning light (on the
dash panel) when transmission oil temperature rises
Oil to be cooled enters port 'C' from the transmission above the safe operating temperature.
SM 2321 07-04 1
Cooling System - Transmission Oil Cooler
Section 210-0060
7. Remove drain plugs (6) on underside of transmission 1. Clean transmission oil cooler (1) before sludge
oil cooler (1) and drain oil into a suitable container. hardens. After transmission oil cooler (1) is completely
drained, circulate a solution of trichloroethane through
8. Remove oil inlet line (10) from heat exchanger (2). the passages surrounding the cooler tubes in heat
By removing bolts (7), washer (8) and split plates (9). exchanger (2) to remove sludge.
Note: Discard and replace 'O'-rings (31).
2. If cooler tubes are badly clogged, circulate an oakite
9. Drain oil inlet line (10) into a suitable container. Cap or alkaline solution through heat exchanger (2).
oil inlet line (10) and heat exchanger boss, to prevent Solution should be circulated through heat exchanger
entry of dirt. (2), in the reverse direction to normal flow, for
approximately 15 minutes, after soaking for 10
10. Remove oil outlet line (13) from Heat exchanger minutes. The duration of circulation depends on how
using same method as in step 8. Drain oil outlet line badly clogged the cooler tubes are. Flush thoroughly
(13) into a suitable container. Cap oil outlet line (13) with clean hot water.
and heat exchanger boss to prevent entry of dirt .
Cleaning Water Side
11. Support transmission oil cooler (1) with a suitable
lifting device and remove locknut (24) from yoke (14), 1. Match mark cooler flanges (3 & 5) and heat
allowing clamp (12) to be moved down to allow access exchanger (2) to aid in assembly.
to heat exchanger unit.
2 SM 2321 07-04
Cooling System - Transmission Oil Cooler
Section 210-0060
2. Remove bolts securing cooler flanges (3 & 5) to heat 1. If clamp (12) had to be removed completely during
exchanger (2). Remove cooler flanges (3 & 5) from disassembly, then using suitable lifting equipment,
heat exchanger (2) and discard gaskets. position transmission oil cooler (1) on saddle (11) on
the right hand frame rail and secure by taking clamp
3. Make up a solution composed of 1/3 muriatic acid (12) and secure using locknuts (24), bolt (22), washer
and 2/3 water. To each 9.5 litres (2.5 gal) of solution, (23) and yoke (14).
add 227 g (0.5 lb) of oxalic acid.
2. If the clamp (12) is still secured to the saddle (11),
4. Immerse heat exchanger (2) in the cleaning solution. carefully rotate clamp (12) back into place over
Cleaning action is noticeable by bubbling and foaming. transmission oil cooler (2) and secure clamp (12) to
The process must be carefully observed and when yoke (14) using locknut (24).
bubbling stops, usually between 30 - 60 sec., remove
heat exchanger (2) from cleaning solution and flush 2. Install inlet line (10) and outlet line (13) to heat
thoroughly with clean, hot water. After cleaning, dip exchanger (2) using O-rings (31) , split plates (9) ,
heat exchanger (2) in light oil. lockwashers (8) and bolts (7).
Note: Severely fouled cooler tubes can be cleaned by 3 . Install coolant outlet tube (17) on connection at
use of a rotary brush if normal cleaning is not port 'D' and secure with sleeve (15) and clamps (16).
sufficient.
5. Install coolant inlet tube (21) on connection at port
'A' and secure with sleeve (19) and clamps (18 & 21).
ASSEMBLY
Numbers in parentheses refer to Fig. 1. 6. Install drain plug in underside of transmission and fill
transmission with transmission oil specified in Section
Note: Tighten all fasteners, without special torques 300-0020, LUBRICATION SYSTEM.
specified, to standard torques listed in Section
300-0080, STANDARD BOLT AND NUT TORQUE 7. Ensure all drain cocks on the cooling system are
SPECIFICATIONS. securely locked and fill cooling system with coolant,
specified in Section 210-0000, COOLING SYSTEM.
1. Install new gaskets to cooler flanges (3 & 5) and
align cooler flanges (3 & 5) to heat exchanger (2), as 8. Start up engine and check for leaks. Tighten lines
match marked at disassembly. Secure with bolts and fittings as required.
tightening alternately to give an even seal around
cooler flange area. 9. Remove wheel blocks from all road wheels.
WARNING
To prevent personal injury and property
damage, be sure wheel blocks and lifting
equipment are properly secured and of
adequate capacity to do the job safely.
SM 2321 07-04 3
STEERING SYSTEM - Steering System Schematic
Section 220-0000
DESCRIPTION Mounted off the frame at the rear of the steering and
Numbers in parentheses refer to Figs. 2 through 6. brake control tank, the accumulator assembly consists
of a charging valve, end cap, cylinder and piston.
The steering system is of the accumulator type which
provides uniform steering, regardless of engine speed, The charging valve is equipped with a locking feature
and provides a limited amount of reserve steering which, when opened, will allow the precharge to be
pressure should the engine stall. checked or the accumulator charged. The piston acts
as a separator dividing the cylinder into two sections.
A brief description of the individual components used
in the steering system are listed below. Detailed The section nearest the charging valve contains the
service and operating instructions for the individual nitrogen precharge. The other section receives the
components can be found in their relative component hydraulic oil from the steering pump, via accumulator
sections in this manual. valve (4).
SM 1591 12-98 1
Steering System - Steering System Schematic
Section 220-0000
The double relief valve is installed in the lines between The steering filter is mounted off the rear left hand side
the steering cylinders and the steering valve. Its transmission mounting bracket. It is connected in the
purpose is to relieve shock loads on the steering steering line between the accumulator valve and the
cylinders by transferring the excessive pressure steering valve.
applied to the oil by the road shock, to the opposite
end of the cylinders. This shock, if left unchecked, There are two external ports A and B and an internal
might damage steering linkage components. bypass port C in the steering filter assembly.
SM - 1335
Pressure Switch (8) FITTING NUT
2 SM 1591 12-98
SM - 1988A
SM 1591 12-98
A A
B B
LT 6
RT
7 5 7
T P
C B 8
G2
COMPONENTS 3
D
1 - Steering and Brake Control Tank
2 - Steering Pump
3 - Accumulator E
4 - Accumulator Valve
5 - Steering Valve
6 - Double Relief Valve G1
7 - Steering Cylinder 4
A SUPPLY TO
8 - Oil Pressure Switch R BRAKE CIRCUIT
9 - Oil Level Switch RETURN FROM MONOBLOCK BRAKE VALVE
RETURN FROM DIRECTIONAL CONTROL, RETARDER
10 - Oil Pressure Switch CONTROL, RETARDER SOLENOID VALVES
10 RETURN FROM TREADLE &
11 - Oil Temperature Switch 12
BRAKE MANIFOLD VALVES
12 - Steering Filter
11 TO TANK BREATHER
3
4
SM - 1988B
A A
Section 220-0000
B B
LT 6
RT
7 5 7
T P
C B 8
G2
COMPONENTS 3
1 - Steering and Brake Control Tank
D
2 - Steering Pump
3 - Accumulator E
4 - Accumulator Valve
5 - Steering Valve
6 - Double Relief Valve G1
7 - Steering Cylinder 4
A SUPPLY TO
Steering System - Steering System Schematic
SM 1591 12-98
SM - 1988C
SM 1591 12-98
A A
B B
LT 6
RT
7 5 7
T P
C B 8
G2
COMPONENTS 3
1 - Steering and Brake Control Tank D
2 - Steering Pump
3 - Accumulator E
4 - Accumulator Valve
5 - Steering Valve
6 - Double Relief Valve G1
7 - Steering Cylinder 4
SUPPLY TO
8 - Oil Pressure Switch R A BRAKE CIRCUIT
9 - Oil Level Switch RETURN FROM MONOBLOCK BRAKE VALVE
RETURN FROM DIRECTIONAL CONTROL, RETARDER
10 - Oil Pressure Switch CONTROL, RETARDER SOLENOID VALVES
11 - Oil Temperature Switch 10 RETURN FROM TREADLE &
12 BRAKE MANIFOLD VALVES
12 - Steering Filter
TO TANK BREATHER
11
PRESSURE TEST POINTS
A - System Pressure 1
9
COLOUR CODES
Red - Pressurized Oil
Blue - Exhaust or Return Oil
Green - Intake Oil 2
Orange - Pilot Pressure
Yellow - Static Oil
Fig. 4 - Steering System Schematic - Engine Running, Steering Valve Left Turn
Section 220-0000
Steering System - Steering System Schematic
5
6
SM - 1988D
A A
Section 220-0000
B B
LT 6
RT
7 5 7
T P
C B 8
G2
COMPONENTS 3
1 - Steering and Brake Control Tank
D
2 - Steering Pump
3 - Accumulator E
4 - Accumulator Valve
5 - Steering Valve
6 - Double Relief Valve G1
7 - Steering Cylinder 4
A SUPPLY TO
Steering System - Steering System Schematic
Fig. 5 - Steering System Schematic - Engine Running, Steering Valve Right Turn
SM 1591 12-98
SM - 1988E
SM 1591 12-98
A A
B B
LT 6
RT
7 5 7
T P
C B 8
G2
COMPONENTS 3
1 - Steering and Brake Control Tank D
2 - Steering Pump
3 - Accumulator E
4 - Accumulator Valve
5 - Steering Valve
6 - Double Relief Valve G1
7 - Steering Cylinder 4
SUPPLY TO
8 - Oil Pressure Switch R A BRAKE CIRCUIT
9 - Oil Level Switch RETURN FROM MONOBLOCK BRAKE VALVE
RETURN FROM DIRECTIONAL CONTROL, RETARDER
10 - Oil Pressure Switch CONTROL, RETARDER SOLENOID VALVES
11 - Oil Temperature Switch 10 RETURN FROM TREADLE &
12 BRAKE MANIFOLD VALVES
12 - Steering Filter
TO TANK BREATHER
11
PRESSURE TEST POINTS
A - System Pressure 1
9
COLOUR CODES
Red - Pressurized Oil
Blue - Exhaust or Return Oil
Green - Intake Oil 2
Orange - Pilot Pressure
Yellow - Static Oil
Fig. 6 - Steering System Schematic - Engine Running, Steering Cylinder Shock Load
Section 220-0000
Steering System - Steering System Schematic
7
Steering System - Steering System Schematic
Section 220-0000
8 SM 1591 12-98
Steering System - Steering System Schematic
Section 220-0000
* * * *
SM 1591 12-98 9
STEERING SYSTEM - Steering and Brake Control Tank
Section 220-0040
SM - 3743
40-41 35
36 13
4
3 13
3 14
9 1
7 22 21 15
8
4 13
39
2
5 18,19
17
6 9 2 16
7 20
8
10
5 26
24 25
26
6 11
9 22 25
7 26
8
38 15
13
29 37 34 13
5 30
23 33 14
6 32
28 34
31 23
9
7
8
27
5
6
1- Tank 11 - Bracket 21 - Rod 31 - Poppet
2 - Sight Glass 12 - Bracket 22 - Nut - wing 32 - Spring
3 - Cap 13 - Hardened Washer 23 - Drain valve 33 - Shim
4 - Gasket 14 - Bolt 24 - Rod bolt 34 - Seal
5 - Access Cover 15 - Nut 25 - Filter element 35 - Breather
6 - Plug 16 - Bolt 26 - Gasket 36 - Nipple
7 - Lockwasher 17 - Washer 27 - Screen assembly 37 - Plate
8 - Bolt 18 - Filter Assembly 28 - Lockwire 38 - Cap
9 - Gasket 19 - Filter Element 29 - Bypass valve 39 - Gasket
10 - Window Nut 20 - Suction Screen 30 - Valve 40 - Oil Level Switch
41 - Seal
Fig. 1 - Exploded View of Steering and Brake Control Tank
DESCRIPTION OPERATION
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1, unless otherwise
specified. Letters in parentheses refer to Fig. 3. Refer to
The Steering and Brake Control Tank can be Fig. 2 for hydraulic schematic of steering and brake
identified as item 1 in Section 220-0000, STEERING control tank.
SYSTEM SCHEMATIC, in this manual.
The steering and brake control oil flow is drawn from
The steering and brake control tank (1) is the common port 'A', through suction screen (20), by the steering
oil reservoir for the steering and brake control systems. pump mounted on the transmission power takeoff. Oil
It is mounted off the left hand frame rail and is partition is then pumped to the accumulator valve in the
of the main hydraulic tank. steering circuit and the brake manifold valve in the
brake control circuit. Internal pump leakage oil is
Integral with tank (1) assembly are filter assembly (18), returned to tank (1) at port 'B' from a line at the case
suction screen (20),sight gauge and window nut (2,10) drain port on the steering pump.
and oil level switch (40). Access covers (5) give easy
access to replace filter assembly (18) and suction Port 'C' is plugged and provides a tank drain point.
screen (20).
SM 2510 03-07 1
Steering System - Steering and Brake Control Tank
Section 220-0040
SM - 1567 SM - 3748
TO TANK BREATHER
E
MANIFOLD VALVES
10
2 11
A B D K J G H B
1
9
F C
1 - Tank
2 - Steering Pump 10 - Oil Pressure Switch A
9 - Oil Level Switch 11 - Oil Temperature Switch
Fig. 2 - Hydraulic Schematic Fig. 3 - Port Locations
Should filter assembly (18) become blocked, oil Return oil from the directional control valve, retarder
restriction pressure will increase and oil pressure control valve and retarder solenoid valve enters tank
switch (10, Fig. 2) will close sending a signal to the (1) at port 'J'.
steering filter restriction warning light on the right hand
dash panel, indicating that a filter change is required. Return oil from the monoblock brake valve enters
tank (1) at port 'K'.
Note: Temperature switch (11, Fig. 2) opens when a
temperature of 50 C (122 F) is reached.
Temperature switch (11, Fig. 2) is connected in series MAINTENANCE
with pressure switch (10, Fig. 2), therefore, steering Numbers in parentheses refer to Fig. 1.
filter restriction warning light will not illuminate until
the oil reaches normal operating temperature. Note: Tighten all fasteners to torques listed in
Section 300-0080, STANDARD BOLT AND NUT
Port 'E' is plugged. TORQUE SPECIFICATIONS.
A breather line at port 'H' is connected to a common If oil is required, remove filler cap (3) and fill tank (1)
2 SM 2510 03-07
Steering System - Steering and Brake Control Tank
Section 220-0040
with hydraulic oil specified in Section 300-0020, SM - 3749
LUBRICATION SYSTEM, until oil shows in bottom
window nut (10). Fit filler cap (3).
If oil is required, remove filler cap (3) and fill tank (1)
with hydraulic oil specified in Section 300-0020,
LUBRICATION SYSTEM, until oil shows full in the
sight gauge (2). Fit filler cap (3).
1 2
Note: When oil in tank (1) is being replaced due to 0040, BODY AND DISC BRAKE COOLING TANK.
overheated oil, hydraulic component failure, or at Reinstall drain plugs in tanks and tighten securely.
recommended change interval, filter assembly (25)
should be replaced. 4. Remove bolts (8), lockwashers (7), access cover (5)
and gasket (9) from tank (1). Discard gasket (9).
Changing Filter Assembly 5. Remove wing nuts (22) from rods (21). Remove and
Change filter assembly (25) at interval specified in discard filter assembly (18) and gasket (39) from tank (1).
Section 300-0020, LUBRICATION SYSTEM.
6. Install new gasket (39) and filter assembly (18) in
tank (1) and secure with wing nuts (22).
WARNING
To prevent personal injury and property 7. Install new gasket (9) and access cover (5) on
damage, be sure wheel blocks are properly tank (1) and secure with bolts (8) and lockwashers (7).
secured and of adequate capacity to do the job
safely. 8. Fill tank (1) to correct level with hydraulic oil
specified in Section 300-0020, LUBRICATION
1. Position the vehicle in a level work area, be sure SYSTEM. Install filler cap (3).
the body is fully lowered, apply the parking brake and
switch off the engine. 9. Remove wheel blocks, start the engine and charge
the steering and brake control systems. Check oil
2. Turn the steering wheel in both directions several level as described under 'Checking Oil Level'.
times to relieve any pressure in the steering system.
Operate treadle valve continuously to discharge
Removing Suction Screen
braking accumulators. Block all road wheels.
Remove and clean suction screen (20) at interval
3. With suitable containers in position, remove drain specified in Section 300-0020, LUBRICATION
plugs from tank (1) and body and disc brake cooling SYSTEM.
tank (2, Fig. 4) and drain the oil. Refer to Section 230-
SM 2510 03-07 3
Steering System - Steering and Brake Control Tank
Section 220-0040
10. Remove wheel blocks, start the engine and charge 7. Remove tank (1) assembly to a suitable work area
the steering and brake control systems. Check oil level for disassembly.
as described under 'Checking Oil Level'.
4 SM 2510 03-07
Steering System - Steering and Brake Control Tank
Section 220-0040
1. If removed, install window nuts (10), sight gauges (2) SPECIAL TOOLS
and rods (21) in tank (1). There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
2. If removed, install new seal on oil level switch (40) SERVICE TOOLS, for part numbers of general
and install level switch assembly in tank (1). service tools required. These tools are available from
your dealer.
3. Install all internal components as previously
described in 'Maintenance'. Renew filter assembly (18)
and gaskets (9 & 39).
Installation
Numbers in parentheses refer to Fig. 1, unless
otherwise specified.
* * * *
SM 2510 03-07 5
STEERING SYSTEM - Steering Pump
Section 220-0050
SM - 375
The Steering Pump can be identified as item 2 in The major pump components are; compensator valve
Section 220-0000, STEERING SYSTEM SCHEMATIC assembly (1 thru 14), pump housing (16), driveshaft
(35), rotating group (23 thru 32) and valve plate (17).
The steering pump is an axial piston, variable
displacement (adjustable) pump, capable of high The variable displacement unit incorporates a
pressure operation. Mounted off the transmission mechanism which governs the angle of the yoke (42)
power takeoff it is the common pressure supply to which controls the stroke length of each piston as the
both the steering and brake control systems. Output cylinder block assembly (23) and driveshaft (35)
is controlled to meet system requirements at any rotate. The valve block (15) also serves as the back
given time. Compensator valve assembly (1 thru 14) cover of the entire unit and includes the inlet and
regulates system pressure at 159 bar (2 300 lbf/in). outlet ports. Tapered bearing (21) in valve block (15)
and tapered bearing (47) in pump housing (16)
The steering pump is assembled for right hand support driveshaft (35).
(clockwise) rotation, as viewed from driveshaft (35) end.
SM 1204 2-98 1
Steering System - Steering Pump
Section 220-0050
SM - 376
YOKE FACE
OUTLET
PORT
INLET
PORT
DRIVESHAFT
SHOE PLATE
INTAKE VALVE
PLATE SLOT
CYLINDER BLOCK BORE
OPERATION SM - 553
Oil flows from the outlet (pressure) port to the axes, as shown by views A, B and C in Fig. 4.
accumulator valve which supplies steering circuit
pressure. Pressure is tapped off from a tee in the During pump operation load or system pressure is
accumulator valve to the brake manifold valve to continually fed to the bias piston and the
supply brake circuit pressure. compensator spool chamber.
Internal pump leakage oil is returned to tank through a The operation of the compensator is such that when
line at the case drain port on the steering pump. the system pressure (pump outlet) reaches the
compensator spring setting the valve spool moves to
meter fluid to the pump control piston.
Variable Displacement
Variable displacement is effected by altering the As the force produced by the control piston
angularity between the shoe plate and driveshaft overcomes the force of the bias piston the shoe plate
2 SM 1204 2-98
Steering System - Steering Pump
Section 220-0050
SM - 377
MAXIMUM SHOE PLATE ANGLE DECREASED SHOE PLATE ANGLE ZERO SHOE PLATE ANGLE
(MAXIMUM DISPLACEMENT) (PARTIAL DISPLACEMENT) (MINIMUM DISPLACEMENT)
SM - 378
angle moves toward the minimum displacement 1. Raise body and secure in place with body safety
position. (View C Fig. 4). The amount of angular pins. Switch off the engine and turn steering wheel in
movement of the shoe plate (i.e. displacement both directions several times to release pressure in
change) is determined by system flow demand and the steering system. Apply the parking brake and
the resulting system pressure. block all road wheels.
Equilibrium is achieved when the new displacement 2. Remove drain plug from bottom of tank and drain
matches the system requirement. oil into a suitable container. Reinstall drain plug.
SM 1204 2-98 3
Steering System - Steering Pump
Section 220-0050
SM - 379
4 SM 1204 2-98
Steering System - Steering Pump
Section 220-0050
5. Pull pump (1) and gasket (7) straight out from the clean during inspection and assembly. The close
mounting flange of pump adaptor (2). Discard gasket tolerance of the parts makes this requirement very
(7). Do not remove pump adaptor from its mounting important. Clean all removed parts using a
unless it is to be replaced. commercial solvent that is compatible with system
fluid. Compressed air may be used in cleaning, but, it
6. Wash the outside of pump (1) thoroughly with a must be filtered to remove water and contamination.
suitable solvent and move to a clean work area for Clean compressed air is particularly useful in cleaning
'Disassembly'. spool, compensator body and valve block passages.
a) Remove lockwire (5) and seal (4), plug (6), backup 2. Pull valve block (15) away from pump housing (16)
ring (7) and 'O' ring (8). then discard gasket (19).
b) Remove spring (9), seat (10) and spool (11) from 3. Remove valve plate (17) and dowel pin (18) from
compensator body (12) and set aside for 'Inspection'. valve block (15) and set aside for 'Inspection'.
c) Do not remove plug (13) unless it is necessary for 4. Remove inner race of tapered bearing (21) and
inspection of the bore. bearing spacer (22) from the end of driveshaft (35).
SM 1204 2-98 5
Steering System - Steering Pump
Section 220-0050
3. Inspect cylinder block (23) face for wear, 13. Inspect inner race of tapered bearing (47) for
scratches and/or erosion between cylinders. Check brinelling, pitting of the rollers and roughness when
spring (26), washers (25 & 27) and retaining ring (24), turned in outer race of tapered bearing (47) located in
located within the cylinder block, for wear. pump housing (16). If tapered bearing (47) is
defective both the inner and outer races must be
4. Check each cylinder block bore for excessive wear. replaced. If the inner race shows no evidence of
Use piston and shoe (32) assemblies for this purpose. wear, do not remove the outer race from pump
The piston should be a very close fit and slide easily in housing (16) or the inner race from driveshaft (35). If
and out of the bore. No bind can be tolerated. If binding the bearing requires removal, perform the following
is evident, clean the cylinder block and piston, lubricate steps 14 thru 18.
with clean hydraulic fluid and try again. Even minor
contamination of the fluid could cause the piston to 14. Inspect yoke (42) face for wear, roughness or
6 SM 1204 2-98
Steering System - Steering Pump
Section 220-0050
scoring. If defective, remove yoke (42), yoke spring SM - 382
(46) and seat (45) as follows:
Note: If shims (38) were destroyed during front tapered bearing (47) was defective perform
disassembly, a yoke bearing pre-load adjustment steps 17 & 18.
must be made at assembly.
17. Remove inner race of tapered bearing (47) from
c) Slide yoke (42) from side to side to loosen the outer driveshaft (35) with the heavy wall tubing shown in
race of tapered bearing (41) within pump housing (16). Fig. 18. Press off with an arbor press.
The outer races are a normal slip fit but may be tight.
Use an open end wrench between the yoke and the 18. Remove outer race of tapered bearing (47) from
pintle bearing to help slide out the races. Apply pump housing (16) as shown in Fig. 9.
pressure to bearing rollers to gently press the inner
race off of the yoke. 19. Remove retaining ring (33) then press shaft seal
(34) from pump housing (16).
15. Remove yoke (42) and driveshaft (35) from pump
housing (16) together. Turn the yoke at an angle and Note: If yoke (42) and front tapered bearing (47)
slide the two parts out of the housing. See Fig. 8. were not defective, perform the following step:
16. After removal of yoke (42) from pump housing 20. Remove and replace shaft seal (34) located
(16), remove seat (45) and yoke spring (46). Seat (44) within pump housing (16) as follows: Refer to Fig. 10.
and roll pin (43) will be attached to yoke (42). Do not
disassemble further unless seat (44) is damaged. a) Install heavy wall tubing over driveshaft (35) within
pump housing (16). The end of the tubing will rest
Note: Normally a wear pattern will exist on seat (44). against the inner race of tapered bearing (47) and
If the seat is damaged or shows heavy wear, replace
seats (44 & 45) and roll pin (43). ARBOR PRESS SM - 383
HERE
RETAINING
Note: If driveshaft (35) is defective perform step 17. If RING
SM - 381
SHAFT
SEAL
38 mm (1.5 in)
HEAVY WALL
TUBING
228 mm (9 in)
LONG
SEE FIG. 16.
Fig. 8 - Removal Of Yoke and Driveshaft From Housing Fig. 10 - Removal Of Inner Race Of Tapered Bearing
SM 1204 2-98 7
Steering System - Steering Pump
Section 220-0050
extend out beyond the end of pump housing (16). 2. Inspect (51 & 53) for worn corners on the hex
Place the complete unit with tubing into an arbor head, stripped threads and burrs in 'O' ring (52)
press with drive spline up. Press driveshaft (35) groove. Use an India stone to remove burrs, if
through the bearing and out of the unit. A 0.025 mm threads are defective replace the plugs.
(0.001 in) press exists between the driveshaft and
bearing so considerable force is required to remove 3. Inspect piston rod (57) for nicks and burrs.
the bearing. See Fig. 10. Remove burrs and sharp edges with an India stone.
b) Remove retaining ring (33) and pull shaft seal (34) 4. Inspect compensator piston (56) for wear at the
from pump housing (16). Be careful not to damage the area of yoke contact. Compensator piston (56) and
aluminium die cast housing in shaft seal (34) area. piston rod (57) are a close tolerance fit and must
assemble together without evidence of wear or bind.
Rotate compensator piston (57) through 360 when
Disassembly of Valve Block checking for bind.
1. Do not disassemble check valve parts (48 thru 50),
unless action of the valve indicates a problem. Check 5. Inspect valve block (15) for burrs, nicks, plugged
the valve action with a pencil or a screwdriver. Press body passages, flatness of the pump valve plate area
check valve in against the spring, it should return and and porosity. Inspect check valve seat (48). Make
hold firm against the seat. If the check valve is sure valve seat (48) is tight within valve block (15)
defective, remove and replace the complete and does not protrude above valve block (15) face.
assembly. Press new valve seat (48) flush with face Repair or replace valve block (15) if defective.
of valve block (15). Do Not scratch the face of valve
block (15).
ASSEMBLY
2. Remove parts (51 thru 57) from valve block (15) Numbers in parentheses refer to Figs. 1 & 6.
and set aside for inspection.
This is largely the reverse numerical sequence to
Note: If tapered bearing (21) was defective, perform Disassembly, but note the following:-
the following step.
8 SM 1204 2-98
Steering System - Steering Pump
Section 220-0050
SM - 385 shaft seal (34) end down. Lay inner race of tapered
ARBOR PRESS
HERE bearing (47) into the outer race. Install yoke spring
(46) and seat (45) into pump housing (16).
SM 1204 2-98 9
Steering System - Steering Pump
Section 220-0050
necessary shims (38) to provide this pre-load as e) Set pump housing (16) on its side and hold
follows: driveshaft (35) horizontal. Slide rotating group into
pump housing (16). Rotate driveshaft (35) to match
Assume the depth readings were 0.736 mm (0.029 in) shaft splines to cylinder block (23) and spherical
and 0.685 mm (0.027 in). Add the two figures together washer (30).
and divide by two to obtain the average. In this case
the calculated average is 0.710 mm (0.028 in). 5. If roll pins (20) were removed, install two roll pins
Subtract the nominal pre-load of 0.203 mm (0.008 in) (20) in pump housing (16). Place gasket (19) over roll
from the calculated average to obtain the required pins (20), cover with craft paper and set aside for
shim thickness. final assembly.
c) Slide three pins (28) into cylinder block (23) 3. Install new 'O' ring (52) on plug (51) and thread
assembly until they bottom against washer (27) within plug (51) into place.
cylinder block (23).
d) Place spherical washer (30) on top of the three Shaft Bearing Pre-load Adjustment
pins, then install shoe plate (31) with nine piston and Note: If the shaft bearings, driveshaft, valve block or
shoe assemblies (32) over spherical washer (30) and pump housing were not replaced, use the bearing
into cylinder block (23). Wobble shoe plate (31) to spacer removed during the disassembly procedure to
make sure that each piston is free within its bore in pre-load the driveshaft and perform step 7. If pre-load
cylinder block (23). adjustment is necessary, perform steps 1 thru 7.
10 SM 1204 2-98
Steering System - Steering Pump
Section 220-0050
1. Install thickest bearing spacer (22) over driveshaft SM - 388
(35) with the chamfer facing pump housing (16)
(toward the shoulder on driveshaft (35)).
Required bearing spacer thickness to provide a 0.076 3. Place valve block (15) on its side.
0.025 mm (0.003 + 0.001 in) bearing pre-load 3.708 +
0.025 mm (0.146 + 0.001 in) 4. Install piston rod (57) into valve block (15) and
attach retainer (54).
5. Remove six mounting screws (14) pump housing
(16) from valve block (15). 5. Install new 'O' ring (55) in piston rod (57) 'O' ring
groove.
6. Remove tapered bearing (21) and bearing
spacer (22). 6. Install compensator piston (56) over piston rod (57).
7. Locate a bearing spacer with calculated 7. Secure pump housing (16) to valve block (15) with
dimensions and place next to the new bearing on six screws (14), hand tight through the housing into
driveshaft (35). Chamfer must face shoulder on the valve block. Cross torque screws (14) to bring
driveshaft (35). Use the original spacer and bearing if valve block (15) and pump housing (16) together
pre-load is not performed. Set aside for final against gasket (19). Torque tighten screws (14) to
assembly. 31 - 35 Nm (23 - 26 lbf ft).
SM 1204 2-98 11
Steering System - Steering Pump
Section 220-0050
Thread four screws (1) through the compensator into 1. The pump must be started with less than 40% of
valve block (15). Cross torque screws (1) to 7 - 8 Nm normal system pressure. This is done by backing off the
(5 - 6 lbf ft). steering pressure relief valve so that the pump will start
under no-load conditions.
INSTALLATION 2. Be sure the pump case drain line is free from
Numbers in parentheses refer to Fig. 5. obstructions that restrict the pump case drain flow
back to tank and cause high case drain pressure
Note: Tighten all hydraulic lines fitted with ORFS which can lead to an early pump failure.
connections, as described in Section 220-0000,
STEERING SYSTEM SCHEMATIC. Renew all 'O' 3. Before starting the engine after pump installation,
rings where used. remove the remaining case drain plug from the pump
and an appropriate plug from the hydraulic tank and
install 0 - 3.5 bar (0 - 50 lbf/in2) gauges in both ports,
WARNING as well as a gauge in the pressure circuit which can
To prevent personal injury and property be read for setting the system steering pressure. Be
damage, ensure lifting equipment is of sure to back out adjusting plug (6) until it is flush with
sufficient capacity and properly secured to do compensator body.
the job safely.
4. Start the engine and monitor the system pressure
1. Install snap ring (4) to coupling (3). gauge. The system should register pressure within
30 seconds. If not, re-check to assure that the
2. Coat coupling (3) spline with molybdenum system is properly filled with oil and that there is no
disulphide grease and engage coupling in PTO drive. restriction to the pump inlet. With the engine at
Maximum No Load rev/min, read the pressures on
3. Assemble 'O' ring (5) to pump adaptor (2) and secure both the tank and the pump case. At no time should
pump adaptor (2) to PTO mounting face using four bolts the case pressure be more than 0.07 - 0.14 bar
(9). Torque tighten bolts (9) to 75 Nm (55 lbf ft). (1 - 2 lbf/in2) above the tank pressure. If it is, there is
either excessive restriction in the case drain line
4. Coat pump driveshaft spline with molybdenum (obstructed or possibly a kinked hose), or the leakage
disulphide grease and place pump (1) and gasket (7) rate in the pump is too high. In either case, the cause
on adaptor mounting flange. should be corrected. The system pressure can then
be set by adjusting the compensator screw until a
5. Push pump inward to engage with coupling (3) and system pressure of 159 bar (2 300 lbf/in) is reached.
PTO drive. Install two mounting bolts (8) and hardened The case to tank pressure differential should still not
washers (6). Torque tighten bolts (8) to 105 Nm (78 lbfft). exceed 0.07 - 0.14 bar (1 - 2 lbf/in2).
6. Remove caps and connect outlet and inlet lines to the 5. Shut off the engine, bleed off tank pressure, and
pump. Before connecting case drain line, fill the pump remove the gauges. Check the steering system for
with oil specified in Section 300-0020, LUBRICATION proper operation.
12 SM 1204 2-98
Steering System - Steering Pump
Section 220-0050
SPECIAL TOOLS
Special tools are shown in Figs. 17, 18, 19 & 20.
SM - 391
ALUMINIUM RING
SM - 390 SM - 392
SM - 393
NOMINAL
PIPE BORE 'A' 'B' 'C'
mm (in) mm (in) mm (in) mm (in)
38 (1.5) 100 (4.0) 41 (1.62) 48 (1.89)
SM 1204 2-98 13
Steering System - Steering Pump
Section 220-0050
TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
6 1 Screw 7-8 5-6
5 8 Bolt 105 78
5 9 Bolt 75 55
6 14 Screw 31 - 35 23 - 26
6 36 Screw 20 - 22 15 - 16
* * * *
14 SM 1204 2-98
STEERING SYSTEM - Accumulator
Section 220-0080
SM - 3201
3
4
5
6
7
8
20 19 18 9
17
21 10
11
12
13
14
15
1
16
DESCRIPTION TESTING
Numbers in parentheses refer to Fig. 1.
SM 2309 06-04 1
Steering System - Accumulator
Section 220-0080
Attempt to reseat the valve core by depressing and
releasing it quickly once or twice. Recheck for leakage. 1. Position the vehicle in a level work area, apply the
If leakage continues, discharge the accumulator as parking brake and switch off the engine.
described under 'Discharging Nitrogen' in this section,
then replace valve core (19), torque to 0.5 Nm ( 5 Ibf 2. Turn the steering wheel in both directions several
in). Tighten locknut (21) to 11Nm (100 Ibf in) and times to relieve pressure in the steering system. Block
replace cap (20) and tighten hand tight. all road wheels.
2 SM 2309 06-04
Steering System - Accumulator
Section 220-0080
DISCHARGING NITROGEN
WARNINGS Numbers in parentheses refer to Fig. 1.
Do not use Oxygen or any gas other than
Nitrogen to charge an accumulator. Oxygen Make sure charging valve assembly (14) is closed
under pressure coming into contact with oil or internally by turning locknut (21) clockwise. Remove
grease will cause a violent explosion. To cap (20) and core (19) from charging valve assembly
prevent personal injury and property damage, (14). Slowly turn locknut (21) anticlockwise to open the
always double check to make sure you are valve.
using Nitrogen.
Do not remove charging valve assembly (14) until all
A high pressure nitrogen pressure the gas has been completely evacuated.
regulator must be used with the charging
assembly kit. Failure to use pressure regulator
could cause property damage, personal injury WARNING
or death. Do not try to discharge the accumulator by
depressing valve core (19).
1. Attach line (1) and the swivel nut to charging valve
assembly (14, Fig. 1) as described in Steps 1 through
4 under the heading 'Testing Precharge Pressure'. Be REMOVAL
sure valves (4 & 6) are closed. Numbers in parentheses refer to Fig. 3.
SM 2309 06-04 3
Steering System - Accumulator
Section 220-0080
1. Make sure all nitrogen gas has been released 1. Lubricate O-rings (4,7 & 11), backup rings (3 & 12),
before starting to disassemble the accumulator. Refer Seal rings (5 & 9), and washers (6 & 8) with hydraulic
to section on 'Discharging Nitrogen'. oil prior to assembly.
2. Remove screw (16) and Protector (15) from Cylinder 2. Install O-ring (3) and backup ring (4) on the end cap
cap (13). (2).
3. Remove charging valve assembly (14) from cylinder 3. Install end cap (2) on cylinder body (1).
cap (13) and Discard O-ring (17).
4. Install new Seal ring (5 & 9), washers (6 & 8) and O-
3. With accumulator lying horizontal, hold accumulator ring (7) on piston (10).
4 SM 2309 06-04
Steering System - Accumulator
Section 220-0080
1. If removed, install mounting brackets and secure in
5. Insert piston (10) into bore of cylinder body (1) with place with bolts (7), hardened washers (8) and locknuts
cupped end facing the open end of the cylinder body (9).
(1). Taking care not to damage any components on the
threads of the Cylinder body (1) on insertion. Use a 2. Insert eyebolts into cylinder cap (13), using an
hammer and wood block to tap the piston into place adequate sling and lifting device, lift accumulator so
until the piston is 50.8mm (2.0 in) below the beginning that oil inlet port is facing downwards and position
of the honed bore. Keep pressure against piston while accumulator relative to mounting brackets.
tapping into place, to ensure piston does not bounce
back. 3. Secure accumulator to mounting brackets with
mounting straps (1), washers (2), lockwashers (3) and
6. Install O-ring (11) and backup ring (12) onto cylinder nuts (4).
cap (13) and install cylinder cap into bore of cylinder
body (1). Tighten cap so that it is flush with the end of 4. Remove caps installed at 'Removal' and install
the cylinder body (1), within 1.6-2.4mm (0.062 - 0.094 hydraulic line securely to the inlet port at underside of
in) above or below. the accumulator.
7. Install charging valve assembly (14). Torque tighten 5. Charge the accumulator with Nitrogen gas as
locknut (21) clockwise to 11Nm (100 Ibf in) to close described under 'Charging the Accumulator' in this
charging valve. Insert valve core (19) and torque to section.
0.5Nm (5 Ibf in), replace valve cap (20) and tighten
hand tight. 6. Check the level of oil in the hydraulic tank. Refer to
Section 230-0040, HYDRAULIC TANK. Add oil if low.
Use oils meeting the specifications outlined in Section
INSTALLATION 300-0020, LUBRICATION SYSTEM.
Numbers in parentheses refer to Fig. 3.
7. Start the engine and check for oil leaks as the oil
Note: Tighten all fasteners without special torques pressure increases. Tighten the hydraulic line and
specified to torques listed in Section 300-0080, fitting as required.
STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS. 8. Remove wheel blocks and check for correct steering
operation.
Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 220-0000,
STEERING SYSTEM SCHEMATIC. Renew all SPECIAL TOOLS
'O' rings where used. Refer to Section 300-0070, SERVICE TOOLS, for the
part numbers of the charging assembly kit and other
general service tools required. These tools are
WARNING available from your dealer.
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.
SM 2309 06-04 5
Steering System - Accumulator
Section 220-0080
WARNING
This vehicle is equipped with precharged nitrogen gas cylinders of more than 2.8 bar (40 lbf/in2).
Special permits may be required when transporting the dumptruck 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.
* * * *
6 SM 2309 06-04
STEERING SYSTEM - Steering Valve
Section 220-0090
SM 1489
1
2
3
26
4
5
7
26
6
26
12 10
9
8
14
16 1415
13
19 17
18
11
20
21
22
23 11 - Centring Pin 19 - Retaining Ring
24 12 - Centring Springs 20 - Check Ball Retainer
25
13 - O-Ring 21 - Check Ball
1 - Cap Screws 6 - Spacer Plate 14 - Bearing Races 22 - O-Ring
2 - End Cap 7 - Driveshaft 15 - Needle Bearing 23 - Check Ball Seat
3 - Spacer 8 - Valve Housing 16 - Quad Ring Seal 24 - O-Ring
4 - Gerotor Housing 9 - Sleeve 17 - Seal Gland Bushing 25 - Set Screw
5 - Gerotor Gear 10 - Spool 18 - Oil Seal 26 - O-Rings
DESCRIPTION SM 282
GEROTOR GEROTOR
Numbers in parentheses refer to Figure 1. Letters in HOUSING
GEAR
parentheses refer to Figures 4 to 8 inclusive.
There are four ports on valve housing (8) as follows: Fig. 2 - Gerotor Gear Set
Port 'P' - Supply from accumulator valve driveshaft (7) which is fastened to the sleeve with
Port 'T' - Return to tank centring pin (11). Rotation of driveshaft (7) causes
Port 'R' - Cylinder supply for right-hand turn gerotor gear (5), which is splined to driveshaft (7), to
Port 'L' - Cylinder supply for left-hand turn rotate in gerotor housing (4). When gerotor gear (5)
rotates, oil in gerotor housing (4) pockets (see Figure 2)
Turning action of the steering wheel is transmitted is forced out and flows through spool (10) and sleeve (9)
through the steering column to sleeve (9) and to the steering cylinder port.
SM 283 SM 556
RIGHT LEFT
SYSTEM TURN TURN
SUPPLY TO RETURN FROM
PRESSURE FEED FEED
CYLINDERS CYLINDERS
METER TO
PORTS TANK
Fig. 3 - Porting of Spool (10) and Sleeve (9) Fig. 6 - Oil Flow for Manual Left Turn
SM 554 SM 557
RETURN
TO TANK
SUPPLY FROM
ACCUMULATOR VALVE
Fig. 4 - Oil Flow for Powered Left Turn Fig. 7 - Oil Flow for Manual Right Turn
SM 555 SM 558
RETURN
TO TANK
SUPPLY FROM SUPPLY FROM
ACCUMULATOR VALVE ACCUMULATOR VALVE
Fig. 5 - Oil Flow for Powered Right Turn Fig. 8 - Steering Valve In 'Neutral' Position
SM 462
WARNINGS
To prevent personal injury and property
damage, turn steering wheel several times in
each direction to relieve pressure in the
steering accumulator.
2. Turn steering wheel in both directions several times Fig. 9 - Exploded View of Steering Valve Installation
to relieve pressure in accumulator and steering
system. Block all road wheels.
Figure 10. Use protective material on the vice jaws. Do
not overtighten jaws.
3. Remove bolts (5), washers (6) and lockwashers (7)
securing cover (3) to the truck. Remove cover (3) from
2. Remove cap screws (1) and end cap (2) from valve
the truck.
housing (8). See Figure 11.
4. Before removal of the steering valve, clean the valve
3. Remove gerotor assembly (3, 4 and 5) from valve
and connecting lines around it to prevent ingress of
housing (8). See Figure 12. Be careful not to drop the
dirt.
gerotor gear (5).
5. Ensure all hydraulic lines connected to steering
4. Remove drive spacer (3) and gerotor gear (5) from
valve (1) are identified for ease of installation and with
gerotor housing (4) Remove and discard the O-ring
suitable containers available to catch spillage,
(26) from the gerotor housing (4). See Figure 12.
disconnect hydraulic lines. Cap all lines and plug all
ports to prevent entry of dirt.
5. Remove driveshaft (7) and spacer plate (6) from
valve housing (8). Remove and discard the O-rings (26)
6. Support steering valve (1) and remove bolts (8) and
from spacer plate (6) and valve housing (8). See Figure 13.
lockwashers (4) securing steering column (2) to
steering valve (1).
6. Remove valve housing (8) from vice. Place valve
housing (8) on a clean, soft cloth to protect surface
7. Carefully lower steering valve (1) until the splined
finish. Use a thin blade screwdriver to pry retaining ring
shaft is free from steering column (2) and cab firewall.
(19) from valve housing (8), as shown in Figure 14.
Move steering valve (1) to a clean area for
disassembly.
7. Push spool (10) and sleeve (9) assembly forward
with your thumbs just far enough to free seal gland
DISASSEMBLY bushing (17) from valve housing (8). See Figure 15.
Remove seal gland bushing (17).
Numbers in parentheses refer to Figure 1.
8. Remove and discard quad ring seal (16) from seal
Note: Although all illustrations do not show steering
gland bushing (17). See Figure 16.
valve in a vice, we recommend that you keep it in a
vice during disassembly. Follow the clamping
9. Use a thin blade screwdriver to pry oil seal (18) from
procedures explained throughout the text.
seal gland bushing (17). Do not damage seal gland
bushing (17). Discard oil seal (18).
1. Clamp steering valve in vice, gerotor housing (4) end
up. Clamp lightly on edges of mounting area. See
SM 288 SM 1492
26
6
7
26
8
6 - Spacer Plate
7 - Driveshaft
8 - Valve Housing
26 - 'O' Rings
SM 1490 SM 292
1
2
4
8
SM 293
1 - Cap Screw
2 - End Cap
8 - Valve Housing
SM 1491
4 26
3 5 8 - Valve Housing
8 17 - Seal Gland Bushing
SM 294
5 - Gerotor Gear
3 - Spacer 8 - Valve Housing 16 - Quad Ring Seal
4 - Gerotor Housing 26 - 'O' Ring 17 - Seal Gland Bushing 18 - Oil Seal
SM295 SM297
8 - Valve Housing
14 - Bearing Race
15 - Needle Bearing
SM296 SM298
8 - Valve Housing
8 - Valve Housing 22 - 'O' Ring
9 - Sleeve
13 - 'O' Ring 23 - Check Ball Seat
10 - Spool
20 - Check Ball Retainer 24 - 'O' Ring
11 - Centring Pin
21 - Check Ball 25 - Set Screw
Fig. 18 - Removing Spool and Sleeve Assembly Fig. 20 - Removing 'O' Ring and Set Screw
10. Remove two bearing races (14) and needle bearing from sleeve (9).
(15) from spool (10) and sleeve (9) assembly. See
Figure 17. 14. Remove the six centring springs (12) from the
spool (10), by hand. See Figure 19.
11. Remove spool (10) and sleeve (9) assembly from
the 14 hole (meter) end of valve housing (8). See 15. Remove and discard the O-ring (13) from the valve
Figure 18. housing (8). See Figure 20.
Note: Do not bind spool (10) and sleeve (9) assembly in 16. Remove set screw (25) from valve housing (8). See
valve housing (8). Rotate spool (10) and sleeve (9) Figure 20.
assembly slowly when removing from valve housing (8).
17. Screw an 1/8-24 machine screw into the end of the
12. Push centring pin (11) from spool (10) and check ball seat (23) and, by pulling on the screw with
sleeve (9) assembly. See Figure 18. pliers, lift the check ball seat (23) out of the valve
housing (8).
13. Remove spool (10) from control end of sleeve (9).
See Figure 19. Rotate spool (10) slowly when removing 18. Remove and discard the O-rings (22 and 24) from
19. Tip valve housing (8) to remove the check ball (21)
and the check ball retainer (20).
INSPECTION
Check all mating surfaces. Replace any parts that
have scratches or burrs that could cause leakage.
Clean all metal parts in a clean solvent. Blow dry with
air. Do not wipe dry with cloth or paper towel because
lint or other matter can get into the hydraulic system
and cause damage. Do not use a coarse grit or try to
file or grind any parts.
8 - Valve Housing 22 - 'O' Ring Note: Lubricate all O-rings and seals (with exception of
13 - 'O' Ring 23 - Check Ball Seat the quad ring seal) with a petroleum jelly.
20 - Check Ball Retainer 24 - 'O' Ring
21 - Check Ball 25 - Set Screw
Replace all O-rings and oil seals with new O-rings and
Fig. 21 - Check Valve Installation oil seals at assembly.
SM300
ASSEMBLY
Numbers in parentheses refer to Figure 1.
SPRING SLOT
1. Use needle nose pliers to lower the check ball
retainer (20) into the check valve hole of the valve
housing (8). See Figure 21. Make sure that the check
ball retainer (20) sits flat in the valve housing (8).
11. Position spool (10) and sleeve (9) assembly so that Fig. 25 - Installing Spool and Sleeve
the splined end of spool (10) enters the 14 hole (meter)
end of valve housing (8) first. See Figure 25.
SM 304
SM 305
13. Install two bearing races (14) and needle bearing
(15) in valve housing (8). See Figure 26. 19
14. Install new oil seal (18) in seal gland bushing (17).
17
Flat or smooth side of oil seal (18) must face down
towards seal gland bushing (17). See Figure 28.
8
15. Install new dry quad ring seal (16) in seal gland
bushing (17). See Figure 28. Smooth quad ring seal
(16) in place with your finger. Do not use any quad ring
seal (16) that falls freely into pocket of seal gland
8 - Valve Housing
bushing (17).
17 - Seal Gland Bushing
19 - Retaining Ring
16. Install seal gland bushing (17) over spool (10) end
Fig. 27 - Seal Bushing Installation
SM 306 SM 309
CENTRING PIN
PARALLEL WITH
PORT FACE
CENTRING PIN
Fig. 29 - Valve Clamped in Vice 17. Install retaining ring (19) in valve housing (8). See
Figures 27 and 28. Tap lightly on retaining ring (19) end
to properly seat retaining ring (19) in its groove.
SM 1493
26
18. Carefully clamp valve housing (8) in vice as shown in
6 Figure 29. Clamp lightly on edges of mounting area.
21. Install gerotor gear (5) and new O-ring (26) in the
gerotor housing (4). See Figure 32.
DRIVE
(MARKED)
22. With seal side of gerotor housing (4) toward spacer
plate (6), align gerotor gear (5) valleys on driveshaft (7),
CENTRING PIN
as shown in Figure 33. Note the parallel relationship of
reference lines A, B, C and D in Figure 33. Align cap PORT FACE
screw (1) holes without disengaging gerotor gear (5)
from driveshaft (7).
24. Align cap screw (1) holes and install seven dry cap
screws (1) in end cap (2). Pre-tighten cap screws (1) to
17 Nm (150 lbf in) then tighten to a torque of 31 Nm
(275 lbf in) torque, in the sequence shown in Figure 35.
Fig. 33 - Aligning Housing and Gerotor
INSTALLATION
Numbers in parentheses refer to Figure 9. SM1495
1
Note: Tighten all fasteners without special torques 2
specified to standard torques listed in Section 4 3
300-0080, Standard Bolt and Nut Torque 8
Specifications.
2. Carefully raise steering valve (1) until the splined 1 - Cap Screw 3 - Spacer
shaft is engaged in steering column (2) through the cab 2 - End Cap 8 - Valve Housing
firewall.
Fig. 34 - End Plate Installation
3. Install bolts (5) and lockwashers (4) through steering
column (2) and secure to cab firewall and steering SM - 313
valve (1).
7. Secure cover (3) to the truck with washers (6), Note: Slight creep or drift of the steering wheel is
lockwashers (7) and bolts (8). normal.
Apparent inability to steer when Dirt in system Drain and flush system. Refill
wheel is turned slowly with clean oil
Slow Steering Excessive wear in sleeve and Renew sleeve and spool
spool
Excessive wear in gerotor Renew gerotor
No steering action Sleeve and spool locked Disassemble and repair or replace
together
* * * *
SM - 3235
20 15 11 10 9 9
A 8 3 12 2 4 5 6 7
14 13 19 18 B
4 16
12 17 8 9 9 10 11 1 15 13 14
DESCRIPTION SM - 561
SM 1208 2-98 1
Steering System - Double Relief Valve
Section 220-0110
When oil flowing through valve body (1) at port 'B', and SM - 560
out of the opposite side exceeds valve (2) setting,
valve (2) is moved off valve seat (3) against the 6
STEERING A A STEERING
pressure of spring (5). See Fig. 4. As valve (2) moves CYLINDER CYLINDER
BASE END ROD END
off valve seat (3), oil flows out of port 'A' to the
opposite end of steering cylinders. After the road STEERING STEERING
B B
shock has been dissipated, pressure is reduced and CYLINDER CYLINDER
ROD END BASE END
spring (5) seats valve (2) against valve seat (3). See
Fig. 3.
LEFT TURN RIGHT TURN
PORT ON PORT ON
STEERING VALVE STEERING VALVE
REMOVAL
Fig. 3 - Double Relief Valve In Neutral Position
WARNINGS SM - 559
Hydraulic fluid pressure will remain within the
system after engine shutdown. To prevent 6
STEERING A A STEERING
personal injury and property damage, turn CYLINDER CYLINDER
steering wheel several times in each direction BASE END ROD END
1. Position the vehicle in a level work area, raise the Fig. 4 - Double Relief Valve - Valve (2) Activated
body and secure in place with the body safety pins.
Apply the parking brake and switch off the engine. and carefully remove adjustment screw (7) from valve
body (1).
2. Turn steering wheel in both directions several times
to relieve any pressure in accumulator and steering
system. Block all road wheels. WARNING
Compressed springs. Use care when removing
3. Before removal of double relief valve from the truck, relief body (13). Springs (5 & 18) are under
clean exterior of the valve and hydraulic oil lines to compression and may spring out of valve body
prevent ingress of dirt. (1) bore, causing personal injury, if
compression is not released carefully.
4. Identify and tag all hydraulic oil lines to aid in
installation and disconnect from double relief valve. 3. Carefully remove relief body (13) assembly from
Cap all lines and plug all ports of the double relief valve body (1). Remove washer (4) and spring end
valve to prevent ingress of dirt. (6) assembly from relief body (13). Remove and
discard 'O' Ring (15) from spring end (6).
5. Remove mounting hardware securing double relief
valve to the truck and move to a clean area for 4. Remove spring (5) from valve body (1).
disassembly.
Note: To remove valve (2) assembly and valve
seat (3) assembly from valve body (1), it is necessary
DISASSEMBLY to turn valve body on its end and tap down on a work
Numbers in parentheses refer to Fig. 1. bench, or other suitable area, to release the parts.
1. If required, remove elbows and tees from double 5. Remove valve (2) assembly from valve body (1).
relief valve and identify to aid in assembly. Remove and discard 'O' Ring (10) and backup
ring (11) from valve (2).
2. Slacken jam nut (14) from adjustment screw (7)
6. Remove valve seat (3) assembly from valve
2 SM 1208 2-98
Steering System - Double Relief Valve
Section 220-0110
body (1). Remove and discard 'O' ring (8) and backup 6. Repeat steps 1 through 5 to assemble remaining
rings (9) from valve seat (3). valve (16) assembly.
7. Follow steps 1 through 6 to disassemble the 7. If removed, install plugs (12) in valve body (1).
remaining valve (16) assembly.
8. Adjust valve as described under 'Adjustment'.
8. If necessary, remove plugs (12) from valve body (1).
9. If removed, install elbows and tees on double relief
valve as tagged at disassembly.
INSPECTION
Numbers in parentheses refer to Fig. 1.
ADJUSTMENT
Note: There is a seal kit available to replace all of the Numbers and letters in parentheses refer to Fig. 1.
seals in the valve. However, if any of the other items
are damaged the valve assembly should be replaced. SM - 165
Refer to the trucks Parts Book for part number of the NEEDLE
seal kit. VALVE
2. Install valve seat (3) assembly in valve body (1) and 3. Install a needle valve in the third leg of the tee,
lightly tap home with a pin punch. Install valve (2) with a line returning from needle valve to oil
assembly in valve body (1). reservoir.
3. Install new 'O' ring (15) on spring end (6) and install 4. Install a plug in one side of port 'A' and a line
spring end (6) assembly in relief body (13). Install returning to oil reservoir in the opposite side of port 'A'.
spring (5) in relief body (13).
5. Open the needle valve and start the pump.
4. Install washer (4) on relief body (13) and thread Gradually close the needle valve. If oil is discharged
relief body (13) assembly into valve body (1). Tighten through port 'A' before relief pressure is reached, turn
relief body (13) to a torque of 60 - 65 Nm (44 - 48 lbf/in2). adjustment screw (7) in until discharge stops.
Continue closing the needle valve and turning
5. Thread adjustment screw (7) into valve body (1). Do adjustment screw (7) until discharge through port 'A'
not secure with jam nut (14) until after pressure setting occurs at relief pressure.
adjustment is complete.
SM 1208 2-98 3
Steering System - Double Relief Valve
Section 220-0110
If oil is discharged through port 'A' only when relief secure in place with mounting hardware.
pressure is exceeded, turn adjustment screw (7) out
and open needle valve slightly. Continue opening 2. Remove blanking caps from hydraulic lines and
needle valve and turning adjustment screw (7) out install lines to double relief valve as identified during
until discharge through port 'A' occurs at relief pressure. removal.
6. Repeat Steps 1 through 5 on opposite end of 3. Check oil level in the steering and brake control tank
double relief valve. Adjust adjustment screw (20) so and add oil if required. Refer to Section 220-0040,
discharge through port 'B' occurs at relief pressure. STEERING AND BRAKE CONTROL TANK for
correct fill level, and, Section 300-0020,
7. Re-check both relief settings before securing LUBRICATION SYSTEM for oil specification.
adjustment screws (7 & 20) with jam nuts (14).
4. Start the engine and bring hydraulic oil to operating
8. Re-check both relief settings before installing temperature.
double relief valve assembly on the truck.
5. Check double relief valve and hydraulic line
connections for leaks and tighten as required.
INSTALLATION
Note: Tighten all fasteners to standard torques listed 6. Remove body safety pins and lower the body to the
in Section 300-0080, STANDARD BOLT AND NUT frame. Remove wheel blocks.
TORQUE SPECIFICATIONS.
Note: Tighten all hydraulic lines fitted with ORFS SPECIAL TOOLS
connections, as described in Section 220-0000, There are no special tools required for procedures
STEERING SYSTEM SCHEMATIC. Renew all outlined in this section. Refer to Section 300-0070,
'O' rings where used. SERVICE TOOLS, for part numbers of general
service tools required. These tools are available from
1. Make certain, area of installation is clean and your dealer.
position double relief valve on mounting bracket and
* * * *
4 SM 1208 2-98
STEERING SYSTEM - Steering Cylinder and Linkage
Section 220-0120
SM - 1526
42 38 29 27
41
28
40
36- LH 30
39 37- RH 32
31
46,47 35
43 44,45 46,47
17
10
10 48
15,16 18 7- LH
18 11, 34 32 8- RH
17 12,
13 26
14 9
1-3 LH
4-6 RH
33 7,8 2,5
20,21,22 32
25
19 1,4 3,6
24,23
1 - Spindle Assembly - LH 13 - Expansion Plug 25 - Seal 37 - Rod End
2 - Spacer 14 - Thrust Washer 26 - Plug 38 - Bolt
3 - Plug 15 - Locking Pin 27 - Bolt 39 - Stud
4 - Spindle Assembly - RH 16 - Nut 28 - Retainer Ring 40 - Bearing
5 - Spacer 17 - Lube Fitting 29 - Plate 41 - Retainer Ring
6 - Plug 18 - Lube Fitting 30 - Bushing 42 - Plate
7 - Steering Arm - LH 19 - Anchor Pin 31 - Ball Pin 43 - Seal
8 - Steering Arm - RH 20 - Bolt 32 - Steering Cylinder 44 - Castle Nut
9 - Bolt 21 - Lockwasher 33 - Lube Fitting 45 - Cotter Pin
10 - Bellcrank 22 - Plate 34 - Steering Stop 46 - Bolt
11 - Pin 23 - Cotter Pin 35 - Tie Rod 47 - Nut
12 - Bushing 24 - Castle Nut 36 - Rod End 48 - Plug
SM 2318 07-04 1
Steering System - Steering Cylinder and Linkage
Section 220-0120
1. Position the vehicle in a level work area, be sure the 5. Break tack welds around expansion plugs (13) and
body is completely lowered, apply the parking brake remove expansion plugs from bellcrank housing.
and switch off the engine.
6. Remove nut (16) from locking pin (15) and, using
2. Turn steering wheel in both directions several times a mild steel drift, tap locking pin (15) out from bellcrank
to relieve pressure in accumulator and steering (10).
system. Block all road wheels.
7. Using suitable lifting equipment, support bellcrank
(10) and, using a mild steel drift (slightly less than
Steering Cylinder 75 mm (3 in) in diameter), drive pin (11) from the
1. Support steering cylinder (32) with suitable blocks bellcrank housing and bellcrank (10).
or lifting device.
8. Remove bellcrank (10) and thrust washers (14)
2. Ensure all hydraulic lines connected to steering from the bellcrank housing.
cylinders (32) are identified for ease of installation and
with suitable containers available to catch spillage, 9. If bushings (12) are to be replaced, use a mild steel drift
disconnect hydraulic lines. Cap all lines and ports to (slightly more than 75 mm (3 in) in diameter) and drive
prevent entry of dirt. bushings out of the bellcrank housing.
3. Remove cotter pin (23) and castle nut (24) from ball pin Note: If removing welds using an air arc, follow the
(31) assembly at rod end of steering cylinder (32). procedures outlined for 'Welding' in Section 100-0010,
CHASSIS, HOOD AND FENDERS.
4. Remove bolts (20), lockwashers (21) and plate (22)
from anchor pin (19) at base end of steering cylinder 10. If one or both steering stops (34) are damaged
(32). Remove anchor pin (19) and carefully lift steering they can be removed by using an air arc to break the
cylinder (32) from bellcrank (10) housing and steering welds.
arm (7). Remove seal (25) from steering arm (7) ball
joint bore.
DISASSEMBLY
5. Drain hydraulic oil from steering cylinder (32)
assembly and place in a clean work area for disassembly. Tie Rod Assembly
Numbers in parentheses refer to Fig. 1.
6. Repeat steps 3 through 5 to remove opposite
steering cylinder (32) from bellcrank (10) and steering Note: To aid in assembly and installation, record
arm (8). assembled length of tie rod (35) assembly for
reference.
2 SM 2318 07-04
Steering System - Steering Cylinder and Linkage
Section 220-0120
SM - 3203
13
14 12
11
10
2
15
16 9
7
1
6
17
18
4
3
1. Remove lube fitting (17) and plug (48) from rod Steering Cylinder - Piston Rod End
end (36). Numbers in parentheses refer to Fig. 1.
2. Place tie rod (35) assembly in a vice, or similar 1. Remove lube fitting (18) and plug (26) from piston
holding device, and remove bolts (38) securing plate rod end of steering cylinder (32).
(42) to rod end (36). Remove plate (42).
2. Place steering cylinder (32) assembly in a vice, or
3. Pry retainer ring (41) out of rod end (36). similar holding device, and remove bolts (27) securing
plate (29) to piston rod end. Remove plate (29).
4. Turn tie rod (35) in vice so that the threaded end of stud
(39) points upwards. Using a soft faced hammer, tap stud 3. Pry retainer ring (28) out of the piston rod eye.
(39) out of rod end (36) and remove bearing (40).
4. Turn steering cylinder (32) in vice so that the
5. Repeat steps 2 through 4 to disassemble rod end threaded end of ball pin (31) points upwards. Using a
(37) of tie rod (35). soft faced hammer, tap ball pin (31) out of piston rod
eye and remove bushing (30).
6. Loosen nuts (47) and bolts (46) and unscrew rod
ends (36 & 37) from tie rod (35).
SM 2318 07-04 3
Steering System - Steering Cylinder and Linkage
Section 220-0120
1. Before disassembling cylinder, wash outer surfaces Note: Apply a light coating of hydraulic oil to all
with a cleaning solvent to remove dirt and grease. components as they are assembled. This will facilitate
assembly procedure. Make sure that all work is done in
2. Using a suitable C- spanner or equivalent, unscrew a clean area so no contaminants can get into the oil.
retainer cap (5), securing piston rod (2) assembly to
tube (1). 1. Insert new wiper seal (7) and rod seal (6) to inner
grooves of retainer cap (5). Position a new backup ring
3. Pull retainer cap(5), piston rod (2) and piston (12) as (4) and 'O' ring (3) into outer groove of retainer cap (5).
an assembly out of tube (1).
4. Position eye end of piston rod (2) in a soft-jawed 2. Press retainer cap (5) into position on piston rod (2).
vice and remove nut (9).
3. Position new wear ring (11) and piston seal (10) on
5. Pull piston (12) off piston rod (2). Remove piston outer grooves of piston (12) and 'O'-ring (13) on the
seal (10), wear ring (11) and 'O'-Ring (13) from piston inner groove.
(12) and discard.
4. Slide piston (12) sub assembly onto piston rod (2)
6. Remove back-up ring (4) and 'O' ring (3) from outer until it bottoms at the rods shoulder. Screw nut (9)
groove of retainer cap (5). Discard both parts. onto threaded end of piston rod (2) and torque tighten
to 475 - 508 Nm ( 350 - 375 lbf ft).
7. Press piston rod (2) out of retainer cap (5).
Note: Nut (9) should not be used more than three
8. Remove wiper (7) and rod seal (6) from inside groove times. Check nut locking collar condition and replace if
of retainer cap (2). Discard wiper (6) and seal (7). it does not produce a firm locking action on piston rod
threads.
9. If necessary, press bushing (8) out of tube (1) eye.
4. If removed, press bushing (8) into tube (1) eye.
10. If necessary, remove lube fitting (18) from base
end of tube (1). 5. Slide tube (1) onto piston rod (2) assembly and
press tightly into position to retainer cap (5). Secure
tube (1) to retainer cap (5) screwing to a torque of 508
INSPECTION - 542 Nm (375 - 400 lbf ft).
1. Clean all metal parts of the steering cylinder in a
suitable solvent and dry with clean, lint-free cloths. 6. If removed, install lube fitting (18) at base end of
Make certain all cylinder ports are free of dirt or tube (1).
contamination.
2. Check cylinder tube and outer diameter of piston for Steering Cylinder - Piston Rod End
scratches, cracks, or other signs of damage. Use a Numbers in parentheses refer to Fig. 1.
fine stone to remove scratches or ridges. Replace
these components, if defects cannot be corrected. 1. Place steering cylinder (32) assembly in a vice, or
similar holding device, with tapped holes in piston rod
3. Inspect piston rod for distortion, cracks or other eye facing up.
defects. Replace piston rod if defective area is
irreparable. 2. Lubricate bushing (30) and ball pin (31) with grease
and tap bushing and ball pin as an assembly into
4. Check bushings for wear and replace if required. piston rod eye end of steering cylinder (32).
5. Repeat steps 1 through 4 for to assemble rod end 5. Place expansion plugs (13) into upper and lower
(37) assembly to opposite end of tie rod (35). bores of bellcrank housing (10) and tack weld each
expansion plug in three places.
6. Install lube fitting (17) and plug (48) in rod end (36).
6. Using suitable lifting equipment, position steering
arm (7) to spindle assembly (1) and secure with
INSTALLATION bolts (9).
Numbers in parentheses refer to Fig. 1.
7. Install seals (43) on studs (39) and, using suitable
Note: Tighten all fasteners without special torques lifting equipment, install tie rod (35) assembly on
specified to standard torques listed in Section bellcrank (10) and steering arm (7) and secure with
300-0080, STANDARD BOLT AND NUT TORQUE castle nuts (44). Tighten castle nuts (44) to a torque of
SPECIFICATIONS. 1 150 - 1 290 Nm (850 - 950 lbf ft).
Note: Tighten all hydraulic lines fitted with ORFS 8. Secure castle nuts (44) to studs (39) with new cotter
connections, as described in Section 220-0000, pins (45).
STEERING SYSTEM SCHEMATIC. Renew all
'O' rings where used. 9. Repeat steps 6 through 8 to install steering arm (8)
and opposite tie rod (35) assembly.
SM 2318 07-04 5
Steering System - Steering Cylinder and Linkage
Section 220-0120
11. If either steering stop (34) was removed, position a SM - 154
new steering stop on the chassis and weld in place. FRONT
Use an E-70 welding rod and build 9 mm (3/8 in) fillet all OF VEHICLE
around steering stop (34).
Steering Cylinder
1. Position seal (25) on steering arm (7) ball joint bore.
3. Secure ball pin (31) to steering arm (7) with castle nut
(24). Tighten castle nut (24) to a torque of
1 560 - 1 630 Nm (1 150 - 1 200 lbf ft) and secure to ball
pin (31) with new cotter pin (23).
Wheel Alignment (Toe-in) Dimensions
4. Install anchor pin (19) and plate (22) at base end of
TYRE TYPE DIMENSION 'Y'
steering cylinder (32) assembly and secure with bolts
(20) and lockwashers (21). Cross-ply 10 - 16 mm (0.38 - 0.62 in)
Radial 0 - 10 mm (0 - 0.38 in)
Note: Plate (22) fits into the slot at the end of anchor
pin (19). Fig. 3 - Plan View of Wheel Alignment
5. Repeat steps 1 through 4 to install the opposite b. Camber - Outward tilt of the top of the front wheels.
steering cylinder (32) to steering arm (8) and bellcrank
housing. c. Toe-in - Inward turning of the front wheels.
6. Remove blanking caps from hydraulic lines and Note: Caster and camber are built into the vehicle and
cylinder ports and connect hydraulic lines to cylinder are not adjustable.
ports, as identified at removal.
Check for toe-in only when the truck is empty and
7. Check oil level in the steering and brake control tank bellcrank (10) is centred. Use a slide bar attached to
and add oil if necessary. Refer to Section the wheel rim edge to make this check.
220-0040, STEERING AND BRAKE CONTROL TANK
for correct oil level and, Section 300-0020, If adjustment is necessary, loosen nuts (47) and
LUBRICATION SYSTEM for oil specification. bolts (46) at each end of tie rod (35) assemblies. Turn
tie rods (35) with a pipe wrench until correct toe-in
8. Remove wheel blocks from all road wheels and start dimension is obtained. Refer to Fig. 3.
the engine. Operate the steering and check hydraulic
lines for leaks. Tighten lines and fittings as required. When tie rod (35) lengths have been established,
secure rod ends (36 & 37) to tie rods (35) with bolts
9. Re-check oil level in the steering and brake control (46) and nuts (47).
tank and add oil if necessary.
ALIGNMENT
Numbers in parentheses refer to Fig. 1.
6 SM 2318 07-04
Steering System - Steering Cylinder and Linkage
Section 220-0120
* * * *
SM 2318 07-04 7
STEERING SYSTEM - Accumulator Valve
Section 220-0130
SM - 169
The Accumulator Valve can be identified as item 4 in Incorporated in this assembly are three valves; a
Section 220-0000, STEERING SYSTEM check valve, accumulator two-way valve and a system
SCHEMATIC, in this manual. pressure protection valve.
SM 1209 2-98 1
Steering System - Accumulator Valve
Section 220-0130
An accumulator two-way valve (13 thru 17) is located the accumulator through port 'E'. Pressure is supplied
in the centre portion of the assembly. In the operating to pressure switch (8, Figs. 2, 3 & 4) and remote
position, engine running and two-way valve energized diagnostic test point through a tee piece in port 'G2'.
(refer to Fig. 2), this valve allows the accumulator to Refer to Fig. 2.
retain its pressure. In its non-operating position,
engine shutdown and two-way valve de-energized During operation of the machine, transmission pilot
(refer to Fig. 3), a controlled bleed-down of the pressure through port 'D' keeps the two-way valve
accumulator pressure to the steering and brake control (13 thru 17) energized (closed). This traps a supply of
tank occurs. This bleed-down takes 3 to 5 minutes. oil in the accumulator.
Relief valve cartridge (8), at the lower portion of the Return oil from the steering valve enters port 'C' and
assembly, is preset to 210 bar (3 050 lbf/in) and exits through port 'R' to tank.
seated. This valve acts as a backup in the event of a
malfunction of the steering pump compensator valve. Port 'G1' is plugged.
Should the compensator valve allow steering system
pressure to exceed the preset pressure of relief valve Should pressure in any of these circuit lines exceed
cartridge (8), valve will open and relieve excess oil the preset pressure setting on relief valve cartridge (8),
pressure to the steering and brake control tank. Refer the relief valve will open and oil will exit through port
to Fig. 4. 'R' to tank. Refer to Fig. 4.
SM - 1323
SUPPLY TO
RETURN FROM STEERING PRESSURE
STEERING VALVE VALVE TEST POINT
SUPPLY TO
ACCUMULATOR
BRAKE
CIRCUIT
RETURN SUPPLY
TO TANK FROM
PUMP
2 SM 1209 2-98
Steering System - Accumulator Valve
Section 220-0130
SM - 1324
PRESSURE
TEST POINT
RETURN FROM
ACCUMULATOR
RETURN
TO TANK
SM - 1325
SUPPLY TO
RETURN FROM STEERING PRESSURE
STEERING VALVE VALVE TEST POINT
SUPPLY TO
ACCUMULATOR
BRAKE
CIRCUIT
RETURN
SUPPLY
TO TANK
FROM
PUMP
SM 1209 2-98 3
Steering System - Accumulator Valve
Section 220-0130
SM - 170
9 - Filter
10 - Breather
11 - 'O' Ring
12 - Spring
13 - Pin
1 - Relief Valve Cartridge 14 - Quad Ring
2 - 'O' Ring 15 - Piston
3 - 'O' Ring 16 - 'O' Ring
4 - Backup Rings 17 - Plug
5 - Valve Body 18 - Plug
6 - Filter 19 - 'O' Ring
7 - Spring 20 - Spring
8 - Plug 21 - Poppet
4 SM 1209 2-98
Steering System - Accumulator Valve
Section 220-0130
plug (18). Discard spring (20). (13) assembly in valve body (5). Install new quad ring
(14) on piston (15) and install piston (15) assembly in
4. Clamp valve body (5) in a soft-jawed vice and valve body (5).
remove relief valve cartridge (1) from valve body (5).
Remove and discard backup rings (4), 'O' ring (3) and 5. Install new 'O' ring (16) on plug (17) and install plug
'O' ring (2) from relief valve cartridge (1). (17) in valve body (5).
Note: Do NOT disassemble relief valve cartridge (1) 6. Install new 'O' ring (19) on plug (18) and install
assembly; it is pressure set and sealed at assembly. If poppet (21), new spring (20) and plug (18) in valve
relief valve cartridge (1) is defective, it must be body (5).
replaced with a new one.
5. Remove plug (8), spring (7) and filter (6) from valve INSTALLATION
body (5). Remove breather (9) from valve body (5). Note: Tighten all fasteners to standard torques listed
Discard filter (6), breather (9) and spring (7). in Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.
3. Check poppet (21) and seats in valve body (5). 2. Connect all hydraulic lines securely to accumulator
Ensure they are not worn, nicked, cracked or scored. valve as tagged at 'Removal'.
4. Check condition of relief valve cartridge (1). Insert a 3. Check the level of oil in the steering and brake
blunt-nosed drift or punch into relief valve cartridge (1) control tank. Refer to Section 220-0040, STEERING
end and depress the piston. If piston does not move AND BRAKE CONTROL TANK. Add oil if low. Use oils
freely, or hangs up, replace relief valve cartridge (1) meeting the specifications outlined in Section
assembly. Relief valve cartridge (1) assembly should 300-0020, LUBRICATION SYSTEM.
also be replaced if lead seal has been removed, as the
relief valve cartridge (1) adjustment may not be 4. Remove wheel chocks, start the engine and slowly
accurate. operate steering system. Check for correct steering
operation and leaks. Tighten lines and fittings if
necessary and re-check oil level.
ASSEMBLY
Numbers in parentheses refer to Fig. 4.
MAINTENANCE
1. Install new filter (6), new spring (7) and plug (8) in valve Numbers in parentheses refer to Fig. 4.
body (5). Install new breather (9) in valve body (5).
1. Check breather (9) regularly for plugging, due to
2. Place valve body (5) in a soft-jawed vice. Install new accumulation of dirt, painting over or plugged with tape
'O' rings (2 & 3) and backup rings (4) on relief valve or other material. Check filter (6) for plugging.
cartridge (1). Install relief valve cartridge (1) assembly
in valve body (5). 2. Clean filter (6) and breather (9) with a suitable
cleaning solvent, or if required, replace.
3. Install new 'O' ring (11) on piston (10). Press piston
(10) into its bore in valve body (5). 3. If painting in the area of the accumulator valve is
necessary, be sure to mask breather (9). Be sure to
4. Install new spring (12) on pin (13) and install pin remove all masking tape from breather (9) after painting.
* * * *
SM 1209 2-98 5
STEERING SYSTEM - Steering Filter
Section 220-0150
SM - 627
filter assembly.
OPERATION
Numbers in parentheses refer to Figure 1.
To prevent personal injury and property 12. Remove wheel blocks and disconnect shipping bar
damage, be sure wheel blocks are properly and place in the stowed position. Start engine, check
secured and of adequate capacity to do the job for correct steering operation and check for leaks.
safely. Tighten lines and fittings, as required.
1. Position the vehicle in a level work area, apply the Note: If there is air in the steering system the system
parking brake and switch off the engine. must be bled, as described in Section
220-0000, Steering System Schematic.
1 2 Bowl 20 15
* * * *
2 SM 1593 Rev 1 06-08
BODY SYSTEM - Body System Schematic
Section 230-0000
The tandem gear pump, mounted off the engine power There are two body hoist cylinders mounted between
takeoff, supplies hydraulic oil for operating the body the frame rails. The cylinders are two-stage with power
and cooling the rear disc brake assemblies. down in the second stage.
The front section draws oil from the body and disc The kick-over valve, mounted off a bracket at the rear
brake cooling tank, then pumps the oil to body control of the transmission, is installed in the hydraulic system
valve (3) where, depending on spool position, oil flows to prevent the body from pulling a void in body
to the body hoist circuit or, with spool in the float cylinders (5) when dumping unbalanced loads. The
position, flows through manifold block (4) to kick-over valve also provides a means of return oil
supplement the disc brake cooling oil. from the body lower circuit to return, through body
control valve (3), to body and disc brake cooling tank
The rear section draws oil from the body and disc (1).
brake cooling tank, then pumps the oil through
manifold block (4) to supply the disc brake cooling
circuit.
Disc Brake Oil Filter (7) Note: The body control joystick should be kept in the
There is one full flow oil filter installed in the hydraulic Float position at all times, except when raising or
line between manifold block (4) and disc brake oil lowering the body.
cooler (8). Internal of the filter housing is a relief valve
which opens at 1 bar (15 lbf/in) and allows oil to
bypass the filter element when it becomes blocked. Relief Valve (10)
The filter indicator should be checked daily, and the Located in the body and disc brake cooling tank, the
element changed when the indicator shows oil at the relief valve controls oil pressure in the disc brake
replace element level. cooling circuit. The relief valve is set to open at 3 bar
(45 lbf/in).
SLEEVE
Pressure Test Points 'O' RING 'O' RING
There are five diagnostic pressure test points in the Fig. 1 - Assembly of Typical ORFS Connector
body hoist system, as shown in Figs. 2 through 5.
a. Ensure 'O' ring/seal is in place and that joining
Note: When checking hydraulic pressures the vehicle surfaces are clean. If necessary, retain 'O' ring/seal in
should be positioned on a level surface and all road place with a light coating of grease or vaseline.
wheels securely blocked.
b. Initially, the nuts should be tightened by hand.
Test Point A
System Relief Pressure - 190 bar (2 750 lbf/in) c. Where a hose is fitted, ensure that it is not twisted or
kinked when the nuts are tightened so that it is allowed
Test Point B to adopt a natural position.
Kick-over Pressure - 172 bar (2 500 lbf/in)
d. Where a tube is fitted, ensure that the connection is
Test Point C aligned correctly.
Accumulator Pressure - 13 bar (188 lbf/in)
e. Tighten the nut a further 1/4 to 1/2 a turn using the
Test Point D correct size spanner (wrench).
Spool Actuation Pressure - Raise Side - Install a tee
into servo line, raise side. f. Check that a satisfactory routing has been achieved.
Test Point E
Spool Actuation Pressure - Lower Side - Install a tee
into servo line, lower side.
5 11 5
Section 230-0000
C 9
COMPONENTS
1 - Body and Disc Brake
6
Cooling Tank 8 B
14
2 - Tandem Pump
3 - Body Control Valve TO OCDB
7
4 - Manifold Block COOLING
5 - Body Cylinder CIRCUIT
6 - Kick-over Valve
7 - Disc Brake Oil Filter
8 - Disc Brake Oil Cooler STEERING TEST D
9 - Remote Control Valve CIRCUIT
10 - Relief Valve 3
11 - Relief Valve 4 TEST E
12 - Tank Breather
13 - Disc Brake Oil Temp Switch
Body System - Body System Schematic
COLOUR CODES
Red - Pressurized Oil
Blue - Exhaust or Return Oil
Green - Intake Oil 13 2 A
Orange - Pilot Pressure 12
Yellow - Static Oil 1
10
Fig. 2 - Body Hoist System Schematic - Body Control Valve in the 'Hold' Position
COMPONENTS
1 - Body and Disc Brake
Cooling Tank 6
2 - Tandem Pump 8 B
14
3 - Body Control Valve
TO OCDB
4 - Manifold Block 7
COOLING
5 - Body Cylinder
CIRCUIT
6 - Kick-over Valve
7 - Disc Brake Oil Filter
8 - Disc Brake Oil Cooler
9 - Remote Control Valve STEERING TEST D
10 - Relief Valve CIRCUIT
11 - Relief Valve 3
12 - Tank Breather 4 TEST E
13 - Disc Brake Oil Temp Switch
14 - Pilot Supply Valve
COLOUR CODES
Red - Pressurized Oil
Blue - Exhaust or Return Oil
Green - Intake Oil
Orange - Pilot Pressure 13 2 A
Yellow - Static Oil 12
1
10
Fig. 3 - Body Hoist System Schematic - Body Control Valve in the 'Raise Position
Body System - Body System Schematic
Section 230-0000
5
6
SM - 2270C
5 11 5
Section 230-0000
C 9
COMPONENTS
1 - Body and Disc Brake 6
8 B
Cooling Tank 14
2 - Tandem Pump TO OCDB
7
3 - Body Control Valve COOLING
4 - Manifold Block CIRCUIT
5 - Body Cylinder
6 - Kick-over Valve
7 - Disc Brake Oil Filter STEERING TEST D
8 - Disc Brake Oil Cooler CIRCUIT
9 - Remote Control Valve
10 - Relief Valve 3
4 TEST E
11 - Relief Valve
12 - Tank Breather
13 - Disc Brake Oil Temp Switch
Body System - Body System Schematic
COLOUR CODES
Red - Pressurized Oil
Blue - Exhaust or Return Oil 13 2 A
Green - Intake Oil
12
Orange - Pilot Pressure
Yellow - Static Oil 1
10
Fig. 4 - Body Hoist System Schematic - Body Control Valve in the Float Position
COMPONENTS
1 - Body and Disc Brake
Cooling Tank 6
8 B
2 - Tandem Pump 14
3 - Body Control Valve TO OCDB
7
4 - Manifold Block COOLING
5 - Body Cylinder CIRCUIT
6 - Kick-over Valve
7 - Disc Brake Oil Filter
8 - Disc Brake Oil Cooler STEERING TEST D
9 - Remote Control Valve CIRCUIT
10 - Relief Valve
3
11 - Relief Valve TEST E
12 - Tank Breather 4
13 - Disc Brake Oil Temp Switch
14 - Pilot Supply Valve
COLOUR CODES
Red - Pressurized Oil
Blue - Exhaust or Return Oil
Green - Intake Oil 13 2 A
Orange - Pilot Pressure
12
Yellow - Static Oil
1
10
Fig. 5 - Body Hoist System Schematic - Body Control Valve in the 'Lower Position
Body System - Body System Schematic
Section 230-0000
7
Body System - Body System Schematic
Section 230-0000
* * * *
SM - 3743
40-41 35
36 13
4
3 13
3 14
9 1
7 22 21 15
8
4 13
39
2
5 18,19
17
6 9 2 16
7 20
8
10
5 26
24 25
26
6 11
9 22 25
7 26
8
38 15
13
29 37 34 13
5 30
23 33 14
6 32
28 34
31 23
9
7
8
27
5
6
1- Tank 11 - Bracket 21 -Rod 31 -Poppet
2 - Sight Glass 12 - Bracket 22 - Nut - wing 32 -Spring
3 - Cap 13 - Hardened Washer 23 - Drain valve 33 -Shim
4 - Gasket 14 - Bolt 24 -Rod bolt 34 -Seal
5 - Access Cover 15 - Nut 25 -Filter element 35 -Breather
6 - Plug 16 - Bolt 26 -Gasket 36 -Nipple
7 - Lockwasher 17 - Washer 27 - Screen assembly 37 -Plate
8 - Bolt 18 - Filter Assembly 28 -Lockwire 38 -Cap
9 - Gasket 19 - Filter Element 29 -Bypass valve 39 -Gasket
10 - Window Nut 20 - Suction Screen 30 -Valve
Fig. 1 - Exploded View of Body and Disc Brake Cooling Tank
DESCRIPTION OPERATION
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1, unless
otherwise specified. Refer to Fig. 2 for hydraulic
The Body and Disc Brake Cooling Tank can be schematic and Fig. 3 for port locations.
identified as item 1 in Section 230-0000, BODY
SYSTEM SCHEMATIC, in this manual. The body hoist oil flow is drawn from port 'B', through
suction screen (27), by the front section of the tandem
The hydraulic tank (1) is the common reservoir for the gear pump mounted off the engine power takeoff. Oil
body hoist system and oil cooled disc brakes (OCDB) is then pumped to the body control valve where,
cooling oil and is a partitioned from the Steering and depending on spool position, oil flows to the body hoist
Disc brake tank. It is mounted off the LH frame rail. circuit or, with spool in the float position, flows through
the manifold block at the rear of the control valve to
Integral with hydraulic tank (1) assembly are filter supplement the disc brake cooling oil.
elements (25) with bypass valve (29), suction screens
(27) and sight gauge (2). Access covers (5) give easy
access to replace filter elements (25) and clean
suction screens (27).
SM - 1685 SM - 3748
F
13
2
12
H A F E D C B
1
10
1 - Hydraulic Tank A
B
2 - Tandem Pump 12 - Breather C
10 - Relief Valve 13 - Oil Temperature Switch J D E
The disc brake cooling oil flow is drawn from port 'C', Port 'G' is plugged.
through suction screen (27), by the rear section of the
tandem gear pump. Oil is then pumped through the A breather installed in a tee at port 'H' is the common
manifold block at the rear of the body control valve to breather to both the body and disc brake cooling tank
the disc brake cooling circuit. and the steering and brake control tank. This allows
any air entering the tanks to be released to
Excess disc brake cooling oil at the manifold block, atmosphere, preventing a pressure build up in the tank
returns to tank at port 'A' and flows through pressure assemblies. See Fig. 4.
relief valve (30) to the tank body.
Port 'J' is plugged and provides a tank drain port.
Return oil from the body hoist circuit enters the tank at
port 'D' from the body control valve. The oil enters filter
element (25) chamber and flows through a centre tube
and filter elements (25) to the tank body, thus ensuring
return oil is filtered before entering the tank.
Return oil from the disc brake cooling circuit enters the
tank at port 'E'. A disc brake oil temperature switch
(13, Fig. 2) is installed in the return tube to indicate if
disc brake cooling oil is overheating. The oil
temperature switch sends a signal to illuminate the
warning light on the dash panel when a temperature of
121 C (250 F) is reached.
SM - 3747
4
5
1
6
2
3
1 - Breather 4 - Bushing
2 - Nipple 5 - Elbow
3 - Tee 6 - Breather Line
MAINTENANCE
Numbers in parentheses refer to Fig. 1, unless fully lowered, the oil level should show full in the sight
otherwise specified. gauge (2). Under all conditions sight gauge (2) should
show half full.
Note: Tighten all fasteners to torques listed in
Section 300-0080, STANDARD BOLT AND NUT If oil is required, remove filler cap (3) and fill hydraulic
TORQUE SPECIFICATIONS. tank (1) with hydraulic oil specified in Section 300-
0020, LUBRICATION SYSTEM, until oil shows in top
Checking Oil Level window nut (2). Fit filler cap (3).
Cold Check: With the engine off and the body fully
lowered, the sight gauge (2) should show half full.
Replacing Hydraulic Oil
Hydraulic tank (1) should be drained, cleaned, and
If oil is required, remove filler cap (3) and fill hydraulic hydraulic oil changed, at interval specified in Section
tank (1) with hydraulic oil specified in Section 300-0020, LUBRICATION SYSTEM. Use only
300-0020, LUBRICATION SYSTEM, until oil shows in hydraulic oil as specified in Section 300-0020,
sight gauge as half full (2). Fit filler cap (3). LUBRICATION SYSTEM.
Hot Check: Operate the body hoist cylinders to their Note: When oil in hydraulic tank (1) is being replaced
fully extended positions to charge both cylinders and due to overheated oil, hydraulic component failure, or
all hoist lines then lower the body. With the engine at recommended change interval, filter elements (25)
running, oil at normal operating temperature and body should be replaced.
WARNING
To prevent personal injury and property
damage, be sure wheel blocks are properly
secured and of adequate capacity to do the job
safely.
7. Install bypass valve (29) in plate (37) and secure 3. With suitable containers in position, remove drain
plate (37) assembly on rods (24) with wing nuts (22). plug (23) from hydraulic tank (1) and drain the oil.
Reinstall drain plug (23) in hydraulic tank (1) and
8. Install new gasket (29) and cover (5) on hydraulic tighten securely. Remove drain plug from steering and
tank (1) and secure with bolts (8) and lockwashers (7).
SM - 464
9. Fill hydraulic tank (1) and steering and brake control
tank to correct level with hydraulic oil as specified in
Section 300-0020, LUBRICATION SYSTEM. Install
filler cap (3).
10. Start the engine and raise and lower the body to
charge the system. Switch off the engine and check oil
level as described under 'Checking Oil Level'. Remove
wheel blocks.
Fig. 6 - Suction Screen Removal/Installation Tool
4. If required, remove inter-connecting hose assembly 14. Start the engine and raise and lower the body to
(3, Fig. 5) from access cover (5). Fit blanking cap and charge the system. Switch off the engine and check oil
plug to hydraulic line and tank port. Remove bolts (8), level as described under 'Checking Oil Level'. Remove
lockwashers (7), access cover (5) and gasket (9) from wheel blocks.
hydraulic tank (1). Discard gasket (9).
WARNING
Splashing liquid. Wear a suitable face shield WARNING
when using compressed air to dry tank and To prevent personal injury and property
components. damage, be sure wheel blocks are properly
secured and of adequate capacity to do the job
8. Clean suction screens (27) and hydraulic tank (1) safely.
with paraffin and dry with compressed air. Inspect for
damage and renew if necessary. 1. Position the vehicle in a level work area, be sure the
body is fully lowered, apply the parking brake and
9. Assemble relief valve (30) in reverse order to switch off the engine.
disassembly. Thoroughly clean and dry threads on
relief valve (30) and tank port and apply Loctite 2. Block all road wheels.
Activator 'T' to threads. Apply Loctite 242 to threads of
relief valve (30) and install relief valve assembly in 3. With suitable containers in position, remove drain
hydraulic tank (1). plug (23) from hydraulic tank (1) and drain the oil.
Reinstall drain plug (23) in hydraulic tank (1) and
10. Insert lockwire (28) in suction screens (27) and tighten securely. Remove drain plug from steering and
install suction screens in hydraulic tank (1). Secure brake control tank and drain the oil. Refer to Section
suction screens (22) in hydraulic tank (1) using a 220-0040, STEERING AND BRAKE CONTROL
suitable tool, as shown in Fig. 6. TANK. Reinstall drain plug in hydraulic tank and
tighten securely.
11. Join ends of lockwire (28) and secure suction
screens (27) together with lockwire (28). 4. Ensure all hydraulic lines connected to hydraulic
tank (1) assembly are identified for ease of installation
Note: Do not grip the body of suction screens (27). and, with suitable containers available to catch
Use a suitable tool, as shown in Fig. 6, to grip the leakage, disconnect all hydraulic lines. Fit blanking
hexagon head at the neck of each suction screen. caps and plugs to all hydraulic lines and tank ports.
12. Install new gasket (9) and access cover (5) on 5. Disconnect breather line (6, Fig. 4) from elbow
hydraulic tank (1) and secure with bolts (8) and (5, Fig. 4). Fit blanking caps to line.
lockwashers (7).
Disassembly 3. If removed, install tee (3, Fig. 4), bushing (4, Fig. 4),
Numbers in parentheses refer to Fig. 4, unless elbow (5, Fig. 4), nipple (2, Fig. 4) and breather (1, Fig. 4)
otherwise specified. on hydraulic tank (1).
WARNING
WARNING To prevent personal injury and property
Splashing liquid. Wear a suitable face shield damage, be sure wheel blocks, blocking
when using compressed air to dry tank and materials and lifting equipment are properly
components. secured and of adequate capacity to do the job
safely.
1. Clean hydraulic tank (1) and components with
paraffin and dry with compressed air. 1. Using suitable lifting equipment, position hydraulic
tank (1) assembly on mounting brackets (11) and
2. Inspect tank for weld cracks and security of internal secure with bolts (14), hardened washers (13) and
pipes and weld fitments. nuts (15).
3. Check suction screens (27) for damage and renew 2. Remove blanking cap from breather line (6, Fig. 4)
if required. and connect breather line to elbow (5, Fig. 4). Tighten
breather line securely.
4. Check pressure relief valve (30) assembly is free of
contaminants and that poppet (31) is free. 3. Remove blanking caps and plugs and install all lines
to hydraulic tank (1) , as tagged at removal.
* * * *
SM - 373
* Shown on Fig. 6.
Fig. 1 - Cutaway View of Tandem Pump
DESCRIPTION OPERATION
Numbers in parentheses refer to Figs. 1 & 6. Numbers in parentheses refer to Figs. 1 & 6. Refer to
Fig. 2 for the operation of a typical gear type
The Tandem Pump can be identified as item 2 in hydraulic pump. Refer to Fig. 3 for hydraulic
Section 230-0000, BODY SYSTEM SCHEMATIC, in schematic of the tandem pump operation.
this manual.
As the drive gear rotates, the driven gear rotates in
The tandem gear pump, mounted off the engine the opposite direction. The pockets between the gear
power takeoff, supplies hydraulic oil for operating the teeth carry oil from the inlet port around the gear
body and cooling the rear disc brake assemblies. housing ID to the pump outlet port. As the gear teeth
re-mesh, this oil is forced out of the outlet port of the
This is a multiple gear type pump consisting of two gear housing. The maximum oil delivery rate of each
separate sections connected together as one section of the tandem pump is fixed by the width of
assembly. The front section consists of driveshaft & its respective gear set and the speed at which
gear (12), driven gear (13) and gear housing (15). driveshaft (12) is turned.
Drive gear (20), driven gear (21) and gear housing
(22) make up the rear section. Connecting shaft (17) The front section of the tandem pump draws oil from
connects the rear section to driveshaft and gear (12). the body and disc brake cooling tank, then pumps the
SM 1213 2-98 1
Body System - Tandem Pump
Section 230-0050
SM - 338 SM - 575
DRIVE GEAR TO BODY
TO BRAKE CONTROL VALVE
COOLING
CIRCUIT
INLET OUTLET
Fig. 2 - Typical Pump Operation Fig. 3 - Hydraulic Schematic of Tandem Pump Operation
WARNING
To prevent personal injury and property
damage, make sure blocking or lifting
equipment is of adequate capacity and
properly secured to do the job safely.
2 SM 1213 2-98
Body System - Tandem Pump
Section 230-0050
SM - 374
21 - Driven Gear
22 - Gear Housing
23 - End Cover
13 - Driven Gear 24 - Name Plate
14 - Seals 25 - Drive Screws
1 - Snap Ring 7 - Plug 15 - Gear Housing 26 - Washers
2 - Spacer 8 - Ring Seals 16 - Seals 27 - Studs
3 - Seal Retainer 9 - Bearings 17 - Connecting Shaft 28 - Nuts
4 - O Ring 10 - Pocket Seals 18 - Bearing Carrier 29 - Pins (if used)
5 - Seal 11 - Thrust Plates 19 - Plug 30 - Seals (if used)
6 - Shaft End Cover 12 - Driveshaft & Gear 20 - Drive Gear 31 - Anti-Vibration Rings
SM 1213 2-98 3
Body System - Tandem Pump
Section 230-0050
3. Tap end cover (23) with a soft hammer and SM - 344
separate from gear housing (22). If end cover (23)
must be pried off, use care to avoid damaging
machined surfaces of the cover and housing. See
Fig. 7. If thrust plate (11) stays with gear housing
(22), it can be tapped out later. Do not damage or
distort the thrust plate.
SM - 341 SM - 346
SM - 342 SM - 347
4 SM 1213 2-98
Body System - Tandem Pump
Section 230-0050
SM - 348 8. Separate and lift off gear housing (15) with care.
See Fig. 12. Remove thrust plate (11) as in Step 4.
10. Pry thrust plate (11) from shaft end cover (6)
carefully to avoid distortion. See Fig. 14.
11. Clamp shaft end cover (6) in vice, mounting face up.
Fig. 13 - Removing Driveshaft Remove snap ring (1) with snap ring pliers. See Fig. 15.
12. Pull spacer (2) from shaft end cover (6) with a
SM - 349
bearing puller. See Fig. 16.
13. Remove seal retainer (3) and seal (5) from shaft
end cover (6). See Fig. 17. The seal retainer removal
tool shown in Fig. 37 can be easily made for this
purpose. Remove and discard 'O' ring (4).
14. Tap seal (5) from seal retainer (3). See Fig. 18.
The tool shown in Fig. 37 can be fashioned to
separate these parts.
Fig. 14 - Removing Thrust Plate 15. If necessary, remove bearings (9) and ring seals
(8) from shaft end cover (6), bearing carrier (18) and
SM - 350 SM - 352
SM - 351 SM - 353
SM 1213 2-98 5
Body System - Tandem Pump
Section 230-0050
Fig. 20 - Removing and Installing Seals Thrust plate side wear permits oil to bypass gears
and allows internal oil slippage and reduced pump
efficiency. Check thrust plate surface wear against
end cover (23). See Figs. 19 & 20.
the size of new thrust plates. If worn more than 0.05
mm (0.002 in), replace the thrust plates.
16. Remove and discard all seals (30), if used, and
pocket seals (10) from thrust plates (11), and seals
8. Bearings (9) should fit into their bores with a light
(14 & 16) from gear housings (15 & 22).
press fit. A tight hand fit is allowable. If the bearings
can fall out of their bores, the bores might be distorted
17. Remove plug (7) only if damaged.
or oversize. When gears are replaced, their bearings
must also be replaced.
18. Remove anti-vibration rings (31) from bearing
carrier (18) only if damaged.
9. Check driveshaft and gear (12) for wear or damage
to splines, and seal areas. Replace the driveshaft and
INSPECTION driven gear matched set if wear is detectable by touch
or measures in excess of 0.05 mm (0.002 in) at the
Numbers in parentheses refer to Figs. 1 & 6.
seal or drive areas. Excessive spline wear requires
driveshaft and matching gear replacement.
1. Clean all parts in suitable solvent and dry all but
bearings with compressed air.
SM - 356
6 SM 1213 2-98
Body System - Tandem Pump
Section 230-0050
ASSEMBLY
Numbers in parentheses refer to Figs. 1 & 6.
SM 1213 2-98 7
Body System - Tandem Pump
Section 230-0050
7. With shaft end cover (6) clamped in a soft-jawed SM - 362
vice, insert driveshaft and gear (12) into the shaft end
cover bore and push down until the gear is snug
against thrust plate (11). Install matched driven gear
(13) hub into its bearing (9) so that the three teeth
marked at 'Disassembly' will mesh. See Fig. 26.
8. Coat new seals (14 & 16) with grease and insert
them into their grooves in both sides of gear housings
(15 & 22). See Fig. 27.
9. Slide gear housing (15) over gears (12 & 13) and,
with match marks made at 'Disassembly' aligned, tap Fig. 27 - Installing Seals
gear housing (15) with a soft hammer until it rests
snugly against shaft end cover (6). See Fig. 28. If a SM - 363
new gear housing is used, make sure the large oil
port will be toward the inlet, and the small port toward
the outlet side of the pump assembly. Be sure seal
(14) is not pinched or dislodged. Coat gears (12 & 13)
with hydraulic fluid for initial lubrication when the
pump is started.
13. Slide gear housing (22) over gears (20 & 21) and,
Fig. 29 - Installing Bearing Carrier
with match marks made at 'Disassembly' aligned, tap
SM - 361 SM - 365
8 SM 1213 2-98
Body System - Tandem Pump
Section 230-0050
SM - 367
15. Insert eight studs (27) through the pump assembly
and thread into shaft end cover (6). Install washers
(26) and nuts (28). Tighten opposite nuts alternately
until snug. See Fig. 33. Rotate driveshaft (12) with a
150 mm (6 in) wrench and check carefully for pump
binding. If the pump rotates freely, torque tighten
alternate nuts (28) to 271 Nm (200 lbf ft). If the pump
binds, the cause should be determined and corrected
before completing the assembly. Check for burrs on
shafts, housings, bearings, etc., or similar causes.
18. Coat a new 'O' ring (4) with grease and install on
seal retainer (3). Oil a seal installation sleeve and
twist into the seal ID carefully. Slide the sleeve and
seal over driveshaft (12) and seat seal (5) and seal
retainer (3) assembly firmly in shaft end cover (6)
bore. Remove seal installation sleeve. See Fig. 35.
Fig. 33 - Installing Stud Nuts
19. Insert spacer (2) over driveshaft (12) and install
SM - 369 SM - 370
SM 1213 2-98 9
Body System - Tandem Pump
Section 230-0050
SM - 371 4. Fill body and disc brake cooling tank to the proper
level. Refer to Section 230-0040, BODY AND DISC
BRAKE COOLING TANK. Refer to Section 300-0020,
LUBRICATION SYSTEM, for correct oil
specifications.
into shaft end cover (6) against seal retainer (3). See 6. Check pump mounting and line connections for leaks.
Fig. 36.
20. Install snap ring (1) in shaft end cover (6) snap LUBRICATION
ring groove. 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,
INSTALLATION AND RUN-IN the oil should be drained, the entire system flushed,
Note: Tighten all fasteners to standard torques listed oil filters replaced, oil screens thoroughly cleaned
in Section 300-0080, STANDARD BOLT AND NUT and fresh hydraulic oil installed to eliminate all metal
TORQUE SPECIFICATIONS. particles or foreign matter.
Note: Tighten all hydraulic lines fitted with ORFS Refer to Section 300-0020, LUBRICATION SYSTEM,
connections, as described in Section 230-0000, for recommended periodic oil drain periods and oil
BODY SYSTEM SCHEMATIC. Renew all 'O' rings specifications.
where used.
SPECIAL TOOLS
WARNING The special tools shown in use in Figs. 17 & 18 can
To prevent personal injury and property be fabricated as shown in Fig. 37.
damage, make sure blocking or lifting
equipment is of adequate capacity and SM - 372
properly secured to do the job safely.
TORQUE
FIG. NO. ITEM NO. NAME Nm lbf ft
1&6 33
28 Nut 271 200
* * * *
10 SM 1213 2-98
BODY SYSTEM - Body Control Valve
Section 230-0060
SM - 3236
34 TO PRESSURE
32
PILOT PRESSURE CHECK POINT
FROM BODY 31 35
CONTROL JOYSTICK FROM
(LOWER) PUMP
36
PRESSURE 15
SWITCH TO KICK-OVER
VALVE 17 16 30
TO BODY
33 37
29 RAISE
14 18
13 20 PORTS
12 11
21
19
38
PILOT PRESSURE
C 22 FROM BODY
H
F
CONTROL JOYSTICK
10 9 8 7 6 (RAISE)
A G B 41
23 24
D
25
2 3 26
5 4
1
J 27
28
E
TO TANK
39
40
1 - Valve Body
2 - Spool 13 - End Cap TO MANIFOLD
3 - Seal 14 - Bolt
4 - 'O' Ring 15 - Plug 24 - 'O' Ring 33 - Elbow
5 - Retainer 16 - Plug 25 - End Cap 34 - Elbow
6 - 'O' Ring 17 - 'O' Ring 26 - Bolt 35 - Reducer
7 - Retainer - Outer Spring 18 - Relief Valve 27 - 'O' Ring 36 - 'O' Ring
8 - Retainer - Inner Spring 19 - Spring 28 - Adaptor 37 - Plug
9 - Inner Spring 20 - 'O' Ring 29 - 'O' Ring 38 - 'O' Ring
10 - Outer Spring 21 - Spring 30 - Plug 39 - Adaptor
11 - Retainer 22 - Poppet 31 - 'O' Ring 40 - 'O' Ring
12 - Spool Extension 23 - Seal 32 - Adaptor 41 - Elbow
Fig. 1 - Exploded View of Body Control Valve
SM - 2271
Relief valve (18) assembly, installed in port 'F', opens
and allows oil to flow back to the body and disc brake
LOWER RAISE CONTROL
cooling tank when pressure in the hydraulic system CIRCUIT CIRCUIT JOYSTICK
exceeds 190 bar (2 750 lbf/in2). TO HPCO &
MAN. BLOCK
Spool (2) blocks the flow of oil to and from the body Fig. 3 - Body Control Valve - 'Raise' Position
hoist cylinders, holding the cylinder pistons in place.
SM - 2273
SUPPLY
Return oil from the body hoist cylinders enters control FROM PUMP
valve body (1) at port 'A', via the kick-over valve, flows
through the passage opened by spool (2) and exits at
Fig. 4 - Body Control Valve - 'Lower' Position
Body 'Lower' (Power Down) Position Relief valve (18) assembly, in port 'F' of valve body
Numbers and letters in parentheses refer to Fig. 1. (1), is set to relieve oil pressure in excess of 190 bar
Refer to Fig. 4 for hydraulic schematic of the body (2 750 lbf/in2). Should oil pressure at inlet port 'C'
control valve operating in the 'Lower' position. exceed 190 bar (2 750 lbf/in2), relief valve (18) will
open and oil will flow through an internal passage in
Moving the hydraulic control joystick to the 'LOWER' valve body (1) and exit at port 'J' to the OCDB
position moves spool (2) position within valve body (1). manifold block. When excess oil pressure is relieved,
Hydraulic oil enters control valve body (1) at port 'C'. relief valve (18) will re-seat allowing normal oil flow
Oil pressure opens poppet (22) and oil flows through through the body control valve.
the passage opened by spool (2) and exits at port 'A'
to the kick-over valve. REMOVAL
Oil travels through the kick-over valve, to the 'Lower' Numbers in parentheses refer to Fig. 6, unless
ports on the body hoist cylinders. Refer to Section otherwise specified.
230-0090, KICK-OVER VALVE, for oil flow through the
kick-over valve.
WARNING
Return oil from the body hoist cylinders enters control Hydraulic fluid pressure will remain within the
valve body at port 'B', flows through the passage system after engine shut down. Operate the
opened by spool (2) and exits at port 'D' to the body body control joystick in both directions
and disc brake cooling tank. approximately 15 times to ensure the pressure
has dissipated from the pilot supply valve
accumulator before carrying out any work on
Body 'Float' Position the body control system or serious injury
Numbers and letters in parentheses refer to Fig. 1. could result.
Refer to Fig. 5 for hydraulic schematic of the body
control valve operating in the 'Float' position. WARNING
To prevent personal injury and property
Note: The control joystick should be kept in the 'Float' damage, be sure wheel blocks and lifting
position at all times, except when raising or lowering equipment are properly secured and of
the body. adequate capacity to do the job safely.
SM - 1821
9 7,10
1
11
8,10
3,4,5
6
8,10
6
2
8,10
13 12
14
15
16 2
16 3,4,5
1. Position the vehicle in a level work place, raise the 6. Support body control valve (1), mounting plate (2),
body and secure in place with the body safety pins. blocks (6 & 13) and manifold block (15) assembly with
Apply the parking brake, switch off the engine. a suitable lifting device and remove nuts (5), bolts (3)
and hardened washers (4). Remove assembly from
2. Operate steering left and right several times to mounting bracket and move clear of the vehicle.
discharge the steering accumulator. Block all road
wheels. 7. Remove bolts (16) securing manifold block (15) and
block (12) to block (6). Remove manifold block (15)
3. Remove drain plug from body and disc brake and block (12). Discard 'O' rings (12 & 14).
cooling tank and drain oil into a suitable container.
Reinstall drain plug in the tank and secure. 8. Remove bolts (7 & 8) and nuts (10) securing body
control valve (1) and block (6) to mounting plate (2).
4. Clean body control valve (1) and surrounding area Remove mounting plate (2).
with a suitable solvent. Identify and tag all hydraulic
lines connected to body control valve (1) and manifold 9. Remove bolt (9) securing block (6) to body control
block (15), to aid in 'Installation'. valve (1). Remove block (6).
5. With suitable containers available to catch spillage, 10. Remove and discard 'O' ring (11) from body
disconnect all hydraulic lines from body control valve control valve (1).
(1) and manifold block (15). Cap all hydraulic lines and
ports to prevent ingress of dirt.
2. Unscrew spool extension (12) and remove retainer Note: If a new check valve poppet (22) or relief valve
(11), outer spring (10) and inner spring (9) from valve (18) is used, the respective seat should be lapped to
spool (2). conform to the new part.
6. Remove bolts (26), end cap (25), seal (23) and 'O' Valve Body
ring (24) from valve body (1). Discard 'O' ring (24). If 1. If removed, install new 'O' rings on adaptors (30 &
required, remove elbow (41) from end cap (25). 39) and elbow (37) and secure in ports 'D', 'B' and 'A' of
valve body (1) respectively.
15335735
* * * *
SM - 1795
2
3
1
5
6
8
7
9
10
8
9
7 - Mounting Bracket
1 - Body Control Joystick 4 - Connector 8 - Screw
2 - Bolt 5 - Elbow 9 - Lockwasher
3 - Lockwasher 6 - Elbow 10 - Cover Plate
DESCRIPTION SM - 1798
OPERATION
The body control joystick controls the hydraulic valve 1 2
which operates the body hoist cylinders. The four
Fig. 2 - Body Control Joystick Schematic Symbol
SM 1597 12-98 1
Body System - Body Control Joystick
Section 230-0081
operating positions of the joystick from front to rear are 2. Operate the body control joystick (1) continuously to
as follows: discharge the pilot valve accumulator. Block all road
wheels.
'LOWER' - This position provides hydraulic force to
power-down the body. It is needed when the body
3. Remove screws (8) and lockwashers (9) securing
cannot be started downward from the fully raised
cover plate (10) to mounting bracket (7) on the
position by gravity. When the body starts lowering by
operator's seat. Remove cover plate (10).
gravity, the joystick should be moved to the 'FLOAT'
position.
4. Ensure all hydraulic lines connected to body control
'FLOAT' - The joystick should be moved to this joystick (1) are identified for ease of installation and, with
position while the body is lowering by gravity and suitable containers available to catch leakage, disconnect
should remain in this position until the body must be hydraulic lines. Fit blanking caps to all open lines.
operated again. The control joystick should always be
kept in 'FLOAT' while the machine is in motion. 5. Remove bolts (2) and lockwashers (3) securing
'HOLD' - Moving the joystick to this position while the body control joystick (1) to mounting bracket (7).
body is being raised or lowered traps the oil in the Remove body control joystick (1).
body hoists to stop and hold the body at any desired
height. The joystick will remain in the detented 'HOLD' 6. Note location of elbows (5 & 6) and connector (4)
position when released. and remove from body control joystick (1) for use on
the new joystick.
'RAISE' - This position directs oil to extend the body
hoists and raise the body. When released, the joystick 7. Install elbows (5 & 6) and connector (4) in new body
will be spring-returned to the 'HOLD' position. control joystick (1) ports as removed from the old joystick.
REMOVAL AND INSTALLATION 8. Secure body control joystick (1) to mounting bracket
Numbers in parentheses refer to Fig. 1. (7) on the operator's seat with bolts (2) and
lockwashers (3).
Note: Tighten all fasteners to standard torques listed
in Section 300-0080, STANDARD BOLT AND NUT 9. Remove blanking caps from hydraulic lines and
TORQUE SPECIFICATIONS. install lines to body control joystick (1) as identified
during removal.
Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 230-0000, BODY 10. Check oil level in the body and disc brake cooling
SYSTEM SCHEMATIC. Renew all 'O' rings where used. tank and add oil if required. Refer to Section 230-0040,
BODY AND DISC BRAKE COOLING TANK for correct
fill level, and, Section 300-0020, LUBRICATION
WARNINGS SYSTEM for oil specification.
Hydraulic fluid pressure will remain within the
system after engine shut down. Operate the 11. Remove wheel blocks, start the engine and bring
body control joystick in both directions hydraulic oil to operating temperature. Operate body
approximately 15 times to ensure the pressure control joystick (1) and check hydraulic line
has dissipated from the pilot supply valve connections for leaks and tighten as required.
accumulator before carrying out any work on
the body control system or serious injury MAINTENANCE
could result. Limited repair of the body control joystick is by
replacement of parts only. Refer to vehicle Parts Book
To prevent personal injury and property for part numbers of kits.
damage, be sure wheel blocks are properly
secured and of adequate capacity to do the job SPECIAL TOOLS
safely.
There are no special tools required for procedures
1. Position the vehicle in a level work area, be sure the outlined in this section. Refer to Section 300-0020,
body is fully lowered, apply the parking brake and SERVICE TOOLS, for part numbers of general service
switch off the engine. tools required. These tools are available from your
dealer.
* * * *
2 SM 1597 12-98
BODY SYSTEM - Kick-over Valve
Section 230-0090
SM - 585
13 - Spring 20 - Screw
1 - Plug 7 - Backup Rings 14 - Spring 21 - Guide
2 - 'O' Ring 8 - 'O' Ring 15 - Spring End 22 - 'O' Ring
3 - 'O' Ring 9 - Spool Seat 16 - 'O' Ring 23 - Spring
4 - Pin Assembly 10 - 'O' Ring 17 - Gasket 24 - Poppet
5 - Valve Body 11 - Backup Ring 18 - Plug 25 - Connector
6 - Plug 12 - Relief Spool 19 - Nut 26 - Cap
SM - 583 SM - 584
Fig. 2 - Kick-over Valve Operating in Body 'Raise' Position Fig. 3 - Kick-over Valve Operating in Body 'Lower' Position
internal porting, and return oil is free to pass around block all road wheels.
relief spool (12), through a passage in the kick-over
valve, to exit at port 'V', and return to tank via the body 2. Clean kick-over valve housing with a suitable
control valve. solvent and tag hydraulic lines to aid in 'Installation'.
Refer to Fig. 3. When the body control valve is used to 3. Disconnect all hydraulic lines from kick-over valve
lower the body, oil is directed to port 'V' of the kick-over and drain oil into a suitable container. Cap all lines and
valve. Oil pressure forces poppet (24) off its seat, oil plug kick-over valve ports to prevent ingress of dirt.
exits at port 'C', and flows to the body cylinders to
power down the body. Return oil from the raise port on 4. Remove mounting hardware securing kick-over valve
the body cylinders returns to tank via the body control to mounting bracket. Move kick-over valve to a clean
valve. work area for 'Disassembly'.
1. Make sure body is completely lowered, or, raise 4. Remove screw (20) and nut (19) from plug (18).
body and secure in place with the body safety pins.
Apply the parking brake, switch off the engine and 5. Remove plug (18) from valve body (5).
INSTALLATION
6. Remove gasket (17), spring end (15), 'O' ring (16), Numbers in parentheses refer to Fig. 1.
springs (13 & 14), relief spool (12), backup ring (11)
and 'O' ring (10) from plug (18). Remove spool seat (9), Note: Tighten all fasteners to standard torques listed in
backup rings (7) and 'O' ring (8) from valve body (5). Section 300-0080, STANDARD BOLT AND NUT
Discard backup rings (7 & 11) and 'O' rings (8, 10 & 16). TORQUE SPECIFICATIONS.
3. Inspect all parts for ridges, nicks, burrs or scoring 4. Check the system relief pressure in accordance with
which may cause leakage. Replace parts if worn or the procedure detailed in 230-0060, BODY CONTROL
damaged. VALVE. Adjust the system relief pressure relief valve if
necessary.
ASSEMBLY 5. Remove the pilot line from port P (1) and fit a
Numbers in parentheses refer to Fig. 1. blanking plug to avoid the ingress of contaminants.
1. Install new 'O' ring (8), and new backup rings (7) on 6. Remove the blanking cap at port G (26) and fit a
spool seat (9). Install spool seat in valve body (5). pressure gauge capable of reading 250 bar
Install new 'O' ring (10) and new backup ring (11) on (approximately 3 625 lbf/in2).
relief spool (12). Install relief spool (12) assembly in
valve body (5). 7. Screw in the adjustment screw on the relief valve
cartridge of the kick-over valve (20) 3 or 4 turns, or
2. Install new 'O' ring (16) on spring end (15) and install until it reaches the end of its adjustment.
in plug (18). Install springs (13 & 14) in plug (18) and
install plug (18) in valve body (5). 8. Check the secondary relief pressure at maximum
rev/min, and with the body cylinders extending through
3. Install nut (19) and screw (20) in plug (18). second stage. Adjust the secondary relief valve until
the secondary relief pressure setting is 207 bar (3 000
4. Install poppet (24) in valve body (5). Install spring lbf/in2).
(23) and new 'O' ring (22) in guide (21). Align with
poppet (24) and install guide (21) assembly in valve Note: Make any adjustments while raising the body.
body (5). If removed, install connector (25) and cap
(26) in guide (21). 9. Slacken back the relief valve cartridge of the kick-
over valve (20) with the body cylinders extending
5. Install plug (6) in valve body (5). through second stage and pilot line removed. Adjust
the kick-over valve relief cartridge until the pressure
6. Install new 'O' ring (3) on pin assembly (4) and install setting is 172 bar (2 500 lbf/in2). This is the kick-over
in valve body (5). Install new 'O' ring (2) on valve set pressure.
plug (1) and install into valve body (5).
10. Remove pressure gauge from port 'G' and install 13. Refit the hose removed in step 12 to the tee piece.
cap (26) on connector (25).
14. Check the level of oil in the body and disc brake
cooling tank. Refer to Section 230-0040, BODY AND
WARNING DISC BRAKE COOLING TANK. Add oil if low. Use oils
Ensure that pressure in the circuit has meeting specifications outlined in Section
dissipated prior to removing the pressure 300-0020, LUBRICATION SYSTEM.
gauge in order to prevent injury.
MAINTENANCE
11. Remove the plug from the pilot line and refit it to Inspect the kick-over valve regularly for any signs of
port P (1). leaks or damage. When carrying out pressure checks
on the truck, check kick-over pressure as described in
12. Undo one of the cylinder hose connections on the 'Installation'.
tee piece that the pilot line connects to. Check that the
tee piece has an internal orifice of the correct diaimeter
for this model of truck. TR45 series trucks have an
orifice with a diameter of 9.5 mm (0.38"). TR60 series
trucks have an orifice with a diameter of 14.224 mm
(0.56").
* * * *
SM - 1803
TO TANK
KICK-OVER VALVE
12 1
13
8
9
11
7
10
5
2
4
1 - Relief Valve 3
2 - Cartridge Assy 6 - Backup Ring 10 - Plug
3 - Cap 7 - 'O' ring 11 - 'O' ring
4 - 'O' ring 8 - Tee Piece 12 - Adaptor
5 - 'O' ring 9 - 'O' ring 13 - 'O' ring
DESCRIPTION SM - 1804
REMOVAL ASSEMBLY
Numbers in parentheses refer to Fig. 1.
WARNING 1. Install new 'O' rings (5 &7), new backup rings (6) on
To prevent personal injury and property cartridge assembly (2). If removed, install new
damage, be sure wheel blocks are properly 'O' ring (4) and cap (3) on cartridge assembly (2).
secured and of adequate capacity to do the job
safely. 2. Install cartridge assembly (2) in valve body (1).
1. Raise body and secure in place with the body safety 3. Install new 'O' ring (13) on adaptor (12). Install
pins. Apply the parking brake, switch off the engine adaptor (12) in valve body (1).
and block all road wheels.
4. Install new 'O' ring (9) on tee piece (8).Install tee
2. Clean relief valve housing with a suitable solvent piece (8) in valve body (1).
and tag hydraulic lines to aid in 'Installation'.
5. Install new 'O' ring (11) on plug (10).Install plug (10)
3. Support relief valve and disconnect all hydraulic in valve body (1).
lines and drain oil into a suitable container. Cap all
lines and plug relief valve ports to prevent ingress of
dirt. INSTALLATION
Numbers in parentheses refer to Fig. 1.
4. Move relief valve to a clean work area for
'Disassembly'. Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 230-0000, BODY
DISASSEMBLY SYSTEM SCHEMATIC. Renew all 'O' rings where used.
Numbers in parentheses refer to Fig 1.
1. Position relief valve and connect hydraulic lines as
marked at 'Removal'.
1. Remove plug (10) from valve body (1). Remove and
discard 'O' ring (11) from plug (10).
2. Remove body safety pins, operate body and check
relief valve and hydraulic lines for leaks.
2. Remove tee piece (8) from valve body (1). Remove
and discard 'O' ring (9) from tee piece (8).
3. Check the system relief pressure in accordance with
the procedure detailed in 230-0060, BODY CONTROL
3. Remove adaptor (12) from valve body (1). Remove VALVE. Adjust the system relief pressure relief valve if
and discard 'O' ring (13) from adaptor (12). necessary.
4. Remove cartridge assembly (2) from valve body (1). 4. Remove the pilot line from port P of the kick-over
Remove 'O' rings (5 & 7) and backup rings (6) from valve and fit a blanking plug to avoid the ingress of
cartridge assembly (2). Discard 'O' rings (5 &7). If contaminants.
required, remove cap (3) and 'O' ring (4) from cartridge
assembly (2).
5. Remove the blanking cap at port G of the kick-over
valve and fit a pressure gauge capable of reading 250
INSPECTION bar (approximately 3 625 lbf/in2).
Numbers in parentheses refer to Fig. 1.
6. Screw in the adjustment screw on the relief valve
cartridge of the kick-over valve (20) 3 or 4 turns, or
1. Clean all metal parts thoroughly in suitable solvent
until it reaches the end of its adjustment.
and dry with compressed air. Inspect valve body (1)
bores, plug (10), adaptor (12) and cartridge assembly
7. Check the secondary relief pressure at maximum
(2) for grooves, deep scratches or excessive wear.
rev/min, and with the body cylinders extending through
second stage. Adjust the secondary relief valve until
2. Inspect all parts for ridges, nicks, burrs or scoring
the secondary relief pressure setting is 207 bar (3 000
which may cause leakage. Replace parts if worn or
lbf/in2).
damaged.
* * * *
SM - 1799
13 2 4,5 3
12
11
PV
6,7,8
TO MANIFOLD
BRACKET IN
T P2
CAB FLOOR 9
10
1
TO STEERING TO MANIFOLD
TANK BRAKE VALVE
9 - Elbow - 90
1 - Valve Body 5 - Seal 10 - Tee Piece
2 - Accumulator 6 - Bolt 11 - Diagnostic Fitting
3 - Mounting Bracket 7 - Lockwasher 12 - Cap
4 - Plug 8 - Washer 13 - Elbow - 45
DESCRIPTION SM - 1800
SM 1599 12-98 1
Body System - Pilot Supply Valve
Section 230-0121
The pilot supply valve is a non-serviceable item and 4. Remove bolts (6), lockwashers (7), washers (8) and
should be replaced completely, if damaged, as follows: pilot supply valve (1) from mounting bracket (3).
Note: Tighten all fasteners to standard torques listed 5. Note location of elbows (9 & 13) and tee piece (10)
in Section 300-0080, STANDARD BOLT AND NUT and remove from pilot supply valve (1) for use on the
TORQUE SPECIFICATIONS. new valve. If necessary, disconnect diagnostic fitting
(11) and cap (12) from elbow (13).
Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 230-0000, BODY 6. Install elbows (9 & 13) and tee piece (10) in new
SYSTEM SCHEMATIC. Renew all 'O' rings where pilot supply valve (1) ports as removed from the old
used. valve. If necessary, install diagnostic fitting (11) and
cap (12) to elbow (13).
* * * *
2 SM 1599 12-98
BODY SYSTEM - Body Cylinder
Section 230-0130
SM - 178
BODY
MAIN FRAME
TORQUE TUBE
1 - Pins
2 - Washer
3 - Lockwasher
4 - Bolt
5 - Cylinder
6 - Lube Fitting
DESCRIPTION 1. Raise body and install body prop pins at rear of unit.
Numbers in parentheses refer to Fig. 1, unless Apply the parking brake, shut off the engine and chock
otherwise specified. all road wheels.
The body cylinders can be identified as item 5 in 2. Install a suitable strap around the cylinder and
Section 230-0000, BODY SYSTEM SCHEMATIC. attach to a lifting device.
There are two body hoist cylinders mounted between 3. Position oil pan beneath cylinder (5). Place body
the frame rails. Cylinder base ends (3, Fig. 2) are control valve lever in 'Float' position. Identify and
connected to the body and retractable ends (26, Fig. 2) remove the hydraulic lines. Cap lines to keep out dirt.
are connected to the frame. The cylinders are two-
stage with power down in the second stage. Cylinder 4. Remove bolt (4), lockwasher (3), washer (2) and
mounting is by pins (1) secured by washers (2), upper pin (1) from cylinder (5) connecting it to the
lockwashers (3) and bolts (4). body.
SM 1221 2-98 1
Body System - Body Cylinder
Section 230-0130
SM - 180
1 - Bolt 8 - Seal
2 - Bushing 9 - Wear Ring 15 - Seal 21 - Wear Ring
3 - Base 10 - Wiper 16 - Tube 22 - Wiper
4 - Backup Ring 11 - Wear Ring 17 - Bushing 23 - 'O' Ring
5 - 'O' Ring 12 - Piston Ring 18 - Nut 24 - Backup Ring
6 - Wear Ring 13 - Tube 19 - Tube 25 - Fitting
7 - Tube 14 - Set Screw 20 - Seal 26 - End
DISASSEMBLY 2. Remove and discard backup ring (4) and 'O' ring (5)
Numbers in parentheses refer to Fig. 2. from base (3).
2 SM 1221 2-98
Body System - Body Cylinder
Section 230-0130
3. Inspect the tubes, for broken welds or deep 8. Install end (26) assembly into tube (13) and tighten
grooves. Shine a light through components to inspect to a torque of 1 900 - 2 300 Nm (1 400 - 1 700 lbf ft).
for damage.
9. Install set screw (14) into tube (13).
4. Remove ridges, nicks and scratches with a fine
stone and clean. Replace any components which 10. Replace 'O' ring (5) and wiper (4) on base (3).
cannot be repaired.
11. Align base (3) and tube (19) as shown in Fig. 3.
5. Inspect all bolts and nuts for thread damage and
replace as necessary. 12. Secure base (3) to tube (19) with bolts (1) and
nuts (18). Tighten bolts (1) to a torque of 142 - 156 Nm
6. Inspect bushings and wear rings for excessive (105 - 115 lbf ft).
wear, and replace as necessary.
SM - 181
SM 1221 2-98 3
Body System - Body Cylinder
Section 230-0130
* * * *
4 SM 1221 2-98
BRAKING SYSTEM - Braking System Schematic
Section 250-0000
Monoblock Brake Valve (8) separate retarder selection switch on the dash panel.
Refer to Section 250-0100, MONOBLOCK BRAKE Pressing the switch at the top will select the OCDB
VALVE. retarder and pressing the bottom will select the
transmission retarder.
Mounted off the left hand frame rail, the monoblock
brake valve incorporates three valves; a pressure Note: The transmission retarder circuit is made up of
reducing valve, pressure relief valve and a shuttle valve. Directional Control Valve (11) and Transmission
Retarder Cylinder (12).
The pressure reducing valve reduces the available
hydraulic oil pressure from the rear brake accumulator
to a pressure of 83 bar (1 200 lbf/in2). Retarder Light Pressure Switch (18)
The retarder light pressure switch is a normally open
The pressure relief valve regulates pressure, after (NO) switch. As retarder pressure increases to 2.7 bar
pressure the reducing valve, to provide a residual (39 lbf/in) and above, the circuit should close and
pressure of 3.5 bar (50 lbf/in2) in the rear brake lines. A send a signal to illuminate the retarder indicator light in
filter system, comprising of a disc filter and a conical the dash panel, and the retarder light at the rear of the
filter, helps protect an orifice plate at the pressure truck. As pressure drops below 2.7 bar (39 lbf/in) the
relief valve. circuit should open and the retarder lights should go
out.
The shuttle valve, depending on spool position,
provides a residual pressure of 3.5 bar (50 lbf/in2) in
the rear brake lines, or, upon actuation of the treadle Pressure Reducing Valve (19)
or retarder valve, the brake actuation pressure Refer to Section 250-0110, PRESSURE REDUCING
overcomes the residual pressure to give a brake VALVE.
application at the rear brake packs.
Mounted on the inside of the left hand frame rail in
front of the body guide, the pressure reducing valve is
Directional Control Valve (9) located in the hydraulic brake circuit between the
Refer to Section 250-0090, DIRECTIONAL CONTROL treadle valve and the front brake callipers.
VALVE.
The pressure reducing valve, on application of the
The directional control valve is located in the 'Px' 50% brake reduction switch, mounted on the dash
hydraulic circuit between the brake manifold valve and panel in the cab, allows the operator to limit the
the treadle valve. The 'Px' circuit hydraulically actuates braking pressure to 50% at the front brakes.
the treadle valve when the park/emergency control
switch is activated. The directional control valve also
controls automatic service brake, applied pressure Pressure Test Points
bleed down, with engine shutdown. There are four diagnostic pressure test points in the
braking system, as shown in Figs. 2 through 7.
Retarder Control Valve (10) Note: When checking hydraulic pressures the vehicle
Refer to Section 250-0130, RETARDER CONTROL should be positioned on a level surface and all road
VALVE. wheels securely blocked.
Pressure should be 11.7 - 12.7 bar (170 - 180 lbf/in2) c. Where a hose is fitted, ensure that it is not twisted or
with the engine operating at 1 500 rev/min, output kinked when the nuts are tightened so that it is allowed
stalled, in all ranges and lockup. to adopt a natural position.
Pressure reading should be 159 bar (2 300 lbf/in2) with f. Check that a satisfactory hose or tube routing has
the engine running and the treadle valve applied. been achieved.
Test Point D
This test point is used to record the Rear Service RELIEVING PRESSURE
Brake Pressure, Residual Brake Pressure and the
Retarder Pressure - Taken from port 'TP2' on the
monoblock brake valve, these pressures can be WARNINGS
checked at diagnostic test point (front) mounted off The braking system is equipped with
rear mounting bracket for the body and disc brake accumulators which maintain pressure in the
cooling tank. Pressure readings should be as follows: system even after engine shutdown. Operate
the treadle valve continuously until the
Rear Service Brakes Pressure - 52 bar (750 lbf/in2), pressure has dissipated before carrying out
with the engine running and treadle valve applied. any work on the braking system or serious
injury could result.
Residual Brake Pressure - 3.5 bar (50 lbf/in2), with the
engine running and both the service brakes and the To prevent personal injury and property
parking brakes released. damage, be sure wheel blocks are properly
secured and of adequate capacity to do the job
Retarder Pressure - 33 bar (480 lbf/in2), with the safely.
engine running and the retarder control lever fully applied.
1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine.
'O' RING FACE SEALS (ORFS)
Where hydraulic lines are fitted with ORFS 2. Operate the treadle valve continuously to discharge
connections, the following procedure should be carried the brake accumulators (pressure in accumulator
out during installation. Refer to Fig. 1. hydraulic lines should be 0 bar (0 lbf/in2)). Block all
road wheels.
SM - 1335
FITTING NUT 3. Carefully loosen brake pipes at base of both the
front and rear accumulators to check that all pressure
TUBE
has been released. Tighten brake pipes.
SERVICE TOOLS
It is recommended that the following tools are used Non-contact Infrared Thermometer
when carrying out pressure or temperature checks The infrared thermometer can be used to spot heat
during maintenance procedures. These tools, along problems early in electrical, mechanical and hydraulic
with other general service tools, are available from systems. Hand held and easy to use, you simply aim, pull
your dealer. Refer to Section 300-0070, SERVICE the trigger, and read the temperature. Since there
TOOLS, for part numbers of these tools. 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.
7 7 C OUTLET
COMPONENTS 19
1 - Steering Pump
TEST
2 - Accumulators
Section 250-0000
7 7 C OUTLET
19
COMPONENTS
1 - Steering Pump TEST
* - Optional Components
A P1
PRESSURE TEST POINTS
A - Park Brake Pressure B T
B - Transmission Pressure 18
C - Front Service Brake Pressure 10 11 A B
D - Rear Service Brake Pressure,
Residual Brake Pressure and
T REG
Retarder Pressure. P
PY P T
COLOUR CODES P
ACC1
Red - Pressurized Oil
Blue - Exhaust or Return Oil ACC2
Green - Intake Oil PS1 PS2
Orange - Pilot Pressure
Yellow - Static Oil 15 14
7
8
SM - 2296C
COMPONENTS 7 7 C OUTLET
19
1 - Steering Pump
2 - Accumulators TEST
Section 250-0000
7 7 C OUTLET
COMPONENTS 19
1 - Steering Pump
2 - Accumulators TEST
9
10
SM - 2296E
7 7 C OUTLET
COMPONENTS 19
1 - Steering Pump
2 - Accumulators TEST
Section 250-0000
COMPONENTS 7 7 C OUTLET
1 - Steering Pump 19
2 - Accumulators
*
17 - Lockup Drop Out Pressure P1 P2
*
Switch
16 A
18 - Retarder Light Pressure Switch B1 B2 P1 P2
1
*
*19 - Pressure Reducing Valve 2 2
3 13 17 6
12
*
* - Optional Components
11
BRAKING SYSTEM - Brake Manifold Valve
Section 250-0050
SM - 1505
6 PY ACC1
P ACC2
7 5,18
PS1 P2
P1
8 1
PS2
9 T PS3
A 20
P
10
B
16
14
12
11
2
17
15 3
19
13
DESCRIPTION Hydraulic oil from the steering pump enters the brake
The brake manifold valve can be identified as item 3 in manifold valve at port 'P'. Oil pressure moves check
Section 250-0000, BRAKING SYSTEM SCHEMATIC. balls (9) from their seats (10) and allows oil to flow
through port 'ACC1' to the front brake accumulator
Mounted off the cab mounting crossmember, the and through port 'ACC2' to the rear brake accumulator.
brake manifold valve distributes hydraulic oil flow from
the steering pump, to the treadle valve, front and rear Pressurised oil exits the brake manifold valve through
brake circuit accumulators and parking brake at the port 'PY' and flows to port 'P1' on the treadle valve,
rear wheels. The valve also provides appropriate and, through port 'P1' on the brake manifold valve to
returns to the steering and brake control tank for the port 'P2' on the treadle valve.
hydraulic oil.
Solenoid Cartridge - De-energized
When the park/emergency brake switch is activated
OPERATION (pushed in), the electrical signal between the switch
Numbers in parentheses refer to Fig. 1. Refer to Figs. and solenoid coil (3) is opened, de-energizing solenoid
2 and 3 for hydraulic schematics. cartridge (2). Oil flows through solenoid cartridge (2)
and exits the brake manifold valve through port 'A' to
SM 1223 2-98 1
Braking System - Brake Manifold Valve
Section 250-0050
SM - 1660
16
PS3 3
TO DIRECTIONAL
A P1 TO PORT 'P2'
CONTROL VALVE
TREADLE VALVE
FROM MONOBLOCK
BRAKE VALVE B T
FROM
STEERING PUMP P
PY
TO PORT 'P1' TREADLE VALVE
ACC1
TO FRONT ACCUMULATOR
TO REAR ACCUMULATOR
ACC2
PS1 PS2
15 14
the directional control valve. The oil travels through the Pressure Switches
directional control valve and into the 'Px' port in the Accumulator pressure switches (19) in ports 'PS1' and
treadle valve for an emergency brake application. 'PS2' send a signal to illuminate warning lights in the
right hand dash panel when the pressure drops below
Return oil from the parking brake circuit flows through 131 bar (1 900 lbf/in).
the monoblock brake valve and enters the brake
manifold valve at port 'B'. The oil flows through Parking brake pressure switch (20) sends a signal to
solenoid cartridge (2) and exits the brake manifold illuminate the parking brake light in the right hand dash
valve at port 'T' to the steering and brake control tank. panel when the pressure in the parking brake circuit
With no pressure in the parking brake circuit to hold drops below 65 bar (940 lbf/in).
the parking brake off, the parking brake is applied.
Return oil from the 'Px' port on the treadle valve flows To prevent personal injury and property
through the directional control valve and into the brake damage, be sure wheel blocks are properly
manifold valve at port 'A'. The oil travels through secured and of adequate capacity to do the job
solenoid cartridge (2) and exits the brake manifold safely.
valve at port 'T' to the steering and brake control tank.
2 SM 1223 2-98
Braking System - Brake Manifold Valve
Section 250-0050
SM - 1661
16
PS3 3
FROM DIRECTIONAL A P1
CONTROL VALVE TO PORT 'P2'
TREADLE VALVE
TO MONOBLOCK
B T
BRAKE VALVE
FROM
P
STEERING PUMP
PY
TO PORT 'P1' TREADLE VALVE
ACC1
TO FRONT ACCUMULATOR
TO REAR ACCUMULATOR
ACC2
PS1 PS2
15 14
1. Position the vehicle in a level work area, apply the 2. Remove plug (5) from valve body (1) and discard 'O'
parking brake and switch off the engine. ring (18).
2. Operate the treadle valve continuously to discharge 3. Carefully remove valve body (1) assembly from the
the brake accumulators. Block all road wheels. vice and remove springs (8) and check balls (9) from
valve body (1).
3. Remove and tag electrical connections to solenoid
coil (3) and pressure switches (19 & 20). 4. If required, clamp valve body (1) lightly in soft jawed
vice and remove check ball seats (10).
4. Clean brake manifold valve assembly and
surrounding area with a suitable solvent. Ensure all 5. Rotate valve body (1) in vice until solenoid coil (3) is
hydraulic lines connected to the brake manifold valve facing up. Lightly clamp valve body (1) in vice and
are identified for ease of installation and, with suitable remove locknut (4) and solenoid coil (3) from solenoid
containers available to catch leakage, disconnect cartridge (2).
hydraulic lines. Fit blanking caps to all open lines.
6. Remove solenoid cartridge (2) assembly from valve
5. Release and remove mounting hardware securing body (1) and discard 'O' rings (11, 12, 14 & 16) and
brake manifold valve to the cab mounting backup rings (13, 15 & 17).
crossmember and remove assembly from the truck.
7. Mark valve body (1) port identification on each of
the pressure switches (19 & 20) and remove from
DISASSEMBLY valve body (1).
Numbers in parentheses refer to Fig. 1.
Note: It is important that the pressure switches are
1. Clamp valve body (1) lightly in a soft jawed vice, clearly identified as the pressure settings between
retainers (6) face up. Do not overtighten jaws. Remove pressure switches (19) and pressure switch (20) are
retainers (6) from valve body (1) and discard 'O' rings (7). different.
SM 1223 2-98 3
Braking System - Brake Manifold Valve
Section 250-0050
8. If required, note orientation and remove hydraulic SM - 1508
line connectors from ports in valve body (1).
6
ASSEMBLY
Numbers in parentheses refer to Fig. 1. 7
9
1. Install new 'O' rings (11, 12, 14 & 16) and backup 8 10
rings (13, 15 & 17) on solenoid cartridge (2) as shown
in Fig. 1.
7. Install pressure switches (19 & 20) in valve body (1) 5. Remove wheel blocks, start the engine and bring
as noted during disassembly. hydraulic oil to operating temperature.
8. If removed, install hydraulic line connectors in valve 6. Check brake manifold valve and hydraulic line
body (1) as noted during disassembly. connections for leaks and tighten as required.
1. Position brake manifold valve assembly to the cab 10. Remove body safety pins and lower the body to
mounting crossmember and secure with mounting the frame.
hardware.
4 SM 1223 2-98
Braking System - Brake Manifold Valve
Section 250-0050
* * * *
SM 1223 2-98 5
BRAKING SYSTEM - Accumulator
Section 250-0060
SM - 277
Piston (5) acts as a separator dividing cylinder (12) 2. Remove valve cap (1A) from charging valve (1)
into two sections. The section nearest charging valve (1) and loosen locknut (1D). Coat open end of charging
contains the nitrogen pre-charge. Hydraulic oil from valve with soapy water. Bubbles indicate leaky valve
SM 1600 12-98 1
Braking System - Accumulator
Section 250-0060
core (1B). Attempt to reseat the valve core by SM - 1273
depressing and releasing it quickly once or twice.
Recheck for leakage, if leakage continues then
discharge the accumulator as described under
'Discharging Nitrogen' in this section, then replace
the valve core. Torque tighten locknut (1D) to 11 Nm
(100 lbf in) and replace valve cap (1A) finger tight.
1. Position the vehicle in a level work area, apply the Nitrogen pressures at ambient temperatures of other
parking brake and switch off the engine. than 21o C (70o F).
2. Operate the treadle valve continuously to 7. Close accumulator valve (4) and open bleeder
discharge the brake accumulators. Block all road valve (10) to dissipate gauge pressure. Close bleeder
wheels. valve (10) after pressure is relieved. If accumulator
needs charged, leave line and chuck attached to
3. Check accumulator mountings to be sure the charging valve and charge the accumulator as
accumulator is held tightly in position. described under 'Charging The Accumulator'.
4. Remove cap (1A, Fig. 1) from accumulator 8. If precharge is 55 bar (800 lbf/in2) at 21o C (70o F),
charging valve (1, Fig. 1). Attach charging line (1) to rotate 'T' handle anticlockwise until it stops, then
charging valve by rotating 'T' handle of valve chuck torque tighten locknut (1D, Fig. 1) on charging valve
(2) anticlockwise until it stops. Screw the swivel nut (1, Fig. 1) to 11 Nm (100 lbf in). Loosen the swivel
down on the valve until it seats. Loosen charging nut and remove the gauging head.
valve locknut (1D, Fig. 1) by turning anticlockwise
one to two turns. 9. Install valve cap (1A, Fig. 1) on charging valve
(1, Fig. 1) and tighten finger tight.
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. CHARGING THE ACCUMULATOR
Numbers in parentheses refer to Fig. 2, unless
6. To read accumulator precharge pressure, slowly otherwise specified.
open accumulator valve (4). Pressure gauge (5) will
register pre-charge pressure, it should be 55 bar Either oil or water pumped nitrogen can be used to
(800 lbf/in2) at 21o C (70o F) ambient temperature. charge the accumulator. Both types are readily
Refer to the table at the end of this section for available from a local compressed gas dealer.
2 SM 1600 12-98
Braking System - Accumulator
Section 250-0060
DISCHARGING NITROGEN
WARNINGS Numbers in parentheses refer to Fig. 1, unless
Do not use Oxygen or any gas other than otherwise specified.
Nitrogen to charge an accumulator. Oxygen
under pressure coming into contact with oil or Make sure charging valve (1) is closed internally by
grease will cause a violent explosion. Always turning locknut (1D) clockwise. Remove valve cap
double check to make sure you are using (1A) and valve core (1B) from charging valve
Nitrogen to prevent personal injury and assembly (1). Slowly turn the locknut (1D)
property damage. anticlockwise to open the charging valve assembly (1).
A high pressure nitrogen pressure DO NOT remove charging valve (1) until all the gas
regulator must be used with the charging has been completely evacuated.
assembly. Failure to use pressure regulator
could cause property damage, personal injury
or death. WARNING
Do not try to discharge the accumulator by
1. Attach line (1) and the swivel nut to charging valve depressing the charging valve core (1B, Fig. 1).
(1, Fig. 1) as described in Steps 1 through 4 under
the heading 'Testing Pre-charge Pressure'. Be sure
valves (4 & 6) are closed. REMOVAL
Numbers in parentheses refer to Fig. 3.
2. Attach gauging head to nitrogen bottle by screwing
down on gland nut (8).
WARNINGS
3. Open tank valve (6) slowly; pressure shown on Make sure that lifting equipment, blocking
gauge (5) is tank pressure. materials and wheel blocks are properly
secured and of adequate capacity to prevent
4. Open accumulator valve (4) slowly and charge personal injury and property damage.
accumulator to 55 bar (800 lbf/in2) at 21o C (70o F)
ambient temperature, closing valve occasionally. Accumulators are charged with Nitrogen.
Refer to the table at the end of this section for the The service pressure is 55 bar (800 lbf/in) at
Nitrogen pressures at ambient temperatures of other 21o C (70o F). Be sure all Nitrogen pressure has
than 21o C (70o F). been relieved before removing accumulator
from the truck. Sudden release of pressure
5. To check accumulator charge, close tank valve may cause personal injury.
(6), relieve pressure between tank and gauge by
opening bleeder valve (10) momentarily. This will 1. Position the vehicle in a level work area, apply the
allow gauge needle to settle, thus giving correct parking brake and switch off the engine.
pressure reading of accumulator charge.
2. Operate the treadle valve continuously to discharge
6. When the correct pressure for the ambient the brake accumulators. Block all road wheels.
temperature has been reached, close valves (4 & 6)
tightly. Bleed pressure off pressure gauge (5) by 3. Remove screws (2, Fig. 1), lockwashers (3, Fig. 1)
opening bleeder valve (10). Close bleeder valve when and protector (4, Fig. 1).
all pressure is bled off the gauge.
4. Discharge nitrogen from accumulators. Refer to
7. Unscrew gland nut (8) from nitrogen bottle. previous section on 'Discharging Nitrogen' for correct
procedure.
8. Rotate 'T' handle of valve chuck (2) anticlockwise
until it stops, torque tighten charging valve locknut 5. Disconnect hydraulic lines from bottom of
(1D, Fig. 1) to 11 Nm (100 lbf in), loosen the swivel accumulators. Drain oil and cap the lines and
nut and remove gauging head. accumulator ports to prevent ingress of dirt.
9. Check accumulator charging valve (1, Fig. 1) for 6. Support the accumulators using an adequate sling
leakage using soapy water. Reinstall valve cap (1A, and lifting device. Remove bolts (1 & 2), washers (3)
Fig. 1) and tighten finger tight. and clamps (4). Remove accumulators.
SM 1600 12-98 3
Braking System - Accumulator
Section 250-0060
DISASSEMBLY SM - 278
WARNING
Accumulators are charged with Nitrogen. The
service pressure is 55 bar (800 lbf/in2) at
21o C (70o F). Do not attempt to remove any
valves or fittings until all nitrogen pressure is
completely relieved to prevent personal injury
and property damage.
4 SM 1600 12-98
Braking System - Accumulator
Section 250-0060
6. Test accumulator hydraulically for leakage or 5. Charge the accumulator with Nitrogen gas as
failure at 255 - 276 bar (3 700 - 4 000 lbf/in2). described under the heading 'Charging the
Discharge after testing. Accumulator' in this section.
MAINTENANCE
WARNING Inspect the accumulators regularly for any signs of
Make sure that lifting equipment, blocking leakage or damage.
materials and wheel chocks are properly
secured and of adequate capacity to prevent Every 500 hours
personal injury and property damage. Check the Nitrogen precharge pressure at the
accumulators, prior to checking braking system
1. Position accumulators on mounting bracket with pressure. Refer to 'Testing Pre-charge Pressure', in
the oil inlet ports downward. this section.
SM 1600 12-98 5
Braking System - Accumulator
Section 250-0060
WARNING
This truck is equipped with precharged nitrogen gas cylinders of more than 2.8 bar (40 lbf/in2).
Special permits may be required when transporting the truck 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.
* * * *
6 SM 1600 12-98
BRAKING SYSTEM - Treadle Valve
Section 250-0070
SM - 1267
1 - Adjustment Collar
2 - Actuator Plunger 16 - Reaction Plunger
3 - Glyde Ring Assembly 17 - Wiper Seal 30 - Nut 43 - Screw
4 - Plunger Return Spring 18 - Backup Ring 31 - Washer 44 - Retainer Plate
5 - Regulator Spring 19 - Seal 32 - U Bolt 45 - Capscrew
6 - Regulator Spring 20 - Valve Body 33 - Screw 46 - Actuator Base
7 - Spring Seat 21 - Plate 34 - Nut 47 - Insert
8 - Regulator Spool 22 - 'O' Ring 35 - Adjustment Screw 48 - Nut
9 - Backup Ring 23 - Face Seal 36 - Actuator Cam 49 - Washer
10 - 'O' Ring 24 - Screw 37 - Insert 50 - Pedal
11 - Backup Ring 25 - 'O' Ring 38 - Pivot Pin 51 - Capscrew
12 - 'O' Ring 26 - Retaining Plug 39 - Return Spring 52 - Insert
13 - 'O' Ring 27 - Base Plate 40 - Return Spring 53 - Capscrew
14 - Regulator Sleeve 28 - Washer 41 - Cap 54 - Lockup Drop Out Pressure Switch
15 - Spool Return Spring 29 - Capscrew 42 - Boot 55 - Stop Light Pressure Switch
SM - 1656 SM - 1657
FROM
TO FRONT FRONT
BRAKES BRAKES
4 4
Px FROM
TO REAR Px REAR
BRAKES BRAKES
T T
SUPPLY SUPPLY
FROM P1 P2 FROM P1 P2
BRAKE BRAKE
MANIFOLD B1 B2 MANIFOLD B1 B2
13 17 13 17
SUPPLY SUPPLY
FROM FROM
BRAKE BRAKE
MANIFOLD MANIFOLD
Fig. 2 - Normal Service Brake Application Fig. 3 - Normal Service Brake Release
SM - 1658 SM - 1659
FROM
TO FRONT FRONT
BRAKES BRAKES
4 4
SUPPLY FROM
Px TO TANK Px
FROM TO REAR REAR
VIA
BRAKE BRAKES BRAKES
BRAKE
MANIFOLD T MANIFOLD T
SOLENOID SOLENOID
P1 P2 P1 P2
SUPPLY SUPPLY
FROM FROM
BRAKE B1 B2 BRAKE B1 B2
MANIFOLD MANIFOLD
13 17 13 17
SUPPLY SUPPLY
FROM FROM
BRAKE BRAKE
MANIFOLD MANIFOLD
operators force on pedal (50). Regulator spools (8) oil in the 'B1' and 'B2' lines to return to tank, releasing
have closed off the inlet ports, outlet ports and the tank the brakes.
port and will remain in this position as long as pedal
(50) is not moved. If the operator further depresses Note: Outlet ports 'B1' and 'B2' will give output
pedal (50), regulator spools (8) will move down and pressure 5% higher when activated by an emergency
build more pressure in the brake until it balances the stop ('Px' circuit) than a brake pedal actuation.
pedal force.
REBUILD CRITERIA
Normal Service Brake Release Inspect the valve regularly for any signs of leakage or
Refer to Fig. 3. When the operator releases pedal (50), damage. Check the actuator for excessive cam rock
regulator spool (8) will become unbalanced and move and replace components if necessary.
upwards, opening outlet ports 'B1' and 'B2' to tank. At
this point, oil in the 'B1' and 'B2' lines is released to The controller should be rebuilt if one or more of the
tank through tank port 'T', releasing the brakes. following conditions exist:
Hydraulic oil pressure will remain 7. Remove retainer plate (44), boot (42) and cap (41)
within the system after engine shut down. as an assembly by grasping boot (42) and gently lifting
Operate the treadle pedal continuously until from actuator base (46).
the pressure has dissipated before carrying
out any work on the braking system or serious 8. Loosen the socket head capscrews from adjustment
injury could result. collars (1) and unscrew adjustment collars (1).
1. Position the vehicle in a level work area, apply the 9. Remove capscrews (45) securing actuator base
parking brake and switch off the engine. (46) to valve body (20). Remove actuator base (46)
from valve body (20).
2. Operate the treadle valve continuously to discharge
the braking accumulators. Block all road wheels. 10. Remove stop light pressure switch (55) and lockup
drop out pressure switch (54) from plate (21).
3. Clean treadle valve assembly and surrounding area
with a suitable solvent. Ensure all hydraulic lines 11. Remove capscrews (53) securing plate (21) on
connected to the treadle valve are identified for ease valve body (20). Remove plate (21) and discard
of installation and, with suitable containers available to 'O' ring (22) and face seals (23).
catch leakage, disconnect hydraulic lines. Fit blanking
caps to all open lines and treadle valve ports. 12. Remove controller from the vice.
4. Remove and tag electrical connections to stop light 13. Remove capscrews (29) and washers (28) from
pressure switch (55) and lockup drop out pressure the base of valve body (20). Remove base plate (27).
switch (54).
14. With valve body (20) upright, retaining plug (26)
5. Release and remove mounting hardware securing should fall out. If retaining plug (26) does not fall out,
the treadle valve to the cab floor. Remove treadle lightly tap the plug to dislodge.
valve assembly to a clean area for 'Disassembly'.
15. Remove and discard 'O' ring (25) from counterbore
in the base of valve body (20).
DISASSEMBLY
Numbers in parentheses refer to Fig. 1. Note: Throughout the following steps it is important to
keep the circuits and circuit components identified as
1. Remove blanking caps from treadle valve ports and to which side of the unit they came from. For a given
drain oil from valve body (20) ports by rotating the circuit, all the components have a tolerance stack
valve over a suitable container. which could vary. Keep the 'B1' and 'B2' components
separate.
2. Secure the controller upright in a table vice.
16. With the controller upright on the work bench, hold
3. Remove pedal (50) from actuator cam (36) by valve body (20) with one hand and push the 'B1'
loosening two capscrews (51) at the pedal heel. Note actuator plunger (2) down with the other hand until
that capscrews (51) need not be removed. regulator sleeve (14) pops loose.
4. Loosen but do not remove nuts (30) from 'U' bolts 17. Repeat the above procedure to loosen the 'B2'
regulator sleeve (14).
18. Turn valve body (20) on its side on the work bench SUB-ASSEMBLY
and remove regulator sleeves (14) from valve body (20). Numbers in parentheses refer to Fig. 1.
19. Remove regulator spools (8), reaction plungers Note: All metal parts should be thoroughly cleaned
(16) and spool return springs (15) from regulator with a suitable solvent, dried, and lubricated with a
sleeves (14). light weight oil before assembly. This valve is built to
extremely close manufacturing tolerances. Great care
20. Remove plunger return springs (4), regulator should be taken to keep components protected from
springs (5 & 6) and spring seats (7) from valve body (20). contamination prior to and during assembly.
2. Inspect actuator plunger (2) for wear on the sides 5. Position boot (42) such that it conforms to the
where it moves through the seals. If axial grooves are contour of cap (41), then set aside. Loctite Prism 410
seen or if any wear is evident, replace actuator requires about 30 minutes to cure.
plunger (2). Actuator plungers (2) with diameter worn
below 18.97 mm (0.747 in) must be replaced.
Threaded Inserts
3. Place regulator spool (8) into regulator sleeve (14) 1. Position actuator base (46) upside down on the
and push the spool lightly through the sleeve. work bench and support directly under each of the four
Regulator spool (8) must be able to move freely and floor mounting holes. Install threaded inserts (47) into
smoothly the entire length of regulator sleeve (14). If it actuator base (46) by tapping lightly with a small
cannot, regulator spool (8) and regulator sleeve (14) hammer until insert (47) flanges become flush with
must be replaced as a matched set. actuator base (46). Be sure actuator base (46) is
supported to prevent braking. Thoroughly clean
Note: Never replace just the spool or sleeve. They actuator base (46) assembly and set aside.
must be replaced as a matched set.
2. Position actuator cam (36) upside down on the work
4. Inspect each spring carefully for cracks or breaks. bench and support it at the centre hole. Insert
Any spring with a crack or break must be replaced. threaded insert (37) by tapping lightly with a small
Also, if the treadle valve was not reaching proper hammer until its flange becomes flush with actuator
regulated pressure, replace all regulator springs. cam (36) surface. Be sure actuator cam (36) is
supported to prevent breaking. Thoroughly clean
5. Inspect threaded inserts (37, 47 & 52) in actuator actuator cam (36) assembly and set aside.
cam (36), actuator base (46) and pedal (50). If any of
the threads are damaged, the inserts must be replaced. 3. Position pedal (50) upside down on the work bench
and support it directly above the two holes near its
Regulator Sleeve
1. Install 'O' ring (10) onto the smallest groove (on the
top) of regulator sleeve (14). Install 'O' ring (12) onto
the middle groove of regulator sleeve (14). Install
'O' ring (13) onto the largest groove (on the bottom) of Fig. 7 - Regulator Sleeve Seal Installation
regulator sleeve (14). See Fig. 7.
Actuator Plunger
2. Install backup ring (11) onto each side of 'O' ring
(12) located in the middle of regulator sleeve (14). See Note: Glyde ring (3) assembly consists of an 'O' ring
Fig. 7. and a split glyde ring.
3. Install backup ring (9) behind 'O' ring (10) located at 1. Install 'O' ring into the 'O' ring groove located at the
the top end of regulator sleeve (14). 'O' ring (10) is the large diameter end of actuator plunger (2).
smallest of the three 'O' rings. Position backup ring (9)
so that it is next to the top of regulator sleeve (14). The 2. Install split glyde ring over the 'O' ring. Twist and
top of regulator sleeve (14) is the end with the smallest squeeze the split glyde ring into a small circle before
OD. See Fig. 7. installing to ensure a tight fit over the 'O' ring.
4. Repeat steps 1 through 3 for the second circuit. 3. Repeat steps 1 and 2 for the second circuit.
ASSEMBLY SM - 1237
4. Lightly lubricate regulator spool (8) assembly and 12. Install base plate (27) on top of retaining plug (26)
install into regulator sleeve (14). The spherical end of and secure with capscrews (29) and washers (28).
regulator spool (8) should be at the top of regulator Tighten capscrews (29) evenly to a torque of
sleeve (14). The top of regulator sleeve (14) is the end 16 - 17 Nm (140 - 150 lbf in), alternating diagonally to
with the smallest OD. evenly seat regulator sleeve (14) assembly.
Note: Check to ensure that regulator spool (8) will 13. Install actuator base (46) on top of valve body (20)
slide smoothly and freely in regulator sleeve (14). and secure with capscrews (45). Make sure to position
Replace the entire spool and sleeve assembly if the properly for correct port direction. Tighten capscrews
spool does not slide smoothly and freely. (45) to a torque of 20 - 21 Nm (180 - 190 lbf in).
5. Remove regulator spool (8) from regulator sleeve 14. Screw adjustment collars (1) onto the top of
(14) before installing sleeve into valve body (20). actuator plungers (2). Screw all the way down until
they bottom on the threads.
6. Lightly lubricate 'O' rings (10, 12 & 13) on regulator
sleeve (14). Note: It is extremely important to bottom-out
adjustment collars (1) to prevent over-stressing and
7. Install regulator sleeve (14) assembly into the breaking the springs during the adjustment process.
correct circuit of valve body (20). Make sure spring
seat (7) is correctly seated in regulator spring (6) 15. Lightly lubricate and install new 'O' ring (22) and
before installing regulator sleeve (14). Push regulator face seals (23) in grooves of plate (21).
sleeve (14) into bore until retaining flange at the base
contacts valve body (20). 16. Install valve body (20) in a vice with tank port 'T'
facing down. Carefully place plate (21) assembly on
8. Install spool return spring (15) into regulator spool (8). valve body (20) and secure with capscrews (53).
Install reaction plunger (16) into regulator spool (8). Tighten capscrews (53) to a torque of 16 - 17 Nm
Reinstall regulator spool (8) into regulator sleeve (14). (140 - 150 lbf in).
SM - 499
PILOT
159 bar
(2 300 lbf/in) RETURN
SUPPLY
SUPPLY
FRONT REAR
BRAKE BRAKE
PRESSURE PRESSURE
SIMULATED
BRAKE VOLUME
17. Install stop light pressure switch (55) and lockup SM - 1238
drop out pressure switch (54) in plate (21) and tighten SCREWDRIVER
OR PRY BAR
securely.
4. Attach tank return line to 'T' port of valve body (20). FINAL ASSEMBLY
Numbers in parentheses refer to Fig. 1.
5. Attach output ports 'B1' and 'B2' to test lines. Check
that all ports are used. Note: Tighten all fasteners without special torques
specified to standard torques listed in Section
6. Set supply line pressure to 159 bar (2 300 lbf/in). 300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
7. Set pilot supply pressure to 159 bar (2 300 lbf/in).
1. Remove pivot pin (38) from actuator base (46).
8. Return line pressure during this test is not to exceed
0.34 bar (5 lbf/in). 2. Assemble actuator cap (41), boot (42) and retainer
plate (44) to actuator base (46) and secure with
9. Test valve with 10W hydraulic oil at 50 + 6 C screws (43).
(120 + 10 F).
3. Insert pivot pin (38) through the hole in actuator
base (46), through the holes in 'U' bolts (32), and
Setting Manual and Pilot Pressure through the pivot pin hole in the other side of actuator
1. Install pivot pin (38) in actuator base (46) by itself base (46). As pivot pin (38) is being inserted, install
without installing pedal (50) assembly. pedal return springs (39 & 40).
2. By taking a screw driver or pry bar and placing it 4. Centre pivot pin (38) and secure with nuts (30) and
under pivot pin (38) and on top of actuator plunger (2) washers (31) on 'U' bolts (32). Tighten nuts (30) to a
assembly, you will be able to actuate each circuit torque of 16 - 17 Nm (140 - 150 lbf in).
individually. See Fig. 10.
5. Install pedal (50) assembly on actuator cam (36)
3. Gradually apply pressure on each circuit to check and secure with capscrews (51), washers (49) and
for leaks. Make sure adjustment collar (1) is screwed nuts (48).
all the way down on the threads.
6. Cycle each circuit 50 times using pilot apply. 3. Set the deadband by placing a 0.64 mm (0.025 in)
shim between the pedal return stop and the boss on
7. Recheck pressures after cycling. If they have the actuator base return stop. See Fig. 11.
changed, readjust.
4. Turn adjustment screw (35) down (clockwise) until it
8. Tighten the capscrews in adjustment collars (1) to is touching actuator cap (41).
3 - 3.5 Nm (25 - 30 lbf in). You may have to rotate
entire actuator plunger (2) to get to the capscrews. 5. Continue turning adjustment screw (35) clockwise
until you start to see a pressure reading on the
9. Check pressures again after tightening the pressure gauge then back-off adjustment screw (35)
capscrews. If the pressures have altered, loosen the 1/8 turn (anticlockwise).
appropriate capscrew and readjust.
Actuator Base 5. Remove wheel blocks, start the engine and bring
Return Stop
hydraulic oil to operating temperature.
1. Position treadle valve assembly on cab floor and Note: If the pressures to the brake circuits have been
secure with mounting hardware. Remove blanking determined as low or high, the pressures can be
caps from ports. raised or lowered by an in service (in situ) adjustment.
11. Install pivot pin (38) in actuator base (46) and by As brake pressure increases to 2.7 bar (39 lbf/in) and
taking a screw driver or pry bar and placing it under above, the circuit should close and send a signal to
pivot pin (38) and on top of actuator plunger (2), you illuminate the brake lights. As pressure drops below
will be able to actuate each circuit individually. 2.7 bar (39 lbf/in) the circuit should open and brake
lights go out.
12. Start engine to ensure full hydraulic pressure.
13. Test front 'B1' and rear 'B2' brake circuit actuating Lockup Drop Out Pressure Switch
pressures at diagnostic test points and adjust if Lockup drop out pressure switch (54) is a normally
necessary. Pressures should be 159 bar (2 300 lbf/in) open switch. Attach a continuity tester to terminals on
for front 'B1' circuit and, 52 bar (750 lbf/in) for rear 'B2' lockup drop out pressure switch (54). The circuit
circuit. should be open.
Note: Turning adjustment collar (1) up (anticlockwise) As brake pressure increases to 20 bar (290 lbf/in) and
will increase the pressure while turning it down above, the circuit should close and send a signal to
(clockwise) will decrease the pressure. Fine the lockup drop out solenoid, which in turn drops the
adjustment will require only turning the collar in 1/8 transmission out of lockup. As pressure drops below
turn increments. 20 bar (290 lbf/in) the circuit should open and lockup
can be engaged.
14. When pressure is set correctly, tighten the
capscrews in adjustment collars (1) to 3 - 3.5 Nm
(25 - 30 lbf in).
MAINTENANCE
SPECIAL TOOLS
There are no special tools required for procedures tools, sealants and adhesives required. These tools,
outlined in this section. Refer to Section 300-0070, sealants and adhesives are available from your dealer.
SERVICE TOOLS, for part numbers of general service
* * * *
SM - 1509
15
P
A
B
15
b
15 a
14
T
7 4 9 8 1 5 7 10
b a
6
6
3 11 12 11 3
2
13
B A
SM 1226 2-98 1
Braking System - Directional Control Valve
Section 250-0090
SM - 1510 SM - 1511
T P T P
BRAKE BRAKE
MANIFOLD MANIFOLD
VALVE VALVE
Fig. 2 - Directional Control Valve - Energized Fig. 3 - Directional Control Valve - De-energized
2 SM 1226 2-98
Braking System - Directional Control Valve
Section 250-0090
3. Clean directional control valve assembly and a. Install hydraulic supply capable of 0 - 159 bar
surrounding area with a suitable solvent. Ensure all (0 - 2 300 lbf/in) to port 'P'.
hydraulic lines connected to the directional control
valve are identified for ease of installation and, with b. Install hydraulic supply capable of 0 - 21 bar
suitable containers available to catch leakage, (0 - 300 lbf/in) to port 'a'.
disconnect hydraulic lines. Fit blanking caps to all
open lines. c. Install a suitable return line to port 'T'.
4. Release and remove mounting hardware securing d. Install a pressure gauge suitable for 0 - 207 bar
directional control valve to the mounting plate on the (0 - 3 000 lbf/in) to port 'B'.
underside of the cab floor and remove assembly from
the truck. 2. Make sure all control valves to supply lines are
closed.
DISASSEMBLY/ASSEMBLY 3. Turn on hydraulic power supplies and make sure
Numbers in parentheses refer to Fig. 1. hydraulic oil is at normal operating temperature.
Note: Tighten all fasteners to standard torques listed 4. Open control valve for port 'P' supply and adjust to
in Section 300-0080, STANDARD BOLT AND NUT give a supply reading of 159 bar (2 300 lbf/in).
TORQUE SPECIFICATIONS. Reading on pressure gauge at port 'B' should be zero.
Note: With the exception of replacing 'O' rings (11 & 12), Note: The directional control valve starts to de-energise
the directional control valve is a non serviceable item (close) when transmission pilot pressure falls below
and should be replaced as a complete assembly. The 7 bar (100 lbf/in) and is fully de-energised when
'O' rings can be replaced as follows: transmission pilot pressure falls to 5.5 bar (80 lbf/in).
1. Note orientation of valve body (1) to sub plate (13) 5. Open control valve for port 'a' supply and slowly
to facilitate assembly. increase this supply pressure from 0 to 21 bar
(0 to 300 lbf/in) thus energising (opening) the
2. Clamp sub plate (13) lightly in a soft jawed vice directional control valve. Pressure reading at port 'B'
and remove allen bolts (9) and spacers (8). should now read 159 7 bar (2 300 100 lbf/in).
Reading on pressure gauge at port 'D' should begin to
3. Separate valve body (1) from sub plate (13) and fall when supply pressure at port 'a' drops to 7 bar
discard 'O' rings (12). (100 lbf/in). This rate of fall should reach a maximum
rate when supply pressure at port 'a' drops to 5.5 bar
4. Install new 'O' rings (12) in valve body (1) and fit (80 lbf/in) or below. With supply pressure at port 'a' at
valve body (1) to sub plate (13) as noted prior to 5.5 bar (80 lbf/in) or less, pressure on gauge at port
disassembly. Install spacers (8) in valve body (1) 'B' should quickly drop to almost zero, by exhausting
and secure valve body (1) to sub plate (13) with allen to tank via port 'T'.
bolts (9).
6. Slowly energise (open) control valve for port 'a'
5. Remove allen bolts (10) and end covers (2) from supply. Pressure reading at port 'B' should start to rise
valve body (1) and discard 'O' rings (11). when pressure at port 'a' reaches 5.5 bar (80 lbf/in).
Rate of pressure increase at port 'B', should reach a
6. Install new 'O' rings (11) in end covers (2) and maximum level, when supply pressure at port 'a'
secure to valve body (1) with allen bolts (10). reaches 7 bar (100 lbf/in) or above.
SM 1226 2-98 3
Braking System - Directional Control Valve
Section 250-0090
* * * *
4 SM 1226 2-98
BRAKING SYSTEM - Monoblock Brake Valve
Section 250-0100
SM - 1363
Pressure reducing valve (9) reduces the available Refer to Fig. 2. With the engine running and the brake
hydraulic oil pressure from the rear brake accumulator manifold valve energized, (park/emergency brake
to a pressure of 83 bar (1 200 lbf/in2). switch deactivated - pulled out) hydraulic oil from the
rear brake accumulator flows through the brake
Pressure relief valve (11) regulates pressure, after manifold valve and enters valve body (1) at port 'P'. Oil
pressure reducing valve (9), to provide a residual flows through pressure reducing valve (9) and exits
pressure of 3.1 0.35 bar (45 5 lbf/in2) in the rear valve body (1) at port 'RB2' to release the parking
brake lines. A filter system, comprising of disc filter (5) brake. Oil pressure is reduced to 83 bar (1 200 lbf/in2)
and conical filter (3), helps protect orifice plate (2) at before leaving valve body (1) at port 'RB2'. Excess oil
pressure relief valve (11). at pressure reducing valve (9) is diverted back to tank
through port 'T' in valve body (1).
REMOVAL SM - 1353
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.
1 - 'O' Ring
To prevent personal injury and property 2 - 'O' Ring 4 - Backup Ring
damage, be sure wheel blocks are properly 3 - 'O' Ring 5 - Backup Ring
secured and of adequate capacity to do the job Fig. 4 - Pressure Reducing Cartridge Seals
safely.
SM - 1354
1. Position the vehicle in a level work area, raise the
body and secure in place with the body safety pins.
Apply the parking brake and switch off the engine.
DISASSEMBLY
Numbers in parentheses refer to Fig. 1, unless
otherwise specified.
2. Remove shuttle valve (10) assembly from valve (1). Remove and discard 'O' rings (8 & 9, Fig. 6) and
body (1). Remove and discard 'O' rings (3, 4 & 6, Fig. 5) backup ring (11, Fig. 6) from relief valve (11).
and backup rings (5 & 7, Fig. 5) from shuttle valve (10).
4. If required, remove blanking plug (8) from valve
3. Remove relief valve (11) assembly from valve body body (1). Remove and discard 'O' ring (7) from
blanking plug (8).
* * * *
DESCRIPTION SM - 2297
OPERATION
6
Numbers in parenthesis refer to Fig. 1.
Refer to Fig. 2. Pressing the 50% brake reduction 1 - Pressure Reducing Valve 6 - Elbow - 90
switch to the 'On' position sends a signal to energize 2 - Solenoid 7 - Adapter
3 - Diagnostic Nipple 8 - Bolt
the solenoid in pressure reducing valve (1). Oil cannot 4 - Dust Cap 9 - Washer
pass through the check valve and is directed through 5 - Cartridge 10 - Pad
the relief valve. The relief valve limits the maximum
Fig. 1 - Pressure Reducing Valve Installation
braking pressure to the front brake callipers to
79.5 bar (1 150 lbf/in).
SM - 2298
Refer to Fig. 3. Pressing the 50% brake reduction TO FRONT BRAKE CALLIPERS
switch to the 'Off' position sends a signal to
OUTLET
de-energize the solenoid in pressure reducing valve 19
(1). In this condition full braking pressure 159 bar TEST
(2 300 lbf/in) is applied to the front brake callipers
when the treadle valve is operated.
REMOVAL/INSTALLATION
INLET TANK
Numbers in parentheses refer to Fig. 1.
FROM BRAKE TREADLE VALVE
Note: Tighten all fasteners to standard torques listed
Fig. 2 - Pressure Reducing Valve - Solenoid Energized
in Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.
SM - 2299
TO FRONT BRAKE CALLIPERS
Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 250-0000, OUTLET
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings 19
WARNING
Hydraulic fluid pressure will remain within the
system after engine shut down. Operate the INLET TANK
treadle valve continuously until the pressure
has dissipated before carrying out any work on FROM BRAKE TREADLE VALVE
the braking system or serious injury could
Fig. 3 - Pressure Reducing Valve - Solenoid De-Energized
result.
SM 1820 9-99 1
Braking System - Pressure Reducing Valve
Section 250-0110
1. Position the vehicle in a level work area, raise the 9. Check oil level in the steering and brake control
body and secure in place with the body safety pins. tank and add oil if required. Refer to Section 220-0040,
Apply the parking brake and switch off the engine. STEERING AND BRAKE CONTROL TANK for correct
fill level, and, Section 300-0020, LUBRICATION
2. Operate the treadle valve continuously to discharge SYSTEM for oil specification.
the brake accumulators. Block all road wheels.
10. Remove wheel blocks, start the engine and bring
3. Clean pressure reducing valve (1) and surrounding hydraulic oil to operating temperature.
area with a suitable solvent. Ensure all hydraulic lines
connected to pressure reducing valve (1) are identified 11. Check pressure reducing valve (1) and hydraulic
for ease of installation and, with suitable containers line connections for leaks and tighten as required.
available to catch leakage, disconnect hydraulic lines.
Fit blanking caps to all open lines. 12. Remove body safety pins and lower the body to
the frame.
4. Support valve body and remove bolts (8) and
washers (9) securing pressure reducing valve (1) to its
mounting. Remove pressure reducing valve (1) from MAINTENANCE
vehicle. Limited repair of the pressure reducing valve is with
replacement of parts only. Refer to vehicle parts book
5. Note location and orientation of elbows (6) and for lists of kits available.
adaptor (7) and remove from pressure reducing valve
(1).
SPECIAL TOOLS
6. Replace all 'O' rings and install elbows (6) and There are no special tools required for procedures
adaptor (7) in pressure reducing brake valve (1) ports outlined in this section. Refer to Section 300-0070,
as identified. SERVICE TOOLS, for part numbers of general service
tools required. These tools are available from your
dealer.
* * * *
2 SM 1820 9-99
BRAKING SYSTEM - Retarder Control Valve
Section 250-0130
SM - 1272
1 - Adjustment Collar
2 - Actuator Plunger 11 - 'O' Ring 20 - Washer 29 - Jam Nut
3 - Plunger Return Spring 12 - 'O' Ring 21 - Capscrew 30 - Set Screw
4 - Regulator Spring 13 - Regulator Sleeve 22 - Housing 31 - Spring
5 - Regulator Spring 14 - Spool Return Spring 23 - Cap 32 - Friction Puck
6 - Spring Seat 15 - Wiper Seal 24 - Cam 33 - Capscrew
7 - Regulator Spool 16 - Backup Ring 25 - Spring Pin 34 - Shaft
8 - Backup Ring 17 - Seal 26 - Plug 35 - Ring
9 - 'O' Ring 18 - Valve Body 27 - Set Screw 36 - Lever
10 - Backup Ring 19 - Retainer 28 - Jam Nut 37 - Knob
SM - 1662
REAR
SERVICE
BRAKES
'P2' PORT
TREADLE
VALVE
FROM
BRAKE
MANIFOLD
VALVE
In the normal position, lever (36) is in the forward OCDB Retarder Application
position and regulator spool (7) is in the up position. Refer to Fig. 2. In this condition the directional control
In this condition the notched area near the top of valve (if fitted) is de-energized.
regulator spool (7) is exposed to the tank cavity in
valve body (18), the lower portion of the notched area When the operator activates lever (36), actuator
is exposed to the regulated pressure outlet port of the plunger (2) is moved down and pushes on regulator
valve. This effects a direct link between tank port 'T' springs (4 & 5) which in turn, push regulator spool (7)
and regulated outlet port 'R'. While regulator spool (7) down. As regulator spool (7) moves down, the
is in this position the retarder is released. metering notches move out of the tank cavity and
close outlet port 'R' off to tank port 'T'. Regulator spool
(7) continues to move downward until the lower edge
OPERATION of the metering notches become exposed to the inlet
Numbers in parentheses refer to Fig. 1, unless pressure port 'P'. This movement opens inlet port 'P'
otherwise specified. to outlet port 'R'.
SM - 1663
REAR
SERVICE
BRAKES
'P2' PORT
TREADLE
VALVE
FROM
BRAKE
MANIFOLD
VALVE
of this operation is a reduced pressure application of Note: Should the operator depress the treadle valve
the rear service brakes. to obtain a full service brake application, when the
retarder is applied, treadle valve pressure takes
As hydraulic pressure builds in the brake, oil flows priority at the shuttle valve in the brake lines when it
through the small orifice in the side of regulator spool exceeds retarder applied pressure. A full service
(7) and into the cavity below the spool. As pressure brake application occurs.
rises in the brake it also rises in the cavity below the
spool forcing regulator spool (7) upwards closing A retarder applied pressure switch (18, Fig. 2)
outlet port 'R'. Regulator spool (7) is now balanced (installed in a tee at port 'R') will close, sending a
between the brake pressure and the pressure of signal to illuminate an indicator light in the dash
regulator springs (4 & 5) generated by lever (36) panel, and a retarder light at the rear of the truck, to
position. Regulator spool (7) has closed off inlet port 'P', indicate that the retarder is applied.
outlet port 'R' and tank port 'T' and will remain in this
position until lever (36) is moved. This maintains the
applied pressure within the brake circuit and provides Transmission Retarder Application
infinitely variable application of the braking force. If Refer to Fig. 3. In this condition the directional control
the operator further actuates lever (36), regulator valve is energized.
spool (7) will move down and build more pressure in
the brake until it balances the lever force.
WARNING
The maximum pressure applied by the retarder Great care should be used if applying the
control valve is governed by the stroke of regulator retarder when road surfaces are slippery. The
spool (7) within the valve. This stroke can be retarder braking effect will occur only at the
adjusted during maintenance operations. driving axle and could make the truck difficult
to control.
SM - 1664
REAR
SERVICE
BRAKES
'P2' PORT
TREADLE
VALVE
FROM
BRAKE
MANIFOLD
VALVE
When the operator activates lever (36), actuator outlet port 'R' and tank port 'T' and will remain in this
plunger (2) is moved down and pushes on regulator position until lever (36) is moved. This maintains the
springs (4 & 5) which in turn, push regulator spool (7) applied pressure within the transmission retarder
down. As regulator spool (7) moves down, the circuit and provides infinitely variable application of
metering notches move out of the tank cavity and the retarder. If the operator further actuates lever
close outlet port 'R' off to tank port 'T'. Regulator (36), regulator spool (7) will move down and build
spool (7) continues to move downward until the lower more pressure in the retarder until it balances the
edge of the metering notches become exposed to the lever force.
inlet pressure port 'P'. This movement opens inlet
port 'P' to outlet port 'R'. The maximum pressure applied by the retarder
control valve is governed by the stroke of regulator
This permits reduced pressure to travel through spool (7) within the valve. This stroke can be
directional control valve (11, Fig. 3) to transmission adjusted during maintenance operations.
retarder cylinder (12, Fig. 3) on the transmission. Oil
fills the cavity around the rotor within the retarder and Note: Should the operator depress the treadle valve
creates drag, which in turn, slows the truck down. to obtain a full service brake application, when the
When the cavity is emptied, the rotor is free of drag. retarder is applied, treadle valve pressure takes
priority at the shuttle valve in the brake lines when it
As hydraulic pressure builds in the retarder, oil flows exceeds retarder applied pressure. A full service
through the small orifice in the side of regulator spool brake application occurs.
(7) and into the cavity below the spool. As pressure
rises in the retarder it also rises in the cavity below A retarder applied pressure switch (18, Fig. 3)
the spool forcing regulator spool (7) upwards closing (installed in a tee at port 'R') will close, sending a
outlet port 'R'. Regulator spool (7) is now balanced signal to illuminate an indicator light in the dash
between the retarder pressure and the pressure of panel, and a retarder light at the rear of the truck, to
regulator springs (4 & 5) generated by lever (36) indicate that the retarder is applied.
position. Regulator spool (7) has closed off inlet port 'P',
SM - 1665
REAR
SERVICE
BRAKES
'P2' PORT
TREADLE
VALVE
FROM
BRAKE
MANIFOLD
VALVE
OCDB Retarder Release (18, Fig. 5) will open, switching off the retarder
Refer to Fig. 4. In this condition the directional control indicator light on the dash panel and retarder light at
valve (if fitted) is de-energized. rear of the truck.
Transmission Retarder Release 2. Retarder valve holds pressure when in the neutral
Refer to Fig. 5. In this condition the directional control position.
valve is in energized.
3. Varying output pressure with the lever fully
When the operator releases lever (36), regulator actuated.
spool (7) will become unbalanced and move upwards
under the influence of the transmission retarder 4. Spring pin securing shaft to actuator cam has
circuit pressure and spool return spring (14). As a failed.
result, regulator spool (7) moves to open outlet port
'R' to tank port 'T', closing inlet pressure port 'P'. The 5. Excessively worn friction pucks. This will be evident
pressure will fall and retarder applied pressure switch through mechanical interference of actuator cam (24),
1. Position the vehicle in a level work area, apply the 7. Remove regulator spool (7) and spool return
parking brake and switch off the engine. spring (14) from regulator sleeve (13).
2. Operate the treadle valve continuously to 8. Remove plunger return spring (3), regulator springs
discharge the braking accumulators. Block all road (4 & 5) and spring seat (6) from valve body (18).
wheels.
9. Remove actuator plunger (2) by pushing down
3. Remove and tag electrical connections to retarder (toward the bottom of valve body (18)) on actuator
pressure switch. plunger (2) by hand, until the plunger slides out.
4. Ensure all hydraulic lines connected to the retarder 10. Remove and discard 'O' rings (9, 11 & 12) and
valve are identified for ease of installation and, with teflon backup rings (8 & 10) from regulator sleeve (13).
suitable containers available to catch leakage,
disconnect hydraulic lines. Fit blanking caps to all 11. Remove and discard wiper seal (15), seal (17)
open lines and retarder valve ports. and backup ring (16) from the actuator section of
valve body (18).
5. Release and remove mounting hardware securing
the retarder control valve in the centre console.
Remove retarder control valve assembly to a clean Actuator
area for 'Disassembly'. 1. Loosen jam nut (29) and remove set screw (30)
from housing (22).
DISASSEMBLY 2. Remove spring (31) from housing (22). Inspect
Numbers in parentheses refer to Fig. 1. spring (31) carefully for cracks or breaks and replace
if required.
1. Remove blanking caps from valve body (18) ports
and drain oil by rotating the valve over a suitable 3. Remove plug (26) from housing (22). Spring pin
container. (25) may have already sheared off. If not, use a
2.3 mm (0.09 in) pin punch to press spring pin (25)
2. Secure the valve upright in a table vice. past shaft (34).
3. Remove capscrews (33) securing housing (22) 4. Rotate lever (36) and shaft (34) sub-assembly to
assembly to valve body (18). Remove housing assembly. release it from cam (24). Pull lever (36) and shaft
(34) sub-assembly from housing (22).
2. Inspect actuator plunger (2) for wear on the sides 3. Measure the distance friction puck (32) protrudes
where it moves through the seals. If axial grooves from housing (22). This distance should be
are seen or if any wear is evident, replace actuator approximately 2.3 mm (0.09 in). If this distance
plunger (2). Actuator plunger (2) must be replaced if varies more than 0.5 mm (0.02 in), replace the
the diameter is worn below 18.97 mm (0.747 in). actuator assembly.
3. Place regulator spool (7) into regulator sleeve (13) 4. Insert cam (24) in housing (22).
and push the spool lightly through the sleeve.
Regulator spool (7) must be able to move freely and 5. Align shaft (34) and lever (36) assembly with
smoothly the entire length of regulator sleeve (13). If housing (22) and cam (24) bore. Insert shaft (34) into
it cannot, regulator spool (7) and regulator sleeve housing (22) and cam (24) bore.
(13) must be replaced as a matched set.
6. Align 3 mm (0.12 in) diameter holes in shaft (34)
Note: Never replace just the spool or sleeve. They and cam (24). Install spring pin (25) until pin is
must be replaced as a matched set. recessed approximately 2.3 mm (0.09 in) below
cam (24) surface.
4. Inspect each spring carefully for cracks or breaks.
Any spring with a crack or break must be replaced. 7. Place second friction puck (32) in housing (22) and
Also, if the retarder valve was not reaching proper place spring (31) behind friction puck (32).
regulated pressure, replace all regulator springs.
8. Install set screw (30) in housing (22).
SUB-ASSEMBLY Note: Set screw (30) will be adjusted later to provide
Numbers in parentheses refer to Fig. 1. the proper spring compression.
Note: All metal parts should be thoroughly cleaned 9. Install jam nut (29) on set screw (30) and tighten
with a suitable solvent, dried, and lubricated with a finger tight.
light weight oil before assembly. This valve is built to
extremely close manufacturing tolerances. Great 10. Install set screw (27) in housing (22) and jam nut
care should be taken to keep components protected (28) on set screw (27). Finger tighten jam nut (28).
from contamination prior to and during assembly.
11. Turn sub-assembly with the bottom side up and
fill the actuation cavity with EP, NLGI grease until
Actuator cam (24) is covered. Refer to Section 300-0020,
1. If new lever (36) and shaft (34) are being fitted LUBRICATION SYSTEM for grease specification.
4. Install wiper seal (15) in the top counterbore. Fig. 6 - Valve Body Seal Installation
Position wiper seal (15) in the groove so that the
register lip is facing up toward the actuator. SM - 1348
Regulator Sleeve
1. Install 'O' ring (9) onto the smallest groove (on the
top) of regulator sleeve (13). Install 'O' ring (11) onto
the middle groove of regulator sleeve (13). Install
'O' ring (12) onto the largest groove (on the bottom)
of regulator sleeve (13). See Fig. 7.
SM - 1349
BRAKE
PRESSURE
8. Lightly lubricate 'O' ring (9) and install into counter 2. Attach main supply input pressure line to port 'P'.
bore in the bottom end of valve body (18).
3. Attach tank return line to port 'T'.
9. Install retainer (19) to valve body (18) and secure
with capscrews (21) and washers (20). Tighten 4. Attach regulated output test line to port 'R'. Check
capscrews (21) evenly to a torque of 20 - 21 Nm that all ports are used.
(180 - 190 lbf in), alternating diagonally to evenly seat
regulator sleeve (13) assembly. 5. Set supply line pressure to 159 bar (2 300 lbf/in2).
10. Screw adjustment collars (1) onto the top of 6. Return line pressure during this test is not to
actuator plunger (2). Screw all the way down until it exceed 0.34 bar (5 lbf/in2).
bottoms on the thread.
7. Test valve with 10W hydraulic oil at 50 + 6 C
Note: It is extremely important to bottom-out (120 + 10 F).
adjustment collar (1) to prevent over-stressing and
breaking the springs during the adjustment process.
Setting Apply Pressure 4. Adjust set screw (27) on top of housing (22) inward
Note: Before actuating the valve, be sure adjustment until the pressure begins to rise. Measure lever (36)
collar (1) is bottomed to prevent excessive pressure angle and back set screw (27) out until a lever angle
from damaging regulator springs (4 & 5). of 6 is achieved.
1. Gradually increase pressure in order to check for Note: Failure to comply with this specification may
leaks. Make sure adjustment collar (1) is screwed all result in the regulated pressure not being released to
the way down on the threads and cap (23) is installed tank.
on valve body (18).
5. Secure jam nut (28) on set screw (27) to lock the
2. Actuate plunger (2) until cap (23) contacts valve initial lever angle.
body (18). The pressure reading should be below
regulated pressure of 33 1.7 bar (480 25 lbf/in2). 6. Fully apply lever (36) to check the maximum
regulated output pressure and readjust if required.
3. To raise the regulated pressure, back adjustment
collar (1) up (anticlockwise) in small increments until Note: The approximate total lever (36) travel is 60
the output pressure is 33 1.7 bar (480 25 lbf/in2) at and this value may be used for reference purposes
port 'R'. Fine adjustment will require only turning the only.
collar in 1/8 turn increments.
7. Apply and hold lever (36) to maintain maximum
Note: Adjust adjustment collar (1) in small increments regulated output pressure. Adjust set screw (30) until
to prevent the valve from being over pressurised sufficient spring (31) force is generated to hold lever
during the adjustment procedure. Excessive pressure (36) in the full apply position.
could cause premature regulator spring failure.
8. Turn set screw inward until friction pucks (32) hold
4. Once regulated pressure has been set, tighten the lever (36) while generating the maximum regulated
capscrew on adjustment collar (1). Check the pressure (approximately 1.5 turns).
pressure again after tightening the capscrew. If the
pressure has moved out of the specified range, loosen 9. Secure set screw (30) in position with jam nut (29)
the capscrew and readjust. to lock spring (31) compression.
6. Check for oil leaks and tighten connections as If the pressure is outwith the specified pressure
necessary. range, inspect the valve and take relevant action
(adjust pressures, strip down and repair or replace
7. Engage retarder. Make sure of a full service brake valve).
application and that retarder light illuminates. Release
retarder.
Retarder Light Pressure Switch
8. Check all connections again for leaks and tighten The retarder light pressure switch is a normally open
as necessary. switch. Attach a continuity tester to terminals on the
pressure switch. The circuit should be open.
* * * *
DESCRIPTION SM - 1350
TO MONOBLOCK
Letters in parentheses refer to Fig. 1. BRAKE VALVE
TESTING WARNINGS
Letters in parentheses refer to Fig. 1. To prevent personal injury and property
damage, ensure wheel blocks are of sufficient
Remove shuttle valve from the truck (as described capacity and properly secured to do the job
under 'Maintenance') and plug outlet port 'A'. Apply safely.
hydraulic oil pressure of 110 bar (1 600 lbf/in)
through inlet port 'P1' and visually inspect inlet port To prevent personal injury, relieve the
'P2' for leaks. Repeat this test for inlet port 'P2'. If pressure in the braking system. The exact
any leakage of hydraulic oil occurs, replace shuttle procedure must be followed as described in
valve. Section 250-0000, BRAKING SYSTEM
SCHEMATIC.
SM 1229 2-98 1
Braking System - Shuttle Valve
Section 250-0140
1. Position the vehicle in a level work area, apply the install lines to shuttle valve as identified during removal.
parking brake and switch off the engine.
7. Check oil level in steering and brake control tank
2. Operate the treadle valve continuously to discharge and add oil if required. Refer to Section 220-0040,
the brake accumulators. Block all road wheels. STEERING AND BRAKE CONTROL TANK for
correct fill level, and, use only oil as specified in
3. Clean shuttle valve assembly and surrounding Section 300-0020, LUBRICATION SYSTEM.
area with a suitable solvent. Ensure all hydraulic
lines connected to the shuttle valve are identified for 8. Remove wheel blocks, start the engine and bring
ease of installation and, with suitable containers hydraulic oil to operating temperature.
available to catch leakage, disconnect hydraulic
lines. Fit blanking caps to all open lines. 9. Apply the brakes and check for oil leaks and
correct operation of the shuttle valve. Tighten line
4. Remove mounting hardware securing the shuttle connections and fittings as necessary.
valve to mounting bracket on the underside of the
cab. Remove shuttle valve and disconnect all fittings
for use on the new valve. SPECIAL TOOLS
There are no special tools required for procedures
5. Install all fittings on the new shuttle valve and outlined in this section. Refer to Section 300-0070,
secure shuttle valve assembly to mounting bracket SERVICE TOOLS, for part numbers of general
with mounting hardware. service tools required. These tools are available from
your dealer.
6. Remove blanking caps from hydraulic lines and
* * * *
2 SM 1229 2-98
OPERATORS COMPARTMENT - Cab and Mounting
Section 260-0010
SM - 2391
9
2 1
16
5
7 17
18 19
15
20
10
13 11
4 6
11 12
8
12
11
14 *21
3
DESCRIPTION
Numbers in parentheses refer to Fig. 1. WARNING
The protection offered by the FOPS protective
Cab assembly (1) is mounted through rubber mounts structure may be impaired if it has been
(12) which damp structure borne noise and vibration. subjected to any modification or damage.
The cab conforms with ISO/SAE, FOPS (Falling Unauthorized modification will void
Object Protective Structure) safety legislation, with certification.
ROPS (Roll Over Protective Structure provided by
the cab guard. Access to cab assembly (1) is from either side and
visibility is unrestricted through tinted glass. A
FOPS - ISO 3449, SAE J231 heater/filter/pressurizer and demisting unit in front of
High electrical current. Turn the ignition 9. Ensure heater lines are identified for ease of
key switch 'Off' before disconnecting any installation, and with suitable containers available to
electrical components. Disconnect electrical catch leakage, disconnect heater lines. Fit blanking
connections in the correct order given to caps to open lines and fittings.
prevent damage to the electrical components.
10. Ensure body control joystick lines are identified
1. Position the vehicle in a level work area, raise the for ease of installation, and with suitable containers
body and install the body safety pins. Refer to available to catch leakage, disconnect hoses at
Section 270-0010, BODY AND MOUNTING. manifold plate in cab floor. Fit blanking caps to open
lines and fittings.
2. Apply the parking brake and switch off the engine.
11. Ensure all connections to cab assembly (1) have
3. Turn the steering wheel in both directions several been removed, prior to removal.
times to relieve any pressure in the steering system.
Operate the treadle valve continuously to discharge 12. Attach suitable lifting equipment to cab assembly
the braking accumulators. Operate the body control (1) and take up the slack. Remove cap (20) from bolt
joystick continuously to discharge the pilot valve head. Remove locknut (14) securing bolt (13) to front
accumulator. Block all road wheels. cab support. Remove locknut (21), if fitted and
slacken off bolts (10) from rear cab supports.
4. Disconnect the electrical cables in the following
4. Remove blanking caps from all body control 13. Check all instruments and controls for proper
joystick lines and connect lines as identified at operation. Remove body safety pins and lower the
removal. Tighten all lines securely. body to the frame.
SM - 2394
3
2
33
32
8
9
13
14
7 21
17
12
6 18
5
10 19 20
11
28
23 26
24 25 27
23 22 1 15 16
31
30
29
28
25 - Hinge
1 - Gasket 9 - Screw 17 - Fixing Plate 26 - Pin
2 - RH Door Frame 10 - Screw 18 - Lock Cover 27 - Split Pin
3 - Sliding Frame 11 - Grommet 19 - Washer 28 - Clip
4 - Seal 12 - Lock 20 - Screw 29 - Washer
5 - Gasket 13 - Locking Plate 21 - Cover 30 - Nut
6 - Spacer 14 - Screw 22 - Nut 31 - Cap
7 - Door Handle 15 - Screw 23 - Retainer 32 - Catch - LH
8 - Screw 16 - Nut 24 - Screw 33 - Catch - RH
Fig. 2 - Exploded View of Right Hand Door Assembly
SM - 1994
64
65
63
3 58 59 60
61
62
34 7 8
33 55
56
32 11
57
48 2
19 18
15
6
46
9
31 4
10
54
30 14
12 13 20 45
27 49
24 66 67 21 68 43
69
29 28 35 44
16 17
47 50 21 1
39
45 40 41
26 22 42
36
23 37 38
25 37
52 53
51
2. If required, fit new inserts (15, Fig. 1) to hinges. 8. Position glass onto panel opening, pressing firmly
so that adhesive bonds sufficiently to allow the glass
3. Attach a suitable lifting device to LH door to be moved or straightened up as required.
assembly (3, Fig. 1) and align the door assembly to
hinges on cab. Install pin (43), aligning holes and 9. Ensuring the glass is adequately supported, allow
secure using split pin (44). Replace caps (45). the sealing adhesive to set properly.
4. Check LH door assembly (3, Fig. 1) for correct 10. Clean off any excess adhesive using a suitable
operation and also that the locks are operating correctly. solvent.
To replace a glass assembly, proceed as follows: This should stop the leak immediately, but since
some sealing compounds should be allowed to set
Note: Ensure the glass is supported adequately before getting wet, wait a few minutes before testing.
before starting to cut the adhesive seal.
SM - 3267
21
31
4 2
1 21
10
3
5
16 11
9
10
8
7
14 12
23 15
22
13
32
17 20
24 30
C 19
A
D 18
B
25
F 26
27 28
29
E
DESCRIPTION The driver seat is secured to the cab floor with bolts
Numbers in parentheses refer to Fig. 1. (28) and lockwashers (29). The seat assembly (1)
consists of a seat cushion (7) and back cushion (5)
mounted to seat frame (2). Seat frame (2) is attached
WARNING to seat base (30) by means of a suspension
By Law, seat belts must be provided. Always assembly. The air seat only reacts when the driver
wear seat belts when travelling in the vehicle. sits on the seat. When unoccupied, the seat sinks to
The following is the list of controls to adjust the seat: 8. If required, remove pop-out button and pull back
A. Height and slope adjustment, front. suspension cover (16) to allow access to suspension
B. Height and slope adjustment, rear. assembly (13).
C. Backrest angle adjustment.
D. Weight adjustment. 9. If required, remove mounting hardware securing
E. Horizontal adjustment (sliderails). dampers (12) to suspension assembly (13). Remove
F. Lumber support adjustment. dampers (12).
WARNING INSPECTION
Do not attempt to adjust the seat or seat belt Numbers in parentheses refer to Fig. 1.
while the machine is moving. Loss of control
may result. Stop the machine; apply the 1. Inspect air lines, control valve (D), dampers (12)
brakes; then adjust. and air spring (15) for leaks and damage and replace if
required.
REMOVAL AND DISASSEMBLY 2. Check all brackets and frame for cracks and/or
Numbers in parentheses refer to Fig. 1. damage. Repair or replace as necessary.
5. Using suitable lifting equipment, position seat The care of the upholstery on seat cover (8) and
assembly on the cab floor and secure with bolts (28) back cover (6) is a relatively simple, but important
and lockwashers (29). matter. Accumulation of dirt on the surface eventually
turns into a hard gritty substance which cuts into the
6. Reconnect compressor connector at the rear of the surface of the upholstery.
seat.
To clean seat cover (8) and back cover (6), use warm
7. Start the engine and charge the air system. Pull water and a mild soap, such as Castile. Work up thin
out control valve button (D) to allow air into seat soap suds on a piece of soft cloth and rub the
suspension system and check seat for proper upholstery briskly. Remove the suds with a damp
operation. cloth, using no soap, and finish by wiping the
upholstery dry with a soft, dry cloth.
8. Remove wheel chocks from road wheels.
Seat belt (21) assembly should be inspected by the
user on a regular basis. Replace Seat belt (21)
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.
* * * *
SM - 2392
A
27 A 31 32
28 B 24
29 30 5
A
4 23
A
22
30 24
29 B A 7
6
B 26 17
25 12 18
28 14
27
18 33 12
9 17 18 19
A 3318 11
A 10
8
13
16
B
15
6
26
20 20
21
21
1 - Seat Cushion
2 - Seat Frame 10 - Spring 18 - Lockwasher 26 - Bolt
3 - Back Cushion 11 - Latch 19 - Washer 27 - Bolt
4 - Bolt 12 - Pad 20 - Bolt 28 - Washer
5 - Lockwasher 13 - Pivot Pin 21 - Lockwasher 29 - Lockwasher
6 - Bracket 14 - Latch Pin 22 - Spacer 30 - Nut
7 - Bolt 15 - Locknut 23 - Bracket 31 - Bolt
8 - Seat Base 16 - Hardened Washer 24 - Washer 32 - Spacer
9 - Hinge 17 - Nut 25 - Lap Belt 33 - Nut
SM 1902 1-00 1
Operator's Compartment - Passenger Seat and Mounting
Section 260-0110
arrangement. Located within seat base (8) are the 8. Remove bolts (27), washers (28), lockwashers (29)
major CEC components; battery equalizer box, and nuts (30) securing lap belt (25) to seat base (8)
electronic control unit (ECU) and CEC interface box. and remove lap belt (25). Remove bolts (26),
lockwashers (18), nuts (33) and brackets (6) from seat
A retractable lap belt (25) is secured to seat base (8) base (8).
using bolts (27), washers (28), lockwashers (29) and
nuts (30). A release button allows quick release of lap 9. If seat base (8) requires to be removed, disconnect
belt (25). the electrical cables in the following order to prevent
damage to the electrical components.
4. Remove mounting hardware, back and seat 3. Connect the electrical cables in the following order
cushions (1 & 3) from seat frame (2). to prevent damage to the electrical components.
5. Remove bolts (7 & 31), washers (24) and spacers a. Connect electrical connections at the ECU.
(22 & 32) securing bracket (23) to seat frame (2). b. Connect battery equalizer positive connections.
Remove bracket (23). c. Connect battery cables to terminal posts (positive
cables first).
6. Remove nut (17), lockwasher (18) and latch pin (14) d. Connect battery equalizer ground cables.
from bracket (23).
4. Position brackets (6) on seat base (8) and secure
7. Remove spring (10) from latch (11) and seat with bolts (26), lockwashers (18) and nuts (33).
base (8). Remove locknut (15), hardened washer (16) Position lap belt (25) on mounting brackets (6) and
and latch (11) from pivot pin (13). Remove nut (17), secure with bolts (27), washers (28), lockwashers (29)
lockwasher (18), washer (19) and pivot pin (13) from and nuts (30).
seat base (8).
2 SM 1902 1-00
Operator's Compartment - Passenger Seat and Mounting
Section 260-0110
7. Install latch pin (14) in bracket (23) and secure with To clean seat cushion (1) and back cushion (3), use
lockwasher (18) and nut (17). warm water and a mild soap, such as Castile. Work up
thin soap suds on a piece of soft cloth and rub the
8. Position bracket (23) on seat frame (2) and secure with upholstery briskly. Remove the suds with a damp
bolts (7 & 31), washers (24) and spacers (22 & 32). cloth, using no soap, and finish by wiping the
upholstery dry with a soft, dry cloth.
9. Position back and seat cushions (1 & 3) on seat
frame (2) and secure with mounting hardware. Lap belt (25) assembly should be inspected by the
user on a regular basis. Replace lap belt (25)
10. Position the seat assembly to hinge (9) of seat immediately if hardware is worn or damage, straps are
base (8) and secure with bolts (4) and lockwashers nicked or frayed, release mechanism is not functioning
(5). Tighten bolts (4) to a torque of 18 Nm (13 lbf ft) correctly, loose stitching is found, or if the strap
lubed. Lower seat assembly on seat base (8) and material has lost strength due to the effects of
ensure latch arrangement is operating correctly. ultraviolet rays.
11. Remove wheel chocks from road wheels. Note: Regardless of appearance, lap belt (25) must be
removed and replaced at least once every three years.
* * * *
SM 1902 1-00 3
OPERATORS COMPARTMENT - Air Conditioning
Section 260-0130
SM - 2430
1 3 IN
D
S OUT
4
5
SM - 2275A
8
5
CAB FIREWALL
1
7
6
2
10
12
23 24
22
11 3
9 20 30
21 1
25
28
17 41
27 26
42
19 29
33
34
32 31 13
15 14 39
18 35 40
36 34 33
16 37
38
SM - 3268
52
43
51
47
50
49
48
45 46
44
44
17. Install drive belt guards (15 & 16) and secure using 1. Periodically clean the condenser coil of debris and
mounting hardware as removed at Removal. dirt using water or air pressure. A partially blocked
condenser coil can reduce the life of the compressor
18. Remove caps from end of refrigerant hoses (1 & 3) belt and/or clutch.
and ports on compressor (13) and connect hoses to
ports as tagged at Removal. 2. If the system has a heater in the same location as
the air conditioning evaporator core, heater valves
19. Connect electrical connection to compressor (13) should be closed.
clutch.
3. To check the refrigerant level, run the engine at
20. Secure all lines with clips and clamps as removed 1 200 rev/min with fans on high speed and thermostat
during removal. Ensure no lines are chaffing on sharp fully open for a minimum of five minutes. If the clutch is
edges or resting against areas where heat will be engaged in this situation, there should be very few
evident. bubbles visible in the receiver-drier sight glass.
21. Charge the air conditioning system as described Note: Unit can operate with some bubbles visible, but
under 'Charging Procedure'. not milky looking.
22. Start up the engine and check for correct operation 4. Ensure all hoses and hose clamps are free from
of the air conditioning system. contact with sharp metal, moving parts or near to
manifolds.
23. Secure hood sides to vehicle and remove wheel
blocks. 5. Inspect condensation drain lines for debris, sharp
bends or breaks.
MAINTENANCE 6. Inspect the clutch wire from the thermostat for bare
spots.
WARNINGS
If you get the slightest trace of R-134a in Maintenance of 'V' belt Drives
your eye, flood the eye immediately with cool 1. Listen for 'ticking' sound - they mean interference
water; then treat with mineral oil or clear with the belts. Visually inspect for bent or damaged
petroleum jelly followed by boric acid rinse. belt guards.
Report to a hospital or doctor as soon as
possible. 2. Replace all belts in a mismatched set at one time to
ensure even load distribution.
2 3
4 7. Switch vacuum pump on, open vacuum pressure
valve (1) until less than 6 mb is reached on vacuum
SUC DIS R gauge (A). The vacuum gauge (A) should remain at
ACCESS E
F this value when vacuum pressure valve (1) is closed to
PORT R indicate that there are no leaks.
I
G
E Note: Minimum evacuation time = 1 hour.
A R
A
N 8. Open the low side hand valve on the manifold and
T
vacuum pressure valve (1) and watch that the gauges
start to register that a vacuum is being drawn. If the
VACUUM PUMP gauges do not register the vacuum then a blockage or
leak is present. Open the high side and pump down
6
until a vacuum of 10 mb is achieved.
1 5
Final Charging Of The System Note: Some R-134a will escape as the hoses are being
removed. Replace protective caps on hoses.
1. Start the engine and run at engine idle speed.
The system is completely charged when;
2. Turn the air conditioning system on with the
thermostat set on maximum cooling and fan on high
a. the sight glass is free from bubbles.
speed.
b. the suction pressure on the gauge is approx.
20 - 30 psig at 25 C ambient.
3. At this point a visual inspection must be made of the
c. the correct weight of refrigerant has been added
sight glass on top of the receiver-drier. As charging
(typically 0.95 - 1.0 kg).
continues, the sight glass will appear milky coloured as
d. the correct superheat can be measured at the
the bubbles in the system circulate. As the system
evaporator, approx. 3 - 6 C.
continues the charging process, the regularity of the
e. the correct sub-cooling can be measured at the
bubbles in the sight glass will gradually diminish.
condenser, approx. 5 - 7 C.
When no bubbles are seen in the sight glass, close the
low pressure valve (blue side) completely.
6. Replace protective caps on hoses and valve fittings.
4. Increase the engine idle speed while observing the
7. Secure hood sides to vehicle and remove wheel
sight glass. If many bubbles are seen resulting from
blocks.
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 SPECIAL TOOLS
glass remains clear, with the increased engine speed,
Refer to Section 300-0070, SERVICE TOOLS, for part
do not add any more R-134a.
numbers of special tools referenced in this section and
general service tools and sealants required. These
Note: Occasionally bubbles are noticed during clutch
tools and sealants are available from your dealer.
cycling or system start-up. This is a normal condition.
* * * *
SM - 1996
BODY
9,28,29 1
FRAME
30,31
32,33 5
2 6
3-4
27
25
42 36
42
35
37
25 27
34
22
24
40
38
41
39 42
43
16 14 11
17 15 23
12 21
18
19 7
26 20
10 13
9 8
OPERATION
The body control joystick, mounted at the left hand WARNING
side of the drivers' seat, controls the body control To prevent personal injury and property
valve which supplies hydraulic oil to operate the body damage, be sure wheel chocks and lifting
hoist cylinders. equipment are properly secured and of
adequate capacity to do the job safely.
The four operating positions of the body control
joystick from front to rear are; Lower, Float, Hold and 1. Position the vehicle in a level work area, apply the
Raise. Refer to Section 230-0060, BODY CONTROL parking brake and block all road wheels.
VALVE and, Section 230-0081, BODY CONTROL
JOYSTICK. 2. Raise body assembly (1) and install body safety
pins (24).
Move the body control joystick all the way back to the 5. Support body hoist cylinders from the rear of the
'Raise' position and accelerate the engine. The body vehicle to prevent them swinging back on removal of
can be stopped at any point by moving the joystick to cylinder mounting pins. Remove cylinder mounting
'Hold'. Decelerate the engine as the last stages of the pins and allow body hoist cylinders to rest against the
body hoists begin to extend to slow the raising speed chassis.
as the hoists approach their maximum extensions.
6. Remove bolts (22) and hardened washers (23)
When the body has been raised to the desired height, securing body hinge pins (21) through body
move the control joystick to the 'Hold' position until the assembly (1) and pin mounting bores.
body is to be lowered.
7. Remove body hinge pins (21) and shims (20) from
body assembly (1) and pin mounting bores. Using
Lowering the Body suitable lifting equipment, sling body assembly (1) and
To lower the body, move the control joystick to the remove from the vehicle.
'Float' position to allow the body's weight to lower it to
the frame. Body descent can be stopped at any Note: Do not remove body pads (10) and shims (14 & 15)
position by moving the joystick back to the 'Hold' unless body pads (10) are being replaced.
position. If the body does not begin to lower by its own
weight, such as after dumping downgrade, move the 8. If required, remove locknuts (13), hardened
control joystick all the way forward to the 'Lower' washers (26), washers (12) and bolts (11) securing
position and power the body downward until it begins body pads (10) and shims (14 & 15) to body
lowering by gravity. Then move the joystick to 'Float' to assembly (1). Remove and discard body pads (10)
allow the body to lower the rest of the way to the and shims (14 & 15).
chassis.
Make sure that the body is completely lowered and the INSTALLATION
control lever is in 'Float' before releasing the brakes Numbers in parentheses refer to Fig. 1.
and moving the vehicle.
Note: Tighten all fasteners to standard torques listed
in Section 300-0080, STANDARD BOLT AND NUT
REMOVAL TORQUE SPECIFICATIONS.
Numbers in parentheses refer to Fig. 1.
Note: Approximate weight of body assembly (1) is
Note: Approximate weight of body assembly (1) is 10 650 kg (23 480 lb).
10 650 kg (23 480 lb).
1. Ensure body hinge pins (21) and bores in body Note: When it becomes necessary, body pads (10)
assembly (1) are thoroughly cleaned with a suitable should be replaced as a set to maintain load
solvent. Coat body hinge pins (21) and bores in body distribution along the chassis. Existing body pads will
assembly (1) with a suitable anti-seize compound. have taken a compression 'set' and a new pad
shimmed to match existing pads will not carry its share
2. Using suitable lifting equipment, sling body of the load, resulting in uneven load distribution along
assembly (1) and centralise over the frame. the chassis.
3. Align body hinge pin (21) bores in body assembly Note: The body guides should also be inspected and
(1) with mounting bores in the frame. Install body hinge rebuilt with shims (29, 30, 31 or 32) as necessary at
pins (21) and secure with bolts (22) and hardened this time.
washers (23).
1. Raise body assembly (1) clear of the frame and
4. Remove lifting equipment from rear lifting points on position body pads (10) roughly in position on the
body assembly (1) and raise the front end of body frame rails. Lower body assembly (1) onto body
assembly (1) to provide access to install body hoist pads (10).
cylinders. Position wooden blocks (or suitable stands)
on the frame rails and lower body assembly (1) to rest 2. Shim the two rear body pads (10) with shims
on the blocks. Remove lifting equipment from body (14 & 15) until body hinge pins (21) are just touching at
assembly (1). the top of body assembly (1) bores.
5. Start the engine and using the body control lever, 3. Shim remaining body pads (10) with shims (14 & 15)
extend the body hoist cylinders until mounting holes to ensure body assembly (1) is resting parallel on the
are aligned with mounting bores on body assembly (1). frame.
Secure both body hoist cylinders to body assembly (1).
Refer to Section 230-0130, BODY CYLINDER. 4. Secure body pads (10) and shims (14 & 15) to body
assembly (1) with bolts (11), washers (12), hardened
6. Raise body assembly (1), remove blocks and lower washers (26) and locknuts (13).
body assembly (1).
5. Centralise body assembly (1) on the frame rails,
7. If removed, install body pads (10) and shims (14 & 15) remove body hinge pins (21) and reinstall with shims
as described under 'Body Shimming Procedure'. (20) to obtain a maximum gap of 1.5 mm (0.060 in)
between inner leg and body pivot. Secure body hinge
8. Centralise body assembly (1) on the frame rails, pins (21) with bolts (22) and hardened washers (23).
remove body hinge pins (21) and shim body hinge pins
(21) with shims (20) as described under 'Body 6. Ensure body assembly (1) is centralised on the
Shimming Procedure'. frame rails and measure gap between body guides on
the frame and the body guides. Secure shims (30, 31,
9. If removed, shim the body guides with shims (30, 32 or 33) to body guides on body assembly (1) using
31, 32 or 33) as described under 'Body Shimming bolts (28), washers (9) and nuts (29) as shown in
Procedure'. Figure 1. Leave a gap of 3.3 mm (0.13 in) between
body and frame guides.
10. Raise and lower body assembly (1) and check for
correct clearance at body hinge pins (21) and body Note: Only one shim (30, 31, 32 or 33) to be used on
guides. each side.
* * * *
Do not work under or near an unblocked or unsupported All change and service periods are recommendations
body. Always use the body safety pins. based on average operating conditions. Lubricants
showing evidence of excessive heat, oxidation or dirt
Do not work under or near any unblocked or should be changed more frequently to prevent these
unsupported linkage, part or vehicle. conditions.
Always relieve pressure before servicing any Lubricant change and service periods must be
pressurized system. Follow the procedures and safety established on the basis of individual job conditions
precautions detailed in the relevant Service Manual utilizing oil sampling and recommendations from
section. lubricant suppliers.
Always deflate the tyre before attempting to remove Thoroughly clean all fittings, caps, plugs, etc., to
any embedded objects or removing the tyre and rim prevent dirt from entering any system while carrying
assembly from the vehicle. out servicing procedures. Lubricants must be at
operating temperature when draining.
Always use a self-attaching chuck with a long airline,
and, stand to one side while the tyre is inflating. Refer Note: Do not operate any system unless oil level is
to Section 160-0050, Wheel Rim and Tyre. within the recommended operating levels as indicated
on oil level dipstick, sight gauge or level plug.
SM3745
7 1 16 21 5 8 26 10 20 28 21 22 19 12 21 25 13 18 9 14
27 29 6 23 22 26 8 10 28 11 28 4 20 2 24 3 15 25 18 17 9 14
*- Fill compartment one half full. Specification EMS19058. Refer to chart under
'Recommended Lubricants'.
Note - Lubricate slowly until excess lube is seen.
EP, NLGI - Extreme Pressure Lithium No. 2 Grease.
EO - Engine Oil. Refer to chart under 'Recommended
Refer to chart under 'Recommended
Lubricants'.
Lubricants'.
EPL - Extreme Pressure Gear Lubricant meeting
*EP, NLGI - Extreme Pressure Lithium No. 2 Grease
specification MIL-L-2105C.
(without 'Molybdenum'). Refer to chart Under
HTF - Hydraulic Transmission Oil Type C-4. Refer to 'Recommended Lubricants'.
chart under 'Recommended Lubricants'.
PAG Oil - Polyalklene Glycol (PAG) Compressor
HO - Hydraulic Transmission Oil meeting Lubricating Oil - Low Viscosity (ISO46).
Engine Air Cleaners - Check air cleaner piping, Coolant Filter(s) - Replace coolant filter(s) if
hoses and clamps. Change air cleaner element only required. When testing the DCA4 concentration,
when air cleaner flow restriction warning light depending on the level of DCA4, the coolant filter(s)
illuminates. Service vacuator valve daily. Inspect may not necessarily have to be changed. Refer to
and remove any obstructions from the vacuator valve Section 210-0000, Cooling System.
lips. Valve lips should be open and pliable with
engine stopped. Drive Belts - Visually check the belts and replace if
they are cracked or frayed. Adjust belts that have a
Note: Service air cleaners more often under glazed or shiny surface which indicates belt slippage.
extremely dusty operating conditions. Correctly installed and tensioned belts will show even
pulley and belt wear. Refer to Section 110-0030,
Radiator Header Tank - Check coolant level and add Engine and Mounting for drive belt tension and
if low. Fill radiator header tank with coolant until adjustment of new and used drive belts.
coolant reaches the bottom of the filler neck and
holds at that level.
Note: This service interval applies to normal driving. Rear Disc Brake Filter(s) - Replace filter element(s)
Check more frequently under more severe when indicator sight gauge shows replacement is
conditions. Thickness of pad friction material should necessary, or after 1000 hours of operation,
never be allowed to wear below 3 mm (0.12 in). whichever occurs first.
Oil Can Points - Oil hinges, and other working parts Steering In-line Filter - Clean filter housing and
with engine oil. install new element when indicated, or after
1000 hours of operation, whichever occurs first.
Fuel Pre-filter - Replace fuel pre-filter element. Refer
to Section 110-0150 Fuel Pre-filter. EVERY 1500 HOURS OF OPERATION
Engine Fan - Inspect the fan condition. Rotate the
EVERY 1000 HOURS OF OPERATION pulley to check for rough or damaged bearings.
Hydraulic System Pressure Checks - Check all Check the bearing end clearance which should be in
steering, body and braking system pressures. the range 0.03-0.25 mm (0.001-0.10 in).
Note: Instructions for checking pressure, and Note: The fan belt is maintained to the correct belt
locations of pressure check points, are contained in tension by a spring loaded idler arm, therefore, there
the relevant service manual section. If the pressures is no need to check or adjust belt tension.
are outwith the specified settings then components in
the relevant system should be inspected, repaired or EVERY 2000 HOURS OF OPERATION
replaced to ensure the correct operation of the Steering Hydraulic Tank Filter - Clean the filter
system. All safety instructions in the relevant housing and install new element when indicated, or
sections should be strictly adhered to. after 2000 hours of operation, whichever occurs first.
SERVICE CAPACITIES
Ref. Service Capacities
Points Identification Lubricant litres US gal
1 Engine Crankcase and Filters EO 60 15.9
2 Transmission and Filters HTF 92 24.3
3 Main Hydraulic Tank HO 250 66
- Main Hydraulic System HO 385 101.7
4 Steering Hydraulic Tank HO 68 18
- Steering Hydraulic System HO 92 24.3
27 Cooling System Coolant 136 35.9
19 Fuel Tank Diesel 606 160.1
8 Front Ride Cylinders (Each) HO 14 3.7
9 Rear Ride Cylinders (Each) HO 17 4.5
16 Engine Power Takeoff EPL 4 1.1
17 Differential EPL 60 15.9
18 Wheel Planetaries (Total) EPL 56 14.8
- Air Conditioning Compressor PAG Oil 0.125 0.033
Note: Capacities given are approximate. Work to the dipstick, sight gauges or level plugs. Use the table in
conjunction with the 'Recommended Lubricants' table.
RECOMMENDED LUBRICANTS
COMPONENT LUBRICANT VISCOSITY (See Note 1)
Engine Engine oil with 1.00 % sulphated ash is Ambient Temp Recommendation
recommended. Sulphated ash must not exceed 0 C and above SAE 20W-40
1.85 % limit. API code CE or CF-4. See Note 2. -10 C and above SAE 15W-40
-25 C to 35 C SAE 10W-30
Transmission Allison C-4 Type Specification; Refer to Ambient Temp Recommendation
www.allisontransmission.com for a complete -35 C SAE 0W-30 or Transynd RD
list of C-4 approved oils. See note 3* -30 C SAE 0W-20 (Arctic)
-28 C DEXRON-III
-20 C SAE 10W
-15 C SAE 15W-40
0 C SAE 30
10 C SAE 40
Hydraulic System Hydraulic Transmission Oil meeting SAE 10W
Specification EMS19058. See Note 4. at ambient temperatures of -18 C to 32 C
SAE 30W
at ambient temps of 32 C and above
Cooling System Heavy Duty Coolant. Refer to Section
210-0000, Cooling System.
Fuel Tank Diesel Fuel Oil with maximum Sulphur 0.5%. DIN EN590
Differential Multipurpose Extreme Pressure type gear oil SAE 80W-90
Planetary Gears meeting MIL-L-2105C Specifications (No Zinc at ambient temperatures of -18 C to 32 C
Power Takeoff Additive). See Note 5.
Grease Fittings Multipurpose Extreme Pressure Lithium No. 2 Consistency
Grease (which may, or may not contain
'Molybdenum'), with a typical melting point of
190 C.
Drivelines Multipurpose Extreme Pressure Lithium No. 2 Consistency
Steering Column Grease (without 'Molybdenum'), with a typical
Wheel Bearings melting point of 190 C.
Ride Cylinders Hydraulic oil meeting MIL-L-2104C SAE 10W
(Nitrogen/Oil) Specifications or API Service code CC or at ambient temperatures of -18 C to 32 C
CD/SC.
Temperature Conversions
Celsius -32 -30 -27 -25 -20 -18 -15 -10 0 10 15 25 32 35 38 45 93 190
Fahrenheit -26 -22 -17 -13 -4 0 5 14 32 50 59 77 90 95 100 113 200 375
* * * *
INTRODUCTION Engine
Contained in this section are recommended service The following tools are recommended for Engine
tools and equipment required for maintenance, Maintenance Procedures and should be used in
overhaul and troubleshooting. In certain instances, conjunction with procedures outlined in the engine
both Metric and Imperial equivalents of the same tools manufacturers service manual.
are listed. These tools are available from your dealer.
15270022 - Valve Seat Inserter Tool
Note: The Company reserves the right to make 15270024 - Valve Spring Compressor
changes in the design or construction of tools and 15270075 - Dial Depth Gauge
equipment without obligation to incorporate such 15269956 - Standard Puller
changes in tools and equipment previously sold. 15270056 - Water Pump Bearing Mandrel
15269957 - Torque Wrench Adaptor
Note: A tool may be of one piece construction or 15272177 - Compressor, Piston Ring
consist of a number of parts. 15270031 - Fuel Passage Cleaning Brush
15270431 - Hydrostatic Tester
15270078 - Manometer
General 15270972 - Main Bearing Cap Puller
*15269784 - Multi-Gauge - Pressure range of 30 in of 15270007 - Dowel Pin Extractor
vacuum to 5 000 lbf/in 15272204 - Mandrel, Air compressor Bushing
15269785 - Non-contact Infrared Thermometer 15269959 - Main Bearing Cap Puller
15268968 - Strap Type Filter Wrench 15272178 - Concentricity Gauge
15268969 - Socket Type Filter Wrench 15270436 - Crosshead Guide Spacer
15268970 - Universal Belt Tension Gauge 15270437 - Piston Ring Expander
15269858 - Digital Tachometer 15272179 - Gauge, Belt Tension
15269859 - Multimeter 15270440 - Water Tube Driver
15269813 - Water Manometer 15270441 - Valve Seat Extractor
15269802 - Dial Indicator Gauge - Metric 15269960 - Dial Gauge Attachment
15269803 - Dial Indicator Gauge - Imperial 15272180 - Compressor, Valve Spring
15269804 - Magnetic Base for Dial Indicator Gauge 15272205 - Torque Wrench (0-150 in lbs)
15269805 - Micrometer - 0 to 25 mm 15272206 - Wrench, Oil Filter
15269806 - Micrometer - 0 to 1 in 15270443 - Pressure Regulator Removal Tool
15269807 - Micrometer - 400 to 500 mm 15270446 - Head Water Testing Kit
15269808 - Micrometer - 16 to 20 in 15269962 - Dial Bore Gauge Kit
15269809 - Internal Micrometer - 50 to 210 mm 15270448 - Connecting Rod Guide Pins
15269810 - Internal Micrometer - 2 to 8 in 15270040 - Valve Spring Tester
15269860 - 92 Piece Heavy Equipment Tool Kit 15272207 - Set, Fillet Ball Gauges
15269861 - Torque Wrench - 3/8 in drive, 15272208 - Puller, Water Pump Impeller
20 - 100 Nm (15 - 80 lbf ft) range 15272209 - Puller, Idler Shaft
15269862 - Torque Wrench - 1/2 in drive, 15270060 - Water Pump Bearing Mandrel
60 - 330 Nm (45 - 250 lbf ft) range 15270061 - Water Pump Bearing Separator
15269863 - Torque Wrench - 3/8 in drive, 15272210 - Tube, Fuel Line Sight #12
4 - 20 Nm (40 - 180 lbf in) range 15272181 - Kit, Valve Seat Grooving (check voltage)
15269864 - Torque Wrench - 3/4 in drive, 15270452 - Liner Installation Tool
300 - 1 000 Nm (200 - 750 lbf ft) range 15270010 - Crack Detection Kit
15269865 - Torque Wrench - 3/4 in drive, 15270458 - Gear Puller Assembly
700 - 1 500 Nm (500 - 1 000 lbf ft) range 15269969 - Universal Cylinder Liner Puller
15269866 - Torque Multiplier - 1/2 in to 1 in drive, 15269961 - Dial Indicator Gauge
25:1 Ratio, 3 000 Nm (2 200 lbf ft) range 15269975 - Pulley Installation Tool
15272183 - Cutter, Oil Filter
* - The following items should be added to the 15272211 - Wrench, Injector Preload Torque
multi-gauge to enable the gauge to be used on 15270047 - Slide Hammer Assembly
diagnostic test points: 15270070 - Coupling Puller
15018226 - Diagnostic Coupling 15269993 - Driver Handle
00118748 - Connector (2 off) 15270480 - Valve Seat Extractor
15004085 - Hose Assembly (-4 HP, 84 in long) 15272184 - Dolly,Valve Insert Staking
SM 2507 03-07 1
Miscellaneous - Service Tools
Section 300-0070
15272182 - Fixture, Cylinder Head Water Test 15269232 - Wire Cutter, Stripper and Terminal
15270481 - Cup Plug Driver Crimper
15270482 - Cup Plug Driver 15269233 - Jumper Wire Set
15270483 - Cup Plug Driver 15269234 - Terminal Crimper
15272185 - Dolly, Valve Seat Staking 15269235 - Terminal Remover - Metri Pack (J1A,
15272186 - Driver, Compressor Seat Installation J1B, J3 and Shift Selector Connector
15272187 - Driver, Compressor Seat Remover Terminals)
15269992 - Expansion Plug Driver 15269236 - Terminal Remover - Speed Sensor and
15270982 - Set, Cylinder Liner Clamp Throttle Position Sensor Terminals
15272188 - Blowby Check Tool (0.406") 15269237 - Terminal Remover - Depress holding
15272189 - Kit, Digital Thermometer prong on ECU and DDL Connector
15272190 - Fixture, Rod Bolt Checking Terminals
15272191 - Kit, Air Compressor Valve Seat 15269238 - PROM Remover
15272192 - Compressor, Piston Ring 15269239 - High Impedance Digital Multimeter Kit
15269999 - Gauge Block 15269240 - AMP Pin Remover - Remove terminal
15270068 - Pump Seal Driver pins from interface and shift selector
15272193 - Kit, Cylinder Head Leak Test Terminals
15272194 - Kit, Guide Stud 15269241 - Terminal Crimper - Weatherpac
15272195 - Handle, T Lift Stud
15272196 - Kit, Pulley Installation Adapter The following tools are required for CEC 2 harness
15271475 - Insite Data Reader wiring repairs;
15272197 - Driver Low Temperature Thermostat Seal 15275719 - Sealed Splice (14-16 AWG)
15272198 - Gauge, Piston Ring Groove 15275720 - Sealed Splice (18-22 AWG)
15272199 - Gauge, Valve Head Thickness Check
15272211 - Kit, Rail Line Pressure 15275721 - Crimper - Deutsch Connector,
15272200 - Gauge, Valve Clearance Trans. Harness Bulkhead, J1939 Conector
15272201 - Driver Oil Seal 15269234 - Crimper (Alternate) - Delphi Packard (DDL
15272202 - Fixture, Injector Timing connector)
15272203 - Gauge, Head Bolts 15275722 - Crimper (Alternate) - Throttle Position
15272204 - Mandrel, Air compressor Bushing Sensor
15272205 - Torque Wrench (0-150 in lbs)
15272206 - Wrench, Oil Filter 15275723 - Wire Stripper
15272207 - Set, Fillet Ball Gauges 15275724 - Remover - Delphi Packard (DDL
15272208 - Puller, Water Pump Impeller Connector), Sump Temperature Sensor
15272209 - Puller, Idler Shaft 15275725 - Remover - Throttle Position Sensor
15272210 - Tube, Fuel Line Sight #12
15272211 - Kit, Rail Line Pressure 15275726 - Remover - Deutsch Connector
15275727 - Crimper - Throttle Position Sensor, Delphi
Transmission Packard (DDL Connector)
CEC Electronic Diagnostic 15275728 - Crimper - Speed Sensors, Throttle Position
15275098 - DDR Multikit (Reader, Cartridge, Cables) Sensor,
15275180 - CEC 1 & 2 Diagnostic Card (For Above)
15268971 - PRO-LINK Diagnostic Data Reader (DDR) 15275729 - Crimper - Repair of broken cable using
15268973 - CEC I and II Cartridge For DDR appropriate Sealed Splice
15268975 - DDR and CEC I and II Cartridge 15275730 - Remover - Deutsch Connector(Optional
Assembly DDL)
15269231 - CEC Off-Highway Diagnostic Service Kit
15269241 - Crimper (Alternate) - Throttle Position
15270344 - LPS NoFlash Electro Contact Cleaner Sensor
15269038 - Portable Printer for use with DDR,
complete with 110 V AC Adaptor 15275731 - Remover - ECU Connectors, Shift Selector
15269039 - Portable Printer for use with DDR, Connection
complete with 220 V AC Adaptor 15275732 - Connector Repair Kit - Transmission
15269040 - Printer Paper for use in above printers - Harness Bulkhead Connector
5 rolls
15275733 - Guide Pin - Transmission Harness
The following tools are contained in CEC
Bulkhead Connector
Off-Highway Diagnostic Service Kit - 15269231:
2 SM 2507 03-07
Miscellaneous - Service Tools
Section 300-0070
15275734 - Insertion Tool - Transmission Harness 15269816 - Refractometer - C Scale
Bulkhead Connector 15269817 - Refractometer - F Scale
15275735 - Terminal Remover - Transmission Harness 15269844 - Portable High Vacuum Charging
Bulkhead Connector Station - R-134a Gas
15269845 - Halogen Leak Tester
15275736 - Crimper - ECU Connectors, Shift Selector
Connection
Cab
The following tools are recommended for Transmission 15271016 - Glass Removal Tool
Maintenance Procedures and should be used in 15271017 - Bonding Kit (Quick Dry)
conjunction with procedures outlined in the
transmission manufacturers service manual.
OCDB Brake Packs
15270422 - Stator Assembly Installing Tool 15267573 - Seal Installation Kit
15270423 - Support Legs 15265300 - Seal Installation Tool
15270424 - Switch Sequence Gauge 15265301 - Seal Installation Tool
15270425 - Shift Inhibitor Clutch Drilling Feature
15270426 - Harness Adaptor
15270427 - Torque Converter Spanner Wrench Lubrication
15270428 - Belville Assembly Spring Compressor 09122784 - Grease Gun Assembly
09175662 - High Pressure Bucket Pump Lube Kit
Wheel, Rim and Tyre
09202013 - Fishtail Wrench Adhesives and Sealants
15251192 - Tyre Inflation Kit (Air) 15269103 - Loctite 221
15269121 - Tyre Inflation Kit (Nitrogen) 09362529 - Loctite 225
15270392 - Hydraulic Bead Breaking Kit 09029849 - Loctite 243
09244598 - Loctite 270
Accumulators/Ride Cylinder Charging 09985300 - Loctite 271
15269104 - Loctite 275
09359489 - Charging Assembly 15269245 - Loctite 277
15233715 - Loctite Prism 406
The following parts can be assembled for 15269111 - Loctite Prism 410
simultaneously charging the rear ride cylinders: 15269105 - Loctite 515
09359489 - Charging Assembly 09007209 - Loctite 574 (50 ml)
00454145 - Tee Piece 09379518 - Loctite 574 (160 ml)
15269788 - Hose 15269106 - Loctite 577 (Superflex)
15269789 - Chuck Valve 15270244 - Loctite 592 Pipe Sealer with Teflon
15269790 - Valve Extension 15023696 - Loctite 635
09371048 - Loctite 638
The following parts can be assembled for 15269107 - Loctite 641
simultaneously charging the front ride cylinders:
15304830 - Loctite 5205 (Ref. Sec. 160-0020)
09359489 - Charging Assembly
15305445 - Loctite 7063 Cleaning Agent
00454145 - Tee Piece
15269108 - Loctite Superclean Safety Solvent 706
00444355 - Coupling 15229541 - Loctite Activator 'N'
15269788 - Hose - 2 required 09243825 - Loctite Activator 'T'
15269789 - Chuck Valve
09175039 - General Adhesive
15269790 - Valve Extension
15269114 - Tectyl 280 Wax Based Rust Preventive
09380475 - Hylosil RTV Silicone Compound
Steering Valve 15270516 - Wynn's STP
15303808 - Silicon Grease (Dielectric)
15270489 - Spring Installation Tool
Pre-Filter
Cooling and Air Conditioning
15503453 - Collar/Vent Cap Wrench
15269814 - DCA4 Test Kit - Metric
SM 2507 03-07 3
Miscellaneous - Service Tools
Section 300-0070
Fabricated Tools
The service tools shown in Figs. 1 through 8 can be
fabricated as shown.
SM - 112
in mm
1/8 3.2
ONE-4340 STL. OR EQUIV.-HDN.-GRIND
1/4 6.4
3/8 9.5
7/16 11.1
1/2 12.7
5/8 15.9
3/4 19.1
29/32 23.0
1 25.4
1 1/8 28.6
ACME THD.
1 1/4 31.8
1 3/8 34.9
1 1/2 38.1
APPROX ONE-4340
STL.-HDN.-GRIND 1 7/8 47.6
2 50.8
2 1/32 51.6
2 1/8 54.0
2 15/32 62.7
2 3/4 69.9
4 3/4 120.7
4 7/8 123.8
5 1/2 139.7
5 3/4 146.0
5 31/32 151.6
6 7/8 174.6
7 1/2 190.5
9 1/2 241.3
4 SM 2507 03-07
Miscellaneous - Service Tools
Section 300-0070
SM - 126
0.56 - 3 HOLES
in mm
EQUALLY SPACED
0.12 3.0
0.50 12.7
0.56 14.22
0.62 15.7
1.00 25.4
1.62 41.1
2.00 50.8
2.50 63.5
MATERIAL: 3.25 82.5
PLAIN CARBON STEEL 3.31 84.0
9.38 238
15.88 403
26.25 668
SM - 1487 SM - 1488
117 16 108 16
77.8 4.45 77.8 4.45
+- 0.13 +- 0.13
R51.6 R51.6
14 7.1 14 7.1
+- 0.13 +- 0.13
66.7 +- 0.25
66.7 +- 0.25
28.4
42.9
42.9
57
42.9
R0.50 R0.50
/0.76 /0.76
in NPT R15
R15 R0.13/0.25
R0.13/0.25
Fig. 3 - Fabrication of Blanking Plate for Port 'B' Fig. 4 - Fabrication of Blanking Plate for Port 'C'
(Section 165-0030, BRAKE PARTS) (Section 165-0030, BRAKE PARTS)
SM 2507 03-07 5
6
0.62
0.50
0.47
0.38
0.26
0.25
0.22
0.19
0.18
0.12
0.06
0.03
0.177
0.139
0.130
INCHES
9.6
6.6
6.3
5.6
4.8
4.6
4.5
3.5
3.3
3.0
mm
15.7
12.7
11.9
1.52
0.76
Section 300-0070
6.00
5.50
4.00
3.00
2.56
2.50
2.00
1.68
1.12
1.00
0.81
0.75
0.72
20.00
INCHES
508
152
140
101
mm
76.2
65.0
63.5
50.8
42.7
28.4
25.4
20.5
19.0
18.2
100 SQ.
STOCK
ITEM #1 - HANDLE
Miscellaneous - Service Tools
.250 DIA.
HOLE THRU.
KNURL
DIA. HOLE
ITEM #5 - 'T' HANDLE
(WELDMENT)
.19 SQ.
8-32 UNC 2B X .38 MIN. FULL STOCK
THD. MINOR DIA. .130/.139 X .72 ITEM #3 - PIVOT BLOCK
DEEP
SM 2507 03-07
Miscellaneous - Service Tools
Section 300-0070
SM - 391
ALUMINIUM RING
SM - 390 SM - 393
Fig. 7 - Shaft Bearing Removal and Installation Tool Fig. 8 - Bearing Inner Race Installation Tools
(Section 220-0050, STEERING PUMP) (Section 220-0050, STEERING PUMP)
* * * *
SM 2507 03-07 7
MISCELLANEOUS - Standard Bolt and Nut Torque Specifications
Section 300-0080
Size SAE Symbol SAE Symbol SAE Symbol SAE Symbol 12 Point Cap Screws
GM 260-M Steel GM 280-M Steel GM 290-M Steel GM 300-M Steel
(SAE GR 2) (SAE GR 5) (SAE GR 7) (SAE GR 8)
Note: Where materials other than GM Standards are used, refer to the conversion table below.
Types of Steel Rockwell Hardness Applicable Torque SAE Bolt Head Symbols
Range Values
* * * *
4. PARKING - After thoroughly cleaning the entire 15. HYDAULIC CYLINDERS - Where possible retract
machine, park it on a hard, dry, level surface that is free cylinders for minimum rod exposure. Coat the
from grease and oil. The oil and grease would cause remaining exposed piston rod surface with a suitable oil
tyre deterioration. Apply the parking brake. or grease.
Note: If the machine is delivered from the Terex facility 16. AIR CYLINDERS - Coat the exposed piston rod
with a wax coating to protect the paint-work, do not surface with a suitable oil or grease.
remove it until the machine is removed from storage.
17. CONTROL CABLES & LINKAGE - All exposed
5. FUEL TANK - Fill the fuel tank to prevent moisture linkage, clevis ends, ball joints etc, wchich are not
condensation within the tank. Coat filler neck and cap protected during "lubrication" should be protected by a
threads with oil. suitable oil or grease.
6. HYDRAULIC TANKS - Coat filler neck and cap 18. OPEN PORTS & HOSE ENDS - Plug or seal with
threads with oil. Fill the tank to operating level if adhesive tape all open ports.
necessary.
19. MACHINED SURFACES - Coat any exposed
7. AIR RESERVOIRS - Open all drain cocks at bottom machined bores and surfaces with a suitable rust
of air tanks. preventative.
8. BATTERIES - Where moderate temperatures are Note: Do not apply oil or grease to brake discs.
expected, the batteries may be left in the machine. Up
to 30 days, the batteries may require a boost at the 20. HINGES - Apply oil to all the hinges.
end of the storage period. Preferably place the batteries
in the shop where they can be inspected, brought up to 21. SEAT SLIDE ADJUSTERS - Coat with grease.
full charge and placed on a trickle charge to keep them
at full charge. In very cold or hot climates, store the 22. SEATS, ARMRESRTS & CUSHIONS - When
SM 2629 12-09 1
Miscellaneous - Unit Storage
Section 300-0090
machine is not equipped with a cab, cover these items Clean 8-19 mm (0.25-0.75 in) gravel under each tyre is
with plastic or waterproof barrier paper, and secure with desirable if the area is not paved. Storage should not be
adhesive tape. Provide an opening in the underside of permitted on blacktop or oil stabilised surfaces.
the protective materials to prevent condensation build
up. Except in very cold weather, stored machines should
be moved occasionally, at least once every six months,
23. CABS - All windows, doors and vents closed. so the same section of the tyre is not always under
strain from deflection.
24. HOODS, HOODSIDES, COVERS, PANELS, ETC -
Installed. Inflation in the tyres must be adjusted to the
recommended service pressure before shipping or
25. SECURITY PANELS AND SECURITY LOCKS - putting a stored machine into service.
Installed and locked.
EXTENDED STORAGE - Over Six Months
EXTENDED STORAGE - Under Six When a machine is to be stored for a period over SIX
Months MONTHS, the following procedure must be followed:
When storing a machine for periods of longer than 30
days, but less than six months, the following procedure Note: These steps are in addition to those given
must be followed, in addition to the procedure previously under 'Extended Storage - Under Six
described above: Months'.
1. ENGINE - Consult the relevant Engine Manual/Dealer 1. WHEEL BEARINGS - Remove, clean, inspect and
for storage procedure for periods longer than 30 days. repack all wheel bearings.
2. TRANSMISSION - Consult the relevant Transmission Note: The above steps must be repeated for every Six
Manual/Dealer for storage procedure for periods longer Month period the machine is in storage.
than 30 days.
3. BATTERIES - Remove the batteries from the REMOVAL FROM EXTENDED STORAGE
machine and store in shop. Protect batteries from
temperature extremes. Coat the terminals and cable The following procedure must be followed when a
ends with acid resistant petroleum jelly. machine is removed from storage.
4. VENTS AND BREATHERS - Remove all vents and 1. FUEL TANK - Drain off any condensation. Remove
breathers and plug all the openings with pipe plugs or covers from openings and re-install breather.
seal with adhesive waterproof tape.
2. HYDRAULIC TANKS - Remove covers from openings
5. BELTS - Release tension on all the belts. and re-install breathers. Fill tank to operating level if
necessary.
6. TYRES - When extended storage is anticipated, the
machines should be blocked up so weight does not 3. AIR RESERVOIRS - Close all drain cocks.
rest on the tyres, and inflation pressure reduced to 1
bar (15 lbf/in2). Storage of such machines should be 4. BATTERIES - Check batteries are fully charged and
under cover if possible; otherwise tyres should be re-install.
protected from the elements by an opaque waterproof
covering. 5. TYRES - Inflate to the recommended pressure.
If it is not possible to block up the machines, inflation 6. TRACKS - Check recoil cylinder pressure and track
pressure in the tyres should be increased to 25% above adjustment.
the rated pressure for the actual load on the tyre in
storage condition. 7. EXHAUSTS - Remove temporary storage covers from
exhaust stack openings.
The storage area surface should be firm, reasonably
level, well drained and free of all oil, fuel or grease. 8. AIR INTAKES - Remove temporary storage covers
from air intake openings.
2 SM 2629 12-09
Section 300-0090
* * * *
SM 2629 12-09 3
Miscellaneous - Unit Storage
Section 300-0090
4 SM 2629 12-09